Company DL405 CPU Comparisons Information Systems Overview DL405 CPU Specifications Programmable D4-430 D4-440 D4-450 Controllers System Capacity Total memory available (words) 6.5K 22.5K 30.8K Field I/O Ladder memory (words) built-in memory 3.5K EEPROM None, requires MC 7.5K flash Software with memory cartridge N/A up to 15.5K up to 15.5K V-memory (words) 3.0K 7.0K 15.3K C-more & Battery backup Yes Yes Yes other HMI Total CPU memory I/O pts. available (actual 1664 (X+Y+CR+GX) 2688 (X+Y,+CR+GX) 8192 (X+Y+GX+GY) I/O points depend on I/O configuration selected) Drives I/O module point density 2/4/8/16/32/64 2/4/8/16/32/64 2/4/8/16/32/64 I/O module slots per base 4/6/8 4/6/8 4/6/8 Soft Local/local expansion 320 in/320 out 320 in/320 out 1024 in/1024 out Starters Serial remote I/O (including local & exp. I/O 1664 max. 1664 max. 4224 max. Motors & Remote I/O Channels 2 2 3 Gearbox I/O pts. per remote module channel 512 512 512; 2048 (port 3) Ethernet Remote I/O (including local/exp. I/O) Yes Yes Yes Steppers/ Servos discrete I/O pts. 1664 max. 2688 max. 8192 max. (Including local and (Including local and (Including local and exp.I/O) exp.I/O) exp.I/O) Motor Analog I/O channels Controls map into V-memory map into V-memory map into V-memory Remote I/O channels Limited by power budget Limited by power budget Limited by power budget I/O per remote channel Proximity Sensors 16,384 (limited to 1664) 16,384 (limited to 2688) 16,384 (16 fully expanded H4-EBC slaves using V-memory and bit-of-word Photo Sensors instructions) Limit Switches Encoders Performance Contact execution (boolean) 3.0µs 0.33µs 0.96µs Current Sensors Typical scan (1K boolean) 8-10ms 2-3ms 4-5ms Programming and Diagnostics Pressure Sensors Yes Yes Yes RLL ladder style Yes/384 Yes/1024 Yes/1024 RLL PLUS/flowchart style (Stages) Temperature No Yes Yes Run time editing Sensors Supports Overrides No No Yes Variable/fixed scan Variable Variable Fixed or variable Pushbuttons/ Instructions 113 170 210 Lights Control relays 480 1024 2048 Timers 128 256 256 Process Counters 128 128 256 Immediate I/O Yes Yes Yes Relays/ Subroutines No Yes Yes Timers For/next loops No Yes Yes Timed interrupt No Yes Yes Comm. Integer math Yes Yes Yes Floating-point math No No Yes Terminal Trigonometric functions No No Yes Blocks & Table instructions No Yes Yes Wiring PID No No Yes Drum sequencers No No Yes Power Bit of word No No Yes Real-time clock/calendar No Yes Yes Circuit Internal diagnostics Yes Yes Yes Protection Password security No Yes Multi-level System and User error log No Yes Yes Enclosures IBox instructions No No Yes Tools CPU Ports Communications Built-in ports 2 ports 2 ports 4 ports Pneumatics K-sequence (proprietary protocol) Yes Yes Yes DirectNET Yes Yes Yes Appendix Modbus master/slave No No Yes ASCII out (Print) No No Yes Maximum baud rate 19.2K 19.2K 38.4K Product Index Part # Index Volume 13 www.aut o ma tiondirect.com/dl405 Programmable Controllers e6-9 D4-450 Key Features 16 PID loops Floating-point math The D4-450 CPU can process up to 16 The D4-450 CPU supports IEEE format DL450 CPU PID loops directly in the CPU. You can floating-point math calculations. This select from various control modes D4-450 <---> feature means the D4-450 includes full including automatic control, manual D4-450DC-1 <---> trigonometric functions and various forms control, and cascade control. There are a of integer/floating point number conver- D4-450DC-2 <---> wide variety of alarms including Process sions. Variable, Rate of Change, and Deviation. The various loop operation parameters Power supplies are stored in V-memory, which allows easy access from operator interfaces. Setup is We offer a choice of three power supplies accomplished with our DirectSOFT for the DL450 CPU. The power supplies Programming Software. An overview of the are built into the CPU. Available power various loop specifications and features is supplies are: on page 6-13. 110/220 VAC version - D4-450 24 VDC version - D4-450DC-1 125 VDC version - D4-450DC-2 D4-450 CPU D4–450 offers four built-in communication ports The D4-450 provides all the capabilities of the D4-430 and D4-440 CPUs, plus several additional features such as DirectSOFT5 IBox instructions. Built-in CPU communications ports The D4-450 offers four built-in ports for extra convenience. The 15-pin port offers our proprietary K-sequence protocol and is primarily used for programming connec- tions to a D4-HPP-1 handheld programmer or to a PC running DirectSOFT software. It can also be used to connect to a C-more panel or other operator interfaces. The 6-pin phone jack also supports K-sequence; plus, it can be a DirectNET slave port or an ASCII output port. The bottom 25-pin port contains two logical ports with different pins for each port. It is primarily a networking port that supports DirectNET master/slave or Modbus master/slave protocols. The bottom port can be used as an ASCII output port for connections to devices that can accept ASCII input. It can also be used as a remote I/O Master. The Communications Ports table on the next page has a complete description of each port. Note: if you are considering a D4-450 CPU to replace a CPU in an existing system, and the system uses specialty modules with an F4 prefix, then these modules may require an upgrade to operate with the D4-450. Contact our Technical Services group prior to placing your order for more information. (This note does not apply to analog modules.) Volume 13 Programmable Controllers 1-800-633-0405 e6-10 Company D4-450 Features Information Systems Overview Programmable The diagrams on this page show the Controllers various hardware features found on the D4-450 CPU. Field I/O Wiring terminals Software CPU battery CPU Keyswitch C-more & Forces CPU to RUN mode. Locks Comm port - will other HMI RUN not receive incoming data. Run relay Drives Allows peripherals (HPP, DCM, DirectSOFT, etc.) to TERM select operating mode 24V auxiliary power Soft Slot for optional STOP Forces CPU out of RUN (400ma) Starters memory cartridge CPU Status Indicators Logic ground Motors & Gearbox ON CPU power good Chassis ground PWR OFF CPU power failure Steppers/ Servos ON CPU is in RUN mode AC power RUN OFF CPU is in STOP mode Motor ON CPU self-diagnostics error Controls CPU OFF CPU self-diagnostics good 110/220 voltage select Proximity ON CPU battery is low BATT Sensors OFF CPU battery is good or disabled ON CPU diagnostics or local bus error Photo DIAG OFF CPU diagnostics or local bus good Sensors ON I/O self-diagnostics error I/O OFF I/O self-diagnostics good Limit Switches ON Data is being transmitted TXD OFF No data is being transmitted Encoders ON Data is being transmitted RXD OFF No data is being transmitted Current Sensors Communications Ports Pressure Sensors Programming Port, RS232C, baud rate selectable up Phone D4-450 communications ports pin-out to 38.4Kb. Connects to DirectSOFT, DV-1000, Temperature Jack C-more panels, network, etc. K-sequence protocol, Sensors Port 2 DirectNET protocol (slave only), ASCII out 15-pin connector Pushbuttons/ Phone jack Lights Programming port, RS232C, 9600 baud, connects to 15-pin HPP, DirectSOFT, DV-1000, C-more panels, etc. Process Port 0 K-sequence protocol (fixed station address=1) Relays/ Timers General purpose port for RS232C and RS422. (RS485 Comm. Remote I/O Master available on Port 3 only.) Baud Port 2 rate selectable via software up to 38.4K baud. Terminal Connects to DirectSOFT, C-more panels, network, etc. Blocks & Port 0 Two logical ports (separate pins on connector). Wiring 25-pin Software selectable protocol includes: Port 1 Protocol Port 1 Port 3 Power and K-sequence ✓✓ Port 3 DirectNETMaster/Slave ✓✓ Circuit 25-pin connector Protection Modbus Master/Slave ✓✓ 25-pin connector Remote I/O n/a ✓ Enclosures ASCII Out ✓✓ Tools Pneumatics Appendix Product Index Part # Index Port 3 Port 1 Volume 13 www.aut o ma tiondirect.com/dl405 Programmable Controllers e6-11 D4-450 Fixed or Variable Scan D4-450 Scan control The D4-450 CPU provides several scan control options, which are useful in some high-speed machine control applications. Variable — The scan varies as necessary from scan to scan. The actual scan time depends on the instructions being executed. Limited — This is similar to a variable scan in that the scan varies as necessary. However, if the actual scan time exceeds a specified target scan time, then a scan overrun condition is indicated. Fixed — If the scan is finished before the time specified, idle time is added to ensure a fixed scan period. If the scan exceeds the time specified, the scan is extended to ensure all instructions are executed. A scan overrun condition is also reported. Memory Rel. 2.1 of DirectSOFT, is required to program the D4-450. The D4-450 has 7.5K of flash memory on board. Upgrade to 15.5K by choosing an optional memory cartridge listed on page 6-14 . The memory cartridge is recommended since it is removable in the event of problems. Full array of instructions Imagine if someone asked you to write a book, but then told you that you could only use 50 different words? That would be a tough job! The same is true for writing a PLC program. The right instruc- tion can greatly simplify your control program. The D4-450 supports over 200 powerful instructions. These include: Four types of drum sequencers, each with 16 steps and up to 16 outputs Leading and trailing edge triggered one- shots Bit of word manipulation (bit set, reset, etc.) Trigonometric functions Floating point conversions Ibox instructions that simplify tasks such as configuring analog modules or performing complex math equations Note: if you are considering a D4-450 CPU to replace a CPU in an existing system, and the system uses specialty modules with an F4 prefix, then these modules may require an upgrade to operate with the D4-450. Contact our Technical Services group prior to placing your order for more information. (This note does not apply to Analog modules.) Volume 13 Programmable Controllers 1-800-633-0405 e6-12 Company D4-450 PID loops Information Systems Overview Programmable Controllers PID Loop Specifications and Key Features Selectable, 16 maximum Number of Loops Field I/O CPU V-memory Required 32 V-memory locations per loop selected (An additional 32 V-memory locations per loop required if using Ramp/Soak) Software Position or velocity form of the PID equation. Optionally specify direct or reverse acting, square root of the error and error squared control. PID Algorithm Open loop step response method and closed loop limit cycle method. Auto Tuning C-more & other HMI Specify the time interval between PV samples, 0.05 to 99.99 in units of seconds or minutes. If using all 16 loops, the smallest sample rate is limited to Sample Rate either 0.2 seconds or (PLC scan time x number of loops). Drives Loop Operation Modes Loop can be in automatic control, manual (operator) control, or cascade control. PV alarm monitoring continues when loops are in manual mode. Soft Ramp/Soak Up to 16 steps (8 ramp, 8 soak) per loop, with indication of Ramp/Soak step. Starters Square Root PV Specify a square root of the PV for a flow control application. Motors & Gearbox Specify a maximum and minimum value for allowable setpoint changes. Limit SP Limit OUT Specify a maximum and minimum value for the output range. Steppers/ Servos Gain Specify proportional gain of 0.01 to 99.99. Specify integral time of 0.1 to 99.98 in units of seconds or minutes. Motor Reset Controls Rate Specify the derivative time, 0.00 to 99.99 seconds. Proximity Specify a derivative gain limiting coefficient to filter the PV used in calculating the derivative term (0 to 20). Rate Limiting Sensors Bias and setpoint are initialized automatically when the loop is switched from manual to automatic. This provides for a bumpless transfer, which Bumpless Transfer I reduces the chance of sharp changes in the output as a result of entering automatic mode. Photo Sensors Bias is set equal to the Output when the module is switched from manual to automatic. This allows switching in and out of automatic mode without Bumpless Transfer II having to re-enter the setpoint. Limit Switches Provides proportional bias adjustment for large setpoint changes. This may stabilize the loop faster and reduce the chance of the output going out of Step Bias range. Step bias should be used in conjunction with the normal adjusted bias operation. Encoders If the position form of the PID equation is specified, the reset action is stopped when the PID output reaches 0 or 100%. Select adjusted bias or freeze Anti-windup Current bias operation. Sensors Error Deadband Specify an incremental value above and below the setpoint in which no change in output is made. Pressure Squaring the error minimizes the effect a small error has on the Loop output, however, both Error Squared and Error Deadband control may be enabled. Sensors Error Squared Alarm Specifications Temperature Sensors Specify 0.1% to 5% alarm deadband on all alarms except Rate of Change. Deadband Pushbuttons/ Specify PV alarm settings for low-low, low, high, and high-high conditions. You can also specify a deadband to minimize the alarm cycles when the PV PV Alarm Points Lights approaches alarm limits. PV Deviation Specify alarms to indicate two ranges of PV deviation from the setpoint value (yellow and red deviation). Process Rate of Change Specify a rate-of-change limit for the PV. Relays/ Timers Need Temperature Control? If you're only interested in controlling temperature, then there may be a better solution than the D4-450 CPU. Check out the F4-4LTC module. This module has the capa- Comm. bilities of our single loop controllers built into one economical module! Detailed specifications can be found later in this section. This module can directly control up to four loops and it even includes built-in relay outputs for heater or chiller control! If you use the built-in PID capability of the D4-450 CPU, you still have to purchase the Terminal analog input modules and the output modules (either discrete or analog) in order to complete the loop. Blocks & This can result in a much higher overall cost when compared to the F4-4LTC. Wiring Power DL405 Analog Output Circuit or Discrete Output Protection Operator Interface D4–450 CPU Enclosures Σ Tools Pneumatics PID Loop Control Appendix Block Diagram Product Index DL405 Analog Input Modules Part # Index Volume 13 www.aut o ma tiondirect.com/dl405 Programmable Controllers e6-13 DL405 Programming Tools and Cables Select a programming device There are two tools for programming the DL405 CPUs: DirectSOFT PC-based programming software and the D4-HPP-1 handheld programmer. DirectSOFT programming software Our powerful Windows-based program- ming packages make it easy for you to program and monitor your DL405 PLC system. The version of the software that supports the DL405 CPUs is described in the table below. See the Software section in the desk reference for detailed information on DirectSOFT. Direct Soft Price Description Part Number Programs all PLC families <---> PC-DSOFT5 DL05/06/105/205/305/405 DL405 programming cables Choose the proper cable to connect the DL405 CPU to your PC running DirectSOFT. CPU Price Port Cable Price Top port <---> <---> D4-DSCBL (15 pin) D4-430/ D4-440 Lower port <---> D3-DSCBL-2 <---> (25 pin) Top port D4-DSCBL <---> (15 pin) Lower port D4-450 <---> D3-DSCBL-2 <---> (25pin) Phone jack <---> D2-DSCBL (RJ12) Handheld programmer There are three optional connect- The D4-HPP-1 handheld programmer ing cables available for use with connects to the 15-pin port on any of the the D4-HPP-1 programmer: DL405 CPUs. A memory cartridge is D4-HPCBL-1: 3m cable located on the side of the handheld D4-HPCBL-2: 1.5m cable programmer. This slot allows you to copy D4-CASCBL: cassette cable memory cartridges (including UV PROMs) and transfer data/programs between the CPU and a memory cartridge. Volume 13 Programmable Controllers 1-800-633-0405 e6-16