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Chapter 2 - AutomationDirect

1. Inputs per module 16 sink source Inputs per module 8 sink source Commons per module 2 isolated Commons per module 8 isolated Input voltage range 10 2 26 4VAC VDC Input voltage range 90 150 VAC VDC Peak voltage 37 5VAC VDC Peak voltage 350 peak lt 1ms AC frequency 47 63 Hz AC frequency 47 63 Hz ON voltage level gt 9 5V ON voltage level gt 90 VDC 75VAC OFF voltage level lt 3 0V OFF voltage level lt 60 VDC 45VAC Input impedance 2 12V 24V 3 2KQ 2 9KQ Input impedance 22 KQ E Input current 12V 24V 3 8 mA 8 3 mA Input current 5 5 mA 120V 22 T Tm v Minimum ON current 4 mA Minimum ON current 4 mA Og Maximum OFF current 1 5 mA Maximum OFF current 2 mA 2o J Base power required 5V 150 mA max Base power required 5V 90 mA max o lt OFF to ON response 5 40 ms OFF to ON response 8 ms p O ON to OFF response 10 50 ms ON to OFF response 15 ms ma Terminal type Remova
2. Points N Points N 8 12 24VDC OUTPUT 8 EN 24 150VDC OUTPUT 4 P Output Current TB 24V FU Output TB OPEN FUSE 64 1 25A point ur 67 f Current 4 Output Current 1 5A point a o 4 N Output Current MN 4 2 0A point ip Wu A 7 2A point 3 7 2 2 3 7 3 7 7 BA common D4 08TD1 7 iud PG F4 08TD1S 0 0 7 T T T T T T T T T 0 10 20 30 40 50 60 C 102 264VDC dO 0 10 20 30 40 50 60 C 24 150VDC G amp M 32 50 68 86 104 122 140 F 0 2mA 2A e 32 50 68 86 104 122 140 F 2A Ambient Temperature C F Ambient Temperature C F RS amp sud 12 24 VDC Bo ence D gn ow ay z y o e 2 Icom pao Lo e a er O i y OUT ES PE ep 1 aye aT cow D H D2 midi rr D tL E 50 2 sup GIS OUT B c Ss L 2 1 of ae ovr amp 12 24 VDC ep 3 2 xe amp C HD COM de l L 3 D L 5 C co our D pu 4 y y com 3 Internally C RUNE W5 co Gp ru 5 connected r D 7 aU a 5 SUP E OUT C L T OUT n Hs s7 4 GE Le or 2 y 9 07 D Kal A H ay out _4 an To lt O 5 Commons p amp Eu MILI COM E 24VDC 6 Supply sup 32 le l 24V To LED ee OUT D Q E L2 D 4 l ommon N es COM 6 X 24V
3. Inputs per module 32 sink source Inputs per module 32 sink source Commons per module 4 isolated Commons per module 4 isolated Input voltage range 20 28VDC Input voltage range 4 75 13 2VDC TTL CMOS Peak voltage 30VDC Peak voltage 15VDC ON voltage level gt 19V ON voltage level gt 4 V use pullup R for TTL in OFF voltage level 10V OFF voltage level lt 2V Input impedance 4 8 KL Input impedance 2 KQ 5V 1 6 KO O 12V Input current 5mA Input current 3 1 mA 5V 7 5 mA O 12V 0 es Minimum ON current 3 5 mA Minimum ON current 1 8 mA Ka o Maximum OFF current 1 6 mA Maximum OFF current 0 8 mA Q os Base power required 5V 150 mA max Base power required 5V 150 mA max e T D OFF to ON response 2 10 ms OFF to ON response 1 4 ms Ba ON to OFF response 2 10 ms ON to OFF response 1 4 ms NC A S E Q Terminal type Removable 40 pin conn Terminal type Removable 40 pin conn Status indicators Logic Side Status indicators Logic Side Weight 6 6 oz 190 g Weight 6 6 oz 190 g i C N Derating Chart C N a Deratng Chart 24VDC INPUT a erating ha 5 12VDC INPUT 987 A B C D 28 A B C D 24 Amr BD 4 24 m Ac rm BD 204 0 4 0 4 20 0 4 0 4 1 5 1 5 1 5 1 5 167 2 6 2 6 167 2 6 2 6 3 _ 3 7
4. Outputs per module 8 relays Outputs per module 8 relays Commons per module 2 isolated Commons per module 8 isolated Operating voltage 5 30VDC 5 250VAC Operating voltage 12 30VDC 12 125VAC 125 250VAC Output type Form A SPST NO Output type 4 Form C SPDT 4 Form A SPST NO Peak voltage 30VDC 256VAC Peak voltage 30VDC 250VAC 10A AC frequency 47 63 Hz AC frequency 47 63 Hz Max current resistive 2A point 5A common Max current resistive 10A point 40A module Max leakage current 0 1mA 265VAC Max leakage current 0 1mA 265VAC 0 es Max inrush current 2A Max inrush current 10A EX Minimum load 5mA Minimum load 100mA 2912 VDC Q os Base power required 5V 550mA max Base power required 5V 575mA max e a 2 External DC required None External DC required None Te OFF to ON response 12 ms OFF to ON response 7 ms 0 S ON to OFF response 12 ms ON to OFF response 9 ms Terminal type Removable Terminal type Removable Status indicators Logic Side Status indicators Logic Side Weight 9 1 oz 260 g Weight 13 2 oz 374 9 Fuses non replaceable 1 8A per common Fuses non replaceable 1 10A 125V per common Typical Relay Life Operations je EN Typical Relay Life Operations RELAY OUTPUT RE
5. Weight 8 8 oz 250 g Points Derating Chart 164 anne m INPUT SIMULATOR 124 TB p B J tai de HE CHE 84 0 4 0 4 0 4 0 4 J s 5 i M 1 5 1 5 4 2 6 2 6 gt a E 3 7 3 7 0o A D4 16ND2F peer 0 10 20 30 40 50 60 C a 32 50 68 86 104 122 140 F TRE LL OFF ON Ambient Temperature C F A0 GIO oA D Al MO 102 264 yt Don lu D 8 or 16 input point selection me pe d Da LL D switch is located on the back A2 ELO SD 1 te of the module A3 MO o 5 5 HD 2 E De l 2 QU Switch ition is indi d M O 0 3 X 6 witch position is indicate A5 MO P E il Go T 3 D by the LEDs above the input 10 2 26 4 am 4 alo A6 MIO w 0 SE 7 D switches 5 cB A7 MO E cue 1 T Ta BO o 6 Ho o La 9 o HL Se ao Do I E amp B1 Current Flow e 1 D B2 e O 4 S ES B3 O 12 20v00 T 000000 i 7 y D Br E gt Common 3 ea B MIO To LED eco G D D B6 B MO A te Optical ap Input Isolator C JJ V e y DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications D4 32ND3 1 24VDC Input D4 32ND3 2 5 12VDC Input
6. 235 20 Loads that require currents under 10 mA co e Loads which must be switched at high speed or heavy duty cycle oe es Relay outputs in the DL405 output Relay with Form A contacts R modules are available in two contact E arrangements shown to the right The ae Form A type or SPST single pole single throw type is normally open and is the m e simplest to use The Form C type or d SPDT single pole double throw type has T a center contact which moves and a de stationary contact on either side This provides a normally closed contact and a normally open contact Relay with Form C contacts Some relay output module s relays share common terminals which connect to the 3 wiper contact in each relay of the bank Other relay modules have relays which OE are completely isolated from each other In 9j O0 all cases the module drives the relay coil Oe when the corresponding output point is on Transient The following pages are intended to give a quick overview of the negative effects of Suppression for transient voltages on a control system and provide some simple advice on how to Inductive Loads in effectively minimize them The need for transient suppression is often not apparent a Control System tothe newcomers in the automation world Many mysterious errors that can afflict an installation can be traced back to a lack of transient suppressio
7. DL405 User Manual 4th Edition Rev A suoneouioedgs pue 3 n v D p e gt 5 Q Installation Wiring and Specifications D4 08NA 110 220VAC Input D4 16NA 110VAC Input Inputs per module 8 Inputs per module 16 Commons per module 2 isolated Commons per module 2 isolated Input voltage range 80 265VAC Input voltage range 80 132VAC Peak voltage 265VAC Peak voltage 132VAC AC frequency 47 63 Hz AC frequency 47 63 Hz ON voltage level gt 70V ON voltage level gt 70V OFF voltage level 30V OFF voltage level 20V Input impedance 12K OQ Input impedance 8KQ 0 Pe Input current 8 5 mA 100VAC Input current 14 5 mA 120VAC 20 mA 230VAC E Minimum ON current 5mA Minimum ON current 7 mA Cc O 9 Maximum OFF current 2mA Maximum OFF current 2mA Oo Zo Base power required 5V 100 mA max Base p
8. DC Power F U U DL405 PLC Power Input Input Module Output Module Inputs Com Outputs Com I I y y hs Loads DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Powering I O Circuits Using In most applications it will be necessary to power the input devices from one power source and to power output loads from another source Loads often require high energy AC power while input sensors use low energy DC If a machine operator is likely to come in close contact with input wiring then safety reasons also require isolation from high energy output circuits It is most convenient if the loads can use the same power source as the PLC and the input sensors can use the auxiliary supply as shown to the left in the figure below If the loads cannot be powered from the PLC supply then a separate supply must be used as shown to the right in the figure below Separate Supplies OH AC Power AC Power Da ES Su P Input P Input E G pn DL405 PLC GE DL405 PLC c 2 Z Auxiliary Input Module Output Module Auxiliary Input Module
9. DL405 User Manual 4th Edition Rev A F4 08TRS 2 Relay Output Installation Wiring and Specifications D4 16TR Relay Output Outputs per module 8 relays Outputs per module 16 relays Commons per module 8 isolated Commons per module 2 isolated Operating voltage 12 30VDC 12 250VAC Operating voltage 5 30VDC 5 250VAC Output type 4 Form C SPDT 4 Form A SPST NO Output type Form A SPST NO Peak voltage 30VDC 250VAC 95A Peak voltage 30VDC 256VAC AC frequency 47 63 Hz AC frequency 47 63 Hz Max current resistive 5A point 40A module Max current resistive 1A point 5A common Max inrush current 10A Max leakage current 0 1mA 265VAC Minimum load 100mA 912 VDC Max inrush current 4A EFA Base power required 5V 575mA max Minimum load 5mA OR External DC required None Base power required 5V 1000mA max D 5 OFF to ON response 7 ms External DC required None gt ON to OFF response 9 ms OFF to ON response 10 ms E Terminal type Removable ON to OFF response 10 ms Ze Status indicators Logic Side Terminal type Removable Weight 13 8 oz 390 g Status indicators Logic Side Fuses user replaceable Typical Relay Life Operations Y 1 10A 250V per common 19379 K 10A Wickman Weight 10 9 oz 310 g Fuses non replacea
10. n 13 74 uci 2 n s 349mm LL O O o o 5 91 4 69 150mm 119mm E E EE O L W o dj E o q n 0 75 lot B 19mm 8 Slot Base m 0 47 IR 441mm 0 28 Mounting hole 12 mm 16 65 7 mm close up N 423mm g O O 0 5 91 4 69 Base mounting 150mm 119mm dimensions given to S i upper fully seated location Ol d n 0 75 19mm DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Panel Layout amp 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 1s The bases must be mounted horizontally to provide proper ventilation 2 There should be a minimum of 7 2 183mm and a maximum of 13 75 850mm between bases 3 A minimum clearance of 2 50mm between t
11. Pce os 4 0 de 0 1 CB D S 3 Es cele 0c7 s gt 01 Ho s Te LIE E EG C6 7 7 5 amp e e D d D 3 T 1 D oe de Current Flow M dc 19 E 20 he os 7 Se A a l 2 30 Common i To LED G Y a 4 S D 4 R F 4 amp D ii To LED D e ww Optical D T GO D ptical Input Isol T KI E Optical P DNE N Y input lso E C JJ Current sourcing configuration shown DL405 User Manual 4th Edition Rev A D4 16ND2F DC Input Installation Wiring and Specifications 2 37 D4 16SIM Input Simulator Inputs per module 16 current sourcing Inputs per module 8 or 16 selectable Commons per module 2 isolated Base power required 5V 150 mA Max Input voltage range 10 2 26 4VDC Terminal type None Peak voltage 26 4VDC Status indicators Logic Side ON voltage level gt 9 5VDC Weight 8 8 oz 250 g OFF voltage level lt 4 0VDC Input impedance 3 2 K Q 12VDC 2 9K Q 24VDC suoneouioedgs pue 3 n m v D p e gt 5 C Input current 12 24 VDC 3 8mA 8 3mA Minimum ON current 3 5 mA Maximum OFF current 1 5 mA Base power required 5V 150 mA max OFF to ON response 1 ms ON to OFF response 1 ms Terminal type Removable Status indicators Logic Side
12. 12 Current 0 4 0 4 yd 0 25A point ue p 6 m uu 2A common 3 7 S 7 D4 16TA 47 T pp sa E e amm mA 0 0 R n W 4 s a 50 60Hz 32 50 68 86 104 122 140F LA D Ambient Temperature C F NS 0 D L CN 18 220 VAC o dB CA 2 L 2x 7 pit 4 D 4 Ho LC D 5 T D 5 T 2 E D2 oh E nee E r D 3 e 3 a 18 220 VAC O Ore T 7 amp 4 L 0 CN CB Qo OH 1 eL E e D 6 0 Es L Se Ste bL ime E 393 e 4 1 qu T IAS 216 y Optica i 7 A iaa Isolator 3 L mer 8 OQ 1 E34 ok gt gt 18 220 VAC Common To LED SN e DL405 User Manual 4th Edition Rev A suoneouioedg pue 3 a m v D p e gt 5 C Installation Wiring and Specifications D4 08TR Relay Output F4 08TRS 1 Relay Output
13. 800mA max Output type NPN Open Collector External DC required 24VDC 10 800mA 50mA per common 7 0A total max es Peak voltage 36 VDC OFF to ON response 0 1 ms ZY ON voltage drop 0 6 VDC 0 1A ON to OFF response lt 0 2 ms os Max current resistive 0 1A point Terminal type 2 Removable 40 pin e BO 1 0A common connectors sold sep DS wo 8 0A module Status indicators Logic Side ea Max leakage current 0 01mA O 36 VDC Weight 7 4 0z 210 g Max inrush current 1A for 1 ms Fuses None 700mA for 100 ms Derating Chart Only 32 status points can be displayed at one time on the front of the Points 64 module In the A B position the status of the first group of 32 output s 24v0G OUTPUT points A0 A17 BO B17 are displayed connector 1 In the C D 56 Output current zh rami 887 141 48 4 0 1A point position the status of the second group of 32 output points CO C17 e ND A 40 4 DO D17 are displayed connector 2 o5 4 3109 4 8 32 4 Bo dy hb c2 2 8 24 Module location this module placement is restricted to the local pice TRU 16 base on DL430 DL440 systems It may also be placed in expansion S 8 7 b
14. O L L L L L L L L L L T ERE oF L L L L L L L L L L L oa E L L L L L L L L i L L oo Y S 7 UO modules UO module w Ribbon connector 37 4375 N 34 8mm id m NOTE Ribb t d a Ribbon connector an y imm D shell extend out past module and may affect depth of cabinet 5 9 150m Handheld programmer cable Base Expansion Cable 4 5 ft 1 5m a 1 6ft 5m 9 1 ft 3m 3 3 ft 1m DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Installing DL405 Bases Three Sizes of All 1 O configurations of the DL405 except for Slice I O will use a selection of either Bases 4 6 or 8 slot base s Local and expansion bases can be 4 6 or 8 slot in size Local and expansion bases differ only in how they are wired in a system Expansion cabl f input connection N Local Base ae Expansion cable _ 7 O9 output connection oO 2 mn 59 o Expansion S cable Lu NC 8 8 slot base E B Expansion xpansion bases Power 6 slot base Supplies 4 slot base b WARNING To minimize the risk of electrical shock personal injury or Y E equipment damage always disconnect the system power before installing or Lo removing any system component Mounting The CPU Expansion Unit Remote Slave must always b
15. Wiring and Specifications D4 64ND2 24 VDC Input Module Module Location CPU base only Base power required 5V 300 mA max Inputs per module 64 current sourcing External power required 24VDC 10 optional 320mA max Commons per module 8 isolated OFF to ON response 2 5 ms typical Input voltage range 20 28 VDC ON to OFF response 5 0 ms typical Peak voltage 30 VDC Terminal type 2 Removable 40 pin connectors OFF voltage level 13V Status indicators Logic Side Input impedance 4 8K Q Weight 7 8 oz 220 g Input current 5 0 mA 24 VDC Minimum ON current 3 6 mA Maximum OFF current Points Derating Chart 2 6 mA oa Since there are only 32 LEDs on the module you on iem R can only display the status for 32 points at one 4 time In the A B position the status of the first Ac BD 2 group of 32 input points A0 A17 BO B17 are R 4 treed NI J displayed connector 1 In the C D position the 15151515 nal status of the second group of 32 input points 2 e 2 s S n i ME MP ME DURUM C0 C17 DO D17 are displayed connector 2 D4 64ND2 32 50 68 86 104 122 140 Ambient Temperature C F Wiring per 32pts Wiring per 32pts Connector Pins using EXT 24VDC Connecta with 24V on Conn
16. 3 7 3 _ 3 7 3 7 44 D4 32ND3 1 44 D4 32ND3 2 0 0 0 10 20 30 40 50 60 C 0 10 20 30 40 50 60 C 32 50 68 86 104122140 F DISPLAY 32 50 68 86 104122 140 F ee Ambient Temperature C F a SELECT A B Ambient Temperature C F E SELECT A B ODO C D FOO C D 9 0 E 9 9 z Current Flow Eso 42 5 0mA CLASS2 Current Flow 5o Sama CLASS2 User C LO AO A4 O User 9 AO A4 O Supply L o At AS Supply L o A AS oo afas Fo o too alas es Current Flow 20 aa o S Current Flow ped MAL S S o o euo l 2 lt 979 loo User I 20 BojB4 llo o User L Oo BolB4 llo o Supply E o Bi B5 o0 Supply o B1 B5 o o B2 B6 o0 B2 B6 o0 So aser 8 So Bie los Current Flow 20 cojo lo o Current Flow FL enel lo o zs coca oo zi coca oo oo oo 4 O oles oo F 4 O oles oo User O_O cac 22 User O_O cac 2 2 Supply OO Supply It jjo o 2 cule o o OO cien o o 9 0 DO D4 o0 Current Flow O O Do D4 o0 too pijos 20 0 L0 palos IZ lt o D2 D6 llo o o D21D6 llo o pos mor a 24 VDC c CN CIV O 5 12 VDC Ss CMCIV O Common M Common J To LED No To LED Ne T 60 Use Display Select switch to view T O Use Display Select switch to view w lal L optica AO A7 BO B7 or C0 C7 DO D7 TEN PEDI Optica A0 A7 BO B7 or CO C7 DO D7 ee ates Curent sinking config shown ie an ene a Current sinking config shown DL405 User Manual 4th Edition Rev A Installation
17. 3M 3801 40 Gray 26 AWG Belden 9L260 40 Gray 28 AWG Belden 9L280 40 Gray 28 AWG DuPont 76825 040 Gray 28 AWG AMP 499116 5 Color coded 26 AWG 3M 3811 40 Color coded 28 AWG Belden 9R280 40 Color coded 28 AWG DuPont 76177 040 Ribbon Cable These ribbon cable connectors are for attaching the ribbon cable to the terminal Connectors block They are all 100 x 100 2 x20 female ribbon connectors with a center bump Description Type Vendor Part Number Connector 3M 3417 7640 Strain Relief 3M 3448 3040 Connector 3M 3417 7640 Strain Relief 3M 3448 3040 Connector pre assembled 3M 89140 0103 TO Strain Relief 3M 3448 89140 Connector with strain relief Thomas amp Betts 622 4041 Connector pre assembled AMP 746286 9 Strain Relief AMP 499252 1 Connector with strain relief DuPont 66902 240 Connector with strain relief Molex 15 29 9940 Interface Terminal Below are terminal blocks which can be used to transition a 40 conductor ribbon Block cable to 40 discrete field wires The terminal block features are 2 x 20 100 x 100 pin center male connector head terminals 2 centers accepting 22 12 AWG no fuses Description Type Vendor Part Number Panel Mount Weidmuller RI 40A 914897 Rail Mount RI 40A 914908 Rail Mount Phoenix Contacts FLKM 40 2281076 Special Mount Augat RDI 2M40FC DIN rail compatible includes ribbon connector DL405 User Manual 4th Edition Rev A jeouioeds
18. Ext DL405 User Manual 4th Edition Rev A D4 08TA 18 220VAC Output Installation Wiring and Specifications D4 16TA 18 220VAC Output Outputs per module 8 Outputs per module 16 Commons per module 2 isolated Commons per module 2 isolated Operating voltage 15 265VAC Operating voltage 15 265VAC Output type SSR triac Output type SSR triac Peak voltage 265VAC Peak voltage 265VAC AC frequency 47 63 Hz AC frequency 47 63 Hz ON voltage drop 1 5VAC 2A ON voltage drop 1 5 VAC 0 5A Max current 2A point 5A com 30 C 2A common 2 60 C Max current 0 5A pt 3A common 45 C 2A common 60 C Max leakage current 5mA 265VAC Max leakage current 4mA 265VAC Max inrush current 30A for 10 ms 10A for 100 ms Max inrush current 15A for 10 ms 10A for 100 ms Minimum load 10 mA Minimum load 10 mA Base power required 5V 250 mA max Base power required 5V 450 mA max OFF to ON response ims OFF to ON response ims ON to OFF response 1 ms 1 2 AC cycle ON to OFF response 1 ms 1 2 AC cycle Terminal type Removable Terminal type Removable Status indicators Logic Side Status indicators Logic Side Weight 11 6 oz 330 g Weight 12 2 oz 350 g Fuses non replaceable 1 8A
19. Logic Logic aa amp aw LS 7r Ground dd T Ground Logic Ground y Et o _ Chassis c Chassis Chassis e lt Q se EI Ground nes Ground Ground D a DI pc E pc a L CD AC Line ES Tu EH N S9 r1 nc 8 DG wl Go AC Neutral amp So le al NN 110 220 a go L D L amp Voltage Select e 6 B Ee LUN Install shunt between LG and G Install shunt for 110 VAC range Recommended screw torque 10 6 Ib in 1 2Nm leave off for 220 VAC range Install shunt between LG and G Connecting You can mount the Handheld directly to Port 0 of any DL405 CPU 15 pin D shell Programming connector or you can use a 9 foot 3m or 4 6 ft 1 5m cable as shown below Devices Cable Mount Direct Mount__ 7 Use cable part no D4 HPCBL 1 or D4 HPCBL 2 Retaining Screws The standard port for use in DirectSOFT programming is the 15 pin port 0 on all DL405 CPUs The cable shown below is approximately 12 feet 3 66m long All DL405 CPUs port 0 O 15 pin D 9 pin D shell t shell male female Ogll h amp A Use cable part no D4 DSCBL SS Ca DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications On the DL450 you may use port 2 instead for DirectSOFT programming The cable shown below is approximately 12 feet 3 66
20. Manual 4th Edition Rev A Installation Wiring and Specifications Ex In some cases using the built in auxiliary 24VDC supply can result in a cost savings for your control system It can power combined loads up to 400 mA Be careful not to exceed the current rating of the supply If you are the system designer for your application you may be able to select and design in field devices which can use the 24VDC auxiliary supply Powering I O All DL405 CPUs feature the internal auxiliary supply If input devices AND output Circuits with the loads need 24VDC power the auxiliary supply may be able to power both circuits Auxiliary Supply as shown in the following diagram 400 mA limit 2 AC Power B 23 Power Input ag DL405 PLC ne of mn 0 pem Auxiliary Input Module Output Module o9 24VDC a Supply Inputs Com Outputs Com 2g i i i S3 oa ty 7 y y O O Loads DC powered DL405 CPUs are designed for application environments in which low voltage DC power is more readily available than AC These include a wide range of battery powered applications such as remotely located control in vehicles portable machines etc For this application type all input devices and output loads typically use the same DC power source Typical wiring for DC powered applications is shown in the following diagram
21. Output Module BF 24VDC 24VDC go Supply Inputs Com Outputs Com Supply Inputs Com Outputs Com oe k ry k ry k k ty 7 y y ty 7 y y O O de ES Loads ib Loads Load Supply Some applications will use the PLC external power source to also power the input circuit This typically occurs on DC powered PLCs as shown in the drawing below to the left The inputs share the PLC power source supply while the outputs have their own separate supply A worst case scenario from a cost and complexity view point is an application which requires separate power sources for the PLC input devices and output loads The example wiring diagram below on the right shows how this can work but also that the auxiliary supply output is an unused resource For these reasons you ll probably want to avoid this situation if possible DC Power DN L N t ey AC Power Power Input Input Module M Output Module Auxiliary Input Module Output Module C O C 24VDC nputs om utputs Com Supply Inputs Com Outputs Com i i I i i Y Y Y Y Y OO mS Loads Load oe Input Loads Load Supply Supply Supply DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Sinking Sourcing Before going further in our study of wiring strategies we must have a solid Concepts understanding of sinking and sourcing concepts Use of these terms occurs freq
22. Ses DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications In the next example we connect a PLC sinking DC output point to the sinking input of afield 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 P DC pwr O BEN R pull up Field Device sourcing sinking Output Input R input E Dm 9 inki LAA cc sinking lt Supply ES L 1 4 Common L Ground os Y a M So Zo NC coe 999999 NOTE 1 DO NOT attempt to drive a heavy load gt 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 inp
23. and Systems ICS 3 Industrial Systems ICS 6 Enclosures for Industrial Control Systems e 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 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 DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Three Levels of The publications mentioned provide many ideas and requirements for system Protection safety At a minimum you should follow these regulations Also you should use the following techniques which provide three levels of system control e Emergency stop switch for disconnecting system power Mechanical disconnect for output module power e Orderly system shutdown sequence in the PLC control program Emergency Stops Itis recommended that emergency stop circuits be incorporated into the system for every machine controlled by a PLC For maximum safety in a PLC system these circuits must not be wired into the controller but should be hardwired external to the PLC The emergency stop switches should be easily accessed by the operator and are generally wired into a mas
24. example suppose a relay contact drives a load at 120VAC 1 2 A Since this example has an AC power source we first we calculate the peak values o 5 a LD Ke o Q g UL suol do Ipeak Irms X 1 414 0 5 x 1 414 0 707 Amperes Vpeak Vrms X 1 414 120 x 1 414 169 7 Volts Now finding the values of R and C we have pe 0 707 C uF 0 05 uF voltage rating 170 Volts 10 10 V 50 R Q Where X lt 1 10x1 V 50 169 7 x 1 1 29 R Q aa 16 Q 1 2 W 5 169 7 10x0 707 DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications I O Module Wiring and Specifications Module Placement n gc xd O KS MC 59 D 0 S So ne E Q 1 0 Module Status Indicators Display status selects a group of signals to be displayed Color Coding of I O Modules Before wiring the I O modules in your system to field devices it s very important to make sure each I O module is in the right slot and base in the system Costly wiring errors may be avoided by doing the following e Do the power budget calculations supply can power all the modules A o E O for each base to verify the base power in the base Information on how to do this is in Chapter 4 System Design and Configuration e Some specialty I O modules may only be installed in particular slots wi
25. output wiring where possible To minimize voltage drops when wires must run a long distance consider using multiple wires for the return lines Where possible avoid running DC wiring in close proximity to AC wiring 9 Avoid creating sharp bends in the wires 10 IMPORTANT To help avoid having a module with a blown fuse we suggest you add external fuses to your I O wiring A fast blow fuse with a lower current rating than the I O module fuse can be added 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 NO W 2 aa T y 9 External Fuses O e e shown with DIN Rail q fuse blocks O e 2 P OF e Sk DL405 User Manual 4th Edition Rev A DL405 Input Module Chart DL405 Output Module Chart The following table lists the available DL405 input modules Specifications begin on the following page Installation Wiring and Specifications DL405 Number of DC Current DC Current AC Input Input Module Type Input Points Sink Input Source Input D4 16ND2 16 Y D4 16ND2F 16 Y D4 32ND3 1 32 Y Y D4 32ND3 2 32 Y Y D4 64ND2 64 Y D4 08NA 8 Y D4 16NA 16 Y D4 16NE3 16 Y Y Y F4 08NE3S 8 Y Y Y D4 08ND3S 8 Y Y The fo
26. per common i Points Derating Chart 18 220VAC OUTPUT 8 TB FU Output Current NS Output 64 1A point Current 0 4 0 5A point E 4 la 3 7 Output Current D4 08TA 275 2A point 2A common 1 5A common 15 265VAC o 10mA 2A 0 10 20 30 40 50 aur 50 60H2 32 50 68 86 104 122 1407 Ambient Temperature C F CA 18 220 VAC Oca 18 220 VAC gt Le Bo HIT e 6 6 T o N m A U o a E a o Zelzele elese selle Que Optical Isolator 7 H e V gt 18 220 VAC Common To LED ap l V ZA Fuses non replaceable 1 6A per common Points Derating Chart 18 220VAC 16 Output Current ML TB id Output ATAN 8S 0 35A point
27. pue one eisu 3 suol do 2 34 Installation Wiring and Specifications UO Wiring Use the following guidelines when wiring the I O modules in your system Checklist 1 Note the limits to the size of wire the modules can accept The table below lists the maximum AWG for each module type Smaller AWG is acceptable to use for each of the modules Module type Suggested AWG Range Suggested Torque CPU 12 AWG 10 63 Ib inch 1 2 Nem 8 point 12 AWG 7 97 lb inch 0 9 Nem 16 point 14 AWG 7 97 lb inch 0 9 Nem 32 point ZipLink ZL 4CBL4 cable ZL CM40 connector block 64 point D4 IOCBL 1 3m pigtail cable with D4 103264S connectors sold D4 103264R ribbon type connector separately D4 103264S solder type connector 29999 Note 12 AWG Type TFFN or Type MTW can be used on 8pt modules 14 AWG Type TFFN or Type MTW can be used on 16pt modules Other types of wire may be acceptable but it really depends on the thickness of the wire insulation If the insulation is too thick and you use all the I O points then the plastic terminal cover may not close properly n gc xd O KS KC 59 D 0 S So ne E Q 2 Always use a continuous length of wire Do not splice wires to attain a needed length Use the shortest possible wire length Where possible use wire trays for routing Avoid running wires near high energy wiring Avoid running input wiring close to
28. the arrow when the switch is closed suoneouioedgs pue 5 a m v D m e E 5 Q Input Sensing 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 The I O module specifications at the end of this chapter list the input or output type Sinking Input Sinking Output PLC PL Input Sho p T Output OO O O Load ls Input Output Ha e Y Sensing Switch E Common Common 4 il E d Ni Sourcing Input Sourcing Output PLC PLC Common T 4 Common v v EL Input Output HL um Y Sensing Switch Y Input tput p O Outpu Load DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications UO Common In order for a PLC 1 O circuit to operate PLC Terminal Concepts current must enter at one terminal and exit Field Main Path L at another This means at least two Device 1 0 Point Y Vo terminals are associated with every I O Creu point In the figure to the right the Input or E Y Output terminal is the main path for the L current One additional terminal must Return Path a provi
29. the PLC in the event of controller failure so that independent and rapid shutdown are available Devices such as mushroom switches or end of travel limit switches should operate motor starter solenoids or other devices without being processed by the PLC These emergency circuits should be designed using simple logic with a minimum number of highly reliable electromechanical components 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 n gc xd O KS MC 59 D 02 S So ne E Q 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
30. to the module make sure the terminal block is tightly seated Be sure to tighten the retaining screws You should also verify the loose terminal block LED is off when system power is applied WARNING For some modules field device power may still be present on the Y IR terminal block even though the PLC system is turned off To minimize the risk A e of electrical shock disconnect all field device power before you remove the connector o gt 20 Ep Loose terminal block OF LED indicator 2 i 9 A TB gt 83 oa Terminal screws AN gt Retaining screw Push tab and lift to remove 30VDC 1A 250VAC 1A S ez su r ADIOS amp l l lelelelelelelel l Amalia J Ol l lOlaleleolelelell ADEIT a Ol l lOl lelelelelel l Amalia amp l l lOl lelalelelell 0000000000000 900000000000 L doo ooo O I O module wiring tray DL405 User Manual 4th Edition Rev A 2 32 Installation Wiring and Specifications Wiring 32 and 64 The 32 point and 64 point I O modules use a different style of connector due to the Point I O Modules increased number of I O points There are several types of connection methods available to choose from A ZIPLink connection system is shown in the figure below Refer t
31. 2 With the device tilted slightly forward hook the plastic tabs into the notch on the base 3 Then gently push the top of the component back toward the base until it is firmly installed into the base 4 Nowtighten the screw at the top of the device to secure it to the base WARNING To minimize the risk of electrical shock personal injury or equipment damage always disconnect the system power before installing or removing any system component VA CE TN DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications CPU and Expansion Unit Wiring Guidelines The main power terminal connections are under the front covers of the DL405 CPUs and Expansion Units The list below describes the function of each of the terminal screws Most of the terminal screws are identical between the CPU and the Expansion Unit If the terminal screw only applies to one of the units it will be noted e Run Relay CPU only indicates to an external device when the CPU is in Run Mode by contact closure Its normally open contacts can also remove power from critical I O points if CPU comes out of Run mode e 24VDC Auxiliary Power can be used to power field devices or I O modules requiring external power It supplies up to 400 mA of current at 20 28VDC ripple less than 1 V P P Not available on DC CPUs Logic Ground internal ground to the system which can be tied to field device
32. Bases I O Modules The ranges that vary for the Handheld Programmer are noted at the bottom of this chart I O module operation may fluctuate depending on the ambient temperature and your application Please refer to the appropriate I O module chapters for the temperature derating curves applying to specific modules Specification Rating Storage temperature 4 F to 158 F 20 C to 70 C Ambient operating temperature 32 F to 140 F 0 C to 60 C Ambient humidity 5 95 relative humidity non condensing Vibration resistance MIL STD 810C Method 514 2 Shock resistance MIL STD 810C Method 516 2 Noise immunity NEMA ICS3 304 Atmosphere No corrosive gases Storage temperature for the Handheld Programmer is 14 to 149 F 10 to 65 C Ambient humidity for the Handheld Programmer is 20 to 90 non condensing The external power source must be capable of suppling voltage and current complying with the PLC power supply specifications Specifications DL405 Series CPUs Voltage withstand dielectric strength 1 min 1500 VAC between primary secondary field ground and run relay Insulation resistance gt 10Mo at 500 VDC Input voltage range D4 430 D4 440 D4 450 D4 EX 85 132 VAC 110 range 170 264 VAC 220 range Input voltage range D4 440DC 1 D4 EXDC 20 29 VDC 24VDC less than 10 ripple In
33. DC Output D tour D B T T 4 L 12 24 m s Ww c D L Li y cou 7 D T VDC Optical 24VDC Optical To LED f A Isolator ap Output Isolator 7 Common V y 3A Ka J DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications D4 16TD1 5 24 VDC Output D4 16TD2 12 24 VDC Output Outputs per module 16 current sinking Outputs per module 16 current sourcing Commons per module 2 internally connected Commons per module 2 isolated Operating voltage peak 4 5 26 4VDC 40 VDC Peak Operating voltage peak 10 2 26 4 VDC 40 VDC Peak Output type NPN Open collector Output type NPN Emitter Follower ON voltage drop 0 5V 0 5A 0 2V 0 1A ON voltage drop 1 5 VDC 9 0 5A Max current resistive 0 5A point 3A common Max current resistive 0 5A point 3A common 50 C 2 5A common 60 C Max leakage current 0 1mA O 40VDC Max leakage current 0 1mA 40 VDC Max inrush current 2A for 10 ms 1A for 100 ms Max inrush current 2A for 10 ms 1A for 100 ms g 2 Minimum load 0 2mA Minimum load 0 2mA m Base power required 5V 200mA max Base power required 5V 400mA max 3 gE External DC required 24VDC 10 125mA External DC required None QS OFF to ON response 0 5 ms OFF to ON response 1 ms 8 ON to OFF response 0 5 ms ON to OFF response 1 ms 32 Terminal type Removable Terminal type Removable Status in
34. Installation Wiring and Specifications In This Chapter Safety Guidelines Mounting Guidelines Installing DL405 Bases Installing Components in the Base CPU and Expansion Unit Wiring Guidelines O Wiring Strategies O Module Wiring and Specifications Glossary of Specification Terms EN 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 A listing of our international affiliates is available on our web site http www automationdirect com WARNING Providing a safe operating environment for personnel and Mz equipment is your responsibility and should be your primary goal during A on 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 Sufficient emergency circuits should be provided to stop either partially or totally the operation of the PLC or the controlled machine or process These circuits should be routed outside
35. LAY OUTPUT Maximum Resistive Operating Voltage en Maximum Resistive Operating Voltage TB or Inductive Inrush E or Inductive Inrush m Load Current 30VDC 125VAC 250VAC n Load Current 30VDC 125VAC 250VAC 0 4 2A resistive 100K 300K 200K 18 1 4 HP 25K NE e 2Ainductive 100K 80K 60K ao EPA a a SUE 0 5A resistive 800K 1M 800K s O Ainductive 300K 300k 200K D4 08TR 3 0A a 125K 50K S Points Derating Chart 2A 50 60Hz d Points Derating Chart INDE Cy B Output SMAA ji Output Current 4 9 OcA 7 curent Lt S amp mus GHR ale e Ho Do 6 1 25A point oo od 41 TA No 5 Aude A Li a 8 Tig Aeon bd IS les CP Output Current pe ST 27 10A point el D 7 Hy ceti Hp Eo EH ioe 0 ee a RN i Me cH s ervepmmem tole Dal o to 2 2 do 50 60 no de T T I T 1 2 D CM 32 50 68 86 104 122 sE 2 D Ji dO cB 2 18 20 30 f i BLK L E yz D D Ambient Temperature C F 2 c aS lm 4 Ambient Temperature C F Do 8 A De No Maximum DC voltage NO J us D t u s a AS rating is 120 VDC s Mie O H D 0 5A 30 000 cycl g SS Oh 5A 30 cycles 3 amp HI 6 up Gia typical Motor starters 3 NO o 4 4 4 y Zl up to and including NC TIS D E Brive NEMA size 3 can be Es D O used with this module js SS prole O 5 Co D Common 490A NO 6 ES 2 D u C D Common Ll 2e D SN K Y To LED E H D NO 7 qu L X Eb HIT D NO Gp NC EN e S Output RELAY rh a T R e Ne
36. Protective device for an output circuit which stops current flow when current exceeds the fuse rating current It may be replaceable or non replaceable or located externally or internally DL405 User Manual 4th Edition Rev A
37. ar it may be listed for various input currents Typical operating current for an active ON input The minimum current for the input circuit to operate reliably in the ON state The maximum current for the input circuit to operate reliably in the OFF state The minimum load current required for an output circuit to operate properly Some output modules require external power for the output circuitry Sometimes called saturation voltage it is the voltage measured from an output point to its common terminal when the output is ON at max load The maximum current a connected maximum load will receive when the output point is OFF The maximum current used by a load for a short duration upon an OFF to ON transition of a output point It is greater than the normal ON state current and is characteristic of inductive loads in AC circuits The 5VDC power from the base required to operate the module Be sure to observe the base power budget calculations The time the module requires to process an OFF to ON state transition The time the module requires to process an ON to OFF state transition The LEDs that indicate the ON OFF status of an input or output point These LEDs are electrically located on the logic CPU side of the I O interface circuit Indicates whether the module s connector is removable or non removable Indicates the weight of the module See Appendix E for a list of the weights for the various DL405 components
38. as a means of removing the power from the entire control system It may be necessary to install a capacitor across the disconnect to protect against a condition known as outrush This condition occurs when the output triacs are turned off by powering off the disconnect thus causing the energy stored in the inductive loads to seek the shortest distance to ground which is often through the triacs 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 Orderly System Ideally the first level of fault detection is Shutdown the PLC control program which can identify machine problems Certain shutdown sequences should be performed The types of problems are usually things such as jammed parts etc that do not pose a risk of personal injury or equipment damage n gc x O KS MC 59 u 0 S So ne Lu we n WARNING The control program must Serm Saw B e not be the only form of protection for ASA Lom any problems that may result
39. ases in DL450 systems that are using the new 1 bases 0 T 0 10 20 30 40 50 60 Cid 32 50 68 86 104 122 140 SELECT A B Ambient Temperature C F using EXT 247DC ean Wiring per 32pts M cru Connector and 5 26V using EXT 24VDC ith 24V 5 26VDC Load Connector Pins 0 1A CLASS2 Connector NZ on Supply CN1 CN2 Connector aa a O O A09 Ojas copo O ca Current Flow Current Flow Current Flow AN RS Ae Hee os too r o Internally Internally Internally e S S x a o 5 ki oo oo Connected Connected d Connected Wo dit Wo ee V cio 9 v cs Oo O vs o0 o0 Aio O O ars Cio O O C14 o0 oo Current Flow ani O O AIS CH O O cis o0 o0 Putent Flow Current Pow ar2 O aie creo O cre o o o o t A13 O O At7 crap O O C17 oo oo x 5 26VDC cial 5 26VDC m co o ve ci 0 6 ve G 6 oo Bol O O B4 DoO O p4 oo oo Current Flow Current Flow Current Flow Bi OO Bs Di ds o o o0 4 ae B2 O Be D2 De oo oo Bajo O B7 v3 9 O p7 oo oo N N N cao o vas c7 O vz7 oo oo 5 26VDC 5 26VDC Bio O O B14 D10 O O Di4 o o oo Current Fl BM O 0 B15 Di O O p15 TUSCE Bi2 O O B16 D12 O O DIE E s E Z Bi3 O O Bt7 D13 O O D17 o o o o yo y w elo 9 va clo 9j ve 6 6 DU ES E E o o o o Optical Optical Optical M99 moej Y Isolator y __Isolator i Isolator O O E HL L Output D Output Y Output EXT 8 4 24VDC To LED E To LED UT To LED F 24VDC 5 26VDC Common Common Common 24VDC Ext y 24VDC Ext 24VDC
40. ate connections for each terminal 125VDC 24VDC Terminal Terminal AC Terminal Strip Strip Strip lt D4 430 CPU 110 220VAC H RUN PRO O Barr D D DirectA05 TERM RUN DH O vo Koyo So cru EJ com amp e amp amp amp ante A O 7 S 24V Auxiliary ron F amp e Ale Power U C 2 s B ates O crna Nr BI tese rouna fe c amp J Chassis lt Chassis 4 Z Chassis l S ae 90 146VDC Ground 20 28VDC Ground Ground l I pc Bl pC ezel ac Line D KIS pc HO oe T II AC Neutral HI E He He 26 DIK ass Z i D D TE Voltage Select 2 B a o y 9 Install shunt between LG and G Install shunt for 110 VAC range Recommended screw torque 10 6 Ib in 1 2Nm leave off for 220 VAC range Install shunt between LG and G DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Expansion The following diagram details the appropriate connections for each terminal Unit Wiring 125VDC 24VDC lt Terminal Strip Terminal Strip AC Terminal Strip pwr L3 amp amp e D IRE l 24v Auxiliary D 7 al D Power E e
41. ation The panel ground termination must be connected to earth ground For this connection you should use 12 AWG stranded copper wire as a minimum Minimum wire sizes color coding and general safety practices should comply with appropriate electrical codes and standards for your area A good common ground reference Earth ground is essential for proper operation of the DL405 which include a Installing a ground rod as close to the panel as possible b Connection to incoming power system ground 8 Installations where the ambient temperature may approach the lower or upper limits of the specifications should be evaluated properly To do this place a temperature probe in the panel close the door and operate the system until the ambient temperature has stabilized If the ambient temperature is not within the operating specification for the DL405 system measures such as installing a cooling heating source must be taken to get the ambient temperature within the DL405 operating specifications 9 Device mounting bolts and ground braid termination bolts should be 10 copper bolts or equivalent Tapped holes instead of nut bolt arrangements should be used whenever possible To assure good contact on termination areas impediments such as paint coating or corrosion should be removed in the area of contact 10 The DL405 system is designed to be powered by 110 VAC 220 VAC or 24 VDC normally available throughout an industrial environment Isola
42. ble Typical Relay Life Operations 1 8A per common EN RELAY OUTPUT um RELAY OUTPUT Maximum Resistive Operating Voltage M aman E Operating Voltage B or Inductive Inrush or Inductive Inrus Load Current 28vDC 120vAC 240VAC 4 Load Current 30VDC 125VAC 250VAC 5 0A 200K 100K 1 5 ES 1A resistive gt 1M 500K 300K 1 5 1 5 3 0A 325K 125K 50K M 1Ainductive 400K 200K 100K 2 6 2 6 05A gt 50M 0 5A resistive gt 2M 800K 500K S ee ia F4 08TRS 2 0 5A inductive g
43. ble Terminal type Removable Status indicators Logic Side Status indicators Logic Side Weight 8 8 oz 250 g Weight 9 oz 256 g Points Derating Chart Points Derating Chart N 16 12 24VAC DC INPUT 84 90 150VAC DC INPUT 12 Ta E 64 TB AA BS a i s a a E 44 E 4 3 7 a 7 2 3 7 0 D4 16NE3 0 F4 08NE3S 04 i 10 2 26 4V 0 10 20 30 40 50 60 C 32 50 68 88 104 122 140 F AUC E 32 50 68 86 104 122 140 F go ssovbe EH Ambient Temperature C F 50 60 Hz DC Ambient Temperature C F a CA IN CA B 0 ag E en On SE in 9 ap a a 1 Lg Or SS O e w EXIT amp s T 5 ec amp O 1 ay So E Cs 6 T 2 D ore ore 2 an D an F Ue CER 0 e E l 3 D T amp IN 2 ag 0 0 7 D _ e D IN 3 IN D ry dps m CB L os a i in L2 Gp HA XE Sete E o o o IN in e Ho 6 diam AN QD e a T9 Ced 500 i D amp la D7 IN an 5 i IN G9 2 SE E Common js a SE C ommon l e S N z A L lO e T O Ml la T D m D so ANN gt T so WW Optical Input To LED Input so SG SS npu U L 0 Current sourcing configuration shown M LM DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications D4 08TD1 12 24VDC Output F4 08TD1S 24 150 VDC Isolated Out Derating Chart Derating Chart Outputs
44. cations Installing Components in the Base Setting the CPU There is one bank of four configuration switches located on the back of DL430 and DIP Switches DL440 CPUs These switches affect battery low detection station address override DL430 440 Only and baud rate of the secondary port 25 pin D connector The figure below indicates the location of these DIP switches Equivalent configuration of the DL450 CPU requires selecting AUX functions on a programming device N Switch 1 o e ON Battery low indicator disabled s OFF Battery low indicator enabled Switch 2 e ON Station address override is enabled address 1 e OFF Station address is set by AUX function with programming device n gc xd O KS MC 59 D 0 S So ne E Q 999999 NOTE Setting Switch 2 on forces the station address to 1 lt does not change the address set by the programming device When Switch 2 is turned off again the address will revert back to the address stored in memory via the AUX function Port 1 Baud Rate Switch 3 Switch 4 300 Off Off 1200 Off On 9600 On Off 19200 On On NOTE Parity Mode and Station address for port 2 is selected by AUX functions 3 using a programming device 1 Note the components have plastictabs Spring loaded at the bottom and a screw at the top sl al
45. de the return path to the power T supply If we had unlimited space and budget for PLC I O terminals then every I O point could have two dedicated terminals just as the figure above shows However providing ao this level of flexibility is not practical or even necessary for most applications So o O most Input or Output points on PLCs are in Mouta groups which share the return path called oo commons The figure to the right shows a Input4 group or bank of 4 input points which 0O O share a common return path In this way LiB the four inputs require only five terminals E T instead of eight Commons Input ut 1 Sensing Cy O n gc xd O KS MC 59 D 0 S So ne E Q L lt C e e e NOTE In the circuit above the current in the common path is 4 times any channel s input current when all inputs are energized This is especially important in output circuits where heavier gauge wire is sometimes necessary on commons Most DL405 input and output modules alae INPUT group their I O points into banks that share TB a common return path The best indication 0 of I O common grouping is on the wiring 2 5 label such as the one shown to the right D The miniature schematic shows two circuit 102 284v0C banks with
46. dicators Logic Side Status indicators Logic Side Weight 9 5 oz 270 g Weight 9 8 oz 280 g Fuses non replaceable 1 5A per common Fuses non replaceable 1 5A per common Derating Chart Derating Chart 0 3A point Za Point d N Point Pa ES 16 5 24VDC OUTPUT 16 12 24VDC OUTPUT N Output Current T6 T zi _ Output Current B 12 0 35A point Ta dr Bo 19 0 35A point 2 5A common Se R 87 Output Current A S 87 N Output Current i i z 0 5A point gt 6 2 6 0 5A point a 6 a 7 47 SA comm
47. e installed in the left most the Base slot in a base This slot is marked on the base as P S CPU The I O modules can be installed in any remaining slots It is not necessary for all slots to be filled for your system to work correctly You may use filler modules to fill the empty slots in the base The base is secured to the equipment panel Mounting hole or machine using four M4 screws in the Base mounting holes closeup corner locations shown to the right The 4 locations mounting cut outs allow removal of the base d after installation without completely removing the mounting screws Full mounting template dimensions are given in the previous section on Mounting Guidelines DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Choosing the There are two types of bases to choose Local Base Type from The standard base type restricts the placement of specialty modules or intelligent modules to the local base with the CPU By using the DL450 CPU and the new expanded bus base type you can also use specialty modules in expansion bases as shown to the right When all bases inthe local expansion system are of the new type the DL450 can communicate with specialty modules in any base In all other respects the new base is an exact replacement for the standard bases Expansion cable Expansion The pa
48. ector DISPLAY o oy c 5o xe olas ce olca SELECT A B zoo eo 9 0 a O A5 c1 O c5 eo C D Current Flow Lo HO oo oo S S eo Internally Ae 6 6 AG Ge M ce 4 2 5 8mA CLASS2 00 Connected 270 A3 A7 C3 C7 CNi CN2 o w o 0 cijo O oV C580 O oV O O 90 9 0 A10 O O A14 C10 O O C14 Loo Loo anio O At5 cit Oo 0 C5 roo roo coa oO oO A12 O o a16 c12 O O ct6 o o o o o0 O70 A13 O O A17 C13 O O c17 a E 979 w o 0 c2 O ov ceo O ov ub 355 ro 0 0 Boo O B4 DO Oo O Dp4 o o o o 0 0 0 0 BIO O B5 Di O O D5 oo oo cer Loo 9 0 B2 O O B6 D2 O O D6 o0 oo 9 0 Current Flow 9 0 B3 B7 D3 O D7 E S E 9 9 ov T4 o o c3 o o ov c o o ov 6 6 S o 2 zaot 2 B10 O O B14 D10 O O D14 o o o o0 pS pS B11 O O B15 DIO O D15 D up 9 19 cor o0 oo B12 O B16 D12 O O D16 Sellos poo 0 0 B13 O O B17 D13 O O Di7 QD ane O o 0 CA o O O0V CBL O O OV o o o o Ov EM a a H ee _J MJ O oO oo oo o o Input Input oOo oo gt TUE e To LED SH a O O Ly E L EXT o T T 24vDCL2 Optical 24VDC Optical Isolator E Isolator LS ui Common Common v Wo 1 Module location this module placement is restricted to the local base on DLA30 DL440 24VDC Ext systems It may also be placed in expansion HC Pi 9 PI bases in DL450 systems that are using the new 7 co 1 bases
49. eight input points in each The common terminal for each is labeled CA F3 and CB respectively t3 In the wiring label example the positive terminal of a DC supply connects to the common terminals Some symbols you will see on the wiring labels and their meanings are 7 ES d islelolelelelelelole o AC supply DC supply AC or DC supply e is kd V Input Switch Output Load o o L DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Connecting DC I O In the previous section on Sourcing and Sinking concepts we explained that DC I O to Solid State circuits sometimes will only allow current to flow one way This is also true for many of Field Devices the field devices which have solid state transistor interfaces In other words field 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 Solid State Several DL405 DC input modules are flexible in that they detect current flow in either Input Sensors direction so they can be wired as either sourcing or sinking In the following circuit a field device has an open collector NPN transistor output It sinks current from the PLC input point which
50. ening Place the diode as close to the inductive field device as possible Use a diode witha peak inverse voltage rating PIV atleast 100 PIV 3A forward current or larger Usea 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 n gc xd O KS MC 59 D 0 S So ne E Q PLC Relay Output Inductive Field Device Input 3 Output npu o o 4 p Supply 4 Common ud Common a UY T E DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications 2 29 Another method of surge suppression is to use a resistor and capacitor RC snubber network The RC network must be located close to the relay module output connector To find the values for the RC snubber network first determine the voltage across the contacts when open and the current through them when closed If the load supply is AC then convert the current and voltage values to peak values Now we are ready to calculate values for R and C according to the formulas j V 50 R Q _ wherex 1 10 10x V C uF C minimum 0 001 uF the voltage rating of C must be V non polarized R minimum 0 5 Q 1 2 W tolerance is 5 HONE E For
51. f Additional Transient Protection DC Coils The most effective protection against transients from a DC coil is a flyback diode A flyback diode can reduce the transient to roughly 1V over the supply voltage as shown in this example DC Flyback Circuit n gc xd O KS MC 59 D 0 S So ne E Q Sinking Sourcing Many AutomationDirect socketed relays and motor starters have add on flyback diodes that plug or screw into the base such as the AD ASMD 250 protection diode module and 784 4C SKT 1 socket module shown below If an add on flyback diode is not available for your inductive load an easy way to add one is to use AutomationDirect s DN D10DR A diode terminal block a 600 VDC power diode mounted in a slim DIN rail housing Al utomationDired Y j so AsuO 250 hs p OLJ p ME rns poes a e v nior L e T L LIER y E k 4 am a am EN O Ve evi y gt a AD ASMD 250 784 4C SKT 1 DN D10DR A Protection Diode Module Relay Socket Diode Terminal Block Two more common options for DC coils are Metal Oxide Varistors MOV or TVS diodes These devices should be connected across the driver PLC output for best protection as shown below The optimum voltage rating for the suppressor is the lowest rated voltage available that will NOT conduct at the supply voltage while allowing a safe margin DL405 User Manual 4th Edition Rev A 2 27 Installation Wiring and Specificatio
52. he base and the top bottom and right side of the cabinet should be provided 4 A minimum clearance of 3 75mm between the base and the left side of the cabinet should be provided DN 5 There must be a minimum of 2 clearance between the panel door and the ctc 0 nearest DL405 component o a Temperature SO Probe LE S0 So E S sin min EU DL405 CPU Base 3 Mg O Fomm i S P A Source n T 0 DL405 Local Expansion Panel 6 O N HH B H o at dd o 50mm O D O O DE min Star Washers BUS Bar Ground Braid gt Panel Ground Copper Lugs Earth Ground Terminal 9 Note there is a minimum of 2 60mm ind the nearest DL40S Component an Star Ze N Panel or Washers Single Point Ground Not to scale 6 Connect the ground terminal on the DL405 base 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 Remove anodized finishes and use copper lugs and star washers at termination points A rule of thumb is to achieve 0 1 ohm of DC resistance between the DL405 base and the single point ground DL405 User Manual 4th Edition Rev A 2 7 Installation Wiring and Specifications 7 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 termin
53. in a risk Us of personal injury or equipment Q damage BST Retract Arm Class 1 Division 2 This equipment is suitable for use in Class 1 Division 2 groups A B C and D or Approval non hazardous locations only Y e WARNING Explosion Hazard Substitution of components may impair Lo suitability for Class 1 Division 2 Y IR WARNING Explosion Hazard Do not disconnect equipment unless power Lon has been switched off or area is known to be non hazardous DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Mounting Guidelines In addition to the panel layout guidelines other specifications can affect the installation of a PLC system Always consider the following e Environmental specifications e Power supply specifications e Regulatory Agency Approvals e Enclosure Selection and Component Dimensions Base Dimensions The following diagram shows the outside dimensions and mounting hole locations for the 4 slot 6 slot and 8 slot bases Make sure you follow the installation 23 guidelines to allow proper spacing from other components os CD 4 375 4 312 22 fimm 1 f mm A So 94 100mm c p Expansion F T o na Unit Remote Slave 5 9 150mm o 4 holes cl nl MIC 4 Slot Base 6 Slot Base 11 54 14 45 0477 N 298mm 367mm oj
54. ll not function properly otherwise Check the corresponding manuals before installation and wiring Whenever possible keep modules with high voltage and current wiring away from sensitive analog modules The diagram below shows the status indicator location for common I O modules Loose terminal LT Te d ay Y Pego Eus Status indicators a T yale OL 1 The DL405 family of I O modules have a color coded stripe on the front bezel to help identify whether the module type is input output or special module The color code meaning is listed below Module Type Color Code Discrete Analog Output Red Discrete Analog Input Blue Other White DL405 User Manual 4th Edition Rev A block indicator Blown fuse mon replaceable indicator Output modules only pt Wire tray Color Bar Installation Wiring and Specifications Wiring a Module You must first remove the front cover of the module prior to wiring To remove the with a Terminal cover depress the bottom tab of the cover and tilt the cover up to loosen from the Block module All DL405 I O module terminal blocks are removable for your convenience To remove the terminal block loosen the retaining screws and and lift the terminal block away from the module When you return the terminal block
55. llowing table lists the available DL405 output modules Specifications begin after the input modules specifications DL405 Number of DC Current DC Current AC Output Output Module Type Output Points Sink Output Source Output D4 08TD1 8 Y F4 08TD1S 8 Y D4 16TD1 16 Y D4 16TD2 16 Y D4 32TD1 32 Y D4 32TD1 1 32 Y D4 32TD2 32 Y D4 64TD1 64 Y D4 08TA Y D4 16TA 16 Y D4 08TR Y Y Y F4 08TRS 1 Y Y Y F4 08TRS 2 Y Y Y D4 16TR 16 Y Y Y DL405 User Manual 4th Edition Rev A suoneouioedgs pue 3 n v D p e gt 5 C Installation Wiring and Specifications D4 08ND3S DC Input D4 16ND2 DC Input Inputs per module 8 sink source Inputs per mod
56. m long DL450 CPU port 2 RJ12 9 pin D shell ecc phone style female Ono O D I 3t Use cable part no e D2 DSCBL Pret 1000 Connecting Operator interfaces usually require data and power connections However the 23 Operator Interface popular DV 1000 Data Access Unit may receive data and power directly from any oy Devices DL405 CPU using the 2 meter 6 56 ft long cable shown below Ya 0 pem 9 All DL405 CPUS port 0 25 DS e aen Basel RJ12 DV 1000 o male phone style a 2 oa Y amp m Ly Use cable part no ud D4 1000CBL The DL450 can connect to a DV 1000 from port 2 using the 2 meter 6 56 ft long cable shown below DL450 CPU port 2 DV 1000 RJ12 RJ12 4 phone style phone style fareet 1000 Er 3 f y 2 Use cable part no An S DV 1000CBL Optimation operator interface panels require separate power and data connections Connect the CPU port O port 1 or port 2 DL450 to an Optimation panel choosing the appropriate 2 meter 6 56 ft long cable fr
57. n What is a Transient Voltage and Why is it Bad Inductive loads devices with a coil generate transient voltages as they transition from being energized to being de energized If not suppressed the transient can be many times greater than the voltage applied to the coil These transient voltages can damage PLC outputs or other electronic devices connected to the circuit and cause unreliable operation of other electronics in the general area Transients must be managed with suppressors for long component life and reliable operation of the control system DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications This example shows a simple circuit with a small 24V 125mA 3W relay As you can see when the switch is opened thereby de energizing the coil the transient voltage generated across the switch contacts peaks at 140V Example Circuit with no Suppression Oscilloscope Da ctc ES 24 VDC EE E Relay Coil SS 24V 125mA 3W 5 D AutomationDirect part no me 750 2C 24D Be g In the same circuit replacing the relay with a larger 24V 290mA 7W relay will generate a transient voltage exceeding 800V not shown Transient voltages like this can cause many problems including e Relay contacts driving the coil may experience arcing which can pit the contacts and reduce the relay s lifespan e Solid state transistor outputs driving the coil can be damaged if the transie
58. ns AutomationDirect s ZL TSD8 24 transorb module is a good choice for 24 VDC circuits It is a bank of 8 uni directional 30 V TVS diodes Since they are uni di rectional be sure to observe the polarity during instal lation MOVs or bi directional TVS diodes would install at the same location but have no polarity con cerns ZL TSD8 24 Transorb Module AC Coils Two options for AC coils are MOVs or bi directional TVS diodes These devices are most effective at protecting the driver from a transient voltage when connected across the driver PLC output but are also commonly connected across the coil The optimum voltage rating for the suppressor is the lowest rated voltage available that will NOT conduct at the supply voltage while allowing a safe margin AutomatiojnDirect s ZL TSD8 120 transorb module is a good choice for 120 VAC circuits It is a bank of eight bi dirctional 180 V TVS diodes ZL TSD8 120 Transorb Module NOTE Manufacturers of devices with coils frequently offer MOV or TVS diode suppressors as an add on option which mount conveniently across the coil Before using them carefully check the suppressor s ratings Just because the suppressor is made specifically for that part does not mean it will reduce the transient voltages to an acceptable level For example a MOV or TVS diode rated for use on 24 48 VDC coils would need to have a high enough voltage rating to NOT conduct at 48V That supp
59. nt voltage exceeds the transistor s ratings In extreme cases complete failure of the output can occur the very first time a coil is de energized e Input circuits which might be connected to monitor the coil or the output driver can also be damaged by the transient voltage A very destructive side effect of the arcing across relay contacts is the electromagnetic interference EMI it can cause This occurs because the arcing causes a current surge which releases RF energy The entire length of wire between the relay contacts the coil and the power source carries the current surge and becomes an antenna that radiates the RF energy It will readily couple into parallel wiring and may disrupt the PLC and other electronics in the area This EMI can make an otherwise stable control system behave unpredictably at times DL405 User Manual 4th Edition Rev A Oscilloscope PLC s Integrated Transient Suppressors Although the PLC s outputs typically have integrated suppressors to protect against transients they are not capable of handling them all It is usually necessary to have some additional transient suppression for an inductive load Here is another example using the same 24V 125mA 3W relay used earlier This example measures the PNP transistor output of a DO 06DD2 PLC which incorporates an integrated Zener diode for transient suppression Instead of the 140V peak in the first example the transient voltage here is limited to ab
60. o the next section for complete information on ribbon and solder type connectors and accessories Another option is to use the D4 IOCBL 1 a 3m prewired solder connector and cable with pigtail op it A T 82 pt Module ES IE P ai EX bee qn g So oc Eo a C Tp LEE Cem ZIPLINK Connector Module The ZIPLink system offers plug and play capability eliminating the need for traditional wiring Simply plug one end of the ZIPLink cable into a 32 or 64 point I O module and the other end into a ZIPlink Connector Module Refer to the Connection Systems section in the catalog for a complete list of cable and connector part numbers 64pt Module Part Numbers for Both types of connectors are available from AutomationDirect Module AutomationDirect Part Numbers Connectors e D4 IO3264R Ribbon cable connectors 2 in a pack Can be used on either 32 point or 64 point modules e D4 103264S Solder type connector 2 in a pack Can be used on either 32 point or 64 point modules DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Ribbon Cable The chart below lists cables which can be used to connect the terminal block with a 32 I O module They have 40 conductors and 050 pitch PVC stranded ribbon cable Description Type Vendor Part Number Gray 26 AWG
61. om the three shown below All DL405 CPUs port 0 or port 1 Optimation Panel 15 pin D shell 15 pin D shell male male OP 4CBL 1 25 pin D shell male a OP 4CBL 2 RJ12 15 pin D shell phone style male E E OP 2CBL DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications I O Wiring Strategies The DL405 PLC system 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 Isolation PLC circuitry is divided into three main regions separated by isolation boundaries Boundaries shown in the drawing below Electrical isolation provides safety so that a fault in one area does not damage another A transformer in the power supply provides magnetic isolation between the primary and secondary sides Opto couplers do provide optical isolation in Input and Output circuits This isolates logic circuitry from to the field side where factory machinery connects Note that the discre
62. on 3 7 3 7 4 SA common 3 7 3 7 J D4 16TD1 D4 16TD2 AR Oe ee al 0 10 20 30 40 50 60 C 5V 26 4AVDC EH 0 10 20 30 40 50 60 C 10 2 26 4VDC 32 50 68 86 104 122 140 F Orem 0 28 32 50 68 86 104 122 140 F 0 5A Ambient Temperature C F Internally CA amp Ambient Temperature C F GA A connecter L J Ji E 5 24 VDC j D Lar 0 dg 12 24 bez 4 GB cal tir 0 de TE 0 L A D E D 4 L ad D E D 4 1 r amp 1 1 T D 1 L ES C D 5 Sa Ae fo 9 9 Tr TA O p ced 4 E D 2 E D 6 2 6 oh C D 3 oh LE dp 3 D7 l 6 D m 7 l 6 D 5 24 VDC H que l 3 an 12 24 VDC cs i 3 D ERER JA LAG A rA LC E D CB L D 5 CB 7E 50 HO 7 E Sy 1 4 E D 6 4 De HI O re E D 2 i L 0 ES C amp a i L 0 dg O lt e TE tC iae ep 1 amp amp 1 2avoc Ly S Sl amp 4 qu S VEM fe er e ot 4 2 ag Optical 4 21 8 7 Common Isolator 7 QE DEP Optical o 1 3 G sn t A A 2 Isolator A A v d Ole amp E 5 y m AW gt 2AVDC T To LED RS GB To LED GB 1 L 24VDC S GB Common J Output L y DL405 User Manual 4th Edition Rev A n gc xd O KS MC 59 D 02 S So ne E Q Installation Wiring and Specifications D4 32TD1 5 24VDC Output D4 32TD1 1 5 15VDC Output Outputs per module 32 current sinking Outputs per module 32 current sinking Commons per module 4 isolated Comm
63. ons per module 4 isolated Operating voltage 4 75 26 4 VDC Operating voltage 5 15 VDC Output type NPN Open Collector Output type NPN Open Collector w pullup Peak voltage 36 VDC Peak voltage 16 5 VDC ON voltage drop 0 6 VDC 0 2A ON voltage drop 0 4 VDC 0 1A Max current resistive 0 2A point 1 6A common Max current resistive 0 09A pt 0 72A com 2 88A mod Max leakage current 0 1mA 36 VDC Max leakage current 0 01mA O 16 5 VDC Max inrush current 1A for 10 ms 0 5A for 100 ms Max inrush current 0 5A for 10ms 0 2A for 100ms Minimum load 0 1mA Minimum load 0 15mA Base power required 5V 250mA max Base power req 5V 250mA max External DC required 24VDC 10 140mA max External DC required 5 15VDC 10 150mA max OFF to ON response 0 1 ms OFF to ON response 0 1 ms ON to OFF response 0 1 ms ON to OFF response 0 1 ms Terminal type Removable Terminal type Removable Status indicators Logic Side Status indicators Logic Side Weight 6 7 oz 190 g Weight 6 7 oz 190 g Fuses None Fuses None Pons Derating Chart 7 Points Derating Chart S 32 5 5 24VDC OUTPUT 32 Output 5 15VDC OUTPUT 284 Output current AB C D 282 Y current AB C D S TEO K p d 24 Output current BIBT po hz BB rod 20 4 o 4 0 4 20 0 015 poin
64. ossary of Specification Terms Inputs or Outputs Per Module Commons Per Module Input Voltage Range Output Voltage Range Peak Voltage AC Frequency ON Voltage Level OFF Voltage Level Input Impedance Input Current Minimum ON Current Maximum OFF Current Minimum Load External DC Required On Voltage Drop Maximum Leakage Current Maximum Inrush Current Base Power Required OFF to ON Response ON to OFF Response Status Indicators Terminal Type Weight Fuses Indicates number of electrical input or output points per module and designates current sinking current sourcing or either Number of electrical commons per module A common is a connection to an input or output module which is shared by multiple I O circuits It is ususally in the return path to the power supply of the I O circuit The operating voltage range of an input circuit measured from an input point to its common terminal when the input is ON The output voltage range of an output circuit measured from an output point to its common terminal when the output is OFF Maximum voltage allowed for an input or output circuit for a short duration AC modules are designed to operate within a specific frequency range The minimum voltage level at which an input point will turn ON The maximum voltage level at which an input point will turn OFF The electrical resistance measured between an input point and its common point Since this resistance is non line
65. out 40V by the Zener diode While the PLC will probably tolerate repeated transients in this range for some time the 40V is still beyond the module s peak output voltage rating of 30V Example Small Inductive Load with Only Integrated Suppression p For this example a 24V 125mA 3VW relay is used AutomationDirect part no 750 2C 24D Oscilloscope Optical Isolator The next example uses the same circuit as above but with a larger 24V 290mA 7W relay thereby creating a larger inductive load As you can see the transient voltage generated is much worse peaking at over 50V Driving an inductive load of this size without additional transient suppression is very likely to permanently damage the PLC output Example Larger Inductive Load with Only Integrated Suppression For this example a 24 290mA 7W relay is used AutomationDirect part no SC E03G 24VDC Optical Isolator DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications suolyeoiinads pue 5 a m v D m e E 5 Q 2 26 Installation Wiring and Specifications Additional transient suppression should be used in both of the preceding examples If you are unable to measure the transients generated by the connected loads of your control system using additional transient suppression on all inductive loads would be the safest practice Types o
66. ower required 5V 150 mA max us OFF to ON response 5 30 ms OFF to ON response 5 30 ms E ON to OFF response 10 50 ms ON to OFF response 10 50 ms Terminal type Removable Terminal type Removable Status indicators Logic Side Status indicators Logic Side Weight 8 4 oz 240 g Weight 9 5 oz 270 g d Derating Chart f Derating Chart ra 110 220VAC Pur coe T10VAC 4 TB 4 TB 64 12 AAN BS 4 0 4 m 0 4 0 ys 2 6 87 x 2 3 7 7 3 7 3 E D4 08NA D4 16NA OT r 0 0 10 20 30 40 50 60 C Se ee 0 10 20 30 40 50 60 C nrp EPH 32 50 68 86 104 122 140 F LES 32 50 68 86 104 122 140 F 50 60Hz Ambient Temperature C F Ambient Temperature C F m CA Ce C Hoes VAC oe oA B 110 VAC 4 0 te ap HD 0 AA Gg T IUE Da L 4 dg Gp HD 1 f EN D di 2 e 5 ke D Lm l 2 ate 05 p CE amp 2 o 6D 110 220 VAC Qs 110 VAG XO ree i t SIS cs gu D 4 m 5 D 4 7 D oe CB pi s 8 amp prem gi c D 6 5 zum mn Mi o Hm Oe pte gt Ds 7 l 5 D 9 D 7 5 l EIS e T ii Fr fO 2 6 fee ae FT D 110 VAC Common 4 7 Ss O aes os Common B 7 amp o 3 step G To LED D r TE le a 9 S ao dam Optical Input m V _ EE Input Isolator V Y DL405 User Manual 4th Edition Rev A D4 16NE3 12 24VAC DC Input Installation Wiring and Specifications F4 08NE3S 90 150VAC DC In
67. per module 8 current sinking Outputs per module 8 current sinking Commons per module 2 internally connected Commons per module 4 isolated Operating voltage 10 2 26 4VDC Operating voltage 24 150VDC Output type NMOS FET open drain Output type MOS FET Peak voltage 40VDC Peak voltage 200 VDC 1mS ON voltage drop 0 5VDC 2A 0 2 VDC 1A ON voltage drop 1VDC 2A Max current resistive 2A point 5A common Max current 2A point 4A common l Max leakage current 0 1mA O 40VDC Max leakage current 5uA es Max inrush current 12A for 10 ms 6A for 100 ms Max inrush current 30A 1ms 6A 10ms 3A 100ms Z Minimum load 0 2mA Minimum load N A S95 Base power required 5V 150mA max Base power required 5V 295 mA max SE External DC required 24VDC 10 35 mA External DC required None Uy OFF to ON response 1ms OFF to ON response 25 us E G ON to OFF response 1ms ON to OFF response 25 us Terminal type Removable Terminal type Removable Status indicators Logic Side Status indicators Logic Side Weight 8 4 oz 240 g Weight 10 oz 282 g Fuses non replaceable 1 7A per common Fuses non replaceable 1 8A per output
68. put voltage range D4 440DC 2 D4 EXDC 2 90 146 VDC 125 VDC less than 10 ripple D4 EXDC 2 Maximum inrush current D4 430 20A D4 440 D4 EX Maximum inrush current D440DC 1 10A D4 EXDC Maximum inrush current DL440DC 2 20A D4 EXDC 2 Maximum power 50VA DL430 DL440 DL450 D4 EX Maximum power DL440DC 1 38W D4 EXDC Maximum power DL440DC 2 SOW 24VDC Auxiliary Power Supply D4 EX only DL405 User Manual 4th Edition Rev A 20 28 VDC 0 4A maximum ripple gt 1V p p Installation Wiring and Specifications Component Before installing your PLC system you will need to know the dimensions for the Dimensions components in your system The diagram on this page provide the component dimensions and should be used to define your enclosure specifications Remember to leave room for potential expansion Appendix E provides the weights for each component Handheld programmer S0mm 5 7 D m j 145mm 4 IS Memory S 0 S Cartridge o gt o 20 L as 3 14 gt 80mm Ys 4 65 L L L L L L L L L I 0 c 118mm oo L J L L L L L L L L 1 L IL lt gt
69. r Manual 4th Edition Rev A Installation Wiring and Specifications D4 32TD2 12 24 VDC Output Module Outputs per module 32 current sourcing External DC required 10 8 26 4VDC Commons per module 4 isolated 1A common including load Operating voltage 10 8 26 4 VDC Output type PNP Open Collector OFF to ON response lt 0 2 ms Peak voltage 30 VDC ON to OFF response lt 0 2 ms ON voltage drop 0 6 VDC 0 2A Terminal type Removable Max current resistive 0 2A point Status indicators Logic Side 1 0A common VUES 67 oz 190g 4 0A module eight 7 OZ g Max leakage current 0 01mA O 26 4 VDC Fuses None Max inrush current 500 mA for 10 ms Minimum load 0 2mA Base power required 5V 350mA max Curent Flow ge sa UT Derating Chart for D4 32TD2 g fo A4 J A B C D Points L Al rp AC jp B D 4 Ep m pO Za qa s 7 A2 28 4 L A6 979 i E S gt 24 Outp
70. ressor might typically start conducting at roughly 60VDC If it were mounted across a 24V coil transients of roughly 84V if sinking output or 60V if sourcing output could reach the PLC output Many semiconductor PLC outputs cannot tolerate such levels DL405 User Manual 4th Edition Rev A jeoyioeds pue onejjeisu 3 suol do Installation Wiring and Specifications Prolonging Relay Relay contacts wear according to the amount of relay switching amount of spark Contact Life 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 op
71. rt numbers for standard bases and the new bases are listed below Standard Bases Expanded Bus Bases suoneouioedgs pue 5 a m v D m e E 5 Q Allows selected i O specialty modules a D4 04B D4 04B 1 in expansion bases 0 o E 8 E 6 H D4 06B B D4 06B 1 o 0 8 6 O D4 08B D4 08B 1 7 b Kai D 0 p 0 0 The base expansion connectors on the new bases have new data signals used in communicating with specialty I O across bases Accordingly you must observe the following restrictions and guidelines with the new bases Only the DL450 type CPU in the local base can communicate with a specialty module in an expansion base nthe above case both local and expansion bases must be the new 1 type e Ofcourse you can still have specialty modules in the local base The new bases can also be used with DL430 and DL440 CPUs however these CPUs cannot communicate with specialty I O in expansion bases e You can mix standard bases with new bases in a system but no specialty I O modules may be used in expansion bases in this case the standard bases do not pass through the specialty I O signals on their expansion connectors NOTE If you are designing a new DL450 CPU based application we recommend using the new bases 1 type so you can add specialty modules in any base later DL405 User Manual 4th Edition Rev A 2 12 Installation Wiring and Specifi
72. s communication ports to unite ground signals Chassis Ground where earth ground is connected to the unit AC Power where the line hot and the neutral common connections are made to the CPU Expansion Unit This is also where the DC power source is connected for the 24 125 VDC CPU The positive connection is tied to line and the negative connection is tied to ground 110 220 Voltage Select a shunt across two of the terminals determines the voltage selection Install the shunt to select 110VAC input power and remove the shunt to select 220VAC power input the shunt is not required for DC powered CPUs or Expansion Units suoneouioedgs pue 3 a m v D m e E 5 Q WARNING Damage will occur to the power supply if 220 VAC is connected to Y T the terminal connections with the 115 VAC shunt installed Once the power Lo wiring is connected install the protective cover to avoid risk of accidental shock CPU Wiring The following diagram details the appropri
73. sources current The power supply can be the 24 auxiliary supply or another supply 12 VDC or 24VDC as long as the input specifications are met Field Device u PLC DC Input z A n a ee MA La K Supply AY 89 A Ground S Common 4 E 26 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 L TPE O NNN sinking L Output sourcing d A Ground Common L Solid State Sometimes an application requires connecting a PLC output point to a solid state Output Loads input on a device This type of connection is usually made to carry a low level control signal not to send DC power to an actuator Several ofthe DL405 DC output modules are the sinking type This means that each DC output provides a path to ground when it is energized 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 Sinking Output Field Device DC pwr O Power V o Output Input 1 Wy e sinking 4 sourcing Y N A 10 30 VDC o Common T Ground hs N S O ome
74. t 1M 300K 200K D4 16TR Points eral Ing al 12 250VAC i 5 250VAC J gaus D Point Derating Chart TASSO eE A D Do 6 Output Current 0 D Output Current 4 AC E DEL a 5A point ale 124 0 6A point oo gr D 1 1 O 40A module NO ae e 9 c4 g p HL ap GELS NO 2 0 D z Do Output Current bmt Apt D 4 NC SE 4 1A point a DI SE e 5A common o al Ac C D 0 m pe Ca SE 5 T D nt 0 10 20 30 40 50 60 D E e oJ AE t D L c amp 32 50 68 86 104 122 OF y NO T r Mel 0 10 20 30 40 50 60 2 m ea Nb Ambient Temperature C F NC T D3 32 50 68 86 104 122 140 F o Da Maximum DC voltage E D zie go 7 Ambient Temperature C F 2 D E MD rating is 120 VDC 2 alo rr Da Al 3 de LIO Ges 0 5A 30 000 cycles NO HS o Ds 7 amp C SS amp typical Motor starters up 3 NC E D 1 CB y Ayo to and including NEMA amp D r Do LT F Do size 3 can be used with 3 s 00 2 Hi s this module 3 NO 7 0 A D ae E D 3 eye A uou e e F Hz Common 5A E i G 1 NO NO ay F e LELE l ES Q ND 5 LS 2 NC ay ba X t X Ww 6 l 7 Sample Relay Output Circuit 1 of 4 6 R E ies 3 D Common NO n To LED e 6 Jae 7 U No eull t NO D R du JL D aH t ap P JJ Output RELAY m S Sample Relay Output Circuit 1 of 4 DL405 User Manual 4th Edition Rev A n gc xd O KS MC 59 u 0 S So ne Lu Installation Wiring and Specifications Gl
75. t point coe s x LI LI dq d zug 1 5 1 5 1 5 1 5 167 2 6 2 6 167 2 6 2 6 124 Output current 3 7 3 7 127 3 7 3 7 8 y 0 2A point D4 32TD1 87 Output current D4 32TD1 1 474 454 0 09A point 9 A 25 Ff 1 0 20 30 40 50 6 0 10 20 30 40 60 C 32 50 68 86 104 122 140 DISPLAY A B 2 50 8 88 i iz Mor SELECT A B Ambient Temperature C F Ambient Temperature C F Current Flow AO C D Current Flow amp can 5 26VDC CLASS 2 5 15VDC CLASS 2 0 2A 0 09A AO A4 A0 A4 A0 As o 20 O 24VDC At A5 At A5 JA LAS 5 15VDC AA alas o o mlas o 0 A3 A7 O A3 A7 O ps o o el oo l SOME o o SUV los 24 VDC B0 B4 o o BO B4 llo o A B1 B5 66 5 15VDC B1 B5 o0 B2 B6 o0 B2 B6 o 0 E BR 048 o o nal oo B3 BZ loo B3 B7 5 a OI VI llo o SUM oo 24 VDC CO C4 o o 5 15VDC coj C4 fo o l cijcs po N cilcs o o Ip oo al o0 C216 5 21 C6 5 o G31 C7 lo o 31 C7 llo o ci vii o o cull vu o o MODO Dolpa o o 5 15VDC DOI D4 9 O 18 E lo off nmn mir o o V Di D5 oo V a o 0 T D2 D6 llo o Optical D2 D6 o o E Output D3 D7 Out i i isolator D3 D7 H Y UON HH D Civ viv O y GIN viv O We ELE 5 15 24 VDC r To LED VDG F Optical To LED Common Isolator Ne m Common R NS DL405 Use
76. te inputs are o isolated from the discrete outputs because each is isolated from the logic side 9 S A cE Isolation boundaries protect the operator interface and the operator from power 2 2 input faults or field wiring faults When wiring a PLC itis extremely important to avoid So making external connections that connect logic side circuits to any other DE Primary Side Secondary or Field Side Logic side PLC backplane Input less ings Power Input Main Module P Power r CPU Supply backplane Output Module Outputs Y Isolation Programming Device 4 Isolation Boundary Operator Interface or Network Boundary The next figure shows the physical layout of a DL405 PLC system as viewed from the front In addition to the basic circuits covered above AC powered CPUs include an auxiliary 24VDC power supply with its own isolation boundary Since the supply output is isolated from the other three circuits it can power input and or output circuits DL4 Primary Side ae Secondary or Main Logic side Power Input T Power Internal Supply CPU gt Backplane Auxiliary 24VDC Out lt 24VDC a Comm Input Module Output Module Supply i U t p 4 1 4 To Programming Inputs Commons Outputs Commons Device Operator l Supply for Interface Network Field Side Output Circuit _ DL405 User
77. ter control relay MCR or a safety control relay SCR that will remove power from the PLC I O system in an emergency MCRs and SCRs provide a convenient means for removing power from the I O system during an emergency situation by de energizing an MCR or SCR coil powerto the input optional and output devices is removed This event occurs when any emergency stop switch opens However the PLC continues to receive power and operate even though all its inputs and outputs are disabled The MCR circuit could be extended by placing a PLC fault relay closed during normal PLC operation in series with any other emergency stop conditions This would cause the MCR circuit to drop the PLC I O power in case of a PLC failure memory error lO communications error etc suoneouioedgs pue 5 a m v D m e E 5 Q Use E Stop and Master Relay ESTOP Power On Guard pa Guard Limit Switch Limit PS a lo e P Ey Master Relay Contacts O o O PLC Power i i lo O D Master Output Relay Module Saw Contacts Arbor L il IX To disconnect outpu a module power DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Emergency Power A properly rated emergency power disconnect should be used to power the PLC Disconnect controlled system
78. tion transformers and noise suppression devices are not normally necessary but may be helpful in eliminating reducing suspect power problems Enclosures Your selection of a proper enclosure is important to ensure safe and proper operation of your DL405 system Applications of DL405 systems vary and may require additional features The minimum considerations for enclosures include e Conformance to electrical standards e Protection from the elements in an industrial environment Common ground reference Maintenance of specified ambient temperature e Access to equipment e Security or restricted access e Sufficient space for proper installation cooling and maintenance Agency Approvals Some applications require agency approvals The DL405 agency approvals for which DL405 products are submitted are e UL Underwriters Laboratories Inc s CE EMC Electromagnetic Compatibility e CUL Canadian Underwriters Laboratories A complete listing of agency approvals for each product in the DL405 family is available in the sales catalog or you may call 1 800 633 0405 U S DL405 User Manual 4th Edition Rev A suoneouioedgs pue 5 a m v D m e E 5 Q n gc xd O KS MC 59 D 0 S So ne E Q Environmental Specifications Power Installation Wiring and Specifications The following table lists the environmental specifications that generally apply to the DL405 system CPU Expansion Unit
79. uently 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 provides a path to supply ground Sourcing provides a path to supply source 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 sinking or sourcing only 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 For example the figure to the right depicts a sinking input To properly connect the hm PLC external supply we just have to connect it O so the input provides a path to ground ening 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 common adding the switch between the supply and the input we have completed the circuit Current flows in the direction of
80. ule 16 current sourcing Commons per module 8 isolated Commons per module 2 isolated Input voltage range 20 52 8VDC Input voltage range 10 2 26 4VDC Peak voltage 52 8VDC Peak voltage 26 4VDC ON voltage level gt 18V ON voltage level gt 9 5VDC OFF voltage level lt 7V OFF voltage level lt 4 0 VDC Input impedance 4 8KQ Input impedance 3 2 KQ O 12VDC 2 9 KO 24VDC De Input current Y 24 48 VDC 5mA 10mA Input current Y 12 24VDC 3 8mA 8 3 mA E Minimum ON current 3 5 mA Minimum ON current 3 5 mA Maximum OFF current 1 5mA Maximum OFF current 1 5mA c O 9 Base power required 5V 100 mA max Base power required 5V 150 mA max Oo Zo OFF to ON response 3 10 ms OFF to ON response 1 7 ms 2 3 typical us ON to OFF response 3 12 ms ON to OFF response 2 12 ms 4 6 typical E Terminal type Removable Terminal type Removable Status indicators Logic Side Status indicators Logic Side Weight 8 8 oz 250 g Weight 8 8 oz 250 g Points Derating Chart s Pon Derating Chart 8 24 48VDC INPUT 16 12 24VDC 6 T3 A R 4 0 4 m 0 4 0 t E a TE 2 J f 44 3 7 3 D4 08ND3S D4 16ND2 0 0 A Iud 0 10 20 30 40 50 60 C ASIA e 5 1 25 29 Jd HE AS e 32 50 68 86 104 122 140 F Ambient Temperature C F Ambient Temperature C F co CA E ee so LA 12 24VDC 50 a LU ge c E i s oA Lea Dot mood dg 25 SS 4 1 D O 1 C2 HD 1 Ss So 9 D e es T D ss E Dra LE ae O 3 6 ale so so 12 24VDC 7 T 3 D cs er E L E DT T 7
81. ut 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 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 V input turn on l input R input 2 V supply 0 7 l V supply R pull up R input P pull up input R pullup Of course the easiest way to drive a sinking input field device as shown below is to use a DC sourcing output module The Darlington NPN stage will have about 1 5 V ON state saturation but this is not a problem with low current solid state loads PLC DC Sourcing Output DC pwr L Common E do J Field Device lt WM Output sourcing Input nos A x sinking Y Supply 18 Ground 4 DL405 User Manual 4th Edition Rev A Installation Wiring and Specifications Relay Output Four output modules in the DL405 I O family feature relay outputs D4 08TH Guidelines F4 08TRS 1 F4 08TRS 2 D4 16TR Relays are best for the following applications Loads that require higher currents than the solid state outputs can deliver e Cost sensitive applications e Some output channels need isolation from other outputs such as when some loads require different voltages than other loads Some applications in which NOT to use relays
82. ut current A3 S 0 2 A pt T A7 00 DASSSIDE 20 1A idama 12 24VDC T coil o 167 L dia DISPLAY _ L Bd 00 SELECT Bo 12 L y O C D 8 mpm Be a 11 26VDC CLASS 47 y 38 a MIS 071 1 1 1 1 L ATT AS 0 10 20 30 40 50 6070 E t E SUIT p Mae vm 32 50 68 86 104 122 140 Tee ND vi LOO ala oo Ambient Temperature C F A3 A7 LLL C0 O ev ies c ca dia BofBa o o L O B1 B5 o o c mess o u 6 o sale 30 v L C3 O L0 LIVI lo o N C7 Co C4 oo 12 24VDC T COM ll O 0 cios oo L 12 24 NN Yd C2 C6 B 3 T voc Optical L m 00 23 7 loo Isolator p E Bi O0 o nr E E z Output D DO D4 L ES 9 0 Di os E o To LED D6 D2 D6 E D3 O_O D3 D7 LE 7 Common ES gt cou IV eMw O 12 24VDC VN EL Only 16 status points can be displayed at one time on the front of the module In the A B position the status of the first group of 16 output points A0 A7 BO B7 is displayed In the C D position the status of the second group of 16 output points CO C7 DO D7 is displayed DL405 User Manual 4th Edition Rev A suoneouioedgs pue 3 n v D p e gt 5 Q Installation Wiring and Specifications D4 64TD1 TTL CMOS 5 24 VDC Output Module Module Location CPU base only Minimum load 0 1mA Outputs per module 64 current sinking Commons per module 8 non isolated Operating voltage 4 75 26 5 VDC Base power required 5V

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