DirectLogic 405: What You Need to Know

Close-up of a DirectLogic CPU.  The DL405 D4-450 CPU is one of several CPUs in AX Control stock.
The DirectLogic D4-450 CPU

The DirectLogic 405 from Koyo is a modular controller with built-in PID instruction. End-users can add a number of different I/O modules to this low-cost controller to create configurations that meet their particular needs.

The DirectLogic 405 offers up to 3,500 local or distributed individual remote I/O points. The I/O and specific PID (proportional integral derivative control) allows command of processes like position, velocity, and temperature. One of our earlier blogs talks more about PID.

DirectLogic 405 Features

As a modular PLC, the DirectLogic 405 uses specialty and expansion modules to complete the system. This includes modules like

  • High-Speed Counters
  • PID Modules
  • SDS Modules
  • Input Simulators
  • 4-loop Temperature Controller
  • Filler Modules
  • Interrupt Modules
  • Relay Output Modules
  • Analog Modules

The DirectLogic 405 PLC offers three CPU modules. This includes the DL430, the DL440, and the DL450. All units offer built-in power supplies and communication ports. They have built-in diagnostics, significant program memory, and a substantial instruction set. However, the CPUs vary in initialization speeds, time required to read input status, and communication request speeds. Also, I/O support may change between modules. Additionally, the DL450 has drum timers and built-in PID loops, along with extra communication ports.

DirectLogic PLC: Uses

The DirectLogic PLC supports 4-20 mA, 0-20 mA, 0-5 V, 0-10 V, 1-5 V, +/-5 V, and +/-10 V. As a low-cost controller with a wide number of application options, the DL405 is popular for many applications. It is widely used in industrial applications where data communications or RTD/thermocouple inputs are required.

A DirectLogic 405 CPU.  Close-up of a DL405 D4-430.
The DirectLogic D4-430 CPU

DL405 Port Comparison

The DL450 offers more network ports than the DL430 or DL440. In comparison, the DL450 includes two network ports. These can serve as ModBus masters or slaves, or as DirectNET masters or slaves.

The DL430 and the DL440 have two built-in communication ports. Meanwhile, the DL450 has four.

Other DirectLogic 405 FAQs

At AX Control we field many questions about our DL405 inventory. Here are the answers to some of the most frequently asked questions.

Do DL405 PLCS offer Ethernet capability? Yes. Order an H4-Ecom Module if you require Ethernet.

What about Modbus protocol? If you have a DL430 or DL440 CPU, you will need a F4-MAS-MB master or a F4-SLV-MB slave module for Modbus. However, a DL450 CPU can support Modbus on port 1 or port 3.

Can the DL405 reset to factory defaults? Yes, it can. We can help with this. If you are resetting equipment in your possession, we suggest referring to directions in the DL405 manual for taking the CPU back to factory defaults.

Can AX Control provide PLC training or PLC programming manuals for DL405 products? Our staff is always happy to help our customers with whatever information we have at our disposal.

A DirectLogic 405 CPU.  Close-up of a DL405 D4-440DC-1
The DirectLogic D4-440DC-1 CPU

Our staff is always ready to help with any Automation Direct components you may need. Talk to us today.

Industries Disrupted by Automation

Heavy equipment moves dirt at a construction site.
Construction is seeing a significant increase in output due to automation.

Disruptive technology, as a term, has been with us for over two decades.  But disruptive technologies like automation have been with us for much longer.  Disruptive technology is some new product or innovation that creates a new market or disrupts an established one. Henry Ford’s Model T was a disruptive technology that revolutionized transportation over 110 years ago. 

Such innovations are found across markets.  When video streaming service Netflix first came on the scene it disrupted cable and video rental brick and mortar chains.   Now it’s disrupting Hollywood production models by creating its own content.  

Other disruptive technology examples include cheap, portable transistor radios. These were completely different from the large, expensive vacuum-tube radios that preceded them. The Internet is another example. It killed off print encyclopedias like Brittanica and World Book while changing the world in countless ways.  This shows how new technologies can change their associated industries by changing markets or by creating new ones.  

In the last few decades, disruptive technologies within automation have made a significant impact on many industries.  Here’s a list of some of the most important changes and the sectors affected by those changes.

Changes to the Automotive Industry

Car manufacturers were early adopters of industrial robotics. They now use robots for a wide variety of tasks including painting surfaces, welding, and assembly. Many plants use robots integrated with machine vision for inspection processes.

In the wake of the global pandemic, plants that relied on heavy automation saw significantly less impact on their outputs due to workforce stoppages than traditional factories. As countries like Germany use more robotics to offset labor shortages, this expansion in automation should continue.

Meanwhile, automated functions are slowly integrating into automobiles heading to consumers. Early automated functions like predictive emergency braking and cruise control are now standard in most cars. Top-of-the-line models now offer advanced features like lane departure warnings, blind-spot detection, and traffic jam assist. By 2025 many cars will offer fully automated safety options and highway autopilot features.

Automation in Healthcare

While much of the healthcare industry is impossible to automate due to the need for empathy and the power of human care, robotics and automation have still made a significant and impressive impact on the sector.

Medical automation may still include human guidance and interaction. For example, automated kiosks may offer patients their first instructions upon entering a doctor’s waiting room, automating steps like scanning new insurance cards, and updating patient information in the hospital database. But this is often followed by interaction with an on-site nurse or front office staff member who can then double-check this information. Additionally, such automated systems allow for healthcare staff to reduce wasted time by automating some aftercare interaction and can improve insights by providing better data insights to providers for performance improvement.

Automation has also spurred healthcare innovations like surgical robots for delicate surgeries like membrane removal for macular degeneration or laparoscopic surgical robots that help surgeons with keyhole procedures. Surgical robotics is expected to be a $20 billion industry by 2024.

In the wake of COVID-19 outbreaks, some hospitals added autonomous ultraviolet cleaning machines. These machines emit a strong UV light to slice apart the virus’s genetic material and can clean a room four times faster than human workers.

Older patients are also benefiting from automation. Automated pill dispensers can dole out months’ worth of medicine on a regulated schedule, and can even alert an offsite caregiver if medicine hasn’t been taken from the dispensing cup on time. This new technology will allow older patients the opportunity to live independently for a longer time.

Automation in Construction

Productivity in construction barely changed in the sixty years between 1950 and 2010. Over that same time, manufacturing increased its output by a factor of eight and agriculture by a factor of sixteen. But in the last decade, construction has begun to adopt more automated technologies, and the result has been an annual output increase of roughly 3.8%, the fastest real output growth of any goods-producing sector.

The technologies that are driving this growth are as varied as the construction industry itself. Robots are now being used for bricklaying, and large automated machines are paving roads. Some are combining both things, laying down brick roadways like a woven carpet.

Automation is also helping control traffic flow around construction sites. This minimizes accidents and the impact on surrounding communities. Automation and data analytics may even be used to schedule some projects to further limit the impact on traffic.

Additive manufacturing (3D printing) is also being used in construction for the creation of facades and components. Some architects have used additive manufacturing to 3D print entire structures. This technology reduces the window for human error, offers the potential for zero-waste construction, and opens up the window to creativity and innovation.

Finally, construction is using automation to improve on-site efficiencies through building information modeling. This allows for the planning, design, and management of a project to come together in a unified plan that identifies issues before work begins, allowing for improved scheduling of labor and materials and the elimination of costly mistakes and delays.

How Model T Thinking Shapes 21st-Century Manufacturing

21st-century manufacturing is based in 20th century tech like the Model T.  Tourists at Gettysburg in a Ford Model T.
“Tourists in a Ford Model T at the ‘Devil’s Den’ at Gettysburg Battlefield in Pennsylvania, c1910-1915” by crackdog is marked under CC PDM 1.0. To view the terms, visit

One of the greatest challenges for any successful business is knowing when it’s time to change.  After all, conventional wisdom says “if it’s not broke, don’t fix it.”   But with 21st-century manufacturing technology changing at such a rapid pace, those who stand still will soon be left behind. 

The last time the world saw technological advancements at this pace, Henry Ford was just figuring out the assembly line.  By looking back at Ford’s adoption of the new technology of his time we may be able to learn how to properly read today’s technological trends. This knowledge will help prepare us for investing in AI and automation at the most advantageous time for our manufacturing, warehousing, and distribution systems.  

Leverage Automation

Sectional view of an early Ford Engine.  21st-century manufacturing built upon 20th century ideas.
“In the Ford Model T, the transmission, magneto, and engine were mounted together as a unit, all lubricated by the same oil” by The Henry Ford is licensed under CC BY-NC-SA 2.0

Henry Ford was not a newcomer to the car business when he began producing the Model T in 1908.  Before starting the Ford Motor Company, Henry worked for several other automotive companies where he contributed to the creation of the Quadricycle and the Ford 999. But he dreamed of a vehicle for ‘the great multitude,’  and so the Model T was born. 

Unfortunately,  the original Model T was still too expensive for most Americans.  When Ford began churning the cars out via assembly line, however, their price dropped significantly. 

In 1909, workers were using traditional methods to piece cars together. That year, a Model T cost $825. Production was under 11,000 units. But in 1916, three years after Ford started using assembly line production,  the Ford Motor Company produced over half a million Model Ts. Each one sold for $345.

Continue reading “How Model T Thinking Shapes 21st-Century Manufacturing”