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DL05 Micro PLC User Manual

Volume 1 of 2

Manual Number: D0-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 on-line 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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~AVERTISSEMENT ~

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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.

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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.

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DL05 Micro 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: D0-USER-M

Issue: Sixth Edition, Rev. D

Issue Date: 10/17

Publication History

Issue Date Description of Changes

Original 12/98 Original issue

2nd Edition 2/00

2nd Edition, Rev. A 7/00

3rd Edition 11/01

3rd Edition, Rev. A 7/02 Added new discrete option modules

4th Edition 11/02 Converted manual to QuarkXPress

5th Edition 6/04

6th Edition 12/08

6th Edition, Rev. A 4/10 Made minor corrections throughout manual.

6th Edition, Rev. B 8/11

6th Edition, Rev. C 2/13

6th Edition, Rev. D 10/17 Converted manual to InDesign, Minor Correction throughout manual

Added PID chapter,analog module chapter and memory cartridge chapter

Added DC power

Removed MC and analog module chapters, corrected drum instruction, several minor corrections, added PLC weights, EU directive additions

Removed option module data, added MC chapter, updated instruction set, inserted memory appendix, made minor corrections

Corrected E-stop, updated instruction set, added DirectSOFT IBox instructions to Chapter 5, revised PID chapter, moved HSIO chapter to Appendices, divided Chapter 4 into Chapters 3 & 4, added Numbering Systems to Appendix section, made corrections throughout manual

Corrected number of registers needed in the print message instruction. Corrected TIME instruction: changed CPU to read Memory Cartridge. Made other minor corrections throughout manual.

Added H0-CTRIO2 references Updated suppression for inductive loads Made minor corrections throughout manual.

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VoLuMe one:

TabLe of conTenTs

Chapter 1: Getting Started

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

DL05 Micro PLC Components 1-4

The DL05 Micro PLC Family 1-4 DirectSOFT Programming for Windows™ 1-4 Handheld Programmer 1-5

I/O Selection Quick Chart 1-5

Quick Start for PLC Checkout and Programming 1-6

Steps to Designing a Successful System 1-10

Questions and Answers about DL05 Micro PLCs 1-12

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Table of Contents

Chapter 2: Installation, Wiring, and Specification

Safety Guidelines 2-2

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

Orientation to DL05 Front Panel 2-5

Connector Removal 2-6

Mounting Guidelines 2-7

Unit Dimensions 2-7 Enclosures 2-7 Panel Layout & Clearances 2-8 Using DIN Rail Mounting Rails 2-9 Environmental Specifications 2-10 Agency Approvals 2-10 Marine Use 2-10

Wiring Guidelines 2-11

Fuse Protection for Input Power 2-11 External Power Source 2-12 Planning the Wiring Routes 2-12 Fuse Protection for Input and Output Circuits 2-13 I/O Point Numbering 2-13

System Wiring Strategies 2-14

PLC Isolation Boundaries 2-14 Connecting Operator Interface Devices 2-15 Connecting Programming Devices 2-15 Sinking/Sourcing Concepts 2-16

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I/O “Common” Terminal Concepts 2-17 Connecting DC I/O to Solid State Field Devices 2-18 Solid State Input Sensors 2-18 Solid State Output Loads 2-18 Relay Output Wiring Methods 2-20 Relay Outputs – Transient Suppression for Inductive Loads in a Control System

2-21 Prolonging Relay Contact Life 2-26 DC Input Wiring Methods 2-28 DC Output Wiring Methods 2-29 High Speed I/O Wiring Methods 2-30

Wiring Diagrams and Specifications 2-32

D0–05AR I/O Wiring Diagram 2-32 D0–05DR I/O Wiring Diagram 2-34 D0–05AD I/O Wiring Diagram 2-36 D0–05DD I/O Wiring Diagram 2-38 D0–05AA I/O Wiring Diagram 2-40 D0–05DA I/O Wiring Diagram 2-42 D0–05DR-D I/O Wiring Diagram 2-44 D0–05DD–D I/O Wiring Diagram 2-46

Glossary of Specification Terms 2-48

Chapter 3: CPU Specifications and Operation

Introduction 3-2

DL05 CPU Features 3-2

CPU Specifications 3-3

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CPU Hardware Setup 3-4

Communication Port Pinout Diagrams 3-4 Connecting the Programming Devices 3-5 CPU Setup Information 3-5 Status Indicators 3-6 Mode Switch Functions 3-6 Changing Modes in the DL05 PLC 3-7 Mode of Operation at Power-up 3-7 Auxiliary Functions 3-8 Clearing an Existing Program 3-8 Initializing System Memory 3-8 Setting Retentive Memory Ranges 3-9 Using a Password 3-10

CPU Operation 3-11

CPU Operating System 3-11 Program Mode 3-12 Run Mode 3-12 Read Inputs 3-13 Service Peripherals and Force I/O 3-13 Update Special Relays and Special Registers 3-14 Solve Application Program 3-14 Write Outputs 3-15 Diagnostics 3-15

I/O Response Time 3-15

Is Timing Important for Your Application? 3-15 Normal Minimum I/O Response 3-15 Normal Maximum I/O Response 3-16 Improving Response Time 3-17

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CPU Scan Time Considerations 3-18

Reading Inputs 3-18 Writing Outputs 3-18 Application Program Execution 3-19 PLC Numbering Systems 3-20 PLC Resources 3-20 V–memory 3-21 Binary-Coded Decimal Numbers 3-21 Hexadecimal Numbers 3-21

Memory Map 3-22

Octal Numbering System 3-22 Discrete and Word Locations 3-22 V-memory Locations for Discrete Memory Areas 3-22 Input Points (X Data Type) 3-23 Output Points (Y Data Type) 3-23 Control Relays (C Data Type) 3-23 Timers and Timer Status Bits (T Data Type) 3-23 Timer Current Values (V Data Type) 3-24 Counters and Counter Status Bits (CT Data type) 3-24 Counter Current Values (V Data Type) 3-24 Word Memory (V Data Type) 3-25 Stages (S Data type) 3-25 Special Relays (SP Data Type) 3-25

DL05 System V-memory 3-26

System Parameters and Default Data Locations (V Data Type) 3-26 DL05 Memory Map Table 3-28

DL05 Aliases 3-29

X Input Bit Map 3-30

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Y Output Bit Map 3-30

Control Relay Bit Map 3-31

Stage Control/Status Bit Map 3-32

Timer Status Bit Map 3-32

Counter Status Bit Map 3-33

Chapter 4: Configuration and Connections

DL05 System Design Strategies 4-2

I/O System Configurations 4-2 Networking Configurations 4-2 Automatic I/O Configuration 4-3 Power Budgeting 4-3

Network Configuration and Connections 4-4

Configuring the DL05’s Comm Ports 4-4 DL05 Port Specifications 4-4 Networking DL05 to DL05 RS-232 4-4 Networking Using RS–422 Converters 4-5 Modbus Port Configuration 4-6 DirectNET Port Configuration 4-7

Network Slave Operation 4-8

Modbus Function Codes Supported 4-8 Determining the Modbus Address 4-8 If Your Host Software Requires the Data Type and Address... 4-9 Example 1: V2100 4-10 Example 2: Y20 4-10 Example 3: T10 Current Value 4-10

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Example 4: C54 4-10 If Your Modbus Host Software Requires an Address ONLY 4-11 Example 1: V2100 584/984 Mode 4-13 Example 2: Y20 584/984 Mode 4-13 Example 3: T10 Current Value 484 Mode 4-13 Example 4: C54 584/984 Mode 4-13

Network Master Operation 4-14

Step 1: Identify Master Port # and Slave # 4-15 Step 2: Load Number of Bytes to Transfer 4-15 Step 3: Specify Master Memory Area 4-16 Step 4: Specify Slave Memory Area 4-16 Communications from a Ladder Program 4-17 Multiple Read and Write Interlocks 4-17

Chapter 5: Standard RLL and Intelligent Box Instructions

Introduction 5-2

Instruction List 5-2

Using Boolean Instructions 5-4

END Statement 5-4 Simple Rungs 5-4 Normally Closed Contact 5-5 Contacts in Series 5-5 Midline Outputs 5-5 Parallel Elements 5-6 Joining Series Branches in Parallel 5-6 Joining Parallel Branches in Series 5-6 Combination Networks 5-6 Comparative Boolean 5-7

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Boolean Stack 5-7 Immediate Boolean 5-8

Boolean Instructions 5-9

Comparative Boolean 5-25

Immediate Instructions 5-31

Timer, Counter and Shift Register Instructions 5-35

Using Timers 5-35 Timer Example Using Discrete Status Bits 5-37 Timer Example Using Comparative Contacts 5-37 Accumulating Timer Example using Discrete Status Bits 5-39 Accumulator Timer Example Using Comparative Contacts 5-39 Using Counters 5-40 Counter Example Using Discrete Status Bits 5-42 Counter Example Using Comparative Contacts 5-42 Stage Counter Example Using Discrete Status Bits 5-44 Stage Counter Example Using Comparative Contacts 5-44 Up / Down Counter Example Using Discrete Status Bits 5-46 Up / Down Counter Example Using Comparative Contacts 5-46

Accumulator/Stack Load and Output Data Instructions 5-48

Using the Accumulator 5-48 Copying Data to the Accumulator 5-48 Changing the Accumulator Data 5-49 Using the Accumulator Stack 5-50 Using Pointers 5-51

Logical Instructions (Accumulator) 5-60

Math Instructions 5-68

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Bit Operation Instructions 5-82

Number Conversion Instructions (Accumulator) 5-87

Shuffle Digits Block Diagram 5-94

Table Instructions 5-96

Copy Data From a Data Label Area to V-memory 5-98

CPU Control Instructions 5-99

Program Control Instructions 5-101

Understanding Master Control Relays 5-106 MLS/MLR Example 5-107

Interrupt Instructions 5-108

External Interrupt Program Example 5-109 Timed Interrupt Program Example 5-110 Independent Timed Interrupt 5-110

Message Instructions 5-111

Fault Example 5-111 Data Label Example 5-113

Intelligent I/O Instructions 5-118

Network Instructions 5-120

Intelligent Box (IBox) Instructions 5-124

(IBOX) Instructions List

Chapter 6: Drum Instruction Programming

DL05 Drum Introduction 6-2

Purpose 6-2 Drum Terminology 6-2

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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) Instruction 6-14

Program Using the Handheld Programmer 6-16

Chapter 7: RLL

PLUS

Stage Programming

Introduction to Stage Programming 7-2

Overcoming “Stage Fright” 7-2

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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

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

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Stage Counter 7-17 Power Flow Transition Technique 7-18 Stage View in DirectSOFT 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

PLUS

RLL

Stage (SG) 7-21 Initial Stage (ISG) 7-22 JUMP (JMP) 7-22 Not Jump (NJMP) 7-22 Converge Stage (CV) and Converge Jump (CVJMP) 7-23

(Stage) Instructions 7-21

Questions and Answers about Stage Programming 7-25

Chapter 8: PID Loop Operation

DL05 PID Control 8-2

DL05 PID Control Features 8-2

Introduction to PID Control 8-4

What is PID Control? 8-4

Introducing DL05 PID Control 8-6

Process Control Definitions 8-8

PID Loop Operation 8-9

Position Form of the PID Equation 8-9 Step Bias Proportional to Step Change in SP 8-10

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Eliminating Proportional, Integral or Derivative Action 8-10 Velocity Form of the PID Equation 8-10 Reset Windup Protection 8-11 Freeze Bias 8-12 Adjusting the Bias 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 Configure the PID Loop 8-25

PID Loop Tuning 8-40

Open-Loop Test 8-40 Manual Tuning Procedure 8-41 Auto Tuning Procedure 8-45 Use Direct SOFT Data View with PID View 8-49 Open a New Data View Window 8-49 Open PID View 8-50

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Using Other PID Features 8-53

How to Change Loop Modes 8-53 Operator Panel Control of PID Modes 8-54 Loop Mode Override 8-54 PV Analog Filter 8-55 Creating an Analog Filter in Ladder Logic 8-56 Use the DirectSOFT Filter Intelligent Box Instruction 8-57 FilterB Example 8-57

Ramp/Soak Generator 8-58

Introduction 8-58 Ramp/Soak Table 8-59 Ramp/Soak Table Flags 8-61 Ramp/Soak Generator Enable 8-61 Ramp/Soak Controls 8-61 Ramp/Soak Profile Monitoring 8-62 Ramp/Soak Programming Errors 8-62 Testing Your Ramp/Soak Profile 8-62

DirectSOFT Ramp/Soak Example 8-63

Setup the Profile in PID Setup 8-63 Program the Ramp/Soak Control in Relay Ladder 8-63 Test the Profile 8-64

Cascade Control 8-65

Introduction 8-65 Cascaded Loops in the DL05 CPU 8-66 Tuning Cascaded Loops 8-67

Time-Proportioning Control 8-68

On/Off Control Program Example 8-69

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Feedforward Control 8-70

Feedforward Example 8-71

PID Example Program 8-72

Program Setup for the PID Loop 8-72

Troubleshooting Tips 8-74

Glossary of PID Loop Terminology 8-76

Bibliography 8-78

Chapter 9: Maintenance and Troubleshooting

Hardware System Maintenance 9-2

Standard Maintenance 9-2

Diagnostics 9-2

Diagnostics 9-2 Fatal Errors 9-2 Non-fatal Errors 9-2 V-memory Error Code Locations 9-3 Special Relays (SP) Corresponding to Error Codes 9-3 DL05 Micro PLC Error Codes 9-4 Program Error Codes 9-5

CPU Indicators 9-6

RUN Indicator 9-7 CPU Indicator 9-7

Communications Problems 9-7

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I/O Point Troubleshooting 9-8

Possible Causes 9-8 Some Quick Steps 9-8 Handheld Programmer Keystrokes Used to Test an Output Point 9-9

Noise Troubleshooting 9-10

Electrical Noise Problems 9-10 Reducing Electrical Noise 9-10

Machine Startup and Program Troubleshooting 9-11

Syntax Check 9-11 Special Instructions 9-12 Duplicate Reference Check 9-13 Run Time Edits 9-14 Forcing I/O Points 9-16 Reset the PLC to Factory Defaults 9-17

Chapter 10: Memory Cartridge/Real Time Clock

General Information about the D0–01MC 10-2

Jumper Selects Write Enable or Disable 10-2 Low Battery Alert 10-2 Clock/Calendar 10-2 Specifications 10-2 New Ladder Instructions 10-2 Error Code Changes 10-2

Setting the Write Enable/Disable Jumper 10-3

Write Enable 10-3 Write Disable 10-3

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Plugging-in the Memory Cartridge 10-4

Remove the Slot Cover 10-4 Insert the Memory Cartridge 10-4

Software and Firmware Requirements 10-5

How to Update Your DirectSOFT Programming Software 10-5 How to Update Your DL05 Firmware 10-5

Naming the Memory Cartridge 10-6

Up to 8 Alphanumeric Characters 10-6 Name is Retained in Cartridge Memory and Project Folder 10-6

Setting the Time and Date 10-7

Memory Transfers 10-8

CPU to MC 10-8 MC to CPU 10-8

LED Indicator Lights 10-9

Password Protected Programs 10-9

Memory Map and Forwarding Range 10-10

Battery Back-up During AC Power Loss 10-11

What if the Battery Dies? 10-11 Battery Type 10-11 Removing and Replacing the Battery 10-11

Specifications and Agency Approvals 10-12

Clock/Calendar Instructions 10-13

Date (DATE) 10-13 Time (TIME) 10-14 Move Memory Cartridge / Load Label (MOVMC) (LDLBL) 10-15

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Copy Data From a Data Label Area to V-memory 10-16 Copy Data From V-memory to a Data Label Area 10-17

Error Codes 10-18

Appendix A: Auxiliary Functions

Introduction A-2

Purpose of 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 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-4

AUX 4* — I/O Configuration A-5

AUX 5* — CPU Configuration A-5

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AUX 31 Clear V-Memory A-4

AUX 41 Show I/O Configuration A-5

AUX 51 Modify Program Name A-5 AUX 53 Display Scan Time A-5 AUX 54 Initialize Scratchpad A-5 AUX 55 Set Watchdog Timer A-5 AUX 56 CPU Network Address A-6 AUX 57 Set Retentive Ranges A-6 AUX 58 Test Operations A-6 AUX 59 Bit Override A-7

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AUX 5B Counter Interface Configuration A-7 AUX 5D Select PLC Scan Mode A-7

AUX 6* — Handheld Programmer Configuration A-8

AUX 61 Show Revision Numbers A-8 AUX 62 Beeper On/Off A-8 AUX 65 Run Self Diagnostics A-8

AUX 7* — EEPROM Operations A-8

Transferrable Memory Areas A-8 AUX 71 CPU to HPP EEPROM A-8 AUX 72 HPP EEPROM to CPU A-9 AUX 73 Compare HPP EEPROM to CPU A-9 AUX 74 HPP EEPROM Blank Check A-9 AUX 75 Erase HPP EEPROM A-9 AUX 76 Show EEPROM Type A-9

AUX 8* — Password Operations A-9

AUX 81 Modify Password A-9 AUX 82 Unlock CPU A-10 AUX 83 Lock CPU A-10

Appendix B: DL05 Error Codes

DL05 Error Codes B-2

Appendix C: Instruction Execution Times

Introduction C-2

V-memory Data Registers C-2 V-memory Bit Registers C-2 How to Read the Tables C-2

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Instruction Execution Times C-3

Boolean Instructions C-3 Comparative Boolean Instructions C-4 Immediate Instructions C-10 Timer, Counter and Shift Register C-10 Accumulator Data Instructions C-11 Logical Instructions

Math Instructions C-12 Bit Instructions C-14 Number Conversion Instructions C-14 Table Instructions C-14 CPU Control Instructions C-15 Program Control Instructions C-15 Interrupt Instructions C-15 Network Instructions C-15 Message Instructions C-16

plus

RLL Drum Instructions C-16 Word Bit Instructions C-17

Instructions C-16

Appendix D: Special Relays

DL05 PLC Special Relays D-2

Appendix E: High-speed Input and Pulse Output Features

Introduction E-2

Built-in Motion Control Solution E-2 Availability of HSIO Features E-2 Dedicated High- Speed I/O Circuit E-3 Wiring Diagrams for Each HSIO Mode E-3

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Choosing the HSIO Operating Mode E-4

Understanding the Six Modes E-4 Default Mode E-4 Configuring the HSIO Mode E-5 Configuring Inputs X0 – X2 E-5

Mode 10: High-Speed Counter E-6

Purpose E-6 Functional Block Diagram E-6 Wiring E-7 Setup for Mode 10 E-8 Presets and Special Relays E-8 Preset Data Starting Location E-9 Using Fewer than 24 Presets E-9 Equal Relay Numbers E-9 Calculating Your Preset Values E-10 X Input Configuration E-10 Writing Your Control Program E-11 Program Example: Counter Without Preset E-12 Program Example (cont’d) E-13 Counter With Presets Program Example E-14 Counter With Preload Program Example E-16 Troubleshooting Guide for Mode 10 E-17 Symptom: The counter does not count. E-17 Symptom: The counter counts but the presets do not function. E-17 Symptom: The counter counts up but will not reset. E-17

Mode 20: Quadrature Counter E-18

Purpose E-18 Functional Block Diagram E-18 Quadrature Encoder Signals E-18 Wiring Diagram E-19

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Table of ContentsTable of Contents

Interfacing to Encoder Outputs E-19 Setup for Mode 20 E-20 X Input Configuration E-20 Writing Your Control Program E-21 Quadrature Counter w/Preload Program Example E-21 Counter Preload Program Example E-23 Troubleshooting Guide for HSIO Mode 20 E-23

Mode 30: Pulse Output E-24

Purpose E-24 Functional Block Diagram E-25 Wiring Diagram E-26 Interfacing to Drive Inputs E-26 Motion Control Profile Specifications E-27 Physical I/O Configuration E-27 Logical I/O Functions E-27 Setup for Mode 30 E-28 Profile / Velocity Select Register E-28 Profile Parameter Table E-29 Trapezoidal Profile E-29 Registration Profile E-29 Velocity Profile E-29 Choosing the Profile Type E-30 Trapezoidal Profile Defined E-30 Registration and Home Search Profiles Defined E-30 Velocity Profile Defined E-30

Trapezoidal Profile Operation E-31

Trapezoidal Profile Applications E-31 Trapezoidal Profile Program Example E-32 Preload Position Value E-33

DL05 Micro PLC User Manual, 6th Edition, Rev. D

xxii

Page 29

Table of Contents

Registration Profile Operation E-34

Registration Applications E-34 Program Example 1: Registration Profile E-35 Program Example 2: Automatic Trapezoidal Profile with Home Search E-37

Velocity Profile Operation E-42

Velocity Profile Applications E-42 Velocity Profile Program Example E-43 Pulse Output Error Codes E-45 Troubleshooting Guide for HSIO Mode 30 E-45

Mode 40: High-Speed Interrupts E-47

Purpose E-47 Functional Block Diagram E-47 Setup for Mode 40 E-48 Interrupts and the Ladder Program E-48 External Interrupt Timing Parameters E-49 External Interrupt Program Example E-50 Timed Interrupt Program Example E-51

Mode 50: Pulse Catch Input E-52

Purpose E-52 Functional Block Diagram E-52 Pulse Catch Timing Parameters E-52 Setup for Mode 50 E-53 X Input Configuration E-53 Pulse Catch Program Example E-54

Mode 60: Discrete Inputs with Filter E-55

Purpose E-55 Functional Block Diagram E-55

DL05 Micro PLC User Manual, 6th Edition, Rev. D

xxiii

Page 30

Table of Contents

Input Filter Timing Parameters E-55 Setup for Mode 60 E-56 X Input Configuration E-56 Filtered Inputs Program Example E-57

Appendix F: PLC Memory

DL05 PLC Memory F-2

Non-volatile V-memory in the DL05 F-3

Appendix G: ASCII Table

ASCII TABLE G-2

Appendix H: Product Weights

Product Weight Table H-2

Appendix I: Numbering System

Introduction I-2

Binary Numbering System I-2

Hexadecimal Numbering System I-3

Octal Numbering System I-4

Binary Coded Decimal (BCD) Numbering System I-5

Real (Floating Point) Numbering System I-5

BCD/Binary/Decimal/Hex/Octal What is the Difference? I-6

xxiv

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 31

Table of Contents

Data Type Mismatch I-7

Signed vs. Unsigned Integers I-8

AutomationDirect.com Products and Data Types I-9

DirectLOGIC PLCs I-9 C-more/C-more Micro-Graphic Panels I-9

Appendix J: European Union Directives (CE)

European Union (EU) Directives J-2

Member Countries J-2 Applicable Directives J-2 Compliance J-2 General Safety J-3 Special Installation Manual J-4 Other Sources of Information J-4

Basic EMC Installation Guidelines J-5

Enclosures J-5 Electrostatic Discharge (ESD) J-5 AC Mains Filters J-6 Suppression and Fusing J-6 Internal Enclosure Grounding J-6 Equi–potential Grounding J-7 Communications and Shielded Cables J-7 Analog and RS232 Cables J-8 Multidrop Cables J-8 Shielded Cables within Enclosures J-9 Analog Modules and RF Interference J-9 Network Isolation J-9 DC Powered Versions J-9 Items Specific to the DL05 J-10

DL05 Micro PLC User Manual, 6th Edition, Rev. D

xxv

Page 32

Table of Contents

Appendix K: Introduction to Serial Communications

Introduction to Serial Communications K-2

Wiring Standards K-2 Communications Protocols K-3 DL05 Port Specifications K-4 DL05 Port Pinouts K-4 Port Setup Using DirectSOFT or Ladder Logic Instructions K-5 Port 2 Setup for RLL Using K-Sequence, DirectNET or Modbus RTU K-6 K-Sequence Communications K-9 DirectNET Communications K-9 Step 1: Identify Master Port # and Slave # K-9 Step 2: Load Number of Bytes to Transfer K-9 Step 3: Specify Master Memory Area K-10 Step 4: Specify Slave Memory Area K-11 Communications from a Ladder Program K-12 Multiple Read and Write Interlocks K-12 Modbus RTU Communications K-13

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DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 33

Chapter

GettinG Started

GeTTinG sTarTeD

In this Chapter

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

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

DL05 Micro PLC Components................................................................... 1–4

Programming Methods............................................................................. 1–4

I/O Selection Quick Chart......................................................................... 1–5

Quick Start for PLC Checkout and Programming.................................... 1–6

Steps to Designing a Successful System................................................. 1–10

Questions and Answers about DL05 Micro PLCs.................................... 1–12

Page 34

Chapter 1: Getting Started

Introduction

The Purpose of this Manual

Thank you for purchasing a DL05 Micro PLC. This manual shows you how to install, program, and maintain all the Micro PLCs in the DL05 family. 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 DL05 PLCs, and for the PLC programmer. If you understand PLC systems our manuals will provide all the information you need to get and keep your system up and running.

Where to Begin

If you already understand the DL05 Micro PLC please read Chapter 2, “Installation, Wiring, and Specifications”, and proceed on to other chapters as needed. Be sure to keep this manual handy for reference when you run into questions. If you are a new DL05 customer, we suggest you read this manual completely so you can understand the wide variety of features in the DL05 family of products. We believe you will be pleasantly surprised with how much you can accomplish with AutomationDirect products.

Supplemental Manuals

The D0–OPTIONS–M manual will be most helpful to select and use any of the optional modules that are available for the DL05 PLC which includes the analog I/O modules. If you have purchased operator interfaces or DirectSOFT programming software you will need to supplement this manual with the manuals that are written for these products.

Technical Support

We realize that even though we strive to be the best, we may have arranged our information in such a way you cannot find what you are looking for. First, check these resources for help in locating the information:

• Table of Contents – chapter and section listing of contents, in the front of this manual

• Appendices – reference material for key topics, near the end of this manual

You can also check our online resources for the latest product support information:

• Internet – the address of our website is: http://www.automationdirect.com

If you still need assistance, please call us at 770–844–4200. Our technical support team will be available to work with you in answering your questions. They are available Monday through Friday from 9:00 A.M. to 6:00 P.M. Eastern Standard Time.

1-2

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 35

Chapter 1: Getting Started

Conventions Used

When you see the “notepad” icon in the left-hand margin, the paragraph to its immediate right will be a special note. Notes represent information that may make your work quicker or more efficient. The word NOTE: in boldface will mark the beginning of the text.

When you see the “exclamation point” 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. Any warning in this manual should be regarded as critical information that should be read in its entirety. 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.

Getting Started

In This Chapter...

General Information

CHAPTER

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

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

DL05 Micro PLC User Manual, 6th Edition, Rev. D

1-3

Page 36

Chapter 1: Getting Started

DL05 Micro PLC Components

The DL05 Micro PLC family is a versatile product line that provides a wide variety of features in a very compact footprint. The PLCs are small, yet offer many features usually found only in larger, more expensive systems. These include a removable connector, and two RS232 communication ports.

The DL05 Micro PLC Family

The DL05 Micro PLC family includes eight different versions. All have the same appearance and CPU performance. The CPU offers the same instruction set as our popular DL240 CPU, plus several more instructions specifically designed for machine control applications. All DL05 PLCs have two RS232 communications ports. Units with DC inputs have selectable highspeed input features on three input points. Units with DC outputs offer selectable pulse output capability on the first and second output points. All DL05 Micro PLCs offer a large amount of program memory, a substantial instruction set and advanced diagnostics. Details of these features and more are covered in Chapter 3, CPU Specifications and Operation. The eight types of DL05 Micro PLCs provide a variety of Input/Output choices, listed in the following table.

DirectSOFT Programming for Windows™

DL05 Micro PLC Family

DL05 Part

Number D0–05AR D0–05DR D0–05AD D0–05DD D0–05AA D0–05DA

D0–05DR–D D0–05DD–D

The DL05 Micro PLC can be programmed with one of the most advanced programming packages in the industry ––DirectSOFT, a Windows-based software package that supports familiar features such as cut-and-paste between applications, point-and-click editing, viewing and editing multiple application programs at the same time, etc.

Discrete Input

Type

AC Relay 95–240 VAC No No DC Relay 95–240 VAC Yes No AC DC 95–240 VAC No Yes DC DC 95–240 VAC Yes Yes AC AC 95–240 VAC No No DC AC 95–240 VAC Yes No DC Relay 12–24 VDC Yes No DC DC 12–24 VDC Yes Yes

Discrete Output

Type

External Power

High-Speed

Input

Pulse Output

1-4

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 37

Chapter 1: Getting Started

DirectSOFT universally supports the DirectLOGIC CPU families. This means you can use the full version of DirectSOFT to program DL05, DL06, DL105, DL205, DL305, DL405 CPUs. The DirectSOFT Programming Software User Manual discusses the programming language in depth. DirectSOFT version 2.4 or later is needed to program the DL05.

Handheld Programmer

All DL05 Micro PLCs have built-in programming ports for use with the handheld programmer (D2–HPP), the same programmer used with the DL06, DL105 and DL205 families. The handheld programmer can be used to create, modify and debug your application program. A separate manual discusses the handheld programmer. Only D2–HPPs with firmware version

1.09 or later will program the DL05.

NOTE: Not all program instructions are available to use with the HHP, such as the DRUM instruction. Use DirectSOFT for these instructions.

I/O Selection Quick Chart

The eight versions of the DL05 have Input/Output circuits which can interface to a wide variety of field devices. In several instances a particular Input or Output circuit can interface to either DC or AC voltages, or both sinking and sourcing circuit arrangements. Check this chart carefully to find the proper DL05 Micro PLC to interface to the field devices in your application.

DL05 Part

Number

D0–05AR

D0–05DR

D0–05AD

D0–05DD

D0–05AA D0–05DA

D0–05DR–D

D0–05DD–D

I/O type/

commons

AC / 2 – 90 – 120 VAC Relay / 2 Sink or Source

DC / 2 Sink or Source 12 – 24 VDC Relay / 2 Sink or Source

AC / 2 – 90 – 120 VAC DC / 1 Sink

DC / 2 Sink or Source 12 – 24 VDC DC / 1 Sink

AC / 2 – 90 – 120 VAC AC / 2 – 17 – 240 VAC, 47 – 63 Hz, 0.5A* DC / 2 Sink or Source 12 – 24 VDC AC / 2 – 17 – 240 VAC, 47 – 63 Hz, 0.5A *

DC / 2 Sink or Source 12 – 24 VDC Relay / 2 Sink or Source

DC / 2 Sink or Source 12 – 24 VDC DC / 1 Sink

INPUTS OUTPUTS

Sink/Source

I/O Selection Chart

Voltage Ranges

I/O type/

commons

Sink/Source Voltage/ Current Ratings

6 – 27VDC, 2A*

6 – 240 VAC, 2A *

6 – 27VDC, 2A*

6 – 240 VAC, 2A *

6 – 27 VDC, 0.5A (Y0–Y2) 6 – 27 VDC, 1.0A (Y3–Y5)

6 – 27 VDC, 2A

6 – 240 VAC, 2A *

6 – 27 VDC, 0.5A (Y0–Y2) 6 – 27 VDC, 1.0A (Y3–Y5)

* See Chapter 2 Specifications for your particular DL05 version.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

1-5

Page 38

Chapter 1: Getting Started

Quick Start for PLC Checkout and Programming

This example is not intended to tell you everything you need to start-up your system, warnings and helpful tips are in the rest of the manual. It is only intended to give you a general picture of what you will need to do to get your system powered-up.

Step 1: Unpack the DL05 Equipment

Unpack the DL05 and gather the parts necessary to build this demonstration system. The recommended components are:

• DL05 Micro PLC

• AC power cord or DC power supply

• Toggle switches or simulator module, F0-08SIM(see Step 2 on next page).

• Hook-up wire, 16-22 AWG

• DL05 User Manual (this manual)

• A small screwdriver, 5/8” flat or #1 Philips type

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

• DirectSOFT Programming Software, DirectSOFT Manual, and a programming cable (connects the DL05 to a personal computer), or

• D2-HPP Handheld Programmer (comes with programming cable), and the Handheld

Programmer Manual

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Chapter 1: Getting Started

D0-O5DR, D0-05DD, D0-05DA

Y0 - Y5: OutputX0 - X7: Input

D0–05AR, D0–05AD, D0–05AA

(AC input versions, 120V AC only)

Toggle Switches, UL Listed

Step 2: Connect Switches to Input Terminals

To finish this quick-start exercise or study other examples in this manual, you’ll need to either connect some input switches as shown below or install the F0-08SIM, simulator module, which needs no wiring, into the option slot. If you have DC inputs you will need to use the FA–24PS (24VDC) or another external 12-24VDC power supply. Be sure to follow the instructions in the accompanying WARNING note.

D0-05DR-D, D0-05DD-D

(DC input versions, 12-24VDC)

–

12–24VDC Power Supply

X0 - X7: Input

Y0 - Y5: Output

Toggle Switches, UL Listed

WARNING: DO NOT wire the

DL05 Micro PLC User Manual, 6th Edition, Rev. D

toggle switches as shown to 240VAC-powered units. The discrete inputs will only accept 120VAC nominal. Also, remove power and unplug the DL05 when wiring the switches. Only use UL-approved switches rated for at least 250VAC, 1A for AC inputs. Firmly mount the switches before using.

1-7

Page 40

Chapter 1: Getting Started

Step 3: Connect the Power Wiring

Connect the power input wiring for the DL05. Observe all precautions stated earlier in this

manual. For more details on wiring, see Chapter 2 on Installation, Wiring, and Specifications. When the wiring is complete, close the connector covers. Do not apply power at this time.

110/220 VAC Power Input

Y0 - Y5: OutputX0 - X7: Input

LGN

95 - 240 VAC

Step 4: Connect the Programming Device

Most programmers will use DirectSOFT programming software, installed on a personal computer. Or, you may need the portability of the Handheld Programmer. Both devices will connect to COM port 1 of the DL05 via the appropriate cable.

Use cable part #

D2–DSCBL

12/24 VDC Power Input

12-24 VDC 20 W max

X0 - X7: Input

Y0 - Y5: Output

1-8

(cable comes with HPP)

For replacement cable, use part #

DV–1000CBL

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 1: Getting Started

Step 5: Switch on the System Power

Apply power to the system and ensure the PWR indicator on the DL05 is on. If not, remove power from the system and check all wiring and refer to the troubleshooting section in Chapter 9 for assistance.

Step 6: Initialize Scratchpad Memory

It’s a good precaution to always clear the system memory (scratchpad memory) on a new DL05. There are two ways to clear the system memory:

• In DirectSOFT, select the PLC menu, then Setup, then Initialize Scratchpad. For additional information, see the DirectSOFT Manual.

• For the Handheld Programmer, use the AUX key and execute AUX 54.

See the Handheld Programmer Manual for additional information.

Step 7: Enter a Ladder Program

At this point, DirectSOFT programmers need to refer to the Quick Start Tutorial in the DirectSOFT Manual. There you will learn how to establish a communications link with the

DL05 PLC, change CPU modes to Run or Program, and enter a program. If you are learning how to program with the Handheld Programmer, make sure the CPU is in Program Mode (the RUN LED on the front of the DL05 should be off). If the RUN LED is on, use the MODE key on the Handheld Programmer to put the PLC in Program Mode. Enter the following keystrokes on the Handheld Programmer.

Equivalent

After entering the simple example program put the PLC in Run mode by using the Mode key on the Handheld Programmer.

The RUN indicator on the PLC will illuminate indicating the CPU has entered the Run mode. If not, repeat this step, ensuring the program is entered properly or refer to the troubleshooting guide in chapter 9.

After the CPU enters the run mode, the output status indicator for Y0 should follow the switch status on input channel X0. When the switch is on, the output will be on.

DirectSOFT display

OUT

END

CLR CLR

OUT

SHFT

STR

AUX ENT

TMR

ENT

ENT CLR

ENT

Clear the Program

Move to the first address and enter X0 contact

Enter output Y0

Enter the END statement

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Page 42

Chapter 1: Getting Started

Steps to Designing a Successful System

Step 1: Review the Installation Guidelines

Always make safety the first priority in any system design. Chapter 2 provides several guidelines that will help you design a safer, more reliable system. This chapter also includes wiring guidelines for the various versions of the DL05 PLC.

Step 2: Understand the PLC Setup Procedures

The PLC is the heart of your automation system. Make sure you take time to understand the various features and setup requirements.

Step 3: Review the I/O Selection Criteria

There are many considerations involved when you select your I/O type and field devices. Take time to understand how the various types of sensors and loads can affect your choice of I/O type.

Step 4: Choose a System Wiring Strategy

It is important to understand the various system design options that are available before wiring field devices and field-side power supplies to the Micro PLC.

Step 5: Understand the System Operation

Before you begin to enter a program, it is very helpful to understand how the DL05 system processes information. This involves not only program execution steps, but also involves the various modes of operation and memory layout characteristics.

+24 VDC

+–

Input

–

DL05

PLC

Common

AC Power

Power Input

Power Up

Initialize Hardware

PLC

Input

Sensing

Loads

8 Inputs Commons

Commons6 Outputs

1-10

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 1: Getting Started

Standard RLL Programming

Timer/Event Drum Sequencer

Stage Programming

Step 6: Review the Programming Concepts

The DL05 PLC instruction set provides for three main approaches to solving the application program, depicted in the figure below.

• 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 also be needed to augment drums and stages.

• The Timer/Event Drum Sequencer features up to 16 steps and offers both time and/or event-

based step transitions. The DRUM instruction is best for a repetitive process based on a single series of steps.

• Stage programming (also called RLL

the ladder program into sections which correspond to the states in a flow chart you draw for your process.

(see Chapter 5)

SP62

After reviewing the programming concepts above, you’ll be equipped with a variety of tools to write your application program.

LDD V1076

CMPD K309482

Y0 OUT

plus

) is based on state-transition diagrams. Stages divide

(see Chapter 6)

DOWN

(see Chapter 7)

Push–UP

LOWER

LIGHT

Step 7: Choose the Instructions

Once you have installed the Micro PLC and understand the main programming concepts, you can begin writing your application program. At that time you will begin to use one of the most powerful instruction sets available in a small PLC.

TMR T1

K30

RAISE

Push–

DOWN

CNT CT3

K10

Step 8: Understand the Maintenance and Troubleshooting Procedures

Sometimes equipment failures occur when we least expect it. Switches fail, loads short and need to be replaced, etc. In most cases, the majority of the troubleshooting and maintenance time is spent trying to locate the problem. The DL05 Micro PLC has many built-in features such as error codes that can help you quickly identify problems.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Page 44

Chapter 1: Getting Started

Questions and Answers about DL05 Micro PLCs

Q. What is the instruction set like?

A. The instruction set is very close to our popular DL240 CPU. However, there are significant

additions, such as the drum instruction, networking, PID control and High-Speed I/O capabilities.

Q. Do I have to buy the full DirectSOFT programming package to program the

DL05?

A. No, DirectSOFT programming software is available for programming DirectLOGIC

PLCs for no additional charge; however, it will only allow 100 maximum words to be programmed. Go to AutomationDirect.com for more information.

Q. Is the DL05 expandable?

A. No, the DL05 series are stand-alone PLCs with one slot for the installation of an available

option module. They do not have expansion bases, such as our DL205 system which has expansion bases, yet are very compact and affordable.

Q. Does the DL05 have motion control capability?

A. Yes. The units with DC I/O have selectable high-speed input features on three inputs. There

is also an optional High-Speed Counter I/O module available with special utility software. Either can accept pulse-type input signals for high-speed counting or timing applications and provide high-speed pulse-type output signals for stepper/servo motor control, monitoring, alarm or other discrete control functions. Three types of motion profiles are available, which are explained in Chapter 3.

Q. Are the ladder programs stored in a removable EEPROM?

A. The DL05 contains a non-removable FLASH memory for program storage, which may be

written and erased thousands of times. You may transfer programs to/from the DL05 using DirectSOFT on a PC, or the HPP (which does support a removable EEPROM). There is an optional CMOS RAM memory cartridge (MC) available (See Chapter 10).

1-12

Q. Does the DL05 contain fuses for its outputs?

A. There are no output circuit fuses. Therefore, we recommend fusing each channel, or fusing

each common. See Chapter 2 for I/O wiring guidelines.

Q. Is the DL05 Micro PLC U.L. approved?

A. The Micro PLC has met the requirements of UL (Underwriters’ Laboratories, Inc.), and

CUL (Canadian Underwriters’ Laboratories, Inc.).

Q. Does the DL05 Micro PLC comply with European Union (EU) Directives?

A. The Micro PLC has met the requirements of the European Union Directives (CE).

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 45

Chapter 1: Getting Started

Q. Which devices can I connect to the communication ports of the DL05?

A. Port 1: The port is RS-232, fixed at 9600 baud, and uses the proprietary K-sequence

protocol. The DL05 can also connect to Modbus RTU and DirectNET networks as a slave device through port 1. The port communicates with the following devices:

• DV-1000 Data Access Unit or Optimation Operator interface panels

• DirectSOFT (running on a personal computer)

• D2-HPP handheld programmer

• Other devices which communicate via K-sequence protocol should work with the DL05 Micro PLC. Contact the vendor for details.

A. Port 2: The port is RS232, with selective baud rates (300-38,400bps), address and parity. It

also supports the proprietary K-sequence protocol as well as DirectNET and Modbus RTU and non-sequence/print protocols.

Q. Can the DL05 accept 5VDC inputs?

A. No, 5 volts is lower than the DC input ON threshold. However, many TTL logic circuits

can drive the inputs if they are wired as open collector (sinking) inputs. See Chapter 2 for I/O wiring guidelines.

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Chapter 1: Getting Started

Notes

1-14

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 47

Chapter

InstallatIon, WIrIng,

insTaLLaTion, WirinG,

and specIfIcatIons

anD sPecificaTions

In this Chapter

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

Orientation to DL05 Front Panel.............................................................. 2–5

Mounting Guidelines................................................................................. 2–7

Wiring Guidelines.................................................................................... 2–11

System Wiring Strategies........................................................................ 2–14

Wiring Diagrams and Specifications....................................................... 2–32

Glossary of Specification Terms.............................................................. 2–48

Chapter

Page 48

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 or damage to equipment. Do not rely on the automation system alone to provide a safe operating environment. You should use external electromechanical devices, such as relays or limit switches, that are independent of the PLC application to provide protection for any part of the system that may cause personal injury or damage. Every automation application is different, so there may be special requirements for your particular application. Make sure you follow all national, state, and local government requirements 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.

2-2

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 49

Chapter 2: Installation, Wiring, and Specifications

Saw Arbor

E STOP

Emergency Stop

Power On

Use E-Stop and Master Relay

Guard Master Link Relay

Guard Line Switc

MR

L to Output ommons

L to nput ommons optional

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.).

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 2: Installation, Wiring, and Specifications

Retract

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.

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.

Jam Detect

Turn off Saw

RST

2-4

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 2: Installation, Wiring, and Specifications

Mode Switc

Orientation to DL05 Front Panel

Most connections, indicators, and labels on the DL05 Micro PLCs are located on its front panel. The communication ports are located on the top side of the PLC. Please refer to the drawing below.

Mounting tab

Input Status Indicators

External Power

Inputs Terminals

The upper section of the connector accepts external power connections on the two left-most terminals. From left to right, the next five terminals are one of the input commons (C0) and input connections X1, X3, X4, and X6. The remaining four connections are an output common (C2) and output terminals Y1, Y3, and Y5.

The lower section of the connector has the chassis ground (G) and the logic ground (LG) on the two left-most terminals. The next two terminals are for the inputs X0 and X2. Next is the other input common (C1) followed by inputs X5 and X7. The last four terminals are for outputs Y0, Y2, Y4, and the second output common (C3). On DC output units, the end terminal on the right accepts power for the output stage.

An option slot is located on the right end of the PLC. This is where the simulator module can be installed for testing. Option module descriptions available for the DL05 can be found either in the DL05/DL06 Options Modules User Manual, D0-OPTIONS-M, in our catalog or on our website.

Discrete Input

Discrete Output

e rminals

Communication Ports

Output Circuit Power Input

or DC output  ersions onl

Output Status Indicators

Status

Indicators

Mounting tab

WARNING: For some applications, field device power may still be present on the terminal block even though the Micro PLC is turned off. To minimize the risk of electrical shock, check all field device power before you expose or remove either connector wire from under a terminal block, or two 18 AWG wires (one on each side of the screw).

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 2: Installation, Wiring, and Specifications

Connector Removal

All of the terminals for the DL05 are contained on one connector block. In some instances, it may be desirable to remove the connector block for easy wiring. The connector is designed for easy removal with just a small screwdriver. The drawing below shows the procedure for removal at one end.

Connector Removal

1. Loosen the retention screws on each end of the connector block.

2. From the center of the connector block, pry upward with the screwdriver until the connector is loose.

The terminal block connector on DL05 PLCs has regular screw terminals, which will accept either standard blade-type or #1 Philips screwdriver tips. Use No. 16 to 18 AWG solid/stranded wire. The maximum torque is 0.343Nm (3.036 inch-lbs).

Spare terminal block connectors and connector covers may be ordered by individual part numbers:

2-6

Spare Parts -Terminal Block and Cover

Part Number Qty Per Package Description

F0-IOCON 2 DL05 I/O Terminal Block

D0-AAC-1 1 each

DL05 Micro PLC User Manual, 6th Edition, Rev. D

DL05 I/O Terminal Block, I/O Terminal

Block Cover, and Option Slot Cover

Page 53

Chapter 2: Installation, Wiring, and Specifications

3.94"

100mm

3.34"

85mm

0.39"

10mm

0.39" 10mm

4.72"

120mm

3.74"

95mm

2.56"

65mm

2.68"

68mm

(DIN Rail)

0.24" mounting tab 6mm

1.46"

37mm

18mm

0.71"

12mm

0.47"

Mounting Guidelines

In addition to the panel layout guidelines, other specifications can affect the definition and installation of a PLC system. Always consider the following:

• Environmental Specifications

• Power Requirements

• Agency Approvals

• Enclosure Selection and Component Dimensions

Unit Dimensions

The following diagram shows the outside dimensions and mounting hole locations for all versions of the DL05. Make sure you follow the installation guidelines to allow proper spacing from other components.

Enclosures

Your selection of a proper enclosure is important to ensure safe and proper operation of your DL05 system. Applications of DL05 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

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 2: Installation, Wiring, and Specifications

Panel Layout & Clearances

There are many things to consider when designing the panel layout. The following items correspond to the diagram shown. Note: there may be additional requirements, depending on your application and use of other components in the cabinet.

1. Mount the PLCs horizontally as shown below to provide proper ventilation. You cannot mount the DL05 units vertically, upside down, or on a flat horizontal surface. If you place more than one unit in a cabinet, there must be a minimum of 7.2” (183mm) between the units.

2. Provide a minimum clearance of 2” (50mm) between the unit and all sides of the cabinet. Note, remember to allow for any operator panels or other items mounted in the door.

3. There should also be at least 3” (78mm) of clearance between the unit and any wiring ducts that run parallel to the terminals.

4. The ground terminal on the DL05 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.

NOTE: There is a minimum clearance requirement of 2” (51cm) between the panel door (or any devices mounted in the panel door) and the nearest DL05 component.

Panel Ground braid

Star Washers

5. 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. Minimum wire sizes, color coding, and general safety practices should comply with appropriate electrical codes and standards for your area.

6. A good common ground reference (Earth ground) is essential for proper operation of the DL05. One side of all control and power circuits and the ground lead on flexible shielded cable must be properly connected to common ground reference. Methods which provide a good common ground reference, include: a) Installing a ground rod as close to the panel as possible. b) Connection to incoming power system ground.

copper lugs

Star Washers

Panel or single

point ground

Power Source

Temperature Probe

Panel Ground Terminal

BusBar

2-8

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Chapter 2: Installation, Wiring, and Specifications

Din Rail Slot

7. Evaluate any installations where the ambient temperature may approach the lower or upper limits of the specifications. If you suspect the ambient temperature will not be within the operating specification for the DL05 system, measures such as installing a cooling/heating source must be taken to get the ambient temperature within the range of specifications.

8. The DL05 systems are designed to be powered by 95-240 VAC or 12–24 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 DL05 PLCs from power surges and EMI/RFI noise. The Automation Powerline Filter, for use with 120 VAC and 240 VAC, 1–5 Amps (part number APF120N05), is an excellent choice, however, you can use a filter of your choice. These units install easily between the power source and the PLC.

NOTE: If you are using other components in your system, make sure you refer to the appropriate manual to determine how those units can affect mounting dimensions.

Using DIN Rail Mounting Rails

DL05 Micro PLCs can be secured to a panel by using mounting rails. We recommend rails that conform to DIN EN standard 50 022. They are approximately 35mm high, with a depth of 7mm. If you mount the Micro PLC on a rail, do consider using end brackets on each side of the PLC. The end bracket helps keep the PLC from sliding horizontally along the rail, reducing the possibility of accidentally pulling the wiring loose. On the bottom of the PLC is a small retaining clip. To secure the PLC to a DIN rail, place it onto the rail and gently push up on the clip to lock it onto the rail. To remove the PLC, pull down on the retaining clip, lift up on the PLC slightly, then pulling it away from the rail.

Din Rail Dimensions

7mm

Use 35mm x 7mm rail conforming to DIN EN 50022

35mm

Retaining clip

NOTE: Refer to our catalog for a complete listing of DINnector connection systems.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 2: Installation, Wiring, and Specifications

Environmental Specifications

The following table lists the environmental specifications that generally apply to DL05 Micro PLCs. The ranges that vary for the Handheld Programmer are noted at the bottom of this chart. Certain output circuit types may have derating curves, depending on the ambient temperature and the number of outputs ON. Please refer to the appropriate section in this chapter pertaining to your particular DL05 PLC.

* 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° to70° C).

** Equipment will operate down to 5% relative humidity. However, static electricity problems

occur much more frequently at low humidity levels (below 30%). Make sure you take adequate precautions when you touch the equipment. Consider using ground straps, antistatic floor coverings, etc. if you use the equipment in low-humidity environments.

Environmental Specifications

Specification Rating

Storage temperature –4° F to 158° F (–20° C to 70° C)

Ambient operating temperature* 32° F to 131° F (0° C to 55° C)

Ambient humidity** 5% – 95% relative humidity (non–condensing)

Vibration resistance MIL STD 810C, Method 514.2

Shock resistance MIL STD 810C, Method 516.2

Noise immunity NEMA (ICS3–304)

Atmosphere No corrosive gases

Agency approvals UL, CE, FCC class A

2-10

Agency Approvals

Some applications require agency approvals for particular components. The DL05 Micro PLC agency approvals are listed below:

• UL (Underwriters’ Laboratories, Inc.)

• CUL (Canadian Underwriters’ Laboratories, Inc.)

• CE (European Economic Union)

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.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 2: Installation, Wiring, and Specifications

Wiring Guidelines

Connect the power input wiring for the DL05. Observe all precautions stated earlier in this manual. Follow the guidelines in this chapter. When the wiring is complete, close the connector covers. Do not apply power at this time.

110/220 VAC Power Input

95 - 240 VAC

WARNING: Once the power wiring is connected, secure the terminal block cover in the closed position. When the cover is open there is a risk of electrical shock if you accidentally touch the connection terminals or power wiring.

Fuse Protection for Input Power

There are no internal fuses for the input power circuits, so external circuit protection is needed to ensure the safety of service personnel and the safe operation of the equipment itself. To meet UL/CUL specifications, the input power must be fused. Depending on the type of input power being used, follow these fuse protection recommendations:

208/240 VAC Operation

When operating the unit from 208/240 VAC, whether the voltage source is a step-down transformer or from two phases, fuse both the line (L) and neutral (N) leads. The recommended fuse size is 1A, such as AutomationDirect’s AGC1, fast-acting fuse.

110/125 VAC Operation

When operating the unit from 110/125 VAC, it is only necessary to fuse the line (L) lead; it is not necessary to fuse the neutral (N) lead. The recommended fuse size is 1.0A.

12/24 VDC Power Input

Y0 - Y5: OutputX0 - X7: Input

12-24 VDC 20 W max

X0 - X7: Input

Y0 - Y5: Output

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Chapter 2: Installation, Wiring, and Specifications

12/24 VDC Operation

When operating at these lower DC voltages, wire gauge size is just as important as proper fusing techniques. Using large conductors minimizes the voltage drop in the conductor. Each DL05 input power terminal can accommodate one 16 AWG wire or two 18 AWG wires. A DC failure can maintain an arc for much longer time and distance than AC failures. Typically, the main bus is fused at a higher level than the branch device, which in this case is the DL05. The recommended fuse size for the branch circuit to the DL05 is 1A, such as AutomationDirect’s AGC1, fast-acting fuse.

External Power Source

The power source must be capable of suppling voltage and current complying with individual Micro PLC specifications, according to the following specifications:

Power Source Specifications

Item DL05 VAC Powered Units DL05 VDC Powered Units

Input Voltage Range

Maximum Inrush Current

Maximum Power

Voltage Withstand (dielectric)

Insulation Resistance

NOTE 1: The rating between all internal circuits is BASIC INSULATION ONLY. NOTE 2: It is possible to use an uninterruptible power supply (UPS); however, the output must be a

sinusoidal waveform for the PLC to perform properly.

Planning the Wiring Routes

The following guidelines provide general information on how to wire the I/O connections to DL05 Micro PLCs. For specific information on wiring a particular PLC refer to the corresponding specification sheet further in this chapter.

1. Each terminal connection of the DL05 PLC can accept one 16 AWG wire or two 18 AWG size wires. Do not exceed this recommended capacity.

2. Always use a continuous length of wire. Do not splice 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.

6. Avoid running input wiring close to output wiring where possible.

7. To minimize voltage drops when wires must run a long distance, consider using multiple wires for the return line.

8. Avoid running DC wiring in close proximity to AC wiring where possible.

9. Avoid creating sharp bends in the wires.

10. Install the recommended powerline filter to reduce power surges and EMI/RFI noise.

110/220 VAC (95–240 VAC) 12–24 VDC (10.8–26.4 VDC)

13 A, 1ms (95–240 VAC)

15 A, 1ms (240–264 VAC)

30 VA 20 W

1 minute @ 1500 VAC between primary, secondary, field ground

> 10 Mq at 500 VDC

10A < 1ms

2-12

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 2: Installation, Wiring, and Specifications

Fuse Protection for Input and Output Circuits

Input and Output circuits on DL05 Micro PLCs do not have internal fuses. In order to protect your Micro PLC, we suggest you add external fuses to your I/O wiring. A fast-blow fuse, with a lower current rating than the I/O bank’s common current rating can be wired 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 the Micro PLC specification tables further in this chapter to find the maximum current per output point or per output common. Adding the external fuse does not guarantee the prevention of Micro PLC damage, but it will provide added protection.

External Fuses

(shown with DIN Rail, Fuse Blocks)

I/O Point Numbering

All DL05 Micro PLCs have a fixed I/O configuration. It follows the same octal numbering system used on other DirectLogic family PLCs, starting at X0 and Y0. The letter X is always used to indicate inputs and the letter Y is always used for outputs.

The I/O numbering always starts at zero and does not include the digits 8 or 9. The reference addresses are typically assigned in groups of 8 or 16, depending on the number of points in an I/O group. For the DL05 the eight inputs use reference numbers X0 – X7. The six output points use references Y0 – Y5.

If an optional input module is installed in the option slot, the reference numbers are X100 – X107. A typical output module installed in the option slot will have references Y100 – Y107. See the DL05/06 Options Modules User Manual (D0-OPTIONS-M) for addressing other optional modules.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 2: Installation, Wiring, and Specifications

inputs

To programming device

Primary Side Secondary,or

Field Side

System Wiring Strategies

The DL05 Micro PLC 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 that 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 which connect to the logic side of the PLC circuits.

PLC

Power input

Filter

Isolation Boundary

Main Power Supply

Logic side

CPU

Programming Device or Operator Interface

Input Circuit

Output Circuit

Discrete inputs

Discrete outputs

Isolation Boundary

2-14

The next figure shows the internal layout of DL05 PLCs, as viewed from the front panel.

DL05

PLC

Power Input

Main Power Supply

Filter

Input Circuit

8 discrete

DL05 Micro PLC User Manual, 6th Edition, Rev. D

or operator interface

CPU

Commons Commons

6 discrete outputs

2 Comm. Ports

Output Circuit

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Chapter 2: Installation, Wiring, and Specifications

Connecting Operator Interface Devices

Operator interfaces require data and power connections. Operator interfaces with a large CRT usually require separate AC power. However, some small operator interface devices, such as the DV-1000 Data Access Unit, may be powered directly from the DL05 Micro PLC. Connect the DV-1000 to communication port 1 on the DL05 Micro PLC with a DV-1000CBL. A single cable contains transmit/receive data wires and +5V power.

DL05 Micro PLC

Operator interface panels require separate power and communications connections. Connect the DL05 with the proper cable and power supply for your application.

DL05 Micro PLC

Connecting Programming Devices

DL05 Micro PLCs are programmed using DirectSOFT 5 programming software on a PC. Limited programming can be accomplished with a handheld programmer. The DL05 can be interfaced to the PC with either a serial cable shown below or a Ethernet cable (Ethernet requires either an H0-ECOM or H0-ECOM100 module installed in the option slot).

RJ12

phone style

RJ12

phone style

RJ12

phone style

15-pin D-shell

male

DV-1000

DL05 Micro PLC

The D2-HPP Handheld Programmer comes with a communications cable. For a replacement cable, order a DV-1000CBL.

DL05 Micro PLC

DL05 Micro PLC User Manual, 6th Edition, Rev. D

RJ12

phone style

RJ12

phone style

(cable comes with HPP)

9-pin D-shell

female

RJ12

phone style

D2–HPP

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Chapter 2: Installation, Wiring, and Specifications

Sinking/Sourcing Concepts

Before going further in our study of wiring strategies, we 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 we give the following short definitions, followed by practical applications.

Sinking = Path to supply ground (–)

Sourcing = Path to supply source (+)

First you will notice that 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 either sinking or sourcing 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, we 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, we just have to connect it so the input provides a path to ground (–). So, we 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, we have completed the circuit. Current flows in the direction of the arrow when the switch is closed.

Input (sinking)

–

Common

PLC

Input Sensing

2-16

By applying the circuit principle above to the four possible combinations of input/output sinking/sourcing types, we have the four circuits as shown below. DL05 Micro PLCs provide all except the sourcing output I/O circuit types.

Sinking Input Sinking Output

Input

–

Sourcing Input Sourcing Output

–

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Common

Input

PLC

Input Sensing

PLC

Input Sensing

Output Switch

PLC

Output

Common

Output

Load

–

Page 63

Chapter 2: Installation, Wiring, and Specifications

PLC

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. This means 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.

If we had unlimited space and budget for I/O terminals, then every I/O point could have two dedicated terminals just 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 point groups on PLCs share the return path among two or more I/O points. The figure to the right shows a group (or bank) of 4 input points which share a common return path. In this way, the four inputs require only five terminals instead of eight.

Field Device

–

Main Path (I/O point)

Return Path

Input 1

Input 2

Input 3

Input 4

Common

I/O

Circuit

Input Sensing

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 DL05 input and output circuits are grouped into banks that share a common return path. The best indication of I/O The I/O common grouping bar, labeled at the right, occurs in the section of wiring label below it. It indicates X0, X1, X2, and X3 share the common terminal located to the left of X1.

The following complete label shows two banks of four inputs and two banks of three outputs. One common is provided for each bank.

The following label is for DC output versions. One common is provided for all of the outputs and the terminal on the bottom right accepts power for the output stage.

AC(L)

AC(N)

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Chapter 2: Installation, Wiring, and Specifications

Field Device

PLC DC Input

Field Device

PLC DC Output

Connecting DC I/O to Solid State Field Devices

In the previous section on Sourcing and Sinking concepts, we explained that DC I/O circuits sometimes will 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

The DL05’s DC inputs are flexible in that 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 opencollector NPN transistor output. It sinks current from the PLC input point, which sources current. The power supply can be the FA-24PS +24 VDC power supply or another supply (+12 VDC or +24VDC), as long as the input specifications are met.

Input

Output

(sinking)

Supply

Ground

In the next circuit, a field device has an open-emitter 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.

Output (sourcing)

Ground Common

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 signal, not to send DC power to an actuator.

The DL05’s DC outputs are sinking-only. This means that each DC output provides a path to ground when it is energized. Also, remember that all six outputs have the same electrical common, even though there are two common terminal screws. Finally, recall that the DC output circuit requires power (20 – 28 VDC) from an external power source.

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.

Power

Output

(sinking)

Common

–

+DC Power

(sourcing)

+–

Common

Input (sinking)

20-28 VDC

PLC DC Input

Input

(sourcing)

Ground

2-18

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Chapter 2: Installation, Wiring, and Specifications

PLC DC Output

In the next example we connect a PLC DC output point to the sinking input of a field device. This is a bit tricky, because both the PLC output and field device input are sinking type. Since the circuit must have one sourcing and one sinking device, we add sourcing capability to the PLC output by using a pull-up resistor. In the circuit below, we connect R output to the DC output circuit power input.

pull-up

from the

Common

input

supply

Power

pull-up

(sourcing)

Output

input (turn–on)

– 0.7

input

–

Supply

input

Field Device

Input

–

pull-up

(sinking)

Ground

. In order to do so, we need to know

pull-up

input

. Then calculate the power

supply

pullup

+DC pwr

(sinking)

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 input) when the input is energized. If this value is not known, it can be calculated as shown (a typical value is 15 mA). Then use I input and the voltage of the external supply to compute R

input

pull-up

P The drawing below shows the actual wiring of the DL05 Micro PLC to the supply and

pull-up resistor.

(in watts), in order to size R

pull-up

properly.

pull-up

Common

–

Supply

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Output

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Chapter 2: Installation, Wiring, and Specifications

Common

Y1 Y2 Y3 Y4

Common

Relay Output Wiring Methods

The D0–05AR and the D0–05DR models feature relay outputs. Relays are best for the following applications:

• Loads that require higher currents than the solid-state DL05 outputs can deliver

• Cost-sensitive applications

• Some output channels need isolation from other outputs (such as when some loads require AC while others require DC)

Some applications in which NOT to use relays:

• Loads that require currents under 10 mA

• Loads which must be switched at high speed and duty cycle

Assuming relays are right for your application, we’re now ready to explore various ways to wire relay outputs to the loads. Note that there are six normally-open SPST relays available. They are organized with three relays per common. The figure below shows the relays and the internal wiring of the PLC. Note that each group is isolated from the other group of outputs.

In the circuit below, all loads use the same AC power supply which powers the DL05 PLC. In this example, all commons are connected together.

2-20

Fuse or Circuit Breaker

In the circuit on the following page, loads for Y0 – Y2 use the same AC power supply which powers the DL05 PLC. Loads for Y3 – Y5 use a separate DC supply. In this example, the commons are separated according to which supply powers the associated load.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Line

Neutral

Ground

Output Point Wiring

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Chapter 2: Installation, Wiring, and Specifications

Fuse or

Circuit Breaker

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

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 24 V/125 mA/3 W 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 140 V.

Example: Circuit with no Suppression

24 VDC

Line

Ground

Neutral

Output Point Wiring

Oscilloscope

Relay Coil (24V/125mA/3W, AutomationDirect part no. 750R-2C-24D)

Volts

160

140

120

100

60 40

-20

–

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 2: Installation, Wiring, and Specifications

2VFLOORVFRSH

In the same circuit, replacing the relay with a larger 24 V/290 mA/7 W relay will generate a

transient voltage exceeding 800 V (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.

Here is another example using the same 24 V/125 mA/3 W 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 140 V peak in the first example, the transient voltage here is limited to about 40 V by the Zener diode. While the PLC will probably tolerate repeated transients in this range for some time, the 40 V is still beyond the module’s peak output voltage rating of 30 V.

Example: Small Inductive Load with Only Integrated Suppression

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The next example uses the same circuit as above, but with a larger 24 V/290 mA/7 W relay, thereby creating a larger inductive load. As you can see, the transient voltage generated is much worse, peaking at over 50 V. Driving an inductive load of this size without additional transient suppression is very likely to permanently damage the PLC output.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

9ROWV

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





Page 69

Chapter 2: Installation, Wiring, and Specifications

2VFLOORVFRSH

Sinking

Sourcing

Example: Larger Inductive Load with Only Integrated Suppression

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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.

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.

DC Flyback Circuit

Oscilloscope

24 VDC

DL05 Micro PLC User Manual, 6th Edition, Rev. D

2-23

Page 70

Chapter 2: Installation, Wiring, and Specifications

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.

AD-ASMD-250

Protection Diode Module

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 24 VDC circuits. It is a bank of 8 uni-directional 30 V 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.

784-4C-SKT-1

Relay Socket

DN-D10DR-A

Diode Terminal Block

2-24

DC MOV or TVS Diode Circuit

24 VDC

ZL-TSD8-24

Transorb Module

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Sinking

Sourcing

Page 71

Chapter 2: Installation, Wiring, and Specifications

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 120 VAC circuits. It is a bank of eight bi-directional 180V TVS diodes.

AC MOV or Bi-Directional Diode Circuit

VAC

ZL-TSD8-120

Transorb Module

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 48 V. That suppressor might typically start conducting at roughly 60 VDC. If it were mounted across a 24 V coil, transients of roughly 84 V (if sinking output) or -60 V (if sourcing output) could reach the PLC output. Many semiconductor PLC outputs cannot tolerate such levels.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

2-25

Page 72

Chapter 2: Installation, Wiring, and Specifications

Inductive Field Device

+–

PLC Relay Output

Output

Common

Input

Common

Supply

R () =C (µF)

10 x I

, where x =

1 +

C minimum = 0.001 µF, the voltage rating of C must be ≥ V, non-polarized

R minimum = 0.5 Ω, 1/2 W, tolerance is ± 5%

peak

= I

rms

x 1.414, = 0.5 x 1.414 = 0.707 Amperes

peak

= V

rms

x 1.414 = 120 x 1.414 = 169.7 Volts

Prolonging Relay Contact Life

Relay contacts wear according to the amount of relay switching, amount of spark created at the time of open or closure, and presence of airborne contaminants. There are some steps you can take to help prolong the life of relay contacts, such as switching the relay on or off only when it is necessary, and if possible, switching the load on or off at a time when it will draw the least current. Also, take measures to suppress inductive voltage spikes from inductive DC loads such as contactors and solenoids.

Adding external contact protection may extend relay life beyond the number of contact cycles listed in the specification tables for relay modules. High current inductive loads such as clutches, brakes, motors, direct-acting solenoid valves and motor starters will benefit the most from external contact protection.

When using an RC network, locate it close to the relay module output connector. To find the values for the RC snubber network, first determine the voltage across the contacts when open, and the current through them when closed. If the load supply is AC, then convert the current and voltage values to peak values.

Now you are ready to calculate values for R and C, according to the formulas:

For example, suppose a relay contact drives a load at 120VAC, 1/2 A. Since this example has

2-26

an AC power source, first calculate the peak values:

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 73

Chapter 2: Installation, Wiring, and Specifications

R (Ω) =

10 x I

, where x =

1 +

0.707

= 0.05 µF, voltage rating ≥ 170 Volts

x =

169.7

1 + = 1.29

R (Ω) =

169.7

10 x 0.707

1.29

= 26 Ω, 1/2 W, ± 5%

C (µF) =

Now, finding the values of R and C,:

For inductive loads in DC circuits we recommend using a suppression diode as shown in the diagram. When the load is energized the diode is reverse-biased (high impedance). When the load is turned off, energy stored in its coil is released in the form of a negative-going voltage spike. At this moment the diode is forward-biased (low impedance) and shunts the energy to ground. This protects the relay contacts from the high voltage arc that would occur just as the contacts are opening.

WARNING: DO NOT use this circuit with an AC power supply.

Place the diode as close to the inductive field device as possible. Use a diode with a peak inverse voltage rating (PIV) at least 100 PIV, 3 A forward current or larger. Use a fast-recovery type (such as Schottky type). DO NOT use a small-signal diode such as 1N914, 1N941, etc. Be sure the diode is in the circuit correctly before operation. If installed backwards, it will short-circuit the supply when the relay energizes.

DO NOT use this circuit with an AC power supply.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Page 74

Chapter 2: Installation, Wiring, and Specifications

PLC DC Input

DC Input Wiring Methods

DL05 Micro PLCs with DC inputs are particularly

flexible because they can be either sinking or sourcing. The dual diodes (shown to the right) allow 10.8 –

26.4 VDC. The target applications are +12 VDC and +24 VDC. You can actually wire half of the inputs as DC sinking and the other half as DC sourcing. Inputs grouped by a common must be all sinking or all sourcing.

In the first and simplest example below, all commons are connected together and all inputs are sinking.

–

+24 VDC

Input

Common

2-28

In the next example, the first four inputs are sinking, and the last four are sourcing.

+24 VDC

DL05 Micro PLC User Manual, 6th Edition, Rev. D

–

+12 VDC

–

Page 75

Chapter 2: Installation, Wiring, and Specifications

Output Point Wiring

DC Output Wiring Methods

DL05 DC output circuits are high-performance transistor switches with low on-resistance and fast switching times. Please note the following characteristics which are unique to the DC output type:

• There is only one electrical common for all six outputs. All six outputs belong to one bank.

• The output switches are current-sinking only. However, you can still use different DC voltages from one load to another.

• The output circuit inside the PLC requires external power. The supply (–) must be connected to a common terminal, and the supply (+) connects the right-most terminal on the upper connector.

In the example below, all six outputs share a common supply.

+24 VDC

In the next example below, the outputs have “split” supplies. The first three outputs are using a +12 VDC supply, and the last three are using a +24 VDC supply. However, you can split the outputs among any number of supplies, as long as:

• all supply voltages are within the specified range

• all output points are wired as sinking

• all source (–) terminals are connected together

+12 VDC

–

Output Point Wiring

–

+24 VDC

DL05 Micro PLC User Manual, 6th Edition, Rev. D

2-29

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Chapter 2: Installation, Wiring, and Specifications

Power Input

High Speed I/O Wiring Methods

DL05 versions with DC type input or output points contain a dedicated High-Speed I/O circuit (HSIO). The circuit configuration is programmable, and it processes select I/O points independently from the CPU scan. Chapter 3 discusses the programming options for HSIO. While the HSIO circuit has six modes, we show wiring diagrams for two of the most popular modes in this chapter. The high-speed input interfaces to points X0 – X2. Properly configured, the DL05 can count quadrature pulses at up to 5 kHz.

Phase B

Phase A

Signal Common

–

12 – 24 VDC

Encoder Input Wiring

DL05 versions with DC type output points can use the High Speed I/O Pulse Output feature. It can generate high-speed pulses up to 7 KHz for specialized control such as stepper motor / intelligent drive systems. Output Y0 and Y1 can generate pulse and direction signals, or it can generate CCW and CW pulse signals respectively. See Appendix E on high-speed input and pulse output options.

Signal Common

Motor Amplifier

Pulse Output Wiring

Pulse

Direction

Encoder

–

+24 VDC

2-30

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Chapter 2: Installation, Wiring, and Specifications

This page is intentionally left blank.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

2-31

Page 78

Chapter 2: Installation, Wiring, and Specifications

Wiring Diagrams and Specifications

The remainder of this chapter dedicates two pages to each of the eight versions of DL05 Micro PLCs. Each section contains a basic wiring diagram, equivalent I/O circuits, and specification tables. Please refer to the section which describes the particular DL05 version used in your application.

D0–05AR I/O Wiring Diagram

The D0–05AR Micro PLC features eight AC inputs and six relay contact outputs. The following diagram shows a typical field wiring example. The AC external power connection uses four terminals at the left as shown.

Power

input wiring

95-240

VAC

90-120

VAC

Input point wiring Output point wiring

OUTPUT

6-240

VAC

6-27

VDC

Internal module circuitry

2-32

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6–27 VDC

6–240 VAC

Equivalent Input Circuit

The eight AC input channels use terminals in the middle of the connector. Inputs are organized into two banks of four. Each bank has a common terminal. The wiring example above shows all commons connected together, but separate supplies and common circuits may be used. The equivalent input circuit shows one channel of a typical bank.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

COM

Line

Equivalent Output Circuit

Derating Chart for Relay Outputs

To LED

Page 79

Chapter 2: Installation, Wiring, and Specifications

The six relay output channels use terminals on the right side of the connector. Outputs are organized into two banks of three normally-open relay contacts. Each bank has a common terminal. The wiring example on the last page shows all commons connected together, but separate supplies and common circuits may be used. The equivalent output circuit shows one channel of a typical bank. The relay contacts can switch AC or DC voltages.

D0-05AR General Specifications

External Power Requirements 95 – 240 VAC, 30 VA maximum,

Communication Port 1, 9600 baud (Fixed), 8 data bits, 1

Communication Port 2, 9600 baud (default), 8 data bits, 1

stop bit, odd parity

Programming cable type D2–DSCBL

Operating Temperature 32 to 131° F (0 to 55 C)

Storage Temperature –4 to 158° F (–20 to 70 C)

Relative Humidity 5 to 95% (non-condensing) Environmental air No corrosive gases permitted

Vibration MIL STD 810C 514.2

Shock MIL STD 810C 516.2

Noise Immunity NEMA ICS3–304

Terminal Type Removable

Wire Gauge One 16AWG or two 18AWG, 24AWG minimum

AC Input Specifications X0-X7

Input Voltage Range (Min. - Max.) 80 – 132 VAC, 47 - 63 Hz

Operating Voltage Range 90 – 120 VAC, 47 -63 Hz

Input Current 8 mA @ 100 VAC at 50 Hz, 10 mA @ 100 VAC at 60 Hz

Max. Input Current 12 mA @ 132 VAC at 50 Hz, 15 mA @ 132 VAC at 60 Hz

Input Impedance 14Kq @50 Hz, 12Kq @60 Hz

ON Current/Voltage >6 mA @ 75 VAC

OFF Current/Voltage <2 mA @ 20 VAC OFF to ON Response < 40 ms ON to OFF Response < 40 ms

Status Indicators Logic Side

Commons 4 channels/common x 2 banks

K–Sequence (Slave), DirectNET (Slave), Modbus (Slave)

K–Sequence (Slave), DirectNET (Master/Slave), Modbus

(Master/Slave) Non-sequence/print

Relay Output Specifications Y0-Y5

Output Voltage Range (Min. – Max.) 5 – 264 VAC (47 -63 Hz), 5 – 30 VDC

Operating Voltage Range 6 – 240 VAC (47 -63 Hz), 6 – 27 VDC

Output Current 2A/point, 6A/ common

Max. leakage current 0.1 mA @264VAC

Smallest Recommended Load 5 mA @5 VDC

OFF to ON Response < 15 ms ON to OFF Response < 10 ms

Status Indicators Logic Side

Commons 3 channels/common x 2 banks

Fuses None (external recommended)

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Page 80

Chapter 2: Installation, Wiring, and Specifications

D0–05DR I/O Wiring Diagram

These micro PLCs feature eight DC inputs and six relay contact outputs. The following diagram shows a typical field wiring example. The AC external power connection uses four terminals at the left as shown.

Power

input wiring

95-240

VAC

12-24

VDC

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Equivalent Circuit, High-speed Inputs (X0-X2)

Derating Chart for Relay Outputs

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Equivalent Output Circuit

SinkSource

6-240 VAC

6-27 VDC

Input point wiring Output point wiring

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Equivalent Circuit, Standard Inputs (X3-X7)

The eight DC input channels use terminals in the middle of the connector. Inputs are organized into two banks of four. Each bank has an isolated common terminal, and may be wired as either sinking or sourcing inputs. The wiring example above shows all commons connected together, but separate supplies and common circuits may be used. The equivalent circuit for standard inputs and the high-speed input circuit are shown above.

The six output channels use terminals on the right side of the connector. Outputs are organized into two banks of three normallyopen relay contacts. Each bank has a common terminal. The wiring example above shows all commons connected together, but separate supplies and common circuits may be used. The equivalent output circuit shows one channel of a typical bank. The relay contacts can switch AC or DC voltages.

6LQN6RXUFH

2-34

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 81

Chapter 2: Installation, Wiring, and Specifications

D0-05DR General Specifications

External Power Requirements 95 – 240 VAC, 30 VA maximum,

Communication Port 1, 9600 baud (Fixed), 8 data bits, 1

Communication Port 2, 9600 baud (default), 8 data bits, 1

Min. - Max. Voltage Range 10.8 – 26.4 VDC 10.8 – 26.4 VDC

Operating Voltage Range 12 -24 VDC 12 -24 VDC

Minimum Pulse Width 100 µs N/A

Max. Input Current 6mA @12VDC, 13mA @24VDC 4mA @12VDC, 8.5mA @24VDC

Minimum ON Current >5 mA >4 mA

Maximum OFF Current < 0.5 mA <0.5 mA

OFF to ON Response <100 µs 2 – 8 ms, 4 ms typical ON to OFF Response < 100 µs 2 – 8 ms, 4 ms typical

stop bit, odd parity

Programming cable type D2–DSCBL

Operating Temperature 32 to 131° F (0 to 55 C)

Storage Temperature –4 to 158° F (–20 to 70 C)

Relative Humidity 5 to 95% (non-condensing) Environmental air No corrosive gases permitted

Vibration MIL STD 810C 514.2

Shock MIL STD 810C 516.2

Noise Immunity NEMA ICS3–304

Terminal Type Removable

Wire Gauge One 16AWG or two 18AWG, 24AWG minimum

DC Input Specifications

Parameter High–Speed Inputs, X0 – X2 Standard DC Inputs X3 – X7

Peak Voltage 30 VDC (5 kHz maximum frequency) 30 VDC

ON Voltage Level > 10 VDC > 10 VDC

OFF Voltage Level < 2.0 VDC < 2.0 VDC

Input Impedance 1.8 kq @ 12 – 24 VDC 2.8 kq @ 12 – 24 VDC

Status Indicators Logic side Logic side

Commons 4 channels/common x 2 bank

Relay Output Specifications

Output Voltage Range (Min. - Max.) 5 -264 VAC (47 -63 Hz), 5 - 30 VDC

Operating Voltage 6 -240 VAC (47 -63 Hz), 6 - 27 VDC

Output Current 2A / point, 6A/ common

Maximum Voltage 264 VAC, 30 VDC

Max leakage current 0.1 mA @264 VAC

Smallest Recommended Load 5 mA

OFF to ON Response < 15 ms ON to OFF Response < 10 ms

Status Indicators Logic Side

Commons 3 channels/common x 2 banks

Fuses None (external recommended)

K–Sequence (Slave), DirectNET (Slave), Modbus (Slave)

K–Sequence (Slave), DirectNET (Master/Slave), Modbus

(Master/Slave) Non-sequence / print

DL05 Micro PLC User Manual, 6th Edition, Rev. D

2-35

Page 82

Chapter 2: Installation, Wiring, and Specifications

D0–05AD I/O Wiring Diagram

The D0–05AD Micro PLC features eight AC inputs and six DC outputs. The following diagram shows a typical field wiring example. The AC external power connection uses four terminals at the left as shown.

Power

input wiring

95-240

VAC

90-12 0

VAC

Input point wiring Output point wiring

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6-27 VDC

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20-28

VDC

2-36

Equivalent Input Circuit

The eight AC input channels use terminals in the middle of the connector. Inputs are organized into two banks of four. Each bank has an isolated common terminal. The wiring example above shows all commons connected together, but separate supplies and common circuits may be used. The equivalent input circuit shows one channel of a typical bank.

The six current sinking DC output channels use terminals on the

Derating Chart for DC Outputs

DL05 Micro PLC User Manual, 6th Edition, Rev. D

right side of the connector. All outputs actually share the same electrical common. Note the requirement for external power on the end (right-most) terminal. The equivalent output circuit shows one channel of the bank of six.

Equivalent Output Circuit

Page 83

Chapter 2: Installation, Wiring, and Specifications

D0-05AD General Specifications

External Power Requirements 95 – 240 VAC, 30 VA maximum,

Communication Port 1, 9600 baud (Fixed),

8 data bits, 1 stop bit, odd parity

Communication Port 2, 9600 baud (default),

8 data bits, 1 stop bit, odd parity

Programming cable type D2–DSCBL

Operating Temperature 32 to 131° F (0 to 55 C)

Storage Temperature –4 to 158° F (–20 to 70 C)

Relative Humidity 5 to 95% (non-condensing) Environmental air No corrosive gases permitted

Vibration MIL STD 810C 514.2

Shock MIL STD 810C 516.2

Noise Immunity NEMA ICS3–304

Terminal Type Removable

Wire Gauge One 16AWG or two 18AWG, 24AWG minimum

AC Input Specifications

Input Voltage Range (Min. - Max.) 80 – 132 VAC, 47 - 63 Hz

Operating Voltage Range 90 – 120 VAC, 47 - 63 Hz

Input Current 8 mA @ 100 VAC (50Hz), 10 mA @ 100 VAC (60Hz)

Max. Input Current 12 mA @ 132 VAC (50Hz), 15 mA @ 132 VAC (60Hz)

Input Impedance 14Kq @50 Hz, 12Kq @60 Hz

ON Current/Voltage >6 mA @ 75 VAC

OFF Current/Voltage <2 mA @ 20 VAC OFF to ON Response < 40 ms ON to OFF Response < 40 ms

Status Indicators Logic Side

Commons 4 channels/common x 2 banks

K–Sequence (Slave), DirectNET (Slave), Modbus (Slave)

K–Sequence (Slave), DirectNET (Master/Slave),

Modbus (Master/Slave) Non-sequence/print

DC Output Specifications

Parameter Pulse Outputs, Y0 – Y1 Standard Outputs, Y2 – Y5

Min. - Max. Voltage Range 5 – 30 VDC 5 – 30 VDC

Operating Voltage 6 – 27 VDC 6 – 27 VDC

Peak Voltage < 50 VDC (7 kHz max. frequency) < 50 VDC

On Voltage Drop 0.3 VDC @ 1A 0.3 VDC @ 1A

Max Current (resistive) 0.5 A/pt. (1A/point for standard pt.) 1.0 A/point

Max leakage current 15 µA @ 30 VDC 15 µA @ 30 VDC

Max inrush current 2 A for 100 mS 2 A for 100 mS

External DC power required 20 - 28 VDC max 150mA 20 - 28 VDC max 150mA

OFF to ON Response <10 µs < 10 µs ON to OFF Response <30 µs < 60 µs

Status Indicators Logic Side Logic Side

Commons 6 channels/common x 1 bank

Fuses None None

DL05 Micro PLC User Manual, 6th Edition, Rev. D

2-37

Page 84

Chapter 2: Installation, Wiring, and Specifications

D0–05DD I/O Wiring Diagram

These micro PLCs feature eight DC inputs and six DC outputs. The following diagram shows a typical field wiring example. The AC external power connection uses four terminals at the left as shown.

Power

input wiring

95-240

VAC

12-24

VDC



9'&

6LQN6RXUFH

Equivalent Circuit, High Speed Input (X0-X2)

SinkSource

Input point wiring Output point wiring

20-28

VDC

6-27 VDC



9'&

6LQN6RXUFH

Equivalent Circuit, Standard Input (X3-X7)

2-38

 9'&

Equivalent Circuit, Standard

Output (Y2-Y5)

Derating Chart for DC Outputs

DL05 Micro PLC User Manual, 6th Edition, Rev. D



9'&

Equivalent Circuit, DC Pulse

Output (Y0-Y1)

together, but separate supplies and common circuits may be used. The equivalent circuits for standard inputs and the high-speed inputs are shown above.

The six current sinking DC output channels use terminals on the right side of the connector. All outputs actually share the same electrical common. Note the requirement for external power on the end (rightmost) terminal. The equivalent output circuit shows one channel of the bank of six.

Page 85

Chapter 2: Installation, Wiring, and Specifications

D0-05DD General Specifications

External Power Requirements 95 – 240 VAC, 30 VA maximum,

Communication Port 1, 9600 baud (Fixed),

8 data bits, 1 stop bit, odd parity

Communication Port 2, 9600 baud (default),

8 data bits, 1 stop bit, odd parity

Programming cable type D2–DSCBL

Operating Temperature 32 to 131° F (0 to 55 C)

Storage Temperature –4 to 158° F (–20 to 70 C)

Relative Humidity 5 to 95% (non-condensing) Environmental air No corrosive gases permitted

Vibration MIL STD 810C 514.2

Shock MIL STD 810C 516.2

Noise Immunity NEMA ICS3–304

Terminal Type Removable

Wire Gauge One16 AWG or two 18 AWG, 24 AWG minimum

DC Input Specifications

Parameter High–Speed Inputs, X0 – X2 Standard DC Inputs X3 – X7

Min. - Max. Voltage Range 10.8 – 26.4 VDC 10.8 – 26.4 VDC

Operating Voltage Range 12 – 24 VDC 12 – 24 VDC

Peak Voltage 30 VDC (5 kHz maximum frequency) 30 VDC

Minimum Pulse Width 100 µs N/A

ON Voltage Level > 9.0 VDC > 9.0 VDC

OFF Voltage Level < 2.0 VDC < 2.0 VDC

Max. Input Current 6mA @12VDC, 13mA @24VDC 4mA @12VDC, 8.5mA @24VDC

Input Impedance 1.8 Kq @ 12 – 24 VDC 2.8 Kq @ 12 – 24 VDC

Minimum ON Current >5 mA >4 mA

Maximum OFF Current < 0.5 mA <0.5 mA

OFF to ON Response <100 µs 2 – 8 ms 4 ms typical ON to OFF Response < 100 µs 2 – 8 ms 4 ms typical

Status Indicators Logic side Logic side

Commons 4 channels/common x 2 banks

DC Output Specifications

Parameter Pulse Outputs Y0 – Y1 Standard Outputs Y3 – Y5

Min. - Max. Voltage Range 5 – 30 VDC 5 – 30 VDC

Operating Voltage 6 – 27 VDC 6 – 27 VDC

Peak Voltage < 50 VDC (7 kHz max. frequency) < 50 VDC

On Voltage Drop 0.3 VDC @ 1 A 0.3 VDC @ 1 A

Max Current (resistive) 0.5 A/pt., 1A/pt. as standard pt. 1.0 A/point

Max leakage current 15 A @ 30 VDC 15 A @ 30 VDC

Max inrush current 2 A for 100 ms 2 A for 100 ms

External DC power required 20 - 28 VDC Max 150mA 20 - 28 VDC Max 150mA

OFF to ON Response < 10µ s < 10 µs ON to OFF Response < 30 µs < 60 µs

Status Indicators Logic Side Logic Side

Commons 6 channels/common x 1 bank

Fuses None (external recommended)

K–Sequence (Slave), DirectNET (Slave),

K–Sequence (Slave), DirectNET (Master/Slave),

Modbus (Master/Slave) Non-sequence/print

Modbus (Slave)

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Chapter 2: Installation, Wiring, and Specifications

D0–05AA I/O Wiring Diagram

The D0–05AA Micro PLC features eight AC inputs and six AC outputs. The following diagram shows a typical field wiring example. The AC external power connection uses four terminals at the left as shown.

Power

input wiring

95-240

VAC

90-120

VAC

Input point wiring Output point wiring

17-240

VAC

2-40

 

9$&

Equivalent Input Circuit

but separate supplies and common circuits may be used. The equivalent input circuit shows one channel of a typical bank.

The six output channels use terminals on the right side of the connector. Outputs are organized into two banks of three triac switches. Each bank has a common terminal. The wiring example above shows all commons connected together, but separate supplies and common circuits may be used. The equivalent output circuit shows one channel of a typical bank.

Derating Chart for AC Outputs

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Equivalent Output Circuit

Page 87

Chapter 2: Installation, Wiring, and Specifications

D0-05AA General Specifications

External Power Requirements 95 – 240 VAC, 30 VA maximum,

Communication Port 1, 9600 baud (Fixed),

8 data bits, 1 stop bit odd parity

Communication Port 2, 9600 baud (default)

8 data bits, 1 stop bit odd parity

Programming cable type D2–DSCBL

Operating Temperature 32 to 131° F (0 to 55 C)

Storage Temperature –4 to 158° F (–20 to 70 C)

Relative Humidity 5 to 95% (non-condensing) Environmental air No corrosive gases permitted

Vibration MIL STD 810C 514.2

Shock MIL STD 810C 516.2

Noise Immunity NEMA ICS3–304

Terminal Type Removable

Wire Gauge One 16AWG or two 18AWG, 24AWG minimum

AC Input Specifications

Input Voltage Range (Min. - Max.) 80 – 132 VAC, 47 - 63 Hz

Operating Voltage Range 90 – 120 VAC, 47 - 63 Hz

Input Current

Max. Input Current

Input Impedance 14 Kq @ 50 Hz, 12 Kq @ 60Hz

ON Current/Voltage > 6 mA @ 75 VAC

OFF Current/Voltage < 2 mA @ 20 VAC OFF to ON Response < 40 ms ON to OFF Response < 40 ms

Status Indicators Logic Side

Commons 4 channels/common x 2 banks

AC Output Specifications

Output Voltage Range (Min. - Max.) 15 – 264 VAC, 47 – 63 Hz

Operating Voltage 17 – 240 VAC, 47 – 63 Hz

On Voltage Drop 1.5 VAC (>50mA) 4.0 VAC (<50mA)

Max Current 0.5 A/point, 1.5 A/common

Max leakage current <4 mA @ 264 VAC

Max inrush current 10 A for 10 ms

Minimum Load 10 mA OFF to ON Response 1 ms ON to OFF Response 1 ms +1/2 cycle

Status Indicators Logic Side

Commons 3 channels/common x 2 banks

Fuses None (external recommended)

K–Sequence (Slave), DirectNET (Slave), Modbus (Slave)

K–Sequence (Slave), DirectNET (Master/Slave), Modbus

(Master/Slave) Non-sequence/print

8 mA @100 VAC at 50 Hz

10 mA @100 VAC at 60 Hz 12 mA @132 VAC at 50 Hz

15 mA @132 VAC at 60 Hz

DL05 Micro PLC User Manual, 6th Edition, Rev. D

2-41

Page 88

Chapter 2: Installation, Wiring, and Specifications

D0–05DA I/O Wiring Diagram

The D0–05DA Micro PLC features eight DC inputs and six AC outputs. The following diagram shows a typical field wiring example. The AC external power connection uses four terminals at the left as shown.

Power

input wiring

95-240

VAC

12-24

VDC



9'&

6LQN6RXUFH

Equivalent Circuit, High Speed Input (X0-X2)

Equivalent Circuit, Output

Derating Chart for AC Outputs

SinkSource

Input point wiring Output point wiring

17-240

VAC



9'&

6LQN6RXUFH

Equivalent Circuit, Standard Input (X3-X7)

The eight DC input channels use terminals in the middle of the connector. Inputs are organized into two banks of four. Each bank has an isolated common terminal, and may be wired as sinking or sourcing inputs. The wiring example above shows all commons connected together, but separate supplies and common circuits may be used. The equivalent circuit for standard inputs and the high-speed input circuit are shown above.

2-42

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 89

Chapter 2: Installation, Wiring, and Specifications

D0-05DA General Specifications

External Power Requirements 95 – 240 VAC, 30 VA maximum,

Communication Port 1, 9600 baud (Fixed), 8 data bits, 1

Communication Port 2, 9600 baud (default), 8 data bits, 1

Input Voltage Range 10.8 – 26.4 VDC 10.8 – 26.4 VDC

Operating Voltage Range 12 – 24 VDC 12 – 24 VDC

Minimum Pulse Width 100 µs N/A

Minimum ON Current >5 mA >4 mA

Maximum OFF Current < 0.5 mA <0.5 mA

OFF to ON Response <100 µs 2 – 8 ms, 4 ms typical ON to OFF Response < 100 µs 2 – 8 ms, 4 ms typical

stop bit, odd parity

Programming cable type D2–DSCBL

Operating Temperature 32 to 131° F (0 to 55 C)

Storage Temperature –4 to 158° F (–20 to 70 C)

Relative Humidity 5 to 95% (non-condensing) Environmental air No corrosive gases permitted

Vibration MIL STD 810C 514.2

Shock MIL STD 810C 516.2

Noise Immunity NEMA ICS3–304

Terminal Type Removable

Wire Gauge One 16 AWG or two 18 AWG, 24AWG minimum

DC Input Specifications

Parameter High–Speed Inputs, X0 – X2 Standard DC Inputs X3 – X7

Maximum Voltage 30 VDC (5 kHz maximum frequency) 30 VDC

ON Voltage Level > 10 VDC > 10 VDC

OFF Voltage Level < 2.0 VDC < 2.0 VDC

Input Impedance 1.8 kq @ 12 – 24 VDC 2.8 kq @ 12 – 24 VDC

Status Indicators Logic side Logic side

Commons 4 channels / common x 2 banks

AC Output Specifications

Output Voltage Range (Min. - Max.) 15 – 264 VAC, 47 – 63 Hz

Operating Voltage 17 – 240 VAC, 47 – 63 Hz

On Voltage Drop 1.5 VAC @> 50mA, 4 VAC @< 50mA

Max Current 0.5 A/point, 1.5 A/common

Max leakage current < 4 mA @ 264 VAC, 60Hz

Max inrush current 10 A for 10 ms

Minimum Load 10 mA OFF to ON Response 1 ms ON to OFF Response 1 ms +1/2 cycle

Status Indicators Logic Side

Commons 3 channels / common x 2 banks

Fuses None (external recommended)

K–Sequence (Slave), DirectNET (Slave),

K–Sequence (Slave), DirectNET (Master/Slave),

Modbus (Master/Slave) Non-sequence/print

Modbus (Slave)

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Page 90

Chapter 2: Installation, Wiring, and Specifications

D0–05DR-D I/O Wiring Diagram

These micro PLCs feature eight DC inputs and six relay contact outputs. The following diagram shows a typical field wiring example. The DC external power connection uses three terminals at the left as shown.

12-24V

20W max.

Power

input wiring

12-24

VDC

12-24 VDC

SinkSource



9'&

6LQN6RXUFH

Equivalent Circuit, High-speed Input (X0-X2)

Equivalent Circuit,

Standard Output

Derating Chart for Relay Outputs

X0 - X7: Input

Input point wiring Output point wiring

The six output channels use terminals on the right side of the connector. Outputs are organized into two banks of three normally-open relay contacts. Each bank has a common terminal. The wiring example above shows all commons connected together, but separate supplies and common circuits may be used. The equivalent output circuit shows one channel of a typical bank. The relay contacts can switch AC or DC voltages.

Y0 - Y5: Output

6-240 VAC

6-27 VDC



9'&

6LQN6RXUFH

Equivalent Circuit, Standard Input (X3-X7)

2-44

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 91

Chapter 2: Installation, Wiring, and Specifications

D0-05DR-D General Specifications

External Power Requirements 12 – 24 VDC, 20 W maximum,

Communication Port 1, 9600 baud (Fixed),

8 data bits, 1 stop bit, odd parity

Communication Port 2, 9600 baud (default),

8 data bits, 1 stop bit, odd parity

Programming cable type D2–DSCBL

Operating Temperature 32 to 131° F (0 to 55 C)

Storage Temperature –4 to 158° F (–20 to 70 C)

Relative Humidity 5 to 95% (non-condensing) Environmental air No corrosive gases permitted

Vibration MIL STD 810C 514.2

Shock MIL STD 810C 516.2

Noise Immunity NEMA ICS3–304

Terminal Type Removable

Wire Gauge One 16AWG or two 18AWG, 24AWG minimum

DC Input Specifications

Parameter High–Speed Inputs, X0 – X2 Standard DC Inputs X3 – X7

Min. - Max. Voltage Range 10.8 – 26.4 VDC 10.8 – 26.4 VDC

Operating Voltage Range 12 -24 VDC 12 -24 VDC

Peak Voltage 30 VDC (5 kHz maximum frequency) 30 VDC

Minimum Pulse Width 100 µs N/A

ON Voltage Level > 10 VDC > 10 VDC

OFF Voltage Level < 2.0 VDC < 2.0 VDC

Input Impedance 1.8 kq @ 12 – 24 VDC 2.8 kq @ 12 – 24 VDC

Max. Input Current 6mA @12VDC ,13mA @24VDC 4mA @12VDC, 8.5mA @24VDC

Minimum ON Current >5 mA >4 mA

Maximum OFF Current < 0.5 mA <0.5 mA

OFF to ON Response <100 µs 2 – 8 ms, 4 ms typical ON to OFF Response < 100 µs 2 – 8 ms, 4 ms typical

Status Indicators Logic side Logic side

Commons 4 channels / common x 2 banks

Relay Output Specifications

Output Voltage Range (Min. - Max.) 5 -264 VAC (47 -63 Hz), 5 - 30 VDC

Operating Voltage 6 -240 VAC (47 -63 Hz), 6 - 27 VDC

Output Current 2A/point 6A/common

Maximum Voltage 264 VAC, 30 VDC

Max leakage current 0.1 mA @264 VAC

Smallest Recommended Load 5 mA

OFF to ON Response < 15 ms ON to OFF Response < 10 ms

Status Indicators Logic Side

Commons 3 channels/common x 2 banks

Fuses None (external recommended)

K–Sequence (Slave), DirectNET (Slave), Modbus (Slave)

K–Sequence (Slave), DirectNET (Master/Slave),

Modbus (Master/Slave) Non-sequence/print

DL05 Micro PLC User Manual, 6th Edition, Rev. D

2-45

Page 92

Chapter 2: Installation, Wiring, and Specifications

D0–05DD–D I/O Wiring Diagram

These micro PLCs feature eight DC inputs and six DC outputs. The following diagram shows a typical field wiring example. The DC external power connection uses four terminals at the left as shown.

12-24V

20W max.

Power

input wiring

12-24

VDC

12-24

VDC



9'&

6LQN6RXUFH

Equivalent Circuit, High Speed Input (X0-X2) Equivalent Circuit, Standard Input (X3-X7)



9'&

Equivalent Circuit,

Standard Output (Y2-Y5)

Derating Chart for DC Outputs

X0 - X7: Input

SinkSource

Input point wiring Output point wiring

 9'&

Equivalent Circuit, Pulse

be used. The equivalent circuit for standard inputs and the highspeed input circuit are shown above.

The six current sinking DC output channels use terminals on the right side of the connector. All outputs actually share the same electrical common. Note the requirement for external power on the end (right-most) terminal. The equivalent output circuit shows one channel of the bank of six.

Y0 - Y5: Output

Output (Y0-Y1)

20-28

VDC

6-27 VDC



9'&

6LQN6RXUFH

2-46

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 93

Chapter 2: Installation, Wiring, and Specifications

D0-05DD-D General Specifications

External Power Requirements 12 – 24 VDC, 20 W maximum,

Communication Port 1, 9600 baud (Fixed),

8 data bits, 1 stop bit, odd parity

Communication Port 2, 9600 baud (default),

8 data bits, 1 stop bit, odd parity

Programming cable type D2–DSCBL

Operating Temperature 32 to 131° F (0 to 55 C)

Storage Temperature –4 to 158° F (–20 to 70 C)

Relative Humidity 5 to 95% (non-condensing) Environmental air No corrosive gases permitted

Vibration MIL STD 810C 514.2

Shock MIL STD 810C 516.2

Noise Immunity NEMA ICS3–304

Terminal Type Removable

Wire Gauge One 16AWG or two 18AWG, 24AWG minimum

K–Sequence (Slave), DirectNET (Slave),

Modbus RTU (Slave)

K–Sequence (Slave), DirectNET (Master/Slave),

Modbus RTU (Master/Slave) Non-sequence/print

DC Input Specifications

Parameter High–Speed Inputs, X0 – X2 Standard DC Inputs X3 – X7

Min. - Max. Voltage Range 10.8 – 26.4 VDC 10.8 – 26.4 VDC

Operating Voltage Range 12 – 24 VDC 12 – 24 VDC

Peak Voltage 30 VDC (5 kHz maximum frequency) 30 VDC

Minimum Pulse Width 100 µs N/A

ON Voltage Level >9.0 VDC > 9.0 VDC

OFF Voltage Level < 2.0 VDC < 2.0 VDC

Max. Input Current 6mA @12VDC, 13mA @24VDC 4mA @12VDC, 8.5mA @24VDC

Input Impedance 1.8 kq @ 12 – 24 VDC 2.8 kq @ 12 – 24 VDC

Minimum ON Current >5 mA >4 mA

Maximum OFF Current < 0.5 mA <0.5 mA

OFF to ON Response <100 µs 2 – 8 ms, 4 ms typical ON to OFF Response < 100 µs 2 – 8 ms, 4 ms typical

Status Indicators Logic side Logic side

Commons 4 channels / common x 2 banks

DC Output Specifications

Parameter Pulse Outputs, Y0 – Y1 Standard Outputs, Y3 – Y5

Min. - Max. Voltage Range 5 – 30 VDC 5 – 30 VDC

Operating Voltage 6 – 27 VDC 6 – 27 VDC

Peak Voltage < 50 VDC (7 kHz max. frequency) < 50 VDC

On Voltage Drop 0.3 VDC @ 1 A 0.3 VDC @ 1 A

Max Current (resistive) 0.5 A/pt., 1A/pt. as standard pt. 1.0 A/point

Max leakage current 15 µA @ 30 VDC 15 µA @ 30 VDC

Max inrush current 2 A for 100 ms 2 A for 100 ms

External DC power required 20 - 28 VDC Max 150mA 20 - 28 VDC Max 150mA

OFF to ON Response < 10 µs < 10 µs ON to OFF Response < 30 µs < 60 µs

Status Indicators Logic Side Logic Side

Commons 6 channels / common x 1 bank

Fuses None (external recommended)

DL05 Micro PLC User Manual, 6th Edition, Rev. D

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Page 94

Chapter 2: Installation, Wiring, and Specifications

Glossary of Specification Terms

Discrete Input

One of eight input connections to the PLC which converts an electrical signal from a field device to a binary status (off or on), which is read by the internal CPU each PLC scan.

Discrete Output

One of six output connections from the PLC which converts an internal ladder program result (0 or 1) to turn On or Off an output switching device. This enables the program to turn on and off large field loads.

I/O Common

A connection in the input or output terminals which is shared by multiple I/O circuits. It usually is in the return path to the power supply of the I/O circuit.

Input Voltage Range

The operating voltage range of the input circuit.

Maximum Voltage

Maximum voltage allowed for the input circuit.

ON Voltage Level

The minimum voltage level at which the input point will turn ON.

OFF Voltage Level

The maximum 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.

CDDc

2-48

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.

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.

Status Indicators

The LEDs that indicate the ON/OFF status of an input or output point. All LEDs on DL05 Micro PLCs are electrically located on the logic side of the input or output circuit.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 95

Chapter

cPu sPecificaTions anD

Chapter

oPeraTion

In this Chapter

Introduction............................................................................................... 3–2

CPU Specifications..................................................................................... 3–3

CPU Hardware Setup................................................................................ 3–4

CPU Operation........................................................................................ 3–11

I/O Response Time.................................................................................. 3–15

CPU Scan Time Considerations.............................................................. 3–18

Memory Map........................................................................................... 3–22

DL05 System V-memory.......................................................................... 3–26

DL05 Aliases............................................................................................. 3–29

X Input Bit Map....................................................................................... 3–30

Y Output Bit Map.................................................................................... 3–30

Control Relay Bit Map............................................................................. 3–31

Stage Control/Status Bit Map................................................................ 3–32

Timer Status Bit Map.............................................................................. 3–32

Counter Status Bit Map........................................................................... 3–33

Page 96

Chapter 3: CPU Specifications and Operation

To Programming Device

8 Discrete Inputs Commons Commons

6 Discrete Outputs

Introduction

The Central Processing Unit (CPU) is the heart of the Micro PLC. Almost all PLC operations are controlled by the CPU, so it is important that it is set up correctly. This chapter provides the information needed to understand:

• Steps required to set up the CPU

• Operation of ladder programs

• Organization of Variable Memory

DL05

PLC

Main Power Supply

CPU

or Operator Interface

2 Comm.

Ports

Output CircuitInput Circuit

Power

Input

NOTE: The High-Speed I/O function (HSIO) consists of dedicated but configurable hardware in the DL05. It is not considered part of the CPU, because it does not execute the ladder program. For more on HSIO operation, see Appendix E.

DL05 CPU Features

The DL05 Micro PLC which has 6K words of memory comprised of 2K of ladder memory and 4K words of V-memory (data registers). Program storage is in the FLASH memory which is a part of the CPU board in the PLC. In addition, there is RAM with the CPU which will store system parameters, V-memory, and other data which is not in the application program. The RAM is backed up by a “super-capacitor”, storing the data for several hours in the event of a power outage. The capacitor automatically charges during powered operation of the PLC.

The DL05 supports fixed I/O which includes eight discrete input points and six output points. If more than the fourteen fixed I/O points are needed, select an I/O module for your application from the DL05/06 Option Modules User Manual. This module will plug into the expansion slot.

Over 120 different instructions are available for program development as well as extensive internal diagnostics that can be monitored from the application program or from an operator interface. Chapters 5, 6, and 7 provide detailed descriptions of the instructions.

The DL05 provides two built-in RS232C communication ports, so you can easily connect a handheld programmer, operator interface, or a personal computer without needing any additional hardware.

3-2

DL05 Micro PLC User Manual, 6th Edition, Rev. D

Page 97

CPU Specifications

Total Program memory (words) Ladder memory (words) Total V-memory (words) User V-memory (words) Non-volatile V-Memory (words) Contact execution (boolean) Typical scan (1k boolean) RLL Ladder Style Programming RLL and RLL Run Time Edits Supports Overrides Scan Handheld programmer DirectSOFT 5 programming for Windows. Built-in communication ports (RS232C) FLASH Memory Local Discrete I/O points available Local Analog input / output channels maximum High-Speed I/O (quad., pulse out, interrupt, pulse catch, etc.) I/O Point Density 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 (external/timed) Subroutines For/Next Loops Math Drum Sequencer Instruction Time of Day Clock/Calendar Internal diagnostics Password security System error log User error log

Battery backup

PLUS

Programming

PLUS

Chapter 3: CPU Specifications and Operation

Specifications

Feature DL05

6K 2048 4096 3968

128

2.0us

2.7–3.2ms Yes Yes Yes Yes

Variable / fixed

Yes Yes Yes

Standard on CPU

None

Yes, 2

8 inputs, 6 outputs

129 512 512 256 128 128 Yes Yes Yes Yes

Integer

Yes

Only with the optional Memory Cartridge

Yes Yes

No No

No (built–in super–cap)

Yes, with memory cartridge

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Chapter 3: CPU Specifications and Operation

Modular Connector

Top View

CPU Hardware Setup

Communication Port Pinout Diagrams

6-pin Female

Cables are available that allow you to quickly and easily connect a Handheld Programmer or a personal computer to the DL05 PLCs. However, if you need to build your own cables, use the pinout information shown below. The DL05 PLCs require an RJ-12 phone plug to fit the built-in jacks.

The Micro PLC has two built-in RS232C communication ports. Port 1 is generally used for connecting to a D2-HPP, a PC with DirectSOFT, operator interface, Modbus slave, or a DirectNET slave. The baud rate is fixed at 9600 baud. Port 2 can be used to connect to a D2-HPP, DirectSOFT, operator interface, Modbus master/slave, or a DirectNET master/slave. Port 2 has a range of speeds from 300 baud to 38.4K baud.

NOTE: The 5V pins are rated at 220mA maximum, primarily for use with some operator interface units.

Port 1 Pin Descriptions

123456

10V Power (–) connection (GND) 25V Power (+) connection 3 RXD Receive Data (RS232C) 4 TXD Transmit Data (RS232C 55V Power (+) conection 60V Power (–) connection (GND)

Port 2 Pin Descriptions

10V Power (–) connection (GND) 25V Power (+) connection 3 RXD Receive Data (RS232C) 4 TXD Transmit Data (RS232C 5RTS Request to Send 60V Power (–) connection (GND)

3-4

Communication Port 1

Com 1 Connects to HPP, DirectSOFT,

operator interfaces, etc. 6-pin, RS232C 9600 Baud (Fixed) Parity - odd (default) Station address 1 (fixed) 8 data bits 1 start, 1 stop bit Asynchronous, Half-duplex, DTE Protocol: (Auto-Select)

K sequence

DirectNET (Slave only) Modbus RTU (Slave only)

DL05 Micro PLC User Manual, 6th Edition, Rev. D

(Slave only)

Communication Port 2

Com 2 Connects to HPP, DirectSOFT,

operator interfaces, etc. 6-pin, RS232C Communication speed (baud)

300, 600, 1200, 2400, 4800,

9600, 19200, 38400 Parity - odd (default), even, none Station address 1 (default) 8 data bits 1 start, 1 stop bit Asynchronous, Half-duplex, DTE Protocol: (Auto-Select)

K sequence

DirectNET (Master/Slave)

Modbus RTU (Master/Slave)

Non-sequence/Print

(Slave only)

Page 99

Chapter 3: CPU Specifications and Operation

D2–DSCBL

Connecting the Programming Devices

If you’re using a Personal Computer with the DirectSOFT 5 programming package, you can connect the computer to either of the DL05’s programming ports. For an engineering office environment (typical during program development), this is the preferred method of programming.

Use cable part no.

The Handheld programmer is connected to the CPU with a handheld programmer cable. This device can be used for maintaining existing installations or making small program changes whenever a PC is not available. The handheld programmer is shipped with a cable, which is approximately 6.5 feet (200 cm) long.

(cable comes with HPP)

For replacement cable, use part #

DV–1000CBL

CPU Setup Information

Even if you have years of experience using PLCs, there are a few things you need to do before you can start entering programs. This section includes some basic things, such as changing the CPU mode, but it also includes some things that you may never have to use. Here’s a brief list of the items that are discussed. Selecting and Changing the CPU Modes

• Using Auxiliary Functions

• Clearing the program (and other memory areas)

• How to initialize system memory

• Setting retentive memory ranges

The following paragraphs provide the setup information necessary to get the CPU ready for programming. They include setup instructions for either type of programming device you are using. The D2–HPP Handheld Programmer Manual provides the Handheld keystrokes required to perform all of these operations. The DirectSOFT 5 Programming Software User Manual provides a description of the menus and keystrokes required to perform the setup procedures.

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Page 100

Chapter 3: CPU Specifications and Operation

Mode Switch

Chapter 3: CPU Specifications and Operation

Status Indicators

The status indicator LEDs on the CPU front panels have specific functions which can help in programming and troubleshooting.

Status

Indicators

Indicator Status Meaning

PWR

RUN

CPU

TX1

RX1

TX2

RX2

Mode Switch Functions

The mode switch on the DL05 PLC provides positions for enabling and disabling program changes in the CPU. Unless the mode switch is in the TERM position, RUN and STOP mode changes will not be allowed by any interface device, (handheld programmer, DirectSOFT 5 programing package or operator interface). Programs may be viewed or monitored but no changes may be made. If the switch is in the TERM position and no program password is in effect, all operating modes as well as program access will be allowed through the connected programming or monitoring device.

ON Power good OFF ON CPU is in Run Mode OFF CPU is in Stop or program Mode

Blinking CPU is in upgrade Mode

ON CPU self diagnostics error OFF CPU self diagnostics good ON Data is being transmitted by the CPU - Port 1 OFF No data is being transmitted by the CPU - Port 1 ON Data is being received by the CPU - Port 1 OFF No data is being received by the CPU - Port 1 ON Data is being transmitted by the CPU - Port 2 OFF No data is being transmitted by the CPU - Port 2 ON Data is being received by the CPU - Port 2 OFF No data is being received by the CPU - Port 2

Power failure

3-6

NOTE: If the DL05 is switched to the RUN Mode without a program in the PLC, the PLC will produce a FATAL ERROR which can be cleared by cycling power to the PLC.

DL05 Micro PLC User Manual, 6th Edition, Rev. D

DL05 Micro PLC User Manual, 6th Edition, Rev. C