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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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

Volume Two:

Table of ConTenTs

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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