Automationdirect.com DirectLOGIC DL205 Series User manual

DL205 PLC User Manual
Volume 1 of 2
Manual Number: D2-USER-M

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DL205 PLC USER MANUAL
Please i clude the Ma ual Number a d the Ma ual Issue, both show below,
whe commu icati g with Tech ical Support regardi g this publicatio .
Ma ual Number: D2-USER-M
Issue: 4th Editio , Rev. B
Issue Date: 2/13
Publication History
Issue Date Description of Changes
1st Edition 1/94 origin l edition
Rev. A 9/95 minor corrections
2nd Edition 6/97 dded DL250, downsized m nu l
Rev. A 5/98 minor corrections
Rev. B 7/99 dded torque specs for b se nd I/O
Rev. C 11/99 minor corrections
Rev. D 3/00 dded new PID fe tures, minor corrections
Rev. E 11/00 dded CE inform tion, minor corrections
Rev. F 11/01 dded surge protection info, corrected RLL nd DRUM instructions,
minor corrections
3rd Edition 6/02 dded DL250–1 nd DL260 CPUs, loc l exp nsion I/O, ASCII nd
MODBUS instructions, split m nu l into two volumes
Rev A 8/03 extensive corrections nd dditions
4th Edition 11/08
ch nged publishing softw re resulting in ch nge of ppe r nce, ddition of IBox
instructions, ch nges to PID ch pter, dded info for ERM nd EBC modules, other
ch nges s necess ry
Rev A 4/10 extensive corrections nd dditions
Rev B 2/13
corrected number of memory registers needed in the print mess ge instruction.
dded new tr nsient suppression for inductive lo ds to Ch pter 2.
dded H2-CTRIO2 nd H2-ERM100 references.

VOLUME ONE:
TABLE OF CONTENTS
Volume One: Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i
Volume Two: Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi
Chapter1:GettingStarted..................................1–1
Introduction .......................................................1–2
ThePurposeofthisManual ...........................................1–2
WheretoBegin ....................................................1–2
SupplementalManuals ..............................................1–2
TechnicalSupport ..................................................1–2
ConventionsUsed ...................................................1–3
KeyTopicsforEachChapter ..........................................1–3
DL205SystemComponents ...........................................1–4
CPUs ............................................................1–4
Bases ............................................................1–4
/OConfiguration ..................................................1–4
/OModules ......................................................1–4
DL205SystemDiagrams .............................................1–5
Programming ethods...............................................1–7
DirectSOFTProgrammingforWindows...................................1–7
HandheldProgrammer ..............................................1–7
DirectLOGIC™PartNumberingSystem ..................................1–8
Quick Start for PLC Validation and Programming . . . . . . . . . . . . . . . . . . . . . . . . .1–10
Steps to Designing a Successful System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–13
Chapter 2: Installation, Wiring and Specifications . . . . . . . . . . . . . . .2–1
SafetyGuidelines ...................................................2–2

PlanforSafety .....................................................2–2
ThreeLevelsofProtection ............................................2–3
EmergencyStops ...................................................2–3
EmergencyPowerDisconnect .........................................2–4
OrderlySystemShutdown ............................................2–4
Class1,Division2,Approval ..........................................2–4
ountingGuidelines ................................................2–5
BaseDimensions ...................................................2–5
PanelMountingandLayout...........................................2–6
Enclosures ........................................................2–7
EnvironmentalSpecifications ..........................................2–8
Power ...........................................................2–8
MarineUse .......................................................2–9
AgencyApprovals ..................................................2–9
24VDCPowerBases ...............................................2–9
InstallingDL205Bases ..............................................2–10
ChoosingtheBaseType ............................................2–10
MountingtheBase ................................................2–10
UsingMountingRails...............................................2–11
InstallingComponentsintheBase ....................................2–12
BaseWiringGuidelines ..............................................2–13
BaseWiring ......................................................2–13
I/OWiringStrategies ...............................................2–14
PLC solationBoundaries ............................................2–14
Powering /O Circuits with the Auxiliary Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .2–15
Powering /O Circuits Using Separate Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . .2–16
Sinking/SourcingConcepts .........................................2–17
/O“Common”TerminalConcepts ....................................2–18
Connecting DC /O to “Solid State” Field Devices . . . . . . . . . . . . . . . . . . . . . . . . .2–19
SolidState nputSensors ............................................2–19
SolidStateOutputLoads ............................................2–19
RelayOutputGuidelines ............................................2–21
Relay Outputs – Transient Suppression for nductive Loads in a Control System . .2–21
I/O odules Position, Wiring, and Specification . . . . . . . . . . . . . . . . . . . . . . . . . .2–26
SlotNumbering...................................................2–26
ModulePlacementRestrictions .......................................2–26
DL205 User Manual, 4th Edition, Rev. B
ii
Table of Contents

Special Placement Considerations for Analog Modules . . . . . . . . . . . . . . . . . . . . .2–27
Discrete nput Module Status ndicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–27
ColorCodingof /OModules ........................................2–27
Wiring the Different Module Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–28
/OWiringChecklist................................................2–29
D2-08ND3,DCInput................................................2–30
D2-16ND3-2,DCInput ..............................................2–30
D2–32ND3,DCInput ...............................................2–31
D2–32ND3–2,DCInput .............................................2–32
D2-08NA-1,ACInput ...............................................2–33
D2-08NA-2,ACInput ...............................................2–34
D2-16NA,ACInput .................................................2–35
F2-08SI ,InputSimulator ...........................................2–35
D2-04TD1,DCOutput ..............................................2–36
D2–08TD1,DCOutput ..............................................2–37
D2–08TD2,DCOutput ..............................................2–37
D2–16TD1–2,DCOutput ............................................2–38
D2–16TD2–2,DCOutput ............................................2–38
F2–16TD1(2)P, DC Output With Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . .2–39
F2–16TD1P, DC Output With Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . .2–40
F2–16TD2P, DC Output with Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–41
D2–32TD1,DCOutput ..............................................2–42
D2–32TD2,DCOutput ..............................................2–42
F2–08TA,ACOutput ................................................2–43
D2–08TA,ACOutput ...............................................2–43
D2–12TA,ACOutput................................................2–44
D2–04TRS,RelayOutput.............................................2–45
D2–08TR,RelayOutput..............................................2–46
F2–08TR,RelayOutput ..............................................2–47
F2–08TRS,RelayOutput .............................................2–48
DL205 User Manual, 4th Edition, Rev. B iii
Table of Contents

D2–12TR,RelayOutput..............................................2–49
D2–08CDR 4 pt., DC Input / 4pt., Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . .2–50
GlossaryofSpecificationTerms .......................................2–51
Chapter 3: CPU Specifications and Operations . . . . . . . . . . . . . . . . . .3–1
CPUOverview ......................................................3–2
GeneralCPUFeatures ...............................................3–2
DL230CPUFeatures ................................................3–2
DL240CPUFeatures ................................................3–2
DL250–1CPUFeatures ..............................................3–3
DL260CPUFeatures ................................................3–3
CPUGeneralSpecifications ...........................................3–4
CPUBaseElectricalSpecifications ......................................3–5
CPUHardwareSetup ................................................3–6
Communication Port Pinout Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–6
Port1Specifications ................................................3–7
Port2Specifications ................................................3–8
Selecting the Program Storage edia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–9
Built-inEEPROM ...................................................3–9
EEPROMSizes .....................................................3–9
EEPROMOperations ................................................3–9
nstallingtheCPU .................................................3–10
Connecting the Programming Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–10
CPUSetup nformation .............................................3–11
Status ndicators ..................................................3–12
ModeSwitchFunctions .............................................3–12
ChangingModesintheDL205PLC ...................................3–13
ModeofOperationatPower-up ......................................3–13
UsingBatteryBackup ...............................................3–14
DL230andDL240 .................................................3–14
DL250-1andDL260 ...............................................3–14
BatteryBackup....................................................3–14
AuxiliaryFunctions.................................................3–15
ClearinganExistingProgram.........................................3–16
nitializingSystemMemory ..........................................3–16
DL205 User Manual, 4th Edition, Rev. B
iv
Table of Contents

SettingtheClockandCalendar .......................................3–16
SettingtheCPUNetworkAddress .....................................3–17
SettingRetentiveMemoryRanges .....................................3–17
UsingaPassword..................................................3–18
Setting the Analog Potentiometer Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–19
CPUOperation ....................................................3–21
CPUOperatingSystem .............................................3–21
ProgramModeOperation ...........................................3–22
RunModeOperation...............................................3–22
Read nputs ......................................................3–23
Read nputs from Specialty and Remote /O . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–23
ServicePeripheralsandForce /O......................................3–23
CPUBusCommunication ...........................................3–24
Update Clock, Special Relays and Special Registers . . . . . . . . . . . . . . . . . . . . . . . .3–24
SolveApplicationProgram...........................................3–25
SolvePDLoopEquations ...........................................3–25
WriteOutputs ....................................................3–25
Write Outputs to Specialty and Remote /O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–26
Diagnostics ......................................................3–26
I/OResponseTime .................................................3–27
s Timing mportant for Your Application? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–27
NormalMinimum /OResponse ......................................3–27
NormalMaximum /OResponse ......................................3–27
mprovingResponseTime ...........................................3–28
CPUScanTimeConsiderations .......................................3–29
nitializationProcess................................................3–30
Reading nputs....................................................3–30
Reading nputsfromSpecialty /O .....................................3–31
ServicePeripherals .................................................3–31
CPUBusCommunication ...........................................3–32
Update Clock/Calendar, Special Relays, Special Registers . . . . . . . . . . . . . . . . . . . .3–32
WritingOutputs...................................................3–32
WritingOutputstoSpecialty /O ......................................3–33
Diagnostics ......................................................3–33
ApplicationProgramExecution .......................................3–34
PLCNumberingSystems.............................................3–35
DL205 User Manual, 4th Edition, Rev. B v
Table of Contents

PLCResources ....................................................3–35
V–Memory.......................................................3–36
Binary-CodedDecimalNumbers ......................................3–36
HexadecimalNumbers..............................................3–36
emory ap......................................................3–37
OctalNumberingSystem ...........................................3–37
DiscreteandWordLocations .........................................3–37
V–Memory Locations for Discrete Memory Areas . . . . . . . . . . . . . . . . . . . . . . . . . .3–37
nputPoints(XDataType) ..........................................3–38
OutputPoints(YDataType) .........................................3–38
ControlRelays(CDataType).........................................3–38
Timers and Timer Status Bits (T Data type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–38
TimerCurrentValues(VDataType)....................................3–39
Counters and Counter Status Bits (CT Data type) . . . . . . . . . . . . . . . . . . . . . . . . .3–39
Counter Current Values (V Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–39
WordMemory(VDataType).........................................3–39
Stages(SDatatype) ...............................................3–40
SpecialRelays(SPDataType) ........................................3–40
Remote /OPoints(GXDataType) ....................................3–40
DL230SystemV-memory ............................................3–41
DL240SystemV-memory ............................................3–43
DL250–1 System V-memory (DL250 also) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–46
DL260SystemV-memory ............................................3–49
DL205Aliases .....................................................3–52
DL230 emory ap ................................................3–53
DL240 emory ap ................................................3–54
DL250–1 emory ap(DL250also) ...................................3–55
DL260 emory ap ................................................3–56
XInput/YOutputBit ap ...........................................3–57
ControlRelayBit ap...............................................3–59
StageControl/StatusBit ap ........................................3–63
TimerandCounterStatusBit aps ....................................3–65
RemoteI/OBit ap ................................................3–66
DL205 User Manual, 4th Edition, Rev. B
vi
Table of Contents

Chapter 4: System Design and Configuration . . . . . . . . . . . . . . . . . . .4–1
DL205SystemDesignStrategies .......................................4–2
/OSystemConfigurations............................................4–2
NetworkingConfigurations ...........................................4–2
odulePlacement ..................................................4–3
SlotNumbering....................................................4–3
ModulePlacementRestrictions ........................................4–3
Automatic /OConfiguration ..........................................4–4
Manual /OConfiguration ............................................4–4
RemovingaManualConfiguration .....................................4–5
Power–On /OConfigurationCheck ....................................4–5
/OPointsRequiredforEachModule....................................4–6
CalculatingthePowerBudget .........................................4–7
ManagingyourPowerResource .......................................4–7
CPUPowerSpecifications ............................................4–7
ModulePowerRequirements ..........................................4–7
PowerBudgetCalculationExample .....................................4–9
Power Budget Calculation Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–10
LocalExpansionI/O ................................................4–11
D2–CMLocalExpansionModule ......................................4–11
D2–EMLocalExpansionModule ......................................4–12
D2–EXCBL–1 Local Expansion Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–12
DL260LocalExpansionSystem .......................................4–13
DL250–1LocalExpansionSystem .....................................4–14
Expansion Base Output Hold Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–15
Enabling /O Configuration Check using DirectSOFT .......................4–16
ExpandingDL205I/O ...............................................4–17
/OExpansionOverview ............................................4–17
Ethernet Remote Master, H2-ERM(100)(-F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–17
Ethernet Remote Master Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . .4–18
nstallingtheERMModule...........................................4–19
Ethernet Base Controller, H2-EBC(100)(-F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–22
nstalltheEBCModule .............................................4–23
SettheModule D .................................................4–23
nserttheEBCModule..............................................4–23
NetworkCabling ..................................................4–24
DL205 User Manual, 4th Edition, Rev. B vii
Table of Contents

10BaseFLNetworkCabling ..........................................4–25
MaximumCableLength ............................................4–25
Add a Serial Remote /O Master/Slave Module . . . . . . . . . . . . . . . . . . . . . . . . . . .4–26
Configuring the CPU’s Remote /O Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–27
ConfigureRemote /OSlaves .........................................4–29
ConfiguringtheRemote /OTable.....................................4–29
Remote /OSetupProgram ..........................................4–30
Remote /OTestProgram ...........................................4–31
Network Connections to odbus and DirectNet..........................4–32
Configuring Port 2 For DirectNet ......................................4–32
ConfiguringPort2ForModbusRTU ...................................4–32
ModbusPortConfiguration ..........................................4–33
DirectNETPortConfiguration ........................................4–34
NetworkSlaveOperation ............................................4–35
ModbusFunctionCodesSupported ...................................4–35
DeterminingtheModbusAddress .....................................4–35
f Your Host Software Requires the Data Type and Address . . . . . . . . . . . . . . . . . .4–35
f Your Modbus Host Software Requires an Address ONLY . . . . . . . . . . . . . . . . . . .4–38
Example1:V2100584/984Mode.....................................4–40
Example2:Y20584/984Mode.......................................4–40
Example 3: T10 Current Value 484 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–40
Example4:C54584/984Mode ......................................4–40
Determining the DirectNETAddress....................................4–40
NetworkMasterOperation ..........................................4–41
Communications from a Ladder Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–44
Multiple Read and Write nterlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–44
Network odbus RTU aster Operation (DL260 only) . . . . . . . . . . . . . . . . . . . .4–45
ModbusFunctionCodesSupported ...................................4–45
ModbusPortConfiguration ..........................................4–46
RS–485Network(Modbusonly) ......................................4–47
RS–232Network ..................................................4–47
ModbusReadfromNetwork(MRX)....................................4–48
MRXSlaveMemoryAddress .........................................4–49
MRXMasterMemoryAddresses ......................................4–49
MRXNumberofElements ...........................................4–49
MRXExceptionResponseBuffer ......................................4–49
ModbusWritetoNetwork(MWX).....................................4–50
DL205 User Manual, 4th Edition, Rev. B
viii
Table of Contents

MWXSlaveMemoryAddress.........................................4–51
MWXMasterMemoryAddresses ......................................4–51
MWXNumberofElements ..........................................4–51
MWXExceptionResponseBuffer ......................................4–51
MRX/MWX Example in DirectSOFT ....................................4–52
Multiple Read and Write nterlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–52
Non–Sequence Protocol (ASCII In/Out and PRINT) . . . . . . . . . . . . . . . . . . . . . . .4–54
Configure the DL260 Port 2 for Non-Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . .4–54
RS–485Network ..................................................4–55
RS–232Network ..................................................4–55
Configure the DL250-1 Port 2 for Non-Sequence . . . . . . . . . . . . . . . . . . . . . . . . .4–56
RS–422Network ..................................................4–57
RS–232Network ..................................................4–57
Chapter 5: RLL and Intelligent Box (IBOX) Instructions . . . . . . . . . . .5–1
Introduction .......................................................5–2
UsingBooleanInstructions............................................5–5
ENDStatement ....................................................5–5
SimpleRungs......................................................5–5
NormallyClosedContact.............................................5–6
ContactsinSeries ..................................................5–6
MidlineOutputs ...................................................5–6
ParallelElements ...................................................5–7
JoiningSeriesBranchesinParallel ......................................5–7
JoiningParallelBranchesinSeries ......................................5–7
CombinationNetworks ..............................................5–7
ComparativeBoolean ...............................................5–8
BooleanStack .....................................................5–8
mmediateBoolean .................................................5–9
BooleanInstructions ...............................................5–10
ComparativeBoolean ...............................................5–27
ImmediateInstructions..............................................5–33
Timer, Counter and Shift Register Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .5–41
UsingTimers .....................................................5–41
Timer Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–43
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Timer Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–43
AccumulatingTimer(TMRA) .........................................5–44
Accumulating Timer Example using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . .5–45
Accumulator Timer Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . .5–45
Counter Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–47
Counter Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . .5–47
Stage Counter Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . .5–49
Stage Counter Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . .5–49
Up/Down Counter Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . .5–51
Up/Down Counter Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . .5–51
Accumulator/Stack Load and Output Data Instructions . . . . . . . . . . . . . . . . . . . .5–53
Logical Instructions (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–71
athInstructions ..................................................5–88
Transcendental Functions (DL260 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–121
BitOperationInstructions ..........................................5–123
Number Conversion Instructions (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . .5–130
TableInstructions .................................................5–144
Clock/CalendarInstructions .........................................5–175
CPUControlInstructions ...........................................5–177
ProgramControlInstructions........................................5–179
InterruptInstructions ..............................................5–187
IntelligentI/OInstructions ..........................................5–191
NetworkInstructions ..............................................5–193
essageInstructions ..............................................5–197
odbusRTUInstructions(DL260) ....................................5–205
ModbusReadfromNetwork(MRX)...................................5–205
ModbusWritetoNetwork(MWX)....................................5–208
ASCIIInstructions(DL260) ..........................................5–211
Intelligent Box (IBox) Instructions (DL250-1/DL260) . . . . . . . . . . . . . . . . . . . . .5-230

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Chapter 6: Drum Instruction Programming (DL250-1/DL260 only) .6–1
Introduction .......................................................6–2
Purpose ..........................................................6–2
DrumTerminology .................................................6–2
DrumChartRepresentation ...........................................6–3
OutputSequences ..................................................6–3
StepTransitions.....................................................6–4
Drum nstructionTypes ..............................................6–4
Timer-OnlyTransitions ...............................................6–4
TimerandEventTransitions ...........................................6–5
Event-OnlyTransitions ...............................................6–6
CounterAssignments................................................6–6
LastStepCompletion ...............................................6–7
OverviewofDrumOperation..........................................6–8
Drum nstructionBlockDiagram .......................................6–8
PowerupStateofDrumRegisters ......................................6–9
DrumControlTechniques............................................6–10
DrumControl nputs ...............................................6–10
Self-ResettingDrum................................................6–11
nitializingDrumOutputs ...........................................6–11
Using Complex Event Step Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–11
DrumInstruction...................................................6–12
Timed Drum with Discrete Outputs (DRUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–12
EventDrum(EDRUM) ..............................................6–14
Handheld Programmer Drum Mnemonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–16
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Masked Event Drum with Discrete Outputs (MDRMD) . . . . . . . . . . . . . . . . . . . . .6–19
Masked Event Drum with Word Output (MDRMW) . . . . . . . . . . . . . . . . . . . . . . . .6–21
Chapter 7: RLLPLUS StageProgramming ........................7–1
IntroductiontoStageProgramming ....................................7–2
Overcoming“StageFright” ...........................................7–2
Learning to Draw State Transition Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–3
ntroductiontoProcessStates .........................................7–3
TheNeedforStateDiagrams..........................................7–3
A2–StateProcess...................................................7–3
RLLEquivalent .....................................................7–4
StageEquivalent ...................................................7–4
Let’sCompare .....................................................7–5
nitialStages ......................................................7–5
WhatStageBitsDo .................................................7–6
Stage nstructionCharacteristics .......................................7–6
Using the Stage Jump Instruction for State Transitions . . . . . . . . . . . . . . . . . . . . .7–7
Stage Jump, Set, and Reset nstructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–7
Stage Program Example: Toggle On/Off Lamp Controller . . . . . . . . . . . . . . . . . . .7–8
A4–StateProcess...................................................7–8
Four Steps to Writing a Stage Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–9
Stage Program Example: A Garage Door Opener . . . . . . . . . . . . . . . . . . . . . . . . .7–10
GarageDoorOpenerExample........................................7–10
DrawtheBlockDiagram ............................................7–10
DrawtheStateDiagram ............................................7–11
AddSafetyLightFeature ............................................7–12
Modify the Block Diagram and State Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–12
UsingaTimer nsideaStage .........................................7–13
AddEmergencyStopFeature.........................................7–14
ExclusiveTransitions................................................7–14
Stage Program Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–15
StageProgramOrganization .........................................7–15
How nstructions Work nside Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–16
Using a Stage as a Supervisory Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–17
StageCounter ....................................................7–17
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UnconditionalOutputs .............................................7–18
PowerFlowTransitionTechnique......................................7–18
ParallelProcessingConcepts .........................................7–19
ParallelProcesses ..................................................7–19
ConvergingProcesses ..............................................7–19
ConvergenceStages(CV) ...........................................7–19
ConvergenceJump(CVJMP) .........................................7–20
ConvergenceStageGuidelines .......................................7–20
anagingLargePrograms ...........................................7–21
StageBlocks(BLK,BEND) ...........................................7–21
BlockCall(BCALL) .................................................7–22
RLLPLUS (Stage)Instructions ..........................................7–23
Stage(SG) .......................................................7–23
nitialStage(SG)..................................................7–24
Jump(JMP) ......................................................7–24
NotJump(NJMP) .................................................7–24
Converge Stage (CV) and Converge Jump (CVJMP) . . . . . . . . . . . . . . . . . . . . . . . .7–25
BlockCall(BCALL) .................................................7–27
Block(BLK) ......................................................7–27
BlockEnd(BEND) .................................................7–27
Stage View in DirectSOFT ...........................................7–28
Questions and Answers about Stage Programming . . . . . . . . . . . . . . . . . . . . . . .7–29
Chapter 8: PID Loop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1
DL250-1 and DL260 PID Loop Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2
MainFeatures .....................................................8–2
IntroductiontoPIDControl ...........................................8–4
WhyusePDControl? ...............................................8–4
IntroducingDL205PIDControl ........................................8–6
ProcessControlDefinitions ...........................................8–8
PIDLoopOperation .................................................8–9
PositionFormofthePDEquation ......................................8–9
ResetWindupProtection ............................................8–10
FreezeBias.......................................................8–11
AdjustingtheBias .................................................8–11
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Step Bias Proportional to Step Change in SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–12
Eliminating Proportional, ntegral or Derivative Action . . . . . . . . . . . . . . . . . . . . . .8–12
VelocityFormofthePDEquation .....................................8–12
BumplessTransfer .................................................8–13
LoopAlarms .....................................................8–13
LoopOperatingModes .............................................8–14
SpecialLoopCalculations ...........................................8–14
Ten Steps to Successful Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–16
PIDLoopSetup ....................................................8–18
Some Things to Do and Know Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–18
PDErrorFlags ....................................................8–18
Establishing the Loop Table Size and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–18
LoopTableWordDefinitions .........................................8–20
P D Mode Setting 1 Bit Descriptions (Addr + 00) . . . . . . . . . . . . . . . . . . . . . . . . . .8–21
P D Mode Setting 2 Bit Descriptions (Addr + 01) . . . . . . . . . . . . . . . . . . . . . . . . . .8–22
Mode/Alarm Monitoring Word (Addr + 06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–23
Ramp/SoakTableFlags(Addr+33) ....................................8–23
Ramp/Soak Table Location (Addr + 34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–24
Ramp/Soak Table Programming Error Flags (Addr + 35) . . . . . . . . . . . . . . . . . . . .8–24
PV Auto Transfer (Addr + 36) from /O Module Base/Slot/Channel Option . . . . . .8–25
PV Auto Transfer (Addr + 36) from V-memory Option . . . . . . . . . . . . . . . . . . . . . .8–25
Control Output Auto Transfer (Addr + 37) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–25
ConfigurethePDLoop .............................................8–26
PIDLoopTuning ...................................................8–41
Open-LoopTest ...................................................8–41
ManualTuningProcedure ...........................................8–42
Alternative Manual Tuning Procedures by Others . . . . . . . . . . . . . . . . . . . . . . . . .8–44
TuningPDControllers..............................................8–44
AutoTuningProcedure .............................................8–45
Use DirectSOFTDataViewwithPDView ...............................8–49
OpenaNewDataViewWindow ......................................8–49
OpenPDView ...................................................8–50
UsingtheSpecialPIDFeatures........................................8–52
HowtoChangeLoopModes.........................................8–52
Operator Panel Control of P D Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–53
PLCModesEffectonLoopModes .....................................8–53
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LoopModeOverride ...............................................8–53
PVAnalogFilter ...................................................8–54
Creating an Analog Filter in Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–55
Use the DirectSOFT 5 Filter ntelligent Box ( BOX) nstruction . . . . . . . . . . . . . . .8–56
FilterBExample ...................................................8–56
Ramp/SoakGenerator ..............................................8–57
ntroduction .....................................................8–57
Ramp/SoakTable ..................................................8–58
Ramp/SoakTableFlags .............................................8–60
Ramp/SoakGeneratorEnable ........................................8–60
Ramp/SoakControls ...............................................8–60
Ramp/SoakProfileMonitoring ........................................8–61
Ramp/SoakProgrammingErrors ......................................8–61
TestingYourRamp/SoakProfile .......................................8–61
DirectSOFTRamp/SoakExample.......................................8–62
SetuptheProfileinPDSetup ........................................8–62
Program the Ramp/Soak Control in Relay Ladder . . . . . . . . . . . . . . . . . . . . . . . . .8–62
TesttheProfile ....................................................8–63
CascadeControl ...................................................8–64
ntroduction .....................................................8–64
CascadedLoopsintheDL205CPU ....................................8–65
TuningCascadedLoops .............................................8–66
Time-ProportioningControl ..........................................8–67
On/OffControlProgramExample .....................................8–68
FeedforwardControl ...............................................8–69
FeedforwardExample ..............................................8–70
PIDExampleProgram...............................................8–71
ProgramSetupforthePDLoop ......................................8–71
TroubleshootingTips ...............................................8–74
GlossaryofPIDLoopTerminology.....................................8–76
Bibliography ......................................................8–78
Chapter 9: aintenance and Troubleshooting . . . . . . . . . . . . . . . . . .9–1
Hardware aintenance ..............................................9–2
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StandardMaintenance...............................................9–2
AirQualityMaintenance .............................................9–2
LowBattery ndicator ...............................................9–2
CPUBatteryReplacement ............................................9–2
Diagnostics ........................................................9–3
Diagnostics .......................................................9–3
FatalErrors........................................................9–3
Non-fatalErrors ....................................................9–3
FindingDiagnostic nformation ........................................9–4
V-memory Locations Corresponding to Error Codes . . . . . . . . . . . . . . . . . . . . . . . .9–4
Special Relays (SP) Corresponding to Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . .9–5
/OModuleCodes ..................................................9–6
ErrorMessageTables ................................................9–7
SystemErrorCodes .................................................9–8
ProgramErrorCodes ................................................9–9
CPUErrorIndicators ................................................9–10
PWRIndicator ....................................................9–11
ncorrectBasePower ...............................................9–11
FaultyCPU.......................................................9–11
Device or Module causing the Power Supply to Shutdown . . . . . . . . . . . . . . . . . .9–12
PowerBudgetExceeded ............................................9–12
Run ndicator.....................................................9–13
CPU ndicator ....................................................9–13
BATT ndicator ....................................................9–13
CommunicationsProblems...........................................9–13
I/O oduleTroubleshooting .........................................9–14
ThingstoCheck ..................................................9–14
/ODiagnostics ...................................................9–14
SomeQuickSteps .................................................9–15
TestingOutputPoints ..............................................9–16
Handheld Programmer Keystrokes Used to Test an Output Point . . . . . . . . . . . . . .9–16
NoiseTroubleshooting ..............................................9–17
ElectricalNoiseProblems ............................................9–17
ReducingElectricalNoise............................................9–17
achine Startup and Program Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .9–18
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