Chapter 1 - AutomationDirect
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1. PeSSSSSSSE DOOSSSSSOr tf inl fal ial int FA inl in in int 3 BeSSSSSSS TETEN LGN G 95 240 VAC Step 4 Connect the Programming Device Most programmers will use DirectSOFT 5 programming software installed on a personal computer Or you may need the portability of the Handheld Programmer Both devices will connect to COM port 1 of the DLO5 via the appropriate cable Use cable part D2 DSCBL cable comes with HPP For replacement cable use part DV 1000CBL 1 8 DL05 Micro PLC User Manual 6th Edition Rev C Step 5 Switch on the System Power Chapter 1 Getting Started Apply power to the system and ensure the PWR indicator on the DLO5 is on If not remove power from the system and check all wiring and refer to the troubleshooting section in Chapter 9 for assistance Step 6 Initialize Scratchpad Memory It s a good precaution to always clear the system memory scratchpad memory on a new DLO5 There are two ways to clear the system memory e In DirectSOFT 5 select the PLC menu then Setup then Initialize Scratchpad For additional information see the DirectSOFT 5 Manual e For the Handheld Programmer use the AUX key and execute AUX 54 See the Handheld Programmer Manual for additional information Step 7 Enter a Ladder Program At this point DirectSOFT 52. DO 05AD DO 05AA AC input versions 120V AC only 95 240 V 30VA 50 60Hz X0 X7 Input YO Y5 Output WARNING DO NOT wire the oenl X1 H x4 ia Y1 x Y5 EE e Ed AE e A toggle switches as shown to PEPEPEPE 240VAC powered units The discrete inputs will only accept BRI CSSSSSCeE 120VAC nominal Also remove power and unplug the DLO5S N when wiring the switches Only use UL approved switches rated q for at least 250VAC 1A for AC inputs Firmly mount the AL switches before using A Toggle Switches UL Listed DL05 Micro PLC User Manual 6th Edition Rev C 1 7 Chapter 1 Getting Started Step 3 Connect the Power Wiring Connect the power input wiring for the DL05 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 12 24 VDC Power Input 12 24 VDC 95 240 V XO X7 Ii 30VA 50 60Hz Roe KET 20 W max AC L AC N CO X1 X3 X4 A CO X1 X3 X4 X G LG X0 X2 C1 X5 X G LG xo X2 c1 X5 x7
3. Started a Steps to Designing a Successful System Step 1 Review the Installation Guidelines 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 DLO5 PLC Step 2 Understand the PLC Setup Procedures The PLC is the heart of your automation system Make sure you take time to understand the various features and setup requirements Step 3 Review the I O Selection Criteria ina E There are many considerations involved when you bas 7 select your I O type and field devices Take time to H D iui understand how the various types of sensors and oa LY Sensing loads can affect your choice of I O type Common ee ee all AC Step 4 Choose a System Wiring Strategy Power It is important to understand the various system design options that are available before Plc Power input 6 Outputs Commons wiring field devices and field side power 424 VDC ep aa supplies to the Micro PLC ai T o o Step 5 Understand the System Operation Before you begin to enter a program it is very helpful to understand how the DL05 system A processes information This involves not only program execution step
4. an available option module They do not have expansion bases such as our DL205 system which has expansion bases yet are very compact and affordable Q Does the DL05 have motion control capability A Yes The units with DC I O have selectable high speed input features on three inputs There is also an optional High Speed Counter I O module available with special utility software Either can accept pulse type input signals for high speed counting or timing applications and provide high speed pulse type output signals for stepper servo motor control monitoring alarm or other discrete control functions Three types of motion profiles are available which are explained in Chapter 3 Q Are the ladder programs stored in a removable EEPROM A The DL05 contains a non removable FLASH memory for program storage which may be written and erased thousands of times You may transfer programs to from the DL05 using DirectSOFT 5 ona PC or the HPP which does support a removable EEPROM There is an optional CMOS RAM memory cartridge MC available See Chapter 10 Q Does the DL05 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 DLO5 Micro PLC U L approved A The Micro PLC has met the requirements of UL Underwriters Laboratories Inc and CUL Canadian Underwriters Laboratories Inc Q Does the DL
5. the DL05 family of products We believe you will be pleasantly surprised with how much you can accomplish with AutomationDirect products Supplemental Manuals The DO OPTIONS M manual will be most helpful to select and use any of the optional modules that are available for the DLO5 PLC which includes the analog I O modules 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 Technical Support 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 website is http www automationdirect com If you still need assistance please call us at 770 844 4200 Our technical support team will be available 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 1 2 DL05 Micro PLC User Manual 6th Edition Rev C Chapter 1 Getting Started Conventions Used Ee When you see the notepad icon i
6. 0 VAC Relay 2 Sink or Source 6240 VAG 2A DO 05DR DC 2 Sink orSource 12 24 VDC Relay 2 Sink or Source Lane DO 05AD AC 2 90 120 vac DC 1 Sink 6 27 VDC 0 5A Wava 6 27 VDC 1 0A Y3 Y5 6 27 VDC 0 5A Y0 Y2 D0 05DD DC 2 Sinkor Source 12 24VDC DC 1 Sink 6 27 VDC 1 0A Wava D0 05AA AC 2 90 120 VAC AC 2 17 240 VAC 47 63 Hz 0 5A DO 05DA DC 2 Sink or Source 12 24 VDC AC 2 a 17 240 VAC 47 63 Hz 0 5A DO 05DR D DC 2 Sink or Source 12 24VDC Relay 2 Sink or Source on eer 6 27 VDC 0 5A YO Y2 DO 05DD D DC 2 Sink or Source 12 24 VDC DC 1 Sink 6 27 VDC 1 0A Wava See Chapter 2 Specifications for your particular DL05 version DL05 Micro PLC User Manual 6th Edition Rev C 1 5 Chapter 1 Getting Started a Quick Start for PLC Checkout and Programming This example is not intended to tell you everything you need to 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 powered up Step 1 Unpack the DL05 Equipment Unpack the DLO5 and gather the parts necessary to build this demonstration system The recommended components are e DL05 Micro PLC e AC power cord or DC power supply e Toggle switches or simulator module FO O8SIM see Step 2 on next page e Hook up wire 16 22
7. 05 Micro PLC comply with European Union EU Directives A The Micro PLC has met the requirements of the European Union Directives CE 1 12 DL05 Micro PLC User Manual 6th Edition Rev C Chapter 1 Getting Started ena E Q Which devices can I connect to the communication ports of the DL05 A Port 1 The port is RS 232C fixed at 9600 baud and uses the proprietary K sequence protocol The DLO5 can also connect to Modbus RTU and DirectNET networks as a slave device through port 1 The port communicates with the following devices e DV 1000 Data Access Unit or Optimation Operator interface panels e DirectSOFT 5 running on a personal computer e D2 HPP handheld programmer e Other devices which communicate via K sequence protocol should work with the DLO5 Micro PLC Contact the vendor for details A Port 2 The port is RS 232C with selective baud rates 300 38 400bps address and parity It also supports the proprietary K sequence protocol as well as DirectNET and Modbus RTU and non sequence print protocols Q Can the DL05 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 T O wiring guidelines DL05 Micro PLC User Manual 6th Edition Rev C l 13
8. 40 CPU plus several more instructions specifically designed for machine control applications All DL05 PLCs have two RS 232C communications ports Units with DC inputs have selectable high speed input features on three input points Units with DC outputs offer selectable pulse output capability on the first and second output points All DLOS Micro PLCs offer a large amount of program memory a substantial instruction set and advanced diagnostics Details of these features and more are covered in Chapter 3 CPU Specifications and Operation The eight types of DLO5 Micro PLCs provide a variety of Input Output choices listed in the following table DLO5 Micro PLC Family DLOS Part Discrete Input Discrete Output High Speed Number Type Type External Power Input Pulse Output DO 05AR 95 240 VAC No No DO 05DR 95 240 VAC Yes No DO 05AD 95 240 VAC No Yes DO 05DD 95 240 VAC Yes Yes DO 05AA 95 240 VAC No No DO 05DA 95 240 VAC Yes No DO 05DR D 12 24 VDC Yes No DO 05DD D 12 24 VDC Yes Yes DirectSOFT 5 Programming for Windows The DLO5 Micro PLC can be programmed with one of the most advanced programming packages in the industry DirectSOFT 5 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 1 4 DL05 Micro PLC User Manual 6th Edition Rev
9. APTER GETTING STARTED In This Chapter Introd cti n sesser bos HRT ESR EDT OREK EMER RE SCOR EX EES 1 2 Conventions Used lt i acpadsd boa ee Rae ee nA eet ees 1 3 DLOS Micro PLC Components ssssusaaanaunu suere 1 4 Programming Methods 6 400000 4g ke eee Pee de eee wS 1 4 I O Selection Quick Chart 0 0 0 0 cece eee ee 1 5 Quick Start for PLC Checkout and Programming 1 6 Steps to Designing a Successful System 2 0005 1 10 Questions and Answers about DLO5 Micro PLCs 1 12 Chapter 1 Getting Started ay Introduction The Purpose of this Manual Thank you for purchasing a DLO5 Micro PLC This manual shows you how to install program and maintain all the Micro PLCs in the DLO5 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 DLO5 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 Where to Begin If you already understand the DLO5 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 DLO5 customer we suggest you read this manual completely so you can understand the wide variety of features in
10. AWG e DL05 User Manual this manual e A small screwdriver 5 8 flat or 1 Philips type You will need at least one of the following programming options e DirectSOFT 5 Programming Software DirectSOFT 5 Manual and a programming cable connects the DLO5 to a personal computer or e D2 HPP Handheld Programmer comes with programming cable and the Handheld Programmer Manual 1 6 DL05 Micro PLC User Manual 6th Edition Rev C Chapter 1 Getting Started Step 2 Connect Switches to Input Terminals ae To finish this quick start exercise or study other examples in this manual you ll need to either connect some input switches as shown below or install the FO O8SIM simulator module which needs no wiring into the option slot If you have DC inputs you will need to use the FA 24PS 24VDC or another external 12 24VDC power supply Be sure to follow the instructions in the accompanying WARNING note DO O5DR D0 05DD D0 05DA D0 05DR D D0 05DD D DC input versions 12 24VDC 95 240 V 30VA 50 60Hz AC L AC N CO X1 X3 X4 X6 C2 Y1 Y3 Y5 GQOILG X0 X2 C1 X5 X7 YO Y2 Y4 v CZO C i PSSSSSSS 2 XO X7 Input Yo Y5 Output HHHH 12 24VDC Power Supply Toggle Switches UL Listed L DO 05AR
11. C Chapter 1 Getting Started DirectSOFT 5 universally supports the DirectLOGIC CPU families This means you can use the full version of DirectSOFT 5 to program DLO5 DL06 DL105 DL205 DL305 DL405 CPUs The DirectSOFT 5 Programming Software User Manual discusses the programming language in depth DirectSOFT version 2 4 or later is needed to program the DLOS Handheld Programmer All DLO5 Micro PLCs have built in programming ports for use with the handheld programmer D2 HPP the same programmer used with the DL06 DL105 and DL205 families The handheld programmer can be used to create modify and debug your application program A separate manual discusses the Handheld Programmer Only D2 HPPs with firmware version 1 09 or later will program the DLO5 NOTE Not all program instructions are available to use with the HHP such as the DRUM instruction Use DirectSOFT 5 for these instructions 1 0 Selection Quick Chart The eight versions of the DL05 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 DLO5 Micro PLC to interface to the field devices in your application 1 0 Selection Chart DLOS Part INPUTS OUTPUTS Number ne Sink Source Fane pile Sink Source Voltage Current Ratings DO O5AR AC 2 90 12
12. derstand the main programming concepts you K30 can begin writing your application program At that time you will begin to use one of the most powerful instruction sets available in a small PLC CNT CT3 K10 Step 8 Understand the Maintenance and Troubleshooting Procedures 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 DLO5 Micro PLC has many built in features such as error codes that can help you quickly identify problems eal o p a o eo o DL05 Micro PLC User Manual 6th Edition Rev C 1 11 Chapter 1 Getting Started a Questions and Answers about DLO5 Micro PLCs Q What is the instruction set like A The instruction set is very close to our popular DL240 CPU However there are significant additions such as the drum instruction networking PID control and High Speed I O capabilities Q Do I have to buy the full DirectSOFT 5 programming package to program the DL05 A No DirectSOFT 5 programming software is available for programming DirectLOGIC PLCs for no additional charge however it will only allow 100 maximum words to be programmed Go to AutomationDirect com for more information Q Is the DLO5 expandable A No the DLO5 series are stand alone PLCs with one slot for the installation of
13. n the left hand margin the paragraph to its immediate j right will be a special note Notes represent information that may make your work quicker or more efficient The word NOTE in boldface will mark the beginning of the text When you see the exclamation point icon in the left hand margin the paragraph to its immediate right will be a warning This information could prevent injury loss of property or even death in extreme cases Any warning in this manual should be regarded as critical information that should be read in its entirety The word WARNING in boldface will mark the beginning of the text Key Topics for Each Chapter The beginning of each chapter will list the key topics that can be found in that chapter Getting Started HAPTER In This Chapter General Information Specifications Lee er DL05 Micro PLC User Manual 6th Edition Rev C 1 3 Chapter 1 Getting Started DLO5 Micro PLC Components The DLO5 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 only in larger more expensive systems These include a removable connector and two RS 232C communication ports The DL05 Micro PLC Family The DLO5 Micro PLC family includes eight different versions All have the same appearance and CPU performance The CPU offers the same instruction set as our popular DL2
14. programmers need to refer to the Quick Start Tutorial in the DirectSOFT 5 Manual There you will learn how to establish a communications link with the DL05 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 DLO5 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 P Clear the Program Equivalent DirectSOFT display CLR CLR 9 xo YO S3 Fi AUX ENT ENT CLR i q OUT Move to the first A NEXT STR gt 0 EN address and enter lt END XO contact Enter output YO Sur 2 o Sxi P Enter the END E N D SHET 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 repeat this step ensuring the program is entered properly or refer to the troubleshooting guide in chapter 9 After the CPU enters the run mode the output status indicator for YO should follow the switch status on input channel X0 When the switch is on the output will be on DL05 Micro PLC User Manual 6th Edition Rev C 1 9 Chapter 1 Getting
15. s but also involves the Initialize Hardware various modes of operation and memory layout characteristics 1 10 DL05 Micro PLC User Manual 6th Edition Rev C Chapter 1 Getting Started Step 6 Review the Programming Concepts The DLO5 PLC instruction set provides for three main approaches to solving the application program depicted in the figure below e RLL diagram style programming is the best tool for solving boolean logic and general CPU register accumulator manipulation It includes dozens of instructions which will also be needed to augment drums and stages e The Timer Event Drum Sequencer features up to 16 steps and offers both time and or event based step transitions The DRUM instruction is best for a repetitive process based on a single series of steps e Stage programming also called RLL US 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 see Chapter 6 see Chapter 7 G O i aT GQ Vio agug nip lt V1076 Iii R300282 SP62 ea CD w COUT After reviewing the programming concepts above you ll be equipped with a variety of tools to write your application program Step 7 Choose the Instructions Once you have installed the Micro PLC and TMR T1 un
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