Chapter 1 - AutomationDirect
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1. 125 VDC Power Input 100 240 VDC G Hlosseg rt 468 94 240VAC 50 60Hz 30VA Step 4 Connect the Programming Device Most programmers will use DirectSOFT programming software installed on a personal computer Or you may need the portability of the Handheld Programmer Both devices will connect the COM1 port of the DL105 via the appropriate cable ooogaoga ire 105 LOGIC _ _ _ oyo a jajad n DL105 PLC User Manual 3rd Edition Use cable part no D2 DSCBL For replacement cable use part no DV 1000CBL Getting Started 1 9 Step 5 Switch on the System Power Apply power to the system and ensure the PWR indicator on the DL105 is on If not remove power from the system and check all wiring and refer to the troubleshooting section in Chapter 8 for assistance oO J Q 09 o ms 00 os Step 6 Initialize Scratchpad Memory It s a good precaution to always clear the system memory scratchpad memory ona new DL105 When a unit has been without power for several days the system RAM contents may have been corrupted and will require initialization e In DirectSOFT select the PLC Menu gt Setup gt Initialize Scratchpad For additional informati2. PHE ie SSE PA A E Nq Ge YO COM Y1 CANA RAB LBE Direct Tag IRCI 105 X T X X X i WARNING DO NOT wire the T 80 132VAC _ 50 60Hz or 90T SZ toggle switches as shown to xja COM Xe 1x3 xa x5 OOM Xe gt 240VAC powered units The discrete inputs will only accept 120VAC nominal Also remove power and unplug the DL105 when wiring the switches Only use UL approved switches rated for at least 250VAC 1A Firmly mount the switches before using NEVER use the input simulator on these units with AC type Toggle Switches UL Listed discrete inputs DL105 PLC User Manual 3rd Edition 1 io Q C9 fe ms 0 Q 1 8 Getting Started Step 3 Connect the Power Wiring xe D o pe n D Cc Oo Connect the power input wiring for the version DL105 you have Observe all precautions stated earlier in this manual For more details on wiring see Chapter 2 on Installation Wiring and Specifications When the wiring is complete close the connector covers Do not apply power at this time 110 220 VAC Power Input 94 240 VAC LI N G 1 RS RF ea aga cef 50 60Hz 30VA 12 24 VDC Power Input 10 30 VDC
3. see Chapter 6 see Chapter 7 LDD 1 V1076 CMPD K309482 SP62 YO CU After reviewing the programming concepts above you ll be equipped with a variety of tools to write your application program Step 7 Once you have installed the Micro PLC TNR F Choose the and understand the main programming K30 Instructions concepts you can begin writing your CNT CT3 application program At that time you will K10 Step 8 Understand the Maintenance and Troubleshooting Procedures begin to use one of the most powerful instruction sets available in a small PLC Sometimes equipment failures occur when we least expect it Switches fail loads short and need to be replaced etc In most cases the majority of the troubleshooting and maintenance time is spent trying to locate the problem The DL105 Micro PLC has many built in features such as error codes that can help you quickly identify problems doogoog8 Prt 4 DL105 PLC User Manual 3rd Edition 1 12 Getting Started Questions and Answers about DL105 Micro PLCs Q What is the instruction set like A The instruction set is very close to our popular DL230 CPU However there are significant additions such as the drum instruction and High Speed I O capability O D o pte n joy Cc Oo Q Do I have to buy the full DirectSOFT5 programming package to program the DL105 A No DirectSOFT100 ca
4. 250 VAC 7A F1 130AD AC 3 80 132 VAC DC 1 Sink 5 30 VDC 0 3A Yo Y1 90 150 VDC 5 30 VDC 0 6A Y3 Y7 F1 130DD DC 3 Sinkor 10 26 4VDC DC 1 Sink 5 30 VDC 0 3A yYo Y1 Source 21 6 26 4 VAC 5 30 VDC 0 6A Y3 Y7 F1 130AA AC 3 80 132 VAC AC 4 20 140 VAC 47 63 Hz 90 150 VDC 1 7A F1 130DA DC 3 Sink or 10 26 4 VDC AC 4 20 140 VAC 47 63 Hz Source 21 6 26 4 VAC 1 7A F1 130DR D DC 3 Sinkor 10 26 4VDC Relay 4 Sink or 12 30 VDC 7A Source 21 6 26 4 VAC Source 12 250 VAC 7A F1 130DD D DC 3 Sinkor 10 26 4VDC DC 1 Sink 5 30 VDC 0 3A yo Y1 Source 21 6 26 4 VAC 5 30 VDC 0 6A Y3 Y7 Subject to temperature derating chart See Chapter 2 Specifications for your particular DL105 version DC outputs have one electrical common but it is accessible at three terminals on the output connector DL105 PLC User Manual 3rd Edition oO Q 09 fev ms 0 ox 1 6 Getting Started Quick Start for PLC Checkout and Programming me 5 If you have experience with PLCs or if you just want to setup a quick example this N example is for you This example is not intended to tell you everything you need to 2 start up your system warnings and helpful tips are in the rest of the manual It is only intended to give you a general picture of what you will need to do to get your system 0 powered up Step 1 Unpack the Re
5. DL205 DL305 DL405 or any new CPU we may add to our product line Upgrade software may be required for new CPUs as they become available DL105 PLC User Manual 3rd Edition Handheld Programmer Getting Started 1 5 There is a separate manual that discusses the DirectSOFT programming software which is included with your software package All DL105 Micro PLCs have a built in programming port for use with the handheld programmer D2 HPP the same programmer used with the DL205 family The handheld programmer can be used to create modify and debug your application program A separate manual discusses the Handheld Programmer I O Quick Chart Selection The eight versions of the DL105 have Input Output circuits which can interface to a wide variety of field devices In several instances a particular Input or Output circuit can interface to either DC or AC voltages or both sinking and sourcing circuit arrangements Check this chart carefully to find the proper DL105 Micro PLC to interface to the field devices in your application DL105 INPUTS OUTPUTS AIA Tp Otype Sink Voltage Ranges I O type Sink Voltage Current commons Source commons Source Ratings F1 130AR AC 3 80 132 VAC Relay 4 Sink or 12 30 VDC 7A 90 150 VDC Source 12 250 VAC 7A F1 130DR DC 3 Sink or 10 26 4 VDC Relay 4 Sink or 12 30 VDC 7A Source 21 6 26 4 VAC Source 12
6. with the input simulator as you learn the DL105 However you may wire individual toggle switches to AC powered units as shown as long as you follow the instructions in the accompanying WARNING note F1i 130DR D F1 130DD D F1 130DR F1 130DR CE DC input versions poses F1 130DD F1 130DD CE wayyy Lt oo H U wi F1 130DA i oe OU INT INP 12 24VDC INPUT SINK SRC ID Mesto irrancrard faracceard ood Ni feeissase 5 E aoe Ste eee aoe Le LS ae J J J J ball J Slide simulator under eg tog DEPA i j 12 250VAC and tighten screws O aes F1 04SIM p i A left most terminals F1 130AR F1 130AD F1 130AA AC input versions 120VAC only Hz HSC INT INP P o COM X2 X3 f X4 SABE
7. Getting Started In This Chapter Introduction Conventions Used DL105 Micro PLC Components Programming Methods O Selection Quick Chart Quick Start for PLC Checkout and Programming Steps to Designing a Successful System Questions and Answers about DL105 Micro PLCs 1 2 Getting Started xe D E o pe n joy Cc Introduction The Purpose of this Manual Where to Begin Supplemental Manuals Technical Support Thank you for purchasing a DL105 Micro PLC This manual shows you how to install program and maintain all the Micro PLCs in the DL105 family It also helps you understand how to interface them to other devices in a control system This manual contains important information for personnel who will install DL105 PLCs and for the PLC programmer If you understand PLC systems our manuals will provide all the information you need to get and keep your system up and running If you already understand the DL105 Micro PLC please read Chapter 2 Installation Wiring and Specifications and proceed on to other chapters as needed Be sure to keep this manual handy for reference when you run into questions If you are a new DL105 customer we suggest you read this manual completely so you can understand the wide variety of features in the DL105 family of products We believe you will be pleasantly surprised with how much you can accomplish with AutomationDire
8. L Underwriters Laboratories Inc and CUL Canadian Underwriters Laboratories Inc Q Can the DL105 accept 5VDC inputs A No 5 volts is lower than the DC input ON threshold However many TTL logic circuits can drive the inputs if they are wired as open collector sinking inputs See Chapter 2 for I O wiring guidelines DL105 PLC User Manual 3rd Edition Getting Started 1 13 Q Which devices can I connect to the Com1 port of the DL105 A The port is RS 232C fixed at 9600 baud and uses the proprietary K sequence protocol The port communicates with the following devices e DV 1000 Data Access Unit or Optimation Operator interface panels e DirectSOFT running on a personal computer e D2 HPP handheld programmer e Other devices which communicate via K sequence protcol should work with the DL105 Micro PLC Contact the vendor for details Q D 5 Co 02 D ai D a DL105 PLC User Manual 3rd Edition
9. aracteristics DL105 PLC User Manual 3rd Edition PLC Input Sensing AC Power A DL105 PLC Power Input 8 Outputs Commons 24 VDC 10 Inputs Commons w y e oo Power up Initialize hardware Getting Started 1 11 Step 6 The DL105 PLC instruction set provides for three main approaches to solving the Review the application program depicted in the figure below Programming Q Concepts e RLL diagram style programming is the best tool for solving boolean logic and general CPU register accumulator manipulation It includes dozens a of instructions which will also be needed to augment drums and stages a e The Timer Event Drum Sequencer features up to 16 steps and offers a both time and or event based step transitions The EDRUM instruction a is best for a repetitive process based on a single series of steps e Stage programming also called RLLPLYS is based on state transition diagrams Stages divide the ladder program into sections which correspond to the states in a flow chart you draw for your process Standard RLL Programming Timer Event Drum Sequencer Stage Programming see Chapter 5
10. boldface text When you see the exclamation mark icon in the left hand margin the paragraph to YZ A On Key Topics for The beginning of each chapter will list the Each Chapter key topics that can be found in that inioduction chapter DL105 PLC User Manual 3rd Edition EES Getting Started O D o pte n joy Cc Oo DL105 Micro PLC Components The DL105 Micro PLC family is a versatile product line that provides a wide variety of features in a very compact footprint The PLCs are small yet offer many features usually found in larger more expensive systems These include removeable connectors RS 232C communication port and 24V auxiliary power supply The DL105 The DL105 Micro PLC family includes eight different versions All have the same Micro PLC Family appearance and CPU performance The CPU offers the same instruction set as our popular DL230 CPU plus several more instructions specifically designed for machine control applications All DL105 PLCs have an RS 232C communications port and the AC powered versions have an auxiliary 24V output Units with DC inputs have selectable high speed input features on four input points Units with DC outputs offer selectable pulse output capability on the first two output points All DL105 Micro PLCs offer a large amount of program memory a substantial instruction set and advanced diagnostics Details of
11. commended DL105 Equipment Unpack the DL105 equipment and verify you have the recommended parts necessary to build this demonstration system The components are e DL105 Micro PLC e AC power cord for AC powered units e F1 04SIM input simulator or toggle switches see Step 2 on next page e Hook up wire 16 20 AWG e DL105 User Manual this manual e A small screwdriver regular or 2 Philips type You will need at least one of the following programming options e DirectSOFT Programming Software DirectSOFT Manual anda programming cable connects the DL105 to a personal computer or e D2 HPP Handheld Programmer comes with programming cable and the Handheld Programmer Manual boon Direct 105 LOGIC aana aai tint OoooonnN aaa a aaa DL105 PLC User Manual 3rd Edition 1 7 Getting Started Step 2 Connect Switches to Input Terminals To finish this quick start exercise or study other examples in this manual you ll need to connect some input switches as shown below For most models the F1 04SIM Input Simulator is a quick way to install four switches on inputs XO X3 DC powered units will require routing DC power to the simulator as shown We recommend using one of the models compatible
12. ct products If you have purchased operator interfaces or DirectSOFT programming software you will need to supplement this manual with the manuals that are written for these products We realize that even though we strive to be the best we may have arranged our information in such a way you cannot find what you are looking for First check these resources for help in locating the information e Table of Contents chapter and section listing of contents in the front of this manual e Appendices reference material for key topics near the end of this manual You can also check our online resources for the latest product support information e Internet the address of our Web site is http www automationdirect com If you still need assistance please call us at 770 844 4200 Our technical support group is glad to work with you in answering your questions They are available Monday through Friday from 9 00 A M to 6 00 P M Eastern Standard Time DL105 PLC User Manual 3rd Edition Getting Started 1 3 Conventions Used immediate right will be a special note zatan When you see the notepad icon in the left hand margin the paragraph to its I The word NOTE in boldface will mark the beginning of the text Q D 5 Co 02 D ai D a its immediate right will be a warning This information could prevent injury loss of property or even death in extreme cases The entire WARNING will be in
13. n be used It has the same features as the full version of DirectSOFT5 but allows only 100 words of ladder code that can be downloaded to the PLC It will also program DLO5 06 205 305 405 systems and it is only available for download online Order programming cable separately 32 bit application Windows 2000 or Windows XP Pro or Home recommended This software is available at no cost to you Q Is the DL105 networkable or expandable A No the DL130 series is stand alone PLCs However our DL205 system is expandable and networkable with DL240 CPU yet very compact and affordable Q Does the DL105 have motion control capability A Yes The High Speed I O features offer either encoder inputs with high speed counting and presets with interrupt or a pulse direction output for stepper control Three types of motion profiles are available which are explained in Chapter 3 Q Are the ladder programs stored in a removable EPROM A The DL105 contains anon removable EEPROM for program storage which may be written and erased thousands of times You may transfer programs to from DirectSOFT on a PC or the HPP which does support a removable EEPROM Q Does the DL105 contain fuses for its outputs A There are no output circuit fuses Therefore we recommend fusing each channel or fusing each common See Chapter 2 for I O wiring guidelines Q Is the DL105 Micro PLC U L approved A The Micro PLC has met the requirements of U
14. on see the DirectSOFT Manual e For the Handheld Programmer use the AUX key and execute AUX 54 For additional information see the Handheld Programmer Manual Step 7 Enter a Ladder Program At this point DirectSOFT programmers need to refer to the Quick Start Tutorial in the DirectSOFT Manual There you will learn how to establish a communications link with the DL105 PLC change CPU modes to Run or Program and enter a program If you are learning how to program with the Handheld Programmer make sure the CPU is in Program Mode the RUN LED on the front of the DL105 should be off If the RUN LED is on use the MODE key on the Handheld Programmer to put the PLC in Program Mode Enter the following keystrokes on the Handheld Programmer Clear the Program Equivalent DirectSOFT display CLR CLR g xo YO c 3 E 3 AUX ENT ENT CLR a OUT A Move to the first atid STR gt o aids address and enter t XO contact END GX gt A ENT Enter output YO OUT o Enter the END E N D SAFT 4 TMR 3 ENT statement After entering the simple example program put the PLC in Run mode by using the Mode key on the Handheld Programmer The RUN indicator on the PLC will illuminate indicating the CPU has entered the Run mode If not repeatthis step ensuring the program is entered properly or refer to the troubleshooting guide in chapter 8 After the CPU enters
15. the run mode the output status indicator for Y should follow the switch status on input channel X0 When the switch is on the output will be on DL105 PLC User Manual 3rd Edition Getting Started Getting Started Steps to Designing a Successful System Step 1 Review the Installation Guidelines Step 2 Understand the PLC Setup Procedures Step 3 Review the I O Selection Criteria Step 4 Choose a System Wiring Strategy Step 5 Understand the System Operation Always make safety the first priority in any system design Chapter 2 provides several guidelines that will help you design a safer more reliable system This chapter also includes wiring guidelines for the various versions of the DL105 PLC The PLC is the heart of your automation system Make sure you take time to understand the various features and setup requirements There are many considerations involved when you select your I O type and field devices Take time to understand how the various types of sensors and loads can affect your choice of I O type It is important to understand the various system design options that are available before wiring field devices and field side power supplies to the Micro PLC Before you begin to enter a program it is very helpful to understand how the DL105 system processes information This involves not only program execution steps but also involves the various modes of operation and memory layout ch
16. these features and more are covered in Chapter 4 CPU Specifications and Operation The eight types of DL105 Micro PLCs provide a variety of Input Output choices listed in the following table DL105 Discrete Discrete External Auxiliary High Speed Pulse Part Number Input Type Output Type Power 24V Output Input Output F1 130AR AC Relay 94 240 VAC Yes No No F1 130DR DC Relay 94 240 VAC Yes Yes No F1 130AD AC DC 94 240 VAC Yes No Yes F1 130DD DC DC 94 240 VAC Yes Yes Yes F1 130AA AC AC 94 240 VAC Yes No No F1 130DA DC AC 94 240 VAC Yes Yes No F1 130DR D DC Relay 10 30 VDC No Yes No F1 130DD D DC DC 10 30 VDC No Yes Yes Programming Methods Two programming methods are available a software programming package anda handheld programmer The software and the handheld programmer support RLL Relay Ladder Logic and RLL LYS STAGE programming DirectSOFT The DL105 Micro PLC can be programmed with one of the most advanced Programming for programming packages in the industry DirectSOFT5 This is the most recent Windows version of DirectSOFT a Windows based software package that supports familiar features such as cut and paste between applications point and click editing viewing and editing multiple application programs at the same time etc DirectSOFT universally supports the DirectLOGIC CPU families This means that you can use the same DirectSOFT package to program DLO5 DLO6 DL105
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