Cutler-Hammer D320 PLC User manual

D320 PLC
User’s Manual

The information contained in this manual is the property of Cutler-Hammer, Inc. Information in this
manual is subject to change without notice and does not represent a commitment on the part of Cutler-
Hammer, Inc.
Any Cutler-Hammer software described in this manual is furnished under a license agreement. The
software may be used or copied only in accordance with the terms of the agreement. It is against the
law to copy the software on any medium except as specifically allowed in the agreement. No part of
this manual may be reproduced or transmitted in any form or by any means, electronic, mechanical,
photocopying, recording or otherwise, without prior written permission of Cutler-Hammer, Inc.
RESTRICTED RIGHTS LEGEND
Use, duplication, or disclosure by the Government is subject to restrictions set forth in paragraph
(b)(3)(B) of the Rights in Technical Data and Computer Software clause of DAR 7-104.9(a).
Contractor/Manufacturer is Cutler-Hammer, P.O. Box 6166, Westerville, OH 43086-6166.
TRADEMARKS
Commercial names of products from other manufacturers or developers that appear in this manual are
registered or unregistered trademarks of those respective manufacturers or developers, which have
expressed neither approval nor disapproval of Cutler-Hammer products.
Copyright Cutler-Hammer, Inc. 1998. All rights reserved.
Catalog Number D320SA100
P/N 01-00408-02

Preface i
Preface
Welcome to Cutler-Hammer’s D320 PLC User's Manual. This preface describes the contents of this
manual and provides information on Support Services.

ii D320 PLC User's Manual
About This Manual
Purpose
This manual focuses on describing the D320 Programmable Logic Controller (PLC).
What’s Inside
This manual is organized in the following way:
Preface
Chapter 1: Introduction
Chapter 2: System Configuration
Chapter 3: Product Specification
Chapter 4: Installation and Wiring
Chapter 5: CPU Operation and Memory
Chapter 6: Instructions
Chapter 7: Testing and Troubleshooting
Chapter 8: Troubleshooting Noise Problems
Chapter 9: External Dimensions
Appendix A: D320 PLC Communication Protocol
Appendix B: PID Loop Control
Appendix C: COM2 UDCP Specification

Preface iii
Support Services
It is Cutler-Hammer’s goal to ensure your greatest possible satisfaction with the operation of our
products. We are dedicated to providing fast, friendly, and accurate assistance. That is why we offer
you so many ways to get the support you need. Whether it’s by phone, fax, modem, or mail, you can
access Cutler-Hammer support information 24 hours a day, seven days a week. Our wide range of
services include:
Technical Support 1-800-809-2772
If you are in the U.S. or Canada, you can take advantage of our toll-free line for technical assistance
with hardware and software product selection, system design and installation, and system debugging
and diagnostics. Technical support engineers are available for calls during regular business hours
(8 am - 5:30 pm EST) by calling 1-800-809-2772. International calls can be made to either the Tech
Line at 1-800-809-2772 (toll call) or the Cutler-Hammer main business line at 614-882-3282.
Emergency Technical Support 1-800-809-2772
Because machines do not run on a nine-to-five schedule, we offer emergency after-hours technical
support. A technical support engineer can be paged for emergencies involving plant down situations or
safety issues. Emergency support calls are automatically routed directly to our answering service after-
hours (5:30 pm - 8 am EST) and weekends. For emergency technical support, call 1-800-809-2772.
Does not currently include product repairs or shipping outside normal business hours.
Technical Support Fax [phone]
You can also contact our technical support engineers by faxing your support requests directly to APSC
Westerville at 614-882-0417.
Information Fax-Back Service 614-899-5323
The latest Cutler-Hammer product information, specifications, technical notes and company news is
available to you via fax through our direct document request service at 614-899-5323. Using a touch-
tone phone, you can select any of the info faxes from our automated product literature and technical
document library, punch in a fax number and receive the information immediately.
Bulletin Board Service 614-899-5209
Parameters: 8 data bits, 1 stop bit, parity none, 9600-28.8K baud.
If you have modem access, you can dial in directly to our electronic bulletin board service for the latest
product and company information. File sharing, product software downloads and our user message
service are just a few of the things you will find online at 614-899-5209.
Website and E-mail Address
http://www.cutlerhammer.eaton.com/automation
[email protected]
If you have Internet capabilities, you also have access to technical support via our website at
http://www.cutlerhammer.eaton.com. The website includes technical notes, frequently asked questions,
release notes, and other technical documentation. This direct technical support connection also offers
you the ability to request assistance and exchange software files electronically.
Technical support messages and files can be sent to [e-mail].

iv D320 PLC User's Manual
Software Update Service 1-800-809-2772
FAX [phone]
We also offer you the opportunity to take advantage of software upgrades, advanced software notices,
and special software promotions through our Software Update Service. When you register your
software, you will receive one-year of free or reduced-price upgrades along with all the other benefits
of membership, including 48-hour shipping of software upgrades. Contact the Software Update Service
at 1-800-809-2772 or fax [phone].
Repair and Upgrade Service 614-882-3282 ext. 7601
FAX [phone]
Our well-equipped Customer Service department is ready to assist you with repairs, upgrades, and
spare parts services. If a situation arises where one of these services is needed, just call 614-882-3282
x7601 or fax [phone].
Product Ordering Service 614-882-3282
FAX [phone]
Authorized Cutler-Hammer distributors may place product orders directly with our Order Processing
department by calling 614-882-3282 x406 or faxing 614-882-6532. For information on your local
distributor, call the Cutler-Hammer Tech Line.
Customer Support Center 1-800-356-1243
Authorized Cutler-Hammer distributors and Cutler-Hammer sales offices can get assistance for Cutler-
Hammer standard and component product lines through the Customer Support Center. Call the
Customer Support Center for the following assistance:
1. Stock availability, proof of shipment, or to place an order.
2. Expedite an existing order.
3. Product assistance and product price information.
4. Product returns other than warranty returns.
For information on your local distributor or sales office, call the Cutler-Hammer Tech Line at 1-800-
809-2772.
Correspondence Address Cutler-Hammer
173 Heatherdown Drive
Westerville, OH 43081

Table of Contents v
Table of Contents
Preface I
About This Manual ................................................................................................................................................ii
Purpose...........................................................................................................................................................ii
What's Inside..................................................................................................................................................ii
Support Services....................................................................................................................................................iii
Table of Contents v
Chapter 1: Introduction 1
Overview of the Manual......................................................................................................................................... 2
Features of the D320 PLC......................................................................................................................................2
Self Diagnostics .............................................................................................................................................3
PID Loop Control...........................................................................................................................................3
Real-time Clock .............................................................................................................................................3
Large Program Memory................................................................................................................................. 3
NOVRAM Battery Backup ............................................................................................................................ 3
I/O and Special Function Module Support..................................................................................................... 3
Peripheral Support..........................................................................................................................................4
System Installation Considerations ........................................................................................................................4
Environmental Considerations ....................................................................................................................... 4
Installing Modules on the System ..................................................................................................................4
Removing Modules from the System............................................................................................................. 4
Preventing PLC System Malfunctions ........................................................................................................... 5
Chapter 2: System Configuration 7
D320 PLC System Components.............................................................................................................................8
D320 PLC Product List.......................................................................................................................................... 9
D320 PLC I/O Configuration...............................................................................................................................14
Module Placement Requirements................................................................................................................. 14
D320 PLC Backplane Configurations.................................................................................................................. 15
Chapter 3: Product Specification 17
Environmental Operating Ranges ........................................................................................................................ 18
CPU Performance Specifications ......................................................................................................................... 19
Name and Function of CPU Components ....................................................................................................20
Chapter 4: Installation And Wiring 23
System Design Considerations.............................................................................................................................24
Power Supply Wiring................................................................................................................................... 24
Interlock Circuit and Emergency Stop Circuit (Safety measures in system design) ....................................24
Momentary Power Failure and Voltage Drop ..............................................................................................25
System Installation Guidelines.............................................................................................................................25
Environmental Usage Conditions.................................................................................................................25
Control Panel Installation.............................................................................................................................26
System Wiring and Installation Procedures .........................................................................................................28
Installation Dimensions................................................................................................................................28
Module Installation ......................................................................................................................................29
Unit Installation Height................................................................................................................................30

vi D320 PLC User's Manual
Expansion Cable Connection....................................................................................................................... 30
Power Supply Wiring .......................................................................................................................................... 31
Power wiring................................................................................................................................................ 31
Grounding.................................................................................................................................................... 31
120/240 VAC Power Supply Wiring Diagram ............................................................................................ 32
I/O Module Wiring .............................................................................................................................................. 33
Digital Input Module Wiring ....................................................................................................................... 33
Digital Output Module Wiring .................................................................................................................... 37
Installation Precautions for I/O Modules..................................................................................................... 38
Terminal Strip Wiring.................................................................................................................................. 39
Connector Module Wiring........................................................................................................................... 40
Connector Module Wiring........................................................................................................................... 40
Alarm Output of Power Supply ................................................................................................................... 42
PLC Communications Wiring ............................................................................................................................. 43
Connecting the PLC to a PC........................................................................................................................ 43
D320 CPU Module Communication Specification...................................................................................... 43
Chapter 5: CPU Operation And Memory 45
Terminology ........................................................................................................................................................ 46
Overview of CPU Operation Mode ..................................................................................................................... 47
What Is the CPU Operation Mode? ............................................................................................................. 47
Run Mode (operating).................................................................................................................................. 47
Stop Mode ................................................................................................................................................... 47
Remote Mode .............................................................................................................................................. 47
Error Mode .................................................................................................................................................. 47
CPU Processing Procedure .................................................................................................................................. 48
Program Processing Procedure .................................................................................................................... 48
Introduction to Registers...................................................................................................................................... 49
Internal/External Address Designation ................................................................................................................ 50
Expression Example ............................................................................................................................................ 51
Double Word Address Designation ..................................................................................................................... 52
Absolute Address Designation............................................................................................................................. 53
I/O Address Designation...................................................................................................................................... 54
Special Internal Addresses................................................................................................................................... 55
Timer/Counter (TC0-255) ................................................................................................................................... 63
Chapter 6: Instructions 67
Basic Instructions................................................................................................................................................. 68
Timer/Counter/SR Instructions............................................................................................................................ 69
Comparison Instructions...................................................................................................................................... 70
Substitution, Increment/Decrement Instructions.................................................................................................. 70
Arithmetic Instructions ........................................................................................................................................ 71
Logic Instructions ................................................................................................................................................ 72
Rotation Instructions............................................................................................................................................ 72
Word Conversion Instructions ............................................................................................................................. 73
Bit Conversion Instructions ................................................................................................................................. 74
Transfer Instructions............................................................................................................................................ 75
Block Processing Instructions.............................................................................................................................. 76
Special Instructions.............................................................................................................................................. 77
How to Read the Description of Instructions....................................................................................................... 78
Instruction.................................................................................................................................................... 78
Ladder.......................................................................................................................................................... 78
Description................................................................................................................................................... 78

Table of Contents vii
Example .......................................................................................................................................................79
Basic Instruction Details ...................................................................................................................................... 80
STR, STN.....................................................................................................................................................80
AND, ANN, (ADN) ..................................................................................................................................... 81
OR, ORN......................................................................................................................................................82
OUT, SET, RST ...........................................................................................................................................83
NOT ............................................................................................................................................................. 84
STR DIF, STR DFN, AND DIF, AND DFN, OR DIF, OR DFN................................................................ 85
ANB, ORB ...................................................................................................................................................86
MCS, MCR ..................................................................................................................................................87
Timer/Counter/SR Instruction Details.................................................................................................................. 88
TIM, SST ..................................................................................................................................................... 88
TOF ..............................................................................................................................................................90
UC, DC.........................................................................................................................................................91
RCT..............................................................................................................................................................93
UDC ............................................................................................................................................................. 94
SR................................................................................................................................................................. 96
Comparison Instruction Details............................................................................................................................ 98
=, <>, >, >=, <=, < .......................................................................................................................................98
Substitution, Increment, Decrement Instruction Details ...................................................................................... 99
LET, DLET ..................................................................................................................................................99
INC, DINC, INCB, DINCB .......................................................................................................................100
DEC, DDEC, DECB, DDECB...................................................................................................................101
Arithmetic Instruction Details............................................................................................................................ 102
ADD, DADD, ADDB, DADDB ................................................................................................................102
SUB, DSUB, SUBB, DSUBB.................................................................................................................... 104
MUL, DMUL, MULB, DMULB ............................................................................................................... 105
DIV, DDIV, DIVB, DDIVB ......................................................................................................................106
ADC, DADC, ADCB, DADCB ................................................................................................................. 107
SBC, DSBC, SBCB, DSBCB.....................................................................................................................109
ABS, DABS, NEG, DNEG, NOT, DNOT.................................................................................................111
Logic Instruction Details.................................................................................................................................... 112
AND, DAND ............................................................................................................................................. 112
OR, DOR....................................................................................................................................................113
XOR, DXOR.............................................................................................................................................. 114
XNR, DXNR.............................................................................................................................................. 115
Rotation Instruction Details ............................................................................................................................... 116
RLC, DRLC ...............................................................................................................................................116
RRC, DRRC...............................................................................................................................................117
ROL, DROL...............................................................................................................................................118
ROR, DROR .............................................................................................................................................. 120
SHL, DSHL................................................................................................................................................ 121
SHR, DSHR ............................................................................................................................................... 123
Word Conversion Instruction Details.................................................................................................................124
BCD, DBCD, BIN, DBIN.......................................................................................................................... 124
XCHG, DXCHG ........................................................................................................................................ 125
SEG ............................................................................................................................................................126
ENCO, DECO............................................................................................................................................ 127
DIS, UNI .................................................................................................................................................... 129
Bit Conversion Instruction Details.....................................................................................................................131
BSET, BRST, BNOT, BTST .....................................................................................................................131
SUM...........................................................................................................................................................133
SC, RC, CC ................................................................................................................................................134

viii D320 PLC User's Manual
Transfer Instruction Details ............................................................................................................................... 135
LDR, DLDR .............................................................................................................................................. 135
STO, DSTO ............................................................................................................................................... 137
MOV, FMOV ............................................................................................................................................ 139
BMOV, BFMV.......................................................................................................................................... 141
Block Processing Instruction Details ................................................................................................................. 142
FOR, DFOR, NEXT .................................................................................................................................. 142
JMP, LBL .................................................................................................................................................. 144
JMPS, JMPE.............................................................................................................................................. 145
CALL, SBR, RET...................................................................................................................................... 147
INT, RETI.................................................................................................................................................. 149
Special Instruction Details ................................................................................................................................. 150
INPR, OUTR ............................................................................................................................................. 150
WAT .......................................................................................................................................................... 152
END........................................................................................................................................................... 153
READ ........................................................................................................................................................ 154
WRITE ...................................................................................................................................................... 156
RMRD ....................................................................................................................................................... 158
RMWR....................................................................................................................................................... 159
RECV......................................................................................................................................................... 160
SEND......................................................................................................................................................... 161
RECVB...................................................................................................................................................... 162
SENDB ...................................................................................................................................................... 163
Chapter 7: Testing And Troubleshooting 165
Test Precautions................................................................................................................................................. 166
System Checks................................................................................................................................................... 166
Testing Procedures............................................................................................................................................. 168
Correcting Errors ............................................................................................................................................... 170
System Check ............................................................................................................................................ 170
Power Supply Check.................................................................................................................................. 171
Run Check ................................................................................................................................................. 172
Error Check................................................................................................................................................ 173
I/O Check................................................................................................................................................... 174
External Environment Check..................................................................................................................... 176
Troubleshooting, Maintenance and Inspection Tables....................................................................................... 177
Periodic Inspection and Preventive Maintenance ...................................................................................... 180
Chapter 8: Troubleshooting Noise Problems 181
Noise Occurrence............................................................................................................................................... 182
Types of Noise........................................................................................................................................... 182
Electrical Noise Fundamental Definitions ................................................................................................. 182
Sources of Noise ........................................................................................................................................ 183
Advised Installation Practices............................................................................................................................ 184
Shield the PLC........................................................................................................................................... 184
Proper Cable Selection .............................................................................................................................. 184
Ground the PLC......................................................................................................................................... 184
Isolation and Filtering Techniques..................................................................................................................... 185
Isolation ..................................................................................................................................................... 185
Filters......................................................................................................................................................... 186
Methods of Handling Large Voltage Spikes Such as Lightning........................................................................ 187
Surge Absorber .......................................................................................................................................... 187
Burying Wire ............................................................................................................................................. 187