Automationdirect.com DL05 - Chapter 9: Maintenance and Troubleshooting

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Maintenance and

Troubleshooting

In This Chapter. . . .

Ċ Hardware System Maintenance

Ċ Diagnostics

Ċ CPU Indicators

Ċ Communications Problems

Ċ I/O Point Troubleshooting

Ċ Noise Troubleshooting

Ċ Machine Startup and Program Troubleshooting

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Default Chapter6
- Table of Contents6
Chapter 1: Getting Started23
Introduction24
- The Purpose of this Manual24
- Where to Begin24
- Supplemental Manuals24
- Technical Support24
Conventions Used25
- Key Topics for each Chapter25
DL05 Micro PLC Components26
- The DL05 Micro PLC Family26
Programming Methods26
- Directsoft Programming for Windows26
- Handheld Programmer27
I/O Selection Quick Chart27
Quick Start for PLC Checkout and Programming28
- Step 1: Unpack the DL05 Equipment28
- Step 2: Connect Switches to Input Terminals29
- Step 3: Connect the Power Wiring30
- Step 4: Connect the Programming Device30
- Step 5: Switch on the System Power31
- Step 6: Initialize Scratchpad Memory31
- Step 7: Enter a Ladder Program31
Steps to Designing a Successful System32
- Step 1 :Review the Installation Guidelines32
- Step 2: Understand the PLC Setup Procedures32
- Step 3: Review the I/O Selection Criteria32
- Step 4: Choose a System Wiring Strategy32
- Step 5: Understand the System Operation32
- Step 6: Review the Programming Concepts33
- Step 7: Choose the Instructions33
- Step 8: Understand the Maintenance and Troubleshooting Procedures33
Questions and Answers about DL05 Micro Plcs34
Chapter 2: Installation, Wiring, and Specifications36
Safety Guidelines36
- Plan for Safety37
- Three Levels of Protection37
- Orderly System Shutdown38
- System Power Disconnect38
- Emergency Stop38
Orientation to DL05 Front Panel39
- Connector Removal40
Mounting Guidelines41
- Unit Dimensions41
- Enclosures41
- Panel Layout & Clearances42
- Using Mounting Rails43
- Agency Approvals44
- Environmental Specifications44
Wiring Guidelines45
- External Power Source46
- Planning the Wiring Routes46
- Fuse Protection for Input and Output Circuits47
System Wiring Strategies48
- Connecting Operator Interface Devices49
- Connecting Programming Devices49
- I/O "Common" Terminal Concepts51
- Connecting DC I/O to "Solid State" Field Devices52
- Solid State Input Sensors52
- Solid State Output Loads52
- Relay Output Wiring Methods54
- Surge Suppresion for Inductive Loads55
- DC Input Wiring Methods57
- DC Output Wiring Methods58
- High-Speed I/O Wiring Methods59
Glossary of Specification Terms60
Wiring Diagrams and Specifications61
- D0-05AR I/O Wiring Diagram61
- D0-05AR General Specifications62
- D0-05DR I/O Wiring Diagram63
- D0-05DR General Specifications64
- DC Input Specifications64
- Relay Output Specifications64
- D0-05AD I/O Wiring Diagram65
- D0-05AD General Specifications66
- AC Input Specifications66
- DC Output Specifications66
- D0-05DD I/O Wiring Diagram67
- DC Input Specifications68
- DC Output Specifications68
- D0-05AA I/O Wiring Diagram69
- D0-05AA General Specifications70
- AC Input Specifications70
- AC Output Specifications70
- D0-05DA I/O Wiring Diagram71
- D0-05DA General Specifications72
- DC Input Specifications72
- AC Output Specifications72
- D0-05DR-D I/O Wiring Diagram73
- D0-05DR-D General Specifications74
- DC Input Specifications74
- Relay Output Specifications74
- D0-05DD-D I/O Wiring Diagram75
- DC Input Specifications76
- DC Output Specifications76
D0-16ND3 DC Input78
D0-10TD1 DC Output79
D0-16TD1 DC Output80
D0-10TD2 DC Output81
D0-16TD2 DC Output82
D0-07CDR DC Input and Output83
D0-08TR Relay Output84
D0-08CDD1 DC Input and Output85
I/O Addressing86
- Module I/O Points and Addressing86
Chapter 3: High-Speed Input and Pulse Output Features87
Introduction88
- Built-In Motion Control Solution88
- Availability of HSIO Features88
- Dedicated High-Speed I/O Circuit89
- Wiring Diagrams for each HSIO Mode89
Choosing the HSIO Operating Mode90
- Understanding the Six Modes90
- Default Mode90
- Configuring the HSIO Mode91
- Configuring Inputs91
Mode 10: High-Speed Counter92
- Purpose92
- Functional Block Diagram92
- Wiring Diagram93
- Interfacing to Counter Outputs93
- Setup for Mode 1094
- Presets and Special Relays94
- Preset Data Starting Location95
- Equal Relay Numbers95
- Using Fewer than 24 Presets95
- Calculating Your Preset Values96
- Input Configuration96
- Writing Your Control Program97
- Program Example: Counter Without Preset98
- Program Example Cont'D99
- Counter with Presets Program Example100
- Counter with Preload Program Example102
- Troubleshooting Guide for Mode 10103
Mode 20: Quadrature Counter104
- Purpose104
- Functional Block Diagram104
- Quadrature Encoder Signals104
- Wiring Diagram105
- Interfacing to Encoder Outputs105
- Setup for Mode 20106
- Input Configuration106
- Writing Your Control Program107
- Quadrature Counter W/Preload Program Example107
- Program Example Cont'D108
- Counter Preload Program Example109
- Troubleshooting Guide for Mode 20109
Mode 30: Pulse Output110
- Purpose110
- Functional Block Diagram111
- Wiring Diagram112
- Interfacing to Drive Inputs112
- Motion Profile Specifications113
- Physical I/O Configuration113
- Logical I/O Functions113
- Setup for Mode 30114
- Profile / Velocity Select Register114
- Profile Parameter Table115
- Trapezoidal Profile115
- Registration Profile115
- Velocity Profile115
- Choosing the Profile Type116
- Trapezoidal Profile Defined116
- Registration and Home Search Profiles Defined116
- Velocity Profile Defined116
- Trapezoidal Profile Operation117
- Trapezoidal Profile Applications117
- Trapezoidal Profile Program Example118
- Program Example Cont'D119
- Preload Position Value119
- Registration Profile Operation120
- Registration Applications120
- Registration Profile Program Example121
- Program Example Cont'D122
- Home Search Program Example123
- Velocity Profile Operation125
- Velocity Profile Applications125
- Velocity Profile Program Example126
- Program Example Cont'D127
- Pulse Output Error Codes128
- Troubleshooting Guide for Mode 30128
Mode 40: High-Speed Interrupts130
- Purpose130
- Functional Block Diagram130
- Setup for Mode 40131
- Interrupts and the Ladder Program131
- External Interrupt Timing Parameters132
- Timed Interrupt Parameters132
- Input / Timed INT Configuration132
- Independent Timed Interrupt132
- External Interrupt Program Example133
- Timed Interrupt Program Example134
Mode 50: Pulse Catch Input135
- Purpose135
- Functional Block Diagram135
- Pulse Catch Timing Parameters135
- Setup for Mode 50136
- Input Configuration136
- Pulse Catch Program Example137
Mode 60: Discrete Inputs with Filter138
- Purpose138
- Functional Block Diagram138
- Input Filter Timing Parameters138
- Setup for Mode 60139
- Input Configuration139
- Filtered Inputs Program Example140
Chapter 4: CPU Specifications and Operation141
Introduction141
CPU Specifications141
CPU Hardware Setup144
- Communication Port Pinout Diagrams144
- Connecting the Programming Devices145
- CPU Setup Information145
- Status Indicators146
- Mode Switch Functions146
- Changing Modes in the DL05 PLC147
- Mode of Operation at Power-Up147
- Auxiliary Functions148
- Clearing an Existing Program148
- Initializing System Memory148
- Setting Retentive Memory Ranges149
- Using a Password150
CPU Operation151
- CPU Operating System151
- Program Mode152
- Run Mode152
- Read Inputs153
- Service Peripherals and Force I/O153
- Update Special Relays and Special Registers154
- Solve Application Program154
- Write Outputs155
- Diagnostics155
I/O Response Time155
- Is Timing Important for Your Application155
- Normal Minimum I/O Response155
- Normal Maximum I/O Response156
- Improving Response Time157
CPU Scan Time Considerations158
- Reading Inputs158
- Writing Outputs158
- Application Program Execution159
PLC Numbering Systems160
- PLC Resources160
- V-Memory161
- Binary-Coded Decimal Numbers161
- Hexadecimal Numbers161
Memory Map162
- Octal Numbering System162
- Discrete and Word Locations162
- Memory Locations for Discrete Memory Areas162
- Input Points (X Data Type)163
- Output Points (y Data Type)163
- Control Relays (C Data Type)163
- Timers and Timer Status Bits (T Data Type)163
- Timer Current Values (V Data Type)164
- Counters and Counter Status Bits (CT Data Type)164
- Counter Current Values (V Data Type)164
- Word Memory (V Data Type)165
- Stages (S Data Type)165
- Special Relays (SP Data Type)165
DL05 System V-Memory166
- DL05 Memory Map168
Input Bit Map169
Y Output Bit Map169
Stage Control / Status Bit Map169
Control Relay Bit Map170
Timer Status Bit Map171
Counter Status Bit Map171
Network Configuration and Connections172
- Configuring the Dl05'S Comm Ports172
- Networking DL05 to DL05 RS-232C172
- Networking PC to Dl05S173
- Networking DL05 Master to Other Plcs173
- MODBUS Port Configuration174
- Directnet Port Configuration175
Network Slave Operation176
- MODBUS Function Codes Supported176
- Determining the MODBUS Address176
- If Your Host Software Requires the Data Type and Address177
- Example 1: V2100178
- Example 2: Y20178
- Example 3: T10 Current Value178
- Example 4: C54178
- If Your MODBUS Host Software Requires an Address ONLY179
- Example 1: V2100 584/984 Mode180
- Example 2: Y20 584/984 Mode180
- Example 4: C54 584/984 Mode180
- Determining the Directnet Address180
Network Master Operation181
- Step 1: Identify Master Port # and Slave182
- Step 2: Load Number of Bytes to Transfer182
- Step 3: Specify Master Memory Area183
- Step 4: Specify Slave Memory Area183
- Communications from a Ladder Program184
- Multiple Read and Write Interlocks184
Chapter 5: Standard RLL Instructions185
Introduction186
Using Boolean Instructions188
- END Statement188
- Simple Rungs188
- Normally Closed Contact188
- Contacts in Series189
- Midline Outputs189
- Parallel Elements189
- Joining Series Branches in Parallel190
- Joining Parallel Branches in Series190
- Combination Networks190
- Comparative Boolean190
- Boolean Stack191
- Immediate Boolean192
Boolean Instructions193
- Store (STR)193
- Store Not (STRN)193
- Or (OR)194
- Or Not (ORN)194
- And (AND)195
- And Not (ANDN)195
- And Store (and STR)196
- Or Store (or STR)196
- Out (OUT)197
- Or out (or OUT)197
- Not (NOT)198
- Positive Differential (PD)198
- Store Positive Differential (STRPD)199
- Store Negative Differential (STRND)199
- Or Positive Differential (ORPD)200
- Or Negative Differential (ORND)200
- And Positive Differential (ANDPD)201
- And Negative Differential (ANDND)201
- Set (SET)202
- Reset (RST)202
- Pause (PAUSE)203
Comparative Boolean204
- Store if Equal (STRE)204
- Store if Not Equal (STRNE)204
- Or if Equal (ORE)205
- Or if Not Equal (ORNE)205
- And if Equal (ANDE)206
- And if Not Equal (ANDNE)206
- Store (STR)207
- Store Not (STRN)207
- Or (OR)208
- Or Not (ORN)208
- And (AND)209
- And Not (ANDN)209
Immediate Instructions210
- Store Immediate (STRI)210
- Store Not Immediate (STRNI)210
- Or Immediate (ORI)210
- Or Not Immediate (ORNI)210
- OR Immediate Instructions Cont'D211
- And Immediate (ANDI)211
- And Not Immediate (ANDNI)211
- Out Immediate (OUTI)212
- Or out Immediate (OROUTI)212
- Set Immediate (SETI)213
- Reset Immediate (RSTI)213
Timer, Counter and Shift Register Instructions214
- Using Timers214
- Timer Example Using Discrete Status Bits216
- Timer Example Using Comparative Contacts216
- Accumulating Timer Example Using Discrete Status Bits218
- Accumulator Timer Example Using Comparative Contacts218
- Using Counters219
- Counter (CNT)220
- Counter Example Using Discrete Status Bits221
- Counter Example Using Comparative Contacts221
- Stage Counter (SGCNT)222
- Stage Counter Example Using Discrete Status Bits223
- Stage Counter Example Using Comparative Contacts223
- Up down Counter (UDC)224
- Up / down Counter Example Using Discrete Status Bits225
- Up / down Counter Example Using Comparative Contacts225
- Shift Register (SR)226
Accumulator / Stack Load and Output Data Instructions227
- Using the Accumulator227
- Copying Data to the Accumulator227
- Changing the Accumulator Data228
- Using the Accumulator Stack229
- Using Pointers230
- Load (LD)232
- Load Double (LDD )233
- Load Formatted (LDF)234
- Load Address (LDA)235
- Out (OUT)236
- Out Double (OUTD)236
- Out Formatted (OUTF)237
- Pop (POP)237
- Pop Instruction Continued238
Logical Instructions (Accumulator)239
- And (AND)239
- And Double (ANDD)240
- Or (OR)241
- Or Double (ORD)242
- Exclusive or (XOR)243
- Exclusive or Double (XORD)244
- Compare (CMP)245
- Compare Double (CMPD)246
Math Instructions247
- Add (ADD)247
- Add Double (ADDD)248
- Subtract (SUB)249
- Subtract Double (SUBD)250
- Multiply (MUL)251
- Multiply Double (MULD)252
- Divide (DIV)253
- Divide Double (DIVD)254
- Increment (INC)255
- Decrement (DEC)255
- Increment Binary (INCB)256
- Decrement Binary (DECB)256
- Add Binary (ADDB)257
- Subtract Binary (SUBB)258
- Multiply Binary (MULB)259
- Divide Binary (DIVB)260
Bit Operation Instructions261
- Sum (SUM)261
- Shift Left (SHFL)261
- Shift Right (SHFR)263
- Encode (ENCO)264
- Decode (DECO)265
Number Conversion Instructions (Accumulator)266
- Binary (BIN)266
- Binary Coded Decimal (BCD)267
- Invert (INV)268
- ASCII to HEX (ATH)269
- HEX to ASCII (HTA)270
- Gray Code (GRAY)272
- Shuffle Digits (SFLDGT)273
- Shuffle Digits Block Diagram273
- Move (MOV)275
- Table Instructions275
- Move Memory Cartridge / Load Label (MOVMC), (LDLBL)276
CPU Control Instructions278
- No Operation (NOP)278
- End (END)278
- Stop (STOP)278
- Reset Watch Dog Timer (RSTWT)279
Program Control Instructions280
- For / Next (FOR) (NEXT)280
- Goto Subroutine (GTS) (SBR)282
- Subroutine Return (RT)282
- Subroutine Return Conditional (RTC)282
- Master Line Set (MLS)285
- Master Line Reset (MLR)285
- Understanding Master Control Relays285
- MLS/MLR Example286
Interrupt Instructions287
- Interrupt (INT)287
- Interrupt Return (IRT)287
- Interrupt Return Conditional (IRTC)287
- Enable Interrupts (ENI)287
- Disable Interrupts (DISI)288
- External Interrupt Program Example288
- Timed Interrupt Program Example289
- Independent Timed Interrupt289
Message Instructions290
- Fault (FAULT)290
- Fault Example290
- Data Label (DLBL)291
- ASCII Constant (ACON)291
- Numerical Constant (NCON)291
- Data Label Example292
- Print Message (PRINT)293
Network Instructions297
- Read from Network (RX)297
- Write to Network (WX)299
Chapter 6: Drum Instruction Programming301
Introduction302
- Purpose302
- Drum Terminology302
- Drum Chart Representation303
- Output Sequences303
Step Transitions304
- Drum Instruction Types304
- Timer-Only Transitions304
- Timer and Event Transitions305
- Event-Only Transitions306
- Counter Assignments306
- Last Step Completion307
Overview of Drum Operation308
- Drum Instruction Block Diagram308
- Powerup State of Drum Registers309
Drum Control Techniques310
- Drum Control Inputs310
- Self-Resetting Drum311
- Initializing Drum Outputs311
- Using Complex Event Step Transitions311
Drum Instruction312
- Timed Drum with Discrete Outputs (DRUM)312
- Event Drum (EDRUM)314
- Handheld Programmer Drum Mnemonics316
Chapter 7 : RLLPLUS Stage Programming320
Introduction to Stage Programming320
- Overcoming "Stage Fright320
Learning to Draw State Transition Diagrams321
- Introduction to Process States321
- The Need for State Diagrams321
- A 2-State Process321
- RLL Equivalent322
- Stage Equivalent322
- Let's Compare323
- Initial Stages323
- What Stage Bits Do324
- Stage Instruction Characteristics324
Using the Stage Jump Instruction for State Transitions325
- Stage Jump, Set, and Reset Instructions325
Stage Program Example: Toggle On/Off Lamp Controller326
- A 4-State Process326
Four Steps to Writing a Stage Program327
Stage Program Example: a Garage Door Opener328
- Garage Door Opener Example328
- Draw the Block Diagram328
- Draw the State Diagram329
- Add Safety Light Feature330
- Modify the Block Diagram and State Diagram330
- Using a Timer Inside a Stage331
- Add Emergency Stop Feature332
- Exclusive Transitions332
Stage Program Design Considerations333
- Stage Program Organization333
- How Instructions Work Inside Stages334
- Using a Stage as a Supervisory Process335
- Stage Counter335
- Power Flow Transition Technique336
- Convergence Stages (CV)337
Parallel Processing Concepts337
- Convergence Jump (CVJMP)338
- Convergence Stage Guidelines338
RLLPLUS (Stage) Instructions339
- Staget (SG)339
- Initial Staget (ISG)340
- Jump (Jmp)340
- Not Jump (NJMP)340
- Converge Stage (CV) and Converge Jump (CVJMP)341
Questions and Answers about Stage Programming343
Chapter 8: PID Loop Operation345
DL05 PID Loop Features346
- Main Features346
- The Basics of PID Loops348
Loop Setup Parameters350
- Loop Table and Number of Loops350
- PID Error Flags350
- Establishing the Loop Table Size and Location351
- Loop Table Word Definitions352
- PID Mode Setting 2 Bit Descriptions (Addr + 01)354
- Mode / Alarm Monitoring Word (Addr + 06)355
- Ramp / Soak Table Flags (Addr + 33)355
- Ramp/Soak Table Location (Addr + 34)356
Loop Sample Rate and Scheduling357
- Loop Sample Rates Addr357
- Choosing the Best Sample Rate357
- Programming the Sample Rate358
- PID Loop Effect on CPU Scan Time359
Ten Steps to Successful Process Control361
- Step 1: Know the Recipe361
- Step 2: Plan Loop Control Strategy361
- Step 3: Size and Scale Loop Components361
- Step 4: Select I/O Modules361
- Step 5: Wiring and Installation362
- Step 6: Loop Parameters362
- Step 7: Check Open Loop Performance362
- Step 8: Loop Tuning362
- Step 9: Run Process Cycle362
- Step 10: Save Parameters362
Basic Loop Operation363
- Data Locations363
- Data Sources363
- Direct Access to Analog I/O364
- Loop Modes365
- CPU Modes and Loop Modes366
- How to Change Loop Modes367
- Operator Panel Control of PID Modes368
- PLC Modes' Effect on Loop Modes368
- Loop Mode Override368
- Bumpless Transfers369
PID Loop Data Configuration370
- Choosing Unipolar or Bipolar Format370
- Handling Data Offsets371
- Setpoint (SP) Limits371
- Remote Setpoint (SP) Location372
- Process Variable (PV) Configuration372
- Control Output Configuration373
- Error Term Configuration374
PID Algorithms375
- Position Algorithm375
- Velocity Algorithm376
- Direct-Acting and Reverse-Acting Loops377
- P-I-D Loop Terms378
- Using a Subset of PID Control379
- Derivative Gain Limiting380
- Bias Term380
- Bias Freeze381
Loop Tuning Procedure382
- Open-Loop Test382
- Manual Tuning Procedure383
- Auto Tuning Procedure384
- Tuning Cascaded Loops388
PV Analog Filter389
- The DL05 Built-In Analog Filter389
- Creating an Analog Filter in Ladder Logic390
Feedforward Control391
- Feedforward Example392
Time-Proportioning Control393
- On/Off Control Program Example394
Cascade Control395
- Introduction395
- Cascaded Loops in the DL05 CPU396
Process Alarms397
- PV Absolute Value Alarms398
- PV Deviation Alarms398
- PV Rate-Of-Change Alarm399
- PV Alarm Hysteresis400
- Alarm Programing Error400
Ramp/Soak Generator401
- Introduction401
- Ramp/Soak Table402
- Ramp/Soak Table Flags404
- Ramp/Soak Generator Enable404
- Ramp/Soak Controls404
- Ramp/Soak Profile Monitoring405
- Ramp/Soak Programming Errors405
- Testing Your Ramp/Soak Profile405
Troubleshooting Tips406
Bibliography407
Glossary of PID Loop Terminology408
Chapter 9: Maintenance and Troubleshooting410
Hardware System Maintenance411
Diagnostics411
CPU Indicators415
Communications Problems416
I/O Point Troubleshooting417
Noise Troubleshooting419
Machine Startup and Program Troubleshooting420
Appendix A: Auxiliary Functions426
Introduction426
- Purpose of Auxiliary Functions427
- Accessing AUX Functions Via Directsoft428
- Accessing AUX Functions Via the Handheld Programmer428
AUX 2* - RLL Operations429
AUX 3* - V-Memory Operations429
AUX 4* - I/O Configuration429
AUX 5* - CPU Configuration430
- AUX 57 Set Retentive Ranges431
AUX 6* - Handheld Programmer Configuration433
AUX 7* - EEPROM Operations433
- Transferrable Memory Areas433
AUX 8* - Password Operations434
- AUX 81 Modify Password434
- AUX 82 Unlock CPU434
- AUX 83 Lock CPU435
Appendix B: DL05 Error Codes436
- DL05 Error Codes437
Appendix C: Instruction Execution Times443
Introduction443
- V-Memory Data Registers444
- V-Memory Bit Registers444
- How to Read the Tables444
Instruction Execution Times445
- Boolean Instructions445
- Comparative Boolean Instructions446
- Immediate Instructions452
- Timer, Counter, and Shift Register452
- Accumulator Data Instructions453
- Logical Instructions454
- Math Instructions454
- Bit Instructions456
- Number Conversion Instructions456
- CPU Control Instructions457
- Program Control Instructions457
- Interrupt Instructions457
- Network Instructions457
- Message Instructions458
- RLLPLUS Instructions458
- Drum Instructions458
Appendix D: Special Relays459
DL05 PLC Special Relays460
- Startup and Real-Time Relays460
- CPU Status Relays460
- System Monitoring461
- Accumulator Status461
- HSIO Pulse Output Relay462
- Communication Monitoring Relays462
Appendix E: DL05 Product Weights465
Product Weight Table465
Appendix F: European Union Directives (CE)467
European Union (EU) Directives467
- Member Countries467
- Special Installation Manual468
- Other Sources of Information469
Basic EMC Installation Guidelines469
- Enclosures469
- Suppression and Fusing470
- Internal Enclosure Grounding470
- Equi-Potential Grounding471
- Communications and Shielded Cables471
- Multidrop Cables472
- Shielded Cables472
- Within Enclosures472
- Network Isolation472
- DC Powered Versions473
- Items Specific to the DL474

Automationdirect.com DL05 - Chapter 9: Maintenance and Troubleshooting

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