Automation Direct DL06 D0-06DD1 Replacement Guide

Port characteristics

Port physical interface protocol supports role baud rate

Port 1 6-pin modular (RJ12) K-sequence, DirectNET, Modbus RTU only fixed from station 9600

Port 2 15 pin HD sub (configurable as RS-232/422/485) K-sequence (slave), DirectNET (master/slave), Modbus RTU (master/slave), ASCII input/output can be set to 300-38400

Replace key points:

Modbus RTU: When the original system uses Modbus RTU communication, DL06 Port 2 can serve as a master or slave, directly replacing the original controller. Support function codes 01/02/03/04/05/06/15/16 and simplify programming through MRX/MWX instructions.

ASCII communication: For barcode scanners, serial printers, or custom protocol devices, DL06 provides instructions such as AIN (ASCII input) and PRIMTV (print V memory ASCII string) without the need for additional converters.

Multi branch network: If multiple slave devices need to be connected, RS-485 mode of Port 2 (only supports Modbus RTU) can be used, with a maximum distance of 1200 meters.

Ethernet Expansion

When it is necessary to connect to the factory Ethernet or communicate with HMI at high speed, H0-ECOM100 module (10/100 Mbit) can be selected. This module supports Modbus TCP protocol and can directly exchange data with the upper computer or SCADA system. When replacing discontinued Woodward Ethernet modules, pay attention to remapping IP addresses and port numbers.

Software programming and logic porting

Use DirectSOFT programming software (free version limited to 100 word programs, full version unlimited). DL06 supports RLL (Relay Ladder Diagram) and RLLPLUS (Staged Flow Diagram), with a rich instruction set of 229 types, including floating-point operations PID、 Drum sequence, etc.

1. Migrating logic from old controllers

Assuming the original Woodward module is programmed using ladder diagrams or C language, the migration steps are as follows:

Map the I/O address to the X (input) and Y (output) of DL06.

Replace time relays and counters with TMR and CNT commands, paying attention to resolution (1ms/10ms/100ms optional).

The original PID circuit can be implemented using PID instructions, and Kp, Ti, and Td parameters need to be tuned.

The CNT or HSC function block is used for high-speed counting input (5kHz), and the DL06 supports a maximum of 7kHz.

2. Quick check of key instructions

Command function replacement scenario

HSC high-speed counter replaces Woodward dedicated counting module

PLS pulse output (Y0/Y1) stepper motor or servo pulse control

MRX/MWX Modbus read-write communication with the original device

AIN asynchronous serial ASCII input reading barcode/weighing instrument

PRIMTV prints V memory string and outputs alarm information to the display screen

CMPV V memory block comparison detects string changes

3. Online debugging and mandatory testing

DL06 supports Run time editing, which allows program modification without stopping the CPU, and supports the override function to force I/O to be set/reset. This is extremely useful for troubleshooting, especially in verifying external wiring during the initial replacement phase.

Power Budget: A 'Checklist' to Prevent System Overload

DL06 has 4 expansion slots that can be equipped with I/O or communication modules. Power budgeting is necessary, otherwise it may result in frequent CPU restarts or module failure.

power supply capacity

Model 5VDC maximum output 24VDC auxiliary output

D0-06DD1 1500mA (if using 24VDC auxiliary)

2000mA (without 24VDC auxiliary) 300mA (when 5V load ≤ 1500mA)

200mA (when 5V load ≥ 1500mA)

Base self consumption

D0-06DD1 itself consumes 600mA (5V) and 280mA (24V, used for output driving).

Calculation example

If configured as follows:

D0-06DD1

D0-16ND3 (16 point input module) → 35mA 5V

D0-10TD1 (10 point output module) → 150mA 5V

D0-08TR (8-point relay module) → 280mA 5V

F0-4AD2DA-1 (4AI/2AO analog) → 100mA 5V

D0-06LCD display screen → 50mA 5V

Total consumption 5V=600+35+150+280+100+50=1215mA

Total consumption 24V=280mA (only base output driver)

If choosing to use 24V auxiliary (option A): residual 5V=1500-1215=285mA, residual 24V=300-280=20mA, with margin and safety.

If the budget is not properly budgeted, difficult faults such as "PLC random shutdown" or "module unrecognizable" may occur.

Optional LCD display screen: on-site diagnosis and operation panel

D0-06LCD can be directly inserted into the front of DL06 (the original plastic cover needs to be removed first), providing:

16 characters x 2 lines backlit LCD.

7 function keys, used for browsing menus, modifying V memory values, and forcing bit operations.

Buzzer button feedback.

Two level password protection.

Replacement value: When the original system is equipped with a Woodward control panel or Honeywell local display, D0-06LCD can achieve the same monitoring function at a lower cost. Only one LCD command is needed to configure the display content, no additional programming is required.

Common troubleshooting and diagnosis

Problem 1: PLC cannot start, PWR indicator light is off

Reason: AC power supply missing or fuse blown; The internal switch power supply is damaged.

Solution: The measured voltage between L-N should be 100-240VAC; Check the external circuit breaker. If the voltage is normal but still does not light up, the CPU needs to be replaced.