DL05 User Manual

1
Manual Revisions
If you contact us in reference to this manual, remember to include the revision number.
Title: DL05 Micro PLC User Manual
Manual Number: D0USERM
Edition/Rev

Date

Description of Changes

Original

12/98

original issue

2nd Edition

2/00

added pid chapter, analog module chapter, and

memory cartridge chapter

2nd Edition,
Rev. A

7/00

added DC power

3rd Edition

11/01

removed MC and analog module chapters, corrected drum instruction, several minor corrections, added PLC weights, EU directive additions

3rd Edition,
Rev. A

7/02

Added new discrete option modules

1
Table of Contents

Chapter 1: Getting Started

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Where to Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplemental Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conventions Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key Topics for Each Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DL05 Micro PLC Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The DL05 Micro PLC Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DirectSOFT Programming for Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handheld Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Selection Quick Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12
12
12
12
12
13
13
15
15
15
15
16
16

Quick Start for PLC Checkout and Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 1: Unpack the DL05 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 2: Connect Switches to Input Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 3: Connect the Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 4: Connect the Programming Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 5: Switch on the System Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 6: Initialize Scratchpad Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 7: Enter a Ladder Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steps to Designing a Successful System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 1 :Review the Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 2: Understand the PLC Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 3: Review the I/O Selection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 4: Choose a System Wiring Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 5: Understand the System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 6: Review the Programming Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 7: Choose the Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 8: Understand the Maintenance and Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . .
Questions and Answers about DL05 Micro PLCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17
17
18
19
19
110
110
110
111
111
111
111
111
111
112
112
112
113

Chapter 2: Installation, Wiring, and Specifications

Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plan for Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three Levels of Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Orderly System Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22
22
22
23

ii
Table of Contents
System Power Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Orientation to DL05 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Layout & Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Mounting Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Protection for Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Planning the Wiring Routes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Protection for Input and Output Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Point Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Wiring Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC Isolation Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Operator Interface Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Programming Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sinking / Sourcing Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Common Terminal Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting DC I/O to Solid State Field Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solid State Input Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solid State Output Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Output Wiring Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surge Suppresion For Inductive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prolonging Relay Contact Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Input Wiring Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Output Wiring Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Speed I/O Wiring Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary of Specification Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23
23
24
25
26
26
26
27
28
29
29
210
210
211
211
212
212
213
213
214
214
215
216
217
217
217
219
220
221
222
223
224
225

Wiring Diagrams and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D005AR I/O Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005AR General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Input Specifications X0 X7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Output Specifications Y0 Y5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005DR I/O Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005DR General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005AD I/O Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005AD General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005DD I/O Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

226
226
227
227
227
228
229
229
229
230
231
231
231
232

iii
Table of Contents
D005DD General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005AA I/O Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005AA General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005DA I/O Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005DA General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005DRD I/O Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005DRD General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005DDD I/O Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D005DDD General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D016ND3 DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

233
233
233
234
235
235
235
236
237
237
237
238
239
239
239
240
241
241
241
243

D010TD1 DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

D016TD1 DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
D010TD2 DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
D016TD2 DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
D007CDR DC Input and Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
D008TR Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
D008CDD1 DC Input and Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
I/O Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Module I/O Points and Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Chapter 3: High-Speed Input and Pulse Output Features

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Built-in Motion Control Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Availability of HSIO Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dedicated High-Speed I/O Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams for Each HSIO Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choosing the HSIO Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Six Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Default Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring the HSIO Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring Inputs X0 X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode 10: High-Speed Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32
32
32
33
33
34
34
34
35
35
36
36

iv
Table of Contents
Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interfacing to Counter Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup for Mode 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Presets and Special Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preset Data Starting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Fewer than 24 Presets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equal Relay Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculating Your Preset Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Writing Your Control Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Example: Counter Without Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Example Contd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter With Presets Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter With Preload Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide for Mode 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode 20: Quadrature Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quadrature Encoder Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interfacing to Encoder Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup for Mode 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Writing Your Control Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quadrature Counter w/Preload Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Example Contd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter Preload Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide for Mode 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode 30: Pulse Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interfacing to Drive Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motion Profile Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Physical I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logical I/O Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup for Mode 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Profile / Velocity Select Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Profile Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trapezoidal Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Registration Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velocity Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choosing the Profile Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trapezoidal Profile Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Registration and Home Search Profiles Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velocity Profile Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trapezoidal Profile Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36
37
37
38
38
39
39
39
310
310
311
312
313
314
316
317
318
318
318
318
319
319
320
320
321
321
322
323
323
324
324
325
326
326
327
327
327
328
328
329
329
329
329
330
330
330
330
331

v
Table of Contents
Trapezoidal Profile Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trapezoidal Profile Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Example Contd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preload Position Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Registration Profile Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Registration Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Registration Profile Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Example Contd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Home Search Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velocity Profile Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velocity Profile Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velocity Profile Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Example Contd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulse Output Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide for Mode 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode 40: High-Speed Interrupts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup for Mode 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interrupts and the Ladder Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Interrupt Timing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timed Interrupt Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X Input / Timed INT Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Independent Timed Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Interrupt Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timed Interrupt Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode 50: Pulse Catch Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulse Catch Timing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup for Mode 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulse Catch Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode 60: Discrete Inputs with Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Filter Timing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup for Mode 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filtered Inputs Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

331
332
333
333
334
334
335
336
337
339
339
340
341
342
342
344
344
344
345
345
346
346
346
346
347
348
349
349
349
349
350
350
351
352
352
352
352
353
353
354

Chapter 4: CPU Specifications and Operation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DL05 CPU Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42
42
43

CPU Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

vi
Table of Contents
Communication Port Pinout Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Programming Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Setup Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Switch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Modes in the DL05 PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode of Operation at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing an Existing Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initializing System Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Retentive Memory Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Read Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Peripherals and Force I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Update Special Relays and Special Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solve Application Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Write Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Is Timing Important for Your Application? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Minimum I/O Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Maximum I/O Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Improving Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Scan Time Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Writing Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application Program Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC Numbering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VMemory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Binary-Coded Decimal Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hexadecimal Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Octal Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discrete and Word Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V Memory Locations for Discrete Memory Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Points (X Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Points (Y Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Relays (C Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timers and Timer Status Bits (T Data type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timer Current Values (V Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counters and Counter Status Bits (CT Data type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter Current Values (V Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44
45
45
46
46
47
47
48
48
48
49
410
411
411
412
412
413
413
414
414
415
415
415
415
415
416
417
418
418
418
419
420
420
421
421
421
422
422
422
422
423
423
423
423
424
424
424

vii
Table of Contents
Word Memory (V Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stages (S Data type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Relays (SP Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DL05 System V-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Parameters and Default Data Locations (V Data Type) . . . . . . . . . . . . . . . . . . . . . . . . . . .
DL05 Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X Input Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

425
425
425
426
426
428
429

Y Output Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429

Stage Control / Status Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Control Relay Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Timer Status Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
Counter Status Bit Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
Network Configuration and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring the DL05s Comm Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Networking DL05 to DL05 RS232C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Networking PC to DL05s RS422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Networking DL05 Master to Other PLCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODBUS Port Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DirectNET Port Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Slave Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODBUS Function Codes Supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining the MODBUS Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If Your Host Software Requires the Data Type and Address... . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 1: V2100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 2: Y20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 3: T10 Current Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 4: C54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If Your MODBUS Host Software Requires an Address ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 1: V2100 584/984 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 2: Y20 584/984 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 3: T10 Current Value 484 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 4: C54 584/984 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining the DirectNET Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Master Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 1: Identify Master Port # and Slave # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 2: Load Number of Bytes to Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 3: Specify Master Memory Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 4: Specify Slave Memory Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communications from a Ladder Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiple Read and Write Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

432
432
432
433
433
434
435
436
436
436
437
438
438
438
438
439
440
440
440
440
440
441
442
442
443
443
444
444

Chapter 5: Standard RLL Instructions

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

viii
Table of Contents
Using Boolean Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
END Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Simple Rungs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normally Closed Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contacts in Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Midline Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joining Series Branches in Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joining Parallel Branches in Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combination Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comparative Boolean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boolean Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Immediate Boolean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boolean Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store (STR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store Not (STRN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or (OR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or Not (ORN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And (AND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And Not (ANDN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And Store (AND STR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or Store (OR STR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Out (OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or Out (OR OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not (NOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positive Differential (PD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store Positive Differential (STRPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store Negative Differential (STRND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or Positive Differential (ORPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or Negative Differential (ORND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And Positive Differential (ANDPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And Negative Differential (ANDND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set (SET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset (RST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pause (PAUSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comparative Boolean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store If Equal (STRE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store If Not Equal (STRNE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or If Equal (ORE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or If Not Equal (ORNE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And If Equal (ANDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And If Not Equal (ANDNE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store (STR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store Not (STRN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or (OR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or Not (ORN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And (AND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And Not (ANDN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54
54
54
54
55
55
55
56
56
56
56
57
58
59
59
59
510
510
511
511
512
512
513
513
514
514
515
515
516
516
517
517
518
518
519
520
520
520
521
521
522
522
523
523
524
524
525
525

ix
Table of Contents
Immediate Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store Immediate (STRI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store Not Immediate (STRNI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or Immediate (ORI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or Not Immediate (ORNI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OR Immediate Instructions Contd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And Immediate (ANDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And Not Immediate (ANDNI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Out Immediate (OUTI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or Out Immediate (OROUTI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set Immediate (SETI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset Immediate (RSTI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timer, Counter and Shift Register Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timer (TMR) and Timer Fast (TMRF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timer Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timer Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulating Timer (TMRA) Accumulating Fast Timer (TMRAF) . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulating Timer Example using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulator Timer Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter (CNT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage Counter (SGCNT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage Counter Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage Counter Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Up Down Counter (UDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Up / Down Counter Example Using Discrete Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Up / Down Counter Example Using Comparative Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Register (SR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulator / Stack Load and Output Data Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copying Data to the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Accumulator Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Accumulator Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Pointers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load (LD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Double (LDD ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Formatted (LDF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Address (LDA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Out (OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Out Double (OUTD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Out Formatted (OUTF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pop (POP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pop Instruction Continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logical Instructions (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
And (AND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

526
526
526
526
526
527
527
527
528
528
529
529
530
530
531
532
532
533
534
534
535
536
537
537
538
539
539
540
541
541
542
543
543
543
544
545
546
548
549
550
551
552
552
553
553
554
555
555

x
Table of Contents
And Double (ANDD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or (OR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or Double (ORD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exclusive Or (XOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exclusive Or Double (XORD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compare (CMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compare Double (CMPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Math Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Add (ADD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Add Double (ADDD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Subtract (SUB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Subtract Double (SUBD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiply (MUL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiply Double (MULD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Divide (DIV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Divide Double (DIVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Increment (INC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decrement (DEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Increment Binary (INCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decrement Binary (DECB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Add Binary (ADDB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Subtract Binary (SUBB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiply Binary (MULB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Divide Binary (DIVB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bit Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sum (SUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Left (SHFL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Right (SHFR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encode (ENCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decode (DECO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number Conversion Instructions (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Binary (BIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Binary Coded Decimal (BCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Invert (INV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASCII to HEX (ATH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEX to ASCII (HTA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gray Code (GRAY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuffle Digits (SFLDGT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuffle Digits Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Move (MOV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Move Memory Cartridge / Load Label (MOVMC), (LDLBL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copy Data From a Data Label Area to V Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Operation (NOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End (END) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop (STOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

556
557
558
559
560
561
562
563
563
564
565
566
567
568
569
570
571
571
572
572
573
574
575
576
577
577
577
579
580
581
582
582
583
584
585
586
588
589
589
591
591
592
593
594
594
594
594

xi
Table of Contents
Reset Watch Dog Timer (RSTWT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For / Next (FOR) (NEXT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Goto Subroutine (GTS) (SBR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Subroutine Return (RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Subroutine Return Conditional (RTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Line Set (MLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Line Reset (MLR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding Master Control Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MLS/MLR Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interrupt Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interrupt (INT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interrupt Return (IRT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interrupt Return Conditional (IRTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enable Interrupts (ENI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disable Interrupts (DISI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Interrupt Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timed Interrupt Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Independent Timed Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Message Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault (FAULT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Label (DLBL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASCII Constant (ACON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Numerical Constant (NCON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Label Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Message (PRINT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Read from Network (RX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Write to Network (WX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

595
596
596
598
598
598
5101
5101
5101
5102
5103
5103
5103
5103
5103
5104
5104
5105
5105
5106
5106
5106
5107
5107
5107
5108
5109
5113
5113
5115

Chapter 6: Drum Instruction Programming

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Chart Representation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Instruction Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timer-Only Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timer and Event Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Event-Only Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Last Step Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of Drum Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62
62
62
63
63
64
64
64
65
66
66
67
68

xii
Table of Contents
Drum Instruction Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powerup State of Drum Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Control Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-Resetting Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initializing Drum Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Complex Event Step Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timed Drum with Discrete Outputs (DRUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Event Drum (EDRUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handheld Programmer Drum Mnemonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68
69
610
610
611
611
611
612
612
614
616

Chapter 7: RLLPLUS Stage Programming

Introduction to Stage Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overcoming Stage Fright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Learning to Draw State Transition Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction to Process States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Need for State Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A 2State Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RLL Equivalent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage Equivalent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lets Compare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What Stage Bits Do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage Instruction Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Stage Jump Instruction for State Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage Jump, Set, and Reset Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage Program Example: Toggle On/Off Lamp Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A 4State Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four Steps to Writing a Stage Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72
72
73
73
73
73
74
74
75
75
76
76
77
77
78
78
79

Stage Program Example: A Garage Door Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Garage Door Opener Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draw the Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draw the State Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Add Safety Light Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modify the Block Diagram and State Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a Timer Inside a Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Add Emergency Stop Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exclusive Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage Program Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage Program Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Instructions Work Inside Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a Stage as a Supervisory Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

710
710
710
711
712
712
713
714
714
715
715
716
717
717

xiii
Table of Contents
Power Flow Transition Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage View in DirectSOFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel Processing Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converging Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Convergence Stages (CV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Convergence Jump (CVJMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Convergence Stage Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RLLPLUS (Stage) Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Staget (SG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Staget (ISG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUMP (JMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not Jump (NJMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converge Stage (CV) and Converge Jump (CVJMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Questions and Answers about Stage Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

718
718
719
719
719
719
720
720
721
721
722
722
722
723
725

Chapter 8: PID Loop Operation

DL05 PID Loop Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Basics of PID Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Table and Number of Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PID Error Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Establishing the Loop Table Size and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Table Word Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PID Mode Setting 1 Bit Descriptions (Addr + 00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PID Mode Setting 2 Bit Descriptions (Addr + 01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode / Alarm Monitoring Word (Addr + 06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp / Soak Table Flags (Addr + 33) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp/Soak Table Location (Addr + 34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp/Soak Table Programming Error Flags (Addr + 35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Sample Rate and Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Sample Rates Addr + 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choosing the Best Sample Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming the Sample Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PID Loop Effect on CPU Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ten Steps to Successful Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 1: Know the Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 2: Plan Loop Control Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 3: Size and Scale Loop Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 4: Select I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 5: Wiring and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 6: Loop Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 7: Check Open Loop Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 8: Loop Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82
82
84
86
86
86
87
88
89
810
811
811
812
812
813
813
813
814
815
817
817
817
817
817
818
818
818
818

xiv
Table of Contents
Step 9: Run Process Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 10: Save Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Loop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Access to Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Modes and Loop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Change Loop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Panel Control of PID Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC Modes Effect on Loop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Mode Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bumpless Transfers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PID Loop Data Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Parameter Data Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choosing Unipolar or Bipolar Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling Data Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setpoint (SP) Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Setpoint (SP) Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Process Variable (PV) Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Output Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Term Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PID Algorithms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Position Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velocity Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct-Acting and Reverse-Acting Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P-I-D Loop Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a Subset of PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Derivative Gain Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bias Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bias Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open-Loop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tuning Cascaded Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PV Analog Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The DL05 Built-in Analog Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Creating an Analog Filter in Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feedforward Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feedforward Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time-Proportioning Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Control Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cascade Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cascaded Loops in the DL05 CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

818
818
819
819
819
820
821
822
823
824
824
824
825
826
826
826
827
827
828
828
829
830
831
831
832
833
834
835
836
836
837
838
838
839
840
844
845
845
846
847
848
849
850
851
851
852

xv
Table of Contents
Process Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PV Absolute Value Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PV Deviation Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PV Rate-of-Change Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PV Alarm Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Programing Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp/Soak Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp/Soak Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp/Soak Table Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp/Soak Generator Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp/Soak Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp/Soak Profile Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp/Soak Programming Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Your Ramp/Soak Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

853
854
854
855
856
856
857
857
858
860
860
860
861
861
861
862

Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 863
Glossary of PID Loop Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 864

Chapter 9: Maintenance and Troubleshooting

Hardware System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92

CPU Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96

Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97

I/O Point Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98

Noise Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910

Machine Startup and Program Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 911

Appendix A: Auxiliary Functions

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose of Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing AUX Functions via DirectSOFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing AUX Functions via the Handheld Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUX 2* RLL Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUX 21 Check Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUX 22 Change Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUX 23 Clear Ladder Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUX 24 Clear Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUX 3* V-memory Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUX 31 Clear V Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUX 4* I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A2
A2
A3
A3
A4
A4
A4
A4
A4
A4
A4
A4

xvi
Table of Contents
AUX 41 Show I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
AUX 5* CPU Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
AUX 51 Modify Program Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
AUX 53 Display Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
AUX 54 Initialize Scratchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
AUX 55 Set Watchdog Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
AUX 56 CPU Network Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
AUX 57 Set Retentive Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6
AUX 58 Test Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6
AUX 59 Bit Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6
AUX 5B Counter Interface Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
AUX 5D Select PLC Scan Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
AUX 6* Handheld Programmer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
AUX 61 Show Revision Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
AUX 62 Beeper On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
AUX 65 Run Self Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
AUX 7* EEPROM Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
Transferrable Memory Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
AUX 71 CPU to HPP EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
AUX 72 HPP EEPROM to CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
AUX 73 Compare HPP EEPROM to CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
AUX 74 HPP EEPROM Blank Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
AUX 75 Erase HPP EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
AUX 76 Show EEPROM Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
AUX 8* Password Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
AUX 81 Modify Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
AUX 82 Unlock CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10
AUX 83 Lock CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10

Appendix B: DL05 Error Codes

Appendix C: Instruction Execution Times
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-Memory Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-Memory Bit Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Read the Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Execution Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boolean Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comparative Boolean Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Immediate Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timer, Counter, and Shift Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulator Data Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logical Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Math Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C2
C2
C2
C2
C3
C3
C4
C10
C10
C11
C12
C12

xvii
Table of Contents
Bit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interrupt Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Message Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RLLPLUS Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C14
C14
C14
C15
C15
C15
C15
C16
C16
C16

Appendix D: Special Relays

DL05 PLC Special Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup and Real-Time Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPU Status Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HSIO Pulse Output Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication Monitoring Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equal Relays for HSIO Mode 10 Counter Presets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D2
D2
D2
D3
D3
D4
D4
D4

Appendix E: DL05 Product Weights

Product Weight Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E2

Appendix F: European Union Directives (CE)

European Union (EU) Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Member Countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Sources of Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic EMC Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suppression and Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Enclosure Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipotential Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communications and Shielded Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog and RS232 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multidrop Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shielded Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
within Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Powered Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Items Specific to the DL 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F2
F2
F3
F4
F4
F4
F5
F5
F6
F6
F7
F7
F7
F7
F7
F8
F9

Getting Started

11

In This Chapter. . . .
Introduction
Conventions Used
DL05 Micro PLC Components
Programming Methods
I/O Selection Quick Chart
Quick Start for PLC Checkout and Programming
Steps to Designing a Successful System
Questions and Answers about DL05 Micro PLCs

12
Getting Started

Getting Started

Introduction
The Purpose of
this Manual

Thank you for purchasing a DL05 Micro PLC. This manual shows you how to install,
program, and maintain all the Micro PLCs in the DL05 family. It also helps you
understand how to interface them to other devices in a control system.This manual
contains important information for personnel who will install DL05 PLCs, and for the
PLC programmer. If you understand PLC systems our manuals will provide all the
information you need to get and keep your system up and running.

Where to Begin

If you already understand the DL05 Micro PLC please read Chapter 2, Installation,
Wiring, and Specifications, and proceed on to other chapters as needed. Be sure to
keep this manual handy for reference when you run into questions. If you are a new
DL05 customer, we suggest you read this manual completely so you can understand
the wide variety of features in the DL05 family of products. We believe you will be
pleasantly surprised with how much you can accomplish with our products

Supplemental
Manuals

The D0OPTIONSM manual will be most helpful to select and use any of the
optional modules that are available for the DL05 PLC which includes the analog I/O
modules. If you have purchased operator interfaces or DirectSOFT, you will need
to supplement this manual with the manuals that are written for these products.

Technical Support

We realize that even though we strive to be the best, we may have arranged our
information in such a way you cannot find what you are looking for. First, check these
resources for help in locating the information:
S

Table of Contents chapter and section listing of contents, in the front

of this manual
S Appendices reference material for key topics, near the end of this
manual
You can also check our online resources for the latest product support information:
S Internet the address of our website is:
In Brazil: http://www.soliton.com.br
If you still need assistance, please call us at 7708444200. Our technical support
team will be available to work with you in answering your questions. They are
available Monday through Friday from 9:00 A.M. to 6:00 P.M. Eastern Standard
Time. If you have a comment or question about any of our products, services, or
manuals, please fill out and return the Suggestions card that was shipped with this
manual.

13
Getting Started

Conventions Used

When you see the notepad icon in the left-hand margin, the paragraph to its
immediate right will be a special note.
The word NOTE: in boldface will mark the beginning of the text.
When you see the exclamation mark icon in the left-hand margin, the paragraph to
its immediate right will be a warning. This information could prevent injury, loss of
property, or even death (in extreme cases).
The word WARNING: in boldface will mark the beginning of the text.
Key Topics for
Each Chapter

The beginning of each chapter will list the

key topics that can be found in that
chapter.

Getting Started

When you see the light bulb icon in the left-hand margin, the paragraph to its
immediate right will give you a special tip.
The word TIP: in boldface will mark the beginning of the text.

14
Getting Started

Getting Started

DL05 Micro PLC Components

The DL05 Micro PLC family is a versatile
product line that provides a wide variety of
features in a very compact footprint. The
PLCs are small, yet offer many features
usually found in larger, more expensive
systems. These include a removeable
connector,
and
two
RS-232C
communication ports.
The DL05
Micro PLC Family

The DL05 Micro PLC family includes eight different versions. All have the same
appearance and CPU performance. The CPU offers the same instruction set as our
popular DL240 CPU, plus several more instructions specifically designed for
machine control applications. All DL05 PLCs have two RS232C communications
ports. Units with DC inputs have selectable high-speed input features on three input
points. Units with DC outputs offer selectable pulse output capability on the first and
second output points. All DL05 Micro PLCs offer a large amount of program memory,
a substantial instruction set and advanced diagnostics. Details of these features and
more are covered in Chapter 4, CPU Specifications and Operation. The eight types
of DL05 Micro PLCs provide a variety of Input/Output choices, listed in the following
table.

DL05
Part Number

Discrete
Input Type

Discrete
Output Type

External
Power

High-Speed
Input

Pulse
Output

D005AR

AC

Relay

95240 VAC

No

No

D005DR

DC

Relay

95240 VAC

Yes

No

D005AD

AC

DC

95240 VAC

No

Yes

D005DD

DC

DC

95240 VAC

Yes

Yes

D005AA

AC

AC

95240 VAC

No

No

D005DA

DC

AC

95240 VAC

Yes

No

D005DRD

DC

Relay

1224 VDC

Yes

No

D005DDD

DC

DC

1224 VDC

Yes

Yes

Programming Methods

DirectSOFT
Programming for
Windows

Two programming methods are available: RLL (Relay Ladder Logic) and RLL PLUS.
RLL PLUS combines the added feature of flow chart programming (Staget) to the
standard RLL language. Both the DirectSOFT programming package and the
handheld programmer support RLL PLUS as well as standard RLL instructions.
The DL05 Micro PLC can be programmed with one of the most advanced
programming packages in the industry DirectSOFT, a Windows-based software
package that supports familiar features such as cut-and-paste between
applications, point-and-click editing, viewing and editing multiple application
programs at the same time, etc.

15
Getting Started

Handheld
Programmer

All DL05 Micro PLCs have built-in programming ports for use with the handheld
programmer (D2HPP), the same programmer used with the DL105 and DL205
families. The handheld programmer can be used to create, modify and debug your
application program. A separate manual discusses the Handheld Programmer. Only
D2HPPs with firmware version 1.09 or later will program the DL05.

I/O Selection Quick Chart

The eight versions of the DL05 have Input/Output circuits which can interface to a
wide variety of field devices. In several instances a particular Input or Output circuit
can interface to either DC or AC voltages, or both sinking and sourcing circuit
arrangements. Check this chart carefully to find the proper DL05 Micro PLC to
interface to the field devices in your application.
DL05
Partt Number
P
N b

INPUTS

OUTPUTS

I/O type /
commons

Sink /
Source

Voltage Ranges

I/O type / Sink /

commons Source

Voltage / Current
Ratings

D005AR

AC / 2

90 120 VAC

Relay / 2 Sink or
Source

6 27 VDC, 2A *
6 240 VAC, 2A *

D005DR

DC / 2

Sink or
Source

12 24 VDC

Relay / 2 Sink or
Source

6 27 VDC, 2A *
6 240 VAC, 2A *

D005AD

AC / 2

90 120 VAC

DC / 1

Sink

6 27 VDC, 0.5A (Y0Y2)

6 27 VDC, 1.0A (Y3Y5)

D005DD

DC / 2

Sink or
Source

12 24 VDC

DC / 1

Sink

6 27 VDC, 0.5A (Y0Y2)

6 27 VDC, 1.0A (Y3Y5)

D005AA

AC / 2

90 120 VAC

AC / 2

17 240 VAC, 47 63 Hz
0.5A *

D005DA

DC / 2

Sink or
Source

12 24 VDC

AC / 2

17 240 VAC, 47 63 Hz
0.5A *

D005DRD

DC / 2

Sink or
Source

12 24 VDC

D005DDD

DC / 2

Sink or
Source

12 24 VDC

* See Chapter 2 Specifications for your particular DL05 version.

Relay / 2 Sink or
Source
DC / 1

Sink

6 27 VDC, 2A *
6 240 VAC, 2A *
6 27 VDC, 0.5A (Y0Y2)
6 27 VDC, 1.0A (Y3Y5)

Getting Started

DirectSOFT universally supports the DirectLOGIC CPU families. This means you
can use the full version of DirectSOFT to program DL05, DL105, DL205, DL305,
DL405 or any new CPUs we may add to our product line. (Upgrade software may be
required for new CPUs as they become available.). A separate manual discusses
DirectSOFT programming software. DirectSOFT version 2.4 or later is needed to
program the DL05.

16
Getting Started

Getting Started

Quick Start for PLC Checkout and Programming

If you have experience with PLCs, or if you just want to setup a quick example, this
example is for you! This example is not intended to tell you everything you need to
start-up your system, warnings and helpful tips are in the rest of the manual. It is only
intended to give you a general picture of what you will need to do to get your system
powered-up.

Step 1: Unpack the DL05 Equipment

Unpack the DL05 and gather the parts necessary to build this demonstration
system. The recommended components are:
S DL05 Micro PLC
S AC power cord or DC power supply
S Toggle switches (see Step 2 on next page).
S Hook-up wire, 16-22 AWG
S DL05 User Manual (this manual)
S A small screwdriver, 5/8 flat or #1 Philips type
You will need at least one of the following programming options:
S DirectSOFT Programming Software, DirectSOFT Manual, and a
programming cable (connects the DL05 to a personal computer),or
S D2HPP Handheld Programmer (comes with programming cable), and
the Handheld Programmer Manual

17
Getting Started

Step 2: Connect Switches to Input Terminals

D005DR, D005DD, D005DA

D005DRD, D005DDD
(DC input versions, 1224VDC)

1224VDC
Power Supply

Toggle Switches, UL Listed

D005AR, D005AD, D005AA

(AC input versions, 120VAC only)

Toggle Switches, UL Listed

WARNING: DO NOT wire the

toggle switches as shown to
240VAC-powered
units.
The
discrete inputs will only accept
120VAC nominal. Also, remove
power and unplug the DL05 when
wiring the switches. Only use
UL-approved switches rated for at
least 250VAC, 1A for AC inputs.
Firmly mount the switches before
using.

Getting Started

To finish this quick-start exercise or study other examples in this manual, youll need
to connect some input switches as shown below. If you have DC inputs you will need
to use the FA24PS (24VDC) or another external 12-24VDC power supply. Be sure
to follow the instructions in the accompanying WARNING note.

18
Getting Started

Getting Started

Step 3: Connect the Power Wiring

Connect the power input wiring for the DL05. Observe all precautions stated earlier
in this manual. For more details on wiring, see Chapter 2 on Installation, Wiring, and
Specifications. When the wiring is complete, close the connector covers. Do not
apply power at this time.
110/220 VAC Power Input

12/24 VDC Power Input

+G
12 24 VDC

LG N
95 240 VAC

Step 4: Connect the Programming Device

Most programmers will use DirectSOFT programming software, installed on a
personal computer. Or, you may need the portability of the Handheld Programmer.
Both devices will connect to COM port 1 of the DL05 via the appropriate cable.

Use cable part #

D2DSCBL

(cable comes with HPP)

For replacement
cable, use part #
DV1000CBL

19
Getting Started

Step 5: Switch on the System Power

Step 6: Initialize Scratchpad Memory

Its a good precaution to always clear the system memory (scratchpad memory) on a
new DL05. There are two ways to clear the system memory:
S In DirectSOFT, select the PLC menu, then Setup, then Initialize
Scratchpad. For additional information, see the DirectSOFT Manual.
S For the Handheld Programmer, use the AUX key and execute AUX 54.
See the Handheld Programmer Manual for additional information.

Step 7: Enter a Ladder Program

At this point, DirectSOFT programmers need to refer to the Quick Start Tutorial in
the DirectSOFT Manual. There you will learn how to establish a communications link
with the DL05 PLC, change CPU modes to Run or Program, and enter a program.
If you are learning how to program with the Handheld Programmer, make sure the
CPU is in Program Mode (the RUN LED on the front of the DL05 should be off). If the
RUN LED is on, use the MODE key on the Handheld Programmer to put the PLC in
Program Mode. Enter the following keystrokes on the Handheld Programmer.
Equivalent DirectSOFT display
X0

CLR
C

Y0
OUT

E
2

NEXT

Clear the Program

CLR

AUX

ENT

A
STR

ENT

ENT

END
GX
OUT

SHFT

A
0

E
4

N
TMR

Move to the first

address and enter
X0 contact
Enter output Y0

ENT

CLR

ENT

Enter the END

statement

After entering the simple example program put the PLC in Run mode by using the
Mode key on the Handheld Programmer.
The RUN indicator on the PLC will illuminate indicating the CPU has entered the Run
mode. If not, repeat this step, ensuring the program is entered properly or refer to the
troubleshooting guide in chapter 8.
After the CPU enters the run mode, the output status indicator for Y0 should follow
the switch status on input channel X0. When the switch is on, the output will be on.

Getting Started

Apply power to the system and ensure the PWR indicator on the DL05 is on. If not,
remove power from the system and check all wiring and refer to the troubleshooting
section in Chapter 9 for assistance.

110
Getting Started

Getting Started

Steps to Designing a Successful System

Step 1:
Review the
Installation
Guidelines

Always make safety the first priority in any

system design. Chapter 2 provides
several guidelines that will help you
design a safer, more reliable system. This
chapter also includes wiring guidelines for
the various versions of the DL05 PLC.

Step 2:
Understand the
PLC Setup
Procedures

The PLC is the heart of your automation

system. Make sure you take time to
understand the various features and setup
requirements.

Step 3:
Review the I/O
Selection Criteria

There are many considerations involved

when you select your I/O type and field
devices. Take time to understand how the
various types of sensors and loads can
affect your choice of I/O type.

Input
+

PLC

Input
Sensing

Common

Step 4:
Choose a System
Wiring Strategy

It is important to understand the various

system design options that are available
before wiring field devices and field-side
power supplies to the Micro PLC.
+24 VDC
+

Step 5:
Understand the
System Operation

AC
Power
Loads
DL05
PLC

Power Input

6 Outputs

Commons

8 Inputs

Commons

Before you begin to enter a program, it is

very helpful to understand how the DL05
system processes information. This
involves not only program execution
steps, but also involves the various modes
of operation and memory layout
characteristics.

Power up
Initialize hardware

111
Getting Started

The DL05 PLC instruction set provides for three main approaches to solving the
application program, depicted in the figure below.
S
S
S

Standard RLL Programming

(see Chapter 5)

X0

RLL diagram-style programming is the best tool for solving boolean logic
and general CPU register/accumulator manipulation. It includes dozens
of instructions, which will also be needed to augment drums and stages.
The Timer/Event Drum Sequencer features up to 16 steps and offers
both time and/or event-based step transitions. The DRUM instruction is
best for a repetitive process based on a single series of steps.
Stage programming (also called RLL Plus) is based on state-transition
diagrams. Stages divide the ladder program into sections which
correspond to the states in a flow chart you draw for your process.
Timer/Event Drum Sequencer
(see Chapter 6)

Stage Programming
(see Chapter 7)
PushUP

RAISE

LDD
V1076
CMPD
K309482

SP62

DOWN

Y0
OUT

LIGHT

LOWER

UP

Push
DOWN

After reviewing the programming concepts above, youll be equipped with a variety
of tools to write your application program.
Step 7:
Choose the
Instructions

Step 8:
Understand the
Maintenance and
Troubleshooting
Procedures

Once you have installed the Micro PLC

and understand the main programming
concepts, you can begin writing your
application program. At that time you will
begin to use one of the most powerful
instruction sets available in a small PLC.

Sometimes equipment failures occur

when we least expect it. Switches fail,
loads short and need to be replaced, etc.
In most cases, the majority of the
troubleshooting and maintenance time is
spent trying to locate the problem. The
DL05 Micro PLC has many built-in
features such as error codes that can help
you quickly identify problems.

TMR

T1
K30
CNT

CT3
K10

Getting Started

Step 6:
Review the
Programming
Concepts

112
Getting Started

Getting Started

Questions and Answers about DL05 Micro PLCs

Q. What is the instruction set like?
A. The instruction set is very close to our popular DL240 CPU. However, there are
significant additions, such as the drum instruction, networking, and High-Speed I/O
capabilities.
Q. Do I have to buy the full DirectSOFT programming package to program the DL05?
A. No. We offer a DL05-specific version of DirectSOFT thats very affordable.
Q. Is the DL05 expandable?
A. No, the DL05 series are stand-alone PLCs. However, our DL205 system is
expandable, yet very compact and affordable.
Q. Does the DL05 have motion control capability?
A. Yes. The High-Speed I/O features offer either encoder inputs with high-speed
counting and presets with interrupt, or a pulse/direction output for stepper control.
Three types of motion profiles are available, which are explained in Chapter 3.
Q. Are the ladder programs stored in a removable EEPROM?
A. The DL05 contains a non-removable FLASH memory for program storage, which
may be written and erased thousands of times. You may transfer programs to/from
DirectSOFT on a PC, or the HPP (which does support a removable EEPROM).
Q. Does the DL05 contain fuses for its outputs?
A. There are no output circuit fuses. Therefore, we recommend fusing each channel,
or fusing each common. See Chapter 2 for I/O wiring guidelines.
Q. Is the DL05 Micro PLC U.L.R approved?
A. The Micro PLC has met the requirements of UL (Underwriters Laboratories, Inc.),
and CUL (Canadian Underwriters Laboratories, Inc.).
Q. Does the DL05 Micro PLC comply with European Union (EU) Directives?
A. The Micro PLC has met the requirements of the European Union Directives (CE).

113
Getting Started

Q. Can the DL05 accept 5VDC inputs?

A. No, 5 volts is lower than the DC input ON threshold. However, many TTL logic
circuits can drive the inputs if they are wired as open collector (sinking) inputs. See
Chapter 2 for I/O wiring guidelines.

Getting Started

Q. Which devices can I connect to the communication ports of the DL05?

A. Port 1: The port is RS-232C, fixed at 9600 baud, and uses the proprietary
K-sequence protocol. The DL05 can also connect to MODBUS and DirectNET
networks as a slave device through port 1. The port communicates with the following
devices:
S DV-1000 Data Access Unit or Optimation Operator interface panels
S DirectSOFT (running on a personal computer)
S D2-HPP handheld programmer
S Other devices which communicate via K-sequence protocol should work
with the DL05 Micro PLC. Contact the vendor for details.
A. Port 2: The port is RS-232C, with selective baud rates (300-38,400bps), address
and parity.It also supports the proprietary K-sequence protocol as well as DirectNet
and Modbus and non-sequence/print protocols.

Installation, Wiring,
and Specifications
In This Chapter. . . .

Safety Guidelines
Orientation to DL05 Front Panel
Mounting Guidelines
Wiring Guidelines
System Wiring Strategies
Glossary of Specification Terms
Wiring Diagrams and Specifications
D0-10ND3 DC Input
D0-16ND3 DC Input
D0-10TD1 DC Output
D0-16TD1 DC Output
D0-10TD2 DC Output
D0-16TD2 DC Output
D0-07CDR DC Input and Output
D0-08TR Relay Output
D0-08CDD1 DC Input and Output

12

22
Installation, Wiring, and Specifications

Safety Guidelines
NOTE: Products with CE marks perform their required functions safely and adhere
to relevant standards as specified by CE directives provided they are used
according to their intended purpose and that the instructions in this manual are
adhered to. The protection provided by the equipment may be impaired if this
equipment is used in a manner not specified in this manual.

Installation, Wiring,
and Specifications

WARNING: Providing a safe operating environment for personnel and equipment is

your responsibility and should be your primary goal during system planning and
installation. Automation systems can fail and may result in situations that can cause
serious injury to personnel or damage to equipment. Do not rely on the automation
system alone to provide a safe operating environment. You should use external
electromechanical devices, such as relays or limit switches, that are independent of
the PLC application to provide protection for any part of the system that may cause
personal injury or damage.
Every automation application is different, so there may be special requirements for
your particular application. Make sure you follow all national, state, and local
government requirements for the proper installation and use of your equipment.
Plan for Safety

The best way to provide a safe operating environment is to make personnel and
equipment safety part of the planning process. You should examine every aspect of
the system to determine which areas are critical to operator or machine safety. If you
are not familiar with PLC system installation practices, or your company does not
have established installation guidelines, you should obtain additional information
from the following sources.
S NEMA The National Electrical Manufacturers Association, located in
Washington, D.C., publishes many different documents that discuss
standards for industrial control systems. You can order these
publications directly from NEMA. Some of these include:
ICS 1, General Standards for Industrial Control and Systems
ICS 3, Industrial Systems
ICS 6, Enclosures for Industrial Control Systems
S NEC The National Electrical Code provides regulations concerning
the installation and use of various types of electrical equipment. Copies
of the NEC Handbook can often be obtained from your local electrical
equipment distributor or your local library.
S Local and State Agencies many local governments and state
governments have additional requirements above and beyond those
described in the NEC Handbook. Check with your local Electrical
Inspector or Fire Marshall office for information.

Three Levels of
Protection

The publications mentioned provide many ideas and requirements for system
safety. At a minimum, you should follow these regulations. Also, you should use the
following techniques, which provide three levels of system control.
S Orderly system shutdown sequence in the PLC control program
S Mechanical disconnect for output module power
S Emergency stop switch for disconnecting system power

23
Installation, Wiring, and Specifications

Orderly System
Shutdown

The first level of fault detection is ideally

the PLC control program, which can
identify machine problems. You must
analyze your application and identify any
shutdown sequences that must be
performed. These types of problems are
usually things such as jammed parts, etc.
that do not pose a risk of personal injury
or equipment damage.

Turn off
Saw

Jam
Detect

RST
RST
Retract
Arm

System Power
Disconnect

Emergency Stop

You should also use electromechanical devices, such as master control relays
and/or limit switches, to prevent accidental equipment startup at an unexpected
time. These devices should be installed in such a manner to prevent any machine
operations from occurring.
For example, if the machine has a jammed part the PLC control program can turn off
the saw blade and retract the arbor. However, since the operator must open the
guard to remove the part, you should also include a bypass switch that disconnects
all system power any time the guard is opened.
The machinery must provide a quick manual method of disconnecting all system
power. The disconnect device or switch must be clearly labeled Emergency Stop.
Use EStop and Master Relay

Guard Limit Switch

Emergency
Stop

E STOP

Power On

Guard
Limit

Master
Relay

Master Relay Contacts

To disconnect
PLC Power

To disconnect PLC
output circuitry

Saw
Arbor

Master Relay Contacts

After an Emergency shutdown or any other type of power interruption, there may be
requirements that must be met before the PLC control program can be restarted. For
example, there may be specific register values that must be established (or
maintained from the state prior to the shutdown) before operations can resume. In
this case, you may want to use retentive memory locations, or include constants in
the control program to ensure a known starting point.

Installation, Wiring,
and Specifications

WARNING: The control program must

not be the only form of protection for any
problems that may result in a risk of
personal injury or equipment damage.

24
Installation, Wiring, and Specifications

Orientation to DL05 Front Panel

Most connections, indicators, and labels on the DL05 Micro PLCs are located on its
front panel. The communication ports are located on the top side of the PLC. Please
refer to the drawing below.
Mode Switch
Mounting tab

Communication Ports

Installation, Wiring,
and Specifications

Output Status Indicators

Input Status Indicators

Status
Indicators

Mounting tab
External Power
Inputs

Discrete Input Discrete Output Output Circuit Power Input

Terminals
(for DC output versions only)
Terminals

The upper section of the connector accepts external power connections on the two
left-most terminals. From left to right, the next five terminals are one of the input
commons (C0) and input connections X1, X3, X4, and X6. The remaining four
connections are an output common (C2) and output terminals Y1, Y3, and Y5.
The lower section of the connector has the chassis ground (G) and the logic ground
(LG) on the two left-most terminals. The next two terminals are for the inputs X0 and
X2. Next is the other input common (C1) followed by inputs X5 and X7. The last four
terminals are for outputs Y0, Y2, Y4, and the second output common (C3). On DC
output units, the end terminal on the right accepts power for the output stage.

WARNING: For some applications, field device power may still be present on the
terminal block even though the Micro PLC is turned off. To minimize the risk of
electrical shock, check all field device power before you expose or remove either
connector

25
Installation, Wiring, and Specifications

Connector
Removal

All of the terminals for the DL05 are contained on one connector block. In some
instances, it may be desireable to remove the connector block for easy wiring. The
connector is designed for easy removal with just a small screwdriver. The drawing
below shows the procedure for removal at one end.
Connector Removal

1. Loosen the retention screws on each end of the connector block.

Installation, Wiring,
and Specifications

2. From the center of the connector block, pry upward with the screwdriver
until the connector is loose.
The terminal block connector on DL05 PLCs have regular screw terminals, which
will accept either standard or #1 Philips screwdriver tips. You can insert one 16 AWG
wire under a terminal, or two 18 AWG wires (one on each side of the screw). Be
careful not to overtighten; maximum torque is 6 inch/ounces.
Spare terminal block connectors and connector covers may be ordered by individual
part numbers:
Part Number

Qty Per Package

Description

D0IOCON

DL05 I/O Terminal Block

D0IOCVR

DL05 I/O Terminal Cover

26
Installation, Wiring, and Specifications

Mounting Guidelines
In addition to the panel layout guidelines, other specifications can affect the
definition and installation of a PLC system. Always consider the following:
S Environmental Specifications
S Power Requirements
S Agency Approvals
S Enclosure Selection and Component Dimensions
Installation, Wiring,
and Specifications

Unit Dimensions

The following diagram shows the outside dimensions and mounting hole locations
for all versions of the DL05. Make sure you follow the installation guidelines to allow
proper spacing from other components.
4.8
120mm

2.6
65mm

3.8
95mm

0.24 mounting tab

6mm
2.72
68mm
(DIN Rail)

0.40
10mm

2 holes, 0.150 dia,

clearance for #6 screw

4.0
100mm

0.20
5mm

3.4
85mm

Enclosures

Your selection of a proper enclosure is important to ensure safe and proper

operation of your DL05 system. Applications of DL05 systems vary and may require
additional features. The minimum considerations for enclosures include:
S Conformance to electrical standards
S Protection from the elements in an industrial environment
S Common ground reference
S Maintenance of specified ambient temperature
S Access to equipment
S Security or restricted access
S Sufficient space for proper installation and maintenance of equipment

27
Installation, Wiring, and Specifications

Panel Layout &

Clearances

There are many things to consider when designing the panel layout. The following items
correspond to the diagram shown. Note: there may be additional requirements,
depending on your application and use of other components in the cabinet.
1. Mount the PLCs horizontally as shown below to provide proper ventilation.
You cannot mount the DL05 units vertically, upside down, or on a flat
horizontal surface. If you place more than one unit in a cabinet, there must
be a minimum of 7.2 (183mm) between the units.

OK

Airflow

2. Provide a minimum clearance of 2 (50mm) between the unit and all sides of
the cabinet. Note, remember to allow for any operator panels or other items
mounted in the door.
3. There should also be at least 3 (78mm) of clearance between the unit and
any wiring ducts that run parallel to the terminals.
Temperature
Probe

DL05
Micro PLC

2"

50mm
min.

Power
Source

Panel

2"
50mm
min.

BUS Bar

2"
50mm
min.

Ground Braid
Copper Lugs
Earth Ground

Panel or
Single Point
Ground
Star Washers Star Washers

Panel Ground
Terminal

Note: there is a minimum of 2 (30mm)

clearance between the panel door
or any devices mounted in the panel door
and the nearest DL05 component.

Not to Scale

4. The ground terminal on the DL05 base must be connected to a single point
ground. Use copper stranded wire to achieve a low impedance. Copper
eye lugs should be crimped and soldered to the ends of the stranded wire to
ensure good surface contact.
5. There must be a single point ground (i.e. copper bus bar) for all devices in
the panel requiring an earth ground return. The single point of ground must
be connected to the panel ground termination. The panel ground
termination must be connected to earth ground. Minimum wire sizes, color
coding, and general safety practices should comply with appropriate
electrical codes and standards for your area.

Installation, Wiring,
and Specifications

28
Installation, Wiring, and Specifications

Installation, Wiring,
and Specifications

6. A good common ground reference (Earth ground) is essential for proper

operation of the DL05. One side of all control and power circuits and the
ground lead on flexible shielded cable must be properly connected to Earth
ground. There are several methods of providing an adequate common
ground reference, including:
a) Installing a ground rod as close to the panel as possible.
b) Connection to incoming power system ground.
7. Evaluate any installations where the ambient temperature may approach
the lower or upper limits of the specifications. If you suspect the ambient
temperature will not be within the operating specification for the DL05
system, measures such as installing a cooling/heating source must be
taken to get the ambient temperature within the range of specifications.
8. The DL05 systems are designed to be powered by 95-240 VAC or 1224
VDC normally available throughout an industrial environment. Electrical
power in some areas where the PLCs are installed is not always stable and
storms can cause power surges. Due to this, powerline filters are
recommended for protecting the DL05 PLCs from power surges and
EMI/RFI noise. The Automation Powerline Filter, for use with 120 VAC and
240 VAC, 15 Amps, is an exellent choice
However, you can use a filter of your choice.
These units install easily between the power source and the PLC.
NOTE: If you are using other components in your system, make sure you refer to the
appropriate manual to determine how those units can affect mounting dimensions.
Using Mounting
Rails

DL05 Micro PLCs can be secured to a panel by using mounting rails. We

recommend rails that conform to DIN EN standard 50 022. They are approximately
35mm high, with a depth of 7mm. If you mount the Micro PLC on a rail, do consider
using end brackets on each side of the PLC. The end bracket helps keep the PLC
from sliding horizontally along the rail, reducing the possibility of accidentally pulling
the wiring loose.
On the bottom of the PLC is a small retaining clip. To secure the PLC to a DIN rail,
place it onto the rail and gently push up on the clip to lock it onto the rail.
To remove the PLC, pull down on the retaining clip, lift up on the PLC slightly, then
pulling it away from the rail.

29
Installation, Wiring, and Specifications

DIN Rail Dimensions

DIN Rail slot.

Use 35mm x 7mm rail conforming to
DIN EN 50022.

7mm

Retaining Clip
NOTE: Refer to our catalog for a complete listing of DINnector connection systems.

Environmental
Specifications

The following table lists the environmental specifications that generally apply to
DL05 Micro PLCs. The ranges that vary for the Handheld Programmer are noted at
the bottom of this chart. Certain output circuit types may have derating curves,
depending on the ambient temperature and the number of outputs ON. Please refer
to the appropriate section in this chapter pertaining to your particular DL05 PLC.
Specification

Rating

Storage temperature

4 F to 158 F (20 C to 70 C)

Ambient operating temperature*

32 F to 131 F (0 C to 55 C)

Ambient humidity**

5% 95% relative humidity (noncondensing)

Vibration resistance

MIL STD 810C, Method 514.2

Shock resistance

MIL STD 810C, Method 516.2

Noise immunity

NEMA (ICS3304)

Atmosphere

No corrosive gases

Agency approvals

UL, CE, FCC class A

* Operating temperature for the Handheld Programmer and the DV1000 is 32 to 122 F (0 to 50 C)
Storage temperature for the Handheld Programmer and the DV1000 is 4 to 158 F (20 to70 C).
**Equipment will operate down to 5% relative humidity. However, static electricity problems occur much
more frequently at low humidity levels (below 30%). Make sure you take adequate precautions when
you touch the equipment. Consider using ground straps, anti-static floor coverings, etc. if you use the
equipment in low-humidity environments.

Agency Approvals

Some applications require agency approvals for particular components. The DL05
Micro PLC agency approvals are listed below:
S UL (Underwriters Laboratories, Inc.)
S CUL (Canadian Underwriters Laboratories, Inc.)
S CE (European Economic Union)

Installation, Wiring,
and Specifications

35 mm

210
Installation, Wiring, and Specifications

Wiring Guidelines
Connect the power input wiring for the DL05. Observe all precautions stated earlier
in this manual. For more details on wiring, see Chapter 2 on Installation, Wiring, and
Specifications. When the wiring is complete, close the connector covers. Do not
apply power at this time.

Installation, Wiring,
and Specifications

110/220 VAC Power Input

12/24 VDC Power Input

LG N
95 240 VAC

+G
12 24 VDC

WARNING: Once the power wiring is connected, secure the terminal block cover in
the closed position. When the cover is open there is a risk of electrical shock if you
accidentally touch the connection terminals or power wiring.

Fuse Protection
for Input Power

There are no internal fuses for the input power circuits, so external circuit protection
is needed to ensure the safety of service personnel and the safe operation of the
equipment itself. To meet UL/CUL specifications, the input power must be fused.
Depending on the type of input power being used, follow these fuse protection
recommendations:
208/240 VAC Operation
When operating the unit from 208/240 VAC, whether the voltage source is a
step-down transformer or from two phases, fuse both the line (L) and neutral (N)
leads. The recommended fuse size is 0.375A.
110/125 VAC Operation
When operating the unit from 110/125 VAC, it is only necessary to fuse the line (L)
lead; it is not necessary to fuse the neutral (N) lead. The recommended fuse size is
0.5A.

211
Installation, Wiring, and Specifications

12/24 VDC Operation

When operating at these lower DC voltages, wire gauge size is just as important as
proper fusing techniques. Using large conductors minimizes the voltage drop in the
conductor. Each DL05 input power terminal can accommodate one 16 AWG wire or
two 18 AWG wires. A DC failure can maintain an arc for much longer time and
distance than AC failures. Typically, the main bus is fused at a higher level than the
branch device, which in this case is the DL05. The recommended fuse size for the
branch circuit to the DL05 is 1A (for example, a Littlefuse 312.001 or equivalent).
The power source must be capable of suppling voltage and current complying with
individual Micro PLC specifications, according to the following specifications:
Item

DL05 VAC Powered Units

DL05 VDC Powered Units

Input Voltage Range

110/220 VAC (95240 VAC)

1224 VDC (10.826.4 VDC)

Maximum Inrush Current

13 A, 1ms (95240 VAC)

15 A, 1ms (240264 VAC)

10A

Maximum Power

30 VA

20 W

Voltage Withstand (dielectric)

1 minute @ 1500 VAC between primary, secondary, field

ground

Insulation Resistance

> 10 M
at 500 VDC

NOTE:The rating between all internal circuits is BASIC INSULATION ONLY.

Planning the
Wiring Routes

The following guidelines provide general information on how to wire the I/O
connections to DL05 Micro PLCs. For specific information on wiring a particular PLC
refer to the corresponding specification sheet further in this chapter.
1. Each terminal connection of the DL05 PLC can accept one 16 AWG wire or
two 18 AWG size wires. Do not exceed this recommended capacity.
2. Always use a continuous length of wire. Do not splice wires to attain a
needed length.
3. Use the shortest possible wire length.
4. Use wire trays for routing where possible.
5. Avoid running wires near high energy wiring.
6. Avoid running input wiring close to output wiring where possible.
7. To minimize voltage drops when wires must run a long distance , consider
using multiple wires for the return line.
8. Avoid running DC wiring in close proximity to AC wiring where possible.
9. Avoid creating sharp bends in the wires.
10. Install the recommended powerline filter to reduce power surges and
EMI/RFI noise.

Installation, Wiring,
and Specifications

External
Power Source

212
Installation, Wiring, and Specifications

Fuse Protection
for Input and
Output Circuits

Input and Output circuits on DL05 Micro PLCs do not have internal fuses. In order to
protect your Micro PLC, we suggest you add external fuses to your I/O wiring. A
fast-blow fuse, with a lower current rating than the I/O banks common current rating
can be wired to each common. Or, a fuse with a rating of slightly less than the
maximum current per output point can be added to each output. Refer to the Micro
PLC specification sheets further in this chapter to find the maximum current per
output point or per output common. Adding the external fuse does not guarantee the
prevention of Micro PLC damage, but it will provide added protection.

Installation, Wiring,
and Specifications

External Fuses
(shown with DIN Rail, Fuse Blocks)

I/O Point
Numbering

All DL05 Micro PLCs have a fixed I/O configuration. It follows the same octal
numbering system used on other DirectLogic family PLCs, starting at X0 and Y0. The
letter X is always used to indicate inputs and the letter Y is always used for outputs.
The I/O numbering always starts at zero and does not include the digits 8 or 9. The
addresses are typically assigned in groups of 8 or 16, depending on the number of
points in an I/O group. For the DL05 the eight inputs use reference numbers X0 X7.
The six output points use references Y0 Y5.

213
Installation, Wiring, and Specifications

System Wiring Strategies

PLC Isolation
Boundaries

Primary Side

Secondary, or
Logic side

PLC

Power
Input

Main
Power
Supply

Filter

Isolation
Boundary

CPU

Field Side
Input
Circuit

Discrete Inputs

Output
Circuit

Discrete Outputs

Programming Device or
Operator Interface

Isolation
Boundary

The next figure shows the internal layout of DL05 PLCs, as viewed from the front
panel.
To Programming Device
or Operator Interface

DL05
PLC

CPU

2 Comm.
Ports

Main
Power
Supply
Input Circuit

Power
Input

Filter

8 Discrete
Inputs

Commons

Output Circuit

6 Discrete Outputs Commons

Installation, Wiring,
and Specifications

The DL05 Micro PLC is very flexible and will work in many different wiring
configurations. By studying this section before actual installation, you can probably
find the best wiring strategy for your application . This will help to lower system cost,
wiring errors, and avoid safety problems.
PLC circuitry is divided into three main regions separated by isolation boundaries,
shown in the drawing below. Electrical isolation provides safety, so that a fault in one
area does not damage another. A powerline filter will provide isolation between the
power source and the power supply. A transformer in the power supply provides
magnetic isolation between the primary and secondary sides. Opto-couplers
provide optical isolation in Input and Output circuits. This isolates logic circuitry from
the field side, where factory machinery connects. Note that the discrete inputs are
isolated from the discrete outputs, because each is isolated from the logic side.
Isolation boundaries protect the operator interface (and the operator) from power
input faults or field wiring faults. When wiring a PLC, it is extremely important to avoid
making external connections that connect logic side circuits to any other.

214
Installation, Wiring, and Specifications

Connecting
Operator Interface
Devices

Operator interfaces require data and power connections. Operator interfaces with a
large CRT usually require separate AC power. However, small operator interface
devices like the popular DV-1000 Data Access Unit and the Optimation panels may
be powered directly from the DL05 Micro PLC.
Connect the DV-1000 to either communication port on the DL05 Micro PLC using the
cable shown below. A single cable contains transmit/receive data wires and +5V
power.
DL05 Micro PLC

Installation, Wiring,
and Specifications

RJ12
phone style

RJ12
phone style

DV-1000

Use cable part no.

DV1000CBL

Optimation operator interface panels require separate power and communications

connections. Connect the DL05 to the proper D-shell connector on the rear of the
Optimation panel using the cable shown below. Optimation panels require 830VDC
power.
DL05 Micro PLC

RJ12
phone style

15-pin D-shell
male

Optimation Panel

Use cable part no.

OP2CBL

Connecting
Programming
Devices

DL05 Micro PLCs can be programmed with either a handheld programmer or with
DirectSOFT on a PC. Connect the DL05 to a PC using the cable shown below.
DL05 Micro PLC

RJ12
phone style

9-pin D-shell
female

Use cable part no.

D2DSCBL

The D2-HPP Handheld Programmer comes with a communications cable. For a

replacement part, use the cable shown below.
DL05 Micro PLC

RJ12
phone style

RJ12
phone style

(cable comes with HPP)

For replacement
cable, use part no.
DV1000CBL

D2HPP

215
Installation, Wiring, and Specifications

Sinking / Sourcing
Concepts

Before going further in our study of wiring strategies, we must have a solid
understanding of sinking and sourcing concepts. Use of these terms occurs
frequently in input or output circuit discussions. It is the goal of this section to make
these concepts easy to understand, further ensuring your success in installation.
First we give the following short definitions, followed by practical applications.

Sinking = Path to supply ground ()

Sourcing = Path to supply source (+)

For example, the figure to the right depicts

a sinking input. To properly connect the
external supply, we just have to connect it
so the the input provides a path to ground
(). So, we start at the PLC input terminal,
follow through the input sensing circuit,
exit at the common terminal, and connect
the supply () to the common terminal. By
adding the switch, between the supply (+)
and the input, we have completed the
circuit. Current flows in the direction of the
arrow when the switch is closed.

Input
(sinking)
+

PLC

Input
Sensing

Common

By applying the circuit principle above to the four possible combinations of

input/output sinking/sourcing types, we have the four circuits as shown below. DL05
Micro PLCs provide all except the sourcing output I/O circuit types.
Sinking Input

Sinking Output
Input

Common

PLC
Input
Sensing

Sourcing Input
Common
+

Input

PLC
Output
Switch

Output

Load
+

Common

Sourcing Output
PLC
Input
Sensing

PLC
Output
Switch

Common
+
Output

Load

Installation, Wiring,
and Specifications

First you will notice that these are only associated with DC circuits and not AC,
because of the reference to (+) and () polarities. Therefore, sinking and sourcing
terminology only applies to DC input and output circuits. Input and output points that
are either sinking or sourcing can conduct current in only one direction. This means it
is possible to connect the external supply and field device to the I/O point with current
trying to flow in the wrong direction, and the circuit will not operate. However, we can
successfully connect the supply and field device every time by understanding
sourcing and sinking.

216
Installation, Wiring, and Specifications

Installation, Wiring,
and Specifications

I/O Common
In order for a PLC I/O circuit to operate,
Terminal Concepts current must enter at one terminal and exit
at another. This means at least two
terminals are associated with every I/O
point. In the figure to the right, the Input or
Output terminal is the main path for the
current. One additional terminal must
provide the return path to the power
supply.
If we had unlimited space and budget for
I/O terminals, then every I/O point could
have two dedicated terminals just as the
figure above shows. However, providing
this level of flexibility is not practical or
even necessary for most applications. So,
most Input or Output point groups on
PLCs share the return path among two or
more I/O points. The figure to the right
shows a group (or bank) of 4 input points
which share a common return path. In this
way, the four inputs require only five
terminals instead of eight.

Field
Device

PLC

Main Path
(I/O Point)

I/O
Circuit

Return Path

PLC
Input 1

Input
Sensing

Input 2
Input 3
Input 4
+

Common

Note: In the circuit above, the current in the common path is 4 times any channels
input current when all inputs are energized. This is especially important in output
circuits, where heavier gauge wire is sometimes necessary on commons.
Most DL05 input and output circuits are
grouped into banks that share a common
return path. The best indication of I/O
common grouping is on the wiring label.
The I/O common grouping bar, labeled at
the right, occurs in the section of wiring
label below it. It indicates X0, X1, X2, and
X3 share the common terminal located to
the left of X1.
The following complete label shows two banks of four inputs and two banks of three
outputs. One common is provided for each bank.

The following label is for DC output versions. One common is provided for all of the
outputs and the terminal on the bottom right accepts power for the output stage.

217
Installation, Wiring, and Specifications

Connecting DC I/O In the previous section on Sourcing and Sinking concepts, we explained that DC I/O
circuits sometimes will only allow current to flow one way. This is also true for many of
to Solid State
the field devices which have solid-state (transistor) interfaces. In other words, field
Field Devices
devices can also be sourcing or sinking. When connecting two devices in a series
DC circuit, one must be wired as sourcing and the other as sinking.
The DL05s DC inputs are flexible in that they detect current flow in either direction,
Solid State
so they can be wired as either sourcing or sinking. In the following circuit, a field
Input Sensors
device has an open-collector NPN transistor output. It sinks current from the PLC
input point, which sources current. The power supply can be the FA-24PS +24 VDC
power supply or another supply (+12 VDC or +24VDC), as long as the input
specifications are met.
Installation, Wiring,
and Specifications

Field Device

PLC DC Input
Input
(sourcing)

Output
(sinking)
Supply
Ground

Common

In the next circuit, a field device has an open-emitter PNP transistor output. It
sources current to the PLC input point, which sinks the current back to ground. Since
the field device is sourcing current, no additional power supply is required.
Field Device
+V

PLC DC Input
Input
Output (sourcing)
Ground

Solid State
Output Loads

(sinking)
Common

Sometimes an application requires connecting a PLC output point to a solid state

input on a device. This type of connection is usually made to carry a low-level signal,
not to send DC power to an actuator.
The DL05s DC outputs are sinking-only. This means that each DC output provides a
path to ground when it is energized. Also, remember that all six outputs have the
same electrical common, even though there are two common terminal screws.
Finally, recall that the DC output circuit requires power (20 28 VDC) from an
external power source.
In the following circuit, the PLC output point sinks current to the output common
when energized. It is connected to a sourcing input of a field device input.
PLC DC Output
+DC pwr

Field Device

Power

+V

Output
(sinking)

Common

Input
(sourcing)
20-28 VDC
Ground

218
Installation, Wiring, and Specifications

In the next example we connect a PLC DC output point to the sinking input of a field
device. This is a bit tricky, because both the PLC output and field device input are
sinking type. Since the circuit must have one sourcing and one sinking device, we
add sourcing capability to the PLC output by using a pull-up resistor. In the circuit
below, we connect Rpull-up from the output to the DC output circuit power input.
PLC DC Output
Power

+DC pwr

Field Device

R pull-up
(sourcing)

Installation, Wiring,
and Specifications

(sinking)

Output
+

Input
(sinking)

Ground

R input

Supply
Common

NOTE: DO NOT attempt to drive a heavy load (>25 mA) with this pull-up method.
NOTE 2: Using the pull-up resistor to implement a sourcing output has the effect of
inverting the output point logic. In other words, the field device input is energized
when the PLC output is OFF, from a ladder logic point-of-view. Your ladder program
must comprehend this and generate an inverted output. Or, you may choose to
cancel the effect of the inversion elsewhere, such as in the field device.
It is important to choose the correct value of R pull-up. In order to do so, we need to
know the nominal input current to the field device (I input) when the input is energized.
If this value is not known, it can be calculated as shown (a typical value is 15 mA).
Then use I input and the voltage of the external supply to compute R pull-up. Then
calculate the power Ppull-up (in watts), in order to size R pull-up properly.

input

R pull-up =

input (turnon)

R input
V supply 0.7
I

R input

pull-up

input

V supply

R pullup

The drawing below shows the actual wiring of the DL05 Micro PLC to the supply and
pull-up resistor.

Common

Supply +

Output

219
Installation, Wiring, and Specifications

Relay Output
Wiring Methods

Assuming relays are right for your application, were now ready to explore various
ways to wire relay outputs to the loads. Note that there are six normally-open SPST
relays available. They are organized with three relays per common. The figure below
shows the relays and the internal wiring of the PLC. Note that each group is isolated
from the other group of outputs.
Y0 Com

Y1

Y2

Y3

Y4 Com

Y5

In the circuit below, all loads use the same AC power supply which powers the DL05
PLC. In this example, all commons are connected together.

Fuse or
Circuit
Breaker

Line
Ground
Neutral

Output Point Wiring

In the circuit on the following page, loads for Y0 Y2 use the same AC power supply
which powers the DL05 PLC. Loads for Y3 Y5 use a separate DC supply. In this
example, the commons are separated according to which supply powers the
associated load.

Installation, Wiring,
and Specifications

The D005AR and the D005DR models feature relay outputs. Relays are best for
the following applications:
S Loads that require higher currents than the solid-state DL05 outputs can
deliver
S Cost-sensitive applications
S Some output channels need isolation from other outputs (such as when
some loads require AC while others require DC)
Some applications in which NOT to use relays:
S Loads that require currents under 10 mA
S Loads which must be switched at high speed and duty cycle

220
Installation, Wiring, and Specifications

Installation, Wiring,
and Specifications

Fuse or
Circuit
Breaker

Line
Ground

Neutral

Output Point Wiring

Surge Suppresion
For Inductive
Loads

Inductive load devices (devices with a coil) generate transient voltages when
de-energized with a relay contact. When a relay contact is closed it bounces, which
energizes and de-energizes the coil until the bouncing stops. The transient
voltages generated are much larger in amplitude than the supply voltage, especially
with a DC supply voltage.
When switching a DC-supplied inductive load the full supply voltage is always
present when the relay contact opens (or bounces). When switching an
AC-supplied inductive load there is one chance in 60 (60 Hz) or 50 (50 Hz) that the
relay contact will open (or bounce) when the AC sine wave is zero crossing. If the
voltage is not zero when the relay contact opens there is energy stored in the
inductor that is released when the voltage to the inductor is suddenly removed. This
release of energy is the cause of the transient voltages.
When inductive load devices (motors, motor starters, interposing relays, solenoids,
valves, etc.) are controlled with relay contacts, it is recommended that a surge
suppression device be connected directly across the coil of the field device. If the
inductive device has plug-type connectors, the suppression device can be installed
on the terminal block of the relay output.
Transient Voltage Suppressors (TVS or transorb) provide the best surge and
transient suppression of AC and DC powered coils, providing the fastest response
with the smallest overshoot.
Metal Oxide Varistors (MOV) provide the next best surge and transient
suppression of AC and DC powered coils.
For example, the waveform in the figure below shows the energy released when
opening a contact switching a 24 VDC solenoid. Notice the large voltage spike.
+24 VDC

24 VDC

+24 VDC

Module Relay Contact

324 VDC

221
Installation, Wiring, and Specifications

This figure shows the same circuit with a transorb (TVS) across the coil. Notice that
the voltage spike is significantly reduced.
+24 VDC
24 VDC

+24 VDC
42 VDC

Module Relay Contact

Prolonging Relay
Contact Life

hhVendor / Catalog

Type (TVS, MOV, Diode)

Inductive Load Voltage

Part Number

General Instrument
Transient Voltage
Suppressors, LiteOn
Diodes; from DigiKey
Catalog; Phone:
1-800-344-4539

TVS

110/120 VAC

P6KE180CAGICTND

TVS

220/240 VAC

P6KE350CA

TVS

12/24 VDC or VAC

P6K30CAGICTND

Diode

12/24 VDC or VAC

1N4004CTND

Harris Metal Oxide

Varistors; from Newark
Catalog; Phone:
1-800-463-9275

MOV

110/120 VAC

V150LA20C

MOV

220/240 VAC

V250LA20C

Relay contacts wear according to the amount of relay switching, amount of spark
created at the time of open or closure, and presence of airborne contaminants.
There are some steps you can take to help prolong the life of relay contacts, such as
switching the relay on or off only when it is necessary, and if possible, switching the
load on or off at a time when it will draw the least current. Also, take measures to
suppress inductive voltage spikes from inductive DC loads such as contactors and
solenoids.
For inductive loads in DC circuits we recommend using a suppression diode as
shown in the following diagram (DO NOT use this circuit with an AC power supply).
When the load is energized the diode is reverse-biased (high impedance). When the
load is turned off, energy stored in its coil is released in the form of a negative-going
voltage spike. At this moment the diode is forward-biased (low impedance) and
shunts the energy to ground. This protects the relay contacts from the high voltage
arc that would occur just as the contacts are opening.
Place the diode as close to the inductive field device as possible. Use a diode with a
peak inverse voltage rating (PIV) at least 100 PIV, 3A forward current or larger. Use a
fast-recovery type (such as Schottky type). DO NOT use a small-signal diode such
as 1N914, 1N941, etc. Be sure the diode is in the circuit correctly before operation. If
installed backwards, it short-circuits the supply when the relay energizes.
Inductive Field Device

PLC Relay Output

Input

Output
Supply
Common

Common

Installation, Wiring,
and Specifications

Use the following table to help select a TVS or MOV suppressor for your application
based on the inductive load voltage.

222
Installation, Wiring, and Specifications

Installation, Wiring,
and Specifications

DC Input Wiring
Methods

DL05 Micro PLCs with DC inputs are particularly

flexible because they can be either sinking or
sourcing. The dual diodes (shown to the right) allow
current to flow in either direction. The inputs accept
10.8 26.4 VDC. The target applications are +12
VDC and +24 VDC. You can actually wire half of the
inputs as DC sinking and the other half as DC
sourcing. Inputs grouped by a common must be all
sinking or all sourcing.

PLC DC Input
Input

Common

In the first and simplest example below, all commons are connected together and all
inputs are sinking.

+24 VDC
+

In the next example, the first four inputs are sinking, and the last four are sourcing.

+24 VDC

+12 VDC

223
Installation, Wiring, and Specifications

DC Output
Wiring Methods

+24 VDC

+
Output Point Wiring

In the next example below, the outputs have split supplies. The first three outputs
are using a +12 VDC supply, and the last three are using a +24 VDC supply.
However, you can split the outputs among any number of supplies, as long as:
S all supply voltages are within the specified range
S all output points are wired as sinking
S all source () terminals are connected together

+12 VDC

+
Output Point Wiring

+24 VDC

Installation, Wiring,
and Specifications

DL05 DC output circuits are high-performance transistor switches with low

on-resistance and fast switching times. Please note the following characteristics
which are unique to the DC output type:
S There is only one electrical common for all six outputs. All six outputs
belong to one bank.
S The output switches are current-sinking only. However, you can still use
different DC voltages from one load to another.
S The output circuit inside the PLC requires external power. The supply
() must be connected to a common terminal, and the supply (+)
connects the the right-most terminal on the upper connector.
In the example below, all six outputs share a common supply.

224
Installation, Wiring, and Specifications

DL05 versions with DC type input or output points contain a dedicated High-Speed
I/O circuit (HSIO). The circuit configuration is programmable, and it processes select
I/O points independently from the CPU scan. Chapter 3 discusses the programming
options for HSIO. While the HSIO circuit has six modes, we show wiring diagrams for
two of the most popular modes in this chapter. The high-speed input interfaces to
points X0 X2. Properly configured, the DL05 can count quadrature pulses at up to
5 kHz from an incremental encoder as shown below.

Installation, Wiring,
and Specifications

High-Speed I/O
Wiring Methods

Signal Common
Phase B
+

12 24 VDC

Phase A

Encoder Input Wiring

Encoder

DL05 versions with DC type output points can use the High Speed I/O Pulse Output
feature. It can generate high-speed pulses for specialized control such as stepper
motor / intelligent drive systems. Output Y0 and Y1 can generate pulse and direction
signals, or it can generate CCW and CW pulse signals respectively. See Chapter 3
on high-speed input and pulse output options.

+
Signal Common
Motor

Amplifier

Pulse
Direction

Pulse Output Wiring

Power Input

+24 VDC

225
Installation, Wiring, and Specifications

Glossary of Specification Terms

One of eight input connections to the PLC which converts an electrical
signal from a field device to a binary status (off or on), which is read by the
internal CPU each PLC scan.

Discrete Output

One of six output connections from the PLC which converts an internal
ladder program result (0 or 1) to turn On or Off an output switching device.
This enables the program to turn on and off large field loads.

I/O Common

A connection in the input or output terminals which is shared by multiple

I/O circuits. It usually is in the return path to the power supply of the I/O
circuit.

Input Voltage Range

The operating voltage range of the input circuit.

Maximum Voltage

Maximum voltage allowed for the input circuit.

ON Voltage Level

The minimum voltage level at which the input point will turn ON.

OFF Voltage Level

The maximum voltage level at which the input point will turn OFF

Input Impedance

Input impedance can be used to calculate input current for a particular

operating voltage.

Input Current

Typical operating current for an active (ON) input.

Minimum ON Current

The minimum current for the input circuit to operate reliably in the ON
state.

Maximum OFF Current The maximum current for the input circuit to operate reliably in the OFF
state.
OFF to ON Response

The time the module requires to process an OFF to ON state transition.

ON to OFF Response

The time the module requires to process an ON to OFF state transition.

Status Indicators

The LEDs that indicate the ON/OFF status of an input or output point. All
LEDs on DL05 Micro PLCs are electrically located on the logic side of the
input or output circuit.

Installation, Wiring,
and Specifications

Discrete Input

226
Installation, Wiring, and Specifications

Wiring Diagrams and Specifications

The remainder of this chapter dedicates two pages to each of the eight versions of
DL05 Micro PLCs. Each section contains a basic wiring diagram, equivalent I/O
circuits, and specification tables. Please refer to the section which describes the
particular DL05 version used in your application.

Installation, Wiring,
and Specifications

D005AR
The D005AR Micro PLC features eight AC inputs and six relay contact outputs. The
I/O Wiring Diagram following diagram shows a typical field wiring example. The AC external power
connection uses four terminals at the left as shown.

Fuse
or
C.B.

Line
Neutral
Ground

Power
Input Wiring

AC or DC
Supply

AC
Supply

Input Point Wiring

Equivalent Input Circuit
+V

Output Point Wiring

Derating Chart for Relay Outputs

+V

Internal module circuitry

Input
Optical
Isolator

2A

6
To LED

Equivalent Output Circuit

Points

Y0 Y5

OUTPUT
L

+V

4
2

Common
COM

0
To other circuits in bank

0
32

10
20
30
40
50
55 C
50
68
86
104
122 131F
Ambient Temperature (C/F)

To LED

Line

627 VDC
6240 VAC

The eight AC input channels use terminals in the middle of the connector. Inputs are
organized into two banks of four. Each bank has a common terminal. The wiring
example above shows all commons connected together, but separate supplies and
common circuits may be used. The equivalent input circuit shows one channel of a
typical bank.

227
Installation, Wiring, and Specifications

The six relay output channels use terminals on the right side of the connector.
Outputs are organized into two banks of three normally-open relay contacts. Each
bank has a common terminal. The wiring example on the last page shows all
commons connected together, but separate supplies and common circuits may be
used. The equivalent output circuit shows one channel of a typical bank. The relay
contacts can switch AC or DC voltages.
D005AR
General
Specifications

Relay Output
Specifications
Y0 Y5

95 240 VAC, 30 VA maximum,

Communication Port 1
9600 baud (Fixed), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Slave)
MODBUS (Slave)

Communication Port 2
9600 baud (default), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Master/Slave)
MODBUS (Master/Slave)
Non-sequence / print

Programming cable type

D2DSCBL

Operating Temperature

32 to 131 F (0 to 55_ C)

Storage Temperature

4 to 158 F (20 to 70_ C)

Relative Humidity

5 to 95% (non-condensing)

Environmental air

No corrosive gases permitted

Vibration

MIL STD 810C 514.2

Shock

MIL STD 810C 516.2

Noise Immunity

NEMA ICS3304

Terminal Type

Removable

Wire Gauge

One AWG16 or two AWG18, AWG24 minimum

Input Voltage Range (Min. - Max.)

80 132 VAC, 47 - 63 Hz

Operating Voltage Range

90 120 VAC, 47 -63 Hz

Input Current

8 mA @ 100 VAC at 50 Hz
10 mA @ 100 VAC at 60 Hz

Max. Input Current

12 mA @ 132 VAC at 50 Hz
15 mA @ 132 VAC at 60 Hz

Input Impedance

14K
@50 Hz, 12K
@60 Hz

ON Current/Voltage

>6 mA @ 75 VAC

OFF Current/Voltage

<2 mA @ 20 VAC

OFF to ON Response

< 40 mS

ON to OFF Response

< 40 mS

Status Indicators

Logic Side

Commons

4 channels / common x 2 banks

Output Voltage Range (Min. Max.)

5 264 VAC (47 -63 Hz), 5 30 VDC

Operating Voltage Range

6 240 VAC (47 -63 Hz), 6 27 VDC

Output Current

2A / point, 6A / common

Max. leakage current

0.1 mA @264VAC

Smallest Recommended Load

5 mA @5 VDC

OFF to ON Response

< 15 mS

ON to OFF Response

< 10 mS

Status Indicators

Logic Side

Commons

3 channels / common x 2 banks

Fuses

None (external recommended)

Installation, Wiring,
and Specifications

AC Input
Specifications
X0 X7

External Power Requirements

228
Installation, Wiring, and Specifications

Installation, Wiring,
and Specifications

These micro PLCs feature eight DC inputs and six relay contact outputs. The
D005DR
I/O Wiring Diagram following diagram shows a typical field wiring example. The AC external power
connection uses four terminals at the left as shown.

Fuse
or
C.B.

Line
Neutral
Ground

Power
Input Wiring

AC or DC
Supply

DC
Supply

Input Point Wiring

Equivalent Circuit,
Standard Inputs (X3 X7)
+V

Derating Chart for Relay Outputs

Equivalent Output Circuit

Points
Internal module circuitry

+V

2A

Input

Output Point Wiring

Optical
Isolator

Y0 Y5

OUTPUT
L

+V

4
To LED

Common

COM

0
0
32

Equivalent Circuit, HighSpeed Inputs (X0 X2)

+V
Input

Optical
Isolator

+
To LED

Common
To all other output circuits

10
20
30
40
50
55 C
50
68
86
104
122
131F
Ambient Temperature (C/F)

To LED

Line

627 VDC
6240 VAC

The eight DC input channels use terminals in the middle of

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

The six output channels use terminals on the right side of the connector. Outputs are
organized into two banks of three normally-open relay contacts. Each bank has a
common terminal. The wiring example above shows all commons connected
together, but separate supplies and common circuits may be used. The equivalent
output circuit shows one channel of a typical bank. The relay contacts can switch AC
or DC voltages.

229
Installation, Wiring, and Specifications

D005DR
General
Specifications

Relay Output
Specifications

95 240 VAC, 30 VA maximum,

Communication Port 1
9600 baud (Fixed), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Slave)
MODBUS (Slave)

Communication Port 2
9600 baud (default), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Master/Slave)
MODBUS (Master/Slave)
Non-sequence / print

Programming cable type

D2DSCBL

Operating Temperature

32 to 131 F (0 to 55_ C)

Storage Temperature

4 to 158 F (20 to 70_ C)

Relative Humidity

5 to 95% (non-condensing)

Environmental air

No corrosive gases permitted

Vibration

MIL STD 810C 514.2

Shock

MIL STD 810C 516.2

Noise Immunity

NEMA ICS3304

Terminal Type

Removable

Wire Gauge

One AWG16 or two AWG18, AWG24 minimum

Parameter

HighSpeed Inputs, X0 X2

Standard DC Inputs X3 X7

Min. - Max. Voltage Range

10.8 26.4 VDC

10.8 26.4 VDC

Operating Voltage Range

12 -24 VDC

12 -24 VDC

Peak Voltage

30 VDC (5 kHz maximum frequency)

30 VDC

Minimum Pulse Width

100 s

N/A

ON Voltage Level

> 10 VDC

> 10 VDC

OFF Voltage Level

< 2.0 VDC

< 2.0 VDC

Input Impedance

1.8 k
@ 12 24 VDC

2.8 k
@ 12 24 VDC

Max. Input Current

6mA @12VDC
13mA @24VDC

4mA @12VDC
8.5mA @24VDC

Minimum ON Current

>5 mA

>4 mA

Maximum OFF Current

< 0.5 mA

<0.5 mA

OFF to ON Response

<100 s

2 8 mS, 4 mS typical

ON to OFF Response

< 100 s

2 8 mS, 4 mS typical

Status Indicators

Logic side

Logic side

Commons

4 channels / common x 2 bank

Output Voltage Range (Min. - Max.)

5 -264 VAC (47 -63 Hz), 5 - 30 VDC

Operating Voltage

6 -240 VAC (47 -63 Hz), 6 - 27 VDC

Output Current

2A / point
6A / common

Maximum Voltage

264 VAC, 30 VDC

Max leakage current

0.1 mA @264 VAC

Smallest Recommended Load

5 mA

OFF to ON Response

< 15 mS

ON to OFF Response

< 10 mS

Status Indicators

Logic Side

Commons

3 channels / common x 2 banks

Fuses

None (external recommended)

Installation, Wiring,
and Specifications

DC Input
Specifications

External Power Requirements

230
Installation, Wiring, and Specifications

Installation, Wiring,
and Specifications

The D005AD Micro PLC features eight AC inputs and six DC outputs. The following
D005AD
I/O Wiring Diagram diagram shows a typical field wiring example. The AC external power connection
uses four terminals at the left as shown.

Fuse
or
C.B.

Line
Neutral
Ground

Power
Input Wiring

AC or DC
Supply

+24 VDC

+
Input Point Wiring Output Point Wiring

Equivalent Input Circuit

+V
Input

Derating Chart for DC Outputs

+V

Optical
Isolator

+V

1A

6
To LED

Y0 Y5

4
2

24VDC
OUTPUT

+ 627
VDC

Internal module circuitry

+V

Common
To other circuits in bank

Equivalent Output Circuit

Points

Optical
Isolator

To LED
COM

0
32

10
20
30
40
50
55 C
50
68
86
104
122 131F
Ambient Temperature (C/F)

The eight AC input channels use terminals in the middle of the connector. Inputs are
organized into two banks of four. Each bank has an isolated common terminal. The
wiring example above shows all commons connected together, but separate
supplies and common circuits may be used. The equivalent input circuit shows one
channel of a typical bank.
The six current sinking DC output channels use terminals on the right side of the
connector. All outputs actually share the same electrical common. Note the
requirement for external power on the end (right-most) terminal. The equivalent
output circuit shows one channel of the bank of six.

231
Installation, Wiring, and Specifications

D005AD
General
Specifications

DC Output
Specifications

95 240 VAC, 30 VA maximum,

Communication Port 1
9600 baud (Fixed), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Slave)
MODBUS (Slave)

Communication Port 2
9600 baud (default), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Master/Slave)
MODBUS (Master/Slave)
Non-sequence / print

Programming cable type

D2DSCBL

Operating Temperature

32 to 131 F (0 to 55_ C)

Storage Temperature

4 to 158 F (20 to 70_ C)

Relative Humidity

5 to 95% (non-condensing)

Environmental air

No corrosive gases permitted

Vibration

MIL STD 810C 514.2

Shock

MIL STD 810C 516.2

Noise Immunity

NEMA ICS3304

Terminal Type

Removable

Wire Gauge

One AWG16 or two AWG18, AWG24 minimum

Input Voltage Range (Min. - Max.)

80 132 VAC, 47 - 63 Hz

Operating Voltage Range

90 120 VAC, 47 - 63 Hz

Input Current

8 mA @ 100 VAC (50Hz)

10 mA @ 100 VAC (60Hz)

Max. Input Current

12 mA @ 132 VAC (50Hz)

15 mA @ 132 VAC (60Hz)

Input Impedance

14K
@50 Hz, 12K
@60 Hz

ON Current/Voltage

>6 mA @ 75 VAC

OFF Current/Voltage

<2 mA @ 20 VAC

OFF to ON Response

< 40 mS

ON to OFF Response

< 40 mS

Status Indicators

Logic Side

Commons

4 channels / common x 2 banks

Parameter

Pulse Outputs, Y0 Y1

Standard Outputs, Y2 Y5

Min. - Max. Voltage Range

5 30 VDC

5 30 VDC

Operating Voltage

6 27 VDC

6 27 VDC

Peak Voltage

< 50 VDC (7 kHz max. frequency)

< 50 VDC

On Voltage Drop

0.3 VDC @ 1A

0.3 VDC @ 1A

Max Current (resistive)

0.5 A / pt. (1A / point for standard pt.)

1.0 A / point

Max leakage current

15 A @ 30 VDC

15 A @ 30 VDC

Max inrush current

2 A for 100 mS

2 A for 100 mS

Extenal DC power required

20 - 28 VDC max 150mA

20 - 28 VDC max 150mA

OFF to ON Response

<10 S

< 10 S

ON to OFF Response

<30 S

< 60 S

Status Indicators

Logic Side

Logic Side

Commons

6 channels / common x 1 banks

Fuses

None

None

Installation, Wiring,
and Specifications

AC Input
Specifications

External Power Requirements

232
Installation, Wiring, and Specifications

Installation, Wiring,
and Specifications

D005DD
These micro PLCs feature eight DC inputs and six DC outputs. The following
I/O Wiring Diagram diagram shows a typical field wiring example. The AC external power connection
uses four terminals at the left as shown.

Fuse
or
C.B.

Line
Neutral
Ground

Power
Input Wiring

+24 VDC

DC
Supply

+
Input Point Wiring Output Point Wiring
Equivalent Circuit,
Standard Inputs (X3 X7)
+V

Derating Chart for DC Outputs

+V

+V

1A

Input

Optical
Isolator

Y0 Y5

4
2

Common

+V
Input

Optical
Isolator

+
To LED

Common
To all other output circuits

+V

Optical
Isolator
OUTPUT

To LED
COM

0
32

Equivalent Circuit, HighSpeed Inputs (X0 X2)

24VDC

+ 627
VDC

Internal module circuitry

To LED

Equivalent Output Circuit

Points

10
20
30
40
50
55 C
50
68
86
104
122 131F
Ambient Temperature (C/F)

The eight DC input channels use terminals in the middle of

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

The six current sinking DC output channels use terminals on the right side of the
connector. All outputs actually share the same electrical common. Note the
requirement for external power on the end (right-most) terminal. The equivalent
output circuit shows one channel of the bank of six.

233
Installation, Wiring, and Specifications

D005DD
General
Specifications

DC Output
Specifications

95 240 VAC, 30 VA maximum,

Communication Port 1
9600 baud (Fixed), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Slave)
MODBUS (Slave)

Communication Port 2
9600 baud (default), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Master/Slave)
MODBUS (Master/Slave)
Non-sequence / print

Programming cable type

D2DSCBL

Operating Temperature

32 to 131 F (0 to 55_ C)

Storage Temperature

4 to 158 F (20 to 70_ C)

Relative Humidity

5 to 95% (non-condensing)

Environmental air

No corrosive gases permitted

Vibration

MIL STD 810C 514.2

Shock

MIL STD 810C 516.2

Noise Immunity

NEMA ICS3304

Terminal Type

Removable

Wire Gauge

One AWG16 or two AWG18, AWG24 minimum

Parameter

HighSpeed Inputs, X0 X2

Standard DC Inputs X3 X7

Min. - Max. Voltage Range

10.8 26.4 VDC

10.8 26.4 VDC

Operating Voltage Range

12 24 VDC

12 24 VDC

Peak Voltage

30 VDC (5 kHz maximum frequency)

30 VDC

Minimum Pulse Width

100 s

N/A

ON Voltage Level

> 9.0 VDC

> 9.0 VDC

OFF Voltage Level

< 2.0 VDC

< 2.0 VDC

Max. Input Current

6mA @12VDC, 13mA @24VDC

4mA @12VDC, 8.5mA @24VDC

Input Impedance

1.8 k
@ 12 24 VDC

2.8 k
@ 12 24 VDC

Minimum ON Current

>5 mA

>4 mA

Maximum OFF Current

< 0.5 mA

<0.5 mA

OFF to ON Response

<100 S

2 8 mS, 4 mS typical

ON to OFF Response

< 100 S

2 8 mS, 4 mS typical

Status Indicators

Logic side

Logic side

Commons

4 channels / common x 2 banks

Parameter

Pulse Outputs, Y0 Y1

Standard Outputs, Y3 Y5

Min. - Max. Voltage Range

5 30 VDC

5 30 VDC

Operating Voltage

6 27 VDC

6 27 VDC

Peak Voltage

< 50 VDC (7 kHz max. frequency)

< 50 VDC

On Voltage Drop

0.3 VDC @ 1 A

0.3 VDC @ 1 A

Max Current (resistive)

0.5 A / pt., 1A / pt. as standard pt.

1.0 A / point

Max leakage current

15 A @ 30 VDC

15 A @ 30 VDC

Max inrush current

2 A for 100 mS

2 A for 100 mS

External DC power required

20 - 28 VDC

OFF to ON Response

< 10 s

< 10 s

ON to OFF Response

< 30 s

< 60 s

Status Indicators

Logic Side

Logic Side

Commons

6 channels / common x 1 banks

Fuses

None (external recommended)

Max 150mA

20 - 28 VDC

Max 150mA

Installation, Wiring,
and Specifications

DC Input
Specifications

External Power Requirements

234
Installation, Wiring, and Specifications

Installation, Wiring,
and Specifications

The D005AA Micro PLC features eight AC inputs and six AC outputs. The following
D005AA
I/O Wiring Diagram diagram shows a typical field wiring example. The AC external power connection
uses four terminals at the left as shown.

Fuse
or
C.B.

Line
Neutral
Ground

Power
Input Wiring

AC
Supply

AC
Supply

Input Point Wiring

Equivalent Input Circuit
+V

Output Point Wiring

Derating Chart for AC Outputs

+V

Input
Optical
Isolator

Internal module circuitry

0.5 A

6
To LED

Equivalent Output Circuit

Points

Y0 Y5

+V
OUTPUT
L

Optical
Isolator

4
2

Common

COM

0
To other circuits in bank

Line

0
32

10
20
30
40
50
55 C
50
68
86
104
122 131F
Ambient Temperature (C/F)

17240
VAC

COM

To LED

The eight AC input channels use terminals in the middle of the connector. Inputs are
organized into two banks of four. Each bank has an isolated common terminal. The
wiring example above shows all commons connected together, but separate
supplies and common circuits may be used. The equivalent input circuit shows one
channel of a typical bank.
The six output channels use terminals on the right side of the connector. Outputs are
organized into two banks of three triac switches. Each bank has a common terminal.
The wiring example above shows all commons connected together, but separate
supplies and common circuits may be used. The equivalent output circuit shows one
channel of a typical bank.

235
Installation, Wiring, and Specifications

D005AA
General
Specifications

AC Output
Specifications

95 240 VAC, 30 VA maximum,

Communication Port 1
9600 baud (Fixed), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Slave)
MODBUS (Slave)

Communication Port 2
9600 baud (default), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Master/Slave)
MODBUS (Master/Slave)
Non-sequence / print

Programming cable type

D2DSCBL

Operating Temperature

32 to 131 F (0 to 55_ C)

Storage Temperature

4 to 158 F (20 to 70_ C)

Relative Humidity

5 to 95% (non-condensing)

Environmental air

No corrosive gases permitted

Vibration

MIL STD 810C 514.2

Shock

MIL STD 810C 516.2

Noise Immunity

NEMA ICS3304

Terminal Type

Removable

Wire Gauge

One AWG16 or two AWG18, AWG24 minimum

Input Voltage Range (Min. - Max.)

80 132 VAC, 47 - 63 Hz

Operating Voltage Range

90 120 VAC, 47 - 63 Hz

Input Current

8 mA @100 VAC at 50 Hz
10 mA @100 VAC at 60 Hz

Max. Input Current

12 mA @132 VAC at 50 Hz
15 mA @132 VAC at 60 Hz

Input Impedance

14K
@50 Hz, 12K
@60Hz

ON Current/Voltage

> 6 mA @ 75 VAC

OFF Current/Voltage

< 2 mA @ 20 VAC

OFF to ON Response

< 40 mS

ON to OFF Response

< 40 mS

Status Indicators

Logic Side

Commons

4 channels / common x 2 banks

Output Voltage Range (Min. - Max.)

15 264 VAC, 47 63 Hz

Operating Voltage

17 240 VAC, 47 63 Hz

On Voltage Drop

1.5 VAC (>50mA)

4.0 VAC (<50mA)

Max Current

0.5 A / point, 1.5 A / common

Max leakage current

<4 mA @ 264 VAC

Max inrush current

10 A for 10 mS

Minimum Load

10 mA

OFF to ON Response

1 mS

ON to OFF Response

1 mS +1/2 cycle

Status Indicators

Logic Side

Commons

3 channels / common x 2 banks

Fuses

None (external recommended)

Installation, Wiring,
and Specifications

AC Input
Specifications

External Power Requirements

236
Installation, Wiring, and Specifications

Installation, Wiring,
and Specifications

The D005DA Micro PLC features eight DC inputs and six AC outputs. The following
D005DA
I/O Wiring Diagram diagram shows a typical field wiring example. The AC external power connection
uses four terminals at the left as shown.

Fuse
or
C.B.

Line
Neutral
Ground

Power
Input Wiring

DC
Supply

AC
Supply

Input Point Wiring

Equivalent Circuit,
Standard Inputs (X3 X7)
+V

Derating Chart for AC Outputs

Equivalent Output Circuit

Points
+V

Optical
Isolator

Internal module circuitry

0.5 A

Input

Output Point Wiring

Y0 Y5

+V
OUTPUT
L

Optical
Isolator

4
To LED

2
COM

Common

Line

0
32

Equivalent Circuit, HighSpeed Inputs (X0 X2)

+V
Input

Optical
Isolator

+
To LED

Common
To all other output circuits

10
20
30
40
50
55 C
50
68
86
104
122 131F
Ambient Temperature (C/F)

17240
VAC

To LED

The eight DC input channels use terminals in the middle

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

The six output channels use terminals on the right side of the connector. Outputs are
organized into two banks of three triac switches. Each bank has a common terminal.
The wiring example above shows all commons connected together, but separate
supplies and common circuits may be used. The equivalent output circuit shows one
channel of a typical bank.

237
Installation, Wiring, and Specifications

D005DA
General
Specifications

AC Output
Specifications

95 240 VAC, 30 VA maximum,

Communication Port 1
9600 baud (Fixed), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Slave)
MODBUS (Slave)

Communication Port 2
9600 baud (default), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Master/Slave)
MODBUS (Master/Slave)
Non-sequence/print

Programming cable type

D2DSCBL

Operating Temperature

32 to 131 F (0 to 55_ C)

Storage Temperature

4 to 158 F (20 to 70_ C)

Relative Humidity

5 to 95% (non-condensing)

Environmental air

No corrosive gases permitted

Vibration

MIL STD 810C 514.2

Shock

MIL STD 810C 516.2

Noise Immunity

NEMA ICS3304

Terminal Type

Removable

Wire Gauge

One AWG16 or two AWG18, AWG24 minimum

Parameter

HighSpeed Inputs, X0 X2

Standard DC Inputs X3 X7

Input Voltage Range

10.8 26.4 VDC

10.8 26.4 VDC

Operating Voltage Range

12 24 VDC

12 24 VDC

Maximum Voltage

30 VDC (5 kHz maximum frequency)

30 VDC

Minimum Pulse Width

100 S

N/A

ON Voltage Level

> 10 VDC

> 10 VDC

OFF Voltage Level

< 2.0 VDC

< 2.0 VDC

Input Impedance

1.8 k
@ 12 24 VDC

2.8 k
@ 12 24 VDC

Minimum ON Current

>5 mA

>4 mA

Maximum OFF Current

< 0.5 mA

<0.5 mA

OFF to ON Response

<100 S

2 8 mS, 4 mS typical

ON to OFF Response

< 100 S

2 8 mS, 4 mS typical

Status Indicators

Logic side

Logic side

Commons

4 channels / common x 2 bank

Output Voltage Range (Min. - Max.)

15 264 VAC, 47 63 Hz

Operating Voltage

17 240 VAC, 47 63 Hz

On Voltage Drop

1.5 VAC @> 50mA, 4 VAC @< 50mA

Max Current

0.5 A / point, 1.5 A / common

Max leakage current

< 4 mA @ 264 VAC, 60Hz

Max inrush current

10 A for 10 mS

Minimum Load

10 mA

OFF to ON Response

1 mS

ON to OFF Response

1 mS +1/2 cycle

Status Indicators

Logic Side

Commons

3 channels / common x 2 banks

Fuses

None (external recommended)

Installation, Wiring,
and Specifications

DC Input
Specifications

External Power Requirements

238
Installation, Wiring, and Specifications

These micro PLCs feature eight DC inputs and six relay contact outputs. The
D005DRD
I/O Wiring Diagram following diagram shows a typical field wiring example. The DC external power
connection uses three terminals at the left as shown.

1224 V

20 W max.

Installation, Wiring,
and Specifications

Fuse
+

1224 VDC

Ground

Power
Input Wiring

AC or DC
Supply

DC
Supply

Input Point Wiring

Equivalent Circuit,
Standard Inputs (X3 X7)
+V

Derating Chart for Relay Outputs

Equivalent Output Circuit

Points
Internal module circuitry

+V

2A

Input

Output Point Wiring

Optical
Isolator

Y0 Y5

OUTPUT
L

+V

4
To LED

Common

COM

0
0
32

Equivalent Circuit, HighSpeed Inputs (X0 X2)

+V
Input

Optical
Isolator

+
To LED

Common
To all other output circuits

10
20
30
40
50
55 C
50
68
86
104
122
131F
Ambient Temperature (C/F)

To LED

Line

627 VDC
6240 VAC

The eight DC input channels use terminals in the middle of

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

The six output channels use terminals on the right side of the connector. Outputs are
organized into two banks of three normally-open relay contacts. Each bank has a
common terminal. The wiring example above shows all commons connected
together, but separate supplies and common circuits may be used. The equivalent
output circuit shows one channel of a typical bank. The relay contacts can switch AC
or DC voltages.

239
Installation, Wiring, and Specifications

D005DRD
General
Specifications

Relay Output
Specifications

12 24 VDC, 20 W maximum,

Communication Port 1
9600 baud (Fixed), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Slave)
MODBUS (Slave)

Communication Port 2
9600 baud (default), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Master/Slave)
MODBUS (Master/Slave)
Non-sequence / print

Programming cable type

D2DSCBL

Operating Temperature

32 to 131 F (0 to 55_ C)

Storage Temperature

4 to 158 F (20 to 70_ C)

Relative Humidity

5 to 95% (non-condensing)

Environmental air

No corrosive gases permitted

Vibration

MIL STD 810C 514.2

Shock

MIL STD 810C 516.2

Noise Immunity

NEMA ICS3304

Terminal Type

Removable

Wire Gauge

One AWG16 or two AWG18, AWG24 minimum

Parameter

HighSpeed Inputs, X0 X2

Standard DC Inputs X3 X7

Min. - Max. Voltage Range

10.8 26.4 VDC

10.8 26.4 VDC

Operating Voltage Range

12 -24 VDC

12 -24 VDC

Peak Voltage

30 VDC (5 kHz maximum frequency)

30 VDC

Minimum Pulse Width

100 s

N/A

ON Voltage Level

> 10 VDC

> 10 VDC

OFF Voltage Level

< 2.0 VDC

< 2.0 VDC

Input Impedance

1.8 k
@ 12 24 VDC

2.8 k
@ 12 24 VDC

Max. Input Current

6mA @12VDC
13mA @24VDC

4mA @12VDC
8.5mA @24VDC

Minimum ON Current

>5 mA

>4 mA

Maximum OFF Current

< 0.5 mA

<0.5 mA

OFF to ON Response

<100 s

2 8 mS, 4 mS typical

ON to OFF Response

< 100 s

2 8 mS, 4 mS typical

Status Indicators

Logic side

Logic side

Commons

4 channels / common x 2 bank

Output Voltage Range (Min. - Max.)

5 -264 VAC (47 -63 Hz), 5 - 30 VDC

Operating Voltage

6 -240 VAC (47 -63 Hz), 6 - 27 VDC

Output Current

2A / point
6A / common

Maximum Voltage

264 VAC, 30 VDC

Max leakage current

0.1 mA @264 VAC

Smallest Recommended Load

5 mA

OFF to ON Response

< 15 mS

ON to OFF Response

< 10 mS

Status Indicators

Logic Side

Commons

3 channels / common x 2 banks

Fuses

None (external recommended)

Installation, Wiring,
and Specifications

DC Input
Specifications

External Power Requirements

240
Installation, Wiring, and Specifications

D005DDD
These micro PLCs feature eight DC inputs and six DC outputs. The following
I/O Wiring Diagram diagram shows a typical field wiring example. The DC external power connection
uses four terminals at the left as shown.

1224 V

20 W max.

Installation, Wiring,
and Specifications

Fuse
+

1224 VDC

Ground

Power
Input Wiring

+24 VDC

DC
Supply

+
Input Point Wiring Output Point Wiring
Equivalent Circuit,
Standard Inputs (X3 X7)
+V

Derating Chart for DC Outputs

+V

+V

1A

Input

Optical
Isolator

Y0 Y5

4
2

Common

+V
Input

Optical
Isolator

+
To LED

Common
To all other output circuits

+V

Optical
Isolator
OUTPUT

To LED
COM

0
32

Equivalent Circuit, HighSpeed Inputs (X0 X2)

24VDC

+ 627
VDC

Internal module circuitry

To LED

Equivalent Output Circuit

Points

10
20
30
40
50
55 C
50
68
86
104
122 131F
Ambient Temperature (C/F)

The eight DC input channels use terminals in the middle of

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

The six current sinking DC output channels use terminals on the right side of the
connector. All outputs actually share the same electrical common. Note the
requirement for external power on the end (right-most) terminal. The equivalent
output circuit shows one channel of the bank of six.

241
Installation, Wiring, and Specifications

D005DDD
General
Specifications

DC Output
Specifications

12 24 VDC, 20 W maximum,

Communication Port 1
9600 baud (Fixed), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Slave)
MODBUS (Slave)

Communication Port 2
9600 baud (default), 8 data bits, 1 stop bit,
odd parity

KSequence (Slave)
DirectNET (Master/Slave)
MODBUS (Master/Slave)
Non-sequence / print

Programming cable type

D2DSCBL

Operating Temperature

32 to 131 F (0 to 55_ C)

Storage Temperature

4 to 158 F (20 to 70_ C)

Relative Humidity

5 to 95% (non-condensing)

Environmental air

No corrosive gases permitted

Vibration

MIL STD 810C 514.2

Shock

MIL STD 810C 516.2

Noise Immunity

NEMA ICS3304

Terminal Type

Removable

Wire Gauge

One AWG16 or two AWG18, AWG24 minimum

Parameter

HighSpeed Inputs, X0 X2

Standard DC Inputs X3 X7

Min. - Max. Voltage Range

10.8 26.4 VDC

10.8 26.4 VDC

Operating Voltage Range

12 24 VDC

12 24 VDC

Peak Voltage

30 VDC (5 kHz maximum frequency)

30 VDC

Minimum Pulse Width

100 s

N/A

ON Voltage Level

> 9.0 VDC

> 9.0 VDC

OFF Voltage Level

< 2.0 VDC

< 2.0 VDC

Max. Input Current

6mA @12VDC, 13mA @24VDC

4mA @12VDC, 8.5mA @24VDC

Input Impedance

1.8 k
@ 12 24 VDC

2.8 k
@ 12 24 VDC

Minimum ON Current

>5 mA

>4 mA

Maximum OFF Current

< 0.5 mA

<0.5 mA

OFF to ON Response

<100 S

2 8 mS, 4 mS typical

ON to OFF Response

< 100 S

2 8 mS, 4 mS typical

Status Indicators

Logic side

Logic side

Commons

4 channels / common x 2 banks

Parameter

Pulse Outputs, Y0 Y1

Standard Outputs, Y3 Y5

Min. - Max. Voltage Range

5 30 VDC

5 30 VDC

Operating Voltage

6 27 VDC

6 27 VDC

Peak Voltage

< 50 VDC (7 kHz max. frequency)

< 50 VDC

On Voltage Drop

0.3 VDC @ 1 A

0.3 VDC @ 1 A

Max Current (resistive)

0.5 A / pt., 1A / pt. as standard pt.

1.0 A / point

Max leakage current

15 A @ 30 VDC

15 A @ 30 VDC

Max inrush current

2 A for 100 mS

2 A for 100 mS

External DC power required

20 - 28 VDC

OFF to ON Response

< 10 s

< 10 s

ON to OFF Response

< 30 s

< 60 s

Status Indicators

Logic Side

Logic Side

Commons

6 channels / common x 1 banks

Fuses

None (external recommended)

Max 150mA

20 - 28 VDC

Max 150mA

Installation, Wiring,
and Specifications

DC Input
Specifications

External Power Requirements

242
Installation, Wiring, and Specifications

Installation, Wiring
and Specifications

D010ND3 DC Input
Inputs per module

10 (sink/source)

Input voltage range

10.826.4 VDC

Operating voltage range

1224 VDC

Peak voltage

30.0 VDC

Input current

Typical:
4.0 mA @ 12 VDC
8.5 mA @ 24 VDC

Maximum input current

11 mA @ 26.4 VDC

Input impedance

2.8k
@ 1224 VDC

ON voltage level

> 10.0 VDC

OFF voltage level

< 2.0 VDC

Minimum ON current

3.5 mA

Maximum OFF current

0.5 mA

OFF to ON response

28 ms, typical 4 ms

ON to OFF response

28 ms, typical 4 ms

Status indicators

Module activity:
one green LED

Commons per module

2 nonisolated

Fuse

N/A

Base power required (5V)

Typical 35 mA (all pts. ON)

Installation and
Safety Guidelines

Derating Chart

0
32

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

Equivalent circuit
Internal module circuitry

V+

INPUT
To LED

COM

Optical
Isolator

1224VDC
COM
Configuration shown is current sinking

Note: The DL05 must have firmware version V4.10 (or later) for this module to function properly.

243
Installation, Wiring, and Specifications

D016ND3 DC Input
16 (sink/source)

Input voltage range

2028 VDC

Operating voltage range

24 VDC

Peak voltage

30.0 VDC

Input current

Typical:
4.0 mA @ 24 VDC

Maximum input current

6 mA @ 28 VDC

Input impedance

4.7k
@ 24 VDC

ON voltage level

> 19.0 VDC

OFF voltage level

< 7.0 VDC

Minimum ON current

3.5 mA

Maximum OFF current

1.5 mA

OFF to ON response

28 ms, typical 4 ms

ON to OFF response

28 ms, typical 4 ms

Status indicators

Module activity:
one green LED

Commons per module

4 nonisolated

Fuse

N/A

Base power required

Typical 35 mA (all pts. ON)

Derating Chart

0
32

Wiring for ZLCM056

Configuration shown is
for current sinking

Installation and
Safety Guidelines

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

Installation, Wiring,
and Specifications

Inputs per module

Equivalent input circuit

Configuration shown is for current sinking

Note: The DL05 must have firmware version V4.10

(or later) for this module to function properly.

Use Ziplink ZLCBL056 cable and ZLCM056 connector

module or build your own cables using 24pin Molex Micro
Fit 3.0 receptacle, part number 43025, or compatible.

244
Installation, Wiring, and Specifications

Installation, Wiring
and Specifications

D010TD1 DC Output
Outputs per module

10 (sinking)

Operating voltage range

627 VDC

Output voltage range

530 VDC

Peak voltage

50.0 VDC

Maximum output current

0.3 A/point, 1.5 A/common

Minimum output current

0.5 mA

Maximum leakage current

15 A @ 30.0 VDC

ON voltage drop

0.5 VDC @ 0.3 A

Maximum inrush current

1 A for 10 ms

OFF to ON response

< 10 s

ON to OFF response

< 60 s

Status indicators

Module activity:
one green LED

Commons per module

2 nonisolated
(5 points/common)

Fuse

N/A

External DC power required

2028 VDC max.

200 mA (all pts. on)

Base power required (5V)

Max. 150 mA (all pts. ON)

Installation and
Safety Guidelines

Derating Chart

0
32

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

Equivalent circuit

Note: The DL05 must have firmware version V4.10 (or later) for this module to function properly.

245
Installation, Wiring, and Specifications

D016TD1 DC Output
16 (sinking)

Operating voltage range

627 VDC

Output voltage range

530 VDC

Peak Voltage

50.0 VDC

Maximum output current

0.1 A/point, 0.8 A/common

Minimum output current

0.5 mA

Maximum leakage current

15 A @ 30.0 VDC

On voltage drop

0.5 VDC @ 0.1 A

Maximum inrush current

1 A for 10 ms

OFF to ON response

< 0.5 ms

ON to OFF response

< 0.5 ms

Status indicators

Module activity:
one green LED

Commons per module

2 isolated (8 points/common)

Fuse

N/A

External DC power required

2028 VDC max. 70 mA

(all pts. on)

Base power required (5V)

Max. 200 mA (all pts. ON)

Installation, Wiring,
and Specifications

Outputs per module

Wiring for ZLCM056

Derating Chart

24 VDC

627 VDC

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

Installation and
Safety Guidelines

0
32

627
VDC

Equivalent input circuit

Note: The DL05 must have firmware version V4.10

(or later) for this module to function properly.

Use Ziplink ZLCBL056 cable and ZLCM056 connector

module or build your own cables using 24pin Molex Micro
Fit 3.0 receptacle, part number 43025, or compatible.

246
Installation, Wiring, and Specifications

Installation, Wiring
and Specifications

D010TD2 DC Output
Outputs per module

10 (sourcing)

Operating voltage range

1224 VDC

Output voltage range

10.826.4 VDC

Peak voltage

50.0 VDC

Maximum output current

0.3 A/point, 1.5 A/common

Minimum output current

0.5 mA

Maximum leakage current

1.5 A @ 30.0 VDC

ON voltage drop

1.0 VDC @ 0.3 A

Maximum inrush current

1 A for 10 ms

OFF to ON response

< 10 s

ON to OFF response

< 60 s

Status indicators

Module activity:
one green LED

Commons per module

2 nonisolated
(5 points/common)

Fuse

N/A

Base power required (5V)

Max. 150 mA (all pts. ON)

Installation and
Safety Guidelines

Derating Chart

0
32

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

Equivalent circuit

Note: The DL05 must have firmware version V4.10 (or later) for this module to function properly.

247
Installation, Wiring, and Specifications

D016TD2 DC Output
16 (sourcing)

Operating voltage range

1224 VDC

Output voltage range

10.826.4 VDC

Peak Voltage

50.0 VDC

Maximum output current

0.1 A/point, 0.8 A/common

Minimum output current

0.5 mA

Maximum leakage current

1.5 A @ 26.4 VDC

ON voltage drop

1.0 VDC @ 0.3 A

Maximum inrush current

1 A for 10 ms

OFF to ON response

< 0.5 ms

ON to OFF response

< 0.5 ms

Status indicators

Module activity:
one green LED

Commons per module

2 nonisolated
(8 points/common)

Fuse

N/A

Base power required (5V)

Max. 200 mA (all pts. ON)

Derating Chart

Wiring for ZLCM056

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

Installation and
Safety Guidelines

0
32

Installation, Wiring,
and Specifications

Outputs per module

Equivalent input circuit

Note: The DL05 must have firmware version V4.10

(or later) for this module to function properly.

Use Ziplink ZLCBL056 cable and ZLCM056 connector

module or build your own cables using 24pin Molex Micro
Fit 3.0 receptacle, part number 43025, or compatible.

248
Installation, Wiring, and Specifications

D007CDR DC Input and Output

Installation, Wiring
and Specifications

Input Specification

Output Specification

Inputs per module

4 (sink/source)

Outputs per module

Operating voltage range

1224 VDC

Operating voltage range

627 VDC / 6240 VAC

Input voltage range

10.826.4 VDC

Output type

Relay, form A, SPST

Peak voltage

30.0 VDC

Peak voltage

30.0 VDC/264 VAC

Maximum input current

11 mA @ 26.4 VDC

Maximum current (resistive)

1 A/point, 4 A/common

Input current

Typical: 4 mA @ 12 VDC
8.5 mA @ 24 VDC

Minimum load current

5 mA @ 5 VDC

Maximum leakage current

0.1 mA @ 264 VAC

Input impedance

2.8k
@ 1224 VDC

ON voltage drop

N/A

ON voltage level

> 10.0 VDC

Maximum inrush current

OFF voltage level

< 2.0 VDC

Output: 3 A for 10 ms
Common: 10 A for 10 ms

Minimum ON current

3.5 mA

OFF to ON response

< 15 ms

Maximum OFF current

0.5 mA

ON to OFF response

< 10 ms

ON to OFF response

28 ms, typical 4 ms

Status indicators

OFF to ON response

28 ms, typical 4 ms

Module activity:
one green LED

Commons

1 (4 points / common)

Commons

1 (3 points/common)

Fuse

N/A

Base power required (5 V)

Max. 200 mA (all points ON)

Installation and
Safety Guidelines

Input Derating Chart

0
32

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

Output Derating Chart

0
32

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

Equivalent input circuit

Equivalent output circuit

Configuration shown is for current sinking

Note: The DL05 must have firmware version V4.10 (or later) for this module to function properly.

249
Installation, Wiring, and Specifications

D008TR Relay Output

8

Operating voltage range

627 VDC/6240 VAC

Output type

Relay, form A, SPST

Peak voltage

30.0 VDC/264 VAC

Maximum current (resistive)

1 A/point, 4 A/common

Minimum load current

0.5 mA

Maximum leakage current

0.1 mA @ 264 VAC

ON voltage drop

N/A

Maximum inrush current

Output: 3 A for 10 ms
Common: 10 A for 10 ms

OFF to ON response

< 15 ms

ON to OFF response

< 10 ms

Status indicators

Module activity:
one green LED

Commons per module

2 isolated
(4 points/common)

Fuse

N/A

Base power required (5 V)

Maximum 280 mA (all pts. ON)

Installation, Wiring,
and Specifications

Outputs per module

Derating Chart

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

Equivalent circuit

Note: The DL05 must have firmware version V4.10 (or later) for this module to function properly.

Installation and
Safety Guidelines

0
32

250
Installation, Wiring, and Specifications

D008CDD1 DC Input and Output

Installation, Wiring
and Specifications

Input Specification

Output Specification

Inputs per module

4 (sink/source)

Outputs per module

4 (sinking)

Operating voltage range

10.826.4 VDC

Operating voltage range

627 VDC

Input voltage range

1224 VDC

Output voltage range

530 VDC

Peak voltage

30.0 VDC

Peak voltage

50.0 VDC

Maximum input current

11 mA @ 26.4 VDC

Maximum output current

0.3 A/point, 1.2 A/common

Input current

Typical: 4 mA @ 12 VDC
8.5 mA @ 24 VDC

Minimum output current

0.5 mA

Maximum leakage current

1.5 A @ 30.0 VDC

Input impedance

2.8k
@ 1224 VDC

ON voltage drop

0.5 VDC @ 0.3 A

ON voltage level

> 10.0 VDC

Maximum inrush current

1 A for 10 ms

OFF voltage level

< 2.0 VDC

OFF to ON response

< 10 s

Minimum ON current

3.5 mA

ON to OFF response

< 60 s

Maximum OFF current

0.5 mA

Status indicators

ON to OFF response

28 ms, typical 4 ms

Module activity:
one green LED

OFF to ON response

28 ms, typical 4 ms

Commons

2 nonisolated (4 pts./common)

Commons

2 nonisolated (4 pts./common)

Fuse

N/A

Base power required (5 V)

Max. 200 mA (all points ON)

External DC power required

(24V)

2028 VDC, maximum 80 mA

(all pts. ON)

Input Derating Chart

Installation and
Safety Guidelines

Output Derating Chart

0
32

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

0
32

10
20
30
40
50 55 C
50
68
86
104
122 131 F
Ambient Temperature (C/F)

Equivalent input circuit

Equivalent output circuit

Configuration shown is for current sinking

Note: The DL05 must have firmware version V4.10 (or later) for this module to function properly.

251
Installation, Wiring, and Specifications

I/O Addressing
Module I/O Points
and Addressing

Each option module has a set number of I/O points. This holds true for both the
discrete modules and the analog modules. The following chart shows the number of
I/O points per module when used in the DL05 PLC.
DC Input Modules
D010ND3
D016ND

DC Output Modules

I/O Points

Slot 1 I/O Address

10 Input

X100 X107 and X110 X111

16 Input

X100 X107 and X110 X117

I/O Points

Slot 1 I/O Address

10 Output

Y100 Y107 and Y110 Y111

D016TD1

16 Output

Y100 Y107 and Y110 Y117

D010TD2

10 Output

Y100 Y107 and Y110 Y111

D016TD2

16 Output

Y100 Y107 and Y110 Y117

Relay Output Modules

D008TR

I/O Points
8 Output

Combination Modules

I/O Points

Slot 1 I/O Address

Y100 X107

Slot 1 I/O Address

D007CDR

4 Input, 3 Output

X100 X103 and Y100 Y102

D008CDD1

4 Input, 4 Output

X100 X103 and Y100 Y103

Installation, Wiring,
and Specifications

D010TD1

Installation and
Safety Guidelines

High-Speed Input and

Pulse Output Features
In This Chapter. . . .

Introduction
Choosing the HSIO Operating Mode
Mode 10: HighSpeed Counter
Mode 20: Quadrature Counter
Mode 30: Pulse Output
Mode 40: HighSpeed Interrupt
Mode 50: Pulse Catch Input
Mode 60: Filtered Inputs

13

32
High-speed Input and Pulse Output Features

Introduction

High-Speed Input and

Pulse Output Features

Built-in Motion
Control Solution

Availability of
HSIO Features

Many machine control applications

require various types of simple
high-speed monitoring and control. These
applications usually involve some type of
motion control, or high-speed interrupts
for time-critical events. The DL05 Micro
PLC solves this traditionally expensive
problem with built-in CPU enhancements.
Lets take a closer look at the available
high-speed I/O features.
The available high-speed input features are:
S High Speed Counter (5 kHz max.) with up to 24 counter presets and
built-in interrupt subroutine, counts up only, with reset
S Quadrature encoder inputs to measure counts and clockwise or counter
clockwise direction (5 kHz max.), counts up or down, with reset
S High-speed interrupt input for immediate response to critical or
time-sensitive tasks
S Pulse catch feature to monitor one input point, having a pulse width as
small as 100mS (0.1ms)
S Programmable discrete filtering (both on and off delay up to 99ms) to
ensure input signal integrity (this is the default mode for inputs X0X2)
The available pulse output features are:
S Single-axis programmable pulse output (7 kHz max.) with three profile
types, including trapezoidal moves, registration, and velocity control
IMPORTANT: Please note the following restrictions on availability of features:
S High-speed input options are available only on DL05s with DC inputs.
S Pulse output options are available only on DL05s with DC outputs.
S Only one HSIO feature may be in use at one time. You cannot use a
highspeed input feature and the pulse output at the same time.
DL05
Part Number

Discrete
Input Type

Discrete
Output Type

High-Speed
Input

Pulse
Output

D005AR

AC

Relay

No

No

D005DR

DC

Relay

Yes

No

D005AD

AC

DC

No

Yes

D005DD

DC

DC

Yes

Yes

D005AA

AC

AC

No

No

D005DA

DC

AC

Yes

No

D005DRD

DC

Relay

Yes

No

D005DDD

DC

DC

Yes

Yes

33
High-Speed Input and Pulse Output Features

Dedicated HighSpeed I/O Circuit

The internal CPUs main task is to execute the ladder program and read/write all I/O
points during each scan. In order to service high-speed I/O events, the DL05
includes a special circuit which is dedicated to a portion of the I/O points. Refer to the
DL05 block diagram in the figure below.
6 Discrete Outputs

DL05
PLC

Output Circuit
Y0, Y1

Y2 - Y5

High-Speed
I/O Circuit

CPU

X0 - X2

X3- X7

Input Circuit

8 Discrete Inputs

Wiring Diagrams
for Each HSIO
Mode

After choosing the appropriate HSIO mode for your application, youll need to refer to
the section in this chapter for that specific mode. Each section includes wiring
diagram(s) to help you connect the High-Speed I/O points correctly to field devices.
An example of the quadrature counter mode diagram is shown below.

Signal Common
Phase B
+

Phase A

12 24 VDC

Encoder Input Wiring

Encoder

High-Speed Input and

Pulse Output Features

The high-speed I/O circuit (HSIO) is dedicated to the first three inputs (X0 X2) and
the first two outputs (Y0 Y1). We might think of this as a CPU helper. In the default
operation (called Mode 60) the HSIO circuit just passes through the I/O signals to
or from the CPU, so that all eight inputs behave equally and all six outputs behave
equally. When the CPU is configured in any other HSIO Mode, the HSIO circuit
imposes a specialized function on the portion of inputs and outputs shown. The
HSIO circuit operates independently of the CPU program scan. This provides
accurate measurement and capturing of high-speed I/O activity while the CPU is
busy with ladder program execution.

34
High-speed Input and Pulse Output Features

Choosing the HSIO Operating Mode

High-Speed Input and

Pulse Output Features

Understanding the The High-Speed I/O circuit operates in one of 6 basic modes as listed in the table
below. The number in the left column is the mode number (later, well use these
Six Modes
numbers to configure the PLC). Choose one of the following modes according to the
primary function you want from the dedicated High-Speed I/O circuit. You can simply
use all eight inputs and six outputs as regular I/O points with Mode 60.
Mode
Number

Mode Name

10

High-Speed
Counter

5 kHz counter with 24 presets and reset input,

counts up only, causes interrupt on preset

20

Quadrature
Counter

Channel A / Channel B 5 kHz quadrature input,

counts up and down

30

Pulse Output

Stepper control pulse and direction signals,

programmable motion profile (7kHz max.)

40

High-Speed
Interrupt

Generates an interrupt based on input transition

or time

50

Pulse Catch

Captures narrow pulses on a selected input

60

Mode Features

Discrete/Filtered Rejects narrow pulses on selected inputs

Input

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

DC Output Points

Mode

X0

X1

X2

Y0

Y1

High-Speed
Counter

Counter clock

Filtered Input

Filtered Input
or Reset Cnt

Regular Output

Regular Output

Quadrature
Counter

Phase A Input

Phase B Input

Filtered Input
or Reset Cnt

Regular Output

Regular Output

High-Speed
Interrupt

Interrupt Input

Filtered Input

Filtered Input

Regular Output

Regular Output

Pulse Catch

Pulse Input

Filtered Input

Filtered Input

Regular Output

Regular Output

Pulse Output

Filtered Input

Filtered Input

Filtered Input,

Pulse
or
CW Pulse

Direction
or
CCW Pulse

Filtered Input

Filtered Input

Filtered Input

Filtered Input

Regular Output

Regular Output

Default Mode

Mode 60 (Filtered Inputs) is the default mode. The DL05 is initialized to this mode at
the factory, and any time you reset V-memory scratchpad. In the default condition,
X0X2 are filtered inputs (10 mS delay) and Y0Y1 are standard outputs.

35
High-Speed Input and Pulse Output Features

Configuring the
HSIO Mode

If you have chosen a mode suited to the high-speed I/O needs of your application,
were ready to proceed to configure the PLC to operate accordingly. In the block
diagram below, notice the V-memory detail in the expanded CPU block. V-memory
location V7633 determines the functional mode of the high-speed I/O circuit. This is
the most important V-memory configuration value for HSIO functions!

Output Circuit

DL05
PLC

Y0, Y1

Y2 - Y5

CPU

I/O data

HighSpeed
I/O Circuit

Vmemory

Mode Select

V7633

X0 - X2

xxxx

X3- X7

Input Circuit

Memory Location V7633

Bits

15

14

13

12 11

10

Bits 8 - 15 are not used

in V7633.

HSIO Mode Setup (BCD)

00 = Not Used
10 = High-Speed Counting Mode
20 = Quadrature Counting Mode
30 = Pulse Output Train
40 = High-Speed Interrupts
50 = Pulse Catching
60 = Discrete Filtered Inputs (default)

Bits 0 7 define the mode number 00, 10.. 60 previously referenced in this chapter.
The example data 2050 shown selects Mode 50 Pulse Catch (BCD = 50). The
DL05 PLC ignores bits 8 - 15 in V7633.
Configuring
Inputs X0 X2

In addition to configuring V7633 for the

HSIO mode, youll need to program the
next three locations in certain modes
according to the desired function of input
points X0 X2. Other memory locations
may require configuring, depending on the
HSIO mode (see the corresponding
section for particular HSIO modes).

Vmemory
Mode
X0
X1
X2

V7633
V7634
V7635
V7636

xxxx
xxxx
xxxx
xxxx

High-Speed Input and

Pulse Output Features

The contents of V7633 is a 16-bit word, to be entered in binarycoded decimal. The

figure below defines what each 4-bit BCD digit of the word represents.

36
High-speed Input and Pulse Output Features

Mode 10: High-Speed Counter

Purpose

Functional Block
Diagram

The HSIO circuit contains one high-speed counter. A single pulse train from an
external source (X0) clocks the counter on each signal leading edge. The counter
counts only upwards, from 0 to 99999999. The counter compares the current count
with up to 24 preset values, which you define. The purpose of the presets is to quickly
cause an action upon arrival at specific counts, making it ideal for such applications
as cut-to-length. It uses counter registers CT76 and CT77 in the CPU.
Refer to the block diagram below. When the lower byte of HSIO Mode register V7633
contains a BCD 10, the high-speed up counter in the HSIO circuit is enabled. X0
automatically becomes the clock input for the high-speed counter, incrementing it
upon each off-to-on transition. The external reset input on X2 is the default
configuration for Mode 10. Input X1 is the filtered input, available to the ladder
program.

DL05
PLC

Output Circuit

High-Speed Input and

Pulse Output Features

Y0, Y1

HSIO

I/O data

COUNTER
CLK

Reset

X0

X2

Y2 - Y5

FILTER

Mode Select

X1

CPU
Vmemory
V7633

0010

X3- X7

Input Circuit

Instead of using X2 as a dedicated reset input, you can configure X2 as a normal

filtered input. In this way, the counter reset must be generated in ladder logic.

DL05
PLC

Output Circuit
Y0, Y1

HSIO

I/O data

COUNTER
CLK
X0

Reset

Y2 - Y5

FILTER

Mode Select

X1, X2

CPU
Vmemory
V7633

0010

X3- X7

Input Circuit

Next, we will discuss how to program the high-speed counter and its presets.

37
High-Speed Input and Pulse Output Features

Wiring Diagram

A general wiring diagram for counters/encoders to the DL05 in HSIO Mode 10 is

shown below. Many types of pulse-generating devices may be used, such as
proximity switches, single-channel encoders, magnetic or optical sensors, etc.
Devices with sinking outputs (NPN open collector) are probably the best choice for
interfacing. If the counter sources to the inputs, it must output 12 to 24 VDC. Note
that devices with 5V sourcing outputs will not work with DL05 inputs.

Signal

Counter Input Wiring

Signal Common

Interfacing to
Counter Outputs

The DL05s DC inputs are flexible in that they detect current flow in either direction,
so they can be wired to a counter with either sourcing or sinking outputs. In the
following circuit, a counter has open-collector NPN transistor outputs. It sinks
current from the PLC input point, which sources current. The power supply can be
the FA24PS or another supply (+12VDC or +24VDC), as long as the input
specifications are met.
Counter Output

X0 Input
Input
(sourcing)

Output
(sinking)
1224 VDC Supply
Ground

Common

In the next circuit, an encoder has open-emitter PNP transistor outputs. It sources
current to the PLC input point, which sinks the current back to ground. Since the
encoder sources current, no additional power supply is required. However, note that
the encoder output must be 12 to 24 volts (5V encoder outputs will not work).
Counter Output
X0 Input

+12 to 24VDC

Input
Output (sourcing)
Ground

(sinking)
Common

High-Speed Input and

Pulse Output Features

1224 VDC Supply

38
High-speed Input and Pulse Output Features

Setup for Mode 10

Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use
BCD 10 in the lower byte of V7633 to select the High-Speed Counter Mode. The
DL05 does not use bits 8 - 15 in V7633.
Memory Location V7633
Bits

15

14

13

12 11

10

Bits 8 - 15 are not used

in V7633.

HSIO Mode Setup (BCD)

High-Speed Input and

Pulse Output Features

10 = High-Speed Counter

Presets and
Special Relays

Choose the most convenient method of programming V7633 from the following:
S Include load and out instructions in your ladder program
S DirectSOFTs memory editor or Data View
S Use the Handheld Programmer D2HPP
We recommend using the first method above so that the HSIO setup becomes an
integral part of your application program. An example program later in this section
shows how to do this.
The goal of counting is to do a special action when the count reaches a preset value.
Refer to the figure below. The counter features 24 presets, which you can program.
A preset is a number you derive and store so that the counter will constantly compare
the current count with the preset. When the two are equal, a special relay contact is
energized and program execution jumps to the interrupt routine. We recommend
using the special relay(s) in the interrupt service routine to cause any immediate
action you desire. After the interrupt service routine is complete, the CPU returns to
the ladder program, resuming program execution from the point of interruption. The
compare function is ready for the next preset event.
CPU Scan
Counter

Input
Update

Current
Value

X0, counter clock

X2, external reset

Reset

Vmemory Preset Data

V2320
V2322
V2324
V2326

0000
0000
0000
0000

1000
2000
2500
3175

V2376

0921

0000

Does
Count =
Preset?

Ladder
Program
Execution
Current
instruction
Output
Update

INT
HSIO
Interrupt
Routine
Program
SPxxx
IRT

39
High-Speed Input and Pulse Output Features

Preset Data
Starting Location

Using Fewer than

24 Presets

Preset Table Pointer

V7630 is a pointer location which points to

the beginning of the Preset Data Table.
The default starting location for the Preset
Data Table is V2320 (default after
initializing
scratchpad
V-memory).
However, you may change this by
programming a different value in V7630.
Use the LDA and OUT instructions as
shown:

V7630

2000
Preset Data

LDA
O2000

Load the octal address,

convert to hex, leave
result in accumulator.

OUT
V7630

Output this address to

V7630, the location of the
pointer to the Preset data.

V2000
V2002
V2004
V2006

0000
0000
0000
0000

1000
2000
2500
3175

V2076

0000

0000

Preset Data
V2320
V2322
V2324
V2326
V2330

0000
0000
0000
0000
0000

1000
2000
2500
3175
FFFF

NOTE: Each successive preset must be greater than the previous preset value. If a
preset value is less than a lower-numbered preset value, the CPU cannot compare
for that value, since the counter can only count upwards.
Equal Relay
Numbers

The following table lists all 24 preset register default locations. Each occupies two
16-bit V-memory registers. The corresponding special relay contact number is in the
next column. We might also call these equal relay contacts, because they are true
(closed) when the present high-speed counter value is equal to the preset value.
Each contact remains closed until the counter value equals the next preset value.
Preset

Preset
V-memory Register

Special
Relay
Number

Preset

Preset
V-memory Register

Special
Relay
Number

V2321 / V2320

SP540

13

V2351 / V2350

SP554

V2323 / V2322

SP541

14

V2353 / V2352

SP555

V2325 / V2324

SP542

15

V2355 / V2354

SP556

V2327 / V2326

SP543

16

V2357 / V2356

SP557

V2331 / V2330

SP544

17

V2361 / V2360

SP560

V2333 / V2332

SP545

18

V2363 / V2362

SP561

V2335 / V2334

SP546

19

V2365 / V2364

SP562

V2337 / V2336

SP547

20

V2367 / V2366

SP563

V2341 / V2340

SP550

21

V2371 / V2370

SP564

10

V2343 / V2342

SP551

22

V2373 / V2372

SP565

11

V2345 / V2344

SP552

23

V2375 / V2374

SP566

12

V2347 / V2346

SP553

24

V2377 / V2376

SP567

High-Speed Input and

Pulse Output Features

When using fewer than 24 preset

registers, the HSIO looks for 0000 FFFF
(use LDD Kffff) in the next preset location
to indicate the last preset has been
reached. The example to the right uses
four presets. The 0000 FFFF in
V2331-V2330 indicates the previous
preset was the last.

310
High-speed Input and Pulse Output Features

Calculating Your
Preset Values

The preset values occupy two data words each. They can range in value from 0000
0000 to 9999 9999, just like the high-speed counter value. All 24 values are absolute
values, meaning that each one is an offset from the counter zero value.
The preset values must be individually derived for each application. In the industrial
lathe diagram below, the PLC monitors the position of the lead screw by counting
pulses. At points A, B, and C along the linear travel, the cutter head pushes into the
work material and cuts a groove.
PLC

Industrial Lathe
A

Counter
Device

X0, counter clock

Motor

Start

High-Speed Input and

Pulse Output Features

The timing diagram below shows the duration of each equal relay contact closure.
Each contact remains on until the next one closes. All go off when the counter resets.
Equal Relays

SP540
SP541
SP542

NOTE: Each successive preset must be two numbers greater than the previous
preset value. In the industrial lathe example, B>A+1 and C>B+1.
X Input
Configuration

The configurable discrete input options for High-Speed Counter Mode are listed in
the table below. Input X0 is dedicated for the counter clock input. Input X1 can be a
normal or filtered input. The section on Mode 60 operation at the end of this chapter
describes programming the filter time constants. Input X2 can be configured as the
counter reset, with or without the interrupt option. The interrupt option allows the
reset input (X2) to cause an interrupt like presets do, but there is no SP relay contact
closure (instead, X2 will be on during the interrupt routine, for 1 scan). Or finally, X2
may be left simply as a filtered input.

311
High-Speed Input and Pulse Output Features

Input

Configuration
Register

Function

Hex Code
Required

X0

V7634

Counter Clock

0001

X1

V7635

Filtered Input

xx06, xx = filter time

0 - 99 ms (BCD)

X2

V7636

Counter Reset (no interrupt)

0007* (default)
0207*

Counter Reset (with interrupt)

0107*
0307*

FIltered Input

xx06, xx = filter time

0 - 99 ms (BCD)

*With the counter reset, you have the option of a normal reset or a faster reset.
However, the fast reset does not recognize changed preset values during program
execution. When 0007 or 0107 are set in V7636 and preset values are changed
during program execution, the DL05 recognizes the changed preset values at the
time of the reset. When 0207 or 0307 are set in V7636 the CPU does not check for
changed preset values, so the DL05 has a faster reset time.
You may recall that the counter instruction is a standard instruction in the DL05
instruction set. Refer to the figure below. The mnemonic for the counter is UDC
(up-down counter).The DL05 can have up to 128 counters, labeled CT0 through
CT177. The high speed counter in the HSIO circuit is accessed in ladder logic by
using UDC CT76. It uses counter registers CT76 and CT77 exclusively when the
HSIO mode 10 is active (otherwise, CT76 and CT77 are available for standard
counter use). The HSIO counter needs two registers because it is a double-word
counter. It has three inputs as shown. The first input (Enable) allows counting when
active. The middle input is a dummy and has no fuction other than it is required by the
built-in compiler. The bottom signal is the reset. The Dummy Input must be off while
the counter is counting.
Standard Counter Function
UP Count

UDC

CTxx

DOWN Count
Reset Input

HSIO Counter Function

Enable Input

UDC

CT76

Dummy Input
Kxxxxxxxx

D Counts UP and DOWN

D Preload counter by write to value
D Reset input is internal only

Reset Input

Kxxxxxxxx

D Counts UP only
D Can use Dummy Input to change count
D Reset may be internal or external

High-Speed Input and

Pulse Output Features

Writing Your
Control Program

312
High-speed Input and Pulse Output Features

The next figure shows how the HSIO counter will appear in a ladder program. Note
that the Enable Interrupt (ENI) command must execute before the counter value
reaches the first preset value. We do this at powerup by using the first scan relay.
When using the counter but not the presets and interrupt, we can omit the ENI.
DirectSOFT

SP1
ENI

Required

XX
Enable Input
XX

High-Speed Input and

Pulse Output Features

XX

Dummy Input
Reset Input

UDC

CT76

Kxxxxxxxx
Preset Range:
1-99999999

When the enable input is energized, the high-speed counter will respond to pulses
on X0 and increment the counter at CT76 CT77. The reset input contact behaves in
a logical OR fashion with the physical reset input X2 (when selected). So,the high
speed counter can receive a reset form either the contact(s) on the reset rung in the
ladder, OR the external reset X2 if you have configured X2 as an external reset.
Program Example: The following example is the simplest way to use the high-speed counter, which
does not use the presets and special relays in the interrupt routine. The program
Counter Without
configures the HSIO circuit for Mode 10 operation, so X0 is automatically the counter
Preset
clock input. It uses the Compare-double (CMPD) instruction to cause action at
certain count values. Note that this allows you to have more than 24 presets.Then it
configures X2 to be the external reset of the counter.

313
High-Speed Input and Pulse Output Features

Program
Example Contd

DirectSOFT

First Scan Only

SP0

Load constant K10 into the accumulator. This

selects Mode 10 as the HSIO mode.

LD
K10

Mode 10

OUT
V7633

Load the constant required to configure X0 as

the counter clock.

LD
K1
OUT
V7634

Configure
Inputs

Output the constant K10 to V7633, the

location of HSIO Mode select register.

LD
K1006
OUT
V7635

Output the constant K1 to V7634, the location of

the setup parameter for X0.
Load the constant required to configure input
as filtered inputs.
Output the constant K1006 to V7635, the location
of setup parameter for X1.
Load the constant required to configure X2 as
an external reset without interrupt.

LD
K7

Output the constant K7 to V7636, the location of

the setup parameter for X2.

SP1
UDC

CT76

SP1
Kxxxxxxxx

CT76 is the HSIO counter. The first rungs SP1

always enables the counter. The dummy input in
the middle is always off. The third rungs Reset
input is always off, because we will use the
external reset.

SP1
SP1

LDD
V1076
CMPD
K309482

SP62

Y0
OUT

END

Load the current count of the HSIO counter in

V1076 and V1077 into the accumulator
Use the Compare-double instruction to compare
the double word in the accumulator to the constant
K309482
The execution of the above CMPD instruction turns
on special relay contact SP62 if the current count
is greater than the comparison number (K309482).
END coil marks the end of the main program.

The compare double instruction above uses the current count of the HSIO counter to
turn on Y0. This technique can make more than 24 comparisons, but it is scan-time
dependent. However, use the 24 built-in presets with the interrupt routine if your
application needs a very fast response time, as shown in the next example.

High-Speed Input and

Pulse Output Features

OUT
V7636

314
High-speed Input and Pulse Output Features

Counter With
Presets
Program Example

Preset Data

The following example shows how to program the HSIO circuit to trigger on three
preset values. You may recall the industrial lathe example from the beginning of this
chapter. This example program shows how to control the lathe cutter head to make
three grooves in the work-piece at precise positions. When the lead screw turns, the
counter device generates pulses which the DL05 can count. The three preset
variables A, B, and C represent the positions (number of pulses) corresponding to
each of the three grooves.

A V2320 0000
B V2322 0000
C V2324 0000
V2326

I/O
Assignments

0000

1500
3780
4850
FFFF

X3 - Cutter head extended

X4 - Cutter head retracted
Y0 - Lead screw motor
Y1 - Cutter head solenoid

Industrial Lathe
A

Counter
Device

Start

Cutter head

Lead screw

DirectSOFT
SP0

High-Speed Input and

Pulse Output Features

ENI
SP0

LD
K10
OUT
V7633
LD
K1
OUT
V7634

Select Mode 10

SP0

Load Presets

LD
K107

Enable Interrupts before reaching a preset

generates an interrupt. Special Relay SP0 is on
during the first CPU scan.
Load constant K10 into the accumulator. This
selects Mode 10 as the HSIO mode.
Output this address to V7633, the location of
HSIO Mode select register.
Load the constant required to configure X0 as
the counter clock.
Output the constant K1 to V7634, the location of
the setup parameter for X0.
Load the constant required to configure X2 as
an external reset with interrupt.

OUT
V7636

Output the constant to V7636, the location of the

setup parameter for X2.

LDA
O2320

Load the octal address O2320 into the

accumulator. This instruction automatically
converts the address into hex.

OUT
V7630

Output this address to V7630, the location of

the pointer to the Preset Table.

LDD
K1500
OUTD
V2320
LDD
K3780
OUTD
V2322

Load the preset A value into the accumulator.

Output the accumulator contents to the memory

location for preset 1.
Load the preset B value into the accumulator.

Output the accumulator contents to the memory

location for preset 2.

315
High-Speed Input and Pulse Output Features

Load the preset C value into the accumulator.

LDD
K4850

Output the accumulator contents to the memory

location for preset 3.

OUTD
V2324

Load the constant Kffff into the accumulator. This

value represents the end of the preset list.

LDD
Kffff

Output the accumulator contents to the memory

location for preset 4 (end of preset marker).

OUTD
V2326
SP1
UDC

CT76

SP1
Kxxxxxxxx

CT76 is the HSIO counter. The first rungs SP1

always enables the counter. The dummy input in
the middle is off (unused in this example).

SP1
The third rungs Reset input is normally off,
because we will use the external reset. You can
optionally reset the counter value on each powerup
using the SP0 contact.

SP0

Y1
RST

X4

Y0
SET

END
INT

Turn lead screw on again, after cutter head has

retracted.
END coil marks the end of the main program.
The INT label marks the beginning of the interrupt
service routine program.

O0
SP540

Input X3 energizes when the groove has finished

cutting. So, we retract the cutter head.

Preset 1

Y0
RSTI

Inside the interrupt service routine, we turn OFF the

lead screw motor immediately.

Y1
SETI

These special equal relays turn on individually as

the corresponding preset is reached. In this
application, each results in the cutting of a groove
(Y1), so they are logically ORed together.

SP541

Preset 2
SP542

Preset 3
X2

C10
SETI
IRT

Input X2 will be energized inside the interrupt

routine if X2 external interrupt was the source.
Return from the interrupt service routine.

Some applications will require a different type of action at each preset. It is possible
for the interrupt routine to distinguish one preset event from another, by turning on a
unique output for each equal relay contact SPxxx. We can determine the source of
the interrupt by examining the equal relay contacts individually, as well as X2. The X2
contact will be on (inside the interrupt routine only) if the interrupt was caused by the
external reset, X2 input.

High-Speed Input and

Pulse Output Features

X3

316
High-speed Input and Pulse Output Features

Counter With
Preload
Program Example

The following example shows how you can preload the current count with another
value. When the preload command input (X4 in this example) is energized, we
disable the counter from counting with C0. Then we write the value K3000 to the
count register (V1076-V1077). We preload the current count of the counter with
K3000. When the preload command (X4) is turned off, the counter resumes counting
any pulses, but now starting from K3000.
DirectSOFT
SP0

Load constant K10 into the accumulator. This

selects Mode 10 as the HSIO mode.

LD
K10

Select Mode 10

Output this address to V7633, the location of

HSIO Mode select register.

OUT
V7633

Load the constant required to configure X0 as

the counter clock.

LD
K1

Output the constant K1 to V7634, the location of

the setup parameter for X0.

OUT
V7634

Load the constant required to configure X2 as

an external reset with interrupt.

High-Speed Input and

Pulse Output Features

LD
K107

Output the constant to V7636, the location of the

setup parameter for X2.

OUT
V7636
C0
SET

C0
UDC

CT76

C1
K99999999

Set C0 on at powerup to enable counting.

CT76 is the HSIO counter. The first rungs C0
contact enables the counter. The dummy input is in
the middle.

C2
The third rungs Reset input is normally off,
because we will use the external reset. You can
optionally reset the counter value on each powerup
using the SP0 contact.

SP0
X4

C0
RST

Load the BCD value K3000 into the

accumulator.

LDD
K3000

Output the constant to V1076/V1077, the location

of the accumulated count for CT76.

OUTD
V1076

C0

C1

When the preload request is made, the user turns

on X4. First we disable counting by resetting C0,
the counters enable input.

C1
PD

Generate a preload counter input pulse, which

causes the counter to preload from V1076-V1077.

C0
SET

Enable the counter by setting C0, when the

preolad pulse on C1 has occurred (C1 is off).

END

END coil marks the end of the main program.

317
High-Speed Input and Pulse Output Features

Troubleshooting
Guide for Mode 10

If youre having trouble with Mode 10 operation, please study the following
symptoms and possible causes. The most common problems are listed below.

Symptom: The counter does not count.

Possible causes:
1. Field sensor and wiring Verify that the encoder, proximity switch,or
counter actually turns on and illuminates the status LED for X0. The
problem could be due to sinking-sourcing wiring problem, etc. Remember
to check the signal ground connection. Also verify that the pulse on-time is
long enough for the PLC to recognize it.
2. Configuration use the Data View window to check the configuration
parameters. V7633 must be set to 10, and V7634 must be set to 1 to enable
the HSIO counter mode.
3. Stuck in reset check the input status of the reset input, X2. If X2 is on, the
counter will not count because it is being held in reset.
4. Ladder program make sure you are using counter CT76 in your
program. The top input is the enable signal for the counter. It must be on
before the counter will count. The middle input is the dummy input. The
bottom input is the counter reset, and must be off during counting.

Symptom: The counter counts up but will not reset.

Possible causes:
1. Check the LED status indicator for X2 to make sure it is active when you
want a reset. Or, if you are using an internal reset, use the status mode of
DirectSOFT to monitor the reset input to the counter.

High-Speed Input and

Pulse Output Features

Symptom: The counter counts but the presets do not function.

Possible causes:
1. Configuration Ensure the preset values are correct. The presets are
32-bit BCD values having a range of 0 to 99999999. Make sure you write all
32 bits to the reserved locations by using the LDD and OUTD instructions.
Use only evennumbered addresses, from V2320 to V2376. If using less
than 24 presets, be sure to place 0000FFFF in the location after the last
preset used.
2. Interrupt routine Only use Interrupt #0. Make sure the interrupt has been
enabled by executing an ENI instruction prior to needing the interrupt. The
interrupt routine must be placed after the main program, using the INT label
and ending with an interrupt return IRT.
3. Special relays Check the special relay numbers in your program. Use
SP540 for Preset 1, SP541 for Preset 2, etc. Remember that only one
special equal relay contact is on at a time. When the counter value reaches
the next preset, the SP contact which is on now goes off and the next one
turns on.

318
High-speed Input and Pulse Output Features

Mode 20: Quadrature Counter

Purpose

Functional Block
Diagram

The counter in the HSIO circuit can count two quadrature signal pulses instead of a
single pulse train (mode 10 operation). Quadrature signals are commonly generated
from incremental encoders, which may be rotary or linear. The quadrature counter
has two ranges from 0 to 99999999 or -8388608 to 8388607. Using CT76 and CT77,
the quadrature counter can count at up to a 5 kHz rate. Unlike Mode 10 operation,
Mode 20 operation can count UP or DOWN, but does not feature automated preset
values or interrupt on external reset capability. However, you have the standard
ladder instruction preset of CT76.
The diagram below shows HSIO functionality in Mode 20. When the lower byte of
HSIO Mode register V7633 contains a BCD 20, the quadrature counter in the HSIO
circuit is enabled. Input X0 is dedicated to the Phase A quadrature signal, and input
X1 receives Phase B signal. X2 is dedicated to reset the counter to zero value when
energized.

DL05
PLC

Output Circuit

High-Speed Input and

Pulse Output Features

Y0, Y1

HSIO

I/O data

COUNTER
Phase
A

Mode Select

Phase
Reset
B

X0

X1

Y2 - Y5

X2

CPU
Vmemory
V7633

0020

X3- X7

Input Circuit

Quadrature
Encoder Signals

Quadrature encoder signals contain position and direction information, while their
frequency represents speed of motion. Phase A and B signals shown below are
phase-shifted 90 degrees, thus the quadrature name. When the rising edge of
Phase A precedes Phase Bs leading edge (indicates clockwise motion by
convention), the HSIO counter counts UP. If Phase Bs rising edge precedes Phase
As rising edge (indicates counter-clockwise motion), the counter counts DOWN.
Leading Edge Signal

90 phase shift

Clockwise sequence
Phase A
Phase B

Counterclockwise sequence
Phase A
Phase B
Leading Edge Signal

one cycle

319
High-Speed Input and Pulse Output Features

Wiring Diagram

A general wiring diagram for encoders to the DL05 in HSIO Mode 20 is shown below.
Encoders with sinking outputs (NPN open collector) are probably the best choice for
interfacing. If the encoder sources to the inputs, it must output 12 to 24 VDC. Note
that encoders with 5V sourcing outputs will not work with DL05 inputs.

Signal Common
Phase B
+

Phase A

12 24 VDC

Encoder Input Wiring

Encoder

The DL05s DC inputs are flexible in that they detect current flow in either direction,
so they can be wired to an encoder with either sourcing or sinking outputs. In the
following circuit, an encoder has open-collector NPN transistor outputs. It sinks
current from the PLC input point, which sources current. The power supply can be
the +24VDC auxiliary supply or another supply (+12VDC or +24VDC), as long as the
input specifications are met.
Encoder Output,
(one phase)

Phase A or B Input
Input
(sourcing)

Output
(sinking)
1224 VDC Supply
Ground

Common

In the next circuit, an encoder has open-emitter PNP transistor outputs. It sources
current to the PLC input point, which sinks the current back to ground. Since the
encoder sources current, no additional power supply is required. However, note that
the encoder output must be 12 to 24 volts (5V encoder outputs will not work).
Encoder Output,
(one phase)
Phase A or B Input

+12 to 24VDC

Input
Output (sourcing)
Ground

(sinking)
Common

High-Speed Input and

Pulse Output Features

Interfacing to
Encoder Outputs

320
High-speed Input and Pulse Output Features

Setup for Mode 20

Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use
BCD 20 in the lower byte of V7633 to select the High-Speed Counter Mode. The
DL05 does not use bits 8 - 15 in V7633.
Memory Location V7633
Bits

15

14

13

12 11

10

Bits 8 - 15 are not used

in V7633.

HSIO Mode Setup (BCD)

High-Speed Input and

Pulse Output Features

20 = Quadrature Counter

Choose the most convenient method of programming V7633 from the following:
S Include load and out instructions in your ladder program
S DirectSOFTs memory editor
S Use the Handheld Programmer D2HPP
We recommend using the first method above so that the HSIO setup becomes an
integral part of your application program. An example program later in this section
shows how to do this.
X Input
Configuration

The configurable discrete input options for High-Speed Counter Mode are listed in
the table below. Input X0 is dedicated for Phase A, and input X1 is for Phase B. Input
X2 is the reset input to the quadrature counter, but it does not cause an interrupt. The
section on Mode 60 operation at the end of this chapter describes programming the
filter time constants.
Input

Configuration
Register

X0

V7634

Function
Phase A

Hex Code
Required
0002 (default)
quadrature, absolute
0 to 99999999
0012
quadrature, absolute
-8388608 to 8388607

X1

V7635

Phase B

0000

X2

V7636

Counter Reset (no interrupt)

0007

Discrete filtered input

1006

321
High-Speed Input and Pulse Output Features

Writing Your
Control Program

You may recall that the Up-Down counter instruction is standard in the DL05
instruction set. Refer to the figure below. The mnemonic for the counter is UDC
(up-down counter).The DL05 can have up to 128 counters, labeled CT0 through
CT177. The quadrature counter in the HSIO circuit is accessed in ladder logic by
using UDC CT76. It uses counter registers CT76 and CT77 exclusively when the
HSIO mode 20 is active (otherwise, CT76 and CT77 are available for standard
counter use). The HSIO counter needs two registers because it is a double-word
counter. It also has three inputs as shown, but they are redefined. The first input is
the enable signal, the middle is a preload (write), and the bottom is the reset. The
enable input must be on before the counter will count. The enable input must be off
during a preload.
Standard Counter Function
UP Count

UDC

HSIO Counter Function

Enable Input

CTxx

DOWN Count
Reset Input

UDC

CT76

Dummy Input
Kxxxxxxxx

Kxxxxxxxx

D Counts UP and DOWN (from X0, X1)

D Can use Dummy Input to change count
D Reset may be internal or external

The next figure shows the how the HSIO quadrature counter will appear in a ladder
program.

Enable Input

UDC

CT76

Dummy Input
Reset Input

Kxxxxxxxx
Preset Range:
1-99999999

When the enable input is energized, the counter will respond to quadrature pulses
on X0 and X1, incrementing or decrementing the counter at CT76 CT77. The reset
input contact behaves in a logical OR fashion with the physical reset input X2. This
means the quadrature counter can receive a reset from either the contact(s) on the
reset rung in the ladder, OR the external reset X2.
Since presets are not available in quadrature counting, this mode is best suited for
Quadrature
Counter w/Preload simple counting and measuring. The example program on the following page shows
Program Example how to configure the quadrature counter. The program configures the HSIO circuit
for Mode 20 operation, so X0 is Phase A and X1 is Phase B clock inputs.

High-Speed Input and

Pulse Output Features

D Counts UP and DOWN

D Preload counter by write to value
D Reset input is internal only

Reset Input

322
High-speed Input and Pulse Output Features

Program
Example Contd

DirectSOFT
SP0

Select Mode 20

High-Speed Input and

Pulse Output Features

Load constant K20 into the accumulator. This selects

Mode 20 as the HSIO mode.

LD
K20
OUT
V7633

Output this address to V7633, the location of the HSIO

Mode select register.

LD
K2

Load the constant required to configure X0 as Phase A

input.

OUT
V7634

Output the constant to V7634, the location of the setup

register for X0.

LD
K0

Load the constant required to configure X1 as Phase B

input.

OUT
V7635

Output the constant to V7635, the location of the setup

register for X1.

LD
K7

Load the constant required to configure X2 as an external

reset.

OUT
V7636

Output the constant to V7636, the location of the setup

register for X2.

C0
SET

Set C0 on at powerup to enable counting.

C0
UDC

CT76 is the HSIO quadrature counter. The first rungs SP1

always enables the counter. The dummy input is used by
the built-in compiler.

CT76

C1
Kxxxxxxxx
C2

The third rungs Reset input is normally off,

because we will use the external reset. You can
optionally reset the counter value on each powerup
using the SP0 contact.

SP0

SP1

Select Mode 20
SP61

Load the current value of the counter into the accumulator

on each scan.

LDD
V1076

Compare the value in the accumulator with the constant

K44292. If they are equal, the SP61 contact will be
turned on.

CMPD
K44292
Y0
SET

Set Y0 to ON when the counter reaches or exceeds

our comparison value while COUNTING UP.

Y1
SET

Set Y1 to ON when the counter reaches or goes below

our comparison value while COUNTING DOWN.

SP62

SP61
SP60

END

END coil marks the end of the main program..

* Note: You can reset Y0 later in the program by using the RST insturuction.

To preload the counter, just add the following example rungs to the program above.

323
High-Speed Input and Pulse Output Features

Counter Preload
Program Example

X4

C0
RST

Preload counter

Load the BCD value K3000 into the

accumulator.

LDD
K3000

Output the constant to V1076/V1077, the location

of the accumulated pulse count.

OUTD
V1076

C0

Troubleshooting
Guide for Mode 20

C1

When the preload request is made, the user turns

on X4. First we disable counting by resetting C0,
the counters enable input.

C1
PD

Generate a preload counter input pulse, which

causes the counter to preload from V1076-V1077.

C0
SET

Enable the counter by setting C0, when the

preload pulse on C1 has occurred (C1 is off).

If youre having trouble with Mode 20 operation, please study the following
symptoms and possible causes. The most common problems are listed below.

High-Speed Input and

Pulse Output Features

Symptom: The counter does not count.

Possible causes:
1. Field sensor and wiring Verify that the encoder or other field device
inputs actually turn on and illuminates the status LEDs for X0 and X1. A
standard incremental encoder will visibly, alternately turn on the LEDs for
X0 and X1 when rotating slowly (1 RPM). Or, the problem could be due to a
sinking-sourcing wiring problem, etc. Remember to check the signal
ground connection. Also verify that the pulse on-time, duty cycle, voltage
level, and frequency are within the input specifications.
2. Configuration make sure all of the configuration parameters are correct.
V7633 must be set to 20, and V7634 must be set to 0002 to enable the
Phase A input, and V7635 must be set to 0000 to enable the Phase B
input.
3. Stuck in reset check the input status of the reset input, X2. If X2 is on, the
counter will not count because it is being held in reset.
4. Ladder program make sure you are using counter CT76 in your
program. The top input is the enable signal for the counter. It must be on
before the counter will count. The middle input is the dummy input and must
be off for the counter to count. The bottom input is the counter reset, and
must be off during counting.
Symptom: The counter counts in the wrong direction (up instead of down, and visa-versa).
Possible causes:
1. Channel A and B assignment Its possible that Channel A and B
assignments of the encoder wires is backwards from the desired
rotation/counting orientation. Just swap the X0 and X1 inputs, and the
counting direction will be reversed.
Symptom: The counter counts up and down but will not reset.
Possible causes:
1. Check the LED status indicator for X2 to make sure it is active when you
want a reset. Also verify the configuration register V7636 for X2 is set to 7.
Or, if you are using an internal reset, use the status mode of DirectSOFT to
monitor the reset input to the counter.

324
High-speed Input and Pulse Output Features

Mode 30: Pulse Output

Purpose

The HSIO circuit in Mode 30 generates

output pulse trains suitable for open-loop
control of a single-axis motion positioning
system. It generates pulse (stepper
increment) and direction signals which
you can connect to motor drive systems
and perform various types of motion
control. Using Mode 30 Pulse Output, you
can select from three profile types detailed
later in this chapter:

Velocity

Trapezoidal Profile

Accel

Decel

Time

High-Speed Input and

Pulse Output Features

S
S

Trapezoidal Accel Slope to Target Velocity to Decel Slope

Registration Velocity to Position Control on Interrupt (also used for
home search moves)
S Velocity Control Speed and Direction only
The HSIO circuit becomes a high-speed pulse generator (up to 7 kHz) in Mode 30.
By programming acceleration and deceleration values, position and velocity target
values, the HSIO function automatically calculates the entire motion profile. The
figure below shows the DL05 generating pulse and direction signals to the drive
amplifier of a stepper positioning system. The pulses accomplish the profile
independently and without interruption to ladder program execution in the CPU.
Stepper
Motor

Drive
Amplifier
DL05 Micro PLC

Pulse

Direction

In the figure above, the DL05 generates

pulse and direction signals. Each pulse
represents the smallest increment of
motion to the positioning system (such as
one step or micro-step to a stepper
system). Alternatively, the HSIO Pulse
Output Mode may be configured to deliver
counter clock-wise (CCW) and clock-wise
(CW) pulse signals as shown to the right.

CCW Pulse

CW Pulse

Drive
Amplifier

NOTE: The pulse output is designed for open loop stepper motor systems. This, plus
its minimum velocity of 40 pps make it unsuitable for servo motor control.

325
High-Speed Input and Pulse Output Features

Functional Block
Diagram

The diagram below shows HSIO functionality in Mode 30. When the lower byte of
HSIO Mode register V7633 contains a BCD 30, the pulse output capability in the
HSIO circuit is enabled. The pulse outputs use Y0 and Y1 terminals on the output
connector. Remember that the outputs can only be DC type to operate.

Output Circuit

DL05
PLC

Y0
(Pulse / CW)

Y1
(Direction / CCW)

Y2 - Y5

HSIO
SP 104 Profile Complete
Y0 Start Profile

PULSE GEN.

CPU

Y1 Preload Position Value

Interrupt

X1 Filtered Input
Mode Select

X0, X1, X2

Vmemory
V7633

xx30

X3- X7

Input Circuit

IMPORTANT NOTE: In Pulse Output Mode, Y0 and Y1 references are redefined or

are used differently in two ways. Physical references refer to terminal screws, while
logical references refer to I/O references in the ladder program. Please read the
items below to understand this very crucial point.
Notice the I/O point assignment and usage in the above diagram:
S X0 and X1 can only be filtered inputs in Pulse Output Mode, and they
are available as an input contacts to the ladder program.
S X2 behaves as an external interrupt to the pulse generator for
registration profiles. In other profile modes, it can be used as a filtered
input just like X1 (registration mode configuration shown above).
S References Y0 and Y1 are used in two different ways. At the discrete
output connector, Y0 and Y1 terminals deliver the pulses to the motion
system. The ladder program uses logical references Y0 and Y1 to
initiate Start Profile and Load Position Value HSIO functions in Mode
30.
Hopefully, the above discussion will explain why some I/O reference names have
dual meanings in Pulse Output Mode. Please read the remainder of this section
with care, to avoid confusion about which actual I/O function is being discussed.

High-Speed Input and

Pulse Output Features

X2 during
Registration
Profile only

FILTER

326
High-speed Input and Pulse Output Features

Wiring Diagram

The generalized wiring diagram below shows pulse outputs Y0 and Y1 connected to
the drive amplifier inputs of a motion control system.

+
Signal Common
Motor

Amplifier

+24 VDC

Pulse
Direction

Pulse Output Wiring

High-Speed Input and

Pulse Output Features

Power Input

Interfacing to
Drive Inputs

The pulse signals from Y0 and Y1 outputs will typically go to drive input circuits as
shown above. Remember that the DL05s DC outputs are sinking-only. It will be
helpful to locate equivalent circuit schematics of the drive amplifier. The following
diagram shows how to interface to a sourcing drive input circuit.
Y0, Y1 Pulse Output
Power
+DC pwr

Drive Input
+V

Output
(sinking)

Input
(sourcing)

Common

Ground

The following circuit shows how to interface to a sinking drive input using a pullup
resistor. Please refer to Chapter 2 to learn how to calculate and install Rpullup.
Y0, Y1 Pulse Output
+DC pwr

Power

R pullup

Drive Input

(sourcing)
(sinking)

Output

Common

Supply

Input
(sinking)

Ground

R input

327
High-Speed Input and Pulse Output Features

Motion Profile
Specifications

The motion control profiles generated in Pulse Output Mode have the following
specifications:
Parameter

Specification

Profiles

Trapezoidal Accel Slope / Target Velocity / Decel Slope

Registration Velocity to Position Control on Interrupt
Velocity Control Speed and Direction only

Physical I/O
Configuration

88388608 to 88388607

Positioning

Absolute / relative command

Velocity Range

40 Hz to 7 kHz

V-memory registers

V2320 to V2325 (Profile Parameter Table)

Current Position

CT76 and CT77 (V1076 and V1077)

The configurable discrete I/O options for Pulse Output Mode are listed in the table
below. The CPU uses SP 104 contact to sense profile complete. V7637 is used to
select pulse/direction or CCW/CW modes for the pulse outputs. Input X2 is
dedicated as the external interrupt for use in registration mode.
Physical
Input

Configuration
Register

V7637

Function

Hex Code
Required

Y0 = Pulse
Y1 = Direction

0103

Y0 = CW Pulse
Y1 = CCW Pulse

0003
xx06, xx = filter time
0 - 99 ms (BCD)

X0

V7634

Discrete filtered input

X1

V7635

Discrete filtered input

X2

V7636

Discrete filtered input

The following logical I/O references define functions that allow the HSIO to
communicate with the ladder program.
Logical
I/O

Function

SP 104

Profile Complete the HSIO turns on SP104 to the CPU when the
profile completes. Goes back off when Start Profile (Y0) turns on.

Y0

Start Profile the ladder program turns on Y0 to start motion. If

turned off before the move completes, motion stops. Turning it on
again will start another profile, unless the current position equals
the target position.

Y1

Preload Position Value if motion is stopped and Start Profile is off,

you can load a new value in CT76/CT77, and turn on Y1. At that
transition, the value in CT76/CT77 becomes the current position.

High-Speed Input and

Pulse Output Features

Logical I/O
Functions

Position Range

328
High-speed Input and Pulse Output Features

Setup for Mode 30

Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use
BCD 30 in the lower byte of V7633 to select the High-Speed Counter Mode. The
DL05 does not use bits 8 - 15 in V7633.
Memory Location V7633
Bits

15

14

13

12 11

10

Bits 8 - 15 are not used

in V7633.

HSIO Mode Setup (BCD)

High-Speed Input and

Pulse Output Features

30 = Pulse Output

Choose the most convenient method of programming V7633 from the following:
S Include load and out instructions in your ladder program
S DirectSOFTs memory editor
S Use the Handheld Programmer D2HPP
We recommend using the first method above so that the HSIO setup becomes an
integral part of your application program. An example program later in this section
shows how to do this.
Profile / Velocity
Select Register

The first location in the Profile Parameter Table stores two key pieces of information.
The upper four bits (1215) select the type of profile required. The lower 12 bits
(011) select the Target Velocity.
Memory Location V2320 (default)
Bits

15

14

13

12 11

10

Profile Select (BCD)

Target Velocity Value

0 = Trapezoidal Profile, Absolute Position

8 = Trapezoidal Profile, Relative Position
9 = Registration Profile, Relative Position
2 = Velocity Profile

Range = 4 to 700, representing

40 Hz to 7 kHz pulse rate

The ladder program must program this location before initiating any of the three
profiles. The LD and OUT instruction will write all 16 bits, so be sure to fully specify
the full four-digit BCD value for the Position / Velocity Select Register each time.
The absolute and relative selection determines how the HSIO circuit will interpret
your specified target position. Absolute position targets are referenced to zero.
Relative position targets are referenced to the current position (previous target
position). You may choose whichever reference method that is most convenient for
your application.

329
High-Speed Input and Pulse Output Features

Profile
Parameter Table

Trapezoidal Profile

V7630 is a pointer location which points to

the beginning of the Profile Parameter
Table. The default starting location for the
profile parameter table is V2320.
However, you may change this by
programming a different value in V7630.
Remember to use the LDA (load address)
instruction, converting octal into hex.
The HSIO uses the next V-memory
register past the bottom of the profile
parameter table to indicate profile errors.
See the error table at the end of this
section for error code definitions.
V-Memory
V2320, bits 1215

V2320
V2321
V2323
V2324
V2325

2320

Profile Parameter Table

xxxx
xxxx
xxxx
xxxx
xxxx
xxxx

Pulse Output Error Code

V2326

00xx

Range

Units

0=absolute,
8=relative

V2320, bits 011

Target Velocity Value

4 to 700

x 10 pps

V2321/ 2322

Target Position Value

8388608 to
8388607

Pulses

V2323

Starting Velocity

4 to 100

x 10 pps

V2324

Acceleration Time

1 to 100

x 100 mS

V2325

Deceleration Time

1 to 100

x 100 mS

V2326

Error Code

(see end of section)

Range

Units

9=relative

V-Memory
V2320, bits 1215

Velocity Profile

Trapezoidal Profile

V7630

Function
Registration Profile

V2320, bits 011

Target Velocity Value

4 to 700

x 10 pps

V2321/ 2322

Target Position Value

8388608 to
8388607

Pulses

V2323

Starting Velocity

4 to 100

x 10 pps

V2324

Acceleration Time

1 to 100

x 100 mS

V2325

Deceleration Time

1 to 100

x 100 mS

V2326

Error Code

(see end of section)

Range

Units

V-Memory

Function

V2320

Velocity Profile

2000 only

V2321/ 2322

Direction Select

80000000=CCW,
0=CW

Pulses

4 to 700

x 10 pps

(see end of section)

V2323

Velocity

V2326

Error Code

High-Speed Input and

Pulse Output Features

Registration Profile

Function

Profile Table Pointer

330
High-speed Input and Pulse Output Features

Choosing the
Profile Type

Pulse Output Mode generates three types of motion profiles. Most applications use
one type for most moves. However, each move can be different if required.
S Trapezoidal Accel Slope to Target Velocity to Decel Slope
S Registration Velocity to Position Control on Interrupt
S Velocity Control Speed and Direction only

Trapezoidal
Profile Defined

The trapezoidal profile is the most

Trapezoidal Profile
common positioning profile. It moves the Velocity
load to a pre-defined target position by
Fixed Velocity
creating a move profile. The acceleration
slope is applied at the starting position.
Accel
Decel
The deceleration slope is applied
backwards from the target position. The
remainder of the move in the middle is
Time
spent traveling at a defined velocity.
Start position Target position

High-Speed Input and

Pulse Output Features

Trapezoidal profiles are best for simple point-to-point moves, when the distance
between the starting and ending positions of the move is known in advance.
Registration and
Home Search
Profiles Defined

Registration profiles solve a class of

motion control problems. In some
applications, product material in work
Scrap
moves past a work tool such as a drill
Finished part area Area
station. Shown to the right, registration
marks on the scrap area of the work-piece
allow a machine tool to register its position
relative to the rectangle, to drill properly.
Home search moves allow open-loop
direction of motion
motion systems to re-calibrate (preload)
Registration marks
the current position value at powerup.
Registration profiles are a combination of
Registration Profile
velocity and position control modes. The
Velocity
Position
move begins by accelerating to a
Control
Control
programmed velocity. The velocity is Velocity
sustained and the move is of indefinite
duration. When an external interrupt
Accel
Decel
signal occurs (due to registration
sensing), the profile switches from velocity
to position control. The move ends by
continuing motion a pre-defined distance
past the interrupt point (such as a drill hole
Target position
location). The deceleration ramp is
applied in advance of the target position. Interrupt

Velocity Profile
Defined

The velocity profile controls only the

direction and speed of motion. There is no
target position specified, so the move can
be of indefinite length. Only the first
velocity value needs to be defined. The
remaining velocity values can be created
while motion is in progress. Arrows in the
profile shown indicate velocity changes.

Velocity

Velocity Profile

Time

331
High-Speed Input and Pulse Output Features

Trapezoidal Profile Operation

Trapezoidal Profile The trapezoidal profile is best suited for simple point-to-point moves, when the target
position is known in advance. Starting velocities must be within the range of 40 pps to
Applications
1k pps. The remainder of the profile parameters are in the profile parameter table.
Trapezoidal Profile
Velocity
Target Velocity
Accel

Decel

Starting
Velocity
Time
Start position
Y0

Profile
Complete

SP104

The time line of signal traces below the profile indicates the order of events.
The HSIO uses logical output Y0 as the Start input to the HSIO, which starts the
profile. Immediately the HSIO turns off the Profile Complete signal (SP104), so the
ladder program can monitor the progress of the move. Typically a ladder program
will monitor this bit so it knows when to initiate the next profile move.
If you are familiar with motion control, youll notice that we do not have to specify the
direction of the move. The HSIO function examines the target position relative to the
current position, and automatically outputs the correct direction information to the
motor drive.
Notice that the motion accelerates immediately to the starting velocity. This segment
is useful in stepper systems so we can jump past low speed areas when low-torque
problems or a resonant point in the motor might cause a stall. (When a stepper motor
stalls, we have lost the position of the load in open-loop positioning systems).
However, is is preferable not to make the starting velocity too large, because the
stepper motor will also slip some pulses due to the inertia of the system.
When you need to change the current position value, use logical Y1 output coil to
load a new value into the HSIO counter. If the ladder program loads a new value in
CT76/CT77 (V1076/V1077), then energizing Y1 will copy that value into the HSIO
circuit counter. This must occur before the profile begins, because the HSIO ignores
Y1 during motion.

High-Speed Input and

Pulse Output Features

Start

Target position

332
High-speed Input and Pulse Output Features

Trapezoidal Profile The trapezoidal profile we want to perform is drawn and labeled in the following
Program Example figure. It consists of a non-zero starting velocity, and moderate target velocity.
Trapezoidal Profile
Velocity
Target Velocity = 1 kHz
Accel = 2 sec

Decel = 4 sec

Starting
Velocity = 40
Time
Start position

Target position = 5000

The following program will realize the profile drawn above, when executed. The
beginning of the program contains all the necessary setup parameters for Pulse
Output Mode 30. We only have to do this once in the program, so we use first-scan
contact SP0 to trigger the setup.
High-Speed Input and
Pulse Output Features

DirectSOFT
SP0

LD
K30

Mode 30

OUT
V7633

Locate Parameter
Table (optional)

LDA
O2320
OUT
V7630

Select Pulse /
Direction

Filtered Inputs

Load constant K30 into the accumulator. This selects

Mode 30 as the HSIO mode.
Output the constant to V7633, the location of the HSIO
Mode select register.
Load the octal address of the beginning of the Profile
Parameter Table. The LDA instruction converts this to a
hex number in the accumulator.
Output this address to V7630, the location of the pointer
to the Profile Parameter Table.

LD
K103

Load the constant K103 which is required to select

pulse and direction for physical Y0 and Y1 functions,
respectively (use K3 if your application needs CCW
and CW).

OUT
V7637

Output this constant to V7637, configuring the pulse

output type.

LD
K1006

Load the constant K1006 which is required to select

filtered inputs with a 10 mS filter time constant.

OUT
V7635

Output this constant to V7635, configuring X1.

OUT
V7636

Output this constant to V7636, configuring X2.

333
High-Speed Input and Pulse Output Features

Program
Example Contd

SP0

Profile / Target
Velocity
Target Position

Load the constant K100 which is required to select

Trapzoidal Profile, absolute positioning, and a target
velocity of 1 kHz.

LD
K100

Output this constant to V2320, the location of the Profile

Select / Starting Velocity setup register.

OUT
V2320

Load the constant K5000 which selects a target

position of 5000 pulses. Dont forget to use double
word size (8-digit BCD position value).

LDD
K5000

Output this constant to V2321 and V2322, the location of

the Target Position double-word register.

OUTD
V2321

Starting Velocity

Load the constant K4 which is required to select a

starting velocity of 40 Hz (4 x 10 pps).

LD
K4

Output this constant to V2323, the location of the starting

velocity parameter register.

OUT
V2323

Acceleration

Load the constant K20 which is required to select an

acceleration time of 2 seconds (20 x 100 mS).

LD
K20

Deceleration

Start Profile
X3

Load the constant K40 which is required to select a

deceleration time of 4 seconds (40 x 100 mS).

LD
K40

Output this constant to V2325, the location of the

deceleration parameter register.

OUT
V2325
Y0
OUT

We use a spare filtered input to allow the operator

to start the profile. When the operator turns X3 ON,
then OFF, logical output Y0 starts the profile.

Profile Complete
SP 104

Preload
Position Value

Y2
OUT

SP104 is the logical output of the HSIO to indicate

the move is complete. We use Y2 to energize an
annunciator that the profile has finished.

At any time you can write (preload) a new position into the current position value.
This often done after a home search (see the registration example programs).
SP0

Profile / Target
Velocity

Load the constant K1000 as the new current position

value.

LDD
K1000

Output this constant to V1076/V1077 (CTA76/CTA77). the

location of the current position value.

OUTD
V1076
Y1
PD

Turn on Y1 for 1 scan. The off-to-on transition

causes the HSIO to preload the current position
with the value in

High-Speed Input and

Pulse Output Features

Output this constant to V2324, the location of the

acceleration parameter register.

OUT
V2324

334
High-speed Input and Pulse Output Features

Registration Profile Operation

Registration
Applications

1.

In a typical application shown to the

right, product material in work moves past
a work tool such as a drill. Registration
marks on the scrap area of the work-piece
allow a machine tool to register its position
relative to the rectangle, to drill properly.

High-Speed Input and

Pulse Output Features

2. In other examples of registration, the

work piece is stationary and the tool
moves. A drill bit may approach the
surface of a part in work, preparing to drill
a hole of precise depth. However, the drill
bit length gradually decreases due to tool
wear. A method to overcome this is to
detect the moment of contact with the part
surface on each drill, moving the bit into
the part a constant distance after contact.

Finished part area

Scrap
Area

direction of motion

Registration marks

Detect contact

3.

The home search move allows a motion system to calibrate its position on
startup. In this case, the positioning system makes an indefinite move and waits for
the load to pass by a home limit switch. This creates an interrupt at the moment when
the load is in a known position. We then stop motion and preload the position value
with a number which equates to the physical home position.
The registration profile begins with only velocity control. When an interrupt pulse
occurs on physical input X2, the starting position is declared to be the present count
(current load position). The velocity control switches to position control, moving the
load to the target position. Note that the minimum starting velocity is 40 pps. This
instantaneous velocity accommodates stepper motors that can stall at low speeds.
Registration Profile

Velocity

Target Velocity
Accel

Decel

Starting
Velocity
Start
position
Start

Target
position

Time

Y0

External Interrupt X2
Profile Complete

SP104

The time line of signal traces below the profile indicates the order of events. The
CPU uses logical output Y0 to start the profile. Immediately the HSIO turns off the
Profile Complete signal (SP104), so the ladder program can monitor the moves
completion by sensing the signals on state.

335
High-Speed Input and Pulse Output Features

Registration Profile The registration profile we want to perform is drawn and labeled in the following
Program Example figure. It consists of a non-zero starting velocity, and moderate target velocity.
Registration Profile
Velocity

Target Velocity = 1 kHz

Accel = 2 sec

Decel = 4 sec

Starting
Velocity = 40
Time
Start position

Target position = 5000

The following program will realize the profile drawn above, when executed. The first
program rung contains all the necessary setup parameters. We only have to do this
once in the program, so we use first-scan contact SP0 to trigger the setup.
DirectSOFT
SP0

Mode 30

OUT
V7633

Locate Parameter
Table (optional)

LDA
O2320
OUT
V7630

Select Pulse /
Direction

LD
K103
OUT
V7637

Filtered Inputs

LD
K2006
OUT
V7635
LD
K1006
OUT
V7636

Load constant K30 into the accumulator. This selects

Mode 30 as the HSIO mode.
Output this constant to V7633, the location of the HSIO
Mode select register.
Load the octal address of the beginning of the Profile
Parameter Table. The LDA instruction converts this to a
hex number in the accumulator.
Output this address to V7630, the location of the pointer
to the Profile Parameter Table.
Load the constant K103 which is required to select
pulse and direction for physical Y0 and Y1 functions,
respectively (your application may use CCW and CW).
Output this constant to V7637, configuring the pulse
output type.
Load the constant K2006 which is required to select X1
as a filtered input with a 20 mS filter time constant.
Output this constant to V7635, configuring X1.

Load the constant K1006 which is required to select the

external interrupt.
Output this constant to V7636, configuring X2, the
registration interrupt input.

High-Speed Input and

Pulse Output Features

LD
K30

336
High-speed Input and Pulse Output Features

Program
Example Contd
SP0

Profile / Target
Velocity
Target Position

LD
K9100
OUT
V2320
LDD
K5000
OUTD
V2321

Starting Velocity

High-Speed Input and

Pulse Output Features

Load the constant K5000 which selects a target

position of 5000 pulses. Dont forget to use double
word size (8-digit BCD position value).
Output this constant to V2321 and V2322, the location of
the Target Position double-word register.

Output this constant to V2323, the location of the starting

velocity parameter register.
Load the constant K20 which is required to select an
acceleration time of 2 seconds (20 x 100 mS).

LD
K20
OUT
V2324

Deceleration

Output this constant to V2320, the location of the Profile

Select / Starting Velocity setup register.

Load the constant K4 which is required to select a

starting velocity of 40 Hz (4 x 10 pps).

LD
K4
OUT
V2323

Acceleration

Load the constant K9100 which is required to select

Registration Profile, relative positioning, and a target
velocity of 1 kHz (9xxx times 10 pps).

Output this constant to V2324, the location of the

acceleration parameter register.
Load the constant K40 which is required to select a
deceleration time of 4 seconds (40 x 100 mS).

LD
K40
OUT
V2325

Output this constant to V2325, the location of the

deceleration parameter register.

Start Profile
X3

Y0
SET

Profile Complete
SP104

Y2
OUT
C0
PD

C0

We use an input to allow the operator to start the

profile. X3 is a momentary Start switch. When the
operator turns X3 ON, logical output Y0 starts the
profile.
SP104 is the logical output of the HSIO to indicate
the move is complete. We use Y2 to energize an
annunciator that the profile has finished. This wont
occur until after the interrupt from X2 has occurred
and the profile is complete.

Y0
RST

The profile will begin when the start input (X3) is given. Then the motion begins an
indefinite move, which lasts until an external interrupt on X2 occurs. Then the motion
continues on for 5000 more pulses before stopping.

337
High-Speed Input and Pulse Output Features

Home Search
Program Example

One of the more challenging aspects of motion control is the establishment of actual
position at powerup. This is especially true for open-loop systems which do not have
a position feedback device. However, a simple limit switch located at an exact
location on the positioning mechanism can provide position feedback at one point.
For most stepper control systems, this method is a good and economical solution.
Load
Motor

Positioning System

Limit Switches
Motion
Numbering System

CCW limit (X1)

-3000

-2000

Home limit (X2)

-1000

1000

CW limit (X3)

2000

3000

DirectSOFT
SP0

LD
K30

Mode 30

OUT
V7633

Locate
Parameter
Table (optional)

LDA
O2320

Selects Mode 30 as
the HSIO mode.

LD
K2006
Configure the address
of the parameter table.

OUT
V7630

Select Pulse /
Direction

LD
K103
OUT
V7637

Filtered Inputs

Configure the Y0 and Y1

pulse outputs for pulse
and direction, respectively.

OUT
V7635

The constant K2006

selects a 20 mS filter
time constant.
Output this constant to
V7635, configuring X1.

LD
K1006

The constant K1006

selects a 10 mS filter
time constant.

OUT
V7636

Output this constant to

V7636, configuring X2, the
registration interrupt input.

High-Speed Input and

Pulse Output Features

In the drawing above, the load moves left or right depending on the CCW/CW
direction of motor rotation. The PLC ladder program senses the CCW and CW limit
switches to stop the motor, before the load moves out-of-bounds and damages the
machine. The home limit switch is used at powerup to establish the actual position.
The numbering system is arbitrary, depending on a machines engineering units.
At powerup, we do not know whether the load is located to the left or to the right of the
home limit switch. Therefore, we will initiate a home search profile, using the
registration mode. The home limit switch is wired to X2, causing the interrupt. We
choose an arbitrary initial search direction, moving in the CW (left-to-right) direction.
S If the home limit switch closes first, then we stop and initialize the
position (this value is typically 0, but it may be different if preferred).
S However, if the CW limit switch closes first, we must reverse the motor
and move until the home limit switch closes, stopping just past it.
In the latter case, we repeat the first move, because we always need to make the
final approach to the home limit switch from the same direction, so that the final
physical position is the same in either case!

338
High-speed Input and Pulse Output Features

Profile / Target Velocity

SP0

LD
K9100

Select Registration Profile,

relative positioning, and a
target velocity of 1000 pps
(9xxx times 10 pps).

OUT
V2320

Starting Velocity

C1

TMR
T0
K5

T0
The constant K4 selects a
starting velocity of 40 Hz
(4 x 10 pps).

LD
K4

CCW past home

OUT
V2323

Acceleration

C2

C3

X2

The constant K20 selects

an acceleration time of 2
seconds (20 x 100 mS).

LD
K20

Deceleration
OUT
V2325

High-Speed Input and

Pulse Output Features

X7

C10
SET

C0

Well choose the same for

the deceleration value.

Target Position

C3

OUTD
V2321
Y0
SET
C0
SET

X2

C1

X3

C4

T1

Set C0 to indicate the CW

home search has begun.

LDD
K80000200
OUTD
V2321
C1
SET

C3
SET

CCW past home

Load a small
positive position
count (go CW).

Turn off Start Profile.

The constant K200
selects a target
position of 200
pulses, which is in
the CCW direction.

Y0
RST

Turn off Start Profile.

C4
SET

Go CW back to
home.
Add a timer to
create a slight
delay before
reversing motor.

C5
SET

CW delay done.

Y0
SET

Start profile again.

Home Limit found, CW search direction

C0 C1 C3 X2

Y0
RST

Start profile again.

TMR
T1
K5

Turn on Start Profile,

searching for either the
home limit or the CW limit
(depends on our starting
position).

CW Limit found
C0

Y0
SET

Home Limit found, CW search direction

Start the home search

when X7 turns on.

The constant K50 selects

a target position of 50
pulses (CW direction).

LDD
K50

CCW delay done.

OUTD
V2321

Search in CW direction
C10

C2
SET

LDD
K50

OUT
V2324

Add a timer to
create a slight
delay before
reversing motor.

C5

Y0
RST

Turn off Start Profile.

LDD
K0

Load the constant

K0 for our initialized
position.

OUTD
V1076

Output this constant

to C1076/V1077.

The CW limit has

been reached.

The home search profile will execute specific parts of the program, based on the
order of detection of the limit switches. Ladder logic sets C0 to initiate a home search
in the CW direction. If the CW limit is encountered, the program searches for home in
the CCW direction, passes it slightly, and does the final CW search for home. After
reaching home, the last ladder rung preloads the current position to 0.

339
High-Speed Input and Pulse Output Features

Velocity Profile Operation

Velocity Profile
Applications

The velocity profile is best suited for applications which involve motion but do not
require moves to specific points. Conveyor speed control is a typical example.
Velocity Profile
Velocity

Time
Y0

Profile
Complete

SP104

The time line of signal traces below the profile indicates the order of events.
Assuming the velocity is set greater than zero, motion begins when the Start input
(Y0) energizes. Since there is no end position target, the profile is considered in
progress as long as the Start input remains active. The profile complete logical input
to ladder logic (X0) correlates directly to the Start input status when velocity profiles
are in use.
While the Start input is active, the ladder program can command a velocity change
by writing a new value to the velocity register (V2323 by default). The full speed
range of 40 Hz to 7 kHz is available. Notice from the drawing that there are no
acceleration or deceleration ramps between velocity updates. This is how velocity
profiling works with the HSIO. However, the ladder program can command more
gradual velocity changes by incrementing or decrementing the velocity value more
slowly. A counter or timer can be useful in creating your own
acceleration/deceleration ramps. Unless the load must do a very complex move, it is
easier to let the HSIO function generate the accel/decel ramps by selecting the
trapezoidal or registration profiles instead.
Unlike the trapezoidal and registration profiles, you must specify the desired
direction of travel with velocity profiles. Load the direction select register
(V2321/V2322 by default) with 8000 0000 hex for CCW direction, or 0 for CW
direction.

High-Speed Input and

Pulse Output Features

Start

340
High-speed Input and Pulse Output Features

Velocity Profile
Program Example

The velocity profile we want to perform is drawn and labeled in the following figure.
Each velocity segment is of indefinite length. The velocity only changes when ladder
logic (or other device writing to V-memory) updates the velocity parameter.
Velocity Profile
Velocity

Time

High-Speed Input and

Pulse Output Features

The following program uses dedicated discrete inputs to load in new velocity values.
This is a fun program to try, because you can create an infinite variety of profiles with
just two or three input switches. The intent is to turn on only one of X1, X2, or X3 at a
time. The beginning of the program contains all the necessary setup parameters for
Pulse Output Mode 30. We only have to do this once in the program, so we use
first-scan contact SP0 to trigger the setup.
DirectSOFT
SP0

LD
K30

Mode 30

OUT
V7633

Locate Parameter
Table (optional)

LDA
O2320
OUT
V7630

Select Pulse /
Direction

LD
K103
OUT
V7637

Filtered Inputs

LD
K1006
OUT
V7635
OUT
V7636

Load constant K30 into the accumulator. This selects

Mode 30 as the HSIO mode.
Output this constant to V7633, the location of the HSIO
Mode select register.
Load the octal address of the beginning of the Profile
Parameter Table. The LDA instruction converts this to
hex number in the accumulator.
Output this address to V7630, the location of the pointer
to the Profile Parameter Table.
Load the constant K103 which is required to select
pulse and direction for physical Y0 and Y1 functions,
respectively (your application may use CCW and CW).
Output this constant to V7637, configuring the pulse
output type.
Load the constant K1006 which is required to select
filtered inputs with a 10 mS filter time constant.
Output this constant to V7635, configuring X1.

Output this constant to V7636, configuring X2.

341
High-Speed Input and Pulse Output Features

Program
Example Contd
SP0

Profile / Target
Velocity
Select Direction

LD
K2000
OUT
V2320
LDD
K80000000
OUTD
V2321

Set Velocity

Load the constant K2000 which is required to select

Velocity Profile. This data word contains no velocity
information in the case of velocity mode.
Output this constant to V2320, the location of the Profile
Select setup register.
Load the constant K80000000 which selects CCW
direction for Velocity Profiles. Dont forget to use double
word size (8-digit BCD position value).
Output this constant to V2321 and V2322, the location of
the Target Position double-word register.
Load the constant K10 which is required to select an
initial velocity of 100 pps (uses x10 multiplier).

LD
K10
OUT
V2323

Output this constant to V2323, the location of the velocity

parameter register. After the program is running, we can
write here again, using discrete input switches.

Start Profile
X1

Go Slow
X2

LD
K50
OUT
V2323

We use a spare filtered input to allow the operator

to start the profile. When the operator turns X1 ON
and leaves it on, logical output Y0 starts the profile.
Load the constant K50 which is required to select a
velocity of 500 pps when the operator closes X2.
Output this constant to V2323, the location of the velocity
parameter register. The speed will change immediately.

Go Moderately
X3

Go Fast
X4

LD
K200
OUT
V2323
LD
K600
OUT
V2323

Load the constant K200 which is required to select a

velocity of 2000 pps when the operator closes X3.
Output this constant to V2323, the location of the velocity
parameter register. The speed will change immediately.
Load the constant K600 which is required to select a
velocity of 6000 pps when the operator closes X4.
Output this constant to V2323, the location of the velocity
parameter register. The speed will change immediately.

High-Speed Input and

Pulse Output Features

Y0
OUT

342
High-speed Input and Pulse Output Features

Pulse Output Error The Profile Parameter Table starting at V2320 (default location) defines the profile.
Certain numbers will result in a error when the HSIO attempts to use the parameters
Codes
to execute a move profile. When an error occurs, the HSIO writes an error code in
V2326.

High-Speed Input and

Pulse Output Features

Error Code

Error Description

0000

No error

0010

Requested profile type code is invalid (must use 0, 1, 2, 8, or 9)

0020

Target Velocity is not in BCD

0021

Target Velocity is specified to be less than 40 pps

0022

Target Velocity is specified to be greater than 7,000 pps

0030

Target Position value is not in BCD

0040

Starting Velocity is not in BCD

0041

Starting Velocity is specified to be less than 40 pps

0042

Starting Velocity is specified to be greater than 1,000 pps

0050

Acceleration Time is not in BCD

0051

Acceleration Time is zero

0052

Acceleration Time is greater than 10 seconds

0060

Deceleration Time is not in BCD

0061

Deceleration Time is zero

0062

Deceleration Time is greater than 10 seconds

Most errors can be corrected by rechecking the Profile Parameter Table values. The
error is automatically cleared at powerup and at Program-to-Run Mode transitions.
Troubleshooting
Guide for Mode 30

If youre having trouble with Mode 30 operation, please study the following
symptoms and possible causes. The most common problems are listed below:

Symptom: The stepper motor does not rotate.

Possible causes:
1. Configuration Verify that the HSIO actually generates pulses on outputs
Y0 and Y1. Watch the status LEDs for Y0 and Y1 when you start a motion
profile. If the LEDs flicker on and off or are steadily on, the configuration is
probably correct.
2. Programming error If there are no pulses on Y0 or Y1 you may have a
programming error. Check the contents of V2326 for an error code that may
be generated when the PLC attempts to do the move profile. Error code
descriptions are given above.
3. Check target value The profile will not pulse if the count value is equal to
the target value (ex. count =0, target=0)

343
High-Speed Input and Pulse Output Features

4. Wiring Verify the wiring to the stepper motor is correct. Remember the
signal ground connection from the PLC to the motion system is required.
5. Motion system Verify that the drive is powered and enabled. To verify the
motion system is working, you can use Mode 60 operation (normal PLC
inputs/outputs) as shown in the test program below. With it, you can
manually control Y0 and Y1 with X0 and X1, respectively. Using an input
simulator is ideal for this type of manual debugging. With the switches you
can single-step the motor in either direction. If the motor will not move with
this simple control, Mode 30 operation will not be possible until the problem
with the motor drive system or wiring is corrected.
DirectSOFT
SP0

Load constant K60 into the accumulator. This

selects Mode 60 as the HSIO mode.

LD
K60

Mode 60

OUT
V7633

Filtered Inputs

LD
K1006

OUT
V7635
OUT
V7636
X0

X1

Load the constant K1006 which is required to configure

filtered inputs with a time constant of 10 mS.
Output this constant to V7634, configuring X0.

Output this constant to V7635, configuring X1.

Output this constant to V7636, configuring X2.

Y0
OUT

Use a switch on X0 input to manually control output Y0.

Y1
OUT

Use a switch on X1 input to manually control output Y1.

END

END coil marks the end of the main program..

6. Memory Error HSIO configuration parameters are stored in the CPU

system memory. Corrupted data in this memory area can sometimes
interfere with proper HSIO operation. If all other corrective actions fail,
initializing the scratchpad memory may solve the problem. With
DirectSOFT, select the PLC menu, then Setup, then Initialize Scratchpad.
Symptom: The motor turns in the wrong direction.
Possible causes:
1. Wiring If you have selected CW and CCW type operation, just swap the
wires on Y0 and Y1 outputs.
2. Direction control If you have selected Pulse and Direction type
operation, just change the direction bit to the opposite state.

High-Speed Input and

Pulse Output Features

OUT
V7634

Output the constant to V7633, the location of the

HSIO Mode select register.

344
High-speed Input and Pulse Output Features

Mode 40: High-Speed Interrupts

Purpose

Functional Block
Diagram

The HSIO Mode 40 provides a high-speed interrupt to the ladder program. This
capability is provided for your choice of the following application scenarios:
S An external event needs to trigger an interrupt subroutine in the CPU.
Using immediate I/O instructions in the subroutine is typical.
S An interrupt routine needs to occur on a timed basis which is different
from the CPU scan time (either faster or slower). The timed interrupt is
programmable, from 5 to 999 mS.
The HSIO circuit creates the high-speed interrupt to the CPU. The following diagram
shows the external interrupt option, which uses X0. In this configuration X1 and X2
are normal filtered inputs.

DL05
PLC

Output Circuit
Y0, Y1

Y2 - Y5

I/O data

High-Speed Input and

Pulse Output Features

HSIO
Interrupt

Interrupt
FILTER

X0

Mode Select

X1, X2

CPU
Vmemory
V7633

0040

X3- X7

Input Circuit

Alternately, you may configure the HSIO circuit to generate interrupts based on a
timer, as shown below. In this configuration, inputs X0 through X2 are filtered inputs.

DL05
PLC

Output Circuit
Y0, Y1

I/O data

HSIO
FILTER

Y2 - Y5

Interrupt

Interrupt

Timer

Mode Select

CPU
Vmemory
V7633
X3- X7

X0, X1, X2

Input Circuit

0040

345
High-Speed Input and Pulse Output Features

Setup for Mode 40

Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use
BCD 40 in the lower byte of V7633 to select the High-Speed Counter Mode. The
DL05 does not use bits 8 - 15 in V7633.
Memory Location V7633
Bits

15

14

13

12 11

10

Bits 8 - 15 are not used

in V7633.

HSIO Mode Setup (BCD)

40 = High-Speed Interrupt

The resulting interrupt uses label INT 0 in the ladder program. Be sure to include the
Enable Interrupt (ENI) instruction at the beginning of your program. Otherwise, the
interrupt routine will not be executed.
CPU Scan
Input
Update

X0, External Interrupt

TIMER
Interrupt source /
Time select
V7634

xxx4

Ladder
Program
Execution
current
instruction
Input
Update

INT
Interrupt
Routine
Program
IRT

High-Speed Input and

Pulse Output Features

Interrupts and the

Ladder Program

Choose the most convenient method of programming V7633 from the following:
S Include load and out instructions in your ladder program
S DirectSOFTs memory editor
S Use the Handheld Programmer D2HPP
We recommend using the first method above so that the HSIO setup becomes an
integral part of your application program. An example program later in this section
shows how to do this.
Refer to the drawing below. The source of the interrupt may be external (X0), or the
HSIO timer function. The setup parameter in V7634 serves a dual purpose:,
S It selects between the two interrupt sources, external (X0) or an internal
timer.
S In the case of the timer interrupt, it programs the interrupt timebase
between 5 and 999 mS.

346
High-speed Input and Pulse Output Features

External Interrupt Signal pulses at X0 must meet certain timing criteria to guarantee an interrupt will
Timing Parameters result. Refer to the timing diagram below. The input characteristics of X0 are fixed (it
is not a programmable filtered input). The minimum pulse width is 0.1 mS. There
must be some delay before the next interrupt pulse arrives, such that the interrupt
period cannot be smaller than 0.5 mS.
0.5 mS minimum
0.1 mS minimum
External
Interrupt

X0
Time

Timed Interrupt
Parameters

When the timed interrupt is selected, the HSIO generates the interrupt to ladder
logic. There is no interrupt pulse width in this case, but the interrupt period can be
adjusted from 5 to 999 mS.
5 mS to 999 mS
Timed
Interrupt

High-Speed Input and

Pulse Output Features

Time

X Input / Timed
INT Configuration

The configurable discrete input options for High-Speed Interrupt Mode are listed in
the table below. Input X0 is the external interrupt when 0004 is in V7634. If you
need a timed interrupt instead, then V7634 contains the interrupt time period, and
input X0 becomes a filtered input (uses X1s filter time constant by default). Inputs
X1, and X2, can only be filtered inputs, having individual configuration registers and
filter time constants. However, X0 will have the same filter time constant as X1 when
the timed interrupt is selected.
Input

Configuration
Register

X0

V7634

Function
External Interrupt

Uses X1s time Filtered Input (when

setting in V7635 timed interrupt is in use)

Hex Code
Required
0004 (default)
xxx4, xxx = INT timebase
5 - 999 ms (BCD)

X1

V7635

Filtered Input

xx06 (xx = filter time)

0 - 99 ms (BCD)

X2

V7636

Filtered Input

xx06 (xx = filter time)

0 - 99 ms (BCD)

Independent Timed Interrupt O1 is also available as an interrupt. This interrupt is independent of the
HSIO features. Interrupt O1 uses an internal timer that is configured in V memory
Interrupt
location V7647. The interrupt period can be adjusted from 5 to 9999 mS. Once the
interrupt period is set and the interrupt is enabled in the program, the CPU will
continuously call the interrupt routine based on the time setting in V7647.
Input

Configuration
Register

Function

Hex Code
Required

V7647

High-Speed
Timed Interrupt

xxxx (xxxx = timer setting)

5 - 9999 mS (BCD)

347
High-Speed Input and Pulse Output Features

External Interrupt
Program Example

The following program selects Mode 40, then selects the external interrupt option.
Inputs X1 and X2 are configured as filtered inputs with a 10 mS time constant. The
program is otherwise generic, and may be adapted to your application.
DirectSOFT
SP0

Load constant K40 into the accumulator. This

selects Mode 40 as the HSIO mode.

LD
K40

Mode 40

OUT
V7633

External Interrupt

LD
K4

Load the constant K4 which is required to select the

external interrupt option. X0 is the interrupt input.

OUT
V7634

Filtered Inputs

LD
K1006
OUT
V7635

Output this constant to V7635, configuring X1.

Output this constant to V7636, configuring X2.

Reset output Y0.

ENI

Enable Interrupts at the beginning of the program.

Insert Main Program rungs here for your application.

END
O0

END coil marks the end of the main program..

The INT label marks the beginning of the interrupt
service routine program.

Interrupt Routine
SP1

Load the constant K1006 which is required to select

filtered inputs with a 10 mS filter time constant.

Y5
RST

Main Program

INT

Output this constant to V7634, configuring the

external interrupt option for X0.

Insert interrupt service routine rungs here for your

application.

Y5
SETI
IRT

Use the pulse catch input to set output Y0 on.

Return to the main ladder program.

High-Speed Input and

Pulse Output Features

OUT
V7636

INT Enable

Output this constant to V7633, the location of the

HSIO Mode select register.

348
High-speed Input and Pulse Output Features

Timed Interrupt
Program Example

The following program selects Mode 40, then selects the timed interrupt option, with
an interrupt period of 100 mS.
100 mS
Timed
Interrupt
Time

Inputs X0, X1, and X2, are configured as filtered inputs with a 10 mS time constant.
Note that X0 uses the time constant from X1. The program is otherwise generic, and
may be adapted to your application.
DirectSOFT

High-Speed Input and

Pulse Output Features

SP0

Load constant K40 into the accumulator. This

selects Mode 40 as the HSIO mode.

LD
K40

Mode 40

OUT
V7633

Timed Interrupt

LD
K1004
OUT
V7634

Filtered Inputs

LD
K1006
OUT
V7635
OUT
V7636

INT Enable

ENI

Output this constant to V7633, the location of the

HSIO Mode select register.
Load the constant K1004 which is required to select
the timed interrrupt option, with a period of 100 mS.
Output this constant to V7634, configuring the timed
interrupt for 100 mS period.
Load the constant K1006 which is required to select
filtered inputs with a 10 mS filter time constant.
Output this constant to V7635, configuring X1 and X0.

Output this constant to V7636, configuring X2.

Enable Interrupts at the beginning of the program.

Insert Main Program rungs here for your application.

Main Program
END
INT

O0

The INT label marks the beginning of the interrupt

service routine program.
Insert interrupt service routine rungs here for your
application.

Interrupt Routine
SP1

END coil marks the end of the main program..

LD
K1

Load constant K1 into the accumulator.

ADD
V2000

Add the value in the accumulator with the value in

memory location V2000.

OUT
V2000

Output the result into memory location V2000.

IRT

Return to the main ladder program.

349
High-Speed Input and Pulse Output Features

Mode 50: Pulse Catch Input

Purpose

Functional Block
Diagram

The HSIO circuit has a pulse-catch mode of operation. It monitors the signal on input
X0, preserving the occurrence of a narrow pulse. The purpose of the pulse catch
mode is to enable the ladder program to see an input pulse which is shorter in
duration than the current scan time. The HSIO circuit latches the input event on input
X0 for one scan. This contact automatically goes off after one scan.
Refer to the block diagram below. When the lower byte of HSIO Mode register V7633
contains a BCD 50, the pulse catch mode in the HSIO circuit is enabled. X0
automatically becomes the pulse catch input, which sets the latch on each rising
edge. The HSIO resets the latch at the end of the next CPU scan. Inputs X1 and X2
are available as filtered discrete inputs.

DL05
PLC

Output Circuit
Y0, Y1

HSIO

Y2 - Y5

I/O data

CPU

Set

Reset

X0

scan

FILTER

Mode Select

X1, X2

High-Speed Input and

Pulse Output Features

LATCH
Vmemory
V7633

0050

X3- X7

Input Circuit

Pulse Catch
Signal pulses at X0 must meet certain timing criteria to guarantee a pulse capture
Timing Parameters will result. Refer to the timing diagram below. The input characteristics of X0 are
fixed (it is not a programmable filtered input). The minimum pulse width is 0.1 mS.
There must be some delay before the next pulse arrives, such that the pulse period
cannot be smaller than 0.5 mS. If the pulse period is smaller than 0.5 mS, the next
pulse will be considered part of the current pulse.
0.5 mS minimum
0.1 mS minimum
Pulse
Input

X0
Time

Note that the pulse catch and filtered input functions are opposite in nature. The
pulse catch feature on X0 seeks to capture narrow pulses, while the filter input
feature on X1 and X2 seeks to reject narrow pulses.

350
High-speed Input and Pulse Output Features

Setup for Mode 50

Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use
BCD 50 in the lower byte of V7633 to select the High-Speed Counter Mode. The
DL05 does not use bits 8 - 15 in V7633.
Memory Location V7633
Bits

15

14

13

12 11

10

Bits 8 - 15 are not used

in V7633.

HSIO Mode Setup (BCD)

High-Speed Input and

Pulse Output Features

50 = Pulse Catch Input

Choose the most convenient method of programming V7633 from the following:
S Include load and out instructions in your ladder program
S DirectSOFTs memory editor
S Use the Handheld Programmer D2HPP
We recommend using the first method above so that the HSIO setup becomes an
integral part of your application program. An example program later in this section
shows how to do this.
X Input
Configuration

The configurable discrete input options for Pulse Catch Mode are listed in the table
below. Input X0 is the pulse input, and must have 0005 loaded into it configuration
register V7634. Inputs X1 and X2 can only be filtered inputs. Each input has its own
configuration register and filter time constant.
Input

Configuration
Register

Function

Hex Code
Required

X0

V7634

Pulse Catch Input

0005

X1

V7635

Filtered Input

xx06 (xx = filter time)

0 - 99 ms (BCD)

X2

V7636

Filtered Input

xx06 (xx = filter time)

0 - 99 ms (BCD)

351
High-Speed Input and Pulse Output Features

Pulse Catch
Program Example

The following program selects Mode 50, then programs the pulse catch code for X0.
Inputs X1 and X2 are configured as filtered inputs with 10 and 30 mS time constants
respectively. The program is otherwise generic, and may be adapted to your
application.
DirectSOFT
SP0

Load constant K50 into the accumulator. This

selects Mode 50 as the HSIO mode.

LD
K50

Mode 50

OUT
V7633

Pulse Catch

LD
K5

Load the constant K5 which is required to configure X0

as the pulse catch input.

OUT
V7634

Filtered Inputs

Output this constant to V7633, the location of the

HSIO Mode select register.

LD
K1006

LD
K3006
OUT
V7636

Load the constant K1006 which is required to select

filtered inputs with a 10 mS filter time constant.
Output this constant to V7635, configuring X1.

Load the constant K3006 which is required to select

filtered inputs with a 30 mS filter time constant.
Output this constant to V7636, configuring X2.

Main Program
X0

Y0
SET
END

Use the pulse catch input to set output Y0 on. This will
work even for a very short pulse on X0.
END coil marks the end of the main program..

High-Speed Input and

Pulse Output Features

OUT
V7635

Output this constant to V7634, configuring the pulse

catch option for X0.

352
High-speed Input and Pulse Output Features

Mode 60: Discrete Inputs with Filter

Purpose

Functional Block
Diagram

The last mode we will discuss for the HSIO circuit is Mode 60, Discrete Inputs with
Filter. The purpose of this mode is to allow the input circuit to reject narrow pulses
and accept wide ones, as viewed from the ladder program. This is useful in
especially noisy environments or other applications where pulse width is important.
In all other modes in this chapter, X0 to X2 usually support the mode functions as
special inputs. Only spare inputs operate as filtered inputs by default. Now in Mode
60, all three inputs X0 through X2 function only as discrete filtered inputs.
Refer to the block diagram below. When the lower byte of HSIO Mode register V7633
contains a BCD 60, the input filter in the HSIO circuit is enabled. Each input X0
through X2 has its own filter time constant. The filter circuit assigns the outputs of the
filters as logical references X0 through X2.

DL05
PLC

Output Circuit

High-Speed Input and

Pulse Output Features

Y0, Y1

Y2 - Y5

HSIO

I/O data

FILTERS

X0-X2
Mode Select

X0

X1

X2

CPU
Vmemory
V7633

0060

X3- X7

Input Circuit

Input Filter
Signal pulses at inputs X0 X2 are filtered by using a delay time. In the figure below,
Timing Parameters the input pulse on the top line is longer than the filter time. The resultant logical input
to ladder is phase-shifted (delayed) by the filter time on both rising and falling edges.
In the bottom waveforms, the physical input pulse width is smaller than the filter time.
In this case, the logical input to the ladder program remains in the OFF state (input
pulse was filtered out).
Filter Time
Physical Input

X0

Logical Input

X0

Filter Time

Time
Physical Input

X0

Logical Input

X0

353
High-Speed Input and Pulse Output Features

Setup for Mode 60

Recall that V7633 is the HSIO Mode Select register. Refer to the diagram below. Use
BCD 60 in the lower byte of V7633 to select the High-Speed Counter Mode. The
DL05 does not use bits 8 - 15 in V7633.
Memory Location V7633
Bits

15

14

13

12 11

10

Bits 8 - 15 are not used

in V7633.

HSIO Mode Setup (BCD)

60 = Discrete Filtered Inputs

X Input
Configuration

The configurable discrete input options for Discrete Filtered Inputs Mode are listed
in the table below. The filter time constant (delay) is programmable from 0 to 99 mS
(the input acts as a normal discrete input when the time constant is set to 0). The
code for this selection occupies the upper byte of the configuration register in BCD.
We combine this number with the required 06 in the lower byte to get xx06, where
xx = 0 to 99. Input X0, X1, and X2 can only be filtered inputs. Each input has its own
configuration register and filter time constant.
Input

Configuration
Register

Function

Hex Code
Required

X0

V7634

Filtered Input

xx06 (xx = filter delay time)

0 - 99 ms (BCD)

X1

V7635

Filtered Input

xx06 (xx = filter delay time)

0 - 99 ms (BCD)

X2

V7636

Filtered Input

xx06 (xx = filter delay time)

0 - 99 ms (BCD)

High-Speed Input and

Pulse Output Features

Choose the most convenient method of programming V7633 from the following:
S Include load and out instructions in your ladder program
S DirectSOFTs memory editor
S Use the Handheld Programmer D2HPP
We recommend using the first method above so that the HSIO setup becomes an
integral part of your application program. An example program later in this section
shows how to to this.

354
High-speed Input and Pulse Output Features

Filtered Inputs
Program Example

The following program selects Mode 60, then programs the filter delay time
constants for inputs X0, X1, and X2. Each filter time constant is different, for
illustration purposes. The program is otherwise generic, and may be adapted to your
application.
DirectSOFT
SP0

Load constant K60 into the accumulator. This

selects Mode 60 as the HSIO mode.

LD
K60

Mode 60

OUT
V7633

Filtered Inputs

LD
K1006
OUT
V7634

High-Speed Input and

Pulse Output Features

LD
K2006
OUT
V7635
LD
K5006
OUT
V7636

Main Program

Output the constant to V7633, the location of the

HSIO Mode select register.
Load the constant K1006 which is required to configure
filtered inputs with a time constant of 10 mS.
Output this constant to V7634, configuring X0.

Load the constant K2006 which is required to select

filtered inputs with a 20 mS filter time constant.
Output this constant to V7635, configuring X1.

Load the constant K5006 which is required to select

filtered inputs with a 50 mS filter time constant.
Output this constant to V7636, configuring X2.

Insert Main Program rungs here for your application.

END

END coil marks the end of the main program..

CPU Specifications
and Operation
In This Chapter. . . .
Introduction
CPU Specifications
CPU Hardware Setup
CPU Operation
Program Mode Operation
Run Mode Operation
I/O Response Time
CPU Scan Time Considerations
PLC Numbering Systems
Memory Map
DL05 System V-Memory
X Input Bit Map
Y Output Bit Map
Staget Control / Status Bit Map
Control Relay Bit Map
Timer Status Bit Map
Counter Status Bit Map
Network Configuration
Network Slave Operation
Network Master Operation

14

42
CPU Specifications and Operation

Introduction
The Central Processing Unit (CPU) is the heart of the Micro PLC. Almost all PLC
operations are controlled by the CPU, so it is important that it is set up correctly. This
chapter provides the information needed to understand:
S Steps required to set up the CPU
S Operation of ladder programs
S Organization of Variable Memory
To Programming Device
or Operator Interface

DL05
PLC

CPU

2 Comm.
Ports

Main
Power
Supply
Input Circuit
Power
Input

8 Discrete Inputs Commons

Output Circuit

6 Discrete Outputs Commons

CPU Specifications
and Operation

NOTE: The High-Speed I/O function (HSIO) consists of dedicated but configurable
hardware in the DL05. It is not considered part of the CPU, because it does not
execute the ladder program. For more on HSIO operation, see Chapter 3.

DL05
CPU Features

The DL05 Micro PLC which has 6K words of memory comprised of 2.0K of ladder
memory and 4K words of V-memory (data registers). Program storage is in the
FLASH memory which is a part of the CPU board in the PLC. In addition, there is
RAM with the CPU which will store system parameters, V-memory, and other data
which is not in the application program. The RAM is backed up by a
super-capacitor, storing the data for several hours in the event of a power outage.
The capacitor automatically charges during powered operation of the PLC.
The DL05 supports fixed I/O which includes eight discrete input points and six output
points. No provision for expansion beyond these fourteen I/O points is available in
the DL05 model PLCs.
Over 120 different instructions are available for program development as well as
extensive internal diagnostics that can be monitored from the application program or
from an operator interface. Chapters 5, 6, and 7 provide detailed descriptions of the
instructions.
The DL05 provides two built-in RS232C communication ports, so you can easily
connect a handheld programmer, operator interface, or a personal computer without
needing any additional hardware.

43
CPU Specifications and Operation

CPU Specifications
Feature

DL05

Total Program memory (words)

6K

Ladder memory (words)

2048

Total V-memory (words)

4096

User V-memory (words)

3968

Non-volatile V Memory (words)

128

Contact execution (boolean)

2.0uS

Typical scan (boolean)

2.73.2mS

RLL Ladder style Programming

Yes

RLL and

RLL PLUS

Programming

Yes
Yes

Scan

Variable / fixed

Handheld programmer

Yes

DirectSOFT programming for Windows

Yes

Built-in communication ports (RS232C)

Yes

FLASH Memory

Standard on CPU

Local Discrete I/O points available

14

Local Analog input / output channels maximum

None

High-Speed I/O (quad., pulse out, interrupt, pulse catch, etc.)

Yes, 2

I/O Point Density

8 inputs, 6 outputs

Number of instructions available (see Chapter 5 for details)

129

Control relays

512

Special relays (system defined)

512

Stages in RLL PLUS

256

Timers

128

Counters

128

Immediate I/O

Yes

Interrupt input (external / timed)

Yes

Subroutines

Yes

For/Next Loops

Yes

Math

Integer

Drum Sequencer Instruction

Yes

Time of Day Clock/Calendar

No

Internal diagnostics

Yes

Password security

Yes

System error log

No

User error log

No

Battery backup

No (builtin supercap)
Yes, with mem cartridge

CPU Specifications
and Operation

Run Time Edits

44
CPU Specifications and Operation

CPU Hardware Setup

Communication
Port Pinout
Diagrams

Cables are available that allow you to quickly and easily connect a Handheld
Programmer or a personal computer to the DL05 PLCs. However, if you need to
build your own cables, use the pinout diagrams shown. The DL05 PLCs require an
RJ-12 phone plug to fit the built-in jacks.
The Micro PLC has two built-in RS232C communication ports. Port 1 is generally
used for connecting to a D2-HPP, DirectSOFT, operator interface, MODBUS
slave, or a DirectNET slave. . The baud rate is fixed at 9600 baud for port 1. Port 2
can be used to connect to a D2-HPP, DirectSOFT, operator interface, MODBUS
master/slave, or a DirectNET master/slave. Port 2 has a range of speeds from
300 baud to 38.4K baud.
Port 1 Pin Descriptions

1234 5 6

6-pin Female
Modular Connector

1
2
3
4
5
6

0V
5V
RXD
TXD
5V
0V

Port 2 Pin Descriptions

Power () connection (GND)

Power (+) connection
Receive Data (RS232C)
Transmit Data (RS232C
Power (+) conection
Power () connection (GND)

1
2
3
4
5
6

0V
5V
RXD
TXD
RTS
0V

Power () connection (GND)

Power (+) connection
Receive Data (RS232C)
Transmit Data (RS232C
Request to Send
Power () connection (GND)

CPU Specifications
and Operation

Top View
Communication Port 1

Communication Port 2

Com 1 Connects to HPP, DirectSOFT,

operator interfaces, etc.
6-pin, RS232C
9600 Baud (Fixed)
Parity - odd (default)
Station address 1 (fixed)
8 data bits
1 start, 1 stop bit
Asynchronous, Half-duplex, DTE
Protocol: (Auto-Select)
K sequence (Slave only)

Com 2 Connects to HPP, DirectSOFT,

operator interfaces, etc.
6-pin, RS232C
Communication speed (baud)
300, 600, 1200, 2400, 4800,
9600, 19200, 38400
Parity - odd (default), even, none
Station address 1 (default)
8 data bits
1 start, 1 stop bit
Asynchronous, Half-duplex, DTE
Protocol: (Auto-Select)
K sequence (Slave only)

DirectNET (Slave only)

MODBUS (Slave only)

DirectNET (Master/Slave)
MODBUS (Master/Slave)
Non-sequence/Print

45
CPU Specifications and Operation

Connecting the
Programming
Devices

If youre using a Personal Computer with the DirectSOFT programming package,

you can connect the computer to either of the DL05s programming ports. For an
engineering office environment (typical during program development), this is the
preferred method of programming.

Use cable part no.

D2DSCBL

The Handheld programmer is connected to the CPU with a handheld programmer

cable. This device is ideal for maintaining existing installations or making small
program changes. The handheld programmer is shipped with a cable, which is
approximately 6.5 feet (200 cm) long.

For replacement
cable, use part no.
DV1000CBL

Even if you have years of experience using PLCs, there are a few things you need to
do before you can start entering programs. This section includes some basic things,
such as changing the CPU mode, but it also includes some things that you may
never have to use. Heres a brief list of the items that are discussed.
S Selecting and Changing the CPU Modes
S Using Auxiliary Functions
S Clearing the program (and other memory areas)
S How to initialize system memory
S Setting retentive memory ranges
The following paragraphs provide the setup information necessary to get the CPU
ready for programming. They include setup instructions for either type of
programming device you are using. The D2HPP Handheld Programmer Manual
provides the Handheld keystrokes required to perform all of these operations. The
DirectSOFT Manual provides a description of the menus and keystrokes required
to perform the setup procedures via DirectSOFT.

CPU Specifications
and Operation

CPU Setup
Information

46
CPU Specifications and Operation

Mode Switch

Status Indicators

Status Indicators

The status indicator LEDs on the CPU front panels have specific functions which can
help in programming and troubleshooting.
Indicator

Status

Meaning

PWR

ON

Power good

OFF

Power failure

ON

CPU is in Run Mode

OFF

CPU is in Stop or program Mode

ON

CPU self diagnostics error

OFF

CPU self diagnostics good

ON

Data is being transmitted by the CPU - Port 1

OFF

No data is being transmitted by the CPU - Port 1

ON

Data is being received by the CPU - Port 1

OFF

No data is being received by the CPU - Port 1

ON

Data is being transmitted by the CPU - Port 2

OFF

No data is being transmitted by the CPU - Port 2

ON

Data is being received by the CPU - Port 2

OFF

No data is being received by the CPU - Port 2

RUN

CPU

TX1

RX1

CPU Specifications
and Operation

TX2

RX2

Mode Switch
Functions

The mode switch on the DL05 PLC provides positions for enabling and disabling
program changes in the CPU. Unless the mode switch is in the TERM position, RUN
and STOP mode changes will not be allowed by any interface device, (handheld
programmer, DirectSOFT programing package or operator interface). Programs
may be viewed or monitored but no changes may be made. If the switch is in the
TERM position and no program password is in effect, all operating modes as well as
program access will be allowed through the connected programming or monitoring
device.

47
CPU Specifications and Operation

Modeswitch Position

CPU Action

RUN

(Run Program)

CPU is forced into the RUN mode if no errors are encountered. No

changes are allowed by the attached programming/monitoring device.

TERM

(Terminal)

RUN, PROGRAM and the TEST modes are available. Mode and
program changes are allowed by the programming/monitoring device.

STOP

CPU is forced into the STOP mode. No changes are allowed by the
programming/monitoring device.

Changing Modes in There are two ways to change the CPU mode. You can use the CPU mode switch to
select the operating mode, or you can place the mode switch in the TERM position
the DL05 PLC
and use a programming device to change operating modes. With the switch in this
position, the CPU can be changed between Run and Program modes. You can use
either DirectSOFT or the Handheld Programmer to change the CPU mode of
operation. With DirectSOFT you use a menu option in the PLC menu. With the
Handheld Programmer, you use the MODE key.

Menu Options

MODE
Key

WARNING: Once the super capacitor has discharged, the system memory
may not retain the previous mode of operation. When this occurs, the PLC can
power-up in either Run or Program Mode if the mode switch is in the term
position. There is no way to determine which mode will be entered as the
startup mode. Failure to adhere to this warning greatly increases the risk of
unexpected
equipment
startup.

CPU Specifications
and Operation

Mode of Operation The DL05 CPU will normally power-up in the mode that it was in just prior to the
power interruption. For example, if the CPU was in Program Mode when the power
at Power-up
was disconnected, the CPU will power-up in Program Mode (see warning note
below).

48
CPU Specifications and Operation

Auxiliary Functions Many CPU setup tasks involve the use of Auxiliary (AUX) Functions. The AUX
Functions perform many different operations, ranging from clearing ladder memory,
displaying the scan time, copying programs to EEPROM in the handheld
programmer, etc. They are divided into categories that affect different system
parameters. Appendix A provides a description of the AUX functions.
You can access the AUX Functions from DirectSOFT or from the D2HPP
Handheld Programmer. The manuals for those products provide step-by-step
procedures for accessing the AUX Functions. Some of these AUX Functions are
designed specifically for the Handheld Programmer setup, so they will not be
needed (or available) with the DirectSOFT package. The following table shows a list
of the Auxiliary functions for the Handheld Programmer.
AUX 2* RLL Operations

Scan Control Setup

22

Change Reference

23

Clear Ladder Range

61

Show Revision Numbers

24

Clear All Ladders

62

Beeper On / Off

AUX 3* V-Memory Operations

65

Run Self Diagnostics

AUX 6* Handheld Programmer

Configuration

Clear V Memory

41

Show I/O Configuration

AUX 5* CPU Configuration

CPU Specifications
and Operation

5D

Check Program

AUX 4* I/O Configuration

AUX 7* EEPROM Operations

71

Copy CPU memory to HPP EEPROM

72

Write HPP EEPROM to CPU

73

Compare CPU to HPP EEPROM

51

Modify Program Name

74

Blank Check (HPP EEPROM)

53

Display Scan Time

75

Erase HPP EEPROM

54

Initialize Scratchpad

76

Show EEPROM Type (CPU and

HPP)

55

Set Watchdog Timer

56

Set Communication Port 2

81

Modify Password

57

Set Retentive Ranges

82

Unlock CPU

58

Test Operations

83

Lock CPU

59

Override Setup

AUX 8* Password Operations

Before you enter a new program, be sure to always clear ladder memory. You can
use AUX Function 24 to clear the complete program.
You can also use other AUX functions to clear other memory areas.
S
S
S

Initializing System
Memory

HSIO Configuration

21

31

Clearing an
Existing Program

5B

AUX 23 Clear Ladder Range

AUX 24 Clear all Ladders
AUX 31 Clear V Memory

The DL05 Micro PLC maintain system parameters in a memory area often referred
to as the scratchpad. In some cases, you may make changes to the system setup
that will be stored in system memory. For example, if you specify a range of Control
Relays (CRs) as retentive, these changes are stored in system memory.
AUX 54 resets the system memory to the default values.

49
CPU Specifications and Operation

WARNING: You may never have to use this feature unless you want to clear any
setup information that is stored in system memory. Usually, youll only need to
initialize the system memory if you are changing programs and the old program
required a special system setup. You can usually load in new programs without ever
initializing system memory.
Remember, this AUX function will reset all system memory. If you have set special
parameters such as retentive ranges, etc. they will be erased when AUX 54 is used.
Make sure you that you have considered all ramifications of this operation before
you select it.
Setting Retentive
Memory Ranges

The DL05 PLCs provide certain ranges of retentive memory by default. The default
ranges are suitable for many applications, but you can change them if your
application requires additional retentive ranges or no retentive ranges at all. The
default settings are:
Memory Area

DL05
Default Range

Available Range

Control Relays

C400 C777

C0 C777

V Memory

V1400 V7777

V0 V7777

Timers

None by default

T0 T177

Counters

CT0 CT177

CT0 CT177

Stages

None by default

S0 S377

You can use AUX 57 to set the retentive ranges. You can also use DirectSOFT
menus to select the retentive ranges. Appendix A contains detailed information
about auxiliary

CPU Specifications
and Operation

WARNING: The DL05 PLCs do not have battery back-up (unless the memory
cartridge, D001MC, is installed) The super capacitor will retain the values in the
event of a power loss, but only for a short period of time, depending on conditions.

410
CPU Specifications and Operation

Using a Password

The DL05 PLCs allow you to use a password to help minimize the risk of
unauthorized program and/or data changes. Once you enter a password you can
lock the PLC against access. Once the CPU is locked you must enter the password
before you can use a programming device to change any system parameters.
You can select an 8-digit numeric password. The Micro PLCs are shipped from the
factory with a password of 00000000. All zeros removes the password protection. If
a password has been entered into the CPU you cannot just enter all zeros to remove
it. Once you enter the correct password, you can change the password to all zeros to
remove the password protection.
WARNING: Make sure you remember your password. If you forget your password
you will not be able to access the CPU. The Micro PLC must be returned to the
factory to have the password removed.
You can use the D2HPP Handheld
Programmer or DirectSOFT to enter a
password. The following diagram shows how
you can enter a password with the Handheld
Programmer.
DirectSOFT

D2HPP

Select AUX 81
CLR

CLR

B
8

AUX

ENT

PASSWORD
00000000

Enter the new 8-digit password

CPU Specifications
and Operation

ENT

PASSWORD
XXXXXXXX

Press CLR to clear the display

There are three ways to lock the CPU once the password has been entered.
1. If the CPU power is disconnected, the CPU will be automatically locked
against access.
2. If you enter the password with DirectSOFT, the CPU will be automatically
locked against access when you exit DirectSOFT.
3. Use AUX 83 to lock the CPU.
When you use DirectSOFT, you will be prompted for a password if the CPU has
been locked. If you use the Handheld Programmer, you have to use AUX 82 to
unlock the CPU. Once you enter AUX 82, you will be prompted to enter the
password.

411
CPU Specifications and Operation

CPU Operation
Achieving the proper control for your equipment or process requires a good
understanding of how DL05 CPUs control all aspects of system operation. There are
four main areas to understand before you create your application program:
S CPU Operating System the CPU manages all aspects of system
control. A quick overview of all the steps is provided in the next section.
S CPU Operating Modes The two primary modes of operation are
Program Mode and Run Mode.
S CPU Timing The two important areas we discuss are the I/O
response time and the CPU scan time.
S CPU Memory Map DL05 CPUs offer a wide variety of resources,
such as timers, counters, inputs, etc. The memory map section shows
the organization and availability of these data types.
CPU Operating
System

Power up
Initialize hardware
Initialize various memory
based on retentive
configuration

Update input
Service peripheral
Update Special Relays
PGM

Mode?

CPU Specifications
and Operation

At powerup, the CPU initializes the

internal electronic hardware. Memory
initialization starts with examining the
retentive memory settings. In general, the
contents of retentive memory is
preserved, and non-retentive memory is
initialized to zero (unless otherwise
specified).
After the one-time powerup tasks, the
CPU begins the cyclical scan activity. The
flowchart to the right shows how the tasks
differ, based on the CPU mode and the
existence of any errors. The scan time is
defined as the average time around the
task loop. Note that the CPU is always
reading the inputs, even during program
mode. This allows programming tools to
monitor input status at any time.
The outputs are only updated in Run
mode. In program mode, they are in the off
state.
Error detection has two levels. Non-fatal
errors are reported, but the CPU remains
in its current mode. If a fatal error occurs,
the CPU is forced into program mode and
the outputs go off.

RUN
Execute program
Update output

Do diagnostics
OK

OK?

YES

NO
Report error, set flag
register, turn on LED

Fatal error
YES
Force CPU into
PGM mode

NO

412
CPU Specifications and Operation

Program Mode

CPU Specifications
and Operation

Run Mode

In Program Mode, the CPU does not

execute the application program or update
the output points. The primary use for
Program Mode is to enter or change an
application program. You also use
program mode to set up the CPU
parameters, such as HSIO features,
retentive memory areas, etc.
You can use a programming device, such
as DirectSOFT or the D2HPP Handheld
Programmer to place the CPU in Program
Mode.

In Run Mode, the CPU executes the

application program and updates the I/O
system. You can perform many operations
during Run Mode. Some of these include:
S
Monitor and change I/O point status
S
Update timer/counter preset values
S
Update Variable memory locations
Run Mode operation can be divided into
several key areas. For the vast majority of
applications, some of these execution
segments are more important than others.
For example, you need to understand how
the CPU updates the I/O points, handles
forcing operations, and solves the
application program. The remaining
segments are not that important for most
applications.
You can use DirectSOFT or the D2HPP
Handheld Programmer to place the CPU
in Run Mode.

Download
Program

Normal Run mode scan

Read Inputs
Service Peripherals
Update Special Relays
Solve the Application Program
Write Outputs
Diagnostics

You can also edit the program during Run Mode. The Run Mode Edits are not
bumpless to the outputs. Instead, the CPU maintains the outputs in their last state
while it accepts the new program information. If an error is found in the new program,
then the CPU will turn all the outputs off and enter the Program Mode. This feature is
discussed in more detail in Chapter 9.
WARNING: Only authorized personnel fully familiar with all aspects of the
application should make changes to the program. Changes during Run Mode
become effective immediately. Make sure you thoroughly consider the impact of any
changes to minimize the risk of personal injury or damage to equipment.

413
CPU Specifications and Operation

Read Inputs

The CPU reads the status of all inputs, then stores it in the image register. Input
image register locations are designated with an X followed by a memory location.
Image register data is used by the CPU when it solves the application program.
Of course, an input may change after the CPU has just read the inputs. Generally,
the CPU scan time is measured in milliseconds. If you have an application that
cannot wait until the next I/O update, you can use Immediate Instructions. These do
not use the status of the input image register to solve the application program. The
Immediate instructions immediately read the input status directly from the I/O
modules. However, this lengthens the program scan since the CPU has to read the
I/O point status again. A complete list of the Immediate instructions is included in
Chapter 5.

Service Peripherals After the CPU reads the inputs from the input modules, it reads any attached
peripheral devices. This is primarily a communications service for any attached
and Force I/O
devices. For example, it would read a programming device to see if any input, output,
or other memory type status needs to be modified. There are two basic types of
forcing available with the DL05 CPUs.
S Forcing from a peripheral not a permanent force, good only for one
scan
S Bit Override holds the I/O point (or other bit) in the current state. Valid
bits are X, Y, C, T, CT, and S. (These memory types are discussed in
more detail later in this chapter).
Regular Forcing This type of forcing can temporarily change the status of a
discrete bit. For example, you may want to force an input on, even though it is really
off. This allows you to change the point status that was stored in the image register.
This value will be valid until the image register location is written to during the next
scan. This is primarily useful during testing situations when you need to force a bit on
to trigger another event.
CPU Specifications
and Operation

Bit Override Bit override can be enabled on a point-by-point basis by using AUX
59 from the Handheld Programmer or, by a menu option from within DirectSOFT.
Bit override basically disables any changes to the discrete point by the CPU. For
example, if you enable bit override for X1, and X1 is off at the time, then the CPU will
not change the state of X1. This means that even if X1 comes on, the CPU will not
acknowledge the change. So, if you used X1 in the program, it would always be
evaluated as off in this case. Of course, if X1 was on when the bit override was
enabled, then X1 would always be evaluated as on.
There is an advantage available when you use the bit override feature. The regular
forcing is not disabled because the bit override is enabled. For example, if you
enabled the Bit Override for Y0 and it was off at the time, then the CPU would not
change the state of Y0. However, you can still use a programming device to change
the status. Now, if you use the programming device to force Y0 on, it will remain on
and the CPU will not change the state of Y0. If you then force Y0 off, the CPU will
maintain Y0 as off. The CPU will never update the point with the results from the
application program or from the I/O update until the bit override is removed.
The following diagram shows a brief overview of the bit override feature. Notice the
CPU does not update the Image Register when bit override is enabled.

414
CPU Specifications and Operation

Input Update

Bit Override OFF

Force from
Programmer
Result of Program
Solution

Input Update
X128
OFF
Y128
OFF
C377
OFF

...
...
...
...
...
...

X2
ON
Y2
ON
C2
ON

X1
ON
Y1
ON
C1
OFF

X0
OFF
Y0
OFF
C0
OFF

Image Register (example)

Force from
Programmer

Bit Override ON

Result of Program
Solution

WARNING: Only authorized personnel fully familiar with all aspects of the
application should make changes to the program. Make sure you thoroughly
consider the impact of any changes to minimize the risk of personal injury or damage
to equipment.

There are certain V-memory locations that contain Special Relays and other
Update Special
Relays and Special dedicated register information. This portion of the execution cycle makes sure these
locations get updated on every scan. Also, there are several different Special
Registers
Relays, such as diagnostic relays, etc., that are also updated during this segment.

CPU Specifications
and Operation

Solve Application
Program

The CPU evaluates each instruction in the

application program during this segment
of the scan cycle. The instructions define
the relationship between the input
conditions and the desired output
response. The CPU uses the output
image register area to store the status of
the desired action for the outputs. Output
image register locations are designated
with a Y followed by a memory location.
The actual outputs are updated during the
write outputs segment of the scan cycle.
There are immediate output instructions
available that will update the output points
immediately instead of waiting until the
write output segment. A complete list of
the Immediate instructions is provided in
Chapter 5.
The internal control relays (C), the stages
(S), and the variable memory (V) are also
updated in this segment.

Normal Run mode scan

Read Inputs
Service Peripherals
Update Special Relays
Solve the Application Program
Write Outputs
Diagnostics

You may recall that you can force various types of points in the system. (This was
discussed earlier in this chapter.) If any I/O points or memory data have been forced,
the output image register also contains this information.

415
CPU Specifications and Operation

Write Outputs

Once the application program has solved the instruction logic and constructed the
output image register, the CPU writes the contents of the output image register to the
corresponding output points. Remember, the CPU also made sure that any forcing
operation changes were stored in the output image register, so the forced points get
updated with the status specified earlier.

Diagnostics

During this part of the scan, the CPU performs all system diagnostics and other tasks
such as calculating the scan time and resetting the watchdog timer. There are many
different error conditions that are automatically detected and reported by the DL05
PLCs. Appendix B contains a listing of the various error codes.
Probably one of the more important things that occurs during this segment is the
scan time calculation and watchdog timer control. The DL05 CPU has a watchdog
timer that stores the maximum time allowed for the CPU to complete the solve
application segment of the scan cycle. If this time is exceeded the CPU will enter the
Program Mode and turn off all outputs. The default value set from the factory is 200
ms. An error is automatically reported. For example, the Handheld Programmer
would display the following message E003 S/W TIMEOUT when the scan overrun
occurs.
You can use AUX 53 to view the minimum, maximum, and current scan time. Use
AUX 55 to increase or decrease the watchdog timer value.

I/O Response Time

Normal Minimum
I/O Response

The I/O response time is shortest when the input changes just before the Read
Inputs portion of the execution cycle. In this case the input status is read, the
application program is solved, and the output point gets updated. The following
diagram shows an example of the timing for this situation.

CPU Specifications
and Operation

Is Timing Important I/O response time is the amount of time required for the control system to sense a
change in an input point and update a corresponding output point. In the majority of
for Your
applications, the CPU performs this task in such a short period of time that you may
Application?
never have to concern yourself with the aspects of system timing. However, some
applications do require extremely fast update times. In these cases, you may need to
know how to to determine the amount of time spent during the various segments of
operation.
There are four things that can affect the I/O response time.
S The point in the scan cycle when the field input changes states
S Input Off to On delay time
S CPU scan time
S Output Off to On delay time
The next paragraphs show how these items interact to affect the response time.

416
CPU Specifications and Operation

Scan

Scan

Solve
Program

Solve
Program
Read
Inputs

Solve
Program

Solve
Program

Write
Outputs

Field Input
CPU Reads
Inputs

CPU Writes
Outputs

Input
Off/On Delay

Output
Off/On Delay

I/O Response Time

In this case, you can calculate the response time by simply adding the following
items:
Input Delay + Scan Time + Output Delay = Response Time
Normal Maximum
I/O Response

The I/O response time is longest when the input changes just after the Read Inputs
portion of the execution cycle. In this case the new input status is not read until the
following scan. The following diagram shows an example of the timing for this
situation.
Scan

CPU Specifications
and Operation

Scan

Solve
Program

Solve
Program
Read
Inputs

Solve
Program

Solve
Program

Write
Outputs

Field Input
CPU Reads
Inputs

CPU Writes
Outputs

Input
Off/On Delay

Output
Off/On Delay

I/O Response Time

In this case, you can calculate the response time by simply adding the following
items:
Input Delay +(2 x Scan Time) + Output Delay = Response Time

417
CPU Specifications and Operation

Improving
Response Time

There are a few things you can do the help improve throughput.
S You can choose instructions with faster execution times
S You can use immediate I/O instructions (which update the I/O points
during the program execution)
S You can use the HSIO Mode 50 Pulse Catch features designed to
operate in high-speed environments. See the Chapter 3 for details on
using this feature.
Of these three things the Immediate I/O instructions are probably the most important
and most useful. The following example shows how an immediate input instruction
and immediate output instruction would affect the response time.
Scan

Scan

Solve
Program

Solve
Program

Normal
Read
Input

Read
Input
Immediate

Solve
Program
Write
Output
Immediate

Solve
Program

Normal
Write
Outputs

Field Input

Input
Off/On Delay

Output
Off/On Delay

I/O Response Time

In this case, you can calculate the response time by simply adding the following
items.

The instruction execution time would be calculated by adding the time for the
immediate input instruction, the immediate output instruction, and any other
instructions in between the two.
NOTE: Even though the immediate instruction reads the most current status from
I/O, it only uses the results to solve that one instruction. It does not use the new
status to update the image register. Therefore, any regular instructions that follow
will still use the image register values. Any immediate instructions that follow will
access the I/O again to update the status.

CPU Specifications
and Operation

Input Delay + Instruction Execution Time + Output Delay = Response Time

418
CPU Specifications and Operation

CPU Scan Time Considerations

CPU Specifications
and Operation

The scan time covers all the cyclical tasks

that are performed by the operating
system. You can use DirectSOFT or the
Handheld Programmer to display the
minimum, maximum, and current scan
times that have occurred since the
previous Program Mode to Run Mode
transition. This information can be very
important
when
evaluating
the
performance of a system.
As weve shown previously there are
several segments that make up the scan
cycle. Each of these segments requires a
certain amount of time to complete. Of all
the segments, the following are the most
important.
S
Input Update
S
Peripheral Service
S
Program Execution
S
Output Update
S
Timed Interrupt Execution
The only one you really have the most
control over is the amount of time it takes
to execute the application program. This is
because different instructions take
different amounts of time to execute. So, if
you think you need a faster scan, then you
can try to choose faster instructions.
Your choice of I/O type and peripheral
devices can also affect the scan time.
However, these things are usually dictated
by the application.
The following paragraphs provide some
general information on how much time
some of the segments can require.

Power up
Initialize hardware
Initialize various memory
based on retentive
configuration

Update input
Service peripheral
Update Special Relays
PGM

Mode?
RUN
Execute program
Update output

Do diagnostics
OK

OK?

YES

NO
Report error, set flag
register, turn on LED

Fatal error

NO

YES
Force CPU into
PGM mode

Reading Inputs

The time required during each scan to read the input status is 40 mS. Dont confuse
this with the I/O response time that was discussed earlier.

Writing Outputs

The time required to write the output status is 629 mS. Dont confuse this with the I/O
response time that was discussed earlier.

419
CPU Specifications and Operation

The CPU processes the program from address 0 to the END instruction. The CPU
Application
Program Execution executes the program left to right and top to bottom. As each rung is evaluated the
appropriate image register or memory location is updated. The time required to
solve the application program depends on the type and number of instructions used,
and the amount of execution overhead.
Just add the execution times for all the instructions in your program to determine to
total execution time. Appendix C provides a complete list of the instruction execution
times for the DL05 Micro PLC. For example, the execution time for running the
program shown below is calculated as follows:
Instruction

Time

STR X0
OR C0
ANDN X1
OUT Y0
STRN C100
LD K10
STRN C101
OUT V2002
STRN C102
LD K50
STRN C103
OUT V2006
STR X5
ANDN X10
OUT Y3
END

2 ms
1.6 ms
1.6 ms
6.8 ms
2.3 ms
42.7 ms
2.3 ms
16.6 ms
2.3 ms
42.7 ms
2.3 ms
16.6 ms
2 ms
1.6 ms
6.8 ms
24 ms

SUBTOTAL

174.2 ms

X1

Y0
OUT

C0

C100

LD
K10

C101

OUT

C102

V2002

LD
K50

C103

X5

DL05
0.66 mS
2.5 ms

OUT

X10

V2006

Y3
OUT

END

TOTAL TIME = (Program execution time + Overhead) x 1.1

The program above takes only 174.2 ms to execute during each scan. The DL05
spends 0.1ms, on internal timed interrupt management, for every 1ms of instruction
time. The total scan time is calculated by adding the program execution time to the
overhead (shown above)and multiplying the result (ms) by 1.1. Overhead includes
all other housekeeping and diagnostic tasks. The scan time will vary slightly from
one scan to the next, because of fluctuation in overhead tasks.
Program Control Instructions the DL05 PLCs have an interrupt routine feature
that changes the way a program executes. Since this instruction interrupts normal
program flow, it will have an effect on the program execution time. For example, a
timed interrupt routine with a 10 mS period interrupts the main program execution
(before the END statement) every 10 mS, so the CPU can execute the interrupt
routine. Chapter 5 provides detailed information on interrupts.

CPU Specifications
and Operation

Overhead
Minimum
Maximum

X0

420
CPU Specifications and Operation

PLC Numbering Systems

If you are a new PLC user or are using
PLCDirect PLCs for the first time, please
take a moment to study how our PLCs use
numbers. Youll find that each PLC
manufacturer has their own conventions
on the use of numbers in their PLCs. We
want to take just a moment to familiarize
you with how numbers are used in
PLCDirect PLCs. The information you
learn here applies to all of our PLCs!

PLC Resources

BCD

binary

0402 ?
7 961428 ASCII
hexadecimal
1001011011
177
1011
?
decimal
A
72B
?
300124
3A9

As any good computer does, PLCs store and manipulate numbers in binary form:
just ones and zeros. So why do we have to deal with numbers in so many different
forms? Numbers have meaning, and some representations are more convenient
than others for particular purposes. Sometimes we use numbers to represent a size
or amount of something. Other numbers refer to locations or addresses, or to time. In
science we attach engineering units to numbers to give a particular meaning.
PLCs offer a fixed amount of resources, depending on the model and configuration.
We use the word resources to include variable memory (V-memory), I/O points,
timers, counters, etc. Most modular PLCs allow you to add I/O points in groups of
eight. In fact, all the resources of our PLCs are counted in octal. Its easier for
computers to count in groups of eight than ten, because eight is an even power of 2.
Octal means simply counting in groups of
eight things at a time. In the figure to the
right, there are eight circles. The quantity
in decimal is 8, but in octal it is 10 (8 and
9 are not valid in octal). In octal, 10
means 1 group of 8 plus 0 (no individuals).

CPU Specifications
and Operation

octal
1482

Decimal 1 2 3 4 5 6 7 8

Octal

1 2 3 4 5 6 7 10

In the figure below, we have two groups of eight circles. Counting in octal we have
20 items, meaning 2 groups of eight, plus 0 individuals Dont say twenty, say
twozero octal. This makes a clear distinction between number systems.
Decimal 1 2 3 4 5 6 7 8

Octal

2 3 4

7 10

9 10 11 12 13 14 15 16

11 12 13 14 15 16 17 20

After counting PLC resources, its time to access PLC resources (theres a
difference). The CPU instruction set accesses resources of the PLC using octal
addresses. Octal addresses are the same as octal quantities, except they start
counting at zero. The number zero is significant to a computer, so we dont skip it.
Our circles are in an array of square
containers to the right. To access a
resource, our PLC instruction will address
its location using the octal references
shown. If these were counters, CT14
would access the black circle location.

X= 0
X
1X
2X

2 3

421
CPU Specifications and Operation

VMemory

Variable memory (called V-memory) stores data for the ladder program and for
configuration settings. V-memory locations and V-memory addresses are the same
thing, and are numbered in octal. For example, V2073 is a valid location, while
V1983 is not valid (9 and 8 are not valid octal digits).
Each V-memory location is one data word wide, meaning 16 bits. For configuration
registers, our manuals will show each bit of a V-memory word. The least significant
bit (LSB) will be on the right, and the most significant bit (MSB) on the left. We use the
word significant, referring to the relative binary weighting of the bits.
V-memory address
(octal)
V2017

Binary-Coded
Decimal Numbers

V-memory data
(binary)

MSB

LSB

0 1 0 0 1 1 1 0 0 0 1 0 1 0 0 1

V-memory data is 16-bit binary, but we rarely program the data registers one bit at a
time. We use instructions or viewing tools that let us work with decimal, octal, and
hexadecimal numbers. All these are converted and stored as binary for us.
A frequently-asked question is How do I tell if a number is octal, BCD, or hex? The
answer is that we usually cannot tell just by looking at the data... but it does not really
matter. What matters is: the source or mechanism which writes data into a
V-memory location and the thing which later reads it must both use the same data
type (i.e., octal, hex, binary, or whatever). The V-memory location is just a storage
box... thats all. It does not convert or move the data on its own.
Since humans naturally count in decimal (10 fingers, 10 toes), we prefer to enter and
view PLC data in decimal as well. However, computers are more efficient in using
pure binary numbers. A compromise solution between the two is Binary-Coded
Decimal (BCD) representation. A BCD digit ranges from 0 to 9, and is stored as four
binary bits (a nibble). This permits each V-memory location to store four BCD digits,
with a range of decimal numbers from 0000 to 9999.
BCD number

0 1 0 0

1 0 0 1

0 0 1 1

0 1 1 0

In a pure binary sense, a 16-bit word can represent numbers from 0 to 65535. In
storing BCD numbers, the range is reduced to only 0 to 9999. Many math
instructions use Binary-Coded Decimal (BCD) data, and DirectSOFT and the
handheld programmer allow us to enter and view data in BCD.
Hexadecimal
Numbers

Hexadecimal numbers are similar to BCD numbers, except they utilize all possible
binary values in each 4-bit digit. They are base-16 numbers so we need 16 different
digits. To extend our decimal digits 0 through 9, we use A through F as shown.
Decimal
Hexadecimal

0 1 2 3
0 1 2 3

4 5
4 5

6
6

7
7

8 9 10 11 12 13 14 15
8 9 A B C D E F

A 4-digit hexadecimal number can represent all 65536 values in a V-memory word.
The range is from 0000 to FFFF (hex). PLCs often need this full range for sensor
data, etc. Hexadecimal is just a convenient way for humans to view full binary data.
Hexadecimal number
V-memory storage

1 0 1 0

0 1 1 1

1 1 1 1

0 1 0 0

CPU Specifications
and Operation

V-memory storage

422
CPU Specifications and Operation

Memory Map
With any PLC system, you generally have many different types of information to
process. This includes input device status, output device status, various timing
elements, parts counts, etc. It is important to understand how the system represents
and stores the various types of data. For example, you need to know how the system
identifies input points, output points, data words, etc. The following paragraphs
discuss the various memory types used in DL05 Micro PLCs. A memory map
overview for the CPU follows the memory descriptions.
Octal Numbering
System

All memory locations and resources are

numbered in Octal (base 8). For example,
the diagram shows how the octal
numbering system works for the discrete
input points. Notice the octal system does
not contain any numbers with the digits 8
or 9.
X0

X1

X2

X3

X4

X5

X6

X7

X10 X11

CPU Specifications
and Operation

Discrete and Word

Locations

V Memory
Locations for
Discrete Memory
Areas

As you examine the different memory

types, youll notice two types of memory
in the DL05, discrete and word memory.
Discrete memory is one bit that can be
either a 1 or a 0. Word memory is referred
to as V memory (variable) and is a 16-bit
location normally used to manipulate
data/numbers, store data/numbers, etc.
Some information is automatically stored
in V memory. For example, the timer
current values are stored in V memory.

Discrete On or Off, 1 bit

X0

Word Locations 16 bits

0 1 0 1 00 0 0 0 0 1 0 0 1 0 1

The discrete memory area is for inputs, outputs, control relays, special relays,
stages, timer status bits and counter status bits. However, you can also access the
bit data types as a V-memory word. Each V-memory location contains 16
consecutive discrete locations. For example, the following diagram shows how the X
input points are mapped into V-memory locations.
8 Discrete (X) Input Points

Bit # 15

14

13

12

11

10

X7

X6

X5

X4

X3

X2

X1

X0

V40400

These discrete memory areas and their corresponding V memory ranges are listed
in the memory area table for DL05 Micro PLCs on the following pages.

423
CPU Specifications and Operation

Input Points
(X Data Type)

The discrete input points are noted by an

X data type. There are 8 discrete input
points and 256 discrete input addresses
available with DL05 CPUs. In this
example, the output point Y0 will be
turned on when input X0 energizes.

Output Points
(Y Data Type)

The discrete output points are noted by a

Y data type. There are 6 discrete outputs
and 256 discrete output addresses
available with DL05 CPUs. In this
example, output point Y1 will be turned
on when input X1 energizes.

Control Relays
(C Data Type)

Control relays are discrete bits normally

used to control the user program. The
control relays do not represent a real
world device, that is, they cannot be
physically tied to switches, output coils,
etc. They are internal to the CPU.
Because of this, control relays can be
programmed as discrete inputs or
discrete outputs. These locations are
used in programming the discrete
memory
locations
(C)
or
the
corresponding word location which
contains 16 consecutive discrete
locations.
In this example, memory location C5 will
energize when input X6 turns on. The
second rung shows a simple example of
how to use a control relay as an input.
Timer status bits reflect the relationship
between the current value and the preset
value of a specified timer. The timer
status bit will be on when the current
value is equal or greater than the preset
value of a corresponding timer.
When input X0 turns on, timer T1 will
start. When the timer reaches the preset
of 3 seconds (K of 30) timer status
contact T1 turns on. When T1 turns on,
output Y12 turns on. Turning off X0
resets the timer.

Y0
OUT

X1

Y1
OUT

X6

C5
OUT

C5

Y10
OUT
Y20
OUT

X0

TMR

T1
K30

T1

Y12
OUT

CPU Specifications
and Operation

Timers and
Timer Status Bits
(T Data type)

X0

424
CPU Specifications and Operation

Timer Current
Values
(V Data Type)

Counters and
Counter Status
Bits
(CT Data type)

As mentioned earlier, some information

is automatically stored in V memory. This
is true for the current values associated
with timers. For example, V0 holds the
current value for Timer 0, V1 holds the
current value for Timer 1, etc.
The primary reason for this is
programming flexibility. The example
shows how you can use relational
contacts to monitor several time intervals
from a single timer.

Counter status bits that reflect the

relationship between the current value
and the preset value of a specified
counter. The counter status bit will be on
when the current value is equal to or
greater than the preset value of a
corresponding counter.

X0

TMR
T1
K1000

V1

K30

Y2
OUT

V1

K50

Y3
OUT

V1

K75

V1

X0

K100

CNT

Y4
OUT

CT3
K10

X1

CT3

Y2
OUT

Each time contact X0 transitions from off to on, the counter increments by one. (If X1
comes on, the counter is reset to zero.) When the counter reaches the preset of 10
counts (K of 10) counter status contact CT3 turns on. When CT3 turns on, output Y2
turns on.

CPU Specifications
and Operation

Counter Current
Values
(V Data Type)

Just like the timers, the counter current

values are also automatically stored in V
memory. For example, V1000 holds the
current value for Counter CT0, V1001
holds the current value for Counter CT1,
etc.
The primary reason for this is
programming flexibility. The example
shows how you can use relational
contacts to monitor the counter values.

X0

CNT

CT3
K10

X1

V1003

K1

Y2
OUT

V1003

K3

Y3
OUT

V1003

K5

V1003

K8

Y4
OUT

425
CPU Specifications and Operation

Word Memory
(V Data Type)

Word memory is referred to as V memory

(variable) and is a 16-bit location
normally
used
to
manipulate
data/numbers, store data/numbers, etc.
Some information is automatically stored
in V memory. For example, the timer
current values are stored in V memory.
The example shows how a four-digit
BCD constant is loaded into the
accumulator and then stored in a
V-memory location.

X0

LD
K1345

OUT

V2000

Word Locations 16 bits

0 0 0 1 00 1 1 0 1 0 0 0 1 0 1

Stages
(S Data type)

Special relays are discrete memory

locations with pre-defined functionality.
There are many different types of special
relays. For example, some aid in
program development, others provide
system operating status information, etc.
Appendix D provides a complete listing of
the special relays.
In this example, control relay C10 will
energize for 50 ms and de-energize for
50 ms because SP5 is a predefined
relay that will be on for 50 ms and off for
50 ms.

Ladder Representation
ISG
S0000

Wait forStart
Start

S1
JMP

X0
S500
JMP
SG

Check for a Part

S0001

Part
Present

S2
JMP

X1
Part
Present

S6
JMP

X1
SG

Clamp the part

S0002

Clamp
SET
S400
S3
JMP

Part
Locked
X2

SP5

C10
OUT

SP4: 1 second clock

SP5: 100 ms clock
SP6: 50 ms clock

CPU Specifications
and Operation

Special Relays
(SP Data Type)

Stages are used in RLL PLUS programs to

create a structured program, similar to a
flowchart. Each program Staget
denotes a program segment. When the
program segment, or Staget, is active,
the logic within that segment is executed.
If the Staget is off, or inactive, the logic
is not executed and the CPU skips to the
next active Staget. (See Chapter 7 for a
more detailed description of RLL PLUS
programming.)
Each Staget also has a discrete status
bit that can be used as an input to
indicate whether the Staget is active or
inactive. If the Staget is active, then the
status bit is on. If the Staget is inactive,
then the status bit is off. This status bit
can also be turned on or off by other
instructions, such as the SET or RESET
instructions. This allows you to easily
control stages throughout the program.

426
CPU Specifications and Operation

DL05 System V-memory

System Parameters The DL05 PLCs reserve several V-memory locations for storing system parameters
or certain types of system data. These memory locations store things like the error
and Default Data
codes, High-Speed I/O data, and other types of system setup information.
Locations
(V Data Type)

CPU Specifications
and Operation

System
V-memory

Description of Contents

V2320V2377

The default location for multiple preset values for the High-Speed Counter

V7620V7627

Locations for DV1000 operator interface parameters

Default Values / Ranges

N/A

V7620 Sets the V-memory location that contains the value.

V0 V2377

V7621 Sets the V-memory location that contains the message.

V0 V2377

V7622 Sets the total number (1 16) of V-memory locations to be displayed.

1 16

V7623 Sets the V-memory location that contains the numbers to be displayed.

V0 V2377

V7624 Sets the V-memory location that contains the character code to be displayed.

V0 V2377

V7625 Contains the function number that can be assigned to each key.

V-memory location for X,

Y, or C points used.

V7626 Powerup operational mode.

0, 1, 2, 12, 3

V7627 Change preset value.

0000 to 9999

V7630

Starting location for the multistep presets for channel 1. The default value is
2320, which indicates the first value should be obtained from V2320. Since
there are 24 presets available, the default range is V2320 V2377. You can
change the starting point if necessary.

Default: V2320
Range: V0 V2320

V7631V7632

Reserved

N/A

V7633

Sets the desired function code for the high speed counter, interrupt, pulse
catch, pulse train, and input filter. Location can also be used to set the
power-up in Run Mode option.

Default: 0060
Lower Byte Range:
Range: 10 Counter
20 Quadrature
30 Pulse Out
40 Interrupt
50 Pulse Catch
60 Filtered
discrete In.
Upper Byte Range:
Bits 812, 14, 15: Unused
Bit 13: Powerup in RUN,
only if Mode Switch is in
TERM position.

V7634

X0 Setup Register for High-Speed I/O functions

Default: 1006

V7635

X1 Setup Register for High-Speed I/O functions

Default: 1006

V7636

X2 Setup Register for High-Speed I/O functions

Default: 1006

V7637V7646

Reserved

N/A

V7647

Timed Interrupt

Default: 0000
Range: 000303E7h
(39999ms)

V7650V7654

Reserved

N/A

V7655

Port 2: Setup for the protocol, time-out, and the response delay time.

Default: 00E0

V7656

Port 2: Setup for the station number, baud rate, STOP bit, and parity.

Default: 8501

427
CPU Specifications and Operation

System
V-memory

Description of Contents

Default Values / Ranges

V7657

Port 2: Setup completion code used to notify the completion of the parameter
setup.

Default: 0A00

V7660

Scan control setup: Keeps the scan control mode.

Default: 0000

V7661

Setup timer over counter: Counts the times the actual scan time exceeds the
user setup time.

N/A

V7662V7717

Reserved

N/A

V7720V7722

N/A

Titled Timer preset value pointer

N/A

V7721

Title Counter preset value pointer

N/A

V7722

HiByte-Titled Timer preset block size, LoByte-Titled Counter preset block size

N/A

V7723V7750

Reserved

N/A

V7751

Fault Message Error Code stores the 4-digit code used with the FAULT
instruction when the instruction is executed.

N/A

V7752V7754

Reserved

N/A

V7755

Error code stores the fatal error code.

V7756

Error code stores the major error code.

V7757

Error code stores the minor error code.

V7760V7762

Reserved

V7763

Program address where syntax error exists

N/A

V7764

Syntax error code

N/A

V7765

Scan stores the total number of scan cycles that have occurred since the
last Program Mode to Run Mode transition.

N/A

V7766V7774

Reserved

N/A

V7775

Scan stores the current scan time (milliseconds).

N/A

V7776

Scan stores the minimum scan time that has occurred since the last
Program Mode to Run Mode transition (milliseconds).

N/A

V7777

Scan stores the maximum scan time that has occurred since the last
Program Mode to Run Mode transition (milliseconds).

N/A

CPU Specifications
and Operation

Locations for DV1000 operator interface parameters.

V7720

428
CPU Specifications and Operation

DL05 Memory Map

Memory Type

Discrete Memory
Reference
(octal)

Word Memory
Reference
(octal)

Qty.
Decimal

Symbol

Input Points
(See note 1)

X0 X377

V40400 - V40417

256

X0

Output Points
(See note 1)

Y0 Y377

V40500 V40517

256

Y0

Control Relays

C0 C777

V40600 - V40637

512

Special Relays

SP0 SP777

V41200 V41237

512

Timers

T0 T177

V41100 V41107

128

Timer Current
Values

None

V0 V177

128

Timer Status Bits T0 T177

V41100 V41107

128

Counters

V41140 V41147

128

CT0 CT177

C0

C0

SP0

TMR
K100

V0

T0

K100

T0

CNT CT0

CPU Specifications
and Operation

K10

Counter
Current Values

None

V1000 V1177

128

Counter Status
Bits

CT0 CT177

V41140 V41147

128

Data Words

None

V1200 V7377

3968

None specific, used with many

instructions

Data Words
Nonvolatile

None

V7400 V7577

128

None specific, used with many

instructions

Stages

S0 S377

V41000 V41017

256

V1000

K100

CT0

S0

SG
S 001

System
parameters

None

V7600 V7777

128

None specific, used for various

purposes

1 The DL05 systems are limited to 8 discrete inputs and 6 discrete outputs with the present available hardware, but 256 point addresses exist.

429
CPU Specifications and Operation

X Input Bit Map

This table provides a listing of individual Input points associated with each V-memory address bit for the
DL05s eight physical inputs. Actual available references are X0 to X377 (V40400 V40417).
MSB

DL05 Input (X) Points

LSB

17

16

15

14

13

12

11

10

007

006

005

004

003

002

001

000

Address
V40400

Y Output Bit Map

This table provides a listing of individual output points associated with each V-memory address bit for the
DL05s six physical outputs. Actual available references are Y0 to Y377 (V40500 V40517).
MSB

DL05 Output (Y) Points

LSB

17

16

15

14

13

12

11

10

005

004

003

002

001

000

Address
V40500

Stage Control / Status Bit Map

This table provides a listing of individual Staget control bits associated with each V-memory address bit.
MSB

DL05 Stage (S) Control Bits

LSB

Address

16

15

14

13

12

11

10

017

016

015

014

013

012

011

010

007

006

005

004

003

002

001

000

V41000

037

036

035

034

033

032

031

030

027

026

025

024

023

022

021

020

V41001

057

056

055

054

053

052

051

050

047

046

045

044

043

042

041

040

V41002

077

076

075

074

073

072

071

070

067

066

065

064

063

062

061

060

V41003

117

116

115

114

113

112

111

110

107

106

105

104

103

102

101

100

V41004

137

136

135

134

133

132

131

130

127

126

125

124

123

122

121

120

V41005

157

156

155

154

153

152

151

150

147

146

145

144

143

142

141

140

V41006

177

176

175

174

173

172

171

170

167

166

165

164

163

162

161

160

V41007

217

216

215

214

213

212

211

210

207

206

205

204

203

202

201

200

V41010

237

236

235

234

233

232

231

230

227

226

225

224

223

222

221

220

V41011

257

256

255

254

253

252

251

250

247

246

245

244

243

242

241

240

V41012

277

276

275

274

273

272

271

270

267

266

265

264

263

262

261

260

V41013

317

316

315

314

313

312

311

310

307

306

305

304

303

302

301

300

V41014

337

336

335

334

333

332

331

330

327

326

325

324

323

322

321

320

V41015

357

356

355

354

353

352

351

350

347

346

345

344

343

342

341

340

V41016

377

376

375

374

373

372

371

370

367

366

365

364

363

362

361

360

V41017

CPU Specifications
and Operation

17

430
CPU Specifications and Operation

Control Relay Bit Map

This table provides a listing of the individual control relays associated with each V-memory address bit.

CPU Specifications
and Operation

MSB

DL05 Control Relays (C)

17

16

15

14

13

12

017

016

015

014

013

037

036

035

034

033

057

056

055

054

077

076

075

117

116

137

LSB

Address

11

10

012

011

010

007

006

005

004

003

002

001

000

V40600

032

031

030

027

026

025

024

023

022

021

020

V40601

053

052

051

050

047

046

045

044

043

042

041

040

V40602

074

073

072

071

070

067

066

065

064

063

062

061

060

V40603

115

114

113

112

111

110

107

106

105

104

103

102

101

100

V40604

136

135

134

133

132

131

130

127

126

125

124

123

122

121

120

V40605

157

156

155

154

153

152

151

150

147

146

145

144

143

142

141

140

V40606

177

176

175

174

173

172

171

170

167

166

165

164

163

162

161

160

V40607

217

216

215

214

213

212

211

210

207

206

205

204

203

202

201

200

V40610

237

236

235

234

233

232

231

230

227

226

225

224

223

222

221

220

V40611

257

256

255

254

253

252

251

250

247

246

245

244

243

242

241

240

V40612

277

276

275

274

273

272

271

270

267

266

265

264

263

262

261

260

V40613

317

316

315

314

313

312

311

310

307

306

305

304

303

302

301

300

V40614

337

336

335

334

333

332

331

330

327

326

325

324

323

322

321

320

V40615

357

356

355

354

353

352

351

350

347

346

345

344

343

342

341

340

V40616

377

376

375

374

373

372

371

370

367

366

365

364

363

362

361

360

V40617

417

416

415

414

413

412

411

410

407

406

405

404

403

402

401

400

V40620

437

436

435

434

433

432

431

430

427

426

425

424

423

422

421

420

V40621

457

456

455

454

453

452

451

450

447

446

445

444

443

442

441

440

V40622

477

476

475

474

473

472

471

470

467

466

465

464

463

462

461

460

V40623

517

516

515

514

513

512

511

510

507

506

505

504

503

502

501

500

V40624

537

536

535

534

533

532

531

530

527

526

525

524

523

522

521

520

V40625

557

556

555

554

553

552

551

550

547

546

545

544

543

542

541

540

V40626

577

576

575

574

573

572

571

570

567

566

565

564

563

562

561

560

V40627

617

616

615

614

613

612

611

610

607

606

605

604

603

602

601

600

V40630

637

636

635

634

633

632

631

630

627

626

625

624

623

622

621

620

V40631

657

656

655

654

653

652

651

650

647

646

645

644

643

642

641

640

V40632

677

676

675

674

673

672

671

670

667

666

665

664

663

662

661

660

V40633

717

716

715

714

713

712

711

710

707

706

705

704

703

702

701

700

V40634

737

736

735

734

733

732

731

730

727

726

725

724

723

722

721

720

V40635

757

756

755

754

753

752

751

750

747

746

745

744

743

742

741

740

V40636

777

776

775

774

773

772

771

770

767

766

765

764

763

762

761

760

V40637

431
CPU Specifications and Operation

Timer Status Bit Map

This table provides a listing of individual timer contacts associated with each V-memory address bit.
MSB

DL05 Timer (T) Contacts

LSB

Address

17

16

15

14

13

12

11

10

017

016

015

014

013

012

011

010

007

006

005

004

003

002

001

000

V41100

037

036

035

034

033

032

031

030

027

026

025

024

023

022

021

020

V41101

057

056

055

054

053

052

051

050

047

046

045

044

043

042

041

040

V41102

077

076

075

074

073

072

071

070

067

066

065

064

063

062

061

060

V41103

117

116

115

114

113

112

111

110

107

106

105

104

103

102

101

100

V41104

137

136

135

134

133

132

131

130

127

126

125

124

123

122

121

120

V41105

157

156

155

154

153

152

151

150

147

146

145

144

143

142

141

140

V41106

177

176

175

174

173

172

171

170

167

166

165

164

163

162

161

160

V41107

Counter Status Bit Map

This table provides a listing of individual counter contacts associated with each V-memory address bit.
MSB

DL05 Counter (CT) Contacts

LSB

Address

16

15

14

13

12

11

10

017

016

015

014

013

012

011

010

007

006

005

004

003

002

001

000

V41140

037

036

035

034

033

032

031

030

027

026

025

024

023

022

021

020

V41141

057

056

055

054

053

052

051

050

047

046

045

044

043

042

041

040

V41142

077

076

075

074

073

072

071

070

067

066

065

064

063

062

061

060

V41143

117

116

115

114

113

112

111

110

107

106

105

104

103

102

101

100

V41144

137

136

135

134

133

132

131

130

127

126

125

124

123

122

121

120

V41145

157

156

155

154

153

152

151

150

147

146

145

144

143

142

141

140

V41146

177

176

175

174

173

172

171

170

167

166

165

164

163

162

161

160

V41147

CPU Specifications
and Operation

17

432
CPU Specifications and Operation

Network Configuration and Connections

Configuring
the DL05s
Comm Ports

This section describes how to configure the CPUs built-in networking ports for either
MODBUS or DirectNET. This will allow you to connect the DL05 PLC system directly
to MODBUS networks using the RTU protocol, or to other devices on a DirectNET
network. MODBUS host systems must be capable of issuing the MODBUS
commands to read or write the appropriate data. For details on the MODBUS
protocol, check with your MODBUS supplier for the lastest version of the Gould
MODBUS Protocol reference Guide. For more details on DirectNET, order our
DirectNET manual, part number DADNETM.

Communication Port 1

Communication Port 2

Com 1 Connects to HPP, DirectSOFT,

operator interfaces, etc.
6-pin, RS232C
9600 Baud (Fixed)
Parity - odd (default)
Station address 1 (fixed)
8 data bits
1 start, 1 stop bit
Asynchronous, Half-duplex, DTE
Protocol: (Auto-Select)
K sequence (Slave only)

Com 2 Connects to HPP, DirectSOFT,

operator interfaces, etc.
6-pin, RS232C
Communication speed (baud)
300, 600, 1200, 2400, 4800,
9600, 19200, 38400
Parity - odd (default), even, none
Station address 1 (default)
8 data bits
1 start, 1 stop bit
Asynchronous, Half-duplex, DTE
Protocol: (Auto-Select)
K sequence (Slave only)

DirectNET (Slave only)

MODBUS (Slave only)

DirectNET (Master/Slave)
MODBUS (Master/Slave)
Non-sequence/Print

CPU Specifications
and Operation

You will need to make sure the network connection is a 3-wire RS232 type.
Normally, the RS232 signals are used for for communications between two devices
with distances up to a maximum of 15 meters.
Networking
DL05 to DL05
RS232C
1234 5 6

Port 1 Pin Descriptions

1
2
3
4
5
6

0V
5V
RXD
TXD
5V
0V

Power () connection (GND)

Power (+) conection
Receive Data (RS232C)
Transmit Data (RS232C
Power (+) conection
Power () connection (GND)

Port 2 Pin Descriptions

1
2
3
4
5
6

0V
5V
RXD
TXD
RTS
0V

Power () connection (GND)

Power (+) conection
Receive Data (RS232C)
Transmit Data (RS232C
Request to Send
Power () connection (GND)

6-pin Female
Modular Connector

DL05
PORT 1 or 2

DL05
PORT 2
1 0V
3 RXD
4 TXD

0V 1
RXD 3
TXD 4

433
CPU Specifications and Operation

Networking
PC to DL05s
RS422

1234 5 6

6-pin Female
Modular Connector

F2UNICON
0V
RXD

0V 1
RXD 3

TXD
RTS

GND

GND

DL05
1 or 6 0V 0V 1 or 6 PORT 2

TXD+

RXD+

3 RXD

RXD 3

TXD

RXD

TXD 4

RXD

TXD

4 TXD
2 CTS

TXD 4
5V 2

RTS 5

RXD+

TXD+

5 5V

RTS 5

FAISONET

Note: When using the DL05 on a multi-drop

network, the RTS ON Delay time must be set
to at least 5ms and the RTS OFF Delay time
must be set to at least 2ms. If you encounter
problems, the time can be increased.

F2UNICON
GND
RXD+
RXD
TXD
TXD+

Networking
DL05 Master
to Other PLCs

5 5V

TXD 4
5V 2
RTS 5

F2UNICON

1 or 6 0V 0V 1 or 6
3 RXD
RXD 3

GND

GND

TXD+
TXD

RXD+
RXD

4 TXD

TXD 4

RXD

TXD

2 CTS

5V 2

RXD+

TXD+

5 5V

4 TXD
2 CTS

DL05
1 or 6 0V 0V 1 or 6 PORT 2
3 RXD
RXD 3
4 TXD
2 CTS
5 5V

TXD 4
5V 2
RTS 5

RTS 5

FAISONET

F2UNICON

DL240

GND

1 0V

RXD+

3 RXD

0V 1 PORT 2
RXD 3

RXD

4 TXD

TXD 4

TXD
TXD+

2 CTS
5 5V

5V 2
RTS 5

CPU Specifications
and Operation

DL05
PORT 2

DL05
1 or 6 0V 0V 1 or 6 PORT 2
3 RXD
RXD 3

434
CPU Specifications and Operation

MODBUS Port
Configuration

In DirectSOFT, choose the PLC menu, then Setup, then Secondary Comm Port.
S Port: From the port number list box at the top, choose Port 2.
S Protocol: Click the check box to the left of MODBUS (use AUX 56 on
the HPP, andselect MBUS), and then youll see the dialog box below.
Setup Communication Ports
Port:
Protocol:

Timeout:

RTS OFF Delay Time:

2 mS

Stop Bits:
Parity:

CPU Specifications
and Operation

S
S

Close

Help

800 mS
5 mS

Baud Rate:

K-sequence
DirectNET
MODBUS
Non-sequence

RTS ON Delay Time:

Station Number:

Port 2

1
38400
1
None

Timeout: amount of time the port will wait after it sends a message to get
a response before logging an error.
RTS ON / OFF Delay Time: The RTS ON Delay Time specifies the time
the DL05 waits to send the data after it has raised the RTS signal line.
The RTS OFF Delay Time specifies the time the DL05 waits to release
the RTS signal line after the data has been sent. When using the DL05 on
a multi-drop network, the RTS ON Delay time must be set to at least 5ms
and the RTS OFF Delay time must be set to at least 2ms. If you
encounter problems, the time can be increased.
Station Number: For making the CPU port a MODBUSR master, choose
1. The possible range for MODBUS slave numbers is from 1 to 247, but
the DL05 network instructions used in Master mode will access only
slaves 1 to 99. Each slave must have a unique number. At powerup, the
port is automatically a slave, unless and until the DL05 executes ladder
logic network instructions which use the port as a master. Thereafter, the
port reverts back to slave mode until ladder logic uses the port again.
Baud Rate: The available baud rates include 300, 600, 1200, 2400,
4800, 9600, 19200, and 38400 baud. Choose a higher baud rate initially,
reverting to lower baud rates if you experience data errors or noise
problems on the network. Important: You must configure the baud rates of
all devices on the network to the same value. Refer to the appropriate
product manual for details.
Stop Bits: Choose 1 or 2 stop bits for use in the protocol.
Parity: Choose none, even, or odd parity for error checking.
Then click the button indicated to send the Port configuration to
the CPU, and click Close.

435
CPU Specifications and Operation

DirectNET Port
Configuration

In DirectSOFT, choose the PLC menu, then Setup, then Secondary Comm Port.
S Port: From the port number list box, choose Port 2 .
S Protocol: Click the check box to the left of DirectNET (use AUX 56 on
the HPP, then select DNET), and then youll see the dialog box below.
Setup Communication Ports
Port:
Protocol:

Timeout:

RTS OFF Delay Time:

2 mS

Stop Bits:
Parity:
Format:

S
S
S

Help

1
38400
1
None
Hex

Timeout: amount of time the port will wait after it sends a message to
get a response before logging an error.
RTS ON / OFF Delay Time: The RTS ON Delay Time specifies the time
the DL05 waits to send the data after it has raised the RTS signal line.
The RTS OFF Delay Time specifies the time the DL05 waits to release
the RTS signal line after the data has been sent. When using the DL05
on a multi-drop network, the RTS ON Delay time must be set to at least
5ms and the RTS OFF Delay time must be set to at least 2ms. If you
encounter problems, the time can be increased.
Station Number: For making the CPU port a DirectNET master,
choose 1. The allowable range for DIrectNET slaves is from 1 to 90
(each slave must have a unique number). At powerup, the port is
automatically a slave, unless and until the DL05 executes ladder logic
instructions which attempt to use the port as a master. Thereafter, the
port reverts back to slave mode until ladder logic uses the port again.
Baud Rate: The available baud rates include 300, 600, 1200, 2400,
4800, 9600, 19200, and 38400 baud. Choose a higher baud rate initially,
reverting to lower baud rates if you experience data errors or noise
problems on the network. Important: You must configure the baud rates
of all devices on the network to the same value.
Stop Bits: Choose 1 or 2 stop bits for use in the protocol.
Parity: Choose none, even, or odd parity for error checking.
Format: Choose between hex or ASCII formats.
Then click the button indicated to send the Port configuration to
the CPU, and click Close.

CPU Specifications
and Operation

Close

800 mS
5 mS

Baud Rate:

K-sequence
DirectNET
MODBUS
Non-sequence

RTS ON Delay Time:

Station Number:

Port 2

436
CPU Specifications and Operation

Network Slave Operation

This section describes how other devices on a network can communicate with a CPU
port that you have configured as a DirectNETslave or MODBUS slave (DL05). A
MODBUS host must use the MODBUS RTU protocol to communicate with the DL05 as
a slave. The host software must send a MODBUS function code and MODBUS address
to specify a PLC memory location the DL05 comprehends. The DirectNET host uses
normal I/O addresses to access applicable DL05 CPU and system. No CPU ladder logic
is required to support either MODBUS slave or DirectNET slave operation.
MODBUS Function The MODBUS function code determines whether the access is a read or a write, and
Codes Supported whether to access a single data point or a group of them. The DL05 supports the
MODBUS function codes described below.
MODBUS
Function Code

CPU Specifications
and Operation

DL05 Data Types

Available

01

Read a group of coils

Y, CR, T, CT

02

Read a group of inputs

X, SP

05

Set / Reset a single coil

Y, CR, T, CT

15

Set / Reset a group of coils

Y, CR, T, CT

03, 04

Determining the
MODBUS Address

Function

Read a value from one or more registers V

06

Write a value into a single register

16

Write a value into a group of registers

There are typically two ways that most host software conventions allow you to
specify a PLC memory location. These are:
S By specifying the MODBUS data type and address
S By specifying a MODBUS address only.

437
CPU Specifications and Operation

If Your Host Software Many host software packages allow you to specify the MODBUS data type and the
Requires the Data
MODBUS address that corresponds to the PLC memory location. This is the easiest
Type and Address... method, but not all packages allow you to do it this way.

The actual equation used to calculate the address depends on the type of PLC data
you are using. The PLC memory types are split into two categories for this purpose.
S

Discrete X, SP, Y, CR, S, T, C (contacts)

S Word V, Timer current value, Counter current value
In either case, you basically convert the PLC octal address to decimal and add the
appropriate MODBUS address (if required). The table below shows the exact
equation used for each group of data.
DL05 Memory Type

QTY
(Dec.)

PLC Range
(Octal)

For Discrete Data Types .... Convert PLC Addr. to Dec.

MODBUS
Address Range
(Decimal)
+

Start of Range

MODBUS
Data Type
+ Data Type

Inputs (X)

256

X0

X377

2048

2303

Input

Special Relays (SP)

512

SP0

SP777

3072

3583

Input

Outputs (Y)

256

Y0

Y377

2048

2303

Coil

Control Relays (CR)

512

C0

C777

3072

4583

Coil

Timer Contacts (T)

128

T0

T177

6144

6271

Coil

Counter Contacts (CT)

128

CT0

CT177

6400

6527

Coil

Stage Status Bits (S)

256

S0

S377

5120

5375

Coil

For Word Data Types ....

Convert PLC Addr. to Dec.

128

V0

V177

Counter Current Values (V)

128

V1000

V Memory, user data (V)

3968

V1200
V7600

V Memory, non-volatile (V) 128

Data Type

127

Input Register

V1177

512

639

Input Register

V7377

640

3839

Holding Register

V7777

3968

4095

Holding Register

CPU Specifications
and Operation

Timer Current Values (V)

438
CPU Specifications and Operation

The following examples show how to generate the MODBUS address and data type
for hosts which require this format.
Example 1: V2100

Find the MODBUS address for User V

location V2100.
1. Find V memory in the table.
2. Convert V2100 into decimal (1088).
3. Use the MODBUS data type from the table.
V Memory, user data (V)

Example 2: Y20

3200

V1200

V7377

256

Y0

Y377

Example 3: T10 Current Find the MODBUS address to obtain the

current value from Timer T10.
Value

1. Find Timer Current Values in the table.

2. Convert T10 into decimal (8).
3. Use the MODBUS data type from the table.

CPU Specifications
and Operation

V2100 = 1088 decimal

1088 + Hold. Reg. = Holding Reg. 1088

640

3839

Holding Register

Find the MODBUS address for output Y20.

PLC Addr. (Dec) + Start Addr. + Data Type
1. Find Y outputs in the table.
Y20 = 16 decimal
2. Convert Y20 into decimal (16).
16 + 2048 + Coil =
Coil 2064
3. Add the starting address for the range
(2048).
4. Use the MODBUS data type from the table.
Outputs (Y)

Timer Current Values (V)

Example 4: C54

PLC Address (Dec.) + Data Type

128

V0

V177

2048

2303

Coil

PLC Address (Dec.) + Data Type

T10 = 8 decimal
8 + Input Reg. = Input Reg. 8

127

Input Register

Find the MODBUS address for Control Relay PLC Addr. (Dec) + Start Addr. +Data Type
C54.
C54 = 44 decimal
1. Find Control Relays in the table.
44 + 3072 + Coil = Coil 3116
2. Convert C54 into decimal (44).
3. Add the starting address for the range
(3072).
4. Use the MODBUS data type from the table.
Control Relays (CR)

512

C0

C777

3072

3583

Coil

439
CPU Specifications and Operation

If Your MODBUS
Host Software
Requires an
Address ONLY

DL05 Memory Type

Some host software does not allow you to specify the MODBUS data type and
address. Instead, you specify an address only. This method requires another step to
determine the address, but its still fairly simple. Basically, MODBUS also separates
the data types by address ranges as well. So this means an address alone can
actually describe the type of data and location. This is often referred to as adding the
offset. One important thing to remember here is that two different addressing
modes may be available in your host software package. These are:
S 484 Mode
S 584/984 Mode
We recommend that you use the 584/984 addressing mode if your host
software allows you to choose. This is because the 584/984 mode allows access
to a higher number of memory locations within each data type. If your software only
supports 484 mode, then there may be some PLC memory locations that will be
unavailable. The actual equation used to calculate the address depends on the type
of PLC data you are using. The PLC memory types are split into two categories for
this purpose.
S Discrete X, SP, Y, CR, S, T, C (contacts)
S Word V, Timer current value, Counter current value
In either case, you basically convert the PLC octal address to decimal and add the
appropriate MODBUS addresses (as required). The table below shows the exact
equation used for each group of data.
QTY
(Dec.)

PLC Range
(Octal)

For Discrete Data Types ... Convert PLC Addr. to Dec. +

MODBUS
Address Range
(Decimal)
Start of Range

484 Mode
Address

584/984
Mode
Address

MODBUS
Data Type

+ Appropriate Mode Address

256

X0

X377

2048

2303

1001

10001

Input

Special Relays (SP)

512

SP0

SP777

3072

3583

1001

10001

Input

Outputs (Y)

256

Y0

Y377

2048

2303

Coil

Control Relays (CR)

512

C0

C777

3072

3583

Coil

Timer Contacts (T)

128

T0

T177

6144

6271

Coil

Counter Contacts (CT)

128

CT0

CT177

6400

6527

Coil

Stage Status Bits (S)

256

S0

S377

5120

5375

Coil

For Word Data Types .... Convert PLC Addr. to Dec.

Timer Current Values (V)

128

V0

V377

Counter Current Values (V)

128

V1000

V Memory, user data (V)

3200

V1400

V Memory, non-volatile (V) 128

V Memory, system (V)

256

Appropriate Mode Address

127

3001

30001

Input Reg.

V1177

512

639

3001

30001

Input Reg

V7377

768

3839

4001

40001

Hold Reg.

V7400

V7577

3840

3967

4001

40001

Hold Reg.

V7600

V7777

3968

4095

4001

40001

Hold Reg.

CPU Specifications
and Operation

Inputs (X)

440
CPU Specifications and Operation

The following examples show how to generate the MODBUS addresses for hosts
which require this format.
Example 1: V2100
584/984 Mode

Find the MODBUS address for User V

location V2100.
1. Find V memory in the table.
2. Convert V2100 into decimal (1088).
3. Add the MODBUS starting address for the
mode (40001).

V Memory, system (V)

128

V1200

V7377

Find the MODBUS address for output Y20.

1. Find Y outputs in the table.
2. Convert Y20 into decimal (16).
3. Add the starting address for the range
(2048).
4. Add the MODBUS address for the mode
(1).

Example 2: Y20
584/984 Mode

Outputs (Y)

256

Y0

Y377

Example 3: T10 Current Find the MODBUS address to obtain the

current value from Timer T10.
Value
484 Mode
1. Find Timer Current Values in the table.

PLC Address (Dec.) + Mode Address

V2100 = 1088 decimal
1088 + 40001 = 41089

3480

3735

4001

40001

Hold Reg.

PLC Addr. (Dec) + Start Addr. + Mode

Y20 = 16 decimal
16 + 2048 + 1 = 2065

2048

2303

Coil

PLC Address (Dec.) + Mode Address

T10 = 8 decimal
8 + 3001 = 3009

2. Convert T10 into decimal (8).

3. Add the MODBUS starting address for the
mode (3001).

CPU Specifications
and Operation

Timer Current Values (V)

128

V0

V177

127

3001

30001

Input Reg.

Find the MODBUS address for Control Relay PLC Addr. (Dec) + Start Address + Mode
C54.
C54 = 44 decimal
1. Find Control Relays in the table.
44 + 3072 + 1 = 3117
2. Convert C54 into decimal (44).
3. Add the starting address for the range
(3072).
4. Add the MODBUS address for the mode
(1).

Example 4: C54
584/984 Mode

Control Relays (CR)

Determining the
DirectNET Address

512

C0

C777

3072

3583

Coil

Addressing the memory types for DirectNET slaves is very easy. Use the ordinary
native address of the slave device itself. To access a slave PLCs memory address
V2000 via DirectNET, for example, the network master will request V2000 from the
slave.

441
CPU Specifications and Operation

Network Master Operation

This section describes how the DL05 can communicate on a MODBUS or DirectNET
network as a master. For MODBUS networks, it uses the MODBUS RTU protocol,
which must be interpreted by all the slaves on the network. Both MODBUS and
DirectNet are single master/multiple slave networks. The master is the only member
of the network that can initiate requests on the network. This section teaches you how
to design the required ladder logic for network master operation.
MODBUS RTU Protocol, or DirectNET

Slave #1

Slave #2

Slave #3

Master

When using the DL05 PLC as the master station, simple RLL instructions are used
to initiate the requests. The WX instruction initiates network write operations, and
the RX instruction initiates network read operations. Before executing either the WX
or RX commands, we will need to load data related to the read or write operation
onto the CPUs accumulator stack. When the WX or RX instruction executes, it uses
the information on the stack combined with data in the instruction box to completely
define the task, which goes to the port.

WX (write)
RX (read)

Slave

Master

The following step-by-step procedure will provide you the information necessary to
set up your ladder program to receive data from a network slave.

CPU Specifications
and Operation

Network

442
CPU Specifications and Operation

Step 1:
Identify Master
Port # and Slave #

Step 2:
Load Number of
Bytes to Transfer

The first Load (LD) instruction identifies

the communications port number on the
network master (DL05) and the address of
the slave station. This instruction can
address up to 99 MODBUS slaves, or 90
DirectNET slaves. The format of the word
is shown to the right. The F2 in the upper
byte indicates the use of the right port of
the DL05 PLC, port number 2. The lower
byte contains the slave address number in
BCD (01 to 99).

Slave address (BCD)

Port number (BCD)
Internal port (hex)
LD
KF201

The second Load (LD) instruction

determines the number of bytes which will
be transferred between the master and
slave in the subsequent WX or RX
instruction. The value to be loaded is in
BCD format (decimal), from 1 to 128
bytes.

(BCD)

# of bytes to transfer
LD
K64

The number of bytes specified also depends on the type of data you want to obtain.
For example, the DL05 Input points can be accessed by V-memory locations or as X
input locations. However, if you only want X0 X27, youll have to use the X input
data type because the V-memory locations can only be accessed in 2-byte
increments. The following table shows the byte ranges for the various types of
DirectLOGIC products.

CPU Specifications
and Operation

DL 05 / 205 / 350 / 405 Memory

Bits per unit

Bytes

V memory
T / C current value

16
16

2
2

Inputs (X, SP)

Outputs
(Y, C, Stage, T/C bits)

Scratch Pad Memory

Diagnostic Status

Bits per unit

Bytes

Data registers
T / C accumulator

8
16

1
2

I/O, internal relays, shift register

bits, T/C bits, stage bits

Scratch Pad Memory

Diagnostic Status(5 word R/W)

16

10

DL330 / 340 Memory

443
CPU Specifications and Operation

Step 3:
Specify Master
Memory Area

The third instruction in the RX or WX

sequence is a Load Address (LDA)
instruction. Its purpose is to load the
starting address of the memory area to be
transferred. Entered as an octal number,
the LDA instruction converts it to hex and
places the result in the accumulator.
For a WX instruction, the DL05 CPU
sends the number of bytes previously
specified from its memory area beginning
at the LDA address specified.
For an RX instruction, the DL05 CPU
reads the number of bytes previously
specified from the slave, placing the
received data into its memory area
beginning at the LDA address specified.

(octal)

Starting address of
master transfer area
LDA
O40600

MSB

V40600

LSB

15

MSB

V40601

LSB

15

NOTE: Since V memory words are always 16 bits, you may not always use the whole
word. For example, if you only specify 3 bytes and you are reading Y outputs from the
slave, you will only get 24 bits of data. In this case, only the 8 least significant bits of
the last word location will be modified. The remaining 8 bits are not affected.
Step 4:
Specify Slave
Memory Area

The last instruction in our sequence is the

WX or RX instruction itself. Use WX to
write to the slave, and RX to read from the
slave. All four of our instructions are
shown to the right. In the last instruction,
you must specify the starting address and
a valid data type for the slave.

SP116

LD
KF201
LD
K64
LDA
O40600

S
S
S

DirectNET slaves specify the same address in the WX and RX

instruction as the slaves native I/O address
MODBUS DL405, DL205, or DL05 slaves specify the same address
in the WX and RX instruction as the slaves native I/O address
MODBUS 305 slaves use the following table to convert DL305
addresses to MODBUS addresses

DL305 Series CPU Memory TypetoMODBUS Cross Reference (excluding 350 CPU)
PLC Memory type

PLC base
address

MODBUS
base addr.

PLC Memory Type

PLC base
address

MODBUS
base addr.

TMR/CNT Current Values

R600

V0

TMR/CNT Status Bits

CT600

GY600

I/O Points

IO 000

GY0

Control Relays

CR160

GY160

Data Registers

R401,
R400

V100

Shift Registers

SR400

GY400

Stage Status Bits (D3330P only)

S0

GY200

CPU Specifications
and Operation

RX
Y0

444
CPU Specifications and Operation

Communications
from a
Ladder Program

Typically network communications will

last longer than 1 scan. The program must
wait for the communications to finish
before starting the next transaction.

SP117

Y1
SET

SP116

LD
KF201

Port Communication Error

LD
K0003

Port Busy

LDA
O40600
RX
Y0

Port 2, which can be a master, has two Special Relay contacts associated with it (see
Appendix D for comm port special relays).One indicates Port busy(SP116), and
the other indicates Port Communication Error(SP117). The example above shows
the use of these contacts for a network master that only reads a device (RX). The
Port Busy bit is on while the PLC communicates with the slave. When the bit is off
the program can initiate the next network request.
The Port Communication Error bit turns on when the PLC has detected an error.
Use of this bit is optional. When used, it should be ahead of any network instruction
boxes since the error bit is reset when an RX or WX instruction is executed.

CPU Specifications
and Operation

Multiple Read and

Write Interlocks

If you are using multiple reads and writes

in the RLL program, you have to interlock
the routines to make sure all the routines
are executed. If you dont use the
interlocks, then the CPU will only execute
the first routine. This is because each port
can only handle one transaction at a time.
In the example to the right, after the RX
instruction is executed, C0 is set. When
the port has finished the communication
task, the second routine is executed and
C0 is reset.
If youre using RLL PLUS Stage
Programing, you can put each routine in a
separate program stage to ensure proper
execution and switch from stage to stage
allowing only one of them to be active at a
time.

Interlocking Relay
SP116 C100

LD
KF201
LD
K0003
LDA
O40600

Interlocking
Relay

SP116 C100

RX
Y0
C100
SET
LD
KF201
LD
K0003
LDA
O40400
WX
Y0
C100
RST

Standard RLL
Instructions
In This Chapter. . . .

15

Boolean Instructions
Comparative Boolean
Immediate Instructions
Timer, Counter and Shift Register Instructions
Accumulator / Stack Load and Output Data Instructions
Logical Instructions (Accumulator)
Math Instructions
Bit Operation Instructions (Accumulator)
Number Conversion Instructions (Accumulator)
Table Instructions
CPU Control Instructions
Program Control Instructions
Interrupt Instructions
Message Instructions

52

Standard RLL Instructions

Introduction
DL05 Micro PLCs offer a wide variety of instructions to perform many different types
of operations. This chapter shows you how to use each standard Relay Ladder Logic
(RLL) instruction. In addition to these instructions, you may also need to refer to the
Drum instruction in Chapter 6, or the Stage programming instructions in Chapter 7.
There are two ways to quickly find the instruction you need.

Instruction

If you know the instruction category (Boolean, Comparative Boolean, etc.)

just use the title at the top of the page to find the pages that discuss the
instructions in that category.

If you know the individual instruction name, use the following table to find
the page(s) that discusses the instruction.

Page

Instruction

Page

ACON

5107

ENCO

580

ADDB

573

END

594

ADD

563

ENI

5103

ADDD

564

AND

511,
555

AND STR

512

ANDD

556

ANDE

525,

522

FAULT

5106

FOR

596

GRAY

588

GTS

598

HTA

586

INC

571

ANDI

527

INCB

572

ANDN

511, 525

INT

5103

INV

584

ANDND

Standard
RLL Instructions

517

ANDNE

522

IRT

5103

ANDNI

527

IRTC

5103

Instruction

Page

OR

510,
557

OR OUT

513

ORE

521

ORI

526

ORN

510, 524

ORND

516

ORNE

521

OR OUTI

528

OR STR

512

ORD

558

ORNI

526

OROUTI

528

ORPD

516

OUT

513, 552

OUTD

552

OUTF

553

OUTI

528

ANDPD

517

ISG

722

ATH

585

JMP

722

BCD

583

LD

548

BIN

582

LDA

551

PAUSE

519

CMP

561

LDD

549

PD

514

CMPD

562

LDF

550

POP

553

CNT

536

LDLBL

592

PRINT

5109

CV

723

MLR

5101

RST

518

CVJMP

723

MLS

5101

RSTI

529

DEC

571

MOV

591

RSTWT

595

DECB

572

MOVMC

592

RT

598

DECO

581

MUL

567

RTC

598

DISI

5104

MULB

575

RX

5113

DIV

569

MULD

568

SBR

598

DIVB

576

NCON

5107

SET

518

DIVD

570

NEXT

596

SETI

529

DLBL

5107

NJMP

722

SFLDGT

589

DRUM

612

NOP

594

SG

721

EDRUM

62, NO TAG

NOT

514

SGCNT

538

524,

53

Instruction Set

Instruction

Page

Instruction

Page

Instruction

Page

SHFL

577

STRND

515

TMR

531

SHFR

579

STRNE

520

TMRA

533

SR

542

STRNI

526

TMRAF

533

STOP

594

STRPD

515

TMRF

531

STR

59, 523

SUB

565

UDC

540

STRE

520

SUBB

574

WX

5115

STRI

526

SUBD

566

XOR

559

STRN

59, 523

SUM

577

XORD

560

Standard
RLL Instructions

54

Standard RLL Instructions

Boolean Instructions

Using Boolean Instructions

END Statement

Do you ever wonder why so many PLC manufacturers always quote the scan time
for a 1K boolean program? Simple. Most all programs utilize many boolean
instructions. These are typically very simple instructions designed to join input and
output contacts in various series and parallel combinations. Since the DirectSOFT
package allows you to use graphic symbols to build the program, you dont
absolutely have to know the mnemonics of the instructions. However, it may helpful
at some point, especially if you ever have to troubleshoot the program with a
Handheld Programmer.The following paragraphs show how these instructions are
used to build simple ladder programs.
All DL05 programs require an END statement as the last instruction. This tells the
CPU that this is the end of the program. Normally, any instructions placed after the
END statement will not be executed. There are exceptions to this such as interrupt
routines, etc. Chapter 5 discusses the instruction set in detail.
X0

Y0

All programs must have

and END statement

OUT

END

Simple Rungs

You use a contact to start rungs that contain both contacts and coils. The boolean
instruction that does this is called a Store or, STR instruction. The output point is
represented by the Output or, OUT instruction. The following example shows how to
enter a single contact and a single output coil.
DirectSOFT Example
X0

Handheld Mnemonics
Y0
OUT

STR X0
OUT Y0
END

END

Standard
RLL Instructions

Normally Closed
Contact

Normally closed contacts are also very common. This is accomplished with the
Store Not or, STRN instruction. The following example shows a simple rung with a
normally closed contact.
DirectSOFT Example
X0

Handheld Mnemonics
Y0
OUT

END

STRN X0
OUT Y0
END

Standard RLL Instructions

Boolean Instructions

Contacts in Series

55

Use the AND instruction to join two or more contacts in series. The following
example shows two contacts in series and a single output coil. The instructions used
would be STR X0, AND X1, followed by OUT Y0.
DirectSOFT Example
X0

Handheld Mnemonics
Y0

X1

OUT

STR X0
AND X1
OUT Y0
END

END

Midline Outputs

Sometimes it is necessary to use midline outputs to get additional outputs that are
conditional on other contacts. The following example shows how you can use the
AND instruction to continue a rung with more conditional outputs.
DirectSOFT Example
X0

Handheld Mnemonics
Y0

X1

OUT
Y1

X2

OUT
X3

STR X0
AND X1
OUT Y0
AND X2
OUT Y1
AND X3
OUT Y2
END

Y2
OUT

END

Parallel Elements

You also have to join contacts in parallel. The OR instruction allows you to do this.
The following example shows two contacts in parallel and a single output coil. The
instructions would be STR X0, OR X1, followed by OUT Y0.
DirectSOFT Example
X0

Handheld Mnemonics
Y0
OUT

X1

Standard
RLL Instructions

END

STR X0
OR X1
OUT Y0
END

56

Standard RLL Instructions

Boolean Instructions

Joining Series
Branches in
Parallel

Quite often it is necessary to join several groups of series elements in parallel. The
Or Store (ORSTR) instruction allows this operation. The following example shows a
simple network consisting of series elements joined in parallel.
DirectSOFT Example
X0

Handheld Mnemonics
Y0

X1

OUT
X2

X3

END

STR X0
AND X1
STR X2
AND X3
ORSTR
OUT Y0
END

You can also join one or more parallel branches in series. The And Store (ANDSTR)
Joining Parallel
Branches in Series instruction allows this operation. The following example shows a simple network
with contact branches in series with parallel contacts.
DirectSOFT Example
X0

Handheld Mnemonics
Y0

X1

OUT
X2

STR X0
STR X1
OR X2
ANDSTR
OUT Y0
END

END

Combination
Networks

You can combine the various types of series and parallel branches to solve most any
application problem. The following example shows a simple combination network.
X0

X2

X5

Y0
OUT

X1

X3

X4

X6

END

Standard
RLL Instructions

Comparative
Boolean

Some PLC manufacturers make it really difficult to do a simple comparison of two

numbers. Some of them require you to move the data all over the place before you
can actually perform the comparison. The DL05 Micro PLCs provide Comparative
Boolean instructions that allow you to quickly and easily solve this problem. The
Comparative Boolean provides evaluation of two 4-digit values using boolean
contacts. The valid evaluations are: equal to, not equal to, equal to or greater than,
and less than.
In the following example when the value
in V-memory location V1400 is equal to
the constant value 1234, Y3 will
energize.

V1400

K1234

Y3
OUT

Standard RLL Instructions

Boolean Instructions

Boolean Stack

57

There are limits to how many elements you can include in a rung. This is because the
DL05 PLCs use an 8-level boolean stack to evaluate the various logic elements. The
boolean stack is a temporary storage area that solves the logic for the rung. Each
time the program encounters a STR instruction, the instruction is placed on the top of
the stack. Any other STR instructions already on the boolean stack are pushed down
a level. The ANDSTR, and ORSTR instructions combine levels of the boolean stack
when they are encountered. An error will occur during program compilation if the
CPU encounters a rung that uses more than the eight levels of the boolean stack.
The following example shows how the boolean stack is used to solve boolean logic.

X0

STR

STR

ORSTR

X1

AND X4

Y0
OUT

X2

STR

AND X3

X5

Output

ANDSTR

OR

STR X0

STR X1

STR X1

STR X2

X2 AND X3

STR X0

STR X1

STR X1

STR X0

STR X0

STR X0

STR X2

AND X3

ORSTR

AND X4

ORNOT X5

X1 OR (X2 AND X3)

X4 AND [X1 OR (X2 AND X3)]

NOT X5 OR X4 AND [X1 OR (X2 AND X3)]

STR X0

STR X0

STR X0

3
S
S

3
S
S

S
S

ANDSTR
1

X0 AND (NOT X5 OR X4) AND [X1 OR (X2 AND X3)]

S
S

Standard
RLL Instructions

58

Standard RLL Instructions

Boolean Instructions

Immediate Boolean The DL05 Micro PLCs can usually complete an operation cycle in a matter of
milliseconds. However, in some applications you may not be able to wait a few
milliseconds until the next I/O update occurs. The DL05 PLCs offer Immediate input
and outputs which are special boolean instructions that allow reading directly from
inputs and writing directly to outputs during the program execution portion of the
CPU cycle. You may recall that this is normally done during the input or output
update portion of the CPU cycle. The immediate instructions take longer to execute
because the program execution is interrupted while the CPU reads or writes the I/O
point. This function is not normally done until the read inputs or the write outputs
portion of the CPU cycle.
NOTE: Even though the immediate input instruction reads the most current status
from the input point, it only uses the results to solve that one instruction. It does not
use the new status to update the image register. Therefore, any regular instructions
that follow will still use the image register values. Any immediate instructions that
follow will access the I/O again to update the status. The immediate output
instruction will write the status to the I/O and update the image register.

CPU Scan
Read Inputs
X11
OFF

...
X2
X1
X0
...
ON OFF OFF
Input Image Register

The CPU reads the inputs from the local

base and stores the status in an input
image register.

OFF

X0

OFF

X1

Read Inputs from Specialty I/O

Solve the Application Program

Standard
RLL Instructions

X0
I

Y0

Write Outputs
Write Outputs to Specialty I/O
Diagnostics

Immediate instruction does not use the

input image register, but instead reads
the status from the module immediately.

I/O Point X0 Changes

ON

X0

OFF

X1

Standard RLL Instructions

Boolean Instructions

59

Boolean Instructions
Store
(STR)

The Store instruction begins a new rung

or an additional branch in a rung with a
normally open contact. Status of the
contact will be the same state as the
associated image register point or
memory location.

Store Not
(STRN)

The Store Not instruction begins a new

rung or an additional branch in a rung
with a normally closed contact. Status of
the contact will be opposite the state of
the associated image register point or
memory location.
Operand Data Type

Aaaa

DL05 Range
A

aaa

Inputs

0377

Outputs

0377

Control Relays

0777

Stage

0377

Timer

Aaaa

0177

Counter

CT

0177

Special Relay

SP

0777

In the following Store example, when input X1 is on, output Y2 will energize.
DirectSOFT
X1

Handheld Programmer Keystrokes

Y2

B
STR

OUT

GX
OUT

1
C
2

ENT
ENT

In the following Store Not example, when input X1 is off output Y2 will energize.
DirectSOFT
X1

Handheld Programmer Keystrokes

Y2
OUT

SP
STRN

GX
OUT

1
2

ENT
ENT

Standard
RLL Instructions

510
Or
(OR)

Or Not
(ORN)

Standard RLL Instructions

Boolean Instructions

The Or instruction logically ors a normally

open contact in parallel with another
contact in a rung. The status of the
contact will be the same state as the
associated image register point or
memory location.

Aaaa

The Or Not instruction logically ors a

normally closed contact in parallel with
another contact in a rung. The status of
the contact will be opposite the state of
the associated image register point or
memory location.

Aaaa

Operand Data Type

DL05 Range
A

aaa

Inputs

0377

Outputs

0377

Control Relays

0777

Stage

0377

Timer

0177

Counter

CT

0177

Special Relay

SP

0777

In the following Or example, when input X1 or X2 is on, output Y5 will energize.

DirectSOFT
X1

Handheld Programmer Keystrokes

Y5

B
STR

OUT

1
C

OR

X2

GX
OUT

2
F
5

ENT
ENT
ENT

In the following Or Not example, when input X1 is on or X2 is off, output Y5 will

energize.
DirectSOFT
X1

Handheld Programmer Keystrokes

Y5
OUT

Standard
RLL Instructions

X2

B
STR

R
ORN

GX
OUT

2
5

ENT
ENT
ENT

Standard RLL Instructions

Boolean Instructions

And
(AND)

The And instruction logically ands a

normally open contact in series with
another contact in a rung. The status of
the contact will be the same state as the
associated image register point or
memory location.

And Not
(ANDN)

The And Not instruction logically ands a

normally closed contact in series with
another contact in a rung. The status of
the contact will be opposite the state of
the associated image register point or
memory location.
Operand Data Type

511

Aaaa

Aaaa

DL05 Range
A

aaa

Inputs

0377

Outputs

0377

Control Relays

0777

Stage

0377

Timer

0177

Counter

CT

0177

Special Relay

SP

0777

In the following And example, when input X1 and X2 are on output Y5 will energize.
DirectSOFT
X1

Handheld Programmer Keystrokes

X2

Y5

B
STR

OUT

V
AND

GX
OUT

2
5

ENT
ENT
ENT

In the following And Not example, when input X1 is on and X2 is off output Y5 will
energize.
DirectSOFT
X1

Handheld Programmer Keystrokes

X2

Y5
OUT

B
1

STR
W
ANDN

GX
OUT

2
5

ENT
ENT
ENT

Standard
RLL Instructions

512

Standard RLL Instructions

Boolean Instructions

And Store
(AND STR)

Or Store
(OR STR)

The And Store instruction logically ands

two branches of a rung in series. Both
branches must begin with the Store
instruction.

OUT

The Or Store instruction logically ors two

branches of a rung in parallel. Both
branches must begin with the Store
instruction.

OUT

In the following And Store example, the branch consisting of contacts X2, X3, and X4
have been anded with the branch consisting of contact X1.
DirectSOFT
X1

Handheld Programmer Keystrokes

X2

X3

Y5

B
STR

OUT

C
STR

X4

V
AND

OR
L
ANDST

ENT
ENT
ENT
ENT

ENT

GX
OUT

F
5

ENT

In the following Or Store example, the branch consisting of X1 and X2 have been
ored with the branch consisting of X3 and X4.
DirectSOFT
X1

Handheld Programmer Keystrokes

X2

Y5

X3

X4

B
STR

OUT

V
AND

STR

V
AND
M
ORST

Standard
RLL Instructions

GX
OUT

E
4

ENT
ENT
ENT
ENT

ENT
F
5

ENT

513

Standard RLL Instructions

Boolean Instructions

Out
(OUT)

The Out instruction reflects the status of

the rung (on/off) and outputs the discrete
(on/off) state to the specified image
register point or memory location.

Aaaa
OUT

Multiple Out instructions referencing the same discrete location should not be used
since only the last Out instruction in the program will control the physical output
point. Instead, use the next instruction, the Or Out.
Operand Data Type

DL05 Range
A

aaa

0377

Outputs

0377

Control Relays

0777

Inputs

In the following Out example, when input X1 is on, output Y2 and Y5 will energize.
DirectSOFT

Handheld Programmer Keystrokes

X1

Y2

Y5
OUT

Or Out
(OR OUT)

B
STR

OUT

ENT

GX
OUT

GX
OUT

ENT

ENT

The Or Out instruction allows more than

one rung of discrete logic to control a
single output. Multiple Or Out
instructions referencing the same output
coil may be used, since all contacts
controlling the output are logically ORed
together. If the status of any rung is on,
the output will also be on.
Operand Data Type

DL05 Range
A

aaa

0177

Outputs

0177

Control Relays

0777

Inputs

A aaa
OR OUT

In the following example, when X1 or X4 is on, Y2 will energize.

X1

Handheld Programmer Keystrokes

Y2

B
STR

OR OUT

O
INST#

1
D

F
3

5
E
4

STR
X4

Y2
OR OUT

O
INST#

F
3

ENT
ENT

ENT

ENT

ENT

ENT
ENT

ENT

Standard
RLL Instructions

DirectSOFT

514

Standard RLL Instructions

Boolean Instructions

Not
(NOT)

The Not instruction inverts the status of

the rung at the point of the instruction.

In the following example when X1 is off, Y2 will energize. This is because the Not
instruction inverts the status of the rung at the Not instruction.
DirectSOFT

Handheld Programmer Keystrokes

X1

Y2

SHFT

ENT

STR

OUT

N
TMR

GX
OUT

O
INST#

T
MLR

ENT

ENT

NOTE: DirectSOFT Release 1.1i and later supports the use of the NOT instruction.
The above example rung is merely intended to show the visual representation of the
NOT instruction. The rung cannot be created or displayed in DirectSOFT versions
earlier than 1.1i.
Positive
Differential
(PD)

The Positive Differential instruction is

typically known as a one shot. When the
input logic produces an off to on
transition, the output will energize for one
CPU scan.

Operand Data Type

DL05 Range
A

aaa

0377

Outputs

0377

Control Relays

0777

Inputs

A aaa
PD

In the following example, every time X1 makes an off to on transition, C0 will

energize for one scan.
Handheld Programmer Keystrokes

DirectSOFT
X1

C0

B
STR

PD

Standard
RLL Instructions

SHFT

1
P
CV

SHFT

ENT
D

A
3

ENT

515

Standard RLL Instructions

Boolean Instructions

Store Positive
Differential
(STRPD)

The Store Positive Differential instruction

begins a new rung or an additional branch
in a rung with a normally open contact.
The contact closes for one CPU scan
when the state of the associated image
register point makes an Off-to-On
transition. Thereafter, the contact remains
open until the next Off-to-On transition
(the symbol inside the contact represents
the transition). This function is sometimes
called a one-shot.

Store Negative
Differential
(STRND)

The Store Negative Differential instruction

begins a new rung or an additional branch
in a rung with a normally closed contact.
The contact closes for one CPU scan
when the state of the associated image
register point makes an On-to-Off
transition. Thereafter, the contact remains
open until the next On-to-Off transition
(the symbol inside the contact represents
the transition).
Operand Data Type

aaa

Inputs

0377

Outputs

0377

Control Relays

0777

Stage

0377

0177

CT

0177

Counter

Aaaa

DL05 Range
A

Timer

Aaaa

In the following example, each time X1 is makes an Off-to-On transition, Y4 will

energize for one scan.
Handheld Programmer Keystrokes

DirectSOFT
X1

Y4
OUT

$
STR

SHFT

GX
OUT

CV
E
4

ENT

ENT

In the following example, each time X1 is makes an On-to-Off transition, Y4 will

energize for one scan.
X1

Y4
OUT

$
STR
GX
OUT

SHFT

N
TMR
E
4

B
3

ENT

ENT

Standard
RLL Instructions

Handheld Programmer Keystrokes

DirectSOFT

516

Standard RLL Instructions

Boolean Instructions

Or Positive
Differential
(ORPD)

Or Negative
Differential
(ORND)

The Or Positive Differential instruction

logically ors a normally open contact in
parallel with another contact in a rung. The
status of the contact will be open until the
associated image register point makes an
Off-to-On transition, closing it for one CPU
scan. Thereafter, it remains open until
another Off-to-On transition.

Aaaa

The Or Negative Differential instruction

logically ors a normally open contact in
parallel with another contact in a rung. The
status of the contact will be open until the
associated image register point makes an
On-to-Off transition, closing it for one CPU
scan. Thereafter, it remains open until
another On-to-Off transition.

Aaaa

Operand Data Type

DL05 Range
A

aaa

Inputs

0377

Outputs

0377

Control Relays

0777

Stage

0377

Timer

0177

CT

0177

Counter

In the following example, Y 5 will energize whenever X1 is on, or for one CPU scan
when X2 transitions from Off to On.
Handheld Programmer Keystrokes

DirectSOFT
X1

$
Y5
OUT

B
STR

Q
OR

X2

1
SHFT

C
3

CV
F

GX
OUT

ENT

ENT

ENT

In the following example, Y 5 will energize whenever X1 is on, or for one CPU scan
when X2 transitions from On to Off.
Handheld Programmer Keystrokes

DirectSOFT
X1

Y5
OUT

B
STR

Standard
RLL Instructions

OR
X2

GX
OUT

1
SHFT

N
TMR
F
5

ENT
D

C
3

ENT

ENT

517

Standard RLL Instructions

Boolean Instructions

And Positive
Differential
(ANDPD)

The And Positive Differential instruction

logically ands a normally open contact in
parallel with another contact in a rung. The
status of the contact will be open until the
associated image register point makes an
Off-to-On transition, closing it for one CPU
scan. Thereafter, it remains open until
another Off-to-On transition.

And Negative
Differential
(ANDND)

The And Negative Differential instruction

logically ands a normally open contact in
parallel with another contact in a rung. The
status of the contact will be open until the
associated image register point makes an
On-to-Off transition, closing it for one CPU
scan. Thereafter, it remains open until
another On-to-Off transition.
Operand Data Type

Aaaa

Aaaa

DL05 Range
A

aaa

Inputs

0377

Outputs

0377

Control Relays

0777

Stage

0377

Timer

0177

CT

0177

Counter

In the following example, Y5 will energize for one CPU scan whenever X1 is on and
X2 transitions from Off to On.
Handheld Programmer Keystrokes

DirectSOFT
X1

X2

$
Y5
OUT

B
STR

Q
OR

1
SHFT

C
3

CV
F

GX
OUT

ENT

ENT

ENT

In the following example, Y5 will energize for one CPU scan whenever X1 is on and
X2 transitions from On to Off.
Handheld Programmer Keystrokes

DirectSOFT
X1

X2

Y5
OUT

B
STR

Q
OR

SHFT

N
TMR
F
5

ENT
D

C
3

ENT

ENT

Standard
RLL Instructions

GX
OUT

518

Standard RLL Instructions

Boolean Instructions

Set
(SET)

The Set instruction sets or turns on an

image register point/memory location or
a consecutive range of image register
points/memory locations. Once the
point/location is set it will remain on until it
is reset using the Reset instruction. It is
not necessary for the input controlling the
Set instruction to remain on.

Reset
(RST)

The Reset instruction resets or turns off

an image register point/memory location
or a range of image registers
points/memory locations. Once the
point/location is reset it is not necessary
for the input to remain on.
Operand Data Type

A aaa
aaa
SET

Optional
memory range

A aaa
aaa
RST

DL05 Range
A

aaa

Inputs

0377

Outputs

0377

Control Relays

0777

Stage

0377

Timer

0177

CT

0177

Counter

Optional
memory range

In the following example when X1 is on, Y2 through Y5 will energize.

DirectSOFT
X1

Handheld Programmer Keystrokes

Y2

Y5
SET

B
STR

X
SET

ENT

F
2

ENT

In the following example when X1 is on, Y2 through Y5 will be reset or deenergized.

DirectSOFT
X1

Handheld Programmer Keystrokes

Y2

Y5

Standard
RLL Instructions

RST

B
STR

S
RST

1
C

ENT
F

ENT

Standard RLL Instructions

Boolean Instructions

Pause
(PAUSE)

The Pause instruction disables the

output update on a range of outputs. The
ladder program will continue to run and
update the image register. However, the
outputs in the range specified in the
Pause instruction will be turned off at the
output points.
Operand Data Type

519

Y aaa
aaa
PAUSE

DL05 Range
aaa

Outputs

0377

In the following example, when X1 is ON, Y3Y5 will be turned OFF. The execution of
the ladder program will not be affected.
DirectSOFT
X1

Y5

Y7

PAUSE

Since the D2HPP Handheld Programmer does not have a specific Pause key, you
can use the corresponding instruction number for entry (#960), or type each letter of
the command.
Handheld Programmer Keystrokes
$

B
STR

O
INST#

1
J

G
9

ENT
A

ENT

ENT

F
3

ENT

In some cases, you may want certain output points in the specified pause range to
operate normally. In that case, use Aux 58 to over-ride the Pause instruction.

Standard
RLL Instructions

520

Standard RLL Instructions

Comparative Boolean Instructions

Comparative Boolean
Store If Equal
(STRE)

The Store If Equal instruction begins a

new rung or additional branch in a rung
with a normally open comparative
contact. The contact will be on when
Vaaa =Bbbb .

Store If Not Equal

(STRNE)

The Store If Not Equal instruction begins

a new rung or additional branch in a rung
with a normally closed comparative
contact. The contact will be on when
Vaaa
Bbbb.
Operand Data Type

V aaa

B bbb

V aaa

B bbb

DL05 Range
B

aaa

bbb

V memory

All (See page 428)

All (See page 428)

Pointer

All (See page 428)

All (See page 428)

Constant

09999

In the following example, when the value in V memory location V2000 = 4933 , Y3 will
energize.
Handheld Programmer Keystrokes

DirectSOFT
V2000

K4933

Y3

$
STR

OUT

SHFT

J
4

GX
OUT

C
4
D

A
0

D
3

9
D

A
2

A
0

ENT

ENT

In the following example, when the value in V memory location V2000
5060, Y3
will energize.
Handheld Programmer Keystrokes

DirectSOFT
V2000

K5060

Y3

SP
STRN

OUT

SHFT

A
5

Standard
RLL Instructions

GX
OUT

C
G
0

D
3

A
2

4
A
6
ENT

A
0

ENT

A
0

Standard RLL Instructions

Comparative Boolean Instructions

Or If Equal
(ORE)

Or If Not Equal
(ORNE)

The Or If Equal instruction connects a

normally open comparative contact in
parallel with another contact. The
contact will be on when Vaaa = Bbbb.

V aaa

B bbb

The Or If Not Equal instruction connects

a normally closed comparative contact in
parallel with another contact. The
contact will be on when Vaaa
Bbbb.

V aaa

B bbb

Operand Data Type

521

DL05 Range
B

aaa

bbb

V memory

All (See page 428)

All (See page 428)

Pointer

All (See page 428)

All (See page 428)

Constant

09999

In the following example, when the value in V memory location V2000 = 4500 or
V2002 = 2345 , Y3 will energize.
DirectSOFT
V2000

Handheld Programmer Keystrokes

K4500

Y3
OUT

$
STR
E

SHFT

4
V2002

K2345

OR
C

SHFT

GX
OUT

A
0

4
D
3

A
2

F
5

A
0

A
0

ENT

A
2

C
4

A
0

C
2

ENT

ENT

In the following example, when the value in V memory location V2000 = 3916 or
V2002
050, Y3 will energize.
Handheld Programmer Keystrokes

DirectSOFT
V2000

K3916

Y3
OUT

$
STR
D

SHFT

3
V2002

K2500

SHFT

G
6

0
D
3

A
2

A
0

A
0

A
0

ENT
C

A
2

R
ORN

GX
OUT

C
4

A
0

C
0

ENT

ENT

Standard
RLL Instructions

522

Standard RLL Instructions

Comparative Boolean Instructions

And If Equal
(ANDE)

The And If Equal instruction connects a

normally open comparative contact in
series with another contact. The contact
will be on when Vaaa = Bbbb.

V aaa

B bbb

And If Not Equal

(ANDNE)

The And If Not Equal instruction connects

a normally closed comparative contact in
series with another contact. The contact
will be on when Vaaa
Bbbb

V aaa

B bbb

Operand Data Type

DL05 Range
A/B

aaa

bbb

V memory

All (See page 428)

All (See page 428)

Pointer

All (See page 428)

All (See page 428)

Constant

09999

In the following example, when the value in V memory location V2000 = 5000 and
V2002 = 2345, Y3 will energize.
DirectSOFT
V2000

Handheld Programmer Keystrokes

K5000

V2002

K2345

Y3

$
STR

OUT

SHFT

SHFT

A
0

4
D
3

A
2

F
5

A
0

A
0

ENT
C

A
2

V
AND

GX
OUT

C
4

A
0

C
2

ENT

ENT

In the following example, when the value in V memory location V2000 = 2550 and
V2002
050, Y3 will energize.
DirectSOFT
V2000

Handheld Programmer Keystrokes

K2550

V2002

K2500

Y3
OUT

$
STR
C

F
5

W
ANDN

SHFT

GX
OUT

C
4

Standard
RLL Instructions

SHFT

A
5

0
D
3

A
2

A
0
ENT

A
0

A
0

ENT
C

A
2

ENT

A
0

C
0

Standard RLL Instructions

Comparative Boolean Instructions

Store
(STR)

The Comparative Store instruction

begins a new rung or additional branch in
a rung with a normally open comparative
contact. The contact will be on when
Aaaa  Bbbb.

Store Not
(STRN)

The Comparative Store Not instruction

begins a new rung or additional branch in
a rung with a normally closed
comparative contact. The contact will be
on when Aaaa < Bbbb.
Operand Data Type

A aaa

B bbb

A aaa

B bbb

523

DL05 Range
A/B

aaa

bbb

V memory

All (See page 428)

All (See page 428)

Pointer

All (See page 428)

All (See page 428)

Constant

09999

Timer

0177

CT

0177

Counter

In the following example, when the value in V memory location V2000  1000, Y3
will energize.
Handheld Programmer Keystrokes

DirectSOFT
V2000

K1000

Y3

$
STR

OUT

SHFT

V
AND

1
GX
OUT

A
2

A
0

A
0

ENT

ENT

In the following example, when the value in V memory location V2000 < 4050, Y3 will
energize.
Handheld Programmer Keystrokes

DirectSOFT
V2000

K4050

Y3

SP
STRN

OUT

SHFT

V
AND

4
GX
OUT

D
3

A
2
0

A
0

A
0

ENT

ENT

Standard
RLL Instructions

524

Standard RLL Instructions

Comparative Boolean Instructions

Or
(OR)

The
Comparative
Or
instruction
connects a normally open comparative
contact in parallel with another contact.
The contact will be on when Aaaa 
Bbbb.

Or Not
(ORN)

A aaa

The Comparative Or Not instruction

connects a normally open comparative
contact in parallel with another contact.
The contact will be on when Aaaa < Bbbb.

Operand Data Type

A aaa

B bbb

DL05 Range
A/B

aaa

bbb

V memory

All (See page 428)

All (See page 428)

Pointer

All (See page 428)

All (See page 428)

Constant

09999

Timer

0177

CT

0177

Counter

B bbb

In the following example, when the value in V memory location V2000 = 6045 or
V2002  2345, Y3 will energize.
Handheld Programmer Keystrokes

DirectSOFT
V2000

K6045

Y3
OUT

$
STR
G

SHFT

6
V2002

OR
C

D
2

GX
OUT

F
5

SHFT

V
AND

4
D
3

A
2

K2345

C
4

A
0

A
0

ENT
C

A
2

A
0

C
2

ENT

ENT

In the following example when the value in V memory location V2000 = 1000 or
V2002 < 050, Y3 will energize.
Handheld Programmer Keystrokes

DirectSOFT

$
V2000

K1000

Y3
OUT

STR
B

SHFT

1
V2002

K2500

F
2

Standard
RLL Instructions

R
ORN

GX
OUT

C
A
0

SHFT

V
AND

A
0

5
D

A
2

0
ENT

A
0

A
0

ENT
C

A
2

ENT

A
0

C
0

Standard RLL Instructions

Comparative Boolean Instructions

And
(AND)

The Comparative And instruction

connects a normally open comparative
contact in series with another contact.
The contact will be on when Aaaa 
Bbbb.

And Not
(ANDN)

The Comparative And Not instruction

connects a normally open comparative
contact in parallel with another contact.
The contact will be on when Aaaa <
Bbbb.
Operand Data Type

B bbb

A aaa

B bbb

DL05 Range
A/B

aaa

bbb

V memory

All (See page 428)

All (See page 428)

Pointer

All (See page 428)

All (See page 428)

Constant

09999

Timer

0177

CT

0177

Counter

A aaa

525

In the following example, when the value in V memory location V2000 = 5000, and
V2002  2345, Y3 will energize.
Handheld Programmer Keystrokes

DirectSOFT
V2000

K5000

V2002

K2345

Y3

$
STR

OUT

SHFT

D
2

A
0

SHFT

V
AND

GX
OUT

A
0

ENT
C

A
2

A
0

C
2

ENT

A
0

V
AND

C
4

ENT

In the following example, when the value in V memory location V2000 = 7000 and
V2002 < 050, Y3 will energize.
DirectSOFT
V2000

Handheld Programmer Keystrokes

K7000

V2002

K2500

Y3
OUT

$
STR
H

SHFT

W
ANDN
C

F
2

GX
OUT

C
4

A
0

SHFT

V
AND

A
0

SHFT

Y
AND

A
0

A
0

ENT
C

A
2

A
0

C
0

ENT
D
3

ENT

Standard
RLL Instructions

526

Standard RLL Instructions

Immediate Instructions

Immediate Instructions
Store
Immediate
(STRI)

The Store Immediate instruction begins a

new rung or additional branch in a rung.
The status of the contact will be the same
as the status of the associated input point
at the time the instruction is executed. The
image register is not updated.

Store Not
Immediate
(STRNI)

The Store Not Immediate instruction

begins a new rung or additional branch in
a rung. The status of the contact will be
opposite the status of the associated input
point at the time the instruction is
executed. The image register is not
updated.
Operand Data Type

X aaa

X aaa

DL05 Range
aaa

Inputs

0377

In the following example, when X1 is on, Y2 will energize.

DirectSOFT
X1

Handheld Programmer Keystrokes

Y2

$
STR

SHFT

B
8

ENT

OUT
GX
OUT

C
2

ENT

In the following example when X1 is off, Y2 will energize.

Handheld Programmer Keystrokes

DirectSOFT
X1

Y2
OUT

SP
STRN
GX
OUT

Standard
RLL Instructions

Or Immediate
(ORI)

Or Not Immediate
(ORNI)

SHFT

B
8

C
2

1
ENT

The Or Immediate connects two contacts

in parallel. The status of the contact will be
the same as the status of the associated
input point at the time the instruction is
executed. The image register is not
updated.

X aaa

The Or Not Immediate connects two

contacts in parallel. The status of the
contact will be opposite the status of the
associated input point at the time the
instruction is executed. The image
register is not updated.

X aaa

ENT

527

Standard RLL Instructions

Immediate Instructions

OR Immediate
Instructions Contd

Operand Data Type

DL05 Range
aaa

Inputs

0377

In the following example, when X1 or X2 is on, Y5 will energize.

DirectSOFT

Handheld Programmer Keystrokes

Y5

X1

OUT

B
STR

Q
OR

X2

1
SHFT

GX
OUT

ENT

C
2

8
F
5

ENT

ENT

In the following example, when X1 is on or X2 is off, Y5 will energize.

Handheld Programmer Keystrokes

DirectSOFT
Y5

X1

B
STR

OUT

R
ORN

X2

1
SHFT

GX
OUT

And Immediate
(ANDI)

The And Immediate connects two

contacts in series. The status of the
contact will be the same as the status of
the associated input point at the time the
instruction is executed. The image
register is not updated.

And Not Immediate

(ANDNI)

The And Not Immediate connects two

contacts in series. The status of the
contact will be opposite the status of the
associated input point at the time the
instruction is executed. The image
register is not updated.
Operand Data Type

ENT

C
2

8
F
5

ENT

ENT

X aaa

X aaa

DL05 Range
aaa

Inputs

0377

In the following example, when X1 and X2 are on, Y5 will energize.

DirectSOFT
X1

Handheld Programmer Keystrokes

X2

Y5

B
STR

OUT

V
AND

1
SHFT

C
2

8
F
5

ENT

ENT

In the following example, when X1 is on and X2 are off, Y5 will energize.

DirectSOFT
X1

Handheld Programmer Keystrokes

X2

Y5
OUT

B
1

STR
W
ANDN
GX
OUT

SHFT

ENT

C
2

8
F
5

ENT

ENT

Standard
RLL Instructions

GX
OUT

ENT

528

Standard RLL Instructions

Immediate Instructions

Out Immediate
(OUTI)

Or Out Immediate
(OROUTI)

The Out Immediate instruction reflects the

status of the rung (on/off) and outputs the
discrete (on/off) status to the specified
module output point and the image register
at the time the instruction is executed. If
multiple Out Immediate instructions
referencing the same discrete point are
used it is possible for the module output
status to change multiple times in a CPU
scan. See Or Out Immediate.

Y aaa
OUTI

The Or Out Immediate instruction has

been designed to use more than 1 rung of
discrete logic to control a single output.
Multiple Or Out Immediate instructions
referencing the same output coil may be
used, since all contacts controlling the
output are ored together. If the status of
any rung is on at the time the instruction is
executed, the output will also be on.
Operand Data Type

Y aaa
OROUTI

DL05 Range
aaa

Outputs

0377

In the following example, when X1 is on, output point Y2 on the output module will
turn on. For instruction entry on the Handheld Programmer, you can use the
instruction number (#350) as shown, or type each letter of the command.
DirectSOFT
X1

Handheld Programmer Keystrokes

Y2

B
STR

OUTI

O
INST#

ENT

1
D

F
3

A
5

ENT

ENT

ENT

In the following example, when X1 or X4 is on, Y2 will energize.

Handheld Programmer Keystrokes

DirectSOFT
X1

Y2
OR OUTI

X4

B
1

STR
O
INST#

F
3

Y2
OR OUTI

Standard
RLL Instructions

2
$

A
5

E
4
D

F
3

C
2

ENT

ENT

ENT

ENT

ENT

STR
O
INST#

ENT

ENT
A

5
ENT

Standard RLL Instructions

Immediate Instructions

Set Immediate
(SETI)

The
Set
Immediate
instruction
immediately sets, or turns on an output or
a range of outputs in the image register
and the corresponding output point(s) at
the time the instruction is executed. Once
the outputs are set it is not necessary for
the input to remain on. The Reset
Immediate instruction can be used to
reset the outputs.

Reset
Immediate
(RSTI)

The
Reset
Immediate
instruction
immediately resets, or turns off an output
or a range of outputs in the image register
and the output point(s) at the time the
instruction is executed. Once the outputs
are reset it is not necessary for the input to
remain on.
Operand Data Type

529

Y aaa
aaa
SETI

Y aaa
aaa
RSTI

DL05 Range
aaa

Outputs

0377

In the following example, when X1 is on, Y2 through Y5 will be set on in the image
register and on the corresponding output points.
Handheld Programmer Keystrokes

DirectSOFT
X1

Y2

Y5
SETI

B
STR

X
SET

1
SHFT

ENT

F
2

ENT

In the following example, when X1 is on, Y5 through Y22 will be reset (off) in the
image register and on the corresponding output module(s).
Handheld Programmer Keystrokes

DirectSOFT
X1

Y2

Y5
RSTI

B
1

STR
S
RST

SHFT

ENT
C

F
2

ENT

Standard
RLL Instructions

530

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Timer, Counter and Shift Register Instructions

Using Timers

Timers are used to time an event for a desired length of time. The single input timer
will time as long as the input is on. When the input changes from on to off the timer
current value is reset to 0. There is a tenth of a second and a hundredth of a second
timer available with a maximum time of 999.9 and 99.99 seconds respectively. There
is a discrete bit associated with each timer to indicate that the current value is equal
to or greater than the preset value. The timing diagram below shows the relationship
between the timer input, associated discrete bit, current value, and timer preset.
1

Seconds
4

X1

TMR

T1
K30

X1

Timer preset

T1
T1
0

Current
Value

10

20

30
40
1/10 Seconds

50

60

Y0
OUT

There are those applications that need an accumulating timer, meaning it has the
ability to time, stop, and then resume from where it previously stopped. The
accumulating timer works similarly to the regular timer, but two inputs are required.
The start/stop input starts and stops the timer. When the timer stops, the elapsed
time is maintained. When the timer starts again, the timing continues from the
elapsed time. When the reset input is turned on, the elapsed time is cleared and the
timer will start at 0 when it is restarted. There is a tenth of a second and a hundredth
of a second timer available with a maximum time of 9999999.9 and 999999.99
seconds respectively. The timing diagram below shows the relationship between the
timer input, timer reset, associated discrete bit, current value, and timer preset.
0

Seconds
4

X1

Start/Stop

X1

X2
X2

Reset Input
T0

Standard
RLL Instructions

Current
Value

10

10

20
30
1/10 Seconds

40

50

TMRA

T0
K30

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Timer (TMR) and

Timer Fast (TMRF)

The Timer instruction is a 0.1 second single

input timer that times to a maximum of
999.9 seconds. The Timer Fast instruction
is a 0.01 second single input timer that
times up to a maximum of 99.99 seconds.
These timers will be enabled if the input
logic is true (on) and will be reset to 0 if the
input logic is false (off).
Instruction Specifications
Timer Reference (Taaa): Specifies the
timer number.
Preset Value (Bbbb): Constant value (K)
or a V memory location.
Current Value: Timer current values are
accessed by referencing the associated V
or T memory location*. For example, the
timer current value for T3 physically
resides in V-memory location V3.
Discrete Status Bit: The discrete status
bit is referenced by the associated T
memory location. Operating as a timer
done bit, it will be on if the current value is
equal to or greater than the preset value.
For example, the discrete status bit for
Timer 2 is TA2.

531

T aaa

TMR
B bbb

Preset

Timer #

TMRF
T aaa
B bbb

Preset

Timer #

The timer discrete status bit and the

current value are not specified in the timer
instruction.

NOTE: Timer preset constants (K) may be changed by using a handheld

programmer, even when the CPU is in Run Mode. Therefore, a V-memory preset is
required only if the ladder program must change the preset.
Operand Data Type

Timers

DL05 Range
A/B

aaa

0177

bbb

V memory for preset

values

12007377
74007577

Pointers (preset only)

12007377
74007577

Constants
(preset only)

09999

Timer discrete status

bits

T/V

0177 or V4110041107

Timer current values

V /T*

0177

You can perform functions when the timer reaches the specified preset using the
discrete status bit. Or, use comparative contacts to perform functions at different
time intervals, based on one timer. The examples on the following page show these
two methods of programming timers.

Standard
RLL Instructions

NOTE: * With the HPP, both the Timer discrete status bits and current value are
accessed with the same data reference. DirectSOFT uses separate references,
such as T2 for discrete status bit for Timer T2, and TA2 for the current value of
Timer T2.

532

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Timer Example
Using Discrete
Status Bits

In the following example, a single input timer is used with a preset of 3 seconds. The
timer discrete status bit (T2) will turn on when the timer has timed for 3 seconds. The
timer is reset when X1 turns off, turning the discrete status bit off and resetting the
timer current value to 0.
Timing Diagram

DirectSOFT
X1

TMR

T2

K30

10

20

Seconds
4

30

40

50

60

X1

Y0

T2

OUT
T2

Y0

Handheld Programmer Keystrokes

$

B
STR

N
TMR

SHFT

Current
Value

ENT
D

STR
GX
OUT

A
0

A
0

3
T
MLR

C
2

1/10 Seconds

ENT

ENT

ENT

In the following example, a single input timer is used with a preset of 4.5 seconds.
Timer Example
Using Comparative Comparative contacts are used to energize Y3, Y4, and Y5 at one second intervals
respectively. When X1 is turned off the timer will be reset to 0 and the comparative
Contacts
contacts will turn off Y3, Y4, and Y5.
Timing Diagram

DirectSOFT
X1

TMR

Seconds

T20

K45
TA20

OUT

TA20

10

20

30

40

50

60

Y3

Y4

K20

X1

Y3

K10

Y4

OUT
Y5
TA20

Y5

K30

T2

OUT

Current
Value

1/10 Seconds
Handheld Programmer Keystrokes
$

B
1

STR
N
TMR

C
2

SHFT

T
MLR

STR

Standard
RLL Instructions

ENT
A

GX
OUT

SHFT

STR

GX
OUT

SHFT

STR
GX
OUT

F
5

F
4

A
2

ENT
B

A
1

ENT

ENT
T
MLR

A
2

C
0

A
0

ENT

ENT
T
MLR
ENT

A
2

D
0

A
3

ENT

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Accumulating
Timer (TMRA)

The Accumulating Timer is a 0.1 second

two input timer that will time to a maximum
of 9999999.9. The Accumulating Fast
Accumulating Fast Timer is a 0.01 second two-input timer that
will time to a maximum of 99999.99. Each
Timer (TMRAF)
one uses two timer registers in V-memory.
These timers have two inputs, an enable
and a reset. The timer starts timing when
the enable is on and stops when the
enable is off (without resetting the count).
The reset will reset the timer when on and
allow the timer to time when off.
Instruction Specifications
Timer Reference (Taaa): Specifies the
timer number.
Preset Value (Bbbb): Constant value (K)
or a V memory location.
Current Value: Timer current values are
accessed by referencing the associated V
or T memory location*. For example, the
timer current value for T3 resides in
V-memory location V3.
Discrete Status Bit: The discrete status
bit is accessed by referencing the
associated T memory location. Operating
as a timer done bit ,it will be on if the
current value is equal to or greater than
the preset value. For example the discrete
status bit for timer 2 would be T2.

Enable

533

T aaa
TMRA
B bbb

Reset

Preset

Enable

Timer #

T aaa
TMRAF
B bbb

Reset

Preset

Timer #

The timer discrete status bit and the

current value are not specified in the
timer instruction.

NOTE: The accumulating type timer uses two consecutive V-memory locations
for the 8-digit value, and therefore two consecutive timer locations. For example, if
TMR 1 is used, the next available timer number is TMR 3.
Operand Data Type

DL05 Range
A/B

aaa

bbb

Timers

0176

V memory for preset

values

12007377
74007577

Pointers (preset only)

12007377
74007577

Constants
(preset only)

099999999

T/V

0176 or V4110041107

Timer current values

V /T*

0176

NOTE: * With the HPP, both the Timer discrete status bits and current value are
accessed with the same data reference. DirectSOFT uses separate references,
such as T2 for discrete status bit for Timer T2, and TA2 for the current value of
Timer T2.
The following examples show two methods of programming timers. One performs
functions when the timer reaches the preset value using the discrete status bit, or
use comparative contacts to perform functions at different time intervals.

Standard
RLL Instructions

Timer discrete status

bits

534

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Accumulating
Timer Example
using Discrete
Status Bits

In the following example, a two input timer (accumulating timer) is used with a preset
of 3 seconds. The timer discrete status bit (T6) will turn on when the timer has timed
for 3 seconds. Notice in this example that the timer times for 1 second , stops for one
second, then resumes timing. The timer will reset when C10 turns on, turning the
discrete status bit off and resetting the timer current value to 0.
Timing Diagram

DirectSOFT
X1
TMRA

T6

10

10

Seconds
4

20

30

40

50

X1

K30
C10

C10

T6

Y7

T6

Current
Value

OUT

Handheld Programmer Keystrokes (cont)

Handheld Programmer Keystrokes

$

B
1

STR
$

SHFT

STR
N
TMR

SHFT

ENT
C

A
3

B
2

1/10 Seconds

A
1

ENT

STR

G
0

ENT

GX
OUT

SHFT

T
MLR

ENT

ENT

Accumulator Timer In the following example, a single input timer is used with a preset of 4.5 seconds.
Comparative contacts are used to energized Y3, Y4, and Y5 at one second intervals
Example Using
respectively. The comparative contacts will turn off when the timer is reset.
Comparative
Contacts
Timing Diagram

DirectSOFT
X1
TMRA

T20
K45

10

10

Seconds
4

20

30

40

50

X1

C10
C10

TA20

Y3

Y3

K10

OUT
Y4
TA20

Y4

K20

Y5

OUT
T20
TA20

Y5

K30

Current
Value

OUT

1/10 Seconds
Handheld Programmer Keystrokes (cont)

Handheld Programmer Keystrokes

$

B
1

Standard
RLL Instructions

STR
$

SHFT

STR
N
TMR
$
STR

SHFT

B
2

A
1

C
0

SHFT

GX
OUT

SHFT

STR

ENT

0
A

2
T
MLR

ENT
E

F
4

5
A

ENT
ENT

ENT
T
MLR

A
2

C
0

SHFT

STR

GX
OUT

A
2

ENT

A
3

GX
OUT

ENT
T
MLR

ENT
F
5

ENT

A
2

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Using Counters

535

Counters are used to count events . The counters available are up counters,
up/down counters, and stage counters (used with RLL PLUS programming).
The up counter has two inputs, a count input and a reset input. The maximum count
value is 9999. The timing diagram below shows the relationship between the counter
input, counter reset, associated discrete bit, current value, and counter preset.
X1

X1

CNT

Up

CT1
K3

X2

X2

Reset
CT1
Current
Value

Counts

Counter preset

The up down counter has three inputs, a count up input, count down input and reset
input. The maximum count value is 99999999. The timing diagram below shows the
relationship between the counter input, counter reset, associated discrete bit,
current value, and counter preset.
X1
X1

Up

CT2
K3

X2

X2

Down

X3

X3

Reset

CT2
Current
Value

UDC

1
Counts

Counter preset

The stage counter has a count input and is reset by the RST instruction. This
instruction is useful when programming using the RLL PLUS structured programming.
The maximum count value is 9999. The timing diagram below shows the relationship
between the counter input, associated discrete bit, current value, counter preset and
reset instruction.
X1

X1

Up

CT2
Current
Value

Counts

CT2

Counter preset
Standard
RLL Instructions

RST
CT2

SGCNT
K3

536
Counter
(CNT)

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

The Counter is a two input counter that

increments when the count input logic
transitions from off to on. When the counter
reset input is on the counter resets to 0.
When the current value equals the preset
value, the counter status bit comes on and
the counter continues to count up to a
maximum count of 9999. The maximum
value will be held until the counter is reset.
Instruction Specifications
Counter Reference (CTaaa): Specifies
the counter number.
Preset Value (Bbbb): Constant value (K)
or a V memory location.
Current Values: Counter current values
are accessed by referencing the
associated V or CT memory locations*.
The V-memory location is the counter
location + 1000. For example, the counter
current value for CT3 resides in V memory
location V1003.

Counter #
Count

CNT

CT aaa
B bbb

Reset

Preset

The counter discrete status bit and the

current value are not specified in the
counter instruction.

Discrete Status Bit: The discrete status bit is accessed by referencing the
associated CT memory location. It will be on if the value is equal to or greater than the
preset value. For example the discrete status bit for counter 2 would be CT2.
NOTE: Counter preset constants (K) may be changed by using a programming
device, even when the CPU is in Run Mode. Therefore, a V-memory preset is
required only if the ladder program must change the preset.

Operand Data Type

aaa

bbb

CT

0177

V memory
(preset only)

12007377
74007577

Pointers (preset only)

12007377
74007577

Constants
(preset only)

09999

Counters

Standard
RLL Instructions

DL05 Range
A/B

Counter discrete
status bits

CT/V

0177 or V4114041147

Counter current
values

V/CT*

0177

NOTE: * With the HPP, both the Counter discrete status bits and current value are
accessed with the same data reference. DirectSOFT uses separate references,
such as CT2 for discrete status bit for Counter CT2, and CTA2 for the current
value of Counter CT2.

537

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Counter Example
Using Discrete
Status Bits

In the following example, when X1 makes an off to on transition, counter CT2 will
increment by one. When the current value reaches the preset value of 3, the counter
status bit CT2 will turn on and energize Y7. When the reset C10 turns on, the counter
status bit will turn off and the current value will be 0. The current value for counter
CT2 will be held in V memory location V1002.
Counting diagram

DirectSOFT
X1
CNT

CT2
X1
K3

C10
C10

Y7

CT2

OUT

Y10
1

Current
Value

Handheld Programmer Keystrokes

$

B
1

STR
$

SHFT

STR
GY
CNT

SHFT

STR
B

A
1

Handheld Programmer Keystrokes (cont)

ENT
C

D
2

GX
OUT

ENT

SHFT

T
MLR

C
2

ENT

ENT

ENT

In the following example, when X1 makes an off to on transition, counter CT2 will
Counter Example
Using Comparative increment by one. Comparative contacts are used to energize Y3, Y4, and Y5 at
different counts. When the reset C10 turns on, the counter status bit will turn off and
Contacts
the counter current value will be 0, and the comparative contacts will turn off.
Counting diagram

DirectSOFT
X1
CNT

CT2
X1
K3

C10
C10

CTA2

Y3

K1

Y3

OUT
Y4
CTA2

Y4

K2

OUT

CTA2

Y5

K3

Y5
1

Current
Value

OUT

Handheld Programmer Keystrokes

Handheld Programmer Keystrokes (cont)

B
STR

1
SHFT

STR
GY
CNT

SHFT

B
2

B
1

A
1

D
3

STR

GX
OUT

C
2

SHFT

ENT

ENT
T
MLR

C
2

SHFT

STR
D
3

ENT

GX
OUT

C
2

SHFT

T
MLR

SHFT

T
MLR

ENT

GX
OUT

ENT
D

SHFT

STR

ENT
C
2

ENT
F
5

ENT

Standard
RLL Instructions

ENT

538

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Stage Counter
(SGCNT)

The Stage Counter is a single input counter

that increments when the input logic
transitions from off to on. This counter
differs from other counters since it will hold
its current value until reset using the RST
instruction. The Stage Counter is designed
for use in RLL PLUS programs but can be
used in relay ladder logic programs. When
the current value equals the preset value,
the counter status bit turns on and the
counter continues to count up to a
maximum count of 9999. The maximum
value will be held until the counter is reset.

Counter #
CT aaa
SGCNT
B bbb
Preset

The counter discrete status bit and the

current value are not specified in the
counter instruction.

Instruction Specifications
Counter Reference (CTaaa): Specifies
the counter number.
Preset Value (Bbbb): Constant value (K)
or a V memory location.
Current Values: Counter current values
are accessed by referencing the
associated V or CT memory locations*.
The V-memory location is the counter
location + 1000. For example, the counter
current value for CT3 resides in V memory
location V1003.
Discrete Status Bit: The discrete status
bit is accessed by referencing the
associated CT memory location. It will be
on if the value is equal to or greater than the
preset value. For example the discrete
status bit for counter 2 would be CT2.
Operand Data Type
aaa

bbb

CT

0177

V memory
(preset only)

12007377
74007577

Pointers (preset only)

12007377
74007577

Constants
(preset only)

09999

Counters

Standard
RLL Instructions

DL05 Range
A/B

Counter discrete
status bits

CT/V

0177 or V4114041147

Counter current
values

V/CT*

10001177

NOTE: * With the HPP, both the Counter discrete status bits and current value are
accessed with the same data reference. DirectSOFT uses separate references,
such as CT2 for discrete status bit for Counter CT2, and CTA2 for the current
value of Counter CT2.

539

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Stage Counter
Example Using
Discrete Status
Bits

In the following example, when X1 makes an off to on transition, stage counter CT7
will increment by one. When the current value reaches 3, the counter status bit CT7
will turn on and energize Y7. The counter status bit CT7 will remain on until the
counter is reset using the RST instruction. When the counter is reset, the counter
status bit will turn off and the counter current value will be 0. The current value for
counter CT7 will be held in V memory location V1007.
Counting diagram

DirectSOFT
X1

SGCNT
K3

CT7

X1

Y7

CT7

Y10

OUT
C5

CT7

Handheld Programmer Keystrokes

B
STR
SHFT

1
S
RST

SHFT
D
3

7
$

SHFT

STR

SHFT

GY
CNT

GX
OUT

SHFT

SHFT

S
RST
SHFT

T
MLR

H
7

ENT

STR

ENT
C

Handheld Programmer Keystrokes (cont)

ENT
G

RST
CT7

RST

Current
Value

F
2

ENT

T
MLR

SHFT

H
7

ENT

ENT

In the following example, when X1 makes an off to on transition, counter CT2 will
increment by one. Comparative contacts are used to energize Y3, Y4, and Y5 at
different counts. Although this is not shown in the example, when the counter is reset
using the Reset instruction, the counter status bit will turn off and the current value
will be 0. The current value for counter CT2 will be held in V memory location V1002.

Stage Counter
Example Using
Comparative
Contacts

Counting diagram

DirectSOFT
X1

SGCNT
CT2
K10
X1

CT2

Y3

K1

OUT

Y3

Y4
CT2

Y4

K2

OUT

CT2

Y5

K3

Y5
Current
Value

OUT

Handheld Programmer Keystrokes (cont)

Handheld Programmer Keystrokes

$

B
STR
S
RST

G
6
B

SHFT

STR
B
1
GX
OUT

SHFT

ENT

0
C
2

GY
CNT

C
2

ENT
SHFT

T
MLR

C
2

SHFT

STR
D
3

ENT

GX
OUT

C
2

SHFT

T
MLR

SHFT

T
MLR

ENT

GX
OUT

ENT
D

SHFT

STR

ENT
C
2

ENT
F
5

ENT

Standard
RLL Instructions

SHFT

540

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Up Down Counter
(UDC)

This Up/Down Counter counts up on each

off to on transition of the Up input and
counts down on each off to on transition of
the Down input. The counter is reset to 0
when the Reset input is on. The count
range is 099999999. The count input not
being used must be off in order for the
active count input to function.
Instruction Specification
Counter Reference (CTaaa): Specifies
the counter number.
Preset Value (Bbbb): Constant value (K)
or two consecutive V memory locations.
Current Values: Current count is a double
word value accessed by referencing the
associated V or CT memory locations*.
The V-memory location is the counter
location + 1000. For example, the counter
current value for CT5 resides in V memory
location V1005 and V1006.
Discrete Status Bit: The discrete status
bit is accessed by referencing the
associated
CT
memory
location.
Operating as a counter done bit it will be
on if the value is equal to or greater than the
preset value. For example the discrete
status bit for counter 2 would be CT2.
Operand Data Type

Down

Reset

UDC

CT aaa
B bbb
Counter #

Preset

Caution: The UDC uses two

V memory locations for the 8 digit
current value. This means that the
UDC uses two consecutive
counter locations. If UDC CT1 is
used in the program, the next
available counter is CT3.
The counter discrete status bit and the
current value are not specified in the
counter instruction.

DL05 Range
A/B

aaa

bbb

CT

0176

V memory
(preset only)

12007377
74007577

Pointers (preset only)

12007377
74007577

Constants
(preset only)

099999999

Counters

Standard
RLL Instructions

Up

Counter discrete
status bits

CT/V

0176 or V4114041147

Counter current
values

V/CT*

0176

NOTE: * With the HPP, both the Counter discrete status bits and current value are
accessed with the same data reference. DirectSOFT uses separate references,
such as CT2 for discrete status bit for Counter CT2, and CTA2 for the current
value of Counter CT2.

541

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Up / Down Counter
Example Using
Discrete Status
Bits

In the following example if X2 and X3 are off ,when X1 toggles from off to on the
counter will increment by one. If X1 and X3 are off the counter will decrement by one
when X2 toggles from off to on. When the count value reaches the preset value of 3,
the counter status bit will turn on. When the reset X3 turns on, the counter status bit
will turn off and the current value will be 0.

DirectSOFT

Counting Diagram

X1
UDC

CT2
X1

K3
X2

X2
X3
X3

CT2

CT2

Y7
OUT

Handheld Programmer Keystrokes

$

B
STR

C
STR

D
3

STR
SHFT

D
ISG

Current
Value

Handheld Programmer Keystrokes (cont)

D

ENT

ENT

ENT

GX
OUT

STR

C
3

ENT
SHFT

2
0

SHFT

T
MLR

C
2

ENT

ENT

C
2

Up / Down Counter
Example Using
Comparative
Contacts

In the following example, when X1 makes an off to on transition, counter CT2 will
increment by one. Comparative contacts are used to energize Y3 and Y4 at different
counts. When the reset (X3) turns on, the counter status bit will turn off, the current
value will be 0, and the comparative contacts will turn off.

DirectSOFT
X1

Counting Diagram
UDC

CT2
V2000

X1

X2
X2
X3
X3

CTA2

Y3

K1

Y3

OUT
Y4
CTA2

Y4

K2

OUT

B
1

C
STR

D
STR

SHFT

SHFT

V
AND

$
STR

D
ISG

ENT

1
GX
OUT

ENT

SHFT

SHFT

A
0

C
2

C
2

STR
C

ENT

ENT

A
0

SHFT

T
MLR

2
ENT
C
2

GX
OUT

ENT
C
2

ENT
E
4

ENT

SHFT

T
MLR

C
2

Standard
RLL Instructions

STR

Handheld Programmer Keystrokes (cont)

Handheld Programmer Keystrokes

$

Current
Value

542

Standard RLL Instructions

Timer, Counter, and Shift Register Instructions

Shift Register
(SR)

The Shift Register instruction shifts data

through a predefined number of control
relays. The control ranges in the shift
register block must start at the beginning
of an 8 bit boundary use 8-bit blocks.
The Shift Register has three contacts.
S Data determines the value (1 or
0) that will enter the register
S Clock shifts the bits one position
on each low to high transition
S Reset resets the Shift Register to
all zeros.

DATA

SR
From A aaa

CLOCK
To

B bbb

RESET

With each off to on transition of the clock input, the bits which make up the shift
register block are shifted by one bit position and the status of the data input is placed
into the starting bit position in the shift register. The direction of the shift depends on
the entry in the From and To fields. From C0 to C17 would define a block of sixteen
bits to be shifted from left to right. From C17 to C0 would define a block of sixteen
bits, to be shifted from right to left. The maximum size of the shift register block
depends on the number of available control relays. The minimum block size is 8
control relays.
Operand Data Type

Control Relay

DL05 Range
A/B

aaa

bbb

0777

0777

DirectSOFT

Handheld Programmer Keystrokes

$

X1

Data Input

B
STR

SR

$
From

X2

STR

C0

Clock Input

D
3

STR
To

X3

C17

Reset Input

SHFT

S
RST

SHFT

H
1

Inputs on Successive Scans

Standard
RLL Instructions

Data

Clock

Reset

0-1-0

0-1-0

0-1-0

0-1-0

0-1-0

- indicates on

Shift Register Bits

C0

C17

- indicates off

ENT
ENT
ENT
R
ORN
ENT

SHFT

A
0

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

543

Accumulator / Stack Load and Output Data Instructions

Using the
Accumulator

Copying Data to
the Accumulator

The accumulator in the DL05 internal CPUs is a 32 bit register which is used as a
temporary storage location for data that is being copied or manipulated in some
manor. For example, you have to use the accumulator to perform math operations
such as add, subtract, multiply, etc. Since there are 32 bits, you can use up to an
8-digit BCD number. The accumulator is reset to 0 at the end of every CPU scan.
The Load and Out instructions and their variations are used to copy data from a
V-memory location to the accumulator, or, to copy data from the accumulator to V
memory. The following example copies data from V-memory location V2000 to
V-memory location V2010.

X1

V2000
LD

V2000
Copy data from V2000 to the
lower 16 bits of the accumulator

Unused accumulator bits

are set to zero
Acc. 0

OUT
V2010

V2010

Copy data from the lower 16 bits

of the accumulator to V2010

Since the accumulator is 32 bits and V memory locations are 16 bits the Load Double
and Out Double (or variations thereof) use two consecutive V-memory locations or 8
digit BCD constants to copy data either to the accumulator from a V-memory
address or from a V-memory address to the accumulator. For example if you wanted
to copy data from V2000 and V2001 to V2010 and V2011 the most efficient way to
perform this function would be as follows:
X1

V2001

LDD
V2000

V2000

Acc. 6

Copy data from V2000 and

V2001 to the accumulator

OUTD
V2010
Copy data from the accumulator to
V2010 and V2011

V2011

V2010

Standard
RLL Instructions

544

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

Changing the
Accumulator Data

X1

Instructions that manipulate data also use the accumulator. The result of the
manipulated data resides in the accumulator. The data that was being manipulated
is cleared from the accumulator. The following example loads the constant value
4935 into the accumulator, shifts the data right 4 bits, and outputs the result to
V2010.

Constant

LD

K4935
Load the value 4935 into the
accumulator

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Acc.

6 5

4 3

The upper 16 bits of the accumulator

will be set to 0
S S

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

SHFR
Acc.

K4

1
0

S S

Shifted out of
accumulator

6 5

4 3

Shift the data in the accumulator

4 bits (K4) to the right

OUT
V2010
0

Output the lower 16 bits of the accumulator to V2010

V2010

Some of the data manipulation instructions use 32 bits. They use two consecutive V
memory locations or an 8 digit BCD constant to manipulate data in the accumulator.
In the following example, when X1 is on, the value in V2000 and V2001 will be loaded
into the accumulator using the Load Double instruction. The value in the
accumulator is added with the value in V2006 and V2007 using the Add Double
instruction. The value in the accumulator is copied to V2010 and V2011 using the
Out Double instruction.
V2001
X1

LDD

V2000

V2000
Load the value in V2000 and
V2001 into the accumulator
ADDD
V2006
Add the value in the
accumulator with the value
in V2006 and V2007

(Accumulator)

+ 2

(V2006 and V2007)

Acc. 8

Standard
RLL Instructions

OUTD
V2010
Copy the value in the
accumulator to V2010 and
V2011

V2011

V2010

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

545

The accumulator stack is used for instructions that require more than one parameter
Using the
Accumulator Stack to execute a function or for user defined functionality. The accumulator stack is used
when more than one Load instruction is executed without the use of an Out
instruction. The first load instruction in the scan places a value into the accumulator.
Every Load instruction thereafter without the use of an Out instruction places a value
into the accumulator and the value that was in the accumulator is placed onto the
accumulator stack. The Out instruction nullifies the previous load instruction and
does not place the value that was in the accumulator onto the accumulator stack
when the next load instruction is executed. Every time a value is placed onto the
accumulator stack the other values in the stack are pushed down one location. The
accumulator is eight levels deep (eight 32 bit registers). If there is a value in the
eighth location when a new value is placed onto the stack, the value in the eighth
location is pushed off the stack and cannot be recovered.
X1

Constant

LD
K3245
Load the value 3245 into the accumulator

Current Acc. value

Acc. 0

Previous Acc. value

Acc. X

Constant

LD
K5151
Load the value 5151 into the accumulator, pushing the value 3245 onto the
stack

Acc. 0

Level 2

Level 3

Level 4

Level 5

Level 6

Level 7

Level 8

LD

Bucket

Accumulator Stack

Previous Acc. value

0

Constant

Load the value 6363 into the accumulator, pushing the value 5151 to the 1st
stack location and the value 3245 to
the 2nd stack location

Current Acc. value

Acc. 0

K6363

Accumulator Stack
Level 1

Level 1

Level 2

Level 3

Level 4

Level 5

Level 6

Level 7

Level 8

Current Acc. value

Acc. 0

Bucket
Accumulator Stack

Previous Acc. value

Acc. 0

Level 1

Level 2

1
5

Level 3

Level 4

Level 5

Level 6

Level 7

Level 8

The POP instruction rotates values upward through the stack into the accumulator.
When a POP is executed the value which was in the accumulator is cleared and the
value that was on top of the stack is in the accumulator. The values in the stack are
shifted up one position in the stack.

Standard
RLL Instructions

Bucket

546

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

X1

Previous Acc. value

POP

Acc. X
POP the 1st value on the stack into the
accumulator and move stack values
up one location

Accumulator Stack

Current Acc. value

Acc. 0

OUT
V2000

V2000

Copy data from the accumulator to

V2000

Level 1

Level 2

2
0

Level 3

Level 4

Level 5

Level 6

Level 7

Level 8

Level 1

Level 2

Level 3

Level 4

Level 5

Level 6

Level 7

Level 8

Level 1

Level 2

Level 3

Level 4

Level 5

Level 6

Level 7

Level 8

Previous Acc. value

POP

Acc. 0
POP the 1st value on the stack into the
accumulator and move stack values
up one location

Accumulator Stack

Current Acc. value

Acc. 0

OUT

V2001

V2001

Copy data from the accumulator to

V2001.
Previous Acc. value
POP

Acc. 0

Accumulator Stack

Current Acc. value

POP the 1st value on the stack into the
accumulator and move stack values
up one location

OUT

V2002
V2002

Copy data from the accumulator to

V2002

Using Pointers

Acc. X

Many of the DL05 series instructions will allow V-memory pointers as a operand
(commonly known as indirect addressing). Pointers allow instructions to obtain data
from V-memory locations referenced by the pointer value.

Standard
RLL Instructions

NOTE: DL05 V-memory addressing is in octal. However, the pointers reference a

V-memory location with values viewed as HEX. Use the Load Address (LDA)
instruction to move an address into the pointer location. This instruction performs the
Octal to Hexadecimal conversion automatically.
In the following simple example we are using a pointer operand in a Load instruction.
V-memory location 2000 is being used as the pointer location. V2000 contains the
value 440 which the CPU views as the Hex equivalent of the Octal address
V-memory location V2100. The CPU will copy the data from V2100 which in this
example contains the value 2635 into the lower word of the accumulator.

547

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

X1

LD
P2000
V1400 (P1400) contains the value 440
HEX. 440 HEX. = 2100 Octal which
contains the value 2635.
V2000
0

V2076

V2077

V2100

V2101

V2102

V2103

V2104

V2105

Accumulator
2

OUT
S
S

V2200
Copy the data from the lower 16 bits of
the accumulator to V2200.

V2200

V2201

The following example is identical to the one above with one exception. The LDA
(Load Address) instruction automatically converts the Octal address to Hex.
X1

LDA
O 2100

Load the lower 16 bits of the

accumulator with Hexadecimal
equivalent to Octal 2100 (440)

0
2100 Octal is converted to Hexadecimal
440 and loaded into the accumulator

Unused accumulator bits

are set to zero
Acc. 0

OUT
V 2000

Copy the data from the lower 16 bits of

the accumulator to V2000

V2000
S
S

LD
P 2000

V2000 (P2000) contains the value 440

Hex. 440 Hex. = 2100 Octal which
contains the value 2635
V2100
0

OUT
V 2200

Copy the data from the lower 16 bits of

the accumulator to V2200

V2076

V2077

V2100

V2101

V2102

V2103

V2104

V2105

Accumulator
0

S
S
V2200

V2201

Standard
RLL Instructions

548
Load
(LD)

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

The Load instruction is a 16 bit instruction

that loads the value (Aaaa), which is either
a V memory location or a 4 digit constant,
into the lower 16 bits of the accumulator.
The upper 16 bits of the accumulator are
set to 0.
Operand Data Type

LD
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All V mem. (See page 428)

Constant

0FFFF

Discrete Bit Flags

Description

SP53

on when the pointer is outside of the available range.

SP70

on when the value loaded into the accumulator by any instruction is zero.

SP76

on when the result in the accumulator is negative.

NOTE: Two consecutive Load instructions will place the value of the first load
instruction onto the accumulator stack.
In the following example, when X1 is on, the value in V2000 will be loaded into the
accumulator and output to V2010.

DirectSOFT

V2000

X1

LD

V2000
The unused accumulator
bits are set to zero

Load the value in V2000 into

the lower 16 bits of the
accumulator

Acc. 0

OUT
V2010
Copy the value in the lower
16 bits of the accumulator to
V2010

V2010

Handheld Programmer Keystrokes

$

B
1

STR
SHFT

L
ANDST

Standard
RLL Instructions

2
GX
OUT

X
SET

3
A
0

SHFT

V
AND

ENT
C

A
2

B
0

A
1

ENT

549

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

Load Double
(LDD )

The Load Double instruction is a 32 bit

instruction that loads the value (Aaaa),
which is either two consecutive V memory
locations or an 8 digit constant value, into
the accumulator.

Operand Data Type

LDD
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All V mem. (See page 428)

Constant

0FFFFFFFF

Discrete Bit Flags

Description

SP53

on when the pointer is outside of the available range.

SP70

on when the value loaded into the accumulator by any instruction is zero.

SP76

on when the value loaded into the accumulator by any instruction is zero.

NOTE: Two consecutive Load instructions will place the value of the first load
instruction onto the accumulator stack.
In the following example, when X1 is on, the 32 bit value in V2000 and V2001 will be
loaded into the accumulator and output to V2010 and V2011.
DirectSOFT
X1

V2001

LDD
V2000

V2000

Acc. 6

Load the value in V2000 and

V2001 into the 32 bit
accumulator

OUTD
V2010

V2011

V2010

Copy the value in the 32 bit

accumulator to V2010 and
V2011
Handheld Programmer Keystrokes
$

B
STR

SHFT

L
ANDST

GX
OUT

SHFT

3
A

ENT

3
A
1

ENT

Standard
RLL Instructions

D
3

ENT

550

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

Load
Formatted
(LDF)

The Load Formatted instruction loads

132 consecutive bits from discrete
memory locations into the accumulator.
The instruction requires a starting location
(Aaaa) and the number of bits (Kbbb) to be
loaded. Unused accumulator bit locations
are set to zero.
Operand Data Type

LDF

A aaa
K bbb

DL05 Range
A

aaa

bbb

Inputs

0377

Outputs

0377

Control Relays

0777

Stage Bits

0377

Timer Bits

0177

Counter Bits

CT

0177

Special Relays

SP

0777

132

Constant

Discrete Bit Flags

Description

SP70

on when the value loaded into the accumulator by any instruction is zero.

SP76

on when the value loaded into the accumulator by any instruction is zero.

NOTE: Two consecutive Load instructions will place the value of the first load
instruction onto the accumulator stack.
In the following example, when C0 is on, the binary pattern of C10C16 (7 bits) will
be loaded into the accumulator using the Load Formatted instruction. The lower 7
bits of the accumulator are output to Y0Y6 using the Out Formatted instruction.
DirectSOFT
C0

LDF

C10
K7

Load the status of 7

consecutive bits (C10C16)
into the accumulator

Location

Constant

C10

K7

C16 C15 C14 C13 C12 C11 C10

OFF OFF OFF ON ON ON OFF

The unused accumulator bits are set to zero

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Acc.

OUTF

6 5

4 3

Y0
K7

Standard
RLL Instructions

Copy the value from the

specified number of bits in
the accumulator to Y0 Y6
Handheld Programmer Keystrokes
$

SHFT

SHFT

L
ANDST

SHFT

GX
OUT

SHFT

STR

ENT

H
0

F
5
7

5
A

H
0

A
2

ENT

ENT

Location

Constant

Y0

K7

Y6

Y5

Y4

Y3

Y2

Y1

Y0

OFF OFF OFF ON ON ON OFF

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

Load Address
(LDA)

The Load Address instruction is a 16 bit

instruction. It converts any octal value or
address to the HEX equivalent value and
loads the HEX value into the accumulator.
This instruction is useful when an address
parameter is required since all addresses
for the DL05 system are in octal.
Operand Data Type

551

LDA
O aaa

DL05 Range
aaa

Octal Address

All V mem. (See page 428)

Discrete Bit Flags

Description

SP70

on when the value loaded into the accumulator by any instruction is zero.

SP76

on when the value loaded into the accumulator by any instruction is zero.

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

Octal

LDA
4

O 40400

Load The HEX equivalent to

the octal number into the
lower 16 bits of the
accumulator

Hexadecimal
0

The unused accumulator

bits are set to zero
Acc. 0

OUT

V2000

V2000
Copy the value in lower 16
bits of the accumulator to
V2000
Handheld Programmer Keystrokes
$

B
1

STR
SHFT

L
ANDST

A
3

0
A

SHFT

V
AND

0
C

ENT
A

A
0

A
0

ENT

Standard
RLL Instructions

GX
OUT

ENT

552

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

Out
(OUT)

The Out instruction is a 16 bit instruction

that copies the value in the lower 16 bits of
the accumulator to a specified V memory
location (Aaaa).
Operand Data Type

OUT
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All V mem. (See page 428)

Discrete Bit Flags

Description

SP53

on when the pointer is outside of the available range.

In the following example, when X1 is on, the value in V2000 will be loaded into the
lower 16 bits of the accumulator using the Load instruction. The value in the lower 16
bits of the accumulator are copied to V2010 using the Out instruction.
Handheld Programmer Keystrokes

DirectSOFT
X1

V2000

LD
8

V2000
Load the value in V2000 into
the lower 16 bits of the
accumulator

The unused accumulator

bits are set to zero
Acc. 0

B
STR

SHFT

L
ANDST

GX
OUT

OUT

ENT

3
A

ENT

SHFT

V
AND

A
2

B
0

A
1

ENT

V2010
Copy the value in the lower
16 bits of the accumulator to
V2010

Out Double
(OUTD)

V2010

The Out Double instruction is a 32 bit

instruction that copies the value in the
accumulator to two consecutive V memory
locations at a specified starting location
(Aaaa).
Operand Data Type

OUTD
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All V mem. (See page 428)

Discrete Bit Flags

Description

SP53

on when the pointer is outside of the available range.

Standard
RLL Instructions

In the following example, when X1 is on, the 32 bit value in V2000 and V2001 will be
loaded into the accumulator using the Load Double instruction. The value in the
accumulator is output to V2010 and V2011 using the Out Double instruction.
V2001

DirectSOFT
6
X1

V2000
9

Handheld Programmer Keystrokes

6

LDD

B
1

STR
V2000

Load the value in V2000 and

V2001 into the accumulator

Acc. 6

OUTD
V2010
Copy the value in the
accumulator to V2010 and
V2011

V2011

V2010

SHFT

L
ANDST

GX
OUT

SHFT

ENT
D
3
A

ENT

3
A
1

ENT

553

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

Out
Formatted
(OUTF)

The Out Formatted instruction outputs

132 bits from the accumulator to the
specified discrete memory locations. The
instruction requires a starting location
(Aaaa) for the destination and the number
of bits (Kbbb) to be output.
Operand Data Type

OUTF
A aaa
K bbb

DL05 Range
A

aaa

bbb

Inputs

0377

Outputs

0377

Control Relays

0777

Constant

132

In the following example, when C0 is on, the binary pattern of C10C16 (7 bits) will
be loaded into the accumulator using the Load Formatted instruction. The lower 7
bits of the accumulator are output to Y0Y6 using the Out Formatted instruction.
DirectSOFT
C0

LDF

C10
K7

Load the status of 7

consecutive bits (C10C16)
into the accumulator

Location

Constant

C10

K7

C16 C15 C14 C13 C12 C11 C10

OFF OFF OFF ON ON ON OFF

The unused accumulator bits are set to zero

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
0

OUTF

Y0

6 5

4 3

Accumulator

K7
Copy the value of the
specified number of bits
from the accumulator to
Y20Y26

Location

Constant

Y26 Y25 Y24 Y23 Y22 Y21 Y20

Y0

K7

OFF OFF OFF ON ON ON OFF

Handheld Programmer Keystrokes

$
STR

SHFT

C
F

SHFT

L
ANDST

SHFT

GX
OUT

SHFT

Pop
(POP)

ENT

5
H
0

ENT

F
5
H

A
1

A
2

ENT

Discrete Bit Flags

Description

SP63

on when the result of the instruction causes the value in the accumulator
to be zero.

POP

Standard
RLL Instructions

The Pop instruction moves the value from

the first level of the accumulator stack (32
bits) to the accumulator and shifts each
value in the stack up one level.

554

Standard RLL Instructions

Accumulator / Stack Load and Output Data Instructions

Pop Instruction
Continued

In the example below, when C0 is on, the value 4545 that was on top of the stack is
moved into the accumulator using the Pop instruction The value is output to V2000
using the Out instruction. The next Pop moves the value 3792 into the accumulator
and outputs the value to V2001. The last Pop moves the value 7930 into the
accumulator and outputs the value to V2002. Please note if the value in the stack
were greater than 16 bits (4 digits) the Out Double instruction would be used and 2 V
memory locations for each Out Double must be allocated.

DirectSOFT

Previous Acc. value

C0

POP

Acc. X

Accumulator Stack

Current Acc. value

Pop the 1st. value on the stack into the
accumulator and move stack values
up one location

Acc. 0

OUT
V2000
V2000

Copy the value in the lower 16 bits of

the accumulator to V2000

Level 1

Level 2

2
0

Level 3

Level 4

Level 5

Level 6

Level 7

Level 8

Level 1

Level 2

Level 3

Level 4

Level 5

Level 6

Level 7

Level 8

Level 1

Level 2

Level 3

Level 4

Level 5

Level 6

Level 7

Level 8

POP
Previous Acc. value
Acc. 0
Pop the 1st. value on the stack into the
accumulator and move stack values
up one location

5
Accumulator Stack

Current Acc. value

Acc. 0

OUT
V2001
Copy the value in the lower 16 bits of
the accumulator to V2001

V2001

POP

Previous Acc. value

Pop the 1st. value on the stack into the

accumulator and move stack values
up one location

Acc. 0

Accumulator Stack

Current Acc. value

Acc. 0

OUT

V2002
Copy the value in the lower 16 bits of
the accumulator to V2002
V2002
Handheld Programmer Keystrokes
$
STR
SHFT

P
CV

Standard
RLL Instructions

GX
OUT
SHFT

P
CV

GX
OUT
SHFT
GX
OUT

P
CV

SHFT

SHFT

O
INST#

SHFT

V
AND

SHFT

O
INST#

SHFT

V
AND

SHFT

O
INST#

SHFT

V
AND

0
CV

ENT
ENT
A

2
CV

A
0

A
0

ENT

B
0

ENT

ENT
A

ENT

2
CV

A
0

A
0

C
0

ENT

555

Standard RLL Instructions

Accumulator Logic Instructions

Logical Instructions (Accumulator)

And
(AND)

The And instruction is a 16 bit instruction

that logically ands the value in the lower
16 bits of the accumulator with a
specified V memory location (Aaaa). The
result resides in the accumulator. The
discrete status flag indicates if the result
of the And is zero.
Operand Data Type

AND
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Discrete Bit Flags

Description

SP63

Will be on if the result in the accumulator is zero

SP70

on when the value loaded into the accumulator by any instruction is zero.

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example, when X1 is on, the value in V2000 will be loaded into the
accumulator using the Load instruction. The value in the accumulator is anded
with the value in V2006 using the And instruction. The value in the lower 16 bits of the
accumulator is output to V2010 using the Out instruction.
DirectSOFT
X1

V2000

LD

V2000

The upper 16 bits of the accumulator

will be set to 0

Load the value in V2000 into

the lower 16 bits of the
accumulator

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

6 5

4 3

Acc.

6A38
AND (V2006)

1
0

Acc.
AND
V2006
AND the value in the
accumulator with
the value in V2006

Acc.
OUT
V2010

V2010

Handheld Programmer Keystrokes

$

B
STR

SHFT
V
AND
GX
OUT

1
L
ANDST

ENT

A
2

3
SHFT

V
AND

SHFT

V
AND

A
0

A
2

A
0

A
2

A
0

0
B

0
G
A

ENT
ENT
ENT

Standard
RLL Instructions

Copy the lower 16 bits of the

accumulator to V2010

556

Standard RLL Instructions

Accumulator Logic Instructions

And Double
(ANDD)

The And Double is a 32 bit instruction that

logically ands the value in the
accumulator with two consecutive V
memory locations or an 8 digit (max.)
constant value (Aaaa). The result
resides in the accumulator. Discrete
status flags indicate if the result of the
And Double is zero or a negative number
(the most significant bit is on).
Operand Data Type

ANDD
K aaa

DL05 Range
aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Constant

0FFFFFFFF

Discrete Bit Flags

Description

SP63

Will be on if the result in the accumulator is zero

SP70

Will be on is the result in the accumulator is negative

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example, when X1 is on, the value in V2000 and V2001 will be loaded
into the accumulator using the Load Double instruction. The value in the
accumulator is anded with 36476A38 using the And double instruction. The value in
the accumulator is output to V2010 and V2011 using the Out Double instruction.
V2000

V2001

DirectSOFT
X1

LDD

V2000
Load the value in V2000 and
V2001 into the accumulator

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

6 5

4 3

Acc.

AND 36476A38

0
1

0
1

0
1

0
1

Acc.
ANDD
K36476A38
AND the value in the
accumulator with
the constant value
36476A38

Acc.

OUTD
1

Standard
RLL Instructions

V2010

V2011

Copy the value in the

accumulator to V2010 and
V2011

V2010

Handheld Programmer Keystrokes

$

B
STR

SHFT

L
ANDST

V
AND

SHFT

SHFT

GX
OUT

ENT
D

3
3
3

C
3

SHFT

K
JMP

A
0

G
3

E
6

A
1

ENT
H

4
ENT

G
7

SHFT

A
0

SHFT

I
3

ENT

557

Standard RLL Instructions

Accumulator Logic Instructions

Or
(OR)

The Or instruction is a 16 bit instruction

that logically ors the value in the lower 16
bits of the accumulator with a specified V
memory location (Aaaa). The result
resides in the accumulator. The discrete
status flag indicates if the result of the Or
is zero.
Operand Data Type

OR
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Discrete Bit Flags

Description

SP63

Will be on if the result in the accumulator is zero

SP70

on when the value loaded into the accumulator by any instruction is zero.

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example, when X1 is on, the value in V2000 will be loaded into the
accumulator using the Load instruction. The value in the accumulator is ored with
V2006 using the Or instruction. The value in the lower 16 bits of the accumulator are
output to V2010 using the Out instruction.
DirectSOFT
X1

V2000

LD

V2000

The upper 16 bits of the accumulator

will be set to 0

Load the value in V2000 into

the lower 16 bits of the
accumulator

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

6 5

4 3

Acc.

6A38
OR (V2006)

1
0

Acc.
OR
V2006
Or the value in the
accumulator with
the value in V2006

Acc.
OUT
V2010

Copy the value in the lower

16 bits of the accumulator to
V2010
Handheld Programmer Keystrokes
$

SHFT
Q
OR
GX
OUT

1
L
ANDST

ENT

C
3

SHFT

V
AND

SHFT

V
AND

A
0

2
A
2

A
0

A
2

A
0
G
6

0
B

A
1

ENT
ENT
ENT

Standard
RLL Instructions

STR

V2010

558

Standard RLL Instructions

Accumulator Logic Instructions

Or Double
(ORD)

The Or Double is a 32 bit instruction that

ors the value in the accumulator with the
value (Aaaa), which is either two
consecutive V memory locations or an 8
digit (max.) constant value. The result
resides in the accumulator. Discrete
status flags indicate if the result of the Or
Double is zero or a negative number (the
most significant bit is on).
Operand Data Type

ORD
K aaa

DL05 Range
aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Constant

0FFFFFFFF

Discrete Bit Flags

Description

SP63

Will be on if the result in the accumulator is zero

SP70

Will be on is the result in the accumulator is negative

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example, when X1 is on, the value in V2000 and V2001 will be loaded
into the accumulator using the Load Double instruction. The value in the
accumulator is ored with 36476A38 using the Or Double instruction. The value in the
accumulator is output to V2010 and V2011 using the Out Double instruction.
DirectSOFT
X1

V2001

LDD

V2000

V2000
E

Load the value in V2000 and

V2001 into accumulator
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

6 5

4 3

Acc.

OR 36476A38

Acc.

0
1

0
1

0
1

0
1

0
1

0
1

0
1

0
1

0
1

0
1

0
1

Acc.
ORD
K36476A38
OR the value in the
accumulator with
the constant value
36476A38
OUTD

Standard
RLL Instructions

V2010
7

Copy the value in the

accumulator to V2010 and
V2011

V2011

V2010

Handheld Programmer Keystrokes

$

B
STR

SHFT

L
ANDST

SHFT

SHFT

OR
GX
OUT

ENT
D

3
3
3

C
3

A
2

SHFT

K
JMP

A
0

A
0

G
3

E
6

A
1

ENT
H

4
ENT

G
7

SHFT

A
0

SHFT

I
3

ENT

559

Standard RLL Instructions

Accumulator Logic Instructions

Exclusive Or
(XOR)

The Exclusive Or instruction is a 16 bit

instruction that performs an exclusive or
of the value in the lower 16 bits of the
accumulator and a specified V memory
location (Aaaa). The result resides in the
in the accumulator. The discrete status
flag indicates if the result of the XOR is
zero.
Operand Data Type

XOR
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Discrete Bit Flags

Description

SP63

Will be on if the result in the accumulator is zero

SP70

on when the value loaded into the accumulator by any instruction is zero.

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example, when X1 is on, the value in V2000 will be loaded into the
accumulator using the Load instruction. The value in the accumulator is exclusive
ored with V2006 using the Exclusive Or instruction. The value in the lower 16 bits of
the accumulator are output to V2010 using the Out instruction.
DirectSOFT
X1

V2000

LD

V2000
Load the value in V2000 into
the lower 16 bits of the
accumulator

The upper 16 bits of the accumulator

will be set to 0
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

6 5

4 3

Acc.

6A38
XOR (V2006)

1
0

Acc.
XOR
V2006
XOR the value in the
accumulator with
the value in V2006

Acc.
OUT
V2010

Copy the lower 16 bits of the

accumulator to V2010

V2010

Handheld Programmer Keystrokes

SHFT

STR

X
SET

SHFT

L
ANDST

SHFT

X
SET

SHFT

SHFT

V
AND

GX
OUT

B
1
SHFT

3
OR

C
2

ENT
V
AND

SHFT

V
AND

A
2

A
0

A
0

A
2
0

0
A

0
ENT

ENT
G

ENT

Standard
RLL Instructions

560

Standard RLL Instructions

Accumulator Logic Instructions

Exclusive Or
Double
(XORD)

The Exclusive OR Double is a 32 bit

instruction that performs an exclusive or
of the value in the accumulator and the
value (Aaaa), which is either two
consecutive V memory locations or an 8
digit (max.) constant. The result resides
in the accumulator. Discrete status flags
indicate if the result of the Exclusive Or
Double is zero or a negative number (the
most significant bit is on).
Operand Data Type

XORD
K aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Constant

0FFFFFFFF

Discrete Bit Flags

Description

SP63

Will be on if the result in the accumulator is zero

SP70

Will be on is the result in the accumulator is negative

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example, when X1 is on, the value in V2000 and V2001 will be loaded
into the accumulator using the Load Double instruction. The value in the
accumulator is exclusively ored with 36476A38 using the Exclusive Or Double
instruction. The value in the accumulator is output to V2010 and V2011 using the Out
Double instruction.
V2001

DirectSOFT
X1

LDD

V2000
E

V2000
Load the value in V2000 and
V2001 into the accumulator

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

6 5

4 3

Acc.

XORD 36476A38

0
1

0
1

1
0

0
1

0
1

0
1

0
1

0
1

XORD

Acc.

K36476A38
XORD the value in the
accumulator with
the constant value
36476A38
OUTD

Acc.
V2010

Standard
RLL Instructions

Copy the value in the

accumulator to V2010
and V2011

V2011

Handheld Programmer Keystrokes

$

B
STR

SHFT

L
ANDST

SHFT

X
SET

3
GX
OUT

D
3
OR

6
SHFT

ENT

4
D

SHFT

G
7

6
2

A
0

A
0

SHFT

K
JMP

SHFT

SHFT

C
3

A
2

A
1

ENT

I
3

ENT

ENT

V2010

Standard RLL Instructions

Accumulator Logic Instructions

Compare
(CMP)

The compare instruction is a 16 bit

instruction that compares the value in the
lower 16 bits of the accumulator with the
value in a specified V memory location
(Aaaa). The corresponding status flag
will be turned on indicating the result of
the comparison.
Operand Data Type

561

CMP
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Discrete Bit Flags

Description

SP60

On when the value in the accumulator is less than the instruction value.

SP61

On when the value in the accumulator is equal to the instruction value.

SP62

On when the value in the accumulator is greater than the instruction

value.

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example when X1 is on, the constant 4526 will be loaded into the
lower 16 bits of the accumulator using the Load instruction. The value in the
accumulator is compared with the value in V2000 using the Compare instruction.
The corresponding discrete status flag will be turned on indicating the result of the
comparison. In this example, if the value in the accumulator is less than the value
specified in the Compare instruction, SP60 will turn on energizing C30.
DirectSOFT
X1

Constant

LD
K4526
Load the constant value
4526 into the lower 16 bits of
the accumulator

The unused accumulator

bits are set to zero
Acc. 0

Compared
with

CMP
V2000

Compare the value in the

accumulator with the value
in V2000
SP60

ENT

SHFT

L
ANDST

SHFT

SHFT

M
ORST

SHFT

SP
STRN

SHFT

STR
GX
OUT

SHFT

K
JMP

F
4

C
A
6

0
A

A
2

CV

C
5

ENT
ENT

G
2

A
0

6
A

ENT
ENT

Standard
RLL Instructions

C30

STR

V2000

Handheld Programmer Keystrokes

$

562

Standard RLL Instructions

Accumulator Logic Instructions

Compare Double
(CMPD)

The Compare Double instruction is a

32bit instruction that compares the
value in the accumulator with the value
(Aaaa), which is either two consecutive V
memory locations or an 8digit (max.)
constant. The corresponding status flag
will be turned on indicating the result of
the comparison.
Operand Data Type

CMPD
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Constant

0FFFFFFFF

Discrete Bit Flags

Description

SP60

On when the value in the accumulator is less than the instruction value.

SP61

On when the value in the accumulator is equal to the instruction value.

SP62

On when the value in the accumulator is greater than the instruction

value.

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example when X1 is on, the value in V2000 and V2001 will be loaded
into the accumulator using the Load Double instruction. The value in the
accumulator is compared with the value in V2010 and V2011 using the CMPD
instruction. The corresponding discrete status flag will be turned on indicating the
result of the comparison. In this example, if the value in the accumulator is less than
the value specified in the Compare instruction, SP60 will turn on energizing C30.
DirectSOFT
X1

V2000

V2001

LDD

Acc. 4

V2000
Load the value in V2000 and
V2001 into the accumulator

Compared
with

CMPD
V2010
6

Compare the value in the

accumulator with the value
in V2010 and V2011

Standard
RLL Instructions

SP60

V2011

V2010

C30

Handheld Programmer Keystrokes

$

B
STR

ENT

SHFT

L
ANDST

D
3

SHFT

SHFT

M
ORST

SHFT

SP
STRN

SHFT

$
STR
GX
OUT

A
2

A
0

C
3

CV
A
6

0
A

A
0

A
2

ENT
ENT

ENT
B

A
1

ENT

Standard RLL Instructions

Math Instructions

563

Math Instructions
Add
(ADD)

Add is a 16 bit instruction that adds a

BCD value in the accumulator with a
BCD value in a V memory location
(Aaaa). The result resides in the
accumulator.
Operand Data Type

ADD
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator
to be zero.

SP66

On when the 16 bit addition instruction results in a carry.

SP67

On when the 32 bit addition instruction results in a carry.

SP70

On anytime the value in the accumulator is negative.

SP75

On when a BCD instruction is executed and a NONBCD number was

encountered.

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

V2000

X1

The unused accumulator

bits are set to zero
0 0 0 0
4

(Accumulator)

(V2006)

LD
V2000
Load the value in V2000 into
the lower 16 bits of the
accumulator
ADD

V2006

Acc.

Add the value in the lower

16 bits of the accumulator
with the value in V2006
OUT
V2010

B
STR

SHFT

L
ANDST

SHFT

GX
OUT

ENT
C

A
2

3
D

A
0

SHFT

V
AND

A
2

A
2

A
0
A
0

B
0

G
0

A
1

ENT

6
ENT

ENT

Standard
RLL Instructions

V2010

Copy the value in the lower

16 bits of the accumulator to
V2010
Handheld Programmer Keystrokes

564

Standard RLL Instructions

Math Instructions

Add Double
(ADDD)

Add Double is a 32 bit instruction that

adds the BCD value in the accumulator
with a BCD value (Aaaa), which is either
two consecutive V memory locations or
an 8digit (max.) BCD constant. The
result resides in the accumulator.
Operand Data Type

ADDD
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Constant

099999999

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator
to be zero.

SP66

On when the 16 bit addition instruction results in a carry.

SP67

On when the 32 bit addition instruction results in a carry.

SP70

On anytime the value in the accumulator is negative.

SP75

On when a BCD instruction is executed and a NONBCD number was

encountered.

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example, when X1 is on, the value in V2000 and V2001 will be loaded
into the accumulator using the Load Double instruction. The value in the
accumulator is added with the value in V2006 and V2007 using the Add Double
instruction. The value in the accumulator is copied to V2010 and V2011 using the
Out Double instruction.
V2001

DirectSOFT
X1

LDD

V2000

V2000
Load the value in V2000 and
V2001 into the accumulator
ADDD
V2006
Add the value in the
accumulator with the value
in V2006 and V2007

(Accumulator)

+ 2

(V2006 and V2007)

Acc. 8

OUTD

Standard
RLL Instructions

V2010

V2011

Copy the value in the

accumulator to V2010 and
V2011

V2010

Handheld Programmer Keystrokes

$

B
1

STR
SHFT

L
ANDST

SHFT

GX
OUT

SHFT

ENT
D

C
3

3
D
3
D
3

A
2

D
3

A
0

C
3

SHFT

A
2

2
V
AND

A
0

G
6

0
B

ENT

A
1

ENT
ENT

Standard RLL Instructions

Math Instructions

Subtract
(SUB)

Subtract is a 16 bit instruction that

subtracts the BCD value (Aaaa) in a V
memory location from the BCD value in
the lower 16 bits of the accumulator. The
result resides in the accumulator.

Operand Data Type

565

SUB
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator
to be zero.

SP64

On when the 16 bit subtraction instruction results in a borrow.

SP65

On when the 32 bit subtraction instruction results in a borrow.

SP70

On anytime the value in the accumulator is negative.

SP75

On when a BCD instruction is executed and a NONBCD number was

encountered.

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

DirectSOFT
X1

(Accumulator)

(V2006)

LD
V2000
Load the value in V2000 into
the lower 16 bits of the
accumulator

The unused accumulator

bits are set to zero
0 0 0 0
y

SUB
V2006

Acc.
Subtract the value in V2006
from the value in the lower
16 bits of the accumulator
OUT
V2010

V2010

Handheld Programmer Keystrokes

$

B
1

STR
SHFT

L
ANDST

SHFT

S
RST

GX
OUT

ENT
C

A
2

3
B
ISG

SHFT

V
AND

C
2

SHFT

V
AND

ENT
A

2
0

A
0

ENT

G
0

ENT

Standard
RLL Instructions

Copy the value in the lower

16 bits of the accumulator to
V2010

566

Standard RLL Instructions

Math Instructions

Subtract Double
(SUBD)

Subtract Double is a 32 bit instruction that

subtracts the BCD value (Aaaa), which is
either two consecutive V memory
locations or an 8-digit (max.) constant,
from the BCD value in the accumulator.
The result resides in the accumulator.
Operand Data Type

SUBD
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Constant

099999999

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator
to be zero.

SP64

On when the 16 bit subtraction instruction results in a borrow.

SP65

On when the 32 bit subtraction instruction results in a borrow.

SP70

On anytime the value in the accumulator is negative.

SP75

On when a BCD instruction is executed and a NONBCD number was

encountered.

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example, when X1 is on, the value in V2000 and V2001 will be loaded
into the accumulator using the Load Double instruction. The value in V2006 and
V2007 is subtracted from the value in the accumulator. The value in the accumulator
is copied to V2010 and V2011 using the Out Double instruction.
V2001

DirectSOFT
X1

V2000

LDD
V2000
Load the value in V2000 and
V2001 into the accumulator
y

SUBD
V2006

ACC.

(Accumulator)

(V2006 and V2007)

The in V2006 and V2007 is

subtracted from the value in
the accumulator
OUTD

Standard
RLL Instructions

V2010

V2011

V2010

Copy the value in the

accumulator to V2010 and
V2011
Handheld Programmer Keystrokes
$

B
STR

SHFT

L
ANDST

SHFT

S
RST

SHFT

GX
OUT

SHFT

ENT
D

B
ISG

A
0

A
2

A
0

B
0

A
1

0
A

1
C

A
2

ENT
A

0
ENT

G
0

ENT

Standard RLL Instructions

Math Instructions

Multiply
(MUL)

Multiply is a 16 bit instruction that

multiplies the BCD value (Aaaa), which is
either a V memory location or a 4digit
(max.) constant, by the BCD value in the
lower 16 bits of the accumulator The
result can be up to 8 digits and resides in
the accumulator.
Operand Data Type

567

MUL
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Constant

09999

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator
to be zero.

SP70

On anytime the value in the accumulator is negative.

SP75

On when a BCD instruction is executed and a NONBCD number was

encountered.

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

V2000

X1

LD

(Accumulator)

(V2006)

V2000
The unused accumulator
bits are set to zero

Load the value in V2000 into

the lower 16 bits of the
accumulator

MUL

Acc.

V2006

The value in V2006 is

multiplied by the value in the
accumulator

OUTD

V2010

V2010

V2010

Handheld Programmer Keystrokes

$

B
STR

SHFT

L
ANDST

SHFT

M
ORST

GX
OUT

SHFT

ENT
C

ISG

A
2

3
L
ANDST

A
2

A
0

2
C

A
0

A
0

B
0

G
0

A
1

ENT

6
ENT

ENT

Standard
RLL Instructions

Copy the value in the

accumulator to V2010 and
V2011

568

Standard RLL Instructions

Math Instructions

Multiply Double
(MULD)

Multiply Double is a 32 bit instruction that

multiplies the 8-digit BCD value in the
accumulator by the 8-digit BCD value in
the two consecutive V-memory locations
specified in the instruction. The lower 8
digits of the results reside in the
accumulator. Upper digits of the result
reside in the accumulator stack.
Operand Data Type

MULD
A aaa

DL05 Range
A

aaa

Vmemory

All (See p. 428)

Pointer

All (See page 428)

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP70

On anytime the value in the accumulator is negative.

SP75

On when a BCD instruction is executed and a NONBCD number was encountered.

NOTE: Status flags are valid only until another instruction uses the same flag.
In the following example, when X1 is on, the constant Kbc614e hex will be loaded
into the accumulator. When converted to BCD the number is 12345678. That
numberis stored in V1400 and V1401. After loading the constant K2 into the
accumulator, we multiply it times 12345678, which is 24691356.
DirectSOFT Display

X1

Kbc614e

V1400

Output the number to

V1400 and V1401 using
the OUTD instruction.

OUTD

Acc.

K2

V1400

Multiply the accumulator

contents (2) by the
8-digit number in V1400
and V1401.

V1402

Move the result in the

accumulator to V1402
and V1403 using the
OUTD instruction.

MULD

OUTD

2
2

V1403

V1500

Standard
RLL Instructions

Handheld Programmer Keystrokes

B
1

SHFT

GX
OUT

SHFT

SHFT

L
ANDST

SHFT

M
ORST

SHFT

GX
OUT

ENT
G

SHFT

L
ANDST

1
B

ISG

SHFT
L
ANDST

D
3

ENT

SHFT

A
4

K
JMP

A
0

C
2
B

E
1

A
4

K
JMP

ENT

A
4

C
0

SHFT

ENT

3
B

Load the constant K2

into the accumulator.

LD

STR

(Accumulator)

V1400

V1401

Convert the value to

BCD format. It will
occupy eight BCD digits
(32 bits).

BCD

Load the hex equivalent

of 12345678 decimal into
the accumulator.

LDD

A
0

ENT

SHFT
ENT

(Accumulator)

569

Standard RLL Instructions

Math Instructions

Divide
(DIV)

Divide is a 16 bit instruction that divides

the BCD value in the accumulator by a
BCD value (Aaaa), which is either a V
memory location or a 4-digit (max.)
constant. The first part of the quotient
resides in the accumulator and the
remainder resides in the first stack
location.
Operand Data Type

DIV
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Constant

19999

Discrete Bit Flags

Description

SP53

On when the value of the operand is larger than the accumulator can work
with.

SP63

On when the result of the instruction causes the value in the accumulator
to be zero.

SP70

On anytime the value in the accumulator is negative.

SP75

On when a BCD instruction is executed and a NONBCD number was

encountered.

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

DirectSOFT
X1

The unused accumulator

bits are set to zero
0 0 0 0
5

(Accumulator)

(V2006)

LD
V2000
Load the value in V2000 into
the lower 16 bits of the
accumulator
DIV

V2006
1

Acc.

The value in the

accumulator is divided by
the value in V2006

1
V2010

SHFT

L
ANDST

SHFT

GX
OUT

ENT
C

SHFT

A
2

3
8

V
AND
V
AND

A
0

A
2

A
2

A
0
A
0

B
0

G
0

A
1

ENT

6
ENT

ENT

Standard
RLL Instructions

Handheld Programmer Keystrokes

B

V2010

Copy the value in the lower

16 bits of the accumulator to
V2010

STR

First stack location contains

the remainder

OUT

570

Standard RLL Instructions

Math Instructions

Divide Double
(DIVD)

Divide Double is a 32 bit instruction that

divides the BCD value in the accumulator
by a BCD value (Aaaa), which must be
obtained from two consecutive V memory
locations. (You cannot use a constant as
the parameter in the box.) The first part of
the quotient resides in the accumulator
and the remainder resides in the first stack
location.
Operand Data Type

DIVD
A aaa

DL05 Range
A

aaa

Vmemory

All (See p. 428)

Pointer

All (See p. 428)

Discrete Bit Flags

Description

SP53

On when the value of the operand is larger than the accumulator can work with.

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP70

On anytime the value in the accumulator is negative.

SP75

On when a BCD instruction is executed and a NONBCD number was encountered.

NOTE: Status flags are valid only until another instruction uses the same flag.
In the following example, when X1 is on, the value in V1400 and V1401 will be loaded
into the accumulator using the Load Double instruction. The value in the
accumulator is divided by the value in V1420 and V1421 using the Divide Double
instruction. The first part of the quotient resides in the accumulator an the remainder
resides in the first stack location. The value in the accumulator is copied to V1500
and V1501 using the Out Double instruction.
DirectSOFT Display

V1401

X1

LDD

V1400

V1400
Load the value in V1400 and
V1401 into the accumulator

The unused accumulator

bits are set to zero

DIVD
V1420

(Accumulator)

(V1421 and V1420)

Acc.

The value in the accumulator

is divided by the value in
V1420 and V1421

Standard
RLL Instructions

V1500

V1501

Copy the value in the

accumulator to V1500
and V1501
Handheld Programmer Keystrokes
B
STR
B

1
E

A
4

1
B

A
0

E
1

0
C

4
F

ENT

ENT
A

2
A

SHFT

0
A

First stack location contains

the remainder

OUTD

L
ANDST

SHFT

ENT
ENT

D
3

3
I

GX
OUT

SHFT

V
AND
D
3

V1500

Standard RLL Instructions

Math Instructions

Increment
(INC)

The Increment instruction increments a

BCD value in a specified V memory location
by 1 each time the instruction is executed.

INC

Decrement
(DEC)

The Decrement instruction decrements a

BCD value in a specified V memory location
by 1 each time the instruction is executed.

DEC

Operand Data Type

571

A aaa

A aaa

DL05 Range
A

aaa

Vmemory

All (See p. 428)

Pointer

All (See p. 428)

Discrete Bit Flags

Description

SP63

on when the result of the instruction causes the value in the accumulator to be zero.

SP75

on when a BCD instruction is executed and a NONBCD number was encountered.

NOTE: Status flags are valid only until another instruction uses the same flag.

In the following increment example, when C5 is on the value in V1400 increases by

one.
DirectSOFT Display

V1400

C5

INC
V1400
Increment the value in
V1400 by 1.

V1400
3

Handheld Programmer Keystrokes

$

C
STR

SHFT

F
5

2
I

N
TMR

ENT

B
2

E
1

A
0

In the following decrement example, when C5 is on the value in V1400 is decreased

by one.
DirectSOFT Display

V1400
DEC

V1400
Decrement the value in
V1400 by 1.
V1400
Handheld Programmer Keystrokes
$

C
STR

SHFT

F
2

E
3

ENT
B

E
1

A
0

Standard
RLL Instructions

C5

572

Standard RLL Instructions

Math Instructions

Increment Binary
(INCB)

The
Increment
Binary
instruction
increments a binary value in a specified V
memory location by 1 each time the
instruction is executed.

Operand Data Type

INCB
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Discrete Bit Flags

Description

SP63

on when the result of the instruction causes the value in the accumulator
to be zero.

In the following example when C5 is on, the binary value in V2000 is increased by 1.
V2000

DirectSOFT
C5

INCB

Handheld Programmer Keystrokes

C

$
STR

V2000

N
TMR

F
2

ENT

C
1

A
2

A
0

A
0

ENT

V2000
4

Decrement Binary
(DECB)

SHFT

Increment the binary value

in the accumulator by1

SHFT

The Decrement Binary instruction

decrements a binary value in a specified V
memory location by 1 each time the
instruction is executed.

Operand Data Type

DECB
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Discrete Bit Flags

Description

SP63

on when the result of the instruction causes the value in the accumulator
to be zero.

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.

Standard
RLL Instructions

In the following example when C5 is on, the value in V2000 is decreased by 1.

V2000

DirectSOFT
C5

DECB

Handheld Programmer Keystrokes

$
STR

V2000

SHFT

Decrement the binary value

in the accumulator by1

V2000
4

D
3

SHFT

C
4

F
2

5
B

ENT
C

A
2

A
0

A
0

ENT

Standard RLL Instructions

Math Instructions

Add Binary
(ADDB)

Add Binary is a 16 bit instruction that adds

the unsigned 2s complement binary value
in the lower 16 bits of the accumulator with
an unsigned 2s complement binary value
(Aaaa), which is either a V memory
location or a 16-bit constant. The result
can be up to 32 bits (unsigned 2s
complement) and resides in the
accumulator.
Operand Data Type

573

ADDB
A aaa

DL05 Range
A

aaa

Vmemory

All (See p. 428)

Pointer

All V mem (See p. 428)

Constant

0FFFF

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP66

On when the 16 bit addition instruction results in a carry.

SP67

On when the 32 bit addition instruction results in a carry.

SP70

On anytime the value in the accumulator is negative.

SP73

On when a signed addition or subtraction results in a incorrect sign bit.

NOTE: Status flags are valid only until another instruction uses the same flag.
In the following example, when X1 is on, the value in V1400 will be loaded into the
accumulator using the Load instruction. The binary value in the accumulator will be
added to the binary value in V1420 using the Add Binary instruction. The value in the
accumulator is copied to V1500 and V1501 using the Out instruction.
DirectSOFT Display
X1

V1400
0

The unused accumulator

bits are set to zero
0
0 0 0 0

LD
V1400
Load the value in V1400 into the
lower 16 bits of the accumulator

ADDB

(Accumulator)

(V1420)

C C

V1420
Acc.

The binary value in the

accumulator is added to the
binary value in V1420

OUTD
V1500

V1500

Standard
RLL Instructions

Copy the value in the lower

16 bits of the accumulator to
V1500 and V1501

Handheld Programmer Keystrokes

$

B
1

STR
B

E
1

A
0

4
E

C
4

ENT

0
A

L
ANDST

ENT

SHFT

ENT

GX
OUT

SHFT

SHFT

3
D

D
3

0
D

B
3

1
B

F
1

A
5

A
0

ENT

574

Standard RLL Instructions

Math Instructions

Subtract Binary
(SUBB)

Subtract Binary is a 16 bit instruction that

subtracts the unsigned 2s complement
binary value (Aaaa), which is either a V
memory location or a 16-bit 2s
complement binary value, from the binary
value in the accumulator. The result
resides in the accumulator.

Operand Data Type

SUBB
A aaa

DL05 Range
A

aaa

Vmemory

All (See p. 428)

Pointer

All (See p. 428)

Constant

0FFFF

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP64

On when the 16 bit subtraction instruction results in a borrow.

SP65

On when the 32 bit subtraction instruction results in a borrow.

SP70

On anytime the value in the accumulator is negative.

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

V1400
1

X1

LD
V1400
Load the value in V1400 into the
lower 16 bits of the accumulator

The unused accumulator

bits are set to zero
0 0 0 0
1

SUBB

(Accumulator)

(V1420)

V1420
Acc.

The binary value in V1420 is

subtracted from the value in
the accumulator

OUT
V1500

V1500

Standard
RLL Instructions

Copy the value in the lower 16

bits of the accumulator to V1500

Handheld Programmer Keystrokes

$

B
1

STR
SHFT

L
ANDST

SHFT

S
RST

SHFT

GX
OUT

SHFT

ENT
B

E
1

B
B

A
0

B
1

ISG

A
4

B
1

F
1

E
1

A
5

A
0

ENT

C
4

ENT

A
2

ENT

Standard RLL Instructions

Math Instructions

Multiply Binary
(MULB)

Multiply Binary is a 16 bit instruction that

multiplies the unsigned 2s complement
binary value (Aaaa), which is either a V
memory location or a 16-bit unsigned 2s
complement binary constant, by the16-bit
binary value in the accumulator The result
can be up to 32 bits and resides in the
accumulator.
Operand Data Type

575

MULB
A aaa

DL05 Range
A

aaa

Vmemory

All (See p. 428)

Pointer

All (See p. 428)

Constant

1FFFF

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP70

On anytime the value in the accumulator is negative.

NOTE: Status flags are valid only until another instruction uses the same flag.
In the following example, when X1 is on, the value in V1400 will be loaded into the
accumulator using the Load instruction. The binary value in V1420 is multiplied by
the binary value in the accumulator using the Multiply Binary instruction. The value in
the accumulator is copied to V1500 using the Out instruction.
DirectSOFT Display

V1400

X1

The unused accumulator

bits are set to zero
0 0 0 0
0

LD

V1400
Load the value in V1400 into the
lower 16 bits of the accumulator

MULB

V1420

Acc.

(Accumulator)

(V1420)

The binary value in V1420 is

multiplied by the binary
value in the accumulator

OUTD
V1500

V1501

V1500

Copy the value in the lower

16 bits of the accumulator to
V1500 and V1501

Handheld Programmer Keystrokes

$

B
STR

1
L
ANDST

SHFT

M
ORST

GX
OUT

SHFT

ISG

E
1

3
L
ANDST

A
0

B
1

B
3

A
4

A
5

A
0

ENT
C

1
F

0
E

A
2

ENT

ENT

Standard
RLL Instructions

SHFT

ENT

576

Standard RLL Instructions

Math Instructions

Divide Binary
(DIVB)

Divide Binary is a 16 bit instruction that

divides the unsigned 2s complement
binary value in the accumulator by a
binary value (Aaaa), which is either a V
memory location or a 16-bit unsigned 2s
complement binary constant. The first part
of the quotient resides in the accumulator
and the remainder resides in the first stack
location.
Operand Data Type

DIVB
A aaa

DL05 Range
A

aaa

Vmemory

All (See p. 428)

Pointer

All (See p. 428)

Constant

0FFFF

Discrete Bit Flags

Description

SP53

On when the value of the operand is larger than the accumulator can work with.

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP70

On anytime the value in the accumulator is negative.

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

DirectSOFT Display

V1400
F

X1

(Accumulator)

(V1420)

LD
V1400
Load the value in V1400 into the
lower 16 bits of the accumulator

The unused accumulator

bits are set to zero
0

DIVB

V1420
Acc.

The binary value in the

accumulator is divided by
the binary value in V1420

0
V1500

V1500

Copy the value in the lower 16

bits of the accumulator to V1500

Handheld Programmer Keystrokes

$

B
STR

SHFT

L
ANDST

SHFT

GX
OUT

SHFT

ENT
B

U
8

E
1

A
0

B
1

B
3

A
4

B
ISG

0
E

A
5

A
0

ENT
C

1
F

First stack location contains

the remainder

OUT

Standard
RLL Instructions

A
2

ENT

ENT

577

Standard RLL Instructions

Bit Operation Instructions

Bit Operation Instructions

Sum
(SUM)

The Sum instruction counts number of bits

that are set to 1 in the accumulator. The
HEX result resides in the accumulator.

SUM

In the following example, when X1 is on, the value formed by discrete locations
X10X17 is loaded into the accumulator using the Load Formatted instruction. The
number of bits in the accumulator set to 1 is counted using the Sum instruction. The
value in the accumulator is copied to V1500 using the Out instruction.
Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

DirectSOFT Display

X17 X16 X15 X14 X13 X12 X11 X10

X1

LDF

ON ON OFF OFF ON OFF ON ON

X10
K8

The unused accumulator

bits are set to zero

Load the value represented by

discrete locations X10X17
into the accumulator

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Acc.

Acc. 0

SUM

6 5

4 3

Sum the number of bits in

the accumulator set to 1

OUT
V1500

V1500

Copy the value in the lower

16 bits of the accumulator
to V1500

Handheld Programmer Keystrokes

$

B
1

STR

ENT

SHFT

L
ANDST

SHFT

S
RST

SHFT

GX
OUT

B
5
ISF

M
ORST
A

A
1

ENT

ENT
A

I
0

ENT

Shift Left is a 32 bit instruction that shifts

the bits in the accumulator a specified
number (Aaaa) of places to the left. The
vacant positions are filled with zeros and
the bits shifted out of the accumulator are
discarded.

SHFL
A aaa

Standard
RLL Instructions

Shift Left
(SHFL)

F
3

578

Standard RLL Instructions

Bit Operation Instructions

Operand Data Type

DL05 Range
A

aaa

V memory

All (See page 428)

Constant

132

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP70

On anytime the value in the accumulator is negative.

In the following example, when X1 is on, the value in V2000 and V2001 will be loaded
into the accumulator using the Load Double instruction. The bit pattern in the
accumulator is shifted 2 bits to the left using the Shift Left instruction. The value in the
accumulator is copied to V2010 and V2011 using the Out Double instruction.
DirectSOFT

V2001

X1

LDD

V2000
5

V2000
Load the value in V2000 and
V2001 into the accumulator
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
SHFL

Acc.

6 5

4 3

K2
The bit pattern in the
accumulator is shifted 2 bit
positions to the left

S S

Shifted out of the

accumulator

S S

OUTD
V2010

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

Copy the value in the

accumulator to V2010 and
V2011

Acc.

0
1

0
1

0
1

Standard
RLL Instructions

STR

SHFT

L
ANDST

SHFT

S
RST

SHFT

GX
OUT

SHFT

ENT
D

C
3

3
H

A
2

F
7

5
C

V2011

Handheld Programmer Keystrokes

$

L
ANDST
A

A
0
C
2

B
0

A
0

A
1

0
ENT
ENT

ENT

0
1

0
1

6 5

4 3

V2010

579

Standard RLL Instructions

Bit Operation Instructions

Shift Right
(SHFR)

Shift Right is a 32 bit instruction that shifts

the bits in the accumulator a specified
number (Aaaa) of places to the right. The
vacant positions are filled with zeros and
the bits shifted out of the accumulator are
lost.
Operand Data Type

SHFR
A aaa

DL05 Range
A

aaa

V memory

All (See page 428)

Constant

132

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP70

On anytime the value in the accumulator is negative.

In the following example, when X1 is on, the value in V2000 and V2001 will be loaded
into the accumulator using the Load Double instruction. The bit pattern in the
accumulator is shifted 2 bits to the right using the Shift Right instruction. The value in
the accumulator is copied to V2010 and V2011 using the Out Double instruction.
DirectSOFT

V2001

X1

Constant 6

LDD

V2000
5

V2000
Load the value in V2000 and
V2001 into the accumulator
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
SHFR

Acc.

6 5

4 3

K2
The bit pattern in the
accumulator is shifted 2 bit
positions to the right

S S

S S

Shifted out of the

accumulator

OUTD
V2010

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Acc.

Copy the value in the

accumulator to V2010 and
V2011

0
1

0
1

1
0

0
1

0
1

0
1

V2011

0
1

6 5

4 3

V2010

Handheld Programmer Keystrokes

$

B
1

STR
L
ANDST

SHFT

S
RST

SHFT

GX
OUT

SHFT

F
7

5
C

A
2

R
ORN
A

A
0
C
2

B
0

A
0

A
1

0
ENT
ENT

ENT

Standard
RLL Instructions

SHFT

ENT

580

Standard RLL Instructions

Bit Operation Instructions

Encode
(ENCO)

The Encode instruction encodes the bit

position in the accumulator having a value
of 1, and returns the appropriate binary
representation. If the most significant bit is
set to 1 (Bit 31), the Encode instruction
would place the value HEX 1F (decimal
31) in the accumulator. If the value to be
encoded is 0000 or 0001, the instruction
will place a zero in the accumulator. If the
value to be encoded has more than one bit
position set to a 1, the least significant 1
will be encoded and SP53 will be set on.

ENCO

Discrete Bit Flags

Description

SP53

On when the value of the operand is larger than the accumulator can work
with.

NOTE: The status flags are only valid until another instruction that uses the same
flags is executed.
In the following example, when X1 is on, The value in V2000 is loaded into the
accumulator using the Load instruction. The bit position set to a 1 in the
accumulator is encoded to the corresponding 5 bit binary value using the Encode
instruction. The value in the lower 16 bits of the accumulator is copied to V2010
using the Out instruction.
V2000

DirectSOFT
1

X1

LD
V2000
Load the value in V2000 into
the lower 16 bits of the
accumulator

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Acc.

6 5

4 3

Bit postion 12 is
converted
to binary
ENCO
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Encode the bit position set
to 1 in the accumulator to a
5 bit binary value

Acc.

6 5

4 3

OUT

Standard
RLL Instructions

V2010
0

Copy the value in the lower 16 bits

of the accumulator to V2010

B
STR

ENT

SHFT

L
ANDST

SHFT

N
TMR

SHFT

V
AND

GX
OUT

A
2

3
2

O
INST#
C

A
0

A
0

ENT

ENT
A

V2010

Handheld Programmer Keystrokes

$

B
0

A
1

ENT

C
Binary value
for 12.

581

Standard RLL Instructions

Bit Operation Instructions

Decode
(DECO)

The Decode instruction decodes a 5 bit

binary value of 031 (01F HEX) in the
accumulator by setting the appropriate bit
position to a 1. If the accumulator contains
the value F (HEX), bit 15 will be set in the
accumulator. If the value to be decoded is
greater than 31, the number is divided by
32 until the value is less than 32 and then
the value is decoded.

DECO

In the following example when X1 is on, the value formed by discrete locations
X10X14 is loaded into the accumulator using the Load Formatted instruction. The
five bit binary pattern in the accumulator is decoded by setting the corresponding bit
position to a 1 using the Decode instruction.
DirectSOFT

X14 X13 X12 X11 X10

X1

OFF ON OFF ON ON

LDF

X10
K5

Load the value in

represented by discrete
locations X10X14 into the
accumulator

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Acc.

6 5

4 3

The binary vlaue

is converted to
bit position 11.

DECO
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Decode the five bit binary
pattern in the accumulator
and set the corresponding
bit position to a 1

Acc.

6 5

4 3

Handheld Programmer Keystrokes

$

B
1

STR
SHFT

L
ANDST

SHFT

E
3

ENT
F

C
4

A
1

5
O
INST#

F
0

ENT

ENT

Standard
RLL Instructions

582

Standard RLL Instructions

Number Conversion Instructions

Number Conversion Instructions (Accumulator)

Binary
(BIN)

The Binary instruction converts a BCD

value in the accumulator to the equivalent
binary value. The result resides in the
accumulator.

BIN

In the following example, when X1 is on, the value in V2000 and V2001 is loaded into
the accumulator using the Load Double instruction. The BCD value in the
accumulator is converted to the binary (HEX) equivalent using the BIN instruction.
The binary value in the accumulator is copied to V2010 and V2011 using the Out
Double instruction. (The handheld programmer will display the binary value in
V2010 and V2011 as a HEX value.)
Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP70

On anytime the value in the accumulator is negative.

SP75

on when a BCD instruction is executed and a NONBCD number was encountered.

V2001

DirectSOFT
X1

LDD

V2000

V2000
Load the value in V2000 and
V2001 into the accumulator
8

Acc. 0

BCD Value

28529 = 16384 + 8192 + 2048 + 1024 + 512 + 256 + 64 + 32 + 16 + 1

Binary Equivalent Value

BIN

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Convert the BCD value in
the accumulator to the
binary equivalent value

Acc.

OUTD
V2010

6 5

4 3

2
1
4
7
4
4
8
3
6
4
8

1
0
7
3
7
4
1
8
2
4

5
3
6
8
7
0
9
1
2

2
6
8
4
3
5
4
5
6

1
3
4
2
1
7
7
2
8

6
7
1
0
8
8
6
4

3
3
5
5
4
4
3
2

1
6
7
7
7
2
1
6

8
3
8
8
6
0
8

4
1
9
4
3
0
4

2
0
9
7
1
5
2

1
0
4
8
5
7
6

5
2
4
2
8
8

2
6
2
1
4
4

1
3
1
0
7
2

6
5
5
3
6

3
2
7
6
8

1
6
3
8
4

8
1
9
2

4
0
9
6

2
0
4
8

1
0
2
4

5
1
2

2
5
6

1 6
2 4
8

3
2

1 8
6

Standard
RLL Instructions

Copy the binary value in the

accumulator to V2010 and V2011

Handheld Programmer Keystrokes

0
$

B
STR

SHFT

L
ANDST

SHFT

GX
OUT

1
SHFT

N
TMR

A
2

A
0

A
0

ENT
C

V2011

ENT

A
2

B
0

A
1

ENT

ENT

V2010

The binary (HEX) value

copied to V2010

583

Standard RLL Instructions

Number Conversion Instructions

Binary Coded
Decimal
(BCD)

The Binary Coded Decimal instruction

converts a binary value in the accumulator
to the equivalent BCD value. The result
resides in the accumulator.

BCD

In the following example, when X1 is on, the binary (HEX) value in V2000 and V2001
is loaded into the accumulator using the Load Double instruction. The binary value in
the accumulator is converted to the BCD equivalent value using the BCD instruction.
The BCD value in the accumulator is copied to V2010 and V2011 using the Out
Double instruction.
Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP70

On anytime the value in the accumulator is negative.

V2001

DirectSOFT
X1

LDD

V2000
0

Binary Value

V2000
Load the value in V2000 and
V2001 into the accumulator

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Acc.

6 5

4 3

2
1
4
7
4
4
8
3
6
4
8

1
0
7
3
7
4
1
8
2
4

5
3
6
8
7
0
9
1
2

2
6
8
4
3
5
4
5
6

1
3
4
2
1
7
7
2
8

6
7
1
0
8
8
6
4

3
3
5
5
4
4
3
2

1
6
7
7
7
2
1
6

8
3
8
8
6
0
8

4
1
9
4
3
0
4

2
0
9
7
1
5
2

1
0
4
8
5
7
6

5
2
4
2
8
8

2
6
2
1
4
4

1
3
1
0
7
2

6
5
5
3
6

3
2
7
6
8

1
6
3
8
4

8
1
9
2

4
0
9
6

2
0
4
8

1
0
2
4

5
1
2

2
5
6

1 6
2 4
8

3
2

1 8
6

BCD

16384 + 8192 + 2048 + 1024 + 512 + 256 + 64 + 32 + 16 + 1 = 28529

Convert the binary value in

the accumulator to the BCD
equivalent value

BCD Equivalent Value

Acc.

OUTD
V2010
0

Copy the BCD value in the

accumulator to V2010 and V2011

V2011

V2010

The BCD value

copied to
V2010 and V2011

Handheld Programmer Keystrokes

B
1

STR
SHFT

L
ANDST

SHFT

GX
OUT

SHFT

ENT
D
D

C
3

A
0

A
0

ENT
C

A
2

A
2

B
0

A
1

ENT

ENT

Standard
RLL Instructions

584

Standard RLL Instructions

Number Conversion Instructions

Invert
(INV)

The Invert instruction inverts or takes the

ones complement of the 32 bit value in the
accumulator. The result resides in the
accumulator.

INV

In the following example, when X1 is on, the value in V2000 and V2001 will be loaded
into the accumulator using the Load Double instruction. The value in the
accumulator is inverted using the Invert instruction. The value in the accumulator is
copied to V2010 and V2011 using the Out Double instruction.
V2001

DirectSOFT
X1

LDD

V2000
5

V2000
Load the value in V2000 and
V2001 into the accumulator
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Acc.

INV
Acc.

6 5

4 3

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

6 5

4 3

Invert the binary bit pattern

in the accumulator

OUTD
V2010
Copy the value in the
accumulator to V2010 and
V2011

Handheld Programmer Keystrokes

$

B
STR

ENT

SHFT

L
ANDST

D
3

SHFT

N
TMR

V
AND

GX
OUT

Standard
RLL Instructions

8
SHFT

A
2

A
0

A
0

ENT
C

V2011

A
2

B
0

A
1

ENT

ENT

V2010

Standard RLL Instructions

Number Conversion Instructions

ASCII to HEX
(ATH)

585

The ASCII TO HEX instruction converts a

ATH
table of ASCII values to a specified table of
V aaa
HEX values. ASCII values are two digits
and their HEX equivalents are one digit.
This means an ASCII table of four V memory locations would only require two V
memory locations for the equivalent HEX table. The function parameters are loaded
into the accumulator stack and the accumulator by two additional instructions.
Listed below are the steps necessary to program an ASCII to HEX table function.
The example on the following page shows a program for the ASCII to HEX table
function.
Step 1: Load the number of V memory locations for the ASCII table into the first
level of the accumulator stack.
Step 2: Load the starting V memory location for the ASCII table into the
accumulator. This parameter must be a HEX value.
Step 3: Specify the starting V memory location (Vaaa) for the HEX table in the
ATH instruction.
Helpful Hint: For parameters that require HEX values when referencing memory
locations, the LDA instruction can be used to convert an octal address to the HEX
equivalent and load the value into the accumulator.

Operand Data Type

DL05 Range
aaa

Vmemory

All (See p. 428)

Discrete Bit Flags

Description

SP53

On when the value of the operand is larger than the accumulator can work with.

In the example on the following page, when X1 is ON the constant (K4) is loaded into
the accumulator using the Load instruction and will be placed in the first level of the
accumulator stack when the next Load instruction is executed. The starting location
for the ASCII table (V1400) is loaded into the accumulator using the Load Address
instruction. The starting location for the HEX table (V1600) is specified in the ASCII
to HEX instruction. The table below lists valid ASCII values for ATH conversion.
ASCII Values Valid for ATH Conversion
Hex Value

ASCII Value

Hex Value

30

38

31

39

32

41

33

42

34

43

35

44

36

45

37

46

Standard
RLL Instructions

ASCII Value

586

Standard RLL Instructions

Number Conversion Instructions

DirectSOFT Display

Hexadecimal
Equivalents

ASCII TABLE
X1

Load the constant value

into the lower 16 bits of the
accumulator. This value
defines the number of V
memory location in the
ASCII table

LD
K4

V1400

O 1400

V1401

31 32

V1402

37 38

V1600

Handheld Programmer Keystrokes

B
STR

SHFT

L
ANDST

SHFT

L
ANDST

SHFT

T
MLR

SHFT
A

HEX to ASCII
(HTA)

V1403

ENT

K
JMP

0
H

V1600

5678

V1601

G
1

A
0

0
A

35 36

ENT

1
B

1234

V1600 is the starting

location for the HEX table

ATH

33 34

Convert octal 1400 to HEX

300 and load the value into
the accumulator

LDA

A
0

ENT
ENT

The HEX to ASCII instruction converts a

table of HEX values to a specified table of
ASCII values. HEX values are one digit and
their ASCII equivalents are two digits.

HTA
V aaa

This means a HEX table of two V memory locations would require four V memory
locations for the equivalent ASCII table. The function parameters are loaded into the
accumulator stack and the accumulator by two additional instructions. Listed below
are the steps necessary to program a HEX to ASCII table function. The example on
the following page shows a program for the HEX to ASCII table function.
Step 1: Load the number of V memory locations in the HEX table into the first level
of the accumulator stack.
Step 2: Load the starting V memory location for the HEX table into the
accumulator. This parameter must be a HEX value.

Standard
RLL Instructions

Step 3: Specify the starting V memory location (Vaaa) for the ASCII table in the
HTA instruction.
Helpful Hint: For parameters that require HEX values when referencing memory
locations, the LDA instruction can be used to convert an octal address to the HEX
equivalent and load the value into the accumulator.

587

Standard RLL Instructions

Number Conversion Instructions

Operand Data Type

DL05 Range
aaa

Vmemory

All (See p. 428)

Discrete Bit Flags

Description

SP53

On when the value of the operand is larger than the accumulator can work with.

In the following example, when X1 is ON the constant (K2) is loaded into the
accumulator using the Load instruction. The starting location for the HEX table
(V1500) is loaded into the accumulator using the Load Address instruction. The
starting location for the ASCII table (V1400) is specified in the HEX to ASCII
instruction.
DirectSOFT Display
X1

Hexadecimal
Equivalents

LD

ASCII TABLE

K2
Load the constant value into
the lower 16 bits of the
accumulator. This value
defines the number of V
locations in the HEX table.

33 34

V1400

31 32

V1401

37 38

V1402

35 36

V1403

1234

V1500
LDA
O 1500
Convert octal 1500 to HEX
340 and load the value into
the accumulator

HTA
V1400

5678

V1501

V1400 is the starting

location for the ASCII table.
The conversion is executed
by this instruction.
Handheld Programmer Keystrokes
$

B
STR

SHFT

L
ANDST

SHFT

L
ANDST

SHFT

T
MLR

ENT
SHFT

3
A
3

K
JMP

0
B
0

A
5

ENT

E
1

A
0

0
A

A
0

ENT
ENT

The table below lists valid ASCII values for HTA conversion.
ASCII Values Valid for HTA Conversion
ASCII Value

Hex Value

ASCII Value

30

38

31

39

32

41

33

42

34

43

35

44

36

45

37

46

Standard
RLL Instructions

Hex Value

588

Standard RLL Instructions

Number Conversion Instructions

Gray Code
(GRAY)

The Gray code instruction converts a 16 bit

gray code value to a BCD value. The BCD
conversion requires 10 bits of the
accumulator. The upper 22 bits are set to
0. This instruction is designed for use
with devices (typically encoders) that use
the grey code numbering scheme. The
Gray Code instruction will directly convert
a gray code number to a BCD number for
devices having a resolution of 512 or 1024
counts per revolution. If a device having a
resolution of 360 counts per revolution is to
be used you must subtract a BCD value of
76 from the converted value to obtain the
proper result. For a device having a
resolution of 720 counts per revolution you
must subtract a BCD value of 152.

GRAY

In the following example, when X1 is ON the binary value represented by X10X27 is

loaded into the accumulator using the Load Formatted instruction. The gray code
value in the accumulator is converted to BCD using the Gray Code instruction. The
value in the lower 16 bits of the accumulator is copied to V2010.
Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP70

On anytime the value in the accumulator is negative.

DirectSOFT

X27 X26 X25

X1

LDF

S S

OFF OFF OFF

K16

X12 X11 X10

S S

ON OFF ON

X10
Load the value represented
by X10X27 into the lower
16 bits of the accumulator

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Acc.

6 5

4 3

GRAY

Convert the 16 bit grey code

value in the accumulator to a
BCD value

31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
Acc.

6 5

4 3

OUT
V2010
Copy the value in the lower
16 bits of the accumulator to
V2010

Gray Code

Handheld Programmer Keystrokes

Standard
RLL Instructions

B
1

STR
SHFT
SHFT
GX
OUT

L
ANDST

R
ORN

ENT
F
5

SHFT

A
0
V
AND

A
1

Y
MLS
C

G
1

ENT
A

B
0

A
1

ENT

ENT

BCD

0000000000

0000

0000000001

0001

0000000011

0002

0000000010

0003

0000000110

0004

0000000111

0005

0000000101

0006

0000000100

0007

S
S

S
S

1000000001

1022

1000000000

1023

V2010

589

Standard RLL Instructions

Number Conversion Instructions

Shuffle Digits
(SFLDGT)

The Shuffle Digits instruction shuffles a

maximum of 8 digits rearranging them in a
specified order. This function requires
parameters to be loaded into the first level
of the accumulator stack and the
accumulator
with
two
additional
instructions. Listed below are the steps
necessary to use the shuffle digit function.
The example on the following page shows
a program for the Shuffle Digits function.

SFLDGT

Step 1: Load the value (digits) to be shuffled into the first level of the accumulator
stack.
Step 2: Load the order that the digits will be shuffled to into the accumulator.
Note: If the number used to specify the order contains a 0 or 9F, the
corresponding position will be set to 0.
See example on the next page.
Note:If the number used to specify the order contains duplicate numbers, the
most significant duplicate number is valid. The result resides in the accumulator.
See example on the next page.
Step 3: Insert the SFLDGT instruction.

Shuffle Digits
Block Diagram

Discrete Bit Flags

Description

SP63

On when the result of the instruction causes the value in the accumulator to be zero.

SP70

On anytime the value in the accumulator is negative.

There are a maximum of 8 digits that can

be shuffled. The bit positions in the first
level of the accumulator stack defines the
digits to be shuffled. They correspond to
the bit positions in the accumulator that
define the order the digits will be shuffled.
The digits are shuffled and the result
resides in the accumulator.

Digits to be
shuffled (first stack location)
9

C D

Specified order (accumulator)

Bit Positions

Result (accumulator)

Standard
RLL Instructions

590

Standard RLL Instructions

Number Conversion Instructions

In the following example when X1 is on, The value in the first level of the accumulator
stack will be reorganized in the order specified by the value in the accumulator.
Example A shows how the shuffle digits works when 0 or 9 F is not used when
specifying the order the digits are to be shuffled. Also, there are no duplicate
numbers in the specified order.
Example B shows how the shuffle digits works when a 0 or 9F is used when
specifying the order the digits are to be shuffled. Notice when the Shuffle Digits
instruction is executed, the bit positions in the first stack location that had a
corresponding 0 or 9F in the accumulator (order specified) are set to 0.
Example C shows how the shuffle digits works when duplicate numbers are used
specifying the order the digits are to be shuffled. Notice when the Shuffle Digits
instruction is executed, the most significant duplicate number in the order specified
is used in the result.
DirectSOFT

X1

V2001

LDD
9

V2000
Load the value in V2000 and
V2001 into the accumulator

V2000
C

Original
8 7 6 5
bit
Positions 9 A B C

V2006
Load the value in V2006 and
V2007 into the accumulator

Specified
order

New bit
Positions

SFLDGT

8
1

7
2

5
7

Acc.

V2001

8 7 6 5
0 F E D

4
C

3
B

2
A

1
9

Acc.

Acc.

V2007
4

C
V2000

V2006
7

V2007

LDD

V2001

7
0

6
4

Acc.

5
3

V2000
C

V2006
3

V2007

Acc.

Acc.

8 7 6 5
0 0 0 0

4
E

3
D

2
A

1
9

V2006

Shuffle the digits in the first

level of the accumulator
stack based on the pattern
in the accumulator. The
result is in the accumulator.
OUTD

V2010
V2010

V2011

V2011

Copy the value in the

accumulator to V2010 and
V2011

Handheld Programmer Keystrokes

$

B
1

Standard
RLL Instructions

STR
SHFT

L
ANDST

SHFT

L
ANDST

SHFT

S
RST

SHFT

GX
OUT

SHFT

ENT
D

F
5

L
ANDST

A
2

A
0

A
2

A
2

A
0

T
MLR

ENT

ENT

B
0

0
G

0
G

A
0

ENT
ENT

V2010

V2011

Acc.

V2010

Acc.

Acc.

Standard RLL Instructions

Table Instructions

591

Table Instructions
Move
(MOV)

The Move instruction moves the values

from a V memory table to another
V memory table the same length. The
function parameters are loaded into the
first level of the accumulator stack and the
accumulator
by
two
additional
instructions. Listed below are the steps
necessary to program the Move function.
S

MOV
V aaa

Step 1: Load the number of V memory locations to be moved into the

first level of the accumulator stack. This parameter is a HEX value (K40
max, 100 octal).
Step 2: Load the starting V memory location for the locations to be
moved into the accumulator. This parameter is a HEX value.
Step 3: Insert the MOVE instruction which specifies starting V
memory location (Vaaa) for the destination table.

S
S

Helpful Hint: For parameters that require HEX values when referencing memory
locations, the LDA instruction can be used to convert an octal address to the HEX
equivalent and load the value into the accumulator.
Operand Data Type

DL05 Range
aaa

V memory

All (See page 428)

Pointer

All (See page 428)

Discrete Bit Flags

Description

SP53

On when the value of the operand is larger than the accumulator can work with.

In the following example, when X1 is on, the constant value (K6) is loaded into the
accumulator using the Load instruction. This value specifies the length of the table
and is placed in the first stack location after the Load Address instruction is
executed. The octal address 2000 (V2000), the starting location for the source table
is loaded into the accumulator. The destination table location (V2030) is specified in
the Move instruction.
S
S

DirectSOFT
X1

K6

Load the constant value 6

(HEX) into the lower 16 bits
of the accumulator

O 2000

Convert octal 2000 to HEX

400 and load the value into
the accumulator

LD

LDA

S
S

V2030
Handheld Programmer Keystrokes
$

B
STR

ENT

SHFT

L
ANDST

SHFT

L
ANDST

D
3

SHFT

M
ORST

O
INST#

V
AND

SHFT

3
A

K
JMP

2
C

A
0

A
2

A
0

D
0

0
A

ENT
ENT

X V2026

X V2027

3 V2000

3 V2030

0 V2001

0 V2031

9 V2002

9 V2032

4 V2003

4 V2033

9 V2004

9 V2034

0 V2005

0 V2035

X V2006

X V2036

X V2007

X V2037

S
S

ENT

S
S

Standard
Rll Instructions

Copy the specified table

locations to a table
beginning at location V2030

MOV

592

Standard RLL Instructions

Table Instructions

Move Memory
Cartridge /
Load Label
(MOVMC), (LDLBL)

The Move Memory Cartridge and the Load Label

instructions are used to copy data from program
ladder memory to V memory. The Load Label
instruction is used with the MOVMC instruction
when copying data from program ladder memory to
V memory.
To copy data from the program ladder memory to V
memory, the function parameters are loaded into the
first two levels of the accumulator stack and the
accumulator by two additional instructions. Listed
below are the steps necessary to program the Move
Memory Cartridge and Load Label functions.
S
S
S
S

Standard
RLL Instructions

LDLBL
K aaa

Step 1: Load the number of words to be copied into the second level
of the accumulator stack.
Step 2: Load the offset for the data label area in ladder memory and
the beginning of the V memory block into the first level of the stack.
Step 3: Load the source data label (LDLBL Kaaa) into the
accumulator when copying data from ladder memory to V memory. This
is the source location of the value.
Step 4: Insert the MOVMC instruction which specifies destination in
V-memory (Vaaa). This is the copy destination.

Operand Data Type

V memory

MOVMC
V aaa

DL05 Range
A

aaa

All (See page 428)

Standard RLL Instructions

Table Instructions

Copy Data From a

Data Label Area to
V Memory

593

In the example to the right, data is copied from a Data Label Area to V memory.
When X1 is on, the constant value (K4) is loaded into the accumulator using the
Load instruction. This value specifies the length of the table and is placed in the
second stack location after the next Load and Load Label (LDLBL) instructions
are executed. The constant value (K0) is loaded into the accumulator, specifying
the offset for the source and destination data. It is placed in the first stack location
after the LDLBL instruction is executed. The source address where data is being
copied from is loaded into the accumulator using the LDLBL instruction. The
MOVMC instruction specifies the destination starting location and executes the
copying of data from the Data Label Area to V memory.
Data Label Area
Programmed
After the END
Instruction

DirectSOFT
X1

DLBL K1
N

C O N

C O N

C O N

C O N

5
1
8

LD
K4

S
S
1

V2000

V2001

V2002

V2003

V2004

Load the value 4 into the

accumulator specifying the
number of locations to be
copied.

LD

K0
Load the value 0 into the
accumulator specifying the
offset for source and
destination locations

LDLBL
K1

S
S

Load the value 1 into the

accumulator specifying the
Data Label Area K1 as the
starting address of the data
to be copied.

Handheld Programmer Keystrokes

$

MOVMC

B
1

STR
SHFT

L
ANDST

SHFT

L
ANDST

SHFT

L
ANDST

D
3

SHFT

M
ORST

O
INST#

ENT

V2000
SHFT

K
JMP

SHFT

K
JMP

L
ANDST

L
ANDST

V
AND

M
ORST

3
3

4
0

V2000 is the destination

starting address for the data
to be copied.

ENT
ENT

ENT
A

A
0

A
0

ENT

Standard
Rll Instructions

594

Standard RLL Instructions

CPU Control Instructions

CPU Control Instructions

No Operation
(NOP)

The No Operation is an empty (not

programmed) memory location.
NOP

Handheld Programmer Keystrokes

DirectSOFT

SHFT
NOP

End
(END)

N
TMR

ENT

CV

The End instruction marks the termination

point of the normal program scan. An End
instruction is required at the end of the
main program body. If the End instruction
is omitted an error will occur and the CPU
will not enter the Run Mode. Data labels,
subroutines and interrupt routines are
placed after the End instruction. The End
instruction is not conditional; therefore, no
input contact is allowed.
DirectSOFT

END

Handheld Programmer Keystrokes

SHFT

END

Stop
(STOP)

O
INST#

N
TMR

ENT

The Stop instruction changes the

operational mode of the CPU from Run to
Program (Stop) mode. This instruction is
typically used to stop PLC operation in an
error condition.

STOP

Standard
RLL Instructions

In the following example, when C0 turns on, the CPU will stop operation and switch
to the program mode.
DirectSOFT

Handheld Programmer Keystrokes

$

C0

STR
STOP
SHFT

S
RST

SHFT

C
2

SHFT

T
MLR

O
INST#

Discrete Bit Flags

Description

SP16

On when the DL05 goes into the TERM_PRG mode.

SP53

On when the DL05 goes into the PRG mode.

ENT
P
CV

ENT

Standard RLL Instructions

CPU Control Instructions

Reset Watch Dog

Timer
(RSTWT)

595

The Reset Watch Dog Timer instruction

resets the CPU scan timer. The default
setting for the watch dog timer is 200ms.
Scan times very seldom exceed 200ms,
RSTWT
but it is possible. For/next loops,
subroutines, interrupt routines, and table
instructions can be programmed such that
the scan becomes longer than 200ms.
When instructions are used in a manner
that could exceed the watch dog timer
setting, this instruction can be used to
reset the timer.
A software timeout error (E003) will occur and the CPU will enter the program
mode if the scan time exceeds the watch dog timer setting. Placement of the
RSTWT instruction in the program is very important. The instruction has to be
executed before the scan time exceeds the watch dog timers setting.
If the scan time is consistently longer than the watch dog timers setting, the
timeout value may be permanently increased from the default value of 200ms by
AUX 55 on the HPP or the appropriate auxiliary function in your programming
package. This eliminates the need for the RSTWT instruction.
In the following example the CPU scan timer will be reset to 0 when the RSTWT
instruction is executed. See the For/Next instruction for a detailed example.
DirectSOFT

Handheld Programmer Keystrokes

SHFT

R
ORN

S
RST

T
MLR

W
ANDN

T
MLR

ENT

RSTWT

Standard
RLL Instructions

596

Standard RLL Instructions

Program Control Instructions

Program Control Instructions

For / Next
(FOR)
(NEXT)

The For and Next instructions are used to

execute a section of ladder logic between
the For and Next instruction a specified
numbers of times. When the For
instruction is enabled, the program will
loop the specified number of times. If the
For instruction is not energized the section
of ladder logic between the For and Next
instructions is not executed.
For / Next instructions cannot be nested.
The normal I/O update and CPU
housekeeping is suspended while
executing the For / Next loop. The program
scan can increase significantly, depending
on the amount of times the logic between
the For and Next instruction is executed.
With the exception of immediate I/O
instructions, I/O will not be updated until
the program execution is completed for
that scan. Depending on the length of time
required to complete the program
execution, it may be necessary to reset the
watch dog timer inside of the For / Next
loop using the RSTWT instruction.

Standard
Rll Instructions

Operand Data Type

DL05 Range
A

aaa

V memory

All (See page 428)

Constant

19999

A aaa
FOR

NEXT

Standard RLL Instructions

Program Control Instructions

597

In the following example, when X1 is on, the application program inside the For /
Next loop will be executed three times. If X1 is off the program inside the loop will not
be executed. The immediate instructions may or may not be necessary depending
on your application. Also, The RSTWT instruction is not necessary if the For / Next
loop does not extend the scan time larger the Watch Dog Timer setting. For more
information on the Watch Dog Timer, refer to the RSTWT instruction.
DirectSOFT
X1

K3

FOR

RSTWT

X20

Y5
OUT

NEXT

Handheld Programmer Keystrokes

$

B
1

STR

ENT

SHFT

F
5

O
INST#

R
ORN

SHFT

R
ORN

S
RST

T
MLR

SHFT

STR
GX
OUT
SHFT

8
F
5

N
TMR

E
4

D
3

ENT

W
ANDN

T
MLR

ENT

ENT

T
MLR

ENT

ENT
X
SET

Standard
RLL Instructions

598

Standard RLL Instructions

Program Control Instructions

Goto Subroutine
(GTS)
(SBR)

The Goto Subroutine instruction allows a

section of ladder logic to be placed outside
the main body of the program execute only
when needed. There can be a maximum
of 64 GTS instructions and 64 SBR
instructions used in a program. The GTS
instructions can be nested up to 8 levels.
An error E412 will occur if the maximum
limits are exceeded. Typically this will be
used in an application where a block of
program logic may be slow to execute and
is not required to execute every scan. The
subroutine label and all associated logic is
placed after the End statement in the
program. When the subroutine is called
from the main program, the CPU will
execute the subroutine (SBR) with the
same constant number (K) as the GTS
instruction which called the subroutine.
By placing code in a subroutine it is only
scanned and executed when needed
since it resides after the End instruction.
Code which is not scanned does not
impact the overall scan time of the
program.
Operand Data Type

K aaa
GTS

K aaa

SBR

DL05 Range
aaa

Constant

Subroutine Return
(RT)

Standard
Rll Instructions

Subroutine Return
Conditional
(RTC)

1FFFF

When a Subroutine Return is executed in

the subroutine the CPU will return to the
point in the main body of the program from
which it was called. The Subroutine Return
is used as termination of the subroutine
which must be the last instruction in the
subroutine and is a stand alone instruction
(no input contact on the rung).
The Subroutine Return Conditional
instruction is a optional instruction used
with a input contact to implement a
conditional return from the subroutine. The
Subroutine Return (RT) is still required for
termination of the Subroutine.

RT

RTC

Standard RLL Instructions

Program Control Instructions

599

In the following example, when X1 is on, Subroutine K3 will be called. The CPU will
jump to the Subroutine Label K3 and the ladder logic in the subroutine will be
executed. If X35 is on the CPU will return to the main program at the RTC instruction.
If X35 is not on Y0Y17 will be reset to off and then the CPU will return to the main
body of the program.
X1

DirectSOFT Display

K3
GTS

C0
LD
K10
S
S
S
END
SBR

K3

X20

Y5
OUTI

X21

Y10
OUTI

X35
RTC
X35

Y0

Y17
RSTI

RT

Handheld Programmer Keystrokes

$

B
1

STR
SHFT

ENT

T
MLR

S
RST

N
TMR

D
3

ENT

S
S
E

SHFT

S
RST

SHFT

SHFT

GX
OUT

SHFT

SHFT

GX
OUT

SHFT

SHFT

SHFT

R
ORN

T
MLR

SP
STRN

SHFT

S
RST

SHFT

SHFT

R
ORN

T
MLR

STR

STR

STR

3
1

ENT
R
ORN
C

D
3
A

2
F

5
C

B
1
A
1

8
D
8

0
F
5

3
C
2

F
3

ENT
ENT

ENT
B

0
ENT

ENT

ENT

8
8

ENT

ENT

2
B

ENT

H
1

ENT

Standard
RLL Instructions

SHFT

5100

Standard RLL Instructions

Program Control Instructions

In the following example, when X1 is on, Subroutine K3 will be called. The CPU will
jump to the Subroutine Label K3 and the ladder logic in the subroutine will be
executed. The CPU will return to the main body of the program after the RT
instruction is executed.
DirectSOFT
X1

K3
GTS

S
S
S
END

SBR

K3

X20

Y5
OUT

X21

Y10
OUT

RT

Handheld Programmer Keystrokes

$

B
1

STR
SHFT

SHFT

SHFT

S
RST

SHFT

SHFT

ENT

T
MLR

S
RST

N
TMR

D
3

ENT

S
S

$
STR

Standard
Rll Instructions

GX
OUT
SHFT

D
3
A

ENT

ENT
C

8
B

R
ORN

R
ORN
C

5
SHFT

ENT

GX
OUT
STR

B
2

A
1

T
MLR

ENT

ENT

ENT

ENT

Standard RLL Instructions

Program Control Instructions

Master Line Set

(MLS)

The Master Line Set instruction allows the

program to control sections of ladder logic
by forming a new power rail controlled by
the main left power rail. The main left rail is
always master line 0. When a MLS K1
instruction is used, a new power rail is
created at level 1. Master Line Sets and
Master Line Resets can be used to nest
power rails up to seven levels deep.
Operand Data Type

5101

K aaa
MLS

DL05 Range
aaa

Constant

Master Line Reset

(MLR)

17

The Master Line Reset instruction marks

the end of control for the corresponding
MLS instruction. The MLR reference is one
less than the corresponding MLS.

Operand Data Type

K aaa
MLR

DL05 Range
aaa

Constant

Understanding
Master Control
Relays

07

The Master Line Set (MLS) and Master Line Reset (MLR) instructions allow you to
quickly enable (or disable) sections of the RLL program. This provides program
control flexibility. The following example shows how the MLS and MLR instructions
operate by creating a sub power rail for control logic.
X0

When contact X0 is on, logic under the first MLS

will be executed.

MLS
K1

Y7

X1

OUT
X2

MLS

When contact X2 and X0 is on, logic

under the second MLS will be
executed.

K2

X3

MLR

K0

K1

The MLR instructions note the end of the Master Control area. (They will be entered in
adjacent addresses.)

Standard
RLL Instructions

X10

MLR

5102

Standard RLL Instructions

Program Control Instructions

MLS/MLR Example In the following MLS/MLR example logic between the first MLS K1 (A) and MLR K0
(B) will function only if input X0 is on. The logic between the MLS K2 (C) and MLR K1
(D) will function only if input X10 and X0 is on. The last rung is not controlled by either
of the MLS coils.
DirectSOFT

Handheld Programmer Keystrokes

X0

K1

X1

Y
MLS

C1

Y0
OUT

X10

K2

Y1

GX
OUT

SHFT

C
STR

GX
OUT

SHFT

Y2

GX
OUT

OUT
X6

Y3

K0
MLR
X7

Y4
OUT

GX
OUT

GX
OUT

T
MLR

2
1

STR

GX
OUT

SHFT

OUT

STR
GX
OUT

T
MLR

3
0
7

STR

Standard
Rll Instructions

GX
OUT

ENT
ENT
C

A
2

B
2

ENT

ENT

ENT
ENT

ENT

ENT
ENT
ENT
ENT
ENT
ENT
ENT
C

C
2

ENT
ENT
ENT
ENT
C

ENT

STR

C2

ENT

STR

MLR
X5

Y
MLS

OUT
K1

STR

STR

OUT
X4

STR

MLS
X5

C0

OUT
X3

A
STR

OUT
X2

MLS

ENT

ENT

Standard RLL Instructions

Interrupt Instructions

5103

Interrupt Instructions
Interrupt
(INT)

The Interrupt instruction allows a section of

ladder logic to be placed below the main
body of the program and executed only
when needed. High-Speed I/O Modes 10,
20, and 40 can generate an interrupt. With
Mode 40, you may select an external
interrupt (input X0), or a time-based
interrupt (5999 mS).

INT

INT

Typically, interrupts are used in an application when a fast response to an input is

needed or a program section must execute faster than the normal CPU scan. The
interrupt label and all associated logic must be placed after the End statement in the
program. When an interrupt occurs, the CPU will complete execution of the current
instruction it is processing in ladder logic, then execute the interrupt routine. After
interrupt routine execution, the ladder program resumes from the point at which it
was interrupted.
See Chapter 3, the section on Mode 40 (Interrupt) Operation for more details on
interrupt configuration. In the DL05, only one hardware interrupt is available.
Operand Data Type
Constant

Interrupt Return
(IRT)

Interrupt Return
Conditional
(IRTC)

0, 1

An Interrupt Return is normally executed as

the last instruction in the interrupt routine. It
returns the CPU to the point in the main
program from which it was called. The
Interrupt Return is a stand-alone
instruction (no input contact on the rung).
The
Interrupt
Return
Conditional
instruction is a optional instruction used
with an input contact to implement a
condtional return from the interrupt
routine. The Interrupt Return is required to
terminate the interrupt routine.

The Enable Interrupt instruction is placed in

the main ladder program (before the End
instruction), enabling the interrupt. The
interrupt remains enabled until the program
executes a Disable Interrupt instruction.

IRT

IRTC

ENI

Standard
RLL Instructions

Enable Interrupts
(ENI)

DL05 Range
O

5104

Standard RLL Instructions

Interrupt Instructions

Disable Interrupts
(DISI)

External Interrupt
Program Example

SP0

A Disable Interrupt instruction in the main

body of the application program (before
the End instruction) will disable the
interupt (either extenal or timed). The
interrupt remains disabled until the
program executes an Enable Interrupt
instruction.

In the following example, we do some initialization on the first scan, using the
first-scan contact SP0. The interrupt feature is the HSIO Mode 40. Then we
configure X0 as the external interrupt by writing to its configuration register, V7634.
See Chapter 3, Mode 40 Operation for more details.
During program execution, when X2 is on the interrupt is enabled. When X2 is off the
interrupt will be disabled. When an interrupt signal (X0) occurs the CPU will jump to
the interrupt label INT O 0. The application ladder logic in the interrupt routine will be
performed. The CPU will return to the main body of the program after the IRT
instruction is executed.
Handheld Programmer Keystrokes

DirectSOFT
LD

Load the constant value

(K40) into the lower 16 bits
of the accumulator

K40

V7633

Copy the value in the lower

16 bits of the accumulator to
V7633

K4

Load the constant value (K4)

into the lower 16 bits of the
accumulator

V7634

Copy the value in the lower

16 bits of the accumulator to
V7634

OUT

LD

OUT

SHFT

STR
SHFT

L
ANDST

GX
OUT
SHFT

3
SHFT

ENI

SHFT

DISI

SP
STRN

V
AND

D
V
AND

E
4

N
TMR
C
2

SHFT

SHFT

SHFT

SHFT

X
SET

SHFT

SHFT

X
SET

SHFT

SHFT

R
ORN

A
0

ENT

SHFT

K
JMP

SHFT

D
6

ENT
S
RST

N
TMR

4
8

N
TMR

T
MLR

I
8

ENT

S
S
S

S
END
O0
STR
X1

X3

Y5
SETI
Y7
SETI

IRT

STR

ENT
A
0
B

1
F

5
D

3
H

7
T
MLR

ENT

ENT
ENT
ENT
ENT

ENT

ENT
ENT

ENT
E

ENT

K
JMP

A
4

ENT

STR

X2

Standard
RLL Instructions

3
SHFT

L
ANDST

SP
STRN

GX
OUT

X2

INT

DISI

ENT

5105

Standard RLL Instructions

Interrupt Instructions

Timed Interrupt
Program Example

In the following example, we do some initialization on the first scan, using the
first-scan contact SP0. The interrupt feature is the HSIO Mode 40. Then we
configure the HSIO timer as a 10 mS interrupt by writing K104 to the configuration
register for X0 (V7634). See Chapter 3, Mode 40 Operation for more details.
When X4 turns on, the interrupt will be enabled. When X4 turns off, the interrupt will
be disabled. Every 10 mS the CPU will jump to the interrupt label INT O 0. The
application ladder logic in the interrupt routine will be performed. If X3 is not on
Y0Y7 will be reset to off and then the CPU will return to the main body of the
program.

DirectSOFT

Handheld Programmer Keystrokes

X1

Load the constant value

(K40) into the lower 16 bits
of the accumulator

LD
K40

B
STR

SHFT
Copy the value in the lower
16 bits of the accumulator to
V7633

OUT
V7633

Load the constant value

(K10) into the lower 16 bits
of the accumulator

LD
K104

L
ANDST

GX
OUT
SHFT

D
3
SHFT

L
ANDST

Copy the value in the lower

16 bits of the accumulator to
V7634

V7634

GX
OUT

SHFT

SHFT

V
AND

STR
OUT

ENT

V
AND

SP
STRN

N
TMR

K
JMP

0
D

SHFT

K
JMP

A
4

3
A

ENT
E
4

0
E

ENT

ENT

ENT

ENT

4
E

SHFT

ENT

ENT

X4
ENI

SHFT

SHFT

SHFT

SHFT

SHFT

SP
STRN

SHFT

X
SET

SHFT

SHFT

R
ORN

S
RST

N
TMR

4
8

N
TMR

T
MLR

I
8

ENT

S
S

X4
DISI
S
S
END
INT

STR

O0

X
SET
X2

Y5
SETI

X3

Y0

Y7

ENT
A
0
C

2
F

5
D
3

8
A
T
MLR

ENT
ENT
ENT
H

ENT

ENT

ENT

RSTI

IRT

Input

Configuration
Register

Function

Hex Code
Required

V7647

High-Speed
Timed Interrupt

xxxx (xxxx = timer setting)

5 - 9999 mS (BCD)

Standard
RLL Instructions

Independent Timed Interrupt O1 is also available as an interrupt. This interrupt is independent of the
HSIO features. Interrupt O1 uses an internal timer that is configured in V memory
Interrupt
location V7647. The interrupt period can be adjusted from 5 to 9999 mS. Once the
interrupt period is set and the interrupt is enabled in the program, the CPU will
continuously call the interrupt routine based on the time setting in V7647.

5106

Standard RLL Instructions

Message Instructions

Message Instructions
Fault
(FAULT)

The Fault instruction is used to display a

message on the handheld programmer or
in the DirectSOFT status bar. The
message has a maximum of 23 characters
and can be either V memory data,
numerical constant data or ASCII text.

FAULT
A aaa

To display the value in a V memory location, specify the V memory location in the
instruction. To display the data in ACON (ASCII constant) or NCON (Numerical
constant) instructions, specify the constant (K) value for the corresponding data
label area.
Operand Data Type

Fault Example

DirectSOFT
S
S
X1

DL05 Range
A

aaa

V memory

All (See page 428)

Constant

1FFFF

Discrete Bit Flags

Description

SP50

On when the FAULT instruction is executed.

In the following example when X1 is on,

the message SW 146 will display on the
handheld programmer. The NCONs use
the HEX ASCII equivalent of the text to
be displayed. (The HEX ASCII for a blank
is 20, a 1 is 31, 4 is 34 ...)
Handheld Programmer Keystrokes

FAULT
K1

END
DLBL
K1
ACON
A SW

NCON
K 2031

NCON
K 3436

B
1

STR

S
S

Standard
RLL Instructions

SW 146

SHFT

SHFT

SHFT

SHFT

SHFT

N
TMR

SHFT

N
TMR

ENT
U
ISG

L
ANDST

T
MLR

N
TMR

L
ANDST

B
1

L
ANDST

C
2

O
INST#

N
TMR

S
RST

W
ANDN

N
TMR

O
INST#
O
INST#

N
TMR

ENT

S
S

ENT

ENT

B
3

0
E

ENT
D
D

1
G

ENT
ENT

Standard RLL Instructions

Message Instructions

Data Label
(DLBL)

The Data Label instruction marks the

beginning of an ASCII / numeric data area.
DLBLs are programmed after the End
statement. A maximum of 64 DLBL
instructions can be used in a program.
Multiple NCONs and ACONs can be used
in a DLBL area.
Operand Data Type

DLBL

5107

K aaa

DL05 Range
aaa

Constant

ASCII Constant
(ACON)

1FFFF

The ASCII Constant instruction is used

with the DLBL instruction to store ASCII
text for use with other instructions. Two
ASCII characters can be stored in an
ACON instruction. If only one character is
stored in a ACON a leading space will be
inserted.
Operand Data Type

ACON
A aaa

DL05 Range
aaa

ASCII

Numerical
Constant
(NCON)

09 AZ

The Numerical Constant instruction is

used with the DLBL instruction to store the
HEX ASCII equivalent of numerical data
for use with other instructions. Two digits
can be stored in an NCON instruction.

Operand Data Type

NCON
K aaa

DL05 Range
aaa

Constant

0FFFF

Standard
RLL Instructions

5108

Standard RLL Instructions

Message Instructions

Data Label
Example

In the following example, an ACON and two NCON instructions are used within a
DLBL instruction to build a text message. See the FAULT instruction for information
on displaying messages. The DV-1000 Manual also has information on displaying
messages.
DirectSOFT
S
S
S
END

DLBL
K1

ACON
A SW

NCON
K 2031

NCON
K 3436

Handheld Programmer Keystrokes

Standard
RLL Instructions

S
S
SHFT

N
TMR

SHFT

L
ANDST

B
1

L
ANDST

SHFT

C
2

O
INST#

N
TMR

S
RST

W
ANDN

SHFT

N
TMR

O
INST#

N
TMR

SHFT

N
TMR

O
INST#

N
TMR

ENT

ENT

B
3

0
E

ENT

D
4

1
G

ENT
ENT

Standard RLL Instructions

Message Instructions

Print Message
(PRINT)

The Print Message instruction prints the

embedded text or text/data variable
message to the specified communications
port (Port 2 on the DL05 CPU), which must
have the communications port configured.
Data Type

Constant

PRINT

5109

A aaa

Hello, this is a PLC message

DL05 Range
A

aaa

You may recall from the CPU specifications in Chapter 3 that the DL05s ports are
capable of several protocols. Port 1 cannot be configured for the non-sequence
portocol. To configure port 2 using the Handheld Programmer, use AUX 56 and
follow the prompts, making the same choices as indicated below on this page. To
configure a port in DirectSOFT, choose the PLC menu, then Setup, then Setup
Secondary Comm Port.
S Port: From the port number list box at the top, choose Port 2.
S Protocol: Click the check box to the left of Non-sequence, and then
youll see the dialog box shown below.

Baud Rate: Choose the baud rate that matches your printer.
Stop Bits, Parity: Choose number of stop bits and parity setting to
match your printer.
Memory Address: Choose a V-memory address for DirectSOFT to use
to store the port setup information. You will need to reserve 9 words in
V-memory for this purpose. Select Always use for printing if it applies.
Then click the button indicated to send the Port 2 configuration
to the CPU, and click Close. Then see Chapter 3 for port wiring
information, in order to connect your printer to the DL05.

Standard
RLL Instructions

S
S

5110

Standard RLL Instructions

Message Instructions

Port 2 on the DL05 has standard RS232 levels, and should work with most printer
serial input connections.
Text element this is used for printing character strings. The character strings are
defined as the character (more than 0) ranged by the double quotation marks. Two
hex numbers preceded by the dollar sign means an 8-bit ASCII character code. Also,
two characters preceded by the dollar sign is interpreted according to the following
table:
#

Character code

Description

$$

Dollar sign ($)

Double quotation ()

$L or $l

Line feed (LF)

$N or $n

Carriage return line feed (CRLF)

$P or $p

Form feed

$R or $r

Carriage return (CR)

$T or $t

Tab

The following examples show various syntax conventions and the length of the
output to the printer.
Example:

Length 0 without character

A
Length 1 with character A

Length 1 with blank
$
Length 1 with double quotation mark
$R$L
Length 2 with one CR and one LF
$0D$0A
Length 2 with one CR and one LF
$$
Length 1 with one $ mark
In printing an ordinary line of text, you will need to include double quotation marks
before and after the text string. Error code 499 will occur in the CPU when the print
instruction contains invalid text or no quotations. It is important to test your PRINT
instruction data during the application development.
The following example prints the message to port 2. We use a PD contact, which
causes the message instruction to be active for just one scan. Note the $N at the end
of the message, which produces a carriage return / line feed on the printer. This
prepares the printer to print the next line, starting from the left margin.

Standard
RLL Instructions

X1

PRINT
K2
Hello, this is a PLC message.$N

Print the message to Port 2 when

X1 makes an off-to-on transition.

Standard RLL Instructions

Message Instructions

5111

V-memory element this is used for printing V-memory contents in the integer
format or real format. Use V-memory number or V-memory number with : and data
type. The data types are shown in the table below. The Character code must be
capital letters.
NOTE: There must be a space entered before and after the V-memory address to
separate it from the text string. Failure to do this will result in an error code 499.
#

Character code

none

:B

4 digit BCD

:D

32-bit binary (decimal number)

:DB

Example:
V2000
V2000 : B
V2000 : D
V2000 : D B

Description
16-bit binary (decimal number)

8 digit BCD

Print binary data in V2000 for decimal number

Print BCD data in V2000
Print binary number in V2000 and V2001 for decimal number
Print BCD data in V2000 and V2001

Example: The following example prints a message containing text and a variable.
The reactor temperature labels the data, which is at V2000. You can use the : B
qualifier after the V2000 if the data is in BCD format, for example. The final string
adds the units of degrees to the line of text, and the $N adds a carriage return / line
feed.
X1

PRINT
K2
Reactor temperature = V2000 deg. $N

Message will read:

Reactor temperature = 0156 deg

Print the message to Port 2

when X1 makes an off-to-on
transition.
represents a space

Standard
RLL Instructions

V-memory text element this is used for printing text stored in V-memory. Use the
% followed by the number of characters after V-memory number for representing the
text. If you assign 0 as the number of characters, the print function will read the
character count from the first location. Then it will start at the next V-memory location
and read that number of ASCII codes for the text from memory.
Example:
V2000 % 16
16 characters in V2000 to V2007 are printed.
V2000 % 0
The characters in V2001 to Vxxxx (determined by the number
in V2000) will be printed.

5112

Standard RLL Instructions

Message Instructions

Bit element this is used for printing the state of the designated bit in V-memory or a
relay bit. The bit element can be assigned by the designating point (.) and bit number
preceded by the V-memory number or relay number. The output type is described as
shown in the table below.
#

Data format

none

: BOOL

: ONOFF

Example:
V2000 . 15
C100
C100 : BOOL
C100 : ON/OFF
V2000.15 : BOOL

Description
Print 1 for an ON state, and 0 for an
OFF state
Print TRUE for an ON state, and
FALSE for an OFF state
Print ON for an ON state, and OFF
for an OFF state

Prints the status of bit 15 in V2000, in 1/0 format

Prints the status of C100 in 1/0 format
Prints the status of C100 in TRUE/FALSE format
Prints the status of C00 in ON/OFF format
Prints the status of bit 15 in V2000 in TRUE/FALSE format

The maximum numbers of characters you can print is 128. The number of characters
for each element is listed in the table below:

Standard
RLL Instructions

Element type

Maximum
Characters

Text, 1 character

16 bit binary

32 bit binary

11

4 digit BCD

8 digit BCD

Floating point (real number)

12

Floating point (real with exponent)

12

V-memory/text

Bit (1/0 format)

Bit (TRUE/FALSE format)

Bit (ON/OFF format)

The handheld programmers mnemonic is PRINT, followed by the DEF field.

Special relay flags SP116 and SP117 indicate the status of the DL05 CPU ports
(busy, or communications error). See the appendix on special relays for a
description.
NOTE: You must use the appropriate special relay in conjunction with the PRINT
command to ensure the ladder program does not try to PRINT to a port that is still
busy from a previous PRINT or WX or RX instruction.

Standard RLL Instructions

Network Instructions

5113

Network Instructions
Read from Network The Read from Network instruction
(RX)
causes the master device on a network to
read a block of data from a slave device on
the same network. The function
parameters are loaded into the
accumulator and the first and second level
of the stack. Listed below are the program
steps necessary to execute the Read from
Network function.

RX
A aaa

Step 1: Load the slave address (090 BCD) into the low byte and F2 into the
high byte of the accumulator (the next two instructions push this word down to the
second layer of the stack).
Step 2: Load the number of bytes to be transferred into the accumulator (the
next instruction pushes this word onto the top of the stack).
Step 3: Load the starting Master CPU address into the accumulator. This is the
memory location where the data read from the slave will be put. This parameter
requires a HEX value.
Step 4: Insert the RX instruction which specifies the starting V memory location
(Aaaa) where the data will be read from in the slave.
Helpful Hint: For parameters that require HEX values, the LDA instruction can
be used to convert an octal address to the HEX equivalent and load the value into
the accumulator.
Operand Data Type

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All V mem. (See page 428)

Inputs

0377

Outputs

0377

Control Relays

0777

Stage

0377

Timer

0177

Counter

CT

0177

Special Relay

SP

0777

02047 (2K program mem.)

Program Memory

Standard RLL
Instructions

5114

Standard RLL Instructions

Network Instructions

In the following example, when X1 is on and the port busy relay SP116 (see special
relays) is not on, the RX instruction will access port 2 operating as a master. Ten
consecutive bytes of data (V2000 V2004) will be read from a CPU at station
address 5 and copied into V memory locations V2300V2304 in the CPU with the
master port.
DirectSOFT
X1

SP116

LD
KF205

Master
CPU

The constant value KF205

specifies the port number (2)
and the slave address (5)

Slave
CPU

S
S

LD
K10
The constant value K10
specifies the number of
bytes to be read
LDA
O 2300
Octal address 2300 is
converted to 4C0 HEX and
loaded into the accumulator.
V2300 is the starting
location for the Master CPU
where the specified data will
be read into

S
S

V2277

X V1777

V2300

V2301

V2001

V2302

V2002

V2303

V2003

V2304

V2004

V2305

X V2005

S
S

V2000

S
S

RX
V2000
V2000 is the starting
location in the for the Slave
CPU where the specified
data will be read from

Handheld Programmer Keystrokes

Standard RLL
Instructions

B
STR

W
ANDN

SHFT

SHFT

L
ANDST

SHFT

L
ANDST

SHFT

L
ANDST

SHFT

R
ORN

X
SET

ENT
SP
STRN

3
3

B
1

ENT

SHFT

K
JMP

SHFT

SHFT

K
JMP

A
3

G
1

A
2

A
0

A
2

ENT
A

0
A

SHFT

0
ENT

ENT

F
0

ENT

Standard RLL Instructions

Network Instructions

Write to Network
(WX)

The Write to Network instruction is used to

write a block of data from the master
device to a slave device on the same
network. The function parameters are
loaded into the accumulator and the first
and second level of the stack. Listed below
are the program steps necessary to
execute the Write to Network function.

5115

WX
A aaa

Step 1: Load the slave address (090 BCD) into the low byte and F2 into the
high byte of the accumulator (the next two instructions push this word down to the
second layer of the stack).
Step 2: Load the number of bytes to be transferred into the accumulator (the
next instruction pushes this word onto the top of the stack).
Step 3: Load the starting Master CPU address into the accumulator. This is the
memory location where the data will be written from. This parameter requires a
HEX value.
Step 4: Insert the WX instruction which specifies the starting V memory location
(Aaaa) where the data will be written to in the slave.
Helpful Hint: For parameters that require HEX values, the LDA instruction can
be used to convert an octal address to the HEX equivalent and load the value into
the accumulator.
Operand Data Type

DL05 Range
A

aaa

V memory

All (See page 428)

Pointer

All V mem. (See page 428)

Inputs

0377

Outputs

0377

Control Relays

0777

Stage

0377

Timer

0177

Counter

CT

0177

Special Relay

SP

0777

02048 (2K program mem.)

Program Memory

Standard RLL
Instructions

5116

Standard RLL Instructions

Network Instructions

In the following example when X1 is on and the module busy relay SP116 (see
special relays) is not on, the WX instruction will access port 2 operating as a master.
Ten consecutive bytes of data is read from the Master CPU and copied to V memory
locations V2000V2004 in the slave CPU at station address 5.
DirectSOFT
X1

SP116

LD
KF205

Master
CPU

The constant value KF205

specifies the port number (2)
and the slave address (5)

Slave
CPU

S
S

LD
K10
The constant value K10
specifies the number of
bytes to be written
LDA
O 2300
Octal address 2300 is
converted to 4C0 HEX and
loaded into the accumulator.
V2300 is the starting
location for the Master CPU
where the specified data will
be read from.

S
S

V2277

X V1777

V2300

V2301

V2001

V2302

V2002

V2303

V2003

V2304

V2004

V2305

X V2005

S
S

V2000

S
S

WX
V2000
V2000 is the starting
location in the for the Slave
CPU where the specified
data will be written to
Handheld Programmer Keystrokes

Standard RLL
Instructions

B
STR

W
ANDN

SHFT

SHFT

L
ANDST

SHFT

L
ANDST

SHFT

L
ANDST

SHFT

W
ANDN

X
SET

ENT
SP
STRN

3
3

C
1

SHFT

K
JMP

SHFT
A

E
1

6
SHFT

K
JMP

0
A
2

0
A

3
A

2
C

ENT

A
2

ENT
A

0
A

SHFT

0
ENT

ENT

F
0

ENT

Drum Instruction
Programming
In This Chapter. . . .

Introduction
Step Transitions
Overview of Drum Operation
Drum Control Techniques
Drum Instruction
EDrum Instruction

16

62
Drum Instruction Programming

Drum Instruction
Programming

Introduction
Purpose

Drum Terminology

The Event Drum (EDRUM) instruction in the DL05 CPU electronically simulates an
electro-mechanical drum sequencer. The instruction offers enhancements to the
basic principle, which we describe first.
Drum instructions are best suited for repetitive processes that consist of a finite
number of steps. They can do the work of many rungs of ladder logic with elegant
simplicity. Therefore, drums can save a lot of programming and debugging time.
We introduce some terminology associated with the drum instruction by describing
the original mechanical drum shown below. The mechanical drum generally has
pegs on its curved surface. The pegs are populated in a particular pattern,
representing a set of desired actions for machine control. A motor or solenoid rotates
the drum a precise amount at specific times. During rotation, stationary wipers sense
the presence of pegs (present = on, absent = off). This interaction makes or breaks
electrical contact with the wipers, creating electrical outputs from the drum. The
outputs are wired to devices on a machine for On/Off control.
Drums usually have a finite number of positions within one rotation, called steps.
Each step represents some process step. At powerup, the drum resets to a
particular step. The drum rotates from one step to the next based on a timer, or on
some external event. During special conditions, a machine operator can manually
increment the drum step using a jog control on the drums drive mechanism. The
contact closure of each wiper generates a unique on/off pattern called a sequence,
designed for controlling a specific machine. Because the drum is circular, it
automatically repeats the sequence once per rotation. Applications vary greatly, and
a particular drum may rotate once per second, or as slowly as once per week.
Pegs

Wipers
Drum

Outputs

Electronic drums provide the benefits of mechanical drums and more. For example,
they have a preset feature that is impossible for mechanical drums: The preset
function lets you move from the present step directly to any other step on command!

63
Drum Instruction Programming

For editing purposes, the electronic drum is presented in chart form in DirectSOFT
and in this manual. Imagine slicing the surface of a hollow drum cylinder between
two rows of pegs, then pressing it flat. Now you can view the drum as a chart as
shown below. Each row represents a step, numbered 1 through 16. Each column
represents an output, numbered 0 through 15 (to match word bit numbering). The
solid circles in the chart represent pegs (On state) in the mechanical drum, and the
open circles are empty peg sites (Off state).
OUTPUTS
STEP 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1
f F f F f f F f f f F f f F f f
2
f F f F F f F f f f f F f f F f
3
f F F F F f F F f f f f f f f f
4
F F f F F f F f F f f f f f f F
5
f f f F f f F f F f F f F f f F
6
f f f F f f F f F f F f F F f F
7
F f f F f f F F F F f F F F f F
8
F f F f f F f F F f f f F f f F
9
f f f f f f f F F f f f F f f f
10
f f f f f f f F F F f f f f f f
11
F f f f F f f f f F f f f f F f
12
f F f f F F f f F f F F f F F f
13
f f F f f f f f f f f F F f F f
14
f f f f f f f F f f f F F f F F
15
F f f f f F f F f F f F f f F F
16
f f F f f f f F f F f F F f f F

Output Sequences The mechanical drum sequencer derives its name from sequences of control
changes on its electrical outputs. The following figure shows the sequence of On/Off
controls generated by the drum pattern above. Compare the two, and you will find
that they are equivalent! If you can see their equivalence, you are well on your way to
understanding drum instruction operation.
Step
Output
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0

10

11

12

13

14

15

16

Drum Instruction
Programming

Drum Chart
Representation

64
Drum Instruction Programming

Drum Instruction
Programming

Step Transitions
Drum Instruction
Types

Timer-Only
Transitions

There are two types of Drum instructions in the DL05 CPU:

S Timed Drum with Discrete Outputs (DRUM)
S Time and Event Drum with Discrete Outputs (EDRUM)
The two drum instructions include time-based step transitions, and the EDRUM
includes event-based transitions as well. Each drum has 16 steps, and each step
has 16 outputs. Refer to the figure below. Each output can be either an X, Y, or C coil,
offering programming flexibility. We assign Step 1 an arbitrary unique output pattern
(f= Off, F= On) as shown. When programming a drum instruction, you also
determine both the output assignment and the On/Off state (pattern) at that time. All
steps use the same output assignment, but each step may have its own unique
output pattern.
Drums move from one step to another based on time and/or an external event
(input). Each step has its own transition condition which you assign during the drum
instruction entry. The figure below shows how timer-only transitions work.
Step 1

Outputs:

F f f f F f F f f f f F F f f f

Outputs:

f f f F f f f f F F f F f f F F

Increment
count timer

No

Has counts per

step expired?
Yes

Step 2

Use next transition criteria

The drum stays in Step 1 for a specific duration (user-programmable). The timebase
of the timer is programmable, from 0.01 seconds to 99.99 seconds. This establishes
the resolution, or the duration of each tick of the clock. Each step uses the same
timebase, but has its own unique counts per step, which you program. When the
counts for Step 1 have expired, then the drum moves to Step 2. The outputs change
immediately to match the new pattern for Step 2.
The drum spends a specific amount of time in each step, given by the formula:
Time in step = 0.01 seconds X Timebase x Counts per step

65
Drum Instruction Programming

NOTE: When first choosing the timebase resolution, a good rule of thumb is to make
it about 1/10 the duration of the shortest step in your drum. Then you will be able to
optimize the duration of that step in 10% increments. Other steps with longer
durations allow optimizing by even smaller increments (percentage-wise). Also,
note that the drum instruction executes once per CPU scan. Therefore, it is pointless
to specify a drum timebase that is much faster than the CPU scan time.

Timer and Event

Transitions

Step transitions may also occur based on time and/or external events. The figure
below shows how step transitions work in these cases.
Step 1

No

Outputs:

F f f f F f F f f f f F F f f f

Is Step event
true?
Yes
Increment
count timer

No

Has step
counts expired?
Yes

Step 2

Outputs:

f f f F f f f f F F f F f f F F

Use next transition criteria

When the drum enters Step 1, it sets the output pattern as shown. Then it begins
polling the external input programmed for that step. You can define event inputs as
X, Y, or C discrete point types. Suppose we select X0 for the Step 1 event input. If X0
is off, then the drum remains in Step 1. When X0 is On, the event criteria is met and
the timer increments. The timer increments as long as the event (X0) remains true.
When the counts for Step 1 have expired, then the drum moves to Step 2. The
outputs change immediately to match the new pattern for Step 2.

Drum Instruction
Programming

For example, if you program a 5 second time base and 12 counts for Step 1, then the
drum will spend 60 seconds in Step 1. The maximum time for any step is given by the
formula:
Max Time per step = 0.01 seconds X 9999 X 9999
= 999,800 seconds = 277.7 hours = 11.6 days

66
Drum Instruction
Programming

Drum Instruction Programming

Event-Only
Transitions

Step transitions do not require both the event and the timer criteria programmed for
each step. You have the option of programming just one of the two, and even mixing
transition types among all the steps of the drum. For example, you might want Step 1
to transition on an event, Step 2 to transition on time only, and Step 3 to transition on
both time and an event. Furthermore, you may elect to use only part of the 16 steps,
and only part of the 16 outputs.
Step 1

No

Outputs:

F f f f F f F f f f f F F f f f

Outputs:

f f f F f f f f F F f F f f F F

Is Step event
true?
Yes

Step 2

Use next transition criteria

Counter
Assignments

Each drum instruction uses the resources of four counters in the CPU. When
programming the drum instruction, you select the first counter number. The drum
also uses the next three counters automatically. The counter bit associated with the
first counter turns on when the drum has completed its cycle, going off when the
drum is reset. These counter values and the counter bit precisely indicate the
progress of the drum instruction, and can be monitored by your ladder program.
Suppose we program a timer drum to have
8 steps, and we select CT10 for the
counter number (remember, counter
numbering is in octal). Counter usage is
shown to the right. The right column holds
typical values, interpreted below.

Counter Assignments
CT10 Counts in step V1010

1528

CT11 Timer Value

V1011

0200

CT12 Preset Step

V1012

0001

CT13 Current Step

V1013

0004

CT10 shows that we are at the 1528th count in the current step, which is step 4
(shown in CT13). If we have programmed step 4 to have 3000 counts, then the step
is just over half completed. CT11 is the count timer, shown in units of 0.01 seconds.
So, each least-significant-digit change represents 0.01 seconds. The value of 200
means that we have been in the current count (1528) for 2 seconds (0.01 x 100).
Finally, CT12 holds the preset step value which was programmed into the drum
instruction. When the drums Reset input is active, it presets to step 1 in this case.
The value of CT12 changes only if the ladder program writes to it, or the drum
instruction is edited and the program is restarted. Counter bit CT10 turns on when
the drum cycle is complete, and turns off when the drum is reset.

67
Drum Instruction Programming

The last step in a drum sequence may be any step number, since partial drums are
valid. Refer to the following figure. When the transition conditions of the last step are
met, the drum sets the counter bit corresponding to the counter named in the drum
instruction box (such as CT0). Then it moves to a final drum complete state. The
drum outputs remain in the pattern defined for the last step. Having finished a drum
cycle, the Start and Jog inputs have no effect at this point.
The drum leaves the drum complete state when the Reset input becomes active (or
on a program-torun mode transition). It resets the drum complete bit (such as CT0),
and then goes directly to the appropriate step number defined as the preset step.
Last step

No

Outputs:

Are transition
conditions met?

F F F f f f F f f F f F F F f F

(Timer and/or
Event criteria)

Yes
Set
CT0 = 1

Set Drum Complete bit

Complete

No

Outputs:

F F F f f f F f f F f F F F f F

Reset Input
Active?
Yes
Reset
CT0 = 0

Reset Drum Complete bit

Go to Preset Step

Drum Instruction
Programming

Last Step
Completion

68
Drum Instruction Programming

Drum Instruction
Programming

Overview of Drum Operation

Drum Instruction
Block Diagram

The drum instruction utilizes various inputs and outputs in addition to the drum
pattern itself. Refer to the figure below.
Inputs

DRUM INSTRUCTION
Block Diagram

Outputs

Start
Realtime
Inputs
(from ladder)

Jog
Reset
Drum
Preset Step
Counts/Step

Step
Control

Step
Pointer

Timebase
Programming
Selections

Events

f
f
f
F
f
f
f
f

f
f
f
F
F
F
F
F

F
f
f
f
F
F
f
F

f
f
f
F
f
f
f
f

f f
f f
F f
F f
F f
F F
F F
f F

Final Drum
Outputs

Counter #
Pattern

Counter Assignments
CT0

Counts in step

V1000

xxxx

CT1

Timer Value

V1001

xxxx

CT2

Preset Step

V1002

xxxx

CT3

Current Step

V1003

xxxx

The drum instruction accepts several inputs for step control, the main control of the
drum. The inputs and their functions are:
S

S
S
S

Start The Start input is effective only when Reset is off. When Start is
on, the drum timer runs if it is in a timed transition, and the drum looks
for the input event during event transitions. When Start is off, the drum
freezes in its current state (Reset must remain off), and the drum
outputs maintain their current on/off pattern.
Jog The jog input is only effective when Reset is off (Start may be
either on or off). The jog input increments the drum to the next step on
each off-to-on transition (only EDRUM supports the jog input).
Reset The Reset input has priority over the Start input. When Reset is
on, the drum moves to its preset step. When Reset is off, then the Start
input operates normally.
Preset Step A step number from 1 to 16 that you define (typically is
step 1). The drum moves to this step whenever Reset is on, and
whenever the CPU first enters run mode.

69
Drum Instruction Programming
S

WARNING: The outputs of a drum are enabled any time the CPU is in Run Mode.
The Start Input does not have to be on, and the Reset input does not disable the
outputs. Upon entering Run Mode, drum outputs automatically turn on or off
according to the pattern of the current step of the drum. This initial step number
depends on the counter memory configuration: non-retentive versus retentive.
Powerup State of
Drum Registers

The choice of the starting step on powerup and program-to-run mode transitions are
important to consider for your application. Please refer to the following chart. If the
counter memory is configured as non-retentive, the drum is initialized the same way
on every powerup or program-to-run mode transition. However, if the counter
memory is configured to be retentive, the drum will stay in its previous state.
Counter Number

Function

CT(n)

Initialization on Powerup
Non-Retentive Case

Retentive Case

Current Step
Count

Initialize = 0

Use Previous (no

change)

CT(n + 1)

Counter Timer
Value

Initialize = 0

Use Previous (no

change)

CT(n + 2)

Preset Step

Initialize = Preset Step #

Use Previous (no

change)

CT(n + 3)

Current Step #

Initialize = Preset Step #

Use Previous (no

change)

Applications with relatively fast drum cycle times typically will need to be reset on
powerup, using the non-retentive option. Applications with relatively long drum cycle
times may need to resume at the previous point where operations stopped, using the
retentive case. The default option is the retentive case. This means that if you
initialize scratchpad V-memory, the memory will be retentive.

Drum Instruction
Programming

S
S

Counts/Step The number of timer counts the drum spends in each

step. Each step has its own counts parameter. However, programming
the counts/step is optional.
Timer Value the current value of the counts/step timer.
Counter # The counter number specifies the first of four consecutive
counters which the drum uses for step control. You can monitor these to
determine the drums progress through its control cycle. The DL05 has
128 counters (CT0 CT177 in octal).
Events Either an X, Y, C, S, T, or CT type discrete point serves as
step transition inputs. Each step has its own event. However,
programming the event is optional.

610
Drum Instruction Programming

Drum Instruction
Programming

Drum Control Techniques

Drum
Control Inputs

Now we are ready to put together the

concepts on the previous pages and
demonstrate general control of the drum
instruction box. The drawing to the right
shows a simplified generic drum
instruction. Inputs from ladder logic
control the Start, Jog, and Reset Inputs
(only the EDRUM instruction supports the
Jog Input). The first counter bit of the drum
(CT0, for example) indicates the drum
cycle is done.

X0

Start

X1

Jog

X2

Setup
Info.

Outputs

Reset
Steps

f
f
f
F
f
f
f
f

f
f
f
F
F
F
F
F

F
f
f
f
F
F
f
F

f
f
f
F
f
f
f
f

f f
f f
F f
F f
F f
F F
F F
f F

The timing diagram below shows an arbitrary timer drum input sequence and how
the drum responds. As the CPU enters Run mode it initializes the step number to the
preset step number (typically it is Step 1). When the Start input turns on the drum
begins running, waiting for an event and/or running the timer (depends on the setup).
After the drum enters Step 2, Reset turns On while Start is still On. Since Reset has
priority over Start, the drum goes to the preset step (Step 1). Note that the drum is
held in the preset step during Reset, and that step does not run (respond to events or
run the timer) until Reset turns off.
After the drum has entered step 3, the Start input goes off momentarily, halting the
drums timer until Start turns on again.
Start
drum
Inputs
Start

1
0

Jog

1
0

Reset

1
0

Reset
drum

Hold
drum

Resume
drum

Drum
Reset
Complete drum

Drum Status
1

Step #
Drum
Complete (CT0)
Outputs (x 16)

...

15

16

16

16

1
0
1
0

When the drum completes the last step (Step 16 in this example), the Drum
Complete bit (CT0) turns on, and the step number remains at 16. When the Reset
input turns on, it turns off the Drum Complete bit (CT0), and forces the drum to enter
the preset step.
NOTE: The timing diagram shows all steps using equal time durations. Step times
can vary greatly, depending on the counts/step programmed.

611
Drum Instruction Programming

Jog
drum
Inputs
Start

1
0

Jog

1
0

Reset

1
0

Reset
drum

Jog
drum

Jog
drum

Drum
Complete

Drum Status
1

Step #
Drum
Complete (CT0)
Outputs (x 16)

Self-Resetting
Drum

Initializing Drum
Outputs

Using Complex
Event Step
Transitions

6,7

...

14

15

16

16

16

1
0
1
0

Applications often require drums that

automatically start over once they
complete a cycle. This is easily
accomplished, using the drum complete
bit. In the figure to the right, the drum
instruction setup is for CT0, so we logically
OR the drum complete bit (CT0) with the
Reset input. When the last step is done,
the drum turns on CT0 which resets itself
to the preset step, also resetting CT0.
Contact X2 still works as a manual reset.

X0

Start

X1

Start

Setup
Info.

X2

Reset

Steps

CT0

Outputs
f
f
f
F
f
f
f
f

f
f
f
F
F
F
F
F

F
f
f
f
F
F
f
F

f
f
f
F
f
f
f
f

f f
f f
F f
F f
F f
F F
F F
f F

The outputs of a drum are enabled any time the CPU is in run mode. On
program-to-run mode transitions, the drum goes to the preset step, and the outputs
energize according to the pattern of that step. If your application requires all outputs
to be off at powerup, make the preset step in the drum a reset step, with all outputs
off.
Each event-based transition accepts only one contact reference for the event.
However, this does not limit events to just one contact. Just use a control relay
contact such as C0 for the step transition event. Elsewhere in ladder logic, you may
use C0 as an output coil, making it dependent on many other events (contacts).

Drum Instruction
Programming

In the figure below, we focus on how the Jog input works on event drums. To the left
of the diagram, note that the off-to-on transitions of the Jog input increments the
step. Start may be either on or off (however, Reset must be off). Two jogs takes the
drum to step three. Next, the Start input turns on, and the drum begins running
normally. During step 6 another Jog input signal occurs. This increments the drum to
step 7, setting the timer to 0. The drum begins running immediately in step 7,
because Start is already on. The drum advances to step 8 normally.
As the drum enters step 14, the Start input turns off. Two more Jog signals moves the
drum to step 16. However, note that a third Jog signal is required to move the drum
through step 16 to drum complete. Finally, a Reset input signal arrives which forces
the drum into the preset step and turns off the drum complete bit.

612
Drum Instruction Programming

Drum Instruction
Programming

Drum Instruction

Timed Drum with

Discrete Outputs
(DRUM)

The DL05 drum instructions may be programmed using DirectSOFT or for the
EDRUM instruction only you can use a handheld programmer (firmware version
v1.8 or later. This section covers entry using DirectSOFT for all instructions plus the
handheld mnemonics for the EDRUM instruction.
The Timed Drum with Discrete Outputs is the most basic of the DL05s drum
instructions. It operates according to the principles covered on the previous pages.
Below is the instruction in chart form as displayed by DirectSOFT.
Step Preset
Timebase

Counter Number

Start

Control
Inputs

Reset

Step Number
Counts per Step
Output Pattern
f= Off, F= On

DRUM

CT aaa

Step Preset

K bb

0.01 sec/Count K cccc

Step #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Counts
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd
Kdddd

Discrete Output Assignment

15

(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)
(Fffff)

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

The Timed Drum features 16 steps and 16 outputs. Step transitions occur only on a
timed basis, specified in counts per step. Unused steps must be programmed with
counts per step = 0 (this is the default entry). The discrete output points may be
individually assigned as X, Y, or C types, or may be left unused. The output pattern
may be edited graphically with DirectSOFT.
Whenever the Start input is energized, the drums timer is enabled. It stops when the
last step is complete, or when the Reset input is energized. The drum enters the
preset step chosen upon a CPU program-to-run mode transition, and whenever the
Reset input is energized.
Drum Parameters

Field

Data Types

Ranges

Counter Number

aaa

0 174

Preset Step

bb

1 16

Timer base

cccc

0 99.99 seconds

Counts per step

dddd

0 9999

Discrete Outputs

Fffff

X, Y, C

see page 428

613
Drum Instruction Programming

Counter Number

Ranges of (n)

Function

Counter Bit Function

CT(n)

0 174

Counts in step

CTn = Drum Complete

CT( n+1)

1 175

Timer value

CT(n+1) = (not used)

CT( n+2)

2 176

Preset Step

CT(n+2) = (not used)

CT( n+3)

3 177

Current Step

CT(n+3) = (not used)

The following ladder program shows the DRUM instruction in a typical ladder
program, as shown by DirectSOFT. Steps 1 through 10 are used, and twelve of the
sixteen output points are used. The preset step is step 1. The timebase runs at (K10
x 0.01) = 0.1 second per count. Therefore, the duration of step 1 is (25 x 0.1) = 2.5
seconds. In the last rung, the Drum Complete bit (CT0) turns on output Y0 upon
completion of the last step (step 10). A drum reset also resets CT0.
DirectSOFT Display
X0

X1

Start
Reset

DRUM

CT 0

Step Preset:

K1

0.01 sec/Count: K 10
Step #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

CT0

Drum Complete

Counts
K0025
K0020
K1500
K0045
K0180
K0923
K1200
K8643
K1200
K4000

15

0
( )

( )

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

( )
( )

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

(C14) (Y10)
(C4)
(Y5)
(Y13)
(C7)
(C30) (Y20)
(C2)
(Y6)
(Y42)
(C10)

F
F
f
f
f
F
F
f
F
f
f
f
f
f
f
f

f
f
F
f
F
f
f
F
F
F
f
f
f
f
f
f

f
F
f
F
f
f
F
f
F
f
f
f
f
f
f
f

F
f
F
f
f
F
f
f
F
F
f
f
f
f
f
f

F
f
f
F
f
f
F
F
F
f
f
f
f
f
f
f

f
F
F
f
F
f
f
f
F
F
f
f
f
f
f
f

f
f
f
f
f
F
F
F
F
f
f
f
f
f
f
f

F
f
f
F
f
f
f
f
F
F
f
f
f
f
f
f

f
f
F
f
f
f
f
f
F
f
f
f
f
f
f
f

f
f
f
f
F
F
f
f
F
F
f
f
f
f
f
f

Y0
OUT

f
F
f
F
f
f
F
F
F
f
f
f
f
f
f
f

F
f
F
f
f
F
f
F
F
f
f
f
f
f
f
f

Drum Instruction
Programming

Drum instructions use four counters in the CPU. The ladder program can read the
counter values for the drums status. The ladder program may write a new preset
step number to CT(n+2) at any time. However, the other counters are for monitoring
purposes only.

614
Drum Instruction
Programming

Drum Instruction Programming

Event Drum
(EDRUM)

The Event Drum (EDRUM) features time-based and event-based step transitions. It
operates according to the general principles of drum operation covered in the
beginning of this chapter. Below is the instruction as displayed by DirectSOFT.
Counter Number
Step Preset
Timebase

Control
Inputs

EDRUM

CT aa 15

Jog

Step Preset:

K bb

Reset

Step Number
Counts per Step
Event per step
Output Pattern
f= Off, F= On

Start

0.01 sec/Count: K cccc

Step #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Counts Event
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee
Kdddd Eeeee

Discrete Output Assignment

0

(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)
(Ffff)

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

f
f
f
f
f
f
f
f
f
f
f
f
f
f
f
f

The Event Drum features 16 steps and 16 discrete outputs. Step transitions occur on
timed and/or event basis. The jog input also advances the step on each off-to-on
transition. Time is specified in counts per step, and events are specified as discrete
contacts. Unused steps and events must be left blank. The discrete output points
may be individually assigned.
Whenever the Start input is energized, the drums timer is enabled. As long as the
event is true for the current step, the timer runs during that step. When the step count
equals the counts per step, the drum transitions to the next step. This process stops
when the last step is complete, or when the Reset input is energized. The drum
enters the preset step chosen upon a CPU program-to-run mode transition, and
whenever the Reset input is energized.
Drum Parameters

Field

Data Types

Ranges

Counter Number

aa

0 174

Preset Step

bb

1 16

Timer base

cccc

Counts per step

dddd

0 9999

Event

eeee

X, Y, C, S, T, CT

see page 428

Discrete Outputs

ffff

X, Y, C

see page 428

0 99.99 seconds

615
Drum Instruction Programming

Counter Number

Ranges of (n)

Function

Counter Bit Function

CT(n)

0 174

Counts in step

CTn = Drum Complete

C( n+1)

1 175

Timer value

CT(n+1) = (not used)

CT( n+2)

2 176

Preset Step

CT(n+2) = (not used)

CT( n+3)

3 177

Current Step

CT(n+3) = (not used)

The following ladder program shows the EDRUM instruction in a typical ladder
program, as shown by DirectSOFT. Steps 1 through 11 are used, and all sixteen
output points are used. The preset step is step 1. The timebase runs at (K10 x 0.01) =
0.1 second per count. Therefore, the duration of step 1 is (1 x 0.1) = 0.1 second. Note
that step 1 is time-based only (event is left blank). And, the output pattern for step 1
programs all outputs off, which is a typically desirable powerup condition. In the last
rung, the Drum Complete bit (CT4) turns on output Y0 upon completion of the last
step (step 11). A drum reset also resets CT4.
DirectSOFT Display
X0

Start

EDRUM

CT 4

15

X1

Jog

Step Preset

K1

(C34)
(Y6)
(C14)
(Y0)
(C4)
(Y5)
(Y1)
(C7)
(Y3)
(Y7)
(C30)
(Y2)
(C2)
(Y6)
(Y4)
(C10)

X2

Reset

0.01 sec/Count: K 10
Step #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

CT4

Drum Complete

Counts Event
K0001
K0020 Y4
K0150 X1
K0048 X2
K0180 C0
K0923 C1
K0120 X0
K0864 X5
K1200 X3
K0400 Y7
K0000 C20

f
F
f
f
f
F
f
F
f
f
F
f
f
f
f
f

f
f
f
F
F
f
F
f
f
F
f
f
f
f
f
f

f
f
F
f
f
f
f
f
f
f
f
f
f
f
f
f

f
F
f
f
F
F
f
F
f
F
f
f
f
f
f
f

f
F
F
f
f
f
f
f
f
F
f
f
f
f
f
f

f
f
f
F
f
f
F
f
f
f
F
f
f
f
f
f

f
f
f
f
f
F
f
F
F
f
f
f
f
f
f
f

f
f
f
f
F
F
f
f
F
f
f
f
f
f
f
f

f
f
F
f
f
f
F
f
F
f
f
f
f
f
f
f

f
f
f
F
F
F
f
F
f
F
F
f
f
f
f
f

f
f
f
F
F
f
f
f
f
F
f
f
f
f
f
f

f
F
F
F
f
f
f
F
f
f
f
f
f
f
f
f

f
f
f
f
F
f
f
F
F
f
f
f
f
f
f
f

f
f
F
F
f
f
F
f
f
F
F
f
f
f
f
f
Y0
OUT

f
F
f
F
f
F
F
f
F
f
F
f
f
f
f
f

f
f
f
f
F
F
f
F
f
f
F
f
f
f
f
f

Drum Instruction
Programming

Drum instructions use four counters in the CPU. The ladder program can read the
counter values for the drums status. The ladder program may write a new preset
step number to CT(n+2) at any time. However, the other counters are for monitoring
purposes only.

616
Drum Instruction
Programming

Drum Instruction Programming

Handheld
Programmer
Drum Mnemonics

The EDRUM instruction may be programmed using either DirectSOFT or a

handheld programmer. This section covers entry via the handheld programmer
(Refer to the DirectSOFT manual for drum instruction entry using that tool).
First, enter Store instructions for the
ladder rungs controlling the drums ladder
inputs. In the example to the right, the
timer drums Start, Jog, and Reset inputs
are controlled by X0, X1 and X2
respectively. The required keystrokes are
listed beside the mnemonic.
These keystrokes precede the EDRUM
instruction mnemonic. Note that the
ladder rungs for Start, Jog, and Reset
inputs are not limited to being
singlecontact rungs.

X0

Start

X1

Jog

Setup
Info.

Reset

Steps

X2

Outputs
Mask
f
f
f
F
f
f
f
f

f
f
f
F
F
F
F
F

F
f
f
f
F
F
f
F

f
f
f
F
f
f
f
f

f f
f f
F f
F f
F f
F F
F F
f F

Handheld Programmer Keystrokes

$

Store X0

A
STR

ENT

(Repeat for Store X1 and Store X2)

After the Store instructions, enter the EDRUM (using Counter CT0) as shown:
Handheld Programmer Keystrokes

EDRUM CNT0

SHFT

D
4

R
ORN

U
ISG

M
ORST

A
0

ENT

After entering the EDRUM mnemonic as above, the handheld programmer creates
an input form for all the drum parameters. The input form consists of approximately
fifty or more default mnemonic entries containing DEF (define) statements. The
default mnemonics are already input for you, so they appear automatically. Use the
NXT and PREV keys to move forward and backward through the form. Only the
editing of default values is required, thus eliminating many keystrokes. The entries
required for the basic timer drum are in the chart below.
Drum Parameters

Multiple
Entries

Mnemonic / Entry

Default
Mnemonic

Valid Data
Types

Ranges

Start Input

STR (plus input rung)

Jog Input

STR (plus input rung)

Reset Input

STR (plus input rung)

Drum Mnemonic

DRUM CNT aa

CT

0 174

Preset Step

bb

DEF K0000

1 16

Timer base

cccc

DEF K0000

1 9999

Output points

16

ffff

DEF 0000

X, Y, C *

see page
428

Counts per step

16

dddd

DEF K0000

0 9999

Events

16

dddd

DEF K0000

X, Y, C, S,
T, CT

see page
428

Output pattern

16

gggg

DEF K0000

0 FFFF

NOTE: Default entries for output points and events are DEF 0000, which means
they are unassigned. If you need to go back and change an assigned output as
unused again, enter K0000. The entry will again show as DEF 0000.

617
Drum Instruction Programming

Step 1

f f f f F f f F f f f F F f F f

Outputs:

converts to:

15

The following diagram shows the method for entering the previous EDRUM example
on the HHP. The default entries of the form are in parenthesis. After the drum
instruction entry (on the fourth row), the remaining keystrokes over-write the
numeric portion of each default DEF statement. NOTE: Drum editing requires
Handheld Programmer firmware version 1.7 or later.
Handheld Programmer Keystrokes

Start

Jog

Reset

Drum Inst.

SHFT

STR
B
STR

ENT

1
C

STR

ENT

2
E

D
4

NOTE: You may use the NXT and PREV keys

to skip past entries for unused outputs or steps.

ENT

R
ORN

Preset Step

( DEF K0001)

NEXT

Time Base

( DEF K0000 )

( DEF 0000 )

SHFT

( DEF 0000 )

SHFT

( DEF 0000 )

SHFT

Y
MLS

( DEF 0000 )

SHFT

Y
MLS

( DEF 0000 )

SHFT

Y
MLS

( DEF 0000 )

SHFT

Y
MLS

( DEF 0000 )

SHFT

( DEF 0000 )

SHFT

( DEF 0000 )

SHFT

Y
MLS

( DEF 0000 )

SHFT

Y
MLS

( DEF 0000 )

SHFT

( DEF 0000 )

SHFT

( DEF 0000 )

SHFT

Y
MLS

( DEF 0000 )

SHFT

Y
MLS

( DEF 0000 )

SHFT

16 ( DEF 0000 )

SHFT

Y
MLS

ENT

NEXT
H

7
B

NEXT
A

1
1
4
5
6

4
C

Outputs

Handheld Programmer Keystrokes contd

E
6

M
ORST

ISG

2
0
2

( DEF K0000 )

NEXT

( DEF K0000 )

NEXT

( DEF K0000 )

NEXT

( DEF K0000 )

NEXT

2
B

( DEF K0000 )

J
B

NEXT

( DEF K0000 )

NEXT

NEXT

( DEF K0000 )

NEXT

NEXT

( DEF K0000 )

NEXT

( DEF K0000 )

NEXT

16 ( DEF K0000 )

NEXT

NEXT

NEXT

( DEF K0000 )

NEXT

0
E

6
C

4
A

2
A

1
I

NEXT
A

(Continued on next page)

NEXT
NEXT
NEXT
NEXT
A

0
A

NEXT

NEXT

NEXT

( DEF K0000 )

NEXT

NEXT

( DEF K0000 )

E
3

Counts/
Step

NEXT

NEXT

3
6

( DEF K0000 )

( DEF K0000 )

NEXT

NEXT

1 ( DEF K0000 )

NEXT

NEXT

skip over
unused steps

Drum Instruction
Programming

Using the DRUM entry chart (two pages before), we show the method of entry for the
basic time/event drum instruction. First, we convert the output pattern for each step
to the equivalent hex number, as shown in the following example.

618
Drum Instruction Programming

Drum Instruction
Programming

Handheld Programmer Keystrokes contd

( DEF 0000 )
( DEF 0000 )

( DEF 0000 )
( DEF 0000 )
( DEF 0000 )

( DEF 0000 )

( DEF 0000 )
( DEF 0000 )

SHFT
SHFT
SHFT
SHFT
SHFT
SHFT

Events
( DEF 0000 )
( DEF 0000 )
( DEF 0000 )

16

skip over unused event

NEXT
SHFT

SHFT
SHFT
SHFT

( DEF 0000 )

NEXT

( DEF 0000 )

NEXT

( DEF 0000 )

NEXT

( DEF 0000 )

NEXT

( DEF 0000 )

NEXT

Handheld Programmer Keystrokes contd

Y
MLS

X
SET

X
SET

4
1
2

2
C

0
B

X
SET

X
SET

X
SET

Y
MLS

C
2

0
5
3
7

( DEF K0000 )

NEXT

( DEF K0000 )

NEXT

( DEF K0000 )

NEXT

( DEF K0000 )

NEXT
NEXT
NEXT
NEXT

Output
Pattern

NEXT

Last rung

( DEF K0000 )

J
D
F

8
I

5
I

NEXT

( DEF K0000 )

NEXT

( DEF K0000 )

NEXT

( DEF K0000 )

NEXT

( DEF K0000 )

NEXT

GY
CNT

Y
MLS

SHFT

J
9

SHFT

6
E

( DEF K0000 )

STR

C
1

B
8

( DEF K0000 )

( DEF K0000 )

16

NEXT

I
9

( DEF K0000 )

( DEF K0000 )
0

( DEF K0000 )

step 1 pattern = 0000

NEXT

( DEF K0000 )

NEXT
A

4
H

NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT

unused steps

0
0

NEXT
NEXT

NOTE: You may use the NXT and PREV keys

to skip past entries for unused outputs or steps.

RLL PLUS
Stage Programming
In This Chapter. . . .

17

Introduction to Stage Programming

Learning to Draw State Transition Diagrams
Using the Stage Jump Instruction for State Transitions
Stage Program Example: Toggle On/Off Lamp Controller
Four Steps to Writing a Stage Program
Stage Program Example: A Garage Door Opener
Stage Program Design Considerations
RLL PLUS (Stage) Instructions
Questions and Answers about Stage Programs

72

RLL PLUS Stage Programming

RLL PLUS
Stage Programming

Introduction to Stage Programming

Overcoming
Stage Fright

Stage Programming provides a way to organize and program complex applications

with relative ease, when compared to purely relay ladder logic (RLL) solutions.
Stage programming does not replace or negate the use of traditional boolean ladder
programming. This is why Stage Programming is also called RLL PLUS. You wont
have to discard any training or experience you already have. Stage programming
simply allows you to divide and organize a RLL program into groups of ladder
instructions called stages. This allows quicker and more intuitive ladder program
development than traditional RLL alone provides.
Many PLC programmers in the industry
have become comfortable using RLL for
X0
C0
every PLC program they write... but often
RST
remain skeptical or even fearful of learning
X4
C1
Y0
new techniques such as stage
programming. While RLL is great at
SET
solving boolean logic relationships, it has
disadvantages as well:
STAGE!
S Large programs can become almost
unmanageable, because of a lack of
structure.
Y2
X3
S In RLL, latches must be tediously
OUT
created from self-latching relays.
S When a process gets stuck, it is
difficult to find the rung where the
error occurred.
S Programs become difficult to modify
later, because they do not intuitively
resemble the application problem
they are solving.
Its easy to see that these inefficiencies consume a lot of additional time, and time is
money. Stage programming overcomes these obstacles! We believe a few
moments of studying the stage concept is one of the greatest investments in
programming speed and efficiency a PLC programmer can make!
So, we encourage you to study stage programming and add it to your toolbox of
programming techniques. This chapter is designed as a self-paced tutorial on stage
programming. For best results:
S Start at the beginning and do not skip over any sections.
S Study each stage programming concept by working through each
example. The examples build progressively on each other.
S Read the Stage Questions and Answers at the end of the chapter for a
quick review.

RLL PLUS Stage Programming

73

Learning to Draw State Transition Diagrams

Introduction to
Process States

Inputs

Ladder
Program

Outputs

PLC Scan
1) Read

Execute

Write

2) Read

Execute

Write

3) Read

(etc....)

Most manufacturing processes consist of a series of activities or conditions , each

lasting for several seconds. minutes, or even hours. We might call these process
states, which are either active or inactive at any particular time. A challenge for RLL
programs is that a particular input event may last for just a brief instant. We typically
create latching relays in RLL to preserve the input event in order to maintain a
process state for the required duration.
We can organize and divide ladder logic into sections called stages, representing
process states. But before we describe stages in detail, we will reveal the secret to
understanding stage programming: state transition diagrams.
The Need for State Sometimes we need to forget about the scan nature of PLCs, and focus our thinking
toward the states of the process we need to identify. Clear thinking and concise
Diagrams
analysis of an application gives us the best chance at writing efficient, bug-free
programs. State diagrams are just a tool to help us draw a picture of our process!
Youll discover that if we can get the picture right, our program will also be right!
A 2State Process Consider the simple process shown to the
Inputs
Outputs
right, which controls an industrial motor.
On
We will use a green momentary SPST
X0
Motor
pushbutton to turn the motor on, and a red
Ladder Y0
one to turn it off. The machine operator will
Program
Off
X1
press the appropriate pushbutton for just a
second or so. The two states of our
process are ON and OFF.
Transition condition
The next step is to draw a state transition
State
diagram, as shown to the right. It shows
X0
the two states OFF and ON, with two
transition lines in-between. When the
OFF
ON
event X0 is true, we transition from OFF to
X1
ON. When X1 is true, we transition from
Output equation: Y0 = ON
ON to OFF.
If youre following along, you are very close to grasping the concept and the
problem-solving power of state transition diagrams. The output of our controller is
Y0, which is true any time we are in the ON state. In a boolean sense, Y0=ON state.
Next, we will implement the state diagram first as RLL, then as a stage program. This
will help you see the relationship between the two methods in problem solving.

RLL PLUS
Stage Programming

Those familiar with ladder program

execution know that the CPU must scan
the ladder program repeatedly, over and
over. Its three basic steps are:
1. Read the inputs
2. Execute the ladder program
3. Write the outputs
The benefit is that a change at the inputs
can affect the outputs in just a few
milliseconds.

74

RLL PLUS Stage Programming

The state transition diagram to the right is

a picture of the solution we need to create.
The beauty of it is this: it expresses the
problem
independently
of
the
programming language we may use to
realize it. In other words, by drawing the
diagram we have already solved the
control problem!

X0

OFF

ON
X1

Output equation: Y0 = ON

RLL PLUS
Stage Programming

First, well translate the state diagram to traditional RLL. Then well show how easy it
is to translate the diagram into a stage programming solution.
RLL Equivalent

Stage Equivalent

The RLL solution is shown to the right. It

consists of a self-latching control relay,
C0. When the On pushbutton (X0) is
pressed, output coil C0 turns on and the
C0 contact on the second row latches
itself on. So, X0 sets the latch C0 on, and
it remains on after the X0 contact opens.
The motor output Y0 also has power flow,
so the motor is now on.
When the Off pushbutton (X1) is pressed,
it opens the normally-closed X1 contact,
which resets the latch. Motor output Y0
turns off when the latch coil C0 goes off.
The stage program solution is shown to
the right. The two inline stage boxes S0
and S1 correspond to the two states OFF
and ON. The ladder rung(s) below each
stage box belong to each respective
stage. This means that the PLC only has
to scan those rungs when the
corresponding stage is active!
For now, lets assume we begin in the OFF
State, so stage S0 is active. When the On
pushbutton (X0) is pressed, a stage
transition occurs. The JMP S1 instruction
executes, which simply turns off the Stage
bit S0 and turns on Stage bit S1. So on the
next PLC scan, the CPU will not execute
Stage S0, but will execute stage S1!
In the On State (Stage S1), we want the
motor to always be on. The special relay
contact SP1 is defined as always on, so Y0
turns the motor on.

Set

Reset

X0

X1

Latch

Latch
C0
OUT

Output

C0

Y0
OUT

SG
S0

OFF State
Transition
S1

X0

JMP

SG
S1

ON State
Output
SP1 Always on

Y0
OUT

Transition
X1

S0
JMP

When the Off pushbutton (X1) is pressed, a transition back to the Off State occurs.
The JMP S0 instruction executes, which simply turns off the Stage bit S1 and turns
on Stage bit S0. On the next PLC scan, the CPU will not execute Stage S1, so the
motor output Y0 will turn off. The Off state (Stage 0) will be ready for the next cycle.

RLL PLUS Stage Programming

Lets Compare

75

Right now, you may be thinking I dont see the big advantage to Stage
Programming... in fact, the stage program is longer than the plain RLL program.
Well, now is the time to exercise a bit of faith. As control problems grow in complexity,
stage programming quickly out-performs RLL in simplicity, program size, etc.
For example, consider the diagram below.
Notice how easy it is to correlate the OFF
SG
and ON states of the state transition
OFF State
S0
diagram below to the stage program at the
S1
X0
right. Now, we challenge anyone to easily
identify the same states in the RLL
JMP
program on the previous page!
ON State
SP1

Y0
OUT

X1

S0

X0

OFF

ON

JMP

X1

Initial Stages

At powerup and Program-to-Run Mode

transitions, the PLC always begins with all
normal stages (SG) off. So, the stage
programs shown so far have actually had
no way to get started (because rungs are
not scanned unless their stage is active).
Assume that we want to always begin in
the Off state (motor off), which is how the
RLL program works. The Initial Stage
(ISG) is defined to be active at powerup. In
the modified program to the right, we have
changed stage S0 to the ISG type. This
ensures the PLC will scan contact X0 after
powerup, because Stage S0 is active.
After powerup, an Initial Stage (ISG)
works just like any other stage!
We can change both programs so that the
motor is ON at powerup. In the RLL below,
we must add a first scan relay SP0,
latching C0 on. In the stage example to the
right, we simply make Stage S1 an initial
stage (ISG) instead of S0.
Powerup in ON State
X0

X1

C0

C0
OUT

Powerup in OFF State

ISG
S0

Initial Stage

JMP
SG
S1
SP1

First Scan

Y0
OUT
S0

X1

JMP

Powerup in ON State
SG
S0
S1

X0

JMP
ISG
S1

Initial Stage
SP1

Y0
OUT

X1

S0

Y0
OUT

SP0

S1

X0

JMP

RLL PLUS
Stage Programming

SG
S1

76

RLL PLUS Stage Programming

RLL PLUS
Stage Programming

We can mark our desired powerup state

as shown to the right, which helps us
remember to use the appropriate Initial
Stages when creating a stage program. It
is permissible to have as many initial
stages as the process requires.

Powerup

X0

OFF

ON
X1

What Stage Bits Do You may recall that a stage is just a section of ladder program which is either active or
inactive at a given moment. All stage bits (S0 to S377) reside in the PLCs image
register as individual status bits. Each stage bit is either a boolean 0 or 1 at any time.
Program execution always reads ladder rungs from top to bottom, and from left to
right. The drawing below shows the effect of stage bit status. The ladder rungs below
the stage instruction continuing until the next stage instruction or the end of program
belong to stage 0. Its equivalent operation is shown on the right. When S0 is true, the
two rungs have power flow.
S If Stage bit S0 = 0, its ladder rungs are not scanned (executed).
S If Stage bit S0 = 1, its ladder rungs are scanned (executed).
Actual Program Appearance

SG
S0

Functionally Equivalent Ladder

S0

(includes all rungs in stage)

Stage Instruction
Characteristics

The inline stage boxes on the left power

rail divide the ladder program rungs into
stages. Some stage rules are:
S Execution Only logic in active
stages are executed on any scan.
S Transitions Stage transition
instructions take effect on the next
occurrence of the stages involved.
S Octal numbering Stages are
numbered in octal, like I/O points,
etc. So S8 is not valid.
S Total Stages The DL05 offers up
to 256 stages (S0 to S377 in octal).
S No duplicates Each stage number
is unique and can be used just once.
S Any order You can skip numbers
and sequence the stage numbers in
any order.
S Last Stage the last stage in the
ladder program includes all rungs
from its stage box until the end coil.

SG
S0

SG
S1

SG
S2

END

77

RLL PLUS Stage Programming

Using the Stage Jump Instruction for State Transitions

Stage Jump, Set,
and Reset
Instructions

The Stage JMP instruction we have used deactivates the stage in which the
instruction occurs, while activating the stage in the JMP instruction. Refer to the
state transition shown below. When contact X0 energizes, the state transition from
S0 to S1 occurs. The two stage examples shown below are equivalent. So, the
Stage Jump instruction is equal to a Stage Reset of the current stage, plus a Stage
Set instruction for the stage to which we want to transition.
X0

S1

SG
S0

SG
S0

Equivalent

S1

X0

S0

X0

JMP

RST
S1
SET

Please Read Carefully The jump instruction is easily misunderstood. The jump
does not occur immediately like a GOTO or GOSUB program control instruction
when executed. Heres how it works:
S The jump instruction resets the stage bit of the stage in which it occurs.
All rungs in the stage still finish executing during the current scan, even
if there are other rungs in the stage below the jump instruction!
S The reset will be in effect on the following scan, so the stage that
executed the jump instruction previously will be inactive and bypassed.
S The stage bit of the stage named in the Jump instruction will be set
immediately, so the stage will be executed on its next occurrence. In the
left program shown below, stage S1 executes during the same scan as
the JMP S1 occurs in S0. In the example on the right, Stage S1
executes on the next scan after the JMP S1 executes, because stage
S1 is located above stage S0.

SG
S0

Executes on next
scan after Jmp

SG
S1
X0

S1

S1

JMP

Executes on same
scan as Jmp

SG
S1
S1

Y0

Y0
OUT

SG
S0
X0

OUT
Note: Assume we start with Stage 0 active and stage 1 inactive for both examples.

S1
JMP

RLL PLUS
Stage Programming

S0

78

RLL PLUS Stage Programming

Stage Program Example: Toggle On/Off Lamp Controller

RLL PLUS
Stage Programming

A 4State Process

In the process shown to the right, we use

an ordinary momentary pushbutton to
control a light bulb. The ladder program
will latch the switch input, so that we will
push and release to turn on the light, push
and release again to turn it off (sometimes
called toggle function). Sure, we could just
buy a mechanical switch with the alternate
on/off action built in... However, this
example is educational and also fun!
Next we draw the state transition diagram.
A typical first approach is to use X0 for
both transitions (like the example shown
to the right). However, this is incorrect
(please keep reading).

Inputs
Toggle

X0

Outputs
Ladder
Program

Powerup

Y0

X0

OFF

ON
X0

Output equation: Y0 = ON

Note that this example differs from the motor example, because now we have just
one pushbutton. When we press the pushbutton, both transition conditions are met.
We would just transition around the state diagram at top speed. If implemented in
Stage, this solution would flash the light on or off each scan (obviously undesirable)!
The solution is to make the the push and the release of the pushbutton separate
events. Refer to the new state transition diagram below. At powerup we enter the
OFF state. When switch X0 is pressed, we enter the Press-ON state. When it is
released, we enter the ON state. Note that X0 with the bar above it denotes X0 NOT.
Powerup

X0

PushON

X0

OFF

ISG
S0

OFF State
S1

X0

ON

JMP

X0

PushOFF

X0

SG
S1

S2

X0

Output equation: Y0 = ON

When in the ON state, another push and

release cycle similarly takes us back to the
OFF state. Now we have two unique states
(OFF and ON) used when the pushbutton is
released, which is what was required to solve
the control problem.
The equivalent stage program is shown to the
right. The desired powerup state is OFF, so
we make S0 an initial stage (ISG). In the ON
state, we add special relay contact SP1,
which is always on.
Note that even as our programs grow more
complex, it is still easy to correlate the state
transition diagram with the stage program!

PushOn State

JMP
SG
S2

ON State
Output
SP1

Y0
OUT

X0

S3
JMP

SG
S3

PushOff State
X0

S0
JMP

RLL PLUS Stage Programming

79

Four Steps to Writing a Stage Program

By now, youve probably noticed that we follow the same steps to solve each
example problem. The steps will probably come to you automatically if you work
through all the examples in this chapter. Its helpful to have a checklist to guide us
through the problem solving. The following steps summarize the stage program
design procedure:

1. Write a Word Description of the application.

2. Draw the Block Diagram.

Inputs represent all the information the process needs for decisions, and outputs
connect to all devices controlled by the process.
S Make lists of inputs and outputs for the process.
S Assign I/O point numbers (X and Y) to physical inputs and outputs.

3. Draw the State Transition Diagram.

The state transition diagram describes the central function of the block diagram,
reading inputs and generating outputs.
S Identify and name the states of the process.
S Identify the event(s) required for each transition between states.
S Ensure the process has a way to re-start itself, or is cyclical.
S Choose the powerup state for your process.
S Write the output equations.

4. Write the Stage Program.

Translate the state transition diagram into a stage program.
S Make each state a stage. Remember to number stages in octal. Up to
256 total stages are available in the DL05, numbered 0 to 377 in octal.
S Put transition logic inside the stage which originates each transition (the
stage each arrow points away from).
S Use an initial stage (ISG) for any states that must be active at powerup.
S Place the outputs or actions in the appropriate stages.
Youll notice that Steps 1 through 3 just prepare us to write the stage program in Step
4. However, the program virtually writes itself because of the preparation
beforehand. Soon youll be able to start with a word description of an application and
create a stage program in one easy session!

RLL PLUS
Stage Programming

Describe all functions of the process in your own words. Start by listing what
happens first, then next, etc. If you find there are too many things happening at once,
try dividing the problem into more than one process. Remember, you can still have
the processes communicate with each other to coordinate their overall activity.

710

RLL PLUS Stage Programming

Stage Program Example: A Garage Door Opener

RLL PLUS
Stage Programming

Garage Door
Opener Example

In this next stage programming example

well create a garage door opener
controller. Hopefully most readers are
familiar with this application, and we can
have fun besides!
The first step we must take is to describe
how the door opener works. We will start
by achieving the basic operation, waiting
to add extra features later. Stage
programs are very easy to modify.
Our garage door controller has a motor
which raises or lowers the door on
command. The garage owner pushes and
releases a momentary pushbutton once to
raise the door. After the door is up, another
push-release cycle will lower the door.

In order to identify the inputs and outputs

of the system, its sometimes helpful to
sketch its main components, as shown in
the door side view to the right. The door
has an up limit and a down limit switch.
Each limit switch closes only when the
door has reach the end of travel in the
corresponding direction. In the middle of
travel, neither limit switch is closed.
The motor has two command inputs: raise
and lower. When neither input is active,
the motor is stopped.
The door command is just a simple
pushbutton. Whether wall-mounted as
shown, or a radio-remote control, all door
control commands logical OR together as
one pair of switch contacts.
Draw the Block
Diagram

Up limit switch
Raise
Lower

Motor

Door
Command
Down limit switch

The block diagram of the controller is Inputs

shown to the right. Input X0 is from the
pushbutton door control. Input X1 Toggle X0
energizes when the door reaches the full
up position. Input X2 energizes when the
Up limit
door reaches the full down position. When
X1
the door is positioned between fully up or
down, both limit switches are open.
Down limit
The controller has two outputs to drive the
X2
motor. Y1 is the up (raise the door)
command, and Y2 is the down (lower the
door) command.

Outputs

To motor:
Ladder
Program Y1

Raise

Y2

Lower

RLL PLUS Stage Programming

Draw the State

Diagram

Now we are ready to draw the state transition diagram. Like the previous light bulb
controller example, this application also has just one switch for the command input.
Refer to the figure below.
S When the door is down (DOWN state), nothing happens until X0
energizes. Its push and release brings us to the RAISE state, where
output Y1 turns on and causes the motor to raise the door.
S We transition to the UP state when the up limit switch (X1) energizes,
and turns off the motor.
S Then nothing happens until another X0 press-release cycle occurs. That
takes us to the LOWER state, turning on output Y2 to command the
motor to lower the door. We transition back to the DOWN state when the
down limit switch (X2) energizes.
X0
PushUP

RAISE

X1

ISG
S0

DOWN State
S1

X0

DOWN

UP

JMP
SG
S1

X2

LOWER

PushDOWN

X0

PushUP State
S2

X0

X0
Output equations: Y1 = RAISE Y2 = LOWER

The equivalent stage program is shown to the

right. For now, we will assume the door is
down at powerup, so the desired powerup
state is DOWN. We make S0 an initial stage
(ISG). Stage S0 remains active until the door
control pushbutton activates. Then we
transition (JMP) to Push-UP stage, S1.
A push-release cycle of the pushbutton takes
us through stage S1 to the RAISE stage, S2.
We use the always-on contact SP1 to
energize the motors raise command, Y1.
When the door reaches the fully-raised
position, the up limit switch X1 activates. This
takes us to the UP Stage S3, where we wait
until another door control command occurs.
In the UP Stage S3, a push-release cycle of
the pushbutton will take us to the LOWER
Stage S5, where we activate Y2 to command
the motor to lower the door. This continues
until the door reaches the down limit switch,
X2. When X2 closes, we transition from Stage
S5 to the DOWN stage S0, where we began.
NOTE: The only special thing about an initial
stage (ISG) is that it is automatically active at
powerup. Afterwards, it is just like any other.

JMP
SG
S2

RAISE State
SP1

Y1
OUT
S3

X1

JMP
SG
S3

UP State
S4

X0

JMP
SG
S4

PushDOWN State
S5

X0

JMP
SG
S5

LOWER State
SP1

X2

Y2
OUT
S0
JMP

RLL PLUS
Stage Programming

Powerup

X0

711

712

RLL PLUS Stage Programming

RLL PLUS
Stage Programming

Add Safety
Light Feature

Next we will add a safety light feature to

the door opener system. Its best to get the
main function working first as we have
done, then adding the secondary features.
The safety light is standard on many
commercially-available garage door
openers. It is shown to the right, mounted
on the motor housing. The light turns on
upon any door activity, remaining on for
approximately 3 minutes afterwards.
This part of the exercise will demonstrate
the use of parallel states in our state
diagram. Instead of using the JMP
instruction, well use the set and reset
commands.

Safety light

Modify the
To control the light bulb, we add an output Inputs
Block Diagram and to our controller block diagram, shown to
Toggle
the right, Y3 is the light control output.
State Diagram
X0
In the diagram below, we add an additional
state called LIGHT. Whenever the
garage owner presses the door control Up limit
X1
switch and releases, the RAISE or
LOWER state is active and the LIGHT
state is simultaneously active. The line to
Down limit
the Light state is dashed, because it is not
X2
the primary path.

Outputs
Y1

Ladder
Program Y2

Y3

Raise

Lower

Light

We can think of the Light state as a parallel process to the raise and lower state. The
paths to the Light state are not a transition (Stage JMP), but a State Set command. In
the logic of the Light stage, we will place a three-minute timer. When it expires, timer
bit T0 turns on and resets the Light stage. The path out of the Light stage goes
nowhere, indicating the Light stage just becomes inactive, and the light goes out!
Output equations:
X0
X0

RAISE

PushUP

X1

Y1 = RAISE
Y2 = LOWER
Y3 = LIGHT

X0

DOWN

LIGHT

UP

T0

X0
X2

LOWER

PushDOWN

X0

X0

713

RLL PLUS Stage Programming

Using a Timer
Inside a Stage

K=1800 counts
The timer has power flow whenever stage
S6 is active. The corresponding timer bit
T0 is set when the timer expires. So three
minutes later, T0=1 and the instruction
Reset S6 causes the stage to be inactive.
While Stage S6 is active and the light is on,
stage transitions in the primary path
continue normally and independently of
Stage 6. That is, the door can go up, down,
or whatever, but the light will be on for
precisely 3 minutes.

ISG
S0

DOWN State
S1

X0

JMP
SG
S1

PushUP State
S2

X0

JMP
S6
SET
SG
S2

RAISE State
SP1

Y1
OUT
S3

X1

JMP
SG
S3

UP State
S4

X0

JMP
SG
S4

PushDOWN State
S5

X0

JMP
S6
SET

SG
S5

LOWER State
SP1

Y2
OUT

X2

S0
JMP

SG
S6

LIGHT State
SP1

Y3
OUT
TMR T0
K1800

T0

S6
RST

RLL PLUS
Stage Programming

The finished modified program is shown to

the right. The shaded areas indicate the
program additions.
In the Push-UP stage S1, we add the Set
Stage Bit S6 instruction. When contact X0
opens, we transition from S1 and go to two
new active states: S2 and S6. In the
Push-DOWN state S4, we make the same
additions. So, any time someone presses
the door control pushbutton, the light turns
on.
Most new stage programmers would be
concerned about where to place the Light
Stage in the ladder, and how to number it.
The good news is that it doesnt matter!
S Just choose an unused Stage
number, and use it for the new stage
and as the reference from other
stages.
S Placement in the program is not
critical, so we place it at the end.
You might think that each stage has to be
directly under the stage that transitions to
it. While it is good practice, it is not
required (thats good, because our two
locations for the Set S6 instruction make
that impossible). Stage numbers and how
they are used determines the transition
paths.
In stage S6, we turn on the safety light by
energizing Y3. Special relay contact SP1
is always on. Timer T0 times at 0.1 second
per count. To achieve 3 minutes time
period, we calculate:
3 min. x 60 sec/min
K=
0.1 sec/count

714

RLL PLUS Stage Programming

RLL PLUS
Stage Programming

Add Emergency
Stop Feature

Some garage door openers today will

detect an object under the door. This halts
further lowering of the door. Usually
implemented
with
a
photocell
(electric-eye), a door in the process of
being lowered will halt and begin raising.
We will define our safety feature to work in
this way, adding the input from the
photocell to the block diagram as shown to
the right. X3 will be on if an object is in the
path of the door.
Next, we make a simple addition to the
state transition diagram, shown in shaded
areas in the figure below. Note the new
transition path at the top of the LOWER
state. If we are lowering the door and
detect an obstruction (X3), we then jump
to the Push-UP State. We do this instead
of jumping directly to the RAISE state, to
give the Lower output Y2 one scan to turn
off, before the Raise output Y1 energizes.

Inputs
Toggle

Outputs
X0

Y1

X1

Ladder Y2
Program

Down limit
X2

Y3

Up limit

Raise
Lower
Light

Obstruction
X3

X0
X0

RAISE

PushUP

X1

X0

DOWN

X3

LIGHT

UP

T0

X0

X2 and X3

LOWER

PushDOWN

X0

X0

Exclusive
Transitions

It is theoretically possible that the down limit (X2) and the obstruction input (X3)
could energize at the same moment. In that case, we would jump to the Push-UP
and DOWN states simultaneously, which does not make sense.
Instead, we give priority to the obstruction
by changing the transition condition to the
SG
LOWER State
DOWN state to [X2 AND NOT X3]. This
S5
ensures the obstruction event has the
SP1
Y2
priority. The modifications we must make
OUT
to the LOWER Stage (S5) logic are shown
to the right. The first rung remains
to DOWN
S0
X2
X3
unchanged. The second and third rungs
JMP
implement the transitions we need. Note
X3
to Push-UP S2
the opposite relay contact usage for X3,
which ensures the stage will execute only
JMP
one of the JMP instructions.

RLL PLUS Stage Programming

715

Stage Program Design Considerations

Stage Program
Organization

Main Process
XXX

= ISG
Idle
Powerup Initialization
Powerup

Fill

Agitate

E-Stop and Alarm Monitoring

Rinse

Spin

Operator Interface

Monitor

Recipe

Control

Status

In a typical application, the separate stage sequences above operate as follows:

S Powerup Initialization This stage contains ladder rung tasks done
just once at powerup. Its last rung resets the stage, so this stage is only
active for one scan (or only as many scans that are required).
S Main Process this stage sequence controls the heart of the process
or machine. One pass through the sequence represents one part cycle
of the machine, or one batch in the process.
S E-Stop and Alarm Monitoring This stage is always active because it
is watching for errors that could indicate an alarm condition or require an
emergency stop. It is common for this stage to reset stages in the main
process or elsewhere, in order to initialize them after an error condition.
S Operator Interface this is another task that must always be active
and ready to respond to an operator. It allows an operator interface to
change modes, etc. independently of the current main process step.
Although we have separate processes,
there can be coordination among them.
For example, in an error condition, the
Status Stage may want to automatically
switch the operator interface to the status
mode to show error information as shown
to the right. The monitor stage could set
the stage bit for Status and Reset the
stages Control and Recipe.

Operator Interface
Recipe

Control

Monitor

Set

E-Stop and
Alarm Monitoring

Status

RLL PLUS
Stage Programming

The examples so far in this chapter used one self-contained state diagram to
represent the main process. However, we can have multiple processes
implemented in stages, all in the same ladder program. New stage programmers
sometimes try to turn a stage on and off each scan, based on the false assumption
that only one stage can be on at a time. For ladder rungs that you want to execute
each scan, just put them in a stage that is always on.
The following figure shows a typical application. During operation, the primary
manufacturing activity Main Process, Powerup Initialization, E-Stop and Alarm
Monitoring, and Operator Interface are all running. At powerup, three initial stages
shown begin operation.

716

RLL PLUS Stage Programming

We can think of states or stages as simply dividing up our ladder program as

How Instructions
Work Inside Stages depicted in the figure below. Each stage contains only the ladder rungs which are
needed for the corresponding state of the process. The logic for transitioning out of a
stage is contained within that stage. Its easy to choose which ladder rungs are active
at powerup by using an initial stage type (ISG).

RLL PLUS
Stage Programming

Stage 0

Stage 1

Stage 2

Most all instructions work just like they do in standard RLL. You can think of a stage
just like a miniature RLL program which is either active or inactive.
Output Coils As expected, output coils in active stages will turn on or off outputs
according to power flow into the coil. However, note the following:
S Outputs work as usual, provided each output reference (such as Y3) is
used in only one stage.
S An output can be referenced from more than one stage, as long as only
one of the stages is active at a time.
S If an output coil is controlled by more than one stage simultaneously, the
active stage nearest the bottom of the program determines the final
output status during each scan. Therefore, use the OROUT instruction
instead when you want multiple stages to have a logical OR control of
an output.
One-Shot or PD coils Use care if you must use a Positive Differential coil in a
stage. Remember that the input to the coil must make a 01 transition. If the coil is
already energized on the first scan when the stage becomes active, the PD coil will
not work. This is because the 01 transition did not occur.
PD coil alternative: If there is a task which you want to do only once (on 1 scan), it can
be placed in a stage which transitions to the next stage on the same scan.
Counter In using a counter inside a stage, the stage must be active for one scan
before the input to the counter makes a 01 transition. Otherwise, there is no real
transition and the counter will not count.
The ordinary Counter instruction does have a restriction inside stages: it may not be
reset from other stages using the RST instruction for the counter bit. However, the
special Stage counter provides a solution (see next paragraph).
Stage Counter The Stage Counter has the benefit that its count may be globally
reset from other stages by using the RST instruction. It has a count input, but no reset
input. This is the only difference from a standard counter.
Drum Realize that the drum sequencer is its own process, and is a different
programming method than stage programming. If you need to use a drum with
stages, be sure to place the drum instruction in an ISG stage that is always active.

717

RLL PLUS Stage Programming

Using a Stage as a You may recall the light bulb on-off

controller example from earlier in this
Supervisory
chapter. For the purpose of illustration, Toggle X0
Process
suppose we want to monitor the
productivity of the lamp process, by
counting the number of on-off cycles
which occurs. This application will require
the addition of a simple counter, but the
key decision is in where to put the counter.

Ladder
Program

Y0

Powerup

Supervisor

Supervisor Process

OFF State
S1

X0

JMP

Powerup

X0

PushON

X0

SG
S1

PushOn State
S2

X0

Main Process

OFF

X0

PushOFF

ON
X0

JMP
SG
S2

ON State
SP1

New stage programming students will

typically try to place the counter inside one the
the stages of the process they are trying to
monitor. The problem with this approach is
that the stage is active only part of the time. In
order for the counter to count, the count input
must transition from off to on at least one scan
after its stage activates. Ensuring this
requires extra logic that can be tricky.
In this case, we only need to add another
supervisory stage as shown above, to watch
the main process. The counter inside the
supervisor stage uses the stage bit S1 of the
main process as its count input. Stage bits
used as a contact let us monitor a process!
Note that both the Supervisor stage and the
OFF stage are initial stages. The supervisor
stage remains active indefinitely.
Stage Counter

Y0
OUT
S3

X0

JMP
SG
S3

PushOff State
S0

X0

JMP
ISG
S4

Supervisor State
S1
SGCNT

CT0

K5000

The counter in the above example is a special Stage Counter. Note that it does not
have a reset input. The count is reset by executing a Reset instruction, naming the
counter bit (CT0 in this case). The Stage Counter has the benefit that its count may
be globally reset from other stages. The standard Counter instruction does not have
this global reset capability. You may still use a regular Counter instruction inside a
stage... however, the reset input to the counter is the only way to reset it.

RLL PLUS
Stage Programming

ISG
S0

718

RLL PLUS Stage Programming

Power Flow
Transition
Technique

Our discussion of state transitions has shown how the Stage JMP instruction makes
the current stage inactive and the next stage (named in the JMP) active. As an
alternative way to enter this in DirectSOFT, you may use the power flow method for
stage transitions.
The main requirement is that the current stage be located directly above the next
(jump-to) stage in the ladder program. This arrangement is shown in the diagram
below, by stages S0 and S1, respectively.
X0

RLL PLUS
Stage Programming

S0

S1

SG
S0

SG
S0
S1

X0

Equivalent

All other rungs in stage...

JMP
X0
SG
S1

Power flow
transition
SG
S1

Recall that the Stage JMP instruction may occur anywhere in the current stage, and
the result is the same. However, power flow transitions (shown above) must occur as
the last rung in a stage. All other rungs in the stage will precede it. The power flow
transition method is also achievable on the handheld programmer, by simply
following the transition condition with the Stage instruction for the next stage.
The power flow transition method does eliminate one Stage JMP instruction, its only
advantage. However, it is not as easy to make program changes as using the Stage
JMP. Therefore, we advise using Stage JMP transitions for most programmers.
Stage View in
DirectSOFT

SG

The Stage View option in DirectSOFT will let you view the ladder program as a flow
chart. The figure below shows the symbol convention used in the diagrams. You may
find the stage view useful as a tool to verify that your stage program has faithfully
reproduced the logic of the state transition diagram you intend to realize.

Stage

Reference to
a Stage

Transition
Logic

Jump

Set Stage

Reset Stage

The following diagram is a typical stage view of a ladder program containing stages.
Note the left-to-right direction of the flow chart.
ISG
S0

SG
S1

SG
S2

SG
S4

SG
S3

SG
S5

719

RLL PLUS Stage Programming

Parallel Processing Concepts

Parallel Processes Previously in this chapter we discussed how a state may transition to either one state
or another, called an exclusive transition. In other cases, we may need to branch
simultaneously to two or more parallel processes, as shown below. It is acceptable
to use all JMP instructions as shown, or we could use one JMP and a Set Stage bit
instruction(s) (at least one must be a JMP, in order to leave S1). Remember that all
instructions in a stage execute, even when it transitions (the JMP is not a GOTO).
Process A

SG
S1

S3

PushOn State
S2

X0

S0

S1

X0

Process B

Converging
Processes

JMP

S4

S4

S5

JMP

Note that if we want Stages S2 and S4 to energize exactly on the same scan, both
stages must be located below or above Stage S1 in the ladder program (see the
explanation at the bottom of page 77). Overall, parallel branching is easy!
Now we consider the opposite case of parallel branching, which is converging
processes. This simply means we stop doing multiple things and continue doing one
thing at a time. In the figure below, processes A and B converge when stages S2 and
S4 transition to S5 at some point in time. So, S2 and S4 are Convergence Stages.
Process A

S1

S2

= Convergence Stage

S5
Process B

Convergence
Stages
(CV)

S3

S6

S4

While the converging principle is simple enough, it brings a new complication. As

parallel processing completes, the multiple processes almost never finish at the
same time. In other words, how can we know whether Stage S2 or S4 will finish last?
This is an important point, because we have to decide how to transition to Stage S5.
The solution is to coordinate the transition
condition out of convergence stages. We
accomplish this with a stage type
designed
for
this
purpose:
the
Convergence Stage (type CV). In the
example to the right, convergence stages
S2 and S4 are required to be grouped
together as shown. No logic is permitted
between CV stages! The transition
condition (X3 in this case) must be located
in the last convergence stage. The
transition condition only has power flow
when all convergence stages in the group
are active.

CV
S2

Convergence
Stages

CV
S4
X3

SG
S5

S5
CVJMP

RLL PLUS
Stage Programming

S2

RLL PLUS
Stage Programming

720

RLL PLUS Stage Programming

Convergence Jump Recall the last convergence stage only

has power flow when all CV stages in the
(CVJMP)
group are active. To complement the
convergence stage, we need a new jump
instruction. The Convergence Jump
(CVJMP) shown to the right will transition
to Stage S5 when X3 is active (as one
might expect), but it also automatically
resets all convergence stages in the
group. This makes the CVJMP jump a
very powerful instruction. Note that this
instruction may only be used with
convergence stages.

Convergence
Stage Guidelines

CV
S2

Convergence
Jump

CV
S4
X3

S5
CVJMP

SG
S5

The following summarizes the requirements in the use of convergence stages,

including some tips for their effective application:
S

S
S
S

S
S

S
S

A convergence stage is to be used as the last stage of a process which

is running in parallel to another process or processes. A transition to the
convergence stage means that a particular process is through, and
represents a waiting point until all other parallel processes also finish.
The maximum number of convergence stages which make up one
group is 16. In other words, a maximum of 16 stages can converge into
one stage.
Convergence stages of the same group must be placed together in the
program, connected on the power rail without any other logic in
between.
Within a convergence group, the stages may occur in any order, top to
bottom. It does not matter which stage is last in the group, because all
convergence stages have to be active before the last stage has power
flow.
The last convergence stage of a group may have ladder logic within the
stage. However, this logic will not execute until all convergence stages
of the group are active.
The convergence jump (CVJMP) is the intended method to be used to
transition from the convergence group of stages to the next stage. The
CVJMP resets all convergence stages of the group, and energizes the
stage named in the jump.
The CVJMP instruction must only be used in a convergence stage, as it
is invalid in regular or initial stages.
Convergence Stages or CVJMP instructions may not be used in
subroutines or interrupt routines.

RLL PLUS Stage Programming

721

RLL PLUS (Stage) Instructions

Staget
(SG)

The Staget instructions are used to

create structured RLL PLUS programs.
Stages are program segments which can
be activated by transitional logic, a jump or
a set stage that is executed from an active
stage. Stages are deactivated one scan
after transitional logic, a jump, or a reset
stage instruction is executed.

S aaa

DL05 Range
aaa

Stage

0377

The following example is a simple RLL PLUS program. This program utilizes an initial
stage, stage, and jump instructions to create a structured program.

DirectSOFT

ISG

Handheld Programmer Keystrokes

U

S0

A
ISG

0
A

STR
X0

Y0
OUT

GX
OUT

STR
X1

S2
SET

X
SET

SHFT

F
STR

X5

K
JMP

SG
S1

1
C

STR

X2

Y1

GX
OUT

SG

OUT
$

2
G
6

STR
SG

S2

GX
OUT

2
7

STR
X6

Y2
OUT

X7

ENT
ENT
ENT
S
RST

C
2

ENT

ENT

S1
JMP

SG

ENT

S1

S0
JMP

V
AND

SHFT

K
JMP

A
0

ENT
ENT
ENT
ENT
ENT
ENT
ENT
ENT
S
RST
ENT

B
1

ENT

RLL PLUS
Stage Programming

Operand Data Type

SG

722

RLL PLUS Stage Programming

Initial Staget
(ISG)

The Initial Staget instruction is normally

used as the first segment of an RLL PLUS
program. Multiple Initial Stages are allowed
in a program. They will be active when the
CPU enters the Run mode allowing for a
starting point in the program.
Operand Data Type

ISG
S aaa

DL05 Range
aaa

RLL PLUS
Stage Programming

Stage

0377

Initial Stages are also activated by transitional logic, a jump or a set stage executed
from an active stage.
JUMP
(JMP)

The Jump instruction allows the program to

transition from an active stage containing
the jump instruction to another stage
(specified in the instruction). The jump
occurs when the input logic is true. The
active stage containing the Jump will
deactivate 1 scan later.
Operand Data Type

S aaa
JMP

DL05 Range
aaa

Stage

Not Jump
(NJMP)

0377

The Not Jump instruction allows the

program to transition from an active stage
which contains the jump instruction to
another which is specified in the instruction.
The jump will occur when the input logic is
off. The active stage that contains the Not
Jump will be deactivated 1 scan after the
Not Jump instruction is executed.
Operand Data Type

S aaa
NJMP

DL05 Range
aaa

Stage

0377

In the following example, only stage ISG0 will be active when program execution.
begins. When X1 is on, program execution will jump from Initial Stage 0 to Stage 1.

RLL PLUS Stage Programming

DirectSOFT

Handheld Programmer Keystrokes

ISG

S0

A
ISG

$
X1

SG

S1

STR

JMP

K
JMP

S1

1
1

SG

$
X2

STR

OUT

GX
OUT

S2
JMP

X7

Y5

S3
NJMP

2
5

STR

K
JMP
SHFT

C
2
N
TMR

SHFT

ENT
ENT
ENT
ENT
ENT
ENT
ENT
ENT
K
JMP

D
3

S
S
S

Converge Stage
The Converge Stage instruction is used to
(CV) and Converge group certain stages together by defining
them as Converge Stages.
Jump (CVJMP)
When all of the Converge Stages within a
group become active, the CVJMP
instruction (and any additional logic in the
final CV stage) will be executed. All
preceding CV stages must be active before
the final CV stage logic can be executed. All
Converge Stages are deactivated one scan
after the CVJMP instruction is executed.
Additional logic instructions are only
allowed following the last Converge Stage
instruction and before the CVJMP
instruction. Multiple CVJUMP instructions
are allowed.
Converge Stages must be programmed in
the main body of the application program.
This means they cannot be programmed in
Subroutines or Interrupt Routines.
Operand Data Type

DL05 Range
aaa
S

0377

CV
S aaa

S aaa
CVJMP

ENT

RLL PLUS
Stage Programming

X7

Stage

723

724

RLL PLUS Stage Programming

In the following example, when Converge Stages S10 and S11 are both active the
CVJMP instruction will be executed when X4 is on. The CVJMP will deactivate S10
and S11, and activate S20. Then, if X5 is on, the program execution will jump back to
the initial stage, S0.
DirectSOFT Display

Handheld Programmer Keystrokes

U

A
ISG

A
0

STR

RLL PLUS
Stage Programming

ISG

S0

X0

Y0
OUT

X1

S1
JMP
S10
JMP

SG

S1

X2

B
1

STR
K
JMP

K
JMP

S10

C
STR

K
JMP

B
C

X4

Y3
OUT

SHFT

S20
CVJMP

SG

S20

X5

S0
JMP

ENT

ENT
ENT
B
1

ENT
B

V
AND

D
STR

GX
OUT

3
4
C
2

A
0

ENT

ENT
ENT

ENT

ENT

C
F

0
B

SHFT

A
1

V
AND

STR
K
JMP

V
AND

ENT

SG

X3

ENT

SHFT

ENT

STR

S11

ENT

SG

SHFT

CV

S11
JMP

CV

GX
OUT

ENT

0
ENT
ENT

K
JMP
ENT

A
2

ENT

RLL PLUS Stage Programming

725

Questions and Answers about Stage Programming

We include the following commonly-asked questions about Stage Programming as
an aid to new students. All question topics are covered in more detail in this chapter.

Q. What are Stage Bits?

A. A stage bit is just a single bit in the CPUs image register, representing the
active/inactive status of the stage in real time. For example, the bit for Stage 0 is
referenced as S0. If S0 = 0, then the ladder rungs in Stage 0 are bypassed (not
executed) on each CPU scan. If S0 = 1, then the ladder rungs in Stage 0 are
executed on each CPU scan. Stage bits, when used as contacts, allow one part of
your program to monitor another part by detecting stage active/inactive status.
Q. How does a stage become active?
A. There are three ways:
S If the Stage is an initial stage (ISG), it is automatically active at powerup.
S Another stage can execute a Stage JMP instruction naming this stage,
which makes it active upon its next occurrence in the program.
S A program rung can execute a Set Stage Bit instruction (such as Set
S0).
Q. How does a stage become inactive?
A. There are three ways:
S Standard Stages (SG) are automatically inactive at powerup.
S A stage can execute a Stage JMP instruction, resetting its Stage Bit to
0.
S Any rung in the program can execute a Reset Stage Bit instruction (such
as Reset S0).
Q. What about the power flow technique of stage transitions?
A. The power flow method of connecting adjacent stages (directly above or below in
the program) actually is the same as the Stage Jump instruction executed in the
stage above, naming the stage below. Power flow transitions are more difficult to edit
in DirectSOFT, we list them separately from two preceding questions.
Q. Can I have a stage which is active for only one scan?
A. Yes, but this is not the intended use for a stage. Instead, just make a ladder rung
active for 1 scan by including a stage Jump instruction at the bottom of the rung.
Then the ladder will execute on the last scan before its stage jumps to a new one.

RLL PLUS
Stage Programming

Q. What does stage programming do that I cant do with regular RLL programs?
A. Stages allow you to identify all the states of your process before you begin
programming. This approach is more organized, because you divide up a ladder
program into sections. As stages, these program sections are active only when they
are actually needed by the process. Most processes can be organized into a
sequence of stages, connected by event-based transitions.

RLL PLUS
Stage Programming

726

RLL PLUS Stage Programming

Q. Isnt a Stage JMP just like a regular GOTO instruction used in software?
A. No, it is very different. A GOTO instruction sends the program execution
immediately to the code location named by the GOTO. A Stage JMP simply resets
the Stage Bit of the current stage, while setting the Stage Bit of the stage named in
the JMP instruction. Stage bits are 0 or 1, determining the inactive/active status of
the corresponding stages. A stage JMP has the following results:
S When the JMP is executed, the remainder of the current stages rungs
are executed, even if they reside past(under) the JMP instruction. On
the following scan, that stage is not executed, because it is inactive.
S The Stage named in the Stage JMP instruction will be executed upon its
next occurrence. If located past (under) the current stage, it will be
executed on the same scan. If located before (above) the current stage,
it will be executed on the following scan.
Q. How can I know when to use stage JMP, versus a Set Stage Bit or Reset Stage Bit?
A. These instructions are used according to the state diagram topology you have
derived:
S Use a Stage JMP instruction for a state transition... moving from one
state to another.
S Use a Set Stage Bit instruction when the current state is spawning a
new parallel state or stage sequence, or when a supervisory state is
starting a state sequence under its command.
S Use a Reset Bit instruction when the current state is the last state in a
sequence and its task is complete, or when a supervisory state is
ending a state sequence under its command.
Q. What is an initial stage, and when do I use it?
A. An initial stage (ISG) is automatically active at powerup. Afterwards, it works just
like any other stage. You can have multiple initial stages, if required. Use an initial
stage for ladder that must always be active, or as a starting point.
Q. Can I have place program ladder rungs outside of the stages, so they are always on?
A. It is possible, but its not good software design practice. Place ladder that must
always be active in an initial stage, and do not reset that stage or use a Stage JMP
instruction inside it. It can start other stage sequences at the proper time by setting
the appropriate Stage Bit(s).
Q. Can I have more than one active stage at a time?
A. Yes, and this is a normal occurrence for many programs. However, it is important
to organize your application into separate processes, each made up of stages. And a
good process design will be mostly sequential, with only one stage on at a time.
However, all the processes in the program may be active simultaneously.

PID Loop Operation

In This Chapter. . . .
DL05 PID Loop Features
Loop Setup Parameters
Loop Sample Rate and Scheduling
Ten Steps to Successful Process Control
Basic Loop Operation
PID Loop Data Configuration
PID Algorithms
Loop Tuning Procedure
PV Analog Filter
Feedforward Control
Time Proportioning Control
Cascade Control
Process Alarms
Ramp/Soak Generator
Troubleshooting Tips
Bibliography
Glossary of PID Loop Terminology

18

82
PID Loop Operation

DL05 PID Loop Features

Main Features

The DL05 process loop control offers a sophisticated set of features to address
many application needs. The main features are:
Up to 4 loops, individual programmable sample rates
Manual/ Automatic/Cascaded loop capability available
Two types of bumpless transfer available
Full-featured alarms
Ramp/soak generator with up to 16 segments
Auto Tuning

The DL05 CPU has process control loop capability in addition to ladder program
execution. You can select and configure up to four loops. All sensor and actuator
wiring connects directly to DL05 analog modules. All process variables, gain values,
alarm levels, etc., associated with each loop reside in a Loop Variable Table in the
CPU. The DL05 CPU reads process variable (PV) inputs during each scan. Then it
makes PID loop calculations during a dedicated time slice on each PLC scan,
updating the control output value. The control loops use a
Proportional-Integral-Derivative (PID) algorithm to generate the control output. This
chapter describes how the loops operate, and what you must do to configure and
tune the loops.
Analog Output
DL05
PID Loop Calculations

Manufacturing Process

Maintenance
and Troubleshooting

PID Loop Operation

S
S
S
S
S
S

Analog Input

The best tool for configuring loops in the DL05 is the DirectSOFT32 programming
software, release 3.0c, or later. DirectSOFT32 uses dialog boxes to help you set up
the individual loops. After completing the setup, you can use DirectSOFT32s PID
Trend View to tune each loop. The configuration and tuning selections you make are
stored in the DL05s FLASH memory, which is retentive. The loop parameters also
may be saved to disk for recall later.

83
PID Loop Operation

Number of loops

Selectable, 4 maximum

CPU V-memory needed

32 words (V locations) per loop selected, 64 words if using ramp/soak

PID algorithm

Position or Velocity form of the PID equation

Control Output polarity

Selectable direct-acting or reverse-acting

Error term curves

Selectable as linear, square root of error, and error squared

Loop update rate (time

between PID calculation)

0.05 to 99.99 seconds, user programmable

Minimum loop update rate

0.05 seconds for 1 to 4 loops,

Loop modes

Automatic, Manual (operator control), or Cascade control

Ramp/Soak Generator

Up to 8 ramp/soak steps (16 segments) per loop with indication of

ramp/soak step number

PV curves

Select standard linear, or square-root extract (for flow meter input)

Set Point Limits

Specify minimum and maximum setpoint values

Process Variable Limits

Specify minimum and maximum Process Variable values

Proportional Gain

Specify gains of 0.01 to 99.99

Integrator (Reset)

Specify reset time of 0.1 to 999.8 in units of seconds or minutes

Derivative (Rate)

Specify the derivative time from 0.01 to 99.99 seconds

Rate Limits

Specify derivative gain limiting from 1 to 20

Bumpless Transfer I

Automatically initialized bias and setpoint when control switches from

manual to automatic

Bumpless Transfer II

Automatically set the bias equal to the control output when control switches
from manual to automatic

Step Bias

Provides proportional bias adjustment for large setpoint changes

Anti-windup

For position form of PID, this inhibits integrator action when the control
output reaches 0% or 100 % (speeds up loop recovery when output
recovers from saturation)

Error Deadband

Specify a tolerance (plus and minus) for the error term (SPPV), so that no
change in control output value is made

Alarm Feature

Specifications

Deadband

Specify 0.1% to 5% alarm deadband on all alarms

PV Alarm Points

Select PV alarm settings for Lowlow, Low, High, and High-high conditions

PV Deviation

Specify alarms for two ranges of PV deviation from the setpoint value

Rate of Change

Detect when PV exceeds a rate of change limit you specify

Maintenance

Specifications

PID Loop Operation

PID Loop Feature

84
PID Loop Operation

The Basics of
PID Loops

The key parts of a PID control loop are shown in the block diagram below. The path
from the PLC to the Manufacturing Process and back to the PLC is the loop in
closed loop control.
External
Disturbances

Loop Configuring
and Monitoring
PLC System
Setpoint Value
+

Error Term

Loop
Calculation

Control Output

Manufacturing
Process

Maintenance
and Troubleshooting

PID Loop Operation

Process Variable

Manufacturing Process the set of actions that adds value to raw materials. The
process can involve physical changes and/or chemical changes to the material. The
changes render the material more useful for a particular purpose, ultimately used in
a final product.
Process Variable a measurement of some physical property of the raw materials.
Measurements are made using some type of sensor. For example, if the
manufacturing process uses an oven, you will most likely want to control
temperature. Temperature is a process variable.
Setpoint Value the theoretically perfect quantity of the process variable, or the
desired amount which yields the best product. The machine operator knows this
value, and either sets it manually or programs it into the PLC for later automated use.
External Disturbances the unpredictable sources of error which the control
system attempts to cancel by offsetting their effects. For example, if the fuel input is
constant an oven will run hotter during warm weather than it does during cold
weather. An oven control system must counter-act this effect to maintain a constant
oven temperature during any season. Thus, the weather (which is not very
predictable), is one source of disturbance to this process.
Error Term the algebraic difference between the process variable and the
setpoint. This is the control loop error, and is equal to zero when the process variable
is equal to the setpoint (desired) value. A well-behaved control loop is able to
maintain a small error term magnitude.
Loop Calculation the real-time application of a mathematical algorithm to the
error term, generating a control output command appropriate for minimizing the
error magnitude. Various control algorithms are available, and the DL05 uses the
Proportional-Integral-Derivative (PID) algorithm (more on this later).
Control Output the result of the loop calculation, which becomes a command for
the process (such as the heater level in an oven).
Loop Configuring operator-initiated selections which set up and optimize the
performance of a control loop. The loop calculation function uses the configuration
parameters in real time to adjust gains, offsets, etc.
Loop Monitoring the function which allows an operator to observe the status and
performance of a control loop. This is used in conjunction with the loop configuring to
optimize the performance of a loop (minimize the error term).

85
PID Loop Operation

The diagram below shows each loop element in the form of its real-world physical
component. The example manufacturing process involves a liquid in a reactor
vessel. A sensor probe measures a process variable which may be pressure,
temperature, or another parameter. The sensor signal is amplified through a
transducer, and is sent through the wire in analog form to the PLC input module.
Using a analog I/O combination module, the PLC reads the PV from its analog input.
The CPU executes the loop calculation, and writes to the analog output. This signal
goes to a device in the manufacturing process, such as a heater, valve, pump, etc.
Over time, the liquid begins to change enough to be measured on the sensor probe.
The process variable changes accordingly. The next loop calculation occurs, and
the loop cycle repeats in this manner continuously.
Loop Configuration
and Monitoring
Process Variable

Control Output

PID Loop Operation

Loop
Calculation

The personal computer shown is used to run DirectSOFT32, the PLC programming
software for DirectLOGIC programmable controllers. DirectSOFT32, release 3.0c
or later, can program the DL05 PLC (including the PID feature). The software
features a forms-based editor to configure loop parameters. It also features a PID
loop trending screen which will be helpful during the loop tuning process. Details on
how to use that software are in the DirectSOFT32 Manual.

Maintenance

Manufacturing
Process

86
PID Loop Operation

Loop Setup Parameters

Loop Table and
Number of Loops

The DL05 PLC gets its PID loop processing instructions only from tables in
V-memory. A PID instruction type in RLL does not exist for the DirectLogic PLCs.
Instead, the CPU reads setup parameters from reserved V-memory locations.
Shown in the table below, you must program a value in V7640 to point to the main
loop table. Then you will need to program V7641 with the number of loops you want
the CPU to calculate. V7642 contains error flags which will be set if V7640 or V7641
are programmed improperly.

Maintenance
and Troubleshooting

PID Loop Operation

Address

Setup Parameter

Data type

Ranges

Read/Write

V7640

Loop Parameter
Table Pointer

Octal

V1200 V7377

write

V7641

Number of Loops

BCD

04

write

V7642

Loop Error Flags

Binary

0 or 1

read

If the number of loops is 0, the loop controller task is turned off during the ladder
program scan. The loop controller will allow use of loops in ascending order,
beginning with 1. For example, you cannot use loop 1 and 4 while skipping 2 and 3.
The loop controller attempts to control the full number of loops specified in V7641.
PID Error Flags

The CPU reports any programming errors

of the setup parameters in V7640 and
V7641. It does this by setting the
appropriate
bits
in
V7642
on
program-to-run mode transitions.

PID Error Flags, V7642

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

If you use the DirectSOFT32 loop setup dialog box, its automatic range checking
prohibits possible setup errors. However, the setup parameters may be written using
other methods such as RLL, so the error flag register may be helpful in those cases.
The following table lists the errors reported in V7642.
Bit

Error Description (0 = no error, 1 = error)

The starting address (in V7640) is out of the lower V-memory range.

The starting address (in V7640) is out of the upper V-memory range.

The number of loops selected (in V7641) is greater than 4.

The loop table extends past (straddles) the boundary at V7377. Use an
address closer to V1200.

As a quick check, if the CPU is in Run mode and V7642=0000, there are no
programming errors.

87
PID Loop Operation

Establishing the
Loop Table Size
and Location

On a program -to-run mode transition, the CPU reads the loop setup parameters as
pictured below. At that moment, the CPU learns the location of the loop table and the
number of loops it configures. Then during the ladder program scan, the PID Loop
task uses the loop data to perform calculations, generate alarms, and so on. There
are some loop table parameters the CPU will read or write on every loop calculation.
CPU Tasks

VMemory Space
User Data

Ladder
Program

READ/
WRITE

LOOP
DATA
CONFIGURE/
MONITOR

PID Loop
Task
READ
(at powerup)

Setup Parameters
V7640, V7641
DirectSOFT32 Programming Software
VMemory

User Data

V2000

LOOP #1

V2037
V2040

LOOP #2

V2077

32 words
32 words

LOOP #3
32 words

PID Loop Operation

The Loop Parameter table contains data

for only as many loops as you selected in
V7641. Each loop configuration occupies
32 words (0 to 37 octal) in the loop table.
For example, suppose you have an
application with 4 loops, and you choose
V2000 as the starting location. The Loop
Parameter will occupy V2000 V2037 for
loop 1, V2040 V2077 for loop 2 and so
on. Loop 4 occupies V2140 V2177.

LOOP #4
32 words

Maintenance

NOTE: The DL05 CPUs PID algorithm requires DirectSOFT32 Version 3.0c (or later)
and firmware version 2.1 (or later).

88
PID Loop Operation

Loop Table
Word Definitions

The parameters associated with each loop are listed in the following table. The
address offset is in octal, to help you locate specific parameters in a loop table. For
example, if a table begins at V2000, then the location of the reset (integral) term is
Addr+11, or V2011. Do not use the word# (in the first column) to calculate addresses.

Maintenance
and Troubleshooting

PID Loop Operation

Word #

Address+Offset Description

Format

Addr + 0

PID Loop Mode Setting 1

bits

Addr + 1

PID Loop Mode Setting 2

bits

Addr + 2

Setpoint Value (SP)

word/binary

Addr + 3

Process Variable (PV)

word/binary

Addr + 4

Bias (Integrator) Value

word/binary

Addr + 5

Control Output Value

word/binary

Addr + 6

Loop Mode and Alarm Status

Addr + 7

Sample Rate Setting

word/BCD

Addr + 10

Gain (Proportional) Setting

word/BCD

10

Addr + 11

Reset (Integral) Time Setting

word/BCD

11

Addr + 12

Rate (Derivative) Time Setting

word/BCD

12

Addr + 13

PV Value, Low-low Alarm

word/binary

13

Addr + 14

PV Value, Low Alarm

word/binary

14

Addr + 15

PV Value, High Alarm

word/binary

15

Addr + 16

PV Value, High-high Alarm

word/binary

16

Addr + 17

PV Value, deviation alarm (YELLOW)

word/binary

17

Addr + 20

PV Value, deviation alarm (RED)

word/binary

18

Addr + 21

PV Value, rate-of-change alarm

word/binary

19

Addr + 22

PV Value, alarm hysteresis setting

word/binary

20

Addr + 23

PV Value, error deadband setting

word/binary

21

Addr + 24

PV low-pass filter constant

word/BCD

22

Addr + 25

Loop derivative gain limiting factor setting

word/BCD

23

Addr + 26

SP value lower limit setting

word/binary

24

Addr + 27

SP value upper limit setting

word/binary

25

Addr + 30

Control output value lower limit setting

word/binary

26

Addr + 31

Control output value upper limit setting

word/binary

27

Addr + 32

Remote SP Value V-Memory Address Pointer

28

Addr + 33

Ramp/Soak Setting Flag

29

Addr + 34

Ramp/Soak Programming Table Starting Address

30

Addr + 35

Ramp/Soak Programming Table Error Flags

31

Addr + 36

PV direct access, channel number

word/hex

32

Addr + 37

Control output direct access, channel number

word/hex

bits

word/hex
bit
word/hex
bits

89
PID Loop Operation

PID Mode Setting 1 The individual bit definitions of the PID Mode Setting 1 word (Addr+00) are listed in
the following table. Additional information about the use of this word is available later
Bit Descriptions
in this chapter.
(Addr + 00)
Bit

PID Mode Setting 1 Description

Read/Write

Bit=0

Bit=1

Manual Mode Loop Operation request

write

01
request

Automatic Mode Loop Operation request

write

01
request

Cascade Mode Loop Operation request

write

01
request

Bumpless Transfer select

write

Mode I

Mode II

Direct or Reverse-Acting Loop select

write

Direct

Reverse

Position / Velocity Algorithm select

write

Position

Velocity

PV Linear / Square Root Extract select

write

Linear

Sq. root

Error Term Linear / Squared select

write

Linear

Squared

Error Deadband enable

write

Disable

Enable

Derivative Gain Limit select

write

Off

On

10

Bias (Integrator) Freeze select

write

Off

On

11

Ramp/Soak Operation select

write

Off

On

12

PV Alarm Monitor select

write

Off

On

13

PV Deviation alarm select

write

Off

On

14

PV rate-of-change alarm select

write

Off

On

15

Loop mode is independent from CPU

mode when set

write

Loop with
CPU mode

Loop
Independent
of CPU mode

PID Loop Operation

Maintenance

810
PID Loop Operation

PID Mode Setting 2 The individual bit definitions of the PID Mode Setting 2 word (Addr+01) are listed in
the following table. Additional information about the use of this word is available later
Bit Descriptions
in this chapter.
(Addr + 01)

Maintenance
and Troubleshooting

PID Loop Operation

Bit

PID Mode Setting 2 Description

Read/Write

Bit=0

Bit=1

Input (PV) and Control Output Range

Unipolar/Bipolar select
(See Notes 1 and 2)

write

unipolar

bipolar

Input/Output Data Format select

(See Notes 1 and 2)

write

12 bit

15 bit

Analog Input filter

write

off

on

SP Input limit enable

write

disable

enable

Integral Gain (Reset) units select

write

seconds

minutes

Select Autotune PID algorithm

write

closed loop

open loop

Autotune selection

write

PID

PI only
(rate = 0)

Autotune start

read/write

autotune
done

force start

PID Scan Clock (internal use)

read

Input/Output Data Format 16-bit select

(See Notes 1 and 2)

write

not
16 bit

select
16 bit

10

Select separate data format for input and

output (See Notes 2, and 3)

write

same
format

separate
formats

11

Control Output Range

Unipolar/Bipolar select
(See Notes 2, and 3)

write

unipolar

bipolar

12

Output Data Format select

(See Notes 2, and 3)

write

12 bit

15 bit

13

Output data format 16-bit select

(See Notes 2, and 3)

write

not
16 bit

select
16 bit

1415

Reserved for future use

Note 1: If the value in bit 9 is 0, then the values in bits 0 and 1 are read. If the value in
bit 9 is 1, then the values in bits 0 and 1 are not read, and bit 9 defines the
data format (the range is automatically unipolar).
Note 2: If the value in bit 10 is 0, then the values in bits 0, 1, and 9 define the input and
output ranges and data formats (the values in bits 11, 12, and 13 are not
read). If the value in bit 10 is 1, then the values in bits 0, 1, and 9 define only
the input range and data format, and bits 11, 12, and 13 are read and define
the output range and data format.
Note 3: If bit 10 has a value of 1 and bit 13 has a value of 0, then bits 11 and 12 are
read and define the output range and data format. If bit 10 and bit 13 each
have a value of 1, then bits 11 and 12 are not read, and bit 13 defines the data
format, (the output range is automatically unipolar).

811
PID Loop Operation

Mode / Alarm
Monitoring Word
(Addr + 06)

The individual bit definitions of the Mode / Alarm monitoring (Addr+06) word is listed
in the following table. More details are in the PID Mode section and Alarms section.
Bit

Mode / Alarm Bit Description

Read/Write

Bit=0

Bit=1

Manual Mode Indication

read

Manual

Automatic Mode Indication

read

Auto

Cascade Mode Indication

read

Cascade

PV Input LOWLOW Alarm

read

Off

On

PV Input LOW Alarm

read

Off

On

PV Input HIGH Alarm

read

Off

On

PV Input HIGHHIGH Alarm

read

Off

On

PV Input YELLOW Deviation Alarm

read

Off

On

PV Input RED Deviation Alarm

read

Off

On

PV Input Rate-of-Change Alarm

read

Off

On

10

Alarm Value Programming Error

read

Error

11

Loop Calculation Overflow/Underflow

read

Error

12

Loop in Auto-Tune indication

read

Off

On

13

Auto-Tune error indication

read

Error

1415

Reserved for Future Use

Ramp / Soak Table The individual bit definitions of the Ramp / Soak Table Flag (Addr+33) word is listed
in the following table. Further details are given in the Ramp / Soak Operation section.
Flags
(Addr + 33)
Bit

Ramp / Soak Flag Bit Description

Read/Write

Bit=0

Bit=1

Start Ramp / Soak Profile

write

01 Start

Hold Ramp / Soak Profile

write

01 Hold

Resume Ramp / soak Profile

write

01
Resume

Jog Ramp / Soak Profile

write

01 Jog

Ramp / Soak Profile Complete

read

Complete

PV Input Ramp / Soak Deviation

read

Off

On

Ramp / Soak Profile in Hold

read

Off

On

Reserved

read

Current Step in R/S Profile

read

815

decode as byte (hex)

Bits 815 must be read as a byte to indicate the current segment number of the
Ramp/Soak generator in the profile. This byte will have the values 1, 2, 3, 4, 5, 6, 7, 8,
9, A, B, C, D, E, F, and 10, which represent segments 1 to 16 respectively. If the
byte=0, then the Ramp/Soak table is not active.

Maintenance

PID Loop Operation

812
PID Loop Operation

Ramp/Soak
Table Location
(Addr + 34)

Each loop that you configure has the option of using a built-in Ramp/Soak generator
dedicated to that loop. This feature generates SP values that follow a profile. To use
the Ramp Soak feature, you must program a separate table of 32 words with
appropriate values. A DirectSOFT32 dialog box makes this easy to do.
In the loop table, the Ramp / Soak Table Pointer at Addr+34 must point to the start of
the ramp/soak data for that loop. This may be anywhere in user memory, and does
not have to adjoin to the Loop Parameter table, as shown to the left. Each R/S table
requires 32 words, regardless of the number of segments programmed.
The ramp/soak table parameters are defined in the table below. Further details are in
the section on Ramp / Soak Operation in this chapter.

VMemory Space

Addr
Offset

Step

User Data

+ 00

+ 01

PID Loop Operation

Addr
Offset

Step

Description

Ramp End SP Value

+ 20

Ramp End SP Value

Ramp Slope

+ 21

Ramp Slope

V2000

LOOP #1

V2037

32 words

+ 02

Soak Duration

+ 22

10

Soak Duration

LOOP #2

+ 03

Soak PV Deviation

+ 23

10

Soak PV Deviation

+ 04

Ramp End SP Value

+ 24

11

Ramp End SP Value

+ 05

Ramp Slope

+ 25

11

Ramp Slope

+ 06

Soak Duration

+ 26

12

Soak Duration

+ 07

Soak PV Deviation

+ 27

12

Soak PV Deviation

+ 10

Ramp End SP Value

+ 30

13

Ramp End SP Value

+ 11

Ramp Slope

+ 31

13

Ramp Slope

+ 12

Soak Duration

+ 32

14

Soak Duration

+ 13

Soak PV Deviation

+ 33

14

Soak PV Deviation

+ 14

Ramp End SP Value

+ 34

15

Ramp End SP Value

+ 15

Ramp Slope

+ 35

15

Ramp Slope

+ 16

Soak Duration

+ 36

16

Soak Duration

+ 17

Soak PV Deviation

+ 37

16

Soak PV Deviation

32 words

Maintenance
and Troubleshooting

Description

V3000

Ramp/Soak #1
32 words

V2034 = 3000 Octal

Pointer to R/S table

Ramp/Soak Table
The individual bit definitions of the Ramp / Soak Table Programming Error Flags
Programming Error word (Addr+35) is listed in the following table. Further details are given in the PID
Loop Mode section and in the PV Alarm section later in this chapter.
Flags
(Addr + 35)
Bit

R/S Error Flag Bit Description

Read/
Write

Bit=0

Bit=1

Starting Addr out of lower V-memory range

read

Error

Starting Addr out of upper V-memory range

read

Error

read

Error

23
4
515

Reserved for Future Use

Starting Addr in System Parameter
V-memory Range
Reserved for Future Use

813
PID Loop Operation

Loop Sample Rate and Scheduling

Loop Sample Rates
Addr + 07

Read
Inputs

Service
Peripherals

PLC
Scan

Ladder
Program

Calculate
PID Loops

Internal
Diagnostics

Write
Outputs

As a starting point, determine a sample rate for your loop which will be fast enough to
avoid control instability (which is extremely important). Follow the procedure on the
next page to find a starting sample rate:

Maintenance

Choosing the Best For any particular control loop, there is no single perfect sample rate to use. A good
sample rate is a compromise that simultaneously satisfies various guidelines:
Sample Rate
S The desired sample rate is proportional to the response time of the PV
to a change in control output. Usually, a process with a large mass will
have a slow sample rate, but a small mass needs a faster sample rate.
S Faster sample rates provide a smoother control output and accurate PV
performance, but use more CPU processing time. Sample rates much
faster than necessary serve only to waste CPU processing power.
S Slower sample rates provide a rougher control output and less accurate
PV performance, but use less CPU processing time.
S A sample rate which is too slow will cause system instability, particularly
when a change in the setpoint or a disturbance occurs.

PID Loop Operation

The main tasks of the CPU fall into categories

as shown to the right. The list represents the
tasks done when the CPU is in Run Mode, on
each PLC scan. Note that PID loop
calculations occur after the ladder logic task.
Note: It is possible to keep the PID loops
running even when the ladder is not. This is
done by selecting direct access in
Addr + 36 and placing a 1 in bit 15 of Addr + 00.
The sample rate of a control loop is simply the
frequency of the PID calculation. Each
calculation generates a new control output
value. With the DL05 CPU, you can set the
sample rate of a loop from 50 mS to 99.99
seconds. Most loops do not require a fresh
PID calculation on every PLC scan. Some
loops may need to be calculated only once in
1000 scans.
You select the desired sample rate for each
loop, and the CPU automatically schedules
and executes PID calculations on the
0appropriate scans.

814
PID Loop Operation

Determining a suitable sample rate (Addr+07):

1. Operate the process open-loop (the loop does not even need to be
configured yet). Place the CPU in run mode (and the loop in Manual mode,
if you have already configured it). Manually set the control output value so
the PV is stable and in the middle of a safe range.
2. Try to choose a time when the process will have negligible external
disturbances. Then induce a sudden 10% step change in the control value.
3. Record the rise or fall time of the PV (time between 10% to 90% points).
4. Divide the recorded rise or fall time by 10. This is the initial sample rate you
can use to begin tuning your loop.

Control
Output

10% of full output range

90%
10%

PV
Sample
Rate

PID Loop Operation

Maintenance
and Troubleshooting

Rise Time

In the figure above, suppose the measured rise time response of the PV was 25
seconds. The suggested sample rate from this measurement will be 2.5 seconds.
For illustration, the sample rate time line shows ten samples within the rise time
period. These show the frequency of PID calculations as the PV changes values. Of
course, the sample rate and PID calculations are continuous during operation.
NOTE: An excessively fast sample rate will diminish the available resolution in the
PV Rate-of-Change Alarm, because the alarm rate value is specified in terms of PV
change per sample period. For example, a 50 mS sample rate means the smallest
PV rate-of-change we can detect is 20 PV counts (least significant bit counts) per
second, or 1200 LSB counts per minute.
Programming the
Sample Rate

The Loop Parameter table for each loop has a data location for the sample rate.
Referring to the figure below, location V+07 contains a BCD number from 00.05 to
99.99 (with an implied decimal point). This represents 50 mS to 99.99 seconds. This
number may be programmed using DirectSOFT32s PID Setup screen, or any other
method of writing to V-memory. It must be programmed before the loop will operate
properly.
Setpoint
+

Error Term

Loop
Calculation

Process Variable
Sample RateV+07
X X

X X BCD

Sample Rate
00.05 to 99.99 sec

Control Output

815
PID Loop Operation

PID Loop Effect

Since PID loop calculations are a task within the CPU scan activities, the use of PID
on CPU Scan Time loops will increase the average scan time. The amount of scan time increase is
proportional to the number of loops used and the sample rate of each loop.
The execution time for a single loop
calculation depends on the number of
options selected, such as alarms, error
squared, etc. The chart to the right gives
the range of times you can expect.

PID Calculation Time

Minimum

150 mS

Typical

250 mS

Maximum

350 mS

To calculate scan time increase, we also must know (or estimate) the scan time of
the ladder (without loops). A fast scan time will increase by a smaller percentage
than a slow scan time will, when adding the same PID loop calculation load in each
case. The formula for average scan time calculation is:

Avg. Scan Time with PID loop =

Scan time without loop

Sample rate of loop

PID calculation time

+ Scan time without loop

For example, suppose the estimated scan time without loop calculations is 50 mS,
and the loop sample time is 3 seconds. Now, calculate the new scan time:

3 sec.

250 mS

50 mS

50.004 mS

As the calculation shows, the addition of only one loop with a slow sample rate has a
very small effect on scan time. Next, expand the equation above to show the effect of
adding any number of loops:
n=L

Avg. Scan Time with PID loops =

Scan time without loop

Sample rate of nth loop

X PID calculation time

PID Loop Operation

50 mS

Average Scan time with PID loop =

Scan time
without loops

n=1

Loop Number Description

Sample Rate

Summation Term

Steam Flow, Inlet valve

0.25 sec

50 mS

Water bath temperature

30 sec

0.42 mS

Dye level, main tank

10 sec

1.25 mS

Steam Pressure, Autoclave

1.5 sec

8.3 mS

Now adding the summation terms, plus the original scan time value, we have:
Avg. Scan Time with PID loops =

50 mS + 0.42 mS + 1.25 mS + 8.3 mS

50 mS

50.06 mS

Maintenance

In the new equation above, you calculate the summation term (inside the brackets)
for each loop from 1 to L (last loop), and add the right-most term scan time without
loops only once at the end. Suppose you have a DL05 PLC controlling four loops.
The table below shows the data and summation term values for each loop.

816
PID Loop Operation

The DL05 CPU only does PID calculation on a particular scan for the loop(s) which
have sample time periods that are due for an update (calculation). The built-in loop
scheduler applies the following rules:
S Loops with sample rates
2 seconds are processed at the rate of as
many loops per scan as is required to maintain each loops sample rate.
Specifying loops with fast sample rates will increase the PLC scan time.
So, use this capability only if you need it!
S Loops with sample rates > 2 seconds are processed at the rate of one
or fewer loops per scan, at the minimum rate required to maintain each
loops sample rate.

Maintenance
and Troubleshooting

PID Loop Operation

The implementation of loop calculation scheduling is shown in the flow chart below.
This is a more detailed look at the contents of the Calculate PID Loops task in the
CPU scan activities flow chart. The pointers I and J correspond to the slow (> 2
sec) and fast (
2 sec) loops, respectively. The flow chart allows the J pointer to
increment from loop 1 to the last loop, if there are any fast loops specified. The I
pointer increments only once per scan, and then only when the next slow loop is due
for an update. In this way, both I and J pointers cycle from 1 to the highest loop
number used, except at different rates. Their combined activity keeps all loops
properly updated.
Loop Sample Times
2 seconds:

Loop Sample Times > 2 seconds:

Begin PID loop task

No

Loop J
Sample rate
2 sec?

No

Yes
No

Loop I
Time up?
Yes
Loop I
PID Calculation

Loop J
Time up?
Yes
Loop J
PID Calculation

No

J > total
number of loops?

Set I = I+1

I > total number

selected loops?
Yes
No

Set J = J+1

Yes

Set J = 0

End PID loop task

Set I=0

817
PID Loop Operation

Ten Steps to Successful Process Control

Modern electronic controllers such as the DL05 CPU provide sophisticated process
control features. Automated control systems can be difficult to debug, because a
given symptom can have many possible causes. We recommend a careful,
step-by-step approach to bringing new control loops online:
Step 1:
Know the Recipe

The most important knowledge is how to make your product. This knowledge is
the foundation for designing an effective control system. A good process recipe
will do the following:
S Identify all relevant Process Variables, such as temperature, pressure, or
flow rates, etc. which need precise control.
S Plot the desired Setpoint values for each process variables for the duration
of one process cycle.

Step 2:
Plan Loop
Control Strategy

This simply means choosing the method the machine will use to maintain control
over the Process Variables to follow their Setpoints. This involves many issues and
trade-offs, such as energy efficiency, equipment costs, ability to service the machine
during production, and more. You must also determine how to generate the Setpoint
value during the process, and whether a machine operator can change the SP.

Maintenance

Step 4:
After deciding the number of loops, PV variables to measure, and SP values, you
Select I/O Modules can choose the appropriate I/O modules. Refer to the figure on the next page. In
many cases, you will be able to share input or output modules, or use a analog I/O
combination module, among several control loops. The example shown sends the
PV and Control Output signals for two loops through the same set of modules.
We offer DL05 analog input modules with 4 channels per module
that accept 0 20mA or 4 20mA signals. Also, analog input and output combination
modules are now available.

PID Loop Operation

Assuming the control strategy is sound, it is still crucial to properly size the actuators
Step 3:
and properly scale the sensors.
Size and Scale
Loop Components
S Choose an actuator (heater, pump. etc.) which matches the size of the
load. An oversized actuator will have an overwhelming effect on your
process after a SP change. However, an undersized actuator will allow
the PV to lag or drift away from the SP after a SP change or process
disturbance.
S Choose a PV sensor which matches the range of interest (and control)
for our process. Decide the resolution of control you need for the PV
(such as within 2 deg. C), and make sure the sensor input value
provides the loop with at least 5 times that resolution (at LSB level).
However, an over-sensitive sensor can cause control oscillations, etc.
The DL05 provides 12bit and 15bit unipolar and bipolar data format
options, and a 16bit unipolar option. This selection affects SP, PV,
Control Output and Integrator sum.

818
PID Loop Operation

DL05 CPU
V-memory

Input
Module

Digital
Output

Channel 1

PV

Loop 1 Data
OUT
SP

Channel 1

Process 1

Channel 2

Loop 2 Data
PV
OUT
SP

Channel 2

Process 2

Channel 3

Maintenance
and Troubleshooting

PID Loop Operation

Channel 4

Step 5:
Wiring and
Installation

After selection and procurement of all loop components and I/O module(s), you can
perform the wiring and installation. Refer to the wiring guidelines in Chapter 2 of this
Manual, and to the D0OPTIONSM manual. The most common wiring errors when
installing PID loop controls are:
S Reversing the polarity of sensor or actuator wiring connections.
S Incorrect signal ground connections between loop components.

Step 6:
Loop Parameters

After wiring and installation, choose the loop setup parameters. The easiest method
for programming the loop tables is using DirectSOFT32 (3.0c or later). This software
provides PID Setup dialog boxes which simplify the task. Note: It is important to
understand the meaning of all loop parameters mentioned in this chapter before
choosing values to enter.

Step 7:
Check Open Loop
Performance

With the sensor and actuator wiring done, and loop parameters entered, we must
manually and carefully check out the new control system (use Manual Mode).
S Verify that the PV value from the sensor is correct.
S If it is safe to do so, gradually increase the control output up above 0%,
and see if the PV responds (and moves in the correct direction!).

Step 8:
Loop Tuning

If the Open Loop Test (see Loop Tuning on page 838) shows the PV reading is
correct and the control output has the proper effect on the process, you can follow
the closed loop tuning procedure (see Automatic Mode on page 839). In this step,
you tune the loop so the PV automatically follows the SP.

Step 9:
If the closed loop test shows the PV will follow small changes in the SP, consider
Run Process Cycle running an actual process cycle. You will need to have completed the programming
which will generate the desired SP in real time. In this step, you may want to run a
small test batch of product through the machine, watching the SP change according
to the recipe.
WARNING: Be sure the Emergency Stop and power-down provision is readily
accessible, in case the process goes out of control. Damage to equipment and/or
serious injury to personnel can result from loss of control of some processes.
Step 10:
Save Parameters

When the loop tests and tuning sessions are complete, be sure to save all loop setup
parameters to disk.

819
PID Loop Operation

Basic Loop Operation

Data Locations

Each PID loop is dependent on the instructions and data values in its respective loop
table. The following diagram shows an example of the loop table locations
corresponding to the main three loop variables: SP, PV, and Control Output. The
example below begins at V2000 (you can use any memory location compatible with
Loop Table requirements). The SP, PV and Control Output are located at the
addresses shown.
Setpoint V+02
+

Error
Term

Loop
Calculation

Control Output V+05

Process Variable V+03

Loop Table
XXXX

Setpoint

V2003

XXXX

Process Variable

V2005

XXXX

Control Output

The data for the SP, PV, and Control Output must interface with real-world devices.
In the figure below, the sources or destinations are shown for each loop variable. The
Control Output and Process Variable values move through the analog input/output
combination module to interface with the process itself.
A few rungs of ladder logic are required to copy data from the analog module to the
loop table, or vice versa. Refer to the analog module chapter of this manual for an
example of the required ladder logic.

Setpoint V+02
+

Control Output V+05

Operator Input
Ramp/soak generator
Ladder Program
Another loops output (cascade)

Analog
Output

Process

Process Variable V+03

Analog
Input

The Setpoint has several possible sources, as listed above. Many applications will
use two or more of the sources at different times, depending on the loop mode. In
addition, the loop control strategy and programming method also determine how the
setpoint is generated.
When using the built-in Ramp/Soak generator or when cascading a loop, the PID
controller automatically writes the setpoint data in location V+02 for you. If you want
to use a setpoint from any other source, the ladder program must write that
setpoint to the loop table location V+02.
Each of the three main loop parameters can have only one source or destination at
any given time. During the application development, it is a good idea to draw loop
schematic diagrams showing data sources, etc., to help avoid mistakes.

Maintenance

Setpoint Sources:

Loop
Calculation

PID Loop Operation

Data Sources

V2002

820
PID Loop Operation

Direct Access
to Analog I/O

The loop controller in the DL05 PLC has the ability to directly access analog input
and output values independent of the ladder logic scan. These values represent the
process variable (PV) and the control output. The Direct Access feature makes it
possible for the loop controller to perform closed-loop control while the CPU is in
Program Mode.
The loop controller can read the analog PV value in the selected data format directly
from the desired analog input module and write the control output value in the same or
a different data format to the desired analog output. The Direct Access feature, when
enabled, accesses the analog values only once per PID calculation for each
respective loop. The ladder logic, however, may simultaneously access the same
analog input data by the standard method (LD instruction) or by the pointer method
whenever the CPU is in Run Mode.
NOTE: If PID direct access is used, do not use the analog output pointer logic to send
data to the outputs.

Maintenance
and Troubleshooting

PID Loop Operation

You may optionally configure each loop to access its analog I/O (PV and control
output) by placing proper values in the associated loop table registers. The figure
below shows the loop table parameters at V+36 and V+37 and their role in direct
access to the analog values.
Setpoint V+02
+

Error

S
-

Loop
Calculation

Control Output V+05

Process Variable V+03

Loop Table
V2036

0F XX

Slot / channel number for PV

V2037

0F XX

Slot / channel number for Output

0F XX
Channel number, 1 to 4
Stands for Option Module.Slot

You may program these loop table parameters directly, or use the appropriate
DirectSOFT32 dialog box for easy configuring. For example, a value of 0F02 in
register V2036 directs the loop controller to read the PV data from channel 1 of the
analog input module. A value of 0000 in either register tells the loop controller not to
access the corresponding analog value directly. In that case, ladder logic must
transfer the value between the loop table and the analog input module.
If the PV or control output values require some math manipulation by ladder logic,
then it will not be possible to use the direct access function of the loop controller. In
this case, ladder logic will have to perform the math and transfer the data from the
analog module as required.
NOTE: The loop controller restricts the transfer of analog data to or from the module
to one method. In other words, you must designate the analog module for direct
access or ladder logic access.

821
PID Loop Operation

Loop Modes

The DL05 gives you the three standard control modes: Manual, Automatic, and
Cascade. The sources of the three basic variables SP, PV, and control output are
different for each mode. An introduction to the three control modes and their signal
sources follows.
In Manual Mode, the loop is not executing PID calculations (however, loop alarms
are still active). With regard to the loop table, the CPU stops writing values to location
V+05 for that loop. It is expected that an operator or other intelligent source is
manually controlling the output, by observing the PV and writing data to V+05 as
necessary to keep the process under control. The drawing below shows the
equivalent schematic diagram of manual mode operation.
Manual

Input from Operator

Control Output V+05

Loop
Calculation

Auto

In Automatic Mode, the loop operates normally and generates new control output
values. It calculates the PID equation and writes the result in location V+05 every
sample period of that loop. The equivalent schematic diagram is shown below.

Control Output V+05

Loop
Calculation

Auto

In Cascade Mode, the loop operates as it does in Automatic Mode, with one
important difference. The data source for the SP changes from its normal location at
V+02, using the control output value from another loop. So in Auto or Manual modes,
the loop calculation uses the data at V+02. In Cascade Mode, the loop calculation
reads the control output from another loops parameter table.

Loop
Calculation

Cascaded loop
Control Output V+05

Cascade
Setpoint
+

Normal SP V+02

Loop
Calculation

Control Output

Auto/Manual

Process Variable

As pictured below, A loop can be changed from one mode to another, but cannot go
from Manual Mode directly to Cascade, or vice versa. This mode change is
prohibited because a loop would be changing two data sources at the same time,
and could cause a loss of control.
Manual

Automatic

Cascade

Maintenance

Another loop

PID Loop Operation

Manual

Input from Operator

822
PID Loop Operation

CPU Modes and

Loop Modes

The DL05 PLC has the ability to run PID calculations while the CPU is in Program
Mode. Usually, a CPU in Program Mode has halted all operations. However, a DL05
PLC in Program Mode may or may not be running PID calculations (and providing
PID control output), depending on your configuration settings. Having the ability to
run loops independent of the ladder logic makes it feasible to make a ladder logic
change while the process is still running. This is especially beneficial for large-mass
continuous processes that are difficult or costly to interrupt.
Loops that run independent of the ladder scan must have the ability to directly
access the analog module channels for the PV and control output values. The loop
controller does have this capability, which is covered in the section on direct access
of analog I/O (located prior to this section in this chapter).
The relationship between CPU modes and loop modes is depicted in the figure
below. The vertical dashed line shows the optional relationship between the mode
changes. Bit 15 of PID Mode 1 setting word (V+00) determines the selection. If set to
zero so the loop follows the CPU mode, then placing the CPU in Program Mode will
force all loops into Manual Mode. Similarly, placing the CPU in Run mode will allow
each loop to return to the mode it was in previously (which includes Manual,
Automatic, and Cascade). With this selection you automatically affect the modes of
the loops by changing the CPU mode.

Maintenance
and Troubleshooting

PID Loop Operation

CPU Modes:
Program

Mode change

Run

Loop Mode Linking

0 = loop follows PLC mode
1 = loop is independent
of PLC mode

PID Mode 1 Setting V+00

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Loop
Modes:
Manual

Mode change

Automatic

Mode change

Cascade

If Bit 15 is set to one, then the loops will run independent of the CPU mode. It is like
having two independent processors in the CPU... one is running ladders and the
other is running the process loops.
NOTE: To make changes to any loop table parameter values, the PID loop must be
in Manual Mode and the PLC must be stopped. If you have selected (as shown
above) to operate the PID loop independent of the CPU mode, then you must take
certain steps to make it possible to make loop parameter changes. You can
temporarily make the loops follow the CPU mode by changing bit 15 to 0. Then your
programming device (such as DirectSOFT32) will be able to place the loop into
Manual Mode. After you change the loops parameter setting, just restore bit 15 to a
value of 1 to re-establish PID operation independent of the CPU.

823
PID Loop Operation

How to Change
Loop Modes

The first three bits of the PID Mode 1 word

(V+00) request the operating mode of the
corresponding loop. Note: these bits are
mode change requests, not commands
(certain conditions can prohibit a
particular mode change see next page).

PID Mode 1 Setting V+00

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Cascade
Manual
Automatic

The normal state of these mode request bits is 000. To request a mode change, you
must SET the corresponding bit to a 1, for one scan. The PID loop controller
automatically resets the bits back to 000 after it reads the mode change request.
Methods of requesting mode changes are:
S DirectSOFT32s PID View this is the easiest method. Click on one of
the radio buttons, and DirectSOFT32 sets the appropriate bit.
S HPP Use Word Status (WD ST) to monitor the contents of V+00,
which will be a 4-digit BCD/hex value. You must calculate and enter a
new value for V+00 that ORs the correct mode bit with its current value.
S Ladder program ladder logic can request any loop mode when the
PLC is in Run Mode. This will be necessary after application startup.
Go to Auto Mode
X0

B2000.1
SET

Operator panel interface the operators panel to ladder logic using

standard methods, then use the technique above to set the mode bit.
Since we can only request mode changes, the PID loop controller decides when to
permit mode changes and provides the loop mode status. It reports the current mode
on bits 0, 1, and 2 of the Loop Mode and Alarm Status word, location V+06 in the loop
table. The parallel request / monitoring functions are shown in the figure below. The
figure also shows the two possible mode-dependent SP sources, and the two
possible Control Output sources.
Manual

Cascade

Control Output
Setpoint
+

Normal Source

Error Term

Loop
Calculation

Auto/Manual

Auto/Cascade

Process Variable
Mode Select

PID Mode
Control

PID Mode 1 Setting V+00

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Loop Mode and Alarm Status V+06

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Mode Monitoring

Mode Request
Cascade

Manual
Automatic

Cascade

Manual
Automatic

Maintenance

Input from Operator

Control Output
from another loop

PID Loop Operation

Use the program shown to the right to SET

the mode bit on (do not use an out coil). On
a 01 transition of X0, the rung sets the
Auto bit = 1. The loop controller resets it.

824
PID Loop Operation

Since the modes Manual, Auto, and Cascade are the most fundamental and
important PID loop controls, you may want to hard-wire mode control switches to
an operators panel. Most applications will need only Manual and Auto selections
(Cascade is used in a few advanced applications). Remember that mode controls
are really mode request bits, and the actual loop mode is indicated elsewhere.
The following figure shows an operators panel using momentary push-buttons to
request PID mode changes. The panels mode indicators do not connect to the
switches, but interface to the corresponding data locations.

Operator Panel
Control of
PID Modes

Operators Panel

Manual
Auto

Mode Request
PID Mode 1 Setting V+00

Maintenance
and Troubleshooting

PID Loop Operation

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Cascade

Mode Monitoring

Loop Mode and Alarm Status V+06

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

PLC Modes Effect

on Loop Modes

If you have selected the option for the loops to follow the PLC mode, the PLC modes
(Program, Run) interact with the loops as a group. The following summarizes this
interaction:
S When the PLC is in Program Mode, all loops are placed in Manual Mode
and no loop calculations occur. However, note that output modules
(including analog outputs) turn off in PLC Program Mode. So, actual
manual control is not possible when the PLC is in Program Mode.
S The only time the CPU will allow a loop mode change is during PLC run
Mode operation. As such, the CPU records the modes of all 16 loops as
the desired mode of operation. If power failure and restoration occurs
during PLC Run Mode, the CPU returns all loops to their prior mode
(which could be Manual, Auto, or Cascade).
S On a Program-to-Run mode transition, the CPU forces each loop to
return to its prior mode recorded during the last PLC Run Mode.
S You can add and configure new loops only when the PLC is in Program
Mode. New loops automatically begin in Manual Mode.

Loop Mode
Override

In normal conditions the mode of a loop is determined by the request to V+00, bits 0,
1, and 2. However, some conditions exist which will prevent a requested mode
change from occurring:
S A loop that is not set independent of PLC mode cannot change modes
when the PLC is in Program mode.
S A major loop of a cascaded pair of loops cannot go from Manual to Auto
until its minor loop is in Cascade mode.
In other situations, the PID loop controller will automatically change the mode of the
loop to ensure safe operation:
S A loop which develops an error condition automatically goes to Manual.
S If the minor loop of a cascaded pair of loops leaves Cascade Mode for
any reason, its major loop automatically goes to Manual Mode.

825
PID Loop Operation

Bumpless
Transfers

In process control, the word transfer has a particular meaning. A loop transfer
occurs when we change its mode of operation, as shown below. When we change
loop modes, what we are really doing is causing a transfer of control of some loop
parameter from one source to another. For example, when a loop changes from
Manual Mode to Automatic Mode, control of the output changes from the operator to
the loop controller. When a loop changes from Automatic Mode to Cascade Mode,
control of the SP changes from its original source in Auto Mode to the output of
another loop (the major loop).

Manual
Operator
generates
loop output

Mode change

Transfer

Mode change

Automatic

Cascade

PID
calculates
loop output
SP
generated
local to loop

Transfer

SP
generated
remotely by
major loop

The bumpless transfer feature of the DL05

loop controller is available in two types:
Bumpless I, and Bumpless II. Use
DirectSOFT32s PID Setup dialog box to
select transfer type. Or, you can use bit 3
of PID Mode 1 V+00 setting as shown.

PID Mode 1 Setting V+00

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Bumpless Transfer I / II select

Transfer
Type

Transfer
Select Bit

PID Algorithm

Manual-to-Auto
Transfer Action

Auto-to-Cascade
Transfer Action

Bumpless
Transfer I

Position

Forces Bias = Control Output

Forces SP = PV

Forces Major Loop Output =

Minor Loop PV

Velocity

Forces SP = PV

Forces Major Loop Output =

Minor Loop PV

Position

Forces Bias = Control Output

none

Velocity

none

none

Maintenance

The characteristics of Bumpless I and II transfer types are listed in the chart below.
Note that their operation also depends on which PID algorithm you are using, the
position or velocity form of the PID equation. Note that you must use Bumpless
Transfer type I when using the velocity form of the PID algorithm.

Bumpless
Transfer II

PID Loop Operation

The basic problem of loop transfers is the two different sources of the loop parameter
being transferred will have different numerical values. This causes the PID
calculation to generate an undesirable step change, or bump on the control output,
thereby upsetting the loop to some degree. The bumpless transfer feature
arbitrarily forces one parameter equal to another at the moment of loop mode
change, so the transfer is smooth (no bump on the control output).

826
PID Loop Operation

PID Loop Data Configuration

Loop Parameter
Data Formats

In choosing the Process Variable range and resolution, a related choice to make is
the data format of the three main loop variables: SP, PV, and Control Output (the
Integrator sum in V+04 also uses this data format). The four data formats available
are 12 or 15 bit (right justified), signed or unsigned (MSB is sign bit in bipolar
formats). The four binary combinations of bits 0 and 1 of PID Mode 2 word V+01
choose the format. The DirectSOFT32 PID Setup dialog sets these bits
automatically when you select the data format from the menu.
Setpoint V+02
+

Loop
Calculation

Control Output V+05

Process Variable V+03

PID Mode 2 Setting V+01

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Data formats

LSB

Maintenance
and Troubleshooting

PID Loop Operation

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Select data
format using
bits 0 and 1.

00

12 bit unipolar

0 to 0FFF (0 to 4095)

01

12 bit bipolar

0 to 0FFF, 8FFF to 8001

(0 to 4095, 4095 to 1)

10

15 bit unipolar

0 to 32767

11

15 bit bipolar

0 to 7FFF, FFF to 8001

(0 to 32767, 32767 to 1)

= sign bit

The data format is a very powerful setting, because it determines the numerical
interface between the PID loop and the PV sensor, and the Control Output device.
The Setpoint must also be in the same data format. Normally, the data format is
chosen during the initial loop configuration and is not changed again.
Choosing Unipolar Choosing the data format involves deciding whether to use unipolar or bipolar
or Bipolar Format numbers. Most applications such as temperature control will use only positive
numbers, and therefore need unipolar format. Usually it is the Control Output which
determines bipolar/unipolar selection. For example, velocity control may include
control of forward and reverse directions. At a zero velocity setpoint the desired
control output is also zero. In that case, bipolar format must be used.

Unipolar

Bipolar

827
PID Loop Operation

In many batch process applications, sensors or actuators interface to DL05 analog

modules using 420 mA signals. This signal type has a built-in 20% offset, because
the zero-point is a 4 mA instead of 0 mA. However, remember the analog modules
convert the signals into data and remove the offset at the same time. For example, a
420 mA signal is often converted to 0000 0FFF hex, or 0 to 4095 decimal. In this
case, all you need to do is choose 12-bit unipolar data format, and make sure the
ladder program copies the data appropriately between the loop table and the analog
modules.
S PV Offset In the event you have a PV value with a 20% offset, convert
it to zerooffset by subtracting 20% of the top of its range, and multiply
by1.25.
S Control Output In the event the Control Output is going to a device
with 20% offset, all you need to do is have the ladder program write a
value equivalent to the offset to the integrator register (V+04), before
transitioning from Manual to Auto mode. The loop will then see this
offset as a part of the process, taking care of it for you automatically.

Setpoint (SP)
Limits

The Setpoint in loop table location V+02 represents the desired value of the process
variable. After selecting the data format for these variables, you can set limits on the
range of SP values which the loop calculation will use. Many loops have two or more
possible sources writing the Setpoint at various times, and the limits you set will help
safeguard the process from the effects of a bad SP value.
In the figure below, the SP has a selectable limit function, enabled by PID Mode 2
Setting V+01 word, bit 3. If enabled, then locations V+26 and V+27 determine the
lower and upper SP limits, respectively. The loop calculation applies this limit
internally, so it is always possible to write any value to V+02.
No
Limits

Setpoint
With
Limits

Loop
Calculation

Control
Output

Loop Table
XXXX

SP Lower Limit

V+27

XXXX

SP Upper Limit

PID Mode 2 Setting V+01

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

SP Limits enable

The loop calculation checks these SP upper and lower limits before each
calculation. This means ladder logic can change the limit settings while a process is
in progress, allowing you to keep a tighter guard band on the SP input value.

Maintenance

Process Variable (PV)

V+26

PID Loop Operation

Handling
Data Offsets

828
PID Loop Operation

Remote Setpoint
(SP) Location

You may recall there are generally several possible data sources for the SP value.
The PID loop controller has the built-in ability to select between two sources
according to the current loop mode. Refer to the figure below. A loop reads its
setpoint from table location V+02 in Auto or Manual modes. If you plan to use
Cascade Mode for the loop at any time, then you must program its loop parameter
table with a remote setpoint pointer.
The Remote SP pointer resides in location V+32 in the loop table. For loops that will
be cascaded (made a minor loop), you will need to program this location with the
address of the major loops Control Output address. Find the starting location of the
major loops parameter table and add offset +05 to it.
Loop Table
V+32

Another loop
(major loop)
Loop
Calculation

Control Output V+05

XXXX

Remote SP Pointer

Cascaded loop
(minor loop)

Cascade
Setpoint
+

Normal SP V+02

PID Loop Operation

Control Output

Auto/Manual

Maintenance
and Troubleshooting

Loop
Calculation

Process Variable

A DirectSOFT32 Loop Setup dialog box will allow you to enter the Remote SP
pointer if you know the address. Otherwise, you can enter it with a HPP or program it
through ladder logic using the LDA instruction.
The process variable input to each loop is the value the loop is ultimately trying to
Process Variable
(PV) Configuration control, to make it equal to the setpoint and follow setpoint changes as quickly as
possible. Most sensors for process variables have a primarily linear response curve.
Most temperature sensors are mostly linear across their sensing range. However,
flow sensing using an orifice plate technique gives a signal representing
(approximately) the square of the flow. Therefore, a square-root extract function is
necessary before using the signal in a linear control system (such as PID).
Some flow transducers are available which will do the square-root extract, but they
add cost to the sensor package. The PID loop PV input has a selectable square-root
extract function, pictured below. You can select between normal (linear) PV data,
and data needing a square-root extract by using PID Mode setting V+00 word, bit 6.
Setpoint
+

Loop
Calculation

Control Output

Linear PV
Process Variable

1 Squareroot PV

PID Mode 1 Setting V+00

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Linear/Square-root PV select

829
PID Loop Operation

IMPORTANT: The scaling of the SP must be adjusted if you use PV square-root

extract, because the loop drives the output so the square root of the PV is equal to
the PV input. Divide the desired SP value by the square root of the analog span, and
use the result in the V+02 location for the SP. This does reduce the resolution of the
SP, but most flow control loops do not require a lot of precision (the recipient of the
flow is integrating the errors). Use one of the following formulas for the SP according
to the data format you are using. Its a good idea to set the SP upper limit to the top of
the allowed range.
Data Format

Control Output
Configuration

SP Scaling
SP = PV input / 64

0 64

0 4095

15-bit

SP = PV input / 181.02

0 181

0 32767

The Control Output is the numerical result of the PID calculation. All of the other
parameter choices ultimately influence the value of a loops Control Output for each
calculation. Some final processing selections dedicated to the Control Output are
available, shown below. At the far right of the figure, the final output may be restricted
by lower and upper limits that you program. The values for V+30 and V+31 may be
set once using DirectSOFT32s PID Setup dialog box.
The Control Output lower and upper limits can help guard against commanding an
excessive correction to an error when a loop fault occurs (such as PV sensor signal
loss). However, do not use these limits to restrict mechanical motion that might
otherwise damage a machine (use hard-wired limit switches instead).

Control Output

Loop
Calculation

Inverted Output

With
Limits

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Loop Table
V+30

XXXX

Control Output Lower Limit

V+31

XXXX

Control Output Upper Limit

Normal / Inverted Output Select

The other available selection is the normal/inverted output selection (called

forward/reverse in DirectSOFT). Use bit 4 of the PID Mode 1 Setting V+00 word to
configure the output. Independently of unipolar or bipolar format, a normal output
goes upward on positive errors and downward on negative errors (where
Error=(SPPV)). The inverted output reverses the direction of the output change.
The
normal/inverted
output
selection
is
used
to
configure
direct-acting/reverse-acting loops. This selection is ultimately determined by the
direction of the response of the process variable to a change in the control output in a
particular direction. Refer to the PID Algorithms section for more on direct-acting and
reverse-acting loops.

Maintenance

Process Variable
PID Mode 1 Setting V+00

PID Loop Operation

PV range

12-bit

Normal Output
Setpoint

SP Range

830
PID Loop Operation

The Error term is internal to the CPUs PID loop controller, and is generated again in
each PID calculation. Although its data is not directly accessible, you can easily
calculate it by subtracting: Error = (SPPV). If the PV square-root extract is enabled,
then Error = (SP (sqrt(PV)). In any case, the size of the error and algebraic sign
determine the next change of the control output for each PID calculation.
Now we will superimpose some special effects on to the error term as described.
Refer to the diagram below. Bit 7 of the PID Mode Setting 1 V+00 word lets you select
a linear or squared error term, and bit 8 enables or disables the error deadband.

Error Term
Configuration

NOTE: When first configuring a loop, its best to use the standard error term. After
the loop is tuned, then you will be able to tell if these functions will enhance control.

Error
Setpoint
+

Error
Term

Error
squared

Error

Error with
Deadband

Loop
Calculation

Maintenance
and Troubleshooting

PID Loop Operation

Process Variable
Loop Table

PID Mode 1 Setting V+00

V+23

XXXX

Error Deadband

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Error Deadband select

Linear/Squared Error select

Error Squared When selected, the squared error function simply squares the
error term (but preserves the original algebraic sign), which is used in the
calculation. This affects the Control Output by diminishing its response to smaller
error values, but maintaining its response to larger errors. Some situations in which
the error squared term might be useful:
S Noisy PV signal using a squared error term can reduce the effect of
low-frequency electrical noise on the PV, which will make the control
system jittery. A squared error maintains the response to larger errors.
S Non-linear process some processes (such as chemical pH control)
require non-linear controllers for best results. Another application is
surge tank control, where the Control Output signal must be smooth.
Error Deadband When selected, the error deadband function takes a range of
small error values near zero, and simply substitutes zero as the value of the error. If
the error is larger than the deadband range, then the error value is used normally.
Loop parameter location V+23 must be programmed with a desired deadband
amount. Units are the same as the SP and PV units (0 to FFF in 12-bit mode, and 0 to
7FFF in 15-bit mode). The PID loop controller automatically applies the deadband
symmetrically about the zero-error point.

831
PID Loop Operation

PID Algorithms
The ProportionalIntegralDerivative (PID) algorithm is widely used in process
control. The PID method of control adapts well to electronic solutions, whether
implemented in analog or digital (CPU) components. The DL05 CPU implements the
PID equations digitally by solving the basic equations in software. I/O modules serve
only to convert electronic signals into digital form (or vise-versa).
The DL05 features two types of PID controls: position and velocity. These terms
usually refer to motion control situations, but here we use them in a different sense:
S PID Position Algorithm The control output is calculated so it responds
to the displacement (position) of the PV from the SP (error term).
S PID Velocity Algorithm The control output is calculated to represent
the rate of change (velocity) for the PV to become equal to the SP.
The majority of applications will use the position form of the PID equation. If you are
not sure of which algorithm to use, try the Position Algorithm first. Use
DirectSOFT32s PID View Setup dialog box to select the desired algorithm. Or, use
bit 5 of PID Mode 1 Setting V+00 word as shown below to select the algorithm.
Loop Calculation

Position Algorithm

Error

Velocity Algorithm

Process Variable

Control Output
1

PID Mode 1 Setting V+00

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

PID Loop Operation

Setpoint

Position / Velocity select

Position Algorithm The Position Algorithm causes the PID equation to calculate the Control Output Mn:
n

Mn = Kc * en +

Ki *

S ei + Kr * (en en1) + Mo

i=1

In the formula above, the sum of the integral terms and the initial output are
combined into the Bias term, Mx. Using the bias term, we define formulas for the
Bias and Control Output as a function of sampling time:

Mxo =Mo
Mxn =Ki * en + Mxn1
n

Mn = Ki *

S ei + Mo

i=1

Mn = Kc * en + Kr * (en en1) + Mxn.....Output for sampling time n

Maintenance

NOTE: The selection of a PID algorithm is very fundamental to control loop

operation, and is normally never changed after the initial configuration of a loop.

832
PID Loop Operation

The position algorithm variables and related variables are:

Ts = Sample rate
Kc = Proportional gain
Ki = Kc * (Ts/Ti) coefficient of integral term
Kr = Kc * (Td/Ts) coefficient of derivative term
Ti = Reset time (integral time)
Td = Rate time (derivative time)
SPn = Set Point for sampling time n (SP value)
PVn = Process variable for sampling time n (PV)
en = SPn PVn = Error term for sampling time n
M0 = Control Output for sampling time 0
Mn = Control Output for sampling time n
Analysis of these equations will be found in most good text books on process control.
At a glance, we can isolate the parts of the PID Position Algorithm which correspond
to the P, I, and D terms, and the Bias as shown below.
n

Mn = Kc * en +

Ki *

S ei + Kr * (en en1) + Mo

i=1

PID Loop Operation

Control
Output

Integral
Term

Derivative
Term

Initial
Output

Bias
Term

The initial output is the output value assumed from Manual mode control when the
loop transitioned to Auto Mode. The sum of the initial output and the integral term is
the bias term, which holds the position of the output. Accordingly, the Velocity
Algorithm discussed next does not have a bias component.
Velocity Algorithm

Maintenance
and Troubleshooting

Proportional
Term

The Velocity Algorithm form of the PID equation can be obtained by transforming
Position Algorithm formula with subtraction of the equation of (n1)th degree from
the equation of nth degree.
The velocity algorithm variables and related variables are:
Ts = Sample rate
Kc = Proportional gain
Ki = Kc * (Ts/Ti) = coefficient of integral term
Kr = Kc * (Td/Ts) = coefficient of derivative term
Ti = Reset time (integral time)
Td = Rate time (derivative time)
SPn = Set Point for sampling time n (SP value)
PVn = Process variable for sampling time n (PV)
en = SPn PVn = Error term for sampling time n
Mn = Control Output for sampling time n
The resulting equations for the Velocity Algorithm form of the PID equation are:

DMn =Mn Mn1

DMn = Kc * (en en1) + Ki * en + Kr * (en 2*en1 +en2)

833
PID Loop Operation

Direct-Acting and
Reverse-Acting
Loops

The gain of a process determines, in part, how it must be controlled. The process
shown in the diagram below has a positive gain, which we call direct-acting. This
means that when the control output increases, the process variable also eventually
increases. Of course, a true process is usually a complex transfer function that
includes time delays. Here, we are only interested in the direction of change of the
process variable in response to a control output change.
Most process loops will be direct-acting, such as a temperature loop. An increase in
the heat applied increases the PV (temperature). Accordingly, direct-acting loops
are sometimes called heating loops.
Direct-Acting Loop
Setpoint
+

Process
Loop
Calculation

Control Output

Process Variable

A reverse-acting loop is one in which the process has a negative gain, as shown
below. An increase in the control output results in a decrease in the PV. This is
commonly found in refrigeration controls, where an increase in the cooling input
causes a decrease in the PV (temperature). Accordingly, reverse-acting loops are
sometimes called cooling loops.

Setpoint
+

Process
Loop
Calculation

Control Output

Process Variable

Maintenance

It is crucial to know whether a particular loop is direct or reverse-acting!

Unless you are controlling temperature, there is no obvious answer. In a flow control
loop, a valve positioning circuit can be configured and wired reverse-acting as easily
as direct-acting. One easy way to find out is to run the loop in Manual Mode, where
you must manually generate control output values. Observe whether the PV goes up
or down in response to a step increase in the control output.
To run a loop in Auto or Cascade Mode, the control output must be correctly
programmed (refer to the previous section on Control Output Configuration). Use
normal output for direct-acting loops, and inverted output for reverse-acting
loops. To compensate for a reverse-acting loop, the PID controller must know to
invert the control output. If you have a choice, configure and wire the loop to be
direct-acting. This will make it easier to view and interpret loop data during the loop
tuning process.

PID Loop Operation

Reverse-Acting Loop

834
PID Loop Operation

P-I-D Loop Terms

You may recall the introduction of the position and velocity forms of the PID loop
equations. The equations basically show the three components of the PID
calculation. The following figure shows a schematic form of the PID calculation, in
which the control output is the sum of the proportional, integral and derivative terms.
On each calculation of the loop, each term receives the same error signal value.
Loop Calculation
P
Setpoint
+

Error Term

PID Loop Operation

Control Output

S
+

Process Variable

Maintenance
and Troubleshooting

+
+

The role of the P, I, and D terms in the control task are as follows:
S Proportional the proportional term simply responds proportionally to
the current size of the error. This loop controller calculates a
proportional term value for each PID calculation. When the error is zero,
the proportional term is also zero.
S Integral the integrator (or reset) term integrates (sums) the error
values. Starting from the first PID calculation after entering Auto Mode,
the integrator keeps a running total of the error values. For the position
form of the PID equation, when the loop reaches equilibrium and there
is no error, the running total represents the constant output required to
hold the current position of the PV.
S Derivative the derivative (or rate) term responds to change in the
current error value from the error used in the previous PID calculation.
Its job is to anticipate the probable growth of the error and generate a
contribution to the output in advance.
The P, I, and D terms work together as a team. To do that effectively, they will need
some additional instructions from us. The figure below shows the P, I, and D terms
contain programmable gain values kp, ki, and kd respectively. The values reside in
the loop table in the locations shown. The goal of the loop tuning process (covered
later) is to derive gain values that result in good overall loop performance.
NOTE: The proportional gain is also simply called gain, in PID loop terminology.
Loop Calculation

Setpoint
+

Error Term

kp

ki

+
+
+

Process Variable

Loop Table

kd

V+10

XX.XX

Proportional gain

V+11

XX.XX

Integral gain

V+12

XX.XX

Derivative gain

Control Output

835
PID Loop Operation

The P, I and D gains are 4-digit BCD

numbers with values from 0000 to 9999.
They contain an implied decimal point in
the middle, so the values are actually
00.00 to 99.99. Some gain values have
units Integral gain may be in units of
seconds or minutes, by programming the
bit shown. Derivative gain is in seconds.
V+10

XX.XX P gain

V+11

XX.XX I gain

0=sec, 1=min.

V+12

XX.XX D gain

sec.

kp

ki

+
+

S
+

kd

PID Mode 2 Setting V+01

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Units select

Using a Subset of
PID Control

P
I
D

Each of the P, I, and D gains allows a setting to eliminate that term from the PID
equation. Many applications actually work best by using a subset of PID control. The
figure below shows the various combinations of PID control offered on the DL05. We
do not recommend using any other combination of control, because most of them
are inherently unstable.

P
+
+

S
+

+
+

Maintenance

NOTE: It is very important to know how to increase and decrease the gains. The
proportional and derivative gains are as one might expect... smaller numbers
produce less gains and larger numbers produce more gain. However, the integral
term has a reciprocal gain(1/Ts), so smaller numbers produce more gain and larger
numbers produce less gain. This is very important to know during loop tuning.

PID Loop Operation

In DirectSOFT32s trend view, you can program the gain values and units in realtime
while the loop is running. This is typically done only during the loop tuning process.
Proportional Gain This is the most basic gain of the three. Values range from
0000 to 9999, but they are used internally as xx.xx. An entry of 0000 effectively
removes the proportional term from the PID equation. This accommodates
applications which need integral-only loops.
Integral Gain Values range from 0001 to 9998, but they are used internally as
xx.xx. An entry of 0000 or 9999causes the integral gain to be R, effectively
removing the integrator term from the PID equation. This accommodates
applications which need proportional-only loops. The units of integral gain may be
either seconds or minutes, as shown above.
Derivative Gain Values range from 0001 to 9999, but they are used internally as
xx.xx. An entry of 0000 allows removal of the derivative term from the PID equation
(a common practice). This accommodates applications which need proportional
and/or integral-only loops. The derivative term has an optional gain limiting feature,
discussed in the next section.

836
PID Loop Operation

The derivative term is unique in that it has an optional gain-limiting feature. This is
provided because the derivative term reacts badly to PV signal noise or other causes
of sudden PV fluctuations. The function of the gain-limiting is shown in the diagram
below. Use bit 9 of PID Mode 1 Setting V+00 word to enable the gain limit.

Derivative Gain
Limiting

Loop Calculation
Proportional

P
Setpoint
+

Error Term

+
+

Integral

Derivative

Control
Output

Process Variable
Derivative,
gain-limited

Loop Table
V+25

00XX

PID Mode 1 Setting V+00

Derivative Gain Limit

Maintenance
and Troubleshooting

PID Loop Operation

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Derivative gain limit select

The derivative gain limit in location V+25 must have a value between 0 and 20, in
BCD format. This setting is operational only when the enable bit = 1.
The gain limit can be particularly useful during loop tuning. Most loops can tolerate
only a little derivative gain without going into wild oscillations.
Bias Term

In the widely-used position form of the PID equation, an important component of the
control output value is the bias term shown below. Its location in the loop table is in
V+04. the loop controller writes a new bias term after each loop calculation.
n

Mn = Kc * en +

Ki *

S ei + Kr * (en en1) + Mo

i=1

Control
Output

Proportional
Term
V+04

XXXX

Bias term

Integral
Term

Derivative
Term

Initial
Output

Bias Term

If we cause the error (en) to go to zero for two or more sample periods, the
proportional and derivative terms cancel. The bias term is the sum of the integral
term and the initial output (Mo). It represents the steady, constant part of the control
output value, and is similar to the DC component of a complex signal waveform.
The bias term value establishes a working region for the control output. When the
error fluctuates around its zero point, the output fluctuates around the bias value.
This concept is very important, because it shows us why the integrator term must
respond more slowly to errors than either the proportional or derivative terms.

837
PID Loop Operation

Bias Freeze

The term reset windup refers to an undesirable characteristic of integrator

behavior which occurs naturally under certain conditions. Refer to the figure below.
Suppose the PV signal becomes disconnected, and the PV value goes to zero.
While this is a serious loop fault, it is made worse by reset windup. Notice the bias
(reset) term keeps integrating normally during the PV disconnect, until its upper limit
is reached. When the PV signal returns, the bias value is saturated (windup) and
takes a long time to return to normal. The loop output consequently has an extended
recovery time. Until recovery, the output level is wrong and causes further problems.

PV
0

PV loss

PV loss

Reset windup

Freeze bias enabled

Bias

Output
Recovery time

Recovery time

For most applications, the freeze bias

feature will work with the loop as
described above. You may enable the
feature using the DirectSOFT32 PID View
setup dialog, or set bit 10 of PID Mode 1
Setting word as shown to the right.

PID Mode 1 Setting V+00

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Bias freeze
select

In the feedforward method discussed later in this chapter, ladder logic writes directly
to the bias term value. However, there is no conflict with the freeze bias feature,
because bias term writes due to feedforward are relatively infrequent when in use.

Maintenance

NOTE: The bias freeze feature stops the bias term from changing when the control
output reaches the end of the data range. If you have set limits on the control output
other than the range (i.e, 04095 for a unipolar/12bit loop), the bias term still uses the
end of range for the stopping point and bias freeze will not work.

PID Loop Operation

In the second PV signal loss episode in the figure, the freeze bias feature is enabled.
It causes the bias value to freeze when the control output goes out of bounds. Much
of the reset windup is thus avoided, and the output recovery time is much less.

838
PID Loop Operation

Loop Tuning Procedure

Maintenance
and Troubleshooting

PID Loop Operation

This is perhaps the most important step in closed-loop process control. The goal of a
loop tuning procedure is to adjust the loop gains so the loop has optimal
performance in dynamic conditions. The quality of a loops performance may
generally be judged by how well the PV follows the SP after a SP step change.
Auto Tuning versus Manual Tuning you may change the PID gain values directly
(manual tuning), or you can have the PID processing engine in the CPU
automatically calculate the gains (auto tuning). Most experienced process
engineers will have a favorite method, and the DL05 will accommodate either
preference. The use of the auto tuning can eliminate much of the trial-and-error of
the manual tuning approach, especially if you do not have a lot of loop tuning
experience. However, note that performing the auto tuning procedure will get the
gains close to optimal values, but additional manual tuning changes can take the
gain values to their optimal values.
WARNING: Only authorized personnel fully familiar with all aspects of the process
should make changes that affect the loop tuning constants. Using the loop auto tune
procedures will affect the process, including inducing large changes in the control
output value. Make sure you thoroughly consider the impact of any changes to
minimize the risk of injury to personnel or damage to equipment. The auto tune in the
DL05 is not intended to perform as a replacement for your process knowledge.
Open-Loop Test

Whether you use manual or auto tuning, it is very important to verify basic
characteristics of a newly-installed process before attempting to tune it. With the
loop in Manual Mode, verify the following items for each new loop.
S Setpoint verify the source which is to generate the setpoint can do so.
You can put the PLC in Run Mode, but leave the loop in Manual Mode.
Then monitor the loop table location V+02 to see the SP value(s). The
ramp/soak generator (if you are using it) should be tested now.
S Process Variable verify the PV value is an accurate measurement,
and the PV data arriving in the loop table location V+03 is correct. If the
PV signal is very noisy, consider filtering the input either through
hardware (RC low-pass filter), or using a digital S/W filter.
S Control Output if it is safe to do so, manually change the output a
small amount (perhaps 10%) and observe its affect on the process
variable. Verify the process is direct-acting or reverse acting, and check
the setting for the control output (inverted or non-inverted). Make sure
the control output upper and lower limits are not equal to each other.
S Sample Rate while operating open-loop, this is a good time to find the
ideal sample rate (procedure give earlier in this chapter). However, if
you are going to use auto tuning, note the auto tuning procedure will
automatically calculate the sample rate in addition to the PID gains.
The discussion beginning on the following page covers the manual tuning
procedure. If want to perform only auto tuning, please skip the next section and
proceed directly to the section on auto tuning.

839
PID Loop Operation

Manual Tuning
Procedure

Now comes the exciting moment when we actually close the loop (go to Auto Mode)
for the first time. Use the following checklist before switching to Auto mode:
S Monitor the loop parameters with a loop trending instrument. We
recommend using the PID view feature of DirectSOFT.
NOTE: We recommend using the PID trend view setup menu to select the vertical
scale feature to manual, for both SP/PV area and Bias/Control Output areas. The
auto scaling feature will otherwise change the vertical scale on the process
parameters and add confusion to the loop tuning process.
S
S

Adjust the gains so the Proportional Gain = 10, Integrator Gain = 9999,
and Derivative Gain =0000. This disables the integrator and derivative
terms, and provides a little proportional gain.
Check the bias term value in the loop parameter table (V+04). If it is not
zero, then write it to zero using DirectSOFT32 or HPP, etc.

Now we can transition the loop to Auto Mode. Check the mode monitoring bits to
verify its true mode. If the loop will not stay in Auto Mode, check the troubleshooting
tips at the end of this chapter.

At this point, the SP should = PV because of the bumpless transfer

feature. Increase the SP a little, in order to develop an error value. With
only the proportional gain active and the bias term=0, we can easily
check the control output value:

PID Loop Operation

CAUTION: If the PV and Control Output values begin to oscillate, reduce the gain
values immediately. If the loop does not stabilize immediately, then transfer the loop
back to Manual Mode and manually write a safe value to the control output. During
the loop tuning procedure, always be near the Emergency Stop switch which
controls power to the loop actuator in case a shutdown is necessary.

Control Output = (SP PV) x proportional gain

If the control output value changed, the loop should be getting more
energy from the actuator, heater, or other device. Soon the PV should
move in the direction of the SP. If the PV does not change, then
increase the proportional gain until it moves slightly.
Now, add a small amount of integral gain. Remember that large
numbers are small integrator gains and small numbers are large
integrator gains! After this step, the PV should = SP, or be very close.

Until this point we have only used proportional and integrator gains. Now we can
bump the process (change the SP by 10%), and adjust the gains so the PV has an
optimal response. Refer to the figure below. Adjust the gains according to what you
see on the PID trend view. The critically- damped response shown gives the fastest
PV response without oscillating.

Maintenance

840
PID Loop Operation
S
S
S

Over-damped response the gains are too small, so gradually increase

them, concentrating on the proportional gain first.
Under-damped response the gains are too large. Reduce the integral
gain first, and then the proportional gain if necessary.
Critically-damped response this is the the optimal gain setting. You
can verify that this is the best response by increasing the proportional
gain slightly. the loop then should make one or two small oscillations.

10% of
SP range

over-damped response
critically-damped response

Maintenance
and Troubleshooting

PID Loop Operation

SP
PV

under-damped response

Now you may want to add a little derivative gain to further improve the
critically-damped response above. Note the proportional and integral gains will be
very close to their final values at this point. Adding some derivative action will allow
you to increase the proportional gain slightly without causing loop oscillations. The
derivative action tends to tame the proportional response slightly, so adjust these
gains together.
Auto Tuning
Procedure

Autotuning is initiated within DirectSOFT32. You can use autotuning to establish

initial PID parameter values (autotuning is not run continuously during operation).
Whenever a substantial change in loop dynamics occurs (mass of process, size of
actuator, etc.), you will need to repeat the tuning procedure to derive the new gains
that are required for optimal control.
WARNING: Only authorized personnel fully familiar with all aspects of the process
should make changes that affect the loop tuning constants. Using the loop auto
tuning procedures will affect the process, including inducing large changes in the
control output value. Make sure you thoroughly consider the impact of any changes
to minimize the risk of injury to personnel or damage to equipment. The auto tune in
the DL05 is not intended to perform as a replacement for your process knowledge.
The loop controller offers both closed-loop and open-loop methods. If you intend to
use the auto tune feature, we recommend you use the open-loop method first. This
will permit you to use the closed-loop method of auto tuning when the loop is
operational (Auto Mode) and cannot be shut down (Manual Mode). The following
sections describe how to use the auto tuning feature, and what occurs in open and
closed-loop auto tuning.

841
PID Loop Operation

The controls for the auto tuning function use three bits in the PID Mode 2 word V+01,
as shown below. DirectSOFT32 will manipulate these bits automatically when you
use the auto tune feature within DirectSOFT. Or, you may have ladder logic access
these bits directly for allowing control from another source such as a dedicated
operator interface. The individual control bits let you to start the auto tune procedure,
select PID or PI tuning, and select closed-loop or open-loop tuning. If you select PI
tuning, the auto tune procedure leaves the derivative gain at 0. The Loop Mode and
Alarm Status word V+06 reports the auto tune status as shown. Bit 12 will be on (1)
when during the auto tuning cycle, automatically returning to off (0) when done.
Auto Tune Function

Auto Tuning
Controls

Start Auto Tune

(0 to 1 transition)

Auto Tune
Active

0=PID tuning,
1=open PI tuning

Auto Tune
Error

0=closed loop,
1=open loop

PID Mode 2 Setting V+01

Auto Tuning
Status
Loop Mode and Alarm Status V+06

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

PLC System
Process Variable
Response

PID Loop Operation

Open-Loop Auto Tuning During an open-loop auto tuning cycle, the loop
controller operates as shown in the diagram below. Before starting this procedure,
place the loop in Manual mode and ensure the PV and control output values are in
the middle of their ranges (away from the end points).

Step Function
Open Loop
Auto Tuning

Error Term

Loop
Calculation

Control
Output

Manufacturing
Process

Process Variable

NOTE: In theory, the SP value does not matter in this case, because the loop is not
closed. However, the firmware requires that the SP value be more than 205 counts
away from the PV value before starting the auto tune cycle (205 counts or more
below the SP for forward-acting loops, or 205 counts or more above the SP for
reverse-acting loops).
When auto tuning, the loop controller induces a step change on the output and
simply observes the response of the PV. From the PV response, the auto tune
function calculates the gains and the sample time. It automatically places the results
in the corresponding registers in the loop table.

Maintenance

Setpoint Value

842
PID Loop Operation

The following timing diagram shows the events which occur in the open-loop auto
tuning cycle. The auto tune function takes control of the control output and induces a
10%-of-span step change. If the PV change which the loop controller observes is
less than 2%, then the step change on the output is increased to 20%-of-span.
Open Loop Auto Tune Cycle Wave: Step Response Method
PV
(%)
SP

Tangent

Rr = Slope

Process Wave
Base Line
LrRr
(%)

Lr
(sec.)
Time (sec)
Step Change Dm=10%

Output Value
(%)
Auto Tune Cycle

Maintenance
and Troubleshooting

PID Loop Operation

PID Cycle

PID Cycle
Auto Tune Start

Auto Tune End

* When Auto Tune starts, step change output Dm=10%

* During Auto Tune, the controller output reached the full scale positive limit.
Auto Tune stopped and the Auto Tune Error bit in the Alarm word bit turned on.
* When PV change is under 2%, output is changed at 20%.

When the loop tuning observations are complete, the loop controller computes Rr
(maximum slope in %/sec.) and Lr (dead time in sec). The auto tune function
computes the gains according to the Ziegler-Nichols equations, shown below:
PID tuning:

PI tuning:

P = 1.2 * Dm/LrRr
I = 2.0 * Lr

P = 0.9 * Dm/LrRr
I = 3.33 * Lr

D = 0.5 * Lr
Sample Rate = 0.056 * Lr

D=0
Sample Rate = 0.12 * Lr

Dm = Output step change (10% = 0.1, 20% = 0.2)

We highly recommend using DirectSOFT32 for the auto tuning interface. The
duration of each auto tuning cycle will depend on the mass of our process. A
slowly-changing PV will result in a longer auto tune cycle time. When the auto tuning
is complete, the proportional, integral, and derivative gain values are automatically
updated in loop table locations V+10, V+11, and V+12 respectively. The sample time
in V+07 is also updated automatically. You can test the validity of the values the auto
tuning procedure yields by measuring the closed-loop response of the PV to a step
change in the output. The instructions on how to do this are in the section on the
manual tuning procedure (located prior to this section on auto tuning).

843
PID Loop Operation

Closed-Loop Auto Tuning During a closed-loop auto tuning cycle, the loop
controller operates as shown in the diagram below.
PLC System
Process Variable
Response

Limit cycle wave

Closed Loop
Auto Tuning

Setpoint Value
+

Error Term

Loop
Calculation

Control
Output

Manufacturing
Process

Process Variable

PID Loop Operation

When auto tuning, the loop controller imposes a square wave on the output. Each
transition of the output occurs when the PV value crosses over (or under) the SP
value. Therefore, the frequency of the limit cycle is roughly proportional to the mass
of the process. From the PV response, the auto tune function calculates the gains
and the sample time. It automatically places the results in the corresponding
registers in the loop table.
The following timing diagram shows the events which occur in the closed-loop auto
tuning cycle. The auto tune function examines the direction of the offset of the PV
from the SP. The auto tune function then takes control of the control output and
induces a full-span step change in the opposite direction. Each time the sign of the
error (SP PV) changes, the output changes full-span in the opposite direction. This
procedes through three full cycles.
Closed Loop Auto Tune Cycle Wave: Limit Cycle Method
Xo
SP
PV

Maintenance

Process Wave

Output Value
M

To
PID Cycle

PID Cycle

Auto Tune Cycle

Auto Tune Start

Auto Tune End

Calculation of
PID parameter

*Mmax = Output Value upper limit setting Mmin = Output Value lower limit setting.
* This example is directacting. When set at reverseacting, output is inverted.

844
PID Loop Operation

When the loop tuning observations are complete, the loop controller computes To
(bump period) and Xo (amplitude of the PV). Then it uses these values to compute
Kpc (sensitive limit) and Tpc (period limit). From these values, the loop controller
auto tune function computes the PID gains and the sample rate according to the
Ziegler-Nichols equations shown below:
Kpc = 4M / ( * Xo)

Tpc = 0

M = amplitude of output
PID tuning:

PI tuning:

P = 0.45 * Kpc
I = 0.60 * Tpc

P = 0.30 *Kpc
I = 1.00 * Tpc

D = 0.10 * Tpc
Sample Rate = 0.014 * Tpc

D=0
Sample Rate = 0.03 * Tpc

Maintenance
and Troubleshooting

PID Loop Operation

Auto tuning error if the auto tune error bit (bit 13 of Loop Mode and Alarm status
word V+06) is on, please verify the PV and SP values are within 5% of full scale
difference, as required by the auto tune function. The bit will also turn on if the
closed-loop method is in use, and the output goes to the limits of the range.
NOTE: If your PV fluctuates rapidly, you probably need to use the built-in analog filter
(see page 845) or create a filter in ladder logic (see example on page 846).
Tuning
Cascaded Loops

In tuning cascaded loops, we will need to de-couple the cascade relationship and
tune the loops individually, using one of the loop tuning procedures previously
covered.
1. If you are not using auto tuning, then find the loop sample rate for the
minor loop, using the method discussed earlier in this chapter. Then set
the sample rate of the major loop slower than the minor loop by a factor
of 10. Use this as a starting point.
2. Tune the minor loop first. Leave the major loop in Manual Mode, and
you will need to generate SP changes for the minor loop manually as
described in the loop tuning procedure.
3. Verify the minor loop gives a critically-damped response to a 10% SP
change while in Auto Mode. Then we are finished tuning the minor loop.
4. In this step, you will need to get the minor loop in Cascade Mode, and
then the Major loop in Auto Mode. We will be tuning the major loop with
the minor loop treated as a series component its overall process.
Therefore, do not go back and tune the minor loop again while tuning
the major loop.
5. Tune the major loop, following the standard loop tuning procedure in
this section. The response of the major loop PV is actually the overall
response of the cascaded loops together.

845
PID Loop Operation

PV Analog Filter

The DL05 Built-in

Analog Filter

A noisy PV signal can make tuning difficult and can cause the control output to be
more extreme than necessary, as the output tries to respond to the peaks and
valleys of the PV. There are two equivalent methods of filtering the PV input to make
the loop more stable. The first method is accomplished using the DL05s built-in
filter. The second method achieves a similar result using ladder logic.
The DL05 provides a selectable first-order low-pass PV input filter which can be
particularly helpful during auto tuning, using the closed-loop method. Shown in the
figure below, we strongly recommend the use of a filter during auto tuning. You
may disable the filter after auto tuning is complete, or continue to use it if the PV input
signal is noisy.

Setpoint
+

Loop
Calculation

Control Output

Unfiltered
PV
Process Variable

Filtered
PV

Loop Table

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

PV filter
enable/disable

V+24

XXXX

FIlter constant

Bit 2 of PID Mode Setting 2 provides the enable/disable control for the low-pass PV
filter (0=disable, 1=enable). The roll-off frequency of the single-pole low-pass filter is
controlled by using register V+24 in the loop parameter table, the filter constant. The
data format of the filter constant value is BCD, with an implied decimal point 00X.X,
as follows:

The filter constant has a valid range of 000.1 to 001.0.

DirectSOFT32 converts values above the valid range to 001.0 and
values below this range to 000.1
Values close to 001.0 result in higher roll-off frequencies, while values
closer to 000.1 result in lower roll-off frequencies.

We highly recommend using DirectSOFT32 for the auto tuning interface. The
duration of each auto tuning cycle will depend on the mass of your process. A
slowly-changing PV will result in a longer auto tune cycle time.
When the auto tuning is complete, the proportional, integral, and derivative gain
values are automatically updated in loop table locations V+10, V+11, and V+12
respectively. The sample time in V+07 is also updated automatically. You can test
the validity of the values the auto tuning procedure yields by measuring the
closed-loop response of the PV to a step change in the output. The instructions on
how to do this are in the section on the manual tuning procedure.

Maintenance

S
S

PID Loop Operation

PID Mode 2 Setting V+01

846
PID Loop Operation

The algorithm which the built-in filter follows is:

yi = k (xi yi1) + yi1
yi is the current output of the filter
xi is the current input to the filter
yi1 is the previous output of the filter
k is the PV Analog Input Filter Factor
Creating an
Analog Filter in
Ladder Logic

A similar algorithm can be built in your ladder program. Your analog inputs can be
filtered effectively using either method. The following programming example
describes the ladder logic you will need. Be sure to change the example memory
locations to those that fit your application.
Filtering can induce a 1 part in 1000 error in your output because of rounding. If
your process cannot tolerate a 1 part in 1000 error, do not use filtering. Because of
the rounding error, you should not use zero or full scale as alarm points. Additionally,
the smaller the filter constant the greater the smoothing effect, but the slower the
response time. Be sure a slower response is acceptable in controlling your process.

PID Loop Operation

SP1

V2200

OUT
V1400

Load the filter constant into the accumulator. To mimick

the built-in filter, use values between 1 and 10. This is
equivalent to the 0.1 to 1.0 range of the built-in filter.
Output the constant to a convenient memory location that
is not in use.

LD
V2200

If the raw analog input (V2200 in our example) is greater

than or equal to the current PV value in the PID Loop Table
(V2003), load the raw analog input into the accumulator.

SUB
V2003

Subtract the Loop Table PV value from the raw

analog input.

LD
K2

V2003

MUL
V1400

Maintenance
and Troubleshooting

DIV
K10

V2200

V2003

The MUL and DIV instructions have the

combined effect of multiplying by a decimal
number between 0.1 and 1.0.

ADD
V2003

Add the adjusted difference (between the raw analog

input and the PV) back to the PV.

OUT
V2003

Replace the previous Loop Table PV value with the

new filtered analog value in the Loop Table.

LD
V2003

If the raw analog input is less than the current PV

value in the PID Loop Table (V2003), load the current
PV value into the accumulator.

SUB
V2200

Subtract the raw analog input the from Loop Table PV

value.

MUL
V1400
DIV
K10

The MUL and DIV instructions have the

combined effect of multiplying by a decimal
number between 0.1 and 1.0.

ADD
V2200

Add the adjusted difference (between the raw analog input

and the PV) back to the analog input value.

OUT
V2003

Replace the previous Loop Table PV value with the

new filtered analog value in the Loop Table.

END

END coil marks the end of the main program.

847
PID Loop Operation

Feedforward Control
Feedforward control is an enhancement to standard closed-loop control. It is most
useful for diminishing the effects of a quantifiable and predictable loop disturbance
or sudden change in setpoint. Use of this feature is an option available to you on the
DL05. However, its best to implement and tune a loop without feedforward, and
adding it only if better loop performance is still needed. The term feed-forward
refers to the control technique involved, shown in the diagram below. The incoming
setpoint value is fed forward around the PID equation, and summed with the output.
Feedforward path

kf
+

Setpoint
+

Loop
Calculation

Control Output

Process Variable

Loop Calculation

kp
Setpoint
+

Error Term

ki

+
+

S
+

Process Variable

V+04
XXXX Bias Term

kd

Control Output

Maintenance

Feedforward is very easy to use in the DL05 loop controller, as shown below. The
bias term has been made available to the user in a special read/write location, at PID
Parameter Table location V+04.

PID Loop Operation

In the previous section on the bias term, we said that the bias term value establishes
a working region or operating point for the control output. When the error fluctuates
around its zero point, the output fluctuates around the bias value. Now, when there
is a change in setpoint, an error is generated and the output must change to a new
operating point. This also happens if a disturbance introduces a new offset in the
loop. The loop does not really know its way to the new operating point... the
integrator (bias) must increment/decrement until the error disappears, and then the
bias has found the new operating point.
Suppose that we are able to know a sudden setpoint change is about to occur
(common in some applications). We can avoid much of the resulting error in the first
place, if we can quickly change the output to the new operating point. If we know
(from previous testing) what the operating point (bias value) will be after the setpoint
change, we can artificially change the output directly (which is feedforward). The
benefits from using feedforward are:
S The SPPV error is reduced during predictable setpoint changes or loop
offset disturbances.
S Proper use of feedforward will allow us to reduce the integrator gain.
Reducing integrator gain gives us an even more stable control system.

848
PID Loop Operation

To change the bias (operating point), ladder logic only has to write the desired value
to V+04. The PID loop calculation first reads the bias value from V+04 and modifies
the value based on the current integrator calculation. Then it writes the result back to
location V+04. This arrangement creates a sort of transparent bias term. All you
have to do to implement feed forward control is write the correct value to the bias
term at the right time (the example below shows you how).
NOTE: When writing the bias term, one must be careful to design ladder logic to
write the value only once, at the moment when the new bias operating point is to
occur. If ladder logic writes the bias value on every scan, the loops integrator is
effectively disabled.

Maintenance
and Troubleshooting

PID Loop Operation

Feedforward
Example

How do we know when to write to the bias term, and what value to write? Suppose we
have an oven temperature control loop, and we have already tuned the loop for
optimal performance. Refer to the figure below. We notice that when the operator
opens the oven door, the temperature sags a bit while the loop bias adjusts to the
heat loss. Then when the door closes, the temperature rises above the SP until the
loop adjusts again. Feedforward control can help diminish this effect.

Oven Closed
door

Open

PV

PV sags

Closed

PV excess

Bias

First, we record the amount of bias change the loop controller generates when the
door opens or closes. Then, we write a ladder program to monitor the position of an
oven door limit switch. When the door opens, our ladder program reads the current
bias value from V+04, adds the desired change amount, and writes it back to V+04.
When the door closes, we duplicate the procedure, but subtracting desired change
amount instead. The following figure shows the results.
Oven Closed
door

Open

Closed

PV
Feed-forward

Feed-forward

Bias

The step changes in the bias are the result of our two feed-forward writes to the bias
term. We can see the PV variations are greatly reduced. The same technique may
be applied for changes in setpoint.

849
PID Loop Operation

Time-Proportioning Control
The PID loop controller in the DL05 CPU generates a smooth control output signal
across a numerical range. The control output value is suitable to drive an analog
output module, which connects to the process. In the process control field, this is
called continuous control, because the output is on (at some level) continuously.
While continuous control can be smooth and robust, the cost of the loop components
(such as actuators, heater amplifiers) can be expensive. A simpler form of control is
called time-proportioning control. This method uses actuators which are either on or
off (no in-between). Loop components for on/off-based control systems are lower
cost than their continuous control counterparts.
In this section, we will show you how to convert the control output of a loop to
time-proportioning control for the applications that need it. Lets take a moment to
review how alternately turning a load on and off can control a process. The diagram
below shows a hot-air balloon following a path across some mountains. The desired
path is the setpoint. The balloon pilot turns the burner on and off alternately, which is
his control output. The large mass of air in the balloon effectively averages the effect
of the burner, converting the bursts of heat into a continuous effect: slowly changing
balloon temperature and ultimately the altitude, which is the process variable.
PID Loop Operation

period
Desired
Effect
On/Off
Control

On
Off

If we were to plot the on/off times of the burner in the hot-air balloon, we would
probably see a very similar relationship to its effect on balloon temperature and
altitude.

Maintenance

Time-proportioning control approximates continuous control by virtue of its

duty-cycle the ratio of ON time to OFF time. The following figure shows an example
of how duty cycle approximates a continuous level when it is averaged by a large
process mass.

850
PID Loop Operation

On/Off Control
Program Example
SP
+

The following ladder segment provides a time proportioned on/off control output. It
converts the continuous output in V2005 to on/off control using the output coil, Y0.
Loop
Calculation

Time
Proportioning

V2005
continuous

PV

Y0

Process

P
V

on/off

The example program uses two timers to generate On/Off control. It makes the
following assumptions, which you can alter to fit your application:
S The loop table starts at V2000, so the control output is at V2005.
S The data format of the control output is 12-bit, unipolar (0 FFF).
S The time base (one full cycle) for the On/Off waveform is 10 seconds.
We use a fast timer (0.01 sec/tick), counting to 1000 ticks (10 seconds).
S The On/Off control output is Y0.
The time proportioning program must match the resolution of the output (1 part in
1000) to the resolution of the time base of T0 (also 1 part in 1000).

PID Loop Operation

NOTE: Some processes change too fast for time proportioning control. Consider the
speed of your process when you choose this control method. Use continuous control
for processes that change too fast for time proportioning control.
T0

TMRF
T0
K1000

T0

LD
V2005

T0

T1

TA1

K0

Maintenance
and Troubleshooting

At the end of the 10 second period, T0 turns on, and

loads the control output value (binary) from the loop table
V+05 location, V2005.
Convert the number in the accumulator to BCD
format, to satisfy the MUL, DIV, and TMRF format
requirement.

BCD

DirectSOFT32

Use a fast timer (0.01 sec. resolution) for the main time
base. The K1000 provides a preset of 10 seconds. The
N.C. T0 contact makes this self-resetting. T0 is on for
one scan each 10 seconds.

MUL
K1000

Multiply the Control Output (BCD) by 1,000. This step

combined with the following DIV function converts the
range to 0 1000.

DIV
K4095

Divide the product of the previous step by 4095. This

completes the conversion of the output range from
0 4095 to 0 1000, which matches the number of
ticks in our 10 second timer range.

OUT
V1400

Output our result to V1400. This is our arbitrary location

for the second timers preset value.

TMRF
T1
V1400

The second fast timer also counts in increments of

.01 seconds, so its range is also 0 1000. This timers
output, T1, turns the output coil, Y0, off when the preset
is reached.

Y0
OUT

END

Using the N.C. T1 contact, invert the T1 timer output, so

the On/Off control output is on at the beginning of the
10-second timebase. Y0 turns off when T1 turns on. The
STRNE contact prevents Y0 from energizing during the
scan when T1 is resetting. Y0 goes to the actuator, heater,
etc. for the loop.
END coil marks the end of the main program.

851
PID Loop Operation

Cascade Control
Cascaded loops are an advanced control technique that is superior to individual loop
control in certain situations. As the name implies, cascade means that one loop is
connected to another loop. In addition to Manual (open loop) and Auto (closed loop)
Modes, the DL05 also provides Cascaded Mode.

Introduction

NOTE: Cascaded loops are an advanced process control technique. Therefore we

recommend their use only for experienced process control engineers.
When a manufacturing process is complex and contains a lag time from control input
to process variable output, even the most perfectly tuned single loop around the
process may yield slow and inaccurate control. It may be the actuator operates on
one physical property, which eventually affects the process variable, measured by a
different physical property. Identifying the intermediate variable allows us to divide
the process into two parts as shown in the following figure.
PROCESS
Control input

Process A

Intermediate
Variable

Process B

Process
Variable (PV)

Setpoint
+

Loop B
Calculation

Output B/
Setpoint A
+

Loop A
Calculation

Output A

Process A
(secondary)

External
Disturbances

Process B
(primary)

Major
Loop

Minor
Loop
PV, Process A
PV, Process B

One of the benefits to cascade control can be seen by examining its response to
external disturbances. Remember the minor loop is faster acting than the major
loop. Therefore, if a disturbance affects process A in the minor loop, the Loop A PID
calculation can correct the resulting error before the major loop sees the effect.

Maintenance

External
Disturbances

PID Loop Operation

The principle of cascaded loops is simply that we add another process loop to more
precisely control the intermediate variable! This separates the source of the control
lag into two parts, as well.
The diagram below shows a cascade control system, showing that it is simply one
loop nested inside another. The inside loop is called the minor loop, and the outside
loop is called the major loop. For overall stability, the minor loop must be the fastest
responding loop of the two. We do have to add the additional sensor to measure the
intermediate variable (PV for process A). Notice the setpoint for the minor loop is
automatically generated for us, by using the output of the major loop. Once the
cascaded control is programmed and debugged, we only need to deal with the
original setpoint and process variable at the system level. The cascaded loops
behave as one loop, but with improved performance over the previous single-loop
solution.

852
PID Loop Operation

Cascaded Loops in In the use of the term cascaded loops, we must make an important distinction. Only
the minor loop will actually be in the Cascade Mode. In normal operation, the major
the DL05 CPU
loop must be in Auto Mode. If you have more than two loops cascaded together, the
outer-most (major) loop must be in Auto Mode during normal operation, and all inner
loops in Cascade Mode.
NOTE: Technically, both major and minor loops are cascaded in strict process
control terminology. Unfortunately, we are unable to retain this convention when
controlling loop modes. Remember that all minor loops will be in Cascade Mode, and
only the outer-most (major) loop will be in Auto Mode.
You can cascade together as many loops as necessary on the DL05, and you may
have multiple groups of cascaded loops. For proper operation on cascaded loops
you must use the same data range (12/15 bit) and unipolar/bipolar settings on the
major and minor loop.
To prepare a loop for Cascade Mode operation as a minor loop, you must program its
remote Setpoint Pointer in its loop parameter table location V+32, as shown below.
The pointer must be the address of the V+05 location (control output) of the major
loop. In Cascade Mode, the minor loop will ignore the its local SP register (V+02),
and read the major loops control output as its SP instead.

Maintenance
and Troubleshooting

PID Loop Operation

Major Loop (Auto mode)

Minor Loop (Cascade Mode)

Loop Table

Loop Table

V+02

XXXX

SP

V+02

XXXX

SP

V+03

XXXX

PV

V+03

XXXX

PV

V+05

XXXX

Control Output

V+05

XXXX

Control Output

V+32

XXXX

Remote SP Pointer

When using DirectSOFT32s PID View to watch the SP value of the minor loop,
DirectSOFT32 automatically reads the major loops control output and displays it for
the minor loops SP. The minor loops normal SP location, V+02, remains
unchanged.
Now, we use the loop parameter arrangement above and draw its equivalent loop
schematic, shown below.
Major loop
Loop
Calculation

Minor Cascaded loop

Cascade

Control Output V+05

Remote
SP

Setpoint
+

Local SP
V+02

Loop
Calculation

Control
Output

Auto/Manual

Process Variable

Remember that a major loop goes to Manual Mode automatically if its minor loop is
taken out of Cascade Mode.

853
PID Loop Operation

Process Alarms
The performance of a process control loop may be generally measured by how
closely the process variable matches the setpoint. Most process control loops in
industry operate continuously, and will eventually lose control of the PV due to an
error condition. Process alarms are vital in early discovery of a loop error condition,
and can alert plant personnel to manually control a loop or take other measures until
the error condition has been repaired.
The DL05 CPU has a sophisticated set of alarm features for each loop:
S PV Absolute Value Alarms monitors the PV with respect to two lower
limit values and two upper limit values. It generates alarms whenever
the PV goes outside these programmed limits.
S PV Deviation Alarm monitors the PV value as compared to the SP. It
alarms when the difference between the PV and SP exceed the
programmed alarm value.
S PV Rate-of-change Alarm computes the rate-of-change of the PV,
and alarms if it exceeds the programmed alarm amount
S Alarm Hysteresis works in conjunction with the absolute value and
deviation alarms to eliminate alarm chatter near alarm thresholds.

Setpoint
+

Error Term

Loop
Calculation

Control Output

Maintenance

Process Variable
1
0

Alarm Generation
PV Value

1
PV Deviation

0
1

PV Rate-of-change

Enable Alarms

PID Mode 1 Setting

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Alarm Enable Bits

PID Loop Operation

The alarm thresholds are fully programmable, and each type of alarm may be
independently enabled and monitored. The following diagram shows the PV
monitoring function. Bits 12, 13, and 14 of PID Mode 1 Setting V+00 word in the loop
parameter table to enable/disable the alarms. DirectSOFT32s PID View setup
dialog screens allow easy programming, enabling, and monitoring of the alarms.
Ladder logic may monitor the alarm status by examining bits 3 through 9 of PID
Mode and alarm Status word V+06 in the loop table.

Monitor Alarms

PID Alarm Word

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Alarm Bits

Unlike the PID calculations, the alarms are always functioning any time the CPU is in
Run Mode. The loop may be in Manual, Auto, or Cascade, and the alarms will be
functioning if the enable bit(s) as listed above are set =1.

854
PID Loop Operation

PV Absolute
Value Alarms

The PV absolute value alarms are organized as two upper and two lower alarms.
The alarm status is false as long as the PV value remains in the region between the
upper and lower alarms, as shown below. The alarms nearest the safe zone are
named High Alarm and Low Alarm. If the loop loses control, the PV will cross one of
these thresholds first. Therefore, you can program the appropriate alarm threshold
values in the loop table locations shown below to the right. The data format is the
same as the PV and SP (12-bit or 15-bit). The threshold values for these alarms
should be set to give an operator an early warning if the process loses control.
Highhigh Alarm

Loop Table

High Alarm
PV
Low Alarm
Lowlow Alarm

XXXX

High-high Alarm

V+15

XXXX

High Alarm

V+14

XXXX

Low Alarm

V+13

XXXX

Low-low Alarm

If the process remains out of control for some time, the PV will eventually cross one
of the outer alarm thresholds, named High-high alarm and Low-low alarm. Their
threshold values are programmed using the loop table registers listed above. A
High-high or Low-low alarm indicates a serious condition exists, and needs the
immediate attention of the operator.

PID Loop Operation

Maintenance
and Troubleshooting

V+16

The PV Absolute Value Alarms are

reported in the four bits in the PID Mode
and Alarm Status word in the loop table, as
shown to the right. We highly recommend
using ladder logic to monitor these bits.
The bit-of-word instructions make this
easy to do. Additionally, you can monitor
PID alarms using DirectSOFT.
PV Deviation
Alarms

PID Mode and Alarm Status V+06

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

High-high Alarm
High Alarm
Low Alarm
Low-low Alarm

The PV Deviation Alarms monitor the PV deviation with respect to the SP value. The
deviation alarm has two programmable thresholds, and each threshold is applied
equally above and below the current SP value. In the figure below, the smaller
deviation alarm is called the Yellow Deviation, indicating a cautionary condition for
the loop. The larger deviation alarm is called the Red Deviation, indicating a strong
error condition for the loop. The threshold values use the loop parameter table
locations V+17 and V+20 as shown.
Red Deviation Alarm

Yellow Deviation Alarm

Red
Yellow
Green

SP
Yellow Deviation Alarm
Red Deviation Alarm

Loop Table
V+17

XXXX

Yellow Deviation Alarm

V+20

XXXX

Red Deviation Alarm

Yellow
Red

The thresholds define zones, which fluctuate with the SP value. The green zone
which surrounds the SP value represents a safe (no alarm) condition. The yellow
zones lie outside the green zone, and the red zones are beyond those.

855
PID Loop Operation

The PV Deviation Alarms are reported in

the two bits in the PID Mode and Alarm
Status word in the loop table, as shown to
the right. We highly recommend using
ladder logic to monitor these bits. The
bit-of-word instructions make this easy to
do. Additionally, you can monitor PID
alarms using DirectSOFT.

PID Mode and Alarm Status V+06

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Red Deviation
Yellow Deviation

The PV Deviation Alarm can be independently enabled and disabled from the other
PV alarms, using bit 13 of the PID Mode 1 Setting V+00 word.
Remember the alarm hysteresis feature works in conjunction with both the deviation
and absolute value alarms, and is discussed at the end of this section.

PV slope OK

Loop Table

PV slope excessive
V+21

XXXX

PV Rate-of-Change Alarm

PV
PID Mode and Alarm Status V+06

rate-of-change alarm

PID Loop Operation

PV Rate-of-Change One powerful way to get an early warning of a process fault is to monitor the
rate-of-change of the PV. Most batch processes have large masses and
Alarm
slowly-changing PV values. A relatively fast-changing PV will result from a broken
signal wire for either the PV or control output, a SP value error, or other causes. If the
operator responds to a PV Rate-of-Change Alarm quickly and effectively, the PV
absolute value will not reach the point where the material in process would be ruined.
The DL05 loop controller provides a programmable PV Rate-of-Change Alarm, as
shown below. The rate-of-change is specified in PV units change per loop sample
time. This value is programmed into the loop table location V+21.

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Sample time

Sample time

As an example, suppose the PV is temperature for our process, and we want an

alarm when the temperature changes faster than 15 degrees / minute. We must
know PV counts per degree and the loop sample rate. Then, suppose the PV value
(in V+03 location) represents 10 counts per degree, and the loop sample rate is 2
seconds. We will use the formula below to convert our engineering units to counts /
sample period:

Alarm Rate-of-Change =

15 degrees
1 minute

10 counts / degree
30 loop samples / min.

150

5 counts / sample period

30

From the calculation result, we would program the value 5 in the loop table for the
rate-of-change. The PV Rate-of-Change Alarm can be independently enabled and
disabled from the other PV alarms, using bit 14 of the PID Mode 1 Setting V+00 word.
The alarm hysteresis feature (discussed next) does not affect the Rate-of-Change
Alarm.

Maintenance

PV Rate of
Change Alarm

856
PID Loop Operation

PV Alarm
Hysteresis

The PV Absolute Value Alarm and PV Deviation Alarm are programmed using
threshold values. When the absolute value or deviation exceeds the threshold, the
alarm status becomes true. Real-world PV signals have some noise on them, which
can cause some fluctuation in the PV value in the CPU. As the PV value crosses an
alarm threshold, its fluctuations cause the alarm to be intermittent and annoy
process operators. The solution is to use the PV Alarm Hysteresis feature.
The PV Alarm Hysteresis amount is programmable from 1 to 200 (hex). When using
the PV Deviation Alarm, the programmed hysteresis amount must be less than the
programmed deviation amount. The figure below shows how the hysteresis is
applied when the PV value goes past a threshold and descends back through it.

Alarm threshold
Hysteresis
Loop Table
PV

V+22

XXXX

PV Alarm Hysteresis

Maintenance
and Troubleshooting

PID Loop Operation

Alarm 1
0

The hysteresis amount is applied after the threshold is crossed, and toward the safe
zone. In this way, the alarm activates immediately above the programmed threshold
value. It delays turning off until the PV value has returned through the threshold by
the hysteresis amount.
Alarm
Programing Error

The PV Alarm threshold values must have

certain mathematical relationships to be
valid. The requirements are listed below. If
not met, the Alarm Programming Error bit
will be set, as indicated to the right.
S
S

PID Mode and Alarm Status V+06

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

PV Absolute Alarm value requirements:

Low-low < Low < High < High-high
PV Deviation Alarm requirements:
Yellow < Red

Alarm Programming Error

857
PID Loop Operation

Ramp/Soak Generator
Introduction

Our discussion of basic loop operation noted the setpoint for a loop will be generated
in various ways, depending on the loop operating mode and programming
preferences. In the figure below, the ramp / soak generator is one of the ways the SP
may be generated. It is the responsibility of your ladder program to ensure only one
source attempts to write the SP value at V+02 at any particular time.

Setpoint Sources:
Operator Input
Ramp/soak generator
Ladder Program
Another loops output (cascade)

Setpoint V+02
+

Loop
Calculation

Control Output

Process Variable

If the SP for your process rarely changes or can tolerate step changes, you probably
will not need to use the ramp/soak generator. However, some processes require
precisely-controlled SP value changes. The ramp / soak generator can greatly
reduce the amount of programming required for these applications.
SP
Soak
Ramp
slope
Time

Ramp/soak table
Ramp/soak controls

Ramp/soak
Generator

Setpoint
+

Loop
Calculation

Process Variable

Control Output

Maintenance

Complex SP profiles can be generated by specifying a series of ramp/soak

segments. The ramp segments are specified in SP units per second time. The soak
time is also programmable in minutes.
It is instructive to view the ramp/soak generator as a dedicated function to generate
SP values, as shown below. It has two categories of inputs which determine the SP
values generated. The ramp/soak table must be programmed in advance,
containing the values that will define the ramp/soak profile. The loop reads from the
table during each PID calculation as necessary. The ramp/soak controls are bits in a
special loop table word that control the real-time start/stop functionality of the
ramp/soak generator. The ladder program can monitor the status of the ramp soak
profile (current ramp/segment number).

PID Loop Operation

The terms ramp and soak have special

meanings in the process control industry,
and refer to desired setpoint (SP) values in
temperature control applications. In the
figure to the right, the setpoint increases
during the ramp segment. It remains
steady at one value during the soak
segment.

858
PID Loop Operation

Now that we have described the general ramp/soak generator operation, we list its
specific features:
S Each loop has its own ramp/soak generator (use is optional).
S You may specify up to eight ramp/soak steps (16 segments).
S The ramp soak generator can run anytime the PLC is in Run mode. Its
operation is independent of the loop mode (Manual or Auto).
S Ramp/soak real-time controls include Start, Hold, Resume, and Jog.
S Ramp/soak monitoring includes Profile Complete, Soak Deviation (SP
minus PV), and current ramp/soak step number.
The following figure shows a SP profile consisting of ramp/soak segment pairs. The
segments are individually numbered as steps from 1 to 16. The slope of each of the
ramp may be either increasing or decreasing. The ramp/soak generator
automatically knows whether to increase or decrease the SP based on the relative
values of a ramps end points. These values come from the ramp/soak table.
16

15
13

Maintenance
and Troubleshooting

PID Loop Operation

5
3
Step
SP

1
Ramp

Ramp

Ramp

Ramp

14

Ramp

Soak

Soak

Soak

Soak

Soak

Ramp/Soak Table
The parameters which define the
ramp/soak profile for a loop are in a
ramp/soak table. Each loop may have its
own ramp/soak table, but it is optional.
Recall the Loop Parameter table consists
a 32-word block of memory for each loop,
and together they occupy one contiguous
memory area. However, the ramp/soak
table for a loop is individually located,
because it is optional for each loop. An
address pointer in location V+34 in the
loop table specifies the starting location of
the ramp/soak table.
In the example to the right, the loop
parameter tables for Loop #1 and #2
occupy contiguous 32-word blocks as
shown. Each has a pointer to its
ramp/soak table, independently located
elsewhere in user V-memory. Of course,
you may locate all the tables in one group,
as long as they do not overlap.

VMemory Space
User Data
V2000

LOOP #1

V2037
V2040

32 words

LOOP #2

V2077

32 words

V3000

Ramp/Soak #1
32 words

V3600

Ramp/Soak #2
32 words

V2034 =
3000 octal
V2074 =
3600 octal

859
PID Loop Operation

The parameters in the ramp/soak table must be user-defined. the most convenient
way is to use DirectSOFT, which features a special editor for this table. Four
parameters are required to define a ramp and soak segment pair, as pictured below.
S Ramp End Value specifies the destination SP value for the end of the
ramp. Use the same data format for this number as you use for the SP.
It may be above or below the beginning SP value, so the slope could be
up or down (we dont have to know the starting SP value for ramp #1).
S Ramp Slope specifies the SP increase in counts (units) per second. It
is a BCD number from 00.00 to 99.99 (uses implied decimal point).
S Soak Duration specifies the time for the soak segment in minutes,
ranging from 000.1 to 999.9 minutes in BCD (implied decimal point).
S Soak PV Deviation (optional) specifies an allowable PV deviation
above and below the SP value during the soak period. A PV deviation
alarm status bit is generated by the ramp/soak generator.

Ramp End
SP Value

Soak
duration

segment becomes active

Ramp/Soak Table
V+00

XXXX

Ramp End SP Value

V+01

XXXX

Ramp Slope

V+02

XXXX

Soak Duration

V+03

XXXX

Soak PV Deviation

The ramp segment becomes active when the previous soak segment ends. If the
ramp is the first segment, it becomes active when the ramp/soak generator is
started, and automatically assumes the present SP as the starting SP.
Offset

Step

+ 00

+ 01

Description

Step

Description

Ramp End SP Value

+ 20

Ramp End SP Value

Ramp Slope

+ 21

Ramp Slope

+ 02

Soak Duration

+ 22

10

Soak Duration

+ 03

Soak PV Deviation

+ 23

10

Soak PV Deviation

+ 04

Ramp End SP Value

+ 24

11

Ramp End SP Value

+ 05

Ramp Slope

+ 25

11

Ramp Slope

+ 06

Soak Duration

+ 26

12

Soak Duration

+ 07

Soak PV Deviation

+ 27

12

Soak PV Deviation

+ 10

Ramp End SP Value

+ 30

13

Ramp End SP Value

+ 11

Ramp Slope

+ 31

13

Ramp Slope

+ 12

Soak Duration

+ 32

14

Soak Duration

+ 13

Soak PV Deviation

+ 33

14

Soak PV Deviation

+ 14

Ramp End SP Value

+ 34

15

Ramp End SP Value

+ 15

Ramp Slope

+ 35

15

Ramp Slope

+ 16

Soak Duration

+ 36

16

Soak Duration

+ 17

Soak PV Deviation

+ 37

16

Soak PV Deviation

Maintenance

Offset

PID Loop Operation

SP

Slope

Soak PV
deviation

860
PID Loop Operation

Ramp/Soak
Table Flags

Many applications do not require all 16 R/S steps. Use all zeros in the table for
unused steps. The R/S generator ends the profile when it finds ramp slope=0.
The individual bit definitions of the Ramp / Soak Table Flag (Addr+33) word is listed
in the following table.
Bit

PID Loop Operation

Maintenance
and Troubleshooting

Ramp/Soak
Controls

Read/Write

Bit=0

Bit=1

Start Ramp / Soak Profile

write

01 Start

Hold Ramp / Soak Profile

write

01 Hold

Resume Ramp / soak Profile

write

01
Resume

Jog Ramp / Soak Profile

write

01 Jog

Ramp / Soak Profile Complete

read

Complete

PV Input Ramp / Soak Deviation

read

Off

On

Ramp / Soak Profile in Hold

read

Off

On

Reserved

read

Off

On

Current Step in R/S Profile

read

815

Ramp/Soak
Generator Enable

Ramp / Soak Flag Bit Description

The main enable control to permit

ramp/soak generation of the SP value is
accomplished with bit 11 in the PID Mode 1
Setting V+00 word, as shown to the right.
The other ramp/soak controls in V+33
shown in the table above will not operate
unless this bit=1 during the entire
ramp/soak process.
The four main controls for the ramp/soak
generator are in bits 0 to 3 of the
ramp/soak settings word in the loop
parameter table. DirectSOFT32 controls
these bits directly from the ramp/soak
settings dialog. However, you must use
ladder logic to control these bits during
program execution. We recommend using
the bit-of-word instructions.

decode as byte (hex)

PID Mode 1 Setting V+00

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Ramp/Soak
Generator Enable

Ramp/Soak Settings V+33

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Jog
Resume
Hold
Start

Ladder logic must set a control bit to a 1 to command the corresponding function.
When the loop controller reads the ramp/soak value, it automatically turns off the bit
for you. Therefore, a reset of the bit is not required, when the CPU is in Run Mode.
The example program rung to the right
shows how an external switch X0 can turn
on, and the PD contact uses the leading
edge to set the proper control bit to start
the ramp soak profile. This uses the Set
Bit-of-word instruction.

Start R/S Generator

X0

B2033.0
SET

861
PID Loop Operation

The normal state for the ramp/soak control bits is all zeros. Ladder logic must set
only one control bit at a time.
S Start a 0-to-1 transition will start the ramp soak profile. The CPU must
be in Run Mode, and the loop can be in Manual or Auto Mode. If the
profile is not interrupted by a Hold or Jog command, it finishes normally.
S Hold a 0-to-1 transition will stop the ramp/soak profile in its current
state, and the SP value will be frozen.
S Resume a 0-to-1 transition cause the ramp/soak generator to resume
operation if it is in the hold state. The SP values will resume from their
previous value.
S Jog a 0-to-1 transition will cause the ramp/soak generator to truncate
the current segment (step), and go to the next segment.

Ramp/Soak
Programming
Errors

The starting address for the ramp/soak

table must be a valid location. If the
address points outside the range of user
V-memory, one of the bits to the right will
turn on when the ramp/soak generator is
started.
We
recommend
using
DirectSOFT32
to
configure
the
ramp/soak table. It automatically range
checks the addresses for you.

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

R/S Profile in Hold

Soak PV Deviation
R/S Profile Complete

Ramp/Soak Settings V+33

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Current Profile Step, 2digit hex

Value = 01 to 10 hex,
or 1 to 16 decimal

Ramp/Soak Table Error V+35

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Starting Address set in

reserved system V-memory
Starting Address set out of
V-memory upper range
Starting Address set out
of V-memory lower range

Its a good idea to test your ramp/soak profile before using it to control the process.
Testing Your
Ramp/Soak Profile This is easy to do, because the ramp/soak generator will run even when the loop is in
Manual Mode. Using DirectSOFT32s PID View will be a real time-saver, because it
will draw the profile on-screen for you. Be sure to set the trending timebase slow
enough to display completed ramp-soak segment pairs in the waveform window.

Maintenance

The number of the current step is available

in the upper 8 bits of the Ramp/Soak
Settings V+33 word. The bits represent a
2-digit hex number, ranging from 1 to 10.
Ladder logic can monitor these to
synchronize other parts of the program
with the ramp/soak profile. Load this word
to the accumulator and shift right 8 bits,
and you have the step number.

Ramp/Soak Settings V+33

PID Loop Operation

Ramp/Soak Profile You can monitor the Ramp/Soak profile

status using other bits in the Ramp/Soak
Monitoring
Settings V+33 word, shown to the right.
S R/S Profile Complete =1 when the
last programmed step is done.
S Soak PV Deviation =1 when the
error (SPPV) exceeds the specified
deviation in the R/S table.
S R/S Profile in Hold =1 when the
profile was active but is now in hold.

862
PID Loop Operation

Troubleshooting Tips
Q. The loop will not go into Automatic Mode.
A. Check the following for possible causes:
S A PV alarm exists, or a PV alarm programming error exists.
S The loop is the major loop of a cascaded pair, and the minor loop is not
in Cascade Mode.

Maintenance
and Troubleshooting

PID Loop Operation

Q. The Control Output stays at zero constantly when the loop is in Automatic Mode.
A. Check the following for possible causes:
S The Control Output upper limit in loop table location V+31 is zero.
S The loop is driven into saturation, because the error never goes to zero
value and changes (algebraic) sign.
Q. The Control Output value is not zero, but it is incorrect.
A. Check the following for possible causes:
S The gain values are entered improperly. Remember, gains are entered
in the loop table in BCD, while the SP and PV are in binary. If you are
using DirectSOFT, it displays the SP, PV, Bias and Control output in
decimal (BCD), converting it to binary before updating the loop table.
Q. The Ramp/Soak Generator does not operate when I activate the Start bit.
A. Check the following for possible causes:
S The Ramp/Soak enable bit is off. Check the status of bit 11 of loop
parameter table location V+00. It must be set =1.
S The hold bit or other bits in the Ramp/Soak control are on.
S The beginning SP value and the first ramp ending SP value are the
same, so first ramp segment has no slope and consequently has no
duration. The ramp/soak generator moves quickly to the soak segment,
giving the illusion the first ramp is not working.
S The loop is in Cascade Mode, and is trying to get the SP remotely.
S The SP upper limit value in the loop table location V+27 is too low.
S Check your ladder program to verify it is not writing to the SP location
(V+02 in the loop table). A quick way to do this is to temporarily place an
end coil at the beginning of your program, then go to PLC Run Mode,
and manually start the ramp/soak generator.
Q. The PV value in the table is constant, even though the analog module receives the PV signal.
A. Your ladder program must read the analog value from the module successfully
and write it into the loop table V+03 location. Verify the analog module is generating
the value, and the ladder is working.
Q. The Derivative gain doesnt seem to have any affect on the output.
A. The derivative limit is probably enabled (see section on derivative gain limiting).

863
PID Loop Operation

PID Loop Operation

Q. The loop Setpoint appears to be changing by itself.

A. Check the following for possible causes:
S The Ramp/Soak generator is enabled, and is generating setpoints.
S If this symptom occurs on loop Manual-to-Auto Mode changes, the loop
automatically sets the SP=PV (bumpless transfer feature).
S Check your ladder program to verify it is not writing to the SP location
(V+02 in the loop table). A quick way to do this is to temporarily place an
end coil at the beginning of your program, then go to PLC Run Mode.
Q. The SP and PV values I enter with DirectSOFT32 work okay, but these values do not work
properly when the ladder program writes the data.
A. The PID View in DirectSOFT32 lets you enter SP, PV, and Bias values in decimal,
and displays them in decimal for your convenience. For example, when the data
format is 12 bit unipolar, the values range from 0 to 4095. However, the loop table
actually requires these in hex, so DirectSOFT32 converts them for you. The values
in the table range from 0 to FFF, for 12-bit unipolar format.
Q. The loop seems unstable and impossible to tune, no matter what I gains I use.
A. Check the following for possible causes:
S The loop sample time is set too long. Refer to the section near the front
of this chapter on selecting the loop update time.
S The gains are too high. Start out by reducing the derivative gain to zero.
Then reduce the integral gain, and the proportional gain if necessary.
S There is too much transfer lag in your process. This means the PV
reacts sluggishly to control output changes. There may be too much
distance between actuator and PV sensor, or the actuator may be
weak in its ability to transfer energy into the process.
S There may be a process disturbance that is over-powering the loop.
Make sure the PV is relatively steady when the SP is not changing.

Bibliography
Application Concepts of Process Control
Author: Paul W. Murrill
Publisher: Instrument Society of America
ISBN 1556170807

PID Controllers: Theory, Design, and Tuning, 2nd Edition

Author: K. Astrom and T Hagglund
Publisher: Instrument Society of America
ISBN 1556175167

Fundamentals of Temperature, Pressure, and Flow

Measurements, Third edition
Author: Robert P. Benedict
Publisher: John Wiley and Sons
ISBN 0471893838

Process / Industrial Instruments & Controls Handbook,

Fourth Edition
Author (Editor-in-Chief): Douglas M. Considine
Publisher: McGraw-Hill, Inc.
ISBN 0070124450

pH Measurement and Control, Second Edition

Author: Gregory K. McMillan
Publisher: Instrument Society of America
ISBN 1556174837

Process Control, Third Edition

Instrument Engineers Handbook
Author (Editor-in-Chief): Bela G. Liptak
Publisher: Chilton
ISBN 0801982421

Process Measurement and Analysis, Third Edition

Instrument Engineers Handbook
Author (Editor-in-Chief): Bela G. Liptak
Publisher: Chilton
ISBN 0801981972

Maintenance

Fundamentals of Process Control Theory, Second Edition

Author: Paul W. Murrill
Publisher: Instrument Society of America
ISBN 1556172974

864
PID Loop Operation

Maintenance
and Troubleshooting

PID Loop Operation

Glossary of PID Loop Terminology

Automatic Mode

An operational mode of a loop, in which it makes PID calculations and updates the
loops control output.

Bias Freeze

A method of preserving the bias value (operating point) for a control output, by inhibiting
the integrator when the output goes out-of-range. The benefit is a faster loop recovery.

Bias Term

In the position form of the PID equation, it is the sum of the integrator and the initial
control output value.

Bumpless Transfer

A method of changing the operation mode of a loop while avoiding the usual sudden
change in control output level. This consequence is avoided by artificially making the SP
and PV equal, or the bias term and control output equal at the moment of mode change.

Cascaded Loops

A cascaded loop receives its setpoint from the output of another loop. Cascaded loops
have a major/minor relationship, and work together to ultimately control one PV.

Cascade Mode

An operational mode of a loop, in which it receives its SP from another loops output.

Continuous Control

Control of a process done by delivering a smooth (analog) signal as the control output.

Direct-Acting Loop

A loop in which the PV increases in response to a control output increase. In other

words, the process has a positive gain.

Error

The difference in value between the SP and PV,

Error Deadband

An optional feature which makes the loop insensitive to errors when they are small. You
can specify the size of the deadband.

Error Squared

An optional feature which multiplies the error by itself, but retains the original algebraic
sign. It reduces the effect of small errors, while magnifying the effect of large errors.

Feedforward

A method of optimizing the control response of a loop when a change in setpoint or

disturbance offset is known and has a quantifiable effect on the bias term.

Control Output

The numerical result of a PID equation which is sent by the loop with the intention of
nulling out the current error.

Derivative Gain

A constant that determines the magnitude of the PID derivative term in response to the
current error.

Integral Gain

A constant that determines the magnitude of the PID integral term in response to the
current error.

Major Loop

In cascade control, it is the loop that generates a setpoint for the cascaded loop.

Manual Mode

An operational mode of a loop, it which the PID calculations are stopped. The operator
must manually control the loop by writing to the control output value directly.

Minor Loop

In cascade control, the minor loop is the subordinate loop that receives its SP from the
major loop.

On / Off Control

A simple method of controlling a process, through on/off application of energy into the
system. The mass of the process averages the on/off effect for a relatively smooth PV. A
simple ladder program can convert the DL05s continuous loop output to on/off control.

PID Loop

A mathematical method of closed-loop control involving the sum of three terms based
on proportional, integral, and derivative error values. The three terms have independent
gain constants, allowing one to optimize (tune) the loop for a particular physical system.

Position Algorithm

The control output is calculated so it responds to the displacement (position) of the PV

from the SP (error term)

Process

A manufacturing procedure which adds value to raw materials. Process control

particularly refers to inducing chemical changes to the material in process.

Process Variable (PV)

A quantitative measurement of a physical property of the material in process, which

affects final product quality and is important to monitor and control.

Error=SP PV

865
PID Loop Operation

PV Absolute Alarm

A programmable alarm that compares the PV value to alarm threshold values.

PV Deviation Alarm

A programmable alarm that compares the difference between the SP and PV values to
a deviation threshold value.

Ramp / Soak Profile

A set of SP values called a profile, which is generated in real time upon each loop
calculation. The profile consists of a series of ramp and soak segment pairs, greatly
simplifying the task of programming the PLC to generate such SP sequences.

Rate

Also called differentiator, the rate term responds to the changes in the error term.

Remote Setpoint

The location where a loop reads its setpoint when it is configured as the minor loop in a
cascaded loop topology.

Reset

Also called integrator, the reset term adds each sampled error to the previous,
maintaining a running total called the bias.

Reset Windup

A condition created when the loop is unable to find equilibrium, and the persistent error
causes the integrator (reset) sum to grow excessively (windup). Reset windup causes
an extra recovery delay when the original loop fault is remedied.

Reverse-Acting Loop

A loop in which the PV increases in response to a control output decrease. In other

words, the process has a negative gain.

Sampling time

The time between PID calculations. The CPU method of process control is called a
sampling controller, because it samples the SP and PV only periodically.

Setpoint (SP)

The desired value for the process variable. The setpoint (SP) is the input command to
the loop controller during closed loop operation.

Soak Deviation

The soak deviation is a measure of the difference between the SP and PV during a soak
segment of the Ramp / Soak profile, when the Ramp / Soak generator is active.

Step Response

The behavior of the process variable in response to a step change in the SP (in closed
loop operation), or a step change in the control output (in open loop operation)

Transfer

To change from one loop operational mode to another (between Manual, Auto, or
Cascade). The word transfer probably refers to the transfer of control of the control
output or the SP, depending on the particular mode change.

Velocity Algorithm

The control output is calculated to represent the rate of change (velocity) for the PV to
become equal to the SP.

Maintenance

A constant that determines the magnitude of the PID proportional term in response to
the current error.

PID Loop Operation

Proportional Gain

Maintenance and
Troubleshooting
In This Chapter. . . .

19

Hardware System Maintenance

Diagnostics
CPU Indicators
Communications Problems
I/O Point Troubleshooting
Noise Troubleshooting
Machine Startup and Program Troubleshooting

92
Maintenance and Troubleshooting

Hardware System Maintenance

Standard
Maintenance

No regular or preventative maintenance is required for this product (there are no

internal batteries); however, a routine maintenance check (about every one or two
months) of your PLC and control system is good practice, and should include the
following items:
S Air Temperature Check the air temperature in the control cabinet, so
the operating temperature range of any component is not exceeded.
S Air Filter If the control cabinet has an air filter, clean or replace it
periodically as required.
S Fuses or breakers Verify that all fuses and breakers are intact.
S Cleaning the Unit Check that all air vents are clear. If the exterior
case needs cleaning, disconnect the input power, and carefully wipe the
case using a damp cloth. Do not let water enter the case through the air
vents and do not use strong detergents because this may discolor the
case.

Maintenance
and Troubleshooting

Diagnostics
Diagnostics

Your DL05 Micro PLC performs many pre-defined diagnostic routines with every
CPU scan. The diagnostics can detect various errors or failures in the PLC. The two
primary error classes are fatal and non-fatal.

Fatal Errors

Fatal errors are errors which may cause the system to function improperly, perhaps
introducing a safety problem. The CPU will automatically switch to Program Mode if
it is in Run Mode. (Remember, in Program Mode all outputs are turned off.) If the fatal
error is detected while the CPU is in Program Mode, the CPU will not allow you to
transition to Run Mode until the error has been corrected.
Some examples of fatal errors are:
S Power supply failure
S Parity error or CPU malfunction
S Particular programming errors

Non-fatal Errors

Non-fatal errors are errors that need your attention, but should not cause improper
operation. They do not cause or prevent any mode transitions of the CPU. The
application program can use special relay contacts to detect non-fatal errors, and
even take the system to an orderly shutdown or switch the CPU to Program Mode if
desired. An example of a non-fatal error is:
S Particular programming errors

Finding Diagnostic The programming devices will notify you of an error if one occurs while online.
Information
S DirectSOFT provides the error number and an error message.
S The handheld programmer displays error numbers and short
descriptions of the error.
Appendix B has a complete list of error messages in order by error number.
Many error messages point to supplemental V-memory locations which contain
related information. Special relays (SP contacts) also provide error indications.

93
Maintenance and Troubleshooting

V-memory Error
Code Locations

The following table names the specific memory locations that correspond to certain
types of error messages.
Error Class

Error Category

Diagnostic
V-memory

User-Defined

Error code used with FAULT instruction

V7751

System Error

Fatal Error code

V7755

Major Error code

V7756

Minor Error code

V7757

Address where syntax error occurs

V7763

Grammatical

Error Code found during syntax check V7764

CPU Scan

Number of scans since last Program

to Run Mode transition

V7765

Current scan time (ms)

V7775

Minimum scan time (ms)

V7776

Maximum scan time (ms)

V7777

Special Relays (SP) The special relay table also includes status indicators which can indicate errors. For
Corresponding to a more detailed description of each of these special relays refer to Appendix D.
Error Codes
SP52

Syntax error

SP11

Forced Run mode

SP53

Cannot solve the logic

SP12

Terminal Run mode

SP54

Communication error

SP13

Test Run mode

SP56

Table instruction overrun

SP15

Test stop mode

SP16

Terminal Program mode

SP17

Forced stop

SP20

STOP instruction was executed

SP22

Interrupt enabled

System Monitoring Relays

Accumulator Status Relays

SP60

Acc. is less than value

SP61

Acc. is equal to value

SP62

Acc. is greater than value

SP63

Acc. result is zero

SP64

Half borrow occurred

SP65

Borrow occurred

SP36

Override setup

SP37

Scan control error

SP40

Critical error

SP66

Half carry occurred

SP41

Non-critical error

SP67

Carry occurred

SP42

Diagnostics error

SP70

Result is negative (sign)

SP44

Program memory error

SP71

Pointer reference error

SP45

I/O error

SP73

Overflow

SP46

Communications error

SP75

Data is not in BCD

SP50

Fault instruction was executed

SP76

Load zero

SP51

Watchdog timeout

Maintenance
and Troubleshooting

CPU Status Relays

94
Maintenance and Troubleshooting

Maintenance
and Troubleshooting

DL05 Micro PLC

Error Codes

These errors can be generated by the CPU or by the Handheld Programmer,

depending on the actual error. Appendix B provides a more complete description of
the error codes.
The errors can be detected at various times. However, most of them are detected at
power-up, on entry to Run Mode, or when a Handheld Programmer key sequence
results in an error or an illegal request.

Error
Code

Description

Error
Code

Description

E003

Software time-out

E525

Mode Switch not in Term position

E004

Invalid instruction
(RAM parity error in the CPU)

E526

Unit is offline

E527

Unit is online

E104

Write failed

E528

CPU mode

E151

Invalid command

E540

CPU locked

E311

Communications error 1

E541

Wrong password

E312

Communications error 2

E542

Password reset

E313

Communications error 3

E601

Memory full

E316

Communications error 6

E602

Instruction missing

E320

Time out

E604

Reference missing

E321

Communications error

E620

Out of memory

E360

HP Peripheral port time-out

E621

EEPROM Memory not blank

E501

Bad entry

E622

No Handheld Programmer EEPROM

E502

Bad address

E624

V memory only

E503

Bad command

E625

Program only

E504

Bad reference / value

E627

Bad write operation

E505

Invalid instruction

E628

Memory type error (should be EEPROM)

E506

Invalid operation

E640

Mis-compare

E520

Bad operation CPU in Run

E650

Handheld Programmer system error

E521

Bad operation CPU in Test Run

E651

Handheld Programmer ROM error

E523

Bad operation CPU in Test Program

E652

Handheld Programmer RAM error

E524

Bad operation CPU in Program

95
Maintenance and Troubleshooting

Program Error
Codes

The following table lists program syntax and runtime error codes. Error detection
occurs during a Program-to-Run mode transition, or when you use AUX 21 Check
Program. The CPU will also turn on SP52 and store the error code in V7755.
Appendix B provides a more complete description of the error codes.

Error Code

Description

Error Code

Description

E4**

No Program in CPU

E438

Invalid IRT address

E401

Missing END statement

E440

Invalid Data Address

E402

Missing LBL

E441

ACON/NCON

E403

HP Peripheral port time-out

E451

Bad MLS/MLR

E404

HP Peripheral port time-out

E453

Missing T/C

E405

HP Peripheral port time-out

E454

Bad TMRA

E406

Missing IRT

E455

Bad CNT

E412

SBR / LBL >64

E456

Bad SR

E421

Duplicate stage reference

E461

Stack Overflow

E422

Duplicate SBR/LBL reference

E462

Stack Underflow

E423

HP Peripheral port time-out

E463

Logic Error

E431

Invalid ISG/SG address

E464

Missing Circuit

E433

Invalid ISG / SG address

E471

Duplicate coil reference

E434

Invalid RTC

E472

Duplicate TMR reference

E435

Invalid RT

E473

Duplicate CNT reference

E436

Invalid INT address

E499

Print instruction

E437

Invalid IRTC

Maintenance
and Troubleshooting

96
Maintenance and Troubleshooting

CPU Indicators
The DL05 Micro PLCs have indicators on the front
to help you determine potential problems with the
system. In normal runtime operation only, the RUN
and PWR indicators are on. The table below is a
quick reference to potential problems.
Indicator Status Potential Problems
PWR (LED off)
1. System voltage incorrect
2. PLC power supply faulty
RUN (LED off)
1. CPU programming error
2. (CPU in program mode)
CPU (LED on)
1. Electrical noise interference
2. Internal CPU defective

PWR Indicator

In general there are three reasons for the CPU power status LED (PWR) to be OFF:
1. Power to the unit is incorrect or is not applied.
2. PLC power supply is faulty.
3. Other component(s) have the power supply shut down.

Maintenance
and Troubleshooting

If the voltage to the power supply is not correct, the PLC may not operate properly or
may not operate at all. Use the following guidelines to correct the problem.
WARNING: To minimize the risk of electrical shock, always disconnect the system
power before inspecting the physical wiring.
1. First, disconnect the external power.
2. Verify that all external circuit breakers or fuses are still intact.
3. Check all incoming wiring for loose connections. If youre using a separate
termination block, check those connections for accuracy and integrity.
4. If the connections are acceptable, reconnect the system power and verify
the voltage at the DL05 power input is within specification. If the voltage is
not correct shut down the system and correct the problem.
5. If all wiring is connected correctly and the incoming power is within the
specifications, the PLC internal supply may be faulty.
The best way to check for a faulty PLC is to substitute a known good one to see if this
corrects the problem. The removable connectors on the DL05 make this relatively
easy. If there has been a major power surge, it is possible the PLC internal power
supply has been damaged. If you suspect this is the cause of the power supply
damage, consider installing an AC line conditioner to attenuate damaging voltage
spikes in the future.

97
Maintenance and Troubleshooting

RUN Indicator

If the CPU will not enter the Run mode (the RUN indicator is off), the problem is
usually in the application program, unless the CPU has a fatal error. If a fatal error
has occurred, the CPU LED should be on. (You can use a programming device to
determine the cause of the error.)
Both of the programming devices, Handheld Programmer and DirectSOFT, will
return an error message describing the problem. Depending on the error, there may
also be an AUX function you can use to help diagnose the problem. The most
common programming error is Missing END Statement. All application programs
require an END statement for proper termination. A complete list of error codes can
be found in Appendix B.

CPU Indicator

If the CPU indicator is on, a fatal error has occurred in the CPU. Generally, this is not
a programming problem but an actual hardware failure. You can power cycle the
system to clear the error. If the error clears, you should monitor the system and
determine what caused the problem. You will find this problem is sometimes caused
by high frequency electrical noise introduced into the CPU from an outside source.
Check your system grounding and install electrical noise filters if the grounding is
suspected. If power cycling the system does not reset the error, or if the problem
returns, you should replace the CPU.

Communications Problems
If you cannot establish communications with the CPU, check these items.
S
S
S
S

For problems in communicating with DirectSOFT on a personal computer, refer to

the DirectSOFT manual. It includes a troubleshooting section that can help you
diagnose PC problems in communications port setup, address or interrupt conflicts,
etc.

Maintenance
and Troubleshooting

S
S
S
S

The cable is disconnected.

The cable has a broken wire or has been wired incorrectly.
The cable is improperly terminated or grounded.
The device connected is not operating at the correct baud rate (9600
baud).
The device connected to the port is sending data incorrectly.
A grounding difference exists between the two devices.
Electrical noise is causing intermittent errors.
The PLC has a bad communication port and should be replaced.

98
Maintenance and Troubleshooting

Maintenance
and Troubleshooting

I/O Point Troubleshooting

Possible Causes

If you suspect an I/O error, there are several things that could be causing the
problem.
S High-Speed I/O configuration error
S A blown fuse in your machine or panel (the DL05 does not have internal
I/O fuses)
S A loose terminal block
S The auxiliary 24 VDC supply has failed
S The Input or Output Circuit has failed

Some Quick Steps

When troubleshooting the DL05 Micro PLCs there are a few facts you should be
aware of. These facts may assist you in quickly correcting an I/O problem.
S HSIO configuration errors are commonly mistaken for I/O point failure
during program development. If the I/O point in question is in X0X2, or
Y0Y1, check all parameter locations listed in Chapter 3 that apply to
the HSIO mode you have selected.
S The output circuits cannot detect shorted or open output points. If you
suspect one or more faulty points, measure the voltage drop from the
common to the suspect point. Remember when using a Digital Volt
Meter, leakage current from an output device such as a triac or a
transistor must be considered. A point which is off may appear to be on
if no load is connected the point.
S The I/O point status indicators are logic-side indicators. This means the
LED which indicates the on or off status reflects the status of the point
with respect to the CPU. On an output point the status indicators could
be operating normally while the actual output device (transistor, triac
etc.) could be damaged. With an input point, if the indicator LED is on
the input circuitry is probably operating properly. Verify the LED goes off
when the input signal is removed.
S Leakage current can be a problem when connecting field devices to an
I/O point. False input signals can be generated when the leakage
current of an output device is great enough to turn on the connected
input device. To correct this install a resistor in parallel with the input or
output of the circuit. The value of this resistor will depend on the amount
of leakage current and the voltage applied but usually a 10K to 20KW
resistor will work. Verify the wattage rating of the resistor is correct for
your application.
S Because of the removable terminal blocks on the DL05, the easiest
method to determine if an I/O circuit has failed is to replace the unit if
you have a spare. However, if you suspect a field device is defective,
that device may cause the same failure in the replacement PLC as well.
As a point of caution, you may want to check devices or power supplies
connected to the failed I/O circuit before replacing the unit with a spare.

99
Maintenance and Troubleshooting

Testing Output
Points

Output points can be set on or off in the DL05 series CPUs. If you want to do an I/O
check out independent of the application program, follow the procedure below:
Step

Action

Use a handheld programmer or DirectSOFT to communicate online to

the PLC.

Change to Program Mode.

Go to address 0.

Insert an END statement at address 0. (This will cause program

execution to occur only at address 0 and prevent the application program from turning the I/O points on or off).

Change to Run Mode.

Use the programming device to set (turn) on or off the points you wish
to test.

When you finish testing I/O points delete the END statement at
address 0.

WARNING: Depending on your application, forcing I/O points may cause

unpredictable machine operation that can result in a risk of personal injury or
equipment damage. Make sure you have taken all appropriate safety precautions
prior to testing any I/O points.
Handheld
Programmer
Keystrokes Used
to Test an Output
Point

END

X0

X2

X1

X3

X5

X7

Y2

X4

END

From a clear display, use the following keystrokes

STAT

16P STATUS
BIT REF
X

ENT

Use the PREV or NEXT keys to select the Y data type

NEXT

A
0

ENT

10

ON
INS

Y2 is now on

Use arrow keys to select point, then use

ON and OFF to change the status
SHFT

10

Maintenance
and Troubleshooting

Insert an END statement

at the beginning of the
program. This disables
the remainder of the
program.

910
Maintenance and Troubleshooting

Maintenance
and Troubleshooting

Noise Troubleshooting
Electrical Noise
Problems

Noise is one of the most difficult problems to diagnose. Electrical noise can enter a
system in many different ways and they fall into one of two categories, conducted or
radiated. It may be difficult to determine how the noise is entering the system but the
corrective actions for either of the types of noise problems are similar.
S Conducted noise is when the electrical interference is introduced into
the system by way of a attached wire, panel connection ,etc. It may
enter through an I/O circuit, a power supply connection, the
communication ground connection, or the chassis ground connection.
S Radiated noise is when the electrical interference is introduced into the
system without a direct electrical connection, much in the same manner
as radio waves.

Reducing
Electrical Noise

While electrical noise cannot be eliminated it can be reduced to a level that will not
affect the system.
S Most noise problems result from improper grounding of the system. A
good earth ground can be the single most effective way to correct noise
problems. If a ground is not available, install a ground rod as close to
the system as possible. Ensure all ground wires are single point
grounds and are not daisy chained from one device to another. Ground
metal enclosures around the system. A loose wire can act as a large
antenna, introducing noise into the system. Therefore, tighten all
connections in your system. Loose ground wires are more susceptible to
noise than the other wires in your system. Review Chapter 2 Installation,
Wiring, and Specifications if you have questions regarding how to
ground your system.
S Electrical noise can enter the system through the power source for the
PLC and I/O circuits. Installing an isolation transformer for all AC
sources can correct this problem. DC sources should be well-grounded
good quality supplies.
S Separate input wiring from output wiring. Never run low-voltage I/O
wiring close to high voltage wiring.

911
Maintenance and Troubleshooting

Machine Startup and Program Troubleshooting

The DL05 Micro PLCs provide several features that can help you debug your
program before and during machine startup. This section discusses the following
topics which can be very helpful.
S Program Syntax Check
S Duplicate Reference Check
S Special Instructions
S Run Time Edits
S Forcing I/O Points
Syntax Check

Even though the Handheld Programmer and DirectSOFT provide error checking
during program entry, you may want to check a program that has been modified.
Both programming devices offer a way to check the program syntax. For example,
you can use AUX 21, CHECK PROGRAM to check the program syntax from a
Handheld Programmer, or you can use the PLC Diagnostics menu option within
DirectSOFT. This check will find a wide variety of programming errors. The following
example shows how to use the syntax check with a Handheld Programmer.
Use AUX 21 to perform syntax check
CLR

B
2

AUX

ENT

AUX 21 CHECK PRO

1:SYN 2:DUP REF

Select syntax check (default selection)

ENT

(You may not get the busy display

if the program is not very long.)

BUSY

Error Display (example)

$00050 E401
MISSING END
(shows location in question)

Syntax OK display

NO SYNTAX ERROR
?

See the Error Codes Section for a complete listing of programming error codes. If
you get an error, just press CLR and the Handheld will display the instruction where
the error occurred. Correct the problem and continue running the Syntax check until
the NO SYNTAX ERROR message appears.

Maintenance
and Troubleshooting

One of two displays will appear

912
Maintenance and Troubleshooting

Special
Instructions

There are several instructions that can be used to help you debug your program
during machine startup operations.
S END
S PAUSE
S STOP
END Instruction: If you need a way to quickly disable part of the program, just insert
an END statement prior to the portion that should be disabled. When the CPU
encounters the END statement, it assumes that is the end of the program. The
following diagram shows an example.
New END disables X10 and Y1

Normal Program
X0

X2

X1

X3

Y0
X4

X0

X2

X1

X3

Y0
X4

Y1

X10

END

Y1

X10
END

END

PAUSE Instruction: This instruction provides a quick way to allow the inputs (or
other logic) to operate while disabling selected outputs. The output image register is
still updated, but the output circuits are not. For example, you could make this
conditional by adding an input contact or CR to control the instruction with a switch or
a programming device. Or, you could just add the instruction without any conditions
so the selected outputs would be disabled at all times.
PAUSE disables Y0 and Y1

Maintenance
and Troubleshooting

Normal Program
X0

X2

X1

X3

Y0

Y0 Y1
PAUSE

X10

X4
Y1

X0

X2

X1

X3

X10

Y0
X4
Y1

END

END

STOP Instruction: Sometimes during machine startup you need a way to quickly
turn off all the outputs and return to Program Mode. You can use the STOP
instruction. When this instruction is executed the CPU automatically exits Run Mode
and enters Program Mode. Remember, all outputs are turned off during Program
Mode. The following diagram shows an example of a condition that returns the CPU
to Program Mode.

913
Maintenance and Troubleshooting

STOP puts CPU in Program Mode

Normal Program
X0

X2

X1

X3

Y0

X7
STOP

X4
Y1

X5

X0

X2

X1

X3

Y0
X4

X5

Y1

END

END

Duplicate
Reference Check

In the example shown above, you could trigger X10 which would execute the STOP
instruction. The CPU would enter Program Mode and all outputs would be turned off.
You can also check for multiple uses of the same output coil. Both programming
devices offer a way to check for this condition.. For example, you can AUX 21,
CHECK PROGRAM to check for duplicate references from a Handheld
Programmer, or you can use the PLC Diagnostics menu option within DirectSOFT.
The following example shows how to perform the duplicate reference check with a
Handheld Programmer.
Use AUX 21 to perform syntax check
CLR

B
2

AUX

ENT

AUX 21 CHECK PRO

1:SYN 2:DUP REF

Select duplicate reference check

ENT

BUSY

One of two displays will appear

Error Display (example)
(shows location in question)

Syntax OK display

$00024 E471
DUP COIL REF

NO DUP REFS
?

If you get an error, just press CLR and the Handheld will display the instruction where
the error occurred. Correct the problem and continue running the Duplicate
Reference check until no duplicate references are found.
NOTE: You can use the same coil in more than one location, especially in programs
containing Stage instructions and / or OROUT instructions. The Duplicate
Reference check will find occurrences, even though they are acceptable.

Maintenance
and Troubleshooting

(You may not get the busy

display if the program is not
very long.)

914
Maintenance and Troubleshooting

Run Time Edits

The DL05 Micro PLC allows you to make changes to the application program during
Run Mode. These edits are not bumpless. Instead, CPU scan is momentarily
interrupted (and the outputs are maintained in their current state) until the program
change is complete. This means if the output is off, it will remain off until the program
change is complete. If the output is on, it will remain on.
WARNING: Only authorized personnel fully familiar with all aspects of the
application should make changes to the program. Changes during Run Mode
become effective immediately. Make sure you thoroughly consider the impact of any
changes to minimize the risk of personal injury or damage to equipment. There are
some important operational changes during Run Time Edits.
1. If there is a syntax error in the new instruction, the CPU will not enter the Run
Mode.
2. If you delete an output coil reference and the output was on at the time, the output
will remain on until it is forced off with a programming device.
3. Input point changes are not acknowledged during Run Time Edits. So, if youre
using a high-speed operation and a critical input comes on, the CPU may not see
the change.

Maintenance
and Troubleshooting

Not all instructions can be edited during a Run Time Edit session. The following list
shows the instructions that can be edited.
Mnemonic

Description

Mnemonic

Description

TMR

Timer

OR, ORN

TMRF

Fast timer

Or greater than or equal

Or less than

TMRA

Accumulating timer

LD

Load data (constant)

TMRAF

Accumulating fast timer

LDD

Load data double (constant)

ADDD

Add data double (constant)

SUBD

Subtract data double (constant)

MUL

Multiply (constant)

DIV

Divide (constant)

CMPD

Compare accumulator (constant)

ANDD

And accumulator (constant)

ORD

Or accumulator (constant)

XORD

Exclusive or accumulator (constant)

LDF

Load discrete points to accumulator

OUTF

Output accumulator to discrete points

SHFR

Shift accumulator right

SHFL

Shift accumulator left

NCON

Numeric constant

CNT

Counter

UDC

Up / Down counter

SGCNT

Stage counter

STR, STRN

Store, Store not

AND, ANDN

And, And not

OR, ORN

Or, Or not

STRE, STRNE

Store equal, Store not equal

ANDE, ANDNE

And equal, And not equal

ORE, ORNE

Or equal, Or not equal

STR, STRN

Store greater than or equal

Store less than

AND, ANDN

And greater than or equal

And less than

915
Maintenance and Troubleshooting

Well use the program logic shown to describe how this process works. In the example, well change X0 to C10. Note, the
example assumes you have already
placed the CPU in Run Mode.

X0

X1

Y0
OUT

C0

Use the MODE key to select Run Time Edits

MODE

NEXT

NEXT

*MODE CHANGE*
RUN TIME EDIT?

ENT

Press ENT to confirm the Run Time Edits

ENT

(Note, the RUN LED on the D2HPP

Handheld starts flashing to indicate
Run Time Edits are enabled.)

*MODE CHANGE*
RUNTIME EDITS

Find the instruction you want to change (X0)

SHFT

X
SET

A
0

SHFT

FD REF
FIND

$00000 STR X0

Press the arrow key to move to the X. Then enter the new contact (C10).
SHFT

B
2

A
1

ENT

RUNTIME EDIT?
STR C10

ENT

(Note, once you press ENT, the next

address is displayed.

OR C0

Maintenance
and Troubleshooting

Press ENT to confirm the change

916
Maintenance and Troubleshooting

Forcing I/O Points

There are many times, especially during machine startup and troubleshooting, that
you need the capability to force an I/O point to be either on or off. Before you use a
programming device to force any data type it is important you understand how the
DL05 CPUs process the forcing requests.
WARNING: Only authorized personnel fully familiar with the application should
make program changes. Do thoroughly consider the impact of any changes to
minimize the risk of personal injury or damage to equipment.
Bit Forcing Bit forcing temporarily changes the status of a discrete bit. For
example, you may want to force an input on even though the program has turned it
off. This allows you to change the point status stored in the image register. The
forced value will be valid until the CPU writes to the image register location during the
next scan. This is useful you just need to force a bit on to trigger another event.
The following diagrams show a brief
example of how you could use the
D2HPP Handheld Programmer to force
an I/O point. The example assumes you
have already placed the CPU into Run
Mode.

X0

Y0
OUT

C0

From a clear display, use the following keystrokes

STAT

16P STATUS
BIT REF
X

ENT

Use the PREV or NEXT keys to select the Y data type. (Once the Y
appears, press 0 to start at Y0.)

Maintenance
and Troubleshooting

NEXT

A
0

ENT

Use arrow keys to select point, then use

ON and OFF to change the status
SHFT

Bit Forcing with

Direct Access

From a blank display, use the following

keystrokes to force Y7 ON
SHFT

Y
MLS

H
7

SHFT

ON
INS

From a blank display, use the following

keystrokes to force Y7 OFF
SHFT

Y
MLS

H
7

SHFT

OFF
DEL

Y2 is now on

ON
INS

10

10

Solid fill indicates point is on.

BIT FORCE
Y7
No fill indicates point is off.

BIT FORCE
Y7

Auxiliary Functions

In This Appendix. . . .

1A

Introduction
AUX 2* RLL Operations
AUX 3* Vmemory Operations
AUX 4* I/O Configuration
AUX 5* CPU Configuration
AUX 6* Handheld Programmer Configuration
AUX 7* EEPROM Operations
AUX 8* Password Operations

A2
Appendix A
Auxiliary Functions

Auxiliary Functions

Introduction
Purpose of
Many CPU setup tasks involve the use of Auxiliary (AUX) Functions. The AUX
Auxiliary Functions Functions perform many different operations, including clearing ladder memory,
displaying the scan time, and copying programs to EEPROM in the handheld
programmer. They are divided into categories that affect different system resources.
You can access the AUX Functions from DirectSOFT or from the D2HPP
Handheld Programmer. The manuals for those products provide step-by-step
procedures for accessing the AUX Functions. Some of these AUX Functions are
designed specifically for the Handheld Programmer setup, so they will not be
needed (or available) with the DirectSOFT package. Even though this Appendix
provides many examples of how the AUX functions operate, you should supplement
this information with the documentation for your choice of programming device.
Note, the Handheld Programmer may have additional AUX functions that are not
supported with the DL05 PLCs.
AUX Function and Description

DL05

AUX 2* RLL Operations

21

Check Program

22

Change Reference

23

Clear Ladder Range

24

Clear All Ladders

AUX 3* V-Memory Operations

31

Clear V Memory

AUX 4* I/O Configuration

41

Show I/O Configuration

AUX Function and Description

61

Show Revision Numbers

62

Beeper On / Off

HP

65

Run Self Diagnostics

HP

AUX 7* EEPROM Operations

71

Copy CPU memory to

HPP EEPROM

HP

72

Write HPP EEPROM to CPU

HP

73

Compare CPU to
HPP EEPROM

HP

AUX 5* CPU Configuration

DL05

AUX 6* Handheld Programmer Configuration

51

Modify Program Name

74

Blank Check (HPP EEPROM)

HP

53

Display Scan Time

75

Erase HPP EEPROM

HP

54

Initialize Scratchpad

76

HP

55

Set Watchdog Timer

Show EEPROM Type

(CPU and HPP)

56

Set Communication Port 2

57

Set Retentive Ranges

58

Test Operations

59

Override Setup

5B

HSIO Interface Configuration

5D

Scan Control Setup

supported
HP Handheld Programmer function

AUX 8* Password Operations

81

Modify Password

82

Unlock CPU

83

Lock CPU

A3
Auxilliary Functions
DirectSOFT provides various menu options during both online and offline
programming. Some of the AUX functions are only available during online
programming, some only during offline programming, and some during both online
and offline programming. The following diagram shows and example of the PLC
operations menu available within DirectSOFT.

Menu Options

Accessing AUX
Functions via the
Handheld
Programmer

You can also access the AUX functions by using a Handheld Programmer. Plus,
remember some of the AUX functions are only available from the Handheld.
Sometimes the AUX name or description cannot fit on one display. If you want to see
the complete description, just press the arrow keys to scroll left and right. Also,
depending on the current display, you may have to press CLR more than once.
CLR

AUX FUNCTION SELECTION

AUX 2* RLL OPERATIONS

AUX

Use NXT or PREV to cycle through the menus

AUX FUNCTION SELECTION

AUX 3* V OPERATIONS

NEXT

Press ENT to select sub-menus

AUX 3* V OPERATIONS
AUX 31 CLR V MEMORY

ENT

You can also enter the exact AUX number to go straight to the sub-menu.
Enter the AUX number directly

CLR

B
3

AUX

AUX 3* V OPERATIONS
AUX 31 CLR V MEMORY

Appendix A
Auxiliary Functions

Accessing AUX
Functions via
DirectSOFT

A4
Appendix A
Auxiliary Functions

Auxiliary Functions

AUX 2* RLL Operations

AUX 21
Check Program

RLL Operations auxiliary functions allow you to perform various operations on the
ladder program.
Both the Handheld and DirectSOFT automatically check for errors during program
entry. However, there may be occasions when you want to check a program that has
already been in the CPU. Two types of checks are available:
S Syntax
S Duplicate References
The Syntax check will find a wide variety of programming errors, such as missing
END statements. If you perform this check and get an error, see Appendix B for a
complete listing of programming error codes. Correct the problem and then continue
running the Syntax check until the message NO SYNTAX ERROR appears.
Use the Duplicate Reference check to verify you have not used the same output coil
reference more than once. Note, this AUX function will also find the same outputs
even if they have been used with the OROUT instruction, which is perfectly
acceptable.
This AUX function is available on the PLC Diagnostics sub-menu from within
DirectSOFT.

AUX 22
Change Reference

There will probably be times when you need to change an I/O address reference or
control relay reference. AUX 22 allows you to quickly and easily change all
occurrences, (within an address range), of a specific instruction. For example, you
can replace every instance of X5 with X10.

AUX 23
Clear Ladder
Range

There have been many times when weve taken existing programs and added or
removed certain portions to solve new application problems. By using AUX 23 you
can select and delete a portion of the program. DirectSOFT does not have a menu
option for this AUX function, but you can just select the appropriate portion of the
program and cut it with the editing tools.

AUX 24
Clear Ladders

AUX 24 clears the entire program from CPU memory. Before you enter a new
program, you should always clear ladder memory. This AUX function is available on
the PLC/Clear PLC sub-menu within DirectSOFT.

AUX 3* V-memory Operations

AUX 31
Clear V Memory

AUX 31 clears all the information from the V-memory locations available for general
use. This AUX function is available on the PLC/Clear PLC sub-menu within
DirectSOFT.

AUX 4* I/O Configuration

AUX 41
Show I/O
Configuration

This AUX function allows you to display the current I/O configuration on the DL05.
Both the Handheld Programmer and DirectSOFT will show the I/O configuration.

A5
Auxilliary Functions

AUX 51
Modify Program
Name

The following auxiliary AUX functions allow you to setup, view, or change the CPU
configuration.
DL05 PLCs can use a program name for the CPU program or a program stored on
EEPROM in the Handheld Programmer. (Note, you cannot have multiple programs
stored on the EEPROM.) The program name can be up to eight characters in length
and can use any of the available characters (AZ, 09). AUX 51 allows you to enter a
program name. You can also perform this operation from within DirectSOFT by
using the PLC/Setup sub-menu. Once youve entered a program name, you can
only clear the name by using AUX 54 to reset the system memory. Make sure you
understand the possible effects of AUX 54 before you use it!

AUX 53 displays the current, minimum, and maximum scan times. The minimum
AUX 53
Display Scan Time and maximum times are the ones that have occurred since the last Program Mode to
Run Mode transition. You can also perform this operation from within DirectSOFT
by using the PLC/Diagnostics sub-menu.
AUX 54
Initialize
Scratchpad

The CPU maintains system parameters in a memory area often referred to as the
scratchpad. In some cases, you may make changes to the system setup that will be
stored in system memory. For example, if you specify a range of Control Relays
(CRs) as retentive, these changes are stored.
NOTE: You may never have to use this feature unless you have made changes that
affect system memory. Usually, youll only need to initialize the system memory if you
are changing programs and the old program required a special system setup. You
can usually change from program to program without ever initializing system
memory.
AUX 54 resets the system memory to the default values. You can also perform this
operation from within DirectSOFT by using the PLC/Setup sub-menu.

AUX 55
Set Watchdog
Timer

DL05 PLCs have a watchdog timer that is used to monitor the scan time. The
default value set from the factory is 200 ms. If the scan time exceeds the watchdog
time limit, the CPU automatically leaves RUN mode and enters PGM mode. The
Handheld displays the following message E003 S/W TIMEOUT when the scan
overrun occurs.
Use AUX 55 to increase or decrease the watchdog timer value. You can also perform
this operation from within DirectSOFT by using the PLC/Setup sub-menu.

AUX 56
CPU Network
Address

Since the DL05 CPU has an additional communication port, you can use the
Handheld to set the network address for port 2 and the port communication
parameters. The default settings are:
S Station address 1
S HEX mode
S Odd parity
You can use this port with either the Handheld Programmer, DirectSOFT, or, as a
communication port for DirectNET and MODBUS. Refer to DirectNET and
MODBUS manuals for additional information about communication settings
required for network operation.

Appendix A
Auxiliary Functions

AUX 5* CPU Configuration

A6
Appendix A
Auxiliary Functions

Auxiliary Functions

NOTE: You will only need to use this procedure if you have port 2 connected to a
network. Otherwise, the default settings will work fine.
Use AUX 56 to set the network address and communication parameters. You can
also perform this operation from within DirectSOFT by using the PLC/Setup
sub-menu.
AUX 57
Set Retentive
Ranges

DL05 CPUs provide certain ranges of retentive memory by default. Some of the
retentive memory locations are backed up by a super-capacitor, and others are in
non-volatile FLASH memory. The FLASH memory locations are V7400 to V7577.
The default ranges are suitable for many applications, but you can change them if
your application requires additional retentive ranges or no retentive ranges at all.
The default settings are:
DL05
Memory Area

Default Range

Available
Range

Control Relays

C400 C777

C0 C777

V Memory

V1400 V7777

V0 V7777

Timers

None by default T0 T177

Counters

CT0 CT177

Stages

None by default S0 S377

CT0 CT177

Use AUX 57 to change the retentive ranges. You can also perform this operation
from within DirectSOFT by using the PLC/Setup sub-menu.
WARNING: The DL05 CPUs do not have battery-backed RAM. The super-capacitor
will retain the values in the event of a power loss, but only up to 3 weeks. (The
retention time may be as short as 4 1/2 days in 60 degree C operating temperature.)
AUX 58
Test Operations

AUX 58 is used to override the output disable function of the Pause instruction. Use
AUX 58 to program a single output or a range of outputs which will operate normally
even when those points are within the scope of the pause instruction.

AUX 59
Bit Override

Bit override can be enabled on a point-by-point basis by using AUX 59 from the
Handheld Programmer or, by a menu option from within DirectSOFT. Bit override
basically disables any changes to the discrete point by the CPU. For example, if you
enable bit override for X1, and X1 is off at the time, then the CPU will not change the
state of X1. This means that even if X1 comes on, the CPU will not acknowledge the
change. So, if you used X1 in the program, it would always be evaluated as off in
this case. Of course, if X1 was on when the bit override was enabled, then X1 would
always be evaluated as on.
There is an advantage available when you use the bit override feature. The regular
forcing is not disabled because the bit override is enabled. For example, if you
enabled the Bit Override for Y0 and it was off at the time, then the CPU would not
change the state of Y0. However, you can still use a programming device to change
the status. Now, if you use the programming device to force Y0 on, it will remain on
and the CPU will not change the state of Y0. If you then force Y0 off, the CPU will
maintain Y0 as off. The CPU will never update the point with the results from the
application program or from the I/O update until the bit override is removed from the
point.

A7
Auxilliary Functions

Bit Override OFF

Bit Override ON

Input Update
Force from
Programmer
Result of Program
Solution

Input Update
X128
OFF
Y128
OFF
C377
OFF

...
...
...
...
...
...

X2
ON
Y2
ON
C2
ON

X1
ON
Y1
ON
C1
OFF

X0
OFF
Y0
OFF
C0
OFF

Image Register (example)

Force from
Programmer
Result of Program
Solution

AUX 5B
Counter Interface
Configuration

AUX 5B is used with the High-Speed I/O (HSIO) function to select the configuration.
You can choose the type of counter, set the counter parameters, etc. See Chapter 3
for a complete description of how to select the various counter features.

AUX 5D
Select PLC
Scan Mode

The DL05 CPU has two program scan modes: fixed and variable. In fixed mode, the
scan time is lengthened to the time you specify (in milliseconds). If the actual scan
time is longer than the fixed scan time, then the error code E504 BAD REF/VAL is
displayed. In variable scan mode, the CPU begins each scan as soon as the
previous scans activities complete.

Appendix A
Auxiliary Functions

The following diagram shows a brief overview of the bit override feature. Notice the
CPU does not update the Image Register when bit override is enabled.

A8
Appendix A
Auxiliary Functions

Auxiliary Functions

AUX 6* Handheld Programmer Configuration

AUX 61
Show Revision
Numbers

The following auxiliary functions allow you to setup, view, or change the Handheld
Programmer configuration.
As with most industrial control products, there are cases when additional features
and enhancements are made. Sometimes these new features only work with certain
releases of firmware. By using AUX 61 you can quickly view the CPU and Handheld
Programmer firmware revision numbers. This information (for the CPU) is also
available from within DirectSOFT from the PLC/Diagnostics sub-menu.

AUX 62
Beeper On/Off

The Handheld has a beeper that provides confirmation of keystrokes. You can use
Auxiliary (AUX) Function 62 to turn off the beeper.

AUX 65
Run Self
Diagnostics

If you think the Handheld Programmer is not operating correctly, you can use AUX 65
to run a self diagnostics program. You can check the following items.
S Keypad
S Display
S LEDs and Backlight
S Handheld Programmer EEPROM check

AUX 7* EEPROM Operations

Transferrable
Memory Areas

AUX 71
CPU to HPP
EEPROM

The following auxiliary functions allow you to move the ladder program from one
area to another and perform other program maintenance tasks.
Many of these AUX functions allow you to copy different areas of memory to and
from the CPU and handheld programmer. The following table shows the areas that
may be mentioned.
Option and Memory Type

DL05 Default Range

1:PGM Program

$00000 $02047

2:V V memory

$00000 $07777

3:SYS System

Non-selectable copies
system parameters

4:etc (All) Program, System and non-volatile Vmemory only

Non-selectable

AUX 71 copies information from the CPU memory to an EEPROM installed in the
Handheld Programmer.You can copy different portions of EEPROM (HP) memory to
the CPU memory as shown in the previous table.

A9
Auxilliary Functions

AUX 72 copies information from the EEPROM installed in the Handheld

Programmer to CPU memory in the DL05. You can copy different portions of
EEPROM (HP) memory to the CPU memory as shown in the previous table.

AUX 73
Compare HPP
EEPROM to CPU

AUX 73 compares the program in the Handheld programmer (EEPROM) with the
CPU program. You can compare different types of information as shown previously.

AUX 74
HPP EEPROM
Blank Check

AUX 74 allows you to check the EEPROM in the handheld programmer to make sure
it is blank. Its a good idea to use this function anytime you start to copy an entire
program to an EEPROM in the handheld programmer.

AUX 75
Erase HPP
EEPROM

AUX 75 allows you to clear all data in the EEPROM in the handheld programmer.
You should use this AUX function before you copy a program from the CPU.

AUX 76
Show EEPROM
Type

You can use AUX 76 to quickly determine what size EEPROM is installed in the
Handheld Programmer.

AUX 8* Password Operations

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

You can use AUX 81 to provide an extra measure of protection by entering a

password that prevents unauthorized machine operations. The password must be
an eight-character numeric (09) code. Once youve entered a password, you can
remove it by entering all zeros (00000000). (This is the default from the factory.)
Once youve entered a password, you can lock the CPU against access. There are
two ways to lock the CPU with the Handheld Programmer.
S The CPU is always locked after a power cycle (if a password is present).
S You can use AUX 82 and AUX 83 to lock and unlock the CPU.

Appendix A
Auxiliary Functions

AUX 72
HPP EEPROM
to CPU

A10
Auxiliary Functions

Appendix A
Auxiliary Functions

You can also enter or modify a password from within DirectSOFT by using the
PLC/Password sub-menu. This feature works slightly differently in DirectSOFT.
Once youve entered a password, the CPU is automatically locked when you exit the
software package. It will also be locked if the CPU is power cycled.
WARNING: Make sure you remember the password before you lock the CPU. Once
the CPU is locked you cannot view, change, or erase the password. If you do not
remember the password, you have to return the CPU to the factory for password
removal.
NOTE: The DL05 CPUs support multi-level password protection of the ladder
program. This allows password protection while not locking the communication port
to an operator interface. The multi-level password can be invoked by creating a
password with an upper case A followed by seven numeric characters (e.g.
A1234567).
AUX 82
Unlock CPU

AUX 82 can be used to unlock a CPU that has been password protected.
DirectSOFT will automatically ask you to enter the password if you attempt to
communicate with a CPU that contains a password.

AUX 83
Lock CPU

AUX 83 can be used to lock a CPU that contains a password. Once the CPU is
locked, you will have to enter a password to gain access. Remember, this is not
necessary with DirectSOFT since the CPU is automatically locked whenever you
exit the software package.

DL05 Error Codes

In This Appendix. . . .

Error Code Table

1B

B2

Appendix B
Error Codes

DL05 Error Codes

DL05 Error Code

Description

E003
SOFTWARE
TIME-OUT

If the program scan time exceeds the time allotted to the watchdog timer, this
error will occur. SP51 will be on and the error code will be stored in V7755. To
correct this problem use AUX 55 to extend the time allotted to the watchdog
timer.

E004
INVALID
INSTRUCTION

The CPU attempted to execute an instruction code, but the RAM contents
had a parity error. Performing a program download to the CPU in an
electrically noisy environment can corrupt a programs contents. Clear the
CPU program memory, and download the program again.

E043
MC BATTERY LOW

The battery in the CMOS RAM cartridge is low and should be replaced.

E104
WRITE FAILED

A write to the CPU was not successful. Disconnect the power, remove the
CPU, and make sure the EEPROM is not write protected. If the EEPROM is
not write protected, make sure the EEPROM is installed correctly. If both
conditions are OK, replace the CPU.

E151
BAD COMMAND

A parity error has occurred in the application program. SP44 will be on and
the error code will be stored in V7755 .This problem may possibly be due to
electrical noise. Clear the memory and download the program again. Correct
any grounding problems. If the error returns replace the Micro PLC.

E311
HP COMM
ERROR 1

A request from the handheld programmer could not be processed by the

CPU. Clear the error and retry the request. If the error continues replace the
CPU. SP46 will be on and the error code will be stored in V7756.

E312
HP COMM
ERROR 2

A data error was encountered during communications with the CPU. Clear
the error and retry the request. If the error continues check the cabling
between the two devices, replace the handheld programmer, then if
necessary replace the CPU. The error code will be stored in V7756.

E313
HP COMM
ERROR 3

An address error was encountered during communications with the CPU.

Clear the error and retry the request. If the error continues check the cabling
between the two devices, replace the handheld programmer, then if
necessary replace the CPU. The error code will be stored in V7756.

E316
HP COMM
ERROR 6

A mode error was encountered during communications with the CPU. Clear
the error and retry the request. If the error continues replace the handheld
programmer, then if necessary replace the CPU. The error code will be stored
in V7756.

E320
HP COMM
TIME-OUT

The CPU did not respond to the handheld programmer communication

request. Check to insure cabling is correct and not defective. Power cycle the
system if the error continues replace the CPU first and then the handheld
programmer if necessary.

E321
COMM ERROR

A data error was encountered during communication with the CPU. Check to
insure cabling is correct and not defective. Power cycle the system and if the
error continues replace the CPU first and then the handheld programmer if
necessary.

B3
DL05 Error Codes

E360
HP PERIPHERAL
PORT TIME-OUT

The device connected to the peripheral port did not respond to the handheld
programmer communication request. Check to insure cabling is correct and
not defective. The peripheral device or handheld programmer could be
defective.

E4**
NO PROGRAM

A syntax error exists in the application program. The most common is a

missing END statement. Run AUX21 to determine which one of the E4**
series of errors is being flagged. SP52 will be on and the error code will be
stored in V7755.

E401
MISSING END
STATEMENT

All application programs must terminate with an END statement. Enter the
END statement in appropriate location in your program. SP52 will be on and
the error code will be stored in V7755.

E402
MISSING LBL

A MOVMC or LDLBL instruction was used without the appropriate label.

Refer to the Chapter 5 for details on these instructions. SP52 will be on and
the error code will be stored in V7755.

E403
MISSING RET

A subroutine in the program does not end with the RET instruction. SP52 will
be on and the error code will be stored in V7755.

E404
MISSING FOR

A NEXT instruction does not have the corresponding FOR instruction. SP52
will be on and the error code will be stored in V7755.

E405
MISSING NEXT

A FOR instruction does not have the corresponding NEXT instruction. SP52
will be on and the error code will be stored in V7755.

E406
MISSING IRT

An interrupt routine in the program does not end with the IRT instruction.
SP52 will be on and the error code will be stored in V7755.

E412
SBR/LBL>64

There is greater than 64 SBR or DLBL instructions in the program. This error
is also returned if there is greater than 2 INT instructions used in the program.
SP52 will be on and the error code will be stored in V7755.

E421
DUPLICATE STAGE
REFERENCE

Two or more SG or ISG labels exist in the application program with the same
number. A unique number must be allowed for each Stage and Initial Stage.
SP52 will be on and the error code will be stored in V7755.

E422
DUPLICATE LBL
REFERENCE

Two or more LBL instructions exist in the application program with the same
number. A unique number must be allowed for each and label. SP52 will be
on and the error code will be stored in V7755.

E423
NESTED LOOPS

Nested loops (programming one FOR/NEXT loop inside of another) are not
allowed. SP52 will be on and the error code will be stored in V7755.

E431
INVALID ISG/SG
ADDRESS

An ISG or SG instruction must not be placed after the end statement (such as
inside a subroutine). SP52 will be on and the error code will be stored in
V7755.

Appendix B
Error Codes

Description

Appendix A
DL405 Error Codes

DL05 Error Code

B4

Appendix B
Error Codes

DL05 Error Codes

DL05 Error Code

Description

E433
INVALID SBR
ADDRESS

A SBR must be programmed after the end statement, not in the main body of
the program or in an interrupt routine. SP52 will be on and the error code will
be stored in V7755.

E434
INVALID RTC
ADDRESS

A RTC must be programmed after the end statement, not in the main body of
the program or in an interrupt routine. SP52 will be on and the error code will
be stored in V7755.

E435
INVALID RT
ADDRESS

A RT must be programmed after the end statement, not in the main body of
the program or in an interrupt routine. SP52 will be on and the error code will
be stored in V7755.

E436
INVALID INT
ADDRESS

An INT must be programmed after the end statement, not in the main body of
the program. SP52 will be on and the error code will be stored in V7755.

E437
INVALID IRTC
ADDRESS

An IRTC must be programmed after the end statement, not in the main body
of the program. SP52 will be on and the error code will be stored in V7755.

E438
INVALID IRT
ADDRESS

An IRT must be programmed after the end statement, not in the main body of
the program. SP52 will be on and the error code will be stored in V7755.

E440
INVALID DATA
ADDRESS

Either the DLBL instruction has been programmed in the main program area
(not after the END statement), or the DLBL instruction is on a rung containing
input contact(s).

E441
ACON/NCON

An ACON or NCON must be programmed after the end statement, not in the
main body of the program. SP52 will be on and the error code will be stored
in V7755.

E451
BAD MLS/MLR

MLS instructions must be numbered in ascending order from top to bottom.

E453
MISSING T/C

A timer or counter contact is being used where the associated timer or

counter does not exist.

E454
BAD TMRA

One of the contacts is missing from a TMRA instruction.

E455
BAD CNT

One of the contacts is missing from a CNT or UDC instruction.

E456
BAD SR

One of the contacts is missing from the SR instruction.

B5
DL05 Error Codes

E461
STACK OVERFLOW

More than nine levels of logic have been stored on the stack. Check the use
of OR STR and AND STR instructions.

E462
STACK
UNDERFLOW

An unmatched number of logic levels have been stored on the stack. Insure
the number of AND STR and OR STR instructions match the number of STR
instructions.

E463
LOGIC ERROR

A STR instruction was not used to begin a rung of ladder logic.

E464
MISSING CKT

A rung of ladder logic is not terminated properly.

E471
DUPLICATE COIL
REFERENCE

Two or more OUT instructions reference the same I/O point.

E472
DUPLICATE TMR
REFERENCE

Two or more TMR instructions reference the same number.

E473
DUPLICATE CNT
REFERENCE

Two or more CNT instructions reference the same number.

E499
PRINT
INSTRUCTION

Invalid PRINT instruct usage. Quotations and/or spaces were not entered or
entered incorrectly.

Appendix B
Error Codes

Description

Appendix A
DL405 Error Codes

DL05 Error Code

B6

Appendix B
Error Codes

DL05 Error Codes

DL05 Error Code

Description

E501
BAD ENTRY

An invalid keystroke or series of keystrokes was entered into the handheld

programmer.

E502
BAD ADDRESS

An invalid or out of range address was entered into the handheld

programmer.

E503
BAD COMMAND

An invalid command was entered in the handheld programmer.

E504
BAD REF/VAL

An invalid value or reference number was entered with an instruction.

E505
INVALID
INSTRUCTION

An invalid instruction was entered into the handheld programmer.

E506
INVALID
OPERATION

An invalid operation was attempted by the handheld programmer.

E520
BAD OPRUN

An operation which is invalid in the RUN mode was attempted by the

handheld programmer.

E521
BAD OPTRUN

An operation which is invalid in the TEST RUN mode was attempted by the
handheld programmer.

E523
BAD OPTPGM

An operation which is invalid in the TEST PROGRAM mode was attempted

by the handheld programmer.

E524
BAD OPPGM

An operation which is invalid in the PROGRAM mode was attempted by the

handheld programmer.

E525
MODE SWITCH

An operation was attempted by the handheld programmer while the CPU

mode switch was in a position other than the TERM position.

E526
OFF LINE

The handheld programmer is in the OFFLINE mode. To change to the

ONLINE mode use the MODE the key.

E527
ON LINE

The handheld programmer is in the ON LINE mode. To change to the OFF

LINE mode use the MODE the key.

E528
CPU MODE

The operation attempted is not allowed during a Run Time Edit.

E540
CPU LOCKED

The CPU has been password locked. To unlock the CPU use AUX82 with the
password.

E541
WRONG
PASSWORD

The password used to unlock the CPU with AUX82 was incorrect.

E542
PASSWORD RESET

The CPU powered up with an invalid password and reset the password to
00000000. A password may be re-entered using AUX81.

E601
MEMORY FULL

Attempted to enter an instruction which required more memory than is

available in the CPU.

E602
INSTRUCTION
MISSING

A search function was performed and the instruction was not found.

B7
DL05 Error Codes

E603
DATA MISSING

A search function was performed and the data was not found.

E604
REFERENCE
MISSING

A search function was performed and the reference was not found.

E620
OUT OF MEMORY

An attempt to transfer more data between the CPU and handheld

programmer than the receiving device can hold.

E621
EEPROM NOT
BLANK

An attempt to write to a non-blank EEPROM in the handheld programmer

was made. Erase the EEPROM and then retry the write.

E622
NO HPP EEPROM

A data transfer was attempted with no EEPROM (or possibly a faulty

EEPROM) installed in the handheld programmer.

E623
SYSTEM EEPROM

A function was requested with an EEPROM in the handheld programmer

which contains system information only.

E624
V-MEMORY ONLY

A function was requested with an EEPROM in the handheld programmer

which contains V-memory data only.

E625
PROGRAM ONLY

A function was requested with an EEPROM in the handheld programmer

which contains program data only.

E626
PROM MC

An attempt to transfer data from a tape to a UVPROM Memory Cartridge.

This transfer must be made using a CMOS RAM Cartridge.

E627
BAD WRITE

An attempt to write to a write-protected or faulty EEPROM in the handheld

programmer was made. Check the write protect jumper and replace the
EEPROM if necessary.

E628
EEPROM TYPE
ERROR

The wrong size EEPROM is being used in the handheld programmer. This
error occurs when the program size is larger than what the HPP can hold.

E640
COMPARE ERROR

A compare between the EEPROM handheld programmer and the CPU was
found to be in error.

E641
VOLUME LEVEL

The volume level of the cassette player is not set properly. Adjust the volume
and retry the operation.

E642
An error was detected while data was being transferred to the handheld
CHECKSUM ERROR programmers Memory Cartridge. Check cabling and retry the operation.
E650
HPP SYSTEM
ERROR

A system error has occurred in the handheld programmer. Power cycle the
handheld programmer. If the error returns replace the handheld programmer.

E651
HPP ROM ERROR

A ROM error has occurred in the handheld programmer. Power cycle the
handheld programmer. If the error returns replace the handheld programmer.

E652
HPP RAM ERROR

A RAM error has occurred in the handheld programmer. Power cycle the
handheld programmer. If the error returns replace the handheld programmer.

Appendix B
Error Codes

Description

Appendix A
DL405 Error Codes

DL05 Error Code

Instruction
Execution Times
In This Appendix. . . .

Introduction
Instruction Execution Times

1C

C2
Instruction Execution Times

Introduction
This appendix contains several tables that provide the instruction execution times
for DL05 Micro PLCs. Many of the execution times depend on the type of data used
with the instruction. Registers may be classified into the following types:
S Data (word) Registers
S Bit Registers
V-Memory Data
Registers

Some V-memory locations are considered data registers, such as timer or counter
current values. Standard user V memory is classified as a V-memory data register.
Note that you can load a bit pattern into these types of registers, even though their
primary use is for data registers. The following locations are data registers:

Appendix C
Inst. Execution Times

Data Registers

V-Memory Bit
Registers

DL05

Timer Current Values

V0 - V177

Counter Current Values

V1000 - V1177

User Data Words

V1200 - V7377
V7400 - V7577

You may recall that some of the discrete points such as X, Y, C, etc. are automatically
mapped into V memory. The following bit registers contain this data:
Bit Registers

How to Read the

Tables

DL05

Input Points (X)

V40400 - V40417

Output Points (Y)

V40500 - V40517

Control Relays (C)

V40600 - V40637

Stages (S)

V41000 - V41017

Timer Status Bits

V41100 - V41107

Counter Status Bits

V41140 - V41147

Special Relays (SP)

V41200 - V41237

Some instructions can have more than

one parameter. For example, the SET
instruction shown in the ladder program to
the right can set a single point or a range of
points.

Two Data Locations Available

X0

X1

Y0 Y7
SET

C0

In these cases, execution times that depend on the amount and type of parameters.
The execution time tables list execution times for both situations, as shown below:
SET
RST

32.2 ms

1st #:

X, Y, C, S

2nd #:

X, Y, C, S

1st #:

X, Y, C, S

2nd #:

X, Y, C, S (N pt)

(N pt)

14ms+3.1msxN
34.4 ms
16+3.2xN

Execution depends
on numbers of
locations and types
of data used

C3
Instruction Execution Times

Instruction Execution Times

Boolean
Instructions

DL05

Boolean Instructions
Instruction

Legal Data Types

Execute

Not Execute

X, Y, C, T, CT, S, SP

2.0 ms

2.0 ms

STRN

X, Y, C, T, CT, S, SP

2.3 ms

2.3 ms

OR

X, Y, C, T, CT, S, SP

1.6 ms

1.6 ms

ORN

X, Y, C, T, CT, S, SP

1.9 ms

1.9 ms

AND

X, Y, C, T, CT, S, SP

1.4 ms

1.4 ms

ANDN

X, Y, C, T, CT, S, SP

1.6 ms

1.6 ms

ANDSTR

None

1.3 ms

1.3 ms

ORSTR

None

1.3 ms

1.3 ms

OUT

X, Y, C

6.8 ms

6.8 ms

OROUT

X, Y, C

6.7 ms

6.7 ms

NOT

None

1.6 ms

1.6 ms

PD

X, Y, C

52.3 ms

53.0 ms

STRPD

X, Y, C, T, CT, S, SP

20.2 ms

12.9 ms

STRND

X, Y, C, T, CT, S, SP

20.1 ms

13.0 ms

ORPD

X, Y, C, T, CT, S, SP

20.0 ms

12.6 ms

ORND

X, Y, C, T, CT, S, SP

19.8 ms

12.7 ms

ANDPD

X, Y, C, T, CT, S, SP

20.0 ms

12.6 ms

ANDND

X, Y, C, T, CT, S, SP

19.9 ms

12.8 ms

SET

1st #:

X, Y, C, S

2nd #:

X, Y, C, S

1st #:

X, Y, C, S

2nd #:

X, Y, C, S (N pt)

1st #:

T, CT

2nd #:

T, CT (N pt)

RST

PAUSE

1wd: Y
2wd: Y (N points)

(N pt)

32.2 ms

3.7 ms

14ms+3.1msxN

4.7 ms

34.4 ms

3.7 ms

16+3.2xN

4.7 ms

63.6 ms

3.7 ms

39+6.7xN

4.9 ms

23.4 ms

23.0 ms

19.7+1.5xN

19.5+1.4xN

Appendix C
Inst. Execution Times

STR

C4
Instruction Execution Times

Comparative
Boolean
Instructions

Instruction
STRE

Appendix C
Inst. Execution Times

DL05

Comparative Boolean Instructions

STRNE

Legal Data Types

Execute

Not Execute

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

17.0 ms
17.0 ms
11.7 ms
42.8 ms
42.8 ms

16.8 ms
16.8 ms
11.6 ms
42.7 ms
42.7 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

17.0 ms
17.0 ms
11.7 ms
42.8 ms
42.8 ms

16.8 ms
16.8 ms
11.6 ms
42.7 ms
42.7 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.8 ms
42.8 ms
38.1 ms
66.8 ms
66.8 ms

42.7 ms
42.7 ms
38.0 ms
66.7 ms
66.7 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.8 ms
42.8 ms
38.1 ms
66.8 ms
66.8 ms

42.7 ms
42.7 ms
38.0 ms
66.7 ms
66.7 ms

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

17.1 ms
17.1 ms
11.8 ms
43.0 ms
43.0 ms

17.3 ms
17.3 ms
12.0 ms
43.1 ms
43.1 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

17.1 ms
17.1 ms
11.8 ms
43.0 ms
43.0 ms

17.3 ms
17.3 ms
12.0 ms
43.1 ms
43.1 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

43.0 ms
43.0 ms
38.2 ms
67.0 ms
67.0 ms

43.1 ms
43.1 ms
38.4 ms
67.1 ms
67.1 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

43.0 ms
43.0 ms
38.2 ms
67.0 ms
67.0 ms

43.1 ms
43.1 ms
38.4 ms
67.1 ms
67.1 ms

C5
Instruction Execution Times

DL05

Comparative Boolean (cont.)

Instruct
ORE

Execute

Not Execute

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

16.6 ms
16.6 ms
11.5 ms
42.6 ms
42.6 ms

16.5 ms
16.5 ms
11.4 ms
42.5 ms
42.5 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

16.6 ms
16.6 ms
11.5 ms
42.6 ms
42.6 ms

16.5 ms
16.5 ms
11.4 ms
42.5 ms
42.5 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

37.7 ms
37.7 ms
42.6 ms
66.5 ms
66.5 ms

37.6 ms
37.6 ms
42.5 ms
66.4 ms
66.4 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

37.7 ms
37.7 ms
42.6 ms
66.5 ms
66.5 ms

37.6 ms
37.6 ms
42.5 ms
66.4 ms
66.4 ms

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

16.7 ms
16.7 ms
11.6 ms
42.7 ms
42.7 ms

16.8 ms
16.8 ms
11.7 ms
42.9 ms
42.9 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

16.7 ms
16.7 ms
11.6 ms
42.7 ms
42.7 ms

16.8 ms
16.8 ms
11.7 ms
42.9 ms
42.9 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.7 ms
42.7 ms
37.8 ms
66.6 ms
66.6 ms

42.8 ms
42.8 ms
38.0 ms
66.7 ms
66.7 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.7 ms
42.7 ms
37.8 ms
66.6 ms
66.6 ms

42.8 ms
42.8 ms
38.0 ms
66.7 ms
66.7 ms

Appendix C
Inst. Execution Times

ORNE

Legal Data Types

C6
Instruction Execution Times

DL05

Comparative Boolean (cont.)

Instruct

Appendix C
Inst. Execution Times

ANDE

ANDNE

Legal Data Types

Execute

Not Execute

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

16.6 ms
16.6 ms
11.5 ms
42.6 ms
42.6 ms

16.5 ms
16.5 ms
11.4 ms
42.5 ms
42.5 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

16.6 ms
16.6 ms
11.5 ms
42.6 ms
42.6 ms

16.5 ms
16.5 ms
11.4 ms
42.5 ms
42.5 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.6 ms
42.6 ms
37.7 ms
66.5 ms
66.5 ms

42.5 ms
42.5 ms
37.6 ms
66.3 ms
66.3 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.6 ms
42.6 ms
37.7 ms
66.5 ms
66.5 ms

42.5 ms
42.5 ms
37.6 ms
66.3 ms
66.3 ms

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

16.7 ms
16.7 ms
11.6 ms
42.7 ms
42.7 ms

16.8 ms
16.8 ms
11.7 ms
42.9 ms
42.9 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

16.7 ms
16.7 ms
11.6 ms
42.7 ms
42.7 ms

16.8 ms
16.8 ms
11.7 ms
42.9 ms
42.9 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.7 ms
42.7 ms
37.9 ms
66.6 ms
66.6 ms

42.9 ms
42.9 ms
38.1 ms
66.8 ms
66.8 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.7 ms
42.7 ms
37.9 ms
66.6 ms
66.6 ms

42.9 ms
42.9 ms
38.1 ms
66.8 ms
66.8 ms

C7
Instruction Execution Times

DL05

Comparative Boolean (cont.)

Instruc
STR

Execute

Not Execute

17.0 ms
17.0 ms
11.7 ms
42.8 ms
42.8 ms

16.9 ms
16.9 ms
11.6 ms
42.7 ms
42.7 ms

1st

2nd

T, CT

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

17.0 ms
17.0 ms
11.7 ms
42.8 ms
42.8 ms

16.9 ms
16.9 ms
11.6 ms
42.7 ms
42.7 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

17.0 ms
17.0 ms
11.7 ms
42.8 ms
42.8 ms

16.9 ms
16.9 ms
11.6 ms
42.7 ms
42.7 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.9 ms
42.9 ms
38.1 ms
66.8 ms
66.8 ms

42.8 ms
42.8 ms
38.0 ms
66.7 ms
66.7 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.9 ms
42.9 ms
38.1 ms
66.8 ms
66.8 ms

42.8 ms
42.8 ms
38.0 ms
66.7 ms
66.7 ms

1st

2nd

T, CT

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

17.1 ms
17.1 ms
11.9 ms
43.0 ms
43.0 ms

17.2 ms
17.2 ms
12.0 ms
43.1 ms
43.1 ms

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

17.1 ms
17.1 ms
11.9 ms
43.0 ms
43.0 ms

17.2 ms
17.2 ms
12.0 ms
43.1 ms
43.1 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

17.1 ms
17.1 ms
11.9 ms
43.0 ms
43.0 ms

17.2 ms
17.2 ms
12.0 ms
43.1 ms
43.1 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

43.0 ms
43.0 ms
38.3 ms
67.0 ms
67.0 ms

43.1 ms
43.1 ms
38.4 ms
67.1 ms
67.1 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

43.0 ms
43.0 ms
38.3 ms
67.0 ms
67.0 ms

43.1 ms
43.1 ms
38.4 ms
67.1 ms
67.1 ms

Appendix C
Inst. Execution Times

STRN

Legal Data Types

C8
Instruction Execution Times

DL05

Comparative Boolean (cont.)

Instruc

Appendix C
Inst. Execution Times

OR

ORN

Legal Data Types

Execute

Not Execute

16.6 ms
16.6 ms
11.5 ms
42.6 ms
42.6 ms

16.5 ms
16.5 ms
11.4 ms
42.5 ms
42.5 ms

1st

2nd

T, CT

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

16.6 ms
16.6 ms
11.5 ms
42.6 ms
42.6 ms

16.5 ms
16.5 ms
11.4 ms
42.5 ms
42.5 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

16.6 ms
16.6 ms
11.5 ms
42.6 ms
42.6 ms

16.5 ms
16.5 ms
11.4 ms
42.5 ms
42.5 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.6 ms
42.6 ms
37.7 ms
66.5 ms
66.5 ms

42.5 ms
42.5 ms
37.6 ms
66.4 ms
66.4 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

42.6 ms
42.6 ms
37.7 ms
66.5 ms
66.5 ms

42.5 ms
42.5 ms
37.6 ms
66.4 ms
66.4 ms

1st

2nd

T, CT

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

15.8 ms
15.8 ms
10.8 ms
41.9 ms
41.9 ms

15.8 ms
15.8 ms
10.8 ms
41.9 ms
41.9 ms

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

15.8 ms
15.8 ms
10.8 ms
41.9 ms
41.9 ms

15.8 ms
15.8 ms
10.8 ms
41.9 ms
41.9 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

15.8 ms
15.8 ms
10.8 ms
41.9 ms
41.9 ms

15.8 ms
15.8 ms
10.8 ms
41.9 ms
41.9 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

41.8 ms
41.8 ms
37.1 ms
65.9 ms
65.9 ms

41.8 ms
41.8 ms
37.1 ms
65.9 ms
65.9 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

41.8 ms
41.8 ms
37.1 ms
65.9 ms
65.9 ms

41.8 ms
41.8 ms
37.1 ms
65.9 ms
65.9 ms

C9
Instruction Execution Times

DL05

Comparative Boolean (cont.)

Instruc
AND

Execute

Not Execute

15.6 ms
15.6 ms
10.9 ms
41.6 ms
41.6 ms

15.6 ms
15.6 ms
10.9 ms
41.6 ms
41.6 ms

1st

2nd

T, CT

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

15.6 ms
15.6 ms
10.9 ms
41.6 ms
41.6 ms

15.6 ms
15.6 ms
10.9 ms
41.6 ms
41.6 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

15.6 ms
15.6 ms
10.9 ms
41.6 ms
41.6 ms

15.6 ms
15.6 ms
10.9 ms
41.6 ms
41.6 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

41.6 ms
41.6 ms
36.9 ms
65.6 ms
65.6 ms

41.6 ms
41.6 ms
36.9 ms
65.6 ms
65.6 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

41.6 ms
41.6 ms
36.9 ms
65.6 ms
65.6 ms

41.6 ms
41.6 ms
36.9 ms
65.6 ms
65.6 ms

1st

2nd

T, CT

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

15.8 ms
15.8 ms
10.8 ms
41.9 ms
41.9 ms

15.7
15.7
10.8
41.9
41.9

1st

2nd

V: Data Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

15.8 ms
15.8 ms
10.8 ms
41.9 ms
41.9 ms

15.7 ms
15.7 ms
10.8 ms
41.9 ms
41.9 ms

V: Bit Reg.

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

15.8 ms
15.8 ms
10.8 ms
41.9 ms
41.9 ms

15.7 ms
15.7 ms
10.8 ms
41.9 ms
41.9 ms

P:Indir. (Data)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

41.8 ms
41.8 ms
37.8 ms
65.9 ms
65.9 ms

41.8 ms
41.8 ms
37.8 ms
65.9 ms
65.9 ms

P:Indir. (Bit)

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

41.8 ms
41.8 ms
37.8 ms
65.9 ms
65.9 ms

41.8 ms
41.8 ms
37.8 ms
65.9 ms
65.9 ms

Appendix C
Inst. Execution Times

ANDN

Legal Data Types

C10
Instruction Execution Times

Immediate
Instructions

Instruction

Appendix C
Inst. Execution Times

Legal Data Types

Execute

Not Execute

STRI

38.2 ms

38.2 ms

STRNI

38.5 ms

38.5 ms

ORI

37.7 ms

37.7 ms

ORNI

38.2 ms

38.2 ms

ANDI

37.7 ms

37.7 ms

ANDNI

38.1 ms

38.1 ms

OUTI

77.5 ms

77.5 ms

OROUTI

85.7 ms

85.7 ms

SETI

1st #:

68.0 ms

2nd #:

1st #:

2nd #:

RSTI

Timer, Counter,
and Shift Register

DL05

Immediate Instructions

(N pt)

108.5ms+1.6msxN

3.2 ms
4.3 ms

(N pt)

66.9
10.8ms+1.7msxN

3.3 ms
4.4 ms

DL05

Timer, Counter, and Shift Register

Instruction
TMR

TMRF

TMRA

TMRAF

CNT

Legal Data Types

1st

2nd

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

1st

2nd

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

1st

2nd

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

1st

2nd

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

1st

2nd

CT

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

Execute

Not Execute

64.0 ms
64.0 ms
58.1 ms
91.0 ms
91.0 ms

59.0 ms
59.0 ms
53.1 ms
86.0 ms
86.0 ms

64.8 ms
64.8 ms
59.5 ms
92.5 ms
92.5 ms

57.3 ms
57.3 ms
52.0 ms
85.0 ms
85.0 ms

72.2 ms
72.2 ms
65.7 ms
99.2 ms
99.2 ms

66.5 ms
66.5 ms
60.0 ms
93.5 ms
93.5 ms

71.4 ms
71.4 ms
65.2 ms
98.9 ms
98.9 ms

65.6 ms
65.6 ms
59.5 ms
93.1 ms
93.1 ms

79.5 ms
79.5 ms
73.7 ms
107.0 ms
107.0 ms

66.9 ms
66.9 ms
61.1 ms
94.4 ms
94.4 ms

C11
Instruction Execution Times

DL05

Timer, Counter, and Shift Register

Instruction
SGCNT

UDC

SR

Accumulator Data
Instructions

Legal Data Types

1st

2nd

CT

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

1st

2nd

CT

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

(N points to shift)

Execute

Not Execute

76.5 ms
76.5 ms
70.8 ms
106.8 ms
106.8 ms

75.3 ms
75.3 ms
69.6 ms
105.4 ms
105.4 ms

118.3 ms
118.3 ms
111.8 ms
145.0 ms
145.0 ms

101.1 ms
101.1 ms
94.6 ms
128.0 ms
128.0 ms

43.4ms+25.6msxN

31.4 ms

DL05

Accumulator / Stack Load and

Output Data Instructions
Instruction

Legal Data Types

Execute

Not Execute

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

43.7 ms
43.7 ms
42.7 ms
68.7 ms
68.7 ms

3.7 ms
3.7 ms
3.7 ms
3.7 ms
3.7 ms

LDD

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

47.1 ms
47.1 ms
42.8 ms
72.2 ms
72.2 ms

3.7 ms
3.7 ms
3.7 ms
3.7 ms
3.7 ms

LDF

1st

2nd

X, Y, C, S
T, CT, SP

K:Constant
(N pt)

65.8ms+13.9msxN

4.9 ms

LDA

O: (Octal constant for address)

42.7 ms

3.7 ms

OUT

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

16.6 ms
16.6 ms
41.8 ms
41.8 ms

3.7 ms
3.7 ms
3.7 ms
3.7 ms

OUTD

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

18.1 ms
18.1 ms
43.3 ms
43.3 ms

3.8 ms
3.8 ms
3.8 ms
3.8 ms

OUTF

1st

2nd

X, Y, C

K:Constant
(N pt)

61.9ms+22msxN

4.7 ms

41.1 ms

2.7 ms

POP

None

Appendix C
Inst. Execution Times

LD

C12
Instruction Execution Times

Appendix C
Inst. Execution Times

Logical
Instructions

Math Instructions

DL05

Logical (Accumulator) Instructions

Instruction

Legal Data Types

Execute

Not Execute

AND

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

23.5 ms
23.5 ms
48.3 ms
48.3 ms

3.9 ms
3.9 ms
3.9 ms
3.9 ms

ANDD

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

23.3 ms
23.3 ms
19.0 ms
48.3 ms
48.3 ms

3.7 ms
3.7 ms
3.9 ms
3.9 ms
3.9 ms

OR

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

23.9 ms
23.9 ms
48.8 ms
48.8 ms

3.7 ms
3.7 ms
3.8 ms
3.8 ms

ORD

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

23.8 ms
23.8 ms
19.4 ms
48.6 ms
48.6 ms

3.8 ms
3.8 ms
3.7 ms
3.7 ms
3.7 ms

XOR

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

23.5 ms
23.5 ms
48.3 ms
48.3 ms

3.9 ms
3.9 ms
3.9 ms
3.9 ms

XORD

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

23.3 ms
23.3 ms
19.0 ms
48.3 ms
48.3 ms

3.7 ms
3.7 ms
3.9 ms
3.9 ms
3.9 ms

CMP

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

25.4 ms
25.4 ms
50.0 ms
50.0 ms

3.7 ms
3.7 ms
3.7 ms
3.7 ms

CMPD

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

37.3 ms
37.3 ms
32.7 ms
62.0 ms
62.0 ms

3.9 ms
3.9 ms
3.7 ms
3.8 ms
3.8 ms
DL05

Math Instructions (Accumulator)

Instruction

Legal Data Types

Execute

Not Execute

ADD

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

140.7 ms
140.7 ms
185.1 ms
185.1 ms

3.7 ms
3.7 ms
3.7 ms
3.7 ms

ADDD

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

152.4 ms
152.4 ms
123.2 ms
193.5 ms
193.5 ms

3.9 ms
3.9 ms
3.7 ms
3.7 ms
3.7 ms

SUB

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

148.1 ms
148.1 ms
192.7 ms
192.7 ms

3.7 ms
3.7 ms
3.7 ms
3.7 ms

C13
Instruction Execution Times

DL05

Math Instructions (Accumulator)

Instruction

Legal Data Types

Execute

Not Execute

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

157.0 ms
157.0 ms
131.4 ms
201.9 ms
201.9 ms

3.9 ms
3.9 ms
3.9 ms
3.7 ms
3.7 ms

MUL

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

305.0 ms
305.0 ms
289.1 ms
349.6 ms
349.6 ms

3.7 ms
3.7 ms
3.7 ms
3.7 ms
3.7 ms

MULD

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

1261.3 ms
1261.3 ms
1307.3 ms
1307.3 ms

3.8 ms
3.8 ms
3.7 ms
3.7 ms

DIV

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

557.1 ms
557.1 ms
530.5 ms
580.5 ms
580.5 ms

3.7 ms
3.7 ms
3.7 ms
3.7 ms
3.7 ms

DIVD

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

562.2 ms
562.2 ms
596.4 ms
596.4 ms

3.8 ms
3.8 ms
3.7 ms
3.7 ms

INC

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

35.7 ms
35.7 ms
60.2 ms
60.2 ms

3.4 ms
3.4 ms
3.4 ms
3.4 ms

DEC

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

41.4 ms
41.4 ms
64.2 ms
64.2 ms

3.3 ms
3.3 ms
3.3 ms
3.3 ms

ADDB

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

69.5 ms
69.5 ms
67.3 ms
94.2 ms
94.2 ms

3.3 ms
3.3 ms
3.3 ms
3.6 ms
3.6 ms

SUBB

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

69.3 ms
69.3 ms
67.8 ms
94.3 ms
94.3 ms

3.3 ms
3.3 ms
3.5 ms
3.2 ms
3.2 ms

MULB

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

23.4 ms
23.4 ms
19.8 ms
48.5 ms
48.5 ms

3.2 ms
3.2 ms
3.3 ms
3.2 ms
3.2 ms

DIVB

V:Data Reg.
V:Bit Reg.
K:Constant
P:Indir. (Data)
P:Indir. (Bit)

76.1 ms
76.1 ms
76.9 ms
105.5 ms
105.5 ms

3.3 ms
3.3 ms
3.3 ms
3.2 ms
3.2 ms

Appendix C
Inst. Execution Times

SUBD

C14
Instruction Execution Times

DL05

Math Instructions (Accumulator)

Instruction

Bit Instructions

Legal Data Types

Appendix C
Inst. Execution Times

Not Execute

INCB

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

23.0 ms
23.0 ms
46.8 ms
46.8 ms

3.4 ms
3.4 ms
3.3 ms
3.3 ms

DECB

V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

23.2 ms
23.2 ms
47.5 ms
47.5 ms

2.5 ms
2.5 ms
3.4 ms
3.4 ms
DL05

Bit Instructions (Accumulator)

Instruction

Number
Conversion
Instructions

Execute

Execute

Not Execute

SUM

None

Legal Data Types

19.2 ms

2.3 ms

SHFR

V:Data Reg. (N bits)

V:Bit Reg. (N bits)
K:Constant (N bits)

23.0 ms
23.0 ms
20.3 ms

3.4 ms
3.4 ms
3.3 ms

SHFL

V:Data Reg. (N bits)

V:Bit Reg. (N bits)
K:Constant (N bits)

29.7 ms
29.7 ms
20.4 ms

3.4 ms
3.4 ms
3.3 ms

ENCO

None

12.6 ms

2.3 ms

DECO

None

20.3 ms

2.3 ms
DL05

Number Conversion Instructions

(Accumulator)
Execute

Not Execute

BIN

Instruction
None

75.8 ms

2.3 ms

BCD

None

159.9 ms

2.2 ms

INV

None

6.2 ms

2.3 ms

ATH

V:Data Reg. (N bits)

V:Bit Reg. (N bits)

97ms+20msxN

3.3 ms

HTA

V:Data Reg. (N bits)

V:Bit Reg. (N bits)

98ms+27msxN

2.1 ms

GRAY

None

224.7 ms

2.3 ms

SFLDGT

None

95.3 ms

2.2 ms

Table Instructions

Legal Data Types

DL05

Table Instructions
Instruction

Legal Data Types

MOV

V:Data Reg. / V:Bit Reg.

P:Indir. (Data) / P:Indir. (Bit)

MOVMC

Move from E2 to V:Data Reg.

Move from E2 to V:Bit Reg.
N= #of words

LDLBL

Execute

Not Execute

63ms+16msxN

3.3 ms

50ms+15msxN

3.3 ms

33.5 ms

4.2 ms

C15
Instruction Execution Times

CPU Control
Instructions

Program Control
Instructions

Network
Instructions

Instruction

Legal Data Types

Execute

Not Execute

NOP

None

1.1 ms

1.1 ms

END

None

24.0 ms

24.0 ms

STOP

None

10.0 ms

1.1 ms

RSTWDT

None

5.9 ms

2.2 ms

NOT

None

1.6 ms

1.6 ms

DL05

Program Control Instructions

Instruction

Legal Data Types

Execute

Not Execute

FOR

V, K

125.9 ms

14.5 ms

NEXT

None

64.4 ms

64.4 ms

GTS

27.5 ms

14.8 ms

SBR

1.5 ms

1.5 ms

RTC

None

25.7 ms

12.1 ms

RT

None

21.2 ms

21.2 ms

MLS

K (17)

35.2 ms

35.2 ms

MLR

K (07)

30.9 ms

30.9 ms

DL05

Interrupt Instructions
Instruction

Legal Data Types

Execute

Not Execute

ENI

None

24.2 ms

2.7 ms

DISI

None

9.4 ms

2.3 ms

INT

O(0,1)

7.5 ms

IRTC

None

0.9 ms

1.3 ms

IRT

None

6.6 ms

DL05

Network Instructions
Instruction

Legal Data Types

Execute

Not Execute

RX

X, Y, C, T, CT, SP, S, $
V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

852.0 ms
852.0 ms
852.0 ms
868.2 ms
868.2 ms

4.4 ms
4.4 ms
4.4 ms
4.2 ms
4.2 ms

WX

X, Y, C, T, CT, SP, S, $
V:Data Reg.
V:Bit Reg.
P:Indir. (Data)
P:Indir. (Bit)

1614.0 ms
1614.0 ms
1614.0 ms
1630.0 ms
1630.0 ms

4.4 ms
4.4 ms
4.4 ms
4.4 ms
4.4 ms

Appendix C
Inst. Execution Times

Interrupt
Instructions

DL05

CPU Control Instructions

C16
Instruction Execution Times

Message
Instructions

Appendix C
Inst. Execution Times

RLL PLUS
Instructions

Drum
Instructions

DL05

Message Instructions
Instruction

Legal Data Types

Execute

Not Execute

65.0 ms
65.0 ms
204.7 ms

4.4 ms
4.4 ms
4.4 ms

FAULT

V:Data Reg.
V:Bit Reg.
K:Constant

DLBL

NCON

ACON

PRINT

ASCII

631.0 ms

3.6 ms

RLL PLUS Instructions

Instruction

Legal Data Types

DL05
Execute

Not Execute

ISG

44.0 ms

41.1 ms

SG

44.0 ms

41.1 ms

JMP

76.0 ms

9.3 ms

NJMP

77.4 ms

9.3 ms

CV

42.1 ms

27.5 ms

CVJMP

89.5 ms

17.6 ms

DL05

Drum Instructions
Instruction

Legal Data Types

Execute

Not Execute

DRUM

CT

840.0 ms

339.6 ms

EDRUM

CT

753.2 ms

357.0 ms

Special Relays

In This Appendix. . . .

DL05 PLC Special Relays

1D

D2
Special Relays

Appendix A

DL05 PLC Special Relays

Special Relays are just contacts that are set by the CPU operating system to
indicate a particular system event has occurred. These contacts are available for
use in your ladder program. Knowing just the right special relay contact to use for a
particular situation can save lot of programming time. Since the CPU operating
system sets and clears special relay contacts, the ladder program only has to use
them as inputs in ladder logic.
Startup and
Real-Time Relays

Appendix D
Special Relays

CPU Status Relays

SP0

First scan

on for the first scan after a power cycle or program to run transition
only. The relay is reset to off on the second scan. It is useful where a
function needs to be performed only on program startup.

SP1

Always ON

provides a contact to insure an instruction is executed every scan.

SP3

1 minute clock

on for 30 seconds and off for 30 seconds.

SP4

1 second clock

on for 0.5 second and off for 0.5 second.

SP5

100 ms clock

on for 50 ms. and off for 50 ms.

SP6

50 ms clock

on for 25 ms. and off for 25 ms.

SP7

Alternate scan

on every other scan.

SP11

Forced run
mode

on when the mode switch is in the run position and the CPU is
running.

SP12

Terminal
run mode

on when the CPU is in the run mode.

SP13

Test
run mode

on when the CPU is in the test run mode.

SP15

Test
stop mode

on when the CPU is in the test stop mode.

SP16

Terminal
PGM mode

on when the mode switch is the the TERM position and the CPU is in
program mode.

SP17

Forced stop

on when the mode switch is in the STOP position.

SP20

Forced
stop mode

on when the STOP instruction is executed.

SP22

Interrupt enabled on when interrupts have been enabled using the ENI instruction.

D3
Special Relays

System Monitoring

Accumulator
Status

Override setup
relay

on when the override function is used.

SP37

Scan control
error

on when the actual scan time runs over the prescribed scan time.

SP40

Critical error

on when a critical error such as I/O communication loss has

occurred.

SP41

Warning

on when a non critical error has occurred.

SP42

Diagnostics error on when a diagnostics error or a system error occurs.

SP44

Program
memory error

on when a memory error such as a memory parity error has

occurred.

SP45

I/O error

on when an I/O error such as a blown fuse occurs.

SP46

Communications
error

on when a communication error occurs on any of the CPU ports.

SP50

Fault instruction

on when a Fault Instruction is executed.

SP51

Watch Dog
timeout

on if the CPU Watch Dog timer times out.

SP52

Grammatical
error

on if a grammatical error has occurred either while the CPU is

running or if the syntax check is run. V7755 will hold the exact error
code.

SP53

Solve logic error

on if CPU cannot solve the logic.

SP54

Communication
error

on whent RX, WX, RD, WT instructions are executed with the wrong
parameters.

SP56

Table instuction
overrun

on if a table instruction with a pointer is executed and the pointer

value is outside the table boundary.

SP60

Value less than

on when the accumulator value is less than the instruction value.

SP61

Value equal to

on when the accumulator value is equal to the instruction value.

SP62

Greater than

on when the accumulator value is greater than the instruction value.

SP63

Zero

on when the result of the instruction is zero (in the accumulator.)

SP64

Half borrow

on when the 16 bit subtraction instruction results in a borrow.

SP65

Borrow

on when the 32 bit subtraction instruction results in a borrow.

SP66

Half carry

on when the 16 bit addition instruction results in a carry.

SP67

Carry

when the 32 bit addition instruction results in a carry.

SP70

Sign

on anytime the value in the accumulator is negative.

SP71

Pointer
reference error

on when the V-memory specified by a pointer (P) is not valid.

SP73

Overflow

on if overflow occurs in the accumulator when a signed addition or

subtraction results in an incorrect sign bit.

SP75

Data error

on if a BCD number is expected and a nonBCD number is

encountered.

SP76

Load zero

on when any instruction loads a value of zero into the accumulator.

Appendix D
Special Relays

SP36

D4

Appendix A

Special Relays

HSIO Pulse
Output Relay

SP104 Profile Complete

on when the pulse output profile is completed. (Mode 30)

Communication
Monitoring Relays

SP116

CPU port busy

Port 2

on when port 2 is the master and sending data.

SP117

Communications on when port 2 is the master and has a communication error.

error Port 2

Appendix D
Special Relays

Equal Relays for

HSIO Mode 10
Counter Presets

SP540 Current = target value

on when the counter current value equals the value in

V2320 / V2321.

SP541 Current = target value

on when the counter current value equals the value in

V2322 / V2323.

SP542 Current = target value

on when the counter current value equals the value in

V2324 / V2325.

SP543 Current = target value

on when the counter current value equals the value in

V2326 / V2327.

SP544 Current = target value

on when the counter current value equals the value in

V2330 / V2331.

SP545 Current = target value

on when the counter current value equals the value in

V2332 / V2333.

SP546 Current = target value

on when the counter current value equals the value in

V2334 / V2335.

SP547 Current = target value

on when the counter current value equals the value in

V2336 / V2337.

SP550 Current = target value

on when the counter current value equals the value in

V2340 / V2341.

SP551 Current = target value

on when the counter current value equals the value in

V2342 / V2343.

SP552 Current = target value

on when the counter current value equals the value in

V2344 / V2345.

SP553 Current = target value

on when the counter current value equals the value in

V2346 / V2347

SP554 Current = target value

on when the counter current value equals the value in

V2350 / V2351.

SP555 Current = target value

on when the counter current value equals the value in

V2352 / V2353.

SP556 Current = target value

on when the counter current value equals the value in

V2354 / V2355.

SP557 Current = target value

on when the counter current value equals the value in

V2356 / V2357.

D5
Special Relays

SP560 Current = target value

on when the counter current value equals the value in

V2360 / V2361.

SP561 Current = target value

on when the counter current value equals the value in

V2362 / V2363.

SP562 Current = target value

on when the counter current value equals the value in

V2364 / V2365.

SP563 Current = target value

on when the counter current value equals the value in

V2366 / V2367.

SP564 Current = target value

on when the counter current value equals the value in

V2370 / V2371.

SP565 Current = target value

on when the counter current value equals the value in

V2372 / V2373.

SP566 Current = target value

on when the counter current value equals the value in

V2374 / V2375.

SP567 Current = target value

on when the counter current value equals the value in

V2376 / V2377.

Appendix D
Special Relays

DL05
Product Weights
In This Appendix. . . .

Product Weight Table

1E

E2
Product Weights

Appendix E
Product Weights

Appendix A

Product Weight Table

PLC

Weight

D005AR

0.60 lb. (272g)

D005DR

0.60 lb. (272g)

D005AD

0.58 lb. (263g)

D005DD

0.56 lb. (254g)

D005AA

0.60 lb. (272g)

D005DA

0.60 lb. (272g)

D005DRD

0.56 lb. (254g)

D005DDD

0.58 lb. (263g)

European Union
Directives (CE)
In This Appendix. . . .

European Union (EU) Directives

Basic EMC Installation Guidelines

1F

F2
European Union Directives

Appendix A

European Union (EU) Directives

NOTE: The information contained in this section is intended as a guideline and is
based on our interpretation of the various standards and requirements. Since the
actual standards are issued by other parties and in some cases Governmental
agencies, the requirements can change over time without advance warning or notice.
Changes or additions to the standards can possibly invalidate any part of the
information provided in this section.

Member Countries

Applicable
Directives

Appendix F
EU Directives

Compliance

This area of certification and approval is absolutely vital to anyone who wants to do
business in Europe. One of the key tasks that faced the EU member countries and
the European Economic Area (EEA) was the requirement to bring several similar yet
distinct standards together into one common standard for all members. The primary
purpose of a single standard was to make it easier to sell and transport goods
between the various countries and to maintain a safe working and living
environment. The Directives that resulted from this merging of standards are now
legal requirements for doing business in Europe. Products that meet these
Directives are required to have a CE mark to signify compliance.
As of January 1, 1997, the members of the EU are Austria, Belgium, Denmark,
Finland, France, Germany, Greece, Ireland, Italy, Luxembourg, The Netherlands,
Portugal, Spain, Sweden, and the United Kingdom. Iceland, Liechtenstein, and
Norway together with the EU members make up the European Economic Area
(EEA) and all are covered by the Directives.
There are several Directives that apply to our products. Directives may be amended,
or added, as required.
S Electromagnetic Compatibility Directive (EMC) this Directive
attempts to ensure that devices, equipment, and systems have the
ability to function satisfactorily in its electromagnetic environment
without introducing intolerable electromagnetic disturbance to anything
in that environment.
S Machinery Safety Directive this Directive covers the safety aspects
of the equipment, installation, etc. There are several areas involved,
including testing standards covering both electrical noise immunity and
noise generation.
S Low Voltage Directive this Directive is also safety related and
covers electrical equipment that has voltage ranges of 501000VAC
and/or 751500VDC.
S Battery Directive this Directive covers the production, recycling, and
disposal of batteries.
Certain standards within each Directive already require mandatory compliance. The
EMC Directive, which has gained the most attention, became mandatory as of
January 1, 1996. The Low Voltage Directive became mandatory as of January 1,
1997.
Ultimately, we are all responsible for our various pieces of the puzzle. As
manufacturers, we must test our products and document any test results and/or
installation procedures that are necessary to comply with the Directives. As a
machine builder, you are responsible for installing the products in a manner which
will ensure compliance is maintained. You are also responsible for testing any
combinations of products that may (or may not) comply with the Directives when
used together.

F3
European Union Directives

The end user of the products must comply with any Directives that may cover
maintenance, disposal, etc. of equipment or various components. Although we
strive to provide the best assistance available, it is impossible for us to test all
possible configurations of our products with respect to any specific Directive.
Because of this, it is ultimately your responsibility to ensure that your machinery (as
a whole) complies with these Directives and to keep up with applicable Directives
and/or practices that are required for compliance.
As of January 1, 1999, the DL05, DL205, DL305, and DL405 PLC systems
manufactured by Koyo Electronics Industries or FACTS Engineering, when properly
installed and used, conform to the Electromagnetic Compatibility (EMC), Low
Voltage Directive, and Machinery Directive requirements of the following standards.
S EMC Directive Standards Revelant to PLCs
EN500811 Generic emission standard for residential, commercial,
and light industry
EN500812 Generic emission standard for industrial environment.
EN500821 Generic immunity standard for residential, commercial,
and light industry
EN500822 Generic immunity standard for industrial environment.
S Low Voltage Directive Standards Applicable to PLCs
EN610101 Safety requirements for electrical equipment for
measurement, control, and laboratory use.
S Product Specific Standard for PLCs
EN611312 Programmable controllers, equipment requirements and
tests. This standard replaces the above generic standards for immunity
and safety. However, the generic emissions standards must still be used
in conjunction with the following standards:
EN 61000-3-2 Harmonics
EN 61000-3-2 Fluctuations
PLCDirect is currently in the process of changing their testing
procedures from the generic standards to the product specific
standards.
Special Installation The installation requirements to comply with the requirements of the Machinery
Directive, EMC Directive and Low Voltage Directive are slightly more complex than
Manual
the normal installation requirements found in the United States. To help with this, we
have published a special manual which you can order:
S DAEUM EU Installation Manual that covers special installation
requirements to meet the EU Directive requirements. Order this manual
to obtain the most up-to-date information.

Appendix F
EU Directives

F4
European Union Directives

Appendix A

Other Sources of
Information

Although the EMC Directive gets the most attention, other basic Directives, such as
the Machinery Directive and the Low Voltage Directive, also place restrictions on the
control panel builder. Because of these additional requirements it is recommended
that the following publications be purchased and used as guidelines:
S BSI publication TH 42073: February 1996 covers the safety and
electrical aspects of the Machinery Directive
S EN 602041:1992 General electrical requirements for machinery, including
Low Voltage and EMC considerations
S IEC 100052: EMC earthing and cabling requirements
S IEC 100051: EMC general considerations
It may be possible for you to obtain this information locally; however, the official
source of applicable Directives and related standards is:
The Office for Official Publications of the European Communities
L2985 Luxembourg; quickest contact is via the World Wide Web at
http://euroop.eu.int/indexn.htm
Another source is:
British Standards Institution Sales Department
Linford Wood
Milton Keynes
MK14 6LE
United Kingdom; the quickest contact is via the World Wide Web at
http://www.bsi.org.uk

Basic EMC Installation Guidelines

Appendix F
EU Directives

Enclosures

The simplest way to meet the safety requirements of the Machinery and Low Voltage
Directives is to house all control equipment in an industry standard lockable steel
enclosure. This normally has an added benefit because it will also help ensure that
the EMC characteristics are well within the requirements of the EMC Directive.
Although the RF emissions from the PLC equipment, when measured in the open
air, are well below the EMC Directive limits, certain configurations can increase
emission levels. Holes in the enclosure, for the passage of cables or to mount
operator interfaces, will often increase emissions.

F5
European Union Directives

AC Mains Filters

DL05, DL205 and DL305 AC

powered base power supplies
require extra mains filtering to
comply with the EMC Directive
on conducted RF emissions.
All PLC equipment has been
tested with filters from
Schaffner,
which
reduce
emissions levels if the filters
are properly grounded (earth
ground). A filter with a current
rating suitable to supply all
PLC power supplies and AC
input modules should be
selected. We suggest the
FN2010 for DL05/DL205
systems and the FN2080 for
DL305
systems.
DL405
systems do not require extra
filtering.

Filter

Schaffner
FN2010

Transient
Suppressor

To AC
Input
Circuitry

Fused
Terminals

Earth
Terminal
L N

NOTE: Very few mains filters can reduce problem emissions to negligible levels. In
some cases, filters may increase conducted emissions if not properly matched to the
problem emissions.
Suppression and
Fusing

In order to comply with the fire risk requirements of the Low Voltage and Machinery

Directive electrical standards EN 610101, and EN 602041, by limiting the power

into unlimited mains circuits with power leads reversed, it is necessary to fuse both
AC and DC supply inputs. You should also install a transient voltage suppressor
across the power input connections of the PLC. Choose a suppressor such as a metal
oxide varistor, with a rating of 275VAC working voltage for 230V nominal supplies
(150VAC working voltage for 115V supplies) and high energy capacity (eg. 140
joules).
Transient suppressors must be protected by fuses and the capacity of the transient
suppressor must be greater than the blow characteristics of the fuses or circuit
breakers to avoid a fire risk. A recommended AC supply input arrangement for Koyo
PLCs is to use twin 3 amp TT fused terminals with fuse blown indication, such as
DINnectors DNF10L terminals, or twin circuit breakers, wired to a Schaffner FN2010
filter or equivalent, with high energy transient suppressor soldered directly across the
output terminals of the filter. PLC system inputs should also be protected from voltage
impulses by deriving their power from the same fused, filtered, and surge-suppressed
supply.
A heavy-duty star earth terminal block should be provided in every cubicle for the
connection of all earth ground straps, protective earth ground connections, mains
filter earth ground wires, and mechanical assembly earth ground connections. This
should be installed to comply with safety and EMC requirements, local standards, and
the requirements found in IEC 100052.The Machinery Directive also requires that
the common terminals of PLC input modules, and common supply side of loads driven
from PLC output modules should be connected to the protective earth ground
terminal.

Appendix F
EU Directives

Internal Enclosure
Grounding

F6
European Union Directives

Appendix A

Equipotential
Grounding

Key

Serial Communication Cable

Equi-potential Bond

Adequate site earth grounding must be provided for equipment containing modern
electronic circuitry. The use of isolated earth electrodes for electronic systems is
forbidden in some countries. Make sure you check any requirements for your
particular destination. IEC 100052 covers equi-potential bonding of earth grids
adequately, but special attention should be given to apparatus and control cubicles
that contain I/O devices, remote I/O racks, or have inter-system communications with
the primary PLC system enclosure. An equi-potential bond wire must be provided
alongside all serial communications cables, and to any separate items of the plant
which contain I/O devices connected to the PLC. The diagram shows an example
of four physical locations connected by a communications cable.

Communications
and Shielded
Cables

Screened
Cable

Conductive
Adapter

Serial
I/O

To Earth
Block
Equi-potential
Bond

Appendix F
EU Directives

Control Cubicle

Good quality 24 AWG minimum twisted-pair shielded cables, with overall foil and
braid shields are recommended for analog cabling and communications cabling
outside of the PLC enclosure. To date it has been a common practice to only provide
an earth ground for one end of the cable shield in order to minimize the risk of noise
caused by earth ground loop currents between apparatus. The procedure of only
grounding one end, which primarily originated as a result of trying to reduce hum in
audio systems, is no longer applicable to the complex industrial environment.
Shielded cables are also efficient emitters of RF noise from the PLC system, and can
interact in a parasitic manner in networks and between multiple sources of
interference.

F7
European Union Directives

Analog and RS232

Cables

Multidrop Cables

The recommendation is to use shielded cables as electrostatic pipes between

apparatus and systems, and to run heavy gauge equi-potential bond wires
alongside all shielded cables. When a shielded cable runs through the metallic wall
of an enclosure or machine, it is recommended in IEC 100052 that the shield
should be connected over its full perimeter to the wall, preferably using a conducting
adapter, and not via a pigtail wire connection to an earth ground bolt. Shields must be
connected to every enclosure wall or machine cover that they pass through.
Providing an earth ground for both ends of the shield for analog circuits provides the
perfect electrical environment for the twisted pair cable as the loop consists of signal
and return, in a perfectly balanced circuit arrangement, with connection to the
common of the input circuitry made at the module terminals. RS232 cables are
handled in the same way.
RS422 twin twisted pair, and RS485 single twisted pair cables also require a 0V link,
which has often been provided in the past by the cable shield. It is now
recommended that you use triple twisted pair cabling for RS422 links, and twin
twisted pair cable for RS485 links. This is because the extra pair can be used as the
0V inter-system link. With loop DC power supplies earth grounded in both systems,
earth loops are created in this manner via the inter-system 0v link. The installation
guides encourage earth loops, which are maintained at a low impedance by using
heavy equi-potential bond wires. To account for nonEuropean installations
using single-end earth grounds, and sites with far from ideal earth ground
characteristics, we recommend the addition of 100 ohm resistors at each 0V
link connection in network and communications cables.
Last Slave
TXD 0V RXD
+
+
100W

Slave n

Master

TXD 0V RXD
+
+

RXD 0V TXD
+
+

100W
100W
Termination

Termination

Appendix F
EU Directives

When you run cables between PLC items within an enclosure which also contains
Shielded Cables
within Enclosures susceptible electronic equipment from other manufacturers, remember that these cables
may be a source of RF emissions. There are ways to minimize this risk. Standard data
cables connecting PLCs and/or operator interfaces should be routed well away from other
equipment and their associated cabling. You can make special serial cables where the
cable shield is connected to the enclosures earth ground at both ends, the same way as
external cables are connected.
For safety reasons, it is a specific requirement of the Machinery Directive that a keyswitch
Network Isolation
must be provided that isolates any network input signal during maintenance, so that
remote commands cannot be received that could result in the operation of the machinery.
The FAISONET does not have a keyswitch! Use a keylock and switch on your enclosure
which when open removes power from the FAISONET. To avoid the introduction of
noise into the system, any keyswitch assembly should be housed in its own earth
grounded steel box and the integrity of the shielded cable must be maintained.
Again, for further information on EU directives we recommend that you get a copy of
our EU Installation Manual (DAEUM). Also, if you are connected to the World
Wide Web, you can check the EU Commisions official site at:
http://europ.eu.int/

F8
European Union Directives

Appendix A

DC Powered
Versions

Due to slightly higher emissions radiated by the DC powered versions of the DL05, and
the differing emissions performance for different DC supply voltages, the following
stipulations must be met.
S The PLC must be housed within a metallic enclosure with a minimum
amount of orifices.
S The communication cable and all I/O cables must pass through suitable
ferrite beads which must be mounted within the enclosure. The I/O
cables can be bundled together and passed through the same ferrite.
Recommended ferrite beads and split cores are detailed below. These were used in
extensive EMC tests and found to successfully attenuate radiated emissions to a
high degree.
For I/O Bundle

Manufacturer

Mfg. Part No.

OD
mm

ID
mm

L
mm

1 Turn
L/25 MHz
W

1 Turn
L/100 MHz
W

2 Turn
L/25 MHz
W

2 Turn
L/100 MHz
W

RS Online

2606795

17.5

9.5

28.5

153

210

649

632

FairRite

2643665702

17.5

9.5

28.5

153

210

649

632

742 700 9

17.5

9.5

28.5

153

210

649

632

Wurth Elektronik

Appendix F
EU Directives

For Communication Cable

RS Online

2224416

26.6

FairRite

0444167281

26.6

Richco

MTFC 231114T

26.6

16.6

72

132

301

547

10.7

16.6

72

132

301

547

10.7

16.6

72

132

301

547

F9
European Union Directives

Items Specific to
the DL05

S
S
S
S
S

S
S

The rating between all circuits in this product are rated as basic
insulation only, as appropriate for single fault conditions.
There is no isolation offered between the PLC and the analog inputs of
this product.
It is the responsibility of the system designer to earth one side of all
control and power circuits, and to earth the braid of screened cables.
This equipment must be properly installed while adhering to the
guidelines of the in house PLC installation manual DAEUM, and the
installation standards IEC 100051, IEC 100052 and IEC 11314.
It is a requirement that all PLC equipment must be housed in a
protective steel enclosure, which limits access to operators by a lock
and power breaker. If access is required by operators or untrained
personnel, the equipment must be installed inside an internal cover or
secondary enclosure.
It should be noted that the safety requirements of the machinery
directive standard EN602041 state that all equipment power circuits
must be wired through isolation transformers or isolating power
supplies, and that one side of all AC or DC control circuits must be
earthed.
Both power input connections to the PLC must be separately fused
using 3 amp T type antisurge fuses, and a transient suppressor fitted
to limit supply overvoltages.
If the user is made aware by notice in the documentation that if the
equipment is used in a manner not specified by the manufacturer the
protection provided by the equipment may be impaired.

Appendix F
EU Directives

1
Index

A
Accumulating Fast Timer instruction, 533
Accumulating Timer instruction, 533
Accumulator Stack Load Instructions, 543

Binary Coded Decimal instruction, 582, 584

Binary instruction, 583
Bit Operation Instructions, 578
Boolean Instructions, 54, 59
Bumpless transfer, 825

Add Binary instruction, 572, 574

Add Double instruction, 564
Add instruction, 563

And Double instruction, 556

Cables
operator interfaces, 214
programming, 19
programming devices, 214

And If Equal instruction, 522

Calculating Program Execution Time, 419

And If Not Equal instruction, 522

Cascade control, 851

And Immediate instruction, 527

Common terminals, 216

And instruction, 511, 555

comparative, 525

Communication Port Specifications, 432

Agency approvals, 28
Alarms, PID, 853

And Negative Differential instruction, 517

Communication ports, 114

pinout diagrams, 44

And Not Immediate instruction, 527

Communications problems, 97

And Not instruction, 511

comparative, 525

Comparative Boolean, 520

And Positive Differential instruction, 517

And Store instruction, 512
ASCII Constant instruction, 5106, 5108
ASCII TO HEX instruction, 586
Auxiliary Functions, 48
Auxiliary functions, A2

B
Bias freeze, 837

Compare Double instruction, 562

Compare instruction, 561
Components, 17
Connections
operator interface, 214
power input, 19
programming devices, 19, 214, 45
Solid State field devices, 217
toggle switches, 18
Connector
common terminals, 216
diagram, 216

Index2
removal, 25
Control Output, 829
Control Relay Bit Map, 430
Converge Jump instruction, 723
Converge Stage instruction, 723
Convergence Stages, 719
Converting Number Formats
ASCII TO HEX, 586
Hex to ASCII, 587
Counter instruction, 536

counter assignments, 66
drum control techniques, 610
EDRUM (Event Drum), 614
handheld programmer mnemonics, 616
overview of drum operation, 68
powerup state, 69
selfresetting, 611
step transition, 64
Drum sequencer programming, 112

Counter Instructions, 530

Emergency stop, 23

Counter Status Bit Map, 431

Enable Interrupt instruction, 5104

CPU
changing modes, 47
configuration, A5
features, 42
hardware setup, 44
indicators, 96
instruction list, 52
Mode switch, 46
specifications, 43
status indicators, 46

Encode instruction, 577, 579, 581

CPU Indicator, 97

Error term, 830

CPU Operation, 411

European Directives, F2

CPU Scan Time, 418

Exclusive Or Double instruction, 560

End Instruction, 54
Environmental specifications, 28
Equal relays, 39, D3, D5
Error codes
code locations, 93
listing, B2B9
pulse output errors, 343

Exclusive Or instruction, 559

D
Data Label instruction, 5106, 5108
Decrement Binary instruction, 571

Execution Times, C3

Derivative term, 834

Fatal Errors, 92

Diagnostics, 92

Fault instruction, 5107

Dimensions, 26

Feed forward control, 847

DIN rail mounting, 29

For instruction, 597

Direct-acting loop, 833

Fuse protection, 210

DirectNET, 435
Divide Double instruction, 570
Divide instruction, 569
DL05 Micro PLC
front panel, 24
mounting guidelines, 26
unit dimensions, 26
Drum instruction, 62, 612
chart representation, 63

G
Goto Subroutine instruction, 599
Gray Code instruction, 589

Index3
H
Handheld programmer, A6
EEPROM operations, A7
HEX TO ASCII instructions, 587

Interrupt Return instruction, 5104

Interrupts
external, 347
HSIO input, 345
timed, 347

Highspeed I/O
configuration, 35
discrete inputs with filter, 353
features, 32
highspeed counter, 36
highspeed interrupts, 345
I/O Point Usage, 34
modes, 34
programming, 311, 322, 341
pulse catch input, 350
pulse output, 325

Invert instruction, 585

Home search profile, 338

Load Double instruction, 549

J
Jump instruction, 77, 722

L
Load Address instruction, 551
Load Formatted instruction, 550

I
I/O Response Time, 415

Load instruction, 548

Load Label instruction, 591, 593
Logical Instructions, 555

I/O Type Selection, 16

Increment Binary instruction, 571
Initial Stage instruction, 722

Initial Stages, 75

Maintenance, 92

Instructions
accumulator / stack Load, 543
bit operation, 578
boolean, 59
capable of run time edits, 914
comparative boolean, 520
drum, 62, 612
execution times, C2, C3, C6
immediate, 526
interrupt, 5104
list of, 52
logical, 555
math, 563
message, 5107
network, 5114
number conversion, 583
program control, 597
stage, 721
stage programming, 72
table, 592
timer, counter, and shift register, 530

Manual, organization, 14

Integral term, 834

Move instruction, 592

Interrupt Instructions, 5104

Move Memory Cartridge instruction, 591, 593

Interrupt Return Conditional instruction, 5104

Master Line Reset instruction, 5102

Master Line Set instruction, 5102
Math Instructions, 563
Memory
EEPROM, 113
FLASH, 113
Memory Map, 422, 428
Message Instructions, 5107
MODBUS, 434, 441
Mode switch, 46
Modes
at powerup, 47
changing, 47
Motion control profile, 325
Mounting guidelines, 26
DIN rail, 29

Index4
Multiply Binary instruction, 576

Out Immediate instruction, 528

Multiply Double instruction, 568

Out instruction, 513, 552

Multiply instruction, 567

Output Data Instructions, 543

Network Configuration and Connections, 432

Panel layout, 27

Network Diagrams, 432, 433

Part Numbers, 15, 16

Network Instructions, 5114

Password, 410, A8

Network master operation, 441

Pause instruction, 519

Network slave operation, 436

On/Off control, 849

PID Loops
Alarms, process, 853
algorithms, 831
basic operation, 819
bibliography, 863
cascade control, 851
data configuration, 826
features, 82
feed forward control, 847
On/Off control, 849
Ramp/Soak generator, 857
sample rate, 813
scheduling, 813
setup parameters, 86
terminology, 84, 864
troubleshooting tips, 862
tuning procedure, 838

One shot, 514

PID loops, auto tuning, 838

Or Double instruction, 558

PLC Numbering Systems, 420

Or If Equal instruction, 521

Pop instruction, 553

Or If Not Equal instruction, 521

Position algorithm, 831

Or Immediate instruction, 526

Positive Differential instruction, 514

Or instruction, 510, 557

comparative, 524

Power indicator, 96

Or Negative Differential instruction, 516

Presets, 38
calculating values, 310
starting location, 39

Next instruction, 597

NonFatal Errors, 92
Normally Closed Contact, 54
Not instruction, 514
Not Jump instruction, 722
Number Conversion Instructions, 583
Numbering Systems, 420
Numerical Constant instruction, 5106, 5108

Or Not Immediate instruction, 526

Or Not instruction, 510
comparative, 524

Power wiring, 19

Print Message instruction, 5110

Or Out Immediate instruction, 528

Process control, 817

Or Out instruction, 513

Product Weight Table, E2

Or Positive Diffential instruction, 516

Profiles
home search, 338
motion control, 325
registration, 330, 335
trapezoidal, 330, 332

Or Store instruction, 512

Out Double instruction, 552
Out Formatted instruction, 553

Index5
velocity, 330, 340
Program Control Instructions, 597
Program Execution Time, 419
Program Mode, 412
Programming, concepts, 112
Programming Methods, 15
examples, 110
Proportional term, 834

Q
Quick Start, 17

corresponding to error codes, 93

Specifications
CPU, 43
D005AA, 234
D005AD, 230
D005AR, 226
D005DA, 236
D005DD, 232
D005DDD, 240
D005DR, 228
D005DRD, 238
Discrete option modules, 242
environmental, 28
input power, 211
motion profiles, 328
Stage Control / Status Bit Map, 429

R
Ramp/soak generator, 857
Read from Network instruction, 5114
Registration profile, 330, 335
Relay wiring, 219
prolonging contact life, 221
Reset Immediate instruction, 529
Reset instruction, 518
Retentive Memory Ranges, 49
Reverse-acting loop, 833
Run Indicator, 97
Run Mode, 412
Run time edits, 914

Stage Counter instruction, 538, 716

Stage instructions, 721
Stage programming, 112, 72
convergence, 719
emergency stop, 714
four steps to writing a stage program, 79
garage door opener example, 710
initial stages, 75
introduction, 72
jump instruction, 77
mutually exclusive transitions, 714
parallel processes, 712
parallel processing concepts, 719
power flow transition, 718
program organization, 715
questions and answers, 725
stage instruction characteristics, 76
stage view, 718
state transition diagrams, 73
supervisor process, 717
timer inside stage, 713

Safety guidelines, 22

Standard RLL Programming, 112

Scratchpad memory, 110

Status Indicators, 46, 96

Set Immediate instruction, 529

Store If Equal instruction, 520

Set instruction, 518

Store If Not Equal instruction, 520

Setpoint, 827

Store immediate instruction, 526

Shift Register instruction, 542

Store instruction, 59
comparative, 523

Shift Register Instructions, 530

Shift Right instruction, 580
Shuffle Digits instruction, 590
Sinking / sourcing I/O, 215
Special relays, 38, D2

Store Negative Differential instruction, 515

Store Not Immediate instruction, 526
Store Not instruction, 59
comparative, 523

Index6
Store Positive Differential instruction, 515
Subroutine Return Conditional instruction, 599

Troubleshooting guide
HSIO Mode 20, 324
HSIO Mode 30, 343

Subroutine Return instruction, 599

Subtract Binary instruction, 573, 575

Subtract double instruction, 566

Subtract instruction, 565

Up Down Counter instruction, 540

Sum instruction, 578

System design, 111

System Vmemory, 426

Vmemory, 426
Velocity algorithm, 831

Velocity profile, 330, 340

Table Instructions, 592

Technical support, 12

Time-proportioning control, 849

Timer Fast instruction, 531

Web site, 12

Timer instruction, 531

Wiring
counter input, 37
counter outputs, 37
DC inputs, 222
DC Outputs, 223
drive inputs, 327
emergency stop, 23
encoder, 33
fuse protection, 212
High Speed I/O, 224
power input, 19, 210, 211
pulse output, 327

Timer Instructions, 530

Timer Status Bit Map, 431
Trapezoidal profile, 330, 332
Troubleshooting, 92
communications, 97
electrical noise, 910
error codes, B2
I/O points, 98
program debug, 911

Informaes sobre programao

www.soliton.com.br - e-mail: soliton@soliton.com.br

SOLITON CONTROLES INDUSTRIAIS LTDA

Rua Alfredo Pujol, 1010 - Santana - So Paulo - SP.
Tel:11 - 6950-1834 / Fax: 11 - 6979-8980 - e-mail: vendas@soliton.com.br