Automationdirect.com DL05 User manual

DL05 Micro PLC User Manual
Volume 1 of 2
Manual Number: D0-USER-M

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Please include the Manual Number and the Manual Issue, both shown below,
when communicating with Technical Support regarding this publication.
Manual Number: D0-USER-M
Issue: Sixth Edition, Rev. D
Issue Date: 10/17
DL05 Micro PLc USER MANUAL
Publication History
Issue Date Description of Changes
Original 12/98 Original issue
2nd Edition 2/00 Added PID chapter,analog module chapter and memory cartridge chapter
2nd Edition, Rev. A 7/00 Added DC power
3rd Edition 11/01 Removed MC and analog module chapters, corrected drum instruction, several minor
corrections, added PLC weights, EU directive additions
3rd Edition, Rev. A 7/02 Added new discrete option modules
4th Edition 11/02 Converted manual to QuarkXPress
5th Edition 6/04 Removed option module data, added MC chapter, updated instruction set,
inserted memory appendix, made minor corrections
6th Edition 12/08
Corrected E-stop, updated instruction set, added DirectSOFT IBox instructions to
Chapter 5, revised PID chapter, moved HSIO chapter to Appendices, divided Chapter
4 into Chapters 3 & 4, added Numbering Systems to Appendix section, made
corrections throughout manual
6th Edition, Rev. A 4/10 Made minor corrections throughout manual.
6th Edition, Rev. B 8/11 Corrected number of registers needed in the print message instruction. Corrected TIME instruction: changed CPU to read Memory Cartridge. Made other
minor corrections throughout manual.
6th Edition, Rev. C 2/13 Added H0-CTRIO2 references Updated suppression for inductive loads
Made minor corrections throughout manual.
6th Edition, Rev. D 10/17 Converted manual to InDesign, Minor Correction throughout manual

VoLuMe one:
TabLe of conTenTs
Chapter 1: Getting Started
Introduction 1-2
The Purpose of this Manual 1-2
Where to Begin 1-2
Supplemental Manuals 1-2
Technical Support 1-2
Conventions Used 1-3
Key Topics for Each Chapter 1-3
DL05 Micro PLC Components 1-4
The DL05 Micro PLC Family 1-4
DirectSOFT Programming for Windows™ 1-4
Handheld Programmer 1-5
I/O Selection Quick Chart 1-5
Quick Start for PLC Checkout and Programming 1-6
Steps to Designing a Successful System 1-10
Questions and Answers about DL05 Micro PLCs 1-12

DL05 Micro PLC User Manual, 6th Edition, Rev. D
ii
Table of Contents
Chapter 2: Installation, Wiring, and Specification
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
Orientation to DL05 Front Panel 2-5
Connector Removal 2-6
Mounting Guidelines 2-7
Unit Dimensions 2-7
Enclosures 2-7
Panel Layout & Clearances 2-8
Using DIN Rail Mounting Rails 2-9
Environmental Specifications 2-10
Agency Approvals 2-10
Marine Use 2-10
Wiring Guidelines 2-11
Fuse Protection for Input Power 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

DL05 Micro PLC User Manual, 6th Edition, Rev. D iii
Table of Contents
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 2-28
DC Output Wiring Methods 2-29
High Speed I/O Wiring Methods 2-30
Wiring Diagrams and Specifications 2-32
D0–05AR I/O Wiring Diagram 2-32
D0–05DR I/O Wiring Diagram 2-34
D0–05AD I/O Wiring Diagram 2-36
D0–05DD I/O Wiring Diagram 2-38
D0–05AA I/O Wiring Diagram 2-40
D0–05DA I/O Wiring Diagram 2-42
D0–05DR-D I/O Wiring Diagram 2-44
D0–05DD–D I/O Wiring Diagram 2-46
Glossary of Specification Terms 2-48
Chapter 3: CPU Specifications and Operation
Introduction 3-2
DL05 CPU Features 3-2
CPU Specifications 3-3

DL05 Micro PLC User Manual, 6th Edition, Rev. D
iv
Table of Contents
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 DL05 PLC 3-7
Mode of Operation at Power-up 3-7
Auxiliary Functions 3-8
Clearing an Existing Program 3-8
Initializing System Memory 3-8
Setting Retentive Memory Ranges 3-9
Using a Password 3-10
CPU Operation 3-11
CPU Operating System 3-11
Program Mode 3-12
Run Mode 3-12
Read Inputs 3-13
Service Peripherals and Force I/O 3-13
Update Special Relays and Special Registers 3-14
Solve Application Program 3-14
Write Outputs 3-15
Diagnostics 3-15
I/O Response Time 3-15
Is Timing Important for Your Application? 3-15
Normal Minimum I/O Response 3-15
Normal Maximum I/O Response 3-16
Improving Response Time 3-17

DL05 Micro PLC User Manual, 6th Edition, Rev. D v
Table of Contents
CPU Scan Time Considerations 3-18
Reading Inputs 3-18
Writing Outputs 3-18
Application Program Execution 3-19
PLC Numbering Systems 3-20
PLC Resources 3-20
V–memory3-21
Binary-Coded Decimal Numbers 3-21
Hexadecimal Numbers 3-21
Memory Map 3-22
Octal Numbering System 3-22
Discrete and Word Locations 3-22
V-memory Locations for Discrete Memory Areas 3-22
Input Points (X Data Type) 3-23
Output Points (Y Data Type) 3-23
Control Relays (C Data Type) 3-23
Timers and Timer Status Bits (T Data Type) 3-23
Timer Current Values (V Data Type) 3-24
Counters and Counter Status Bits (CT Data type) 3-24
Counter Current Values (V Data Type) 3-24
Word Memory (V Data Type) 3-25
Stages (S Data type) 3-25
Special Relays (SP Data Type) 3-25
DL05 System V-memory 3-26
System Parameters and Default Data Locations (V Data Type) 3-26
DL05 Memory Map Table 3-28
DL05 Aliases 3-29
X Input Bit Map 3-30

DL05 Micro PLC User Manual, 6th Edition, Rev. D
vi
Table of Contents
Y Output Bit Map 3-30
Control Relay Bit Map 3-31
Stage Control/Status Bit Map 3-32
Timer Status Bit Map 3-32
Counter Status Bit Map 3-33
Chapter 4: Configuration and Connections
DL05 System Design Strategies 4-2
I/O System Configurations 4-2
Networking Configurations 4-2
Automatic I/O Configuration 4-3
Power Budgeting 4-3
Network Configuration and Connections 4-4
Configuring the DL05’s Comm Ports 4-4
DL05 Port Specifications 4-4
Networking DL05 to DL05 RS-232 4-4
Networking Using RS–422 Converters 4-5
Modbus Port Configuration 4-6
DirectNET Port Configuration 4-7
Network Slave Operation 4-8
Modbus Function Codes Supported 4-8
Determining the Modbus Address 4-8
If Your Host Software Requires the Data Type and Address... 4-9
Example 1: V2100 4-10
Example 2: Y20 4-10
Example 3: T10 Current Value 4-10

DL05 Micro PLC User Manual, 6th Edition, Rev. D vii
Table of Contents
Example 4: C54 4-10
If Your Modbus Host Software Requires an Address ONLY 4-11
Example 1: V2100 584/984 Mode 4-13
Example 2: Y20 584/984 Mode 4-13
Example 3: T10 Current Value 484 Mode 4-13
Example 4: C54 584/984 Mode 4-13
Network Master Operation 4-14
Step 1: Identify Master Port # and Slave # 4-15
Step 2: Load Number of Bytes to Transfer 4-15
Step 3: Specify Master Memory Area 4-16
Step 4: Specify Slave Memory Area 4-16
Communications from a Ladder Program 4-17
Multiple Read and Write Interlocks 4-17
Chapter 5: Standard RLL and Intelligent Box Instructions
Introduction 5-2
Instruction List 5-2
Using Boolean Instructions 5-4
END Statement 5-4
Simple Rungs 5-4
Normally Closed Contact 5-5
Contacts in Series 5-5
Midline Outputs 5-5
Parallel Elements 5-6
Joining Series Branches in Parallel 5-6
Joining Parallel Branches in Series 5-6
Combination Networks 5-6
Comparative Boolean 5-7

DL05 Micro PLC User Manual, 6th Edition, Rev. D
viii
Table of Contents
Boolean Stack 5-7
Immediate Boolean 5-8
Boolean Instructions 5-9
Comparative Boolean 5-25
Immediate Instructions 5-31
Timer, Counter and Shift Register Instructions 5-35
Using Timers 5-35
Timer Example Using Discrete Status Bits 5-37
Timer Example Using Comparative Contacts 5-37
Accumulating Timer Example using Discrete Status Bits 5-39
Accumulator Timer Example Using Comparative Contacts 5-39
Using Counters 5-40
Counter Example Using Discrete Status Bits 5-42
Counter Example Using Comparative Contacts 5-42
Stage Counter Example Using Discrete Status Bits 5-44
Stage Counter Example Using Comparative Contacts 5-44
Up / Down Counter Example Using Discrete Status Bits 5-46
Up / Down Counter Example Using Comparative Contacts 5-46
Accumulator/Stack Load and Output Data Instructions 5-48
Using the Accumulator 5-48
Copying Data to the Accumulator 5-48
Changing the Accumulator Data 5-49
Using the Accumulator Stack 5-50
Using Pointers 5-51
Logical Instructions (Accumulator) 5-60
Math Instructions 5-68

DL05 Micro PLC User Manual, 6th Edition, Rev. D ix
Table of Contents
Bit Operation Instructions 5-82
Number Conversion Instructions (Accumulator) 5-87
Shuffle Digits Block Diagram 5-94
Table Instructions 5-96
Copy Data From a Data Label Area to V-memory 5-98
CPU Control Instructions 5-99
Program Control Instructions 5-101
Understanding Master Control Relays 5-106
MLS/MLR Example 5-107
Interrupt Instructions 5-108
External Interrupt Program Example 5-109
Timed Interrupt Program Example 5-110
Independent Timed Interrupt 5-110
Message Instructions 5-111
Fault Example 5-111
Data Label Example 5-113
Intelligent I/O Instructions 5-118
Network Instructions 5-120
Intelligent Box (IBox) Instructions 5-124
(IBOX) Instructions List
Chapter 6: Drum Instruction Programming
DL05 Drum Introduction 6-2
Purpose 6-2
Drum Terminology 6-2

DL05 Micro PLC User Manual, 6th Edition, Rev. D
x
Table of Contents
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) Instruction 6-14
Program Using the Handheld Programmer 6-16
Chapter 7: RLLPLUS Stage Programming
Introduction to Stage Programming 7-2
Overcoming “Stage Fright” 7-2

DL05 Micro PLC User Manual, 6th Edition, Rev. D xi
Table of Contents
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
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

DL05 Micro PLC User Manual, 6th Edition, Rev. D
xii
Table of Contents
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
Questions and Answers about Stage Programming 7-25
Chapter 8: PID Loop Operation
DL05 PID Control 8-2
DL05 PID Control Features 8-2
Introduction to PID Control 8-4
What is PID Control? 8-4
Introducing DL05 PID Control 8-6
Process Control Definitions 8-8
PID Loop Operation 8-9
Position Form of the PID Equation 8-9
Step Bias Proportional to Step Change in SP 8-10

DL05 Micro PLC User Manual, 6th Edition, Rev. D xiii
Table of Contents
Eliminating Proportional, Integral or Derivative Action 8-10
Velocity Form of the PID Equation 8-10
Reset Windup Protection 8-11
Freeze Bias8-12
Adjusting the Bias 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
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
Auto Tuning Procedure 8-45
Use DirectSOFT Data View with PID View 8-49
Open a New Data View Window 8-49
Open PID View 8-50

DL05 Micro PLC User Manual, 6th Edition, Rev. D
xiv
Table of Contents
Using Other PID Features 8-53
How to Change Loop Modes 8-53
Operator Panel Control of PID 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 Instruction 8-57
FilterB Example 8-57
Ramp/Soak Generator 8-58
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 DL05 CPU 8-66
Tuning Cascaded Loops 8-67
Time-Proportioning Control 8-68
On/Off Control Program Example 8-69