The DL06 can pass an analog input value to an analog output through PLC data memory, but a direct copy is correct only when the card ranges and the PWM motor driver's command input are compatible. The driver’s 24 VDC supply is separate from its analog command signal; verify the input terminals and allowed signal range before connecting anything.
Confirm the driver command range before wiring
The motor driver is presently controlled by a 10 kΩ potentiometer, and the desired command signal is described as 0–3 V. Treat that as the required command range only after checking the driver documentation or measuring the existing pot wiper at its signal terminal across the full adjustment travel. The stated 24 VDC refers to the driver, not necessarily to the analog command input.
- Identify the driver’s analog command input, signal common, and permitted voltage range.
- Identify the potentiometer’s reference, wiper, and common connections. Do not connect the wiper to a PLC output.
- Check the analog option card’s supported input and output signal ranges and configure the channels accordingly.
Do not connect the PLC output and pot wiper together as a quick way to select control. That can make the two sources electrically drive one another. Plan source selection with a suitable switching arrangement or with a PLC input/output strategy that keeps the sources isolated and the driver within its specified command range.
Check: Record the driver command range, pot wiper range, and configured analog channel ranges before proceeding. Stop if the driver input range or terminal function is unknown.
Configure the card and locate its data words
After configuring the analog option card, determine which V-memory word receives the input conversion and which word supplies the output command. The example addresses V2000 and V3000 are illustrative; use the locations assigned in the actual card configuration, not those addresses by default.
The card converts an input voltage to a numeric value in memory, and the output channel converts the value written to its assigned word back into voltage. The discussion gives 0–4095 (BCD) as the normal low-to-high representation for a 0–10 V input or output. That range is not a substitute for checking the actual card setup, channel range, and data format.
Confirm that both channels are enabled, the input and output words are distinct and correctly assigned, and the data representation expected by the card matches the value used by the ladder logic.
Check: With the card configuration available, identify the actual input and output V-memory words and verify the channel ranges and format. Do not download a program using example addresses until those assignments match.
Test the input and output scaling separately
Before copying values, test each side independently. Apply a known, safe input voltage within the card’s configured input range and monitor its input word in DirectSOFT. Then write a conservative test value to the output word and measure the output at the card terminals with a suitable meter. Keep the driver command disconnected during the output test if the test voltage could command unintended motor operation.
For example, if both channels are configured for 0–10 V and use the same 0–4095 representation, an input of 3 V corresponds to about 1229 counts: 3 / 10 × 4095 ≈ 1229. Writing that count to an identically ranged output should produce about 3 V. This is a labeled calculation for matched 0–10 V ranges, not a universal card value. If the ranges differ, direct copying will not preserve voltage; scale the value using the configured ranges and verify it by measurement.
A quick fix of copying a displayed word without checking the analog output can fail because the displayed count may be correct while the output channel uses a different range or format. A quick fix of forcing the output word can also leave a motor command active; disconnect or safely inhibit the drive as the equipment procedure allows while testing.
Check: Confirm the measured card output matches the intended voltage for a test value before connecting it to the driver.
Copy the input word to the output word
For a transparent pass-through, load the configured input word and write the value to the configured output word. The example uses V2000 for input and V3000 for output:
SP1 LD V2000
OUT V3000SP1 is described as an always-on special contact. It provides a continuously true rung condition so the copy executes repeatedly while the PLC runs. Use the actual configured V-memory locations in place of the example words. Confirm that the instructions are accepted by the DirectSOFT programming environment for the DL06 and that the rung is placed in the intended program location.
This pass-through is appropriate only when the input and output values represent the same engineering voltage. If one channel is scaled differently, add a scaling operation rather than copying unchanged raw data. A raw data copy is not a way to change the output’s configured range.
Check: Monitor both words online while varying the input. The output word should track the input word, and the measured output voltage should track the expected command voltage.
Select between PLC and potentiometer control safely
The stated requirement includes occasional pot control for finer adjustment. A pass-through rung alone does not select between the pot and PLC; it simply transfers the value in the analog input word to the output word. Decide explicitly how the two command sources will be selected.
- If the pot is connected to the card’s analog input, the input word can represent the pot position, and the PLC can pass that value to the output.
- If the PLC is also expected to generate an independent command, provide a separate command value and a deliberate selection condition in the program, using the available hardware and configured channels.
- If the driver must switch electrically between pot and PLC output, use an appropriate source-selection device or circuit designed for the signal and common arrangement. Do not parallel two active voltage sources.
The equipment description does not specify whether the pot will connect to a PLC input, remain wired to the driver, or be selected by separate hardware. Resolve that wiring decision before commissioning; it determines whether a single input-to-output copy meets the need.
Check: With the motor prevented from starting unexpectedly, test each selected source separately and confirm the unselected source cannot affect the driver command.
Commission the command path and prove the result
- Verify the card’s configured ranges, memory assignments, and wiring against the card and driver documentation.
- With the motor safely inhibited, enable the pass-through and observe the input word, output word, and measured output voltage together.
- Apply the pot through its usable travel and confirm that the output voltage follows without exceeding the driver’s command range.
- Test the PLC command and source-selection behavior independently, then confirm that changing selection does not cause an unexpected command step.
- Reconnect or enable the motor system under the machine’s approved commissioning procedure and verify that the motor response matches the command at low-risk operating conditions.
If the input word changes but the output does not, check the output word assignment, rung execution, channel configuration, and wiring. If the output word tracks but voltage does not, check the output channel range, format, terminal wiring, and common. If the voltage is correct at the card but wrong at the driver, inspect the interconnection and driver input configuration.
Check: Complete a full-range test of each command source and confirm the PLC word, measured analog voltage, and motor response agree. Do not return the machine to automatic operation until source selection and command limits behave as intended.
FAQ
How do I copy a DL06 analog input to an analog output?
Configure the card, identify its assigned input and output V-memory words, then load the input word and write it to the output word. The example uses LD V2000 and OUT V3000; substitute the addresses assigned in your configuration.
How do I keep a DL06 pass-through rung active?
Use the always-on special contact SP1 as the rung condition for a continuously executed copy. Confirm the rung is executing online and that both data words update as expected.
Will copying the analog input word produce the same voltage?
Only when the input and output scaling and data formats match. For matched 0–10 V channels using 0–4095 counts, about 1229 counts represents 3 V; verify the actual output voltage with a meter.
How do I use the 10 kΩ pot as an alternate command?
Decide whether the pot feeds a PLC analog input or remains a separate driver source, then implement deliberate source selection. Never parallel the pot wiper and an active analog output.
When should I stop commissioning a DL06 analog output?
Stop if the driver input range, card channel configuration, or source-selection wiring is unknown, or if measured voltage disagrees with the expected command. Keep the motor inhibited and contact AutomationDirect official support with the DL06 and card model information, configuration, and measured input/output values.