Chapter 1 - AutomationDirect

Chapter 1 - AutomationDirect
Getting Started
11
In This Chapter. . . .
— Introduction
— Conventions Used
— DL105 Micro PLC Components
— Programming Methods
— I/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
Getting Started
Introduction
The Purpose of
this Manual
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.
Where to Begin
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
AutomationDirect products.
Supplemental
Manuals
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:
Table of Contents -- chapter and section listing of contents, in the front
of this manual
S 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:
S 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.
S
DL105 PLC User Manual, 3rd Edition
Getting Started
1--3
Conventions Used
When you see the “exclamation mark” 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).
The entire WARNING: will be in boldface text.
Key Topics for
Each Chapter
The beginning of each chapter will list the
key topics that can be found in that
chapter.
1
DL105 PLC User Manual, 3rd Edition
Getting Started
When you see the “notepad” icon in the left-hand margin, the paragraph to its
immediate right will be a special note.
The word NOTE: in boldface will mark the beginning of the text.
1--4
Getting Started
Getting Started
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
Micro PLC Family
DL105
Part Number
The DL105 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 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 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.
Discrete
Input Type
Discrete
Output Type
External
Power
Auxiliary
24V Output
High-Speed
Input
Pulse
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
DirectSOFT
Programming for
Windows
Two programming methods are available: a software programming package and a
handheld programmer. The software and the handheld programmer support RLL
(Relay Ladder Logic) and RLL PLUS (STAGE) programming.
The DL105 Micro PLC can be programmed with one of the most advanced
programming packages in the industry ----DirectSOFT5. This is the most recent
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 DL05, DL06, DL105,
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
Getting Started
1--5
Handheld
Programmer
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
Partt N
P
Number
b
INPUTS
OUTPUTS
I/O type /
commons
Sink /
Source
Voltage Ranges
I/O type / Sink /
commons Source
Voltage / Current
Ratings
F1--130AR
AC / 3
--
80 -- 132 VAC
90 -- 150 VDC
Relay / 4 Sink or
Source
12 -- 30 VDC, 7A *
12 -- 250 VAC, 7A *
F1--130DR
DC / 3
Sink or
Source
10 -- 26.4 VDC
21.6 -- 26.4 VAC
Relay / 4 Sink or
Source
12 -- 30 VDC, 7A *
12 -- 250 VAC, 7A *
F1--130AD
AC / 3
--
80 -- 132 VAC
90 -- 150 VDC
DC / 1 **
Sink
5 -- 30 VDC, 0.3A (Y0--Y1)
5 -- 30 VDC, 0.6A (Y3--Y7)
F1--130DD
DC / 3
Sink or
Source
10 -- 26.4 VDC
21.6 -- 26.4 VAC
DC / 1 **
Sink
5 -- 30 VDC, 0.3A (Y0--Y1)
5 -- 30 VDC, 0.6A (Y3--Y7)
F1--130AA
AC / 3
--
80 -- 132 VAC
90 -- 150 VDC
AC / 4
--
20 -- 140 VAC, 47 -- 63 Hz
1.7A *
F1--130DA
DC / 3
Sink or
Source
10 -- 26.4 VDC
21.6 -- 26.4 VAC
AC / 4
--
20 -- 140 VAC, 47 -- 63 Hz
1.7A *
F1--130DR--D
DC / 3
Sink or
Source
10 -- 26.4 VDC
21.6 -- 26.4 VAC
Relay / 4 Sink or
Source
F1--130DD--D
DC / 3
Sink or
Source
10 -- 26.4 VDC
21.6 -- 26.4 VAC
DC / 1 **
Sink
12 -- 30 VDC, 7A *
12 -- 250 VAC, 7A *
5 -- 30 VDC, 0.3A (Y0--Y1)
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
Getting Started
There is a separate manual that discusses the DirectSOFT programming software
which is included with your software package.
1--6
Getting Started
Getting Started
Quick Start for PLC Checkout and Programming
If you have experience with PLCs, or if you just want to setup a quick example, this
example is for you! 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 Recommended DL105
Equipment
Unpack the DL105 equipment and verify you have the recommended parts
necessary to build this demonstration system. The components are:
S DL105 Micro PLC
S AC power cord for AC-powered units
S F1--04SIM input simulator, or toggle switches (see Step 2 on next page).
S Hook-up wire, 16-20 AWG
S DL105 User Manual (this manual)
S A small screwdriver, regular or #2 Philips type
You will need at least one of the following programming options:
S DirectSOFT Programming Software, DirectSOFT Manual, and a
programming cable (connects the DL105 to a personal computer),or
S D2--HPP Handheld Programmer (comes with programming cable), and
the Handheld Programmer Manual
DL105 PLC User Manual, 3rd Edition
Getting Started
1--7
Step 2: Connect Switches to Input Terminals
F1--130DR/F1--130DR--CE,
F1--130DD/F1--130DD--CE,
F1--130DA
ON
FACTS
engineering
F1--04SIM
(DC input versions)
F1--130DR--D, F1--130DD--D
(DC-powered versions)
Slide simulator under
left-most terminals
and tighten screws.
OFF
F1--130AR, F1--130AD, F1--130AA
(AC input versions, 120VAC only)
ON
FACTS
engineering
F1--04SIM
Toggle Switches, UL Listed
OFF
WARNING: DO NOT wire the
toggle switches as shown to
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
discrete inputs.
DL105 PLC User Manual, 3rd Edition
Getting Started
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 X0 -- X3. DC-powered
units will require routing DC power to the simulator as shown. We recommend using
one of the models compatible 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.
1--8
Getting Started
Getting Started
Step 3: Connect the Power Wiring
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.
12/24 VDC Power Input
110/220 VAC Power Input
125 VDC Power Input
94 -- 240 VAC
L
N
10 -- 30 VDC
+
-- G
100 -- 240 VDC
G
+
--
G
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.
Use cable part no.
D2--DSCBL
(cable comes with HPP)
For replacement
cable, use part no.
DV--1000CBL
DL105 PLC User Manual, 3rd Edition
Getting Started
1--9
Step 5: Switch on the System Power
Step 6: Initialize Scratchpad Memory
It’s a good precaution to always clear the system memory (scratchpad memory) on a
new DL105. When a unit has been without power for several days, the system RAM
contents may have been corrupted and will require initialization.
S In DirectSOFT, select the PLC Menu > Setup > Initialize Scratchpad.
For additional information, see the DirectSOFT Manual.
S 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.
Equivalent DirectSOFT display
X0
Y0
OUT
CLR
C
2
NEXT
Clear the Program
CLR
E
$
AUX
4
ENT
A
STR
0
ENT
ENT
END
GX
OUT
SHFT
A
E
4
0
N
TMR
3
Move to the first
address and enter
X0 contact
Enter output Y0
ENT
D
CLR
ENT
Enter the END
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 8.
After the CPU enters 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
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.
1--10
Getting Started
Getting Started
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 DL105 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
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.
Input
+
PLC
Input
Sensing
-Common
Step 4:
Choose a System
Wiring Strategy
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.
AC
Power
Loads
DL105 Power Input
PLC
+24 VDC
+
Step 5:
Understand the
System Operation
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
characteristics.
DL105 PLC User Manual, 3rd Edition
8 Outputs
10 Inputs
--
Power up
Initialize hardware
Commons
Commons
1--11
Getting Started
S
S
S
Standard RLL Programming
(see Chapter 5)
X0
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.
The Timer/Event Drum Sequencer features up to 16 steps and offers
both time and/or event-based step transitions. The EDRUM instruction
is best for a repetitive process based on a single series of steps.
Stage programming (also called RLL PLUS) 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.
Timer/Event Drum Sequencer
(see Chapter 6)
Stage Programming
(see Chapter 7)
Push--UP
RAISE
LDD
V1076
DOWN
CMPD
K309482
SP62
Y0
OUT
LIGHT
LOWER
UP
Push-DOWN
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
Step 8:
Understand the
Maintenance and
Troubleshooting
Procedures
Once you have installed the Micro PLC
and understand the main programming
concepts, you 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.
TMR
K30
T1
CNT
K10
CT3
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.
DL105 PLC User Manual, 3rd Edition
Getting Started
The DL105 PLC instruction set provides for three main approaches to solving the
application program, depicted in the figure below.
Step 6:
Review the
Programming
Concepts
1--12
Getting Started
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.
Q. Do I have to buy the full DirectSOFT5 programming package to program the DL105?
A. No, DirectSOFT100R can 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 DL05/06/205/305/405 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 a non-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.R approved?
A. The Micro PLC has met the requirements of UL (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
DL105 PLC User Manual, 3rd Edition
Getting Started
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:
S DV-1000 Data Access Unit or Optimation Operator interface panels
S DirectSOFT (running on a personal computer)
S D2-HPP handheld programmer
S Other devices which communicate via K-sequence protcol should work
with the DL105 Micro PLC. Contact the vendor for details.
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