Volume 2 Table Of Contents Contents2

User Manual: Volume 2 Table of Contents DL06 User Manual

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Table of Contents
Chapter 1: Getting Started
Introduction................................................................................................................ 1–2
The Purpose of this Manual....................................................................................... 1–2
Supplemental Manuals.............................................................................................. 1–2
Technical Support..................................................................................................... 1–2
Conventions Used....................................................................................................... 1–3
Key Topics for Each Chapter...................................................................................... 1–3
DL06 Micro PLC Overview.......................................................................................... 1–4
The DL06 PLC Features............................................................................................. 1–4
DirectSOFT Programming for Windows™................................................................. 1–4
Handheld Programmer.............................................................................................. 1–5
I/O Quick Selection Guide.......................................................................................... 1–5
Quick Start.................................................................................................................. 1–6
Steps to Designing a Successful System.................................................................. 1–10
Questions and Answers about DL06 Micro PLCs..................................................... 1–12

Chapter 2: Installation, Wiring, and Specifications
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
Class 1, Division 2 Approval...................................................................................... 2–4
Orientation to DL06 Front Panel............................................................................... 2–5
Terminal Block Removal............................................................................................ 2–6
Mounting Guidelines.................................................................................................. 2–7

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Unit Dimensions........................................................................................................ 2–7
Enclosures................................................................................................................. 2–7
Panel Layout & Clearances........................................................................................ 2–8
Using Mounting Rails................................................................................................ 2–9
Environmental Specifications................................................................................... 2–10
Agency Approvals.................................................................................................... 2–10
Marine Use.............................................................................................................. 2–10
Wiring Guidelines..................................................................................................... 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
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....................................................................................... 2–27
DC Output Wiring Methods.................................................................................... 2–28
High-Speed I/O Wiring Methods............................................................................. 2–29
Wiring Diagrams and Specifications........................................................................ 2–30
D0–06AA I/O Wiring Diagram................................................................................. 2–30
D0–06AR I/O Wiring Diagram................................................................................. 2–32
D0–06DA I/O Wiring Diagram................................................................................ 2–34
D0–06DD1 I/O Wiring Diagram.............................................................................. 2–36
D0–06DD2 I/O Wiring Diagram.............................................................................. 2–38
D0–06DR I/O Wiring Diagram................................................................................. 2–40
D0–06DD1–D I/O Wiring Diagram.......................................................................... 2–42
D0–06DD2–D I/O Wiring Diagram.......................................................................... 2–44
D0–06DR–D I/O Wiring Diagram............................................................................ 2–46

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

Chapter 3: CPU Specifications and Operation
Overview.3–2
DL06 CPU Features................................................................................................... 3–2
CPU Specifications...................................................................................................... 3–3
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 DL06 PLC............................................................................ 3–7
Mode of Operation at Power-up............................................................................... 3–7
Using Battery Backup................................................................................................. 3–8
Battery Backup.......................................................................................................... 3–8
Auxiliary Functions.................................................................................................... 3–9
Clearing an Existing Program.................................................................................... 3–9
Initializing System Memory....................................................................................... 3–9
Setting Retentive Memory Ranges........................................................................... 3–10
Using a Password.................................................................................................... 3–11
CPU Operation.......................................................................................................... 3–12
CPU Operating System............................................................................................ 3–12
Program Mode........................................................................................................ 3–13
Run Mode............................................................................................................... 3–13
Read Inputs............................................................................................................. 3–14
Service Peripherals and Force I/O............................................................................ 3–14
CPU Bus Communication........................................................................................ 3–15
Update Clock, Special Relays and Special Registers.................................................. 3–15
Solve Application Program...................................................................................... 3–16
Solve PID Loop Equations........................................................................................ 3–16
Write Outputs......................................................................................................... 3–16
Write Outputs to Specialty I/O................................................................................ 3–16
Diagnostics.............................................................................................................. 3–17
I/O Response Time................................................................................................... 3–17
Is Timing Important for Your Application?............................................................... 3–17

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Normal Minimum I/O Response.............................................................................. 3–18
Normal Maximum I/O Response............................................................................. 3–18
Improving Response Time....................................................................................... 3–19
CPU Scan Time Considerations................................................................................ 3–20
Reading Inputs........................................................................................................ 3–20
Writing Outputs...................................................................................................... 3–20
Service Peripherals................................................................................................... 3–21
CPU Bus Communication........................................................................................ 3–21
Update Clock/Calendar, Special Relays, Special Registers........................................ 3–21
Application Program Execution............................................................................... 3–22
PLC Numbering Systems......................................................................................... 3–23
PLC Resources......................................................................................................... 3–23
V–Memory.............................................................................................................. 3–24
Binary-Coded Decimal Numbers............................................................................. 3–24
Hexadecimal Numbers............................................................................................ 3–24
Memory Map............................................................................................................ 3–25
Octal Numbering System........................................................................................ 3–25
Discrete and Word Locations................................................................................... 3–25
V-memory Locations for Discrete Memory Areas..................................................... 3–25
Input Points (X Data Type)...................................................................................... 3–26
Output Points (Y Data Type)................................................................................... 3–26
Control Relays (C Data Type).................................................................................. 3–26
Timers and Timer Status Bits (T Data Type)............................................................. 3–26
Timer Current Values (V Data Type)........................................................................ 3–27
Counters and Counter Status Bits (CT Data type).................................................... 3–27
Counter Current Values (V Data Type).................................................................... 3–27
Word Memory (V Data Type).................................................................................. 3–28
Stages (S Data type)................................................................................................ 3–28
Special Relays (SP Data Type).................................................................................. 3–28
DL06 System V-memory........................................................................................... 3–29
System Parameters and Default Data Locations (V Data Type)................................ 3–29
DL06 Aliases.............................................................................................................. 3–31
DL06 Memory Map................................................................................................... 3–32
X Input/Y Output Bit Map....................................................................................... 3–33
Stage Control/Status Bit Map.................................................................................. 3–34
Control Relay Bit Map.............................................................................................. 3–36

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Timer Status Bit Map................................................................................................ 3–38
Counter Status Bit Map............................................................................................ 3–38
GX and GY I/O Bit Map........................................................................................... 3–39

Chapter 4: System Design and Configuration
DL06 System Design Strategies................................................................................. 4–2
I/O System Configurations........................................................................................ 4–2
Networking Configurations....................................................................................... 4–2
Module Placement...................................................................................................... 4–3
Slot Numbering........................................................................................................ 4–3
Automatic I/O Configuration..................................................................................... 4–4
Manual I/O Configuration......................................................................................... 4–4
Power Budgeting........................................................................................................ 4–5
Power supplied ........................................................................................................ 4–5
Power required by base unit .................................................................................... 4–5
Power required by option cards ............................................................................... 4–5
Configuring the DL06’s Comm Ports......................................................................... 4–7
DL06 Port Specifications............................................................................................ 4–7
DL06 Port Pinouts..................................................................................................... 4–7
Choosing a Network Specification............................................................................. 4–8
RS-232 Network........................................................................................................ 4–8
RS-422 Network........................................................................................................ 4–8
RS-485 Network........................................................................................................ 4–8
Connecting to MODBUS and DirectNET Networks................................................... 4–9
MODBUS Port Configuration..................................................................................... 4–9
DirectNET Port Configuration.................................................................................. 4–10
Non–Sequence Protocol (ASCII In/Out and PRINT)................................................ 4–11
Non-Sequence Port Configuration........................................................................... 4–11
Network Slave Operation......................................................................................... 4–12
MODBUS Function Codes Supported...................................................................... 4–12
Determining the MODBUS Address......................................................................... 4–12
If Your Host Software Requires the Data Type and Address..................................... 4–13
Example 1: V2100................................................................................................... 4–14
Example 2: Y20....................................................................................................... 4–14
Example 3: T10 Current Value................................................................................. 4–14

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Example 4: C54....................................................................................................... 4–14
If Your MODBUS Host Software Requires an Address ONLY.................................... 4–15
Example 1: V2100 584/984 Mode.......................................................................... 4–16
Example 2: Y20 584/984 Mode.............................................................................. 4–16
Example 3: T10 Current Value 484 Mode............................................................... 4–17
Example 4: C54 584/984 Mode.............................................................................. 4–17
Network Master Operation...................................................................................... 4–17
Step 1: Identify Master Port # and Slave #.............................................................. 4–18
Step 2: Load Number of Bytes to Transfer............................................................... 4–18
Step 3: Specify Master Memory Area....................................................................... 4–19
Step 4: Specify Slave Memory Area......................................................................... 4–20
Communications from a Ladder Program................................................................ 4–21
Multiple Read and Write Interlocks.......................................................................... 4–21
Network Master Operation (using MRX and MWX Instructions).......................... 4–22
MODBUS Function Codes Supported...................................................................... 4–22
MODBUS Read from Network(MRX)....................................................................... 4–23
MRX Slave Memory Address.................................................................................... 4–24
MRX Master Memory Addresses.............................................................................. 4–24
MRX Number of Elements....................................................................................... 4–24
MRX Exception Response Buffer.............................................................................. 4–24
MODBUS Write to Network (MWX)........................................................................ 4–25
MWX Slave Memory Address.................................................................................. 4–26
MWX Master Memory Addresses............................................................................. 4–26
MWX Number of Elements...................................................................................... 4–26
MWX Exception Response Buffer............................................................................. 4–26
MRX/MWX Example in DirectSOFT......................................................................... 4–27
Multiple Read and Write Interlocks.......................................................................... 4–27

Chapter 5: Standard RLL Instructions
Introduction................................................................................................................ 5–2
Using Boolean Instructions........................................................................................ 5–5
END Statement......................................................................................................... 5–5
Simple Rungs............................................................................................................ 5–5
Normally Closed Contact.......................................................................................... 5–6
Contacts in Series...................................................................................................... 5–6
Midline Outputs........................................................................................................ 5–6

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Parallel Elements........................................................................................................ 5–7
Joining Series Branches in Parallel.............................................................................. 5–7
Joining Parallel Branches in Series.............................................................................. 5–7
Combination Networks............................................................................................. 5–7
Comparative Boolean................................................................................................ 5–8
Boolean Stack............................................................................................................ 5–8
Immediate Boolean................................................................................................... 5–9
Boolean Instructions ................................................................................................ 5–10
Comparative Boolean............................................................................................... 5–26
Immediate Instructions............................................................................................ 5–32
Timer, Counter and Shift Register Instructions....................................................... 5–39
Using Timers........................................................................................................... 5–39
Timer Example Using Discrete Status Bits................................................................ 5–41
Timer Example Using Comparative Contacts........................................................... 5–41
Accumulating Timer Example using Discrete Status Bits.......................................... 5–43
Accumulator Timer Example Using Comparative Contacts...................................... 5–43
Using Counters....................................................................................................... 5–44
Counter Example Using Discrete Status Bits............................................................ 5–46
Counter Example Using Comparative Contacts....................................................... 5–46
Stage Counter Example Using Discrete Status Bits................................................... 5–48
Stage Counter Example Using Comparative Contacts............................................. 5–48
Up / Down Counter Example Using Discrete Status Bits.......................................... 5–50
Up / Down Counter Example Using Comparative Contacts..................................... 5–50
Accumulator/Stack Load and Output Data Instructions......................................... 5–52
Using the Accumulator............................................................................................ 5–52
Copying Data to the Accumulator........................................................................... 5–52
Changing the Accumulator Data............................................................................. 5–53
Using the Accumulator Stack................................................................................... 5–54
Using Pointers......................................................................................................... 5–55
Logical Instructions (Accumulator).......................................................................... 5–69
Math Instructions..................................................................................................... 5–86
Transcendental Functions...................................................................................... 5–118
Bit Operation Instructions...................................................................................... 5–120
Number Conversion Instructions (Accumulator)................................................... 5–127
Shuffle Digits Block Diagram................................................................................. 5–139

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Table Instructions................................................................................................... 5–141
Copy Data From a Data Label Area to V-memory.................................................. 5–143
Clock/Calendar Instructions................................................................................... 5–171
CPU Control Instructions........................................................................................ 5–173
Program Control Instructions................................................................................ 5–175
Interrupt Instructions............................................................................................. 5–183
Message Instructions.............................................................................................. 5–186
Move Block Instruction (MOVBLK)........................................................................ 5–189
Copy Data From a Data Label Area to V-memory.................................................. 5–189
Intelligent I/O Instructions..................................................................................... 5–194
Read from Intelligent Module (RD)........................................................................ 5–194
Write to Intelligent Module (WT).......................................................................... 5–195
Network Instructions.............................................................................................. 5–196
Direct Text Entry................................................................................................... 5–200
Embedding date and/or time variables.................................................................. 5–201
Embedding V-memory data.................................................................................. 5–201
Data Format Suffixes for Embedded V-memory Data............................................ 5–202
Text Entry from V-memory.................................................................................... 5–203
MODBUS RTU Instructions .................................................................................... 5–204
MRX Slave Address Ranges.................................................................................... 5–205
MWX Slave Address Ranges.................................................................................. 5–208
MWX Master Memory Address Ranges.................................................................. 5–208
MWX Number of Elements ................................................................................. 5–208
MWX Exception Response Buffer........................................................................... 5–208
ASCII Instructions................................................................................................... 5–210
Reading ASCII Input Strings................................................................................... 5–210
Writing ASCII Output Strings................................................................................. 5–210
Managing the ASCII Strings.................................................................................. 5–211
Intelligent Box (IBox) Instructions......................................................................... 5–230

Chapter 6: Drum Instruction Programming
Introduction................................................................................................................ 6–2

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Volume Two:
Table of Contents
Purpose..................................................................................................................... 6–2
Drum Terminology.................................................................................................... 6–2
Drum Chart Representation....................................................................................... 6–3
Output Sequences..................................................................................................... 6–3
Step Transitions.......................................................................................................... 6–4
Drum Instruction Types............................................................................................. 6–4
Timer-Only Transitions.............................................................................................. 6–4
Timer and Event Transitions...................................................................................... 6–5
Event-Only Transitions............................................................................................... 6–6
Counter Assignments................................................................................................ 6–6
Last Step Completion................................................................................................ 6–7
Overview of Drum Operation.................................................................................... 6–8
Drum Instruction Block Diagram............................................................................... 6–8
Powerup State of Drum Registers.............................................................................. 6–9
Drum Control Techniques........................................................................................ 6–10
Drum Control Inputs............................................................................................... 6–10
Self-Resetting Drum................................................................................................ 6–11
Initializing Drum Outputs........................................................................................ 6–11
Using Complex Event Step Transitions.................................................................... 6–11
Drum Instruction...................................................................................................... 6–12
Timed Drum with Discrete Outputs (DRUM)........................................................... 6–12
Event Drum (EDRUM)............................................................................................. 6–14
Handheld Programmer Drum Mnemonics............................................................... 6–16
Masked Event Drum with Discrete Outputs (MDRMD)............................................ 6–19
Masked Event Drum with Word Output (MDRMW)................................................ 6–21

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Chapter 7: RLLPLUS Stage Programming
Introduction to Stage Programming......................................................................... 7–2
Overcoming “Stage Fright”....................................................................................... 7–2
Learning to Draw State Transition Diagrams............................................................ 7–3
Introduction to Process States................................................................................... 7–3
The Need for State Diagrams.................................................................................... 7–3
A 2–State Process...................................................................................................... 7–3
RLL Equivalent........................................................................................................... 7–4
Stage Equivalent........................................................................................................ 7–4
Let’s Compare........................................................................................................... 7–5
Initial Stages.............................................................................................................. 7–5
What Stage Bits Do................................................................................................... 7–6
Stage Instruction Characteristics................................................................................ 7–6
Using the Stage Jump Instruction for State Transitions........................................... 7–7
Stage Jump, Set, and Reset Instructions..................................................................... 7–7
Stage Program Example: Toggle On/Off Lamp Controller....................................... 7–8
A 4–State Process...................................................................................................... 7–8
Four Steps to Writing a Stage Program.................................................................... 7–9
1. Write a Word Description of the application......................................................... 7–9
2. Draw the Block Diagram....................................................................................... 7–9
3. Draw the State Transition Diagram....................................................................... 7–9
4. Write the 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
RLLPLUS (Stage) Instructions..................................................................................... 7–21
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
Block Call (BCALL)................................................................................................... 7–25
Block (BLK).............................................................................................................. 7–25
Block End (BEND).................................................................................................... 7–25
Questions and Answers about Stage Programming............................................... 7–27

Chapter 8: PID Loop Operation
DL06 PID Control........................................................................................................ 8–2
DL06 PID Control Features........................................................................................ 8–2
Introduction to PID Control....................................................................................... 8–4
What is PID Control?................................................................................................. 8–4
Introducing DL06 PID Control................................................................................... 8–6
Process Control Definitions........................................................................................ 8–8
PID Loop Operation.................................................................................................... 8–9
Position Form of the PID Equation............................................................................. 8–9
Reset Windup Protection......................................................................................... 8–10
Freeze Bias.............................................................................................................. 8–11
Adjusting the Bias.................................................................................................... 8–11
Step Bias Proportional to Step Change in SP........................................................... 8–12
Eliminating Proportional, Integral or Derivative Action............................................ 8–12
Velocity Form of the PID Equation........................................................................... 8–12

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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
Alternative Manual Tuning Procedures by Others.................................................... 8–44
Tuning PID Controllers............................................................................................ 8–44
Auto Tuning Procedure........................................................................................... 8–45
Use DirectSOFT 5 Data View with PID View............................................................ 8–49
Open a New Data View Window............................................................................. 8–49
Open PID View........................................................................................................ 8–50
Using the Special PID Features................................................................................ 8–53
How to Change Loop Modes.................................................................................. 8–53
Operator Panel Control of PID Modes..................................................................... 8–54
PLC Modes Effect on Loop 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 Instructions.............................................. 8-57
FilterB Example........................................................................................................ 8-57
Ramp/Soak Generator.............................................................................................. 8–58

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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 DL06 CPU........................................................................... 8–66
Tuning Cascaded Loops.......................................................................................... 8–67
Time-Proportioning Control..................................................................................... 8–68
On/Off Control Program Example........................................................................... 8–69
Feedforward Control................................................................................................ 8–70
Feedforward Example.............................................................................................. 8–71
PID Example Program.............................................................................................. 8–72
Program Setup for the PID Loop............................................................................. 8–72
Troubleshooting Tips............................................................................................... 8–75
Glossary of PID Loop Terminology.......................................................................... 8–77
Bibliography ............................................................................................................ 8–79

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
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DL06 Micro PLC Error Codes..................................................................................... 9–4
Program Error Codes................................................................................................. 9–5
CPU Indicators............................................................................................................ 9–6
PWR Indicator........................................................................................................... 9–6
RUN Indicator........................................................................................................... 9–7
CPU Indicator............................................................................................................ 9–7
Communications Problems........................................................................................ 9–7
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
Run Time Edit Example........................................................................................... 9–15
Forcing I/O Points................................................................................................... 9–16
Regular Forcing with Direct Access.......................................................................... 9–18
Bit Override Forcing................................................................................................ 9–19
Bit Override Indicators............................................................................................. 9–19
Reset the PLC to Factory Defaults............................................................................ 9–20

Chapter 10: LCD Display Panel
Introduction to the DL06 LCD Display Panel.......................................................... 10–2
Keypad... 10–2
Snap-in installation................................................................................................... 10–3
Display Priority......................................................................................................... 10–4
Menu Navigation...................................................................................................... 10–5
Confirm PLC Type, Firmware Revision Level, Memory Usage, Etc......................... 10–6
Examining Option Slot Contents............................................................................. 10–8

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Menu 2, M2:SYSTEM CFG. ..................................................................................... 10–8
Monitoring and Changing Data Values................................................................. 10–10
Menu 3, M3:MONITOR ....................................................................................... 10–10
Data Monitor........................................................................................................ 10–10
V-memory values................................................................................................... 10–10
Pointer values........................................................................................................ 10–12
Bit Monitor............................................................................................................. 10–13
Bit status............................................................................................................... 10–13
Changing Date and Time....................................................................................... 10–14
Menu 4, M4 : CALENDAR R/W.............................................................................. 10–14
Setting Password and Locking............................................................................... 10–17
Menu 5, M5 : PASSWORD R/W............................................................................. 10–17
Reviewing Error History.......................................................................................... 10–20
Menu 6, M6 : ERR HISTORY.................................................................................. 10–20
Toggle Light and Beeper, Test Keys...................................................................... 10–21
Menu 7, M7 : LCD TEST&SET............................................................................... 10–21
PLC Memory Information for the LCD Display Panel........................................... 10–22
Data Format Suffixes for Embedded V-memory Data............................................ 10–22
Reserved memory registers for the LCD Display Panel........................................... 10–23
V7742 bit definitions............................................................................................. 10–24
Changing the Default Screen................................................................................. 10–25
Example program for setting the default screen message...................................... 10–25
DL06 LCD Display Panel Instruction (LCD)............................................................ 10–26
Source of message................................................................................................ 10–26
ASCII Character Codes.......................................................................................... 10–27
Example program: alarm with embedded date/time stamp.................................. 10–28
Example program: alarm with embedded V-memory data.................................... 10–29
Example program: alarm text from V-memory with embedded V-memory data... 10–30

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

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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 31 Clear V-memory...........................................................................................A–4
AUX 4* — I/O Configuration......................................................................................A–5
AUX 41 Show I/O Configuration...............................................................................A–5
AUX 5* — CPU 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
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

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Appenedix B: DL06 Error codes
DL06 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
Instruction Execution Times.......................................................................................C–3
Boolean Instructions..................................................................................................C–3
Comparative Boolean Instructions.............................................................................C–4
Immediate Instructions............................................................................................C–11
Bit of Word Boolean Instructions.............................................................................C–12
Timer, Counter and Shift Register...........................................................................C–13
Accumulator Data Instructions................................................................................C–14
Logical Instructions.................................................................................................C–15
Math Instructions....................................................................................................C–16
Differential Instructions...........................................................................................C–19
Bit Instructions........................................................................................................C–19
Number Conversion Instructions.............................................................................C–20
Table Instructions....................................................................................................C–20
CPU Control Instructions.........................................................................................C–22
Program Control Instructions..................................................................................C–22
Interrupt Instructions...............................................................................................C–22
Network Instructions...............................................................................................C–22
Intelligent I/O Instructions.......................................................................................C–23
Message Instructions...............................................................................................C–23
RLLPLUS Instructions..................................................................................................C–23
Drum Instructions...................................................................................................C–23
Clock/Calendar Instructions.....................................................................................C–24
MODBUS Instructions..............................................................................................C–24
ASCII Instructions....................................................................................................C–24

Appendix D: Special Relays
DL06 PLC Special Relays............................................................................................ D–2
Startup and Real-Time Relays................................................................................... D–2

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CPU Status Relays..................................................................................................... D–2
System Monitoring................................................................................................... D–3
Accumulator Status.................................................................................................. D–3
HSIO Input Status..................................................................................................... D–4
HSIO Pulse Output Relay.......................................................................................... D–4
Communication Monitoring Relay............................................................................ D–4
Option Slot Communication Monitoring Relay......................................................... D–4
Option Slot Special Relay......................................................................................... D–4
Counter 1 Mode 10 Equal Relays............................................................................. D–5
Counter 2 Mode 10 Equal Relays............................................................................. D–6

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
Choosing the HSIO Operating Mode......................................................................... E–4
Understanding the Six Modes................................................................................... E–4
Default Mode............................................................................................................ E–5
Configuring the HSIO Mode..................................................................................... E–6
Configuring Inputs X0 – X3....................................................................................... E–6
Mode 10: High-Speed Counter.................................................................................. E–7
Purpose..................................................................................................................... E–7
Functional Block Diagram.......................................................................................... E–7
Wiring Diagram......................................................................................................... E–8
Interfacing to Counter Inputs.................................................................................... E–8
Setup for Mode 10.................................................................................................... E–9
Presets and Special Relays......................................................................................... E–9
Absolute and Incremental Presets............................................................................ E–10
Preset Data Starting Location.................................................................................. E–11
Using Fewer than 24 Presets................................................................................... E–11
Equal Relay Numbers.............................................................................................. E–12
Calculating Your Preset Values................................................................................. E–13
X Input Configuration............................................................................................. E–14
Writing Your Control Program................................................................................. E–15
Program Example 1: Counter Without Presets......................................................... E–16
Program Example 2: Counter With Presets.............................................................. E–18

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Program Example 3: Counter With Preload............................................................. E–21
Troubleshooting Guide for Mode 10....................................................................... E–23
Symptom: The counter does not count................................................................... E–23
Symptom: The counter counts but the presets do not function.............................. E–23
Symptom: The counter counts up but will not reset............................................... E–23
Mode 20: Up/Down Counter................................................................................... E–24
Purpose................................................................................................................... E–24
Functional Block Diagram........................................................................................ E–24
Quadrature Encoder Signals.................................................................................... E–25
Wiring Diagram....................................................................................................... E–25
Interfacing to Encoder Outputs............................................................................... E–26
Setup for Mode 20.................................................................................................. E–27
Presets and Special Relays....................................................................................... E–27
X Input Configuration............................................................................................. E–28
Mode 20 Up/Down Counter................................................................................... E–28
Writing Your Control Program................................................................................. E–29
Program Example 1: Quadrature Counting with an Interrupt.................................. E–30
Program Example 2: Up/Down Counting with Standard Inputs.............................. E–32
Program Example 3: Quadrature Counting............................................................. E–34
Troubleshooting Guide for Mode 20....................................................................... E–37
Symptom: The counter does not count................................................................... E–37
Symptom: The counter counts in the wrong direction........................................... E–37
Symptom: The counter counts up and down but will not reset............................... E–37
Mode 30: Pulse Output............................................................................................ E–38
Purpose................................................................................................................... E–38
Functional Block Diagram........................................................................................ E–39
Wiring Diagram....................................................................................................... E–40
Interfacing to Drive Inputs....................................................................................... E–40
Motion Profile Specifications................................................................................... E–41
Physical I/O Configuration....................................................................................... E–41
Logical I/O Functions.............................................................................................. E–41
Setup for Mode 30.................................................................................................. E–42
Profile/Velocity Select Register................................................................................. E–43
Profile Parameter Table............................................................................................ E–43
Automatic Trapezoidal Profile.................................................................................. E–43
Step Trapezoidal Profile........................................................................................... E–44
Velocity Control...................................................................................................... E–44

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Step Trapezoidal Profile........................................................................................... E–44
Choosing the Profile Type....................................................................................... E–45
Automatic Trapezoidal Profile Defined..................................................................... E–45
Step Trapezoidal Profiles Defined............................................................................ E–46
Velocity Control Defined......................................................................................... E–46
Automatic Trapezoidal Profile Operation................................................................. E–47
Program Example 1: Automatic Trapezoidal Profile without External Interrupt........ E–48
Preload Position Value............................................................................................. E–49
Program Example 2: Automatic Trapezoidal Profile with External Interrupt............. E–50
Program Example 3: Automatic Trapezoidal Profile with Home Search.................... E–53
Step Trapezoidal Profile Operation.......................................................................... E–58
Program Example 4: Step Trapezoidal Profile ......................................................... E–59
Velocity Profile Operation........................................................................................ E–62
Program Example 5: Velocity Profile........................................................................ E–63
Automatic Trapezoidal Profile Error Codes............................................................... E–65
Troubleshooting Guide for Mode 30....................................................................... E–65
Symptom: The stepper motor does not rotate........................................................ E–65
Symptom: The motor turns in the wrong direction................................................. E–66
Mode 40: High-Speed Interrupts............................................................................. E–67
Purpose................................................................................................................... E–67
Functional Block Diagram........................................................................................ E–67
Setup for Mode 40.................................................................................................. E–68
Interrupts and the Ladder Program......................................................................... E–68
External Interrupt Timing Parameters...................................................................... E–69
Timed Interrupt Parameters..................................................................................... E–69
X Input/Timed INT Configuration........................................................................... E–69
Program Example 1: External Interrupt .................................................................. E–70
Program Example 2: Timed Interrupt ..................................................................... E–71
Mode 50: Pulse Catch Input..................................................................................... E–72
Purpose................................................................................................................... E–72
Functional Block Diagram........................................................................................ E–72
Pulse Catch Timing Parameters............................................................................... E–72
Setup for Mode 50.................................................................................................. E–73
X Input Configuration............................................................................................. E–74
Program Example 1: Pulse Catch ............................................................................ E–75
Mode 60: Discrete Inputs with Filter....................................................................... E–76
Purpose................................................................................................................... E–76

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Functional Block Diagram........................................................................................ E–76
Input Filter Timing Parameters................................................................................ E–76
Setup for Mode 60.................................................................................................. E–77
X Input Configuration............................................................................................. E–77
Program Example: Filtered Inputs ........................................................................... E–78

Appendix F: PLC Memory
DL06 PLC Memory.......................................................................................................F-2
Non-volatile V-memory in the DL06...........................................................................F-3

Appendix G: ASCII Table
ASCII Conversion Table............................................................................................. G-2

Appendix H: Product Weights
Product Weight Table............................................................................................... H–2

Appendix I: Numbering Systems
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
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

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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-8
Analog Modules and RF Interference...........................................................................J-9
Network Isolation........................................................................................................J-9
DC Powered Versions..................................................................................................J-9
Items Specific to the DL06........................................................................................J-10

Appendix K: Introduction to Serial Communications
Introduction to Serial Communications...................................................................K–2
Wiring Standards.......................................................................................................K–2
Communications Protocols........................................................................................K–3
DL06 Port Specifications............................................................................................K–5
DL06 Port Pinouts.....................................................................................................K–5
Port Setup Using DirectSOFT 5 or Ladder Logic Instructions.....................................K–6
Port 2 Setup for RLL Using K-Sequence, DirectNET or MODBUS RTU........................K–7
K-Sequence Communications..................................................................................K–10
DirectNET Communications....................................................................................K–10
Step 1: Identify Master Port # and Slave #..............................................................K–10
Step 2: Load Number of Bytes to Transfer...............................................................K–10
Step 3: Specify Master Memory Area.......................................................................K–11
Step 4: Specify Slave Memory Area.........................................................................K–12
Communications from a Ladder Program................................................................K–13
Multiple Read and Write Interlocks..........................................................................K–13

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MODBUS RTU Communications..............................................................................K–14
ASCII Communications............................................................................................K–14

Index

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Notes

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