DL06 Micro PLC User Manual

Volume 1 of 2

Manual Number: D0-06USER-M

DL06 Micro PLC User Manual, 3rd Edition, Rev. D

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DL06 Micro PLc USER MANUAL

Please include the Manual Number and the Manual Issue, both shown below, when communicating with Technical Support regarding this publication.

Manual Number: D0-06USER-M

Issue: 3rd Edition, Rev. D

Issue Date: 6/16

Publication HistoryIssue Date Description of Changes

First Edition 7/02 OriginalRev. A 10/02 Updated drawing images and made minor corrections.Rev. B 6/03 Added new PLC and made numerous corrections.

2nd Edition 3/04 Added two appendices, removed discrete module data and made numerous corrections.

3rd Edition 3/07

Corrected all tables, many corrections to Chapters 2, 3, 4, 5, 6, and 7; Chapter 3 (HSIO) was moved to the Appendices and Chapter 4 was divided into Chapters 3 & 4; added DS5 Intelligent Boxes to Chapter 5; added Ramp/Soak example to Chapter 8; Numbering Systems and Serial Communications were added to Appendices; many minor corrections were made throughout manual.

Rev. A 5/07 Minor corrections and updates.

Rev. B 6/11Updated Chapter 5 with current DirectSOFT dialog views, corrected number of registers needed to use the print message instruction, removed fuses and corrected I/O wiring drawings, and other minor corrections and updates.

Rev. C 2/13Added H0-CTRIO2 references. Minor corrections and updates. Added transient suppression for inductive loads.

Rev. D 6/16 Corrections and updates.

DL06 Micro PLC User Manual

Notes

Table of ConTenTs

Chapter 1: Getting StartedIntroduction ...............................................................................................................12

The Purpose of this Manual ......................................................................................12Supplemental Manuals .............................................................................................12Technical Support ....................................................................................................12

Conventions Used ......................................................................................................13Key Topics for Each Chapter .....................................................................................13

DL06 Micro PLC Overview .........................................................................................14The DL06 PLC Features ............................................................................................14DirectSOFT Programming for Windows ................................................................14Handheld Programmer .............................................................................................15

I/O Quick Selection Guide .........................................................................................15

Quick Start .................................................................................................................16

Steps to Designing a Successful System .................................................................110

Questions and Answers about DL06 Micro PLCs ....................................................112

Chapter 2: Installation, Wiring, and SpecificationsSafety Guidelines .......................................................................................................22

Plan for Safety ..........................................................................................................22Three Levels of Protection ........................................................................................23Emergency Stops ......................................................................................................23Emergency Power Disconnect ..................................................................................24Orderly System Shutdown ........................................................................................24Class 1, Division 2 Approval .....................................................................................24

Orientation to DL06 Front Panel ..............................................................................25Terminal Block Removal ...........................................................................................26

Mounting Guidelines .................................................................................................27

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Unit Dimensions .......................................................................................................27Enclosures ................................................................................................................27Panel Layout & Clearances .......................................................................................28Using Mounting Rails ...............................................................................................29Environmental Specifications ..................................................................................210Agency Approvals ...................................................................................................210Marine Use .............................................................................................................210

Wiring Guidelines ....................................................................................................211External Power Source ............................................................................................212Planning the Wiring Routes ....................................................................................212Fuse Protection for Input and Output Circuits ........................................................213I/O Point Numbering .............................................................................................213

System Wiring Strategies ........................................................................................214PLC Isolation Boundaries ........................................................................................214Connecting Operator Interface Devices ..................................................................215Connecting Programming Devices .........................................................................215Sinking / Sourcing Concepts ..................................................................................216I/O Common Terminal Concepts ........................................................................217Connecting DC I/O to Solid State Field Devices ..................................................218Solid State Input Sensors ........................................................................................218Solid State Output Loads ........................................................................................218Relay Output Wiring Methods ................................................................................220Relay Outputs-Transient Suppression For Inductive Loads in a Control System .......221Prolonging Relay Contact Life ................................................................................226DC Input Wiring Methods ......................................................................................227DC Output Wiring Methods ...................................................................................228High-Speed I/O Wiring Methods ............................................................................229

Wiring Diagrams and Specifications .......................................................................230D006AA I/O Wiring Diagram ................................................................................230D006AR I/O Wiring Diagram ................................................................................232D006DA I/O Wiring Diagram ...............................................................................234D006DD1 I/O Wiring Diagram .............................................................................236D006DD2 I/O Wiring Diagram .............................................................................238D006DR I/O Wiring Diagram ................................................................................240D006DD1D I/O Wiring Diagram .........................................................................242D006DD2D I/O Wiring Diagram .........................................................................244D006DRD I/O Wiring Diagram ...........................................................................246

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Table of Contents

Glossary of Specification Terms ..............................................................................248

Chapter 3: CPU Specifications and OperationOverview 32

DL06 CPU Features ..................................................................................................32

CPU Specifications .....................................................................................................33

CPU Hardware Setup .................................................................................................34Communication Port Pinout Diagrams .....................................................................34Connecting the Programming Devices .....................................................................35CPU Setup Information ............................................................................................35Status Indicators .......................................................................................................36Mode Switch Functions ............................................................................................36Changing Modes in the DL06 PLC ...........................................................................37Mode of Operation at Power-up ..............................................................................37

Using Battery Backup ................................................................................................38Battery Backup .........................................................................................................38Auxiliary Functions ...................................................................................................39Clearing an Existing Program ...................................................................................39Initializing System Memory ......................................................................................39Setting Retentive Memory Ranges ..........................................................................310Using a Password ...................................................................................................311

CPU Operation .........................................................................................................312CPU Operating System ...........................................................................................312Program Mode .......................................................................................................313Run Mode ..............................................................................................................313Read Inputs ............................................................................................................314Service Peripherals and Force I/O ...........................................................................314CPU Bus Communication .......................................................................................315Update Clock, Special Relays and Special Registers .................................................315Solve Application Program .....................................................................................316Solve PID Loop Equations .......................................................................................316Write Outputs ........................................................................................................316Write Outputs to Specialty I/O ...............................................................................316Diagnostics .............................................................................................................317

I/O Response Time ..................................................................................................317Is Timing Important for Your Application? ..............................................................317

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Normal Minimum I/O Response .............................................................................318Normal Maximum I/O Response ............................................................................318Improving Response Time ......................................................................................319

CPU Scan Time Considerations ...............................................................................320Reading Inputs .......................................................................................................320Writing Outputs .....................................................................................................320Service Peripherals ..................................................................................................321CPU Bus Communication .......................................................................................321Update Clock/Calendar, Special Relays, Special Registers .......................................321Application Program Execution ..............................................................................322PLC Numbering Systems ........................................................................................323PLC Resources ........................................................................................................323VMemory .............................................................................................................324Binary-Coded Decimal Numbers ............................................................................324Hexadecimal Numbers ...........................................................................................324

Memory Map ...........................................................................................................325Octal Numbering System .......................................................................................325Discrete and Word Locations ..................................................................................325V-memory Locations for Discrete Memory Areas ....................................................325Input Points (X Data Type) .....................................................................................326Output Points (Y Data Type) ..................................................................................326Control Relays (C Data Type) .................................................................................326Timers and Timer Status Bits (T Data Type) ............................................................326Timer Current Values (V Data Type) .......................................................................327Counters and Counter Status Bits (CT Data type) ...................................................327Counter Current Values (V Data Type) ...................................................................327Word Memory (V Data Type) .................................................................................328Stages (S Data type) ...............................................................................................328Special Relays (SP Data Type) .................................................................................328

DL06 System V-memory ..........................................................................................329System Parameters and Default Data Locations (V Data Type) ...............................329

DL06 Aliases .............................................................................................................331

DL06 Memory Map ..................................................................................................332

X Input/Y Output Bit Map ......................................................................................333

Stage Control/Status Bit Map .................................................................................334

Control Relay Bit Map .............................................................................................336

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Table of Contents

Timer Status Bit Map ...............................................................................................338

Counter Status Bit Map ...........................................................................................338

GX and GY I/O Bit Map ..........................................................................................339

Chapter 4: System Design and ConfigurationDL06 System Design Strategies ................................................................................42

I/O System Configurations .......................................................................................42Networking Configurations ......................................................................................42

Module Placement .....................................................................................................43Slot Numbering........................................................................................................43Automatic I/O Configuration ....................................................................................44Manual I/O Configuration ........................................................................................44

Power Budgeting .......................................................................................................45Power supplied .......................................................................................................45Power required by base unit ...................................................................................45Power required by option cards ..............................................................................45

Configuring the DL06s Comm Ports ........................................................................47DL06 Port Specifications ...........................................................................................47DL06 Port Pinouts ....................................................................................................47Choosing a Network Specification ............................................................................48RS-232 Network .......................................................................................................48RS-422 Network .......................................................................................................48RS-485 Network .......................................................................................................48

Connecting to MODBUS and DirectNET Networks ..................................................49MODBUS Port Configuration ....................................................................................49DirectNET Port Configuration .................................................................................410

NonSequence Protocol (ASCII In/Out and PRINT) ...............................................411Non-Sequence Port Configuration ..........................................................................411

Network Slave Operation ........................................................................................412MODBUS Function Codes Supported .....................................................................412Determining the MODBUS Address ........................................................................412If Your Host Software Requires the Data Type and Address ....................................413Example 1: V2100 ..................................................................................................414Example 2: Y20 ......................................................................................................414Example 3: T10 Current Value ................................................................................414

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Table of Contents

Example 4: C54 ......................................................................................................414If Your MODBUS Host Software Requires an Address ONLY ...................................415Example 1: V2100 584/984 Mode .........................................................................416Example 2: Y20 584/984 Mode .............................................................................416Example 3: T10 Current Value 484 Mode ..............................................................417Example 4: C54 584/984 Mode .............................................................................417

Network Master Operation .....................................................................................417Step 1: Identify Master Port # and Slave #..............................................................418Step 2: Load Number of Bytes to Transfer ..............................................................418Step 3: Specify Master Memory Area ......................................................................419Step 4: Specify Slave Memory Area ........................................................................420Communications from a Ladder Program ...............................................................421Multiple Read and Write Interlocks .........................................................................421

Network Master Operation (using MRX and MWX Instructions) .........................422MODBUS Function Codes Supported .....................................................................422MODBUS Read from Network(MRX) ......................................................................423MRX Slave Memory Address ...................................................................................424MRX Master Memory Addresses .............................................................................424MRX Number of Elements ......................................................................................424MRX Exception Response Buffer .............................................................................424MODBUS Write to Network (MWX) .......................................................................425MWX Slave Memory Address .................................................................................426MWX Master Memory Addresses ............................................................................426MWX Number of Elements .....................................................................................426MWX Exception Response Buffer ............................................................................426MRX/MWX Example in DirectSOFT ........................................................................427Multiple Read and Write Interlocks .........................................................................427

Chapter 5: Standard RLL InstructionsIntroduction ...............................................................................................................52

Using Boolean Instructions .......................................................................................55END Statement ........................................................................................................55Simple Rungs ...........................................................................................................55Normally Closed Contact .........................................................................................56Contacts in Series .....................................................................................................56Midline Outputs .......................................................................................................56

DL06 Micro PLC User Manual, 3rd Edition, Rev. D vii

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Parallel Elements .......................................................................................................57Joining Series Branches in Parallel .............................................................................57Joining Parallel Branches in Series .............................................................................57Combination Networks ............................................................................................57Comparative Boolean ...............................................................................................58Boolean Stack ...........................................................................................................58Immediate Boolean ..................................................................................................59

Boolean Instructions ...............................................................................................510

Comparative Boolean ..............................................................................................526

Immediate Instructions ...........................................................................................532

Timer, Counter and Shift Register Instructions ......................................................539Using Timers ..........................................................................................................539Timer Example Using Discrete Status Bits ...............................................................541Timer Example Using Comparative Contacts ..........................................................541Accumulating Timer Example using Discrete Status Bits .........................................543Accumulator Timer Example Using Comparative Contacts .....................................543Using Counters.......................................................................................................544Counter Example Using Discrete Status Bits ...........................................................546Counter Example Using Comparative Contacts ......................................................546Stage Counter Example Using Discrete Status Bits ..................................................548Stage Counter Example Using Comparative Contacts ............................................548Up / Down Counter Example Using Discrete Status Bits .........................................550Up / Down Counter Example Using Comparative Contacts ....................................550

Accumulator/Stack Load and Output Data Instructions ........................................552Using the Accumulator ...........................................................................................552Copying Data to the Accumulator ..........................................................................552Changing the Accumulator Data ............................................................................553Using the Accumulator Stack ..................................................................................554Using Pointers ........................................................................................................555

Logical Instructions (Accumulator) .........................................................................569

Math Instructions ....................................................................................................586

Transcendental Functions......................................................................................5118

Bit Operation Instructions .....................................................................................5120

Number Conversion Instructions (Accumulator) ..................................................5127Shuffle Digits Block Diagram ................................................................................5139

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Table of Contents

Table Instructions ..................................................................................................5141Copy Data From a Data Label Area to V-memory .................................................5143

Clock/Calendar Instructions ..................................................................................5171

CPU Control Instructions .......................................................................................5173

Program Control Instructions ...............................................................................5175

Interrupt Instructions ............................................................................................5183

Message Instructions .............................................................................................5186Move Block Instruction (MOVBLK) .......................................................................5189Copy Data From a Data Label Area to V-memory .................................................5189

Intelligent I/O Instructions ....................................................................................5194Read from Intelligent Module (RD) .......................................................................5194Write to Intelligent Module (WT) .........................................................................5195

Network Instructions .............................................................................................5196Direct Text Entry ..................................................................................................5200Embedding date and/or time variables .................................................................5201Embedding V-memory data .................................................................................5201Data Format Suffixes for Embedded V-memory Data............................................5202Text Entry from V-memory ...................................................................................5203

MODBUS RTU Instructions ...................................................................................5204MRX Slave Address Ranges ...................................................................................5205MWX Slave Address Ranges..................................................................................5208MWX Master Memory Address Ranges .................................................................5208MWX Number of Elements ................................................................................5208MWX Exception Response Buffer ..........................................................................5208

ASCII Instructions ..................................................................................................5210Reading ASCII Input Strings ..................................................................................5210Writing ASCII Output Strings ................................................................................5210Managing the ASCII Strings .................................................................................5211

Intelligent Box (IBox) Instructions ........................................................................5230

Chapter 6: Drum Instruction ProgrammingIntroduction ...............................................................................................................62

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Table of Contents

Purpose ....................................................................................................................62Drum Terminology ...................................................................................................62Drum Chart Representation ......................................................................................63Output Sequences ....................................................................................................63

Step Transitions .........................................................................................................64Drum Instruction Types ............................................................................................64Timer-Only Transitions .............................................................................................64Timer and Event Transitions .....................................................................................65Event-Only Transitions ..............................................................................................66Counter Assignments ...............................................................................................66Last Step Completion ...............................................................................................67

Overview of Drum Operation ...................................................................................68Drum Instruction Block Diagram ..............................................................................68Powerup State of Drum Registers .............................................................................69

Drum Control Techniques .......................................................................................610Drum Control Inputs ..............................................................................................610Self-Resetting Drum................................................................................................611Initializing Drum Outputs .......................................................................................611Using Complex Event Step Transitions ...................................................................611

Drum Instruction .....................................................................................................612Timed Drum with Discrete Outputs (DRUM) ..........................................................612Event Drum (EDRUM) ............................................................................................614Handheld Programmer Drum Mnemonics ..............................................................616Masked Event Drum with Discrete Outputs (MDRMD) ...........................................619Masked Event Drum with Word Output (MDRMW) ...............................................621

Volume Two: Table of ConTenTs

DL06 Micro PLC User Manual, 3rd Edition, Rev. Dx

Table of Contents

Chapter 7: RLLPLUS Stage ProgrammingIntroduction to Stage Programming ........................................................................72

Overcoming Stage Fright ......................................................................................72

Learning to Draw State Transition Diagrams ...........................................................73Introduction to Process States ..................................................................................73The Need for State Diagrams ...................................................................................73A 2State Process .....................................................................................................73RLL Equivalent ..........................................................................................................74Stage Equivalent .......................................................................................................74Lets Compare ..........................................................................................................75Initial Stages .............................................................................................................75What Stage Bits Do ..................................................................................................76Stage Instruction Characteristics ...............................................................................76

Using the Stage Jump Instruction for State Transitions ..........................................77Stage Jump, Set, and Reset Instructions ....................................................................77

Stage Program Example: Toggle On/Off Lamp Controller ......................................78A 4State Process .....................................................................................................78

Four Steps to Writing a Stage Program ...................................................................791. Write a Word Description of the application. .......................................................792. Draw the Block Diagram. .....................................................................................793. Draw the State Transition Diagram. .....................................................................794. Write the Stage Program. .....................................................................................79

Stage Program Example: A Garage Door Opener ..................................................710Garage Door Opener Example ...............................................................................710Draw the Block Diagram ........................................................................................710Draw the State Diagram .........................................................................................711Add Safety Light Feature ........................................................................................712Modify the Block Diagram and State Diagram .......................................................712Using a Timer Inside a Stage ..................................................................................713Add Emergency Stop Feature .................................................................................714Exclusive Transitions ...............................................................................................714

Stage Program Design Considerations ...................................................................715Stage Program Organization ..................................................................................715How Instructions Work Inside Stages ......................................................................716Using a Stage as a Supervisory Process ...................................................................717

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Table of Contents

Stage Counter ........................................................................................................717Power Flow Transition Technique ...........................................................................718Stage View in DirectSOFT .......................................................................................718

Parallel Processing Concepts ...................................................................................719Parallel Processes ....................................................................................................719Converging Processes .............................................................................................719Convergence Stages (CV) .......................................................................................719Convergence Jump (CVJMP) ...................................................................................720Convergence Stage Guidelines ...............................................................................720

RLLPLUS (Stage) Instructions ....................................................................................721Stage (SG) ..............................................................................................................721Initial Stage (ISG) ...................................................................................................722Jump (JMP).............................................................................................................722Not Jump (NJMP) ...................................................................................................722Converge Stage (CV) and Converge Jump (CVJMP) ...............................................723Block Call (BCALL) ..................................................................................................725Block (BLK) .............................................................................................................725Block End (BEND) ...................................................................................................725

Questions and Answers about Stage Programming ..............................................727

Chapter 8: PID Loop OperationDL06 PID Control .......................................................................................................82

DL06 PID Control Features .......................................................................................82

Introduction to PID Control ......................................................................................84What is PID Control? ................................................................................................84

Introducing DL06 PID Control ..................................................................................86Process Control Definitions .......................................................................................88

PID Loop Operation ...................................................................................................89Position Form of the PID Equation ............................................................................89Reset Windup Protection ........................................................................................810Freeze Bias .............................................................................................................811Adjusting the Bias ...................................................................................................811Step Bias Proportional to Step Change in SP ..........................................................812Eliminating Proportional, Integral or Derivative Action ...........................................812Velocity Form of the PID Equation ..........................................................................812

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Table of Contents

Bumpless Transfer ..................................................................................................813Loop Alarms ...........................................................................................................813Loop Operating Modes ..........................................................................................814Special Loop Calculations .......................................................................................814

Ten Steps to Successful Process Control.................................................................816

PID Loop Setup ........................................................................................................818Some Things to Do and Know Before Starting .......................................................818PID Error Flags ........................................................................................................818Establishing the Loop Table Size and Location .......................................................818Loop Table Word Definitions ..................................................................................820PID Mode Setting 1 Bit Descriptions (Addr + 00) ...................................................821PID Mode Setting 2 Bit Descriptions (Addr + 01) ...................................................822Mode/Alarm Monitoring Word (Addr + 06) ...........................................................823Ramp/Soak Table Flags (Addr + 33) .......................................................................823Ramp/Soak Table Location (Addr + 34) ..................................................................824Ramp/Soak Table Programming Error Flags (Addr + 35).........................................824Configure the PID Loop..........................................................................................825

PID Loop Tuning ......................................................................................................840Open-Loop Test .....................................................................................................840Manual Tuning Procedure ......................................................................................841Alternative Manual Tuning Procedures by Others ...................................................844Tuning PID Controllers ...........................................................................................844Auto Tuning Procedure ..........................................................................................845Use DirectSOFT 5 Data View with PID View ...........................................................849Open a New Data View Window ............................................................................849Open PID View .......................................................................................................850

Using the Special PID Features ...............................................................................853How to Change Loop Modes .................................................................................853Operator Panel Control of PID Modes ....................................................................854PLC Modes Effect on Loop Modes ..........................................................................854Loop Mode Override ..............................................................................................854PV Analog Filter ......................................................................................................855Creating an Analog Filter in Ladder Logic ...............................................................856Use the DirectSOFT Filter Intelligent Box Instructions ............................................. 8-57FilterB Example ....................................................................................................... 8-57

Ramp/Soak Generator .............................................................................................858

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Table of Contents

Introduction ...........................................................................................................858Ramp/Soak Table ...................................................................................................859Ramp/Soak Table Flags ...........................................................................................861Ramp/Soak Generator Enable .................................................................................861Ramp/Soak Controls ...............................................................................................861Ramp/Soak Profile Monitoring ................................................................................862Ramp/Soak Programming Errors .............................................................................862Testing Your Ramp/Soak Profile ..............................................................................862

DirectSOFT Ramp/Soak Example ............................................................................. 8-63Setup the Profile in PID Setup ................................................................................ 8-63Program the Ramp/Soak Control in Relay Ladder ................................................... 8-63Test the Profile ....................................................................................................... 8-64

Cascade Control .......................................................................................................865Introduction ...........................................................................................................865Cascaded Loops in the DL06 CPU ..........................................................................866Tuning Cascaded Loops .........................................................................................867

Time-Proportioning Control ....................................................................................868On/Off Control Program Example ..........................................................................869

Feedforward Control ...............................................................................................870Feedforward Example .............................................................................................871

PID Example Program .............................................................................................872Program Setup for the PID Loop ............................................................................872

Troubleshooting Tips...............................................................................................875

Glossary of PID Loop Terminology .........................................................................877

Bibliography ...........................................................................................................879

Chapter 9: Maintenance and TroubleshootingHardware System Maintenance ................................................................................92

Standard Maintenance .............................................................................................92

Diagnostics .................................................................................................................92Diagnostics ...............................................................................................................92Fatal Errors ...............................................................................................................92Non-fatal Errors ........................................................................................................92V-memory Error Code Locations ...............................................................................93Special Relays (SP) Corresponding to Error Codes ....................................................93

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Table of Contents

DL06 Micro PLC Error Codes ....................................................................................94Program Error Codes ................................................................................................95

CPU Indicators ...........................................................................................................96PWR Indicator ..........................................................................................................96RUN Indicator ..........................................................................................................97CPU Indicator ...........................................................................................................97

Communications Problems .......................................................................................97

I/O Point Troubleshooting ........................................................................................98Possible Causes ........................................................................................................98Some Quick Steps ....................................................................................................98Handheld Programmer Keystrokes Used to Test an Output Point .............................99

Noise Troubleshooting ............................................................................................910Electrical Noise Problems ........................................................................................910Reducing Electrical Noise........................................................................................910

Machine Startup and Program Troubleshooting ...................................................911Syntax Check .........................................................................................................911Special Instructions .................................................................................................912Duplicate Reference Check .....................................................................................913Run Time Edits .......................................................................................................914Run Time Edit Example ..........................................................................................915Forcing I/O Points ..................................................................................................916Regular Forcing with Direct Access .........................................................................918Bit Override Forcing ...............................................................................................919Bit Override Indicators ............................................................................................919Reset the PLC to Factory Defaults ...........................................................................920

Chapter 10: LCD Display PanelIntroduction to the DL06 LCD Display Panel .........................................................102

Keypad .. 102

Snap-in installation ..................................................................................................103

Display Priority ........................................................................................................104

Menu Navigation .....................................................................................................105

Confirm PLC Type, Firmware Revision Level, Memory Usage, Etc. .......................106

Examining Option Slot Contents ............................................................................108

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Menu 2, M2:SYSTEM CFG. ....................................................................................108

Monitoring and Changing Data Values ................................................................1010Menu 3, M3:MONITOR ......................................................................................1010Data Monitor .......................................................................................................1010V-memory values ..................................................................................................1010Pointer values .......................................................................................................1012

Bit Monitor ............................................................................................................1013Bit status ..............................................................................................................1013

Changing Date and Time ......................................................................................1014Menu 4, M4 : CALENDAR R/W .............................................................................1014

Setting Password and Locking ..............................................................................1017Menu 5, M5 : PASSWORD R/W ............................................................................1017

Reviewing Error History .........................................................................................1020Menu 6, M6 : ERR HISTORY .................................................................................1020

Toggle Light and Beeper, Test Keys .....................................................................1021Menu 7, M7 : LCD TEST&SET ..............................................................................1021

PLC Memory Information for the LCD Display Panel ..........................................1022Data Format Suffixes for Embedded V-memory Data............................................1022Reserved memory registers for the LCD Display Panel ..........................................1023V7742 bit definitions ............................................................................................1024

Changing the Default Screen ................................................................................1025Example program for setting the default screen message .....................................1025

DL06 LCD Display Panel Instruction (LCD) ...........................................................1026Source of message ...............................................................................................1026ASCII Character Codes .........................................................................................1027Example program: alarm with embedded date/time stamp .................................1028Example program: alarm with embedded V-memory data ...................................1029Example program: alarm text from V-memory with embedded V-memory data ..1030

Appendix A: Auxiliary FunctionsIntroduction ...............................................................................................................A2

Purpose of Auxiliary Functions ..................................................................................A2Accessing AUX Functions via DirectSOFT ..................................................................A3Accessing AUX Functions via the Handheld Programmer ..........................................A3

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AUX 2* RLL Operations .........................................................................................A4AUX 21 Check Program ...........................................................................................A4AUX 22 Change Reference .......................................................................................A4AUX 23 Clear Ladder Range .....................................................................................A4AUX 24 Clear Ladders ..............................................................................................A4

AUX 3* V-memory Operations ..............................................................................A4AUX 31 Clear V-memory ..........................................................................................A4

AUX 4* I/O Configuration .....................................................................................A5AUX 41 Show I/O Configuration ..............................................................................A5

AUX 5* CPU Configuration ...................................................................................A5AUX 51 Modify Program Name ................................................................................A5AUX 53 Display Scan Time .......................................................................................A5AUX 54 Initialize Scratchpad ....................................................................................A5AUX 55 Set Watchdog Timer ...................................................................................A5AUX 56 CPU Network Address .................................................................................A6AUX 57 Set Retentive Ranges ...................................................................................A6AUX 58 Test Operations ...........................................................................................A6AUX 59 Bit Override .................................................................................................A7AUX 5B Counter Interface Configuration ..................................................................A7AUX 5D Select PLC Scan Mode ................................................................................A7

AUX 6* Handheld Programmer Configuration ....................................................A8AUX 61 Show Revision Numbers ..............................................................................A8AUX 62 Beeper On/Off .............................................................................................A8AUX 65 Run Self Diagnostics ....................................................................................A8

AUX 7* EEPROM Operations .................................................................................A8Transferrable Memory Areas .....................................................................................A8AUX 71 CPU to HPP EEPROM ...................................................................................A8AUX 72 HPP EEPROM to CPU ...................................................................................A9AUX 73 Compare HPP EEPROM to CPU ...................................................................A9AUX 74 HPP EEPROM Blank Check ...........................................................................A9AUX 75 Erase HPP EEPROM ......................................................................................A9AUX 76 Show EEPROM Type ....................................................................................A9

AUX 8* Password Operations ...............................................................................A9AUX 81 Modify Password .........................................................................................A9AUX 82 Unlock CPU ...............................................................................................A10AUX 83 Lock CPU...................................................................................................A10

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Appenedix B: DL06 Error codesDL06 Error Codes .......................................................................................................B2

Appendix C: Instruction Execution TimesIntroduction ...............................................................................................................C2

V-Memory Data Registers .........................................................................................C2V-Memory Bit Registers ............................................................................................C2How to Read the Tables ...........................................................................................C2

Instruction Execution Times ......................................................................................C3Boolean Instructions .................................................................................................C3Comparative Boolean Instructions ............................................................................C4Immediate Instructions ...........................................................................................C11Bit of Word Boolean Instructions ............................................................................C12Timer, Counter and Shift Register...........................................................................C13Accumulator Data Instructions ...............................................................................C14Logical Instructions.................................................................................................C15Math Instructions ...................................................................................................C16Differential Instructions ..........................................................................................C19Bit Instructions .......................................................................................................C19Number Conversion Instructions ............................................................................C20Table Instructions ...................................................................................................C20CPU Control Instructions ........................................................................................C22Program Control Instructions .................................................................................C22Interrupt Instructions ..............................................................................................C22Network Instructions ..............................................................................................C22Intelligent I/O Instructions ......................................................................................C23Message Instructions ..............................................................................................C23RLLPLUS Instructions .................................................................................................C23Drum Instructions ..................................................................................................C23Clock/Calendar Instructions ....................................................................................C24MODBUS Instructions .............................................................................................C24ASCII Instructions ...................................................................................................C24

Appendix D: Special RelaysDL06 PLC Special Relays ........................................................................................... D2

Startup and Real-Time Relays .................................................................................. D2

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CPU Status Relays .................................................................................................... D2System Monitoring .................................................................................................. D3Accumulator Status ................................................................................................. D3HSIO Input Status .................................................................................................... D4HSIO Pulse Output Relay ......................................................................................... D4Communication Monitoring Relay ........................................................................... D4Option Slot Communication Monitoring Relay ........................................................ D4Option Slot Special Relay ........................................................................................ D4Counter 1 Mode 10 Equal Relays ............................................................................ D5Counter 2 Mode 10 Equal Relays ............................................................................ D6

Appendix E: High-speed Input and Pulse Output FeaturesIntroduction ............................................................................................................... E2

Built-in Motion Control Solution .............................................................................. E2Availability of HSIO Features ..................................................................................... E2Dedicated High- Speed I/O Circuit ........................................................................... E3Wiring Diagrams for Each HSIO Mode ..................................................................... E3

Choosing the HSIO Operating Mode ........................................................................ E4Understanding the Six Modes .................................................................................. E4Default Mode ........................................................................................................... E5Configuring the HSIO Mode .................................................................................... E6Configuring Inputs X0 X3 ...................................................................................... E6

Mode 10: High-Speed Counter ................................................................................. E7Purpose .................................................................................................................... E7Functional Block Diagram ......................................................................................... E7Wiring Diagram ........................................................................................................ E8Interfacing to Counter Inputs ................................................................................... E8Setup for Mode 10 ................................................................................................... E9Presets and Special Relays ........................................................................................ E9Absolute and Incremental Presets ........................................................................... E10Preset Data Starting Location ................................................................................. E11Using Fewer than 24 Presets .................................................................................. E11Equal Relay Numbers ............................................................................................. E12Calculating Your Preset Values ................................................................................ E13X Input Configuration ............................................................................................ E14Writing Your Control Program ................................................................................ E15Program Example 1: Counter Without Presets ........................................................ E16Program Example 2: Counter With Presets ............................................................. E18

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Program Example 3: Counter With Preload ............................................................ E21Troubleshooting Guide for Mode 10 ...................................................................... E23Symptom: The counter does not count. ................................................................. E23Symptom: The counter counts but the presets do not function. ............................ E23Symptom: The counter counts up but will not reset. ............................................. E23

Mode 20: Up/Down Counter .................................................................................. E24Purpose .................................................................................................................. E24Functional Block Diagram ....................................................................................... E24Quadrature Encoder Signals ................................................................................... E25Wiring Diagram ...................................................................................................... E25Interfacing to Encoder Outputs .............................................................................. E26Setup for Mode 20 ................................................................................................. E27Presets and Special Relays ...................................................................................... E27X Input Configuration ............................................................................................ E28Mode 20 Up/Down Counter .................................................................................. E28Writing Your Control Program ................................................................................ E29Program Example 1: Quadrature Counting with an Interrupt ................................. E30Program Example 2: Up/Down Counting with Standard Inputs ............................. E32Program Example 3: Quadrature Counting ............................................................ E34Troubleshooting Guide for Mode 20 ...................................................................... E37Symptom: The counter does not count. ................................................................. E37Symptom: The counter counts in the wrong direction .......................................... E37Symptom: The counter counts up and down but will not reset. ............................. E37

Mode 30: Pulse Output ........................................................................................... E38Purpose .................................................................................................................. E38Functional Block Diagram ....................................................................................... E39Wiring Diagram ...................................................................................................... E40Interfacing to Drive Inputs ...................................................................................... E40Motion Profile Specifications .................................................................................. E41Physical I/O Configuration ...................................................................................... E41Logical I/O Functions ............................................................................................. E41Setup for Mode 30 ................................................................................................. E42Profile/Velocity Select Register ................................................................................ E43Profile Parameter Table ........................................................................................... E43Automatic Trapezoidal Profile ................................................................................. E43Step Trapezoidal Profile .......................................................................................... E44Velocity Control ..................................................................................................... E44

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Step Trapezoidal Profile .......................................................................................... E44Choosing the Profile Type ...................................................................................... E45Automatic Trapezoidal Profile Defined .................................................................... E45Step Trapezoidal Profiles Defined ........................................................................... E46Velocity Control Defined ........................................................................................ E46Automatic Trapezoidal Profile Operation ................................................................ E47Program Example 1: Automatic Trapezoidal Profile without External Interrupt ....... E48Preload Position Value ............................................................................................ E49Program Example 2: Automatic Trapezoidal Profile with External Interrupt ............ E50Program Example 3: Automatic Trapezoidal Profile with Home Search ................... E53Step Trapezoidal Profile Operation ......................................................................... E58Program Example 4: Step Trapezoidal Profile ........................................................ E59Velocity Profile Operation ....................................................................................... E62Program Example 5: Velocity Profile ....................................................................... E63Automatic Trapezoidal Profile Error Codes .............................................................. E65Troubleshooting Guide for Mode 30 ...................................................................... E65Symptom: The stepper motor does not rotate. ...................................................... E65Symptom: The motor turns in the wrong direction. ............................................... E66

Mode 40: High-Speed Interrupts ............................................................................ E67Purpose .................................................................................................................. E67Functional Block Diagram ....................................................................................... E67Setup for Mode 40 ................................................................................................. E68Interrupts and the Ladder Program ........................................................................ E68External Interrupt Timing Parameters ..................................................................... E69Timed Interrupt Parameters .................................................................................... E69X Input/Timed INT Configuration .......................................................................... E69Program Example 1: External Interrupt .................................................................. E70Program Example 2: Timed Interrupt .................................................................... E71

Mode 50: Pulse Catch Input .................................................................................... E72Purpose .................................................................................................................. E72Functional Block Diagram ....................................................................................... E72Pulse Catch Timing Parameters .............................................................................. E72Setup for Mode 50 ................................................................................................. E73X Input Configuration ............................................................................................ E74Program Example 1: Pulse Catch ........................................................................... E75

Mode 60: Discrete Inputs with Filter ...................................................................... E76Purpose .................................................................................................................. E76

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Functional Block Diagram ....................................................................................... E76Input Filter Timing Parameters ............................................................................... E76Setup for Mode 60 ................................................................................................. E77X Input Configuration ............................................................................................ E77Program Example: Filtered Inputs .......................................................................... E78

Appendix F: PLC MemoryDL06 PLC Memory ......................................................................................................F-2

Non-volatile V-memory in the DL06 ..........................................................................F-3

Appendix G: ASCII TableASCII Conversion Table ............................................................................................G-2

Appendix H: Product WeightsProduct Weight Table .............................................................................................. H2

Appendix I: Numbering SystemsIntroduction ................................................................................................................I2

Binary Numbering System .........................................................................................I2

Hexadecimal Numbering System ...............................................................................I3

Octal Numbering System ...........................................................................................I4

Binary Coded Decimal (BCD) Numbering System ....................................................I5

Real (Floating Point) Numbering System ..................................................................I5

BCD/Binary/Decimal/Hex/Octal -What is the Difference? ........................................I6

Data Type Mismatch...................................................................................................I7

Signed vs. Unsigned Integers .....................................................................................I8

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