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What is a PLC?

What are PLCs and how Discrete


do they work? applications
PLCs are often defined as miniature indus- PLCs are often used to
trial computers that contain hardware and control machines or
software used to perform control functions. processes that are sequential in nature, Today’s PLC
A PLC consists of two basic sections: the using “discrete” inputs and outputs that
central processing unit (CPU) and the have defined states. For example, if a limit As PLC technology has advanced, so have
input/output interface system. The CPU, switch detects the presence of an object, it programming languages and communica-
which controls all PLC activity, can further provides an “ON” signal to the PLC; if no tions capabilities, along with many other
be broken down into the processor and object is detected, it provides an “OFF” important features. Today's PLCs offer
memory system. The input/output system signal. The machine or device typically faster scan times, space efficient high-
is physically connected to field devices performs actions based on time or events density input/output systems, and special
(e.g., switches, sensors, etc.) and provides in a pre-defined order. The expected interfaces to allow non-traditional devices
the interface between the CPU and the sequence is typically interrupted only when to be attached directly to the PLC. Not only
information providers (inputs) and control- an abnormal condition occurs. can they communicate with other control
lable devices (outputs). systems, they can also perform reporting
functions and diagnose their own failures,
To operate, the CPU “reads” input data Process control as well as the failure of a machine or
from connected field devices through the
use of its input interfaces, and then
applications process.
“executes” or performs the control PLCs can also control continuous Size is typically used to categorize today’s
program that has been stored in its processes that use analog I/O. For PLC, and is often an indication of the
memory system. Programs are typically example, a temperature sensor may features and types of applications it will
created in ladder logic, a language that provide a variable signal, such as 0-10 accommodate. Small, non-modular PLCs
closely resembles a relay-based wiring volts, based on the measurement of an (also known as fixed I/O PLCs) generally
schematic, and are entered into the CPU’s actual temperature. The PLC program have less memory and accommodate a
memory prior to operation. Finally, based monitors the sensed values continuously small number of inputs and outputs in
on the program, the PLC “writes” or and operates devices that may also be fixed configurations. Modular PLCs have
updates output devices via the output analog in nature. This could include bases or racks that allow installation of
interfaces. This process, also known as setting the position of a valve between multiple I/O modules, and will accommo-
scanning, typically continues in the same 0-100% open, or controlling the speed of date more complex applications.
sequence without interruption, and a motor. Continuous applications are so
changes only when a change is made to called because they typically have no Which PLC is right
the control program. defined start or end once they are initiated;
they maintain a process in a “steady”
for you?
operating state. Choosing the most effective PLC for your
application depends on a number of
factors. To begin the selection process, a
drawing of the machine or process is a
good start. This can help identify field
devices and physical requirements for
hardware locations. From the drawing, you
can determine how many analog and/or
discrete devices you will have.
Once the field device requirements and
hardware locations are defined, you can
review PLCs that will meet your require-
ments. See the PLC Selection Worksheet in
this section that will help you work through
the considerations for determining the type
of PLC you will need, regardless of which
manufacturers you are evaluating.

1–2 PLC Products 1 - 80 0 - 633 - 0405


PLC Applications PLC
Overview

DL05/06
PLC
Company’s DL205 PLCs D2-250-1 PLCs
automated machines and data acquisition control and monitor DL105
PLC
control steps of shutter software perform batch heatshrink tubing DL205
production with DL205 management production process PLC

PLC in textile dyeing DL305


PLC
G&L Technologies in Alpharetta, GA, builds
automated machines that complete all of
facilities DL405
the processes of plantation shutter manufac- Cubex, Inc. developed a Windows-based PLC
turing, from cutting to final assembly. The Batch Management System that utilizes the
Field I/O
company chose AUTOMATIONDIRECT’s AUTOMATIONDIRECT DL205 line of proces-
DL205 as an integral part of their machines. sors. All production data for historical trend-
One machine, the LPS-36T, controls louver ing, alarm logging, machine control and Software
production. Louvers are the pieces that go production/efficiency/cycle reporting is pro-
C-more
across each shutter frame that can be vided through OPC and housed in a HMIs
manipulated with a tilt rod to open and Microsoft SQL Server 2000 database. Tools
close the shutter. The machine uses the are included for controlling, configuring and Other HMI

DL205 PLC to manage the operation of all scheduling machines, formula manage-
electromechanical components and com- ment, procedure management, reporting AC Drives
munication, including index speed and dis- and troubleshooting.
tance, system stapling, drill and pin Texloc LTD of Fort Worth, Texas is a man- Motors
sequencing, and parts infeed coordination. ufacturer of fluoroplastic tubing, including
An operator interface provides the operator convoluted and corrugated tubing,
Steppers/
with information such as louver width and smooth bore, heating tubing, and profiles Servos
machine status. The PLC is programmed so and assemblies. The company uses sever-
that a range of production parameters is al AUTOMATIONDIRECT products, including Motor
Controls
supported on the louver production operator interfaces, AC drives, and
machine. This allows many different manu- D2-250-1 and D4-450 PLC systems. Proximity
Sensors
facturers to take advantage of the automat- One process at Texloc is based on a D2-
ed systems, regardless of the shutter size and 250-1 system that, along with Photo
LookoutDirect, runs and monitors the Sensors
style they are manufacturing. The raw louver
stock comes in many different lengths and plant’s tube extruding and curing systems Limit
can be produced in various wood types, as on five production lines. The D2-250-1 Switches
well as plastics and composites. The LPS- controls and monitors all digital logic and
Encoders
36T system accommodates raw louver stock analog signals. Descriptive process infor-
lengths between 18 inches and 16 feet and mation is shown to the operator via the
touch panel. All controls except power Current
allows the operator to enter louver length, Sensors
width and thickness using the operator inter- and E-stop originate in the touch panel.
face panel. The F2-CP128 BASIC co-processor has a Pushbuttons/
Lights
custom program that communicates with
two smart servomotors. It passes speed Process
and operation parameters to the servos
The system has been installed in four textile and polls the servos for status, torque and
dyeing facilities controlling 23 textile dye Relays/
position information. An Ethernet module Timers
machines. The flexible system allows the in the PLC is connected to a 10-megabit
machines to run in either stand-alone or network and data is collected by Comm.
hosted modes, using a touch screen for LookoutDirect software. The data contains
local machine setup and control. Another all operational parameters for statistical TB’s &
application, Process Explorer, uses the same Wiring
analysis and process data collection. The
architecture for collecting and reporting Ethernet module also allows backup of Power
process data. and modification to the D2-250-1’s pro-
gram effortlessly over the network. Circuit
Protection

Enclosures

Appendix

Part Index

w w w. a u to m at i o n d i re c t . c o m PLC Products 1–3


Considerations for Choosing a PLC
PLC Selection Worksheet
Use the worksheet on the following pages as a checklist of the things to consider when determining PLC requirements. It lists the most
important areas to consider when choosing a PLC system, and provides space for recording determinations of your system needs.

Consideration Information to Record Why this is important


Determine whether your system is new or existing: Will your system
be installed from scratch or are there existing products already
installed? The rest of your system will need to be compatible with
1. _____ Existing new components.
Proposed System ____ New system system Why this is important: Certain PLC products may not be compatible
with others. Making sure your existing products are compatible
with any PLC products you are researching will save you time and
money. Check appropriate entry.
Consider any environmental issues that will affect your application
(temperature, dust, vibration, codes specific to your facility, etc.).
Why this is important: Certain environments may affect the opera-
____ No codes or tion of a PLC. For example, typical PLCs have an operating
2. ____ Codes/environ-
environmental temperature of 0-55 degrees Celsius (32-130 degrees F). If your
Environmental mental issues to
issues to con-
Issues consider application will include any extreme environmental conditions, or
sider you have specific codes at your facility that must be met, you will
need to either research products that meet those specifications or
design the installation to meet requirements. Check appropriate
entry.
Determine how many discrete devices your system will have. Which
types (AC, DC, etc.) are needed?
_____ Total inputs: _____ Total outputs: Why this is important: The number and type of devices your system
3. _____ AC _____ AC will include is directly linked to the amount of I/O that will be
Discrete Devices necessary for your system. You will need to choose a PLC model
_____ DC _____ DC that supports your I/O count requirements and has modules that
support your signal types.Enter quantities and type based on corre-
sponding field devices.

Determine how many analog devices your system will have.


_____ Total inputs: Which types (voltage, current, temperature, etc.) are needed?
_____ Total outputs:
____ Voltage Why this is important: The number and type of devices your system
4. ____ Voltage will include is directly linked to the amount of I/O that will be
____ Current
Analog Devices ____ Current necessary for your system. You will need to choose a PLC model
____ Thermo that supports your I/O count requirements and has modules that
____ RTD support your signal types. Enter quantities and type based on corre-
sponding field devices.
_____ High speed counter Determine whether your system will require any specialty features:
_____ Positioning Will your application require high-speed counting or positioning?
5. What about a real-time clock or other specialty feature?
Specialty _____ Servo/stepper
Modules or _____ BASIC programming
Why this is important: Specialty functions are not necessarily avail-
Features able in the PLC CPU or in standard I/O modules. Understanding
(application- _____ Real-time clock the special functions your system may perform will help you deter-
specific)
mine whether or not you will need to purchase additional specialty
_____ Others (list) modules. Check all features required.

Table continued on the following page

1–4 PLC Products 1 - 80 0 - 633 - 0405


Considerations for Choosing a PLC PLC
Overview

DL05/06
PLC

DL105
Consideration Information to Record Why this is important PLC

Determine the type of CPU you will need: How much memory will your DL205
PLC
Hardware requirements: system require? How many devices will your system have (determines data
memory)? How large is your program, and what types of instructions will your DL305
program include (determines program memory)? How fast a scan time do PLC
________ K program memory required you need? DL405
(estimated) Why this is important: Data memory refers to the amount of memory needed PLC
for dynamic data manipulation and storage in the system. For example,
Field I/O
________ K data memory required counter and timer instructions typically use data memory to store setpoints,
(estimated) current values, and other internal flags. If the application requires historical
data retention, such as measured device values over a long period of time, Software
the size of the data tables required may determine the CPU model you
C-more
______ Fast scan time required? choose. Program memory is the amount of memory needed to store the HMIs
6. sequence of PLC program instructions that have been programmed to
perform the application. Each type of instruction requires a specific amount Other HMI
CPU Required ______ Battery backup required?
of program memory, typically defined in a PLC's programming manual.
Applications that are basically sequential in nature can rely on the I/O device AC Drives
Software/special function rule of thumb to estimate program memory (five words of memory for each
requirements: I/O device); complex applications will be more difficult to judge. Motors
If scan time is important in your application, consider the CPU processor
____ PID speed as well as instruction execution speed. Some CPUs are faster at Steppers/
Servos
boolean logic but slower with data handling instructions.
If special functions such as PID are required, the CPU you select may make Motor
____ Floating Point Math Controls
those functions easier to perform.
For program memory required, follow this rule of thumb: 5 words of pro- Proximity
Others (see Programming section below) gram memory for each discrete device and 25 words for each analog Sensors

device. Check or calculate all requirements that apply. Photo


Sensors
Determine where your I/O will be located: Will your system require only
local I/O, or both local and remote I/O locations? Limit
Switches
_______ _______ Remote Locations Why this is important: If subsystems will be needed at long distances from
Local . . . the CPU, you will need a PLC model that supports remote I/O. You will Encoders
only also have to determine if the remote distances and speeds supported by
7. Specific remote I/O protocol
I/O Locations the PLC will be adequate for your application. Serial and Ehternet-based
required? Which one? Current
I/O hardware are two typical choices available for most PLC systems. This Sensors
I/O may also be referred to as distributed I/O, and may require a partic-
____________________ Pushbuttons/
ular fieldbus, such as DeviceNet or Profibus. Lights
Enter number of physical locations needed, and if/what specific protocol
Process
may be required.
_____ Ethernet Determine your communication requirements: Will your system
Relays/
_____ PLC to PLC ) be communicating to other networks, systems or field devices? Timers

_____ Modbus RTU Why this is important: Communication ports (other than the programming
8. Comm.
Commuications port) are not always included with a PLC. Knowing your system communi-
_____ ASCII (interface to serial devices)
cation requirements will help you choose a CPU that supports your
_____ DeviceNet TB’s &
communication requirements, or additional communication modules if Wiring
_____ Profibus necessary. Check any/all communications functions required.
Power
Determine your programming requirements: Does your application require
_____ PID loops only traditional programming instructions, or are special instructions neces-
_____ Circuit
Floating sary? Protection
_____ number of loops needed
point math Why this is important: Certain PLCs may not support every type of instruction.
Enclosures
9. _____ Subroutines You will need to choose a PLC that supports all instructions that you may need
Programming _____ for a specific application. For example, built-in PID functions are much easier
Drum to use than writing your own code to perform closed-loop process control. Appendix
sequencer _____ Direct interrupts
Typical instructions such as timers, counters, etc. are available in most
_____ Others (list) PLCs; note any other special instructions required here. Check any/all pro- Part Index
gramming functions required.

w w w. a u to m at i o n d i re c t . c o m PLC Products 1–5


DirectLOGIC Programmable Logic Controllers
DL05: Offers incredible
features with an expansion slot
The DL05 series is a fixed I/O PLC with eight inputs and six outputs with
one option card slot, and features you won’t find in most bricks — six
I/O combinations of AC, DC and relay I/O, and advanced program-
ming functions such as PID and drum sequencing.
• Eight inputs and six outputs • Thermocouple and RTD
• 2 K program memory temperature input modules
• 4 K data memory • Ethernet and serial communi-
• Two built-in communication ports cations modules
• 129 instructions, including four • 1-channel high-speed
PID loops input/pulse output module
• Removable terminal block • Memory cartridge/real-time
• 12/24 VDC powered versions clock module
starts on page 2-1
• Discrete and high-resolution • DeviceNet™ / Profibus modules
analog I/O modules • Basic CoProcessor module

DL06: Mighty micro with


36 I/O and four expansion slots
The DL06 series combines its fixed I/O of 20 inputs and 16 outputs
with four option card slots for expansion (discrete, analog, commu-
nications modules, etc.), all in the same package. With the DL06,
you can use the same PLC panel layout for all applications from 36
to 100 I/O.
• 20 inputs and 16 outputs • Built-in real-time clock/calendar
• 7.5 K program memory • Discrete and high-resolution
• 7.3 K data memory analog I/O option modules
• Two built-in communication • Thermocouple and RTD
ports - one RS232 and one temperature input modules
RS232/422/485 port • Ethernet and serial communica-
• 229 instructions, including tions modules
eight PID loops and ASCII • High speed input/pulse output
• Removable terminal blocks module
• Built-in 300 mA 24 VDC • DeviceNet™ and Profibus modules
starts on page 2-1 auxiliary power supply for field • Basic CoProcessor module
devices • Optional plug-in LCD display
• 12/24 VDC powered versions

DL105: Micro PLC


The DL105 series is a fixed-I/O micro PLC with 10 inputs and eight
outputs. Eight configurations are available in combinations of AC,
DC and relay I/O, as well as AC and DC powered units.

• 10 inputs and eight outputs • 91-instruction programming


• 2 K program memory includes time or event-based drum
• 384 words data memory sequencer, timed interrupt,
• 110/220 VAC or 24 VDC power immediate I/O, etc.
supply versions • Heavy-duty seven amp relays with
• Powerful built-in 0.5A, 24 VDC built-in surge suppression on
auxiliary power supply for models with relay outputs
field devices • DeviceNet slave I/O units available
starts on page 3-1 • One RS-232 communication port

1–6 PLC Products 1 - 80 0 - 633 - 0405


DirectLOGIC Programmable Logic Controllers PLC
Overview

DL05/06

DL205
PLC

DL105
PLC
The world’s most powerful micro-modular PLC
with a wide range of I/O and communications modules DL205
PLC

If your application requires the flexibility of a modular control system, a DL305


DL205 PLC is the lowest cost, most versatile solution you’ll find. Check PLC
out all our modules, bases and communications options.
DL405
PLC
• Four CPUs and four base sizes available
• Local expansion up to four bases • Ethernet and serial remote I/O master Field I/O
plus CPU base and slave modules
• 16 buit-in PID loops using D2-260 CPU • High-speed counter/pulse output Four CPUs from 2.4 K memory to
Software
30.4 K memory, and up to 16,384
• AC/DC input/output modules - module I/O.
up to 32 points per module • Counter input/pulse output Four base sizes with built-in
starts on page 4-1 C-more
• Basic CoProcessor module power supply, including 12/24 HMIs
• Up to 10 A relay outputs VDC, 110/220 VAC and 125 VDC
• 12-bit and 16-bit analog I/O modules • Ethernet, DeviceNet™ and Profibus powered bases. Other HMI
• Thermocouple and RTD input modules slave controller modules
• Ethernet and serial communications • Triple port serial module for WinPLCs
AC Drives
modules and EBCs

Motors

DL305
We’ve still got it!
Steppers/
Servos

Motor
The DL305 series is a small modular PLC that has been marketed by Controls
various name brand PLC manufacturers for over 23 years. This Koyo Proximity
design revolutionized the small PLC market, and you can keep your Sensors
DL305 system operating with these compatible components.
Photo
Sensors
• Three standard CPUs, including the D3-350 • AC, DC and relay outputs
Limit
with PID control and two communication • Eight or 12-bit analog input/output Switches
ports
• Five, eight and 10 slot bases starts on page 5-1 Encoders
• 110/220 VAC or 24 VDC power supply
• AC, DC inputs Current
Sensors

DL405
Specialty modules for complex applications
Pushbuttons/
Lights

Process

The DL405 product line packs a lot of power for its size and price. It has the most Relays/
comprehensive choice of of I/O modules and configurations of all our PLCs. Timers

Comm.

• Three CPUs and three base sizes available • High-speed counter module TB’s &
Wiring
• Local expansion up to three bases • Counter input module (HSC)
plus CPU base • CoProcessor module Power
• 16 built-in PID loops (D4-450 CPU) • Interrupt module
up to 96 loops using PID modules Circuit
•AC/DC input/output modules - Protection
up to 64 points per module
Enclosures
• 10 A relay outputs
• 12-bit and 16-bit analog I/O modules Three CPUs from 6.5 K memory to 30.8 K memory,
and up to 16,384 I/O
• Thermocouple and RTD input modules Appendix
Three base sizes with built-in power supply, starts on page 6-1
• Ethernet and serial communications modules including 12/24 VDC, 110/220 VAC and 125 VDC
• Ethernet and serial remote I/O master and powered bases. Part Index
slave modules

w w w. a u to m at i o n d i re c t . c o m PLC Products 1–7


Reviewing PLC Capabilities
The following functionality tables (A, B and C) provide an overview of the capabilities of our various DirectLOGIC
PLC families. When you have identified the type and quantity of I/O devices required by your application, the I/O
Availability table shows you which family or families will meet those specifications.

Check the I/O types supported by the


A I/O Availability
DirectLOGIC PLC families

BUILT-IN I/O ANALOG I/O


I/O CAPACITY DISCRETE I/O MODULES
(DL05/06/105) MODULES

Analog 4-20 or Volt Isol. Out


Analog 4-20 Out or Volt Out
Mix of I/O (inputs/outputs)

AC/DC Isolated Relay out

Analog 4-20 In or Volt In


DC Sink/Source In

Analog Isolated In
AC/DC Relay Out
Total Possible I/O

DC In/Relay Out

AC In/Relay Out

DC Source Out

Temperature In
DC In/DC Out
DC In/AC Out

AC In/DC Out

High Speed In
AC In/AC Out

DC Source In

DC Sink Out
CPU/Device

AC/DC In

Pulse Out
DL Family

Local I/O

AC Out
TTL In

AC In
D0-05DR(-D) 14 8 in/6 out 30 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D0-05DD(-D) 14 8 in/6 out 30 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
DL05

D0-05DA 14 8 in/6 out 30 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓


D0-05AR 14 8 in/6 out 30 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D0-05AD 14 8 in/6 out 30 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D0-05AA 14 8 in/6 out 30 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D0-06DD1(-D) 36 20 in/16 out 100 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D0-06DD2(-D) 36 20 in/16 out 100 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
DL06

D0-06DR(-D) 36 20 in/16 out 100 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓


D0-06AA 36 20 in/16 out 100 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D0-06DA 36 20 in/16 out 100 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D0-06AR 36 20 in/16 out 100 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
F1-130DR(-D) 18 10 in/8 out 18 ✓ ✓
F1-130DD(-D) 18 10 in/8 out 18 ✓ ✓ ✓
DL105

F1-130DA 18 10 in/8 out 18 ✓ ✓


F1-130AR 18 10 in/8 out 18 ✓
F1-130AD 18 10 in/8 out 18 ✓ ✓
F1-130AA 18 10 in/8 out 18 ✓
D2-230 256 128 in/128 out 256 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
DL205

D2-240 256 any mix 896 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓


D2-250-1 256 any mix 2048 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D2-260 256 any mix 16,384 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D3-330 168 any mix 168 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
DL305

D3-340 168 any mix 184 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓


D3-350 168 any mix 880 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D4-430 640 320 in/320 out 1152 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D4-440(DC-1)
640 320 in/320 out 1664 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D4-440(DC-2)
DL405

D4-450(DC-1)
2048* 1024 in/1024 out 16,384 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D4-450(DC-2)

Built-in I/O Optional I/O Modules


*1280 total local I/O if using 1 or more of the non “-1” bases (Example: D4-08B vs. D4-08B-1)

1–8 PLC Products 1 - 80 0 - 633 - 0405


Reviewing PLC Capabilities PLC
Overview

DL05/06
The Communications table lists all the supported protocols and which CPU can communicate using that protocol. You PLC
can also see which families support Ethernet communications, remote I/O and ASCII coprocessing. All CPUs and fixed
DL105
I/O base units have built-in communications ports (except D3-330). The DL05, DL06 and DL205 families also have PLC
a variety of Fieldbus slave controllers to integrate our I/O with popular networks such as DeviceNet and Profibus.
DL205

B
PLC
Communications Check the communications types
supported by the DirectLOGIC DL305
PLC
PLC families DL405
PLC
CPU PORT COMMUNICATIONS AND SPECIALTY MODULES Field I/O
SUPPORTED PROTOCOLS

Software

ETHERNET Remote I/O Master


ETHERNET Remote I/O Slave
Serial Remote I/O Master
C-more

Serial Remote I/O Slave


DirectNet Master/Slave
ETHERNET - 100 Mbit
HMIs

ETHERNET - 10 Mbit
Modbus RTU Master

Remote I/O Master


Modbus RTU Slave

Modbus RTU Slave


Basic Coprocessor
Other HMI
DirectNet Master

ASCII Out (Print)


K-Sequence Slave

DeviceNet Slave
DirectNet Slave

Profibus Slave
ASCII IN/Out

AC Drives

SDS Slave
DL06 DL05 DL Family

RS485

RS232
RS422
Motors
CPU

Steppers/
Servos
All DL05 models ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Motor
Controls
All DL06 models ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Proximity
Sensors
F1-130DR(-D) ✓ ✓
Photo
F1-130DD(-D) ✓ ✓ Sensors
DL105

F1-130DA ✓ Limit
Switches
F1-130AR ✓ ✓
Encoders
F1-130AD ✓

F1-130AA ✓ Current
Sensors
D2-230 ✓
Pushbuttons/
DL205

D2-240 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ * * * Lights
D2-250-1 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ * * * Process
D2-260 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ * * *
D3-330 ✓ ✓ ✓ Relays/
Timers
DL305

D3-340 ✓ ✓ ✓
Comm.
D3-350 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

D4-430 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ TB’s &


Wiring
DL405

D4-440(DC-1)
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Power
D4-440(DC-2)
D4-450(DC-1)
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D4-450(DC-2) Circuit
Protection
* These slave modules take the place of a DL205 CPU in any DL205 base populated with I/O, for use
with Fieldbus networks. Enclosures

Appendix

Part Index

w w w. a u to m at i o n d i re c t . c o m PLC Products 1–9


Reviewing PLC Capabilities
The Programming table provides a listing of the major program functions. It also shows the amount of memory and
instruction capability for each CPU. The programming descriptions below explain the various programming tools that
can be used to configure the CPUs.

Check the programming instructions


C Programming supported by the DirectLOGIC PLC families
INSTRUCTIONS TOOLS

Trigonometric Instructions

Full Program PC-DSOFT5


Handheld Programmer
Floating Point Math

IBox instructions**
Max. Instructions

Timer/Counters

Clock/Calendar
For/Next Loops
Battery Backup

Immediate I/O
Max. Variables

Control Relays
Total Memory

Run-Time Edit

Subroutines
DL Family

RLL Plus

Drums
CPU

PID
DL05 All DL05 models 6.0K 2048 4096 ✓* ✓ ✓ 512 128/128 ✓ ✓ ✓ ✓ ✓ ✓* ✓ ✓ ✓
DL06 All DL06 models 14.8K 7.5K 7.3K ✓ ✓ ✓ 1024 256/128 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
DL105 All DL105 models 2.4K 2048 256 ✓ ✓ 256 64/64 ✓ ✓ ✓ ✓
D2-230 2.4K 2048 384 ✓ ✓ ✓ 256 64/64 ✓ ✓ ✓
D2-240 3.8K 2560 1280 ✓ ✓ ✓ 256 128/128 ✓ ✓ ✓ ✓ ✓ ✓
DL205
D2-250-1 14.8K 7680 7168 ✓ ✓ ✓ 1024 256/128 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D2-260 30.4K 15.8K 14.6K ✓ ✓ ✓ 2048 256/256 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D3-330 3.8K 3.7K 128 ✓ 140 64 ✓ ✓
DL305 D3-340 3.9K 3.7K 192 ✓ 196 64 ✓ ✓
D3-350 14.8K 7680 7168 ✓ ✓ ✓ 1024 256/128 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D4-430 6.5K 3.5K 3.0K ✓ ✓ ✓ 480 128/128 ✓ ✓ ✓
D4-440(DC-1)
DL405 22.5K 15.5K* 7.0K ✓ ✓ ✓ 1024 256/128 ✓ ✓ ✓ ✓ ✓ ✓
D4-440(DC-2)
D4-450(DC-1)
30.8K 15.5K* 15.3K ✓ ✓ ✓ 2048 256/256 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
D4-450(DC-2)

* Requires memory card ** with supporting firmware

Standard RLL programming IBox instructions


RLL (relay ladder logic) diagram-style programming is the IBoxes (Intelligent Box Instructions) are parameterized
best tool for solving boolean logic and general CPU ‘fill-in-the-blank’ style instructions that allow you to enter
register/accumulator various parameters into a
manipulation. It includes X0 control box to configure
LDD
dozens of instructions, V1076 your code. This easy style
which will augment drums, CMP D
of programming eliminates
stages, and loops. K309482 the need for potentially
S P 62 X0 Y0 lengthy rungs of ladder
OUT code. IBoxes create the
ladder code and execute it
in the background so you
never have to see it.
Stage programming
Stage programming (also called Push ± UP DOWN PID loop operation
RLL Plus) is based on state-
transition diagrams. The PID loop operation uses setup tables to configure
Stages divide the ladder DOWN LIGHT UP the loops. Features include: auto tuning, alarms, SP
program into sections ramp/soak generation, S P
which correspond to the states in LOWER
Push ±
DOWN
and more. +
PID Process S
a flow chart of your process. --
PV

1–10 PLC Products 1 - 80 0 - 633 - 0405


Part Numbering System PLC
Overview

DL05/06
D2- 260 PLC
Our brand name — CPUs • Specialty CPUs
DirectLOGIC DL205 D2/H2 D4- 450
Refer to the PLC DL105
Product Family DL305 D3/F3 PLC
D4- 450DC -1 sections in this catalog for
We use the brand name “DirectLOGIC” DL405 D4
information on and technical
230, 240, (250-1), 260 DL205
for our PLC products. Many first time specifications for all avail- PLC
330, 340, 350, OMUX-(1/2)
customers get confused by our use of the Specific CPU within family 430, 440, 450 (AC CPUs)*
able PLCs, modules and
brand name abbreviation “DL”. This is 440DC-1, 440DC-2 (DC CPUs)* accessories DL305
*(DL405 only - power is 450DC-1, 450DC-2 (DC CPUs)* PLC
especially true when we’re making
connected CPU, not base) WPLCx-xx (for 205 bases only) D2- 06B -1
product family or CPU references such as DL405
“DL205 System”. We use the term Bases D4- 08B -1 PLC
D2- 09B DC1 -1
“DL205” as a generic term for the DL205 Product family D2, D3, D4*
Field I/O
family of products. Number of slots ##B
Type of base (blank=AC bases), DC(x) Software
DL05, DL06 and DL105 Denotes differentiation of -1 (standard),
features -NR (305 0nly; Class1, Div2) C-more
These families use a part numbering F2- 08 T R
Discrete I/O Modules HMIs
scheme that is very similar to our modular
D0/F0 D3/F3 D0- 10 N D 3 F
PLC products. However, since the I/O Product family
D2/F2 D4/F4
Other HMI
points in the base unit are always fixed, we D2- 16 T D 1 -2
Number of points 04/08/10/12/16/32/64
do not include the I/O count in our part AC Drives
Input N
number. The table below will help you Output T
understand the numbering scheme used Combination C Motors
for the DL05, DL06 and DL105 families. AC A
DC D
Fixed I/O ‘Brick” PLC part numbering* Either E Steppers/
Servos
Product Family D0- 05DR Relay R
Current sinking 1 Motor
DL05 D0 D0- 06DD1 -D
Current sourcing 2 Controls
Product Family DL06 D0
Current sinking/sourcing 3
DL105 F1
High current H Proximity
CPU Isolation S (blank = standard)
Sensors
05 Fast I/O F
Photo
Specific CPU 06 Sensors
Denotes a differentiation (Blank), -1, -2, -3, -4
130 between similar modules
Input Type F2- 04 AD -1 Limit
Analog I/O Modules Switches
AC A F0 F3 F2- 02 DA S -2
DC (sink/source) D Product family
F2 F4 Encoders
Output Type F4- 16 AD -1
Number of channels 02/04/08/16
AC A Input (analog to digital) AD Current
(DC, 1: sink)(2: source) D, D1, D2 Output (digital to analog) DA Sensors
Relay R Thermocouple THM
RTD RTD Pushbuttons/
Power Supply Type Lights
AC Blank Isolated S, (blank = standard)
DC D Process
*DL05/06 option module part numbering Denotes a differentiation -1(L) (L = 12VDC operation)
between similar modules -2(L) (blank = standard)
scheme is shown in the table to the right. Relays/
Communications, Networking and D0- DCM Timers
Specialty I/O Modules
DL205, DL305, DL405 Product family D0/H0 D3/F3
H2- ECOM100
Comm.
D2/F2/H2 D4/F4/H4
(and DL05/06 options) DL05 / DL06 ECOM100, DCM, CP128,
H4- CTRIO
TB’s &
Our modular product families offer a option modules CTRIO, DEVNETS, PSCM, MC See PLC sections Wiring
considerable number of products and ERM, ECOM100, DCM, CTRIO, for all communications,
DL205 communication networking and specialty Power
therefore use a slightly more complex part EBC, SERIO, PBC, DEVNETS,
and specialty modules
CP128, CTRINT, RMSM/ RSSS modules
numbering system (see table at right). This
table also includes option modules avail- ERM, EBC, ECOM100, DCM, Circuit
DL405 communications Protection
CTRIO, CPxxx, INT, MAS/MB,
able for the DL05 and DL06 families. Our and specialty modules
PID, 4LTC, RM/SM, ERM - Ethernet remote I/O master module
part numbering scheme may help you INT - Interrupt module Enclosures
quickly identify key product characteristics Module suffix identifiers: MAS/MB - Modbus master/slave
DCM - Data communications module PID - PID Coprocessor
just by examining the part number. This PSCM - Profibus slave Appendix
DEVNETS - DeviceNet module
may also help you to find the products CPxxx - CoProcessor module RMSM/RSSS - Serial remote I/O
you need in the price list, or in the PLC CTRIO - High speed counter module RM/SM - Serial remote I/O
SERIO - Serial port module Part Index
technical sections of this desk reference. EBC - Ethernet base controlle module
ECOM100 - Ethernet communications module

w w w. a u to m at i o n d i re c t . c o m PLC Products 1–11


Get The Training You Need,
When And Where You Need It
Doug Bell and
InterConnecting
Automation, Inc.
Would you be interested in a PLC or drives
training course focused entirely on
AUTOMATIONDIRECT’s products, taught by
someone who has used most of our products in
real-world applications? Would it be extra
convenient if the training was held in a city near
you? We thought so! Doug has expanded his
offering to now include:
• Basic PLC training course (three days)
covering basic PLC theory of operation
including CPU, bases, discrete I/O,
analog I/O, and communications
• Advanced PLC training course (three days)
covering advanced programming and
debugging, with remote I/O, networking,
“Introduction to PLC Logic and Principles”
modems and more video or DVD and training kit
• PID training course (two days) covering PID Doug has condensed the most
loop setup, tuning and troubleshooting, as important lessons from his three-
day basic PLC seminar into a
well as shortcuts and tools the experts use step-by-step two-video or DVD
• AC Drives training course (two days) covering set. Course content includes:
AC inductive motor and variable frequency • Basic wiring and logic
drive fundamentals, power circuit analysis instructions
and maintenance • Scan time, addressing, I/O
Check the Appendix for a complete schedule • Using DirectSOFT
of classes for 2007 and 2008 in major cities program ming software
across the U.S. • Programming and debugging:
using inputs and outputs,
Training sets debugging and status mode,
PLC commands, troubleshooting
Now available on DVD and in Spanish Check the Appendix for a complete description of the
Want to learn how to program our PLCs in training kit and course contents. Available with Spanish captions.
the comfort of your own office? Doug Bell
has created two hands-on training kits, one PLC analog I/O training video or DVD set
based on his world-famous basic PLC training Learn the ins and outs of using
class, the other focusing on PLC analog prin- analog I/O with PLCs in this
ciples. The basic PLC training kit includes two step-by-step training set. Course
videotapes or one DVD, a pre-wired trainer content includes:
containing a DL05 PLC, and the DL05 User • Analog I/O principles - volt
Manual. age, current, thermocouples
The analog training kit includes two video- • PLC analog modules - input,
tapes or one DVD, a pre-wired trainer with output, thermocouple
potentiometers and meters, a DL05 analog • DL05 PLC analog-tutorial
input/output module, I/O cable and 24 VDC includes configuration,
power supply. Each kit sells for only $795, wiring, scaling and
and can be ordered directly from programming
• Application programming
Interconnecting Automation examples, including
1-414-425-8348 controlling motor speed with a drive and an analog output card in a PLC
www.interconnectingautomation.com Check the Appendix for a complete description of the
(DirectSOFT programming software must be training kit and course contents. Available with Spanish captions.
purchased separately.)

1–12 PLC Products 1 - 80 0 - 633 - 0405