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DL205 PLC User Manual

Volume 1 of 2

Manual Number: D2-USER-M

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

WARNING

Thank you for purchasing automation equipment from Automationdirect.com®, doing business as, AutomationDirect. We want your new automation equipment to operate safely. Anyone who installs or

uses this equipment should read this publication (and any other relevant publications) before installing or operating the equipment.

To minimize the risk of potential safety problems, you should follow all applicable local and national codes that regulate the installation and operation of your equipment. These codes vary from area to area and usually change with time. It is your responsibility to determine which codes should be followed, and to verify that the equipment, installation, and operation is in compliance with the latest revision of these codes.

At a minimum, you should follow all applicable sections of the National Fire Code, National Electrical Code, and the codes of the National Electrical Manufacturer's Association (NEMA). There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation.

Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards. We do not guarantee the products described in this publication are suitable for your particular application, nor do we assume any responsibility for your product design, installation, or operation.

Our products are not fault-tolerant and are not designed, manufactured or intended for use or resale as online control equipment in hazardous environments requiring fail-safe performance, such as in the operation of nuclear facilities, aircraft navigation or communication systems, air traffic control, direct life support machines, or weapons systems, in which the failure of the product could lead directly to death, personal injury, or severe physical or environmental damage ("High Risk Activities"). AutomationDirect specifically disclaims any expressed or implied warranty of fitness for High Risk Activities.

For additional warranty and safety information, see the Terms and Conditions section of our catalog. If you have any questions concerning the installation or operation of this equipment, or if you need additional information, please call us at 770-844-4200.

This publication is based on information that was available at the time it was printed. At AutomationDirect we constantly strive to improve our products and services, so we reserve the right to make changes to the products and/or publications at any time without notice and without any obligation. This publication may also discuss features that may not be available in certain revisions of the product.

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Trademarks

This publication may contain references to products produced and/or offered by other companies. The product and company names may be trademarked and are the sole property of their respective owners. AutomationDirect disclaims any proprietary interest in the marks and names of others.

No part of this manual shall be copied, reproduced, or transmitted in any way without the prior, written consent of Automationdirect.com Incorporated. AutomationDirect retains the exclusive rights to all information included in this document.

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

AVERTISSEMENT

Nous vous remercions d'avoir acheté l'équipement d'automatisation de Automationdirect.comMC, en faisant des affaires comme, AutomationDirect. Nous tenons à ce que votre nouvel équipement d'automatisation fonctionne en toute sécurité. Toute personne qui installe ou utilise cet équipement doit lire la présente publication (et toutes les autres publications pertinentes) avant de l'installer ou de l'utiliser.

Afin de réduire au minimum le risque d'éventuels problèmes de sécurité, vous devez respecter tous les codes locaux et nationaux applicables régissant l'installation et le fonctionnement de votre équipement. Ces codes diffèrent d'une région à l'autre et, habituellement, évoluent au fil du temps. Il vous incombe de déterminer les codes à respecter et de vous assurer que l'équipement, l'installation et le fonctionnement sont conformes aux exigences de la version la plus récente de ces codes.

Vous devez, à tout le moins, respecter toutes les sections applicables du Code national de prévention des incendies, du Code national de l'électricité et des codes de la National Electrical Manufacturer's Association (NEMA). Des organismes de réglementation ou des services gouvernementaux locaux peuvent également vous aider à déterminer les codes ainsi que les normes à respecter pour assurer une installation et un fonctionnement sûrs.

L'omission de respecter la totalité des codes et des normes applicables peut entraîner des dommages à l'équipement ou causer de graves blessures au personnel. Nous ne garantissons pas que les produits décrits dans cette publication conviennent à votre application particulière et nous n'assumons aucune responsabilité à l'égard de la conception, de l'installation ou du fonctionnement de votre produit.

Nos produits ne sont pas insensibles aux défaillances et ne sont ni conçus ni fabriqués pour l'utilisation ou la revente en tant qu'équipement de commande en ligne dans des environnements dangereux nécessitant une sécurité absolue, par exemple, l'exploitation d'installations nucléaires, les systèmes de navigation aérienne ou de communication, le contrôle de la circulation aérienne, les équipements de survie ou les systèmes d'armes, pour lesquels la défaillance du produit peut provoquer la mort, des blessures corporelles ou de graves dommages matériels ou environnementaux («activités à risque élevé»). La société AutomationDirect nie toute garantie expresse ou implicite d'aptitude à l'emploi en ce qui a trait aux activités à risque élevé.

Pour des renseignements additionnels touchant la garantie et la sécurité, veuillez consulter la section Modalités et conditions de notre documentation. Si vous avez des questions au sujet de l'installation ou du fonctionnement de cet équipement, ou encore si vous avez besoin de renseignements supplémentaires, n'hésitez pas à nous téléphoner au 770-844-4200.

Cette publication s'appuie sur l'information qui était disponible au moment de l'impression. À la société AutomationDirect, nous nous efforçons constamment d'améliorer nos produits et services. C'est pourquoi nous nous réservons le droit d'apporter des modifications aux produits ou aux publications en tout temps, sans préavis ni quelque obligation que ce soit. La présente publication peut aussi porter sur des caractéristiques susceptibles de ne pas être offertes dans certaines versions révisées du produit.



Marques de commerce

La présente publication peut contenir des références à des produits fabriqués ou offerts par d'autres entreprises. Les

désignations des produits et des entreprises peuvent être des marques de commerce et appartiennent exclusivement à leurs propriétaires respectifs. AutomationDirect nie tout intérêt dans les autres marques et désignations.

Nulle partie de ce manuel ne doit être copiée, reproduite ou transmise de quelque façon que ce soit sans le consentement préalable écrit de la société Automationdirect.com Incorporated. AutomationDirect conserve les droits exclusifs à l'égard de tous les renseignements contenus dans le présent document.

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DL205 PLC USER MANUAL

Please include the Manual Number and the Manual Issue, both shown below, when communicating with Technical Support regarding this publication.

Manual Number: D2-USER-M

Issue: 4th Edition, Rev. B

Issue Date: 2/13

Publication History

Issue Date Description of Changes

1st Edition 1/94 original edition

Rev. A 9/95 minor corrections

2nd Edition 6/97 added DL250, downsized manual

Rev. A 5/98 minor corrections

Rev. B 7/99 added torque specs for base and I/O

Rev. C 11/99 minor corrections

Rev. D 3/00 added new PID features, minor corrections

Rev. E 11/00 added CE information, minor corrections

Rev. F 11/01

3rd Edition 6/02

Rev A 8/03 extensive corrections and additions

4th Edition 11/08

Rev A 4/10 extensive corrections and additions

Rev B 2/13

added surge protection info, corrected RLL and DRUM instructions, minor corrections

added DL250–1 and DL260 CPUs, local expansion I/O, ASCII and MODBUS instructions, split manual into two volumes

changed publishing software resulting in change of appearance, addition of IBox instructions, changes to PID chapter, added info for ERM and EBC modules, other changes as necessary

corrected number of memory registers needed in the print message instruction. added new transient suppression for inductive loads to Chapter 2. added H2-CTRIO2 and H2-ERM100 references.

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VOLUME ONE:

ABLE OF CONTENTS

Volume One: Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i

Volume Two: Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

Chapter 1: Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2

The Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2

Where to Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2

Supplemental Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2

Conventions Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3

Key Topics for Each Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3

DL205 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4

CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4

Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4

I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4

I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4

DL205 System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–5

Programming Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7

DirectSOFT Programming for Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7

Handheld Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7

DirectLOGIC™ Part Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8

Quick Start for PLC Validation and Programming . . . . . . . . . . . . . . . . . . . . . . . . .1–10

Steps to Designing a Successful System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–13

–1

Chapter 2: Installation, Wiring and Specifications . . . . . . . . . . . . . . .2–1

Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–2

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Table of Contents

Plan for Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–2

Three Levels of Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–3

Emergency Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–3

Emergency Power Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–4

Orderly System Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–4

Class 1, Division 2, Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–4

Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–5

Base Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–5

Panel Mounting and Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–6

Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–7

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–8

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–8

Marine Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–9

Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–9

24 VDC Power Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–9

Installing DL205 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–10

Choosing the Base Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–10

Mounting the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–10

Using Mounting Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–11

Installing Components in the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–12

Base Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–13

Base Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–13

I/O Wiring Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–14

PLC Isolation Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–14

Powering I/O Circuits with the Auxiliary Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .2–15

Powering I/O Circuits Using Separate Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . .2–16

Sinking / Sourcing Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–17

I/O “Common” Terminal Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–18

Connecting DC I/O to “Solid State” Field Devices . . . . . . . . . . . . . . . . . . . . . . . . .2–19

Solid State Input Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–19

Solid State Output Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–19

Relay Output Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–21

Relay Outputs – Transient Suppression for Inductive Loads in a Control System . .2–21

I/O Modules Position, Wiring, and Specification . . . . . . . . . . . . . . . . . . . . . . . . . .2–26

Slot Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–26

Module Placement Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–26

DL205 User Manual, 4th Edition, Rev. B

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Table of Contents

Special Placement Considerations for Analog Modules . . . . . . . . . . . . . . . . . . . . .2–27

Discrete Input Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–27

Color Coding of I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–27

Wiring the Different Module Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–28

I/O Wiring Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–29

D2-08ND3, DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–30

D2-16ND3-2, DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–30

D2–32ND3, DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–31

D2–32ND3–2, DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–32

D2-08NA-1, AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–33

D2-08NA-2, AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–34

D2-16NA, AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–35

F2-08SIM, Input Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–35

D2-04TD1, DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–36

D2–08TD1, DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–37

D2–08TD2, DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–37

D2–16TD1–2, DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–38

D2–16TD2–2, DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–38

F2–16TD1(2)P, DC Output With Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . .2–39

F2–16TD1P, DC Output With Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . .2–40

F2–16TD2P, DC Output with Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–41

D2–32TD1, DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–42

D2–32TD2, DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–42

F2–08TA, AC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–43

D2–08TA, AC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–43

D2–12TA, AC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–44

D2–04TRS, Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–45

D2–08TR, Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–46

F2–08TR, Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–47

F2–08TRS, Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–48

DL205 User Manual, 4th Edition, Rev. B

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Table of Contents

D2–12TR, Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–49

D2–08CDR 4 pt., DC Input / 4pt., Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . .2–50

Glossary of Specification Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–51

Chapter 3: CPU Specifications and Operations . . . . . . . . . . . . . . . . . .3–1

CPU Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–2

General CPU Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–2

DL230 CPU Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–2

DL240 CPU Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–2

DL250–1 CPU Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–3

DL260 CPU Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–3

CPU General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–4

CPU Base Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–5

CPU Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–6

Communication Port Pinout Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–6

Port 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–7

Port 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–8

Selecting the Program Storage Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–9

Built-in EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–9

EEPROM Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–9

EEPROM Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–9

Installing the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–10

Connecting the Programming Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–10

CPU Setup Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–11

Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–12

Mode Switch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–12

Changing Modes in the DL205 PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–13

Mode of Operation at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–13

Using Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–14

DL230 and DL240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–14

DL250-1 and DL260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–14

Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–14

Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–15

Clearing an Existing Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–16

Initializing System Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–16

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Setting the Clock and Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–16

Setting the CPU Network Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–17

Setting Retentive Memory Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–17

Using a Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–18

Setting the Analog Potentiometer Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–19

CPU Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–21

CPU Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–21

Program Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–22

Run Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–22

Read Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–23

Read Inputs from Specialty and Remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–23

Service Peripherals and Force I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–23

CPU Bus Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–24

Update Clock, Special Relays and Special Registers . . . . . . . . . . . . . . . . . . . . . . . .3–24

Solve Application Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–25

Solve PID Loop Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–25

Write Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–25

Write Outputs to Specialty and Remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–26

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–26

I/O Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–27

Is Timing Important for Your Application? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–27

Normal Minimum I/O Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–27

Normal Maximum I/O Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–27

Improving Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–28

CPU Scan Time Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–29

Initialization Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–30

Reading Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–30

Reading Inputs from Specialty I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–31

Service Peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–31

CPU Bus Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–32

Update Clock/Calendar, Special Relays, Special Registers . . . . . . . . . . . . . . . . . . . .3–32

Writing Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–32

Writing Outputs to Specialty I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–33

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–33

Application Program Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–34

PLC Numbering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–35

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PLC Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–35

V–Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–36

Binary-Coded Decimal Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–36

Hexadecimal Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–36

Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–37

Octal Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–37

Discrete and Word Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–37

V–Memory Locations for Discrete Memory Areas . . . . . . . . . . . . . . . . . . . . . . . . . .3–37

Input Points (X Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–38

Output Points (Y Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–38

Control Relays (C Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–38

Timers and Timer Status Bits (T Data type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–38

Timer Current Values (V Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–39

Counters and Counter Status Bits (CT Data type) . . . . . . . . . . . . . . . . . . . . . . . . .3–39

Counter Current Values (V Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–39

Word Memory (V Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–39

Stages (S Data type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–40

Special Relays (SP Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–40

Remote I/O Points (GX Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–40

DL230 System V-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–41

DL240 System V-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–43

DL250–1 System V-memory (DL250 also) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–46

DL260 System V-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–49

DL205 Aliases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–52

DL230 Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–53

DL240 Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–54

DL250–1 Memory Map (DL250 also) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–55

DL260 Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–56

X Input/Y Output Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–57

Control Relay Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–59

Stage Control/Status Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–63

Timer and Counter Status Bit Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–65

Remote I/O Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–66

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Chapter 4: System Design and Configuration . . . . . . . . . . . . . . . . . . .4–1

DL205 System Design Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–2

I/O System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–2

Networking Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–2

Module Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–3

Slot Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–3

Module Placement Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–3

Automatic I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–4

Manual I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–4

Removing a Manual Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–5

Power–On I/O Configuration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–5

I/O Points Required for Each Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–6

Calculating the Power Budget . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–7

Managing your Power Resource . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–7

CPU Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–7

Module Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–7

Power Budget Calculation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–9

Power Budget Calculation Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–10

Local Expansion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–11

D2–CM Local Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–11

D2–EM Local Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–12

D2–EXCBL–1 Local Expansion Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–12

DL260 Local Expansion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–13

DL250–1 Local Expansion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–14

Expansion Base Output Hold Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–15

Enabling I/O Configuration Check using DirectSOFT . . . . . . . . . . . . . . . . . . . . . . .4–16

Expanding DL205 I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–17

I/O Expansion Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–17

Ethernet Remote Master, H2-ERM(100)(-F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–17

Ethernet Remote Master Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . .4–18

Installing the ERM Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–19

Ethernet Base Controller, H2-EBC(100)(-F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–22

Install the EBC Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–23

Set the Module ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–23

Insert the EBC Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–23

Network Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–24

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10BaseFL Network Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–25

Maximum Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–25

Add a Serial Remote I/O Master/Slave Module . . . . . . . . . . . . . . . . . . . . . . . . . . .4–26

Configuring the CPU’s Remote I/O Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–27

Configure Remote I/O Slaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–29

Configuring the Remote I/O Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–29

Remote I/O Setup Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–30

Remote I/O Test Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–31

Network Connections to Modbus and DirectNet . . . . . . . . . . . . . . . . . . . . . . . . . .4–32

Configuring Port 2 For DirectNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–32

Configuring Port 2 For Modbus RTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–32

Modbus Port Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–33

DirectNET Port Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–34

Network Slave Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–35

Modbus Function Codes Supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–35

Determining the Modbus Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–35

If Your Host Software Requires the Data Type and Address . . . . . . . . . . . . . . . . . .4–35

If Your Modbus Host Software Requires an Address ONLY . . . . . . . . . . . . . . . . . . .4–38

Example 1: V2100 584/984 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–40

Example 2: Y20 584/984 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–40

Example 3: T10 Current Value 484 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–40

Example 4: C54 584/984 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–40

Determining the DirectNET Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–40

Network Master Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–41

Communications from a Ladder Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–44

Multiple Read and Write Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–44

Network Modbus RTU Master Operation (DL260 only) . . . . . . . . . . . . . . . . . . . .4–45

Modbus Function Codes Supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–45

Modbus Port Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–46

RS–485 Network (Modbus only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–47

RS–232 Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–47

Modbus Read from Network (MRX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–48

MRX Slave Memory Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–49

MRX Master Memory Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–49

MRX Number of Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–49

MRX Exception Response Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–49

Modbus Write to Network (MWX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–50

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MWX Slave Memory Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–51

MWX Master Memory Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–51

MWX Number of Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–51

MWX Exception Response Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–51

MRX/MWX Example in DirectSOFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–52

Multiple Read and Write Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–52

Non–Sequence Protocol (ASCII In/Out and PRINT) . . . . . . . . . . . . . . . . . . . . . . .4–54

Configure the DL260 Port 2 for Non-Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . .4–54

RS–485 Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–55

RS–232 Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–55

Configure the DL250-1 Port 2 for Non-Sequence . . . . . . . . . . . . . . . . . . . . . . . . .4–56

RS–422 Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–57

RS–232 Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–57

Chapter 5: RLL and Intelligent Box (IBOX) Instructions . . . . . . . . . . .5–1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–2

Using Boolean Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–5

END Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–5

Simple Rungs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–5

Normally Closed Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–6

Contacts in Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–6

Midline Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–6

Parallel Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–7

Joining Series Branches in Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–7

Joining Parallel Branches in Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–7

Combination Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–7

Comparative Boolean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–8

Boolean Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–8

Immediate Boolean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–9

Boolean Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–10

Comparative Boolean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–27

Immediate Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–33

Timer, Counter and Shift Register Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .5–41

Using Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–41

Timer Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–43

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Timer Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–43

Accumulating Timer (TMRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–44

Accumulating Timer Example using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . .5–45

Accumulator Timer Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . .5–45

Counter Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–47

Counter Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . .5–47

Stage Counter Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . .5–49

Stage Counter Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . .5–49

Up/Down Counter Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . .5–51

Up/Down Counter Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . .5–51

Accumulator/Stack Load and Output Data Instructions . . . . . . . . . . . . . . . . . . . .5–53

Logical Instructions (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–71

Math Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–88

Transcendental Functions (DL260 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–121

Bit Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–123

Number Conversion Instructions (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . .5–130

Table Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–144

Clock/Calendar Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–175

CPU Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–177

Program Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–179

Interrupt Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–187

Intelligent I/O Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–191

Network Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–193

Message Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–197

Modbus RTU Instructions (DL260) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–205

Modbus Read from Network (MRX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–205

Modbus Write to Network (MWX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–208

ASCII Instructions (DL260) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–211

Intelligent Box (IBox) Instructions (DL250-1/DL260) . . . . . . . . . . . . . . . . . . . . .5-230

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VOLUME TWO:

ABLE OF CONTENTS

Chapter 6: Drum Instruction Programming (DL250-1/DL260 only) .6–1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–2

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–2

Drum Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–2

Drum Chart Representation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–3

Output Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–3

Step Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–4

Drum Instruction Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–4

Timer-Only Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–4

Timer and Event Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–5

Event-Only Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–6

Counter Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–6

Last Step Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–7

Overview of Drum Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–8

Drum Instruction Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–8

Powerup State of Drum Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–9

Drum Control Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–10

Drum Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–10

Self-Resetting Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–11

Initializing Drum Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–11

Using Complex Event Step Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–11

Drum Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–12

Timed Drum with Discrete Outputs (DRUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–12

Event Drum (EDRUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–14

Handheld Programmer Drum Mnemonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–16

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Masked Event Drum with Discrete Outputs (MDRMD) . . . . . . . . . . . . . . . . . . . . .6–19

Masked Event Drum with Word Output (MDRMW) . . . . . . . . . . . . . . . . . . . . . . . .6–21

Chapter 7: RLL

Introduction to Stage Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–2

Overcoming “Stage Fright” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–2

Learning to Draw State Transition Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–3

Introduction to Process States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–3

The Need for State Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–3

A 2–State Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–3

RLL Equivalent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–4

Stage Equivalent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–4

Let’s Compare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–5

Initial Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–5

What Stage Bits Do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–6

Stage Instruction Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–6

Using the Stage Jump Instruction for State Transitions . . . . . . . . . . . . . . . . . . . . .7–7

Stage Jump, Set, and Reset Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–7

Stage Program Example: Toggle On/Off Lamp Controller . . . . . . . . . . . . . . . . . . .7–8

A 4–State Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–8

Four Steps to Writing a Stage Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–9

Stage Program Example: A Garage Door Opener . . . . . . . . . . . . . . . . . . . . . . . . .7–10

Garage Door Opener Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–10

Draw the Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–10

Draw the State Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–11

Add Safety Light Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–12

Modify the Block Diagram and State Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–12

Using a Timer Inside a Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–13

Add Emergency Stop Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–14

Exclusive Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–14

PLUS

Stage Programming . . . . . . . . . . . . . . . . . . . . . . . .7–1

Stage Program Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–15

Stage Program Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–15

How Instructions Work Inside Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–16

Using a Stage as a Supervisory Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–17

Stage Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–17

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Unconditional Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–18

Power Flow Transition Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–18

Parallel Processing Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–19

Parallel Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–19

Converging Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–19

Convergence Stages (CV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–19

Convergence Jump (CVJMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–20

Convergence Stage Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–20

Managing Large Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–21

Stage Blocks (BLK, BEND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–21

Block Call (BCALL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–22

PLUS

RLL

(Stage) Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–23

Stage (SG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–23

Initial Stage (ISG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–24

Jump (JMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–24

Not Jump (NJMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–24

Converge Stage (CV) and Converge Jump (CVJMP) . . . . . . . . . . . . . . . . . . . . . . . .7–25

Block Call (BCALL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–27

Block (BLK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–27

Block End (BEND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–27

Stage View in DirectSOFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–28

Questions and Answers about Stage Programming . . . . . . . . . . . . . . . . . . . . . . .7–29

Chapter 8: PID Loop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1

DL250-1 and DL260 PID Loop Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2

Main Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2

Introduction to PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4

Why use PID Control? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4

Introducing DL205 PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–6

Process Control Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–8

PID Loop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–9

Position Form of the PID Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–9

Reset Windup Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–10

Freeze Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–11

Adjusting the Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–11

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Step Bias Proportional to Step Change in SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–12

Eliminating Proportional, Integral or Derivative Action . . . . . . . . . . . . . . . . . . . . . .8–12

Velocity Form of the PID Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–12

Bumpless Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–13

Loop Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–13

Loop Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–14

Special Loop Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–14

Ten Steps to Successful Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–16

PID Loop Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–18

Some Things to Do and Know Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–18

PID Error Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–18

Establishing the Loop Table Size and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–18

Loop Table Word Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–20

PID Mode Setting 1 Bit Descriptions (Addr + 00) . . . . . . . . . . . . . . . . . . . . . . . . . .8–21

PID Mode Setting 2 Bit Descriptions (Addr + 01) . . . . . . . . . . . . . . . . . . . . . . . . . .8–22

Mode/Alarm Monitoring Word (Addr + 06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–23

Ramp/Soak Table Flags (Addr + 33) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–23

Ramp/Soak Table Location (Addr + 34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–24

Ramp/Soak Table Programming Error Flags (Addr + 35) . . . . . . . . . . . . . . . . . . . .8–24

PV Auto Transfer (Addr + 36) from I/O Module Base/Slot/Channel Option . . . . . .8–25

PV Auto Transfer (Addr + 36) from V-memory Option . . . . . . . . . . . . . . . . . . . . . .8–25

Control Output Auto Transfer (Addr + 37) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–25

Configure the PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–26

PID Loop Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–41

Open-Loop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–41

Manual Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–42

Alternative Manual Tuning Procedures by Others . . . . . . . . . . . . . . . . . . . . . . . . .8–44

Tuning PID Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–44

Auto Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–45

Use DirectSOFT Data View with PID View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–49

Open a New Data View Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–49

Open PID View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–50

Using the Special PID Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–52

How to Change Loop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–52

Operator Panel Control of PID Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–53

PLC Modes Effect on Loop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–53

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Loop Mode Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–53

PV Analog Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–54

Creating an Analog Filter in Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–55

Use the DirectSOFT 5 Filter Intelligent Box (IBOX) Instruction . . . . . . . . . . . . . . .8–56

FilterB Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–56

Ramp/Soak Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–57

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–57

Ramp/Soak Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–58

Ramp/Soak Table Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–60

Ramp/Soak Generator Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–60

Ramp/Soak Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–60

Ramp/Soak Profile Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–61

Ramp/Soak Programming Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–61

Testing Your Ramp/Soak Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–61

DirectSOFT Ramp/Soak Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–62

Setup the Profile in PID Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–62

Program the Ramp/Soak Control in Relay Ladder . . . . . . . . . . . . . . . . . . . . . . . . .8–62

Test the Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–63

Cascade Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–64

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–64

Cascaded Loops in the DL205 CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–65

Tuning Cascaded Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–66

Time-Proportioning Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–67

On/Off Control Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–68

Feedforward Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–69

Feedforward Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–70

PID Example Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–71

Program Setup for the PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–71

Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–74

Glossary of PID Loop Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–76

Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–78

Chapter 9: Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . .9–1

Hardware Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–2

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Standard Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–2

Air Quality Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–2

Low Battery Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–2

CPU Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–2

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–3

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–3

Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–3

Non-fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–3

Finding Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–4

V-memory Locations Corresponding to Error Codes . . . . . . . . . . . . . . . . . . . . . . . .9–4

Special Relays (SP) Corresponding to Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . .9–5

I/O Module Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–6

Error Message Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–7

System Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–8

Program Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–9

CPU Error Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–10

PWR Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–11

Incorrect Base Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–11

Faulty CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–11

Device or Module causing the Power Supply to Shutdown . . . . . . . . . . . . . . . . . .9–12

Power Budget Exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–12

Run Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–13

CPU Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–13

BATT Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–13

Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–13

I/O Module Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–14

Things to Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–14

I/O Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–14

Some Quick Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–15

Testing Output Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–16

Handheld Programmer Keystrokes Used to Test an Output Point . . . . . . . . . . . . . .9–16

Noise Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–17

Electrical Noise Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–17

Reducing Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–17

Machine Startup and Program Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .9–18

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Syntax Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–18

Duplicate Reference Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–19

TEST-PGM and TEST-RUN Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–20

Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–22

Run Time Edits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–24

Forcing I/O Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–26

Regular Forcing with Direct Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–28

Bit Override Forcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–29

Bit Override Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–29

Appendix A: Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–2

What are Auxiliary Functions? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–2

Accessing AUX Functions via DirectSOFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–3

Accessing AUX Functions via the Handheld Programmer . . . . . . . . . . . . . . . . . . . . .A–3

AUX 2* — RLL Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–4

AUX 21-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–4

AUX 21 Check Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–4

AUX 22 Change Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–4

AUX 23 Clear Ladder Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–4

AUX 24 Clear Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–4

AUX 3* — V-memory Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–5

AUX 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–5

AUX 31 Clear V-Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–5

AUX 4* — I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–5

AUX 41-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–5

AUX 41 Show I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–5

AUX 42 I/O Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–5

AUX 44 Power-up Configuration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–5

AUX 45 Select Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–6

AUX 46 to I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–6

AUX 5* — CPU Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–7

AUX 51-5C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–7

AUX 51 Modify Program Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–7

AUX 52 Display/Change Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–7

AUX 53 Display Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–8

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AUX 54 Initialize Scratchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–8

AUX 55 Set Watchdog Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–8

AUX 56 CPU Network Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–8

AUX 57 Set Retentive Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–9

AUX 58 Test Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–9

AUX 59 Bit Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–10

AUX 5B Counter Interface Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–10

AUX 5C Display Error History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–11

AUX 6* — Handheld Programmer Configuration . . . . . . . . . . . . . . . . . . . . . . . . .A–12

AUX 61, 62 and 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–12

AUX 61 Show Revision Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–12

AUX 62 Beeper On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–12

AUX 65 Run Self Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–12

AUX 7* - EEPROM Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–12

AUX 71 - 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–12

Transferrable Memory Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–13

AUX 71 CPU to HPP EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–13

AUX 72 HPP EEPROM to CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–13

AUX 73 Compare HPP EEPROM to CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–13

AUX 74 HPP EEPROM Blank Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–13

AUX 75 Erase HPP EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–13

AUX 76 Show EEPROM Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–13

AUX 8* — Password Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–14

AUX 81 - 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–14

AUX 81 Modify Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–14

AUX 82 Unlock CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–14

AUX 83 Lock CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A–14

Appendix B: DL205 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B–1

Appendix C: Instruction Execution Times . . . . . . . . . . . . . . . . . . . . . .C–1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–2

V-Memory Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–2

V-Memory Bit Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–2

How to Read the Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–2

Boolean Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–3

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Comparative Boolean Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–4

Bit of Word Boolean Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–13

Immediate Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–14

Timer, Counter and Shift Register Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .C–15

Accumulator Data Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–16

Logical Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–18

Math Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–20

Differential Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–23

Bit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–24

Number Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–25

Table Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–25

CPU Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–27

Program Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–27

Interrupt Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–28

Network Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–28

Intelligent I/O Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–28

Message Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–29

PLUS

RLL

DRUM Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–29

Clock / Calender Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–30

Modbus Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–30

ASCII Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–30

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C–29

Appendix D: Special Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–1

DL230 CPU Special Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–2

Startup and Real-Time Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–2

CPU Status Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–2

System Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–2

Accumulator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–3

Counter Interface Module Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–3

Equal Relays for Multi-step Presets with Up/Down Counter #1 / DL230

(for use with a Counter Interface Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–4

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DL240/DL250-1/DL260 CPU Special Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–5

Startup and Real-Time Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–5

CPU Status Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–5

System Monitoring Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–6

Accumulator Status Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–6

Counter Interface Module Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–7

Communications Monitoring Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–8

Equal Relays for Multi-step Presets with Up/Down Counter #1

(for use with a Counter Interface Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–9

Equal Relays for Multi-step Presets with Up/Down Counter #2

(for use with a Counter Interface Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D–10

Appendix E: PLC Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

DL205 PLC Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Non-volatile V-memory in the DL205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Appendix F: DL205 Product Weight Table . . . . . . . . . . . . . . . . . . . . . .F-1

DL205 Product Weight Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

Appendix G: ASCII Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

ASCII Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2

Appendix H: Numbering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–2

Binary Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–2

Hexadecimal Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–3

Octal Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–4

Binary Coded Decimal (BCD) Numbering System . . . . . . . . . . . . . . . . . . . . . . . . .H–5

Real (Floating Point) Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–5

BCD/Binary/Decimal/Hex/Octal -What is the Difference? . . . . . . . . . . . . . . . . . . .H–6

Data Type Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–7

Signed vs. Unsigned Integers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–8

AutomationDirect.com Products and Data Types . . . . . . . . . . . . . . . . . . . . . . . . . .H–9

DL205 User Manual, 4th Edition, Rev. B

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Table of Contents

DirectLOGIC PLCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–9

C-more/C-more Micro-Graphic Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H–9

Appendix I: European Union Directives (CE) . . . . . . . . . . . . . . . . . . . .I-1

European Union (EU) Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-2

Member Countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-2

Applicable Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-2

Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-2

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-3

Special Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-4

Other Sources of Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-4

Basic EMC Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5

Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5

Electrostatic Discharge (ESD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5

AC Mains Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6

Suppression and Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6

Internal Enclosure Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6

Equi–potential Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-7

Communications and Shielded Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-7

Analog and RS232 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-8

Shielded Cables within Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-8

Analog Modules and RF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-9

Network Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-9

DC Powered Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-9

Items Specific to the DL205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-10

Index

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Page 26

CHAPTER

GETTING STARTED

In This Chapter...

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2

Conventions Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3

DL205 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4

Programming Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7

DirectLOGIC™ Part Numbering System . . . . . . . . . . . . . . . . . . . . . .1–8

Quick Start for PLC Validation and Programming . . . . . . . . . . . . . .1–10

Steps to Designing a Successful System . . . . . . . . . . . . . . . . . . . . .1–13

Page 27

Chapter 1: Getting Started

Introduction

The Purpose of this Manual

Thank you for purchasing our DL205 family of products. This manual shows you how to install, program, and maintain the equipment. It also helps you understand how to interface them to other devices in a control system.

This manual contains important information for personnel who will install DL205 PLCs and components and for the PLC programmer. If you understand PLC systems, our manuals will provide all the information you need to start and keep your system up and running.

Where to Begin

If you already understand PLCs please read Chapter 2, “Installation, Wiring, and Specifications”, and proceed on to other chapters as needed. Keep this manual handy for reference when you have questions. If you are a new DL205 customer, we suggest you read this manual completely to understand the wide variety of features in the DL205 family of products. We believe you will be pleasantly surprised with how much you can accomplish with our products.

Supplemental Manuals

If you have purchased operator interfaces or DirectSOFT, you will need to supplement this

manual with the manuals that are written for these products.

Technical Support

We strive to make our manuals the best in the industry. We rely on your feedback to let us know if we are reaching our goal. If you cannot find the solution to your particular application, or, if for any reason you need technical assistance, please call us at:

Our technical support group will work with you to answer your questions. They are available Monday through Friday from 9:00 A.M. to 6:00 P.M. Eastern Time. We also encourage you to visit our web site where you can find technical and non-technical information about our products and our company.

If you have a comment, question or suggestion about any of our products, services, or manuals, please fill out and return the ‘Suggestions’ card that was included with this manual.

770–844–4200

http://www.automationdirect.com

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Conventions Used

Getting Started

CHAPTER

In This Chapter...

.................................................................1-2

...........................................................................1-4Specifications

General Information

When you see the “notepad” icon in the left–hand margin, the paragraph to its immediate right will be a special note.

The word NOTE in boldface will mark the beginning of the text.

Chapter 1: Getting Started

When you see the “exclamation mark” icon in the left–hand margin, the paragraph to its immediate right will be a warning. This information could prevent injury, loss of property, or even death (in extreme cases).

The word WARNING in boldface will mark the beginning of the text.

Key Topics for Each Chapter

The beginning of each chapter will list the key topics that can be found in that chapter.

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Page 29

Chapter 1: Getting Started

DL205 System Components

The DL205 family is a versatile product line that provides a wide variety of features in an extremely compact package. The CPUs are small, but offer many instructions normally only found in larger, more expensive systems. The modular design also offers more flexibility in the fast moving industry of control systems. The following is a summary of the major DL205 system components.

CPUs

There are four feature-enhanced CPUs in this product line, the DL230, DL240, DL250–1 and DL260. All CPUs include built-in communication ports. Each CPU offers a large amount of program memory, a substantial instruction set and advanced diagnostics. The DL250–1 features drum timers, floating–point math, 4 built-in PID loops with automatic tuning and 2 bases of local expansion capability.

The DL260 features ASCII IN/OUT and extended MODBUS communications, table and trigonometric instructions, 16 PID loops with autotuning and up to 4 bases of local expansion. Details of these CPU features and more are covered in Chapter 3, CPU Specifications and Operation.

Bases

Four base sizes are available: 3, 4, 6 and 9 slot. The DL205 PLCs use bases that can be expanded. The part numbers for these bases end with –1. These bases have a connector for local expansion located on the right end of the base. They can serve in local, local expansion and remote I/O configurations. All bases include a built-in power supply. The bases with the –1 suffix can replace existing bases without a suffix if expansion is required.

I/O Configuration

The DL230 and DL240 CPUs can support up to 256 local I/O points. The DL250–1 can support up to 768 local I/O points with up to two expansion bases. The DL260 can support up to 1280 local I/O points with up to four expansion bases. These points can be assigned as input or output points. The DL240, DL250–1 and DL260 systems can also be expanded by adding remote I/O points. The DL250–1 and DL260 provide a built–in master for remote I/O networks. The I/O configurations are explained in Chapter 4, System Design and Configuration. I/O Modules

I/O Modules

The DL205 has some of the most powerful modules in the industry. A complete range of discrete modules which support 24 VDC, 110/220 VAC and up to 10A relay outputs (subject to derating) are offered. The analog modules provide 12 and 16 bit resolution and several selections of input and output signal ranges (including bipolar). Several specialty and communications modules are also available.

1–4

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Chapter 1: Getting Started

Getting Started

Networking

RS232C

(max.50ft/16.2m)

RS232C

(max.50ft/16.2m)

(max.

6.5ft / 2m)

Handheld Programmer

Operator Interface

Programming or

Computer Interface

Simple Motion Control

Flexible solutions in one package

High-speed counting (up to 100 KHz)

Pulse train output (up to 50KHz

High–speed Edge timing

Machine

Control

Packaging

Conveyors

Elevators

Programming or Computer Interface

RS232C

(max.50ft/16.2m)

Handheld Programmer

DL240

RS232/422 Convertor

Simple programming

through the RLL Program

DL260 with H2–CTRIO(2) High Speed I/O Module

DL240

DL250–1 or DL260

DL305

Pulse

Output

Drive

Amplifier

Stepper Motor

Local I/O Expansion

DCM

DL205 System Diagrams

The diagram below shows the major components and configurations of the DL205 system. The next two pages show specific components for building your system.

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Chapter 1: Getting Started

PROGRAMMING

Handheld Programmer

with Built-in RLL

PLUS

Direct SOFT Programming

for Windows

AC INPUT

8pt110 VA C

16pt110 VA C

Direct LOGIC DL205 Family

DC INPUT

8pt12–24 VDC

16pt 24 VDC

32pt 24 VDC

32pt 5–15 VDC

SPECIALTY MODULES

High Speed Counters CPU Slot Controllers

Remote Masters Remote Slaves

Communications Temperature Input Filler Module

AC OUTPUT

8pt18–220 VAC

12pt18–110 VAC

2 commons

RELAY OUTPUT

4pt 5–30 VDC

5–240VAC

8pt 5–30 VDC

5 –240 VAC

12pt 5–30VDC

5–240VAC (isolated pts.module available)

ANALOG

CPUs

DL230 – 2.0K Built-in EEPROM Memory DL240 – 2.5K Built-in EEPROM Memory DL250–1 – 7.6K Built-in Flash Memory DL260 – 15.8K Built-in Flash Memory

BASES

3 Slot Base, 110/220VAC, 24VDC 4 Slot Base, 110/220VAC, 24VDC

6 Slot Base, 110/220VAC, 24VDC, 125 VDC 9 Slot Base, 110/220VAC, 24VDC, 125 VDC

DC OUTPUT

4pt12–24 VDC 8pt12–24 VDC

16pt12–24 VDC

2 Commons

32pt12–24 VDC

4 Commons

4CH INPUT 8CH INPUT 2CH OUTPUT 8CH OUTPUT

4 IN/2 OUT 8 IN/4 OUT

ANALOG

1–6

DL205 User Manual, 4th Edition, Rev. B

Page 32

Programming Methods

There are two programming methods available for the DL205 CPUs, RLL (Relay Ladder Logic) and RLL the handheld programmer support RLL and Stage.

DirectSOFT Programming for Windows.

The DL205 can be programmed with one of the most advanced programming packages in the industry ––DirectSOFT5. DirectSOFT5 is a Windows-based software package that supports many Windows features you already know, such as cut and paste between applications, point and click editing, viewing and editing multiple application programs at the same time, etc. DirectSOFT5 universally supports the DirectLOGIC CPU families. This means you can use the same DirectSOFT5 package to program DL05, DL06, DL105, DL205, DL305, DL405 or any new CPUs we may add to our product line. There is a separate manual that discusses the DirectSOFT5 programming software which is included with your software package.

Handheld Programmer

All DL205 CPUs have a built-in programming port for use with the handheld programmer (D2–HPP). The handheld programmer can be used to create, modify and debug your application program. A separate manual that discusses the DL205 Handheld Programmer is available.

PLUS

(Stage Programming). Both the DirectSOFT5 programming package and

Chapter 1: Getting Started

DL205 User Manual, 4th Edition, Rev. B

1–7

Page 33

Chapter 1: Getting Started

CPUs

Specialty CPUs

DL05/06 Product family DL105 Product family DL205 Product family DL305 Product family DL405 Product family

D0/F0 D1/F1 D2/F2 D3/F3 D4/F4

Class of CPU / Abbreviation 230...,330...,430...

Denotes a differentiation between similar modules

–1, –2, –3, –4

Bases

D2/F2 D3/F3 D4/F4

Number of slots ##B

Type of Base DC or empty

Discrete I/O

Number of points 04/08/12/16/32/64

Input N

Input

Output

Combination

AC A

ACDCA

Either

Relay

Current Sinking 1

Current Sinking

Current Sourcing

Current Sinking/Sourcing

High Current H

High Current

Isolation

Fast I/O S

Denotes a differentiation between similar modules

–1, –2, –3, –4

D3– 16 N D 2 –1

D4– 16 N D 2 F

D3– 05B DC

D4– 440DC –1

DL205 Product family DL305 Product family DL405 Product family

DL05/06 Product family DL205 Product family DL305 Product family DL405 Product family

D0/F0 D2/F2 D3/F3 D4/F4

DirectLOGIC™ Part Numbering System

As you examine this manual, you will notice there are many different products available. Sometimes it is difficult to remember the specifications for any given product. However, if you take a few minutes to understand the numbering system, it may save you some time and confusion. The charts below show how the part numbering systems work for each product category. Part numbers for accessory items such as cables, batteries, memory cartridges, etc., are typically an abbreviation of the description for the item.

1–8

DL205 User Manual, 4th Edition, Rev. B

Page 34

Chapter 1: Getting Started

Analog I/O

DL05/06 Product family

D0/F0

DL205 Product family

D2/F2

DL305 Product family

DL405 Product family

D3/F3

D4/F4 Number of channels 02/04/08/16

Input (Analog to Digital) AD

Input (Analog to Digital)

Output (Digital to Analog)

Combination

AND Isolated S

Denotes a differentiation between Similar modules

–1, –2, –3, –4

Communication and Networking

Special I/O and Devices

Programming

DL205 Product family

DL305 Product family

DL405 Product family

D2/F2

D3/F3

D4/F4

Name Abbreviation see example

CoProcessors and ASCII BASIC Modules

DL205 Product family D2/F2

DL205 Product family

DL305 Product family

D2/F2

D3/F3

DL305 Product family

DL405 Product family

D3/F3

D4/F4

CoProcessor CP

CoProcessor

ASCII BASIC

64K memory 64

64K memory

128K memory

128

128K memory

512K memory

128

512

Radio modem R

Radio modem

Telephone modem

F4– CP 128 – R

F3– 04 AD S –1

F3– 08 THM –n

note: –n indicates thermocouple type

Alternate example of Analog I/O

such as: J, K, T, R, S or E

using abbreviations

D3– HPP

D3– HSC

D4– DCM

HPP (RLL PLUS Handheld Programmer)

HSC (High Speed Counter)

DCM (Data Communication Module)

DL205 User Manual, 4th Edition, Rev. B

1–9

Page 35

Chapter 1: Getting Started

Quick Start for PLC Validation and Programming

If you have experience using PLCs, or want to setup a quick example, this section is what you want to use. This example is not intended to explain everything needed to start-up your system. It is only intended to provide a general picture of what is needed to get your system powered-up.

Step 1: Unpack the DL205 Equipment

Unpack the DL205 equipment and verify you have the parts necessary to build this

demonstration system. The minimum parts needed are as follows:

• Base

• CPU

• A discrete input module such as a D2–16ND3–2 DC or a F2–08SIM input simulator module

• A discrete output module such as a D2–16TD1–2 DC

• *Power cord

• *Hook up wire

• *One or more toggle switches (if not using the input simulator module)

• *A screwdriver, blade or Phillips type

*These items are not supplied with your PLC.

You will need at least one of the following programming options:

• DirectSOFT5 Programming Software, DirectSOFT5 Manual, and a programming cable (connects the CPU to a personal computer), or

• D2–HPP Handheld Programmer and the Handheld Programmer Manual.

1–10

DL205 User Manual, 4th Edition, Rev. B

Page 36

Chapter 1: Getting Started

Toggle switch

Input

Module

Output Module

Step 2: Install the CPU and I/O Modules

Insert the CPU and I/O into the base. The CPU must be inserted into the first slot of the base (next to the power supply).

• Each unit has a plastic retaining clip at the top and bottom. Slide the retainer clips to the out position before installing the module.

• With the unit square to the base, slide it in using the upper and lower guides.

• Gently push the unit back until it is firmly seated in the backplane.

• Secure the unit to the base by pushing in the retainer clips.

Placement of discrete, analog and relay modules are not critical and may go in any slot in any base, however for this example, install the output module in the slot next to the CPU and the input module in the next. Limiting factors for other types of modules are discussed in Chapter 4, System Design and Configuration. You must also make sure you do not exceed the power budget for each base in your system configuration. Power budgeting is also discussed in Chapter 4.

Step 3: Remove Terminal Strip Access Cover

Remove the terminal strip cover. It is a small strip of clear plastic that is located on the base power supply.

Step 4: Add I/O Simulation

To finish this quick start exercise or study other examples in this manual, you will need to install an input simulator module (or wire an input switch as shown below), and add an output module. Using an input simulator is the quickest way to get physical inputs for checking out the system or a new program. To monitor output status, any discrete output module will work.

Lift off

Retaining Clips

CPU must reside in first slot!

Wire the switches or other field devices prior to applying power to the system to ensure a point is not accidentally turned on during the wiring operation. This example uses DC input and output modules. Wire the input module, X0, to the toggle switch and 24VDC auxiliary power supply on the CPU terminal strip as shown. Chapter 2, Installation, Wiring, and Specifications provides a list of I/O wiring guidelines.

DL205 User Manual, 4th Edition, Rev. B

1–11

Page 37

Chapter 1: Getting Started

Ground

Line

Neutral

END

STR

ENT

OUT

ENT

Handheld Program Keystrokes

Step 5: Connect the Power Wiring

Connect the wires as shown. Observe all precautions stated earlier in this manual. For details on wiring see Chapter 2 Installation, Wiring, and Specifications. When the wiring is complete, replace the CPU and module covers. Do not apply power at this time.

Step 6: Connect the Programmer

Either connect the programming cable connected to a computer loaded with DirectSOFT Programming Software or a D2-HPP Handheld Programmer (comes with programming cable) to the top port of the CPU.

Step 7: Switch On the System Power

Apply power to the system and ensure the PWR indicator on the CPU is on. If not, remove power from the system, check all wiring and refer to the troubleshooting section in Chapter 9 for assistance.

Step 8: Enter the Program

Slide the switch on the CPU to the STOP position (250–1 / 260 only) and then back to the TERM position. This puts the CPU in the program mode and allows access to the CPU program. Edit a DirectSOFT program using the relay ladder diagram below and load it into the PLC. If using an HPP, the PGM indicator should be illuminated on the HPP. Enter the following keystrokes on the HPP:

1–12

NOTE: It is not necessary for you to configure the I/O for this system since the DL205 CPUs automatically examine any installed modules and establish the correct configuration.

After entering the example program put the CPU in the RUN mode with DirectSOFT or after entering the program using the HPP, slide the switch from the TERM position to the RUN position and back to TERM. The RUN indicator on the CPU will come on indicating the CPU has entered the run mode. If not repeat Step 8 insuring the program is entered properly or refer to the troubleshooting guide in chapter 9.

During Run mode operation, the output status indicator “0” on the output module should reflect the switch status. When the switch is on the output should be on.

DL205 User Manual, 4th Edition, Rev. B

Page 38

Steps to Designing a Successful System

Power up

Initialize hardware

Check I/O module

config. and verify

16pt Input

8pt Input

X17

X20

X27

8pt Output

Step 1: Review the Installation Guidelines

Always make safety your first priority in any system application. Chapter 2 provides several guidelines that will help provide a safer, more reliable system. This chapter also includes wiring guidelines for the various system components.

Chapter 1: Getting Started

Step 2: Understand the CPU Setup Procedures

The CPU is the heart of your automation system and is explained in Chapter 3. Make sure you take time to understand the various features and setup requirements.

Step 3: Understand the I/O System

Configurations

It is important to understand how your local I/O system can be configured. It is also important to understand how the system Power Budget is calculated. This can affect your I/O placement and/or configuration options. See Chapter 4 for more information.

Step 4: Determine the I/O Module Specifications and

Wiring Characteristics

There are many different I/O modules available with the DL205 system. Chapter 2 provides the specifications and wiring diagrams for the discrete I/O modules.

NOTE: Analog and specialty modules have their own manuals and are not included in this manual.

Step 5: Understand the System Operation

Before you begin to enter a program, it is very helpful to understand how the DL205 system processes information. This involves not only program execution steps, but also involves the various modes of operation and memory layout characteristics. See Chapter 3 for more information.

DL205 User Manual, 4th Edition, Rev. B

1–13

Page 39

Chapter 1: Getting Started

Standard RLL Programming

(see Chapter 5)

LDD V1076

CMPD K309482

SP62

OUT

Timer/Event Drum Sequencer

(see Chapter 6)

Push–UP

Push–

DOWN

LOWER

RAISE

LIGHT

Stage Programming

(see Chapter 7)

PID Loop Operation

(see Chapter 8)

PID Process

–

TMR T1

K30

CNT CT3

K10

Step 6: Review the Programming Concepts

The DL205 provides four main approaches to solving the application program, including the

PID loop task depicted in the next figure.

• RLL diagram style programming is the best tool for solving boolean logic and general CPU register/ accumulator manipulation. It includes dozens of instructions, which will augment drums, stages and loops.

• The DL250-1 and DL260 have four timer/event drum types, each with up to 16 steps. They offer both time and/or event-based step transitions. Drums are best for a repetitive process based on a single series of steps.

• Stage programming, called RLL program into sections which correspond to the states in a flow chart of your process.

• The DL260 PID loop operation uses setup tables to configure 16 loops. The DL250-1 PID loop operation uses setup to configure 4 loops. Features include: auto tuning, alarms, SP ramp/soak generation and more.

PLUS

, is based on state-transition diagrams. Stages divide the ladder

Step 7: Choose the Instructions

1–14

Once you have installed the system and understand the theory of operation, you can choose from one of the most powerful instruction sets available.

Step 8: Understand the Maintenance and

Troubleshooting Procedures

Equipment failures can occur at any time. Switches fail, batteries need to be replaced, etc. In most cases, the majority of the troubleshooting and maintenance time is spent trying to locate the problem. The DL205 system has many built-in features that help you quickly identify problems. Refer to Chapter 9 for diagnostics.

DL205 User Manual, 4th Edition, Rev. B

Page 40

INSTALLATION, WIRING

CHAPTER

AND

In This Chapter:

SPECIFICATIONS

Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–2

Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–5

Installing DL205 Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–10

Installing Components in the Base . . . . . . . . . . . . . . . . . . . . . . . . .2–12

Base Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–13

I/O Wiring Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–14

I/O Modules Position, Wiring, and Specification . . . . . . . . . . . . . .2–26

Glossary of Specification Terms . . . . . . . . . . . . . . . . . . . . . . . . . . .2–51

Page 41

Chapter 2: Installation, Wiring and Specifications

Safety Guidelines

NOTE: Products with CE marks perform their required functions safely and adhere to relevant standards as

specified by CE directives, provided they are used according to their intended purpose and that the instructions in this manual are adhered to. The protection provided by the equipment may be impaired if this equipment is used in a manner not specified in this manual. A listing of our international affiliates is available on our Web site: http://www.automationdirect.com

WARNING: Providing a safe operating environment for personnel and equipment is your responsibility and should be your primary goal during system planning and installation. Automation systems can fail and may result in situations that can cause serious injury to personnel and/or damage equipment. Do not rely on the automation system alone to provide a safe operating environment. Sufficient emergency circuits should be provided to stop either partially or totally the operation of the PLC or the controlled machine or process. These circuits should be routed outside the PLC in the event of controller failure, so that independent and rapid shutdown are available. Devices, such as “mushroom” switches or end of travel limit switches, should operate motor starter, solenoids, or other devices without being processed by the PLC. These emergency circuits should be designed using simple logic with a minimum number of highly reliable electromechanical components. Every automation application is different, so there may be special requirements for your particular application. Make sure all national, state, and local government requirements are followed for the proper installation and use of your equipment.

Plan for Safety

The best way to provide a safe operating environment is to make personnel and equipment safety part of the planning process. You should examine every aspect of the system to determine which areas are critical to operator or machine safety.

If you are not familiar with PLC system installation practices, or your company does not have established installation guidelines, you should obtain additional information from the following sources.

• NEMA — The National Electrical Manufacturers Association, located in Washington, D.C., publishes many different documents that discuss standards for industrial control systems. You can order these publications directly from NEMA. Some of these include:

ICS 1, General Standards for Industrial Control and Systems

ICS 3, Industrial Systems

ICS 6, Enclosures for Industrial Control Systems

• NEC — The National Electrical Code provides regulations concerning the installation and use of various types of electrical equipment. Copies of the NEC Handbook can often be obtained from your local electrical equipment distributor or your local library.

• Local and State Agencies — many local governments and state governments have additional requirements above and beyond those described in the NEC Handbook. Check with your local Electrical Inspector or Fire Marshall office for information.

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DL205 User Manual, 4th Edition, Rev. B

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Chapter 2: Installation, Wiring and Specifications

Output Module

Saw

Arbor

E STOP

Master

Relay

Emergency

Stop

Power On

Master Relay Contacts

To disconnect output

module power

Use E-Stop and Master Relay

Guard

Limit

Guard Limit Switch

Master

Relay

Contacts

Three Levels of Protection

The publications mentioned provide many ideas and requirements for system safety. At a minimum, you should follow these regulations. Also, you should use the following techniques, which provide three levels of system control.

• Emergency stop switch for disconnecting system power

• Mechanical disconnect for output module power

• Orderly system shutdown sequence in the PLC control program

Emergency Stops

It is recommended that emergency stop circuits be incorporated into the system for every machine controlled by a PLC. For maximum safety in a PLC system, these circuits must not be wired into the controller, but should be hardwired external to the PLC. The emergency stop switches should be easily accessed by the operator and are generally wired into a master control relay (MCR) or a safety control relay (SCR) that will remove power from the PLC I/O system in an emergency.

MCRs and SCRs provide a convenient means for removing power from the I/O system during an emergency situation. By de-energizing an MCR (or SCR) coil, power to the input (optional) and output devices is removed. This event occurs when any emergency stop switch opens. However, the PLC continues to receive power and operate even though all its inputs and outputs are disabled.

The MCR circuit could be extended by placing a PLC fault relay (closed during normal PLC operation) in series with any other emergency stop conditions. This would cause the MCR circuit to drop the PLC I/O power in case of a PLC failure (memory error, I/O communications error, etc.).

DL205 User Manual, 4th Edition, Rev. B

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Page 43

Chapter 2: Installation, Wiring and Specifications

Turn off

Saw

Jam

Detect

RST

Retract

Arm

Emergency Power Disconnect

A properly rated emergency power disconnect should be used to power the PLC controlled system as a means of removing the power from the entire control system. It may be necessary to install a capacitor across the disconnect to protect against a condition known as “outrush”. This condition occurs when the output Triacs are turned off by powering off the disconnect, thus causing the energy stored in the inductive loads to seek the shortest distance to ground, which is often through the Triacs.

After an emergency shutdown or any other type of power interruption, there may be requirements that must be met before the PLC control program can be restarted. For example, there may be specific register values that must be established (or maintained from the state prior to the shutdown) before operations can resume. In this case, you may want to use retentive memory locations, or include constants in the control program to insure a known starting point.

Orderly System Shutdown

Ideally, the first level of fault detection is the PLC control program, which can identify machine problems. Certain shutdown sequences should be performed. The types of problems are usually things such as jammed parts, etc. that do not pose a risk of personal injury or equipment damage.

2–4

WARNING: The control program must not be the only form of protection for any problems that may result in a risk of personal injury or equipment damage.

Class 1, Division 2, Approval

This equipment is suitable for use in Class 1, Division 2, Zone 2, groups A, B, C and D or non-hazardous locations only.

WARNING: Explosion Hazard! Substitution of components may impair suitability for Class 1, Division 2, Zone 2.

WARNING: Explosion Hazard - Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous.

WARNING: All DL205 products used with connector accessories must use R/C (ECBT2) mating plugs. All mating plugs must have suitable ratings for the devices.

DL205 User Manual, 4th Edition, Rev. B

Page 44

Mounting Guidelines

2.99”

(76mm)

3.54”

(90mm)

DIN Rail slot. Use rail conforming to DIN EN 50022.

2.95”

(75mm)

3.62”

(92mm)

12 or 16pt I/O

4 or 8pt . I/O

with D2–EM Expansion Unit

4.45”

(113mm)

32pt.

ZIPLink cable or

base exp. unit cable

5.85”

(148mm)

D2–DSCBL–1

on port 2

Mounting depths with:

Before installing the PLC system you will need to know the dimensions of the components considered. The diagrams on the following pages provide the component dimensions to use in defining your enclosure specifications. Remember to leave room for potential expansion.

NOTE: If you are using other components in your system, refer to the appropriate manual to determine how those units can affect mounting dimensions.

Chapter 2: Installation, Wiring and Specifications

Base Dimensions

The following information shows the proper mounting dimensions. The height dimension is the same for all bases. The depth varies depending on your choice of I/O module. The length varies as the number of slots increase. Make sure you have followed the installation guidelines for proper spacing.

3-slot 6.77” 172mm 6.41” 163mm 5.8” 148mm 7.24” 184mm 4-slot 7.99” 203mm 7.63” 194mm 7.04” 179mm 8.46” 215mm 6-slot 10.43” 265mm 10.07” 256mm 9.48” 241mm 10.90” 277mm 9-slot 14.09” 358mm 13.74” 349mm 13.14” 334mm 14.56” 370mm

Base

(Base Total Width) B (Mounting Hole) C (Component Width) D (Width with Exp. Unit)

Inches Millimeters Inches Millimeters Inches Millimeters Inches Millimeters

DL205 User Manual, 4th Edition, Rev. B

2–5

Page 45

Chapter 2: Installation, Wiring and Specifications

Airflow

Safety Guidelines

Earth Ground

Panel Ground

erminal

DL205 CPU Base

Power

Source

Temperature

Probe

Star Washers

Panel

Ground Braid

Copper Lugs

Panel or

Single Point

Ground

Star Washers

BUS Bar

Note: there is a minimum of 2” (50mm)

clearance between the panel door

or any devices mounted in the panel door

2”

50mm

min.

2”

50mm

min.

and the nearest DL205 component

2”

50mm

min.

2”

50mm

min.

Panel Mounting and Layout

It is important to design your panel properly to help ensure the DL205 products operate within their environmental and electrical limits. The system installation should comply with all appropriate electrical codes and standards. It is important the system also conforms to the operating standards for the application to insure proper performance. The diagrams below reference the items in the following list.

1. Mount the bases horizontally to provide proper ventilation.

2. If you place more than one base in a cabinet, there should be a minimum of 7.2” (183mm) between bases.

3. Provide a minimum clearance of 2” (50mm) between the base and all sides of the cabinet. There should also be at least 1.2” (30mm) of clearance between the base and any wiring ducts.

4. There must be a minimum of 2” (50mm) clearance between the panel door and the nearest DL205 component.

NOTE: The cabinet configuration below is not suitable for EU installations. Refer to Appendix I European Union Directives.

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DL205 User Manual, 4th Edition, Rev. B

Page 46

Chapter 2: Installation, Wiring and Specifications

5. The ground terminal on the DL205 base must be connected to a single point ground. Use copper stranded wire to achieve a low impedance. Copper eye lugs should be crimped and soldered to the ends of the stranded wire to ensure good surface contact. Remove anodized finishes and use copper lugs and star washers at termination points. A general rule is to achieve a 0.1 ohm of DC resistance between the DL205 base and the single point ground.

6. There must be a single point ground (i.e. copper bus bar) for all devices in the panel requiring an earth ground return. The single point of ground must be connected to the panel ground termination. The panel ground termination must be connected to earth ground. For this connection you should use #12 AWG stranded copper wire as a minimum. Minimum wire sizes, color coding, and general safety practices should comply with appropriate electrical codes and standards for your region. A good common ground reference (Earth ground) is essential for proper operation of the DL205. There are several methods of providing an adequate common ground reference, including:

a) Installing a ground rod as close to the panel as possible.

b) Connection to incoming power system ground.

7. Properly evaluate any installations where the ambient temperature may approach the lower or upper limits of the specifications. Place a temperature probe in the panel, close the door and operate the system until the ambient temperature has stabilized. If the ambient temperature is not within the operating specification for the DL205 system, measures such as installing a cooling/heating source must be taken to get the ambient temperature within the DL205 operating specifications.

8. Device mounting bolts and ground braid termination bolts should be #10 copper bolts or equivalent. Tapped holes instead of nut–bolt arrangements should be used whenever possible. To ensure good contact on termination areas impediments such as paint, coating or corrosion should be removed in the area of contact.

9. The DL205 system is designed to be powered by 110/220 VAC, 24 VDC, or 125 VDC normally available throughout an industrial environment. Electrical power in some areas where the PLCs are installed is not always stable and storms can cause power surges. Due to this, powerline filters are recommended for protecting the DL205 PLCs from power surges and EMI/RFI noise. The Automation Powerline Filter, for use with 120 VAC and 240 VAC, 1–5 Amps, is an excellent choice (can be located at www.automationdirect.com), however, you can use a filter of your choice. These units install easily between the power source and the PLC.

Enclosures

Your selection of a proper enclosure is important to ensure safe and proper operation of your DL205 system. Applications of DL205 systems vary and may require additional features. The minimum considerations for enclosures include:

• Conformance to electrical standards

• Protection from the elements in an industrial environment

• Common ground reference

• Maintenance of specified ambient temperature

• Access to equipment

• Security or restricted access

• Sufficient space for proper installation and maintenance of equipment

DL205 User Manual, 4th Edition, Rev. B

2–7

Page 47

Chapter 2: Installation, Wiring and Specifications

Environmental Specifications

Storage temperature

Ambient operating temperature* Ambient humidity** Vibration resistance

Shock resistance Noise immunity

Atmosphere

* Operating temperature for the Handheld Programmer and the DV-1000 is 32° to 122° F (0° to 50° C) Storage temperature

for the Handheld Programmer and the DV-1000 is - 4° to 158° F (- 20° to 70° C).

** Equipment will operate below 30% humidity. However, static electricity problems occur much more frequently at lower

humidity levels. Make sure you take adequate precautions when you touch the equipment. Consider using ground straps, anti-static floor coverings, etc., if you use the equipment in low humidity environments.

The following table lists the environmental specifications that generally apply to the DL205 system (CPU, Bases, I/O Modules). The ranges that vary for the Handheld Programmer are noted at the bottom of this chart. I/O module operation may fluctuate depending on the ambient temperature and your application. Please refer to the appropriate I/O module specifications for the temperature derating curves applying to specific modules.

Specification Rating

–4° F to 158° F (–20° C to 70° C)

32° F to 131° F (0° C to 55° C)

30% – 95% relative humidity (non–condensing)

MIL STD 810C, Method 514.2

MIL STD 810C, Method 516.2

NEMA (ICS3–304)

No corrosive gases

Power

The power source must be capable of supplying voltage and current complying with the base power supply specifications.

Specification AC Powered Bases 24 VDC Powered Bases 125 VDC Powered Bases

Part Numbers

Input Voltage Range

Maximum Inrush Current

Maximum Power Voltage Withstand (dielectric)

Insulation Resistance

Auxiliary 24 VDC Output

Fusing (internal to base power supply)

D2–03B–1, D2–04B–1, D2–06B–1 D2–09B–1

100–240 VAC (+10%/ –15%) 50/60 Hz

30A 10A 20A

80VA 25W 30W

1 minute @ 1500 VAC between primary, secondary, and field ground > 10 MΩ at 500 VDC

20–28 VDC, less than 1V p-p 300mA max.

Non–replaceable 2A @ 250V slow blow fuse

D2–03BDC1–1, D2–04BDC1–1, D2–06BDC1–1, D2–09BDC1–1

10.2 – 28.8VDC (24VDC) with less than 10% ripple

None

Non–replaceable 3.15A @ 250V slow blow fuse

D2–06BDC2–1, D2–09BDC2–1

104–240 VDC +10% –15%

20–28 VDC, less than 1V p-p 300mA max.

Non–replaceable 2A @ 250V slow blow fuse

2–8

DL205 User Manual, 4th Edition, Rev. B

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Chapter 2: Installation, Wiring and Specifications

Marine Use

American Bureau of Shipping (ABS) certification requires flame-retarding insulation as per 4-8-3/5.3.6(a). ABS will accept Navy low smoke cables, cable qualified to NEC “Plenum rated” (fire resistant level 4), or other similar flammability resistant rated cables. Use cable specifications for your system that meet a recognized flame retardant standard (i.e. UL, IEEE, etc.), including evidence of cable test certification (i.e. tests certificate, UL file number, etc.).

NOTE: Wiring needs to be “low smoke” per the above paragraph. Teflon coated wire is also recommended.

Agency Approvals

Some applications require agency approvals. Typical agency approvals which your application may require are:

• UL (Underwriters’ Laboratories, Inc.)

• CSA (Canadian Standards Association)

• FM (Factory Mutual Research Corporation)

• CUL (Canadian Underwriters’ Laboratories, Inc.)

24 VDC Power Bases

Follow these additional installation guidelines when installing D2-03BDC1-1, D2-04BDC11, D2-06BDC1-1 and D2-09BDC1-1 bases:

• Install these bases in compliance with the enclosure, mounting, spacing, and segregation

requirements of the ultimate application.

• These bases must be used within their marked ratings.

• These bases are intended to be installed within an enclosure rated at least IP54.

• Provesions should be made to prevent the rated voltage being exceeded by transient disturbances of

more than 40%.

DL205 User Manual, 4th Edition, Rev. B

2–9

Page 49

Chapter 2: Installation, Wiring and Specifications

Power Wiring

Connections

CPU Slot

I/O Slots

Mounting Tabs

Installing DL205 Bases

Choosing the Base Type

The DL205 system offers four different sizes of bases and three different power supply options.

The following diagram shows an example of a 6-slot base.

Mounting the Base

Your choice of base depends on three things:

• Number of I/O modules required

• Input power requirement (AC or DC power)

• Available power budget

All I/O configurations of the DL205 may use any of the base configurations. The bases are secured to the equipment panel or mounting location using four M4 screws in the corner tabs of the base. The full mounting dimensions are given in the previous section on Mounting Guidelines.

WARNING: To minimize the risk of electrical shock, personal injury, or equipment damage, always

disconnect the system power before installing or removing any system component.

2–10

DL205 User Manual, 4th Edition, Rev. B

Page 50

Chapter 2: Installation, Wiring and Specifications

35 mm

7.5mm

Retaining Clips

DIN Rail Dimensions

Using Mounting Rails

The DL205 bases can also be secured to the cabinet by using mounting rails. You should use rails that conform to DIN EN standard 50 022. Refer to our catalog for a complete line of DIN rail, DINnectors and DIN rail mounted apparatus. These rails are approximately 35mm high, with a depth of 7.5mm. If you mount the base on a rail, you should also consider using end brackets on each end of the rail. The end brackets help keep the base from sliding horizontally along the rail. This helps minimize the possibility of accidentally pulling the wiring loose.

If you examine the bottom of the base, you’ll notice small retaining clips. To secure the base to a DIN rail, place the base onto the rail and gently push up on the retaining clips. The clips lock the base onto the rail.

To remove the base, pull down on the retaining clips, lift up on the base slightly, and pull it away from the rail.

DL205 User Manual, 4th Edition, Rev. B

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Page 51

Chapter 2: Installation, Wiring and Specifications

Align module PC board to

slots in base and slide in

Push the retaining

clips in to secure the module

to the DL205 base

CPU must be positioned in

the first slot of the base

Installing Components in the Base

To insert components into the base: first slide the module retaining clips to the out position and align the PC board(s) of the module with the grooves on the top and bottom of the base. Push the module straight into the base until it is firmly seated in the backplane connector. Once the module is inserted into the base, push in the retaining clips to firmly secure the module to the base.

WARNING: Minimize the risk of electrical shock, personal injury, or equipment damage. Always

disconnect the system power before installing or removing any system component.

2–12

DL205 User Manual, 4th Edition, Rev. B

Page 52

Base Wiring Guidelines

125 VDC Base Terminal Strip12/24 VDC Base Terminal Strip

12 – 24 VDC

–

115 – 264 VDC

24 VDC OUT,

0.3A

–

110/220 VAC Base T erminal Strip

85 – 264 VAC

24 VDC OUT,

0.3A

Base Wiring

The diagrams show the terminal connections located on the power supply of the DL205 bases. The base terminals can accept up to 16 AWG. You may be able to use larger wiring depending on the type of wire used, but 16 AWG is the recommended size. Do not overtighten the connector screws; the recommended torque value is 7.81 ld-in (0.882 N•m).

Chapter 2: Installation, Wiring and Specifications

NOTE: You can connect either a 115 VAC or 220 VAC supply to the AC terminals. Special wiring or jumpers are not required as with some of the other DirectLOGIC. products.

WARNING: Once the power wiring is connected, install the plastic protective cover. When the cover is removed there is a risk of electrical shock if you accidentally touch the wiring or wiring terminals.

DL205 User Manual, 4th Edition, Rev. B

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Chapter 2: Installation, Wiring and Specifications

Safety Guidelines

Input Module

CPU

Comm.

Main

Power

Supply

Auxiliary +24VDC

Supply

To Programming

Device, Operator

Inputs Commons CommonsOutputs

+24VDC Out

PLC

DL205

Interface, Network

Output Module

Internal

Backplane

Supply for Output Circuit

Primary Side Secondary, or

Logic side

Field Side

Filter

Power Input

CPU

Input

Module

Main

Power

Supply

Inputs

Outputs

Power Input

Output Module

Primary Side Secondary, or

Logic side

Field Side

PLC

Programming Device, Operator Interface, or Network

Isolation Boundary

(backplane)

Filter

I/O Wiring Strategies

The DL205 PLC system is very flexible and will work in many different wiring configurations. By studying this section before actual installation, you can probably find the best wiring strategy for your application. This will help to lower system cost, wiring errors, and avoid safety problems.

PLC Isolation Boundaries

PLC circuitry is divided into three main regions separated by isolation boundaries, shown in the drawing below. Electrical isolation provides safety, so that a fault in one area does not damage another. A powerline filter will provide isolation between the power source and the power supply. A transformer in the power supply provides magnetic isolation between the primary and secondary sides. Opto-couplers provide optical isolation in Input and Output circuits. This isolates logic circuitry from the field side, where factory machinery connects. Note the discrete inputs are isolated from the discrete outputs, because each is isolated from the logic side. Isolation boundaries protect the operator interface (and the operator) from power input faults or field wiring faults. When wiring a PLC, it is extremely important to avoid making external connections that connect logic side circuits to any other.

In addition to the basic circuits covered above, AC-powered and 125VDC bases include an auxiliary +24VDC power supply with its own isolation boundary. Since the supply output is isolated from the other three circuits, it can power input and/or output circuits!

2–14

DL205 User Manual, 4th Edition, Rev. B

Page 54

Chapter 2: Installation, Wiring and Specifications

Input Module

Auxiliary +24VDC

Supply

Power Input

DL205 PLC

Output Module

Loads

AC Power or 125VDC Bases

–

Inputs Com. Outputs Com.

Input Module

Power Input

DL205 PLC

Output Module

Loads

DC Power

–

Inputs Com. Outputs Com.

Powering I/O Circuits with the Auxiliary Supply

In some cases, using the built-in auxiliary +24VDC supply can result in a cost savings for your control system. It can power combined loads up to 300mA. Be careful not to exceed the current rating of the supply. If you are the system designer for your application, you may be able to select and design in field devices which can use the +24VDC auxiliary supply.

All AC powered and 125VDC DL205 bases feature the internal auxiliary supply. If input devices AND output loads need +24VDC power, the auxiliary supply may be able to power both circuits as shown in the following diagram.

The 12/24VDC powered DL205 bases are designed for application environments in which low-voltage DC power is more readily available than AC. These include a wide range of battery–powered applications, such as remotely-located control, in vehicles, portable machines, etc. For this application type, all input devices and output loads typically use the same DC power source. Typical wiring for DC-powered applications is shown in the following diagram.

DL205 User Manual, 4th Edition, Rev. B

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Page 55

Input Module

Auxiliary

+24VDC

Supply

Power Input

DL205 PLC

Output Module

Loads

AC Power

–

Inputs Com. Outputs Com.

Input Module

Auxiliary

+24VDC

Supply

Power Input

DL205 PLC

Output Module

Loads

AC Power

–

Inputs Com. Outputs Com.

Load

Supply

Input Module

Power Input

DL205 PLC

Output Module

Loads

DC Power

–

Inputs Com. Outputs Com.

Load

Supply

Input Module

Auxiliary

+24VDC

Supply

Power Input

DL205 PLC

Output Module

Loads

AC Power

–

Inputs Com. Outputs Com.

Load

Supply

Input

Supply

Chapter 2: Installation, Wiring and Specifications

Powering I/O Circuits Using Separate Supplies

In most applications it will be necessary to power the input devices from one power source, and to power output loads from another source. Loads often require high-energy AC power, while input sensors use low-energy DC. If a machine operator is likely to come in close contact with input wiring, then safety reasons also require isolation from high-energy output circuits. It is most convenient if the loads can use the same power source as the PLC, and the input sensors can use the auxiliary supply, as shown to the left in the figure below.

If the loads cannot be powered from the PLC supply, then a separate supply must be used as shown to the right in the figure below.

2–16

Some applications will use the PLC external power source to also power the input circuit. This typically occurs on DC-powered PLCs, as shown in the drawing below to the left. The inputs share the PLC power source supply, while the outputs have their own separate supply. A worst-case scenario, from a cost and complexity viewpoint, is an application which requires separate power sources for the PLC, input devices, and output loads. The example wiring diagram below on the right shows how this can work, but also the auxiliary supply output is an unused resource. You will want to avoid this situation if possible.

DL205 User Manual, 4th Edition, Rev. B

Page 56

Chapter 2: Installation, Wiring and Specifications

–

Input

Sensing

PLC

Input

Common

(sinking)

–

Input

Sensing

Load

Sinking Input Sinking Output

Sourcing Input Sourcing Output

PLC

Input

Common

–

Output Switch

PLC

Output

Common

–

Input

Sensing

Load

PLC

Input

Common

–

Output Switch

PLC

Output

Common

Sinking / Sourcing Concepts

Before going further in the study of wiring strategies, you must have a solid understanding of “sinking” and “sourcing” concepts. Use of these terms occurs frequently in input or output circuit discussions. It is the goal of this section to make these concepts easy to understand, further ensuring your success in installation. First the following short definitions are provided, followed by practical applications.

Sinking = provides a path to supply ground (–)

Sourcing = provides a path to supply source (+)

First you will notice these are only associated with DC circuits and not AC, because of the reference to (+) and (–) polarities. Therefore, sinking and sourcing terminology only applies to DC input and output circuits. Input and output points that are sinking only or sourcing only can conduct current in only one direction. This means it is possible to connect the external supply and field device to the I/O point with current trying to flow in the wrong direction, and the circuit will not operate. However, you can successfully connect the supply and field device every time by understanding “sourcing” and “sinking”.

For example, the figure to the right depicts a “sinking” input. To properly connect the external supply, you will have to connect it so the input provides a path to ground (–). Start at the PLC input terminal, follow through the input sensing circuit, exit at the common terminal, and connect the supply (–) to the common terminal. By adding the switch, between the supply (+) and the input, the circuit has been completed . Current flows in the direction of the arrow when the switch is closed.

Apply the circuit principle above to the four possible combinations of input/output sinking/sourcing types as shown below. The I/O module specifications at the end of this chapter list the input or output type.

DL205 User Manual, 4th Edition, Rev. B

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Page 57

AC supply AC or DC supply

Input Switch

Output Load

DC supply

+–

–

I/O

Circuit

PLC

(I/O Point)

Return Path

Field

Device

Main Path

–

Input

Sensing

PLC

Input 4

Common

Input 3

Input 2

Input 1

20-28VDC 8mA CLASS 2

D2-16ND3-2

IN 24

D2–16ND3–2

VDC

Chapter 2: Installation, Wiring and Specifications

I/O “Common” Terminal Concepts

In order for a PLC I/O circuit to operate, current must enter at one terminal and exit at another. Therefore, at least two terminals are associated with every I/O point. In the figure to the right, the Input or Output terminal is the main path for the current. One additional terminal must provide the return path to the power supply.

2–18

If there was unlimited space and budget for I/O terminals, every I/O point could have two dedicated terminals as the figure above shows. However, providing this level of flexibility is not practical or even necessary for most applications. So, most Input or Output points on PLCs are in groups which share the return path (called commons). The figure to the right shows a group (or bank) of four input points which share a common return path. In this way, the four inputs require only five terminals instead of eight.

NOTE: In the circuit above, the current in the common path is 4 times any channel’s input current when all inputs are energized. This is especially important in output circuits, where heavier gauge wire is sometimes necessary on commons.

Most DL205 input and output modules group their I/O points into banks that share a common return path. The best indication of I/O common grouping is on the wiring label, such as the one shown to the right. There are two circuit banks with eight input points in each. The common terminal for each is labeled “CA” and “CB”, respectively.

In the wiring label example, the positive terminal of a DC supply connects to the common terminals. Some symbols you will see on the wiring labels, and their meanings are:

DL205 User Manual, 4th Edition, Rev. B

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Chapter 2: Installation, Wiring and Specifications

Field Device

+–

PLC DC Input

Output

Ground

Input

Common

Supply

(sinking)

(sourcing)

Field Device

PLC DC Input

Output (sourcing)

Ground

Input

Common

(sinking)

Field Device

Output

Ground

Input

Common

PLC DC Sinking Output

+DC pwr

–

(sourcing)

(sinking)

Power

10–30 VDC

Connecting DC I/O to “Solid State” Field Devices

In the previous section on Sourcing and Sinking concepts, the DC I/O circuits were explained to sometimes only allow current to flow one way. This is also true for many of the field devices which have solid-state (transistor) interfaces. In other words, field devices can also be sourcing or sinking. When connecting two devices in a series DC circuit, one must be

wired as sourcing and the other as sinking.

Solid State Input Sensors

Several DL205 DC input modules are flexible because they detect current flow in either direction, so they can be wired as either sourcing or sinking. In the following circuit, a field device has an open-collector NPN transistor output. It sinks current from the PLC input point, which sources current. The power supply can be the +24 auxiliary supply or another supply (+12 VDC or +24VDC), as long as the input specifications are met.

In the next circuit, a field device has an open-collector PNP transistor output. It sources current to the PLC input point, which sinks the current back to ground. Since the field device is sourcing current, no additional power supply is required.

Solid State Output Loads

Sometimes an application requires connecting a PLC output point to a solid state input on a device. This type of connection is usually made to carry a low-level control signal, not to send DC power to an actuator.

Several of the DL205 DC output modules are the sinking type. This means that each DC output provides a path to ground when it is energized. In the following circuit, the PLC output point sinks current to the output common when energized. It is connected to a sourcing input of a field device input.

DL205 User Manual, 4th Edition, Rev. B

2–19

Page 59

Field Device

Output

Ground

Input

Common

PLC DC Sourcing Output

+DC pwr

–

(sourcing)

(sinking)

Supply

input

Field Device

Output

Ground

Input

Common

PLC DC Output

+DC pwr

–

(sourcing)

(sinking)

ower

(sinking)

pull-up

Supply

input

pull-up

input

supply

– 0.7

–

input

input (turn–on)

input

pull-up

supply

pullup

Chapter 2: Installation, Wiring and Specifications

In the next example a PLC sinking DC output point is connected to the sinking input of a field device. This is a little tricky, because both the PLC output and field device input are sinking type. Since the circuit must have one sourcing and one sinking device, a sourcing capability needs to be added to the PLC output by using a pull-up resistor. In the circuit below, a R

is connected from the output to the DC output circuit power input.

pull-up

2–20

NOTE 1: DO NOT attempt to drive a heavy load (>25 mA) with this pull-up method NOTE 2: Using the pull-up resistor to implement a sourcing output has the effect of inverting the output

point logic. In other words, the field device input is energized when the PLC output is OFF, from a ladder logic point of view. Your ladder program must comprehend this and generate an inverted output. Or, you may choose to cancel the effect of the inversion elsewhere, such as in the field device.

It is important to choose the correct value of R the nominal input current to the field device (I is not known, it can be calculated as shown (a typical value is 15 mA). Then use I the voltage of the external supply to compute R watts), in order to size R

Of course, the easiest way to drive a sinking input field device as shown below is to use a DC sourcing output module. The Darlington NPN stage will have about 1.5 V ON-state saturation, but this is not a problem with low-current solid-state loads.

DL205 User Manual, 4th Edition, Rev. B

pull-up

properly.

. In order to do so, you need to know

pull-up

) when the input is energized. If this value

input

. Then calculate the power P

pull-up

input

pull-up

and

(in

Page 60

Chapter 2: Installation, Wiring and Specifications

Relay with Form A contacts

Relay with Form C contacts

Relay Output Guidelines

Several output modules in the DL205 I/O family feature relay outputs: D2–04TRS, D2–08TR, D2–12TR, D2–08CDR, F2–08TR and F2–08TRS. Relays are best for the following applications:

• Loads that require higher currents than the solid-state outputs can deliver

• Cost-sensitive applications

• Some output channels need isolation from other outputs (such as when some loads require different

voltages than other loads)

Some applications in which NOT to use relays:

• Loads that require currents under 10 mA

• Loads which must be switched at high speed or heavy duty cycle

Relay Outputs – Transient Suppression for Inductive Loads in a Control System

Relay outputs in the DL205 output modules are available in two contact arrangements, shown to the right. The Form A type, or SPST (single pole, single throw) type is normally open and is the simplest to use. The Form C type, or SPDT (single pole, double throw) type has a center contact which moves and a stationary contact on either side. This provides a normally closed contact and a normally open contact.

Some relay output module’s relays share common terminals, which connect to the wiper contact in each relay of the bank. Other relay modules have relays which are completely isolated from each other. In all cases, the module drives the relay coil when the corresponding output point is on.

The following pages are intended to give a quick overview of the negative effects of transient voltages on a control system and provide some simple advice on how to effectively minimize them. The need for transient suppression is often not apparent to the newcomers in the automation world. Many mysterious errors that can afflict an installation can be traced back to a lack of transient suppression.

What is a Transient Voltage and Why is it Bad?

Inductive loads (devices with a coil) generate transient voltages as they transition from being energized to being de-energized. If not suppressed, the transient can be many times greater than the voltage applied to the coil. These transient voltages can damage PLC outputs or other electronic devices connected to the circuit, and cause unreliable operation of other electronics in the general area. Transients must be managed with suppressors for long component life and reliable operation of the control system.

This example shows a simple circuit with a small 24V/125mA/3W relay. As you can see, when the switch is opened, thereby de-energizing the coil, the transient voltage generated across the switch contacts peaks at 140V.

DL205 User Manual, 4th Edition, Rev. B

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Page 61

Oscilloscope

Relay Coil (24V/125mA/3W, AutomationDirect part no. 750-2C-24D)

24 VDC

160

140

120

100

-20

Volts

Chapter 2: Installation, Wiring and Specifications

Example: Circuit with no Suppression

In the same circuit, replacing the relay with a larger 24V/290mA/7W relay will generate a transient voltage exceeding 800V (not shown). Transient voltages like this can cause many problems, including:

• Relay contacts driving the coil may experience arcing, which can pit the contacts and reduce the relay's lifespan.

• Solid state (transistor) outputs driving the coil can be damaged if the transient voltage exceeds the transistor's ratings. In extreme cases, complete failure of the output can occur the very first time a coil is de-energized.

• Input circuits, which might be connected to monitor the coil or the output driver, can also be damaged by the transient voltage.

A very destructive side-effect of the arcing across relay contacts is the electromagnetic interference (EMI) it can cause. This occurs because the arcing causes a current surge, which releases RF energy. The entire length of wire between the relay contacts, the coil, and the power source carries the current surge and becomes an antenna that radiates the RF energy. It will readily couple into parallel wiring and may disrupt the PLC and other electronics in the area. This EMI can make an otherwise stable control system behave unpredictably at times.

PLC's Integrated Transient Suppressors

Although the PLC's outputs typically have integrated suppressors to protect against transients, they are not capable of handling them all. It is usually necessary to have some additional transient suppression for an inductive load.

The next example uses the same 24V/125mA/3W relay used earlier. This example measures the PNP transistor output of a D0-06DD2 PLC, which incorporates an integrated Zener diode for transient suppression. Instead of the 140V peak in the first example, the transient voltage here is limited to about 40V by the Zener diode. While the PLC will probably tolerate repeated transients in this range for some time, the 40V is still beyond the module's peak output voltage rating of 30V.

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DL205 User Manual, 4th Edition, Rev. B

Page 62

Chapter 2: Installation, Wiring and Specifications

Relay Coil*

VDC

Oscilloscope

* For this example, a 24/290mA/7W

relay is used (AutomationDirect

part no. SC-E03G-24VDC)

-10

Volts

Relay Coil*

VDC

Oscilloscope

* For this example, a 24V/125mA/3W

relay is used (AutomationDirect

part no. 750-2C-24D)

-5

Volts

Example: Small Inductive Load with Only Integrated Suppression

The next example uses the same circuit as above, but with a larger 24V/290mA/7W relay, thereby creating a larger inductive load. As you can see, the transient voltage generated is much worse, peaking at over 50V. Driving an inductive load of this size without additional transient suppression is very likely to permanently damage the PLC output.

Example: Larger Inductive Load with Only Integrated Suppression

Additional transient suppression should be used in both these examples. If you are unable to measure the transients generated by the connected loads of your control system, using additional transient suppression on all inductive loads would be the safest practice.

DL205 User Manual, 4th Edition, Rev. B

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Page 63

Oscilloscope

24 VDC

DC Flyback Circuit

Sinking

Sourcing

-5

Volts

Chapter 2: Installation, Wiring and Specifications

Types of Additional Transient Protection

DC Coils:

The most effective protection against transients from a DC coil is a flyback diode. A flyback diode can reduce the transient to roughly 1V over the supply voltage, as shown in this example.

2–24

Many AutomationDirect socketed relays and motor starters have add-on flyback diodes that plug or screw into the base, such as the AD-ASMD-250 protection diode module and 784-4C-SKT-1 socket module shown below. If an add-on flyback diode is not available for your inductive load, an easy way to add one is to use AutomationDirect's DN-D10DR-A diode terminal block, a 600VDC power diode mounted in a slim DIN rail housing.

DL205 User Manual, 4th Edition, Rev. B

AD-ASMD-250

Protection Diode Module

784-4C-SKT-1

Relay Socket

DN-D10DR-A

Diode Terminal Block

Page 64

Chapter 2: Installation, Wiring and Specifications

24 VDC

DC MOV or TVS Diode Circuit

Sinking

Sourcing

VAC

AC MOV or Bi-Directional Diode Circuit

Two more common options for DC coils are Metal Oxide Varistors (MOV) or TVS diodes. These devices should be connected across the driver (PLC output) for best protection as shown below. The optimum voltage rating for the suppressor is the lowest rated voltage available that will NOT conduct at the supply voltage, while allowing a safe margin.

AutomationDirect's ZL-TSD8-24 transorb module is a good choice for 24VDC circuits. It is a bank of 8 uni-directional 30V TVS diodes. Since they are uni-directional, be sure to observe the polarity during installation. MOVs or bi-directional TVS diodes would install at the same location, but have no polarity concerns.

AC Coils:

Two options for AC coils are MOVs or bi-directional TVS diodes. These devices are most effective at protecting the driver from a transient voltage when connected across the driver (PLC output) but are also commonly connected across the coil. The optimum voltage rating for the suppressor is the lowest rated voltage available that will NOT conduct at the supply voltage, while allowing a safe margin.

AutomationDirect's ZL-TSD8-120 transorb module is a good choice for 120VAC circuits. It is a bank of eight bi-directional 180V TVS diodes.

NOTE: Manufacturers of devices with coils frequently offer MOV or TVS diode suppressors as an add-on option which mount conveniently across the coil. Before using them, carefully check the suppressor's ratings. Just because the suppressor is made specifically for that part does not mean it will reduce the transient voltages to an acceptable level.

For example, a MOV or TVS diode rated for use on 24-48 VDC coils would need to have a high enough voltage rating to NOT conduct at 48V. That suppressor might typically start conducting at roughly 60VDC. If it were mounted across a 24V coil, transients of roughly 84V (if sinking output) or -60V (if sourcing output) could reach the PLC output. Many semiconductor PLC outputs cannot tolerate such levels.

DL205 User Manual, 4th Edition, Rev. B

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Chapter 2: Installation, Wiring and Specifications

CPU Slot I/O Slots

Slot 0 Slot 1 Slot 2 Slot 3 Slot 4

I/O Modules Position, Wiring, and Specification

Slot Numbering

The DL205 bases each provide different numbers of slots for use with the I/O modules. You may notice the bases refer to 3-slot, 4-slot, etc. One of the slots is dedicated to the CPU, so you always have one less I/O slot. For example, you have five I/O slots with a 6-slot base. The I/O slots are numbered 0 – 4. The CPU slot always contains a PLC CPU or other CPU–slot controller and is not numbered.

Module Placement Restrictions

The following table lists the valid locations for all types of modules in a DL205 system:

Module/Unit Local CPU Base Local Expansion Base Remote I/O Base

CPUs DC Input Modules . AC Input Modules DC Output Modules AC Output Modules Relay Output Modules Analog Input and Output Modules

Local Expansion

Base Expansion Module Base Controller Module

Serial Remote I/O

Remote Master Remote Slave Unit Ethernet Remote Master

CPU Interface

Ethernet Base Controller WinPLC DeviceNet Profibus SDS

Specialty Modules

Counter Interface Counter I/O Data Communications Ethernet Communications BASIC CoProcessor Simulator Filler

* When used with H2-ERM(100) Ethernet Remote I/O system

CPU Slot Only

  

 



Slot 0 Only Slot 0 Only*

Slot 0 Only



  

CPU Slot Only

*

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DL205 User Manual, 4th Edition, Rev. B

Page 66

Chapter 2: Installation, Wiring and Specifications

Wire tray area

Status indicators

erminal Cover

(installed)

behind terminal cover

erminal

Module Type

Discrete/Analog Output Discrete/Analog Input Other

Color Code

Red Blue White

Color Bar

Special Placement Considerations for Analog Modules

In most cases, the analog modules can be placed in any slot. However, the placement can also depend on the type of CPU you are using and the other types of modules installed to the left of the analog modules. If you’re using a DL230 CPU (or a DL240 CPU with firmware earlier than V1.4) you should check the DL205 Analog I/O Manual for any possible placement restrictions related to your particular module. You can order the DL205 Analog I/O Manual by ordering part number D2–ANLG–M.

Discrete Input Module Status Indicators

The discrete modules provide LED status indicators to show the status of the input points.

Color Coding of I/O Modules

The DL205 family of I/O modules have a color coding scheme to help you quickly identify if a module is either an input module, output module, or a specialty module. This is done through a color bar indicator located on the front of each module. The color scheme is listed below:

DL205 User Manual, 4th Edition, Rev. B

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Chapter 2: Installation, Wiring and Specifications

Wiring the Different Module Connectors

There are two types of module connectors for the DL205 I/O. Some modules have normal screw terminal connectors. Other modules have connectors with recessed screws. The recessed screws help minimize the risk of someone accidentally touching active wiring.

Both types of connectors can be easily removed. If you examine the connectors closely, you’ll notice there are squeeze tabs on the top and bottom. To remove the terminal block, press the squeeze tabs and pull the terminal block away from the module.

We also have DIN rail mounted terminal blocks, DINnectors (refer to our catalog for a complete listing of all available products). ZIPLinks come with special pre–assembled cables with the I/O connectors installed and wired.

WARNING: For some modules, field device power may still be present on the terminal block even though the PLC system is turned off. To minimize the risk of electrical shock, check all field device power before you remove the connector.

2–28

DL205 User Manual, 4th Edition, Rev. B

Page 68

Chapter 2: Installation, Wiring and Specifications

Safety Guidelines

DINnector External Fuses

(DIN rail mounted Fuses)

I/O Wiring Checklist

Use the following guidelines when wiring the I/O modules in your system.

1. There is a limit to the size of wire the modules can accept. The table below lists the suggested AWG for each module type. When making terminal connections, follow the suggested torque values.

Module type Suggested AWG Range Suggested Torque

4 point 16* – 24 AWG 7.81 lb-inch (0.882 N•m) 8 point 16* – 24 AWG 7.81 lb-inch (0.882 N•m) 12 point 16* – 24 AWG 2.65 lb-in (0.3 N•m) 16 point 16* – 24 AWG 2.65 lb-in (0.3 N•m)

*NOTE: 16 AWG Type TFFN or Type MTW is recommended. Other types of 16 AWG may be acceptable, but it really depends on the thickness and stiffness of the wire insulation. If the insulation is too thick or

stiff and a majority of the module’s I/O points are used, then the plastic terminal cover may not close properly or the connector may pull away from the module. This applies especially for high temperature thermoplastics such as THHN.

2. Always use a continuous length of wire, do not combine wires to attain a needed length.

3. Use the shortest possible wire length.

4. Use wire trays for routing where possible.

5. Avoid running wires near high energy wiring. Also, avoid running input wiring close to output wiring where possible.

6. To minimize voltage drops when wires must run a long distance , consider using multiple wires for the return line.

7. Avoid running DC wiring in close proximity to AC wiring where possible.

8. Avoid creating sharp bends in the wires.

9. To reduce the risk of having a module with a blown fuse, we suggest you add external fuses to your I/O wiring. A fast blow fuse, with a lower current rating than the I/O module fuse can be added to each common, or a fuse with a rating of slightly less than the maximum current per output point can be added to each output. Refer to our catalog for a complete line of DINnectors, DIN rail mounted fuse blocks.

NOTE: For modules which have soldered or non-replaceable fuses, we recommend you return your module to us and let us replace your blown fuse(s) since disassembling the module will void your warranty.

DL205 User Manual, 4th Edition, Rev. B

2–29

Page 69

Chapter 2: Installation, Wiring and Specifications

Optica l

COM

Isolator

INP UT

12--24VDC

V+

To LE D

Internal module circuitry

COM

12--24VDC

Internally connected

10 20 30 40 50 55

Ambient Tempera ture (°C/°F )

50 68 86 104 122 131C°F°

Derating Chart

Points

10.2--26.4VDC 4--12mA

D2--08 ND3

IN 12--24

D2--08ND3

VDC

0 1 2 3

4 5 6 7

Sink

Source

Sink

Source

20--28VDC 8mA

IN 24

D2--16ND3 --2

VDC

0 1 2 3

4 5 6 7

CLASS2

Optica l

COM

Isolator

Derating Chart

INP UT

24 VDC

V+

To LE D

Internal module circuitry

Points

0 10 20 30 40 50 55

Ambient Tempera ture (°C/°F )

32 50 68 86 104 122 131C°F°

Sink

Source

24 VDC

Sink

Source

Sink

Source

24 VDC

D2-08ND3, DC Input

D2-08ND3 DC Input

(sink/source)

Inputs per Module Commons per Module Input Voltage Range Peak Voltage ON Voltage Level OFF Voltage Level AC Frequency Input Impedance

Input Current

Minimum ON Current Maximum OFF Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

8 1 (2 I/O terminal points)

0.2-26.4 VDC

26.4 VDC

9.5 VDC minimum

3.5 VDC maximum N/A

2.7 k

4.0 mA @ 12 VDC

8.5 mA @ 24 VDC

3.5 mA

1.5 mA 50 mA 1 to 8 ms 1 to 8 ms Removable, D2-8IOCON Logic side

2.3 oz. (65 g)

D2-16ND3-2, DC Input

D2-16ND3-2 DC Input

6 (sink/source)

Inputs per Module

Commons per Module

Input Voltage Range Peak Voltage ON Voltage Level OFF Voltage Level AC Frequency Input Impedance Input Current Minimum ON Current Maximum OFF Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

isolated (8 I/O terminal

2 points/com)

20-28 VDC 30 VDC (10 mA)

9 VDC minimum

1 7VDC maximum N/A

3.9 k 6 mA @ 24 VDC

3.5 mA

1.5 mA 100 mA 3 to 9 ms 3 to 9 ms Removable, D2-16IOCON Logic side

2.3 oz. (65 g)

2–30

DL205 User Manual, 4th Edition, Rev. B

Page 70

Optica l

COM

Isolator

INP UT

24 VDC

V+

ToLogic

Interna l module circuitry

IN 24

D2--32ND3

VDC

ACT

22--26VDC 4--6mA CLASS 2

A0 A1 A2 A3

A4 A5 A6 A7

C0 C1 C2 C3

C4 C5 C6 C7

B0 B1 B2 B3

B4 B5

D0 D1 D2 D3

D4 D5 D6 D7

CI CI

CII

CIII

CIV

CIII

CIV

COMI

COMII

COM III

COMIV

Points

10 20 30 40 50 55

Ambient Temperature (°C/°F )

50 68 86 104 122 131C°F°

Derating Chart

24VDC

Sink

Source

Sink

Source

Sink

Source

Sink

Source

Sink

Source

Chapter 2: Installation, Wiring and Specifications

D2–32ND3, DC Input

D2-32ND3 DC Input

2 (sink/source)

Inputs per Module Commons per Module Input Voltage Range Peak Voltage ON Voltage Level OFF Voltage Level AC Frequency Input Impedance Input Current Minimum ON Current Maximum OFF Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (not included) Status Indicator Weight

Connector sold separately. See Terminal Blocks and Wiring for wiring options.

3 4 isolated (8 I/O terminal points / com) 20-28 VDC 30 VDC

9 VDC minimum

1 7 VDC maximum N/A

4.8 k

8.0 mA @ 24 VDC

3.5 mA

1.5 mA 25 mA 3 to 9 ms 3 to 9 ms Removable 40-pin Connector Module Activity LED

2.1 oz. (60 g)

DL205 User Manual, 4th Edition, Rev. B

2–31

Page 71

Chapter 2: Installation, Wiring and Specifications

Sink

Source

5-15VDC

Sink

Source

5-15VDC

Sink

Source

5-15VDC

Sink

Source

5-15VDC



  



D2–32ND3–2, DC Input

D2-32ND3-2 DC Input

Inputs per Module Commons per Module Input Voltage Range Peak Voltage ON Voltage Level OFF Voltage Level AC Frequency Input Impedance

Input Current

Maximum Input Current Minimum ON Current Maximum OFF Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (not included) Status Indicator Weight

Connector sold separately.

See Terminal Blocks and Wiring for wiring options.

32 (Sink/Source) 4 4 16 VDC 4 VDC minimum 2 VDC maximum N/A

1.0 k @ 5-15 VDC 4 mA @ 5 VDC

11 mA @ 12 VDC 14 mA @ 15 VDC

16 mA @ 15.6 VDC 3 mA

0.5 mA 25 mA 3 to 9 ms 3 to 9 ms Removable 40-pin connector Module activity LED

2.1 oz (60 g)

isolated (8 I/O terminal points / com) .50 to 15.6 VDC min. to max.

2–32

DL205 User Manual, 4th Edition, Rev. B

Page 72

Chapter 2: Installation, Wiring and Specifications

Optica l

COM

Isolator

INP UT

110 VAC

V+

To LE D

Internal module circuitry

COM

Internally

connected

110 VA C

10 20 30 40 50 55

Ambient Tempe rature (˚C/˚F )

50 68 86 104 122 131

C˚

F˚

Points

80-132VAC 10-20mA

D2--08 NA-1

IN 110

D 2 -- 0 8 N A -- 1

VAC

0 1 2 3

4 5 6 7

50/60Hz

Line

Derating C hart

D2-08NA-1, AC Input

Inputs per Module Commons per Module Input Voltage Range Peak Voltage ON Voltage Level OFF Voltage Level AC Frequency Input Impedance

Input Current

Minimum ON Current Maximum OFF Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

D2-08NA-1 AC Input

(2 I/O terminal points)

1 80-132 VAC 132 VAC

5 VAC minimum

7 20 VAC maximum 47-63 Hz 12 k @ 60 Hz 13 mA @ 100 VAC, 60 Hz

11 mA @ 100 VAC, 50 Hz 5 mA 2 mA 50 mA 5 to 30 ms 10 to 50 ms Removable; D2-8IOCON Logic side

2.5 oz. (70 g)

DL205 User Manual, 4th Edition, Rev. B

2–33

Page 73

Chapter 2: Installation, Wiring and Specifications

Optica l

COM

Isolator

INP UT

220VAC

V+

To LE D

Interna l module circuitry

COM

Internally connected

220VAC

10 20 30 40 50 55

Ambient Tempe rature ( ˚C/˚F)

50 68 86 104 122 131

C˚

F˚

Points

Derating Chart

D2-08NA-2, AC Input

D2-08NA-2 AC Input

Inputs per Module Commons per Module

Input Voltage Range Peak Voltage ON Voltage Level OFF Voltage Level AC Frequency Input Impedance

Input Current

Minimum ON Current Maximum OFF Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

1 (2 I/O terminal points) 170-265 VAC 265 VAC 150 VAC minimum 40 VAC maximum 47-63 Hz 18 k @ 60 Hz 9 mA @ 220 VAC, 50 Hz

11 mA @ 265 VAC, 50 Hz 10 mA @ 220 VAC, 60 Hz 12 mA @ 265 VAC, 60 Hz

10 mA 2 mA 100 mA 5 to 30 ms 10 to 50 ms Removable; D2-8IOCON Logic side

2.5 oz. (70 g)

Operating Temperature Storage Temperature Humidity Atmosphere Vibration Shock Insulation Withstand Voltage Insulation Resistance

Noise Immunity

RFI

2ºF to 131ºF (0º to 55ºC)

-4ºF to 158ºF (-20ºC to 70ºC) 5% to 95% (non-condensing)

o corrosive gases permitted

IL STD 810C 514.2

M MIL STD 810C 516.2 1,500 VAC 1 minute (COM-GND) 10M  @ 500 VDC NEMA 1,500V 1 minute

SANKI 1,000V 1 minute 150 MHz, 430 MHz

2–34

DL205 User Manual, 4th Edition, Rev. B

Page 74

Chapter 2: Installation, Wiring and Specifications

0 10 20 30 40 50 55

Ambient Tempe rature ( ˚C/˚F )

32 50 68 86 104 122 131

C˚

F˚

Optica l Isolator

INP UT

110 VAC

V+

To LE D

Internal module c ircuitry

COM

Points

110 VAC

80--132VAC 10--20mA

D2--16 NA

IN 11 0

D2--16NA

VAC

0 1 2 3

4 5 6 7

50/60Hz

Derating C hart

IN S IM

F2--08SIM

0 1 2 3

4 5 6 7

D2-16NA, AC Input

Inputs per Module Commons per Module Input Voltage Range Peak Voltage ON Voltage Level OFF Voltage Level AC Frequency Input Impedance

Input Current

Minimum ON Current Maximum OFF Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

D2-16NA AC Input

(isolated)

2 80-132 VAC

32 VAC

1 70 VAC minimum 20 VAC maximum 47-63 Hz 12 k @ 60 Hz 11 mA @ 100 VAC, 50 Hz

13 mA @ 100 VAC, 60 Hz 15 mA @ 132 VAC, 60 Hz

5 mA 2 mA 100 mA 5 to 30 ms 10 to 50 ms Removable; D2-16IOCON Logic side

2.4 oz. (68g)

F2-08SIM, Input Simulator

F2-08SIM Input Simulator

Inputs per Module Base Power Required 5VDC Terminal Type Status Indicator Weight

8 50 mA None Switch side

2.65 oz. (75 g)

DL205 User Manual, 4th Edition, Rev. B

2–35

Page 75

Chapter 2: Installation, Wiring and Specifications

10 20 30 40 50 55

Ambient Tempe rature ( ˚C/˚F)

32 50 68 86 104 122 131

C˚

F˚

Points

2A/Pt.

3A/Pt.

4A/Pt.

24V

24VDC

Internally connected

12- -24VDC

+24V

10.2--26.4VDC 50mA--4A

D2--04 TD1

OU T 12--24

D2--04T D1

VDC

0 1 2 3

Common

12- -24

+--

24VDC

VDC

To LE D

Optica l

Isolator

Output

Othe r

Circuits

Reg

Inductive Load

0.1A 1400 600

0.5A 300 120

1.0A 140 60

1.5A 90 35

2.0A 70 --

Load

8000

1600

100ms

800

540

3.0A

400

270 -- --

40ms7msCurrent

Duration of output in ON state

4.0A 200

-- --

Maximum Number of Switching Cycles pe r Minute

6.3A

Derating C hart

D2-04TD1, DC Output

Outputs per Module Output Points Consumed Commons per Module Output Type Operating Voltage Peak Voltage ON Voltage Drop AC Frequency Max Load Current

(resistive) Max Leakage Current Max Inrush Current Minimum Load Current

2–36

D2-04TD1 DC Output

4 (current sinking) 8 points (only first 4 pts. used) 1 (4 I/O terminal points) NMOS FET (open drain)

10.2-26.4 VDC 40 VDC

0.72 VDC maximum N/A 4A/point

8A/common

0.1 mA @ 40 VDC 6A for 100 ms, 15A for 10 ms 50 mA

DL205 User Manual, 4th Edition, Rev. B

External DC Required Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

Fuses

At 40 mS duration, loads of 3.0A or greater cannot be used.

At 100 mS duration, loads of 2.0A or greater cannot be used.

Find the load current you expect to use and the duration that the output is ON. The number at the intersection of the row and column represents the switching cycles per minute. For example, a 1A inductive load that is on for 100 ms can be switched on and off a maximum of 60 times per minute. To convert this to duty cycle percentage use: (duration x cycles)/60. In this example, (60 x .1)/60 = .1, or 10% duty cycle.

24 VDC @ 20 mA max. 60 mA 1 ms 1 ms Removable; D2-8IOCON Logic side

2.8 oz. (80 g) 4 (1 per point)

(6.3 A slow blow, non-replaceable)

Page 76

Chapter 2: Installation, Wiring and Specifications

Optica l

Isolator

COM

OUTP UT

12--24VDC

Internal module circuitry

12--24VDC Internally

connected

10 20 30 40 50 55

Ambient Tempera ture (˚C/˚F)

32 50 68 86 104 122 131

C˚

F˚

Points

10.2--26.4VDC

0.2mA-0.3A

D2--08T D1

OUT 12 -- 24

D2-- 08TD1

VDC

0 1 2 3

4 5 6 7

Derating Chart



D2–08TD1, DC Output

D2-08TD1 DC Output

Outputs per Module Commons per Module Output Type Operating Voltage Peak Voltage ON Voltage Drop AC Frequency Minimum Load Current Max Load Current Max Leakage Current Max Inrush Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

Fuses

8 (current sinking) 1 (2 I/O terminal points) NPN open collector

10.2-26.4 VDC 40 VDC

1.5 VDC maximum N/A

0.5 mA

0.3A/point; 2.4A/common

0.1 mA @ 40 VDC 1A for 10 ms 100 mA 1 ms 1 ms Removable; D2-8IOCON Logic side

2.3 oz. (65g) 1 per common

5A fast blow, non-replaceable

D2–08TD2, DC Output

D2-08TD2 DC Output

Outputs per Module Commons per Module Output Type Operating Voltage Output Voltage Peak Voltage ON Voltage Drop AC Frequency Minimum Load Current Max Load Current Max Leakage Current Max Inrush Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

Fuses

8 (current sourcing) 1 PNP open collector 12 to 24 VDC

10.8 to 26.4 VDC 40 VDC

1.5 VDC N/A N/A

0.3A per point; 2.4A per common

1.0 mA @ 40 VDC 1A for 10 ms 100 mA 1 ms 1 ms Removable; D2-8IOCON Logic side

2.1 oz. (60g) 1 per common

5A fast blow, non-replaceable

DL205 User Manual, 4th Edition, Rev. B

2–37

Page 77

Chapter 2: Installation, Wiring and Specifications

Optica l Isolator

COM

OUTP UT

12--24

Internal module circuitry

24VDC

0 10 20 30 40 50 55

Ambient Tempera ture (˚C/˚F)

32 50 68 86 104 122 131

C˚

F˚

Points

COM

Internally

connected

12--24VDC

24VDC

10.2--26.4 VDC0. 1A

OU T 12--24

D2--16T D1 --2

VDC

0 1 2 3

4 5 6 7

CLASS2

VDC

* Ca n also be u sed wit h 5VDC su pply

DeratingChart

D2–16TD1–2, DC Output

Outputs per Module

Commons per Module Output Type External DC required

Operating Voltage Peak Voltage

ON Voltage Drop AC Frequency Minimum Load Current

Max Load Current

Max Leakage Current

Max Inrush Current Base Power Required 5VDC

OFF to ON Response ON to OFF Response Terminal Type (included)

Status Indicator Weight

Fuses

D2-16TD1-2 DC Output

16 (current sinking)

(2 I/O terminal points)

1 NPN open collector 24 VDC ±4V @ 80 mA max

10.2-26.4 VDC 30 VDC

0.5 VDC maximum N/A

0.2 mA

0.1A/point

1.6A/common

0.1 mA @ 30 VDC 150 mA for 10 ms 200 mA

0.5 ms

0.5 ms Removable; D2-16IOCON Logic side

2.3 oz. (65g)

None

D2–16TD2–2, DC Output

D2-16TD2-2 DC Output

Outputs per Module Commons per Module Output Type Operating Voltage Peak Voltage ON Voltage Drop AC Frequency Minimum Load Current

Max Load Current

Max Leakage Current Max Inrush Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight Fuses

16 (current sourcing) 2 NPN open collector

10.2-26.4 VDC 30 VDC

1.0 VDC maximum N/A

0.2 mA

0.1A/point

1.6A/module

0.1 mA @ 30 VDC 150 mA for 10 ms 200 mA

0.5 ms

0.5 ms Removable; D2-16IOCON Logic side

2.8 oz. (80g) None

2–38

DL205 User Manual, 4th Edition, Rev. B

Page 78

Chapter 2: Installation, Wiring and Specifications

Slot 0 Slot 1 Slot 2 Slot 3 Slot 4

F2–16TD1(2)P, DC Output With Fault Protection

NOTE: Not supported in D2-230, D2-240 and D2-250 CPUs.

These modules detect the following fault status and turn the related X bit(s) on.

1. Missing external 24VDC for the module

2. Open load

3. Over temperature (the output is shut down)

4. Over load current (the output is shut down)

Fault Status X bit Fault Status Indication

Missing external 24VDC All 16 X bits are on. Open load

Over temperature Over load current

When these modules are installed, 16 X bits are automatically assigned as the fault status indicator. Each X bit indicates the fault status of each output.

In this example, X10-X27 are assigned as the fault status indicator.

X10: Fault status indicator for Y0 X11: Fault status indicator for Y1

Only the X bit assigned to the faulted output is on

Example

D2-250-1 or D2-260

D2-08ND3

F2-16TD1P or F2-16TD2P

X26: Fault status indicator for Y16 X27: Fault status indicator for Y17

The fault status indicators (X bits) can be reset by performing the indicated operations in the following table:

Fault Status Operation

Missing external 24VDC Apply external 24VDC Open load

Over temperature Over load current

NOTE 1: Open load detection can be disabled by removing the jumper switch J6 on the module PC board.

Connect the load.

Turn the output (Y bit) off or power cycle the PLC

Continued on next two pages.

X0 - X7

Jumper Switch J6

PC Board

DL205 User Manual, 4th Edition, Rev. B

X10 - X27 Y0 - Y17

2–39

Page 79

Chapter 2: Installation, Wiring and Specifications

Derating Chart

24VDC

Ambient Temperature (°C/°F)

Points

24V

Internally

connected

12–24VDC

10.2-26.4 VDC 0.25A CLASS2

OUT 12-24

F2–16TD1P

VDC

0 1 2 3

4 5 6 7

24V

When the A/B switch is in the A position, the LEDs display the output status of the module’s first 8 output points. Positon B displays the output status of the module’s second group of 8 output points.

10 20 30 40 50 55°C

131°F

32 50 68 86 104 122

Optical

Isolator

OUTPUT

12–24

Internal module circuitry

24V

24VDC

VDC

F2–16TD1P, DC Output With Fault Protection

2–40

NOTE: Not supported in D2-230, D2-240 and D2-250 CPUs.

NOTE: Supporting Firmware: D2-250-1 must be V4.80 or later D2-260 must be V2.60 or later

NOTE: This module does not currently support Think & Do 8.0. It does not support Think & Do Live! or Studio.

DL205 User Manual, 4th Edition, Rev. B

F2-16TD1P DC Output with Fault Protection

Inputs per module Outputs per module Commons per module Output type Operating voltage Peak voltage AC frequency ON voltage drop Overcurrent trip

Maximum load current

Maximum OFF current

Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses External DC required External DC overvoltage

shutdown

16 (status indication) 16 (current sinking) 1 (2 I/O terminal points) NMOS FET (open drain)

10.2 -26.4 VDC, external 40 VDC N/A

0.7 V (output current 0.5 A)

0.6 A min., 1.2 A max.

0.25 A continuous, 0.5 A peak

Jumper J6 installed: 200 A; J6 removed: 30 A

70 mA

0.5 ms

0.5 ms Removable (D2-16IOCON) Logic Side

2.0 oz. (25g) None 24 VDC /10% @ 50 mA 27 V, outputs are restored

when voltage is within limits

Page 80

Chapter 2: Installation, Wiring and Specifications

Derating Chart

24VDC

Ambient Temperature (°C/°F)

Points

24V

10.2-26.4 VDC 0.25A CLASS2

OUT 12-24

F2–16TD2P

VDC

0 1 2 3

4 5 6 7

24V

10 20 30 40 50 55°C

131°F

32 50 68 86 104 122

12–24VDC

24V

+–

24VDC

OUTPUT

Reg

12–24VDC

Optical

Isolator

F2–16TD2P, DC Output with Fault Protection

NOTE: Not supported in D2-230, D2-240 and D2-250 CPUs.

NOTE: Supporting Firmware: D2-250-1 must be V4.80 or later D2-260 must be V2.60 or later

NOTE: This module does not currently support Think & Do 8.0. It does not support Think & Do Live! or Studio.

F2-16TD2P DC Output with Fault Protection

Inputs per module Outputs per module Commons per module Output type Operating voltage Peak voltage AC frequency ON voltage drop Overcurrent trip

Maximum load current

Maximum OFF current

Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses External DC required External DC overvoltage

shutdown

16 (status indication) 16 (current sourcing) 1 NMOS FET (open source)

10.2 -26.4 VDC, external 40 VDC N/A

0.7 V (output current 0.5 A)

0.6 A min., 1.2A max.

0.25 A continuous, 0.5 A peak

Jumper J6 installed: 200 A; J6 removed: 30 A

70 mA

0.5 ms

0.5 ms Removable (D2-16IOCON) Logic Side

2.0 oz. (25g) None 24 VDC /10% @ 50 mA 27 V, outputs are restored

when voltage is within limits

DL205 User Manual, 4th Edition, Rev. B

2–41

Page 81

Chapter 2: Installation, Wiring and Specifications

D2–32TD1, DC Output

Outputs per Module Commons per Module

Output Type Operating Voltage Peak Voltage

ON Voltage Drop Minimum Load Current

Max Load Current Max Leakage Current Max Inrush Current

Base Power Required 5VDC OFF to ON Response

ON to OFF Response Terminal Type (not included)

Status Indicator

Weight

Fuses

External DC Power Required

Connector sold separately.

See Terminal Blocks and Wiring for wiring options.

D2-32TD1 DC Output

32 (current sinking) 4 (8 I/O terminal points) NPN open collector 12-24 VDC 30 VDC

0.5 VDC maximum

0.2 mA

0.1A/point; 3.2A per module

0.1 mA @ 30 VDC 150 mA for 10 ms 350 mA

0.5 ms

0.5 ms removable 40-pin connector Module activity (no I/O status

indicators)

2.1 oz. (60g) None 20-28 VDC max. 120 mA (all

points on)

D2–32TD2, DC Output

D2-32TD2 DC Output

Outputs per Module Commons per Module Output Type Operating Voltage Peak Voltage ON Voltage Drop Minimum Load Current Max Load Current Max Leakage Current Max Inrush Current Base Power Required 5VDC OFF to ON Response

ON to OFF Response Terminal Type (not included)

Status Indicator

Weight Fuses

Connector sold separately.

See Terminal Blocks and Wiring for wiring options.

32 (current sourcing) 4 (8 I/O terminal points) Transistor 12 to 24 VDC 30 VDC

0.5 VDC @ 0.1 A

0.2 mA

0.1A/point; 0.8A/common

0.1 mA @ 30 VDC 150 mA @ 10 ms 350 mA

0.5 ms

0.5 ms Removable 40-pin connector Module activity (no I/O status

indicators)

2.1 oz (60g) None

2–42

DL205 User Manual, 4th Edition, Rev. B

Page 82

Chapter 2: Installation, Wiring and Specifications

F2–08TA, AC Output D2–08TA, AC Output

F2-08TA AC Output

Outputs per Module Commons per Module Output Type Operating Voltage Peak Voltage ON Voltage Drop AC Frequency Minimum Load Current

Max Load Current

Max Leakage Current Peak One Cycle Surge

Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight Fuses

8 2 (Isolated) SSR (Triac with zero crossover) 24-140 VAC 140 VAC

1.6 V(rms) @ 1.5A 47 to 63 Hz 50 mA

1.5A / pt @ 30ºC

1.0A / pt @ 60ºC

4.0A / common; 8.0A / module @ 60ºC

0.7 mA(rms)

15A

250 mA

0.5 ms - 1/2 cycle

0.5 ms - 1/2 cycle Removable; D2-8IOCON Logic side

3.5 oz. None

D2-08TA AC Output

Outputs per Module Commons per Module Output Type Operating Voltage Peak Voltage

ON Voltage Drop

AC Frequency Minimum Load Current Max Load Current

Max Leakage Current

Max Inrush Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

Fuses

8 1 (2 I/O terminal points)

SR (Triac)

5-264 VAC

1 264 VAC < 1.5 VAC (>0.1A)

< 3.0 VAC (<0.1A) 47 to 63 Hz 10 mA

0.5A/point; 4A/common 4 mA (264 VAC, 60 Hz)

1.2 mA (100 VAC, 60 Hz)

0.9 mA (100 VAC, 50 Hz) 10A for 10 ms 250 mA 1 ms 1 ms + 1/2 cycle Removable; D2-8IOCON Logic side

2.8 oz. (80g) 1 per common, 6.3A slow blow,

non-replaceable

DL205 User Manual, 4th Edition, Rev. B

2–43

Page 83

Chapter 2: Installation, Wiring and Specifications

Addres ses Use d

Yes Yes Yes Yes Yes

Points

Yn+0 Yn+1 Yn+2 Yn+3 Yn+4 Yn+5 Yes

Us e d?

NoYn+6

Yn+7 No

n is the starting addr ess

Yes Yes Yes Yes Yes

Points

Yn+10 Yn+11 Yn+12 Yn+13 Yn+14 Yn+15 Yes

Us e d?

NoYn+16

Yn+17 No

Optica l

COM

Isolator

OUTP UT

To LE D

Interna l module circuitry

3.15A

15--132

Points

VAC

250mA / Pt.

300mA / Pt.

15--132 VAC

0 10 20 30 40 50 55

Ambient Tempe rature ( ˚C/˚F)

32 50 68 86 104 122 131

C˚

F˚

15--132VAC 10mA--0.3A

D2--12TA

O UT 18--110

D2--12TA

VAC

0 1 2 3

4 5

50/60 Hz

Derating Chart

D2–12TA, AC Output

Outputs per Module Outputs Points Consumed

Commons per Module Output Type

Operating Voltage Peak Voltage

ON Voltage Drop

AC Frequency

Minimum Load Current Max Load Current

D2-12TA AC Output

6 (four unused, see chart below)

1 2 (isolated) SSR (Triac) 15-132 VAC 132 VAC < 1.5VAC (>50mA)

< 4.0VAC (<50mA) 47 to 63 Hz 10 mA

0.3A/point; 1.8A/common

Max Leakage Current Max Inrush Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

Fuses

mA (132 VAC, 60 Hz)

2 10A for 10 ms

50 mA

3 1 ms 1 ms + 1/2 cycle Removable; D2-16IOCON Logic side

2.8 oz. (80g) (2) 1 per common

3.15A slow blow, replaceable Order D2-FUSE-1 (5 per pack)

2–44

DL205 User Manual, 4th Edition, Rev. B

Page 84

D2–04TRS, Relay Output

5--30 VDC

5-240VAC 4A50/ 60Hz

D2--04 TR S

OU T RE LAY

D2--04TRS

0 1 2 3

5--30VDC 10mA--4A

5--240 VAC

10 20 30 40 50 55

Ambient Tempera ture (˚C/˚F )

50 68 86 104 122 131

C˚

F˚

Points

2A /

Pt.

3A /

Pt.

4A /

Pt.

COM

OUTP UT

To LE D

Internal module circuitry

6.3A

5--240 VAC

5--30 VDC

Derating Chart

D2-04TRS Relay Output

Outputs per Module Outputs Points Consumed Commons per Module Output Type Operating Voltage Peak Voltage ON Voltage Drop AC Frequency Minimum Load Current Max Load Current (resistive)

(only 1st 4pts. are used)

8 4 (isolated) Relay, form A (SPST) 5-30 VDC / 5-240 VAC 30 VDC, 264 VAC

0.72 VDC maximum 47 to 63 Hz 10 mA 4A/point; 8A/module (resistive)

Chapter 2: Installation, Wiring and Specifications

Max Leakage Current Max Inrush Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

Fuses

0.1 mA @ 264 VAC 5A for < 10 ms 250 mA 10 ms 10 ms Removable; D2-8IOCON Logic side

2.8 oz. (80 g) 1 per point

6.3A slow blow, replaceable Order D2-FUSE-3 (5 per pack)

Typical Relay Life (Operations)

Voltage &Load Current Type of Load 1A 2A 3A 4A

24 VDC Resistive 500k 200k 100k 50k 24 VDC Solenoid 100k 40k –– – 110 VAC Resistive 500k 250k 150k 100k 110 VAC Solenoid 200k 100k 50k – 220 VAC Resistive 350k 150k 100k 50k 220 VAC Solenoid 100k 50k –– ––

At 24 VDC, solenoid (inductive) loads over 2A cannot be used.

At 100 VAC, solenoid (inductive) loads over 3A cannot be used.

At 220 VAC, solenoid (inductive) loads over 2A cannot be used.

DL205 User Manual, 4th Edition, Rev. B

2–45

Page 85

Chapter 2: Installation, Wiring and Specifications

Points

0.5A / P t.

COM

OUTP UT

To L E D

Internal module circuitry

6.3A

5--240 VAC

5--30 VDC

1A/Pt.

Internally

connected

5--240 VAC

5--30 VDC

0 10 20 30 40 50 55

Ambient Temperature (˚C/˚F)

32 50 68 86 104 122 131

C˚

F˚

5-240VAC 1A50/ 60Hz

D2--08 TR

OU T RE LAY

D2--08TR

0 1 2 3

4 5 6 7

5--30V D C 5mA--1A

Derating Chart

D2–08TR, Relay Output

Outputs per Module

Outputs Points Consumed Commons per Module

Output Type Operating Voltage Peak Voltage

ON Voltage Drop AC Frequency

Minimum Load Current Max Load Current (resistive)

D2-08TR Relay Output

8 8 1 (2 I/O terminals) Relay, form A (SPST) 5-30 VDC; 5-240 VAC 30 VDC, 264 VAC N/A 47 to 60 Hz 5mA @ 5VDC 1A/point; 4A/common

Max Leakage Current

Max Inrush Current

Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

Fuses

.1 mA @265 VAC

utput: 3A for 10 ms

ommon: 10A for 10 ms

C 250 mA 12 ms 10 ms Removable; D2-8IOCON Logic side

3.9 oz. (110g) One 6.3A slow blow, replaceable

Order D2-FUSE-3 (5 per pack)

2–46

Typical Relay Life (Operations)

Voltage/Load Current Closures

24 VDC Resistive 1A 500k 24 VDC Solenoid 1A 100k 110 VDC Resistive 1A 500k 110 VDC Solenoid 1A 200k 220 VAC Resistive 1A 350k 220 VAC Solenoid 1A 100k

DL205 User Manual, 4th Edition, Rev. B

Page 86

OUT R ELAY

F2--08TR

0 1 2 3

4 5

12--250VAC 10A 50/ 60Hz 12--28VDC 10ma--10A

6 7

Common

Typical Cir cuit

12--250VAC

12--28VDC

Internal Circuitry

0 10 20 30 40 50 55

Ambient Temperature (°C/°F)

32 50 68 86 104 122 131C°F°

10 A/pt.

Number

Points On

(100% duty

cycle)

NO 4

NO 5

C4-7

NO 2

NO 3

NO 1

C0-3

NO 0

NO 6

NO 7

Derating Chart

3 A/pt.

2.5 A/pt.

5A/pt.

F2–08TR, Relay Output

Chapter 2: Installation, Wiring and Specifications

Outputs per Module Outputs Points Consumed Commons per Module Output Type

Operating Voltage

Peak Voltage ON Voltage Drop AC Frequency Minimum Load Current

Max Load Current (resistive)

Max Leakage Current Max Inrush Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight Fuses

F2-08TR Relay Output

8 8 2 (isolated), 4-pts. per common

, Form A (SPST normally open)

8 7A @ 12-28 VDC, 12-250VAC;

0.5A @ 120 VDC 150 VDC, 265 VAC N/A 47 to 63Hz 10 mA @ 12 VDC

10A/point 33(subject to derating) Max of 10A/common

N/A 12A 670 mA 15 ms (typical) 5 ms (typical) Removable; D2-8IOCON Logic side

5.5 oz. (156g) None

Typical Relay Life1(Operations) at Room

Voltage & Load Current Type of Load

24 VDC Resistive 10M 600k 300k 24 VDC Solenoid - 150k 75k 110 VDC Resistive – 600k 300k 110 VDC Solenoid – 500k 200k 220 VAC Resistive – 300k 150k 220 VAC Solenoid – 250k 100k

1) Contact life may be extended beyond those values shown with the use of arc suppression techniques described in the DL205 User Manual. Since these modules have no leakage current, they do not have built-in snubber. For example, if you place a diode across a 24 VDC inductive load, you can significantly increase the life of the relay.

2) At 120 VDC 0.5A resistive load, contact life cycle is 200k cycles.

3) Normally closed contacts have 1/2 the current handling capability of the normally open contacts.

DL205 User Manual, 4th Edition, Rev. B

Temperature

50mA 5A 7A

2–47

Page 87

Chapter 2: Installation, Wiring and Specifications

12--250VAC 7A50/ 60Hz

OUT REL AY

F2--08TRS

0 1 2 3

4 5

NO 0

NC 0

NO 3

NO 5

NC 7

NO 6

NC 6

NO 4

NO 2

NO 1

NO7

12--28VDC 10ma--7A

6 7

Common

Typica l Circ uit

Common

12--250VAC

12--28VDC

12--250VAC

12--28VDC

Internal Circuitry

Typica l Circ uit

(Points 0, 6, & 7 only)

(po int s 1,2,3,4,5)

5A/pt.

0 102030405055

AmbientTemperature (˚C/˚F)

32 50 68 86 104 122 131

C˚

F˚

4A/

pt.

7A/pt.

6A/

pt.

Number

Points On

(100% duty

cycle)

NC 6

NC 7

NO 4

NO 5

NO 2

NO 3

NO 1

NC 0

NO 0

NO 6

NO 7

12--28VDC

12--250VAC

12--28VDC

12--250VAC

12--28VDC

12--250VAC

12--28VDC

12--250VAC

12--28VDC

12--250VAC

norm ally clos ed

12--28VDC

12--250VAC

norm ally clos ed

12--28VDC

12--250VAC

12--28VDC

12--250VAC

norm ally clos ed

Derating Chart

F2–08TRS, Relay Output

F2-08TRS Relay Output

Outputs per Module Outputs Points Consumed Commons per Module

Output Type

Operating Voltage

Peak Voltage ON Voltage Drop AC Frequency Minimum Load Current Max Load Current (resistive) Max Leakage Current Max Inrush Current Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight Fuses

8 8 8 (isolated) 3, Form C (SPDT)

5, Form A (SPST normally open) 7A @ 12-28 VDC, 12-250 VAC

0.5A @ 120VDC 150 VDC, 265 VAC N/A 47 to 63Hz 10 mA @ 12 VDC

7A/point 33(subject to derating) N/A 12A 670 mA 15 ms (typical) 5 ms (typical) Removable; D2-16IOCON Logic side

5.5oz. (156g) None

Typical Relay Life1(Operations) at Room

Temperature

Voltage & Load Current Type of Load

24 VDC Resistive 10M 600k 300k 24 VDC Solenoid - 150k 75k 110 VDC Resistive – 600k 300k 110 VDC Solenoid – 500k 200k 220 VAC Resistive – 300k 150k 220 VAC Solenoid – 250k 100k

2) At 120 VDC 0.5A resistive load, contact life cycle is 200k cycles.

3) Normally closed contacts have 1/2 the current handling capability of the normally open contacts.

50mA 5A 7A

2–48

DL205 User Manual, 4th Edition, Rev. B

Page 88

D2–12TR, Relay Output

5--240VAC

1.5A 50/60Hz

D2--12T R

OU T REL AY

D2-- 12TR

0 1 2 3

4 5

5--30VDC

Points

COM

OUTP UT

To LE D

Internal module circuitry

5--240 VAC

5--30 VDC

0.5A / Pt.

0 10 20 30 40 50 55

Ambient Temperature (˚C/˚F)

32 50 68 86 104 122 131

C˚

F˚

1.5A / Pt.

0.75A / Pt.

5mA--1.5A

5--240 VAC

5--30 VDC

5--240 VAC

5--30 VDC

1.25A / Pt.

Derating Chart

D2-12TR Relay Output

Outputs per Module Outputs Points Consumed Commons per Module Output Type Operating Voltage Peak Voltage ON Voltage Drop AC Frequency Minimum Load Current Max Load Current (resistive) Max Leakage Current

Max Inrush Current

Base Power Required 5VDC OFF to ON Response ON to OFF Response Terminal Type (included) Status Indicator Weight

Fuses

1 16 (four unused, see chart below)

(6-pts. per common)

2 Relay, form A (SPST) 5-30 VDC; 5-240 VAC 30 VDC; 264 VAC N/A 47 to 60 Hz 5 mA @ 5VDC

1.5 A/point; Max of 3A/common

0.1 mA @ 265 VAC Output: 3A for 10 ms

Common: 10A for 10 ms 450 mA 10 ms 10 ms Removable; D2-16IOCON Logic side

4.6 oz. (130g) (2) 4A slow blow, replaceable

Order D2-FUSE-4 (5 per pack)

Chapter 2: Installation, Wiring and Specifications

Typical Relay Life (Operations)

Voltage/Load Current Closures

24 VDC Resistive 1A 500k 24 VDC Solenoid 1A 100k 110 VDC Resistive 1A 500k 110 VDC Solenoid 1A 200k 220 VAC Resistive 1A 350k 220 VAC Solenoid 1A 100k

Addresses Used

Points Used? Points Used?

Yn+0 Yes Yn+10 Yes Yn+1 Yes Yn+11 Yes Yn+2 Yes Yn+12 Yes Yn+3 Yes Yn+13 Yes Yn+4 Yes Yn+14 Yes Yn+5 Yes Yn+15 Yes Yn+6 No Yn+16 No Yn+7 No Yn+17 No

n is the starting address

DL205 User Manual, 4th Edition, Rev. B

2–49

Page 89

Chapter 2: Installation, Wiring and Specifications

D2--0 8CDR 20--28VDC

8mA

IN/ 24VDC

D2-- 08CDR

RELAY

0 1 2 3

OUT

Points

Out puts

1A/Pt.

Derating Chart

COM

OUTP UT

To LE D

Internal module circuitry

6.3A

5--240 VAC

5--30 VDC

5--240 VAC

5--30 VDC

0 10 20 30 40 50 55

Ambient Temperature (°C/°F)

32 50 68 86 104 122131C°F°

5--240VAC 1A50/ 60Hz 5--30VDC 5mA--1A

Inputs 5mA /

Pt.

Optica l

COM

Isolator

INP UT

24VDC

V+

To LE D

Internal module circuitry

24VDC

+--

Sink

Source

Sink

Source

D2–08CDR, 4 pt. DC Input / 4pt. Relay Output

2–50

D2-08CDR 4-pt. DC In / 4pt. Relay Out

General Specifications Base Power Required 5VDC Terminal Type (included) Status Indicator Weight

200 mA Removable; D2-8IOCON Logic side

3.5 oz. (100 g)

Input Specifications Inputs per Module Input Points Consumed Commons per Module Input Voltage Range Peak Voltage ON Voltage Level OFF Voltage Level AC Frequency Input Impedance Input Current Maximum Current Minimum ON Current Maximum OFF Current OFF to ON Response ON to OFF Response Fuses (input circuits)

4 (sink/source) 8 (only first 4-pts. are used) 1 20-28 VDC 30 VDC 19 VDC minimum 7 VDC maximum N/A

4.7 k 5 mA @ 24 VDC 8 mA @ 30 VDC

4.5 mA

1.5 mA 1 to 10 ms 1 to 10 ms None

Typical Relay Life (Operations)

Voltage/Load Current Closures

24 VDC Resistive 1A 500k 24 VDC Solenoid 1A 100k 110 VAC Resistive 1A 500k 110 VAC Solenoid 1A 200k 220 VAC Resistive 1A 350k 220 VAC Solenoid 1A 100k

DL205 User Manual, 4th Edition, Rev. B

Output Specifications Outputs per Module Outputs Points Consumed Commons per Module Output Type Operating Voltage Peak Voltage ON Voltage Drop AC Frequency Minimum Load Current Max Load Current (resistive) Max Leakage Current

Max Inrush Current

OFF to ON Response ON to OFF Response

Fuses (output circuits)

4 8 (only first 4-pts. are used) 1

elay, form A (SPST)

R 5-30 VDC; 5-240 VAC 30 VDC; 264 VAC N/A 47 to 63 Hz 5 mA @ 5 VDC 1A/point ; 4A/module

0.1 mA @ 264 VAC 3A for < 100 ms

10 A for < 10 ms (common) 12 ms 10 ms 1 (6.3A slow blow, replaceable);

Order D2-FUSE-3 (5 per pack)

Page 90

Chapter 2: Installation, Wiring and Specifications

Glossary of Specification Terms

Inputs or Outputs Per Module

Indicates number of input or output points per module and designates current sinking, current sourcing, or either.

Commons Per Module

Number of commons per module and their electrical characteristics.

Input Voltage Range

The operating voltage range of the input circuit.

Output Voltage Range

The operating voltage range of the output circuit.

Peak Voltage

Maximum voltage allowed for the input circuit.

AC Frequency

AC modules are designed to operate within a specific frequency range.

ON Voltage Level

The voltage level at which the input point will turn ON.

OFF Voltage Level

The voltage level at which the input point will turn OFF.

Input impedance

Input impedance can be used to calculate input current for a particular operating voltage.

Input Current

Typical operating current for an active (ON) input.

Minimum ON Current

The minimum current for the input circuit to operate reliably in the ON state.

Maximum OFF Current

The maximum current for the input circuit to operate reliably in the OFF state.

Minimum Load

The minimum load current for the output circuit to operate properly.

External DC Required

Some output modules require external power for the output circuitry.

ON Voltage Drop

Sometimes called “saturation voltage”, it is the voltage measured from an output point to its common terminal when the output is ON at max. load.

DL205 User Manual, 4th Edition, Rev. B

2–51

Page 91

Chapter 2: Installation, Wiring and Specifications

Maximum Leakage Current

The maximum current a connected maximum load will receive when the output point is OFF.

Maximum Inrush Current

The maximum current used by a load for a short duration upon an OFF to ON transition of a output point. It is greater than the normal ON state current and is characteristic of inductive loads in AC circuits.

Base Power Required

Power from the base power supply is used by the DL205 input modules and varies between different modules. The guidelines for using module power is explained in the power budget configuration section in Chapter 4–7.

OFF to ON Response

The time the module requires to process an OFF to ON state transition.

ON to OFF Response

The time the module requires to process an ON to OFF state transition.

Terminal Type

Indicates whether the terminal type is a removable or non-removable connector or a terminal.

Status Indicators

The LEDs that indicate the ON/OFF status of an input point. These LEDs are electrically located on either the logic side or the field device side of the input circuit.

Weight

Indicates the weight of the module. See Appendix F for a list of the weights for the various DL205 components.

Fuses

Protective devices for an output circuit, which stop current flow when current exceeds the fuse rating. They may be replaceable or non–replaceable, or located externally or internally.

2–52

DL205 User Manual, 4th Edition, Rev. B

Page 92

CHAPTER

CPU SPECIFICATIONS AND

CHAPTER

OPERATIONS

In This Chapter

CPU Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–2

CPU General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–4

CPU Base Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .3–5

CPU Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–6

Selecting the Program Storage Media . . . . . . . . . . . . . . . . . . . . . . .3–9

Using Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–14

CPU Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–21

I/O Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–27

CPU Scan Time Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . .3–29

PLC Numbering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–35

Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–37

DL230 System V-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–41

DL240 System V-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–43

DL250–1 System V-memory (DL250 also) . . . . . . . . . . . . . . . . . . .3–46

DL260 System V-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–49

DL205 Aliases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–52

DL230 Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–53

DL240 Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–54

DL250–1 Memory Map (DL250 also) . . . . . . . . . . . . . . . . . . . . . . .3–55

DL260 Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–56

X Input/Y Output Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–57

Control Relay Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–59

Stage Control/Status Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–63

Timer and Counter Status Bit Maps . . . . . . . . . . . . . . . . . . . . . . . .3–65

Remote I/O Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–66

Page 93

Chapter 3: CPU Specifications and Operations

CPU Overview

The Central Processing Unit is the heart of the PLC. Almost all system operations are controlled by the CPU, so it is important that it is set-up and installed correctly. This chapter provides the information needed to understand:

• The differences between the various models of CPUs

• The steps required to setup and install the CPU

General CPU Features

The DL230, DL240, DL250–1 and D2–260 are modular CPUs which can be installed in 3, 4, 6, or 9 slot bases. All I/O modules in the DL205 family will work with any of the CPUs. The DL205 CPUs offer a wide range of processing power and program instructions. All offer RLL and Stage program instructions (See Chapter 5). They also provide extensive internal diagnostics that can be monitored from the application program or from an operator interface.

DL230 CPU Features

The DL230 has 2.4K words of memory comprised of 2.0K of ladder memory and approximately 400 words of V-memory (data registers). It has 92 different instructions available for programming, and supports a maximum of 256 I/O points.

Program storage is in the factory-installed EEPROM. In addition to the EEPROM there is also RAM on the CPU which will store system parameters, V-memory, and other data which is not in the application program.

The DL230 provides one built-in RS-232 communication port, so you can easily connect a handheld programmer or a personal computer without needing any additional hardware.

DL240 CPU Features

The DL240 has a maximum of 3.8K of memory comprised of 2.5K of ladder memory and approximately 1.3K of V-memory (data registers). There are 129 instructions available for program development and a maximum of 256 points local I/O and 896 points with remote I/O are supported.

Program storage is in the factory-installed EEPROM. In addition to the EEPROM there is also RAM on the CPU which will store system parameters, V-memory and other data which is not in the application program.

The DL240 has two communication ports. The top port is the same port configuration as the DL230. The bottom port also supports the DirectNET protocol, so you can use the DL240 in a DirectNET network. Since the port is RS-232, you must use an RS-232/RS-422 converter for multi-drop connections.

3–2

DL205 User Manual, 4th Edition, Rev. B

Page 94

Chapter 3: CPU Specifications and Operations

DL250–1 CPU Features

The DL250–1 replaces the DL250 CPU. It offers all the DL240 features, plus more program instructions and a built–in Remote I/O Master port. It offers all the features of the DL250 CPU with the addition of supporting Local expansion I/O. It has a maximum of 14.8K of program memory comprised of 7.6K of ladder memory and 7.2K of V-memory (data registers). It supports a maximum of 256 points of local I/O and a maximum of 768 I/O points (max. of two local expansion bases). In addition, port 2 supports up to 2048 points if you use the DL250–1 as a Remote master. It includes an internal RISC–based microprocessor for greater processing power. The DL250–1 has 240 instructions. The instructions are in addition to the DL240 instruction set which include drum timers, a print function, floating point math, PID loop control for 4 loops and the Intelligent Box (IBox) instructions.

The DL250–1 has a total of two built–in communications ports. The top port is identical to the top port of the DL240, with the exception of the DirectNet slave feature. The bottom port is a 15–pin RS-232/RS-422 port. It will interface with DirectSOFT and operator interfaces, and provides DirectNet and Modbus RTU Master/Slave connections.

DL260 CPU Features

The DL260 offers all the DL250–1 features, plus ASCII IN/OUT and expanded Modbus instructions. It also supports up to 1280 local I/O points by using up to four local expansion bases. It has a maximum of 30.4K of program memory comprised of 15.8K of ladder memory (saved on flash memory) and 14.6K of V-memory (data registers). It also includes an internal RISC–based microprocessor for greater processing power. The DL260 has 297 instructions. In addition to those in the DL250–1 instruction set, the DL260 instruction set includes table instructions, trigonometric instructions and support for 16 PID loops.

The DL260 has a total of two built–in communications ports. The top port is identical to the top port of the DL250–1. The bottom port is a 15–pin RS-232/RS-422/RS-485 port. It will interface with DirectSOFT (version 4.0 or later), operator interfaces, and provides DirectNet, Modbus RTU Master/Slave connections. Port 2 also supports ASCII IN/OUT instructions.

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CPU General Specifications

Total Program memory (words) Ladder memory (words) V-memory (words) Non-volatile V Memory (words) Boolean execution /K RLL and RLL Handheld programmer

DirectSOFT programming for Windows.

Built-in communication ports

EEPROM

Total CPU memory I/O points available

Local I/O points available Local Expansion I/O points (including

local I/O and expansion I/O points)

Serial Remote I/O points (including local I/O and expansion I/O points)

Serial Remote I/O Channels

Max Number of Serial Remote Slaves

Ethernet Remote I/O Discrete points

Ethernet Remote I/O Analog I/O channels

Ethernet Remote I/O channels

Max Number of Ethernet slaves per channel

Feature DL230 DL240 DL250–1 DL260

2.4K 3.8K 14.8K 30.4K 2048 2560 7680 (Flash) 15872 (Flash) 256 1024 7168 14592 128 256 No No

PLUS

Programming

4–6 ms 10–12 ms 1.9ms 1.9ms Yes Yes Yes Yes Yes Yes Yes Yes

Yes Yes Yes

One RS–232 Two RS–232

Standard on CPU Standard on CPU Flash Flash

256 (X,Y,CR) 896 (X,Y,CR) 2048 (X,Y,CR)

256 256 256 256

N/A N/A

N/A 896 2048 8192

N/A 2 8 8

N/A 7 Remote / 31 Slice 7 Remote / 31 Slice 7 Remote / 31 Slice

N/A 896 2048 8192

N/A Map into V–memory Map into V–memory Map into V–memory

N/A

N/A 16 16 16

I/O points per Remote channel

N/A

I/O Module Point Density

Slots per Base

4/8/12/16/32 4/8/12/16/32 4/8/12/16/32 4/8/12/16/32 3/4/6/9 3/4/6/9 3/4/6/9 3/4/6/9

limited by power budget

16,384 (limited to 896 by CPU)

One RS–232 One RS–232 or RS–422

768 (2 exp. bases max.)

limited by power budget

16,384 (16 fully expanded H4–EBC slaves using V–memory and bit–of–word instructions)

Yes (requires version 4.0 or higher)

One RS–232 One RS–232, RS–422 or RS–485

8192 (X,Y,CR,GX,GY)

1280 (4 exp. bases max.)

limited by power budget

16,384 (16 fully expanded H4–EBC slaves using V–memory and bit–of–word instructions

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Feature DL230 DL240 DL250–1 DL260

Number of instructions available (see Chapter 5 for details)

Control relays Special relays (system defined) Stages in RLL Timers Counters Immediate I/O Interrupt input (hardware / timed) Subroutines Drum Timers Table Instructions For/Next Loops

Math

ASCII PID Loop Control, Built In Time of Day Clock/Calendar Run Time Edits Supports Overrides Internal diagnostics Password security System error log User error log Battery backup

PLUS

Chapter 3: CPU Specifications and Operations

92 129 240 297

256 256 1024 2048 112 144 144 144 256 512 1024 1024 64 128 256 256 64 128 128 256 Yes Yes Yes Yes Yes / No Yes / Yes Yes / Yes Yes / Yes No Yes Yes Yes No No Yes Yes No No No Yes No Yes Yes Yes

Integer Integer

No No Yes, OUT Yes, IN/OUT No No Yes, 4 Loops Yes, 16 Loops No Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes No Yes Yes Yes Yes (optional) Yes (optional) Yes (optional) Yes (optional)

Integer, Floating Point

Integer, Floating Point, Trigonometric

CPU Base Electrical Specifications

Specification AC Powered Bases 24 VDC Powered Bases 125 VDC Powered Bases

D2–03B–1

Part Numbers

Input Voltage Range

Maximum Inrush Current Maximum Power Voltage Withstand (dielectric) Insulation Resistance

Auxiliary 24 VDC Output

Fusing (internal to base power supply)

100–240 VAC +10% –15%

30 A 10 A 20 A 80 VA 25 W 30 W 1 minute @ 1500 VAC between primary, secondary, field ground, and run relay > 10 M⏲ at 500 VDC 20–28 VDC, less than 1V p-p

300 mA max. non–replaceable 2 A @ 250 V

slow blow fuse; external fusing recommended

D2–04B–1 D2–06B–1 D2–09B–1

10.2–28.8 VDC (24 VDC) with less than 10% ripple

None

non–replaceable 3.15 A @ 250 V slow blow fuse; external fusing recommended

DL205 User Manual, 4th Edition, Rev. B

D2–03BDC1–1 D2–04BDC1–1 D2–06BDC1–1 D2–09BDC1–1

D2–06BDC2–1 D2–09BDC2–1

104–240 VDC +10% –15%

20–28 VDC, less than 1V p-p 300 mA max.

non–replaceable 2 A @ 250 V slow blow fuse; external fusing recommended

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RJ12 Phone Jack RS-232, 9600 baud Communication Port –K-sequence –DirectNET slave –Modbus RTU slave –easily connect DirectSOFT, handhelds, operator interfaces, any DirectNet master

Port 1 DL250–1 and DL260

Port 2 Additional DL260 Features

CH1

CH2

CH3

CH4

RUN

TERM

RUN CPU

PWR

BATT

PORT 1

PORT 2

DL240

CPU

RUN

PWR

BATT

PORT 1?

CPU

RJ12 Phone Jack RS-232, 9600 baud Communication Port –K-sequence –easily connect Direct SOFT, handhelds, operator interfaces, etc.

Port 1

RJ12 Phone Jack RS-232, up to 19.2K baud Communication Port –K-sequence –DirectNET slave –easily connect DirectSOFT, handhelds, operator interfaces, or any DirectNet master

Port 2

15-pin HD Connector RS-232/RS-422, up to 38.4K baud Communication Port –K-sequence –DirectNET Master/Slave –Modbus RTU Master/Slave –easily connect Direct SOFT, handhelds, operator interfaces, any DirectNet or Modbus master or slave

DL260

Port 2 DL250–1 and DL260

–ASCII IN/OUT Instructions –Extended Modbus Instructions –RS-485 support

CPU

DL230

CPU Hardware Setup

Communication Port Pinout Diagrams

Cables are available that allow you to quickly and easily connect a Handheld Programmer or a personal computer to the DL205 CPUs. However, if you need to build a cable(s), use the pinout descriptions shown on the following pages. You can also use the Tech Support/Cable Wiring diagrams located on our website.

The DL240, DL250–1 and DL260 CPUs have two ports while the DL230 has only one. All of the CPUs require at least one RJ-12 connector. The DL250-1 and DL260 require one 15 pin D-shell connector.

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230

240

250-1

260

ý ý

þ þ

230

240

250-1

260

6-pin Female

Modular Connector

6-pin Female

Modular Connector

Port 1 Specifications

The operating parameters for Port 1 on the DL230 and DL240 CPUs are fixed.

• 6-pin female modular (RJ12 phone jack) type connector

• K–sequence protocol (slave only)

• RS-232, 9600 baud

• Connect to DirectSOFT, D2–HPP, DV–1000, HMI panels

• Fixed station address of 1

• 8 data bits, one stop

• Asynchronous, Half–duplex, DTE

• Odd parity

Port 1 Specifications

Port 1 Pin Descriptions (DL230 and DL240)

1 0V Power (–) connection (GND) 2 5V Power (+) connection 3 RXD Receive Data (RS-232) 4 TXD Transmit Data (RS-232) 5 5V Power (+) connection 6 0V Power (–) connection (GND)

The operating parameters for Port 1 on the DL250–1 and DL260 CPU are fixed. This applies to the DL250 as well.

• 6-pin female modular (RJ12 phone jack) type connector

• K–sequence protocol (slave only)

• DirectNET (slave only)

• Modbus RTU (slave only)

• RS-232, 9600 baud

• Connect to DirectSOFT, D2–HPP, DV1000 or DirectNET master

• 8 data bits, one start, one stop

• Asynchronous, Half–duplex, DTE

• Odd parity

Port 1 Pin Descriptions (DL250-1 and DL260)

1 0V Power (–) connection (GND) 2 5V Power (+) connection 3 RXD Receive Data (RS-232C) 4 TXD Transmit Data (RS-232C 5 5V Power (+) connection 6 0V Power (–) connection (GND)

NOTE: The 5V pins are rated at 200mA maximum, primarily for use with some operator interface units.

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6-pin Female

Modular Connector

15-pin Female

D Connector

ý ý

230

240

250-1

260

ý ý

þ þ

230

240

250-1

260

Port 2 Specifications

The operating parameters for Port 2 on the DL240 CPU are configurable using Aux functions on a programming device.

• 6-Pin female modular (RJ12 phone jack) type connector

• K–sequence protocol, DirectNET (slave),

• RS-232, Up to 19.2K baud

• Address selectable (1–90)

• Connect to DirectSOFT, D2–HPP, DV-1000, HMI, or DirectNET master

• 8 data bits, one start, one stop

• Asynchronous, Half–duplex, DTE

• Odd or no parity

Port 2 Specifications

Port 2 on the DL250-1 and DL260 CPUs is located on the 15-pin D-shell connector. It is configurable using AUX functions on a programming device. This applies to the DL250 as well.

• 15-Pin female D type connector

• Protocol: K-sequence, DirectNET Master/Slave, Modbus RTU Master/Slave, Remote I/O, (ASCII IN/OUT DL260 only)

• RS-232, non-isolated, distance within 15 m (approx. 50 feet)

• RS-422, non-isolated, distance within 1000 m

• RS-485, non–isolated, distance within 1000m (DL260 only)

• Up to 38.4K baud

• Address selectable (1–90)

• Connects to DirectSOFT, D2–HPP, operator interfaces, any DirectNET or Modbus master/slave, (ASCII devices-DL260 only)

• 8 data bits, one start, one stop

• Asynchronous, Half–duplex, DTE Remote I/O

• Odd/even/none parity

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Port 2 Pin Descriptions (DL240 only)

1 0V Power (–) connection (GND) 2 5V Power (+) connection 3 RXD Receive Data (RS-232) 4 TXD Transmit Data (RS-232) 5 RTS Request to Send 6 0V Power (–) connection (GND)

Port 2 Pin Descriptions (DL250–1 / DL260)

1 5V 5 VDC 2 TXD2 Transmit Data (RS-232) 3 RXD2 Receive Data (RS-232) 4 RTS2 Ready to Send (RS–232) 5 CTS2 Clear to Send (RS–232) 6 RXD2 – Receive Data – (RS–422) (RS–485 DL260) 7 0V Logic Ground 8 0V Logic Ground

9 TXD2 + Transmit Data + (RS–422) (RS–485 DL260) 10 TXD2 – Transmit Data – (RS–422) (RS–485 DL260) 11 RTS2 + Request to Send + (RS–422) (RS–485 DL260) 12 RTS2 – Request to Send – (RS–422)(RS–485 DL260) 13 RXD2 + Receive Data + (RS–422) (RS–485 DL260) 14 CTS2 + Clear to Send + (RS422) (RS–485 DL260) 15 CTS2 – Clear to Send – (RS–422) (RS–485 DL260)

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Chapter 3: CPU Specifications and Operations

Jumper in position shown selects write

protect for EEPROM

EEPROM

230

240

250-1

260

Selecting the Program Storage Media

Built-in EEPROM

The DL230 and DL240 CPUs provide built-in EEPROM storage. This type of memory is non-volatile and is not dependent on battery backup to retain the program. The EEPROM can be electrically reprogrammed without being removed from the CPU. You can also set Jumper 3, which will write protect the EEPROM. The jumper is set at the factory to allow changes to EEPROM. If you select write protection by changing the jumper position, you cannot make changes to the program.

WARNING: Do NOT change Jumper 2. This is for factory test operations. If you change Jumper 2, the CPU will not operate properly.

4 5

8 9

EEPROM Sizes

The DL230 and DL240 CPUs use different sizes of EEPROMs. The CPUs come from the factory with EEPROMs already installed. However, if you need extra EEPROMs, select one that is compatible with the following part numbers.

CPU Type EEPROM Part Number Capacity

DL230 Hitachi HN58C65P–25 8K byte (2Kw) DL240 Hitachi HN58C256P–20 32K byte (3Kw)

EEPROM Operations

There are many AUX functions specifically for use with an EEPROM in the Handheld Programmer. This enables you to quickly and easily copy programs between a program developed offline in the Handheld and the CPU. Also, you can erase EEPROMs, compare them, etc. See the DL205 Handheld Programmer Manual for details on using these AUX functions with the Handheld Programmer.

NOTE: If the instructions are supported in both CPUs and the program size is within the limits of the DL230, you can move a program between the two CPUs. However, the EEPROM installed in the Handheld Programmer must be the same size (or larger) than the CPU being used. For example, you could not install a DL240 EEPROM in the Handheld Programmer and download the program to a DL230. Instead, if the program is within the size limits of the DL230, use a DL230 chip in the Handheld when you obtain the program from the DL240.

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