KOYO D2-240 CPU Module – DirectLOGIC DL240 PLC Processor | DL240 Series Platform
Engineering Background: The KOYO D2-240 is the flagship CPU of the DirectLOGIC DL240 mid-range PLC family, engineered by Koyo Electronics (now marketed under the AutomationDirect brand in North America). Designed for demanding discrete and process control applications, the D2-240 delivers a robust instruction set, high I/O capacity, and deterministic scan performance — making it a trusted choice for OEM machine builders and plant automation engineers worldwide.
Product Positioning: The D2-240 sits at the top of the DL240 CPU lineup, offering the maximum I/O expansion, built-in communication ports, and advanced math/data-handling instructions. It is the preferred processor for applications requiring coordinated multi-rack I/O, serial communications, and PID loop control within a cost-effective mid-range PLC platform.
Complete Technical Specifications
- Part Number: D2-240
- Brand / Manufacturer: KOYO Electronics (AutomationDirect)
- Series / Platform: DirectLOGIC DL240
- CPU Type: Fixed-configuration CPU module
- Program Memory: 7,616 words (ladder logic)
- Data / V-Memory: 4,096 words (V0–V7377 octal)
- Maximum Local I/O: 256 discrete I/O points (local base)
- Maximum Total I/O: 2,048 discrete I/O points (with expansion)
- Analog I/O Support: Yes (via D2-series analog modules)
- Communication Ports: 2 × RS-232C / RS-422 (Port 1: programming; Port 2: Modbus RTU / DirectNET)
- Supported Protocols: Modbus RTU (master/slave), DirectNET, K-sequence
- PID Loops: Up to 4 software PID loops
- Scan Time: ~0.4 ms per 1K of ladder logic (typical)
- Instruction Set: Boolean, timer/counter, math, comparison, data move, shift register, drum sequencer, PID
- Power Supply: Supplied by base unit (D2-04B / D2-06B / D2-09B / D2-10B)
- Operating Temperature: 0 °C to 60 °C (32 °F to 140 °F)
- Storage Temperature: –20 °C to 70 °C
- Relative Humidity: 5% to 95% non-condensing
- Vibration Resistance: IEC 68-2-6 compliant
- Weight: Approx. 320 g
- Country of Origin: United States
- Programming Software: DirectSOFT (DS-WIN-ALL)
Proven Application Environments
- Conveyor and material handling systems requiring multi-rack I/O coordination
- Packaging machinery with PID-controlled temperature or pressure loops
- Water and wastewater treatment plants using Modbus RTU SCADA integration
- Automotive assembly lines with high discrete I/O point counts
- Food and beverage processing with analog sensor monitoring
- Building automation and HVAC control panels
- OEM machine retrofits replacing obsolete DL240-series CPUs
Engineering Advantages
- Maximum I/O Scalability: Supports up to 2,048 I/O points across multiple expansion racks — the highest capacity in the DL240 family.
- Dual Serial Ports: Independent RS-232C/RS-422 ports allow simultaneous programming and Modbus/DirectNET communications without additional hardware.
- Deterministic Scan Performance: ~0.4 ms/1K ladder scan ensures reliable real-time control for high-speed discrete applications.
- Rich Instruction Set: Drum sequencer, PID, and advanced math instructions reduce external hardware requirements and simplify program architecture.
- Long-Term Platform Support: DirectSOFT programming software remains actively maintained; extensive legacy documentation and community support available.
- Drop-In Replacement Compatibility: Pin-compatible with D2-230 and D2-250-1 in the same base, enabling phased upgrades without rewiring.
System Architecture & Signal Flow
The D2-240 CPU installs into slot 0 of any DL240-compatible base (D2-04B, D2-06B, D2-09B, or D2-10B). The CPU communicates with local I/O modules via the internal backplane bus. Remote I/O expansion is achieved through D2-RMSM / D2-RSSS remote I/O master/slave modules connected via the DL240 remote I/O network. Serial Port 1 connects to a PC running DirectSOFT for program upload/download and online monitoring. Serial Port 2 interfaces with HMIs, drives, or SCADA systems via Modbus RTU or DirectNET protocol. Analog signals are processed through dedicated D2-series analog input/output modules seated in the same or expansion base.
Sourcing & Quality Verification
- Source: Authorized distribution channels and verified OEM surplus inventory
- Inspection: Each unit undergoes visual inspection, label verification, and functional power-on testing before shipment
- Authenticity: Firmware version and hardware revision confirmed against KOYO/AutomationDirect factory records
- Packaging: Anti-static bag + foam-lined carton; original factory packaging preserved where available
- Warranty: 12-month replacement warranty against manufacturing defects
- Traceability: Batch and serial number records maintained for all units shipped
Procurement Process
- Submit your inquiry via support@konmask.com or the on-page quote form, including quantity and required delivery date.
- Receive a formal quotation with unit price, lead time, and shipping options within 24 business hours.
- Confirm purchase order; payment via T/T, PayPal, or credit card accepted.
- Unit inspected, packed, and dispatched with tracking number within 1–3 business days.
- Post-delivery technical support available via email or WhatsApp.
Technical FAQ
Q: Is the D2-240 compatible with the D2-04B base?
A: Yes. The D2-240 is compatible with all standard DL240 bases: D2-04B, D2-06B, D2-09B, and D2-10B.
Q: Can the D2-240 replace a D2-230 or D2-250-1?
A: The D2-240 is physically and electrically compatible with the D2-230 (same base slot). The D2-250-1 offers higher memory; a program review is recommended before substitution.
Q: What programming software is required?
A: DirectSOFT (DS-WIN-ALL), available from AutomationDirect. The D2-240 is not compatible with Ladder Logic software from other PLC vendors.
Q: Does the D2-240 support Ethernet communications?
A: Not natively. Ethernet connectivity requires an optional H2-ECOM or H2-ECOM100 Ethernet communication module installed in the base.
Q: What is the maximum number of PID loops?
A: The D2-240 supports up to 4 software PID loops using the built-in PID instruction.
Q: Is this a new or refurbished unit?
A: Konmask.com supplies both new OEM stock and fully tested refurbished units. Unit condition is clearly stated on the final quotation.
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