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Automation Direct DL205 Manual

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DL205
Installation and I/O
Manual
Manual Number D2- - INST- - M

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Summary of Contents for Automation Direct DL205

  • Page 1 DL205 Installation and I/O Manual Manual Number D2- - INST- - M...
  • Page 2 WARNING Thank you for purchasing automation equipment from Automationdirect.comä. We want your new DirectLOGICä 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. To minimize the risk of potential safety problems, you should follow all applicable local and national codes that regulate the installation and operation of your equipment.
  • Page 3 AVERTISSEMENT Nous vous remercions d’avoir acheté l’équipement d’automatisation de Automationdirect.comä. Nous tenons à ce que votre nouvel équipement d’automatisation DirectLOGICä fonctionne en toute sécurité. Toute personne qui installe ou utilise cet équipement doit lire laprésente publication(et toutes les autres publications pertinentes)avant del’installer oude l’utiliser.
  • Page 4 Manual Revisions If you contact us in reference to this manual, be sure and include the revision number. Title: DL205 Installation and I/O Manual Manual Number: D2–INST–M Edition/Rev Date Description of Changes First Edition 10/98 original issue Rev A 04/01...

  • Page 5: Table Of Contents

    1–4 DL205 System I/O Components ............
  • Page 6 Table of Contents Solid State Input Sensors ............3–7 Solid State Output Loads .
  • Page 7 A–8 Items Specific to the DL205 ............

  • Page 8: Chapter 1: Introduction

    Introduction In This Chapter..— About This Manual — Conventions Used — CPU-slot Controllers — DL205 System Components...

  • Page 9: The Purpose Of This Manual

    This manual is written for the user of this Manual non-traditional CPU-slot controllers or I/O controllers who are also using our DL205 I/O products. This manual shows you how to install and wire the equipment. It provides specifications for input and output modules.

  • Page 10: Conventions Used

    This information could prevent injury, loss of property, or even death (in extreme cases). The word WARNING: in boldface will mark the beginning of the text. DL205 Installation and I/O Manual, Rev. B...

  • Page 11: Cpu-Slot Controllers

    Getting Started CPU-slot Controllers There are currently six “base controllers” or “I/O controllers” available for the DL205. Five of the six require connection to a PC running PC-based Control software. The sixth contains the CPU and operating system onboard the module.

  • Page 12: Dl205 System I/O Components

    The number of I/O points that can be supported is CPU–slot controller dependent. I/O Modules The DL205 has some of the most powerful modules in the industry. A complete range of discrete modules which support 24 VDC, 110/220 VAC and up to 10A relay outputs are offered.

  • Page 13: Chapter 2: Installation And Power Wiring

    Installation and Power Wiring In This Chapter..— Safety Guidelines — Mounting Guidelines — Installing DL205 Bases — Installing Components in the Base — Base Wiring Guidelines...

  • Page 14: Plan For Safety

    At a minimum, you should follow these regulations. Using the techniques listed below will further help reduce the risk of safety problems. • Orderly system shutdown sequence in the control program. • Emergency stop switch for disconnecting system power. DL205 Installation and I/O Manual, Rev. B...

  • Page 15: Orderly System Shutdown

    In this case, you may want to use retentive memory locations, or include constants in the control program to ensure a known starting point. DL205 Installation and I/O Manual , Rev. B...

  • Page 16: Mounting Guidelines

    Installation and Wiring Mounting Guidelines Before installing the DL205 system you will need to know the dimensions for the components. The diagrams on the following pages provide the component dimensions to use in defining your enclosure specifications. Remember to leave room for potential expansion.

  • Page 17: Panel Mounting And Layout

    2–5 Installation and Wiring Panel Mounting It is important to design your panel properly to help ensure the DL205 products and Layout operate within their environmental and electrical limits. The system installation should comply with all appropriate electrical codes and standards. It is important the system also conforms to the operating standards for the application to insure proper performance.

  • Page 18: Enclosures

    Remove anodized finishes and use copper lugs and star washers at termination points. A general rule is to achieve a 0.1 ohm of DC resistance between the DL205 base and the single point ground.

  • Page 19: Environmental Specifications

    The following table lists the environmental specifications that generally apply to the Specifications DL205 bases and I/O modules (Be sure to check the specifications of the CPU-slot controller you are using). I/O module operation may fluctuate depending on the ambient temperature and your application. Please refer to the appropriate I/O module specifications for the temperature derating curves applying to specific modules.

  • Page 20: Component Dimensions

    2–8 Installation and Wiring Component Before installing your DL205 system you will need to know the dimensions for the Dimensions components in your system. The diagrams on the following pages provide the component dimensions and should be used to define your enclosure specifications.

  • Page 21: Installing Dl205 Bases

    Available power budget Mounting the Base All I/O configurations of the DL205 may use any of the base configurations. The bases are secured to the equipment panel or mounting location using four M4 screws in the corner tabs of the base. The full mounting dimensions are given in the previous section on Mounting Guidelines.
  • Page 22 2–10 Installation and Wiring Using Mounting The DL205 bases can also be secured to the cabinet by using mounting rails. You Rails should use rails that conform to DIN EN standard 50 022. Refer to our catalog for a complete line of DIN rail and DINnectors, DIN rail mounted apparatus. These rails are approximately 35mm high, with a depth of 7.5mm.

  • Page 23: Installing Components In The Base

    DL205 base WARNING: Minimize the risk of electrical shock, personal injury, or equipment damage. Always disconnect the system power before installing or removing any system component. DL205 Installation and I/O Manual , Rev. B...

  • Page 24: Base Wiring Guidelines

    DL205 bases. The base terminals 110/220 VAC Base Terminal Strip can accept up to 16 AWG. You may be able to use larger wiring depending on the type of wire used, but 16 AWG is the 85 –...

  • Page 25: Chapter 3: I/O Wiring And Specifications

    I/O Wiring and Specifications In This Chapter..— I/O Wiring Strategies — I/O Modules Position, Wiring, and Specifications — Glossary of Specification Terms...

  • Page 26: Dl205 System Isolation Boundaries

    Isolation boundaries protect the operator interface (and the operator) from power input faults or field wiring faults. When wiring a DL205 system, it is extremely important to avoid making external connections that connect logic side circuits to any other.

  • Page 27: Powering I/O Circuits With The Auxiliary Supply

    +24VDC auxiliary supply. Powering I/O All AC powered DL205 bases feature the internal auxiliary supply. If input devices AND output loads need +24VDC power, the auxiliary supply may be able to power Circuits with the both circuits as shown in the following diagram.

  • Page 28: Powering I/O Circuits Using Separate Supplies

    It is most convenient if the loads can use the same power source as the DL205 system, and the input sensors can use the auxiliary supply, as shown to the left in the figure below.

  • Page 29: Sinking / Sourcing Concepts

    “sinking” input. To properly connect the Input external supply, you will have to connect it (sinking) so the input provides a path to ground (–). Start at the DL205 system input terminal, Input follow through the input sensing circuit, Sensing –...
  • Page 30 DC supply connects to the common terminals. Some symbols you will see on the wiring labels, and their meanings are: AC supply DC supply AC or DC supply D2-16ND3-2 – Input Switch Output Load DL205 Installation and I/O Manual, Rev. B...

  • Page 31: Connecting Dc I/O To "Solid State" Field Devices

    DC power to an actuator. Several of the DL205 DC output modules are the sinking type. This means that each DC output provides a path to ground when it is energized. In the following circuit, the output point sinks current to the output common when energized.
  • Page 32 In the next example a sinking DC output point is connected to the sinking input of a field device. This is a little tricky, because both the DL205 system output and field device input are sinking type. Since the circuit must have one sourcing and one sinking device, a sourcing capability needs to be added to the DL205 system output by using a pull-up resistor.
  • Page 33 3–9 I/O Wiring and Specifications Relay Output Six output modules in the DL205 I/O family feature relay outputs: D2–04TRS, Guidelines D2–08TR, D2–12TR, D2–08CDR, F2–08TR and F2–08TRS. Relays are best for the following applications: • Loads that require higher currents than the solid-state outputs can deliver •...
  • Page 34 Suppressors, LiteOn 12/24 VDC or VAC P6K30CAGICT–ND Diodes; from DigiKey Catalog; Phone: Diode 12/24 VDC or VAC 1N4004CT–ND 1-800-344-4539 Harris Metal Oxide 110/120 VAC V150LA20C Varistors; from Newark 220/240 VAC V250LA20C Catalog; Phone: 1-800-463-9275 DL205 Installation and I/O Manual, Rev. B...
  • Page 35 High current inductive loads such as clutches, brakes, motors, direct-acting solenoid valves, and motor starters will benefit the most from external contact protection. DL205 Installation and I/O Manual, Rev. B...
  • Page 36 = 0.05 mF, voltage rating w 170 Volts C (mF) = R (W) = , where x= 10 x I 169.7 = 26 W, 1/2 W, " 5% = 1.29 R (W) = 1.29 169.7 10 x 0.707 DL205 Installation and I/O Manual, Rev. B...
  • Page 37 DO NOT use a small-signal diode such as 1N914, 1N941, etc. Be sure the diode is in the circuit correctly before operation. If installed backwards, it short-circuits the supply when the relay energizes. DL205 Installation and I/O Manual, Rev. B...
  • Page 38 I/O Modules Position, Wiring, and Specification Slot Numbering The DL205 bases each provide different numbers of slots for use with the I/O modules. You may notice the bases refer to 3-slot, 4-slot, etc. One of the slots is dedicated to the CPU-slot controller, so you always have one less I/O slot. For example, you have five I/O slots with a 6-slot base.
  • Page 39 (installed) behind terminal cover Color Coding of I/O The DL205 family of I/O modules have a color coding scheme to help you quickly Modules identify if the module as either an input module, output module, or a specialty module. This is done through a color bar indicator located on the front of each module.
  • Page 40 WARNING: For some modules, field device power may still be present on the terminal block even though the DL205 system is turned off. To minimize the risk of electrical shock, check all field device power before you remove the connector.
  • Page 41 (DIN rail mounted Fuses) NOTE: For modules which have soldered or non-replaceable fuses, we recommend you return your module to us and let us replace your blown fuse(s) since disassembling the module will void your warranty. DL205 Installation and I/O Manual, Rev. B...
  • Page 42 It is greater than the normal ON state current and is characteristic of inductive loads in AC circuits. Base Power Power from the base power supply is used by the DL205 input modules and varies between different modules. The guidelines for using module power are explained in the power budget Required section of the manual for your CPU-slot device.
  • Page 43 12–24VDC 24 VDC module’s first 8 input points. Positon B displays the input status of the module’s Configuration shown is current sinking second group of 8 input points. Configuration shown is current sinking DL205 Installation and I/O Manual, Rev. B...
  • Page 44 CII CII Current Flow Internal module circuitry 24VDC COM III – CIII INPUT CIII To Logic Current Flow Optical 24VDC Isolator – COM IV 24 VDC Configuration shown is current sinking 22–26VDC 4–6mA CLASS2 DL205 Installation and I/O Manual, Rev. B...
  • Page 45 CIII CIII – COM IV 50 55 C ° 122 131 F ° Internal module circuitry Ambient Temperature (°C/°F) INPUT To Logic 5–15VDC Optical Isolator 4–14mA CLASS2 5–15VDC Configuration shown is current sinking DL205 Installation and I/O Manual, Rev. B...
  • Page 46 80 132VAC 220VAC 10 20mA 10 20mA 50/60Hz 50/60Hz Internal module circuitry Internal module circuitry D2–08NA-1 INPUT D2–08NA-2 INPUT To LED To LED Optical Optical Isolator Isolator Line Line 110 VAC 220 VAC DL205 Installation and I/O Manual, Rev. B...
  • Page 47 Optical Isolator the LEDs display the input status of the Line module’s first 8 input points. Positon B 110 VAC displays the input status of the module’s second group of 8 input points. DL205 Installation and I/O Manual, Rev. B...
  • Page 48 (Duration x cycles) / 60. Our example would be (60x.1) / 60 = .1 (10% duty cycle). 24VDC – To LED Output D2–04TD1 6.3A 12–24 Optical – Isolator Common Other Circuits DL205 Installation and I/O Manual, Rev. B...
  • Page 49 When the AB switch is in the A position, the LEDs display the output status of the module’s first 8 output points. Positon B displays the output status of the mod- ule’s second group of 8 output points. DL205 Installation and I/O Manual, Rev. B...

  • Page 50: D2-32Td2 Dc Output

    COM IV V IV Current Flow Internal module circuitry Equivalent Input Circuit 12–24VDC Fuse 12–24VDC – 12–24VDC Internal module circuitry 0.1A Optical Isolator CLASS2 Optical Isolator To LED D2–08TD2 Output To LED OUTPUT (Y0) DL205 Installation and I/O Manual, Rev. B...

  • Page 51: D2-16Td2-2 Dc Output

    From Logic 12–24 the LEDs display the output status of the OUTPUT module’s first 8 output points. Positon B displays the output status of the mod- ule’s second group of 8 output points. DL205 Installation and I/O Manual, Rev. B...

  • Page 52: D2-08Ta Ac Output

    Internally 50-60Hz connected 1.5A 15-264VAC 10mA-0.5A 50/60Hz 20–125VAC C0–3 C0–3 20–125VAC C4–7 C4–7 Internal module circuitry Internal module circuitry OUTPUT OUTPUT Optical Isolator To LED To LED D2–08TA Line 20–125 Line 6.3A 110–220 DL205 Installation and I/O Manual, Rev. B...

  • Page 53: D2-12Ta Ac Output

    When the AB switch is in the A position, the LEDs display the output status of the module’s first 8 output points. Positon B displays the output status of the mod- ule’s second group of 8 output points. DL205 Installation and I/O Manual, Rev. B...

  • Page 54: D2-04Trs Relay Output

    At 220 VAC, solenoid (inductive) loads over 2A cannot be used. D2–04TRS 5 240VAC 4A 50/60Hz 5-30VDC 10mA-4A Internal module circuitry 5–30 VDC 5–240 VAC OUTPUT To LED Line 6.3A 5–30 VDC 5–240 VAC D2–04TRS DL205 Installation and I/O Manual, Rev. B...

  • Page 55: D2-08Tr Relay Output

    50 55 C ° 1A 50/60Hz 5-30VDC 5–30 VDC 122 131 F ° 5mA-1A Internally 5–240 VAC connected Ambient Temperature (°C/°F) Internal module circuitry OUTPUT To LED D2–08TR Line 6.3A 5–30 VDC 5–240 VAC DL205 Installation and I/O Manual, Rev. B...

  • Page 56: F2-08Tr Relay Output

    12–250VAC Internal Circuitry Line C 0-3 Common NO 2 NO 3 NO 3 NO 4 NO 4 NO 5 NO 5 C 4-7 C 4–7 NO 6 NO 6 NO 7 NO 7 DL205 Installation and I/O Manual, Rev. B...

  • Page 57: F2-08Trs Relay Output

    NO 4 NO 5 Internal Circuitry 12–250VAC NO 5 Line NC 6 NC 6 normally closed NC 7 Common NC 7 normally closed 12–28VDC NO 6 12–250VAC 12–28VDC 12–250VAC NO 6 NO 7 DL205 Installation and I/O Manual, Rev. B...

  • Page 58: D2-12Tr Relay Output

    8 output points. Positon B displays the output status of the mod- Yn+2 Yn+12 ule’s second group of 8 output points. Yn+3 Yn+13 Yn+4 Yn+14 Yn+5 Yn+15 Yn+6 Yn+16 Yn+7 Yn+17 n is the starting address DL205 Installation and I/O Manual, Rev. B...

  • Page 59: D2-08Cdr 4 Pt. Dc Input / 4Pt. Relay Output

    Solenoid 100K D2-08CDR 20-28VDC INPUT 24VDC To LED – Optical Isolator 24VDC Internal module circuitry OUTPUT 5-240VAC 1A 50/60Hz 5-30VDC 5mA-1A 5–30 VDC To LED 5–240 VAC Line 6.3A 5–30 VDC 5–240 VAC DL205 Installation and I/O Manual, Rev. B...

  • Page 60: F2-04Ad-1 4 Channel 4-20Ma Analog Input

    To avoid “ground loop” errors, recommended 4–20mA transmitter types are: 2 or 3 wire: Isolation between input signal and power supply. 4 wire: Isolation between input signal, power supply, and 4–20mA output DL205 Installation and I/O Manual, Rev. B...

  • Page 61: F2-04Ad-1L 4 Channel 4-20Ma Analog Input

    To avoid “ground loop” errors, recommended 4–20mA transmitter types are: 4 wire: Isolation between input signal, power supply, and 4–20mA output 2 or 3 wire: Isolation between input signal and power supply. DL205 Installation and I/O Manual, Rev. B...

  • Page 62: F2-04Ad-2 4 Channel Voltage Analog Input

    CH2- 0-5VDC -5-+5VDC CH2+ – +24V A to D Voltage Converter CH3- CH1– Transmitter CH1+ CH3+ CH2– – CH4- CH2+ Voltage CH4+ Transmitter CH3– CH3+ CH4– – CH4+ Voltage Transmitter 0-10VDC -10-+10VDC F2–04AD–2 DL205 Installation and I/O Manual, Rev. B...

  • Page 63: F2-04Ad-2L 4 Channel Voltage Analog Input

    CH2- 0-5VDC -5-+5VDC CH2+ – +12V A to D Voltage Converter CH3- CH1– Transmitter CH1+ CH3+ CH2– – CH4- CH2+ Voltage CH4+ Transmitter CH3– CH3+ CH4– – CH4+ Voltage Transmitter 0-10VDC -10-+10VDC F2–04AD–2L DL205 Installation and I/O Manual, Rev. B...

  • Page 64: F2-08Ad-1 8 Channel 4-20Ma Analog Input

    To avoid “ground loop” errors, recommended 4–20mA transmitter types are: 2 or 3 wire: Isolation between input signal and power supply. 4 wire: Isolation between input signal, power supply, and 4–20mA output DL205 Installation and I/O Manual, Rev. B...

  • Page 65: F2-08Ad-2 8 Channel Voltage Analog Input

    CH5+ +24V Voltage CH6+ CH1+ Transmitter CH2+ CH3+ CH7+ CH7+ CH4+ Voltage CH5+ CH8+ Transmitter CH6+ CH7+ 0 VDC CH8+ F2–08AD–2 – Transmitter Supply Note 1: Connect unused channels (CH2+, CH4+,CH6+, CH8+, COM) DL205 Installation and I/O Manual, Rev. B...
  • Page 66 1. The three wires connecting the RTD to the module must be the same type and length. Do not use the shield or drain wire for the third connection. 2. If a RTD sensor has 4 wires, the plus sense wire should be left unconnected as shown. DL205 Installation and I/O Manual, Rev. B...

  • Page 67: F2-04Thm 4 Channel Thermocouple Input

    Supply Module CH3+ Supply 18–26.4VDC CH3– 18–26.4VDC CH4+ CH4– Note 1: Connect unused channels (CH4+,CH4–, Com) Note 1: Terminate shields at the respective signal source Note 2: Connect unused channels (CH4+,CH4–, Com) F2-04THM-n DL205 Installation and I/O Manual, Rev. B...

  • Page 68: F2-02Da-1(L) 2 Channel 4-20Ma Analog Output

    – output circuits upon loop power supply 24 VDC Loop Load range 12VDC for power supply F2–02DA–1 F2–02DA–1L 30 VDC 0 to 1200 24 VDC 0 to 910 18 VDC 0 to 620 DL205 Installation and I/O Manual, Rev. B...

  • Page 69: F2-02Da-2(L) 2 Channel Voltage Analog Output

    Ch 2 load CH2+ Converter 2K W +24V minimum Ch 2 CH1– Voltage sink/source CH1+ D to A CH2– Converter CH2+ Transient protected precision digital to analog converter output circuits 0-10VDC -10-+10VDC F2–02DA–2 DL205 Installation and I/O Manual, Rev. B...

  • Page 70: F2-08Da-1

    250 ohms 7–I 6–O 7–I typical 7–O 7–O 8–I 8–I 8–O Ch 8 load 8–O 250 ohms typical – 18–30VDC NOTE 1: Shields should be connected to the 0V terminal of the module. DL205 Installation and I/O Manual, Rev. B...

  • Page 71: F2-08Da-2 8-Channel Voltage Analog Output

    D to A NOTE 1: Shields should be connected to Converter to the 0V terminal of the module. Ch 8 Voltage source NOTE 1 D to A Ch 8 load Converter F2–08DA–2 1K–10K ohms minimum DL205 Installation and I/O Manual, Rev. B...

  • Page 72: F2-02Das-1 Isolated 2 Channel 4-20Ma Analog Output

    See NOTE 2 NOTE 1 –I1 – Loop Supply 4–20 mA current sourcing 12–32VDC –I2 Ch 2 load D to A 100 ohms 0–525 ohms –I2 Converter See NOTE 2 NOTE 1 F2–02DAS–1 DL205 Installation and I/O Manual, Rev. B...

  • Page 73: F2-02Das-2 Isolated 2 Channel Voltage Analog Output

    Note 3 F2-02DAS–2 Loop – Supply 24VDC 0-5VDC CH1-V 0-10VDC Voltage source CH1+V Note 1 Note 2 CH1–V Loop – Supply CH1+V 24VDC CH2-V Voltage source CH2+V Note 1 Note 2 CH2–V CH2+V F2–02DAS–2 DL205 Installation and I/O Manual, Rev. B...

  • Page 74: F2-4Ad2Da 4-Channel Analog Input / 2-Channel Analog Output

    Ch 1 load D to A CH2+ 0–910 W Converter (@ 24V) Ch 2 Current sinking F2-4AD2DA Ch 2 load 0–910 W – (@ 24V) Loop Supply See NOTE 8 See NOTE 1 DL205 Installation and I/O Manual, Rev. B...
  • Page 75 European Union Directives (CE) In This Appendix..European Union (EU) Directives Basic EMC Installation Guidelines...

  • Page 76: Appendix A: European Union Directives (Ce)

    You are also responsible for testing any combinations of products that may (or may not) comply with the Directives when used together. DL205 Installation and I/O Manual, Rev. B...

  • Page 77: Special Installation Manual

    Currently, the DL05, DL06, DL205, 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) and Low Voltage Directive requirements of the following standards.

  • Page 78: Basic Emc Installation Guidelines

    I/O common disconnect switch earthed *Ferrite choke Panel or on I/O wiring Panel Ground Braid Single Point Copper Lugs Ground Lock Nut Star Washers Lock Nut Illustrations are not to scale Star Washers DL205 Installation and I/O Manual, Rev. B...

  • Page 79: Electrostatic Discharge (Esd)

    PLC system inputs should also be protected from voltage impulses by deriving their power from the same fused, filtered, and surge-suppressed supply. DL205 Installation and I/O Manual, Rev. B...

  • Page 80: Internal Enclosure Grounding

    To Earth Block Equi-potential Bond Control Cubicle Good quality 24 AWG minimum twisted-pair shielded cables, with overall foil and braid shields are recommended for analog cabling and communications cabling outside of the PLC enclosure. DL205 Installation and I/O Manual, Rev. B...

  • Page 81: Analog And Rs232 Cables

    You can make special serial cables where the cable shield is connected to the enclosure’s earth ground at both ends, the same way as external cables are connected. DL205 Installation and I/O Manual, Rev. B...

  • Page 82: Network Isolation

    Input power cables must be externally fused and have an externally mounted switch or circuit breaker, preferably mounted near the PLC. Note: The DL205 internal base power supply has a 2A@250V slow blow fuse; however, it is not replaceable, so external fusing is required.

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