Chapter 1
Contents
1. Technical Support We strive to make our manuals the best in the industry We rely on your feedback to let us know if we are reaching our goal If you cannot find the solution to your particular application or if for any reason you need technical assistance please call us at 770 844 4200 Our technical support group will work with you to answer your questions They are available Monday through Friday from 9 00 A M to 6 00 P M Eastern Time We also encourage you to visit our web site where you can find technical and non technical information about our products and our company http www automationdirect com If you have a comment question or suggestion about any of our products services or manuals please fill out and return the Suggestions card included with this manual 1 2 DL06 Micro PLC User Manual 3rd Edition Rev C Chapter 1 Getting Started Conventions Used seem When you see the notepad icon in the left hand margin the paragraph to its ES immediate right will be a special note Notes represent information that may make your work quicker or more efficient The word NOTE in boldface type 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 UN property or even death in extreme cases Any warning in this manual should be regarded as critical infor2. I O types and power supply voltages are available Consult the following table to find the model number of the PLC that best fits your application DLO6 Micro PLC Family DLOG Part Discrete Input Discrete Output High Speed Type Type External Power Input Pulse Output AC 95 240 VAC No No Relay 95 240 VAC No No AC 95 240 VAC Yes No DC Sinking 95 240 VAC Yes Yes DC Sourcing 95 240 VAC Yes Yes Relay 95 240 VAC Yes No DC Sinking 12 24 VDC Yes Yes DC Sourcing 12 24 VDC Yes Relay 12 24 VDC Yes No DirectSOFT 5 Programming for Windows The DL06 Micro PLC can be programmed with DirectSOFT 5 Ver 5 or later 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 floating views intelligent boxes etc Firmware version 2 10 is needed in order to use the intelligent boxes 1 4 DL06 Micro PLC User Manual 3rd Edition Rev C Chapter 1 Getting Started ____ DirectSOFT 5 part number PC DSOFTS supports the DirectLOGIC CPU families You can use DirectSOFT 5 to program the DL05 DL06 DL105 DL205 DL305 and DL405 CPUs A separate manual discusses DirectSOFT 5 programming software Earlier programming software versions such as DirectSOFT32 version 4 0 can also be used to program the DLO6 Handheld Programmer All DLO6 Micro PLCs have a bui
3. Specifications When the wiring is complete close the connector covers Do not apply power at this time tij E T A 110 220 VAC Power Input 12 24 VDC Power Input O O l i a SSSSSSE SO 1 jigbeeeeeod SSeOoSeGSSO SSSSOSOSOSE s fis ov vo v2 c1 ys v7 Jv1 cOicz nc vo Y2 ci Ys vz i0 IAC L AC N 24v CO Y1 Y3 Y4 Y6 C2 C CO Ytj Y3 Y4 Y6 C2 Y1 OUTPUT 17 240V _50 60Hz 0 5A PWR 100 240V 50 60 OUTPUT Sinking Output 6 27V 10A PWR 12 24 20W YOOVDADODOVADODOO E YOPOPDODODVDODAPDODDDIOOOE 10 11 12 13 14 DOODODOODOOIDE xODDDDOODOOOOOOOE INPUT 90 120V 15mA ae 12 24V 3 15mA Step 4 Connect the Programming Device Most programmers will use DirectSOFT programming software installed on a personal computer An alternative if you need a compact portable programming device is the Handheld Programmer firmware version 2 20 or later Both devices will connect to COM port 1 of the DLO06 via the appropriate cable Use cable part D2 DSCBL cable comes with HPP For replacement cable use part DV 1000CBL NOTE The Handheld Programmer cannot create or access LCD ASCII or MODBUS instructions 1 8 DL06 Micro PLC User Manual 3rd Edition Rev C Step 5 Switch
4. e Toggle switches see Step 2 on next page e Hook up wire 16 22 AWG e DLO6 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 V5 0 or later PC DSOFT5 DirectSOFT 5 Programming Software Manual included with the software and a programming cable D2 DSCBL connects the DLO6 to a personal computer or e D2 HPP Handheld Programmer firmware version 2 0 or later comes with programming cable Please purchase Handheld Programmer Manual D2 HPP M separately Fee FE E OOOO Be SOOO E OOOO Iz EI O00008 Sl OLODODO g i ecese bed S E 00000 U FI OOOO 9 1 6 DL06 Micro PLC User Manual 3rd Edition Rev C Chapter 1 Getting Started Step 2 Connect Switches to Input Terminals To proceed with this quick start exercise or to follow other examples in this manual you will Ea need to connect one or more input switches as shown below If you have DC inputs on an AC supply DL06 you can use the auxiliary 24VDC supply on the output terminal block or other extern
5. on the System Power Apply power to the system and ensure the PWR indicator on the DLO6 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 DLO6 There are two ways to clear the system memory Chapter 1 Getting Started nnn RRR e In DirectSOFT select the PLC menu then Setup and Initialize Scratch Pad Initializing Scratch Pad will return secondary comm port settings and retentive range settings to default If you have made any changes to these you will need to note these changes and re enter them after initializing Scratchpad 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 5 programmers need to refer to Chapter 2 Quick Start in the DirectSOFT 5 Programming Software Manual There you will learn how to establish a communications link with the DL06 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 DL06 should be off If the RUN LED is on use the MODE key on the Handheld Programmer to put the PLC in Program Mode then switch to TERM E
6. 1 Y2 Y1 h D0 06DD2 DC 5 Sink or Source 12 24 VDC DC 4 Source 12 24 VDC 0 5A 12 24 VDC 1 0A Y0 Y1 Y2 Y1 n D0 06DR DC 5 Sink or Source 12 24 VDC Relay 4 Sink or Source 6 27VDC 2A 6 240 VAC 2A D0 06DD1 D DC 5 Sink or Source 12 24 VDC DC 4 Sink 6 27 VDC 0 5A 6 27 VDC 1 0A Y0 Y1 Y2 Y1 h D0 06DD2 D DC 5 Sink or Source 12 24 VDC DC 4 Source 12 24 VDC 0 5A 12 24 VDC 1 0A Y0 Y1 Y2 Y1 D DC 5 Sink or Source 12 24 VDC Relay 4 Sink or Source 6 27 VDC 2A 6 240 VAC 2A See Chapter 2 Specifications for more information about a particular DL06 version DL06 Micro PLC User Manual 3rd Edition Rev C 1 5 Chapter 1 Getting Started E Quick Start E This example is not intended to tell you everything you need to know about programming and starting up a complex control system It is only intended to give you an opportunity to demonstrate to yourself and others the basic steps necessary to power up the PLC and confirm its operation Please look for warnings and notes throughout this manual for important information you will not want to overlook Step 1 Unpack the DL06 Equipment Unpack the DL06 and gather the parts necessary to build this demonstration system The recommended components are e DLO6 Micro PLC e AC power cord or DC power supply
7. GETTING STARTED In This Chapter DNF UIE MINN oe serie ve arco ans A se eh ee ee 8 E a ee ee 1 2 Conventions Used ocr oc bS 50 Raped heed Cee Ree Lae eee eS 1 3 DLOG Micro PLC Overview ss 4 44s os aaedic nd 440 44 bee 4 SEES 1 4 I O Quick Selection Guide 25 64 404 lt c0de 209 2 44 400018405 1 5 Quick SCE ino a ee bone race ease hoes eS Coe ee E eee 1 6 Steps to Designing a Successful System 20005 1 10 Questions and Answers about DLO6 Micro PLCs 1 12 Chapter 1 Getting Started E Introduction mE The Purpose of this Manual Thank you for purchasing a DL06 Micro PLC This manual shows you how to install program and maintain all PLCs in the DLO6 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 DLO06 PLCs and for the PLC programmer This user manual will provide the information you need to get and keep your system up and running Supplemental Manuals The DO OPTIONS M manual contains technical information about the option cards available for the DLO6 PLCs This information includes specifications and wiring diagrams that will be indispensable if you use any of the optional I O or communications cards If you have purchased one of our operator interface panels or DirectSOFT programming software you will want to refer to the manuals that are written for these products
8. al 12 24VDC power supply Be sure to follow the instructions in the accompanying WARNING on this page D0 06DA D0 06DD1 iii DO 06DD2 DO 06DR Direct 06 T DO DD1 D and DO 06DR1 D Koyo DC Input F xO X2 A a x Terte SSSSESSSESSESSSES L SSSeSeSseSSSSSSESS 12 24 VDC i A Toggle Switches N UL Listed Q Ni D0 06AA and D0 06AR AC input only Dies 06 Koyo F XO 7 X2 E EG F ea wy SBSSSSSSSSSSEO e 90 120 VAC SPeeeseSeSeSeSeseseses ap Toggle Switches 3J Q UL Listed N WARNING Remove power and unplug the DLO6 when wiring the switches Use only UL approved switches rated for at N least 250VAC 1A for AC inputs Firmly mount the switches m before using NG DLO06 Micro PLC User Manual 3rd Edition Rev C 1 7 Chapter 1 Getting Started E Step 3 Connect the Power Wiring Connect the power input wiring for the DL06 Observe all precautions stated earlier in this manual For more details on wiring see Chapter 2 on Installation Wiring and
9. lt in programming port for use with the handheld programmer D2 HPP the same programmer used with the DLO5 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 2 0 or later will program the DLO6 1 0 Quick Selection Guide The nine versions of the DLO6 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 NOTE Not all instructions are available to use with the HPP the real number instructions for example DirectSOFT will be needed to program instructions such as these either DC or AC voltages or both sinking and sourcing circuit arrangements Check this guide to find the proper DL06 Micro PLC to interface to the field devices in your application 1 0 Selection Guide DLO6 Part Number INPUTS OUTPUTS 1 0 type commons Sink Source Voltage Ranges 1 0 type commons Sink Source Voltage Current Ratings AC 5 90 120 VAC AC 4 17 240 VAC 50 60 Hz 0 5A AC 5 90 120 VAC Relay 4 Sink or Source 6 27VDC 2A 6 240 VAC 2A DC 5 Sink or Source 12 24 VDC AC 4 17 240 VAC 50 60 Hz 0 5A DO 06DD1 DC 5 Sink or Source 12 24 VDC DC 4 Sink 6 27 VDC 0 5A 6 27 VDC 1 0A Y0 Y
10. mation that should be read in its entirety The word WARNING in boldface type 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 DL06 Micro PLC User Manual 3rd Edition Rev C 1 3 The DLOG6 PLC Features Chapter 1 Getting Started DLO6 Micro PLC Overview The DL06 micro PLC family is a versatile product line that combines powerful features and a very compact footprint The DL06 PLCs offer expandable I O high speed counter floating point PID etc There are a number of communication options and an optional LCD display The DL06 Micro PLC family includes nine different versions All have the same appearance and CPU performance The CPU offers an instruction set very similar to our powerful new DL260 CPU including new easy to use ASCII and MODBUS instructions All DL06 PLCs have two built in communications ports that can be used for programming operator interface networking etc 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 and second output points Details of these features and more are covered in Chapter 3 CPU Specifications and Operation There are nine versions of the DLO6 PLC The most common industrial
11. nels e DirectSOFT running on a personal computer e D2 HPP handheld programmer e Other devices which communicate via K sequence Directnet MODBUS RTU protocols should work with the DLO6 Micro PLC Contact the vendor for details A Port 2 This is a multi function port It supports RS 232C RS422 or RS485 with selective baud rates 300 38 400 bps address and parity It also supports the proprietary K sequence protocol as well as DirectNet and MODBUS RTU ASCII In Out and non sequence print protocols Q Can the DL06 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 DL06 Micro PLC User Manual 3rd Edition Rev C l 13
12. nter the following keystrokes on the Handheld Programmer Equivalent Direct SOFT display X0 Yo our END Clear the Program CLR CLR c E 3 A AUX ENT ENT CLR A Move to the first NEXT STR gt o END address and enter XO contact GX A Enter output YO OUT gt 0 ENT SHET E N D ENT Enter the END 4 TMR 3 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 DL06 Micro PLC User Manual 3rd Edition Rev C 1 9 Chapter 1 Getting Started E Steps to Designing a Successful System E 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 DL06 PLC Step 2 Understand the PLC Setup Procedures The PLC is the heart of your automation s
13. re motion functionality Q Are the ladder programs stored in a removable EEPROM A No The DL06 contains a non removable FLASH memory for program storage which may be written and erased thousands of times You may transfer programs to from DirectSOFT ona PC Q Does the DL06 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 DLO6 Micro PLC U L approved A The Micro PLC has met the requirements of UL Underwriters Laboratories Inc and CUL Canadian Underwriters Laboratories Inc See our website www Automationdirect com for complete details Q Does the DLO6 Micro PLC comply with European Union EU Directives A The Micro PLC has met the requirements of the European Union Directives CE See our website www Automationdirect com for complete details l 12 DL06 Micro PLC User Manual 3rd Edition Rev C Chapter 1 Getting Started mmm Q Which devices can I connect to the communication ports of the DL06 A Port 1 The port is RS 232C fixed at 9600 baud odd parity address 1 and uses the proprietary K sequence protocol The DL06 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 C more DirectTouch LookoutDirect DSData or Optimation Operator interface pa
14. rying to locate the problem The DL06 Micro PLC has many built in features such as error codes that can help you quickly identify problems DL06 Micro PLC User Manual 3rd Edition Rev C l 1 1 Chapter 1 Getting Started E Questions and Answers about DL06 Micro PLCs es Q What is the instruction set like A The instruction set is very close to that of our DL260 CPU The DLO6 instructions include the drum sequencing instruction networking ASCII MODBUS LCD intelligent boxes and High Speed I O capabilities High Speed inputs are available on units with DC inputs only high speed outputs are available on units with DC outputs only Q Do I have to buy the full D recfSOFT 5 programming package to program the DL06 A Yes The part number for DirectSOFT 5 PC DSOFTS is now used for all PLCs in the DirectLOGIC family and the price is very affordable Q Is the DLO6 expandable A Yes the DLO6 series function as stand alone PLCs However option card slots allow you to expand the system without changing the footprint Q Does the DL06 have motion control capability A Yes the DL06 has limited motion control capabilities 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 Appendix E The HO CTRIO 2 option module can also be used to provide mo
15. umulator manipulation It includes dozens of instructions which will also be needed to augment drums and stages 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 S 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 p Z Ve gy LDD i lt V1076 R300482 c s QD SP62 Yo OUT CLowe GAD 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 a understand the main programming concepts you K30 NT 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 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 t
16. ystem Make sure you take time to understand the various features and setup requirements Step 3 Review the I O Selection Criteria 2s he There are many considerations involved when you e i select your I O type and field devices Take time to gt i put understand how the various types of sensors and T L Sensing loads can affect your choice of I O type Common ea ee eee ee ee za Step 4 Choose a System Wiring Strategy AC It is important to understand the various J system design options that are available before BLOB Bower input 16 Outputs Commons wiring field devices and field side power Se oe supplies to the Micro PLC i i 4 f o Step 5 Understand the System Operation Before you begin to enter a program it is very helpful to understand how the DL06 system Taser Ua processes information This involves not only program execution steps but also involves the various modes of operation and memory layout characteristics Initialize Hardware l 10 DL06 Micro PLC User Manual 3rd Edition Rev C Chapter 1 Getting Started Ea Step 6 Review the Programming Concepts The DL06 PLC instruction set provides for three main approaches to solving the application aA program depicted in the figure below e RLL diagram style programming is the best tool for solving boolean logic and general CPU register acc
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