Company AC Output Modules Information Systems Overview Programmable Controllers D4-08TA AC Output <---> D4-16TA AC Output <---> 8 Outputs per Module Outputs per Module 16 Field I/O Commons per Module 2 (isolated) 2 (isolated) Commons per Module Software 15-265VAC Operating Voltage Operating Voltage 15-265VAC C-more & SSR (triac) Output Type Output Type SSR (triac) other HMI Peak Voltage 265VAC 265VAC Peak Voltage Drives 47-63Hz AC Frequency AC Frequency 47-63Hz 1.5VAC @ 2A Soft ON Voltage Drop ON Voltage Drop 1.5VAC @ 0.5A Starters 2A/point 0.5A/point Max Current 5A/common @ 30° C Max Current 3A/common @ 45° C Motors & Gearbox 2A/common @ 60° C 2A/common @ 60° C Max Leakage Current 5mA @ 265VAC Steppers/ 4mA @ 265VAC Max Leakage Current Servos 30A for 10ms Max Inrush Current 15A for 10ms 10A for 100ms Max Inrush Current Motor 10A for 100ms Controls Minimum Load 10mA Minimum Load 10mA Proximity Base Power Required 5V 250mA max Sensors 450mA max Base Power Required 5V 1ms OFF to ON Response 1ms OFF to ON Response Photo ON to OFF Response 1ms + 1/2 cycle Sensors ON to OFF Response 1ms + 1/2 cycle Terminal Type (included Removable (D4-8IOCON) Limit Removable (D4-16IOCON) Terminal Type (included) Switches Logic side Status Indicators Logic Side Status Indicators Weight 11.6oz. (330g) Encoders Weight 12.2oz. (350g) Fuses 1 (8A) per common, non-replaceable Current 1 (5A) per common, non-replaceable Fuses Sensors See Wiring Solutions for part numbers of ZIPLink cables and Pressure connection modules compatible with this I/O module. Sensors Note: When used with the ZIPLink wiring system, relay outputs Temperature are derated not to exceed 2 Amps per point max. Sensors Pushbuttons/ Lights Process Relays/ Timers Comm. Terminal Blocks & Wiring Power Circuit Protection Enclosures Tools Pneumatics Safety Appendix Product Index Part # Index Volume 14 www.aut oma tiondirect.com/dl405 Programmable Controllers e6-71 Check the Power Budget This logo is placed next to I/O modules Verify your power budget Calculating your power that are supported by the ZIPLink connec- requirements tion systems. usage See the I/O module specifications at the Your I/O configuration choice can be The following example shows how to affected by the power requirements of the end of this section. calculate the power budget for the DL405 I/O modules you choose. When deter- system. The example is constructed around mining the types and quantity of I/O a single 8-slot base using the devices modules you will be using, it is important shown. It is recommended you construct a to remember there is a limited amount of similar table for each base in your system. power available from the power supply. The chart on the opposite page indicates A the power supplied and used by each Base Number External 24 VDC DL405 device. The adjacent chart shows Device Type 5 VDC (mA) 0 Power (mA) an example of how to calculate the power used by your particular system. These two B CURRENT SUPPLIED charts should make it easy for you to CPU/Expansion Unit D4-440 CPU 3700 400 determine if the devices you have chosen /Remote Slave fit within the power budget of your system C CURRENT REQUIRED configuration. D4-16ND2 +150 +0 If the I/O you have chosen exceeds the SLOT 0 maximum power available from the power SLOT 1 D4-16ND2 +150 +0 supply, you can resolve the problem by SLOT 2 F4-04DA +120 +100 shifting some of the modules to an expan- D4-08ND3S +100 +0 SLOT 3 sion base or remote I/O base (if you are using remote I/O). SLOT 4 D4-08ND3S +100 +0 Warning: It is extremely important to calculate the SLOT 5 D4-16TD2 +100 +0 power budget correctly. If you exceed the power budg- D4-16TD2 +100 +0 et, the system may operate in an unpredictable man- SLOT 6 ner which may result in a risk of personal injury or SLOT 7 D4-16TR +1000 +0 equipment damage. D OTHER D4-08B +80 +0 Use ZIPLinks to reduce BASE Handheld Programmer D4-HPP +320 +0 power requirements 2820 100 E Maximum Current Required If your application requires a lot of relay outputs, consider using the ZipLink AC or F Remaining Current Available 3700-2820=880 400-100=300 DC relay output modules. These modules 1. Using a chart similar to the 3one above, fill in column 2. can switch high current (10A) loads 2. Using the tables on the opposite page, enter the current supplied and used by each device (columns 3 and 4). Pay special attention to the cur- rent supplied by the CPU, Expansion Unit, and Remote Slave since they differ. Devices which fall into the "Other" category (Row D) are devices such without putting a load on your base power as the Base and the Handheld programmer, which also have power requirements, but do not plug directly into the base. 3. Add the current used by the system devices (columns 3 and 4) starting with Slot 0 and put the total in the row labeled "maximum current budget. Refer to Wiring System for DL405 required" (Row E). PLCs later in this section for more informa- 4. Subtract the row labeled "Maximum current required" (Row E), from the row labeled "Current Supplied" (Row B). Place the difference in the row labeled "Remaining Current Available" (Row F). tion. 5. If "Maximum Current Required" is greater than "Current Supplied" in either column 3 or 4, the power budget will be exceeded. It will be unsafe to use this configuration and you will need to restructure your I/O configuration. Note the auxiliary 24 VDC power supply does not need to supply all the external power. If you need more than the 400mA supplied, you can add an external 24VDC power supply. This will help keep you within your power budget for external power. DL405 CPU power supply specifications and power requirements Specification AC Powered Units 24 VDC Powered Units 125 VDC Powered Units D4-450, D4-440, D4-430, D4-450DC-1, D4-440DC-1, D4-450DC-2 Part Numbers D4-EX (expansion base unit), D4-EXDC (expansion base unit), D4-440DC-2 D4-RS (remote slave unit) D4-RSDC (remote slave unit) Voltage Withstand (dielectric) 1 minute @ 1,500 VAC between primary, secondary, field ground, and run relay > 10M� at 500VDC Insulation Resistance 85-132 VAC (110 range) 170-264 VAC (220 20-28 VDC (24 VDC) 90-146 VDC (125 VDC) Input Voltage Range range with less than 10% ripple with less than 10% ripple 20 A 20 A 20 A Maximum Inrush Current Maximum Power 50 VA 38 W 30 W Volume 14 Programmable Controllers 1-800-633-0405 e6-24 Company Power Requirements Information Systems Overview Programmable Power Supplied Controllers CPUs/Remote Units/ 5 VDC Current 24V Aux Power CPUs/Remote 5V Current Supplied 24VAux. Power Expansion Units Supplied in mA Supplied in mA Units/Expansion Units in mA Supplied in mA Field I/O D4-430 CPU 3700 400 D4-EX 4000 400 D4-440 CPU 3700 400 D4-EXDC 4000 NONE Software D4-440DC-1 CPU 3700 NONE D4-EXDC-2 3700 NONE D4-440DC-2 CPU 3700 NONE D4-RS 3700 400 C-more & D4-450 CPU 3100 400 D4-RSDC 3700 NONE other HMI D4-450DC-1 CPU 3100 NONE H4-EBC 3470 400 D4-450DC-2 CPU 3100 NONE H4-EBC-F 3300 400 Drives Power Consumed Soft Power-consuming 5V Current External 24VD Power-consuming 5V Current External 24VDC Starters Device Consumed Current Required Device Consumed Current Required Motors & I/O Bases Analog Modules (continued) Gearbox Steppers/ D4-04B-1 80 NONE Servos F4-16AD-1 75 100 D4-06B-1 80 NONE F4-16AD-2 75 100 D4-08B-1 80 NONE F4-04DA-1 70 75+20per circuit Motor Controls F4-04DA-2 90 90 F4-04DAS-1 60 60 per circuit F4-04DAS-2 60 60 per circuit Proximity DC Input Modules Sensors F4-08DA-1 90 100+20 per circuit F4-08DA-2 80 150 F4-16DA-1 90 100+20 per circuit Photo Sensors F4-16DA-2 80 25 max. D4-08ND3S 100 NONE F4-08RTD 80 NONE D4-16ND2 150 NONE F4-08THM-n 120 50 Limit D4-16ND2F 150 NONE Switches F4-08THM 110 60 D4-32ND3-1 150 NONE D4-32ND3-2 150 NONE Encoders D4-64ND2 300 max. NONE Remote I/O Current Sensors AC Input Modules H4-ERM 320 NONE Pressure D4-08NA 100 NONE Sensors H4-ERM-F 450 NONE D4-16NA 150 NONE D4-RM 300 NONE Temperature Sensors AC/DC Input Modules D4-16NE3 150 NONE Communications and Networking Pushbuttons/ F4-08NE3S 90 NONE Lights DC Output Modules H4-ECOM100 300 NONE Process H4-ECOM-F 670 NONE D4-08TD1 150 35 D4-DCM 500 NONE Relays/ F4-08TD1S 295 NONE F4-MAS-MB 235 NONE Timers D4-16TD1 200 125 FA-UNICON NONE 65 D4-16TD2 400 NONE Comm. D4-32TD1 250 140 D4-32TD1-1 250 140 (15V) D4-32TD2 350 120 (4A max Terminal CoProcessors Blocks & including loads) Wiring D4-64TD1 800 NONE F4-CP128-1 305 NONE Power AC Output Modules Specialty Modules D4-08TA 250 NONE Circuit Protection D4-16TA 450 NONE H4-CTRIO 400 NONE Relay Output Modules Enclosures D4-INT 100 NONE D4-HSC 300 NONE Tools D4-08TR 550 NONE F4-16PID 160 NONE F4-08TRS-1 575 NONE F4-8MPI 225 170 F4-08TRS 575 NONE D4-16SIM 150 NONE Pneumatics D4-16TR 1000 NONE F4-4LTC 280 75 Safety Analog Modules Programming Appendix D4-HPP-1 (Handheld Prog.) 320 NONE Product Operator Interface F4-04AD 85 100 Index F4-04ADS 270 120 DV-1000 150 NONE F4-08AD 75 90 Part # C-more Micro-Graphic 210 NONE Index Volume 14 www.aut oma tiondirect.com/dl405 Programmable Controllers e6-25 Wiring Solutions solutions available when using the ZIPLink System ranging from Wiring Solutions using the ZIPLink PLC I/O-to-ZIPLink Connector Modules that are ready for field Wiring System termination, options for connecting to third party devices, GS, DuraPulse and SureServo Drives, and specialty relay, transorb and ZIPLinks eliminate the normally tedious process of wiring between communications modules. Pre-printed I/O-specific adhesive label devices by utilizing prewired cables and DIN rail mount connector strips for quick marking of ZIPLink modules are provided with modules. It's as simple as plugging in a cable connector at either ZIPLink cables. See the following solutions to help determine the end or terminating wires at only one end. Prewired cables keep best ZIPLink system for your application. installation clean and efficient, using half the space at a fraction of the cost of standard terminal blocks. There are several wiring Solution 1: DirectLOGIC, CLICK and Productivity3000 I/O Modules to ZIPLink Connector Modules Using the PLC I/O Modules to ZIPLink Connector When looking for quick and easy I/O-to-field termination, a ZIPLink Modules selector tables located in this section, connector module used in conjunction with a prewired ZIPLink cable, 1. Locate your I/O module/PLC. consisting of an I/O terminal block at one end and a multi-pin 2. Select a ZIPLink Module. connector at the other end, is the best solution. 3. Select a corresponding ZIPLink Cable. Solution 2: DirectLOGIC, CLICK and Productivity3000 I/O Modules to 3rd Party Devices When wanting to connect I/O to another device within close proximity Using the I/O Modules to 3rd Party Devices selector tables of the I/O modules, no extra terminal blocks are necessary when using located in this section, the ZIPLink Pigtail Cables. ZIPLink Pigtail Cables are prewired to an I/O 1. Locate your PLC I/O module. terminal block with color-coded pigtail with soldered-tip wires on the 2. Select a ZIPLink Pigtail Cable that is compatible other end. with your 3rd party device. Using the Drives Communication selector tables located in this section, Solution 3: GS Series and DuraPulse Drives 1. Locate your Drive and type of communications. Communication Cables 2. Select a ZIPLink cable and other associated hardware. Need to communicate via Modbus RTU to a drive or a network of drives? ZIPLink cables are available in a wide range of configurations for connecting to PLCs and SureServo, SureStep, Stellar Soft Starter and AC drives. Add a ZIPLink communications module to quickly and easily set up a multi-device network. Volume 14 Programmable Controllers 1-800-633-0405 e6-56 Company Wiring Solutions Information Systems Overview Programmable Controllers Solution 4: Serial Communications Cables Using the Serial Communications Cables selector ZIPLink offers communications cables for use with DirectLOGIC, CLICK, Field I/O table located in this section, and Productivity3000 CPUs, that can also be used with other communica- tions devices. Connections include a 6-pin RJ12 or 9-pin, 15-pin and 25- Software 1. Locate your connector type pin D-sub connectors which can be used in conjunction with the RJ12 or 2. Select a cable. C-more & D-Sub Feedthrough modules. other HMI Drives Soft Starters Motors & Gearbox Steppers/ Servos Motor Controls Solution 5: Specialty ZIPLink Modules Proximity For additional application solutions, ZIPLink modules are available in a Using the ZIPLink Specialty Modules selector table Sensors variety of configurations including stand-alone relays, 24VDC and located in this section, Photo 120VAC transorb modules, D-sub and RJ12 feedthrough modules, 1. Locate the type of application. Sensors communication port adapter and distribution modules, and SureServo 2. Select a ZIPLink module. Limit 50-pin I/O interface connection. Switches Encoders Current Sensors Pressure Sensors Temperature Sensors Pushbuttons/ Lights Process Relays/ Timers Solution 6: ZIPLink Connector Modules to 3rd Party Comm. Devices Using the Universal Connector Modules and Pigtail Terminal If you need a way to connect your device to terminal blocks without Cables table located in this section, Blocks & Wiring all that wiring time, then our pigtail cables with color-coded 1. Select module type. soldered-tip wires are a good solution. Used in conjunction with any 2. Select the number of pins. Power compatible ZIPLink Connector Modules, a pigtail cable keeps wiring 3. Select cable. Circuit clean and easy and reduces troubleshooting time. Protection Enclosures Tools Pneumatics Safety Appendix Product Index Part # Index Volume 14 www.aut oma tiondirect.com/dl405 Programmable Controllers e6-57 PLC I/O Modules to ZIPLink Connector Modules - DL405 DL405 PLC Input Module ZIPLink Selector DL405 PLC Output Module ZIPLink Selector PLC ZIPLink PLC ZIPLink Input # of Module Part Cable Part Output Module Part Cable Part Component # of Terms Component Module Terms No. No. Module No. No. D4-08ND3S 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* D4-08TD1³ 11 See Note 3 ³ Feedthrough ZL-RTB20 ZL-D4-CBL20* 20 See Note 3 F4-08TD1S D4-16ND2 20 Sensor ZL-LTB16-24 ZL-D4-CBL20* Feedthrough ZL-RTB20 ZL-D4-CBL20* D4-16TD1 20 6 Feedthrough ZL-RTB20 ZL-D4-CBL20* Fuse ZL-RFU20 ZL-D4-CBL20* D4-16ND2F 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* Sensor ZL-LTB16-24 ZL-D4-CBL20* 6 D4-16TD2 20 Fuse ZL-D4-CBL20* ZL-RFU20 Feedthrough ZL-RTB40 ZL-D24-CBL40* D4-32ND3-1² 40 ZL-D24-CBL40*X Relay ZL-RRL16-24-2 ZL-D4-CBL20* Sensor ZL-LTB32-24 Feedthrough ZL-RTB40 ZL-D24-CBL40* Feedthrough ZL-RTB40 ZL-D24-CBL40* D4-32TD1² 40 D4-32ND3-2² 40 ZL-D24-CBL40*X 6 Fuse ZL-RFU40 ZL-D24-CBL40*X Sensor ZL-LTB32-24 Feedthrough ZL-RTB40 ZL-D24-CBL40* Feedthrough ZL-RTB40 D4-32TD1-1 40 ZL-D24-CBL40* ZL-D24-CBL40*X D4-64ND2¹ 40 6 Fuse ZL-RFU40 ZL-D24-CBL40*X Sensor ZL-LTB32-24 Feedthrough ZL-RTB40 ZL-D24-CBL40* D4-08NA³ 11 See Note 3 D4-32TD2² 40 ZL-D24-CBL40*X 6 Fuse ZL-RFU40 D4-16NA 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* Feedthrough ZL-RTB40 ZL-D24-CBL40* 1 40 D4-16NA-1 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* D4-64TD1 ZL-D24-CBL40*X 6 Fuse ZL-RFU40 Feedthrough ZL-RTB20 ZL-D4-CBL20* ³ 11 See Note 3 D4-08TA D4-16NE3 20 Sensor ZL-LTB16-24 ZL-D4-CBL20* Feedthrough ZL-RTB20 ZL-D4-CBL20* D4-16TA 20 F4-08NE3S 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* 6 Fuse ZL-D4-CBL20* ZL-RFU20 ³ 11 See Note 3 D4-08TR DL405 PLC Analog Module ZIPLink Selector 5 F4-08TRS-1 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* PLC ZIPLink 5 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* F4-08TRS-2 Analog # of Terms Component Module Cable Module Feedthrough ZL-RTB20 ZL-D4-CBL20* 4 D4-16TR 20 F4-04AD 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* 6 Fuse ZL-RFU20 ZL-D4-CBL20* F4-04ADS 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* * Select the cable length by replacing the * with: Blank = 0.5m, -1 = 1.0m, F4-08AD 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* or -2 = 2.0m. 1 F4-16AD-1 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* The D4-64ND2 and D4-64TD1 modules have two 32-point connectors and require two ZIPLink cables and two ZIPLink connector modules. F4-16AD-2 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* 2 To make a custom cable for the 32 or 64-point modules, use: Ribbon-style F4-04DA-1 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* Connector ZL-D24-CON-R, Solder-style 180° connector ZL-D24-CON or Solder- F4-04DA-2 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* style 45° connector ZL-D24-CON-X 3 F4-08DA-1 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* These modules are not supported by the ZIPLink wiring system. 4 F4-16DA-1 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* Caution: The D4-16TR realy outpus are derated not to exceed 2 Amps per point and 4 Amps per common when used with the ZIPLink wiring system. F4-08DA-2 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* 5 The F4-08TRS-1 and F4-08TRS-2 are derated not to exceed 2 Amps per point F4-16DA-2 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* and 2 Amps per common when used with the ZIPLink wiring system. F4-04DAS-1 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* 6 Note: Fuses (5 x 20 mm) are not included. See Edison Electronic Fuse section for (5 x 20 mm) fuse. S500 and GMA electronic circuit protection for fast-acting F4-04DAS-2 20 Feedthrough ZL-RTB20 ZL-D4-CBL20* maximum protection. S506 and GMC electronic circuit protection for time- ³ delay performance. Ideal for inductive circuits. To ensure proper operation, do T/C Wire Only See Note 3 F4-08THM not exceed the voltage and current rating of ZIPLink module. ZL-RFU20 = 2A ³ T/C Wire Only See Note 3 F4-08THM-n per circuit; ZL-RFU40 = 400 mA per circuit. ³ T/C Wire Only See Note 3 F4-08RTD NOTE: ZIPLINK CONNECTOR MODULES AND ZIPLINK CABLES SPECIFICATIONS ARE IN THE ZIPLINK CATALOG SECTION. Volume 14 Programmable Controllers 1-800-633-0405 e6-58