Page 1 DL05 Micro PLC User Manual Volume 2 of 2 Manual Number: D0-USER-M...
Page 2 Notes...
Page 3 WARNING ® Thank you for purchasing automation equipment from Automationdirect.com , doing business as AutomationDirect. We want your new automation equipment to operate safely. Anyone who installs or uses this equipment should read this publication (and any other relevant publications) before installing or operating the equipment.
Page 4 AVERTISSEMENT Nous vous remercions d'avoir acheté l'équipement d'automatisation de Automationdirect.com , en faisant des affaires comme, AutomationDirect. Nous tenons à ce que votre nouvel équipement d'automatisation fonctionne en toute sécurité. Toute personne qui installe ou utilise cet équipement doit lire la présente publication (et toutes les autres publications pertinentes) avant de l'installer ou de l'utiliser.
Page 5: Table Of Contents
DL05 Drum Introduction ........
Page 6 Stage View in DirectSOFT 5 ......... .7–18 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 7 Introducing DL05 PID Control ........
Page 8 Ramp/Soak Profile Monitoring ........8–60 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 9 Cascaded Loops in the DL05 CPU ........
Page 10 How to Update Your DL05 Firmware ........10–5...
Page 11 AUX 24 Clear Ladders ..........A–4 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 12 DL05 Error Codes ........
Page 13 DL05 PLC Special Relays ........
Page 14 Writing Your Control Program ........E–21 xvii DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 15 Velocity Profile Program Example ........E–40 xviii DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 16 Non-volatile V-memory in the DL05 ........
Page 17 Suppression and Fusing ..........J–5 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 18 Items Specific to the DL05 ........
Page 19 Table of Contents Notes xxii DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 20 In This Chapter: DL05 Drum Introduction ....... . .6–2 Step Transitions ........6–4 Overview of Drum Operation .
Page 21: Chapter 6: Drum Instruction Programming
Chapter 6: Drum Instruction Programming DL05 Drum Introduction Purpose The Drum (DRUM) instruction in the DL05 CPU electronically simulates an electro- mechanical drum sequencer. The instruction offers enhancements to the basic principle, which we describe first. Drum Terminology Drum instructions are best suited for repetitive processes that consist of a finite number of steps.
Page 22: Drum Chart Representation
Compare the two, and you will find that they are equivalent! If you can see their equivalence, you are well on your way to understanding drum instruction operation. Step Output 6–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 23: Step Transitions
Chapter 6: Drum Instruction Programming Step Transitions Drum Instruction Types There are two types of Drum instructions in the DL05 CPU: • Timed Drum with Discrete Outputs (DRUM) • Time and Event Drum with Discrete Outputs (EDRUM) The two drum instructions include time-based step transitions, and the EDRUM includes event-based transitions as well.
Page 24: Timer And Event Transitions
(X0) remains true. When the counts for Step 1 have expired, then the drum moves to Step . The outputs change immediately to match the new pattern for Step 2. 6–5 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 25: Event-Only Transitions
Counter bit CT10 turns on when the drum cycle is complete, and turns off when the drum is reset. 6–6 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 26: Last Step Completion
(Timer and/or conditions met? Event criteria) Set Drum Complete bit CT10 = 1 Complete Outputs: R eset Input Active? Reset Reset Drum Complete bit CT10 = 0 Go to Preset Step 6–7 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 27: Overview Of Drum Operation
• Preset Step – A step number from 1 to 16 that you define (typically is step 1). The drum moves to this step whenever Reset is on, and whenever the CPU first enters run mode. 6–8 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 28: Powerup State Of Drum Registers
You can monitor these to determine the drum’s progress through its control cycle. The DL05 has 128 counters (CT0 – CT177 in octal). • Events – Either an X, Y, C, S, T, or CT type discrete point serves as step transition inputs. Each step has its own event.
Page 29: Drum Control Techniques
Drum Complete bit (CT0), and forces the drum to enter the preset step. NOTE: The timing diagram shows all steps using equal time durations. Step times can vary greatly, depending on the counts/step programmed. 6–10 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 30: Self-Resetting Drum
Just use a control relay contact such as C0 for the step transition event. Elsewhere in ladder logic, you may use C0 as an output coil, making it dependent on many other “events” (contacts). 6–11 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 31: Drum Instruction
EDRUM instruction. Timed Drum with Discrete Outputs (DRUM) The Timed Drum with Discrete Outputs is the most basic of the DL05’s drum instructions. It operates according to the principles covered on the previous pages. Below is a diagram of the instruction in chart form as displayed by DirectSOFT 5.
Page 32 Therefore, the duration of step 1 is (25 x 0.1) = 2.5 seconds. In the last rung, the Drum Complete bit (CT0) turns on output Y0 upon completion of the last step (step 10). A drum reset also resets CT0. Direct SOFT 5 Display 6–13 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 33: Event Drum (Edrum) Instruction
Counts per step dddd 0 -- 9999 Event eeee X, Y, C, S, T, CT see page 4 -- 28 Discrete Outputs ffff X, Y, C see page 4 -- 28 6–14 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 34 In the last rung, the Drum Complete bit (CT4) turns on output Y0 upon completion of the last step (step 11). A drum reset also resets CT4. Start Reset Drum Complete Direct SOFT 5 Display 6–15 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 35: Program Using The Handheld Programmer
Counts per step dddd DEF K0000 0 -- 9999 Events dddd DEF K0000 X, Y, C, S, T, CT see page 4 -- 28 Output pattern gggg DEF K0000 0 -- FFFF 6–16 DL05 Micro PLC User Manual, 5th Edition, 6/04...
Page 36 SHFT NEXT ( DEF K0000 ) NEXT (Continued on next page ) NOTE: You may use the NXT and PREV keys to skip past entries for unused outputs or steps. 6–17 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 37 ( DEF 0000 ) NEXT NEXT ( DEF K0000 ) NEXT Last rung SHFT NEXT NOTE: You may use the NXT and PREV keys to skip past entries for unused outputs or steps. 6–18 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 38 HAPTER HAPTER HAPTER PLUS TAGE ROGRAMMING In This Chapter: Introduction to Stage Programming ......7–2 Learning to Draw State Transition Diagrams ....7–3 Using the Stage Jump Instruction for State Transitions .
Page 39: Chapter 7: Rll Plus Stage Programming
• Study each stage programming concept by working through each example. The examples build progressively on each other. • Read the Stage Questions and Answers at the end of the chapter for a quick review. 7–2 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 40: Learning To Draw State Transition Diagrams
ON state. In a boolean sense, Y0=ON state. Next, we will implement the state diagram first as RLL, then as a stage program. This will help you see the relationship between the two methods in problem solving. 7–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 41: Rll Equivalent
PLC scan, the CPU will not execute Stage S1, so the motor output Y0 will turn off. The Off state (Stage 0) will be ready for the next cycle. 7–4 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 42: Let's Compare
NOTE: If the ISG is within the retentive range for stages, the ISG will remain in the state it was in before power down and will NOT turn itself on during the first scan. 7–5 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 43: What Stage Bits Do
• Octal numbering – Stages are numbered in octal, like I/O points, etc. So “S8” is not valid. • Total Stages – The DL05 offers up to 256 stages (S0 to S377 in octal). • No duplicates – Each stage number is unique and can be used just once.
Page 44: Using The Stage Jump Instruction For State Transitions
JMP S1 executes, because stage S1 is located above stage S0. Executes on next scan after Jmp Executes on same scan as Jmp NOTE: Assume we start with Stage 0 active and stage 1 inactive for both examples. 7–7 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 45: Stage Program Example: Toggle On/Off Lamp Controller
SP1, which is always on. Push–Off State Note that even as our programs grow more complex, it is still easy to correlate the state transition diagram with the stage program! 7–8 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 46: Four Steps To Writing A Stage Program
However, the program virtually writes itself because of the preparation beforehand. Soon you’ll be able to start with a word description of an application and create a stage program in one easy session! 7–9 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 47: Stage Program Example: A Garage Door Opener
Raise The controller has two outputs to drive the motor. Down limit Y1 is the up (raise the door) command, and Y2 is the Lower down (lower the door) command. 7–10 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 48: Draw The State Diagram
Stage S5 to the DOWN stage S0, where we began. NOTE: The only special thing about an initial stage (ISG) is that it is automatically active at powerup. Afterwards, it is just like any other. 7–11 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 49: Add Safety Light Feature
Light stage. The path out of the Light stage goes nowhere, indicating the Light stage just becomes inactive, and the light goes out! Output equations: Y1 = RAISE Y2 = LOWER Y3 = LIGHT RAISE Push–UP DOWN LIGHT LOWER Push–DOWN 7–12 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 50: Using A Timer Inside A Stage
Stage 6. That is, the door can go up, down, or whatever, but the light will be on for precisely 3 minutes. K1800 7–13 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 51: Add Emergency Stop Feature
The second and third rungs implement the transitions we need. Note the opposite relay contact usage for X3, which ensures to Push-UP the stage will execute only one of the JMP instructions. 7–14 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 52: Stage Program Design Considerations
The monitor stage could set the stage bit Monitor Status for Status and Reset the stages Control and Recipe. E-Stop and Alarm Monitoring 7–15 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 53: How Instructions Work Inside Stages
Drum – Realize that the drum sequencer is its own process, and is a different programming method than stage programming. If you need to use a drum with stages, be sure to place the drum instruction in an ISG stage that is always active. 7–16 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 54: Using A Stage As A Supervisory Process
The standard Counter instruction does not have this global reset capability. You may still use a regular Counter instruction inside a stage... however, the reset input to the counter is the only way to reset it. 7–17 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 55: Power Flow Transition Technique
Jump Set Stage Logic a Stage Reset Stage The following diagram is a typical stage view of a ladder program containing stages. Note the left-to-right direction of the flow chart. 7–18 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 56: Parallel Processing Concepts
CV stages! The transition condition (X3 in this case) CVJMP must be located in the last convergence stage. The transition condition only has power flow when all convergence stages in the group are active. 7–19 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 57: Convergence Jump (Cvjmp)
• The CVJMP instruction must only be used in a convergence stage, as it is invalid in regular or initial stages. • Convergence Stages or CVJMP instructions may not be used in subroutines or interrupt routines. 7–20 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 58: Rll Plus (Stage) Instructions
The following example is a simple RLL PLUS program. This program utilizes an initial stage, stage, and jump instructions to create a structured program. Direct SOFT Direct SOFT32 Handheld Programmer Keystrokes SHFT SHFT 7–21 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 59: Initial Stage (Isg)
Stage ....... . . S 0–377 7–22 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 60: Converge Stage (Cv) And Converge Jump (Cvjmp)
Stage ....... . . S 0–377 7–23 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 61 S20. Then, if X5 is on, the program execution will jump back to the initial stage, S0. Direct SOFT Direct SOFT32 Handheld Programmer Keystrokes SHFT SHFT SHFT SHFT CVJMP 7–24 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 62: Questions And Answers About Stage Programming
1 scan by including a stage Jump instruction at the bottom of the rung. Then the ladder will execute on the last scan before its stage jumps to a new one. 7–25 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 63 And a good process design will be mostly sequential, with only one stage on at a time. However, all the processes in the program may be active simultaneously. 7–26 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 64 DL05 PID Control ........8–2...
Page 65: Chapter 8: Pid Loop Operation
DL05 analog I/O modules. All process variables, gain values, alarm levels, etc., associated with each loop reside in a Loop Variable Table in the CPU. The DL05 CPU reads process variable (PV) inputs during each scan. Then it makes PID loop calculations during a dedicated time slice on each PLC scan, updating the control output value.
Page 66 Select PV alarm settings for Low–low, Low, High, and High-high conditions PV Deviation Specify alarms for two ranges of PV deviation from the setpoint value Rate of Change Detect when PV exceeds a rate of change limit you specify 8–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 67: Introduction To Pid Control
The ON-OFF controller is used in some industrial control applications, but is not practical in the majority of industrial control processes. The most common process controller that is used in industry is the PID controller. 8–4 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 68 Its job is to anticipate the probable growth of the error and generate a contribution to the output in advance. 8–5 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 69: Introducing Dl05 Pid Control
Chapter 8: PID Loop Operation Introducing DL05 PID Control The DL05 is capable of controlling a process variable such as those already mentioned. As previously mentioned, the control of a variable, such as temperature, at a given level (setpoint) as long as there are no disturbances (cold water) in the process.
Page 70 Chapter 8: PID Loop Operation Standard DL05/06 analog input modules are used to interface to field transmitters to obtain the PV. These transmitters normally provide a 4-20mA current or an analog voltage of various ranges for the control loop. For temperature control, thermocouple or RTD can be connected directly to the appropriate module.
Page 71: Process Control Definitions
Loop Monitoring – The function which allows an operator to observe the status and performance of a control loop. This is used in conjunction with the loop configuring to optimize the performance of a loop (minimize the error term). 8–8 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 72: Pid Loop Operation
I/O modules serve only to convert electronic signals into digital form (or vice versa). The DL05 uses two types of PID controls: “position” and “velocity”. These terms usually refer to motion control situations, but here we use them in a different sense: •...
Page 73: Reset Windup Protection
- Kr(PV ) + Mx The DL05 by default will keep the normalized output M in the range of 0.0 to 1.0. This is done by clamping M to the nearer of 0.0 or 1.0 whenever the calculated output falls outside this range.
Page 74: Freeze Bias
The choice of whether to use the default loop action or to freeze the bias is dependent on the application. If large, step changes to the setpoint are anticipated, then it is probably better to select the freeze bias option (see page 8-34). 8–11 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 75: Step Bias Proportional To Step Change In Sp
“n” from the equation at time “n-1”. The velocity equation is given by: = M - M = Kc * (e ) + Ki * (PV - 2 * PV + PV 8–12 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 76: Bumpless Transfer
II (see page 8-26). The transfer type is selected when the loop is set up. Loop Alarms The DL05 allows the user to specify alarm conditions that are to be monitored for each loop. Alarm conditions are reported to the CPU by setting up the alarms in DirectSOFT 5 using the PID setup alarm dialog when the loop is setup.
Page 77: Loop Operating Modes
V-memory. All alarms are monitored while in automatic. Cascade Cascade mode is an option with the DL05 PLC and is used in special control applications. If the cascade feature is used, the loop will operate as it would if in automatic mode except for the fact that a cascaded loop has a setpoint which is the control output from another loop.
Page 78 M = Kc * e - Kr * (Y ) + Mx Velocity Algorithm M = Kc * (e ) + Ki * e - Kr * (Y - 2 * Y 8–15 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 79: Ten Steps To Successful Process Control
5 times that resolution (at LSB level). However, an over- sensitive sensor can cause control oscillations, etc. The DL05 provides 12–bit and 15–bit unipolar and bipolar data format options, and a 16–bit unipolar option. This selection affects SP, PV, Control Output and Integrator sum.
Page 80 Damage to equipment and/or serious injury to personnel can result from loss of control of some processes. Step 10: Save Parameters When the loop tests and tuning sessions are complete, be sure to save all loop setup parameters to disk. 8–17 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 81: Pid Loop Setup
Some Things to Do and Know Before Starting Have your analog module installed and operational before beginning the loop setup (refer to the DL05/06 Option Modules User Manual, D0-OPTIONS-M). The DL05 PLC gets its PID loop processing instructions from V-memory tables. There isn’t a PID instruction that can be used in RLL, such as a block, to setup the PID loop control.
Page 82 NOTE: Have an edited program open, then click on PLC > Setup > PID to access the Setup PID dialog. 8–19 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 83: Loop Table Word Definitions
Chapter 8: PID Loop Operation Loop Table Word Definitions These are the loop parameters associated with each of the four loops available in the DL05. The parameters are listed in the following table. The address offset is in octal, to help you locate specific parameters in the loop table.
Page 84: Pid Mode Setting 1 Bit Descriptions (Addr + 00)
13 PV Deviation alarm select write 14 PV rate-of-change alarm select write Loop with CPU Loop Independent 15 Loop mode is independent from CPU mode when set write mode of CPU mode 8–21 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 85: Pid Mode Setting 2 Bit Descriptions (Addr + 01)
If bit 10 and bit 13 each have a value of 1, then bits 11 and 12 are not read, and bit 13 defines the data format (the output range is automatically unipolar). 8–22 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 86: Mode/Alarm Monitoring Word (Addr + 06)
This byte will have the values 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, F, and 10, which represent segments 1 to 16 respectively. If the byte=0, then the Ramp/Soak table is not active. 8–23 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 87: Ramp/Soak Table Location (Addr + 34)
Starting Addr out of upper V-memory range read – Error 2–3 Reserved for Future Use – – – Starting Addr in System Parameter V-memory Range read – Error 5–15 Reserved for Future Use – – – 8–24 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 88: Configure The Pid Loop
Each calculation generates a new control output value. With Ladder Program the DL05 CPU, you can set the sample rate of a loop from 50 ms to Scan 99.99 seconds. Most loops do not require a fresh PID calculation on Calculate every PLC scan.
Page 89 (-4095 to 4095 or -32767 to 32767) and requires a sign bit. Bipolar selection displays input/output as magnitude plus sign, not two’s compliment. The bipolar selection is not available when 16-bit data format is selected. 8–26 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 90 PID loop modes will be helpful. The DL05 provides the three standard control modes: Manual, Automatic, and Cascade. The sources of the three basic variables SP, PV and control output are different for each mode.
Page 91 If bit 15 is set to one, then the loops will run independent of the CPU mode. It is like having two independent processors in the CPU...one is running the RLL program and the other is running the process loops. 8–28 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 92 Slot number “F” and the Channel number will automatically appear. Since there is only one option slot in the DL05, the letter F represents the default option slot. Also, select the analog input channel of your choice.
Page 93 Enable Limiting. This will activate the Upper and Lower fields for the values to be entered. Set the limits around the SP value to prevent an operator from entering a 8–30 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 94 Common format has been chosen (see page 8-26). WARNING: If the Upper Limit is set to zero, the output will never get above zero. In effect, there will be no control output. 8–31 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 95 XX.XX. An entry of “0000” allows removal of the derivative term from the PID equation (a common practice). This accommodates applications which require only proportional and/or integral loops. Most control loops will operate as a PI loop. 8–32 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 96 • Non-linear process – some processes (such as chemical pH control) require non-linear controllers for best results. Another application is surge tank control, where the Control Output signal must be smooth. 8–33 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 97 If you have set limits on the control output other than the range (i.e, 0–4095 for a unipolar/12bit loop), the bias term still uses the end of range for the stopping point and bias freeze will not work. 8–34 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 98 Low-low Alarm Low–low Alarm NOTE: The Alarm dialog can be left as it first appears, without alarm entries. The alarms can then be setup in the DirectSOFT 5 PID View. 8–35 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 99 13 of the PID Mode 1 Setting V+00 word. Remember the alarm hysteresis feature works in conjunction with both the deviation and absolute value alarms, and is discussed at the end of this section. 8–36 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 100 PV absolute value will not reach the point where the material in process would be ruined. The DL05 loop controller provides a programmable PV Rate-of-Change Alarm, as shown below. The rate-of-change is specified in PV units change per loop sample time. This value is programmed into the loop table location V+21.
Page 101 NOTE: Overflow/underflow can be alarmed in PID View. The optional C-more IO panel (see the automationdirect.com website) can also be set up to read these error bits using the PID Faceplate templates. 8–38 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 102 NOTE: It is good practice to save your project after setting up the PID loop by selecting File from the menu toolbar, then Save project > to disk. In addition to saving your entire project, all the PID parameters are also saved. 8–39 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 103: Pid Loop Tuning
Make sure you thoroughly consider the impact of any changes to minimize the risk of injury to personnel or damage to equipment. The auto tune in the DL05 is not intended to be used as a replacement for your process knowledge.
Page 104: Manual Tuning Procedure
• Increase the Proportional gain in small increments, such as 4, 6, 7, etc. until the control output response begins to oscillate. This is the Proportional gain that should be recorded. 8–41 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 105 Small adjustments of the parameters can make the control output more precise or more unstable. It is sometimes acceptable to have a small overshoot to make the control output react quicker. 8–42 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 106 If there is little or no response, increase the derivative by increments of 0.5 until there is an improvement to the output trend. Recall that the derivative gain reacts with a rate of change of the error. 8–43 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 107: Auto Tuning Procedure
Make sure you thoroughly consider the impact of any changes to minimize the risk of injury to personnel or damage to equipment. The auto tune in the DL05 is not intended to be used as a replacement for your process knowledge.
Page 108 SP value must be more than 5% of the PV range from the actual PV before starting the auto tune cycle (for the DL05, 12 bit PV should be 205 counts or more below the SP for forward-acting loops, or 205 counts or more above the SP for reverse-acting loops).
Page 109 From the PV response, the auto tune function calculates the gains and the sample time. It automatically places the results in the corresponding registers in the loop table. 8–46 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 110 NOTE: If your PV fluctuates rapidly, you probably need to use the built-in analog filter (see page 8–53) or create a filter in ladder logic (see example on page 8–54). 8–47 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 111: Use Directsoft 5 Data View With Pid View
The Data View window can be used just as it is shown above for troubleshooting your PID logic, and it can be most useful when tuning the PID loop. 8–48 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 112: Open Pid View
The PID View will open and appear over the Ladder View which can be brought into view by clicking on its tab. When using the Data View and the PID View together, each view can be sized for better use as shown on the facing page. 8–49 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 113 Process Variable and Setpoint trends are color coded. The loop name area turns red whenever there is an overflow error. 8–50 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 114: How To Change Loop Modes
Chapter 8: PID Loop Operation Using Other PID Features It’s a good idea to understand the special features of the DL05 and how to use them. You may want to incorporate some of these features for your PID. How to Change Loop Modes...
Page 115: Operator Panel Control Of Pid Modes
• A loop which develops an error condition automatically goes to Manual. • If the minor loop of a cascaded pair of loops leaves Cascade Mode for any reason, its major loop automatically goes to Manual Mode. 8–52 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 116: Pv Analog Filter
The DL05 Built-in Analog Filter The DL05 provides a selectable first-order low-pass PV input filter. We only recommend the use of a filter during auto tuning or PID control if there is noise on the input signal. You may disable the filter after auto tuning is complete, or continue to use it if the PV input signal is noisy.
Page 117: Creating An Analog Filter In Ladder Logic
PV) back to the analog input value. V2200 Replace the previous Loop Table PV value with the new filtered analog value in the Loop Table. V2003 END coil marks the end of the main program. 8–54 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 118: Use The Directsoft 5 Filter Intelligent Box Instruction
A value of 1 results with no filtering. The filtered value will be placed in V2100. See Chapter 5, page 138, for more detailed information. 8–55 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 119: Ramp/Soak Generator
The ladder program can monitor the status of the ramp soak profile (current ramp/segment number). Ramp/soak table Setpoint Control Output Ramp/soak Loop Generator Calculation Ramp/soak controls – Process Variable 8–56 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 120: Ramp/Soak Table
Ramp/Soak #2 32 words ramp/soak table, independently located elsewhere in user V-memory. Of course, you may locate all the tables in one group, as long as they do not overlap. 8–57 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 121 Ramp End SP Value + 15 Ramp Slope + 35 Ramp Slope + 16 Soak Duration + 36 Soak Duration + 17 Soak PV Deviation + 37 Soak PV Deviation 8–58 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 122: Ramp/Soak Table Flags
X0 can turn on and the PD contact uses the leading B2033.0 edge to set the proper control bit to start the ramp soak profile. This uses the Set Bit-of-word instruction. 8–59 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 123: Ramp/Soak Profile Monitoring
Using DirectSOFT 5’s PID View will be a real time-saver, because it will draw the profile on- screen for you. Be sure to set the trending timebase slow enough to display completed ramp- soak segment pairs in the waveform window. 8–60 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 124: Directsoft 5 Ramp/Soak Example
Refer to the Ramp/Soak Flag Bit Description table on page 8-59 when adding the control rungs to your program similar to the ladder rungs below. For the example below, PID parameters begin at V7000. The Ramp/Soak bit flags are located at V7033. 8–61 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 125: Test The Profile
PID View. If there are any changes to be made in the profile, they are made in the PID Setup R/S profile. Make the chages in Program mode then start the Ramp/Soak process again. 8–62 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 126: Cascade Control
Cascaded loops are an advanced control technique that is superior to individual loop control in certain situations. As the name implies, cascade means that one loop is connected to another loop. In addition to Manual (open loop) and Auto (closed loop) Modes, the DL05 also provides Cascaded Mode.
Page 127: Cascaded Loops In The Dl05 Cpu
Cascade Mode, and only the outer-most (major) loop will be in Auto Mode. You can cascade together as many loops as necessary on the DL05, and you may have multiple groups of cascaded loops. For proper operation on cascaded loops you must use the same data range (12/15 bit) and unipolar/bipolar settings on the major and minor loop.
Page 128: Tuning Cascaded Loops
5. Tune the major loop, following the standard loop tuning procedure in this section. The response of the major loop PV is actually the overall response of the cascaded loops together. 8–65 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 129: Time-Proportioning Control
Chapter 8: PID Loop Operation Time-Proportioning Control The PID loop controller in the DL05 CPU generates a smooth control output signal across a numerical range. The control output value is suitable to drive an analog output module, which connects to the process. In the process control field, this is called continuous control, because the output is on (at some level) continuously.
Page 130: On/Off Control Program Example
Y0 turns off when T1 times out. The STRNE contact prevents Y0 from energizing during the one scan when T0 resets T1. Y0 is the actual control output. END coil marks the end of the main program. 8–67 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 131: Feedforward Control
Use of this feature is an option available to you on the DL05. However, it’s best to implement and tune a loop without feedforward, and adding it only if better loop performance is still needed.
Page 132: Feedforward Example
The step changes in the bias are the result of our two feed-forward writes to the bias term. We can see the PV variations are greatly reduced. The same technique may be applied for changes in setpoint. 8–69 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 133: Pid Example Program
This example assumes that the PID table for loop 1 has a beginning address of V2100. All of the analog I/O modules used with the DL05 are setup in a similar manner. Refer to the DL05/DL06 Options Manual for the setup information for the particular module that you will be using.
Page 134 AN-MISC-012, titled “PID tutorial - Powerpoint slide show”. This a Windows Power Point documentation. The Power Point Viewer can be downloaded from our website if you do not have Power Point to view the tutorial. 8–71 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 135: Troubleshooting Tips
Q. The Derivative gain doesn’t seem to have any affect on the output. A. The derivative limit is probably enabled (see section on derivative gain limiting). 8–72 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 136 • There may be a process disturbance that is over-powering the loop. Make sure the PV is relatively steady when the SP is not changing. 8–73 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 137: Glossary Of Pid Loop Terminology
On/Off Control A simple method of controlling a process, through on/off application of energy into the system. The mass of the process averages the on/off effect for a relatively smooth PV. A simple ladder program can convert the DL05’s continuous loop output to on/off control. 8–74...
Page 138 The word “transfer” probably refers to the transfer of control of the control output depending on the particular mode change. Velocity Algorithm The control output is calculated to represent the rate of change (velocity) for the PV become equal to the SP. 8–75 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 139: Bibliography
Author (Editor-in-Chief): Bela G. Liptak Engineer’s Handbook Publisher: Chilton..ISBN 0–8019–8242–1 Author (Editor-in-Chief): Bela G. Liptak Publisher: Chilton..ISBN 0–8019–8197–2 8–76 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 140 HAPTER HAPTER HAPTER AINTENANCE AND ROUBLESHOOTING In This Chapter: Hardware System Maintenance ......9–2 Diagnostics .
Page 141: Chapter 9: Maintenance And Troubleshooting
Diagnostics Diagnostics Your DL05 Micro PLC performs many pre-defined diagnostic routines with every CPU scan. The diagnostics can detect various errors or failures in the PLC. The two primary error classes are fatal and non-fatal.
Page 142: V-Memory Error Code Locations
Program memory error SP45 I/O error SP46 Communications error SP50 Fault instruction was executed SP51 Watchdog timeout SP52 Syntax error SP53 Cannot solve the logic SP54 Communication error SP56 Table instruction overrun 9–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 143: Dl05 Micro Plc Error Codes
Handheld Programmer ROM error E523 Bad operation – CPU in Test Program E652 Handheld Programmer RAM error E524 Bad operation – CPU in Program E525 Mode Switch not in Term position 9–4 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 144: Program Error Codes
Invalid ISG / SG address E471 Duplicate coil reference E434 Invalid RTC E472 Duplicate TMR reference E435 Invalid RT E473 Duplicate CNT reference E436 Invalid INT address E499 Print instruction E437 Invalid IRTC 9–5 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 145: Cpu Indicators
4. If the connections are acceptable, reconnect the system power and verify the voltage at the DL05 power input is within specification. If the voltage is not correct shut down the system and correct the problem.
Page 146: Run Indicator
For problems in communicating with DirectSOFT 5 on a personal computer, refer to the DirectSOFT 5 manual. It includes a troubleshooting section that can help you diagnose PC problems in communications port setup, address or interrupt conflicts, etc. 9–7 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 147: I/O Point Troubleshooting
• Because of the removable terminal blocks on the DL05, the easiest method to determine if an I/O circuit has failed is to replace the unit if you have a spare. However, if you suspect a field device is defective, that device may cause the same failure in the replacement PLC as well.
Page 148: Handheld Programmer Keystrokes Used To Test An Output Point
Chapter 9: Maintenance and Troubleshooting Output points can be set on or off in the DL05 series CPUs. If you want to do an I/O check out independent of the application program, follow the procedure below: Step Action Use a handheld programmer or Direct SOFT to communicate online to the PLC.
Page 149: Noise Troubleshooting
Installing an isolation transformer for all AC sources can correct this problem. DC sources should be well-grounded good quality supplies. • Separate input wiring from output wiring. Never run low-voltage I/O wiring close to high voltage wiring. 9–10 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 150: Machine Startup And Program Troubleshooting
Chapter 9: Maintenance and Troubleshooting Machine Startup and Program Troubleshooting The DL05 Micro PLCs provide several features that can help you debug your program before and during machine startup. This section discusses the following topics which can be very helpful.
Page 151: Special Instructions
CPU automatically exits Run Mode and enters Program Mode. Remember, all outputs are turned off during Program Mode. The following diagram shows an example of a condition that returns the CPU to Program Mode. 9–12 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 152: Duplicate Reference Check
NOTE: You can use the same coil in more than one location, especially in programs containing Stage instructions and/or OROUT instructions. The Duplicate Reference check will find occurrences, even though they are acceptable. 9–13 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 153 Chapter 9: Maintenance and Troubleshooting Run Time Edits The DL05 Micro PLC allows you to make changes to the application program during Run Mode. These edits are not “bumpless.” Instead, CPU scan is momentarily interrupted (and the outputs are maintained in their current state) until the program change is complete. This means if the output is off, it will remain off until the program change is complete.
Page 154: Runtime Edits
Press the arrow key to move to the X. Then enter the new contact (C10). RUNTIME EDIT? SHFT STR C10 Press ENT to confirm the change. (Note, once you press ENT, the next address is displayed.) OR C0 9–15 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 155: Forcing I/O Points
There are many times, especially during machine startup and troubleshooting, that you need the capability to force an I/O point to be either on or off. Before you use a programming device to force any data type it is important you understand how the DL05 CPUs process the forcing requests.
Page 156 HAPTER HAPTER HAPTER EMORY ARTRIDGE LOCK In This Chapter... General Information about the D0–01MC ....10–2 Setting the Write Enable/Disable Jumper ....10–3 Plugging-in the Memory Cartridge .
Page 157: General Information About The D0-01Mc
LED flashes to confirm the direction and success of the memory copy. WARNING: The D0–01MC will only work in the DL05 PLC, it will not work in the DL06 PLC. Jumper Selects Write Enable or Disable A jumper enables/disables the write function in the MC.
Page 158: Setting The Write Enable/Disable Jumper
Memory Cartridge to be overwritten. Write Enable Disable WARNING: Power to the DL05 PLC must be disconnected before inserting or removing the D0–01MC Memory Cartridge. Failure to disconnect power could result in serious damage to the module, the PLC or both. Write Disable Set the jumper as shown in Figure 2 if you do not want the CPU or DirectSOFT 5 to be able to overwrite the Memory Cartridge.
Page 159: Plugging-In The Memory Cartridge
Chapter 10: Memory Cartridge Plugging-in the Memory Cartridge Remove the Slot Cover Remove the protective cover from the DL05 option card slot by squeezing the pinch tabs and lifting the cover off. Pinch Tabs Option Card Slot Cover Insert the Memory Cartridge Insert the D0-01MC module into the open option card slot.
Page 160: Software And Firmware Requirements
DirectSOFT, contact AutomationDirect about a software upgrade to DirectSOFT 5 (PC-DSOFT5). Your DL05 must have Version 5.10, or later, firmware to operate correctly with all features of the D0–01MC. To determine your firmware revision level, connect to the DL05 with DirectSOFT 5 programming software, and click on PLC >...
Page 161: Naming The Memory Cartridge
Memory Cartridge even if the program in the PLC originated as a program in another Memory Cartridge that has a different name. If you require the name of your Memory Cartridge to change, you must change it using the screen shown. 10–6 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 162: Setting The Time And Date
Chapter 10: Memory Cartridge Setting the Time and Date Use DirectSOFT 5 to set the date and time in your Memory Cartridge, connect to the DL05. Inside the Project Window, click on PLC/Setup/Calendar to bring up the Calendar window. NOTE: You can also use ladder instructions to set the date and time. See Clock/Calendar Instructions beginning on page 10–13.
Page 163: Memory Transfers
NOTE: Memory transfer functions cannot be accessed while the PLC is in RUN mode. Use the toggle switch on the DL05 to switch the PLC out of RUN mode, or use DirectSOFT 5 programming software to make the change.
Page 164: Led Indicator Lights
(< LED keeps blinking) (< LED keeps blinking) Program Disable Disable (> LED keeps blinking) (> LED keeps blinking) Disable Disable (> & < LED keeps blinking) (> & < LED keeps blinking) 10–9 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 165: Memory Map And Forwarding Range
Chapter 10: Memory Cartridge Memory Map and Forwarding Range The Memory Cartridge’s on-board memory maps one-for-one to the DL05 PLC. The memory types represented in the table below have the same designated locations in either the Memory Cartridge or the DL05 PLC.
Page 166: Battery Back-Up During Ac Power Loss
Battery Back-up During AC Power Loss What if the Battery Dies? In the event of AC power loss to the DL05 PLC, the on-board lithium battery will back-up the program logic and data values for a period up to three years.
Page 167: Specifications And Agency Approvals
Indication: illuminates red LED and sets SP43 to "1" Write Protect Internal jumper pins Memory Type CMOS RAM 32KBytes Frequency accuracy: ±20PPM (25°C) Calendar Temperature characteristic: +10/-20PPM (0°- 55°C) Agency Approvals UL, CE (pending) 10–12 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 168: Clock/Calendar Instructions
2000 – 2069. V2001 V2000 DATE V2000 Format Set the date in the CPU using the value in V2000 and V2001 Handheld Programmer Keystrokes Year Month Day of Week SHFT SHFT SHFT 10–13 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 169: Time (Time)
V2001 V2000 Format V2001 V2000 TIME V2000 Set the time in the CPU using the value in V2000 and V2001 Hour Minutes Seconds Handheld Programmer Keystrokes Used SHFT SHFT SHFT 10–14 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 170: Move Memory Cartridge / Load Label (Movmc) (Ldlbl)
NOTE: The MOVMC instruction supports K values only when the D0–01MC is installed. Without the D0–01MC installed, the MOVMC instruction supports V-memory values only. Discrete Bit Flags Description SP53 On if there is a table pointer error 10–15 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 171: Copy Data From A Data Label Area To V-Memory
DLBL NCON K1234 NCON Handheld Programmer Keystrokes K4532 NCON K6151 SHFT SHFT ANDST NCON SHFT SHFT ANDST K8845 SHFT ANDST ANDST ANDST NCON SHFT K7777 ORST INST# ORST 10–16 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 172: Copy Data From V-Memory To A Data Label Area
DLBL NCON K1234 NCON Handheld Programmer Keystrokes K4532 NCON K6151 SHFT SHFT ANDST NCON SHFT SHFT ANDST K8845 SHFT ANDST NCON K7777 SHFT SHFT ORST INST# ORST 10–17 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 173: Error Codes
Chapter 10: Memory Cartridge Error Codes The full list of Error Codes associated with the DL05 PLC is contained in Appendix B. The following error codes have different or expanded definitions when associated with the D0–01MC Memory Cartridge. Also see page 10–3 concerning error messages you may encounter when the Memory Cartridge is in the Write Disable position.
Page 174 PPENDIX PPENDIX PPENDIX UXILIARY UNCTIONS In This Appendix: Introduction ......... . .A–2 AUX 2* —...
Page 175: Appendix A: Auxiliary Functions
Set Watchdog Timer Lock CPU Set Communication Port 2 Set Retentive Ranges Test Operations Override Setup HSIO Interface Configuration Scan Control Setup NOTE: - Supported HP - Handheld Programmer function A–2 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 176: Accessing Aux Functions Via Directsoft 5
AUX 31 CLR V MEMORY You can also enter the exact AUX number to go straight to the sub-menu. Enter the AUX number directly AUX 3* V OPERATIONS AUX 31 CLR V MEMORY A–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 177: Aux 21 Check Program
AUX 31 Clear V-Memory AUX 31 clears all the information from the V-memory locations available for general use. This AUX function is available on the PLC/Clear PLC sub-menu within DirectSOFT 5. A–4 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 178: Aux 4* - I/O Configuration
AUX 55 Set Watchdog Timer DL05 PLCs have a “watchdog” timer that is used to monitor the scan time. The default value set from the factory is 200 ms. If the scan time exceeds the watchdog time limit, the CPU automatically leaves RUN mode and enters PGM mode.
Page 179: Aux 56 Cpu Network Address
Appendix A: Auxiliary Functions AUX 56 CPU Network Address Since the DL05 CPU has an additional communication port, you can use the Handheld to set the network address for port 2 and the port communication parameters. The default settings are: •...
Page 180: Aux 59 Bit Override
AUX 5D Select PLC Scan Mode The DL05 CPU has two program scan modes: fixed and variable. In fixed mode, the scan time is lengthened to the time you specify (in milliseconds). If the actual scan time is longer than the fixed scan time, then the error code E504 BAD REF/VAL is displayed.
Page 181: Aux 6* - Handheld Programmer Configuration
AUX 71 copies information from the CPU memory to an EEPROM installed in the Handheld Programmer. You can copy different portions of EEPROM (HP) memory to the CPU memory as shown in the previous table. A–8 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 182: Aux 72 Hpp Eeprom To Cpu
AUX 72 HPP EEPROM to CPU AUX 72 copies information from the EEPROM installed in the Handheld Programmer to CPU memory in the DL05. You can copy different portions of EEPROM (HPP) memory to the CPU memory as shown in the previous table.
Page 183: Aux 82 Unlock Cpu
CPU to the factory for password removal. It is the policy of AutomationDirect to clear the PLC memory which includes the password and the program. NOTE: The DL05 CPUs support multi-level password protection of the ladder program. This allows password protection while not locking the communication port to an operator interface. The multi-level password can be invoked by creating a password with an upper case “A”...
Page 184: Appendix B: Dl05 Error Codes
DL05 Error Codes ........B–1...
Page 185 A data error was encountered during communication with the CPU. Check to ensure cabling E321 is correct and not defective. Power cycle the system. If the error continues, replace the CPU COMM ERROR first and then the handheld programmer, if necessary. B–2 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 186 An ISG or SG instruction must not be placed after the end statement (such as inside a INVALID ISG/SG subroutine). ADDRESS SP52 will be on and the error code will be stored in V7755. B–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 187 BAD TMRA E455 One of the contacts is missing from a CNT or UDC instruction. BAD CNT E456 One of the contacts is missing from the SR instruction. BAD SR B–4 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 188 REFERENCE E473 DUPLICATE CNT Two or more CNT instructions reference the same number. REFERENCE E499 Invalid PRINT instruct usage. PRINT Quotations and/or spaces were not entered or entered incorrectly. INSTRUCTION B–5 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 189 BAD REF/VAL An invalid instruction was entered into the handheld programmer or a program which E505 includes an instruction requiring a Memory Cartridge (D0-01MC) to be installed in the DL05, INVALID INSTRUCTION but was placed in RUN without the MC.
Page 190 If the error returns replace the handheld programmer. E652 A RAM error has occurred in the handheld programmer. Power cycle the handheld HPP RAM ERROR programmer. If the error returns replace the handheld programmer. B–7 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 191 Appendix B: DL05 Error Codes Notes B–8 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 192 PPENDIX PPENDIX PPENDIX NSTRUCTION XECUTION IMES In This Appendix: Introduction ......... .C–2 Instruction Execution Times .
Page 193: Appendix C: Instruction Execution Times
Appendix C: Instruction Execution Times Introduction This appendix contains several tables that provide the instruction execution times for DL05 Micro PLCs. Many of the execution times depend on the type of data used with the instruction. Registers may be classified into the following types: •...
Page 194: Instruction Execution Times
2nd #: T, CT (N pt) 80.9 µs + 2.6 µs x N 4.8 µs 1wd: Y 31.6 µs 31.1 µs PAUSE 2wd: Y (N pt) 48.4 µs + 12.1 µs x N 48.8 µs C–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 195: Comparative Boolean Instructions
P: Indir. (Bit) V:Data Reg 63.3 µs 63.4 µs V:Bit Reg 63.3 µs 63.4 µs K:Constant 57.4 µs 57.5 µs P:Indir. (Data) 106.9 µs 107.0 µs P:Indir. (Bit) 106.9 µs 107.0 µs C–4 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 196 P: Indir. (Bit) V:Data Reg. 62.7 µs 62.9 µs V:Bit Reg. 62.7 µs 62.9 µs K:Constant 57.0 µs 57.1 µs P:Indir. (Data) 106.5 µs 106.6 µs P:Indir. (Bit) 106.5 µs 106.6 µs C–5 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 197 P: Indir. (Bit) V:Data Reg. 62.7 µs 62.85 µs V:Bit Reg. 62.7 µs 62.85 µs K:Constant 57.0 µs 57.10 µs P:Indir. (Data) 106.5 µs 106.6 µs P:Indir. (Bit) 106.5 µs 106.6 µs C–6 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 198 P: Indir. (Bit) V:Data Reg. 63.2 µs 63.4 µs V:Bit Reg. 63.2 µs 63.4 µs K:Constant 57.4 µs 57.5 µs P:Indir. (Data) 106.9 µs 107.0 µs P:Indir. (Bit) 106.9 µs 107.0 µs C–7 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 199 P: Indir. (Bit) V:Data Reg. 62.7 µs 62.9 µs V:Bit Reg. 62.7 µs 62.9 µs K:Constant 57.0 µs 57.1 µs P:Indir. (Data) 106.5 µs 106.6 µs P:Indir. (Bit) 106.5 µs 106.6 µs C–8 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 200 P: Indir. (Bit) V:Data Reg. 62.8 µs 62.9 µs V:Bit Reg. 62.8 µs 62.9 µs K:Constant 57.0 µs 57.1 µs P:Indir. (Data) 106.5 µs 106.6 µs P:Indir. (Bit) 106.5 µs 106.6 µs C–9 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 201: Immediate Instructions
128.15 µs V:Data Reg. 102.53 µs 81.5 µs V:Bit Reg. 102.53 µs 81.5 µs K:Constant 97.1 µs 76.1 µs P:Indir. (Data) 151.4 µs 130.4 µs P:Indir. (Bit) 151.4 µs 130.4 µs C–10 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 202: Accumulator Data Instructions
65.27 µs 3.35 µs P:Indir. (Bit) 65.27 µs 3.35 µs OUTF 49.8 µs + 5.4 µs x N 4.3 µs X, Y, C K:Constant (N pt) None 42.3 µs 2.2 µs C–11 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 203: Logical Instructions
P:Indir. (Bit) 222.2 µs 3.8 µs V:Data Reg. 175.3 µs 3.9 µs V:Bit Reg 175.3 µs 3.9 µs P:Indir. (Data) 219.9 µs 3.9 µs P:Indir. (Bit) 219.9 µs 3.9 µs C–12 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 204 V:Data Reg. 80.9 µs 3.8 µs V:Bit Reg. 80.9 µs 3.8 µs DIVB K:Constant 77.25 µs 3.8 µs P:Indir. (Data) 124.9 µs 3.8 µs P:Indir. (Bit) 124.9 µs 3.8 µs C–13 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 205: Bit Instructions
136.1 µs + 20.8 µs x N 3.25 µs Vdata/Bit Reg (N pt) MOVMC V: Data/Bit Reg <=> E (N pt) 86.0 µs + 30.7 µs x N LDLBL K: Constant 33.2 µs C–14 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 206: Cpu Control Instructions
X, Y, C, T, CT, SP, S, V 1691.0 µs 4.2 µs V:Data Reg. 1691.0 µs 4.2 µs V:Bit Reg. 1691.0 µs 4.2 µs P:Indir. (Data) 1726.0 µs 4.2 µs P:Indir. (Bit) 1726.0 µs 4.2 µs C–15 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 207: Message Instructions
38.9 µs 38.9 µs CVJMP 26.0 µs 26.0 µs Drum Instructions Drum Instructions DL05 Instruction Legal Data Types Execute Not Execute DRUM 1204.0 µs 398.2 µs EDRUM 989.2 µs 421.05 µs C–16 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 208: Word Bit Instructions
P:Indir. (Bit) 68.4 µs 63.7 µs V:Data Reg. 9.8 µs 4.8 µs V:Bit Reg. 9.8 µs 4.7 µs RSTB P:Indir. (Data) 35.1 µs 30.0 µs P:Indir. (Bit) 68.7 µs 63.7 µs C–17 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 209 Appendix C: Instruction Execution Times Notes C–18 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 210: Appendix D: Special Relays
In This Appendix: DL05 PLC Special Relays ....... . .D–2...
Page 211 On when the mode switch is in the STOP position. SP20 Forced stop mode On when the STOP instruction is executed. SP22 Interrupt enabled On when interrupts have been enabled using the ENI instruction. D–2 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 212 Data error On if a BCD number is expected and a non–BCD number is encountered. SP76 Load zero On when any instruction loads a value of zero into the accumulator. D–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 213 On when the counter current value equals the value in V2374 / V2375. SP567 Current = target value On when the counter current value equals the value in V2376 / V2377. D–4 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 214 PPENDIX PPENDIX SPEED NPUT AND ULSE UTPUT EATURES In This Chapter: Introduction ......... . .E–2 Choosing the HSIO Operating Mode .
Page 215: Appendix E: High-Speed Input And Pulse Output Features
Specifications DL05 Part Number Discrete Input Type Discrete Output Type High-Speed Input Pulse Output D0–05AR Relay D0–05DR Relay D0–05AD D0–05DD D0–05AA D0–05DA D0–05DR–D Relay D0–05DD–D E–2 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 216: Dedicated High-Speed I/O Circuit
The internal CPU’s main task is to execute the ladder program and read/write all I/O points during each scan. In order to service high-speed I/O events, the DL05 includes a special circuit which is dedicated to a portion of the I/O points. Refer to the DL05 block diagram in the figure below.
Page 217: Choosing The Hsio Operating Mode
Regular Output Default Mode Mode 60 (Filtered Inputs) is the default mode. The DL05 is initialized to this mode at the factory, and any time you reset V-memory scratchpad. In the default condition, X0–X2 are filtered inputs (10 ms delay) and Y0–Y1 are standard outputs E–4...
Page 218: Configuring The Hsio Mode
Bits 0 – 7 define the mode number 10, 20.. 60 previously referenced in this chapter. The example data “2050” shown selects Mode 50 – Pulse Catch (BCD = 50). The DL05 PLC ignores bits 8 - 12, 14 and 15 in V7633 (see System V-memory Map on page E-26).
Page 219: Mode 10: High-Speed Counter
Y2 - Y5 HSIO I/O data V-memory COUNTER Mode Select FILTER V7633 0010 Reset X1-X2 X3-X7 Input Circuit Next, we will discuss how to program the high-speed counter and its presets. E–6 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 220: Wiring Diagram
Signal Common Interfacing to Counter Outputs The DL05’s DC inputs are flexible in that they detect current flow in either direction, so they can be wired to a counter with either sourcing or sinking outputs. In the following circuit, a counter has open-collector NPN transistor outputs.
Page 221: Setup For Mode 10
Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use BCD 10 in the lower byte of V7633 to select the High-Speed Counter Mode. The DL05 does not use bits 8 - 12, 14 and 15 in V7633.
Page 222: Preset Data Starting Location
V2341 / V2340 SP550 V2371 / V2370 SP564 V2343 / V2342 SP551 V2373 / V2372 SP565 V2345 / V2344 SP552 V2375 / V2374 SP566 V2347 / V2346 SP553 V2377 / V2376 SP567 E–9 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 223: Calculating Your Preset Values
SP relay contact closure (instead, X2 will be on during the interrupt routine, for 1 scan). Or finally, X2 may be left simply as a filtered input. E–10 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 224: Writing Your Control Program
‘0107’ are set in V7636 and preset values are changed during program execution, the DL05 recognizes the changed preset values at the time of the reset. When ‘0207’ or ‘0307’ are set in V7636 the CPU does not check for changed preset values, so the DL05 has a faster reset time.
Page 225: Program Example: Counter Without Preset
Compare-double (CMPD) instruction to cause action at certain count values. Note that this allows you to have more than 24 “presets”. Then it configures X2 to be the external reset of the counter. E–12 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 226 Y0. This technique can make more than 24 comparisons, but it is scan-time dependent. However, use the 24 built-in presets with the interrupt routine if your application needs a very fast response time, as shown in the next example. E–13 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 227: Counter With Presets Program Example
When the lead screw turns, the counter device generates pulses which the DL05 can count. The three preset variables A, B, and C represent the positions (number of pulses) corresponding to each of the three grooves.
Page 228 X2. The X2 contact will be on (inside the interrupt routine only) if the interrupt was caused by the external reset, X2 input. E–15 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 229: Counter With Preload Program Example
V1076-V1077. Enable the counter by setting C0, when the preolad pulse on C1 has occurred (C1 is off). END coil marks the end of the main program. E–16 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 230: Troubleshooting Guide For Mode 10
1. Check the LED status indicator for X2 to make sure it is active when you want a reset. Or, if you are using an internal reset, use the status mode of DirectSOFT 5 to monitor the reset input to the counter. E–17 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 231: Mode 20: Quadrature Counter
Phase A’s rising edge (indicates counter-clockwise motion), the counter counts DOWN. 90˚ phase shift Leading Edge Signal Clockwise sequence Phase A Phase B Counterclockwise sequence Phase A Phase B one cycle Leading Edge Signal E–18 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 232: Wiring Diagram
Encoder Interfacing to Encoder Outputs The DL05’s DC inputs are flexible in that they detect current flow in either direction, so they can be wired to an encoder with either sourcing or sinking outputs. In the following circuit, an encoder has open-collector NPN transistor outputs. It sinks current from the PLC input point, which sources current.
Page 233: Setup For Mode 20
Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use BCD 20 in the lower byte of V7633 to select the High-Speed Counter Mode. The DL05 does not use bits 8 - 12, 14 and 15 in V7633.
Page 234: Writing Your Control Program
Appendix E: High-speed Input and Pulse Output Features Writing Your Control Program You may recall that the Up-Down counter instruction is standard in the DL05 instruction set. Refer to the figure below. The mnemonic for the counter is UDC (up-down counter).
Page 235 SP60 END coil marks the end of the main program. * NOTE: You can reset Y0 and Y1 at a convenient stage in the program by using the RST instruction. E–22 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 236: Counter Preload Program Example
V7636 for X2 is set to 7. Or, if you are using an internal reset, use the status mode of DirectSOFT 5 to monitor the reset input to the counter. E–23 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 237: Mode 30: Pulse Output
HSIO function automatically calculates the entire motion profile. The figure below shows the DL05 generating pulse and direction signals to the drive amplifier of a stepper positioning system. The pulses accomplish the profile independently and without interruption to ladder program execution in the CPU.
Page 238: Functional Block Diagram
Hopefully, the above discussion will explain why some I/O reference names have dual meanings in Pulse Output Mode. Please read the remainder of this section with care, to avoid confusion about which actual I/O function is being discussed. E–25 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 239: Wiring Diagram
The pulse signals from Y0 and Y1 outputs will typically go to drive input circuits as shown above. Remember that the DL05’s DC outputs are sinking-only. It will be helpful to locate equivalent circuit schematics of the drive amplifier. The following diagram shows how to interface to a sourcing drive input circuit.
Page 240: Motion Control Profile Specifications
Preload Position Value – if motion is stopped and Start Profile is off, you can load a new value in CT76/CT77, and turn on Y1. At that transition, the value in CT76/CT77 becomes the current position. E–27 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 241: Setup For Mode 30
Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use BCD 30 in the lower byte of V7633 to select the High-Speed Counter Mode. The DL05 does not use bits 8 - 12, 14 and 15 in V7633.
Page 242: Profile Parameter Table
Units V2320 Velocity Profile 2000 only – V2321/ 2322 Direction Select 80000000=CCW, 0=CW Pulses V2323 Velocity 4 to 700 x 10 pps V2326 Error Code (see end of section) – E–29 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 243: Choosing The Profile Type
Only the first velocity value needs to be defined. The remaining velocity values can be created while motion is in progress. Arrows in the profile Time shown indicate velocity changes. E–30 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 244: Trapezoidal Profile Operation
HSIO counter. If the ladder program loads a new value in CT76/CT77 (V1076/V1077), then energizing Y1 will copy that value into the HSIO circuit counter. This must occur before the profile begins, because the HSIO ignores Y1 during motion. E–31 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 245: Trapezoidal Profile Program Example
O u tp u t this constant to V7636, configuring X2. V7636 * If the Locate Parameter Table is not used you must remove both the LDA function and the OUT function below it. E–32 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 246: Preload Position Value
Velocity V1076 Turn on Y1 for 1 scan. The of f -to-on transition causes the HSIO to preload the current position with the value E–33 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 247: Registration Profile Operation
Y0 to start the profile. Immediately the HSIO turns off the Profile Complete signal (SP104), so the ladder program can monitor the move’s completion by sensing the signal’s on state. E–34 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 248: Registration Profile Program Example
Output this constant to V7636, configuring X2, the registration interrupt input. V7636 * If the Locate Parameter Table is not used you must remove both the LDA function and the OUT function below it. E–35 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 249 The profile will begin when the start input (X3) is given. Then the motion begins an indefinite move, which lasts until an external interrupt on X2 occurs. Then the motion continues on for 5000 more pulses before stopping. E–36 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 250: Home Search Program Example
V7636, configuring X2, the V7636 registration interrupt input. V7637 * If the Locate Parameter Table is not used you must remove both the LDA function and the OUT function below it. E–37 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 251 If the CW limit is encountered, the program searches for home in the CCW direction, passes it slightly, and does the final CW search for home. After reaching home, the last ladder rung preloads the current position to “0”. E–38 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 252: Velocity Profile Operation
Unlike the trapezoidal and registration profiles, you must specify the desired direction of travel with velocity profiles. Load the direction select register (V2321/V2322 by default) with 8000 0000 hex for CCW direction, or 0 for CW direction. E–39 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 253: Velocity Profile Program Example
Output this constant to V7636, configuring X2. V7636 * If the Locate Parameter Table is not used you must remove both the LDA function and the OUT function below it. E–40 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 254 Load the constant K600 which is required to select a velocity of 6000 pps when the operator closes X4. K600 Output this constant to V2323, the location of the velocity parameter register . The speed will change immediately. V2323 E–41 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 255: Pulse Output Error Codes
Error code descriptions are given above. 3. Check target value – The profile will not pulse if the count value is equal to the target value (ex. count = 0, target= 0) E–42 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 256: Symptom: The Motor Turns In The Wrong Direction
1. Wiring – If you have selected CW and CCW type operation, just swap the wires on Y0 and Y1 outputs. 2. Direction control – If you have selected Pulse and Direction type operation, just change the direction bit to the opposite state. E–43 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 257: Mode 40: High-Speed Interrupts
In this configuration, inputs X0 through X2 are filtered inputs. DL05 Output Circuit Y0, Y1 Y2 - Y5 HSIO I/O data Interrupt Interrupt V-memory Timer FILTER Mode select V7633 0040 X0, X1, X2 X3 - X7 Input Circuit E–44 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 258: Setup For Mode 40
Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use BCD 40 in the lower byte of V7633 to select the High-Speed Counter Mode. The DL05 does not use bits 8 - 12, 14 and 15 in V7633.
Page 259: External Interrupt Timing Parameters
CPU will continuously call the interrupt routine based on the time setting in V7647. Input Configuration Register Function Hex Code Required – V7647 High-Speed Timed Interrupt xxxx (xxxx = timer setting) 5- 9999 ms (BCD) E–46 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 260: External Interrupt Program Example
Interrupt Routine Insert interrupt service routine rungs here for your application. Use the pulse catch input to set output Y5 on. SETI Return to the main ladder program. E–47 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 261: Timed Interrupt Program Example
Load constant K1 into the accumulator. Add the value in the accumulator with the value in memory location V2000. V2000 Output the result into memory location V2000. V2000 Return to the main ladder program. E–48 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 262: Mode 50: Pulse Catch Input
NOTE The pulse catch and filtered input functions are opposite in nature. The pulse catch feature on X0 seeks to capture narrow pulses, while the filter input feature on X1 and X2 seeks to reject narrow pulses. E–49 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 263: Setup For Mode 50
Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use BCD 50 in the lower byte of V7633 to select the High-Speed Counter Mode. The DL05 does not use bits 8 - 12,14 and 15 in V7633.
Page 264: Pulse Catch Program Example
Use the pulse catch input to set output Y0 on. This will work even for a very short pulse on X0. END coil marks the end of the main program. E–51 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 265: Mode 60: Discrete Inputs With Filter
In this case, the logical input to the ladder program remains in the OFF state (input pulse was filtered out). Filter Time Filter Time Physical Input Logical Input Time Physical Input Logical Input E–52 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 266: Setup For Mode 60
Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use BCD 60 in the lower byte of V7633 to select the High-Speed Counter Mode. The DL05 does not use bits 8 - 12,14 and 15 in V7633.
Page 267: Filtered Inputs Program Example
50 ms filter time constant. K5006 Output this constant to V7636, configuring X2. V7636 Main Program Insert Main Program rungs here for your application. END coil marks the end of the main program.. E–54 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 268 DL05 PLC Memory ........F–2...
Page 269: Appendix F: Plc Memory
When designing a PLC application, it is important for the PLC user to understand the different types of memory in the PLC. The DL05 PLC uses two types of memory: RAM and EEPROM. RAM is Random Access Memory and EEPROM is Electrically Erasable Programmable Read Only Memory.
Page 270: Non-Volatile V-Memory In The Dl05
V7400 = 1111 V7400 = 1111 K2222 OUT V7400 V7400 = 2222 V7400 = 1111 Not changed Cycle power Copy V7400 = 1111 V7400 = 1111 This appears to be previous data returning. DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 271 Appendix F: PLC Memory Notes DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 272: Ascii Table
PPENDIX PPENDIX PPENDIX ASCII T ABLE In this Appendix ASCII Conversion Table ........G–2...
Page 273 Appendix G: ASCII Table DECIMAL TO HEX TO ASCII CONVERTER ASCII ASCII ASCII ASCII space “ & ‘ < > DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 274: Product Weight Table
PPENDIX PPENDIX RODUCT EIGHTS In This Appendix: Product Weight Table ........H–2...
Page 275 0.60 lb. (272g) D0–05DR 0.60 lb. (272g) D0–05AD 0.58 lb. (263g) D0–05DD 0.56 lb. (254g) D0–05AA 0.60 lb. (272g) D0–05DA 0.60 lb. (272g) D0–05DR–D 0.56 lb. (254g) D0–05DD–D 0.58 lb. (263g) H–2 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 276 PPENDIX PPENDIX PPENDIX UMBERING YSTEMS In this Appendix Introduction ......... . .I–2 Binary Numbering System .
Page 277: Appendix I: Numbering Systems
213 (1*2 + 1*2 +1*2 + 1*2 +1*2 or 128 + 64 + 16 Binary/Decimal Bit Pattern Bit # Power Decimal Bit Value 65535 Max Value Table 2 I–2 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 278: Hexadecimal Numbering System
“h” at the end is just a label to make sure we know that it is a hex number. Also, D8AF can be written with a labeling prefix as “0xD8AF”. I–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 279: Octal Numbering System
= 0 x 3 x 8 = 3 x 7 x 8 = 7 x 64 = 448 4 x 8 = 4 x 512 = 2048 2520 decimal equivalent I–4 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 280: Binary Coded Decimal (Bcd) Numbering System
The first bit of the mantissa is typically assumed to be “1.fff ”, where “f ” is the field of fraction bits. The Internet can provide a more in-depth explanation of the floating point numbering system. One website to look at is: http://www.psc.edu/general/software/packages/ieee/ieee.html I–5 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 281: Bcd/Binary/Decimal/Hex/Octal -What Is The Difference
The unfortunate side effect is that unless the data type is documented, it’s difficult to know what the data type is unless it contains the letters A-F. I–6 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 282: Data Type Mismatch
Look at the following example and note the same value represented by the different numbering systems. 0100 0011 Binary 0001 0010 0011 0100 Binary Decimal Decimal 0110 0111 0100 0110 0110 0000 Octal Octal I–7 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 283: Signed Vs. Unsigned Integers
Two’s Complement Decimal Binary 0000 0000 0110 0100 -100 1111 1111 1001 1100 Table 12 More information about 2’s complement can be found on the Internet at the following websites: http://www.evergreen.edu/biophysics/technotes/program/2s_comp.htm I–8 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 284: Automationdirect.com Products And Data Types
Real number format is “Floating PT 32”. More available formats are, “BCD int 32”, “Unsigned int 32” and “Signed int 32”. I–9 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 285 Appendix I: Numbering Systems Notes I–10 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 286: Appendix J: European Union Directives (Ce)
PPENDIX PPENDIX PPENDIX UROPEAN NION (CE) IRECTIVES In This Appendix: European Union (EU) Directives ......J–2 Basic EMC Installation Guidelines .
Page 287: Member Countries
Ultimately, we are all responsible for our various pieces of the puzzle. As manufacturers, we must test our products and document any test results and/or installation procedures that are necessary to comply with the Directives. As a machine builder, you are responsible for J–2 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 288: General Safety
(as a whole) complies with these Directives and to keep up with applicable Directives and/or practices that are required for compliance. As of August 1, 2002, the DL05, DL06, DL205, DL206, DL305, and DL405 PLC systems manufactured by Koyo Electronics Industries, FACTS Engineering or HOST Engineering when properly installed and used, conform to the Electromagnetic Compatibility (EMC), Low Voltage Directive, and Machinery Directive requirements of the following standards.
Page 289: Special Installation Manual
World Wide Web at http://euro–op.eu.int/indexn.htm Another source is: British Standards Institution – Sales Department Linford Wood Milton Keynes MK14 6LE United Kingdom; the quickest contact is via the World Wide Web at http://www.bsi.org.uk J–4 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 290: Basic Emc Installation Guidelines
PLC system inputs should also be protected from voltage impulses by deriving their power from the same fused, filtered, and surge-suppressed supply. J–5 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 291: Internal Enclosure Grounding
IEC 1000–5–2 that the shield should be connected over its full perimeter to the wall, preferably using a conducting adapter, and not via a pigtail wire J–6 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 292: Analog And Rs232 Cables
100 ohm resistors at each 0V link connection in network and communications cables. Last Slave Master Slave n TXD 0V TXD 0V – – – – – – Termination Termination J–7 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 293: Shielded Cables Within Enclosures
Again, for further information on EU directives we recommend that you get a copy of our EU Installation Manual (DA–EU–M). Also, if you are connected to the World Wide Web, you can check the EU commission’s official site at: http://ec.europa.eu/index_en.htm J–8 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 294: Dc Powered Versions
Appendix J: European Union Directives (CE) DC Powered Versions Due to slightly higher emissions radiated by the DC powered versions of the DL05, and the differing emissions performance for different DC supply voltages, the following stipulations must be met: • The PLC must be housed within a metallic enclosure with a minimum amount of orifices.
Page 295 Appendix J: European Union Directives (CE) Notes J–10 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 296 PPENDIX PPENDIX PPENDIX NTRODUCTION TO ERIAL OMMUNICATIONS In this Appendix Introduction to Serial Communications ..... .K–2...
Page 297: Appendix K: Introduction To Serial Communications
Phone Jack Loop Port 1 Connections Port 2 Connections Back NOTE: Port 2 on the DL05 uses an RJ12 phone type connector (see page 4-4 and 4-5 for the cable connections. K–2 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 298 RXD– RXD– RTS+ RTS+ TXD+ TXD+ RTS– RXD+ RTS– RXD+ Cable: Use Belden CTS+ CTS+ 9841 or equivalent CTS– CTS– TXD– TXD– DL06 CPU Port 2 DL06 CPU Port 2 K–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 299: Communications Protocols
DirectSOFT programming software and to an operator interface. DirectNET protocol is available for use by a master or by a slave DL05 PLC. This, and the fact that it is ‘native’ protocol, makes it ideal for PLC-to-PLC communication over a point- to-point to multipoint network using the RX and WX instructions.
Page 300: Dl05 Port Specifications
RTS off delay time = 0ms Station Number = 1 Baud rate = 19200 Stop bits = 1 Parity = odd Format = Hex Echo Suppression = RS-422/485 (4-wire) or RS-232C K–5 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 301: Port Setup Using Directsoft 5 Or Ladder Logic Instructions
Appendix K: Introduction to Serial Communications Port Setup Using DirectSOFT 5 or Ladder Logic Instructions Port 2 on the DL05 can be configured for communications using the various protocols which have been previously mentioned. Also, the communications parameters can be configured to match the parameters in the other device(s) with which the PLC will be communicating.
Page 302: Port 2 Setup For Rll Using K-Sequence, Directnet Or Modbus Rtu
( Direct NET) xaaaaaaa ( Direct NET) & Modbus RTU _aaaaaaa (K-Seq. & pps0 ebbb xaaa aaaa Modbus RTU) 0 = Hex K-Sequence: 1-90 1 = ASCII Direct NET: 1-90 Modbus: 1-247 K–7 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 303: Port 2 Setup For Rll Using Ascii
1 = RS-485 (2 wire) 001 = 600 11 = Even 010 = 1200 011 = 2400 DL05/06: V7656 100 = 4800 101 = 9600 110 = 19200 111 = 38400 K–8 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 304 RS232-C/RS422, 19,200 baud, 8 data bits, V-memory buffer starting at V2000 and no flow control you would use the relay ladder logic shown below. K3012 V7655 K8670 V7656 O2000 V7650 K–9 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 305: K-Sequence Communications
The K-Sequence protocol can be used for communication with DirectSOFT 5, an operator interface or any other device that can be a K-Sequence master. The DL05 PLC can be a K- Sequence slave on either port 1 or port 2. The DL05 PLC cannot be a K-Sequence master.
Page 306: Step 3: Specify Master Memory Area
The number of bytes specified also depends on the type of data you want to obtain. For example, the DL05 Input points can be accessed by V-memory locations or as X input locations. However, if you only want X0 – X27, you’ll have to use the X input data type because the V-memory locations can only be accessed in 2-byte increments.
Page 307: Step 4: Specify Slave Memory Area
• DirectNET slaves – specify the same address in the WX and RX instruction as the slave’s native I/O address • Modbus DL405, DL205, or DL05 slaves – specify the same address in the WX and RX instruction as the slave’s native I/O address •...
Page 308: Communications From A Ladder Program
O40400 execution and switch from stage to stage allowing only one of them to be active at a time. C100 K–13 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 309: Modbus Rtu Communications
Modbus RTU protocol. The protocol is very common and is probably the closest thing to an “industry standard” protocol in existence. The DL05 can be a Modbus RTU slave on either port 1 or port 2, and it can be a Modbus TRU master on port 2. The RS 485 wiring standard may be used on port 2 for the Modbus RTU protocol only.
Page 310: Index
NDEX ASCII Constant Instruction, 5–112 ASCII Table, G-1 Accessing AUX Functions DECIMAL TO HEX TO ASCII via direct entry, A–3 CONVERTER, G-2 via DirectSOFT 5, A–3 ASCII to HEX Instruction, 5–90 via the Handheld Programmer, A–3 Auto tuning error, 8–47 Accumulating Fast Timer Instruction, 5–38 Auto Tuning Procedure, 8–44 Accumulating Timer Instruction, 5–38...
Page 311 Drum Control Techniques, 6–10 Drum Instruction, 6–12 Changing Modes, 3–7 Drum Introduction, 6–2 Features, 3–2 Chart Representation, 6–3 Hardware Setup, 3–4 Terminology, 6–2 Mode Switch, 3–6 Drum Operation, 6–8 Operation, 3–11 Specifications, 3–3 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 312 Instructions, C–16 HEX to ASCII Instruction, 5–91 Table Instructions, C–14 Hexadecimal Numbering System, I–3 Timer, Counter and Shift Register, C–10 High- Speed I/O Word Bit Instructions, C–17 Configuring, E–5 Instruction List, 5–2 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 313 Move Memory Cartridge instruction, 10–15 High-Speed, E–44 Naming Cartridge, 10–6 Timed, E–46 Time instruction, 10–14 Timed Interrupt Program Example, 5–110 Write Enable/Disable Jumper, 10–3 Invert, 5–89 Memory Map, 3–22 Table, 3–28 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 314 Number Conversion Instructions, 5–87 Converging Processes, 7–19 Numbering Systems, 3–20, I-1 Parallel Processes, 7–19 Numerical Constant Instruction, 5–112 Part Number, 1–4, 1–5 Password, 3–10 Pause Instruction, 5–24 Octal Numbering System, I–4 Analog Filter, 8–53 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 315 PID Mode 2 Word Description, 8–22 PID Mode Setting 1 Description, 8–21 PLC Numbering Systems, 3–20 POP instruction, 5–58 Position Algorithm, 8–9, 8–15, 8–75 Position Form, 8–9 Ramp/Soak Generator, 8–56 Positive Differential Instruction, 5–18 Controls, 8–59 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 316 Stage Instruction Characteristics, 7–6 Shift Register Instructions, 5–35 Stage View, 7–18 Shift Register (SR), 5–47 State Diagrams, 7–3 Shift Right Instruction, 5–84 Supervisory Process, 7–17 Timer Inside a Stage, 7–13 Shuffle Digits Instruction, 5–94 DL05 Micro PLC User Manual, 6th Edition, Rev. A...
Page 317 Timer Fast Instruction, 5–36 Input Power, 2–11 Timer Instruction, 5–36 Power Input, 1–9 Timer Status Bit Map, 3–32 Write to Network Instruction, 5–122 Transfer Mode, 8–26 Trapezoidal Profile, E–30, E–32 Troubleshooting DL05 Micro PLC User Manual, 6th Edition, Rev. A...

Automation Direct DL05 User Manual

Chapter 6: Drum Instruction Programming

DL05 Drum Introduction

Step Transitions

Overview of Drum Operation

Drum Control Techniques

Drum Instruction

Event Drum (EDRUM) Instruction

Chapter 7: RLL PLUS Stage Programming

Introduction to Stage Programming

Learning to Draw State Transition Diagrams

Using the Stage Jump Instruction for State Transitions

Stage Program Example: Toggle On/Off Lamp Controller

Four Steps to Writing a Stage Program

Stage Program Example: a Garage Door Opener

Stage Program Design Considerations

Parallel Processing Concepts

RLL PLUS (Stage) Instructions

Questions and Answers about Stage Programming

Chapter 8: PID Loop Operation

DL05 PID Control

Introduction to PID Control

Introducing DL05 PID Control

PID Loop Operation

Ten Steps to Successful Process Control

PID Loop Setup

PID Loop Tuning

Use Directsoft 5 Data View with PID View

Use the Directsoft 5 Filter Intelligent Box Instruction

Ramp/Soak Generator

Directsoft 5 Ramp/Soak Example

Cascade Control

Time-Proportioning Control

Feedforward Control

PID Example Program

Troubleshooting Tips

Glossary of PID Loop Terminology

Bibliography

Chapter 9: Maintenance and Troubleshooting

Hardware System Maintenance

Diagnostics

CPU Indicators

Communications Problems

I/O Point Troubleshooting

Noise Troubleshooting

Machine Startup and Program Troubleshooting

Chapter 10 : Memory Cartridge/Real Time Clock

General Information about the D0-01MC

Setting the Write Enable/Disable Jumper

Plugging-In the Memory Cartridge

Software and Firmware Requirements

How to Update Your Directsoft Programming Software

Naming the Memory Cartridge

Setting the Time and Date

Memory Transfers

LED Indicator Lights

Password Protected Programs

Memory Map and Forwarding Range

Battery Back-Up During AC Power Loss

Specifications and Agency Approvals

Clock/Calendar Instructions

Error Codes

Appendix A: Auxiliary Functions

Introduction

Aux 2* Rll Operations

AUX 3* - V-Memory Operations

AUX 4* - I/O Configuration

AUX 5* - CPU Configuration

AUX 6* - Handheld Programmer Configuration

AUX 7* - EEPROM Operations

AUX 8* - Password Operations

Appendix B: DL05 Error Codes

DL05 Error Codes

Appendix C: Instruction Execution Times

Introduction

Instruction Execution Times

Appendix D: Special Relays

DL05 PLC Special Relays

Appendix E: High-Speed Input and Pulse Output Features

Introduction