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Installation, Wiring, and Specifications

In This Chapter. . . .

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Safety Guidelines Mounting Guidelines Installing DL405 Bases Installing Components in the Base CPU and Expansion Unit Wiring Guidelines I/O Wiring Strategies I/O Module Wiring and Specifications Glossary of Specification Terms

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Installation, Wiring, and Specifications

Safety Guidelines
WARNING: Providing a safe operating environment for personnel and equipment is your responsibility and should be your primary goal during system planning and installation. Automation systems can fail and may result in situations that can cause serious injury to personnel or damage to equipment. Do not rely on the automation system alone to provide a safe operating environment. You should use external electromechanical devices, such as relays or limit switches, that are independent of the PLC system to provide protection for any part of the system that may cause personal injury or damage. Installation, Wiring, and Specifications Every automation application is different, so there may be special requirements for your particular application. Make sure you follow all National, State, and local government requirements for the proper installation and use of your equipment. Plan for Safety The best way to provide a safe operating environment is to make personnel and equipment safety part of the planning process. You should examine every aspect of the system to determine which areas are critical to operator or machine safety. If you are not familiar with PLC system installation practices, or your company does not have established installation guidelines, you should obtain additional information from the following sources. NEMA The National Electrical Manufacturers Association, located in Washington, D.C., publishes many different documents that discuss standards for industrial control systems. You can order these publications directly from NEMA. Some of these include: ICS 1, General Standards for Industrial Control and Systems ICS 3, Industrial Systems ICS 6, Enclosures for Industrial Control Systems NEC The National Electrical Code provides regulations concerning the installation and use of various types of electrical equipment. Copies of the NEC Handbook can often be obtained from your local electrical equipment distributor or your local library. S Local and State Agencies many local governments and state governments have additional requirements above and beyond those described in the NEC Handbook. Check with your local Electrical Inspector or Fire Marshall office for information. The publications mentioned provide many ideas and requirements for system safety. We recommend following these regulations as a minimum. Using the techniques listed below will further help reduce the risk of safety problems. Orderly system shutdown sequence in the PLC control program. System power disconnects (guard limits, emergency stop switches, etc.)

Installation and Safety Guidelines

Safety Techniques

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Installation , Wiring, and Specifications Orderly System Shutdown The PLC control program can provide the first level of protection when used to identify machine problems. After analyzing your application, identify any shutdown sequences that must be performed. Typical problems include part jams, empty bins, etc. that do not pose a risk of personal injury or equipment damage. WARNING: The control program must not be the only form of protection for any problems that may result in a risk of personal injury or equipment damage.
Jam Detect

Turn off Saw RST RST Retract Arm

Installation, Wiring, and Specifications

System Power Disconnect

By using electro-mechanical devices such as master control relays and/or limit switches, you can prevent accidental equipment startup. When installed properly, these devices will prevent any machine operations from occurring. For example, if the machine has a jammed part the PLC control program can turn off the saw blade and retract the arbor. However, since the operator must open the guard to remove the part, you must include a disconnect switch that removes all system power any time the guard is opened. The machine operator must also have a quick and easy method of manually disconnecting all system power. This is accomplished with a mechanical device that is clearly labeled as an Emergency Stop switch.
Use E-Stop and Master Relay E STOP Power On Guard Limit Master Relay

Guard Limit Switch

Emergency Stop
Master Relay Contacts Master Relay Contacts

Installation and Safety Guidelines

To disconnect PLC Power Output Module

Master Relay Contacts

Saw Arbor

To disconnect output module power

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.

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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: Environmental specifications Power supply specifications Regulatory Agency Approvals Enclosure Selection and Component 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 guidelines to allow proper spacing from other components.
4.375 111mm 3.94 100mm 4.312 110mm

Base Dimensions Installation, Wiring, and Specifications

CPU ExpansionUnit, Remote Slave


5.9 150mm

4 holes, clearance for M4 screw 0.47 12 mm

4 Slot Base
11.54 293mm 10.83 275mm

6 Slot Base
14.45 367mm 13.74 349mm

Installation and Safety Guidelines

5.91 4.69 150mm 119mm

0.75 19 mm 0.28 7 mm Mounting hole close-up 0.47 12 mm

8 Slot Base

17.36 441mm 16.65 423mm

Base mounting dimensions given to upper (fully seated) location

5.91 4.69 150mm 119mm

0.75 19 mm

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Installation , Wiring, and Specifications

Panel Layout & Clearances

There are many things to consider when designing the panel layout. The following items correspond to the diagram shown. Note: there may be additional requirements, depending on your application and use of other components in the cabinet. 1. 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 (350mm) between bases. 3. A minimum clearance of 2 (50mm) between the 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. 5. There must be a minimum of 2 clearance between the panel door and the nearest DL405 component.
Temperature Probe

Installation, Wiring, and Specifications


Power Source 3 75mm min. DL405 CPU Base

50mm min.
2 50mm min. 7.2 13.75

DL405 Local Expansion Base Panel

183 350mm

Installation and Safety Guidelines

Star Washers Ground Braid Copper Lugs

BUS Bar

2 50mm min.

Earth Ground

Panel Ground Terminal Note: there is a minimum of 2 (50mm) clearance between the panel door and the nearest DL405 component.

Star Washers Panel or 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.

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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 termination. 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: Installation, Wiring, and Specifications 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 nutbolt 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. Isolation transformers and noise suppression devices are not normally necessary, but may be helpful in eliminating/reducing suspect power problems. Enclosures Installation and Safety Guidelines 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: Conformance to electrical standards Protection from the elements in an industrial environment Common ground reference Maintenance of specified ambient temperature Access to equipment Security or restricted access S Sufficient space for proper installation, cooling, and maintenance Some applications require agency approvals. The DL405 agency approvals for which DL405 products are submitted are; UL (Underwriters Laboratories, Inc.) CE EMC (Electromagnetic Compatibility) 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 18006330405 (U.S.).

Agency Approvals

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Installation , Wiring, and Specifications Environmental Specifications The following table lists the environmental specifications that generally apply to the DL405 system (CPU, Expansion Unit, 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 Storage temperature Ambient operating temperature Ambient humidity Vibration resistance Shock resistance Noise immunity Atmosphere Rating 4 F to 158 F (20 C to 70 C)* 32 F to 140 F (0 C to 60 C) 5% 95% relative humidity (noncondensing) ** MIL STD 810C, Method 514.2 MIL STD 810C, Method 516.2 NEMA (ICS3304) No corrosive gases

Installation, Wiring, and Specifications

*Storage temperature for the Handheld Programmer is 14 to 149F (10 to 65 C) **Ambient humidity for the Handheld Programmer is 20% to 90% non-condensing.

Power

The external power source must be capable of suppling voltage and current complying with the PLC power supply specifications.
Specifications Voltage withstand (dielectric strength) Insulation resistance Input voltage range D4430 / D4440 / D4450 / D4EX Input voltage range D4440DC1 / D4EXDC Input voltage range D4440DC2 / D4EXDC2 Maximum inrush current D4430 / D4440 / D4EX Maximum inrush current D440DC1 / D4EXDC DL405 Series CPUs 1 min. @ 1500 VAC between primary, secondary, field ground and run relay > 10MW at 500 VDC 85132 VAC (110 range) / 170264 VAC (220 range) 2029 VDC (24VDC) less than 10% ripple

Installation and Safety Guidelines

90146 VDC (125 VDC) less than 10% ripple 20A 10A

Maximum inrush current DL440DC2 / 20A D4EXDC2 Maximum power DL430/DL440/DL450, D4EX Maximum power DL440DC1, D4EXDC Maximum power DL440DC2, D4EXDC2 24VDC Auxiliary Power Supply (D4EX only) 50VA

38W 30W 2028 VDC @ 0.4A maximum, ripple > 1V p-p

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Installation, Wiring, and Specifications Component Dimensions Before installing your PLC system you will need to know the dimensions for the 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
5.7 145mm 1.2 30mm

Installation, Wiring, and Specifications

Memory Cartridge
3.14 80mm

4.65 118mm

I/O modules
4.375 111mm 4 100mm 1.37 34.8mm

I/O module w/Ribbon connector


NOTE: Ribbon connector and D shell extend out past module and may affect depth of cabinet

5.9 150m

Installation and Safety Guidelines

Handheld programmer cable


4.5 ft.(1.5m) 9.1 ft. (3m)

Base Expansion Cable


1.6ft. (.5m) 3.3 ft. (1m)

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Installation , Wiring, and Specifications

Installing DL405 Bases


Three Sizes of Bases All I/O configurations of the DL405 (except for Slice I/O) will use a selection of either 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 cable input connection

Local Base Installation, Wiring, and Specifications


Expansion cable output connection

Expansion cable

8 slot base

Expansion Bases

Expansion Power Supplies

6 slot base

4 slot 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. Mounting the Base The CPU/Expansion Unit/Remote Slave must always be installed in the left-most 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 or machine using four M4 screws in the corner locations shown to the right. The mounting cut-outs allow removal of the base after installation, without completely removing the mounting screws. Full mounting template dimensions are given inthe previous section on Mounting Guidelines.
Base mounting holes, 4 locations Mounting hole close-up

Installation and Safety Guidelines

210
Installation, Wiring, and Specifications Choosing the Base Type There are two types of bases to choose 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 in the 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.
Local
S R M M

CPU

Expansion cable Expansion

EXP

S M

Installation, Wiring, and Specifications

The part numbers for standard bases and the new bases are listed below. Standard Bases Expanded Bus Bases
Allows selected specialty modules in expansion bases

D404B

D404B1

D406B

D406B1

D408B

D408B1

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. In the above case, both local and expansion bases must be the new (1) type. Of course, 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). 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 CPUbased application, we recommend using the new bases (1 type) so you can add specialty modules in any base later.

Installation and Safety Guidelines

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Installation , Wiring, and Specifications

Installing Components in the Base


Setting the CPU DIP Switches (DL430/440 Only) There is one bank of four configuration switches located on the back of DL430 and DL440 CPUs. These switches affect battery low detection, station address override 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. Switch 1 S ON = Battery low indicator disabled S OFF= Battery low indicator enabled Switch 2 S ON = Station address override is enabled (address 1) S OFF= Station address is set by AUX function with programming device
ON 1

Installation, Wiring, and Specifications

NOTE: Setting Switch 2 on forces the station address to 1. It 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 300 1200 9600 19200 Switch 3 Off Off On On Switch 4 Off On Off On

NOTE: Parity, Mode and Station address for port 2 is selected by AUX functions using a programming device. 1. Note the components have plastic tabs at the bottom and a screw at the top. 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. Now tighten the screw at the top of the device to secure it to the base.
Spring loaded securing screw

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.

2 3 4

Installation and Safety Guidelines

212
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. 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. 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 2028VDC, 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 devices/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.) WARNING: Damage will occur to the power supply if 220 VAC is connected to the terminal connections with the 115 VAC shunt installed. Once the power wiring is connected, install the protective cover to avoid risk of accidental shock. CPU Wiring Installation and Safety Guidelines
125VDC Terminal Strip

Installation, Wiring, and Specifications

The following diagram details the appropriate connections for each terminal.
24VDC Terminal Strip

AC Terminal Strip

24V Auxiliary Power Logic Ground Chassis Ground + DC DC Logic Ground Chassis Ground + DC DC Logic Ground Chassis Ground AC Line AC Neutral 110/220 Voltage Select

Install shunt between LG and G Recommended screw torque: 10.6 lbin (1.2Nm)

Install shunt for 110 VAC range, leave off for 220 VAC range.

Install shunt between LG and G

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Installation , Wiring, and Specifications Expansion Unit Wiring
125VDC Terminal Strip

The following diagram details the appropriate connections for each terminal.
24VDC Terminal Strip

AC Terminal Strip

24V Auxiliary Power Logic Ground Chassis Ground + DC DC Logic Ground Chassis Ground + DC DC Logic Ground Chassis Ground AC Line AC Neutral 110/220 Voltage Select

Installation, Wiring, and Specifications

Install shunt between LG and G Recommended screw torque: 10.6 lbin (1.2Nm)

Install shunt for 110 VAC range, leave off for 220 VAC range.

Install shunt between LG and G

Connecting Programming Devices

You can mount the Handheld directly to Port 0 of any DL405 CPU (15-pin D-shell connector), or you can use a 9 foot (3m) or 4.6 ft (1.5m) cable as shown below. Cable Mount Direct Mount

Installation and Safety Guidelines

Use cable part no. D4HPCBL1, or D4HPCBL2

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
15-pin Dshell male 9-pin D-shell female

Use cable part no. D4DSCBL

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Installation, Wiring, and Specifications On the DL450, you may use port 2 instead for DirectSOFT programming. The cable shown below is approximately 12 feet (3.66m) long.
DL450 CPU, port 2
RJ12 phone style 9-pin D-shell female

Use cable part no. D2DSCBL

Installation, Wiring, and Specifications

Connecting Operator Interface Devices

Operator interfaces usually require data and power connections. However, the popular DV-1000 Data Access Unit may receive data and power directly from any DL405 CPU, using the 2 meter (6.56 ft.) long cable shown below.
All DL405 CPUs, port 0
15-pin D-shell male RJ12 phone style

DV-1000

Use cable part no. D41000CBL

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
RJ12 phone style RJ12 phone style

DV-1000

Use cable part no. DV1000CBL

Installation and Safety Guidelines

Optimation operator interface panels require separate power and data connections. Connect the CPU port 0, port 1, or port 2 (DL450) to an Optimation panel choosing the appropriate 2 meter (6.56 ft.) long cable from the three shown below.
All DL405 CPUs, port 0 or port 1
15-pin D-shell male 15-pin D-shell male

Optimation Panel

OP4CBL1
25-pin D-shell male

OP4CBL2 DL450 CPU, port 2


RJ12 phone style 15-pin D-shell male

Optimation Panel

OP2CBL

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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 circuitry is divided into three main regions separated by isolation boundaries, shown in the drawing below. Electrical isolation provides safety, so that a fault in one area does not damage another. A transformer in the power supply provides magnetic isolation between the primary and secondary sides. Opto-couplers provide optical isolation in Input and Output circuits. This isolates logic circuitry from the field side, where factory machinery connects. Note that the discrete inputs are isolated from the discrete outputs, because each is isolated from the logic side. Isolation boundaries protect the operator interface (and the operator) from power input faults or field wiring faults. When wiring a PLC, it is extremely important to avoid making external connections that connect logic side circuits to any other.
Primary Side PLC
Power Input

PLC Isolation Boundaries

Installation, Wiring, and Specifications

Secondary, or Logic side


(backplane)

Field Side

Main Power Supply

Input Module Output Module


Isolation Boundary

Inputs

CPU
(backplane) Outputs

Isolation Boundary

Programming Device, Operator Interface, or Network

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!
Primary Side
Power Input

Installation and Safety Guidelines

DL405 PLC Main Power Supply Internal

Secondary, or Logic side


Backplane

CPU

+24VDC Out

Auxiliary +24VDC Supply

Comm.

Input Module

Output Module

To Programming Device, Operator Interface, Network

Inputs Commons

Outputs Commons Supply for Output Circuit

Field Side

216
Installation, Wiring, and Specifications 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. All DL405 CPUs feature the internal auxiliary supply. If input devices AND output loads need +24VDC power, the auxiliary supply may be able to power both circuits as shown in the following diagram (400 mA limit).

Powering I/O Circuits with the Auxiliary Supply

Installation, Wiring, and Specifications

AC Power Power Input

DL405 PLC Input Module Inputs Com. Output Module Outputs Com.

Auxiliary +24VDC Supply

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 batterypowered 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. +
+ DC Power

Installation and Safety Guidelines

DL405 PLC
Power Input

Input Module Inputs Com.

Output Module Outputs Com.

Loads

217
Installation , Wiring, and Specifications Powering I/O Circuits Using Separate Supplies 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.
AC Power Power Input

AC Power Power Input

Installation, Wiring, and Specifications

DL405 PLC Input Module Inputs Com. Output Module Outputs Com.

DL405 PLC Input Module Inputs Com. Output Module Outputs Com.

Auxiliary +24VDC Supply

Auxiliary +24VDC Supply

Loads

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, youll probably want to avoid this situation if possible. +
+ DC Power AC Power

Installation and Safety Guidelines

DL405 PLC
Power Input

Power Input

DL405 PLC Input Module Inputs Com. Output Module Outputs Com.

Input Module Inputs Com.

Output Module Outputs Com.

Auxiliary +24VDC Supply

+
Loads Load Supply

Input Supply Loads Load Supply

218
Installation, Wiring, and Specifications Sinking / Sourcing Concepts Before going further in our study of wiring strategies, we must have a solid understanding of sinking and sourcing concepts. Use of these terms occurs frequently in input or output circuit discussions. It is the goal of this section to make these concepts easy to understand, further ensuring your success in installation. First we give the following short definitions, followed by practical applications.

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

Installation, Wiring, and Specifications

Input Sensing

Installation and Safety Guidelines

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
Input + Common PLC Input Sensing

Sinking Output
PLC Output Switch Output Load + Common

Sourcing Input
Common + Input PLC Input Sensing

Sourcing Output
PLC Output Switch Common + Output Load

219
Installation , Wiring, and Specifications I/O Common In order for a PLC I/O circuit to operate, Terminal Concepts current must enter at one terminal and exit at another. This means at least two terminals are associated with every I/O point. In the figure to the right, the Input or Output terminal is the main path for the current. One additional terminal must provide the return path to the power supply. If we had unlimited space and budget for I/O terminals, then every I/O point could have two dedicated terminals just as the figure above shows. However, providing this level of flexibility is not practical or even necessary for most applications. So, most Input or Output points on PLCs are in groups which share the return path (called commons). The figure to the right shows a group (or bank) of 4 input points which share a common return path. In this way, the four inputs require only five terminals instead of eight.
Field Device + Return Path Main Path (I/O Point) PLC I/O Circuit

PLC

Installation, Wiring, and Specifications

Input 1 Input 2 Input 3 Input 4 + Common

Input Sensing

NOTE: In the circuit above, the current in the common path is 4 times any channels input current when all inputs are energized. This is especially important in output circuits, where heavier gauge wire is sometimes necessary on commons. Most DL405 input and output modules group their I/O points into banks that share a common return path. The best indication of I/O common grouping is on the wiring label, such as the one shown to the right. The miniature schematic shows two circuit banks with eight input points in each. The common terminal for each is labeled CA and CB, respectively. 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:
AC supply DC supply + AC or DC supply
1224VDC
TB A 0 1 2 3 4 5 6 7 0 1 2 3

INPUT
B 4 5 6 7

Installation and Safety Guidelines

D416ND2
10.226.4VDC 412mA

CA 0 4 1 5 2 6 3 7 CB 4 0 5 1 6 2 7 3

Input Switch

Output Load
L

220
Installation, Wiring, and Specifications Connecting DC I/O In the previous section on Sourcing and Sinking concepts, we explained that DC I/O circuits sometimes will only allow current to flow one way. This is also true for many of to Solid State the field devices which have solid-state (transistor) interfaces. In other words, field Field Devices devices can also be sourcing or sinking. When connecting two devices in a series DC circuit, one must be wired as sourcing and the other as sinking. Several DL405 DC input modules are flexible in that they detect current flow in either Solid State direction, so they can be wired as either sourcing or sinking. In the following circuit, a Input Sensors field device has an open-collector NPN transistor output. It sinks current from the PLC input point, which sources current. The power supply can be the +24 auxiliary supply or another supply (+12 VDC or +24VDC), as long as the input specifications are met. Installation, Wiring, and Specifications
Field Device Output (sinking) Supply Ground Input (sourcing) PLC DC Input

Common

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

Installation and Safety Guidelines

Solid State Output Loads

Sometimes an application requires connecting a PLC output point to a solid state input on a device. This type of connection is usually made to carry a low-level control signal, not to send DC power to an actuator. Several of the 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 Power +DC pwr Output (sinking) Common + Input (sourcing) 1030 VDC Ground Field Device +V

221
Installation , Wiring, and Specifications In the next example we connect a PLC sinking DC output point to the sinking input of a field device. This is a bit tricky, because both the PLC output and field device input are sinking type. Since the circuit must have one sourcing and one sinking device, we add sourcing capability to the PLC output by using a pull-up resistor. In the circuit below, we connect Rpull-up from the output to the DC output circuit power input.
PLC DC Output +DC pwr Power Field Device Input (sinking) Ground

R pull-up
(sourcing) (sinking) Output + Supply Common

R input
Installation, Wiring, and Specifications

NOTE 1: DO NOT attempt to drive a heavy load (>25 mA) with this pull-up method NOTE 2: Using the pull-up resistor to implement a sourcing output has the effect of inverting the output point logic. In other words, the field device input is energized when the PLC output is OFF, from a ladder logic point-of-view. Your ladder program must comprehend this and generate an inverted output. Or, you may choose to cancel the effect of the inversion elsewhere, such as in the field device. It is important to choose the correct value of R pull-up. In order to do so, we need to know the nominal input current to the field device (I input) when the input is energized. If this value is not known, it can be calculated as shown (a typical value is 15 mA). Then use I input and the voltage of the external supply to compute R pull-up. Then calculate the power Ppull-up (in watts), in order to size R pull-up properly.

input

input (turn-on)

R input V supply - 0.7 I


input

R pullup =

- R input

pullup

2 V supply R pullup

Installation and Safety Guidelines

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 Common Field Device Output (sourcing) Supply + Input (sinking) Ground

R input

222
Installation, Wiring, and Specifications Relay Output Guidelines Four output modules in the DL405 I/O family feature relay outputs: D408TR, F408TRS1, F408TRS2, D416TR. Relays are best for the following applications: Loads that require higher currents than the solid-state outputs can deliver Cost-sensitive applications Some output channels need isolation from other outputs (such as when some loads require different voltages than other loads)

Installation, Wiring, and Specifications

Some applications in which NOT to use relays: S Loads that require currents under 10 mA Loads which must be switched at high speed or heavy duty cycle
Relay with Form A contacts

Installation and Safety Guidelines

Relay outputs in the DL405 output modules are available in two contact arrangements, shown to the right. The Form A type, or SPST (single pole, single throw) type is normally open and is the simplest to use. The Form C type, or SPDT (single pole, double throw) type has a center contact which moves and a stationary contact on either side. This provides a normally closed contact and a normally open contact. Some relay output modules relays share common terminals, which connect to the wiper contact in each relay of the bank. Other relay modules have relays which are completely isolated from each other. In all cases, the module drives the relay coil when the corresponding output point is on. Surge Suppresion For Inductive Loads

Relay with Form C contacts

Inductive load devices (devices with a coil) generate transient voltages when de-energized with a relay contact. When a relay contact is closed it bounces, which energizes and de-energizes the coil until the bouncing stops. The transient voltages generated are much larger in amplitude than the supply voltage, especially with a DC supply voltage. When switching a DC-supplied inductive load the full supply voltage is always present when the relay contact opens (or bounces). When switching an AC-supplied inductive load there is one chance in 60 (60 Hz) or 50 (50 Hz) that the relay contact will open (or bounce) when the AC sine wave is zero crossing. If the voltage is not zero when the relay contact opens there is energy stored in the inductor that is released when the voltage to the inductor is suddenly removed. This release of energy is the cause of the transient voltages.

223
Installation , Wiring, and Specifications When inductive load devices (motors, motor starters, interposing relays, solenoids, valves, etc.) are controlled with relay contacts, it is recommended that a surge suppression device be connected directly across the coil of the field device. If the inductive device has plug-type connectors, the suppression device can be installed on the terminal block of the relay output. Transient Voltage Suppressors (TVS or transorb) provide the best surge and transient suppression of AC and DC powered coils, providing the fastest response with the smallest overshoot. Metal Oxide Varistors (MOV) provide the next best surge and transient suppression of AC and DC powered coils. For example, the waveform in the figure below shows the energy released when opening a contact switching a 24 VDC solenoid. Notice the large voltage spike.
+24 VDC

Installation, Wiring, and Specifications

+24 VDC

24 VDC

Module Relay Contact 324 VDC

This figure shows the same circuit with a transorb (TVS) across the coil. Notice that the voltage spike is significantly reduced. Installation and Safety Guidelines
+24 VDC +24 VDC 42 VDC 24 VDC

Module Relay Contact

224
Installation, Wiring, and Specifications Use the following table to help select a TVS or MOV suppressor for your application based on the inductive load voltage.
hhVendor / Catalog General Instrument Transient Voltage Suppressors, LiteOn Diodes; from DigiKey Catalog; Phone: 1-800-344-4539 Harris Metal Oxide Varistors; from Newark Catalog; Phone: 1-800-463-9275 Type (TVS, MOV, Diode) TVS TVS TVS Diode MOV MOV Inductive Load Voltage 110/120 VAC 220/240 VAC 12/24 VDC or VAC 12/24 VDC or VAC 110/120 VAC 220/240 VAC Part Number P6KE180CAGICTND P6KE350CA P6K30CAGICTND 1N4004CTND V150LA20C V250LA20C

Installation, Wiring, and Specifications

Prolonging Relay Contact Life

Installation and Safety Guidelines

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

Input

Common

225
Installation , Wiring, and Specifications 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: I 10
2

C (mF) =

R (W) =

V 10 x I
x

, where x= 1 +

50 V Installation, Wiring, and Specifications

C minimum = 0.001 mF, the voltage rating of C must be w V, non-polarized R minimum = 0.5 W, 1/2 W, tolerance is " 5% For 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: 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: C (mF) = I 10 V 10 x I 50 169.7
x 2

0.707 10

= 0.05 mF, voltage rating w 170 Volts 50 V

R (W) =

, where x= 1 +

x= 1 +

= 1.29

R (W) =

169.7 10 x 0.707 1.29

= 16 W, 1/2 W, " 5%

Installation and Safety Guidelines

226
Installation, Wiring, and Specifications

I/O Module Wiring and Specifications


Module Placement Before wiring the I/O modules in your system to field devices, its 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: Installation, Wiring, and Specifications S I/O Module Status Indicators

?
Loose terminal block indicator Blown fuse (non-replaceable) indicator (Output modules only)

Do the power budget calculations for each base to verify the base power supply can power all the modules in the base. Information on how to do this is in Chapter 4, System Design and Configuration. Some specialty I/O modules may only be installed in particular slots (will 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.

Status indicators

Display status (selects a group of signals to be displayed)

Installation and Safety Guidelines

Wire tray

Color Coding of I/O Modules

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 Discrete/Analog Output Discrete/Analog Input Other Color Code Red Blue White

110VAV TB A 0 1 4 5 6 7 0 1 2 3 B 4 5 6 7

INPUT

Color Bar

2 3 D416NA

80132VAC 8020mA 50/60Hz CA 0

227
Installation , Wiring, and Specifications Wiring a Module with a Terminal Block You must first remove the front cover of the module prior to wiring. To remove the cover depress the bottom tab of the cover and tilt the cover up to loosen from the 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 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 terminal block even though the PLC system is turned off. To minimize the risk of electrical shock, disconnect all field device power before you remove the connector. Installation, Wiring, and Specifications
Loose terminal block LED indicator

Retaining screw

Terminal screws Retaining screw Push tab and lift to remove

Installation and Safety Guidelines

I/O module wiring tray

228
Installation, Wiring, and Specifications Wiring 32 and 64 Point I/O Modules The 32 point and 64 point I/O modules use a different style of connector due to the 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 to the next section for complete information on ribbon and solder type connectors and accessories. Another option is to use the D4IOCBL1, a 3m prewired solder connector and cable with pigtail.

Installation, Wiring, and Specifications

32 pt. Module

ZIPLINK Cable

ZIPLINK Connector Module


64pt. Module

Installation and Safety Guidelines

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.

229
Installation , Wiring, and Specifications Part Numbers for Module Connectors Both types of connectors are available from PLCDirect. These same connectors are also available from other Fujitsu Microelectronics, Inc. Use the following part numbers to order these connectors. PLCDirect Part Numbers S D4IO3264R Ribbon cable connectors, 2 in a pack. Can be used on either 32 point or 64 point modules. S D4IO3264S Solder type connector, 2 in a pack. Can be used on either 32 point or 64 point modules. Installation, Wiring, and Specifications

Fujitsu Part Numbers For connectors made by Fujitsu, you may contact Fijitsu at the following address: Fujitsu Microelectronics, Inc. Electronic Components Division 3545 North First Street San Jose, CA 951341804 USA 4089229000 FCN367J040AU/F, or AG/F 32 / 64 point ribbon cable connector FCN361J040AU, or AG 32 / 64 point solder type connector (AU connectors use gold over palladium plating. AG connectors use silver plating.) Vendors For the Parts Used in the Terminal Block Configuration If you wish to use a terminal block with your 32 or 64 point module, here is a partial list of vendors who can provide the parts you will need to build the configuration shown earlier consisting of a ribbon cable, a ribbon cable connector and a terminal block.
Vendors 3M Electronic Products Division 6801 River Place Blvd. Austin, TX 787269000 8002255373 Augat/RDI 525 Randy Rd. Carol Stream, IL 60188 7086824100 AMP Incorporated P.O. Box 3608 Harrisburg, PA 171053608 7175640100 Cooper Industries, Belden Div. P.O. Box 1980 Richmond, IN 47375 3179835200 Newark Electronics 4108 North Ravenswood Ave. Chicago, Il 60640 3127845100 DuPont Connector Systems Barley Mill Plaza Wilmington, DE 198980019 8002372374 Phoenix Contacts Products P.O. Box 4100 Harrisburg, PA 171110100 7179441300 Thomas & Betts Electronics Div. 200 Executive Center Drive Greenville, SC 29616 8036762900 Weidmuller, Inc. 821 Southlake Blvd. Richmond, VA 23236 8047942877 (Newark Electronics is a distributor for all of the above product manufacturers except for Phoenix Contacts Products)

Installation and Safety Guidelines

230
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 Gray / 26 AWG Gray / 26 AWG Gray / 28 AWG Gray / 28 AWG Gray / 28 AWG Color coded / 26 AWG Color coded / 28 AWG Color coded / 28 AWG Vendor 3M Belden Belden DuPont AMP 3M Belden DuPont Part Number 3801 / 40 9L260 40 9L280 40 76825040 4991165 3811 / 40 9R280 40 76177040

Installation, Wiring, and Specifications

Ribbon Cable Connectors

These ribbon cable connectors are for attaching the ribbon cable to the terminal block. They are all .100 x .100 2 x20 female ribbon connectors with a center bump.
Description/Type Connector Strain Relief Connector Strain Relief Connector (pre-assembled) Strain Relief Connector (with strain relief) Connector (pre-assembled) Strain Relief Connector (with strain relief) Vendor 3M 3M 3M 3M 3M 3M Thomas & Betts AMP AMP DuPont Molex Part Number 34177640 34483040 34177640 34483040 891400103T0 344889140 6224041 7462869 4992521 66902240 15299940

Installation and Safety Guidelines

Connector (with strain relief)

Interface Terminal Block

Below are terminal blocks which can be used to transition a 40 conductor ribbon 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 2212 AWG, no fuses.
Description/Type Panel Mount Rail Mount Rail Mount Special Mount (DIN rail compatible) includes ribbon connector Vendor Weidmuller Phoenix Contacts Augat/RDI Part Number RI40A /914897 RI40A /914908 FLKM 40 / 2281076 2M40FC

231
Installation , Wiring, and Specifications I/O Wiring Checklist Use the following guidelines when wiring the I/O modules in your system. 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 CPU 8 point 16 point 32 point 64 point
(connectors sold separately)

Suggested AWG Range Suggested Torque 12 AWG 12 AWG 14 AWG 10.63 lb-inch (1.2 Nm) 7.97 lb-inch (0.9 Nm) 7.97 lb-inch (0.9 Nm) Installation, Wiring, and Specifications

ZipLink: ZL4CBL4# cable / ZLCM40 connector block

D4IOCBL1 (3m pigtail cable with D4IO3264S) D4IO3264R (ribbon type connector) D4IO3264S (solder type connector)

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. 2. Always use a continuous length of wire. Do not splice wires to attain a needed length. 3. Use the shortest possible wire length. 4. Where possible use wire trays for routing . 5. Avoid running wires near high energy wiring. 6. Avoid running input wiring close to output wiring where possible. 7. To minimize voltage drops when wires must run a long distance, consider using multiple wires for the return lines. 8. 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.
External Fuses (shown with DIN Rail, fuse blocks)

Installation and Safety Guidelines

NOTE: For modules which have soldered-in or non-replaceable fuses, we recommend that you return your module to us and let us replace your blown fuse(s) since disassembling the module will void the warranty.

232
Installation, Wiring, and Specifications DL405 Input Module Chart The following table lists the available DL405 input modules. Specifications begin on the following page.
DL405 Input Module Type D416ND2 D416ND2F D432ND31 D432ND32 Number of Input Points 16 16 32 32 64 8 16 16 8 8 DC Current Sink Input DC Current Source Input AC Input

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

Installation, Wiring, and Specifications

D464ND2 D408NA D416NA D416NE3 F408NE3S D408ND3S

DL405 Output Module Chart

The following table lists the available DL405 output modules. Specifications begin after the input modules specifications.
DL405 Output Module Type D408TD1 F408TD1S Number of Output Points 8 8 16 16 32 32 32 64 8 16 8 8 8 16 DC Current Sink Output DC Current Source Output AC Output

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

Installation and Safety Guidelines

D416TD1 D416TD2 D432TD1 D432TD11 D432TD2 D464TD1 D408TA D416TA D408TR F408TRS1 F408TRS2 D416TR

233
Installation , Wiring, and Specifications

D408ND3S DC Input
Inputs per module Commons per module Input voltage range Peak voltage ON voltage level OFF voltage level Input impedance Input current @ 24 / 48 VDC Minimum ON current Maximum OFF current Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight
Points 8 6 4 2 0 0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)
+ + + + + + + + 0 C1 1 C2 2 C3 3 C4 4 C5 5 C6 6 C7 7 C0
0 1 2 3 4 5 6 7

D416ND2 DC Input
Inputs per module Commons per module Input voltage range Peak voltage ON voltage level OFF voltage level Input impedance Input current @ 12 / 24VDC Minimum ON current Maximum OFF current Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight
Points 16 12 8 4 0
0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)
1224VDC + CA 0 4 1 5 2 6 3 1224VDC + 7 CB 4 0 5 1 6 2 7 3 Current Flow
0 1 2 3

8 (sink/source) 8 (isolated) 2052.8VDC 52.8VDC >18 V < 7V 4.8 K W 5 mA / 10 mA 3.5 mA 1.5 mA 100 mA max 310 ms 312 ms Removable Logic Side 8.8 oz. (250 g)

16 (current sourcing) 2 (isolated) 10.226.4VDC 26.4VDC > 9.5VDC < 4.0 VDC 3.2 KW @ 12VDC 2.9 KW @24VDC

Installation, Wiring, and Specifications

3.8 mA / 8.3 mA 3.5 mA 1.5 mA 150 mA max 17 ms (2.3 typical) 212 ms (4.6 typical) Removable Logic Side 8.8 oz. (250 g)

Derating Chart
2448VDC
TB

Derating Chart
1224VDC
TB A 4 5 6 7 0 1 2 3 B 4 5 6 7

INPUT

INPUT

D408ND3S 2052.8VDC 412mA C0 0 C1 1 C2 2 C3 3 C4 4 C5 5 C6 6 C7 7 Common To LED 1224VDC +

D416ND2 10.226.4VDC 412mA CA 0 4 1 5 2 6 3 7 CB 4 0 5 1 6 2 7 Common To LED 3

Installation and Safety Guidelines

+ Optical Isolator

Input

Input

Optical Isolator

Current sourcing configuration shown

234
Installation, Wiring, and Specifications

D416ND2F DC Input
Inputs per module Commons per module Input voltage range Peak voltage ON voltage level OFF voltage level Input impedance 16 (current sourcing) 2 (isolated) 10.226.4VDC 26.4VDC > 9.5VDC < 4.0VDC 3.2 K W @ 12VDC 2.9 K W @ 24VDC 3.8 mA / 8.3 mA 3.5 mA 1.5 mA 150 mA max 1 ms 1 ms Removable Logic Side 8.8 oz. (250 g) Derating Chart
1224VDC
TB A B 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3

D416SIM Input Simulator


Inputs per module Base power required 5V Terminal type Status indicators Weight 8 or 16, selectable 150 mA Max None Logic Side 8.8 oz. (250 g)

Installation, Wiring, and Specifications

Input current @ 12 / 24 VDC Minimum ON current Maximum OFF current Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight
Points 16 12 8 4 0

INPUT

INPUT SIMULATOR
8 A 0 1 2 3 4 5 6 7 0 1 2 3 16 B 4 5 6 7

D416ND2F

D416SIM OFF A0 ON

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)

10.226.4VDC 412mA CA

Installation and Safety Guidelines

10.226.4 VDC

+ CA 0 4 1 5 2 6 3 7 CB 4 0 5 1 6 2 7 3 Current Flow

0 4 1 5 2 6 3 7 CB 4 0 5 1 6 2

8 or 16 input point selection switch is located on the back of the module Switch position is indicated by the LEDs above the input switches

A1 A2 A3 A4 A5 A6 A7 B0 B1 B2 B3 B4 B5 B6 B7

10.226.4 VDC

1224VDC +

7 Common To LED 3

Input

Optical Isolator

235
Installation , Wiring, and Specifications

D432ND31, 24VDC Input


Inputs per module Commons per module Input voltage range Peak voltage ON voltage level OFF voltage level Input impedance Input current Minimum ON current Maximum OFF current Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight
Points 32 28 24 20 16 12 8 4 0

D432ND32 512VDC Input


Inputs per module Commons per module Input voltage range Peak voltage ON voltage level OFF voltage level Input impedance Input current Minimum ON current Maximum OFF current Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight 32 (sink/source) 4 (isolated) 4.7513.2VDC (TTL, CMOS) 15VDC > 4 V (use pullup R for TTL in) <2V 2 KW @ 5V,1.6 KW @ 12V 3.1 mA @ 5V, 7.5 mA @ 12V

32 (sink/source) 4 (isolated) 2028VDC 30VDC > 19V < 10 V 4.8 K W 5 mA 3.5 mA 1.6 mA 150 mA max 210 ms 210 ms Removable, 40 pin conn. Logic Side 6.6 oz. (190 g)

Installation, Wiring, and Specifications

1.8 mA 0.8 mA 150 mA max 14 ms 14 ms Removable, 40 pin conn. Logic Side 6.6 oz. (190 g)

Derating Chart

24VDC
A/C 0 1 2 3 4 5 6 7 0 1 2 3

INPUT
A-B C-D B/D 4 5 6 7

D432ND31

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)


Current Flow User Supply +
A0 A4 A1 A5 A2 A6 A3 A7 COM I B0 B4 B1 B5 B2 B6 B3 B7 COM II C0 C4 C1 C5 C2 C6 C3 C7 COM III D0 D4 D1 D5 D2 D6 D3 D7 COM IV

Points 32 28 24 20 16 12 8 4 0

Derating Chart

512VDC
A/C 0 1 2 3 4 5 6 7 0 1 2 3

INPUT
A-B C-D B/D 4 5 6 7

D432ND32

DISPLAY SELECT

A-B C-D

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)


Current Flow User Supply +
A0 A4 A1 A5 A2 A6 A3 A7 COM I B0 B4 B1 B5 B2 B6 B3 B7 COM II C0 C4 C1 C5 C2 C6 C3 C7 COM III D0 D4 D1 D5 D2 D6 D3 D7 COM IV

DISPLAY SELECT

A-B C-D

2028VDC, CLASS2 4.25.8mA A0 A4 A1 A5 A2 A6 A3 A7 CI CI B0 B4 B1 B5 B2 B6 B3 B7 CII CII C0 C4 C1 C5 C2 C6 C3 C7 CIII CIII D0 D4 D1 D5 D2 D6 D3 D7 CIV CIV

4.7513.2VDC, CLASS2 3.18.2mA A0 A4 A1 A5 A2 A6 A3 A7 CI CI B0 B4 B1 B5 B2 B6 B3 B7 CII CII C0 C4 C1 C5 C2 C6 C3 C7 CIII CIII D0 D4 D1 D5 D2 D6 D3 D7 CIV CIV

Installation and Safety Guidelines

Current Flow User Supply +

Current Flow User Supply +

Current Flow

Current Flow

+ User Supply Current Flow

+ User Supply Current Flow

24 VDC Common + To LED

512 VDC +

Common To LED Optical (A0A7, Isolator

Use Display Select switch to view Optical(A0A7, B0B7) or (C0C7, D0D7)


Input Isolator

Current sinking config. shown

Input

Use Display Select switch to view B0B7) or (C0C7, D0D7) Current sinking config. shown

236
Installation, Wiring, and Specifications

D464ND2, 24 VDC Input Module


Module Location Inputs per module Commons per module Input voltage range Peak voltage ON voltage level Installation, Wiring, and Specifications OFF voltage level Input impedance Input current Minimum ON current Maximum OFF current
Points
64

CPU base only * 64 (current sourcing) 8 (isolated) 20 28 VDC 30 VDC > 20 V < 13 V 4.8 K W 5.0 mA @ 24 VDC 3.6 mA 2.6 mA

Base power required 5V 300 mA max External power required 24VDC "10%, (optional) 320mA max OFF to ON response ON to OFF response Terminal type 2.5 ms (typical) 5.0 ms (typical) 2, Removable 40 pin connectors (sold separately) Logic Side 7.8 oz. (220 g)

Status indicators Weight

Derating Chart

32

0 0 32 10 20 30 40 50 60 C 50 68 86 104 122 140F Ambient Temperature (C/F)

Since there are only 32 LEDs on the module, you can only display the status for 32 points at one time. In the A - B position the status of the first group of 32 input points (A0A17, B0B17) are displayed (connector 1). In the C - D position the status of the second group of 32 input points (C0C17, D0D17) are displayed (connector 2).
Wiring per 32pts. with 24V on Connector A0 A1 A2 A3 C1 A10 A11 A12 A13 C2 B0 B1 B2 B3 C3 B10 B11 B12 B13 C4 Connector Pins A4 A5 A6 A7 0V A14 A15 A16 A17 0V B4 B5 B6 B7 0V B14 B15 B16 B17 0V C0 C1 C2 C3 C5 C10 C11 C12 C13 C6 D0 D1 D2 D3 C7 D10 D11 D12 D13 C8 C4 C5 C6 C7 0V C14 C15 C16 C17 0V D4 D5 D6 D7 0V D14 D15 D16 D17 0V

24VDC
A/C 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3

INPUT
B/D 4 5 6 7 0 1 2 3 4 5 6 7

D464ND2

Wiring per 32pts. using EXT 24VDC Connector

DISPLAY SELECT

A-B

Current Flow

Current Flow

Internally Connected 0v

24VDC +
COM

C-D 2028VDC 4.25.8mA CLASS2 CN2 CN1

Current Flow

Current Flow

Installation and Safety Guidelines

24VDC

0v

COM

Current Flow Current Flow

0v

COM

+ 24VDC

Current Flow

0v

COM

Input

Input

To LED

To LED

EXT 24VDC
Optical Isolator
Common

24VDC +
Common

Optical Isolator

0V

0V

24VDC Ext +

* Module location this module placement is restricted to the local base on DL430/DL440 systems. It may also be placed in expansion bases in DL450 systems that are using the new (1) bases.

237
Installation , Wiring, and Specifications

D408NA 110220VAC Input


Inputs per module Commons per module Input voltage range Peak voltage AC frequency ON voltage level OFF voltage level Input impedance Input current Minimum ON current Maximum OFF current Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight
Points 8 6 4 2 0
0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)
110220 VAC CA 0 1 2 3 110220 VAC CB 4 5 6 7 4 5 6 3 2 0 1
0 1 2 3 4 5 6 7

D416NA 110VAC Input


Inputs per module Commons per module Input voltage range Peak voltage AC frequency ON voltage level OFF voltage level Input impedance Input current Minimum ON current Maximum OFF current Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight
Points 16 12 8 4 0
0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)
110 VAC 0 4 1 5 2 6 3 7 110 VAC CB 4 0 5 1 6 2 7 3 CA

8 2 (isolated) 80265VAC 265VAC 4763 Hz > 70V < 30 V 12 K W 8.5 mA @100VAC 20 mA @ 230VAC 5 mA 2 mA 100 mA max 530 ms 1050 ms Removable Logic Side 8.4 oz. (240 g)

16 2 (isolated) 80132VAC 132VAC 4763 Hz > 70V < 20 V 8KW 14.5 mA @120VAC 7 mA 2 mA 150 mA max 530 ms 1050 ms Removable Logic Side 9.5 oz. (270 g)

Installation, Wiring, and Specifications

Derating Chart
110220VAC
TB

Derating Chart
110VAC
TB A 0 1 2 3 4 5 6 7 0 1 2 3 B 4 5 6 7

INPUT

INPUT

D408NA 80265VAC 1030mA 50/60Hz CA

D416NA 80132VAC 8020mA 50/60Hz CA 0 4 1 5 2 6 3 7 CB 4 0 5 1 6 2

Installation and Safety Guidelines

CB

110 VAC 110220 VAC Common To LED 7

Common To LED

7 3

Input

Optical Isolator

Input

Optical Isolator

238
Installation, Wiring, and Specifications

D4-16NE3 1224VAC/DC Input


Inputs per module Commons per module Input voltage range Peak voltage AC frequency ON voltage level OFF voltage level Input impedance @ 12V/24V 16 (sink/source) 2 (isolated) 10.226.4VAC/VDC 37.5VAC/VDC 4763 Hz > 9.5V < 3.0V 3.2 K W / 2.9 K W 3.8 mA / 8.3 mA 4 mA 1.5 mA 150 mA max 540 ms 1050 ms Removable Logic Side 8.8 oz. (250 g) Derating Chart
1224VAC/DC
TB A 0 1 2 3 4 5 6 7 0 1 2 3 B 4 5 6 7

F4-08NE3S 90150VAC/DC In
Inputs per module Commons per module Input voltage range Peak voltage AC frequency ON voltage level OFF voltage level Input impedance Input current Minimum ON current Maximum OFF current Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight
Points 8 6 4 2 0
0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)
IN 1 IN 1 IN 0 IN 0 0 1 2 3

8 (sink/source) 8 (isolated) 90150 VAC/VDC 350 peak < 1ms 4763 Hz > 90 VDC / 75VAC < 60 VDC / 45VAC 22 K W 5.5 mA @ 120V 4 mA 2 mA 90 mA max 8 ms 15 ms Removable Logic Side 9 oz. (256 g)

Installation, Wiring, and Specifications

Input current @ 12V / 24V Minimum ON current Maximum OFF current Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight
Points 16 12 8 4 0

Derating Chart
90150VAC/DC
TB 4 5 6 7

INPUT

INPUT

D416NE3

F408NE3S 90150VDC 90150VAC


IN 0 IN 0

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)

Installation and Safety Guidelines

10.226.4V AC/DC 418mA 50/60 Hz/DC CA 0 4 1

CA 0 4 1 5 2 6 3 7 CB 4 0 5 1 6 2 7 3

IN 1 IN 1

5 2 6 3 7 CB 4 0 5 1 6 2 Common +
IN 5 IN 5 IN 7 IN 7 IN 3 IN 3

IN 2 IN 2 IN 3 IN 3 IN 2 IN 2

IN 4 IN 4 IN 6 IN 6

IN 5 IN 5 IN 7 IN 7

IN 4 IN 4 IN 6 IN 6

Common To LED + Optical Isolator

7 3 Optical Isolator

Input

Input

To LED

Current sourcing configuration shown

239
Installation , Wiring, and Specifications

D408TD1 1224 VDC Output


Outputs per module Commons per module Operating voltage Output type Peak voltage ON voltage drop Max current (resistive) Max leakage current Max inrush current Minimum load Base power required 5V External DC required OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses (non-replaceable)
Points 8 6 4 2 0
0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)
1224 VDC +
L L L L

F4-08TD1S 24150 VDC Isolated Out


Outputs per module Commons per module Operating voltage Output type Peak voltage ON voltage drop Max current Max leakage current Max inrush current Minimum load Base power required 5V External DC required OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses (non-replaceable)
OUTPUT
FU

8 (current sinking) 2 internally connected 10.226.4VDC NMOS FET (open drain) 40VDC 0.5VDC @ 2A, 0.2 VDC @1A 2A / point, 5A / common 0.1mA @ 40VDC 12A for 10 ms, 6A for 100 ms 0.2mA 150mA max 24VDC "10%@35 mA 1 ms 1 ms Removable Logic Side 8.4 oz. (240 g) 1 (7A) per common
1224VDC

8 (current sinking) 4 (isolated) 24150VDC MOS FET 200 VDC, <1mS 1VDC @ 2A 2A / point, 4A / common 5 mA
30A /1ms, 6A / 10ms, 3A / 100ms

Installation, Wiring, and Specifications

N/A 295 mA max None 25 ms 25 ms Removable Logic Side 10 oz. (282 g) 1 (3A) per output
24150VDC OUTPUT
OPEN FUSE 4 5 6 7 0 1 2 3 4 5 6 7

Derating Chart
Output Current 1.25A/point Output Current 2A/point (5A/common)
0 1 2 3 TB 4 5 6 7 24V

Points 8 6 4 2 0

Derating Chart
Output Current 1.5A/point
TB 0 1 2 3

Output Current 2.0A/point Output Current 4.0A/point

D408TD1 10.226.4VDC 0.2mA2A

F408TD1S 24150VDC 2A

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)

Installation and Safety Guidelines

C 0
L

C 0 1

+ + + +

L L

OUT 0 OUT 1 SUP B

SUP A COM 0 COM 1 OUT 2 OUT 3 SUP C COM 4 COM 5 OUT 6 OUT 7

OUT 0 OUT 1 SUP B COM 2 COM 3 OUT 4 OUT 5 SUP D COM 6 COM 7

SUP A COM 0 COM 1 OUT 2 OUT 3 SUP C COM 4 COM 5 OUT 6 OUT 7

1 2 3 C 4 2 3 Internally connected
L L L

COM 2 COM 3 OUT 4 OUT 5 SUP D

1224 VDC +
L

L L

L L L

5 6 7

4 5

L L

COM 6 COM 7

To Commons

+ 24VDC +24V To LED

6 7 +

Supply Common

+ 24VDC
L

Output C Optical Isolator Common 24VDC Output


L

+ 1224 VDC

Optical Isolator

To LED

3A

240
Installation, Wiring, and Specifications

D4-16TD1 5-24 VDC Output


Outputs per module Commons per module Operating voltage / peak Output type ON voltage drop Max current (resistive) Max leakage current 16 (current sinking) 2 internally connected 4.526.4VDC, 40 VDC Peak NPN Open collector 0.5V @ 0.5A, 0.2V @ 0.1A 0.5A / point, 3A / common 0.1mA @ 40VDC 2A for 10 ms, 1A for 100 ms 0.2mA 200mA max 24VDC "10% @125mA 0.5 ms 0.5 ms Removable Logic Side 9.5 oz. (270 g) 1 (5A) per common
524VDC OUTPUT
24V A 0 1 2 3 4 5 6 7 0 1 2 3 B 4 5 6 7 FU

D4-16TD2, 1224 VDC Output


Outputs per module Commons per module Operating voltage / peak Output type ON voltage drop Max current (resistive) Max leakage current Max inrush current Minimum load Base power required 5V External DC required OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses (non-replaceable)
Points 16 12 8 4 0

16 (current sourcing) 2 (isolated) 10.226.4 VDC, 40 VDC Peak NPN Emitter Follower 1.5 VDC @ 0.5A 0.5A / point, 3A / common @ 50 C, 2.5A /common @ 60C 0.1mA @ 40 VDC 2A for 10 ms, 1A for 100 ms 0.2mA 400mA max None 1 ms 1 ms Removable Logic Side 9.8 oz. (280 g) 1 (5A) per common
0.3A/point
1224VDC OUTPUT
FU A 0 1 2 3 4 5 6 7 0 1 2 3 B 4 5 6 7

Installation, Wiring, and Specifications

Max inrush current Minimum load Base power required 5V External DC required OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses (non-replaceable)
Points 16 12 8 4 0

Derating Chart
Output Current 0.35A/point Output Current 0.5A/point (3A/common)
TB

Derating Chart
Output Current 0.35A/point Output Current 0.5A/point (3A/common)

2.5A/common

TB

D416TD1

D416TD2

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F) Internally

5V26.4VDC 0.2mA0.5A CA
L L

Installation and Safety Guidelines

connected

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)


1224 VDC
L L L L L L L

10.226.4VDC 0.5A CA CA
L L

524 VDC +
L

0
L L L L L L

CA 4 1 5 2 6 3 CB 0 5
L L

0 4 1 5 2 6

+ 0

0 4 1 5 2 6 3

4 1 5 2 6 3 7 CB 4 0 5 1 6 2 7 3

524 VDC +
L

7 4

3 7 CB
L L

1224 VDC

L L

L L L L L L L

7 CB
L L

1 6 2 7 3

L L L L

4 0 5 1

4 0 5 1 6

24VDC + +
L

6 2 7 Optical Isolator 3 + To LED + 24VDC 1224 VDC To LED


L

24VDC

24V Output

Common

Optical Isolator

2 7 3

+ 24 VDC Common

Output

241
Installation , Wiring, and Specifications

D432TD1, 524VDC Output


Outputs per module Commons per module Operating voltage Output type Peak voltage ON voltage drop Max current (resistive) Max leakage current Max inrush current Minimum load Base power required 5V External DC required OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses
Points 32 28 24 20 16 12 8 4 0 0 32

D432TD11, 515VDC Output


Outputs per module Commons per module Operating voltage Output type Peak voltage ON voltage drop Max current (resistive) Max leakage current Max inrush current Minimum load Base power req., 5V External DC required OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses
Points

32 (current sinking) 4 (isolated) 4.7526.4 VDC NPN Open Collector 36 VDC 0.6 VDC @ 0.2A 0.2A / point, 1.6A / common 0.1mA @ 36 VDC 1A for 10 ms, 0.5A for 100 ms 0.1mA 250mA max 24VDC "10%, 140mA max 0.1 ms 0.1 ms Removable Logic Side 6.7 oz. (190 g) None

32 (current sinking) 4 (isolated) 515 VDC NPN Open Collector (w / pullup) 16.5 VDC 0.4 VDC @ 0.1A 0.09A/pt, 0.72A/com, 2.88A/ mod. 0.01mA @ 16.5 VDC

Installation, Wiring, and Specifications

0.5A for 10ms, 0.2A for 100ms 0.1mA 250mA max 515VDC "10%, 700mA max 0.1 ms 0.1 ms Removable Logic Side 6.7 oz. (190 g) None

Derating Chart
524VDC OUTPUT
A-B C-D B/D 0 1 2 3 4 5 6 7

Derating Chart
Output current 0.06A / point
515VDC
A/C 0 1 2 3 4 5 6 7 0 1 2 3

Output current 0.1A / point


0 1 2 3

A/C 4 5 6 7

Output current 0.2A / point

D432TD1

32 28 24 20 16 12 8 4 0 0 32

OUTPUT
A-B C-D B/D 4 5 6 7

Output current 0.015A / point Output current 0.09A / point


10 20 30 40 50 60C 50 68 86 104 122 140F Ambient Temperature (C/F) Current Flow
L L L L L L

D432TD11

10 20 30 40 50 60C 50 68 86 104 122 140F Ambient Temperature (C/F) Current Flow A0 L


L L L L L

DISPLAY SELECT

A-B C-D

DISPLAY SELECT

A-B

Installation and Safety Guidelines

C-D
A0 A4 A1 A5 A2 A6 A3 A7 COM I VI B0 B4 B1 B5 B2 B6 B3 B7 COM II V II C0 C4 C1 C5 C2 C6 C3 C7 COM III V III D0 D4 D1 D5 D2 D6 D3 D7 COM IV V IV

L L

24VDC

+
L L L L L L

24 VDC

L L

L L L L L L L

24 VDC

L L L L L L L

24 VDC

A4 A1 A5 A2 A6 A3 A7 COM I VI B0 B4 B1 B5 B2 B6 B3 B7 COM II V II C0 C4 C1 C5 C2 C6 C3 C7 COM III V III D0 D4 D1 D5 D2 D6 D3 D7 COM IV V IV

526VDC,CLASS 2 0.2A A0 A1 A2 A3 CI B0 B1 B2 B3 CII C0 C1 C2 C3 CIII D0 D1 D2 D3 CIV A4 A5 A6 A7 VI B4 B5 B6 B7 VII C4 C5 C6 C7 VIII D4 D5 D6 D7 VIV 515 + VDC Common

515VDC, CLASS 2 0.09A A0 A1 A2 A3 CI B0 B1 B2 B3 CII C0 C1 C2 C3 CIII D0 D1 D2 D3 CIV A4 A5 A6 A7 VI B4 B5 B6 B7 VII C4 C5 C6 C7 VIII D4 D5 D6 D7 VIV

L L

515VDC

+
L L L L L L

L L

515VDC

+
L L L L L L L

515VDC

L L L L L L L L

515VDC

V+
L

V+ 1.5K
L

Output

Out

Optical Isolator

+ 24 VDC Common

To LED Optical Isolator

To LED

242
Installation, Wiring, and Specifications

D432TD2, 1224 VDC Output Module


Outputs per module Commons per module Operating voltage Output type Peak voltage ON voltage drop Max current (resistive) 32 (current sourcing) 4 (isolated) 10.826.4 VDC PNP Open Collector 30 VDC 0.6 VDC @ 0.2A 0.2A / point 1.0A / common 4.0A / module 0.01mA @ 26.4 VDC 500 mA for 10 ms 0.2mA 350mA max OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses < 0.2 ms < 0.2 ms Removable Logic Side 6.7 oz. (190 g) None External DC required 10.826.4VDC 1A / common including load

Installation, Wiring, and Specifications

Max leakage current Max inrush current Minimum load Base power required 5V
Current Flow

L L L L L L L L

1224VDC +

L L L L L L L L

1224VDC

+
L L L L L L L L

1224VDC +

L L L L L L L L

1224VDC +

A0 A4 A1 A5 A2 A6 A3 A7 COM I VI B0 B4 B1 B5 B2 B6 B3 B7 COM II V II C0 C4 C1 C5 C2 C6 C3 C7 COM III V III D0 D4 D1 D5 D2 D6 D3 D7 COM IV V IV

1224VDC
A/C 0 1 2 3 4 5 6 7 0 1 2 3

OUTPUT
A-B C-D B/D 4 5 6 7

Derating Chart for D432TD2


Points 32 28 24 20 16 12 8 4 0 0 32

D432TD2

Output current 0.2 A /pt (1A /common)

DISPLAY SELECT

A-B C-D

1126VDC, CLASS2 0.2A A0 A1 A2 A3 CI B0 B1 B2 B3 CII C0 C1 C2 C3 CIII D0 D1 D2 D3 CIV A4 A5 A6 A7 VI B4 B5 B6 B7 VII C4 C5 C6 C7 VIII D4 D5 D6 D7 VIV

Installation and Safety Guidelines

10 20 30 40 50 60C 50 68 86 104 122 140F Ambient Temperature (C/F)

V+

1224 VDC Output


L

Optical Isolator

To LED

Common

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 (A0A7, B0B7) is displayed. In the C - D position the status of the second group of 16 output points (C0C7, D0D7) is displayed.

243
Installation , Wiring, and Specifications

D464TD1, TTL/CMOS/524 VDC Output Module


Module Location Outputs per module Commons per module Operating voltage Output type CPU base only * 64 (current sinking) 8 (isolated) 4.7526.5 VDC NPN Open Collector Minimum load 0.1mA Base power required 5V 800mA max

External DC required

Peak voltage ON voltage drop Max current (resistive)

36 VDC 0.6 VDC @ 0.1A 0.1A / point 1.0A / common 8.0A / module 0.01mA @ 36 VDC 1A for 1 ms 700mA for 100 ms

OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses

Max leakage current Max inrush current


Derating Chart

24VDC "10%, (800mA + 50mA per common) 7.0A total max < 0.1 ms < 0.2 ms 2, Removable 40-pin connectors (sold sep.) Logic Side 7.4 oz. (210 g) None

Installation, Wiring, and Specifications

Points 64 56 48 40 32 24 16 8 0 0 32

Output current 0.1A / point

Only 32 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 32 output points (A0A17, B0B17) are displayed (connector 1). In the C - D position the status of the second group of 32 output points (C0C17, D0D17) are displayed (connector 2). * Module location this module placement is restricted to the local base on DL430/DL440 systems. It may also be placed in expansion bases in DL450 systems that are using the new (1) bases.

524VDC
A/C 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3

OUTPUT
B/D 4 5 6 7 0 1 2 3 4 5 6 7

D464TD1

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

60 C 140 F Wiring per 32pts. with 24V on Connector


L L L

DISPLAY SELECT

A-B C-D

Wiring per 32pts. using EXT 24VDC Connector


L L

Wiring per 32pts. using EXT 24VDC Connector and 526VDC Load Supply
L L L

Connector Pins
A0 A1 Internally Connected +V A2 A3 C1 A10 A11 A12 A13 A4 A5 A6 A7 V1 A14 A15 A16 A17 V2 B4 B5 B6 B7 V3 B14 B15 B16 B17 V4 C0 C1 C2 C3 C5 C10 C11 C12 C13 C6 D0 D1 D2 D3 C7 D10 D11 D12 D13 C8 C4 C5 C6 C7 V5 C14 C15 C16 C17 V6 D4 D5 D6 D7 V7 D14 D15 D16 D17 V8

526V 0.1A CN1

CLASS2 CN2

Installation and Safety Guidelines

Current Flow

L L L L L L

Current Flow Internally Connected +V 24VDC


+

L L L L L

Current Flow Internally Connected +V


+ 526VDC

L L L L L

COM
L

COM
L

L L L L L L L L L

L L L L L L L L L

Current Flow

Current Flow 526VDC +V


+

L L L L

Current Flow
COM

+V
L L L

526VDC

COM

+V
L L L

C2 B0 B1 B2 B3 C3 B10 B11 B12 B13

L L L

Current Flow

L L L L L

Current Flow

L L L L L

Current Flow

L L L L L

+V
L L L L L L L L L L L

COM
L

+V 526VDC +

L L L L L L L L

COM

+V

526VDC +

L L L L

Current Flow

+V

COM

+V

COM

+V

C4

Optical Isolator L

Optical Isolator L

Optical Isolator

L Output + To LED 24VDC Common

Output + To LED Common 24VDC Ext + 526VDC

Output

EXT 24VDC
To LED

Common 24VDC Ext + +

24VDC Ext + +

244
Installation, Wiring, and Specifications

D408TA, 18220VAC Output D416TA, 18220VAC Output


Outputs per module Commons per module Operating voltage Output type Peak voltage AC frequency ON voltage drop Max current 8 2 (isolated) 15265VAC SSR (triac) 265VAC 4763 Hz 1.5VAC @ 2A 2A / point, 5A / com. @ 30C 2A / common @ 60 C 5mA @ 265VAC 30A for 10 ms, 10A for 100 ms 10 mA 250 mA max 1 ms 1 ms +1/2 AC cycle Removable Logic Side 11.6 oz. (330 g) 1 (8A) per common
18220VAC
TB

Outputs per module Commons per module Operating voltage Output type Peak voltage AC frequency ON voltage drop Max current Max leakage current Max inrush current Minimum load Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses (non-replaceable)
OUTPUT
FU 4 5 6 7

16 2 (isolated) 15265VAC SSR (triac) 265VAC 4763 Hz 1.5 VAC @ 0.5A 0.5A / pt, 3A / common @ 45 C 2A / common @ 60 C 4mA @ 265VAC 15A for 10 ms, 10A for 100 ms 10 mA 450 mA max 1 ms 1 ms +1/2 AC cycle Removable Logic Side 12.2 oz. (350 g) 1 (5A) per common
18220VAC
TB

Installation, Wiring, and Specifications

Max leakage current Max inrush current Minimum load Base power required 5V OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses (non-replaceable)
Points 8 6 4 2 0

Derating Chart
Output Current 0.5A/point

Points 16 12 8 4

Derating Chart
Output Current 0.35A/point Output Current 0.5A/point 3A/common Output Current 0.25A/point (2A/common)

OUTPUT
FU B

Output Current 1A/point

A 0 1 2 3 4 5 6 7 0 1 2 3

0 1 2 3

4 5 6 7

Output Current 2A/point (5A/common)


0 32

(2A/common)

D408TA 15265VAC 10mA2A 50/60Hz CA 0 1 2 3 CB

D416TA 15265VAC 10mA0.5A 50/60Hz CA


L

0 0 32 10 20 30 40 50 60C 50 68 86 104 122 140F Ambient Temperature (C/F) CA


L L L L L

Installation and Safety Guidelines

10 20 30 40 50 60C 50 68 86 104 122 140F Ambient Temperature (C/F) CA


L L L L

0 4 1 5

18220 VAC

18220 VAC

0 1 2 3 CB

0 4 1 5 2
L

2 6 3 7

6 3 7 CB 4 0 5 1 6 2 7 3
L L

L L

18220 VAC
L L L L L

18220 VAC
L L L L

CB 4 0 5 1 6

4 5 6 7
L

4
L

L L

5 6

2 Output
L

Output
L

Optical Isolator

Optical Isolator

7 3

18220 VAC

Common

To LED

18220 VAC

Common

To LED

245
Installation , Wiring, and Specifications

D408TR, Relay Output


Outputs per module Commons per module Operating voltage Output type Peak voltage AC frequency Max current (resistive) Max leakage current Max inrush current Minimum load Base power required 5V External DC required OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses (non-replaceable) 8 relays 2 (isolated) 530VDC / 5250VAC Form A (SPSTNO) 30VDC / 256VAC 4763 Hz 2A / point, 5A / common 0.1mA @ 265VAC 2A 5mA 550mA max None 12 ms 12 ms Removable Logic Side 9.1 oz. (260 g) 1 (8A) per common
RELAY
TB 0 1 2 3 4 5 6 7

F408TRS1, Relay Output


Outputs per module Commons per module 8 relays 8 (isolated) Operating voltage:1230VDC, 12125VAC, 125250VAC* Output type: 4, Form C (SPDT), 4, Form A (SPSTNO) Peak voltage AC frequency Max current (resistive) Max leakage current Max inrush current Minimum load Base power required 5V External DC required OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses (non-replaceable)
OUTPUT
FU

30VDC / 250VAC @10A 4763 Hz 10A / point, 40A / module 0.1mA @ 265VAC

Installation, Wiring, and Specifications

10A 100mA @12 VDC 575mA max None 7 ms 9 ms Removable Logic Side 13.2 oz. (374 g) 1 (10A/125V) per common
RELAY OUTPUT

Typical Relay Life (Operations)


Maximum Resistive Operating Voltage or Inductive Inrush Load Current 30VDC 125VAC 250VAC 2A resistive 2A inductive 0.5A resistive 0.5A inductive
Points CA
L L L L

Typical Relay Life (Operations)


Maximum Resistive Operating Voltage or Inductive Inrush Load Current 30VDC 125VAC 250VAC 1/4 HP 10.0A 5.0A 3.0A 0.5A 50K 200K 325K >50M
Points 8 6
L TB 0 1 2 3 4 5 6 7

100K 100K 800K 300K

300K 80K 1M 300K

200K 60K 800K 200K

D408TR 5250VAC 2A 50/60Hz 530VDC 5mA2A CA + + +


L

25K 50K 100K 125K

TB

50K

F408TRS1
12250VAC 10A 50/60Hz 1230VDC 10mA10A

Derating Chart
Output Current 1.25A/point Output Current 2A/point (5A/common)

Derating Chart
Output Current 5A/point 8A/point 10A/point

8 6 4 2 0

0 1 2 3 CB 4
L

0C
L L L L L L L L

0 NO 1 C 1 NC 2 NO 3 C 3 NC 4 NO 5 NO 6 NO

0 C 0 NC 1 N0 2 C 2 NC 3 NO 4 C 5 C 6 C 7 C

Installation and Safety Guidelines

0 + 1 2 3 CB + +

0 NO 1 C 1 NC 2 NO 3 C 3 NC 4 NO 5 NO 6 NO 7 NO

4 2 0

0 NC 1 NO 2 C 2 NC 3 NO 4 C 5 C 6 C 7 C

+
L

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140 F Ambient Temperature (C/F)

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140F Ambient Temperature (C/F)

5 6

L L

+
L

4 5 6

Maximum DC voltage rating is 120 VDC @ 0.5A, 30,000 cycles typical. Motor starters up to and including NEMA size 3 can be used with this module. 10A

Common

Common To LED

7 NO
L

7 NO

NC
L

Output

RELAY

246
Installation, Wiring, and Specifications

F408TRS2, Relay Output


Outputs per module Commons per module Operating voltage Peak voltage AC frequency Max current (resistive) Max inrush current 8 relays 8 (isolated) 1230VDC, 12250VAC 30VDC / 250VAC @5A 4763 Hz 5A / point, 40A / module 10A 100mA @12 VDC 575mA max None 7 ms 9 ms Removable Logic Side 13.8 oz. (390 g) 1 (10A, 250V) per common 19379K10A Wickman Typical Relay Life (Operations)
RELAY OUTPUT

D416TR, Relay Output


Outputs per module Commons per module Operating voltage Output type Peak voltage AC frequency Max current (resistive) Max leakage current Max inrush current Minimum load Base power required 5V External DC required OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses (non-replaceable) 16 relays 2 (isolated) 530VDC / 5250VAC Form A (SPSTNO) 30VDC / 256VAC 4763 Hz 1A / point, 5A / common 0.1mA @ 265VAC 4A 5mA 1000mA max None 10 ms 10 ms Removable Logic Side 10.9 oz. (310 g) 1 (8A) per common
RELAY
TB A 0 1 2 3 4 5 6 7 0 1 2 3 B 4 5 6 7

Output type: 4 Form C (SPDT), 4 Form A (SPSTNO)

Installation, Wiring, and Specifications

Minimum load Base power required 5V External DC required OFF to ON response ON to OFF response Terminal type Status indicators Weight Fuses, (user replaceable)

Typical Relay Life (Operations)


TB 0 1 2 3 4 5 6 7

Maximum Resistive Operating Voltage or Inductive Inrush Load Current 28VDC 120VAC 240VAC 5.0A 3.0A .05A 200K 325K >50M
Points 8 + + +
L L L L L L L L L

Maximum Resistive Operating Voltage or Inductive Inrush Load Current 30VDC 125VAC 250VAC 1A resistive 1A inductive 0.5A resistive 0.5A inductive >1M 400K >2M >1M
Points 16 12
CA
L L L L L L L

OUTPUT
FU

100K 125K

50K

FU TB

F408TRS2
12250VAC 5A 50/60Hz 1230VDC 10mA5A

Derating Chart
Output Current 5A/point (40A/module)

500K 200K 800K 300K

300K 100K 500K 200K

D416TR 5250VAC 1A 50/60Hz 530VDC 5mA1A CA


L

Derating Chart
Output Current 0.6A/point Output Current 1A/point (5A/common)

Installation and Safety Guidelines

0C 0 NO 1 C 1 NC 2 NO 3 C 3 NC 4 NO 5 NO 6 NO 7 NO 0 NC 1 NO 2 C 2 NC 3 NO 4 C 5 C 6 C 7 C

6 4 2 0

+ + + +

0 NO 1 C

0 C 0 NC 1 NO 2 C 2 NC 3 NO 4 C 5 C 6 C 0 4 1 5 2 6 3
L + L L L L L L L L

0 4 1 5 2 6 3 7 CB

8 4 0

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140F Ambient Temperature (C/F)

1 NC 2 NO 3 C 3 NC 4 NO 5 NO 6 NO 7 NO

+
L

Maximum DC voltage rating is 120 VDC @ 0.5A, 30,000 cycles typical. Motor starters up to and including NEMA size 3 can be used with this module.

7 CB 4 0 5 1 6 2 7 3

0 10 20 30 40 50 60 C 32 50 68 86 104 122 140F Ambient Temperature (C/F)

L L

4 0 5 1 6 2 7

Common 5A NO
L L

NC Common 5A NO

Sample Relay Output Circuit (1 of 4)

Common
7 C

3 To LED

Sample Relay Output Circuit (1 of 4)

Output

RELAY

247
Installation , Wiring, and Specifications

Glossary of Specification Terms


Inputs or Outputs Per Module Commons Per Module 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-linear, 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.

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

Installation, Wiring, and Specifications

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 kpower from the baserequired 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 modules 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. 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.

Installation and Safety Guidelines

Base Power Required OFF to ON Response ON to OFF Response Status Indicators Terminal Type Weight Fuses