Automationdirect.com D4-454 plc User manual

D4-454 PLC User Manual

Manual Number: D4-454-M

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D4-454 PLC USER MANUAL

Please include the Manual Number and the Manual Issue, both shown below,

when communicating with Technical Support regarding this publication.

Manual Number: D4-454-M

Issue: 1st Ed. Rev. D

Issue Date: 03/23

Publication History

Issue Date Description of Changes

Original 06/17 Original Issue

Rev A 09/17 Minor Changes

Rev B 05/18 Updates and general corrections

Rev C 06/20 Added note to Appendix F: D4-454 will only support D4-HSC firmware v2.3.

Rev D 03/23 Removed Type 1 fonts

Table of Contents

Chapter 1: Getting Started

Introduction.....................................................................................................................................1-2

The Purpose of this Manual�� 1-2

Where to Begin �� 1-2

Technical Support �� 1-2

Key Topics for Each Chapter �� 1-3

DL405 System Components.......................................................................................................1-4

CPUs �� 1-4

Bases �� 1-4

I/O Configuration�� 1-4

I/O Modules�� 1-4

Programming Methods.................................................................................................................1-4

DirectSOFT Programming for Windows™ �� 1-4

DL405 System Diagrams �� 1-5

Steps to Designing a Successful System............................................................................ 1-12

Frequently Asked Questions................................................................................................... 1-14

Chapter 2: Installation, Wiring, and Specifications

Safety Guidelines...........................................................................................................................2-2

Emergency Power Disconnect�� 2-4

Orderly System Shutdown�� 2-4

Mounting Guidelines .....................................................................................................................2-5

Base Dimensions �� 2-5

Panel Layout and Clearances �� 2-6

Enclosures�� 2-7

Agency Approvals �� 2-8

Environmental Specifications�� 2-8

Power�� 2-8

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D

ii

Installing DL405 Bases................................................................................................................ 2-9

Three Sizes of Bases��2-9

Installing Components in the Base ........................................................................................ 2-10

CPU and Expansion Unit Wiring Guidelines......................................................................... 2-11

CPU Wiring �� 2-11

Expansion Unit Wiring ��2-12

Connecting Program Devices �� 2-12

Connecting Operator Interfaces Devices��2-13

I/O Wiring Strategies ................................................................................................................. 2-14

PLC Isolation Boundaries �� 2-14

Powering I/O Circuits with the Auxiliary Supply�� 2-15

Powering I/O Circuits Using Separate Supplies �� 2-16

Sinking / Sourcing Concepts �� 2-17

I/O “Common” Terminal Concepts�� 2-18

Connecting DC I/O to “Solid State” Field Devices�� 2-19

Solid State Input Sensors�� 2-19

Relay Output Guidelines�� 2-21

Transient Suppression for Inductive Loads in a Control System�� 2-21

I/O Modules Wiring, and Specification ................................................................................. 2-26

Slot Numbering�� 2-26

Module Placement Restrictions�� 2-26

Module Placement�� 2-27

I/O Module Status Indicators �� 2-27

Color Coding of I/O Modules�� 2-27

Wiring the Different Module Connectors �� 2-28

Wiring 32 and 64 Point I/O Modules�� 2-29

I/O Wiring Checklist �� 2-30

DL405 Input Module Chart�� 2-31

DL405 Output Module Chart�� 2-31

Chapter 3: CPU Specifications and Operation

Overview.......................................................................................................................................... 3-2

General CPU Features ��3-2

CPU Electrical Specifications ��3-2

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D iii

CPU Specifications.......................................................................................................................3-3

Toggle Switch Functions ��3-4

Status Indicators�� 3-5

Communication Ports �� 3-6

Port 0 Specifications��3-6

Port 1 Specifications��3-7

Port 2 Specifications��3-8

Port 3 Specifications��3-9

Using Battery Backup ............................................................................................................... 3-10

CPU Setup Information ............................................................................................................ 3-11

Setting the Clock and Calendar �� 3-11

Variable/Fixed Scan Time Feature�� 3-11

Password Protection�� 3-11

Clearing an Existing Program�� 3-11

Initializing System Memory �� 3-12

Setting Retentive Memory Ranges�� 3-12

CPU Operation............................................................................................................................ 3-13

CPU Operating System �� 3-13

Program Mode Operation�� 3-14

Run Mode Operation �� 3-14

Read Inputs �� 3-15

Read Inputs from Specialty and Remote I/O�� 3-15

Service Peripherals and Force I/O �� 3-15

Update Special Relays and Special Registers�� 3-16

CPU Bus Communication �� 3-16

Update Clock, Special Relays and Special Registers�� 3-17

Solve Application Program �� 3-17

Solve PID Loop Equations�� 3-18

Write Outputs�� 3-18

Write Outputs to Specialty and Remote I/O�� 3-18

Diagnostics �� 3-18

I/O Response Time .................................................................................................................... 3-19

Is Timing Important for Your Application �� 3-19

Normal Minimum I/O Response�� 3-19

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D

iv

Normal Minimum I/O Response��3-19

Improving Response Time ��3-20

CPU Scan Time Considerations..............................................................................................3-21

Initialization Process��3-22

Reading Inputs��3-22

Update Clock/Calendar, Special Relays, Special Registers��3-22

Reading Inputs from Specialty I/O ��3-23

CPU Bus Communications��3-24

Writing Outputs ��3-24

Writing Outputs to Specialty I/O��3-25

Diagnostics ��3-25

Application Program Execution ��3-26

Program Control Instructions ��3-26

PLC Numbering Systems..........................................................................................................3-27

PLC Resources��3-27

V-Memory��3-28

Binary-Coded Decimal Numbers��3-28

Hexadecimal Numbers ��3-28

Memory Map.................................................................................................................................3-29

Octal Numbering Systems................................................................................... 3-29

Discrete and Word Locations��3-29

V-Memory Locations for Discrete Memory Areas ��3-29

Input Points (X Data Type)��3-30

Output Points (Y Data Type) ��3-30

Control Relays (C Data Type) ��3-30

Timers and Timer Status Bits (T Data Type)��3-30

Timer Current Values (V Data Type)��3-31

Counters and Counter Status Bits (CT Data type)��3-31

Counter Current Values (V Data Type)��3-31

Word Memory (V Data Type) ��3-31

Stages (S Data type)��3-32

Special Relays (SP Data Type)��3-32

Remote I/O Points (GX and GY Data Type) ��3-32

System Parameters (V Data Type)��3-33

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D v

DL405 Aliases .............................................................................................................................. 3-36

X Input / Y Output Bit Map........................................................................................................ 3-37

Control Relay Bit Map ................................................................................................................ 3-39

Timer and Counter Status Bit Map......................................................................................... 3-43

Remote I/O Bit Map .................................................................................................................... 3-44

Stage Control / Status Bit Map ............................................................................................... 3-48

Chapter 4: System Design and Conguration

I/O System Congurations........................................................................................... 4–2

Network Configurations.......................................................................................................... 4–3

Module Placement and Configuration .................................................................................... 4–4

Valid Module/Unit Locations ��4–4

I/O Configuration Methods ��4–5

Automatic Configuration��4–5

Manual Configuration��4–5

Power-On I/O Configuration Check��4–6

Calculating the Power Budget................................................................................................... 4–7

Managing your Power Resource ��4–7

CPU Power Specifications ��4–7

Module Power Requirements��4–7

Power Budget Calculation Example ��4–9

Power Budget Calculation Worksheet �� 4–10

Local I/O Expansion .............................................................................................. 4–11

Local Base and I/O................................................................................................................... 4–11

Local Expansion Base and I/O ............................................................................................. 4–11

Remote I/O Expansion............................................................................................................... 4–12

How to Add Remote I/O Channels �� 4–12

Configuring the CPU’s Remote I/O Channel �� 4–13

Configure Remote I/O Slaves�� 4–15

Configuring the Remote I/O Table �� 4–15

Remote I/O Setup Program �� 4–16

Remote I/O Test Program �� 4–17

Network Connections to MODBUS ® and DirectNet......................................................... 4–18

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D

vi

Configuring the CPU’s Comm Ports��4–18

MODBUS Port Configuration��4–20

Network Slave Operation .......................................................................................................4–22

Determining the MODBUS Address ��4–23

If Your Host Software Requires the Data Type and Address ��4–23

If Your MODBUS Host Software Requires an Address Only��4–25

Network Master Operation ....................................................................................................4–28

Step 1: Identify Master Port # and Slave # ��4–29

Step 2: Load Number of Bytes to Transfer��4–29

Step 3: Specify Master Memory Area��4–30

Step 4: Specify Slave Memory Area��4–31

Communications from a Ladder Program ��4–31

Multiple Read and Write Interlocks��4–32

Chapter 5: Standard RLL Instructions

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

Parallel Elements�� 5-7

Joining Series Branches in Parallel �� 5-7

Joining Parllel 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 .............................................................................................................. 5-25

Immediate Instructions ........................................................................................................... 5-31

Timer, Counter and Shift Register Instructions............................................................... 5-38

Using Timers�� 5-38

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D vii

Timer Example Using Discrete Status Bits �� 5-40

Timer Example Using Comparative Contacts�� 5-40

Accumulating Timer Example using Discrete Status Bits�� 5-42

Accumulator Timer Example Using Comparative Contacts �� 5-42

Using Counters�� 5-43

Counter Example Using Discrete Status Bits �� 5-45

Counter Example Using Comparative Contacts�� 5-45

Stage Counter Example Using Discrete Status Bits �� 5-47

Stage Counter Example Using Comparative Contacts �� 5-47

Up / Down Counter Example Using Discrete Status Bits �� 5-49

Up / Down Counter Example Using Comparative Contacts �� 5-49

Accumulator/Stack Load and Output Data Instructions............................................... 5-51

Using the Accumulator�� 5-51

Copying Data to the Accumulator�� 5-51

Changing the Accumulator Data �� 5-52

Using the Accumulator Stack �� 5-53

Accumulator and Accumulator Stack Memory Locations�� 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

Table Instructions................................................................................................................... 5-141

Copy Data From a Data Label Area to V-memory ��5-143

Clock/Calendar Instructions................................................................................................5-173

CPU Control Instructions...................................................................................................... 5-175

Program Control Instructions .............................................................................................5-177

Interrupt Instructions ............................................................................................................ 5-185

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D

viii

Message Instructions ............................................................................................................ 5-187

Chapter 6: Drum Instruction Programming

Introduction...................................................................................................................................6-2

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

Power Up State of Drum Registers�� 6-9

Drum Control Techniques ...................................................................................................... 6-10

Drum Control Inputs �� 6-10

Initializing Drum Outputs�� 6-11

Using Complex Event Step Transitions �� 6-11

Self-Resetting Drum�� 6-11

Drum Instructions ..................................................................................................................... 6-12

Timed Drum with Discrete Outputs (DRUM)�� 6-12

Event Drum (EDRUM)�� 6-14

Masked Event Drum with Discrete Outputs (MDRMD)�� 6-16

Masked Event Drum with Word Output (MDRMW) �� 6-18

Chapter 7: RLL

PLUS

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

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D ix

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

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 Obstruction 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

Stage Counter�� 7-17

Power Flow Transition Technique�� 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

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D

x

RLL

PLUS

(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 End (BEND)�� 7-25

Block (BLK) �� 7-25

Chapter 8: PID Loop Operation... ................................................................. 8-1

D4-454 PID Control .....................................................................................................................8-2

D4-454 PID Control Features �� 8-2

Introduction to PID Control.......................................................................................................8-4

What is PID Control?�� 8-4

Introducing D4-454 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

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

Establishing the Loop Table Size and Location�� 8-19

Loop Table Word Definitions �� 8-21

PID Mode Setting 1 Bit Descriptions (Addr + 00)�� 8-22

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D xi

PID Mode Setting 2 Bit Descriptions (Addr + 01)�� 8-23

Mode/Alarm Monitoring Word (Addr + 06)�� 8-24

Ramp/Soak Table Flags (Addr + 33) �� 8-24

Ramp/Soak Table Location (Addr + 34) �� 8-25

Ramp/Soak Table Programming Error Flags (Addr + 35)�� 8-25

Configure the PID Loop�� 8-26

PID Loop Tuning........................................................................................................................ 8-42

Open-Loop Test�� 8-42

Manual Tuning Procedure �� 8-43

Alternative Manual Tuning Procedures by Others�� 8-46

Tuning PID Controllers�� 8-46

Auto Tuning Procedure �� 8-47

Use DirectSOFT Data View with PID View�� 8-51

Open a New Data View Window�� 8-51

Open PID View �� 8-52

Using the Special PID Features ............................................................................................ 8-54

How to Change Loop Modes �� 8-54

Operator Panel Control of PID Modes�� 8-55

PLC Modes Effect on Loop Modes�� 8-55

Loop Mode Override �� 8-56

PV Analog Filter�� 8-57

Creating an Analog Filter in Ladder Logic�� 8-58

Use the DirectSOFT Filter Intelligent Box Instruction �� 8-59

Ramp/Soak Generator............................................................................................................. 8-60

Introduction�� 8-60

Ramp/Soak Table�� 8-61

Ramp/Soak Table Flags�� 8-63

Ramp/Soak Generator Enable �� 8-63

Ramp/Soak Controls �� 8-63

Testing Your Ramp/Soak Profile�� 8-64

Ramp/Soak Profile Monitoring�� 8-64

Ramp/Soak Programming Errors�� 8-64

DirectSOFT Ramp/Soak Example ........................................................................................ 8-65

Setup the Profile in PID Setup �� 8-65

Program the Ramp/Soak Control in Relay Ladder�� 8-65

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D

xii

Test the Profile ��8-66

Cascade Control ......................................................................................................................8-67

Introduction��8-67

Cascaded Loops in the D4-454 CPU��8-68

Tuning Cascaded Loops��8-69

Time-Proportioning Control .................................................................................................8-70

On/Off Control Program Example ��8-71

Feedforward Control...............................................................................................................8-72

PID Example Program.............................................................................................................8-74

Program Setup for the PID Loop ��8-74

Troubleshooting Tips..........................................................................................................8-77

Glossary of PID Loop Terminology..................................................................................8-79

Bibliography ...........................................................................................................................8-81

Chapter 9: Maintenance and Troubleshooting

Hardware System Maintenance ............................................................................................ 9-2

Standard Maintenance �� 9-2

Battery Replacement�� 9-2

Diagnostics.................................................................................................................................. 9-3

Fatal Errors�� 9-3

Non-fatal Errors�� 9-3

V-memory Error Code Locations �� 9-4

Special Relays (SP) Corresponding to Error Codes�� 9-5

I/O Module Codes�� 9-6

Error Message Tables�� 9-6

Program Error Codes�� 9-7

CPU Status Indicators .............................................................................................................. 9-8

PWR Indicator�� 9-9

RUN Indicator ��9-10

CPU Indicator ��9-11

BATT Indicator ��9-11

DIAG Indicator��9-11

TXD and RXD Indicators��9-12

I/O Point Troubleshooting.....................................................................................................9-13

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D xiii

Some Quick Steps��9-13

Testing Output Points �� 9-14

Noise Troubleshooting.............................................................................................................9-15

Electrical Noise Problems �� 9-15

Reducing Electrical Noise�� 9-15

Machine Startup and Program Troubleshooting ..............................................................9-16

Syntax Check �� 9-16

Special Debug Instructions �� 9-18

Run Time Edits �� 9-20

Forcing I/O Points�� 9-21

Bit Override Forcing�� 9-23

Appendix A: Error Codes.......................................................................................

D4-454 Error Codes�� A-2

Appendix B: Special Relays... ...............................................................................

Startup and Real-Time Relays ��B-2

CPU Status Relays��B-2

System Monitoring��B-3

Accumulator Status ��B-3

Communication Monitoring Relay��B-4

Appendix C: Product Weights..............................................................................

Product Weight ...........................................................................................................................C-2

Appendix D: ASCII Conversion Table

ASCII Conversion Table �� D-2

Appendix E: Numbering Systems

Introduction................................................................................................................................... E-2

Binary Numbering System......................................................................................................... E-2

Hexadecimal Numbering System............................................................................................ E-3

Octal Numbering System........................................................................................................... E-4

Binary Coded Decimal (BCD) Numbering System .............................................................. E-5

Real (Floating Point) Numbering System .............................................................................. E-5

Table of Contents

D4-454 PLC User Manual, 1st Edition, Rev. D

xiv

BCD/Binary/Decimal/Hex/Octal -

What is the Difference?............................................................................................................... E-6

Data Type Mismatch .................................................................................................................... E-7

Signed vs. Unsigned Integers.................................................................................................... E-8

AutomationDirect.com Products and Data Types .............................................................. E-9

DirectLOGIC PLCs��E-9

C-more/C-more Micro-Graphic Panels ��E-9

1

GettinG Started Chapter

Chapter

In This Chapter...

Introduction..................................................................................................................................1-2

Conventions Used.......................................................................................................................1-3

DL405 System Components....................................................................................................1-4

Programming Methods..............................................................................................................1-4

DL405 Family................................................................................................................................1-6

Quick Start for PLC Checkout and Programming .............................................................1-8

Steps to Designing a Successful System......................................................................... 1-12

Frequently Asked Questions................................................................................................ 1-14

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