Getting Started - AutomationDirect
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1. Communication max 3300ft 1000m 1 ONLINE OFFLINE Programming ganso l5 e 2 Reporting ES 3 Monitoring li E gt 4 Debugging b Ge SA22 Port o max 3300ft1000m DirectNET Communication max 3300ft 1000m Local Operator Interface or handheld programmer 405 o 0 Bi UE d go RM o ae pom E pc onnects to EX o A DL405 Program E ming Port ie Max 3 3ft 1m E TE b D O EX o O Up to 3 expansion 1 bases total B only 2 shown o 8 d O rm O HRS il E jo REMOTE I O e 1 Flexible RS Placement of I O 2 Reduced Io Installation o D Costs 3 Versatile I O Offering DL405 User Manual 4th Edition Rev A Getting Started To a job E Direct LOGIC op rH 2 P oe mm Ez L DC INPUT 5 Q2. CPUs and Micro PLCs Specialty CPUs Product family D1 F1 D4 440DC 3 D2 F2 D3 F3 D4 F4 Class of CPU Abbreviation 230 330 430 Denotes a differentiation between 1 2 3 4 similar modules Bases Product family D2 F2 D3 05B DC D3 F3 D4 F4 Number of slots B Type of Base DC or empty D4 16 WII 2 F Discrete I O DL205 Product family D2 F2 pe ie 70 8 e e RS DL305 Product family D3 F3 L L DL405 Product family D4 F4 Number of points 04 08 12 16 32 64 Input N Output T Combination C AC A j DC D Either E i Relay R Current Sinking 1 Current Sourcing 2 Current Sinking Sourcing 3 i High Current H i Isolation S Fast I O F a E E Denotes a differentiation between 1 2 3 4 Similar modules DL405 User Manual 4th Edition Rev A Getting Started DirectLOGIC Part Numbering System C 2 3 Analog I O ela ao oe let el DL205 Product family D2 F2 o DL305 Product family D3 F3 2 DL405 Product family D4 F4 2 Number of channels 02 04 08 16 Input Analog to Digital AD Alternate example of Ana
3. 85 132 TL Q3 Siue amp E Install shunt to select 170 264VAC AERE wh WH E 110 VAC range leave shunt s 606z Ly 89 A 2 off to select 220 VAC range ONE e 2 O Sg A 110 220 OPEN i q Voltage Z 170 964 H Select Step 6 Add I O To finish this quick start exercise or study other examples in this manual you ll need Simulation to install an input simulator module or wire an input switch as shown below and add an output module Using an input simulator is the quickest way to get physical inputs for checking out the system or a new program To monitor output status any discrete output module will do c DL4 430 CPU 110 220VAC r N 2ieed b y T Koyo stoe ceu EJ cow D O B eal f a e el Il rie za EE ES O E e e 3 pS EE Q ge E el 4 m r1 se S A eS eS O amp j S O mw b We Input X 3 Output Module Toggle switch Module Wire the switches or other field devices prior to applying power to the system to ensure a point is not accidentally turned on during the wiring operation Wire the input modul
4. apt 24 48 VDC rj FERE 16pt 12 24 VD Ples 4 LEER i6pt 12 24 VDC CIF AC INPUT __ AC DC INPUT j 1ms response HE 8pt 110 200 VAC MIEJ 8pt 90 150 VAC DC JESE 32pt 24 VDC oe 16pt 110 VAC JEJ Isolated c ij 32pt 5 12 VDC ETE tE J 16pt 12 24 VAC DC WEI 64pt 24VDC LE dem LEG 2 era i Ze E oO W i n olololololololJololJolo ho Oe _ PROGRAMMING E with Built in RLLP US DirectSOFT 5 Program ming for Windows e Handheld Programmer amp COPROCESSOR MODULES CPUs hove DL430 110 220 VAC PIS Program Memory Ranges 6 5K Built in EPROM Memory i from 128K to 512K DL440 110 220 VAC P S o 22 5K Memory Memory Cartridge Required o DL440 24 VDC or 125 VDC P S 22 5K Memory Memory Cartridge Required l o DL450 110 220 VAC P S 7 5K Built in Flash Memory DL450 24 VDC or 125 VDC P S 7 5K Built in Flash Memory BASES SPECIALTY MODULES 4 Slot Bases expandable or nonexpandable 6 Slot Bases expandable or nonexpandable SO Inner Pour nc 8 Slot Base expandable or nonexpandable High Speed Counter Module 8 pt Magnetic Pulse Input Module MEMORY CARTRIDGES Oo BBBBBBBBBBBABBBB S 16 Loop PID Module CMOS RAM w battery 4 Loop Temperature Controller UVPR
5. 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 checkthese 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 e Index alphabetical listing of key words at the end of this manual You can also check our online resources for the latest product support information e Internet Our Web address is http www automationdirect com If you still need assistance please call us at 770 844 4200 Our technical support group is glad 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 If you have acommentor question about any of our products services or manuals please fill out and return the Suggestions card that was shipped with this manual DL405 User Manual 4th Edition Rev A Getting Started BEN Conventions Used CD o v When you see the light bulb icon in the left hand margin the paragraph to its E E B immediate right will give you a special tip e da The word TIP in boldface will mark the beginning of the text a E Q pataa When you see the notepad icon in the le
6. memory contains parameters such as retentive ranges communications port settings etc Q How often should the CPU backup battery be changed A All of the 405 CPUs have an LED indicator that will flash when the battery voltage is getting low The typical battery life is 5 years Q Where can I obtain the most current firmware for the DL450 A In the tech support section of www automationdirect com The firmware and instructions on how to update the CPU are available Q Do the DL405 PLCs have ethernet capability A Yes the H4 ECOM module is needed to support ethernet Q Can the DL405 use the Modbus protocol A The DL450 supports Modbus on port 1 or 3 as a master or slave The DL 430 440 can support Modbus using the F4 MAS MB master or F4 SLV MB slave module Q Can have more than 16 PID loops on a system using the DL450 A Yes You can still use the 16 loop PID module in the base plus the DL450 s loops Q What are the networking capabilities of the DL450 A The DL430 DL440 CPUS can serve as DirectNET slaves The DL450 has two network ports which can serve as DirectNET masters or slaves or MODBUS masters or slaves Q Are more FAQs available for the DL405 and other products A Yes visit www automationdirect com for more FAQs and other technical information DL405 User Manual 4th Edition Rev A
7. Getting Started In This Chapter Introduction DL405 System Components Programming Methods DirectLOGIC Part Numbering System Quick Start for PLC Checkout and Programming Steps to Designing a Successful System Frequently Asked Questions EE Getting Started Introduction The Purpose of Thank you for purchasing our DL405 this Manual family of products This manual shows you how to install program and maintain the equipment It also helps you understand how to interface them to other devices in a control system This manual contains important information for personnel who will install DL405 PLCs and components 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 Kel D E o i o joy en eo Where to Begin If you already understand PLCs 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 have questions If you are a new DL405 customer we suggest you read this manual completely so you can understand the wide variety of features in the DL405 family of products We believe you will be pleasantly surprised with how much you can accomplish with our products Supplemental If you have purchased operator interfaces or DirectSOFT you will need to Manuals supplement this
8. OM SDS Interface Module EEPROM li Filler Module DL405 User Manual 4th Edition Rev A Getting Started Q DL405 Family g e 0 E RELAY OUTPUT s 2 EE 8pt Uia ae I a Lg 8pt 5A pt DCOUTPUT ar acouTpuT BE apt 2A pt Bet le apt 12 24 VDC P Hes ie 8pt 18 220 VAC fe i6pt 1A pt Be 8pt 24 250VDC h HSal is 16pt 18 220 VAC eel is 16pt 5 24 VDC es el Her lel em 16pt 12 24 VDC f 5 ea e ae 3 32pt 5 24 VDC Ra ae EG 32pt 12 24 VDC i Hale E 64pt 5 24VDC e i ES D N N N l O SYSTEMS Expansion Bases Local Base Expansion Unit 110 220 VAC P S Local Base Expansion Unit 24 VDC P S o Local Base Expansion Unit 125 VDC P S Remote I O Remote I O Master Module Remote I O Slave Unit 110 220 VAC Remote I O Slave Unit 24 VDC DL450 CPU Direct r
9. U features are covered in Chapter 3 CPU Specifications and Operation Three base sizes are available in the system 4 slot 6 slot and 8 slot The DL430 440 CPUs can support up to 640 I O between the CPU base and expansion bases the DL450 up to 1024 local I O A maximum of 512 additional I O forthe DL430 1024 for the DL440 or 1536 for the DL450 can be added tothe system inthe form of remote I O bases and slice I O blocks Each of these I O configurations is explained in Chapter 4 System Design and configuration The DL405 family has some of the most powerful modules in the industry They include a complete range of discrete modules which support 24 VDC 125 VDC 110 220 VAC and up to 10A relay outputs Analog modules provide 12 bit resolution and several selections of input and output signal ranges including bipolar Specialty modules include a 100KHz high speed input thermocouple general purpose communication magnetic pulse input 16 loop PID function and more Programming Methods DirectSOFT Programming for Windows Handheld Programmer There are two programming methods available to the DL405 CPUs RLL Relay Ladder Logic and RLLPLUS Stage Programing Both the DirectSOFT programming package and the handheld programmer support RLL and Stage The DL405 CPUs can be programmed with one of the most advanced programming packages in the industry DirectSOFT 5 Ver 5 or later DirectSOFT 5 is a Windows based software package th
10. a safer more reliable system This chapter also includes wiring guidelines for the various system components o 2 Step 1 Review the Always make safety your first priority in e Installation any system application Chapter 2 Guidelines provides several guidelines that will help D o Step 2 Understand The CPU is the heart of your automation the CPU Setup system Make sure you take time to Procedures understand its various features and setup requirements Step 3 Understand It is important to understand how to the I O System configure the I O system You have Configurations several different types of systems E lm lm le le 6 s Local System 1 X0 X20 X30 YO Y20 Y30 e Expansion System fi sas dae oed as e Remote I O System O O e Network connections It is also important to understand how the system Power Budget is calculated See Chapter 4 for more information Step 4 Determine There are many different I O modules the I O Module available with the DL405 system Chapter 32 pt Module Specifications and 2 provides the specifications and wiring Wiring diagrams for the discrete I O modules Characteristics Ribbon connecter NOTE Analog and other specialty modules have their own manuals and are not R included in this manual DL405 User Manual 4th Edition Rev A Step 5 Understand Before you begin t
11. at supports many of the Windows features you already know such as cut and paste between applications point and click editing viewing and editing multiple application programs at the same time browsers and newly added Intelligent Box IBox Instructions which will help ease your programming tasks DirectSOFT 5 universally supports the DirectLOGIC CPU families This means you can use the same DirectSOFT 5 package to program DL105 DL205 DL305 DL405 or any new CPUs that we add to our product line There is a separate manual for the DirectSOFT 5 programming software All DL405 CPUs have a built in programming port for use with the handheld programmer D4 HPP The HPP can be used to create modify and debug your application program A separate manual for the DL405 HPP is available DL405 User Manual 4th Edition Rev A Getting Started DL405 System The diagram below shows the major components and configurations of the DL405 Diagrams system The next two pages show specific components for building your system A oO COMPUTERS PEER TO PEER and Ei MASTER SLAVE 311905 Uno ac wwe gm E ES Epeen oI Q 7 DirectNET Modbus Communication DirectNET Modbus max 3300ft 1000m
12. components into the base tilt the component slightly forward sliding the tab on the bottom of the component into the slot in the base Push the top of the component into the base until itis seated firmly then tighten the securing screw at the top of the module unit Placement of discrete analog and relay modules are not critical and may go in any slot in any base however for this example install the output module in the slot next to the CPU slot 0 and the input module in the next slot slot 1 Limiting factors for other types of modules are discussed in Chapter 4 Bases Expansion Units and I O Configuration You must also make sure you do not exceed the power budget for Q D 3 Co e D zi D a each base in your system configuration Power budgeting is discussed in Chapter 4 System Design and Configuration e Each unit has a plastic tab at the bottom and a screw at the top e With the unit tilted slightly forward hook the module s plastic tab on the base e Gently push the top of the unit back until it is firmly installed in the base Secure the unit to the base by tightening the top screw Remove the terminal strip cover It has a small retention snap on the left edge Push in and up then pull the cover off If you are using a DL440 CPU optional on DL450 you need to install the memory cartridge in the slot to the right of the battery Make sure it is firmly seated To find out more about memory cartri
13. dges see Chapter 3 X 0 0 Push in d and lift off a SE L Je o I Oo 1 JO aca TN Memory Cartridge If you are using 110VAC install the voltage select jumper on the bottom two terminals If you are using 220VAC power do not install the jumper You can find a detailed explanation of the terminal block on both the CPU and expansion units in Chapter 2 Installation Wiring and Specifications DL405 User Manual 4th Edition Rev A Getting Started WARNING Damage will occur to the power supply if 220 VAC is connected to 8 jJ WZ the terminal connections with the 110 VAC shunt in place T n N f O o o 2 m 50 60Hz i ap DL4 430 CPU 110 220VAC E an E trait runs E eo If using DA 0X 1 type bases ey sro cu F3 cov install this shunt to connect ES o grounds for proper noise r D 24V ze AD X immunity 24VDC OUT Auxiliary RUN Hi P L D Power amp C Log ic UR d us 7 D Ground z is Wy 4 Chassis RD G9 Ground se G
14. e X0 to the toggle switch and 24VDC auxiliary power supply on the CPU terminal strip as shown below for the 16ND2 input module Chapter 2 Installation Wiring and Specifications provides a list of I O wiring guidelines DL405 User Manual 4th Edition Rev A Getting Started ERN Step 7 Connect Connect the wires as shown Observe all the Power Wiring precautions stated earlier in this manual For details on wiring see Chapter 2 C oO Installation Wiring and Specifications EE When the wiring is complete replace the je O E es CPU and module covers Do not apply Ground Je a power at this time tife e d a O Neutral mE i E A E Lie ale y Step 8 Connect Remove the connector cover at the top Securing screws the Handheld right of the CPU Join the Handheld D Programmer programmer s 15 pin D type connector 0 O located on the back to the connector you just uncovered on the CPU Finger tighten the securing screws on the top and bottom l i of the Handheld programmer 0 EL uH H z225 Step 9 Switch On Apply power to the system and ensure the PWR indicator on the CPU is on If not the System Power remo
15. e CPU with a memory cartridge if you are using a DL440 or DL450 e D4 16ND2 DC input module or a D4 16SIM input simulator module e D4 16TR Relay output module e Power cord e Hook up wire A24 VDC toggle switch if not using the input simulator module e A screwdriver regular or Philips type You will need at least one of the following programming options e DirectSOFT Programming Software Direct SOFT Manual and a programming cable connects the CPU to a personal computer or e D4 HPP Handheld Programmer programming cable is optional and the Handheld Programmer Manual naond nuna I W e e eoe eee eoe I D NUNG 100 UU D UT UU DL405 User Manual 4th Edition Rev A Step 2 Install the CPU and I O Modules Step 3 Remove Terminal Strip Access Cover Step 4 Install Memory Cartridge Step 5 Select Operating Power Range Getting Started BRUN Insert the CPU and I O into the base The CPU must go into the far left side of the base in the position marked CPU Power Supply When inserting
16. emote I O link on Port 3 e ele ele Eeee ES ES NETWORKING i Es s ANALOG FER ee Ethernet Communication Module e ACH Input ac ls Data Communication Module 8CH input Bech as DirectNET Network Modbus 16CH Input Lee S DL450 CPU Ports 1 and 3 4CH Output eral ie DirectNET Network Modbus 8CH Output Sal tee Modbus Master Module 16CH Output al eS Modbus Slave Module P 8CH Thermocouple Input ee TIWAY Network Interface Module 8CH RTD Input Bac Shared Data Network Module S DL405 User Manual 4th Edition Rev A Getting Started Getting Started DirectLOGIC Part Numbering System A DL405 PLC control system may be comprised of many products from the DL405 family The part numbering system below shows how the part numbering systems work for each product category Part numbers for accessory items such as cables batteries memory cartridges etc are typically an abbreviation of the description for the item
17. ft hand margin the paragraph to its R immediate right will be a special note The word NOTE in boldface will mark the beginning of the text When you see the exclamation mark icon in the left hand margin the paragraph to its immediate right will be a warning This information could prevent injury loss of property or even death in extreme cases The word WARNING and text will be in boldface VA TS Key Topics for The beginning of each chapter will list the Each Chapter key topics that can be found in that Introduction chapter DL405 User Manual 4th Edition Rev A ELE Getting Started DL405 System Components Kel D E o i o joy en eo CPUS Bases 1 O Configuration I O Modules The DL405 product family is one of the most versatile and widely accepted PLCs used for medium control applications The CPUs are small yet powerful Their modular design and expansion capability blend well with todays fast moving industry The following is a summary of the major DL405 system components There are three feature enhanced CPUs in this product line the DL430 DL440 and the DL450 All include a built in power supply and communication ports Each CPU offers a large amount of program memory a substantial instruction set and advanced diagnostics The DL450 features drum timers floating point math built in PID loops and additional communications ports Details of these CP
18. log I O Output Digital to Analog DA using abbreviations Combination xADxDA rs is Ub su Isolated S note n indicates thermocouple type Denotes a differentiation between 1 2 8 4 such as J K LR S or E Similar modules Communication and Networking D4 DCM DCM Data Communication Module Special I O and Devices D3 HSC HSC High Speed Counter Programming D3 HPP HPP RLL PLUS Handheld Programmer DL205 Product family D2 F2 DL305 Product family D3 F3 DL405 Product family D4 F4 Name Abbreviation see example CoProcessors and ASCII BASIC Modules p JL Ce 25 R DL205 Product family D2 F2 DL305 Product family D3 F3 DL405 Product family D4 F4 CoProcessor CP ASCII BASIC AB 64K memory 64 128K memory 128 512K memory 512 Radio modem R Telephone modem T DL405 User Manual 4th Edition Rev A 1 10 Getting Started Quick Start for PLC Checkout and Programming If you have experience with PLCs or if you just want to setup a quick example this section is for you This example is not intended to tell you everything you need to start up your system It is only intended to give you a general picture of what you will need to do to get your system powered up Kel D E o i o joy en eo Step 1 Unpack the Unpack the DL405 equipment and verify you have the parts necessary to build this DL405 Equipment demonstration system The minimum parts you will need are e Base
19. o enter a program it is the CPU Operation Step 6 Review the Programming Getting Started BER very helpful to understand how the DL405 Power up CPU processes information This involves o not only program execution steps but also Initialize hardware zi involves the various modes of operation D and memory layout characteristics See a cay a Chapter 3 for more information d Q The DL405 PLC provides four main approaches to solving the application program including the PID loop task depicted in the next figure Concepts e RLL diagram style programming is the best tool for solving boolean logic g y p and general CPU register accumulator manipulation It includes dozens of instructions which will augment drums stages and loops e The DL450 has four timer event drum types each with up to 16 steps They offer both time and or event based step transitions Drums are best for a repetitive process based on a single series of steps e Stage programming also called RLLP vs is based on state transition diagrams Stages divide the ladder program into sections which correspond to the states in a flow chart you draw for your process e The DL450 PID Loop Operation uses setup tables to configure up to 16 loops Features include alarms SP ramp soak generation and more Standard RLL Programming Timer Event Drum Sequence
20. r see Chapter 5 m LDD d V1076 CMPD K309482 SP62 YO OUT Stage Programming PID Loop Operation see Chapter 7 see Chapter 8 SP PID Process PV Step 7 Choose the After installation and studying the main TMR Ti Instructions programming concepts you can begin K30 nt Te CNT CT3 writing the application program or K10 configuring loop operation You ll discover a powerful instruction set DL405 User Manual 4th Edition Rev A 1 16 Getting Started Step 8 Understand Sometimes equipment failures occur the Maintenance when we least expect it Switches fail and loads short and need replacement etc O Troubleshooting Often the majority of the troubleshooting Procedures time is spent in locating the problem The DL405 system has many built in features such as error codes that can help you quickly identify problems See Chapter 9 for diagnostics and troubleshooting tips Kel D E c i o joy en eo O SeS Frequently Asked Questions Q How do I reset my DL405 CPU back to factory defaults A Resetting the processor to factory defaults is a two step process First clear the processor memory using DirectSOFT PLC gt CLEAR PLC MEMORY Next initialize the scratchpad PLC gt SETUP gt INITIALIZE SCRATCHPAD Be aware that initializing the scratchpad will reset the system V memory to defaults System V
21. ve power from the system and check all wiring and refer to the troubleshooting section in Chapter 9 for assistance Step 10 Enter the Turn the key switch on the CPU to the STOP position and then back to the TERM Program position This puts the CPU in the program mode and allows access to the CPU program The PGM indicator should be illuminated on the HPP Enter the following keystrokes on the HPP NOTE Itis not necessary for you to configure the I O for this system since the DL430 CPUs automatically configure I O and the DL440 and DL450 CPUs default to automatic I O configuration CLR CLR XO Yo AUX 2 4 C 2 CLR AD 0 NXT STR X IN 0 IN END our your 0 oH END After entering the simple example program turn the key switch from the TERM position to the RUN position and back to TERM The RUN indicator on the CPU will come on indicating the CPU has entered the run mode If not repeat Step 10 insuring the program is entered properly or refer to the troubleshooting guide in chapter 9 During Run mode operation the output status indicator O on the output module should reflect the switch status When the switch is on the output should be on DL405 User Manual 4th Edition Rev A Getting Started Steps to Designing a Successful System provide
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