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Table of Contents

Power Flow Transition Technique

7–18

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Stage View in DirectSOFT

7–18

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Parallel Processing Concepts

7–19

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Parallel Processes

7–19

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Converging Processes

7–19

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Convergence Stages (CV)

7–19

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Convergence Jump (CVJMP)

7–20

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Convergence Stage Guidelines

7–20

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RLLPLUS (Stage) Instructions

7–21

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Staget (SG)

7–21

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Initial Staget (ISG)

7–22

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JUMP (JMP)

7–22

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Not Jump (NJMP)

7–22

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Converge Stage (CV) and Converge Jump (CVJMP)

7–23

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Questions and Answers about Stage Programming

7–25

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Chapter 8: PID Loop Operation

DL05 PID Loop Features

8–2

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Main Features

8–2

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The Basics of PID Loops

8–4

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Loop Setup Parameters

8–6

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Loop Table and Number of Loops

8–6

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PID Error Flags

8–6

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Establishing the Loop Table Size and Location

8–7

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Loop Table Word Definitions

8–8

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PID Mode Setting 1 Bit Descriptions (Addr + 00)

8–9

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PID Mode Setting 2 Bit Descriptions (Addr + 01)

8–10

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Mode / Alarm Monitoring Word (Addr + 06)

8–11

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Ramp / Soak Table Flags (Addr + 33)

8–11

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Ramp/Soak Table Location (Addr + 34)

8–12

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Ramp/Soak Table Programming Error Flags (Addr + 35)

8–12

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Loop Sample Rate and Scheduling

8–13

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Loop Sample Rates Addr + 07

8–13

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Choosing the Best Sample Rate

8–13

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Programming the Sample Rate

8–14

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PID Loop Effect on CPU Scan Time

8–15

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Ten Steps to Successful Process Control

8–17

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Step 1: Know the Recipe

8–17

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Step 2: Plan Loop Control Strategy

8–17

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Step 3: Size and Scale Loop Components

8–17

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Step 4: Select I/O Modules

8–17

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Step 5: Wiring and Installation

8–18

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Step 6: Loop Parameters

8–18

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Step 7: Check Open Loop Performance

8–18

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Step 8: Loop Tuning

8–18

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Summary of Contents for DL05

Page 1: ...DL05 User Manual Automationdirect com ...

Page 2: ...DL05 User Manual Automationdirect com ...

Page 3: ...ents requiring fail safe performance such as in the operation of nuclear facilities aircraft navigation or communication systems air traffic control direct life support machines or weapons systems in which the failure of the product could lead directly to death personal injury or severe physical or environmental damage High Risk Activities Automationdirect com specifically disclaims any expressed ...

Page 4: ...absolue par exemple l exploitation d installations nucléaires les systèmes de navigation aérienne ou de communication le contrôle de la circulation aérienne les équipements de survie ou les systèmes d armes pour lesquels la défaillance du produit peut provoquer la mort des blessures corporelles ou de graves dommages matériels ou environnementaux activités à risque élevé La société Automationdirect...

Page 5: ...scription of Changes Original 12 98 original issue 2nd Edition 2 00 added pid chapter analog module chapter and memory cartridge chapter 2nd Edition Rev A 7 00 added DC power 3rd Edition 11 01 removed MC and analog module chapters corrected drum in struction several minor corrections added PLC weights EU di rective additions 3rd Edition Rev A 7 02 Added new discrete option modules ...

Page 6: ...onnect the Programming Device 1 9 Step 5 Switch on the System Power 1 10 Step 6 Initialize Scratchpad Memory 1 10 Step 7 Enter a Ladder Program 1 10 Steps to Designing a Successful System 1 11 Step 1 Review the Installation Guidelines 1 11 Step 2 Understand the PLC Setup Procedures 1 11 Step 3 Review the I O Selection Criteria 1 11 Step 4 Choose a System Wiring Strategy 1 11 Step 5 Understand the ...

Page 7: ...I O Common Terminal Concepts 2 16 Connecting DC I O to Solid State Field Devices 2 17 Solid State Input Sensors 2 17 Solid State Output Loads 2 17 Relay Output Wiring Methods 2 19 Surge Suppresion For Inductive Loads 2 20 Prolonging Relay Contact Life 2 21 DC Input Wiring Methods 2 22 DC Output Wiring Methods 2 23 High Speed I O Wiring Methods 2 24 Glossary of Specification Terms 2 25 Wiring Diagr...

Page 8: ...l Specifications 2 41 DC Input Specifications 2 41 DC Output Specifications 2 41 D0 16ND3 DC Input 2 43 D0 10TD1 DC Output 2 44 D0 16TD1 DC Output 2 45 D0 10TD2 DC Output 2 46 D0 16TD2 DC Output 2 47 D0 07CDR DC Input and Output 2 48 D0 08TR Relay Output 2 49 D0 08CDD1 DC Input and Output 2 50 I O Addressing 2 51 Module I O Points and Addressing 2 51 Chapter 3 High Speed Input and Pulse Output Fea...

Page 9: ...ring Diagram 3 19 Interfacing to Encoder Outputs 3 19 Setup for Mode 20 3 20 X Input Configuration 3 20 Writing Your Control Program 3 21 Quadrature Counter w Preload Program Example 3 21 Program Example Cont d 3 22 Counter Preload Program Example 3 23 Troubleshooting Guide for Mode 20 3 23 Mode 30 Pulse Output 3 24 Purpose 3 24 Functional Block Diagram 3 25 Wiring Diagram 3 26 Interfacing to Driv...

Page 10: ...etup for Mode 40 3 45 Interrupts and the Ladder Program 3 45 External Interrupt Timing Parameters 3 46 Timed Interrupt Parameters 3 46 X Input Timed INT Configuration 3 46 Independent Timed Interrupt 3 46 External Interrupt Program Example 3 47 Timed Interrupt Program Example 3 48 Mode 50 Pulse Catch Input 3 49 Purpose 3 49 Functional Block Diagram 3 49 Pulse Catch Timing Parameters 3 49 Setup for...

Page 11: ...uts 4 15 Diagnostics 4 15 I O Response Time 4 15 Is Timing Important for Your Application 4 15 Normal Minimum I O Response 4 15 Normal Maximum I O Response 4 16 Improving Response Time 4 17 CPU Scan Time Considerations 4 18 Reading Inputs 4 18 Writing Outputs 4 18 Application Program Execution 4 19 PLC Numbering Systems 4 20 PLC Resources 4 20 V Memory 4 21 Binary Coded Decimal Numbers 4 21 Hexade...

Page 12: ...n 4 35 Network Slave Operation 4 36 MODBUS Function Codes Supported 4 36 Determining the MODBUS Address 4 36 If Your Host Software Requires the Data Type and Address 4 37 Example 1 V2100 4 38 Example 2 Y20 4 38 Example 3 T10 Current Value 4 38 Example 4 C54 4 38 If Your MODBUS Host Software Requires an Address ONLY 4 39 Example 1 V2100 584 984 Mode 4 40 Example 2 Y20 584 984 Mode 4 40 Example 3 T1...

Page 13: ... 5 11 And Store AND STR 5 12 Or Store OR STR 5 12 Out OUT 5 13 Or Out OR OUT 5 13 Not NOT 5 14 Positive Differential PD 5 14 Store Positive Differential STRPD 5 15 Store Negative Differential STRND 5 15 Or Positive Differential ORPD 5 16 Or Negative Differential ORND 5 16 And Positive Differential ANDPD 5 17 And Negative Differential ANDND 5 17 Set SET 5 18 Reset RST 5 18 Pause PAUSE 5 19 Comparat...

Page 14: ...g Comparative Contacts 5 34 Using Counters 5 35 Counter CNT 5 36 Counter Example Using Discrete Status Bits 5 37 Counter Example Using Comparative Contacts 5 37 Stage Counter SGCNT 5 38 Stage Counter Example Using Discrete Status Bits 5 39 Stage Counter Example Using Comparative Contacts 5 39 Up Down Counter UDC 5 40 Up Down Counter Example Using Discrete Status Bits 5 41 Up Down Counter Example U...

Page 15: ...B 5 73 Subtract Binary SUBB 5 74 Multiply Binary MULB 5 75 Divide Binary DIVB 5 76 Bit Operation Instructions 5 77 Sum SUM 5 77 Shift Left SHFL 5 77 Shift Right SHFR 5 79 Encode ENCO 5 80 Decode DECO 5 81 Number Conversion Instructions Accumulator 5 82 Binary BIN 5 82 Binary Coded Decimal BCD 5 83 Invert INV 5 84 ASCII to HEX ATH 5 85 HEX to ASCII HTA 5 86 Gray Code GRAY 5 88 Shuffle Digits SFLDGT...

Page 16: ...ogram Example 5 104 Timed Interrupt Program Example 5 105 Independent Timed Interrupt 5 105 Message Instructions 5 106 Fault FAULT 5 106 Fault Example 5 106 Data Label DLBL 5 107 ASCII Constant ACON 5 107 Numerical Constant NCON 5 107 Data Label Example 5 108 Print Message PRINT 5 109 Network Instructions 5 113 Read from Network RX 5 113 Write to Network WX 5 115 Chapter 6 Drum Instruction Program...

Page 17: ...7 4 Stage Equivalent 7 4 Let s Compare 7 5 Initial Stages 7 5 What Stage Bits Do 7 6 Stage Instruction Characteristics 7 6 Using the Stage Jump Instruction for State Transitions 7 7 Stage Jump Set and Reset Instructions 7 7 Stage Program Example Toggle On Off Lamp Controller 7 8 A 4 State Process 7 8 Four Steps to Writing a Stage Program 7 9 Stage Program Example A Garage Door Opener 7 10 Garage D...

Page 18: ...lags 8 6 Establishing the Loop Table Size and Location 8 7 Loop Table Word Definitions 8 8 PID Mode Setting 1 Bit Descriptions Addr 00 8 9 PID Mode Setting 2 Bit Descriptions Addr 01 8 10 Mode Alarm Monitoring Word Addr 06 8 11 Ramp Soak Table Flags Addr 33 8 11 Ramp Soak Table Location Addr 34 8 12 Ramp Soak Table Programming Error Flags Addr 35 8 12 Loop Sample Rate and Scheduling 8 13 Loop Samp...

Page 19: ...8 28 Process Variable PV Configuration 8 28 Control Output Configuration 8 29 Error Term Configuration 8 30 PID Algorithms 8 31 Position Algorithm 8 31 Velocity Algorithm 8 32 Direct Acting and Reverse Acting Loops 8 33 P I D Loop Terms 8 34 Using a Subset of PID Control 8 35 Derivative Gain Limiting 8 36 Bias Term 8 36 Bias Freeze 8 37 Loop Tuning Procedure 8 38 Open Loop Test 8 38 Manual Tuning ...

Page 20: ...ossary of PID Loop Terminology 8 64 Chapter 9 Maintenance and Troubleshooting Hardware System Maintenance 9 2 Diagnostics 9 2 CPU Indicators 9 6 Communications Problems 9 7 I O Point Troubleshooting 9 8 Noise Troubleshooting 9 10 Machine Startup and Program Troubleshooting 9 11 Appendix A Auxiliary Functions Introduction A 2 Purpose of Auxiliary Functions A 2 Accessing AUX Functions via DirectSOFT...

Page 21: ...M Operations A 8 Transferrable Memory Areas A 8 AUX 71 CPU to HPP EEPROM A 8 AUX 72 HPP EEPROM to CPU A 9 AUX 73 Compare HPP EEPROM to CPU A 9 AUX 74 HPP EEPROM Blank Check A 9 AUX 75 Erase HPP EEPROM A 9 AUX 76 Show EEPROM Type A 9 AUX 8 Password Operations A 9 AUX 81 Modify Password A 9 AUX 82 Unlock CPU A 10 AUX 83 Lock CPU A 10 Appendix B DL05 Error Codes Appendix C Instruction Execution Times...

Page 22: ...tput Relay D 4 Communication Monitoring Relays D 4 Equal Relays for HSIO Mode 10 Counter Presets D 4 Appendix E DL05 Product Weights Product Weight Table E 2 Appendix F European Union Directives CE European Union EU Directives F 2 Member Countries F 2 Special Installation Manual F 3 Other Sources of Information F 4 Basic EMC Installation Guidelines F 4 Enclosures F 4 Suppression and Fusing F 5 Int...

Page 23: ...ter Introduction Conventions Used DL05 Micro PLC Components Programming Methods I O Selection Quick Chart Quick Start for PLC Checkout and Programming Steps to Designing a Successful System Questions and Answers about DL05 Micro PLCs ...

Page 24: ...use any of the optional modules that are available for the DL05 PLC which includes the analog I O modules If you have purchased operator interfaces or DirectSOFT you will need to supplement this manual with the manuals that are written for these products We realize that even though we strive to be the best we may have arranged our information in such a way you cannot find what you are looking for ...

Page 25: ...raph to its immediate right will be a special note The word NOTE in boldface will mark the beginning of the text When you see the exclamation mark icon in the left hand margin the paragraph to its immediate right will be a warning 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 The beginning of e...

Page 26: ... Chapter 4 CPU Specifications and Operation The eight types of DL05 Micro PLCs provide a variety of Input Output choices listed in the following table DL05 Part Number Discrete Input Type Discrete Output Type External Power High Speed Input Pulse Output D0 05AR AC Relay 95 240 VAC No No D0 05DR DC Relay 95 240 VAC Yes No D0 05AD AC DC 95 240 VAC No Yes D0 05DD DC DC 95 240 VAC Yes Yes D0 05AA AC A...

Page 27: ...of field devices In several instances a particular Input or Output circuit can interface to either DC or AC voltages or both sinking and sourcing circuit arrangements Check this chart carefully to find the proper DL05 Micro PLC to interface to the field devices in your application DL05 P t N b INPUTS OUTPUTS Part Number I O type commons Sink Source Voltage Ranges I O type commons Sink Source Volta...

Page 28: ...ed up Step 1 Unpack the DL05 Equipment Unpack the DL05 and gather the parts necessary to build this demonstration system The recommended components are S DL05 Micro PLC S AC power cord or DC power supply S Toggle switches see Step 2 on next page S Hook up wire 16 22 AWG S DL05 User Manual this manual S A small screwdriver 5 8 flat or 1 Philips type You will need at least one of the following progr...

Page 29: ...tructions in the accompanying WARNING note Toggle Switches UL Listed D0 05AR D0 05AD D0 05AA AC input versions 120VAC only WARNING DO NOT wire the toggle switches as shown to 240VAC powered units The discrete inputs will only accept 120VAC nominal Also remove power and unplug the DL05 when wiring the switches Only use UL approved switches rated for at least 250VAC 1A for AC inputs Firmly mount the...

Page 30: ...e the connector covers Do not apply power at this time 110 220 VAC Power Input 95 240 VAC L N G 12 24 VDC Power Input 12 24 VDC G Step 4 Connect the Programming Device Most programmers will use DirectSOFT programming software installed on a personal computer Or you may need the portability of the Handheld Programmer Both devices will connect to COM port 1 of the DL05 via the appropriate cable Use ...

Page 31: ...the DL05 PLC change CPU modes to Run or Program and enter a program If you are learning how to program with the Handheld Programmer make sure the CPU is in Program Mode the RUN LED on the front of the DL05 should be off If the RUN LED is on use the MODE key on the Handheld Programmer to put the PLC in Program Mode Enter the following keystrokes on the Handheld Programmer ENT CLR 3 D TMR N 4 E SHFT...

Page 32: ...s and loads can affect your choice of I O type Input Sensing PLC Input Common It is important to understand the various system design options that are available before wiring field devices and field side power supplies to the Micro PLC 8 Inputs Commons Commons 6 Outputs Power Input PLC DL05 Loads 24 VDC AC Power Before you begin to enter a program it is very helpful to understand how the DL05 syst...

Page 33: ...mming Push UP UP DOWN LOWER RAISE LIGHT Timer Event Drum Sequencer Stage Programming see Chapter 5 see Chapter 6 see Chapter 7 X0 LDD V1076 CMPD K309482 SP62 OUT Y0 After reviewing the programming concepts above you ll be equipped with a variety of tools to write your application program Once you have installed the Micro PLC and understand the main programming concepts you can begin writing your a...

Page 34: ... presets with interrupt or a pulse direction output for stepper control Three types of motion profiles are available which are explained in Chapter 3 Q Are the ladder programs stored in a removable EEPROM A The DL05 contains a non removable FLASH memory for program storage which may be written and erased thousands of times You may transfer programs to from DirectSOFT on a PC or the HPP which does ...

Page 35: ...running on a personal computer S D2 HPP handheld programmer S Other devices which communicate via K sequence protocol should work with the DL05 Micro PLC Contact the vendor for details A Port 2 The port is RS 232C with selective baud rates 300 38 400bps address and parity It also supports the proprietary K sequence protocol as well as DirectNet and Modbus and non sequence print protocols Q Can the...

Page 36: ...nes Ċ Wiring Guidelines Ċ System Wiring Strategies Ċ Glossary of Specification Terms Ċ Wiring Diagrams and Specifications Ċ D0 10ND3 DC Input Ċ D0 16ND3 DC Input Ċ D0 10TD1 DC Output Ċ D0 16TD1 DC Output Ċ D0 10TD2 DC Output Ċ D0 16TD2 DC Output Ċ D0 07CDR DC Input and Output Ċ D0 08TR Relay Output Ċ D0 08CDD1 DC Input and Output ...

Page 37: ... personnel and equipment safety part of the planning process You should examine every aspect of the system to determine which areas are critical to operator or machine safety If you are not familiar with PLC system installation practices or your company does not have established installation guidelines you should obtain additional information from the following sources S NEMA The National Electric...

Page 38: ...C control program can turn off the saw blade and retract the arbor However since the operator must open the guard to remove the part you should also include a bypass switch that disconnects all system power any time the guard is opened The machinery must provide a quick manual method of disconnecting all system power The disconnect device or switch must be clearly labeled Emergency Stop To disconn...

Page 39: ...rminals From left to right the next five terminals are one of the input commons C0 and input connections X1 X3 X4 and X6 The remaining four connections are an output common C2 and output terminals Y1 Y3 and Y5 The lower section of the connector has the chassis ground G and the logic ground LG on the two left most terminals The next two terminals are for the inputs X0 and X2 Next is the other input...

Page 40: ...he connector block 2 From the center of the connector block pry upward with the screwdriver until the connector is loose The terminal block connector on DL05 PLCs have regular screw terminals which will accept either standard or 1 Philips screwdriver tips You can insert one 16 AWG wire under a terminal or two 18 AWG wires one on each side of the screw Be careful not to overtighten maximum torque i...

Page 41: ...low proper spacing from other components 4 8 120mm 3 8 95mm 2 6 65mm 2 72 68mm DIN Rail 4 0 100mm 3 4 85mm 0 40 10mm 0 20 5mm 2 holes 0 150 dia clearance for 6 screw 0 24 mounting tab 6mm Your selection of a proper enclosure is important to ensure safe and proper operation of your DL05 system Applications of DL05 systems vary and may require additional features The minimum considerations for enclo...

Page 42: ...nd any wiring ducts that run parallel to the terminals Earth Ground Panel Ground Terminal DL05 Power Source Temperature Probe Star Washers Panel Ground Braid Copper Lugs Panel or Single Point Ground Star Washers BUS Bar À Note there is a minimum of 2 30mm clearance between the panel door or any devices mounted in the panel door 2 50mm min Æ 2 50mm min Ä Å and the nearest DL05 component 2 50mm min ...

Page 43: ...s stable and storms can cause power surges Due to this powerline filters are recommended for protecting the DL05 PLCs from power surges and EMI RFI noise The Automation Powerline Filter for use with 120 VAC and 240 VAC 1 5 Amps is an exellent choice locate at www automationdirect com however you can use a filter of your choice These units install easily between the power source and the PLC NOTE If...

Page 44: ...y 5 95 relative humidity non condensing Vibration resistance MIL STD 810C Method 514 2 Shock resistance MIL STD 810C Method 516 2 Noise immunity NEMA ICS3 304 Atmosphere No corrosive gases Agency approvals UL CE FCC class A Operating temperature for the Handheld Programmer and the DV 1000 is 32 to 122 F 0 to 50 C Storage temperature for the Handheld Programmer and the DV 1000 is 4 to 158 F 20 to70...

Page 45: ... touch the connection terminals or power wiring There are no internal fuses for the input power circuits so external circuit protection is needed to ensure the safety of service personnel and the safe operation of the equipment itself To meet UL CUL specifications the input power must be fused Depending on the type of input power being used follow these fuse protection recommendations 208 240 VAC ...

Page 46: ...r 30 VA 20 W Voltage Withstand dielectric 1 minute 1500 VAC between primary secondary field ground Insulation Resistance 10 M at 500 VDC NOTE The rating between all internal circuits is BASIC INSULATION ONLY The following guidelines provide general information on how to wire the I O connections to DL05 Micro PLCs For specific information on wiring a particular PLC refer to the corresponding specif...

Page 47: ... or per output common Adding the external fuse does not guarantee the prevention of Micro PLC damage but it will provide added protection External Fuses shown with DIN Rail Fuse Blocks All DL05 Micro PLCs have a fixed I O configuration It follows the same octal numbering system used on other DirectLogic family PLCs starting at X0 and Y0 The letter X is always used to indicate inputs and the letter...

Page 48: ... isolation in Input and Output circuits This isolates logic circuitry from the field side where factory machinery connects Note that the discrete inputs are isolated from the discrete outputs because each is isolated from the logic side Isolation boundaries protect the operator interface and the operator from power input faults or field wiring faults When wiring a PLC it is extremely important to ...

Page 49: ...ce panels require separate power and communications connections Connect the DL05 to the proper D shell connector on the rear of the Optimation panel using the cable shown below Optimation panels require 8 30VDC power DL05 Micro PLC Optimation Panel Use cable part no OP 2CBL 15 pin D shell male RJ12 phone style DL05 Micro PLCs can be programmed with either a handheld programmer or with DirectSOFT o...

Page 50: ...urrent trying to flow in the wrong direction and the circuit will not operate However we can successfully connect the supply and field device every time by understanding sourcing and sinking For example the figure to the right depicts a sinking input To properly connect the external supply we just have to connect it so the the input provides a path to ground So we start at the PLC input terminal f...

Page 51: ... input points which share a common return path In this way the four inputs require only five terminals instead of eight Input Sensing PLC Input 4 Common Input 3 Input 2 Input 1 Note In the circuit above the current in the common path is 4 times any channel s input current when all inputs are energized This is especially important in output circuits where heavier gauge wire is sometimes necessary o...

Page 52: ... next circuit a field device has an open emitter PNP transistor output It sources current to the PLC input point which sinks the current back to ground Since the field device is sourcing current no additional power supply is required Field Device PLC DC Input Output sourcing Ground Input Common V sinking Sometimes an application requires connecting a PLC output point to a solid state input on a de...

Page 53: ...he effect of inverting the output point logic In other words the field device input is energized when the PLC output is OFF from a ladder logic point of view Your ladder program must comprehend this and generate an inverted output Or you may choose to cancel the effect of the inversion elsewhere such as in the field device It is important to choose the correct value of R pull up In order to do so ...

Page 54: ... re now ready to explore various ways to wire relay outputs to the loads Note that there are six normally open SPST relays available They are organized with three relays per common The figure below shows the relays and the internal wiring of the PLC Note that each group is isolated from the other group of outputs Y0 Com Y1 Y2 Y3 Y4 Com Y5 In the circuit below all loads use the same AC power supply...

Page 55: ...nergy stored in the inductor that is released when the voltage to the inductor is suddenly removed This release of energy is the cause of the transient voltages When inductive load devices motors motor starters interposing relays solenoids valves etc are controlled with relay contacts it is recommended that a surge suppression device be connected directly across the coil of the field device If the...

Page 56: ... only when it is necessary and if possible switching the load on or off at a time when it will draw the least current Also take measures to suppress inductive voltage spikes from inductive DC loads such as contactors and solenoids For inductive loads in DC circuits we recommend using a suppression diode as shown in the following diagram DO NOT use this circuit with an AC power supply When the load...

Page 57: ...accept 10 8 26 4 VDC The target applications are 12 VDC and 24 VDC You can actually wire half of the inputs as DC sinking and the other half as DC sourcing Inputs grouped by a common must be all sinking or all sourcing PLC DC Input Input Common In the first and simplest example below all commons are connected together and all inputs are sinking 24 VDC In the next example the first four inputs are ...

Page 58: ...The output circuit inside the PLC requires external power The supply must be connected to a common terminal and the supply connects the the right most terminal on the upper connector In the example below all six outputs share a common supply Output Point Wiring 24 VDC In the next example below the outputs have split supplies The first three outputs are using a 12 VDC supply and the last three are ...

Page 59: ...s to points X0 X2 Properly configured the DL05 can count quadrature pulses at up to 5 kHz from an incremental encoder as shown below Encoder Input Wiring 12 24 VDC Phase A Phase B Encoder Signal Common DL05 versions with DC type output points can use the High Speed I O Pulse Output feature It can generate high speed pulses for specialized control such as stepper motor intelligent drive systems Out...

Page 60: ...cuit Maximum Voltage Maximum voltage allowed for the input circuit ON Voltage Level The minimum voltage level at which the input point will turn ON OFF Voltage Level The maximum voltage level at which the input point will turn OFF Input Impedance Input impedance can be used to calculate input current for a particular operating voltage Input Current Typical operating current for an active ON input ...

Page 61: ...left as shown Output Point Wiring Ground Neutral Line Power Input Wiring Input Point Wiring AC or DC Supply Equivalent Input Circuit Optical Common Input V Isolator To other circuits in bank AC Supply Fuse or C B Derating Chart for Relay Outputs 0 2 4 6 Points 0 10 20 30 40 50 55 Ambient Temperature C F 32 50 68 86 104 122 131 C F Y0 Y5 2 A V To LED Equivalent Output Circuit COM OUTPUT To LED Inte...

Page 62: ... 20 to 70_ C Relative Humidity 5 to 95 non condensing Environmental air No corrosive gases permitted Vibration MIL STD 810C 514 2 Shock MIL STD 810C 516 2 Noise Immunity NEMA ICS3 304 Terminal Type Removable Wire Gauge One AWG16 or two AWG18 AWG24 minimum Input Voltage Range Min Max 80 132 VAC 47 63 Hz Operating Voltage Range 90 120 VAC 47 63 Hz Input Current 8 mA 100 VAC at 50 Hz 10 mA 100 VAC at...

Page 63: ...nals in the middle of the connector Inputs are organized into two banks of four Each bank has an isolated common terminal and may be wired as either sinking or sourcing inputs The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent circuit for standard inputs is shown above and the high speed input circuit is shown to the l...

Page 64: ...x Voltage Range 10 8 26 4 VDC 10 8 26 4 VDC Operating Voltage Range 12 24 VDC 12 24 VDC Peak Voltage 30 VDC 5 kHz maximum frequency 30 VDC Minimum Pulse Width 100 s N A ON Voltage Level 10 VDC 10 VDC OFF Voltage Level 2 0 VDC 2 0 VDC Input Impedance 1 8 k 12 24 VDC 2 8 k 12 24 VDC Max Input Current 6mA 12VDC 13mA 24VDC 4mA 12VDC 8 5mA 24VDC Minimum ON Current 5 mA 4 mA Maximum OFF Current 0 5 mA 0...

Page 65: ...rnal module circuitry L V 24VDC VDC V To LED Equivalent Input Circuit Optical Common Input V Isolator To other circuits in bank V To LED The eight AC input channels use terminals in the middle of the connector Inputs are organized into two banks of four Each bank has an isolated common terminal The wiring example above shows all commons connected together but separate supplies and common circuits ...

Page 66: ... Voltage Range 90 120 VAC 47 63 Hz Input Current 8 mA 100 VAC 50Hz 10 mA 100 VAC 60Hz Max Input Current 12 mA 132 VAC 50Hz 15 mA 132 VAC 60Hz Input Impedance 14K 50 Hz 12K 60 Hz ON Current Voltage 6 mA 75 VAC OFF Current Voltage 2 mA 20 VAC OFF to ON Response 40 mS ON to OFF Response 40 mS Status Indicators Logic Side Commons 4 channels common x 2 banks Parameter Pulse Outputs Y0 Y1 Standard Outpu...

Page 67: ...V Isolator V To LED The eight DC input channels use terminals in the middle of the connector Inputs are organized into two banks of four Each bank has an isolated common terminal and may be wired as either sinking or sourcing inputs The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent circuit for standard inputs is shown...

Page 68: ...z maximum frequency 30 VDC Minimum Pulse Width 100 s N A ON Voltage Level 9 0 VDC 9 0 VDC OFF Voltage Level 2 0 VDC 2 0 VDC Max Input Current 6mA 12VDC 13mA 24VDC 4mA 12VDC 8 5mA 24VDC Input Impedance 1 8 k 12 24 VDC 2 8 k 12 24 VDC Minimum ON Current 5 mA 4 mA Maximum OFF Current 0 5 mA 0 5 mA OFF to ON Response 100 S 2 8 mS 4 mS typical ON to OFF Response 100 S 2 8 mS 4 mS typical Status Indicat...

Page 69: ... L VAC Line V Equivalent Input Circuit Optical Common Input V Isolator To other circuits in bank V To LED The eight AC input channels use terminals in the middle of the connector Inputs are organized into two banks of four Each bank has an isolated common terminal The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent inpu...

Page 70: ... or two AWG18 AWG24 minimum Input Voltage Range Min Max 80 132 VAC 47 63 Hz Operating Voltage Range 90 120 VAC 47 63 Hz Input Current 8 mA 100 VAC at 50 Hz 10 mA 100 VAC at 60 Hz Max Input Current 12 mA 132 VAC at 50 Hz 15 mA 132 VAC at 60 Hz Input Impedance 14K 50 Hz 12K 60Hz ON Current Voltage 6 mA 75 VAC OFF Current Voltage 2 mA 20 VAC OFF to ON Response 40 mS ON to OFF Response 40 mS Status In...

Page 71: ...eight DC input channels use terminals in the middle of the connector Inputs are organized into two banks of four Each bank has an isolated common terminal and may be wired as sinking or sourcing inputs The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent circuit for standard inputs is shown above and the high speed input...

Page 72: ...puts X3 X7 Input Voltage Range 10 8 26 4 VDC 10 8 26 4 VDC Operating Voltage Range 12 24 VDC 12 24 VDC Maximum Voltage 30 VDC 5 kHz maximum frequency 30 VDC Minimum Pulse Width 100 S N A ON Voltage Level 10 VDC 10 VDC OFF Voltage Level 2 0 VDC 2 0 VDC Input Impedance 1 8 k 12 24 VDC 2 8 k 12 24 VDC Minimum ON Current 5 mA 4 mA Maximum OFF Current 0 5 mA 0 5 mA OFF to ON Response 100 S 2 8 mS 4 mS ...

Page 73: ...rminals in the middle of the connector Inputs are organized into two banks of four Each bank has an isolated common terminal and may be wired as either sinking or sourcing inputs The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent circuit for standard inputs is shown above and the high speed input circuit is shown to th...

Page 74: ...Voltage Range 10 8 26 4 VDC 10 8 26 4 VDC Operating Voltage Range 12 24 VDC 12 24 VDC Peak Voltage 30 VDC 5 kHz maximum frequency 30 VDC Minimum Pulse Width 100 s N A ON Voltage Level 10 VDC 10 VDC OFF Voltage Level 2 0 VDC 2 0 VDC Input Impedance 1 8 k 12 24 VDC 2 8 k 12 24 VDC Max Input Current 6mA 12VDC 13mA 24VDC 4mA 12VDC 8 5mA 24VDC Minimum ON Current 5 mA 4 mA Maximum OFF Current 0 5 mA 0 5...

Page 75: ... VDC 12 24 V 20 W max The eight DC input channels use terminals in the middle of the connector Inputs are organized into two banks of four Each bank has an isolated common terminal and may be wired as either sinking or sourcing inputs The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent circuit for standard inputs is sho...

Page 76: ...maximum frequency 30 VDC Minimum Pulse Width 100 s N A ON Voltage Level 9 0 VDC 9 0 VDC OFF Voltage Level 2 0 VDC 2 0 VDC Max Input Current 6mA 12VDC 13mA 24VDC 4mA 12VDC 8 5mA 24VDC Input Impedance 1 8 k 12 24 VDC 2 8 k 12 24 VDC Minimum ON Current 5 mA 4 mA Maximum OFF Current 0 5 mA 0 5 mA OFF to ON Response 100 S 2 8 mS 4 mS typical ON to OFF Response 100 S 2 8 mS 4 mS typical Status Indicator...

Page 77: ... VDC OFF voltage level 2 0 VDC Minimum ON current 3 5 mA Maximum OFF current 0 5 mA OFF to ON response 2 8 ms typical 4 ms ON to OFF response 2 8 ms typical 4 ms Status indicators Module activity one green LED Commons per module 2 non isolated Fuse N A Base power required 5V Typical 35 mA all pts ON Optical COM Isolator Configuration shown is current sinking INPUT 12 24VDC V To LED Internal module...

Page 78: ...ponse 2 8 ms typical 4 ms ON to OFF response 2 8 ms typical 4 ms Status indicators Module activity one green LED Commons per module 4 non isolated Fuse N A Base power required Typical 35 mA all pts ON Equivalent input circuit 0 10 20 30 40 50 55 Ambient Temperature C F 32 50 68 86 104 122 131 C F Derating Chart Wiring for ZL CM056 Use Ziplink ZL CBL056 cable and ZL CM056 connector module or build ...

Page 79: ...VDC ON voltage drop 0 5 VDC 0 3 A Maximum inrush current 1 A for 10 ms Maximum inrush current 1 A for 10 ms OFF to ON response 10 s ON to OFF response 60 s Status indicators Module activity one green LED Commons per module 2 non isolated 5 points common Fuse N A External DC power required 20 28 VDC max 200 mA all pts on Base power required 5V Max 150 mA all pts ON Derating Chart 0 10 20 30 40 50 5...

Page 80: ...nse 0 5 ms ON to OFF response 0 5 ms Status indicators Module activity one green LED Commons per module 2 isolated 8 points common Fuse N A External DC power required 20 28 VDC max 70 mA all pts on Base power required 5V Max 200 mA all pts ON Equivalent input circuit Derating Chart Wiring for ZL CM056 Use Ziplink ZL CBL056 cable and ZL CM056 connector module or build your own cables using 24 pin M...

Page 81: ...t current 0 5 mA Maximum leakage current 1 5 A 30 0 VDC ON voltage drop 1 0 VDC 0 3 A Maximum inrush current 1 A for 10 ms OFF to ON response 10 s ON to OFF response 60 s Status indicators Module activity one green LED Commons per module 2 non isolated 5 points common Fuse N A Base power required 5V Max 150 mA all pts ON Equivalent circuit Derating Chart 0 10 20 30 40 50 55 Ambient Temperature C F...

Page 82: ...inrush current 1 A for 10 ms OFF to ON response 0 5 ms ON to OFF response 0 5 ms Status indicators Module activity one green LED Commons per module 2 non isolated 8 points common Fuse N A Base power required 5V Max 200 mA all pts ON Equivalent input circuit Derating Chart Wiring for ZL CM056 Use Ziplink ZL CBL056 cable and ZL CM056 connector module or build your own cables using 24 pin Molex Micro...

Page 83: ...erating voltage range 6 27 VDC 6 240 VAC Output type Relay form A SPST Peak voltage 30 0 VDC 264 VAC Maximum current resistive 1 A point 4 A common Minimum load current 5 mA 5 VDC Maximum leakage current 0 1 mA 264 VAC ON voltage drop N A Maximum inrush current Output 3 A for 10 ms Common 10 A for 10 ms OFF to ON response 15 ms ON to OFF response 10 ms Status indicators Module activity one green L...

Page 84: ...leakage current 0 1 mA 264 VAC ON voltage drop N A ON voltage drop N A Maximum inrush current Output 3 A for 10 ms Common 10 A for 10 ms OFF to ON response 15 ms ON to OFF response 10 ms Status indicators Module activity one green LED Commons per module 2 isolated 4 points common Fuse N A Fuse N A Base power required 5 V Maximum 280 mA all pts ON Equivalent circuit 0 10 20 30 40 50 55 Ambient Temp...

Page 85: ...oltage range 6 27 VDC Output voltage range 5 30 VDC Peak voltage 50 0 VDC Maximum output current 0 3 A point 1 2 A common Minimum output current 0 5 mA Maximum leakage current 1 5 A 30 0 VDC ON voltage drop 0 5 VDC 0 3 A Maximum inrush current 1 A for 10 ms OFF to ON response 10 s ON to OFF response 60 s Status indicators Module activity one green LED Commons 2 non isolated 4 pts common Fuse N A B...

Page 86: ...I O Address D0 10ND3 10 Input X100 X107 and X110 X111 D0 16ND 16 Input X100 X107 and X110 X117 DC Output Modules I O Points Slot 1 I O Address D0 10TD1 10 Output Y100 Y107 and Y110 Y111 D0 16TD1 16 Output Y100 Y107 and Y110 Y117 D0 10TD2 10 Output Y100 Y107 and Y110 Y111 D0 16TD2 16 Output Y100 Y107 and Y110 Y117 Relay Output Modules I O Points Slot 1 I O Address D0 08TR 8 Output Y100 X107 Combina...

Page 87: ...eatures In This Chapter Ċ Introduction Ċ Choosing the HSIO Operating Mode Ċ Mode 10 HighĆSpeed Counter Ċ Mode 20 Quadrature Counter Ċ Mode 30 Pulse Output Ċ Mode 40 HighĆSpeed Interrupt Ċ Mode 50 Pulse Catch Input Ċ Mode 60 Filtered Inputs ...

Page 88: ...feature to monitor one input point having a pulse width as small as 100mS 0 1ms S Programmable discrete filtering both on and off delay up to 99ms to ensure input signal integrity this is the default mode for inputs X0 X2 The available pulse output features are S Single axis programmable pulse output 7 kHz max with three profile types including trapezoidal moves registration and velocity control I...

Page 89: ...ust passes through the I O signals to or from the CPU so that all eight inputs behave equally and all six outputs behave equally When the CPU is configured in any other HSIO Mode the HSIO circuit imposes a specialized function on the portion of inputs and outputs shown The HSIO circuit operates independently of the CPU program scan This provides accurate measurement and capturing of high speed I O...

Page 90: ... choosing one of the six high speed I O modes the I O points listed in the table below operate only as the function listed If an input point is not specifically used to support a particular mode it usually operates as a filtered input by default Similarly output points operate normally unless Pulse Output mode is selected Physical I O Point Usage DC Input Points DC Output Points Mode X0 X1 X2 Y0 Y...

Page 91: ... word represents 0 15 14 13 12 Memory Location V7633 11 10 1 2 3 4 5 6 7 8 9 Bits 0 0 0 0 0 0 1 0 1 0 0 HSIO Mode Setup BCD 0 0 0 0 00 Not Used 10 High Speed Counting Mode 20 Quadrature Counting Mode 30 Pulse Output Train 0 40 High Speed Interrupts 50 Pulse Catching 60 Discrete Filtered Inputs default 5 0 0 0 Bits 8 15 are not used in V7633 Bits 0 7 define the mode number 00 10 60 previously refer...

Page 92: ... contains a BCD 10 the high speed up counter in the HSIO circuit is enabled X0 automatically becomes the clock input for the high speed counter incrementing it upon each off to on transition The external reset input on X2 is the default configuration for Mode 10 Input X1 is the filtered input available to the ladder program Output Circuit Input Circuit CPU PLC DL05 X0 Y0 Y1 X3 X7 Y2 Y5 VĆmemory V7...

Page 93: ...n 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 It sinks current from the PLC input point which sources current The power supply can be the FA 24PS or another supply 12VDC or 24VDC as long as the input specifications are met Counter Output X0 Input Output Ground Input Common 12...

Page 94: ... goal of counting is to do a special action when the count reaches a preset value Refer to the figure below The counter features 24 presets which you can program A preset is a number you derive and store so that the counter will constantly compare the current count with the preset When the two are equal a special relay contact is energized and program execution jumps to the interrupt routine We re...

Page 95: ...t must be greater than the previous preset value If a preset value is less than a lower numbered preset value the CPU cannot compare for that value since the counter can only count upwards The following table lists all 24 preset register default locations Each occupies two 16 bit V memory registers The corresponding special relay contact number is in the next column We might also call these equal ...

Page 96: ...act closure Each contact remains on until the next one closes All go off when the counter resets Equal Relays SP540 SP541 SP542 A B C NOTE Each successive preset must be two numbers greater than the previous preset value In the industrial lathe example B A 1 and C B 1 The configurable discrete input options for High Speed Counter Mode are listed in the table below Input X0 is dedicated for the cou...

Page 97: ...L05 instruction set Refer to the figure below The mnemonic for the counter is UDC up down counter The DL05 can have up to 128 counters labeled CT0 through CT177 The high speed counter in the HSIO circuit is accessed in ladder logic by using UDC CT76 It uses counter registers CT76 and CT77 exclusively when the HSIO mode 10 is active otherwise CT76 and CT77 are available for standard counter use The...

Page 98: ...and increment the counter at CT76 CT77 The reset input contact behaves in a logical OR fashion with the physical reset input X2 when selected So the high speed counter can receive a reset form either the contact s on the reset rung in the ladder OR the external reset X2 if you have configured X2 as an external reset The following example is the simplest way to use the high speed counter which does...

Page 99: ...thout interrupt OUT V7636 Output the constant K7 to V7636 the location of the setup parameter for X2 LD K1006 Load the constant required to configure input as filtered inputs OUT V7635 Output the constant K1006 to V7635 the location of setup parameter for X1 Mode 10 Configure Inputs SP1 LDD V1076 Load the current count of the HSIO counter in V1076 and V1077 into the accumulator CMPD K309482 Use th...

Page 100: ...ects Mode 10 as the HSIO mode OUT V7633 Output this address to V7633 the location of HSIO Mode select register LD K107 Load the constant required to configure X2 as an external reset with interrupt OUT V7636 Output the constant to V7636 the location of the setup parameter for X2 Select Mode 10 DirectSOFT SP0 ENI Enable Interrupts before reaching a preset generates an interrupt Special Relay SP0 is...

Page 101: ...sents the end of the preset list OUTD V2326 Output the accumulator contents to the memory location for preset 4 end of preset marker SP541 SP542 These special equal relays turn on individually as the corresponding preset is reached In this application each results in the cutting of a groove Y1 so they are logically ORed together Preset 1 Preset 2 Preset 3 SETI Y1 SP0 X2 SETI Input X2 will be energ...

Page 102: ...tSOFT SET Set C0 on at powerup to enable counting C0 X4 RST When the preload request is made the user turns on X4 First we disable counting by resetting C0 the counter s enable input UDC CT76 K99999999 C1 C0 C2 CT76 is the HSIO counter The first rung s C0 contact enables the counter The dummy input is in the middle C0 PD Generate a preload counter input pulse which causes the counter to preload fr...

Page 103: ...er reset and must be off during counting Symptom The counter counts but the presets do not function Possible causes 1 Configuration Ensure the preset values are correct The presets are 32 bit BCD values having a range of 0 to 99999999 Make sure you write all 32 bits to the reserved locations by using the LDD and OUTD instructions Use only even numbered addresses from V2320 to V2376 If using less t...

Page 104: ... BCD 20 the quadrature counter in the HSIO circuit is enabled Input X0 is dedicated to the Phase A quadrature signal and input X1 receives Phase B signal X2 is dedicated to reset the counter to zero value when energized Output Circuit Input Circuit CPU PLC DL05 X0 Y0 Y1 X3 X7 Y2 Y5 VĆmemory V7633 0020 Mode Select I O data HSIO COUNTER Phase A Phase B X2 Reset X1 Quadrature encoder signals contain ...

Page 105: ...In the following circuit an encoder has open collector NPN transistor outputs It sinks current from the PLC input point which sources current The power supply can be the 24VDC auxiliary supply or another supply 12VDC or 24VDC as long as the input specifications are met Encoder Output one phase Phase A or B Input Output Ground Input Common 12Ć24 VDC Supply sinking sourcing In the next circuit an en...

Page 106: ...rogrammer D2 HPP We recommend using the first method above so that the HSIO setup becomes an integral part of your application program An example program later in this section shows how to do this The configurable discrete input options for High Speed Counter Mode are listed in the table below Input X0 is dedicated for Phase A and input X1 is for Phase B Input X2 is the reset input to the quadratu...

Page 107: ...t DOWN Count Standard Counter Function HSIO Counter Function D Counts UP and DOWN D Counts UP and DOWN from X0 X1 D Reset input is internal only D Reset may be internal or external D Preload counter by write to value D Can use Dummy Input to change count The next figure shows the how the HSIO quadrature counter will appear in a ladder program Preset Range 1 99999999 Reset Input UDC CT76 Kxxxxxxxx ...

Page 108: ...the constant required to configure X2 as an external reset OUT V7636 Output the constant to V7636 the location of the setup register for X2 SET Set C0 on at powerup to enable counting C0 SP0 Select Mode 20 The third rung s Reset input is normally off because we will use the external reset You can optionally reset the counter value on each powerup using the SP0 contact SP1 LDD V1076 Load the curren...

Page 109: ...within the input specifications 2 Configuration make sure all of the configuration parameters are correct V7633 must be set to 20 and V7634 must be set to 0002 to enable the Phase A input and V7635 must be set to 0000 to enable the Phase B input 3 Stuck in reset check the input status of the reset input X2 If X2 is on the counter will not count because it is being held in reset 4 Ladder program ma...

Page 110: ...e 30 By programming acceleration and deceleration values position and velocity target values the 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 111: ...nces refer to I O references in the ladder program Please read the items below to understand this very crucial point Notice the I O point assignment and usage in the above diagram S X0 and X1 can only be filtered inputs in Pulse Output Mode and they are available as an input contacts to the ladder program S X2 behaves as an external interrupt to the pulse generator for registration profiles In oth...

Page 112: ...at 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 Drive Input Output Ground Input Common V Y0 Y1 Pulse Output DC pwr sourcing sinking Power The following circuit shows how to interface to a sinking drive input using a pullup resistor Please refer ...

Page 113: ...use in registration mode Physical Input Configuration Register Function Hex Code Required V7637 Y0 Pulse Y1 Direction 0103 Y0 CW Pulse Y1 CCW Pulse 0003 X0 V7634 Discrete filtered input xx06 xx filter time 0 99 BCD X1 V7635 Discrete filtered input 0 99 ms BCD X2 V7636 Discrete filtered input The following logical I O references define functions that allow the HSIO to communicate with the ladder pr...

Page 114: ... information The upper four bits 12 15 select the type of profile required The lower 12 bits 0 11 select the Target Velocity 0 15 14 13 12 Memory Location V2320 default 11 10 1 2 3 4 5 6 7 8 9 Bits 0 0 0 0 0 0 0 0 0 0 0 Target Velocity Value Profile Select BCD 0 1 1 1 0 Trapezoidal Profile Absolute Position 8 Trapezoidal Profile Relative Position Range 4 to 700 representing 40 Hz to 7 kHz pulse ra...

Page 115: ...nits V2320 bits 12 15 Trapezoidal Profile 0 absolute 8 relative V2320 bits 0 11 Target Velocity Value 4 to 700 x 10 pps V2321 2322 Target Position Value 8388608 to 8388607 Pulses V2323 Starting Velocity 4 to 100 x 10 pps V2324 Acceleration Time 1 to 100 x 100 mS V2325 Deceleration Time 1 to 100 x 100 mS V2326 Error Code see end of section V Memory Function Range Units V2320 bits 12 15 Registration...

Page 116: ...s on the scrap area of the work piece allow a machine tool to register its position relative to the rectangle to drill properly Home search moves allow open loop motion systems to re calibrate preload the current position value at powerup Registration profiles are a combination of velocity and position control modes The move begins by accelerating to a programmed velocity The velocity is sustained...

Page 117: ...u are familiar with motion control you ll notice that we do not have to specify the direction of the move The HSIO function examines the target position relative to the current position and automatically outputs the correct direction information to the motor drive Notice that the motion accelerates immediately to the starting velocity This segment is useful in stepper systems so we can jump past l...

Page 118: ...he HSIO mode OUT V7633 Output the constant to V7633 the location of the HSIO Mode select register LDA O2320 Load the octal address of the beginning of the Profile Parameter Table The LDA instruction converts this to a hex number in the accumulator OUT V7630 Output this address to V7630 the location of the pointer to the Profile Parameter Table DirectSOFT Mode 30 LD K1006 Load the constant K1006 wh...

Page 119: ...0 which is required to select an acceleration time of 2 seconds 20 x 100 mS Acceleration OUT V2325 Output this constant to V2325 the location of the deceleration parameter register LD K40 Load the constant K40 which is required to select a deceleration time of 4 seconds 40 x 100 mS Deceleration X3 OUT We use a spare filtered input to allow the operator to start the profile When the operator turns ...

Page 120: ...sitioning system makes an indefinite move and waits for the load to pass by a home limit switch This creates an interrupt at the moment when the load is in a known position We then stop motion and preload the position value with a number which equates to the physical home position The registration profile begins with only velocity control When an interrupt pulse occurs on physical input X2 the sta...

Page 121: ...SIO Mode select register LDA O2320 Load the octal address of the beginning of the Profile Parameter Table The LDA instruction converts this to a hex number in the accumulator OUT V7630 Output this address to V7630 the location of the pointer to the Profile Parameter Table DirectSOFT Mode 30 LD K2006 Load the constant K2006 which is required to select X1 as a filtered input with a 20 mS filter time...

Page 122: ...put this constant to V2324 the location of the acceleration parameter register LD K20 Load the constant K20 which is required to select an acceleration time of 2 seconds 20 x 100 mS Acceleration OUT V2325 Output this constant to V2325 the location of the deceleration parameter register LD K40 Load the constant K40 which is required to select a deceleration time of 4 seconds 40 x 100 mS Deceleratio...

Page 123: ...mit switch Therefore we will initiate a home search profile using the registration mode The home limit switch is wired to X2 causing the interrupt We choose an arbitrary initial search direction moving in the CW left to right direction S If the home limit switch closes first then we stop and initialize the position this value is typically 0 but it may be different if preferred S However if the CW ...

Page 124: ...position OUTD V1076 Output this constant to C1076 V1077 SET Go CW back to home C4 Home Limit found CW search direction Turn off Start Profile SET The CW limit has been reached C1 C0 RST Y0 Home Limit found CW search direction Turn off Start Profile Turn off Start Profile SET C0 Set C0 to indicate the CW home search has begun C0 C1 X3 X7 SET C10 Start the home search when X7 turns on C1 TMR K5 Add ...

Page 125: ...t is active the ladder program can command a velocity change by writing a new value to the velocity register V2323 by default The full speed range of 40 Hz to 7 kHz is available Notice from the drawing that there are no acceleration or deceleration ramps between velocity updates This is how velocity profiling works with the HSIO However the ladder program can command more gradual velocity changes ...

Page 126: ...ger the setup SP0 LD K30 Load constant K30 into the accumulator This selects Mode 30 as the HSIO mode OUT V7633 Output this constant to V7633 the location of the HSIO Mode select register LDA O2320 Load the octal address of the beginning of the Profile Parameter Table The LDA instruction converts this to hex number in the accumulator OUT V7630 Output this address to V7630 the location of the point...

Page 127: ...stant K10 which is required to select an initial velocity of 100 pps uses x10 multiplier Set Velocity X1 OUT We use a spare filtered input to allow the operator to start the profile When the operator turns X1 ON and leaves it on logical output Y0 starts the profile Y0 Start Profile LD K50 OUT V2323 X2 Output this constant to V2323 the location of the velocity parameter register The speed will chan...

Page 128: ...Deceleration Time is not in BCD 0061 Deceleration Time is zero 0062 Deceleration Time is greater than 10 seconds Most errors can be corrected by rechecking the Profile Parameter Table values The error is automatically cleared at powerup and at Program to Run Mode transitions If you re having trouble with Mode 30 operation please study the following symptoms and possible causes The most common prob...

Page 129: ...he HSIO Mode select register DirectSOFT Mode 60 OUT V7635 Output this constant to V7635 configuring X1 Filtered Inputs OUT V7636 Output this constant to V7636 configuring X2 LD K1006 Load the constant K1006 which is required to configure filtered inputs with a time constant of 10 mS OUT V7634 Output this constant to V7634 configuring X0 END END coil marks the end of the main program X0 OUT Use a s...

Page 130: ...The timed interrupt is programmable from 5 to 999 mS The HSIO circuit creates the high speed interrupt to the CPU The following diagram shows the external interrupt option which uses X0 In this configuration X1 and X2 are normal filtered inputs Output Circuit Input Circuit CPU PLC DL05 X0 Y0 Y1 X3 X7 Y2 Y5 VĆmemory V7633 0040 Mode Select I O data HSIO Interrupt X1 X2 Interrupt FILTER Alternately y...

Page 131: ...ove so that the HSIO setup becomes an integral part of your application program An example program later in this section shows how to do this Refer to the drawing below The source of the interrupt may be external X0 or the HSIO timer function The setup parameter in V7634 serves a dual purpose S It selects between the two interrupt sources external X0 or an internal timer S In the case of the timer...

Page 132: ... uses X1 s filter time constant by default Inputs X1 and X2 can only be filtered inputs having individual configuration registers and filter time constants However X0 will have the same filter time constant as X1 when the timed interrupt is selected Input Configuration Register Function Hex Code Required X0 V7634 External Interrupt 0004 default Uses X1 s time setting in V7635 Filtered Input when t...

Page 133: ...635 Output this constant to V7635 configuring X1 Filtered Inputs OUT V7636 Output this constant to V7636 configuring X2 LD K4 Load the constant K4 which is required to select the external interrupt option X0 is the interrupt input OUT V7634 Output this constant to V7634 configuring the external interrupt option for X0 External Interrupt INT Enable ENI Enable Interrupts at the beginning of the prog...

Page 134: ...35 Output this constant to V7635 configuring X1 and X0 Filtered Inputs OUT V7636 Output this constant to V7636 configuring X2 LD K1004 Load the constant K1004 which is required to select the timed interrrupt option with a period of 100 mS OUT V7634 Output this constant to V7634 configuring the timed interrupt for 100 mS period Timed Interrupt INT Enable ENI Enable Interrupts at the beginning of th...

Page 135: ...xt CPU scan Inputs X1 and X2 are available as filtered discrete inputs Output Circuit Input Circuit CPU PLC DL05 X0 Y0 Y1 X3 X7 Y2 Y5 VĆmemory V7633 0050 Mode Select I O data HSIO LATCH Set Reset X1 X2 scan FILTER Signal pulses at X0 must meet certain timing criteria to guarantee a pulse capture will result Refer to the timing diagram below The input characteristics of X0 are fixed it is not a pro...

Page 136: ...program S DirectSOFT s memory editor S Use the Handheld Programmer D2 HPP We recommend using the first method above so that the HSIO setup becomes an integral part of your application program An example program later in this section shows how to do this The configurable discrete input options for Pulse Catch Mode are listed in the table below Input X0 is the pulse input and must have 0005 loaded i...

Page 137: ...ode 50 LD K1006 Load the constant K1006 which is required to select filtered inputs with a 10 mS filter time constant OUT V7635 Output this constant to V7635 configuring X1 Filtered Inputs OUT V7636 Output this constant to V7636 configuring X2 LD K5 Load the constant K5 which is required to configure X0 as the pulse catch input OUT V7634 Output this constant to V7634 configuring the pulse catch op...

Page 138: ... V7633 contains a BCD 60 the input filter in the HSIO circuit is enabled Each input X0 through X2 has its own filter time constant The filter circuit assigns the outputs of the filters as logical references X0 through X2 Output Circuit Input Circuit CPU PLC DL05 X0 Y0 Y1 X3 X7 Y2 Y5 VĆmemory V7633 0060 Mode Select I O data HSIO FILTERS X0 X2 X1 X2 Signal pulses at inputs X0 X2 are filtered by usin...

Page 139: ...ecomes an integral part of your application program An example program later in this section shows how to to this The configurable discrete input options for Discrete Filtered Inputs Mode are listed in the table below The filter time constant delay is programmable from 0 to 99 mS the input acts as a normal discrete input when the time constant is set to 0 The code for this selection occupies the u...

Page 140: ...e select register DirectSOFT Mode 60 LD K2006 Load the constant K2006 which is required to select filtered inputs with a 20 mS filter time constant OUT V7635 Output this constant to V7635 configuring X1 Filtered Inputs OUT V7636 Output this constant to V7636 configuring X2 LD K1006 Load the constant K1006 which is required to configure filtered inputs with a time constant of 10 mS OUT V7634 Output...

Page 141: ... Operation Run Mode Operation I O Response Time CPU Scan Time Considerations PLC Numbering Systems Memory Map DL05 System V Memory X Input Bit Map Y Output Bit Map Staget Control Status Bit Map Control Relay Bit Map Timer Status Bit Map Counter Status Bit Map Network Configuration Network Slave Operation Network Master Operation ...

Page 142: ...d 4K words of V memory data registers Program storage is in the FLASH memory which is a part of the CPU board in the PLC In addition there is RAM with the CPU which will store system parameters V memory and other data which is not in the application program The RAM is backed up by a super capacitor storing the data for several hours in the event of a power outage The capacitor automatically charge...

Page 143: ...ts RS232C Yes FLASH Memory Standard on CPU Local Discrete I O points available 14 Local Analog input output channels maximum None High Speed I O quad pulse out interrupt pulse catch etc Yes 2 I O Point Density 8 inputs 6 outputs Number of instructions available see Chapter 5 for details 129 Control relays 512 Special relays system defined 512 Stages in RLLPLUS 256 Timers 128 Counters 128 Immediate...

Page 144: ...3 RXD Receive Data RS232C 4 TXD Transmit Data RS232C 5 5V Power conection 6 0V Power connection GND 6 pin Female Modular Connector Port 2 Pin Descriptions 1 0V Power connection GND 2 5V Power connection 3 RXD Receive Data RS232C 4 TXD Transmit Data RS232C 5 RTS Request to Send 6 0V Power connection GND 1 2 3 4 5 6 Top View 1 1 Communication Port 1 Com 1 Connects to HPP DirectSOFT operator interfac...

Page 145: ... are a few things you need to do before you can start entering programs This section includes some basic things such as changing the CPU mode but it also includes some things that you may never have to use Here s a brief list of the items that are discussed S Selecting and Changing the CPU Modes S Using Auxiliary Functions S Clearing the program and other memory areas S How to initialize system me...

Page 146: ... CPU Port 1 TX2 ON Data is being transmitted by the CPU Port 2 OFF No data is being transmitted by the CPU Port 2 RX2 ON Data is being received by the CPU Port 2 OFF No data is being received by the CPU Port 2 The mode switch on the DL05 PLC provides positions for enabling and disabling program changes in the CPU Unless the mode switch is in the TERM position RUN and STOP mode changes will not be ...

Page 147: ...nged between Run and Program modes You can use either DirectSOFT or the Handheld Programmer to change the CPU mode of operation With DirectSOFT you use a menu option in the PLC menu With the Handheld Programmer you use the MODE key Menu Options MODE Key The DL05 CPU will normally power up in the mode that it was in just prior to the power interruption For example if the CPU was in Program Mode whe...

Page 148: ... AUX 3 V Memory Operations 65 Run Self Diagnostics 31 Clear V Memory AUX 7 EEPROM Operations AUX 4 I O Configuration 71 Copy CPU memory to HPP EEPROM 41 Show I O Configuration 72 Write HPP EEPROM to CPU AUX 5 CPU Configuration 73 Compare CPU to HPP EEPROM 51 Modify Program Name 74 Blank Check HPP EEPROM 53 Display Scan Time 75 Erase HPP EEPROM 54 Initialize Scratchpad 76 Show EEPROM Type CPU and H...

Page 149: ...vide certain ranges of retentive memory by default The default ranges are suitable for many applications but you can change them if your application requires additional retentive ranges or no retentive ranges at all The default settings are Memory Area DL05 Memory Area Default Range Available Range Control Relays C400 C777 C0 C777 V Memory V1400 V7777 V0 V7777 Timers None by default T0 T177 Counte...

Page 150: ...rd you will not be able to access the CPU The Micro PLC must be returned to the factory to have the password removed You can use the D2 HPP Handheld Programmer or DirectSOFT to enter a password The following diagram shows how you can enter a password with the Handheld Programmer D2 HPP 00000000 PASSWORD DirectSOFT XXXXXXXX PASSWORD CLR CLR AUX 8 I 1 B ENT X X ENT X Select AUX 81 Enter the new 8 di...

Page 151: ...entive memory settings In general the contents of retentive memory is preserved and non retentive memory is initialized to zero unless otherwise specified After the one time powerup tasks the CPU begins the cyclical scan activity The flowchart to the right shows how the tasks differ based on the CPU mode and the existence of any errors The scan time is defined as the average time around the task l...

Page 152: ...s For example you need to understand how the CPU updates the I O points handles forcing operations and solves the application program The remaining segments are not that important for most applications You can use DirectSOFT or the D2 HPP Handheld Programmer to place the CPU in Run Mode Read Inputs Solve the Application Program Write Outputs Diagnostics Update Special Relays Service Peripherals No...

Page 153: ...may want to force an input on even though it is really off This allows you to change the point status that was stored in the image register This value will be valid until the image register location is written to during the next scan This is primarily useful during testing situations when you need to force a bit on to trigger another event Bit Override Bit override can be enabled on a point by poi...

Page 154: ...am during this segment of the scan cycle The instructions define the relationship between the input conditions and the desired output response The CPU uses the output image register area to store the status of the desired action for the outputs Output image register locations are designated with a Y followed by a memory location The actual outputs are updated during the write outputs segment of th...

Page 155: ...ndheld Programmer would display the following message E003 S W TIMEOUT when the scan overrun occurs You can use AUX 53 to view the minimum maximum and current scan time Use AUX 55 to increase or decrease the watchdog timer value I O Response Time I O response time is the amount of time required for the control system to sense a change in an input point and update a corresponding output point In th...

Page 156: ...response time is longest when the input changes just after the Read Inputs portion of the execution cycle In this case the new input status is not read until the following scan The following diagram shows an example of the timing for this situation Solve Program Read Inputs Write Outputs Solve Program Scan Solve Program Field Input Input Off On Delay CPU Reads Inputs Output Off On Delay I O Respon...

Page 157: ...l Write Outputs Solve Program Scan Solve Program Field Input Input Off On Delay Output Off On Delay I O Response Time Scan Solve Program Normal Read Input Write Output Immediate In this case you can calculate the response time by simply adding the following items Input Delay Instruction Execution Time Output Delay Response Time The instruction execution time would be calculated by adding the time ...

Page 158: ...xecute the application program This is because different instructions take different amounts of time to execute So if you think you need a faster scan then you can try to choose faster instructions Your choice of I O type and peripheral devices can also affect the scan time However these things are usually dictated by the application The following paragraphs provide some general information on how...

Page 159: ...ms LD K50 42 7 ms STRN C103 2 3 ms OUT V2006 16 6 ms STR X5 2 ms ANDN X10 1 6 ms OUT Y3 6 8 ms END 24 ms SUBTOTAL 174 2 ms Overhead DL05 Minimum 0 66 mS Maximum 2 5 ms TOTAL TIME Program execution time Overhead x 1 1 The program above takes only 174 2 ms to execute during each scan The DL05 spends 0 1ms on internal timed interrupt management for every 1ms of instruction time The total scan time is...

Page 160: ...st modular PLCs allow you to add I O points in groups of eight In fact all the resources of our PLCs are counted in octal It s easier for computers to count in groups of eight than ten because eight is an even power of 2 Octal means simply counting in groups of eight things at a time In the figure to the right there are eight circles The quantity in decimal is 8 but in octal it is 10 8 and 9 are n...

Page 161: ...ation is just a storage box that s all It does not convert or move the data on its own Since humans naturally count in decimal 10 fingers 10 toes we prefer to enter and view PLC data in decimal as well However computers are more efficient in using pure binary numbers A compromise solution between the two is Binary Coded Decimal BCD representation A BCD digit ranges from 0 to 9 and is stored as fou...

Page 162: ...s of memory in the DL05 discrete and word memory Discrete memory is one bit that can be either a 1 or a 0 Word memory is referred to as V memory variable and is a 16 bit location normally used to manipulate data numbers store data numbers etc Some information is automatically stored in V memory For example the timer current values are stored in V memory 0 1 1 0 1 0 0 0 0 0 0 1 0 0 1 0 X0 Discrete ...

Page 163: ...ol relays can be programmed as discrete inputs or discrete outputs These locations are used in programming the discrete memory locations C or the corresponding word location which contains 16 consecutive discrete locations In this example memory location C5 will energize when input X6 turns on The second rung shows a simple example of how to use a control relay as an input C5 OUT X6 Y10 OUT C5 Y20...

Page 164: ...current value is equal to or greater than the preset value of a corresponding counter Y2 OUT CT3 X0 CNT CT3 K10 X1 Each time contact X0 transitions from off to on the counter increments by one If X1 comes on the counter is reset to zero When the counter reaches the preset of 10 counts K of 10 counter status contact CT3 turns on When CT3 turns on output Y2 turns on V1003 K8 Just like the timers the...

Page 165: ... status bit that can be used as an input to indicate whether the Staget is active or inactive If the Staget is active then the status bit is on If the Staget is inactive then the status bit is off This status bit can also be turned on or off by other instructions such as the SET or RESET instructions This allows you to easily control stages throughout the program Ladder Representation ISG S0000 St...

Page 166: ... 0 1 2 12 3 0000 to 9999 V7630 Starting location for the multi step presets for channel 1 The default value is 2320 which indicates the first value should be obtained from V2320 Since there are 24 presets available the default range is V2320 V2377 You can change the starting point if necessary Default V2320 Range V0 V2320 V7631 V7632 Reserved N A V7633 Sets the desired function code for the high s...

Page 167: ... A V7723 V7750 Reserved N A V7751 Fault Message Error Code stores the 4 digit code used with the FAULT instruction when the instruction is executed N A V7752 V7754 Reserved N A V7755 Error code stores the fatal error code V7756 Error code stores the major error code V7757 Error code stores the minor error code V7760 V7762 Reserved V7763 Program address where syntax error exists N A V7764 Syntax er...

Page 168: ...0 V41107 128 Counters CT0 CT177 V41140 V41147 128 Counter Current Values None V1000 V1177 128 Counter Status Bits CT0 CT177 V41140 V41147 128 Data Words None V1200 V7377 3968 None specific used with many instructions Data Words Non volatile None V7400 V7577 128 None specific used with many instructions Stages S0 S377 V41000 V41017 256 System parameters None V7600 V7777 128 None specific used for v...

Page 169: ...0 Address 017 016 015 014 013 012 011 010 007 006 005 004 003 002 001 000 V41000 037 036 035 034 033 032 031 030 027 026 025 024 023 022 021 020 V41001 057 056 055 054 053 052 051 050 047 046 045 044 043 042 041 040 V41002 077 076 075 074 073 072 071 070 067 066 065 064 063 062 061 060 V41003 117 116 115 114 113 112 111 110 107 106 105 104 103 102 101 100 V41004 137 136 135 134 133 132 131 130 127...

Page 170: ...05 304 303 302 301 300 V40614 337 336 335 334 333 332 331 330 327 326 325 324 323 322 321 320 V40615 357 356 355 354 353 352 351 350 347 346 345 344 343 342 341 340 V40616 377 376 375 374 373 372 371 370 367 366 365 364 363 362 361 360 V40617 417 416 415 414 413 412 411 410 407 406 405 404 403 402 401 400 V40620 437 436 435 434 433 432 431 430 427 426 425 424 423 422 421 420 V40621 457 456 455 454...

Page 171: ...55 154 153 152 151 150 147 146 145 144 143 142 141 140 V41106 177 176 175 174 173 172 171 170 167 166 165 164 163 162 161 160 V41107 Counter Status Bit Map This table provides a listing of individual counter contacts associated with each V memory address bit MSB DL05 Counter CT Contacts LSB Address 17 16 15 14 13 12 11 10 7 6 5 4 3 2 1 0 Address 017 016 015 014 013 012 011 010 007 006 005 004 003 ...

Page 172: ...nly DirectNET Slave only MODBUS Slave only Communication Port 2 Com 2 Connects to HPP DirectSOFT operator interfaces etc 6 pin RS232C Communication speed baud 300 600 1200 2400 4800 9600 19200 38400 Parity odd default even none Station address 1 default 8 data bits 1 start 1 stop bit Asynchronous Half duplex DTE Protocol Auto Select K sequence Slave only DirectNET Master Slave MODBUS Master Slave ...

Page 173: ...ng DL05 Master to Other PLCs GND TXD RXD RXD TXD DL05 PORT 2 1 or 6 0V 0V 1 or 6 TXD 4 RXD 3 3 RXD 4 TXD GND RXD TXD F2 UNICON FA ISONET 1 or 6 0V 0V 1 or 6 TXD 4 RXD 3 3 RXD 4 TXD 5V 2 2 CTS 1 0V 0V 1 TXD 4 RXD 3 3 RXD 4 TXD F2 UNICON TXD RXD GND RXD TXD TXD RXD DL240 PORT 2 DL05 PORT 2 Note When using the DL05 on a multi drop network the RTS ON Delay time must be set to at least 5ms and the RTS ...

Page 174: ... least 5ms and the RTS OFF Delay time must be set to at least 2ms If you encounter problems the time can be increased S Station Number For making the CPU port a MODBUSR master choose 1 The possible range for MODBUS slave numbers is from 1 to 247 but the DL05 network instructions used in Master mode will access only slaves 1 to 99 Each slave must have a unique number At powerup the port is automati...

Page 175: ...network the RTS ON Delay time must be set to at least 5ms and the RTS OFF Delay time must be set to at least 2ms If you encounter problems the time can be increased S Station Number For making the CPU port a DirectNET master choose 1 The allowable range for DIrectNET slaves is from 1 to 90 each slave must have a unique number At powerup the port is automatically a slave unless and until the DL05 e...

Page 176: ...NET slave operation The MODBUS function code determines whether the access is a read or a write and whether to access a single data point or a group of them The DL05 supports the MODBUS function codes described below MODBUS Function Code Function DL05 Data Types Available 01 Read a group of coils Y CR T CT 02 Read a group of inputs X SP 05 Set Reset a single coil Y CR T CT 15 Set Reset a group of ...

Page 177: ...s the exact equation used for each group of data DL05 Memory Type QTY Dec PLC Range Octal MODBUS Address Range Decimal MODBUS Data Type For Discrete Data Types Convert PLC Addr to Dec Start of Range Data Type Inputs X 256 X0 X377 2048 2303 Input Special Relays SP 512 SP0 SP777 3072 3583 Input Outputs Y 256 Y0 Y377 2048 2303 Coil Control Relays CR 512 C0 C777 3072 4583 Coil Timer Contacts T 128 T0 ...

Page 178: ...the MODBUS data type from the table PLC Addr Dec Start Addr Data Type Y20 16 decimal 16 2048 Coil Coil 2064 Outputs Y 256 Y0 Y377 2048 2303 Coil Find the MODBUS address to obtain the current value from Timer T10 1 Find Timer Current Values in the table 2 Convert T10 into decimal 8 3 Use the MODBUS data type from the table PLC Address Dec Data Type T10 8 decimal 8 Input Reg Input Reg 8 Timer Curren...

Page 179: ...is purpose S Discrete X SP Y CR S T C contacts S Word V Timer current value Counter current value In either case you basically convert the PLC octal address to decimal and add the appropriate MODBUS addresses as required The table below shows the exact equation used for each group of data DL05 Memory Type QTY Dec PLC Range Octal MODBUS Address Range Decimal 484 Mode Address 584 984 Mode Address MO...

Page 180: ...tain the current value from Timer T10 1 Find Timer Current Values in the table 2 Convert T10 into decimal 8 3 Add the MODBUS starting address for the mode 3001 PLC Address Dec Mode Address T10 8 decimal 8 3001 3009 Timer Current Values V 128 V0 V177 0 127 3001 30001 Input Reg Find the MODBUS address for Control Relay C54 1 Find Control Relays in the table 2 Convert C54 into decimal 44 3 Add the st...

Page 181: ...e 3 Master MODBUS RTU Protocol or DirectNET Slave 2 When using the DL05 PLC as the master station simple RLL instructions are used to initiate the requests The WX instruction initiates network write operations and the RX instruction initiates network read operations Before executing either the WX or RX commands we will need to load data related to the read or write operation onto the CPU s accumul...

Page 182: ... BCD format decimal from 1 to 128 bytes 6 4 BCD of bytes to transfer LD K64 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 183: ...8 least significant bits of the last word location will be modified The remaining 8 bits are not affected The last instruction in our sequence is the WX or RX instruction itself Use WX to write to the slave and RX to read from the slave All four of our instructions are shown to the right In the last instruction you must specify the starting address and a valid data type for the slave LD KF201 LD K...

Page 184: ... of this bit is optional When used it should be ahead of any network instruction boxes since the error bit is reset when an RX or WX instruction is executed If you are using multiple reads and writes in the RLL program you have to interlock the routines to make sure all the routines are executed If you don t use the interlocks then the CPU will only execute the first routine This is because each p...

Page 185: ...Register Instructions Ċ Accumulator Stack Load and Output Data Instructions Ċ Logical Instructions Accumulator Ċ Math Instructions Ċ Bit Operation Instructions Accumulator Ċ Number Conversion Instructions Accumulator Ċ Table Instructions Ċ CPU Control Instructions Ċ Program Control Instructions Ċ Interrupt Instructions Ċ Message Instructions ...

Page 186: ...DD 5 64 AND 5 11 5 25 5 55 AND STR 5 12 ANDD 5 56 ANDE 5 22 ANDI 5 27 ANDN 5 11 5 25 ANDND 5 17 ANDNE 5 22 ANDNI 5 27 ANDPD 5 17 ATH 5 85 BCD 5 83 BIN 5 82 CMP 5 61 CMPD 5 62 CNT 5 36 CV 7 23 CVJMP 7 23 DEC 5 71 DECB 5 72 DECO 5 81 DISI 5 104 DIV 5 69 DIVB 5 76 DIVD 5 70 DLBL 5 107 DRUM 6 12 EDRUM 6 2 NO TAG Instruction Page ENCO 5 80 END 5 94 ENI 5 103 FAULT 5 106 FOR 5 96 GRAY 5 88 GTS 5 98 HTA ...

Page 187: ... 77 SHFR 5 79 SR 5 42 STOP 5 94 STR 5 9 5 23 STRE 5 20 STRI 5 26 STRN 5 9 5 23 Instruction Page STRND 5 15 STRNE 5 20 STRNI 5 26 STRPD 5 15 SUB 5 65 SUBB 5 74 SUBD 5 66 SUM 5 77 Instruction Page TMR 5 31 TMRA 5 33 TMRAF 5 33 TMRF 5 31 UDC 5 40 WX 5 115 XOR 5 59 XORD 5 60 ...

Page 188: ...statement as the last instruction This tells the CPU that this is the end of the program Normally any instructions placed after the END statement will not be executed There are exceptions to this such as interrupt routines etc Chapter 5 discusses the instruction set in detail OUT Y0 X0 END All programs must have and END statement You use a contact to start rungs that contain both contacts and coil...

Page 189: ...ts that are conditional on other contacts The following example shows how you can use the AND instruction to continue a rung with more conditional outputs OUT Y0 X0 END X1 DirectSOFT Example Handheld Mnemonics STR X0 AND X1 OUT Y0 AND X2 OUT Y1 AND X3 OUT Y2 END X2 OUT Y1 X3 OUT Y2 You also have to join contacts in parallel The OR instruction allows you to do this The following example shows two c...

Page 190: ...n combine the various types of series and parallel branches to solve most any application problem The following example shows a simple combination network OUT Y0 X0 END X2 X3 X1 X4 X5 X6 Some PLC manufacturers make it really difficult to do a simple comparison of two numbers Some of them require you to move the data all over the place before you can actually perform the comparison The DL05 Micro P...

Page 191: ...ions combine levels of the boolean stack when they are encountered An error will occur during program compilation if the CPU encounters a rung that uses more than the eight levels of the boolean stack The following example shows how the boolean stack is used to solve boolean logic X1 OR X2 AND X3 STR X0 STR X1 STR X2 1 STR X0 2 3 4 5 6 7 8 1 STR X1 2 STR X0 3 4 5 6 7 8 1 STR X2 2 STR X1 3 STR X0 4...

Page 192: ...ite outputs portion of the CPU cycle NOTE Even though the immediate input instruction reads the most current status from the input point it only uses the results to solve that one instruction It does not use the new status to update the image register Therefore any regular instructions that follow will still use the image register values Any immediate instructions that follow will access the I O a...

Page 193: ...tact Status of the contact will be opposite the state of the associated image register point or memory location Aaaa Operand Data Type DL05 Range A aaa Inputs X 0 377 Outputs Y 0 377 Control Relays C 0 777 Stage S 0 377 Timer T 0 177 Counter CT 0 177 Special Relay SP 0 777 In the following Store example when input X1 is on output Y2 will energize STR 1 B ENT OUT GX 2 C ENT Handheld Programmer Keys...

Page 194: ... will be opposite the state of the associated image register point or memory location Aaaa Operand Data Type DL05 Range A aaa Inputs X 0 377 Outputs Y 0 377 Control Relays C 0 777 Stage S 0 377 Timer T 0 177 Counter CT 0 177 Special Relay SP 0 777 In the following Or example when input X1 or X2 is on output Y5 will energize STR 1 B ENT OR Q 2 C ENT OUT GX 5 F ENT Y5 OUT X1 X2 Handheld Programmer K...

Page 195: ... be opposite the state of the associated image register point or memory location Aaaa Operand Data Type DL05 Range A aaa Inputs X 0 377 Outputs Y 0 377 Control Relays C 0 777 Stage S 0 377 Timer T 0 177 Counter CT 0 177 Special Relay SP 0 777 In the following And example when input X1 and X2 are on output Y5 will energize STR 1 B ENT 2 C ENT OUT GX 5 F ENT AND V Y5 OUT X1 X2 Handheld Programmer Ke...

Page 196: ...ingAnd Store example the branch consisting of contacts X2 X3 and X4 have been anded with the branch consisting of contact X1 STR 1 B ENT STR ENT 2 C AND V ENT 3 D OR Q ENT 4 E ANDST L ENT OUT GX 5 F ENT Y5 OUT X1 X2 X4 X3 Handheld Programmer Keystrokes DirectSOFT In the following Or Store example the branch consisting of X1 and X2 have been ored with the branch consisting of X3 and X4 STR 1 B ENT ...

Page 197: ...input X1 is on output Y2 and Y5 will energize STR 1 B ENT OUT GX 2 C ENT OUT GX ENT 5 F Y2 OUT X1 Y5 OUT Handheld Programmer Keystrokes DirectSOFT The Or Out instruction allows more than one rung of discrete logic to control a single output Multiple Or Out instructions referencing the same output coil may be used since all contacts controlling the output are logically ORed together If the status o...

Page 198: ...OT instruction The above example rung is merely intended to show the visual representation of the NOT instruction The rung cannot be created or displayed in DirectSOFT versions earlier than 1 1i The Positive Differential instruction is typically known as a one shot When the input logic produces an off to on transition the output will energize for one CPU scan A aaa PD Operand Data Type DL05 Range ...

Page 199: ...tact closes for one CPU scan when the state of the associated image register point makes an On to Off transition Thereafter the contact remains open until the next On to Off transition the symbol inside the contact represents the transition Aaaa Operand Data Type DL05 Range A aaa Inputs X 0 377 Outputs Y 0 377 Control Relays C 0 777 Stage S 0 377 Timer T 0 177 Counter CT 0 177 In the following exa...

Page 200: ...image register point makes an On to Off transition closing it for one CPU scan Thereafter it remains open until another On to Off transition Aaaa Operand Data Type DL05 Range A aaa Inputs X 0 377 Outputs Y 0 377 Control Relays C 0 777 Stage S 0 377 Timer T 0 177 Counter CT 0 177 In the following example Y 5 will energize whenever X1 is on or for one CPU scan when X2 transitions from Off to On Y5 O...

Page 201: ...ated image register point makes an On to Off transition closing it for one CPU scan Thereafter it remains open until another On to Off transition Aaaa Operand Data Type DL05 Range A aaa Inputs X 0 377 Outputs Y 0 377 Control Relays C 0 777 Stage S 0 377 Timer T 0 177 Counter CT 0 177 In the following example Y5 will energize for one CPU scan whenever X1 is on and X2 transitions from Off to On Y5 O...

Page 202: ...mage register point memory location or a range of image registers points memory locations Once the point location is reset it is not necessary for the input to remain on A aaa RST aaa Optional memory range Operand Data Type DL05 Range A aaa Inputs X 0 377 Outputs Y 0 377 Control Relays C 0 777 Stage S 0 377 Timer T 0 177 Counter CT 0 177 In the following example when X1 is on Y2 through Y5 will en...

Page 203: ...puts Y 0 377 In the following example when X1 is ON Y3 Y5 will be turned OFF The execution of the ladder program will not be affected DirectSOFT PAUSE X1 Y5 Y7 Since the D2 HPP Handheld Programmer does not have a specific Pause key you can use the corresponding instruction number for entry 960 or type each letter of the command STR 1 B ENT Handheld Programmer Keystrokes 5 F ENT INST O 9 J 6 G 0 A ...

Page 204: ... Vaaa Bbbb B bbb Operand Data Type DL05 Range B aaa bbb V memory V All See page 4 28 All See page 4 28 Pointer P All See page 4 28 All See page 4 28 Constant K 0 9999 In the following example when the value in V memory location V2000 4933 Y3 will energize V2000 K4933 Y3 OUT DirectSOFT Handheld Programmer Keystrokes STR SHFT 4 E 2 C 0 A 0 A 0 A 4 E 9 J 3 D 3 D ENT OUT GX ENT 3 D In the following ex...

Page 205: ...ge 4 28 Pointer P All See page 4 28 All See page 4 28 Constant K 0 9999 In the following example when the value in V memory location V2000 4500 or V2002 2345 Y3 will energize 2 C 3 D 4 E 5 F ENT 4 E 5 F ENT 0 A 0 A Y3 OUT V2002 K2345 V2000 K4500 DirectSOFT Handheld Programmer Keystrokes SHFT 4 E 2 C 0 A 0 A 0 A STR OR Q SHFT 4 E 2 C 0 A 0 A 2 C OUT GX ENT 3 D In the following example when the valu...

Page 206: ... 28 Pointer P All See page 4 28 All See page 4 28 Constant K 0 9999 In the following example when the value in V memory location V2000 5000 and V2002 2345 Y3 will energize 2 C 3 D 4 E 5 F ENT 5 F 0 A ENT 0 A 0 A 2 C STR SHFT 4 E 0 A 0 A 0 A AND V SHFT 4 E 2 C 0 A 0 A 2 C OUT GX ENT 3 D Y3 OUT V2002 K2345 V2000 K5000 DirectSOFT Handheld Programmer Keystrokes In the following example when the value ...

Page 207: ... Operand Data Type DL05 Range A B aaa bbb V memory V All See page 4 28 All See page 4 28 Pointer P All See page 4 28 All See page 4 28 Constant K 0 9999 Timer T 0 177 Counter CT 0 177 In the following example when the value in V memory location V2000 1000 Y3 will energize ENT 3 D Y3 OUT V2000 K1000 DirectSOFT Handheld Programmer Keystrokes STR ENT OUT GX SHFT AND V 2 C 0 A 0 A 0 A 1 B 0 A 0 A 0 A ...

Page 208: ...28 Pointer P All See page 4 28 All See page 4 28 Constant K 0 9999 Timer T 0 177 Counter CT 0 177 In the following example when the value in V memory location V2000 6045 or V2002 2345 Y3 will energize 2 C 3 D 4 E 5 F ENT 6 G 0 A Y3 OUT V2000 K6045 V2002 K2345 DirectSOFT Handheld Programmer Keystrokes SHFT 4 E 2 C 0 A 0 A 0 A ENT STR OR Q OUT GX ENT 3 D 4 E 5 F SHFT AND V 2 C 0 A 0 A 2 C In the fol...

Page 209: ...r P All See page 4 28 All See page 4 28 Constant K 0 9999 Timer T 0 177 Counter CT 0 177 In the following example when the value in V memory location V2000 5000 and V2002 2345 Y3 will energize ENT 3 D 2 C 3 D 4 E 5 F ENT ENT 0 A 0 A 5 F 0 A 2 C Y3 OUT V2000 K5000 V2002 K2345 DirectSOFT Handheld Programmer Keystrokes STR SHFT 4 E 0 A 0 A 0 A AND V OUT GX SHFT AND V 2 C 0 A 0 A 2 C In the following ...

Page 210: ...a Inputs X 0 377 In the following example when X1 is on Y2 will energize ENT 2 C 1 B ENT X1 Y2 OUT Handheld Programmer Keystrokes DirectSOFT STR SHFT 8 I OUT GX In the following example when X1 is off Y2 will energize ENT 2 C 1 B ENT X1 Y2 OUT Handheld Programmer Keystrokes DirectSOFT STRN SP SHFT 8 I OUT GX aaa X The Or Immediate connects two contacts in parallel The status of the contact will be...

Page 211: ...he associated input point at the time the instruction is executed The image register is not updated aaa X The And Not Immediate connects two contacts in series The status of the contact will be opposite the status of the associated input point at the time the instruction is executed The image register is not updated Operand Data Type DL05 Range aaa Inputs X 0 377 In the following example when X1 a...

Page 212: ...rencing the same output coil may be used since all contacts controlling the output are ored together If the status of any rung is on at the time the instruction is executed the output will also be on OROUTI Y aaa Operand Data Type DL05 Range aaa Outputs Y 0 377 In the following example when X1 is on output point Y2 on the output module will turn on For instruction entry on the Handheld Programmer ...

Page 213: ... of outputs in the image register and the output point s at the time the instruction is executed Once the outputs are reset it is not necessary for the input to remain on RSTI Operand Data Type DL05 Range aaa Outputs Y 0 377 In the following example when X1 is on Y2 through Y5 will be set on in the image register and on the corresponding output points 1 B ENT X1 Y2 SETI Y5 DirectSOFT Handheld Prog...

Page 214: ... Current Value Timer preset T1 Y0 OUT Seconds 1 10 Seconds There are those applications that need an accumulating timer meaning it has the ability to time stop and then resume from where it previously stopped The accumulating timer works similarly to the regular timer but two inputs are required The start stop input starts and stops the timer When the timer stops the elapsed time is maintained Whe...

Page 215: ...te status bit for Timer 2 is TA2 TMR B bbb Preset Timer TMRF B bbb Preset Timer The timer discrete status bit and the current value are not specified in the timer instruction NOTE Timer preset constants K may be changed by using a handheld programmer even when the CPU is in Run Mode Therefore a V memory preset is required only if the ladder program must change the preset Operand Data Type DL05 Ran...

Page 216: ...ds 1 B ENT 3 D 0 A ENT ENT 0 A In the following example a single input timer is used with a preset of 4 5 seconds Comparative contacts are used to energize Y3 Y4 and Y5 at one second intervals respectively When X1 is turned off the timer will be reset to 0 and the comparative contacts will turn off Y3 Y4 and Y5 1 B ENT Handheld Programmer Keystrokes X1 TMR T20 K45 TA20 K10 TA20 K20 TA20 K30 Y4 OUT...

Page 217: ...equal to or greater than the preset value For example the discrete status bit for timer 2 would be T2 TMRA B bbb Enable Reset Preset Timer TMRAF B bbb Enable Reset Preset Timer The timer discrete status bit and the current value are not specified in the timer instruction NOTE The accumulating type timer uses two consecutive V memory locations for the 8 digit value and therefore two consecutive tim...

Page 218: ... ENT 2 C 1 B 0 A TMR N SHFT 0 A 3 D 0 A ENT STR SHFT MLR T ENT OUT GX ENT 0 A 6 G 1 B 1 B ENT 6 G In the following example a single input timer is used with a preset of 4 5 seconds Comparative contacts are used to energized Y3 Y4 and Y5 at one second intervals respectively The comparative contacts will turn off when the timer is reset Handheld Programmer Keystrokes TA20 K10 TA20 K20 TA20 K30 Y4 OU...

Page 219: ...nter has three inputs a count up input count down input and reset input The maximum count value is 99999999 The timing diagram below shows the relationship between the counter input counter reset associated discrete bit current value and counter preset X1 X1 CT2 1 2 1 2 3 0 Current Value X2 X2 UDC CT2 K3 X3 X3 Counter preset Up Down Reset Counts The stage counter has a count input and is reset by ...

Page 220: ...set Counter The counter discrete status bit and the current value are not specified in the counter instruction Discrete Status Bit The discrete status bit is accessed by referencing the associated CT memory location It will be on if the value is equal to or greater than the preset value For example the discrete status bit for counter 2 would be CT2 NOTE Counter preset constants K may be changed by...

Page 221: ... ENT 0 A 1 B 2 C MLR T 2 C Handheld Programmer Keystrokes cont SHFT In the following example when X1 makes an off to on transition counter CT2 will increment by one Comparative contacts are used to energize Y3 Y4 and Y5 at different counts When the reset C10 turns on the counter status bit will turn off and the counter current value will be 0 and the comparative contacts will turn off Handheld Pro...

Page 222: ...V or CT memory locations The V memory location is the counter location 1000 For example the counter current value for CT3 resides in V memory location V1003 Discrete Status Bit The discrete status bit is accessed by referencing the associated CT memory location It will be on if the value is equal to or greater than the preset value For example the discrete status bit for counter 2 would be CT2 SGC...

Page 223: ...SHFT 2 C 7 H ENT SHFT RST S 6 G SHFT ENT Handheld Programmer Keystrokes cont SHFT SHFT SHFT MLR T In the following example when X1 makes an off to on transition counter CT2 will increment by one Comparative contacts are used to energize Y3 Y4 and Y5 at different counts Although this is not shown in the example when the counter is reset using the Reset instruction the counter status bit will turn o...

Page 224: ...eferencing the associated CT memory location Operating as a counter done bit it will be on if the value is equal to or greater than the preset value For example the discrete status bit for counter 2 would be CT2 UDC B bbb Up Down Reset Caution The UDC uses two V memory locations for the 8 digit current value This means that the UDC uses two consecutive counter locations If UDC CT1 is used in the p...

Page 225: ...C STR 3 D SHFT ISG U 3 D 2 C 2 C ENT ENT STR SHFT ENT OUT GX ENT 0 A 1 B 2 C MLR T 2 C SHFT In the following example when X1 makes an off to on transition counter CT2 will increment by one Comparative contacts are used to energize Y3 and Y4 at different counts When the reset X3 turns on the counter status bit will turn off the current value will be 0 and the comparative contacts will turn off AND ...

Page 226: ...the status of the data input is placed into the starting bit position in the shift register The direction of the shift depends on the entry in the From and To fields From C0 to C17 would define a block of sixteen bits to be shifted from left to right From C17 to C0 would define a block of sixteen bits to be shifted from right to left The maximum size of the shift register block depends on the numb...

Page 227: ...y location V2000 to V memory location V2010 V2000 LD V2000 X1 Copy data from V2000 to the lower 16 bits of the accumu lator Copy data from the lower 16 bits of the accumulator to V2010 OUT V2010 V2010 Acc 8 9 3 5 8 9 3 5 0 0 0 0 8 9 3 5 Unused accumulator bits are set to zero Since the accumulator is 32 bits and V memory locations are 16 bits the Load Double and Out Double or variations thereof us...

Page 228: ...22 21 20 19 18 17 16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 The upper 16 bits of the accumulator will be set to 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 Acc Acc Some of the data manipulation instructions use 32 bits They use two consecutive V memory locations or an 8 digit BCD constant to manipulate data in the...

Page 229: ...pushing the value 3245 onto the stack Load the value 6363 into the accumu lator pushing the value 5151 to the 1st stack location and the value 3245 to the 2nd stack location LD K3245 X1 LD K5151 LD K6363 Constant 3 2 4 5 0 0 0 0 3 2 4 5 Acc X X X X X X X X Current Acc value Previous Acc value X X X X X X X X Level 1 X X X X X X X X Level 2 X X X X X X X X Level 3 X X X X X X X X Level 4 X X X X X ...

Page 230: ...stack values up one location OUT V2000 OUT V2001 Acc V2001 3 7 9 2 0 0 0 0 4 5 4 5 Acc 0 0 0 0 3 7 9 2 Previous Acc value Current Acc value Acc V2002 7 9 3 0 0 0 0 0 3 7 9 2 Acc X X X X 7 9 3 0 Previous Acc value Current Acc value OUT V2002 Copy data from the accumulator to V2000 Copy data from the accumulator to V2001 Copy data from the accumulator to Copy data from the accumulator to V2002 Many ...

Page 231: ...nstruction automatically converts the Octal address to Hex V2000 P2000 contains the value 440 Hex 440 Hex 2100 Octal which contains the value 2635 LDA O 2100 X1 OUT V 2000 Copy the data from the lower 16 bits of the accumulator to V2000 V2100 0 4 4 0 V2076 X X X X V2077 X X X X V2100 2 6 3 5 V2101 X X X X V2102 X X X X V2103 X X X X V2104 X X X X V2105 X X X X S S V2200 2 6 3 5 V2201 X X X X S S L...

Page 232: ...SP70 on when the value loaded into the accumulator by any instruction is zero SP76 on when the result in the accumulator is negative NOTE Two consecutive Load instructions will place the value of the first load instruction onto the accumulator stack In the following example when X1 is on the value in V2000 will be loaded into the accumulator and output to V2010 LD V2000 X1 Load the value in V2000 ...

Page 233: ...he accumulator by any instruction is zero SP76 on when the value loaded into the accumulator by any instruction is zero NOTE Two consecutive Load instructions will place the value of the first load instruction onto the accumulator stack In the following example when X1 is on the 32 bit value in V2000 and V2001 will be loaded into the accumulator and output to V2010 and V2011 1 B ENT 2 C 0 A 0 A 0 ...

Page 234: ... of the first load instruction onto the accumulator stack In the following example when C0 is on the binary pattern of C10 C16 7 bits will be loaded into the accumulator using the Load Formatted instruction The lower 7 bits of the accumulator are output to Y0 Y6 using the Out Formatted instruction 0 A 7 H ENT Handheld Programmer Keystrokes LDF C10 K7 C0 Load the status of 7 consecutive bits C10 C1...

Page 235: ...y any instruction is zero NOTE Two consecutive Load instructions will place the value of the first load instruction onto the accumulator stack In the following example when X1 is on the octal number 40400 will be converted to a HEX 4100 and loaded into the accumulator using the Load Address instruction The value in the lower 16 bits of the accumulator is copied to V2000 using the Out instruction 1...

Page 236: ...00 8 9 3 5 8 9 3 5 0 0 0 0 8 9 3 5 DirectSOFT The unused accumulator bits are set to zero STR SHFT ANDST L 3 D OUT GX SHFT AND V 2 C 0 A 1 B 0 A ENT OUTD A aaa The Out Double instruction is a 32 bit instruction that copies the value in the accumulator to two consecutive V memory locations at a specified starting location Aaaa Operand Data Type DL05 Range A aaa V memory V All See page 4 28 Pointer ...

Page 237: ...the status of 7 consecutive bits C10 C16 into the accumulator OUTF Y0 K7 Copy the value of the specified number of bits from the accumulator to Y20 Y26 K7 C10 Location Constant 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 K7 Y0 Location Constant C...

Page 238: ...or Stack 0 0 0 0 7 9 3 0 Level 1 X X X X X X X X Level 2 X X X X X X X X Level 3 X X X X X X X X Level 4 X X X X X X X X Level 5 X X X X X X X X Level 6 X X X X X X X X Level 7 X X X X X X X X Level 8 Accumulator Stack X X X X X X X X Level 1 X X X X X X X X Level 2 X X X X X X X X Level 3 X X X X X X X X Level 4 X X X X X X X X Level 5 X X X X X X X X Level 6 X X X X X X X X Level 7 X X X X X X X...

Page 239: ...n the accumulator is anded with the value in V2006 using the And instruction The value in the lower 16 bits of the accumulator is output to V2010 using the Out instruction AND V2006 Handheld Programmer Keystrokes LD V2000 X1 Load the value in V2000 into the lower 16 bits of the accumulator AND V2006 AND the value in the accumulator with the value in V2006 OUT V2010 Copy the lower 16 bits of the ac...

Page 240: ...ruction The value in the accumulator is anded with 36476A38 using the And double instruction The value in the accumulator is output to V2010 and V2011 using the Out Double instruction AND 36476A38 Handheld Programmer Keystrokes LDD V2000 X1 Load the value in V2000 and V2001 into the accumulator ANDD K36476A38 AND the value in the accumulator with the constant value 36476A38 OUTD V2010 Copy the val...

Page 241: ...or is ored with V2006 using the Or instruction The value in the lower 16 bits of the accumulator are output to V2010 using the Out instruction 3 D OR V2006 Handheld Programmer Keystrokes LD V2000 X1 Load the value in V2000 into the lower 16 bits of the accumulator OR V2006 Or the value in the accumulator with the value in V2006 OUT V2010 Copy the value in the lower 16 bits of the accumulator to V2...

Page 242: ... Double instruction The value in the accumulator is ored with 36476A38 using the Or Double instruction The value in the accumulator is output to V2010 and V2011 using the Out Double instruction JMP K OR 36476A38 Handheld Programmer Keystrokes LDD V2000 X1 Load the value in V2000 and V2001 into accumulator ORD K36476A38 OR the value in the accumulator with the constant value 36476A38 OUTD V2010 Cop...

Page 243: ...ve ored with V2006 using the Exclusive Or instruction The value in the lower 16 bits of the accumulator are output to V2010 using the Out instruction XOR V2006 Handheld Programmer Keystrokes LD V2000 X1 Load the value in V2000 into the lower 16 bits of the accumulator XOR V2006 XOR the value in the accumulator with the value in V2006 OUT V2010 Copy the lower 16 bits of the accumulator to V2010 0 0...

Page 244: ...e instruction The value in the accumulator is exclusively ored with 36476A38 using the Exclusive Or Double instruction The value in the accumulator is output to V2010 and V2011 using the Out Double instruction JMP K SHFT SHFT 3 D OR Q XORD 36476A38 Handheld Programmer Keystrokes LDD V2000 X1 Load the value in V2000 and V2001 into the accumulator XORD K36476A38 XORD the value in the accumulator wit...

Page 245: ...same flags is executed In the following example when X1 is on the constant 4526 will be loaded into the lower 16 bits of the accumulator using the Load instruction The value in the accumulator is compared with the value in V2000 using the Compare instruction The corresponding discrete status flag will be turned on indicating the result of the comparison In this example if the value in the accumula...

Page 246: ...another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 and V2001 will be loaded into the accumulator using the Load Double instruction The value in the accumulator is compared with the value in V2010 and V2011 using the CMPD instruction The corresponding discrete status flag will be turned on indicating the result of the comparison In thi...

Page 247: ... The status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 will be loaded into the accumulator using the Load instruction The value in the lower 16 bits of the accumulator are added to the value in V2006 using the Add instruction The value in the accumulator is copied to V2010 using the Out instruction D...

Page 248: ...as encountered NOTE The status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 and V2001 will be loaded into the accumulator using the Load Double instruction The value in the accumulator is added with the value in V2006 and V2007 using the Add Double instruction The value in the accumulator is copied to ...

Page 249: ...NOTE The status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 will be loaded into the accumulator using the Load instruction The value in V2006 is subtracted from the value in the accumulator using the Subtract instruction The value in the accumulator is copied to V2010 using the Out instruction DirectS...

Page 250: ... a NON BCD number was encountered NOTE The status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 and V2001 will be loaded into the accumulator using the Load Double instruction The value in V2006 and V2007 is subtracted from the value in the accumulator The value in the accumulator is copied to V2010 and...

Page 251: ...status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 will be loaded into the accumulator using the Load instruction The value in V2006 is multiplied by the value in the accumulator The value in the accumulator is copied to V2010 and V2011 using the Out Double instruction DirectSOFT Handheld Programmer K...

Page 252: ...nto the accumulator When converted to BCD the number is 12345678 That numberis stored in V1400 and V1401 After loading the constant K2 into the accumulator we multiply it times 12345678 which is 24691356 DirectSOFT Display Handheld Programmer Keystrokes LDD Kbc614e X1 Load the hex equivalent of 12345678 decimal into the accumulator BCD Convert the value to BCD format It will occupy eight BCD digit...

Page 253: ...er was encountered NOTE The status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 will be loaded into the accumulator using the Load instruction The value in the accumulator will be divided by the value in V2006 using the Divide instruction The value in the accumulator is copied to V2010 using the Out in...

Page 254: ...he same flag In the following example when X1 is on the value in V1400 and V1401 will be loaded into the accumulator using the Load Double instruction The value in the accumulator is divided by the value in V1420 and V1421 using the Divide Double instruction The first part of the quotient resides in the accumulator an the remainder resides in the first stack location The value in the accumulator i...

Page 255: ...ccumulator to be zero SP75 on when a BCD instruction is executed and a NON BCD number was encountered NOTE Status flags are valid only until another instruction uses the same flag In the following increment example when C5 is on the value in V1400 increases by one Handheld Programmer Keystrokes DirectSOFT Display C5 INC V1400 Increment the value in V1400 by 1 V1400 8 9 3 5 V1400 8 9 3 6 STR 8 I TM...

Page 256: ... A 3 D STR 2 C 5 F SHFT ENT SHFT 8 I TMR N 2 C 1 B 2 C 0 A 0 A 0 A ENT A aaa DECB The Decrement Binary instruction decrements a binary value in a specified V memory location by 1 each time the instruction is executed Operand Data Type DL05 Range A aaa V memory V All See page 4 28 Pointer P All See page 4 28 Discrete Bit Flags Description SP63 on when the result of the instruction causes the value ...

Page 257: ...when a signed addition or subtraction results in a incorrect sign bit NOTE Status flags are valid only until another instruction uses the same flag In the following example when X1 is on the value in V1400 will be loaded into the accumulator using the Load instruction The binary value in the accumulator will be added to the binary value in V1420 using the Add Binary instruction The value in the ac...

Page 258: ...OTE Status flags are valid only until another instruction uses the same flag In the following example when X1 is on the value in V1400 will be loaded into the accumulator using the Load instruction The binary value in V1420 is subtracted from the binary value in the accumulator using the Subtract Binary instruction The value in the accumulator is copied to V1500 using the Out instruction DirectSOF...

Page 259: ...he same flag In the following example when X1 is on the value in V1400 will be loaded into the accumulator using the Load instruction The binary value in V1420 is multiplied by the binary value in the accumulator using the Multiply Binary instruction The value in the accumulator is copied to V1500 using the Out instruction DirectSOFT Display Handheld Programmer Keystrokes LD V1400 X1 Load the valu...

Page 260: ...s flags are valid only until another instruction uses the same flag In the following example when X1 is on the value in V1400 will be loaded into the accumulator using the Load instruction The binary value in the accumulator is divided by the binary value in V1420 using the Divide Binary instruction The value in the accumulator is copied to V1500 using the Out instruction DirectSOFT Display Handhe...

Page 261: ...F X10 K8 X1 Load the value represented by discrete locations X10 X17 into the accumulator SUM Sum the number of bits in the accumulator set to 1 OUT V1500 Copy the value in the lower 16 bits of the accumulator to V1500 X10 X11 X12 X13 ON ON OFF ON X14 X15 X16 X17 OFF OFF ON ON 0 0 0 0 0 0 0 0 1 1 0 0 1 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 31 30 29 28 27 26 25...

Page 262: ...ammer Keystrokes DirectSOFT LDD V2000 X1 Load the value in V2000 and V2001 into the accumulator SHFL K2 The bit pattern in the accumulator is shifted 2 bit positions to the left OUTD V2010 Copy the value in the accumulator to V2010 and V2011 0 0 1 1 0 0 0 1 0 0 0 0 0 0 0 1 V2010 1 1 0 0 0 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 31 30 29 28 27 26 ...

Page 263: ...in the accumulator is copied to V2010 and V2011 using the Out Double instruction Handheld Programmer Keystrokes DirectSOFT LDD V2000 X1 Load the value in V2000 and V2001 into the accumulator SHFR K2 The bit pattern in the accumulator is shifted 2 bit positions to the right OUTD V2010 Copy the value in the accumulator to V2010 and V2011 0 0 1 1 0 0 0 1 0 0 0 0 0 0 0 1 V2010 0 1 0 0 1 1 0 0 0 1 0 0 ...

Page 264: ...The bit position set to a 1 in the accumulator is encoded to the corresponding 5 bit binary value using the Encode instruction The value in the lower 16 bits of the accumulator is copied to V2010 using the Out instruction Handheld Programmer Keystrokes DirectSOFT LD V2000 X1 Load the value in V2000 into the lower 16 bits of the accumulator ENCO Encode the bit position set to 1 in the accumulator t...

Page 265: ...ponding bit position to a 1 using the Decode instruction Handheld Programmer Keystrokes DirectSOFT LDF X10 K5 X1 Load the value in represented by discrete locations X10 X14 into the accumulator DECO Decode the five bit binary pattern in the accumulator and set the corresponding bit position to a 1 X10 X11 X12 X13 ON ON OFF ON X14 OFF 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ...

Page 266: ...T 0 0 0 0 6 F 7 1 V2010 V2011 Handheld Programmer Keystrokes DirectSOFT LDD V2000 X1 Load the value in V2000 and V2001 into the accumulator BIN Convert the BCD value in the accumulator to the binary equivalent value 1 0 0 0 0 1 0 1 0 0 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 8 4 2 1 8 4 2 1 8 4 2 1 8 4 2 1 8 4 2 1 8 4 2 1 8 4 2 1 8 4 2 1 Acc 0 0 0 2 8 5 2 9 V2000 V2001 BCD Value Binary Equival...

Page 267: ...value in the accumulator to the BCD equivalent value 0 1 1 0 1 1 1 1 0 1 1 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 Acc 0 0 0 0 6 F 7 1 V2000 V2001 BCD Equivalent Value Binary Value 1 0 0 0 0 1 0 1 0 0 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 Acc 1 2 4 8 1 6 3 2...

Page 268: ...T LDD V2000 X1 Load the value in V2000 and V2001 into the accumulator INV Invert the binary bit pattern in the accumulator OUTD V2010 Copy the value in the accumulator to V2010 and V2011 0 0 0 0 0 0 1 0 0 1 0 1 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 0 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 Acc 0 4 0 5 0 2...

Page 269: ...ng V memory location Vaaa for the HEX table in the ATH instruction Helpful Hint For parameters that require HEX values when referencing memory locations the LDA instruction can be used to convert an octal address to the HEX equivalent and load the value into the accumulator Operand Data Type DL05 Range aaa Vmemory V All See p 4 28 Discrete Bit Flags Description SP53 On when the value of the operan...

Page 270: ...igit and their ASCII equivalents are two digits This means a HEX table of two V memory locations would require four V memory locations for the equivalent ASCII table The function parameters are loaded into the accumulator stack and the accumulator by two additional instructions Listed below are the steps necessary to program a HEX to ASCII table function The example on the following page shows a p...

Page 271: ...d Programmer Keystrokes LD K2 X1 Load the constant value into the lower 16 bits of the accumulator This value defines the number of V locations in the HEX table LDA O 1500 Convert octal 1500 to HEX 340 and load the value into the accumulator HTA V1400 V1400 is the starting location for the ASCII table The conversion is executed by this instruction ASCII TABLE Hexadecimal Equivalents 1234 33 34 V14...

Page 272: ...copied to V2010 Discrete Bit Flags Description SP63 On when the result of the instruction causes the value in the accumulator to be zero SP70 On anytime the value in the accumulator is negative Handheld Programmer Keystrokes DirectSOFT LDF K16 X10 X1 Load the value represented by X10 X27 into the lower 16 bits of the accumulator GRAY Convert the 16 bit grey code value in the accumulator to a BCD v...

Page 273: ...0 See example on the next page Note If the number used to specify the order contains duplicate numbers the most significant duplicate number is valid The result resides in the accumulator See example on the next page Step 3 Insert the SFLDGT instruction Discrete Bit Flags Description SP63 On when the result of the instruction causes the value in the accumulator to be zero SP70 On anytime the value...

Page 274: ...the result D E F 0 9 A B C Handheld Programmer Keystrokes DirectSOFT LDD V2000 X1 Load the value in V2000 and V2001 into the accumulator LDD V2006 Load the value in V2006 and V2007 into the accumulator OUTD V2010 Copy the value in the accumulator to V2010 and V2011 SFLDGT Shuffle the digits in the first level of the accumulator stack based on the pattern in the accumulator The result is in the acc...

Page 275: ...inter P All See page 4 28 Discrete Bit Flags Description SP53 On when the value of the operand is larger than the accumulator can work with In the following example when X1 is on the constant value K6 is loaded into the accumulator using the Load instruction This value specifies the length of the table and is placed in the first stack location after the Load Address instruction is executed The oct...

Page 276: ...isted below are the steps necessary to program the Move Memory Cartridge and Load Label functions LDLBL aaa K S Step 1 Load the number of words to be copied into the second level of the accumulator stack S Step 2 Load the offset for the data label area in ladder memory and the beginning of the V memory block into the first level of the stack S Step 3 Load the source data label LDLBL Kaaa into the ...

Page 277: ...ation and executes the copying of data from the Data Label Area to V memory DirectSOFT LD K4 X1 Load the value 4 into the accumulator specifying the number of locations to be copied LD K0 Load the value 0 into the accumulator specifying the offset for source and destination locations LDLBL K1 Load the value 1 into the accumulator specifying the Data Label Area K1 as the starting address of the dat...

Page 278: ...e placed after the End instruction The End instruction is not conditional therefore no input contact is allowed END DirectSOFT Handheld Programmer Keystrokes END SHFT 4 E TMR N 3 D ENT The Stop instruction changes the operational mode of the CPU from Run to Program Stop mode This instruction is typically used to stop PLC operation in an error condition STOP In the following example when C0 turns o...

Page 279: ...he program mode if the scan time exceeds the watch dog timer setting Placement of the RSTWT instruction in the program is very important The instruction has to be executed before the scan time exceeds the watch dog timer s setting If the scan time is consistently longer than the watch dog timer s setting the timeout value may be permanently increased from the default value of 200ms by AUX 55 on th...

Page 280: ...instructions cannot be nested The normal I O update and CPU housekeeping is suspended while executing the For Next loop The program scan can increase significantly depending on the amount of times the logic between the For and Next instruction is executed With the exception of immediate I O instructions I O will not be updated until the program execution is completed for that scan Depending on the...

Page 281: ...ay or may not be necessary depending on your application Also The RSTWT instruction is not necessary if the For Next loop does not extend the scan time larger the Watch Dog Timer setting For more information on the Watch Dog Timer refer to the RSTWT instruction X1 DirectSOFT Handheld Programmer Keystrokes K3 FOR RSTWT X20 Y5 OUT NEXT 1 2 3 STR SHFT 5 F INST O ORN R SHFT ORN R RST S MLR T ANDN W ML...

Page 282: ...me constant number K as the GTS instruction which called the subroutine By placing code in a subroutine it is only scanned and executed when needed since it resides after the End instruction Code which is not scanned does not impact the overall scan time of the program GTS K aaa SBR Operand Data Type DL05 Range aaa Constant K 1 FFFF When a Subroutine Return is executed in the subroutine the CPU wi...

Page 283: ... will be reset to off and then the CPU will return to the main body of the program DirectSOFT Display Handheld Programmer Keystrokes SBR K3 X1 K3 GTS END Y5 OUTI S S S X20 Y10 OUTI X21 X35 RTC X35 RSTI Y0 Y17 RT K10 LD C0 STR SHFT 6 G MLR T RST S SHFT RST S 1 B ORN R STR SHFT 8 I 2 C 0 A ENT OUT GX STR SHFT 8 I 3 D ENT 5 F OUT GX SHFT ORN R MLR T ENT SHFT 4 E TMR N 3 D ENT 1 B ENT 3 D ENT 3 D ENT ...

Page 284: ...n the subroutine will be executed The CPU will return to the main body of the program after the RT instruction is executed DirectSOFT Handheld Programmer Keystrokes SBR K3 X1 K3 GTS END Y5 OUT S S S X20 Y10 OUT X21 RT S S STR SHFT 6 G MLR T RST S SHFT RST S 1 B ORN R STR SHFT 8 I 2 C 0 A ENT OUT GX STR SHFT 8 I 2 C ENT 1 B OUT GX SHFT ORN R MLR T ENT SHFT 4 E TMR N 3 D ENT 1 B ENT 3 D ENT 3 D ENT ...

Page 285: ...ponding MLS instruction The MLR reference is one less than the corresponding MLS MLR Operand Data Type DL05 Range aaa Constant K 0 7 The Master Line Set MLS and Master Line Reset MLR instructions allow you to quickly enable or disable sections of the RLL program This provides program control flexibility The following example shows how the MLS and MLR instructions operate by creating a sub power ra...

Page 286: ...her of the MLS coils K1 MLS X0 C0 OUT X1 C1 OUT X2 Y0 OUT X3 K2 MLS X10 Y1 OUT X5 Y2 OUT X4 K1 MLR C2 OUT X5 Y3 OUT X6 K0 MLR Y4 OUT X7 A C D B DirectSOFT Handheld Programmer Keystrokes STR ENT 0 A MLS Y 1 B ENT STR 1 B ENT OUT GX SHFT ENT 2 C 0 A STR ENT 2 C OUT GX SHFT ENT 2 C 1 B STR ENT 3 D OUT GX ENT 0 A STR ENT 0 A 1 B MLS Y ENT 2 C STR ENT 5 F OUT GX ENT 1 B STR ENT OUT GX ENT 4 E 2 C MLR T...

Page 287: ...he ladder program resumes from the point at which it was interrupted See Chapter 3 the section on Mode 40 Interrupt Operation for more details on interrupt configuration In the DL05 only one hardware interrupt is available Operand Data Type DL05 Range Constant O 0 1 An Interrupt Return is normally executed as the last instruction in the interrupt routine It returns the CPU to the point in the main...

Page 288: ...der logic in the interrupt routine will be performed The CPU will return to the main body of the program after the IRT instruction is executed DirectSOFT INT O 0 X2 ENI DISI S S S X2 END Y5 SETI X1 Y7 SETI X3 IRT Handheld Programmer Keystrokes S S 8 I ORN R MLR T STR SHFT 8 I 1 B ENT SHFT 8 I 5 F ENT STR SHFT 8 I 3 D ENT SHFT 8 I ENT 7 H SHFT 4 E TMR N 3 D ENT STR ENT 2 C SHFT 4 E TMR N 8 I ENT ST...

Page 289: ...V7633 STR SHFT ANDST L 3 D SHFT 0 A OUT GX SHFT AND V ENT JMP K 1 B ENT 7 H 6 G 3 D 4 E STR SHFT 4 E TMR N 8 I ENT STRN SP SHFT ENT 3 D 8 I RST S 8 I 8 I ORN R MLR T STR SHFT 8 I 2 C ENT SHFT 8 I 5 F ENT SHFT 8 I ENT SHFT 8 I ENT 0 A SHFT 4 E TMR N 3 D ENT SHFT 8 I TMR N MLR T ENT SHFT ENT 0 A 1 B ENT ENT ENT 4 E 4 E 7 H 3 D SET X SET X STRN SP LD K104 Load the constant value K10 into the lower 16...

Page 290: ...rea Operand Data Type DL05 Range A aaa V memory V All See page 4 28 Constant K 1 FFFF Discrete Bit Flags Description SP50 On when the FAULT instruction is executed In the following example when X1 is on the message SW 146 will display on the handheld programmer The NCONs use the HEX ASCII equivalent of the text to be displayed The HEX ASCII for a blank is 20 a 1 is 31 4 is 34 SW 146 DirectSOFT DLB...

Page 291: ...t instruction is used with the DLBL instruction to store ASCII text for use with other instructions Two ASCII characters can be stored in an ACON instruction If only one character is stored in a ACON a leading space will be inserted Operand Data Type DL05 Range aaa ASCII A 0 9 A Z K aaa NCON The Numerical Constant instruction is used with the DLBL instruction to store the HEX ASCII equivalent of n...

Page 292: ...ion for information on displaying messages The DV 1000 Manual also has information on displaying messages DirectSOFT Handheld Programmer Keystrokes DLBL K1 S S END S ACON A SW NCON K 2031 NCON K 3436 S S SHFT 4 E TMR N 3 D ENT SHFT 3 D ANDST L 1 B ANDST L 1 B ENT SHFT 0 A 2 C INST O TMR N SHFT TMR N 2 C INST O TMR N SHFT TMR N 2 C INST O TMR N ENT 3 D 3 D 4 E 6 G ENT 3 D 2 C 0 A 1 B ENT RST S ANDN...

Page 293: ...ed below on this page To configure a port in DirectSOFT choose the PLC menu then Setup then Setup Secondary Comm Port S Port From the port number list box at the top choose Port 2 S Protocol Click the check box to the left of Non sequence and then you ll see the dialog box shown below S Baud Rate Choose the baud rate that matches your printer S Stop Bits Parity Choose number of stop bits and parit...

Page 294: ...the output to the printer Example Length 0 without character A Length 1 with character A Length 1 with blank Length 1 with double quotation mark R L Length 2 with one CR and one LF 0 D 0 A Length 2 with one CR and one LF Length 1 with one mark In printing an ordinary line of text you will need to include double quotation marks before and after the text string Error code 499 will occur in the CPU w...

Page 295: ...lowing example prints a message containing text and a variable The reactor temperature labels the data which is at V2000 You can use the B qualifier after the V2000 if the data is in BCD format for example The final string adds the units of degrees to the line of text and the N adds a carriage return line feed X1 Print the message to Port 2 when X1 makes an off to on transition PRINT K2 Reactor te...

Page 296: ...ints the status of C00 in ON OFF format V2000 15 BOOL Prints the status of bit 15 in V2000 in TRUE FALSE format The maximum numbers of characters you can print is 128 The number of characters for each element is listed in the table below Element type Maximum Characters Text 1 character 1 16 bit binary 6 32 bit binary 11 4 digit BCD 4 8 digit BCD 8 Floating point real number 12 Floating point real ...

Page 297: ...ransferred into the accumulator the next instruction pushes this word onto the top of the stack Step 3 Load the starting Master CPU address into the accumulator This is the memory location where the data read from the slave will be put This parameter requires a HEX value Step 4 Insert the RX instruction which specifies the starting V memory location Aaaa where the data will be read from in the sla...

Page 298: ...e number of bytes to be read LDA O 2300 Octal address 2300 is converted to 4C0 HEX and loaded into the accumulator V2300 is the starting location for the Master CPU where the specified data will be read into RX V2000 V2000 is the starting location in the for the Slave CPU where the specified data will be read from V2001 8 5 3 4 V2002 1 9 3 6 V2003 9 5 7 1 V2004 1 4 2 3 S S S S V1777 X X X X V2000 ...

Page 299: ... into the accumulator the next instruction pushes this word onto the top of the stack Step 3 Load the starting Master CPU address into the accumulator This is the memory location where the data will be written from This parameter requires a HEX value Step 4 Insert the WX instruction which specifies the starting V memory location Aaaa where the data will be written to in the slave Helpful Hint For ...

Page 300: ...tes to be written LDA O 2300 WX V2000 V2000 is the starting location in the for the Slave CPU where the specified data will be written to V2001 8 5 3 4 V2002 1 9 3 6 V2003 9 5 7 1 V2004 1 4 2 3 S S S S V1777 X X X X V2000 3 4 5 7 Master CPU SP116 V2005 X X X X V2301 8 5 3 4 V2302 1 9 3 6 V2303 9 5 7 1 V2304 1 4 2 3 S S S S V2277 X X X X V2300 3 4 5 7 V2305 X X X X Slave CPU Octal address 2300 is c...

Page 301: ...16 Drum Instruction Programming In This Chapter Ċ Introduction Ċ Step Transitions Ċ Overview of Drum Operation Ċ Drum Control Techniques Ċ Drum Instruction Ċ EDrum Instruction ...

Page 302: ...eraction makes or breaks electrical contact with the wipers creating electrical outputs from the drum The outputs are wired to devices on a machine for On Off control Drums usually have a finite number of positions within one rotation called steps Each step represents some process step At powerup the drum resets to a particular step The drum rotates from one step to the next based on a timer or on...

Page 303: ... f F F F f F F f F f f F f F F f f f F f f F f f f F f f F f F f F f F f f F f f f F f f F f F f F f F F f F f f f f f f f F F f f f F f f f f f f f f f f F F F f f f f f f F f f f F f f f f F f f f f F f f F f f F F f f F f F F f F F f f f F f f f f f f f f F F f F f f f f f f f f F f f f F F f F F F f f f f F f F f F f F f f F F f f F f f f f F f F f F F f f F 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 304: ...tep to another based on time and or an external event input Each step has its own transition condition which you assign during the drum instruction entry The figure below shows how timer only transitions work F f f f F f F f f f f F F f f f Step 1 Outputs f f f F f f f f F F f F f f F F Step 2 Outputs Has counts per step expired No Yes Increment count timer Use next transition criteria The drum st...

Page 305: ...hat is much faster than the CPU scan time Step transitions may also occur based on time and or external events The figure below shows how step transitions work in these cases Is Step event true F f f f F f F f f f f F F f f f Step 1 Outputs f f f F f f f f F F f F f f F F Step 2 Outputs No Yes Increment count timer Has step counts expired No Yes Use next transition criteria When the drum enters St...

Page 306: ...e progress of the drum instruction and can be monitored by your ladder program Suppose we program a timer drum to have 8 steps and we select CT10 for the counter number remember counter numbering is in octal Counter usage is shown to the right The right column holds typical values interpreted below CT10 Counts in step V1010 1528 CT11 Timer Value V1011 0200 CT12 Preset Step V1012 0001 CT13 Current ...

Page 307: ...r the last step Having finished a drum cycle the Start and Jog inputs have no effect at this point The drum leaves the drum complete state when the Reset input becomes active or on a program to run mode transition It resets the drum complete bit such as CT0 and then goes directly to the appropriate step number defined as the preset step Are transition conditions met F F F f f f F f f F f F F F f F...

Page 308: ... the drum The inputs and their functions are S Start The Start input is effective only when Reset is off When Start is on the drum timer runs if it is in a timed transition and the drum looks for the input event during event transitions When Start is off the drum freezes in its current state Reset must remain off and the drum outputs maintain their current on off pattern S Jog The jog input is onl...

Page 309: ... configuration non retentive versus retentive The choice of the starting step on powerup and program to run mode transitions are important to consider for your application Please refer to the following chart If the counter memory is configured as non retentive the drum is initialized the same way on every powerup or program to run mode transition However if the counter memory is configured to be r...

Page 310: ...running waiting for an event and or running the timer depends on the setup After the drum enters Step 2 Reset turns On while Start is still On Since Reset has priority over Start the drum goes to the preset step Step 1 Note that the drum is held in the preset step during Reset and that step does not run respond to events or run the timer until Reset turns off After the drum has entered step 3 the ...

Page 311: ...um Applications often require drums that automatically start over once they complete a cycle This is easily accomplished using the drum complete bit In the figure to the right the drum instruction setup is for CT0 so we logically OR the drum complete bit CT0 with the Reset input When the last step is done the drum turns on CT0 which resets itself to the preset step also resetting CT0 Contact X2 st...

Page 312: ...f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f Fffff Fffff Fffff Fffff Fffff Fffff Fffff Fffff Fffff Fffff Fffff Fffff Fffff Fffff Fffff Fffff Discrete Output Assignment Counter Number Step Preset Timebase Control Inputs Step Number Counts...

Page 313: ...1 second per count 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 1 K0025 DRUM CT 0 Step Preset K 1 0 01 sec Count K 10 Step Counts 2 K0020 3 K1500 4 K0045 5 K0180 6 K0923 7 K1200 8 K8643 9 K1200 10 K4000 11 12 13 14 15 16 Start Reset f f f f F f f F F f f F...

Page 314: ... Counter Number Step Preset Timebase Control Inputs Step Number Counts per Step Output Pattern f Off F On Start Reset Jog Step Counts Event Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Eeeee Event per step 15 0 The Event Drum features 16 steps and 16 discrete outputs Step transitions occur on timed and or event basis The jog input also advances the step...

Page 315: ...is left blank And the output pattern for step 1 programs all outputs off which is a typically desirable powerup condition 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 1 K0001 EDRUM CT 4 Step Preset K 1 0 01 sec Count K 10 2 K0020 3 K0150 4 K0048 5 K0180 6 K0923 7 K0120 8 K0864 9 K1200 10 K0400 11 K0000 12 13 14 ...

Page 316: ...G U ORST M 0 A ENT After entering the EDRUM mnemonic as above the handheld programmer creates an input form for all the drum parameters The input form consists of approximately fifty or more default mnemonic entries containing DEF define statements The default mnemonics are already input for you so they appear automatically Use the NXT and PREV keys to move forward and backward through the form On...

Page 317: ...000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 Outputs DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 Counts Step skip over unused steps NOTE You may use the NXT and PREV keys to skip past entries for unused outputs or steps Continued on ne...

Page 318: ... DEF K0000 DEF K0000 DEF K0000 step 1 pattern 0000 Last rung Events 6 G 1 16 NEXT SHFT MLS Y 4 E NEXT SHFT SET X 1 B NEXT SHFT SET X 2 C NEXT SHFT 2 C 0 A NEXT SHFT 2 C NEXT 1 B SHFT SET X NEXT 0 A SHFT SET X NEXT 5 F SHFT SET X 3 D NEXT SHFT MLS Y 7 H NEXT SHFT 2 C 2 C 0 A NEXT NEXT NEXT NEXT NEXT NEXT NEXT 9 J 8 I 1 B NEXT 2 C 2 C 8 I 9 J 4 E NEXT DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 4 E...

Page 319: ... Diagrams Ċ Using the Stage Jump Instruction for State Transitions Ċ Stage Program Example Toggle On Off Lamp Controller Ċ Four Steps to Writing a Stage Program Ċ Stage Program Example A Garage Door Opener Ċ Stage Program Design Considerations Ċ RLLPLUS Stage Instructions Ċ Questions and Answers about Stage Programs ...

Page 320: ...s well S Large programs can become almost unmanageable because of a lack of structure S In RLL latches must be tediously created from self latching relays S When a process gets stuck it is difficult to find the rung where the error occurred S Programs become difficult to modify later because they do not intuitively resemble the application problem they are solving STAGE Y2 X3 OUT X0 RST C0 X4 SET ...

Page 321: ...the states of the process we need to identify Clear thinking and concise analysis of an application gives us the best chance at writing efficient bug free programs State diagrams are just a tool to help us draw a picture of our process You ll discover that if we can get the picture right our program will also be right Consider the simple process shown to the right which controls an industrial moto...

Page 322: ... OUT Y0 C0 Set Reset Latch Output Latch The stage program solution is shown to the right The two inline stage boxes S0 and S1 correspond to the two states OFF and ON The ladder rung s below each stage box belong to each respective stage This means that the PLC only has to scan those rungs when the corresponding stage is active For now let s assume we begin in the OFF State so stage S0 is active Wh...

Page 323: ...ges SG off So the stage programs shown so far have actually had no way to get started because rungs are not scanned unless their stage is active Assume that we want to always begin in the Off state motor off which is how the RLL program works The Initial Stage ISG is defined to be active at powerup In the modified program to the right we have changed stage S0 to the ISG type This ensures the PLC w...

Page 324: ...eration is shown on the right When S0 is true the two rungs have power flow S If Stage bit S0 0 its ladder rungs are not scanned executed S If Stage bit S0 1 its ladder rungs are scanned executed SG S0 Actual Program Appearance Functionally Equivalent Ladder S0 includes all rungs in stage The inline stage boxes on the left power rail divide the ladder program rungs into stages Some stage rules are...

Page 325: ...ted Here s how it works S The jump instruction resets the stage bit of the stage in which it occurs All rungs in the stage still finish executing during the current scan even if there are other rungs in the stage below the jump instruction S The reset will be in effect on the following scan so the stage that executed the jump instruction previously will be inactive and bypassed S The stage bit of ...

Page 326: ... at top speed If implemented in Stage this solution would flash the light on or off each scan obviously undesirable The solution is to make the the push and the release of the pushbutton separate events Refer to the new state transition diagram below At powerup we enter the OFF state When switch X0 is pressed we enter the Press ON state When it is released we enter the ON state Note that X0 with t...

Page 327: ... point numbers X and Y to physical inputs and outputs 3 Draw the State Transition Diagram The state transition diagram describes the central function of the block diagram reading inputs and generating outputs S Identify and name the states of the process S Identify the event s required for each transition between states S Ensure the process has a way to re start itself or is cyclical S Choose the ...

Page 328: ...it switch Each limit switch closes only when the door has reach the end of travel in the corresponding direction In the middle of travel neither limit switch is closed The motor has two command inputs raise and lower When neither input is active the motor is stopped The door command is just a simple pushbutton Whether wall mounted as shown or a radio remote control all door control commands logica...

Page 329: ...til the door control pushbutton activates Then we transition JMP to Push UP stage S1 A push release cycle of the pushbutton takes us through stage S1 to the RAISE stage S2 We use the always on contact SP1 to energize the motor s raise command Y1 When the door reaches the fully raised position the up limit switch X1 activates This takes us to the UP Stage S3 where we wait until another door control...

Page 330: ...gram below we add an additional state called LIGHT Whenever the garage owner presses the door control switch and releases the RAISE or LOWER state is active and the LIGHT state is simultaneously active The line to the Light state is dashed because it is not the primary path Ladder Program Inputs Outputs Toggle X0 Y1 Raise Y2 Lower Up limit X1 Down limit X2 Y3 Light We can think of the Light state ...

Page 331: ...red that s good because our two locations for the Set S6 instruction make that impossible Stage numbers and how they are used determines the transition paths In stage S6 we turn on the safety light by energizing Y3 Special relay contact SP1 is always on Timer T0 times at 0 1 second per count To achieve 3 minutes time period we calculate The timer has power flow whenever stage S6 is active The corr...

Page 332: ...urn off before the Raise output Y1 energizes Ladder Program Inputs Outputs Toggle X0 Y1 Raise Y2 Lower Up limit X1 Down limit X2 Y3 Light Obstruction X3 X0 Push UP UP Push DOWN DOWN X0 LOWER RAISE X0 X1 X0 X2 and LIGHT X0 X0 T0 X3 X3 It is theoretically possible that the down limit X2 and the obstruction input X3 could energize at the same moment In that case we would jump to the Push UP and DOWN ...

Page 333: ...er rung tasks done just once at powerup Its last rung resets the stage so this stage is only active for one scan or only as many scans that are required S Main Process this stage sequence controls the heart of the process or machine One pass through the sequence represents one part cycle of the machine or one batch in the process S E Stop and Alarm Monitoring This stage is always active because it...

Page 334: ...a logical OR control of an output One Shot or PD coils Use care if you must use a Positive Differential coil in a stage Remember that the input to the coil must make a 0 1 transition If the coil is already energized on the first scan when the stage becomes active the PD coil will not work This is because the 0 1 transition did not occur PD coil alternative If there is a task which you want to do o...

Page 335: ...e to watch the main process The counter inside the supervisor stage uses the stage bit S1 of the main process as its count input Stage bits used as a contact let us monitor a process Note that both the Supervisor stage and the OFF stage are initial stages The supervisor stage remains active indefinitely S1 X0 JMP ISG S0 S2 JMP SG S1 OUT Y0 OFF State SP1 S3 X0 JMP SG S2 SG S3 X0 S0 JMP X0 Push On S...

Page 336: ...t The power flow transition method is also achievable on the handheld programmer by simply following the transition condition with the Stage instruction for the next stage The power flow transition method does eliminate one Stage JMP instruction its only advantage However it is not as easy to make program changes as using the Stage JMP Therefore we advise using Stage JMP transitions for most progr...

Page 337: ...doing multiple things and continue doing one thing at a time In the figure below processes A and B converge when stages S2 and S4 transition to S5 at some point in time So S2 and S4 are Convergence Stages S5 S1 S3 S2 S4 S6 Convergence Stage Process A Process B While the converging principle is simple enough it brings a new complication As parallel processing completes the multiple processes almost...

Page 338: ...ocesses also finish S The maximum number of convergence stages which make up one group is 16 In other words a maximum of 16 stages can converge into one stage S Convergence stages of the same group must be placed together in the program connected on the power rail without any other logic in between S Within a convergence group the stages may occur in any order top to bottom It does not matter whic...

Page 339: ...truction is executed Operand Data Type DL05 Range aaa Stage S 0 377 The following example is a simple RLLPLUS program This program utilizes an initial stage stage and jump instructions to create a structured program X0 ISG S0 Y0 OUT X1 S2 SET SG S1 X5 X2 Y1 OUT SG S2 X6 Y2 OUT X7 S0 JMP S1 JMP S1 DirectSOFT Handheld Programmer Keystrokes ISG U 0 A ENT STR OUT GX STR SET X SHFT RST S 2 C ENT STR JM...

Page 340: ...r stage specified in the instruction The jump occurs when the input logic is true The active stage containing the Jump will deactivate 1 scan later JMP Operand Data Type DL05 Range aaa Stage S 0 377 aaa S The Not Jump instruction allows the program to transition from an active stage which contains the jump instruction to another which is specified in the instruction The jump will occur when the in...

Page 341: ...he CVJMP instruction and any additional logic in the final CV stage will be executed All preceding CV stages must be active before the final CV stage logic can be executed All Converge Stages are deactivated one scan after the CVJMP instruction is executed Additional logic instructions are only allowed following the last Converge Stage instruction and before the CVJMP instruction Multiple CVJUMP i...

Page 342: ...p back to the initial stage S0 DirectSOFT Display ISG S0 CV S11 X3 Y3 OUT X4 S20 CVJMP SG S20 X0 Y0 OUT X1 S1 JMP S10 JMP SG S1 X2 S11 JMP Handheld Programmer Keystrokes CV S10 X5 S0 JMP ISG U 0 A ENT STR JMP K 1 B ENT SG 2 1 B ENT STR OUT GX JMP K ENT SHFT JMP K ENT 3 D ENT 1 B ENT 2 C ENT ENT 0 A OUT GX ENT 0 A STR ENT JMP K 1 B ENT 0 A 1 B 1 B 2 C AND V 1 B 0 A SHFT ENT 2 C AND V 1 B 1 B STR EN...

Page 343: ...another part by detecting stage active inactive status Q How does a stage become active A There are three ways S If the Stage is an initial stage ISG it is automatically active at powerup S Another stage can execute a Stage JMP instruction naming this stage which makes it active upon its next occurrence in the program S A program rung can execute a Set Stage Bit instruction such as Set S0 Q How do...

Page 344: ...rom one state to another S Use a Set Stage Bit instruction when the current state is spawning a new parallel state or stage sequence or when a supervisory state is starting a state sequence under its command S Use a Reset Bit instruction when the current state is the last state in a sequence and its task is complete or when a supervisory state is ending a state sequence under its command Q What is...

Page 345: ...ling Ten Steps to Successful Process Control Basic Loop Operation PID Loop Data Configuration PID Algorithms Loop Tuning Procedure PV Analog Filter Feedforward Control Time Proportioning Control Cascade Control Process Alarms Ramp Soak Generator Troubleshooting Tips Bibliography Glossary of PID Loop Terminology ...

Page 346: ...e 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 The control loops use a Proportional Integral Derivative PID algorithm to generate the control output This chapter describes how the loops operate and what you must do to configure a...

Page 347: ... gains of 0 01 to 99 99 Integrator Reset Specify reset time of 0 1 to 999 8 in units of seconds or minutes Derivative Rate Specify the derivative time from 0 01 to 99 99 seconds Rate Limits Specify derivative gain limiting from 1 to 20 Bumpless Transfer I Automatically initialized bias and setpoint when control switches from manual to automatic Bumpless Transfer II Automatically set the bias equal...

Page 348: ...their effects For example if the fuel input is constant an oven will run hotter during warm weather than it does during cold weather An oven control system must counter act this effect to maintain a constant oven temperature during any season Thus the weather which is not very predictable is one source of disturbance to this process Error Term the algebraic difference between the process variable ...

Page 349: ...the manufacturing process such as a heater valve pump etc Over time the liquid begins to change enough to be measured on the sensor probe The process variable changes accordingly The next loop calculation occurs and the loop cycle repeats in this manner continuously Loop Calculation Manufacturing Process Control Output Process Variable Loop Configuration and Monitoring The personal computer shown ...

Page 350: ...g with 1 For example you cannot use loop 1 and 4 while skipping 2 and 3 The loop controller attempts to control the full number of loops specified in V7641 The CPU reports any programming errors of the setup parameters in V7640 and V7641 It does this by setting the appropriate bits in V7642 on program to run mode transitions PID Error Flags V7642 0 1 3 4 5 6 7 8 9 10 11 12 13 14 15 2 Bit If you us...

Page 351: ... Program PID Loop Task DirectSOFT32 Programming Software V7640 V7641 The Loop Parameter table contains data for only as many loops as you selected in V7641 Each loop configuration occupies 32 words 0 to 37 octal in the loop table For example suppose you have an application with 4 loops and you choose V2000 as the starting location The Loop Parameter will occupy V2000 V2037 for loop 1 V2040 V2077 f...

Page 352: ... Alarm word binary 13 Addr 14 PV Value Low Alarm word binary 14 Addr 15 PV Value High Alarm word binary 15 Addr 16 PV Value High high Alarm word binary 16 Addr 17 PV Value deviation alarm YELLOW word binary 17 Addr 20 PV Value deviation alarm RED word binary 18 Addr 21 PV Value rate of change alarm word binary 19 Addr 22 PV Value alarm hysteresis setting word binary 20 Addr 23 PV Value error deadb...

Page 353: ...ode I Mode II 4 Direct or Reverse Acting Loop select write Direct Reverse 5 Position Velocity Algorithm select write Position Velocity 6 PV Linear Square Root Extract select write Linear Sq root 7 Error Term Linear Squared select write Linear Squared 8 Error Deadband enable write Disable Enable 9 Derivative Gain Limit select write Off On 10 Bias Integrator Freeze select write Off On 11 Ramp Soak O...

Page 354: ...ame format separate formats 11 Control Output Range Unipolar Bipolar select See Notes 2 and 3 write unipolar bipolar 12 Output Data Format select See Notes 2 and 3 write 12 bit 15 bit 13 Output data format 16 bit select See Notes 2 and 3 write not 16 bit select 16 bit 14 15 Reserved for future use Note 1 If the value in bit 9 is 0 then the values in bits 0 and 1 are read If the value in bit 9 is 1...

Page 355: ... 13 Auto Tune error indication read Error 14 15 Reserved for Future Use The individual bit definitions of the Ramp Soak Table Flag Addr 33 word is listed in the following table Further details are given in the Ramp Soak Operation section Bit Ramp Soak Flag Bit Description Read Write Bit 0 Bit 1 0 Start Ramp Soak Profile write 0Õ1 Start 1 Hold Ramp Soak Profile write 0Õ1 Hold 2 Resume Ramp soak Pro...

Page 356: ...PV Deviation 04 3 Ramp End SP Value 24 11 Ramp End SP Value 05 3 Ramp Slope 25 11 Ramp Slope 06 4 Soak Duration 26 12 Soak Duration 07 4 Soak PV Deviation 27 12 Soak PV Deviation 10 5 Ramp End SP Value 30 13 Ramp End SP Value 11 5 Ramp Slope 31 13 Ramp Slope 12 6 Soak Duration 32 14 Soak Duration 13 6 Soak PV Deviation 33 14 Soak PV Deviation 14 7 Ramp End SP Value 34 15 Ramp End SP Value 15 7 Ram...

Page 357: ...eripherals Ladder Program Calculate PID Loops Internal Diagnostics Write Outputs PLC Scan For any particular control loop there is no single perfect sample rate to use A good sample rate is a compromise that simultaneously satisfies various guidelines S The desired sample rate is proportional to the response time of the PV to a change in control output Usually a process with a large mass will have...

Page 358: ...n the sample rate time line shows ten samples within the rise time period These show the frequency of PID calculations as the PV changes values Of course the sample rate and PID calculations are continuous during operation NOTE An excessively fast sample rate will diminish the available resolution in the PV Rate of Change Alarm because the alarm rate value is specified in terms of PV change per sa...

Page 359: ... without loop calculations is 50 mS and the loop sample time is 3 seconds Now calculate the new scan time Average Scan time with PID loop 50 mS 3 sec X 250 mS 50 mS 50 004 mS As the calculation shows the addition of only one loop with a slow sample rate has a very small effect on scan time Next expand the equation above to show the effect of adding any number of loops Avg Scan Time with PID loops ...

Page 360: ...ing is shown in the flow chart below This is a more detailed look at the contents of the Calculate PID Loops task in the CPU scan activities flow chart The pointers I and J correspond to the slow 2 sec and fast 2 sec loops respectively The flow chart allows the J pointer to increment from loop 1 to the last loop if there are any fast loops specified The I pointer increments only once per scan and ...

Page 361: ...size of the load An oversized actuator will have an overwhelming effect on your process after a SP change However an undersized actuator will allow the PV to lag or drift away from the SP after a SP change or process disturbance S Choose a PV sensor which matches the range of interest and control for our process Decide the resolution of control you need for the PV such as within 2 deg C and make s...

Page 362: ...m use Manual Mode S Verify that the PV value from the sensor is correct S If it is safe to do so gradually increase the control output up above 0 and see if the PV responds and moves in the correct direction If the Open Loop Test see Loop Tuning on page 8 38 shows the PV reading is correct and the control output has the proper effect on the process you can follow the closed loop tuning procedure s...

Page 363: ...e required to copy data from the analog module to the loop table or vice versa Refer to the analog module chapter of this manual for an example of the required ladder logic Process Variable V 03 Loop Calculation S Control Output V 05 Setpoint V 02 Analog Output Analog Input Setpoint Sources Operator Input Ramp soak generator Ladder Program Another loop s output cascade Process The Setpoint has sev...

Page 364: ...e associated loop table registers The figure below shows the loop table parameters at V 36 and V 37 and their role in direct access to the analog values Process Variable V 03 Loop Calculation S Error Control Output V 05 Setpoint V 02 Loop Table V2036 Slot channel number for PV 0F XX V2037 Slot channel number for Output 0F XX 0F XX Channel number 1 to 4 Stands for Option Module Slot You may program...

Page 365: ...ates new control output values It calculates the PID equation and writes the result in location V 05 every sample period of that loop The equivalent schematic diagram is shown below Loop Calculation Control Output V 05 Input from Operator Manual Auto In Cascade Mode the loop operates as it does in Automatic Mode with one important difference The data source for the SP changes from its normal locat...

Page 366: ...ws the CPU mode then placing the CPU in Program Mode will force all loops into Manual Mode Similarly placing the CPU in Run mode will allow each loop to return to the mode it was in previously which includes Manual Automatic and Cascade With this selection you automatically affect the modes of the loops by changing the CPU mode Manual Automatic Cascade Mode change 0 loop follows PLC mode Mode chan...

Page 367: ...This will be necessary after application startup Use the program shown to the right to SET the mode bit on do not use an out coil On a 0 1 transition of X0 the rung sets the Auto bit 1 The loop controller resets it X0 SET B2000 1 Go to Auto Mode S Operator panel interface the operator s panel to ladder logic using standard methods then use the technique above to set the mode bit Since we can only ...

Page 368: ...So actual manual control is not possible when the PLC is in Program Mode S The only time the CPU will allow a loop mode change is during PLC run Mode operation As such the CPU records the modes of all 16 loops as the desired mode of operation If power failure and restoration occurs during PLC Run Mode the CPU returns all loops to their prior mode which could be Manual Auto or Cascade S On a Progra...

Page 369: ... output thereby upsetting the loop to some degree The bumpless transfer feature arbitrarily forces one parameter equal to another at the moment of loop mode change so the transfer is smooth no bump on the control output The bumpless transfer feature of the DL05 loop controller is available in two types Bumpless I and Bumpless II Use DirectSOFT32 s PID Setup dialog box to select transfer type Or yo...

Page 370: ...095 to 1 0 to 32767 0 to 7FFF FFF to 8001 0 to 32767 32767 to 1 Data formats 0 1 3 4 5 6 7 8 9 10 11 12 13 14 15 2 Bit PID Mode 2 Setting V 01 0 0 0 1 1 0 1 1 Select data format using bits 0 and 1 sign bit LSB The data format is a very powerful setting because it determines the numerical interface between the PID loop and the PV sensor and the Control Output device The Setpoint must also be in the...

Page 371: ...part of the process taking care of it for you automatically The Setpoint in loop table location V 02 represents the desired value of the process variable After selecting the data format for these variables you can set limits on the range of SP values which the loop calculation will use Many loops have two or more possible sources writing the Setpoint at various times and the limits you set will he...

Page 372: ... to enter the Remote SP pointer if you know the address Otherwise you can enter it with a HPP or program it through ladder logic using the LDA instruction The process variable input to each loop is the value the loop is ultimately trying to control to make it equal to the setpoint and follow setpoint changes as quickly as possible Most sensors for process variables have a primarily linear response...

Page 373: ...be set once using DirectSOFT32 s PID Setup dialog box The Control Output lower and upper limits can help guard against commanding an excessive correction to an error when a loop fault occurs such as PV sensor signal loss However do not use these limits to restrict mechanical motion that might otherwise damage a machine use hard wired limit switches instead Process Variable Loop Calculation S Contr...

Page 374: ... Error Deadband XXXX Error Squared When selected the squared error function simply squares the error term but preserves the original algebraic sign which is used in the calculation This affects the Control Output by diminishing its response to smaller error values but maintaining its response to larger errors Some situations in which the error squared term might be useful S Noisy PV signal using a...

Page 375: ... of applications will use the position form of the PID equation If you are not sure of which algorithm to use try the Position Algorithm first Use DirectSOFT32 s PID View Setup dialog box to select the desired algorithm Or use bit 5 of PID Mode 1 Setting V 00 word as shown below to select the algorithm Process Variable S Setpoint PID Mode 1 Setting V 00 0 1 3 4 5 6 7 8 9 10 11 12 13 14 15 2 Bit Po...

Page 376: ...Bias Term The initial output is the output value assumed from Manual mode control when the loop transitioned to Auto Mode The sum of the initial output and the integral term is the bias term which holds the position of the output Accordingly the Velocity Algorithm discussed next does not have a bias component The Velocity Algorithm form of the PID equation can be obtained by transforming Position ...

Page 377: ... in the cooling input causes a decrease in the PV temperature Accordingly reverse acting loops are sometimes called cooling loops Process Variable Loop Calculation S Control Output Setpoint Process Reverse Acting Loop It is crucial to know whether a particular loop is direct or reverse acting Unless you are controlling temperature there is no obvious answer In a flow control loop a valve positioni...

Page 378: ...ing Auto Mode the integrator keeps a running total of the error values For the position form of the PID equation when the loop reaches equilibrium and there is no error the running total represents the constant output required to hold the current position of the PV S Derivative the derivative or rate term responds to change in the current error value from the error used in the previous PID calcula...

Page 379: ...emoving the integrator term from the PID equation This accommodates applications which need proportional only loops The units of integral gain may be either seconds or minutes as shown above Derivative Gain Values range from 0001 to 9999 but they are used internally as xx xx An entry of 0000 allows removal of the derivative term from the PID equation a common practice This accommodates application...

Page 380: ...ttle derivative gain without going into wild oscillations In the widely used position form of the PID equation an important component of the control output value is the bias term shown below Its location in the loop table is in V 04 the loop controller writes a new bias term after each loop calculation S Mn Kc en Ki ei Kr en en 1 Mo i 1 n Control Output Proportional Term Initial Output Integral Te...

Page 381: ...ure is enabled It causes the bias value to freeze when the control output goes out of bounds Much of the reset windup is thus avoided and the output recovery time is much less For most applications the freeze bias feature will work with the loop as described above You may enable the feature using the DirectSOFT32 PID View setup dialog or set bit 10 of PID Mode 1 Setting word as shown to the right ...

Page 382: ...5 is not intended to perform as a replacement for your process knowledge Whether you use manual or auto tuning it is very important to verify basic characteristics of a newly installed process before attempting to tune it With the loop in Manual Mode verify the following items for each new loop S Setpoint verify the source which is to generate the setpoint can do so You can put the PLC in Run Mode...

Page 383: ...alues immediately If the loop does not stabilize immediately then transfer the loop back to Manual Mode and manually write a safe value to the control output During the loop tuning procedure always be near the Emergency Stop switch which controls power to the loop actuator in case a shutdown is necessary S At this point the SP should PV because of the bumpless transfer feature Increase the SP a li...

Page 384: ...iated within DirectSOFT32 You can use autotuning to establish initial PID parameter values autotuning is not run continuously during operation Whenever a substantial change in loop dynamics occurs mass of process size of actuator etc you will need to repeat the tuning procedure to derive the new gains that are required for optimal control WARNING Only authorized personnel fully familiar with all a...

Page 385: ... 5 6 7 8 9 10 11 12 13 14 15 2 Bit Loop Mode and Alarm Status V 06 Auto Tune Active Auto Tune Error Auto Tuning Status Open Loop Auto Tuning During an open loop auto tuning cycle the loop controller operates as shown in the diagram below Before starting this procedure place the loop in Manual mode and ensure the PV and control output values are in the middle of their ranges away from the end point...

Page 386: ...ning observations are complete the loop controller computes Rr maximum slope in sec and Lr dead time in sec The auto tune function computes the gains according to the Ziegler Nichols equations shown below P 1 2 Dm LrRr I 2 0 Lr D 0 5 Lr PID tuning PI tuning P 0 9 Dm LrRr I 3 33 Lr Sample Rate 0 056 Lr Sample Rate 0 12 Lr D 0 Dm Output step change 10 0 1 20 0 2 We highly recommend using DirectSOFT3...

Page 387: ...he sample time It automatically places the results in the corresponding registers in the loop table The following timing diagram shows the events which occur in the closed loop auto tuning cycle The auto tune function examines the direction of the offset of the PV from the SP The auto tune function then takes control of the control output and induces a full span step change in the opposite directi...

Page 388: ... example on page 8 46 In tuning cascaded loops we will need to de couple the cascade relationship and tune the loops individually using one of the loop tuning procedures previously covered 1 If you are not using auto tuning then find the loop sample rate for the minor loop using the method discussed earlier in this chapter Then set the sample rate of the major loop slower than the minor loop by a ...

Page 389: ...e control for the low pass PV filter 0 disable 1 enable The roll off frequency of the single pole low pass filter is controlled by using register V 24 in the loop parameter table the filter constant The data format of the filter constant value is BCD with an implied decimal point 00X X as follows S The filter constant has a valid range of 000 1 to 001 0 S DirectSOFT32 converts values above the val...

Page 390: ...ual to the current PV value in the PID Loop Table V2003 load the raw analog input into the accumulator Subtract the raw analog input the from Loop Table PV value END END coil marks the end of the main program Add the adjusted difference between the raw analog input and the PV back to the analog input value If the raw analog input is less than the current PV value in the PID Loop Table V2003 load t...

Page 391: ... a new operating point This also happens if a disturbance introduces a new offset in the loop The loop does not really know its way to the new operating point the integrator bias must increment decrement until the error disappears and then the bias has found the new operating point Suppose that we are able to know a sudden setpoint change is about to occur common in some applications We can avoid ...

Page 392: ...e have already tuned the loop for optimal performance Refer to the figure below We notice that when the operator opens the oven door the temperature sags a bit while the loop bias adjusts to the heat loss Then when the door closes the temperature rises above the SP until the loop adjusts again Feedforward control can help diminish this effect PV Bias Oven door PV sags PV excess Closed Open Closed ...

Page 393: ... time proportioning control for the applications that need it Let s take a moment to review how alternately turning a load on and off can control a process The diagram below shows a hot air balloon following a path across some mountains The desired path is the setpoint The balloon pilot turns the burner on and off alternately which is his control output The large mass of air in the balloon effecti...

Page 394: ...and loads the control output value binary from the loop table V 05 location V2005 Convert the number in the accumulator to BCD format to satisfy the MUL DIV and TMRF format requirement OUT V1400 Output our result to V1400 This is our arbitrary location for the second timer s preset value DirectSOFT32 END END coil marks the end of the main program T1 OUT Y0 Using the N C T1 contact invert the T1 ti...

Page 395: ...ntermediate variable This separates the source of the control lag into two parts as well The diagram below shows a cascade control system showing that it is simply one loop nested inside another The inside loop is called the minor loop and the outside loop is called the major loop For overall stability the minor loop must be the fastest responding loop of the two We do have to add the additional s...

Page 396: ...ode operation as a minor loop you must program its remote Setpoint Pointer in its loop parameter table location V 32 as shown below The pointer must be the address of the V 05 location control output of the major loop In Cascade Mode the minor loop will ignore the its local SP register V 02 and read the major loop s control output as its SP instead Loop Table V 02 SP XXXX V 03 PV XXXX V 32 Remote ...

Page 397: ...eeds the programmed alarm amount S Alarm Hysteresis works in conjunction with the absolute value and deviation alarms to eliminate alarm chatter near alarm thresholds The alarm thresholds are fully programmable and each type of alarm may be independently enabled and monitored The following diagram shows the PV monitoring function Bits 12 13 and 14 of PID Mode 1 Setting V 00 word in the loop parame...

Page 398: ... operator The PV Absolute Value Alarms are reported in the four bits in the PID Mode and Alarm Status word in the loop table as shown to the right We highly recommend using ladder logic to monitor these bits The bit of word instructions make this easy to do Additionally you can monitor PID alarms using DirectSOFT PID Mode and Alarm Status V 06 0 1 3 4 5 6 7 8 9 10 11 12 13 14 15 2 Bit High high Al...

Page 399: ...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 Loop Table V 21 PV Rate of Change Alarm XXXX PV PV slope OK Sample time PV slope excessive rate of change alarm Sam...

Page 400: ... figure below shows how the hysteresis is applied when the PV value goes past a threshold and descends back through it Loop Table V 22 PV Alarm Hysteresis XXXX PV Alarm threshold Alarm 0 1 Hysteresis The hysteresis amount is applied after the threshold is crossed and toward the safe zone In this way the alarm activates immediately above the programmed threshold value It delays turning off until th...

Page 401: ...n the process control industry and refer to desired setpoint SP values in temperature control applications In the figure to the right the setpoint increases during the ramp segment It remains steady at one value during the soak segment Time SP Ramp Soak slope Complex SP profiles can be generated by specifying a series of ramp soak segments The ramp segments are specified in SP units per second tim...

Page 402: ...s of a ramp s end points These values come from the ramp soak table SP Ramp Soak Step 1 2 Ramp Soak 3 4 Ramp Soak 5 6 Ramp Soak 13 14 Ramp Soak 15 16 The parameters which define the ramp soak profile for a loop are in a ramp soak table Each loop may have its own ramp soak table but it is optional Recall the Loop Parameter table consists a 32 word block of memory for each loop and together they occ...

Page 403: ...us bit is generated by the ramp soak generator Ramp Soak Table V 00 Ramp End SP Value XXXX SP Soak PV deviation V 01 Ramp Slope XXXX V 02 Soak Duration XXXX V 03 Soak PV Deviation XXXX Ramp End SP Value Soak duration segment becomes active Slope The ramp segment becomes active when the previous soak segment ends If the ramp is the first segment it becomes active when the ramp soak generator is sta...

Page 404: ...able above will not operate unless this bit 1 during the entire ramp soak process PID Mode 1 Setting V 00 0 1 3 4 5 6 7 8 9 10 11 12 13 14 15 2 Bit Ramp Soak Generator Enable The four main controls for the ramp soak generator are in bits 0 to 3 of the ramp soak settings word in the loop parameter table DirectSOFT32 controls these bits directly from the ramp soak settings dialog However you must us...

Page 405: ...lable in the upper 8 bits of the Ramp Soak Settings V 33 word The bits represent a 2 digit hex number ranging from 1 to 10 Ladder logic can monitor these to synchronize other parts of the program with the ramp soak profile Load this word to the accumulator and shift right 8 bits and you have the step number Ramp Soak Settings V 33 0 1 3 4 5 6 7 8 9 10 11 12 13 14 15 2 Bit Current Profile Step 2 di...

Page 406: ...lowing for possible causes S The Ramp Soak enable bit is off Check the status of bit 11 of loop parameter table location V 00 It must be set 1 S The hold bit or other bits in the Ramp Soak control are on S The beginning SP value and the first ramp ending SP value are the same so first ramp segment has no slope and consequently has no duration The ramp soak generator moves quickly to the soak segme...

Page 407: ...zero Then reduce the integral gain and the proportional gain if necessary S There is too much transfer lag in your process This means the PV reacts sluggishly to control output changes There may be too much distance between actuator and PV sensor or the actuator may be weak in its ability to transfer energy into the process S There may be a process disturbance that is over powering the loop Make s...

Page 408: ...rrors Feedforward A method of optimizing the control response of a loop when a change in setpoint or disturbance offset is known and has a quantifiable effect on the bias term Control Output The numerical result of a PID equation which is sent by the loop with the intention of nulling out the current error Derivative Gain A constant that determines the magnitude of the PID derivative term in respo...

Page 409: ...or causes the integrator reset sum to grow excessively windup Reset windup causes an extra recovery delay when the original loop fault is remedied Reverse Acting Loop A loop in which the PV increases in response to a control output decrease In other words the process has a negative gain Sampling time The time between PID calculations The CPU method of process control is called a sampling controlle...

Page 410: ...d Troubleshooting In This Chapter Ċ Hardware System Maintenance Ċ Diagnostics Ċ CPU Indicators Ċ Communications Problems Ċ I O Point Troubleshooting Ċ Noise Troubleshooting Ċ Machine Startup and Program Troubleshooting ...

Page 411: ...tem to function improperly perhaps introducing a safety problem The CPU will automatically switch to Program Mode if it is in Run Mode Remember in Program Mode all outputs are turned off If the fatal error is detected while the CPU is in Program Mode the CPU will not allow you to transition to Run Mode until the error has been corrected Some examples of fatal errors are S Power supply failure S Pa...

Page 412: ...PU Status Relays SP11 Forced Run mode SP12 Terminal Run mode SP13 Test Run mode SP15 Test stop mode SP16 Terminal Program mode SP17 Forced stop SP20 STOP instruction was executed SP22 Interrupt enabled System Monitoring Relays SP36 Override setup SP37 Scan control error SP40 Critical error SP41 Non critical error SP42 Diagnostics error SP44 Program memory error SP45 I O error SP46 Communications e...

Page 413: ...ut E321 Communications error E360 HP Peripheral port time out E501 Bad entry E502 Bad address E503 Bad command E504 Bad reference value E505 Invalid instruction E506 Invalid operation E520 Bad operation CPU in Run E521 Bad operation CPU in Test Run E523 Bad operation CPU in Test Program E524 Bad operation CPU in Program Error Code Description E525 Mode Switch not in Term position E526 Unit is offl...

Page 414: ...P Peripheral port time out E405 HP Peripheral port time out E406 Missing IRT E412 SBR LBL 64 E421 Duplicate stage reference E422 Duplicate SBR LBL reference E423 HP Peripheral port time out E431 Invalid ISG SG address E433 Invalid ISG SG address E434 Invalid RTC E435 Invalid RT E436 Invalid INT address E437 Invalid IRTC Error Code Description E438 Invalid IRT address E440 Invalid Data Address E441...

Page 415: ... the risk of electrical shock always disconnect the system power before inspecting the physical wiring 1 First disconnect the external power 2 Verify that all external circuit breakers or fuses are still intact 3 Check all incoming wiring for loose connections If you re using a separate termination block check those connections for accuracy and integrity 4 If the connections are acceptable reconne...

Page 416: ...system and determine what caused the problem You will find this problem is sometimes caused by high frequency electrical noise introduced into the CPU from an outside source Check your system grounding and install electrical noise filters if the grounding is suspected If power cycling the system does not reset the error or if the problem returns you should replace the CPU Communications Problems I...

Page 417: ...s are logic side indicators This means the LED which indicates the on or off status reflects the status of the point with respect to the CPU On an output point the status indicators could be operating normally while the actual output device transistor triac etc could be damaged With an input point if the indicator LED is on the input circuitry is probably operating properly Verify the LED goes off...

Page 418: ...ou wish to test 7 When you finish testing I O points delete the END statement at address 0 WARNING Depending on your application forcing I O points may cause unpredictable machine operation that can result in a risk of personal injury or equipment damage Make sure you have taken all appropriate safety precautions prior to testing any I O points BIT REF X 16P STATUS From a clear display use the fol...

Page 419: ...hat will not affect the system S Most noise problems result from improper grounding of the system A good earth ground can be the single most effective way to correct noise problems If a ground is not available install a ground rod as close to the system as possible Ensure all ground wires are single point grounds and are not daisy chained from one device to another Ground metal enclosures around t...

Page 420: ...e program syntax from a Handheld Programmer or you can use the PLC Diagnostics menu option within DirectSOFT This check will find a wide variety of programming errors The following example shows how to use the syntax check with a Handheld Programmer 1 SYN 2 DUP REF AUX 21 CHECK PRO Use AUX 21 to perform syntax check BUSY Select syntax check default selection MISSING END 00050 E401 One of two displ...

Page 421: ...abling selected outputs The output image register is still updated but the output circuits are not For example you could make this conditional by adding an input contact or CR to control the instruction with a switch or a programming device Or you could just add the instruction without any conditions so the selected outputs would be disabled at all times PAUSE disables Y0 and Y1 Y0 X0 END X2 X3 X1...

Page 422: ...w to perform the duplicate reference check with a Handheld Programmer DUP COIL REF 00024 E471 One of two displays will appear NO DUP REFS Error Display example Syntax OK display shows location in question 1 SYN 2 DUP REF AUX 21 CHECK PRO Use AUX 21 to perform syntax check BUSY Select duplicate reference check You may not get the busy display if the program is not very long CLR 1 B 2 C AUX ENT ENT ...

Page 423: ...3 Input point changes are not acknowledged during Run Time Edits So if you re using a high speed operation and a critical input comes on the CPU may not see the change Not all instructions can be edited during a Run Time Edit session The following list shows the instructions that can be edited Mnemonic Description TMR Timer TMRF Fast timer TMRA Accumulating timer TMRAF Accumulating fast timer CNT ...

Page 424: ...ey to select Run Time Edits RUNTIME EDITS MODE CHANGE Press ENT to confirm the Run Time Edits MODE ENT ENT NEXT 00000 STR X0 Find the instruction you want to change X0 Press the arrow key to move to the X Then enter the new contact C10 SHFT SET X 0 A SHFT FD REF FIND Note the RUN LED on the D2 HPP Handheld starts flashing to indicate Run Time Edits are enabled STR C10 RUNTIME EDIT SHFT 1 B 2 C 0 A...

Page 425: ...he forced value will be valid until the CPU writes to the image register location during the next scan This is useful you just need to force a bit on to trigger another event The following diagrams show a brief example of how you could use the D2 HPP Handheld Programmer to force an I O point The example assumes you have already placed the CPU into Run Mode X0 Y0 OUT C0 Use arrow keys to select poi...

Page 426: ...pendix Ċ Introduction Ċ AUX 2 Ċ RLL Operations Ċ AUX 3 Ċ VĆmemory Operations Ċ AUX 4 Ċ I O Configuration Ċ AUX 5 Ċ CPU Configuration Ċ AUX 6 Ċ Handheld Programmer Configuration Ċ AUX 7 Ċ EEPROM Operations Ċ AUX 8 Ċ Password Operations ...

Page 427: ...e Note the Handheld Programmer may have additional AUX functions that are not supported with the DL05 PLCs AUX Function and Description DL05 AUX 2 RLL Operations 21 Check Program 22 Change Reference 23 Clear Ladder Range 24 Clear All Ladders AUX 3 V Memory Operations 31 Clear V Memory AUX 4 I O Configuration 41 Show I O Configuration AUX 5 CPU Configuration 51 Modify Program Name 53 Display Scan T...

Page 428: ...available from the Handheld Sometimes the AUX name or description cannot fit on one display If you want to see the complete description just press the arrow keys to scroll left and right Also depending on the current display you may have to press CLR more than once AUX 2 RLL OPERATIONS AUX FUNCTION SELECTION Use NXT or PREV to cycle through the menus AUX 3 V OPERATIONS AUX FUNCTION SELECTION Press...

Page 429: ...to change an I O address reference or control relay reference AUX 22 allows you to quickly and easily change all occurrences within an address range of a specific instruction For example you can replace every instance of X5 with X10 There have been many times when we ve taken existing programs and added or removed certain portions to solve new application problems By using AUX 23 you can select an...

Page 430: ...ever have to use this feature unless you have made changes that affect system memory Usually you ll only need to initialize the system memory if you are changing programs and the old program required a special system setup You can usually change from program to program without ever initializing system memory AUX 54 resets the system memory to the default values You can also perform this operation ...

Page 431: ...ed to override the output disable function of the Pause instruction Use AUX 58 to program a single output or a range of outputs which will operate normally even when those points are within the scope of the pause instruction Bit override can be enabled on a point by point basis by using AUX 59 from the Handheld Programmer or by a menu option from within DirectSOFT Bit override basically disables a...

Page 432: ...m Programmer AUX 5B is used with the High Speed I O HSIO function to select the configuration You can choose the type of counter set the counter parameters etc See Chapter 3 for a complete description of how to select the various counter features 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 actua...

Page 433: ...agnostics program You can check the following items S Keypad S Display S LEDs and Backlight S Handheld Programmer EEPROM check AUX 7 EEPROM Operations The following auxiliary functions allow you to move the ladder program from one area to another and perform other program maintenance tasks Many of these AUX functions allow you to copy different areas of memory to and from the CPU and handheld prog...

Page 434: ...ns available that you can use to modify or enable the CPU password You can use these features during on line communications with the CPU or you can also use them with an EEPROM installed in the Handheld Programmer during off line operation This will allow you to develop a program in the Handheld Programmer and include password protection S AUX 81 Modify Password S AUX 82 Unlock CPU S AUX 83 Lock C...

Page 435: ...OTE 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 followed by seven numeric characters e g A1234567 AUX 82 can be used to unlock a CPU that has been password protected DirectSOFT will auto...

Page 436: ...1B DL05 Error Codes In This Appendix Ċ Error Code Table ...

Page 437: ...grammer could not be processed by the CPU Clear the error and retry the request If the error continues replace the CPU SP46 will be on and the error code will be stored in V7756 E312 HP COMM ERROR 2 A data error was encountered during communications with the CPU Clear the error and retry the request If the error continues check the cabling between the two devices replace the handheld programmer th...

Page 438: ... corresponding FOR instruction SP52 will be on and the error code will be stored in V7755 E405 MISSING NEXT A FOR instruction does not have the corresponding NEXT instruction SP52 will be on and the error code will be stored in V7755 E406 MISSING IRT An interrupt routine in the program does not end with the IRT instruction SP52 will be on and the error code will be stored in V7755 E412 SBR LBL 64 ...

Page 439: ... programmed after the end statement not in the main body of the program SP52 will be on and the error code will be stored in V7755 E438 INVALID IRT ADDRESS An IRT must be programmed after the end statement not in the main body of the program SP52 will be on and the error code will be stored in V7755 E440 INVALID DATA ADDRESS Either the DLBL instruction has been programmed in the main program area ...

Page 440: ...uctions match the number of STR instructions E463 LOGIC ERROR A STR instruction was not used to begin a rung of ladder logic E464 MISSING CKT A rung of ladder logic is not terminated properly E471 DUPLICATE COIL REFERENCE Two or more OUT instructions reference the same I O point E472 DUPLICATE TMR REFERENCE Two or more TMR instructions reference the same number E473 DUPLICATE CNT REFERENCE Two or ...

Page 441: ...pted by the handheld programmer E524 BAD OP PGM An operation which is invalid in the PROGRAM mode was attempted by the handheld programmer E525 MODE SWITCH An operation was attempted by the handheld programmer while the CPU mode switch was in a position other than the TERM position E526 OFF LINE The handheld programmer is in the OFFLINE mode To change to the ONLINE mode use the MODE the key E527 O...

Page 442: ...UVPROM Memory Cartridge This transfer must be made using a CMOS RAM Cartridge E627 BAD WRITE An attempt to write to a write protected or faulty EEPROM in the handheld programmer was made Check the write protect jumper and replace the EEPROM if necessary E628 EEPROM TYPE ERROR The wrong size EEPROM is being used in the handheld programmer This error occurs when the program size is larger than what ...

Page 443: ...1C Instruction Execution Times In This Appendix Ċ Introduction Ċ Instruction Execution Times ...

Page 444: ... You may recall that some of the discrete points such as X Y C etc are automatically mapped into V memory The following bit registers contain this data Bit Registers DL05 Input Points X V40400 V40417 Output Points Y V40500 V40517 Control Relays C V40600 V40637 Stages S V41000 V41017 Timer Status Bits V41100 V41107 Counter Status Bits V41140 V41147 Special Relays SP V41200 V41237 Some instructions ...

Page 445: ... 1 3 ms 1 3 ms OUT X Y C 6 8 ms 6 8 ms OROUT X Y C 6 7 ms 6 7 ms NOT None 1 6 ms 1 6 ms PD X Y C 52 3 ms 53 0 ms STRPD X Y C T CT S SP 20 2 ms 12 9 ms STRND X Y C T CT S SP 20 1 ms 13 0 ms ORPD X Y C T CT S SP 20 0 ms 12 6 ms ORND X Y C T CT S SP 19 8 ms 12 7 ms ANDPD X Y C T CT S SP 20 0 ms 12 6 ms ANDND X Y C T CT S SP 19 9 ms 12 8 ms SET 1st X Y C S 2nd X Y C S N pt 32 2 ms 14ms 3 1msxN 3 7 ms ...

Page 446: ...16 8 ms 16 8 ms 11 6 ms 42 7 ms 42 7 ms 16 8 ms 16 8 ms 11 6 ms 42 7 ms 42 7 ms 42 7 ms 42 7 ms 38 0 ms 66 7 ms 66 7 ms 42 7 ms 42 7 ms 38 0 ms 66 7 ms 66 7 ms STRNE 1st 2nd V Data Reg V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit V Bit Reg V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit P Indir Data V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit P Indir Bit V Data Re...

Page 447: ...ms 66 5 ms 16 5 ms 16 5 ms 11 4 ms 42 5 ms 42 5 ms 16 5 ms 16 5 ms 11 4 ms 42 5 ms 42 5 ms 37 6 ms 37 6 ms 42 5 ms 66 4 ms 66 4 ms 37 6 ms 37 6 ms 42 5 ms 66 4 ms 66 4 ms ORNE 1st 2nd V Data Reg V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit V Bit Reg V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit P Indir Data V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit P Indir Bit...

Page 448: ...ms 66 5 ms 16 5 ms 16 5 ms 11 4 ms 42 5 ms 42 5 ms 16 5 ms 16 5 ms 11 4 ms 42 5 ms 42 5 ms 42 5 ms 42 5 ms 37 6 ms 66 3 ms 66 3 ms 42 5 ms 42 5 ms 37 6 ms 66 3 ms 66 3 ms ANDNE 1st 2nd V Data Reg V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit V Bit Reg V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit P Indir Data V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit P Indir Bi...

Page 449: ...s 66 8 ms 16 9 ms 16 9 ms 11 6 ms 42 7 ms 42 7 ms 16 9 ms 16 9 ms 11 6 ms 42 7 ms 42 7 ms 42 8 ms 42 8 ms 38 0 ms 66 7 ms 66 7 ms 42 8 ms 42 8 ms 38 0 ms 66 7 ms 66 7 ms STRN 1st 2nd T CT V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 17 1 ms 17 1 ms 11 9 ms 43 0 ms 43 0 ms 17 2 ms 17 2 ms 12 0 ms 43 1 ms 43 1 ms 1st 2nd V Data Reg V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit...

Page 450: ...s 66 5 ms 16 5 ms 16 5 ms 11 4 ms 42 5 ms 42 5 ms 16 5 ms 16 5 ms 11 4 ms 42 5 ms 42 5 ms 42 5 ms 42 5 ms 37 6 ms 66 4 ms 66 4 ms 42 5 ms 42 5 ms 37 6 ms 66 4 ms 66 4 ms ORN 1st 2nd T CT V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 15 8 ms 15 8 ms 10 8 ms 41 9 ms 41 9 ms 15 8 ms 15 8 ms 10 8 ms 41 9 ms 41 9 ms 1st 2nd V Data Reg V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit ...

Page 451: ...s 65 6 ms 65 6 ms 15 6 ms 15 6 ms 10 9 ms 41 6 ms 41 6 ms 15 6 ms 15 6 ms 10 9 ms 41 6 ms 41 6 ms 41 6 ms 41 6 ms 36 9 ms 65 6 ms 65 6 ms 41 6 ms 41 6 ms 36 9 ms 65 6 ms 65 6 ms ANDN 1st 2nd T CT V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 15 8 ms 15 8 ms 10 8 ms 41 9 ms 41 9 ms 15 7 15 7 10 8 41 9 41 9 1st 2nd V Data Reg V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit V Bit ...

Page 452: ...ant P Indir Data P Indir Bit 64 0 ms 64 0 ms 58 1 ms 91 0 ms 91 0 ms 59 0 ms 59 0 ms 53 1 ms 86 0 ms 86 0 ms TMRF 1st 2nd T V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 64 8 ms 64 8 ms 59 5 ms 92 5 ms 92 5 ms 57 3 ms 57 3 ms 52 0 ms 85 0 ms 85 0 ms TMRA 1st 2nd T V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 72 2 ms 72 2 ms 65 7 ms 99 2 ms 99 2 ms 66 5 ms 66 5 ms 60 0 ms 93 ...

Page 453: ... DL05 Instruction Legal Data Types Execute Not Execute LD V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 43 7 ms 43 7 ms 42 7 ms 68 7 ms 68 7 ms 3 7 ms 3 7 ms 3 7 ms 3 7 ms 3 7 ms LDD V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 47 1 ms 47 1 ms 42 8 ms 72 2 ms 72 2 ms 3 7 ms 3 7 ms 3 7 ms 3 7 ms 3 7 ms LDF 1st 2nd X Y C S K Constant T CT SP N pt 65 8ms 13 9msxN 4 9 ms LDA O O...

Page 454: ... ms 48 3 ms 3 9 ms 3 9 ms 3 9 ms 3 9 ms XORD V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 23 3 ms 23 3 ms 19 0 ms 48 3 ms 48 3 ms 3 7 ms 3 7 ms 3 9 ms 3 9 ms 3 9 ms CMP V Data Reg V Bit Reg P Indir Data P Indir Bit 25 4 ms 25 4 ms 50 0 ms 50 0 ms 3 7 ms 3 7 ms 3 7 ms 3 7 ms CMPD V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 37 3 ms 37 3 ms 32 7 ms 62 0 ms 62 0 ms 3 9 ms 3 9 ...

Page 455: ...7 ms DIVD V Data Reg V Bit Reg P Indir Data P Indir Bit 562 2 ms 562 2 ms 596 4 ms 596 4 ms 3 8 ms 3 8 ms 3 7 ms 3 7 ms INC V Data Reg V Bit Reg P Indir Data P Indir Bit 35 7 ms 35 7 ms 60 2 ms 60 2 ms 3 4 ms 3 4 ms 3 4 ms 3 4 ms DEC V Data Reg V Bit Reg P Indir Data P Indir Bit 41 4 ms 41 4 ms 64 2 ms 64 2 ms 3 3 ms 3 3 ms 3 3 ms 3 3 ms ADDB V Data Reg V Bit Reg K Constant P Indir Data P Indir Bi...

Page 456: ...g N bits V Bit Reg N bits K Constant N bits 29 7 ms 29 7 ms 20 4 ms 3 4 ms 3 4 ms 3 3 ms ENCO None 12 6 ms 2 3 ms DECO None 20 3 ms 2 3 ms Number Conversion Instructions Accumulator DL05 Instruction Legal Data Types Execute Not Execute BIN None 75 8 ms 2 3 ms BCD None 159 9 ms 2 2 ms INV None 6 2 ms 2 3 ms ATH V Data Reg N bits V Bit Reg N bits 97ms 20msxN 3 3 ms HTA V Data Reg N bits V Bit Reg N ...

Page 457: ...K 1 7 35 2 ms 35 2 ms MLR K 0 7 30 9 ms 30 9 ms Interrupt Instructions DL05 Instruction Legal Data Types Execute Not Execute ENI None 24 2 ms 2 7 ms DISI None 9 4 ms 2 3 ms INT O 0 1 7 5 ms IRTC None 0 9 ms 1 3 ms IRT None 6 6 ms Network Instructions DL05 Instruction Legal Data Types Execute Not Execute RX X Y C T CT SP S V Data Reg V Bit Reg P Indir Data P Indir Bit 852 0 ms 852 0 ms 852 0 ms 868...

Page 458: ...NCON K ACON A PRINT ASCII 631 0 ms 3 6 ms RLLPLUS Instructions DL05 Instruction Legal Data Types Execute Not Execute ISG S 44 0 ms 41 1 ms SG S 44 0 ms 41 1 ms JMP S 76 0 ms 9 3 ms NJMP S 77 4 ms 9 3 ms CV S 42 1 ms 27 5 ms CVJMP S 89 5 ms 17 6 ms Drum Instructions DL05 Instruction Legal Data Types Execute Not Execute DRUM CT 840 0 ms 339 6 ms EDRUM CT 753 2 ms 357 0 ms Message Instructions RLLPLU...

Page 459: ...1D Special Relays In This Appendix Ċ DL05 PLC Special Relays ...

Page 460: ...es a contact to insure an instruction is executed every scan SP3 1 minute clock on for 30 seconds and off for 30 seconds SP4 1 second clock on for 0 5 second and off for 0 5 second SP5 100 ms clock on for 50 ms and off for 50 ms SP6 50 ms clock on for 25 ms and off for 25 ms SP7 Alternate scan on every other scan SP11 Forced run mode on when the mode switch is in the run position and the CPU is ru...

Page 461: ...uted with the wrong parameters SP56 Table instuction overrun on if a table instruction with a pointer is executed and the pointer value is outside the table boundary SP60 Value less than on when the accumulator value is less than the instruction value SP61 Value equal to on when the accumulator value is equal to the instruction value SP62 Greater than on when the accumulator value is greater than ...

Page 462: ...n V2332 V2333 SP546 Current target value on when the counter current value equals the value in V2334 V2335 SP547 Current target value on when the counter current value equals the value in V2336 V2337 SP550 Current target value on when the counter current value equals the value in V2340 V2341 SP551 Current target value on when the counter current value equals the value in V2342 V2343 SP552 Current ...

Page 463: ...quals the value in V2364 V2365 SP563 Current target value on when the counter current value equals the value in V2366 V2367 SP564 Current target value on when the counter current value equals the value in V2370 V2371 SP565 Current target value on when the counter current value equals the value in V2372 V2373 SP566 Current target value on when the counter current value equals the value in V2374 V23...

Page 464: ...1E DL05 Product Weights In This Appendix Ċ Product Weight Table ...

Page 465: ...Weights E 2 Product Weights Product Weight Table PLC Weight D0 05AR 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 ...

Page 466: ...1F European Union Directives CE In This Appendix Ċ European Union EU Directives Ċ Basic EMC Installation Guidelines ...

Page 467: ...European Economic Area EEA and all are covered by the Directives There are several Directives that apply to our products Directives may be amended or added as required S Electromagnetic Compatibility Directive EMC this Directive attempts to ensure that devices equipment and systems have the ability to function satisfactorily in its electromagnetic environment without introducing intolerable electr...

Page 468: ...t EN50082 1 Generic immunity standard for residential commercial and light industry EN50082 2 Generic immunity standard for industrial environment S Low Voltage Directive Standards Applicable to PLCs EN61010 1 Safety requirements for electrical equipment for measurement control and laboratory use S Product Specific Standard for PLCs EN61131 2 Programmable controllers equipment requirements and tes...

Page 469: ... is The Office for Official Publications of the European Communities L 2985 Luxembourg quickest contact is via the 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 Basic EMC Installation Guidelines The simplest way...

Page 470: ...de varistor with a rating of 275VAC working voltage for 230V nominal supplies 150VAC working voltage for 115V supplies and high energy capacity eg 140 joules Transient suppressors must be protected by fuses and the capacity of the transient suppressor must be greater than the blow characteristics of the fuses or circuit breakers to avoid a fire risk A recommended AC supply input arrangement for Ko...

Page 471: ... the PLC The diagram shows an example of four physical locations connected by a communications cable ÎÎÎÎ ÎÎÎÎ Screened Cable Equi potential Bond Control Cubicle To Earth Block Conductive Adapter Serial I O 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 To date i...

Page 472: ...r non European installations using single end earth grounds and sites with far from ideal earth ground characteristics we recommend the addition of 100 ohm resistors at each 0V link connection in network and communications cables RXD Master RXD TXD 0V Slave n TXD 0V Last Slave RXD TXD 0V Termination 100W 100W Termination 100W When you run cables between PLC items within an enclosure which also con...

Page 473: ...ndled together and passed through the same ferrite Recommended ferrite beads and split cores are detailed below These were used in extensive EMC tests and found to successfully attenuate radiated emissions to a high degree For I O Bundle Manufacturer Mfg Part No OD mm ID mm L mm 1 Turn L 25 MHz W 1 Turn L 100 MHz W 2 Turn L 25 MHz W 2 Turn L 100 MHz W RS Online 260 6795 17 5 9 5 28 5 153 210 649 6...

Page 474: ...ctive steel enclosure which limits access to operators by a lock and power breaker If access is required by operators or untrained personnel the equipment must be installed inside an internal cover or secondary enclosure S It should be noted that the safety requirements of the machinery directive standard EN60204 1 state that all equipment power circuits must be wired through isolation transformer...

Page 475: ...instruction 5 106 5 108 ASCII TO HEX instruction 5 86 Auxiliary Functions 4 8 Auxiliary functions A 2 B Bias freeze 8 37 Binary Coded Decimal instruction 5 82 5 84 Binary instruction 5 83 Bit Operation Instructions 5 78 Boolean Instructions 5 4 5 9 Bumpless transfer 8 25 C Cables operator interfaces 2 14 programming 1 9 programming devices 2 14 Calculating Program Execution Time 4 19 Cascade contr...

Page 476: ...n 5 70 Divide instruction 5 69 DL05 Micro PLC front panel 2 4 mounting guidelines 2 6 unit dimensions 2 6 Drum instruction 6 2 6 12 chart representation 6 3 counter assignments 6 6 drum control techniques 6 10 EDRUM Event Drum 6 14 handheld programmer mnemonics 6 16 overview of drum operation 6 8 powerup state 6 9 self resetting 6 11 step transition 6 4 Drum sequencer programming 1 12 E Emergency ...

Page 477: ...er conversion 5 83 program control 5 97 stage 7 21 stage programming 7 2 table 5 92 timer counter and shift register 5 30 Integral term 8 34 Interrupt Instructions 5 104 Interrupt Return Conditional instruction 5 104 Interrupt Return instruction 5 104 Interrupts external 3 47 HSIO input 3 45 timed 3 47 Invert instruction 5 85 J Jump instruction 7 7 7 22 L Load Address instruction 5 51 Load Double ...

Page 478: ...tion 5 13 Or Positive Diffential instruction 5 16 Or Store instruction 5 12 Out Double instruction 5 52 Out Formatted instruction 5 53 Out Immediate instruction 5 28 Out instruction 5 13 5 52 Output Data Instructions 5 43 P Panel layout 2 7 Part Numbers 1 5 1 6 Password 4 10 A 8 Pause instruction 5 19 PID Loops Alarms process 8 53 algorithms 8 31 basic operation 8 19 bibliography 8 63 cascade cont...

Page 479: ...0 D0 05AR 2 26 D0 05DA 2 36 D0 05DD 2 32 D0 05DD D 2 40 D0 05DR 2 28 D0 05DR D 2 38 Discrete option modules 2 42 environmental 2 8 input power 2 11 motion profiles 3 28 Stage Control Status Bit Map 4 29 Stage Counter instruction 5 38 7 16 Stage instructions 7 21 Stage programming 1 12 7 2 convergence 7 19 emergency stop 7 14 four steps to writing a stage program 7 9 garage door opener example 7 10...

Page 480: ...1 Timer instruction 5 31 Timer Instructions 5 30 Timer Status Bit Map 4 31 Trapezoidal profile 3 30 3 32 Troubleshooting 9 2 communications 9 7 electrical noise 9 10 error codes B 2 I O points 9 8 program debug 9 11 Troubleshooting guide HSIO Mode 20 3 24 HSIO Mode 30 3 43 U Up Down Counter instruction 5 40 V V memory 4 26 Velocity algorithm 8 31 Velocity profile 3 30 3 40 W Web site 1 2 Wiring co...

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