Chapter 4 - AutomationDirect
Contents
1. 5 slot local CPU base 8 slot local CPU base with a 8 slot local CPU base with a with a maximum of two 5 5 slot expansion base 8 slot and 5 slot expansion slot expansion bases base 8 am ER Bn e 6 jo S o Bi RE 9 T F o ER LED e c er l Q Peri pclae f Q og zm a1 S 33 re re ag r 8 sio Jo o co LO Y 9 o P Q o Q q O 5 9 e 9 9 Q 2 N E 0 i f a i5 8 slot local CPU base with a 8 slot expansion base d b Q o Q 8 sio A 9 p 9 o 1 Gy LO ft 0 DL350 User Manual 2nd Edition c ie 49 E 2 c e Oo c O O m 2 Ao Nc t System Design and Configuration 8 slot local CPU base with two 8 10 slot local CPU base with a 10 slot local CPU base with a slot expansion bases 5 slot expansion base 10 slot expansion base a i So 5 sI5 B sb E i 9 A Of dg e Yo E e 70 tT 15 Lo 6 6 LO x o Q o2. I O Point 5V Power 9V Power 24V Power External Power Required Required in mA Required in mA Required in mA Source Required Relay Output Modules D3 08TR 0 360 0 None F3 08TRS 1 8 0 296 0 None F3 08TRS 2 8 0 296 0 None D3 16TR 16 0 480 0 None Analog D3 04AD 16 0 55 0 24VDC 9 65mA max F3 04ADS 16 0 183 50 None F3 08AD 16 0 25 37 None F3 08TEMP 16 0 25 37 None F3 08THM n 16 0 50 34 None F3 16AD 16 0 33 47 None D3 02DA 16 0 80 0 24VDC 9 170mA max F3 04DA 1 16 0 144 108 None F3 04DA 2 16 0 144 108 None F3 04DAS 16 0 154 145 None Communications and Networking FA UNICON 0 0 0 0 24 VDC or 5 VDC 100mA ASCII BASIC Modules F3 AB128 R 16 0 205 0 None F3 AB128 T 16 0 205 0 None F3 AB128 16 0 90 0 None F3 AB64 16 0 90 0 None Specialty Modules D3 08SIM 8 0 10 112 None D3 HSC 16 0 70 0 None Programming D2 HPP 200 50 0 Optional DL350 User Manual 2nd Edition Power Budget 4 7 System Design and Configuration The following example shows how to calculate the power budget for the DL305 Calculation system Example Base Module Type 5 VDC mA 9 VDC mA Auxiliary Power Source 0 24 VDC Output mA Available D3 05B 1000 2000 600 Base Power CPU Slot D3 350 500 120 Slot 0 D3 16NE3 0 130 0 Slot
3. ft 1 5 ft 0 5m Connecting The local CPU base is connected to the expansion base using a 1 5 ft cable Expansion Bases D3 EXCBL The base must be connected as shown in the diagram below The top expansion connector on the base is the input from a previous base The bottom expansion connector on the base is the output to an expansion base The expansion cable is marked with CPU Side and Expansion Side The CPU Side ofthe cable is connected to the bottom port of the base and the Expansion Side of the cable is connected to the top port of the next base Expansion Cable o 060 040 020 000 910 to to to to z DL305 CPU Side 077 057 037 017 U Q a 9 1 5 ft 0 5 m O 200 160 140 120 100 eO to to to to to DL305 Expansion Side CPU Side 217 177 157 137 117 Q oo Q EN 320 300 260 240 220 9 Expansion Side id is ig i is DL305 337 317 277 257 237 Q on OQ Note Avoid placing the expansion cable in the same wiring tray as the I O and power source wiring DL350 User Manu
4. MODBUS Function DL305 Data Types Function Code 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 Read a value from one or more registers V 06 Write a value into a single register V 16 Write a value into a group of registers V Determining the There are typically two ways that most host software conventions allow you to MODBUS Address specify a PLC memory location These are e By specifying the MODBUS data type and address e By specifying a MODBUS address only S aL 67 Og 33 Qu 6 wn Eo o gt DL350 User Manual 2nd Edition ELM System Design and Configuration 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 e Discrete X SP Y CR S T C contacts e 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 use
5. c O 49 12 5 2 e Oo c DD O m 2 Ao oc 40 DL350 User Manual 2nd Edition System Design and Configuration I O Configurations with a 10 Slot Local CPU Base 10 Slot Base Jumper Jumper Sw2 SW1 EXP 100 EXP CPU Total I O Rime s m j 2 8 pt modules 72 2 mcm 16 pt modules 144 i lm 2 aol a aa sat 7 a a a t lan a ail L J 10 Slot Base and Jumper Jumper 5 Slot Expansion 9We SW1 Base with EXP 100 EXP CPU 16 Point I O mom OF 200 s j mom 207 rE 2 laal 210 alja o ees n a to E I i a Q 217 LJ ao o ac Total I O 8 pt modules 112 EXP1 EXP2 16 pt modules 224 Ol o imo E A 330 E a l FL mo n Q LJ ao n a 10 Slot Base and Jumper Jumper 10 Slot Expansion SW2 SWI1 Base with EXP 100 6 EXP CPU H I 1 16 Point I O m Es z00 LTEM E E 207 E omi ar ete nomi To Aeris i Q 217 H a 2 a Total I O l Cc L 8 pt modules 152 SW2 SW1 16 pt modules 304 00 100 6 a EXP CPU I 1 to I 1 slm sm 447 nsi al i m
6. Subtract the row labeled Total power required from the row labeled Available Base Power Place the difference in the row labeled Remaining Power Available If Total Power Required is greater than the power available from the base the power budget will be exceeded It will be unsafe to used this configuration and you will need to restructure your I O configuration WARNING It is extremely important to calculate the power budget If you exceed the power budget the system may operate in an unpredictable manner which may result in a risk of personal injury or equipment damage DL350 User Manual 2nd Edition System Design and Configuration 4 9 Local I O Expansion Base Uses Table It is helpful to understand how you can use the various DL305 bases in your control system The following table shows how the bases can be used Can Be Used As Can Be Used As Base Part Number of Slots A Local CPU An Expansion Base Base D3 05B 1 5 Yes Yes D3 05BDC 1 5 Yes Yes D3 08B 1 8 Yes Yes D3 08BDC 1 8 Yes Yes D3 10B 1 10 Yes Yes D3 10BDC 1 10 Yes Yes Local Expansion The configurations below show the valid combinations of local and expansion bases Connectivity using the DL350 CPU m NOTE You should use one of the configurations listed below when designing an expansion system If you use a configuration not listed below the system will not function properly
7. E 2 c e Oo c OD O m 2 pas Nc t Network Master Operation This section describes how the DL350 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 networkthat can initiate requests on the network This section teaches you how to design the required ladder logic for network master operation Slave 1 Master Slave 2 Slave 3 MODBUS RTU Protocol or DirectNET When using the DL350 CPU as the master station you use simple RLL instructions to initiate the requests The WX instruction initiates network write operations and the RX instruction initiates network read operations Before executing either the WX or RX commands we will need to load data related to the read or write operation onto the CPU s 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 Master Slave Network 1 T
8. Be sure to include this contact after any Remote I O setup program Remote I O Now we can verify the remote I O link and DirectSOFT Test Program setup program operation A simple quick xeo Y40 check can be done with one rung of ladder QUT shown to the right It connects the first input of the remote base with the first output After placing the PLC in RUN mode we can go to the remote base and activate its first input Then its first output should turn on WEA ueis s iu er Q e J p Q fab 2 DL350 User Manual 2nd Edition 4 22 System Design and Configuration Network Connections to MODBUS and DirectNET Configuring This section describes how to configure the CPU s built in networking ports for the CPU s either MODBUS or DirectNET This will allow you to connect the DL305 PLC system Comm Port directly to MODBUS networks using the RTU protocol or to other devices on a DirectNET network MODBUS hosts system on the network must be capable of issuing the MODBUS commands to read or write the appropriate data For details on the MODBUS protocol please refer to the Gould MODBUS Protocol reference Guide P1 MBUS 300 Rev B In the event a more recent version is available check with your MODBUS supplier before ordering the documentation
9. 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 e 484 Mode e 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 e Discrete X SP Y CR S T C contacts e 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 DL350 Memory Type QTY PLC Range MODBUS 484 Mode 584 984 MODBUS Dec Octal Address Range Address Mode Data Type Decimal Address For Discrete Data Types Convert PLC Addr to Dec Start of Range Appropriate Mode Address Inputs X 512 XO X777 2048 2560 1001 10001 Input Special Relays SP 512 SPO SP777 3072 3584 10
10. a series resistor at the 1 resistor last slave as shown to the right If less than D D4 RM 330 330 ohms parallel a matching resistance 5 ohm across the slave s pins 1 and 2 instead Pee 150 Remember to size the termination resistor 3 at Port 2 to match the cables rated RE impedance The resistance values should be between 100 and 500 ohms DL350 User Manual 2nd Edition System Design and Configuration 4 19 Configure Remote After configuring the DL350 CPU s Port 2 and wiring it to the remote slave s use the I O Slaves Configuring the Remote I O Table following checklist to complete the configuration of the remote slaves Full instructions for these steps are in the Remote I O manual e Set the baud rate to match CPU s Port 2 setting e Select a station address for each slave from 1 to 7 Each device on the remote link must have a unique station address There can be only one master address 0 on the remote link The beginning of the configuration table for the built in remote I O channel is the memory address we selected in the Port 2 Memory Addr Pointer 37700 setup The table consists of blocks of four words Remote I O data which correspond to each slave in the Reserved V37700 xxxx system as shown to the right The first V37701 xxxx four table locations are reserved V37708 3oxx The CPU reads data from the table after V37703 xoox powerup interpret
11. available baud rates include 300 600 900 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 wm Then click the button indicated to send the Port configuration to the CPU and click Close DL350 User Manual 2nd Edition System Design and Configuration EZ This section describes how other devices on a network can communicate with a CPU port that you have configured as a DirectNET slave or MODBUS slave DL350 A MODBUS host must use the MODBUS RTU protocol to communicate with the DL350 as a slave The host software must send a MODBUS function code and MODBUS address to specify a PLC memory location the DL850 comprehends The DirectNET host uses normal I O addresses to access the applicable DL305 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 DL350 supports the MODBUS function codes described below Network Slave Operation
12. only want XO X27 you ll 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 DL205 305 405 Memory Bits per unit Bytes V memory 16 2 o 20 T C current value 16 2 EU Inputs X SP 8 1 EE Outputs 8 1 Qo Y C Stage T C bits g o Scratch Pad Memory 8 1 95 Diagnostic Status 8 1 DL305C DL330 340 CPUs Bits per unit Bytes Memory Data registers 8 1 T C accumulator 16 2 I O internal relays shift register 8 1 bits T C bits stage bits Scratch Pad Memory 8 2 Diagnostic Status 5 word R W 16 10 DL350 User Manual 2nd Edition EN System Design and Configuration c ie 49 5 2 c e Oo c OD O m 2 AD Nc t 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 DL350 CPU sends the number of bytes previously specified from its memory area beginning at the LDA address specified For an RX instruction the DL350 CPU reads the number of bytes previously specified from the slave placing th
13. 01 10001 Input Outputs Y 512 YO Y777 2048 2560 1 1 Coil Control Relays CR 1024 CO C3777 3072 4095 1 1 Coil Timer Contacts T 256 TO 1377 6144 6399 1 1 Coil Counter Contacts CT 128 CTO CT177 6400 6527 1 1 Coil Stage Status Bits S 1024 SO S1777 5120 6143 1 1 Coil For Word Data Types Convert PLC Addr to Dec Appropriate Mode Address Timer Current Values V 256 VO V377 0 255 3001 30001 Input Reg Counter Current Values V 128 V1000 V1177 512 639 3001 30001 Input Reg V Memory user data V 3072 V1400 V7377 768 3839 4001 40001 Hold Reg 4096 V10000 V17777 4096 8192 V Memory system V 256 V7400 V7777 3840 3735 4001 40001 Hold Reg DL350 User Manual 2nd Edition System Design and Configuration The following examples show how to generate the MODBUS addresses for hosts which require this format Example 1 V2100 Find the MODBUS address for User V PLC Address Dec Mode Address 584 984 Mode location V2100 V2100 1088 decimal 1 Find V memory in the table 1088 40001 41089 2 Convert V2100 into decimal 1088 3 Addthe MODBUS starting address forthe mode 40001 V Memory system V 320 V700 V777 448 768 4001 40001 Hold Reg V7400 V7777 3840 3735 Example 2 Y20 Find the MODBUS address for output Y20 PLC Addr Dec Start Addr Mode 584 984 Mode 1 Find Y outputs in the ta
14. 1 D3 16NE3 0 130 0 Slot 2 F3 16TA 2 0 250 0 Slot 3 F3 16TA 2 0 250 0 Slot 4 Slot 5 0 Slot 6 0 Slot 7 0 Other Handheld Prog D2 HPP 200 200 0 Total Power Required 700 1080 0 Remaining Power Available 1000 700 300 2000 1080 920 600 0 600 wee OLD T 1 Use the power budget table to fill in the power requirements for all the system components First enter the amount of power supplied by the base Next list the requirements for the CPU any I O modules and any other devices such as the Handheld Programmer or the DV 1000 operator interface Remember even though the Handheld or the DV 1000 are not installed in the base they still obtain their power from the system Also make sure you obtain any external power requirements such as the 24VDC power required by the analog modules Add the current columns starting with Slot O and put the total in the row labeled Total power required Subtract the row labeled Total power required from the row labeled Available Base Power Place the difference in the row labeled Remaining Power Available If Total Power Required is greater than the power available from the base the power budget will be exceeded It will be unsafe to used this configuration and you will need to restructure your I O configuration WARNING It is extremely important to calculate the power budget If you exceed the power budget the system may operate in
15. AAEABE Total I O 8 pt modules 96 16 pt modules 192 Jumper Switch EXP o U ARARNAR A ARABERE S 8 Slot Base and One 8 slot and one 5 slot Expansion Bases ooooooo0o0 m X U o U a AE ot RRERRBRBEH ARARRARA Total I O 1 Expansion Base 8 pt modules 120 16 pt modules 240 Jumper Switch m X U m X U 1 a gel e aL 2 Expansion Bases uo n ul og 1 8 slot 1 5 slot a s ox og 8 pt modules 160 a o a Zu 16 pt modules 320 S Jumper Switch o o e gt RRHRRHRH BERBERE S DL350 User Manual 2nd Edition System Design and Configuration 8 Slot Base and Jumper Switch two 8 slot a Expansion Bases a eee a lee aos Total I O eee J 2 Expansion Bases Jumper Switch 2 8 slot 8 pt modules 184 ae 16 pt modules 368 mom EE a o alle lan a aol e L J Jumper Switch EXP CPU I fre hh Jr c o cel n e alle L
16. DL305 modules The column labeled External Power Source Required is for module operation and is not for field wiring Use these currents when calculating the power budget for your system If 24 VDC is needed for external devices the 24 VDC 100mA maximum output at the base terminal strip may be used as long as the power budget is not exceeded I O Points 5V Power 9V Power 24V Power External Power Required Required mA Required in A Required mA Source Required CPUs D3 350 500 20 0 None DC Input Modules D3 08ND2 8 0 10 112 None D3 16ND2 1 16 0 25 224 None D3 16ND2 2 16 0 24 209 None D3 16ND2F 16 0 25 224 None F3 16ND3F 16 0 148 68 None AC Input Modules D3 08NA 1 8 0 10 0 None D3 08NA 2 8 0 10 0 None D3 16NA 16 0 100 0 None AC DC Input Modules D3 08NE3 8 0 10 0 None D3 16NE3 16 0 130 0 None DC Output Modules a D3 08TD1 8 0 20 24 None ag D3 08TD2 8 0 30 0 None OF D3 16TD1 1 16 0 40 96 None 33 D3 16TD1 2 16 0 40 96 None E g D3 16TD2 16 0 180 0 None RUE AC Output Modules D3 04TAS 8 0 12 0 None F3 08TAS 8 0 80 0 None F3 08TAS 1 8 0 25 0 None D3 08TA 1 8 0 96 0 None D3 08TA 2 8 0 160 0 None F3 16TA 2 16 0 250 0 None D3 16TA 2 16 0 400 0 None DL350 User Manual 2nd Edition c O 49 E 2 c e Oo c O O m 2 pas Nc System Design and Configuration
17. For more details on DirectNET order our DirectNET manual part number DA DNET M You will need to determine whether the network connection is a 3 wire RS 232 type or a 5 wire RS 422 type Normally the RS 232 signals are used for shorter distances 15 meters max for communications between two devices RS 422 signals are for longer distances 1000 meters max and for multi drop networks from 2 to 247 devices Use termination resistors at both ends of RS 422 network wiring matching the impedance rating of the cable for example to match the termination resistance to Belden 9841 use a 120 ohm resistor Resistors should be insatlled close to the end of the cable at the master and last slave connections fa TON 16 TXD 9 RXD z 10 RXD T 19 RTS n 18 RTS T 11 CTS t 23 CTS Ga TDD 4 DDP 7 GND 16 TXD 16 TXD se 9 RXD y9 RXD 10 RXD 10 RXD 19 RTS 19 RTS dbi 18 RTS 18 RTS 11 CTS 11 CTS ES 23 CTS 23 CTS de 7 GND 7 GND 25 Se M E Slave Last Slave 25 The recommended cable for RS422 is Beldon 8102 or equivalent Oe c o 14 in i cu c ae Port 2 Pin Descriptions DL350 CPU Port 2 Pin Descriptions Cont d o 9 1 notused 14 TXD Transmit Data RS 422 Bus TXD Transmit Data RS232C 15 notused 9 o 3 RXD Receive Data RS232C 16 TXD Transmit Data RS 422 i o 4 RTS _ Ready to Send RS 232C 17 not used o 9 5 CTS Clear to Send RS 232C 18 RTS Request to Send RS 422 o5 6 notused 19 RTS Request to Send
18. RS 422 9 7 OV Power connection GND 20 not used o o 8 ov Power connection GND 21 not used o 5 9 RXD Receive Data RS 422 22 not used MS 10 RXD Receive Data RS 422 23 CTS Clear to Send RS 422 11 CTS Clear to Send RS422 24 RXD Receive Data REMIO 12 TXD Transmit Data REMIO 25 RXD Receive Data REMIO po ines 13 TXD Transmit Data REMIO DL350 User Manual 2nd Edition System Design and Configuration EZ MODBUS Port In Direct SOFT choose the PLC menu then Setup then Secondary Comm Port Configuration e Port From the port number list box at the top choose Port 2 e Protocol Click the check box to the left of MODBUS use AUX 56 on the HPP and select MBUS and then you ll see the dialog box below Setup Communication Ports Port Port 2 I Close Protocol Base Timeout K Sequence 800 ms sm wm DirectNET 800 ms Help iv MODBUS 500 ms EC ue Non Sequence 3 Characters Remote 1 0 Time out Base Timeout x 1 E RTS on delay time 0 ms RTS off delay time 0 ms Station Number 1 Baud rate 38400 Echo Suppression C RS 422 485 4 wire Stop bits 1 R ire Parity Odd i Port 2 15 Pin e Timeout amount of time the port will wait after it sends a message to get a response before logging an error Response Delay Time The amount of time between raising the RTS line and sending the
19. S S DiteetNET 800 ms Help MODBUS 500 ms rac 3 Characters Station Number 1 El 2 Baud rate 38400 by Memory Address TAO gt Port 2 15 Pin Memory Address Choose a V memory address to use as the starting location of a Remote I O configuration table V37700 is the default This table is separate and independent from the table for any Remote Master s in the system e Station Number Choose 0 as the station number which makes the DL350 the master Station numbers 1 7 are reserved for remote slaves e Baud Rate The baud rates 19200 and 38400 baud are available Choose 38400 initially as the remote I O baud rate and revert to 19200 baud if you experience data errors or noise problems on the link Important You must configure the baud rate on the Remote Slaves via DIP switches to match the baud rate selection for the CPU s Port 2 Then click the button indicated to send the Port 2 configuration wml to the CPU and click Close S aL 67 Og 33 eU c o wn ao O3 DL350 User Manual 2nd Edition 4 18 System Design and Configuration c ie 49 E 2 c e Oo c O O m 2 pas Nc t DL350 CPU Port 2 The next step is to make the connections between all devices on the Remote I O link The location of the Port 2 on the DL350 is an onthe 25 pin connector as pictured to the od right 99 e e Pin7 S
20. System Design and Configuration In This Chapter DL305 System Design Strategies Module Placement Calculating the Power Budget Expansion I O Remote I O Network Connections to MODBUS and DirectNET Network Slave Operation Network Master Operation EZN System Design and Configuration DL305 System Design Strategies c ie 49 E 2 c e Oo c O O m 2 pas Nc t I O System Configurations Networking Configurations Base Configurations The DL350 CPU offers the following ways to add I O to the system e Local I O consists of I O modules located in the same base as the CPU Remote I O consists of I O modules located in bases which are serially connected to the bottom port on a DL350 CPU e Expansion I O consists of I O modules located in expansion bases located close to the local base Expansion cables connect them to the local CPU base s serial bus in a daisy chain fashion A DL305 system can be developed using many different arrangements of these configurations All I O configurations use the standard complement of DL305 1 0 modules and bases The DL350 CPU offers the following way to add networking to the system e DL350 Communications Port The DL350 CPU has a 25 Pin connector on Port 2 that provides a built in RTU MODBUS connection e MODBUS Master Module MODBUS master modules can be used in any slot for connecting as a master to a MODBUS network
21. al 2nd Edition System Design and Configuration 4 11 Setting the Base Switches Jumper Switch The 5 and 8 slot bases have a jumper switch between slot 3 and 4 used to set the base to local CPU base or expansion base The 10 slot base has two jumpers one is located between slots 4 and 5 and the other is located between slot 5 and 6 The second switch sets I O addressing ranges for the DL330 340 CPUs This switch should always be bridged to the right hand position for the DL350 CPU io TI OT I H 80 B kl i fS n ml r4 u 5 and 8 slot bases 10 slot base TI SEE SEER ol BBBBBBBB 5 E 67 Og 323 eU EO Bo oe gt DL350 User Manual 2nd Edition System Design and Configuration I O Configurations with a 5 Slot Local CPU Base Switch settings The 5 slot base has a jumper switch on the inside of the base between slots 3 and 4 which allows you to select Type of Base Switch Position Local CPU right side bridged First Expan
22. an unpredictable manner which may result in a risk of personal injury or equipment damage DL350 User Manual 2nd Edition S aL 67 Og PE Qu 6 wn Eo oe gt EM System Design and Configuration Power Budget This blank chart is provided for you to copy and use in your power budget Calculation calculations Worksheet Base Module Type 5 VDC mA 9 VDC mA Auxiliary 0 Power Source 24 VDC Output mA Available Base Power CPU Slot Slot 0 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Other Handheld Prog D2 HPP Total Power Required c ie 49 5 2 c e Oo c OD O m es 2 AD Nc v d OLD T Remaining Power Available 1 Use the power budget table to fill in the power requirements for all the system components First enter the amount of power supplied by the base Next list the requirements for the CPU any I O modules and any other devices such as the Handheld Programmer or the DV 1000 operator interface Remember even though the Handheld or the DV 1000 are not installed in the base they still obtain their power from the system Also make sure you obtain any external power requirements such as the 24VDC power required by the analog modules Add the current columns starting with Slot O and put the total in the row labeled Total power required
23. and the system configuration is comprised of two 5 slot bases slots 1 and 2 of the expansion base are valid locations The following table provides the general placement rules for the DL305 components Module Restriction aL CPU The CPU must reside in the first slot of the local CPU Og base The first slot is the closest slot to the power supply 33 16 Point I O eg Modules ADY siot 2o Analog Modules Any slot S ASCII Basic Modules Any slot High Speed The D3 350 CPU does not support a high speed counter Counter module I O Configuration O addresses use octal numbering starting in the slot next to the CPU The addresses are assigned in groups of 16 for each slot regardless of what module is in the slot The discrete input and output modules can be mixed in any order but there may be restrictions placed on some specialty modules DL350 User Manual 2nd Edition EZHE System Design and Configuration Calculating the Power Budget Managing your Power Resource lad TN Base Power Specifications c ie 49 12 5 2 e Oo c 7 O m 2 AO Nc t When you determine the types and quantity of I O modules you will be using in the DL305 system it is important to remember there is a limited amount of power available from the power supply We have provided a chart to help you easily see the amount of power available with each base The followi
24. annel RM Net 3050 ft 1000m Total distance 512 I O Points Total NH c ie 49 E 2 c e Oo CPU Base c OD O m 2 pas Nc t DL350 CPU Only RM Net DL350 User Manual 2nd Edition System Design and Configuration EX Configuring the This section describes how to configure the DL350 s built in remote I O channel CPU s Remote Additional information is in the Remote I O manual D2 REMIO M which you will I O Channel need in configuring the Remote slave units on the network The DL350 CPU s built in remote I O channel has the same capability as the DL250 and DL450 CPUs It can communicate with up to seven remote bases containing a maximum of 512 I O points at a maximum distance of 1000 meters You may recall from the CPU specifications in Chapter 3 that the DL350 s Port 2 is capable of several protocols To configure the port using the Handheld Programmer use AUX 56 and follow the prompts making the same choices as indicated below on this page To configure the port in DirectSOFT choose the PLC menu then Setup then Setup Secondary Comm Port e Port From the port number list box at the top choose Port 2 e Protocol Click the check box to the left of Remote I O called M NET on the HPP and then you ll see the dialog box shown below Setup Communication Ports Port Port 2 Me Close Protocol Base Timeout K Sequence 800 ms
25. ble Y20 16 decimal 2 Convert Y20 into decimal 16 16 2048 1 2 2065 3 Add the starting address for the range 2048 4 Addthe MODBUS address for the mode 1 Outputs Y 1024 YO Y1777 2048 3071 1 1 Coil Example 3 T10 Current Find the MODBUS address to obtain the PLC Address Dec Mode Address Value current value from Timer T10 T10 8 decimal 484 Mode 1 Find Timer Current Values in the table 8 3001 3009 2 Convert T10 into decimal 8 3 Addthe MODBUS starting address forthe mode 3001 Timer Current Values V 256 VO V377 0 255 3001 30001 Input Reg S o Example 4 C54 Find the MODBUS address for Control Relay PLC Addr Dec Start Address Mode a 584 984 Mode C54 C54 44 decimal Sg s 1 Find Control Relays n the table 44 4307241 3117 eu 2 Convert C54 into decimal 44 co 3 Add the starting address for the range 30 3072 4 Add the MODBUS address for the mode 1 Control Relays CR 2048 CO C8777 3072 5119 1 1 Coil Determining the Addressing the memory types for DirectNET slaves is very easy Use the ordinary DirectNET Address native address of the slave device itself To access a slave PLC s memory address V2000 via DirectNET for example the network master will request V2000 from the slave DL350 User Manual 2nd Edition 4 30 System Design and Configuration c ie 49
26. cimal 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 Oupuis TY w vum Find the MODBUS address to obtain the PLC Address Dec Data Type current value from Timer T10 T10 8 decimal 1 Find Timer Current Values in the table 8 Input Reg Input Reg 8 2 Convert T10 into decimal 8 3 Usethe MODBUS data type from the table Timer Current Values V 256 VO V377 0 255 Input Register Find the MODBUS address for Control Relay PLC Addr Dec Start Addr Data Type C54 C54 44 decimal Find Control Relays in the table 44 3072 Coil 2 Coil 3116 SERI ueis s iu er Q e Q fab 2 2 Convert C54 into decimal 44 3 Add the starting address for the range 3072 4 Usethe MODBUS data type from the table Control Relays CR 2048 CO C3777 3072 5119 DL350 User Manual 2nd Edition LER System Design and Configuration c ie 49 5 2 c e Oo c 7 O m E 2 pas Nc 40 If Your MODBUS Host Software Requires an Address ONLY 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 it s still fairly simple Basically MODBUS also separates the data types by address ranges as well
27. d for each group of data DL350 Memory Type QTY PLC Range MODBUS MODBUS Dec Octal Address Range Data Type Decimal For Discrete Data Types Convert PLC Addr to Dec Start of Range Data Type o Counter Contacts CT CTO CT177 6400 6271 For Word Data Convert PLC Addr to Dec Data Type Timer Current Values V ye V377 rer Tm Register Counter Current Values V CEU Mhz 512 639 Input Register V Memory user data V 3072 V1400 V7377 768 3839 Holding Register 4096 V10000 V17777 4096 8191 V Memory system V V7400 V7777 3480 3735 Holding Register c ie 49 12 5 2 e Oo c 7 O m 2 Ao oc 40 DL350 User Manual 2nd Edition Example 1 V2100 Example 2 Y20 Example 3 T10 Current Value Example 4 C54 System Design and Configuration The following examples show how to generate the MODBUS address and data type for hosts which require this format Find the MODBUS address for User V PLC Address Dec Data Type sn venu V2100 1088 decimal je Pind meme Metalle 1088 Hold Reg Holding Reg 1088 2 Convert V2100 into decimal 1088 3 Usethe MODBUS data type from the table V Memory user data V 3072 V1400 V7377 768 3839 Holding Register 12288 V10000 V37777 4096 16383 Find the MODBUS address for output Y20 PLC Addr Dec Start Addr Data Type 1 Find Y outputs in the table Y20 16 de
28. data This is for devices that do not use RTS CTS handshaking The RTS and CTS lines must be bridged together for the CPU to send any data e Station Number For making the CPU port a MODBUS master choose 1 The possible range for MODBUS slave numbers is from 1 to 247 but the DL350 network instructions used in Master mode will access only slaves 1 to 90 Each slave must have a unique number At powerup the port is automatically a slave unless and until the DL350 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 e Baud Rate The available baud rates include 300 600 900 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 e Stop Bits Choose 1 or 2 stop bits for use in the protocol e 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 5 aL 67 Og 33 eU co wn Bo O3 DL350 User Manual 2nd Edition 4 24 System Design and Configuration c ie 49 3 2 c e Oo c OD O m 2 Ao Nc t DirectNET Port Config
29. e received data into its memory area beginning at the LDA address specified 4 0 6 00 i Starting address of master transfer area LDA 040600 V40600 MSB LSB 15 MSB V40601 LSB 15 octal 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 i LD KF101 LD K128 LDA O40600 RX YO DirectNET slaves specify the same address in the WX and RX instruction as the slave s native I O address MODBUS DL405 DL305 DL350 CPU or DL205 slaves specify the same address in the WX and RX instruction as the slave s native I O address MODBUS 305C DL330 340 CPUS slaves use the following table to convert DL305 add
30. e I O modules You may notice the bases refer to 5 slot 8 slot etc One of the slots is dedicated to the CPU so you always have one less I O slot For example you have four I O slots with a 5 slot base The I O slots are numbered 0 3 The CPU slot always contains a CPU and is not numbered The examples below show the I O numbering for a 5 slot local CPU base with 8 point I O and a 5 slot local CPU base with 16 point I O 5 Slot Base Using 8 Point I O Modules 5 Slot Base Using 16 Point I O Modules 060 040 020 060 040 000 to to to to o to 067 047 027 067 047 027 007 DL305 070 050 030 010 to to to to Q P 077 057 037 017 on Q Slot Number 3 2 1 0 Slot Number 3 2 1 0 I O Module There are some limitations that determine where you can place certain types of Placement Rules modules Some modules require certain locations and may limit the number or placement of other modules The table on pages 4 6 and 4 7 should clear up any gray areas in the explanation and you will probably find the configuration you intend to use in your installation In all ofthe configurations mentioned the number of slots from the CPU that are to be used can roll over into an expansion base if necessary For example if a rule states a module must reside in one of the six slots adjacent to the CPU
31. e MODBUS Slave Module MODBUS slave modules can be used in any slot for connecting as a slave to a MODBUS network Module Unit Master Slave DirectNET DL350 CPU M eae K Sequence MODBUS RTU The DL305 system currently offers two types of bases Both types come in 5 8 or 10 slot configurations All DL305 CPUs will work in either type of base The xxxxx 1 bases are designed to compliment the features of the DL350 CPU however all other DL305 CPUs will work in these bases You can also mix the bases in a system By mixing the bases or by installing the DL350 in an conventional base you will loose some of the features of the CPU The DL350 will revert back to 8 bit addressing and will virtually function like a DL340 CPU This section will focus on the xxxxx 1 bases using the DL350 CPU If you will be using the DL350 in a conventional base or if you are mixing bases in a system refer to Appendix F for base I O and module placement information The xxxxx 1 bases support a 8 bit parallel bus that allows the use of intelligent modules when using the DL350 CPU The addressing scheme is simplified and also extends the number of I O points you can use You will have a bigger power budget to work with due to the increase in the power supply capacity to 2 0A DL350 User Manual 2nd Edition System Design and Configuration EXN Module Placement Slot Numbering The DL305 bases each provide different numbers of slots for use with th
32. e master and slave will be 38400 kB We can map the remote I O points as any type of I O point simply by choosing the appropriate range of V memory Since we have plenty of standard I O addresses available X and Y we will have the remote I O points start at the next X and Y addresses after the main base points X60 and Y40 respectively Main Base with CPU as Master Remote Slave Worksheet Remote Base Address 1 Choose 1 7 DL350 16 16 16 16 16 CPU Slot Module INFUT OUTPUT Number Name Input Addr No Inputs Output Addr No Outputs O Oo I I o O8ND3S xoeo 8 Port 1 O8ND3S X070 8 2 08TD1 Y040 8 Y20 Y37 YO Y17 X40 X57 X20 X37 X0 X17 J 3 08TD1 Y050 8 V40501 V40500 V40402 V40401 40400 4 Remote Slave 5 D2 8 RSSS 8 8 8 8 Slave I I o o Input Bit Start Address X060V Memory Address V 40403 Total Input Points 16 Output Bit Start Address Y040 V Memory Address V 40502 X60 X67 X70 X77 Y40 Y47 Y50 Y57 Total Output Points 16 V40403 V40404 V40502 V40503 mm Remote I O Using the Remote Slave Worksheet DirectSOFT Setup Program shown above can help organize our SPO system data in preparation for writing our LDA Slave 1 ladder program a blank full page copy of this worksheet is in the Remote l O OUT Manual The four key paramete
33. he following step by step procedure will provide you the information necessary to set up your ladder program to receive data from a network slave DL350 User Manual 2nd Edition Step 1 Identify Master Port and Slave Step 2 Load Number of Bytes to Transfer System Design and Configuration EX The first Load LD instruction identifies E 3 9 3 the communications port number on the network master DL350 and the address M of the slave station This instruction can address up to 90 MODBUS slaves or 90 L Slave address BCD DirectNET slaves The format of the word Port number BCD is shown to the right The F in the upper nibble tells the CPU the port is internal to Internal port hex the CPU and notin aslotin the base The second nibble indicates the port number LD 1 This is the logical port number 0 for top KF101 port and 1 for the bottom The lower byte contains the slave address number in BCD 01 to 90 The second Load LD instruction 1 2 8 BCD determines the number of bytes which will be transferred between the master and slave in the subsequent WX or RX i instruction The value to be loaded is in of bytes to transfer BCD format decimal from 1 to 128 bytes LD K128 The number of bytes specified also depends on the type of data you want to obtain For example the DL305 Input points can be accessed by V memory locations or as X input locations However if you
34. ignal GND E lt Pin 12 TXD E e Pin 13 TXD o o o e Pin24 RXD oe i O e RXD Pin 25 RXD BXD 8 3 Now we are ready to discuss wiring the DL350 to the remote slaves on the remote base s The remote I O link is a 3 wire half duplex type Since Port 2 of the DL350 CPU is a 5 wire port we must jumper its transmit and receive lines together as shown below converts it to 3 wire half duplex D2 RSS D4 RM OV 7e Remote I O Slave Remote I O Slave O S inati i T Jumper TA o Termination a 255 AN dg Pe TXD RXD QD il QD a TXD 7 a wxp 9 RXD Signal GND as 265 Internal Ew 7 Sra y cra 330 ohm Connect shield to resistor Remote I O Master signal grine Ns STD end of chain The twisted shielded pair connects to the DL350 Port 2 as shown Be sure to connect the cable shield wire to the signal ground connection A termination resistor must be added externally to the CPU as close as possible to the connector pins Its purpose is to minimize electrical reflections that occur over long cables Be sure to add the jumper at the last slave to connect the required internal termination resistor Ideally the two termination resistors at Addiseries externalresistor the cables opposite ends and the cable s rated impedance will all three T match For cable impedances greater dp Internal than 330 ohms add
35. ing the four data words in each block with these meanings Slave 1 V37704 xxxx 1 Starting address of slave s input data V37705 xxxx 2 Number of slave s input points V37706 xxxx 3 Starting address of outputs in slave V37707 xxxx 4 Number of slave s output points e e The table is 32 words long If your system has fewerthan seven remote slave bases then the remainder of the table must be Slave 7 V3 734 0000 filled with zeros For example a 3 slave V37735 0000 system will have a remote configuration V37736 0000 table containing 4 reserved words 12 V37737 0000 words of data and 16 words of 0000 Se A portion of the ladder program must DirectSOFT Oo configure this table only once at og powerup Use the LDA instruction as ub LDA eo shown to the right to load an address to 040000 co place in the table Use the regular LD Bo constant to load the number of the slave s OT d 9 input or output points The following page gives a short program LD example for one slave K16 OUT V37705 DL350 User Manual 2nd Edition c lel 49 E 2 c e Oo c O O m 2 pas Nc t System Design and Configuration Consider the simple system featuring Remote I O shown below The DL350 s built in Remote I O channel connects to one slave base which we will assign a station address 1 The baud rates on th
36. it should be ahead of any network instruction boxes since the error bit is reset when an RX or WX instruction is executed Multiple Read and If you are using multiple reads and writes Interlocking Relay Write Interlocks in the RLL program you have to interlock sp416 C100 the routines to make sure all the routines py Keibi are executed If you don t use the l interlocks then the CPU will only execute LD the first routine This is because each port K0003 can only handle one transaction at a time In the example to the right after the RX Enea re instruction is executed CO is set When EX the port has finished the communication cm raise T task the second routine is executed and interlocking YO S CO is reset Rel EU If you re using RLL LYS Stage Programing ii Aus es 1 oY you can put each routine in a separate SET eG program stage to ensure proper execution SP116 C100 D 5 and switch from stage to stage allowing only AM KF101 one of them to be active at a time LD K0003 LDA O40400 WX YO C100 RSD DL350 User Manual 2nd Edition
37. ng chart will help you calculate the amount of power you need with your I O selections At the end of this section you will also find an example of power budgeting and a worksheet for your own calculations WARNING It is extremely important to calculate the power budget If you exceed the power budget the system may operate in an unpredictable manner which may result in a risk of personal injury or equipment damage This chart shows the amount of current available for the three voltages supplied on the new xxxxx 1 bases Use these currents when calculating the power budget for your system Auxiliary Bases 5V Power 9V Power 24V Power 24 VDC Supplied in Supplied in Supplied in Output at Amps Amps Amps Base Terminal D3 05B 1 1 0A 50 C 2 0 0 6 100mA max 0 7A 60 C D3 05BDC 1 4A 50 C 0 8 0 6 None 0 7A 60 C D3 08B 1 1 0A 50 C 2 0 0 6 100mA max 0 7A 60 C D3 10B 1 1 0A 50 C 2 0 0 6 100mA max 0 7A 60 C D3 10BDC 1 4A 50 C 1 7 0 6 None 0 7A 60 C DL350 User Manual 2nd Edition System Design and Configuration I O Points Required Each type of module requires a certain number of I O points This is also true for the for Each Module specialty modules such as analog counter interface etc The table on page 4 5 lists the number and type of I O points required for each module Module Power The next three pages show the amount of maximum current required for each of the Requirements
38. resses to MODBUS addresses DL305C DL330 340 CPUs Series CPU Memory Type to MODBUS Cross Reference PLC Memory type PLC base MODBUS PLC Memory Type PLC base MODBUS address base addr address base addr TMR CNT Current Values R600 VO TMR CNT Status Bits CT600 GY600 I O Points IO 000 GYO Control Relays CR160 GY160 Data Registers R401 V100 Shift Registers SR400 GY400 R400 Stage Status Bits D3 330P only S0 GY200 DL350 User Manual 2nd Edition System Design and Configuration ER Communications Typically network communications will sp117 yi from a last longer than 1 scan The program must SET Ladder Program wait for the communications to finish before starting the next transaction SP116 LD KF101 Port Communication Error Port Busy rae LDA 040600 RX YO The port 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
39. rs we V37704 need to place in our Remote 1 0 configuration table is in the lower right LD corner of the worksheet You can K16 determine the address values by using the memory map given at the end of Chapter OUT ds 3 CPU Specifications and Operation The program segment required to transfer LDA Slave 1 our worksheet results to the Remote I O 040502 Output configuration table is shown to the right Remember to use the LDA or LD DUT as instructions appropriately The next page covers the remainder of the LD required program to get this remote I O K16 link up and running OUT V37707 DL350 User Manual 2nd Edition System Design and Configuration When configuring a Remote I O channel DirectSOFT for fewer than 7 slaves we must fill the remainder of the table with zeros This is KO necessary because the CPU will try to interpret any non zero number as slave OUTD information V37710 We continue our setup program from the previous page by adding a segment which fills the remainder of the table with zeros The example to the right fills zeros for OUTD slave numbers 2 7 which do not exist in V37736 our example system C740 SED On the last rung in the example program above we set a special relay contact C740 This particular contact indicates to the CPU the ladder program has finished specifying a remote I O system At that moment the CPU begins remote I O communications
40. sion left side bridged Last Expansion right side bridged 5 Slot Base Total 1 0 um 5 EXP CPU 8 pt modules 32 060 040 020 000 al ess ed 16 pt modules 64 067 047 027 007 S 01305 r lao a aol 070 050 030 010 Y ween even o ob of B Emm Jumper Switch 5 Slot Base and up Total I O to two 5 Slot 1 Expansion base Expansion Bases 8 Pt modules 72 EM ee 16 pt modules 144 j oom l o aol lm o aol 2 Expansion Bases a l s xl 8 pt modules 112 i i 16 pt modules 224 Jumper Switch m X V CPU 200 160 140 to to to 4 207 167 147 120 100 to to 127 107 DL305 RRHRRHRH BBB BEEBE 1380 110 to to 137 117 Q 8 170 150 to to to Q 217 177 157 Jumper Switch of E X P o p c ie 49 5 2 c e Oo c O O m 2 pas Nc t HRRRRRHRH ARRAARAR DL350 User Manual 2nd Edition System Design and Configuration I O Configurations with an 8 Slot Local CPU Base 8 Slot Base EXP o U c Total I O 8 pt modules 56 16 pt modules 112 RRHRRRHRH KITTEN Jumper Switch 8 Slot Base and 5 Slot Expansion Base EXP e U c RRRRRRHRH AB
41. u n l 450 oer m SIET El 457 E eal AER Q E L J L J DL350 User Manual 2nd Edition ES System Design and Configuration Remote I O Expansion How to Add Remote I O is useful for a system that has a sufficient number of sensors and other Remote I O field devices located a relative long distance away up to 1000 meters or 3050 feet Channels from the more central location of the CPU The DL350 supports a built in Remote master however the DL305 family does not have any Remote I O modules Therefore you must use a DL205 or DL405 base for the slave channels The methods of adding remote I O are e DL350 CPU The CPU s comm port 2 features a built in Remote I O channel DL350 Maximum number of Remote Masters supported in 1 the local CPU base 1 channel per Remote Master CPU built in Remote I O channels 1 Maximum I O points supported by each channel 512 Maximum Remote I O points supported 512 Maximum number of remote I O bases per channel 7 RM NET Remote I O points map into different CPU memory locations therefore it does not reduce the number of local I O points Refer to the DL205 Remote I O manual for details on remote I O configuration and numbering Configuring the built in remote I O channel is described in the following section The following figure shows 1 CPU base with seven remote bases The remote bases can be DL205 or DL405 bases EM Remote I O 7 Bases per ch
42. uration In DirectSOFT choose the PLC menu then Setup then Secondary Comm Port Port From the port number list box choose Port 2 Protocol Click the check box to the left of DirectNET use AUX 56 on the HPP then select DNET and then you ll see the dialog box below Setup Communication Ports Port Port 2 Y Close Protocol Base Timeout K Sequence 800 ms il il Iv Di ctNET 800 ms Help MODBUS 500 ms E NonSequence 3 Characters Remote 1 0 Time out e ase Timeout x 1 v RTS on delay time fo ms RTS off delaytime oms Station Number l Baud rate 38400 v Stop bsh Party Odd Foma He v Port 2 15 Pin Timeout amount of time the port will wait after it sends a message to get a response before logging an error Response Delay Time The amount of time between raising the RTS line and sending the data This is for devices that do not use RTS CTS handshaking The RTS and CTS lines must be bridged together for the CPU to send any data 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 DL350 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
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