Name: Automationdirect.com DL05
Brand: Automationdirect.com
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Appendix A

Appendix E

Product Weights

E–2

Product Weights

Product Weight Table

PLC Weight

D0–05AR 0.60 lb. (272g)

D0–05DR 0.60 lb. (272g)

D0–05AD 0.58 lb. (263g)

D0–05DD 0.56 lb. (254g)

D0–05AA 0.60 lb. (272g)

D0–05DA 0.60 lb. (272g)

D0–05DR–D 0.56 lb. (254g)

D0–05DD–D 0.58 lb. (263g)

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

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Automationdirect.com DL05 Specifications

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Brand	Automationdirect.com
Model	DL05
Category	Controller
Language	English

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