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AutomationDirect DL105, User Manual

The AutomationDirect DL105 is a versatile programmable logic controller (PLC) ideal for small to mid-sized automation applications. Easily program and control your processes with the user-friendly interface. For detailed instructions, download the free user manual from our website. Get the manual at manualshive.com.

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Table of Contents

DL105 PLC User Manual, 3rd Edition

Chapter 7: RLL

PLUS

Stage Programming

Introduction to Stage Programming

7--2

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Overcoming “Stage Fright”

7--2

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Learning to Draw State Transition Diagrams

7--3

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Introduction to Process States

7--3

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The Need for State Diagrams

7--3

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A 2--State Process

7--3

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RLL Equivalent

7--4

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Stage Equivalent

7--4

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Let’s Compare

7--5

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Initial Stages

7--5

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What Stage Bits Do

7--6

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Stage Instruction Characteristics

7--6

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Using the Stage Jump Instruction for State Transitions

7--7

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Stage Jump, Set, and Reset Instructions

7--7

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Stage Program Example: Toggle On/Off Lamp Controller

7--8

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A 4--State Process

7--8

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Four Steps to Writing a Stage Program

7--9

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Stage Program Example: A Garage Door Opener

7--10

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Garage Door Opener Example

7--10

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Draw the Block Diagram

7--10

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Draw the State Diagram

7--11

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Add Safety Light Feature

7--12

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Modify the Block Diagram and State Diagram

7--12

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Using a Timer Inside a Stage

7--13

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Add Emergency Stop Feature

7--14

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Exclusive Transitions

7--14

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Stage Program Design Considerations

7--15

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Stage Program Organization

7--15

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How Instructions Work Inside Stages

7--16

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Using a Stage as a Supervisory Process

7--17

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Stage Counter

7--17

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Power Flow Transition Technique

7--18

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Stage View in DirectSOFT

7--18

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RLL

PLUS

Stage Instructions

7--19

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Stage (SG)

7--19

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Initial Stage (ISG)

7--20

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JUMP (JMP)

7--20

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Questions and Answers about Stage Programming

7--21

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Chapter 8: Maintenance and Troubleshooting

Hardware System Maintenance

8--2

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Diagnostics

8--2

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CPU Indicators

8--6

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Summary of Contents for DL105

Page 1: ...uy your excess underutilized and idle equipment along with credit for buybacks and trade ins Custom engineering so your equipment works exactly as you specify Critical and expedited services Leasing R...

Page 2: ...DL105 PLC User Manual Manual Number D1 USER M...

Page 3: ...t in hazardous environments requiring fail safe performance such as in the operation of nuclear facilities aircraft navigation or communication systems air traffic control direct life support machines...

Page 4: ...x n cessitant une s curit absolue par exemple l exploitation d installations nucl aires les syst mes de navigation a rienne ou de communication le contr le de la circulation a rienne les quipements de...

Page 5: ...sion number Title DL105 Micro PLC User Manual Manual Number D1 USER M Edition Rev Date Description of Changes Original 9 96 Original Issue 2nd Edition 5 98 Updated 2nd Edition Rev A 7 03 Updated with...

Page 6: ...1 8 Step 5 Switch on the System Power 1 9 Step 6 Initialize Scratchpad Memory 1 9 Step 7 Enter a Ladder Program 1 9 Steps to Designing a Successful System 1 10 Step 1 Review the Installation Guidelin...

Page 7: ...Interface Devices 2 17 Connecting Programming Devices 2 17 Sinking Sourcing Concepts 2 18 I O Common Terminal Concepts 2 19 Connecting DC I O to Solid State Field Devices 2 20 Solid State Input Sensor...

Page 8: ...nterfacing to Counter Outputs 3 7 Setup for Mode 10 3 8 Presets and Special Relays 3 8 Preset Data Starting Location 3 9 Using Fewer than 24 Presets 3 9 Equal Relay Numbers 3 9 Calculating Your Preset...

Page 9: ...tration Profile Operation 3 33 Registration Applications 3 33 Registration Profile Program Example 3 34 Program Example Cont d 3 35 Home Search Program Example 3 36 Velocity Profile Operation 3 38 Vel...

Page 10: ...nctions 4 8 Clearing an Existing Program 4 9 Initializing System Memory 4 9 Setting Retentive Memory Ranges 4 9 Using a Password 4 10 CPU Operation 4 11 CPU Operating System 4 11 Program Mode 4 12 Run...

Page 11: ...memory 4 26 System Parameters and Default Data Locations V Data Type 4 26 DL105 Aliases 4 28 DL105 Memory Map 4 29 X Input Bit Map 4 30 Y Output Bit Map 4 30 Control Relay Bit Map 4 30 Stage Control S...

Page 12: ...5 23 And Immediate ANDI 5 24 And Not Immediate ANDNI 5 24 Or Out Immediate OROUTI 5 25 Set Immediate SETI 5 26 Reset Immediate RSTI 5 26 Timer Counter and Shift Register Instructions 5 27 Using Timers...

Page 13: ...ccumulator 5 52 And AND 5 52 And Double ANDD 5 53 Or OR 5 54 Or Double ORD 5 55 Exclusive Or XOR 5 56 Exclusive Or Double XORD 5 57 Compare CMP 5 58 Compare Double CMPD 5 59 Math Instructions 5 60 Add...

Page 14: ...ASCII Constant ACON 5 84 Numerical Constant NCON 5 84 Data Label Example 5 85 Chapter 6 Drum Instruction Programming Introduction 6 2 Purpose 6 2 Drum Terminology 6 2 Drum Chart Representation 6 3 Out...

Page 15: ...Writing a Stage Program 7 9 Stage Program Example A Garage Door Opener 7 10 Garage Door Opener Example 7 10 Draw the Block Diagram 7 10 Draw the State Diagram 7 11 Add Safety Light Feature 7 12 Modif...

Page 16: ...uration A 4 AUX 41 Show I O Configuration A 4 AUX 5 CPU Configuration A 5 AUX 51 Modify Program Name A 5 AUX 53 Display Scan Time A 5 AUX 54 Initialize Scratchpad A 5 AUX 55 Set Watchdog Timer A 5 AUX...

Page 17: ...onversion Instructions C 9 Table Instructions C 9 CPU Control Instructions C 10 Program Control Instructions C 10 Interrupt Instructions C 10 Message Instructions C 10 RLLPLUS Instructions C 10 Append...

Page 18: ...lation F 7 Appendix G Numbering Systems Introduction G 2 Binary Numbering System G 2 Hexadecimal Numbering System G 3 Octal Numbering System G 4 Binary Coded Decimal BCD Numbering System G 5 Real Floa...

Page 19: ...r 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 a...

Page 20: ...products We believe you will be pleasantly surprised with how much you can accomplish with AutomationDirect products If you have purchased operator interfaces or DirectSOFT programming software you wi...

Page 21: ...in boldface will mark the beginning of the text 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 inj...

Page 22: ...ty of Input Output choices listed in the following table DL105 Part Number Discrete Input Type Discrete Output Type External Power Auxiliary 24V Output High Speed Input Pulse Output F1 130AR AC Relay...

Page 23: ...b INPUTS OUTPUTS Part Number I O type commons Sink Source Voltage Ranges I O type commons Sink Source Voltage Current Ratings F1 130AR AC 3 80 132 VAC 90 150 VDC Relay 4 Sink or Source 12 30 VDC 7A 12...

Page 24: ...ack 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 co...

Page 25: ...red units as shown as long as you follow the instructions in the accompanying WARNING note engineering ON OFF FACTS F1 04SIM engineering ON OFF FACTS F1 04SIM Slide simulator under left most terminals...

Page 26: ...close the connector covers Do not apply power at this time 110 220 VAC Power Input 94 240 VAC 125 VDC Power Input 100 240 VDC 12 24 VDC Power Input L N G G 10 30 VDC G Step 4 Connect the Programming...

Page 27: ...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 th...

Page 28: ...types of sensors and loads can affect your choice of I O type Input Sensing PLC Input Common It is important to understand the various system design options that are available before wiring field devi...

Page 29: ...Programming Push UP UP Push DOWN DOWN LOWER RAISE LIGHT Timer Event Drum Sequencer Stage Programming see Chapter 5 see Chapter 6 see Chapter 7 X0 LDD V1076 CMPD K309482 SP62 OUT Y0 After reviewing the...

Page 30: ...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 dire...

Page 31: ...0 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 person...

Page 32: ...ing and Specifications In This Chapter Safety Guidelines Orientation to DL105 Front Panel Mounting Guidelines Wiring Guidelines System Wiring Strategies Wiring Diagrams and Specifications Glossary of...

Page 33: ...ith PLC system installation practices or your company does not have established installation guidelines you should obtain additional information from the following sources S NEMA The National Electric...

Page 34: ...are generally wired into a master control relay MCR or a safety control relay SCR that will remove power from the PLC I O system in an emergency MCRs and SCRs provide a convenient means for removing...

Page 35: ...o the shutdown before operations can resume In this case you may want to use retentive memory locations or include constants in the control program to ensure a known starting point Ideally the first l...

Page 36: ...er to the Micro PLC also powers the loads and output circuit so this terminal block groups them together The lower connector delivers the internal 24VDC auxiliary supply output on the two left most te...

Page 37: ...ectors are designed for easy removal with just a small screwdriver The drawing below shows the procedure for removal at one end You ll need to work at both ends of the connector so the ends move upwar...

Page 38: ...rom other components 5 12 129 9mm 3 16 80 3mm 3 48 88 3mm 3 63 92 1mm DIN Rail 1 5 min 3 recommended 38 1 mm 76 2mm Cable 4 82 122 33mm 2 86 72 64mm 0 15 0 38mm 0 15 0 38mm 2 holes 0 150 dia clearance...

Page 39: ...ing ducts that run parallel to the terminals Earth Ground Panel Ground Terminal DL105 Power Source Temperature Probe Star Washers Panel Ground Braid Copper Lugs Panel or Single Point Ground Star Washe...

Page 40: ...can affect mounting dimensions Some applications require agency approvals for particular components The DL105 Micro PLC approval are listed below S UL Underwriters Laboratories Inc S CUL Canadian Und...

Page 41: ...helps keep the PLC from sliding horizontally along the rail reducing the possibility of accidentally pulling the wiring loose These items can be ordered from AutomationDirect com website or from our...

Page 42: ...a risk of electrical shock if you accidentally touch the connection terminals or power wiring There are no internal fuses for the input power circuits so external circuit protection is needed to ensur...

Page 43: ...and or connection creates a voltage drop so try to keep the number of connections to a minimum In general when using 12 24 VDC input power observe the same double fusing techniques that are used with...

Page 44: ...Auxiliary Supply is current limited In order to protect your Micro PLC we suggest you add external fuses to your I O wiring A fast blow fuse with a lower current rating than the I O bank s common curr...

Page 45: ...e outputs because each is isolated from the logic side Isolation boundaries protect the operator interface and the operator from power input faults or field wiring faults When wiring a PLC it is extre...

Page 46: ...ply can power both circuits as shown in the following diagram 10 Discrete Inputs Commons Commons 8 Discrete Outputs Power Input PLC DL105 Loads 24VDC Out AC Power Fuse or Circuit Breaker DC powered DL...

Page 47: ...10 Discrete Inputs Commons Commons 8 Discrete Outputs Power Input PLC DL105 Loads 24VDC Out AC Power Load Supply Fuse or Circuit Breaker Fuse or Circuit Breaker Some applications will use the Micro P...

Page 48: ...onnections Connect the DL105 COM1 port to the 15 pin D shell connector on the rear of the Optimation panel using the cable shown below Optimation panels require 8 30VDC power so use separate wiring to...

Page 49: ...I O point with current trying to flow in the wrong direction and the circuit will not operate However we can successfully connect the supply and field device every time by understanding sourcing and s...

Page 50: ...is way the four inputs require only five terminals instead of eight Input Sensing PLC Input 4 Common Input 3 Input 2 Input 1 Note In the circuit above the current in the common path is 4 times any cha...

Page 51: ...ing In the next circuit a field device has an open emitter PNP transistor output It sources current to the PLC input point which sinks the current back to ground Since the field device is sourcing cur...

Page 52: ...cing output has the effect of inverting the output point logic In other words the field device input is energized when the PLC output is OFF from a ladder logic point of view Your ladder program must...

Page 53: ...pplication we re now ready to explore various ways to wire relay outputs to the loads Note that there are eight normally open SPST relays available They are organized into four pairs with individual c...

Page 54: ...opens there is energy stored in the inductor that is released when the voltage to the inductor is suddenly removed This release of energy is the cause of the transient voltages When inductive load dev...

Page 55: ...as switching the relay on or off only when it is necessary and if possible switching the load on or off at a time when it will draw the least current Also take measures to suppress inductive voltage s...

Page 56: ...ther AC or DC voltages will work The target applications are 12 VDC 24 VDC and 24 VAC You can actually wire part of the inputs as DC sinking others as DC sourcing and the rest as AC PLC DC Input Input...

Page 57: ...right most terminal on the upper connector NOTE Always connect all three common terminals together at the connector with short wires do not leave some common terminals unconnected This provides three...

Page 58: ...ed input interfaces to points X0 X3 Properly configured the DL105 can count quadrature pulses at up to 5 kHz from an incremental encoder as shown below Encoder Input Wiring 12 24 VDC Phase A Phase B E...

Page 59: ...power input to connect to the two left most terminals on the simulator wiring shown below since DC powered units do not generate 24VDC auxiliary output Polarity does not matter since the inputs can be...

Page 60: ...k Common Output V devices Derating Chart for Relay Outputs 0 2 4 6 8 Points 0 10 20 30 40 50 60 Ambient Temperature C F 32 50 68 86 104 122 140 C F 7A AC or DC Supply 6A 7A Fuse or C B Fuse or C B The...

Page 61: ...ve Humidity 5 to 95 non condensing Environmental air No corrosive gases permitted Vibration MIL STD 810C 514 2 Shock MIL STD 810C 516 2 Noise Immunity NEMA ICS3 304 Terminal Type Removable Wire Gauge...

Page 62: ...on terminal and may be wired as either sinking or sourcing inputs The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent cir...

Page 63: ...uts X0 X3 Standard DC Inputs X4 X11 Input Voltage Range 10 26 4 VDC 10 26 4 VDC or 21 6 26 4 VAC Maximum Voltage 30 VDC 5 kHz maximum frequency 30 VDC Minimum Pulse Width 100 s N A ON Voltage Level 9...

Page 64: ...The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent input circuit shows one channel of a typical bank The eight current s...

Page 65: ...or 150 VDC ON Current Voltage 4 mA 80 VAC or 90 VDC OFF Current Voltage 2 mA 45 VAC or 60 VDC OFF to ON Response 8 mS ON to OFF Response 15 mS Status Indicators Logic Side Commons 4 channels common x...

Page 66: ...be wired as either sinking or sourcing inputs The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent circuit for standard in...

Page 67: ...Minimum Pulse Width 100 s N A ON Voltage Level 9 0 VDC 9 0 VDC OFF Voltage Level 2 0 VDC 2 0 VDC Input Impedance 2 8 k 12 24 VDC 2 8 k 12 24 VDC Minimum ON Current 3 mA 3 mA Maximum OFF Current 0 5 m...

Page 68: ...r plus one bank of two Each bank has an isolated common terminal In the case of DC input signals the input may be wired in as either the sourcing or sinking type The wiring example above shows all com...

Page 69: ...0 132 VAC or 90 150 VDC Input Current 6 mA 132 VAC 6 8 mA 150 VDC Maximum Voltage 132 VAC or 150 VDC ON Current Voltage 4 mA 80 VAC or 90 VDC OFF Current Voltage 2 mA 45 VAC or 60 VDC OFF to ON Respon...

Page 70: ...mmon terminal and may be wired as sinking or sourcing inputs The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent circuit...

Page 71: ...DC 10 26 4 VDC or 21 6 26 4 VAC Maximum Voltage 30 VDC 5 kHz maximum frequency 30 VDC Minimum Pulse Width 100 S N A ON Voltage Level 9 0 VDC 9 0 VDC OFF Voltage Level 2 0 VDC 2 0 VDC Input Impedance 2...

Page 72: ...common terminal and may be wired as sinking or sourcing inputs The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent circu...

Page 73: ...s X4 X11 Input Voltage Range 10 26 4 VDC 10 26 4 VDC or 21 6 26 4 VAC Maximum Voltage 30 VDC 5 kHz maximum frequency 30 VDC Minimum Pulse Width 100 s N A ON Voltage Level 9 0 VDC 9 0 VDC OFF Voltage L...

Page 74: ...an be wired as either sinking or sourcing inputs The wiring example above shows all commons connected together but separate supplies and common circuits may be used The equivalent circuit for standard...

Page 75: ...0 VDC Minimum Pulse Width 100 s N A ON Voltage Level 9 0 VDC 9 0 VDC OFF Voltage Level 2 0 VDC 2 0 VDC Input Impedance 2 8 k 12 24 VDC 2 8 k 12 24 VDC Minimum ON Current 3 mA 3 mA Maximum OFF Current...

Page 76: ...owed for the input circuit ON Voltage Level The minimum voltage level at which the input point will turn ON OFF Voltage Level The maximum voltage level at which the input point will turn OFF Input Imp...

Page 77: ...utput Features In This Chapter Introduction Choosing the HSIO Operating Mode Mode 10 High Speed Counter Mode 20 Quadrature Counter Mode 30 Pulse Output Mode 40 High Speed Interrupt Mode 50 Pulse Catch...

Page 78: ...ulse catch feature to monitor one input point having a pulse width as small as 100 S 0 1ms S Programmable discrete filtering both on and off delay up to 99ms to ensure input signal integrity this is t...

Page 79: ...the HSIO circuit just passes through the I O signals to or from the CPU so that all ten inputs behave equally and all eight outputs behave equally When the CPU is configured in any other HSIO Mode the...

Page 80: ...sted in the table below operate only as the function listed If an input point is not specifically used to support a particular mode it usually operates as a filtered input by default Similarly output...

Page 81: ...ry Location V7633 11 10 1 2 3 4 5 6 7 8 9 Bits 0 0 1 0 0 0 1 0 1 0 0 HSIO Mode Setup BCD Miscellaneous Setup BCD 0 0 0 0 00 Power Up in Previous Mode 20 Power Up in Run Mode Always 00 Not Used 10 High...

Page 82: ...er V7633 contains a BCD 10 the high speed up counter in the HSIO circuit is enabled X0 automatically becomes the clock input for the high speed counter incrementing it upon each off to on transition T...

Page 83: ...in either direction so they can be wired to a counter with either sourcing or sinking outputs In the following circuit a counter has open collector NPN transistor outputs It sinks current from the PLC...

Page 84: ...An example program later in this section shows how to to this The goal of counting is to do a special action when the count reaches a preset value Refer to the figure below The counter features 24 pre...

Page 85: ...successive preset must be greater than the previous preset value If a preset value is less than a lower numbered preset value the CPU cannot compare for that value since the counter can only count upw...

Page 86: ...2 A B C NOTE Each successive preset must have a greater value than the previous preset value In the industrial lathe example B A and C B The configurable discrete input options for High Speed Counter...

Page 87: ...alue D Can use Preload input to change count The next figure shows how the HSIO counter will appear in a ladder program Note that the Enable Interrupt ENI command must execute before the counter value...

Page 88: ...Output the constant K7 to V7636 the location of the setup parameter for X2 LD K1006 Load the constant required to configure inputs as filtered inputs OUT V7635 Output the constant K1006 to V7635 the...

Page 89: ...umulator This selects Mode 10 as the HSIO mode OUT V7633 Output this address to V7633 the location of HSIO Mode select register LD K107 Load the constant required to configure X2 as an external reset...

Page 90: ...or This value represents the end of the preset list OUTD V2326 Output the accumulator contents to the memory location for preset 4 end of preset marker SP541 SP542 These special equal relays turn on i...

Page 91: ...T Set C0 on at powerup to enable counting C0 X4 RST When the preload request is made the user turns on X4 First we disable counting by resetting C0 the counter s enable input UDC CT76 K99999999 C1 C0...

Page 92: ...count The bottom input is the counter reset and must be off during counting Symptom The counter counts but the presets do not function Possible causes 1 Configuration Ensure the preset values are corr...

Page 93: ...he HSIO circuit is enabled Input X0 is dedicated to the Phase A quadrature signal and input X1 receives Phase B signal X2 is dedicated to reset the counter to zero value when energized X3 can only be...

Page 94: ...r sinking outputs In the following circuit an encoder has open collector NPN transistor outputs It sinks current from the PLC input point which sources current The power supply can be the 24VDC auxili...

Page 95: ...t instructions in your ladder program S DirectSOFT s memory editor S Use the Handheld Programmer D2 HPP We recommend using the first method above so that the HSIO setup becomes an integral part of you...

Page 96: ...Input Reset Input UDC CTxx Kxxxxxxxx UP Count DOWN Count Standard Counter Function HSIO Counter Function D Counts UP and DOWN D Counts UP and DOWN from X0 X1 D Reset input is internal only D Reset ma...

Page 97: ...he location of the setup register for X1 LD K7 Load the constant required to configure X2 as an external reset OUT V7636 Output the constant to V7636 the location of the setup register for X2 LD K1006...

Page 98: ...frequency are within the input specifications 2 Configuration make sure all of the configuration parameters are correct V7633 must be set to 20 and V7634 must be set to 0012 to enable the Phase A inp...

Page 99: ...30 By programming acceleration and deceleration values position and velocity target values the HSIO function automatically calculates the entire motion profile The figure below shows the DL105 genera...

Page 100: ...and this very crucial point Notice the I O point assignment and usage in the above diagram S Physical input X0 is not used so the terminal screw will not be wired However the HSIO function uses logica...

Page 101: ...Remember that the DL105 s DC outputs are sinking only It will be helpful to locate equivalent circuit schematics of the drive amplifier The following diagram shows how to interface to a sourcing driv...

Page 102: ...and X3 can only be filtered inputs Input X2 is dedicated as the external interrupt for use in registration mode Physical Input Configuration Register Function Hex Code Required V7634 Y0 Pulse Y1 Direc...

Page 103: ...rst location in the Profile Parameter Table stores two key pieces of information The upper four bits 12 15 select the type of profile required The lower 12 bits 0 11 select the Target Velocity 0 15 14...

Page 104: ...nction Range Units V2320 bits 12 15 Trapezoidal Profile 0 absolute 8 relative V2320 bits 0 11 Target Velocity Value 4 to 700 x 10 pps V2321 2322 Target Position Value 88388608 to 88388607 Pulses V2323...

Page 105: ...egistration marks on the scrap area of the work piece allow a machine tool to register its position relative to the rectangle to drill properly Home search moves allow open loop motion systems to re c...

Page 106: ...ofile move If you are familiar with motion control you ll notice that we do not have to specify the direction of the move The HSIO function examines the target position relative to the current positio...

Page 107: ...OUT V7633 Output the constant to V7633 the location of the HSIO Mode select register LDA O2320 Load the octal address of the beginning of the Profile Parameter Table The LDA instruction converts this...

Page 108: ...oad the constant K20 which is required to select an acceleration time of 2 seconds 20 x 100 mS Acceleration OUT V2325 Output this constant to V2325 the location of the deceleration parameter register...

Page 109: ...his case the positioning system makes an indefinite move and waits for the load to pass by a home limit switch This creates an interrupt at the moment when the load is in a known position We then stop...

Page 110: ...select register LDA O2320 Load the octal address of the beginning of the Profile Parameter Table The LDA instruction converts this to a hex number in the accumulator OUT V7630 Output this address to...

Page 111: ...UT V2324 Output this constant to V2324 the location of the acceleration parameter register LD K20 Load the constant K20 which is required to select an acceleration time of 2 seconds 20 x 100 mS Accele...

Page 112: ...herefore we will initiate a home search profile using the registration mode The home limit switch is wired to X2 causing the interrupt We choose an arbitrary initial search direction moving in the CW...

Page 113: ...ur initialized position OUTD V1076 Output this constant to C1076 V1077 SET Go CW back to home C4 Home Limit found CW search direction Turn off Start Profile SET The CW limit has been reached C1 C0 RST...

Page 114: ...the Start input is active the ladder program can command a velocity change by writing a new value to the velocity register V2323 by default The full speed range of 40 Hz to 7 kHz is available Notice f...

Page 115: ...up SP0 LD K30 Load constant K30 into the accumulator This selects Mode 30 as the HSIO mode OUT V7633 Output this constant to V7633 the location of the HSIO Mode select register LDA O2320 Load the octa...

Page 116: ...K10 Load the constant K10 which is required to select an initial velocity of 100 pps uses x10 multiplier Set Velocity X1 OUT We use a spare filtered input to allow the operator to start the profile Wh...

Page 117: ...ation Time is zero 0052 Acceleration Time is greater than 10 seconds 0010 Deceleration Time is not in BCD 0010 Deceleration Time is zero 0010 Deceleration Time is greater than 10 seconds Most errors c...

Page 118: ...e location of the HSIO Mode select register DirectSOFT Mode 60 OUT V7635 Output this constant to V7635 configuring X1 Filtered Inputs OUT V7636 Output this constant to V7636 configuring X2 LD K1006 Lo...

Page 119: ...slower The timed interrupt is programmable from 5 to 999 mS The HSIO circuit creates the high speed interrupt to the CPU The following diagram shows the external interrupt option which uses X0 In this...

Page 120: ...se the Handheld Programmer D2 HPP We recommend using the first method above so that the HSIO setup becomes an integral part of your application program An example program later in this section shows h...

Page 121: ...999 mS The configurable discrete input options for High Speed Interrupt Mode are listed in the table below Input X0 is the external interrupt when 0004 is in V7634 If you need a timed interrupt instea...

Page 122: ...0 mS filter time constant OUT V7635 Output this constant to V7635 configuring X1 Filtered Inputs OUT V7636 Output this constant to V7636 configuring X2 OUT V7637 Output this constant to V7637 configur...

Page 123: ...which is required to select filtered inputs with a 10 mS filter time constant OUT V7635 Output this constant to V7635 configuring X1 and X0 Filtered Inputs OUT V7636 Output this constant to V7636 conf...

Page 124: ...he latch at the end of the next CPU scan The latch output is available to the ladder program through the special relay contact SP100 Inputs X1 X2 and X3 are available as filtered discrete inputs Outpu...

Page 125: ...llowing S Include load and out instructions in your ladder program S DirectSOFT s memory editor S Use the Handheld Programmer D2 HPP We recommend using the first method above so that the HSIO setup be...

Page 126: ...lect filtered inputs with a 10 mS filter time constant OUT V7635 Output this constant to V7635 configuring X1 Filtered Inputs OUT V7636 Output this constant to V7636 configuring X2 OUT V7637 Output th...

Page 127: ...Mode register V7633 contains a BCD 60 the input filter in the HSIO circuit is enabled Each input X0 through X3 has its own filter time constant The filter circuit assigns the outputs of the filters as...

Page 128: ...se the Handheld Programmer D2 HPP We recommend using the first method above so that the HSIO setup becomes an integral part of your application program An example program later in this section shows h...

Page 129: ...006 which is required to select filtered inputs with a 20 mS filter time constant OUT V7635 Output this constant to V7635 configuring X1 Filtered Inputs OUT V7636 Output this constant to V7636 configu...

Page 130: ...re Setup CPU Operation Program Mode Operation Run Mode Operation I O Response Time CPU Scan Time Considerations PLC Numbering Systems Memory Map DL105 System V Memory X Input Bit Map Y Output Bit Map...

Page 131: ...4K words of memory comprised of 2 0K of ladder memory and 384 words of V memory data registers Program storage is in the FLASH memory which is a part of the CPU board in the PLC In addition there is R...

Page 132: ...rogramming for Windows Yes Built in communication ports RS232C Yes EEPROM or FLASH Standard on CPU Local Discrete I O points available 18 Local Analog input output channels maximum None High Speed I O...

Page 133: ...are available that allow you to quickly and easily connect a Handheld Programmer or a personal computer to the DL105 PLCs However if you need to build your own cables use the pinout diagrams shown The...

Page 134: ...PLCs there are a few things you need to do before you can start entering programs This section includes some basic things such as changing the CPU mode but it also includes some things that you may n...

Page 135: ...ry to enable this feature we ll show you how to set the bit later in this chapter WARNING If bit 13 in memory location V7633 is not set once the super capacitor has discharged the system memory may no...

Page 136: ...screte I O The diagram shows how the upper and lower bytes of V7633 are used For example if you entered 2060 into V7633 the powerup in run option is selected and the discrete filtered inputs are selec...

Page 137: ...mer setup so they will not be needed or available with the DirectSOFT package The following table shows a list of the Auxiliary functions for the Handheld Programmer AUX 2 RLL Operations AUX 6 Handhel...

Page 138: ...emory Remember this AUX function will reset all system memory If you have set special parameters such as retentive ranges etc they will be erased when AUX 54 is used Make sure you that you have consid...

Page 139: ...rget your password you will not be able to access the CPU The Micro PLC must be returned to the factory to have the password removed You can use the D2 HPP Handheld Programmer or DirectSOFT to enter a...

Page 140: ...examining the retentive memory settings In general the contents of retentive memory is preserved and non retentive memory is initialized to zero unless otherwise specified After the one time powerup t...

Page 141: ...rtant than others For example you need to understand how the CPU updates the I O points handles forcing operations and solves the application program The remaining segments are not that important for...

Page 142: ...n This is primarily useful during testing situations when you just need to force a bit on to trigger another event Forced Inputs The CPU reads the status of X inputs during the Read Inputs portion of...

Page 143: ...nformation Once the application program has solved the instruction logic and constructed the output image register the CPU writes the contents of the output image register to the corresponding output...

Page 144: ...the scan cycle when the field input changes states S Input Off to On delay time S CPU scan time S Output Off to On delay time The next paragraphs show how these items interact to affect the response...

Page 145: ...read until the following scan The following diagram shows an example of the timing for this situation Solve Program Read Inputs Write Outputs Solve Program Scan Solve Program Field Input Input Off On...

Page 146: ...Immediate Normal Write Outputs Solve Program Scan Solve Program Field Input Input Off On Delay Output Off On Delay I O Response Time Scan Solve Program Normal Read Input Write Output Immediate In thi...

Page 147: ...ime it takes to execute the application program This is because different instructions take different amounts of time to execute So if you think you need a faster scan then you can try to choose faste...

Page 148: ...T V2006 60 s STR X5 3 3 s ANDN X10 2 7 s OUT Y3 3 4 s END 27 s TOTAL 308 1 s Overhead DL105 Minimum 0 86 mS Maximum 3 85 ms X0 X1 Y0 OUT C0 C100 LD K10 C101 OUT V2002 C102 LD K50 C103 OUT V2006 X5 X10...

Page 149: ...emory I O points timers counters etc Most modular PLCs allow you to add I O points in groups of eight In fact all the resources of our PLCs are counted in octal It s easier for computers to count in g...

Page 150: ...hatever The V memory location is just a storage box that s all It does not convert or move the data on its own Since humans naturally count in decimal 10 fingers 10 toes we prefer to enter and view PL...

Page 151: ...ce two types of memory in the DL105 discrete and word memory Discrete memory is one bit that can be either a 1 or a 0 Word memory is referred to as V memory variable and is a 16 bit location normally...

Page 152: ...be programmed as discrete inputs or discrete outputs These locations are used in programming the discrete memory locations C or the corresponding word location which contains 16 consecutive discrete...

Page 153: ...be on when the current value is equal to or greater than the preset value of a corresponding counter Y2 OUT CT3 X0 CNT CT3 K10 X1 Each time contact X0 transitions from off to on the counter increments...

Page 154: ...ch stage also has a discrete status bit that can be used as an input to indicate whether the stage is active or inactive If the stage is active then the status bit is on If the stage is inactive then...

Page 155: ...gned to each key Powerup operational mode Change preset value V0 V2377 V0 V2377 1 16 V0 V2377 V0 V2377 V memory location for X Y or C points used 0 1 2 12 3 0000 to 9999 V7630 Starting location for th...

Page 156: ...struction is executed N A V7752 V7754 Not used N A V7755 Error code stores the fatal error code V7756 Error code stores the major error code V7757 Error code stores the minor error code V7760 V7762 No...

Page 157: ...ry reference for discrete bits X0 through X17 therefore it s alias is VX0 V40401 is the word memory reference for discrete bits X20 through X37 therefore it s alias is VX20 V40500 VY0 V40500 is the wo...

Page 158: ...77 V41100 V41103 64 Counters CT0 CT77 64 Counter Current Values None V1000 V1077 64 Counter Status Bits CT0 CT77 V41140 V41143 64 Data Words See Appendix E None V2000 V2377 256 None specific used with...

Page 159: ...9 8 7 6 5 4 3 2 1 0 Address 017 016 015 014 013 012 011 010 007 006 005 004 003 002 001 000 V40600 037 036 035 034 033 032 031 030 027 026 025 024 023 022 021 020 V40601 057 056 055 054 053 052 051 05...

Page 160: ...73 272 271 270 267 266 265 264 263 262 261 260 V41013 317 316 315 314 313 312 311 310 307 306 305 304 303 302 301 300 V41014 337 336 335 334 333 332 331 330 327 326 325 324 323 322 321 320 V41015 357...

Page 161: ...hift Register Instructions Accumulator Stack Load and Output Data Instructions Logical Instructions Accumulator Math Instructions Bit Operation Instructions Accumulator Number Conversion Instructions...

Page 162: ...e s that discusses the instruction Instruction Page ACON 5 84 ADD 5 60 ADDD 5 61 AND 5 11 5 22 5 52 AND STR 5 12 ANDD 5 53 ANDE 5 19 ANDI 5 24 ANDN 5 11 5 22 ANDNE 5 19 ANDNI 5 24 BCD 5 72 BIN 5 71 CM...

Page 163: ...rectSOFT program has been developed and accepted compiled Each instruction listed in this chapter will have a small chart to indicate how the instruction is used with DirectSOFT and the HPP DS Implied...

Page 164: ...ollowing example shows two contacts in series and a single output coil The instructions used would be STR X0 AND X1 followed by OUT Y0 OUT Y0 X0 END X1 DirectSOFT Example Handheld Mnemonics STR X0 AND...

Page 165: ...lements in parallel The Or Store ORSTR instruction allows this operation The following example shows a simple network consisting of series elements joined in parallel OUT Y0 X0 END X2 X1 X3 DirectSOFT...

Page 166: ...mbers Some of them require you to move the data all over the place before you can actually perform the comparison The DL105 Micro PLCs provide Comparative Boolean instructions that allow you to quickl...

Page 167: ...nd ORSTR instructions combine levels of the boolean stack when they are encountered An error will occur during program compilation if the CPU encounters a rung that uses more than the eight levels of...

Page 168: ...inputs or the write outputs portion of the CPU cycle NOTE Even though the immediate input instruction reads the most current status from the input point it only uses the results to solve that one ins...

Page 169: ...t Status of the contact will be opposite the state of the associated image register point or memory location Aaaa Operand Data Type DL130 Range A aaa Inputs X 0 11 Outputs Y 0 7 Control Relays C 0 377...

Page 170: ...be opposite the state of the associated image register point or memory location Aaaa Operand Data Type DL130 Range A aaa Inputs X 0 11 Outputs Y 0 7 Control Relays C 0 377 Stage S 0 377 Timer T 0 77 C...

Page 171: ...posite the state of the associated image register point or memory location Aaaa Operand Data Type DL130 Range A aaa Inputs X 0 11 Outputs Y 0 7 Control Relays C 0 377 Stage S 0 377 Timer T 0 77 Counte...

Page 172: ...Store example the branch consisting of contacts X2 X3 and X4 have been anded with the branch consisting of contact X1 STR 1 B ENT STR ENT 2 C AND V ENT 3 D OR Q ENT 4 E ANDST L ENT OUT GX 5 F ENT Y5 O...

Page 173: ...e And Store and Or Store instructions combine levels of the stack when they are encountered Since the stack is only eight levels an error will occur if the CPU encounters a rung that uses more than th...

Page 174: ...put X1 is on output Y2 and Y5 will energize STR 1 B ENT OUT GX 2 C ENT OUT GX ENT 5 F Y2 OUT X1 Y5 OUT Handheld Programmer Keystrokes DirectSOFT The Or Out instruction allows more than one rung of dis...

Page 175: ...s on an image register point memory location or a consecutive range of image register points memory locations Once the point location is set it will remain on until it is reset using the Reset instruc...

Page 176: ...continue to run and update the image register However the outputs in the range specified in the Pause instruction will be turned off at the output points PAUSE Operand Data Type DL130 Range aaa Output...

Page 177: ...ve contact The contact will be on when Vaaa Bbbb B bbb Operand Data Type DL130 Range B aaa bbb V memory V All See page 4 29 All See page 4 29 Constant K 0 FFFF In the following example when the value...

Page 178: ...V memory V All See page 4 29 All See page 4 29 Constant K 0 FFFF In the following example when the value in V memory location V2000 4500 or V2002 2345 Y3 will energize 2 C 3 D 4 E 5 F ENT 4 E 5 F ENT...

Page 179: ...mory V All See page 4 29 All See page 4 29 Constant K 0 FFFF In the following example when the value in V memory location V2000 5000 and V2002 2345 Y3 will energize 2 C 3 D 4 E 5 F ENT 5 F 0 A ENT 0 A...

Page 180: ...ct will be on when Aaaa Bbbb A aaa B bbb Operand Data Type DL130 Range A B aaa bbb V memory V All See page 4 29 All See page 4 29 Constant K 0 FFFF Timer T 0 77 Counter CT 0 77 In the following exampl...

Page 181: ...mory V All See page 4 29 All See page 4 29 Constant K 0 FFFF Timer T 0 77 Counter CT 0 77 In the following example when the value in V memory location V2000 6045 or V2002 2345 Y3 will energize 2 C 3 D...

Page 182: ...l See page 4 29 All See page 4 29 Constant K 0 FFFF Timer T 0 77 Counter CT 0 77 In the following example when the value in V memory location V2000 5000 and V2002 2345 Y3 will energize ENT 3 D 2 C 3 D...

Page 183: ...pe DL130 Range aaa Inputs X 0 11 In the following example when X1 is on Y2 will energize ENT 2 C 1 B ENT X1 Y2 OUT Handheld Programmer Keystrokes DirectSOFT STR SHFT 8 I OUT GX In the following exampl...

Page 184: ...the status of the associated input point at the time the instruction is executed The image register is not updated aaa X The And Not Immediate connects two contacts in series The status of the contac...

Page 185: ...utput will also be on OROUTI Y aaa Operand Data Type DL130 Range aaa Outputs Y 0 177 In the following example when X1 is on output point Y2 on the output module will turn on For instruction entry on t...

Page 186: ...tput or a range of outputs in the image register and the output point s at the time the instruction is executed Once the outputs are reset it is not necessary for the input to remain on RSTI Operand D...

Page 187: ...20 30 40 50 60 0 Current Value Timer preset T1 Y0 OUT Seconds 1 10 Seconds There are those applications that need an accumulating timer meaning it has the ability to time stop and then resume from whe...

Page 188: ...he preset value For example the discrete status bit for Timer 2 is TA2 TMR B bbb Preset Timer TMRF B bbb Preset Timer The timer discrete status bit and the current value are not specified in the timer...

Page 189: ...10 Seconds Seconds 1 B ENT 3 D 0 A ENT ENT 0 A In the following example a single input timer is used with a preset of 4 5 seconds Comparative contacts are used to energize Y3 Y4 and Y5 at one second i...

Page 190: ...it will be on if the current value is equal to or greater than the preset value For example the discrete status bit for timer 2 would be T2 TMRA B bbb Enable Reset Preset Timer TMRAF B bbb Enable Res...

Page 191: ...ont STR STR SHFT ENT 2 C 1 B 0 A TMR N SHFT 0 A 3 D 0 A ENT STR SHFT MLR T ENT OUT GX ENT 0 A 6 G 1 B 1 B ENT 6 G In the following example a single input timer is used with a preset of 4 5 seconds Com...

Page 192: ...The up down counter has three inputs a count up input count down input and reset input The maximum count value is 99999999 The timing diagram below shows the relationship between the counter input co...

Page 193: ...tion V1003 CNT B bbb Count Reset Preset Counter The counter discrete status bit and the current value are not specified in the counter instruction Discrete Status Bit The discrete status bit is access...

Page 194: ...SHFT ENT OUT GX ENT 0 A 1 B 2 C MLR T 2 C Handheld Programmer Keystrokes cont SHFT In the following example when X1 makes an off to on transition counter CT2 will increment by one Comparative contacts...

Page 195: ...are accessed by referencing the associated V or CT memory locations The V memory location is the counter location 1000 For example the counter current value for CT3 resides in V memory location V1003...

Page 196: ...T 2 C 5 F RST S SHFT 2 C 7 H ENT SHFT RST S 6 G SHFT ENT Handheld Programmer Keystrokes cont SHFT SHFT SHFT MLR T In the following example when X1 makes an off to on transition counter CT2 will increm...

Page 197: ...discrete status bit is accessed by referencing the associated CT memory location Operating as a counter done bit it will be on if the value is equal to or greater than the preset value For example the...

Page 198: ...R 1 B ENT STR 2 C STR 3 D SHFT ISG U 3 D 2 C 2 C ENT ENT STR SHFT ENT OUT GX ENT 0 A 1 B 2 C MLR T 2 C SHFT In the following example when X1 makes an off to on transition counter CT2 will increment by...

Page 199: ...t position and the status of the data input is placed into the starting bit position in the shift register The direction of the shift depends on the entry in the From and To fields From C0 to C17 woul...

Page 200: ...the accumulator to V2010 OUT V2010 V2010 Acc 8 9 3 5 8 9 3 5 0 0 0 0 8 9 3 5 Unused accumulator bits are set to zero Since the accumulator is 32 bits and V memory locations are 16 bits the Load Double...

Page 201: ...6 5 4 3 2 1 0 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 Acc Acc Some of the data manipulation instructions use 32 bits They use two consecutive V...

Page 202: ...he accumu lator pushing the value 3245 onto the stack Load the value 6363 into the accumu lator pushing the value 5151 to the 1st stack location and the value 3245 to the 2nd stack location LD K3245 X...

Page 203: ...lator and move stack values up one location OUT V2000 OUT V2001 Acc V2001 3 7 9 2 0 0 0 0 4 5 4 5 Acc 0 0 0 0 3 7 9 2 Previous Acc value Current Acc value Acc V2002 7 9 3 0 0 0 0 0 3 7 9 2 Acc X X X X...

Page 204: ...A Load Address instruction automatically converts the Octal address to Hex V2000 P2000 contains the value 440 Hex 440 Hex 2100 Octal which contains the value 2635 LDA O 2100 X1 OUT V 2000 Copy the dat...

Page 205: ...gs Description SP76 on when the value loaded into the accumulator by any instruction is zero NOTE Two consecutive Load instructions will place the value of the first load instruction onto the accumula...

Page 206: ...en the value loaded into the accumulator by any instruction is zero NOTE Two consecutive Load instructions will place the value of the first load instruction onto the accumulator stack In the followin...

Page 207: ...struction onto the accumulator stack In the following example when C0 is on the binary pattern of C10 C16 7 bits will be loaded into the accumulator using the Load Formatted instruction The lower 7 bi...

Page 208: ...ero NOTE Two consecutive Load instructions will place the value of the first load instruction onto the accumulator stack In the following example when X1 is on the octal number 40400 will be converted...

Page 209: ...10 V2010 Acc V2000 8 9 3 5 8 9 3 5 0 0 0 0 8 9 3 5 DirectSOFT The unused accumulator bits are set to zero STR SHFT ANDST L 3 D OUT GX SHFT AND V 2 C 0 A 1 B 0 A ENT OUTD A aaa The Out Double instructi...

Page 210: ...C10 K7 C0 Load the status of 7 consecutive bits C10 C16 into the accumulator OUTF Y0 K7 Copy the value of the specified number of bits from the accumulator to Y20 Y26 K7 C10 Location Constant 0 0 0 0...

Page 211: ...Level 8 Accumulator Stack 0 0 0 0 7 9 3 0 Level 1 X X X X X X X X Level 2 X X X X X X X X Level 3 X X X X X X X X Level 4 X X X X X X X X Level 5 X X X X X X X X Level 6 X X X X X X X X Level 7 X X X...

Page 212: ...value in V2006 using the And instruction The value in the lower 16 bits of the accumulator is output to V2010 using the Out instruction AND V2006 Handheld Programmer Keystrokes LD V2000 X1 Load the va...

Page 213: ...nstruction The value in the accumulator is anded with 36476A38 using the And double instruction The value in the accumulator is output to V2010 and V2011 using the Out Double instruction AND 36476A38...

Page 214: ...nstruction The value in the lower 16 bits of the accumulator are output to V2010 using the Out instruction 3 D OR V2006 Handheld Programmer Keystrokes LD V2000 X1 Load the value in V2000 into the lowe...

Page 215: ...oad Double instruction The value in the accumulator is ored with 36476A38 using the Or Double instruction The value in the accumulator is output to V2010 and V2011 using the Out Double instruction JMP...

Page 216: ...e Or instruction The value in the lower 16 bits of the accumulator are output to V2010 using the Out instruction XOR V2006 Handheld Programmer Keystrokes LD V2000 X1 Load the value in V2000 into the l...

Page 217: ...ble instruction The value in the accumulator is exclusively ored with 36476A38 using the Exclusive Or Double instruction The value in the accumulator is output to V2010 and V2011 using the Out Double...

Page 218: ...he same flags is executed In the following example when X1 is on the constant 4526 will be loaded into the lower 16 bits of the accumulator using the Load instruction The value in the accumulator is c...

Page 219: ...il another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 and V2001 will be loaded into the accumulator using the Load Double instruction Th...

Page 220: ...OTE The status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 will be loaded into the accumulator using t...

Page 221: ...was encountered NOTE The status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 and V2001 will be loaded...

Page 222: ...ed NOTE The status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 will be loaded into the accumulator usi...

Page 223: ...and a NON BCD number was encountered NOTE The status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 and V...

Page 224: ...he status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 will be loaded into the accumulator using the Lo...

Page 225: ...mber was encountered NOTE The status flags are only valid until another instruction that uses the same flags is executed In the following example when X1 is on the value in V2000 will be loaded into t...

Page 226: ...ent the binary value in the accumulator by 1 V2000 4 A 3 C V2000 4 A 3 D STR 2 C 5 F SHFT ENT SHFT 8 I TMR N 2 C 1 B 2 C 0 A 0 A 0 A ENT A aaa DECB The Decrement Binary instruction decrements a binary...

Page 227: ...the Out Double instruction 2 C ENT Handheld Programmer Keystrokes DirectSOFT LDD V2000 X1 Load the value in V2000 and V2001 into the accumulator SHFL K2 The bit pattern in the accumulator is shifted 2...

Page 228: ...truction Handheld Programmer Keystrokes DirectSOFT LDD V2000 X1 Load the value in V2000 and V2001 into the accumulator SHFR K2 The bit pattern in the accumulator is shifted 2 bit positions to the righ...

Page 229: ...oad instruction The bit position set to a 1 in the accumulator is encoded to the corresponding 5 bit binary value using the Encode instruction The value in the lower 16 bits of the accumulator is copi...

Page 230: ...tting the corresponding bit position to a 1 using the Decode instruction Handheld Programmer Keystrokes DirectSOFT LDF X10 K5 X1 Load the value in represented by discrete locations X10 X14 into the ac...

Page 231: ...V2001 into the accumulator BIN Convert the BCD value in the accumulator to the binary equivalent value 1 0 0 0 0 1 0 1 0 0 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 8 4 2 1 8 4 2 1 8 4 2 1 8 4 2 1 8...

Page 232: ...1 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 Acc 0 0 0 0 6 F 7 1 V2...

Page 233: ...trokes DirectSOFT LDD V2000 X1 Load the value in V2000 and V2001 into the accumulator INV Invert the binary bit pattern in the accumulator OUTD V2010 Copy the value in the accumulator to V2010 and V20...

Page 234: ...e into the accumulator Operand Data Type DL130 Range aaa V memory V All See page 4 28 In the following example when X1 is on the constant value K6 is loaded into the accumulator using the Load instruc...

Page 235: ...S Step 1 Load the number of words to be copied into the second level of the accumulator stack S Step 2 Load the offset for the data label area in ladder memory and the beginning of the V memory block...

Page 236: ...on starting location and executes the copying of data from the Data Label Area to V memory DirectSOFT32 LD K4 X1 Load the value 4 into the accumulator specifying the number of locations to be copied L...

Page 237: ...U will not enter the Run Mode Data labels subroutines and interrupt routines are placed after the End instruction The End instruction is not conditional therefore no input contact is allowed END Direc...

Page 238: ...rks the end of control for the corresponding MLS instruction The MLR reference is one less than the corresponding MLS MLR Operand Data Type DL130 Range aaa Constant K 0 6 The Master Line Set MLS and M...

Page 239: ...ntrolled by either of the MLS coils K1 MLS X0 C0 OUT X1 C1 OUT X2 Y0 OUT X3 K2 MLS X10 Y1 OUT X5 Y2 OUT X4 K1 MLR C2 OUT X5 Y3 OUT X6 K0 MLR Y4 OUT X7 A C D B DirectSOFT Handheld Programmer Keystrokes...

Page 240: ...ne execution the ladder program resumes from the point at which it was interrupted See Chapter 3 the section on Mode 40 Interrupt Operation for more details on interrupt configuration In the DL105 onl...

Page 241: ...s executed DirectSOFT INT O 0 X2 ENI DISI S S S X2 END Y5 SETI X1 Y7 SETI X3 IRT Handheld Programmer Keystrokes S S 8 I ORN R MLR T STR SHFT 8 I 1 B ENT SHFT 8 I 5 F ENT STR SHFT 8 I 3 D ENT SHFT 8 I...

Page 242: ...ogram DirectSOFT INT O0 X4 ENI DISI S S S X4 END Y5 SETI X2 X3 RSTI Y0 Y7 IRT Handheld Programmer Keystrokes LD K40 X1 Load the constant value K40 into the lower 16 bits of the accumulator OUT V7633 C...

Page 243: ...uction takes a considerable amount of time to execute This is because the FAULT parameters are stored in EEPROM Be sure to consider the instructions execution times shown in Appendix C if you are atte...

Page 244: ...e ASCII Constant instruction is used with the DLBL instruction to store ASCII text for use with other instructions Two ASCII characters can be stored in an ACON instruction If only one character is st...

Page 245: ...FAULT instruction for information on displaying messages The DV 1000 Manual also has information on displaying messages DirectSOFT Handheld Programmer Keystrokes DLBL K1 S S END S ACON A SW NCON K 20...

Page 246: ...16 Drum Instruction Programming In This Chapter Introduction Step Transitions Overview of Drum Operation Drum Control Techniques Drum Instruction...

Page 247: ...sent off This interaction makes or breaks electrical contact with the wipers creating electrical outputs from the drum The outputs are wired to devices on a machine for On Off control Drums usually ha...

Page 248: ...f F f f F F F F f F F F f F F f F f f F f F F f f f F f f F f f f F f f F f F f F f F f f F f f f F f f F f F f F f F F f F f f f f f f f F F f f f F f f f f f f f f f f F F F f f f f f f F f f f F f...

Page 249: ...sed on time and or an external event input Each step has its own transition condition which you assign during the drum instruction entry The figure below shows how timer only transitions work F f f f...

Page 250: ...drum timebase that is much faster than the CPU scan time Step transitions may also occur based on time and or external events The figure below shows how step transitions work in these cases Is Step e...

Page 251: ...sely indicate the progress of the drum instruction and can be monitored by your ladder program Suppose we program a timer drum to have 8 steps and we select CT10 for the counter number remember counte...

Page 252: ...ttern defined for the last step Having finished a drum cycle the Start and Jog inputs have no effect at this point The drum leaves the drum complete state when the Reset input becomes active or on a p...

Page 253: ...step control the main control of the drum The inputs and their functions are S Start The Start input is effective only when Reset is off When Start is on the drum timer runs if it is in a timed trans...

Page 254: ...memory configuration non retentive versus retentive The choice of the starting step on powerup and program to run mode transitions are important to consider for your application Please refer to the fo...

Page 255: ...aiting for an event and or running the timer depends on the setup After the drum enters Step 2 Reset turns On while Start is still On Since Reset has priority over Start the drum goes to the preset st...

Page 256: ...6 Jog 0 1 Jog drum Applications often require drums that automatically start over once they complete a cycle This is easily accomplished using the drum complete bit In the figure to the right the drum...

Page 257: ...specified in counts per step and events are specified as discrete contacts Unused steps must be programmed with counts per step 0 and event K0000 The discrete output points may be individually assign...

Page 258: ...sed CT n 2 2 76 Preset Step CT n 2 not used CT n 3 3 77 Current Step CT n 1 not used The following ladder program shows the EDRUM instruction in a typical ladder program as shown by DirectSOFT Steps 1...

Page 259: ...4 E 3 D ORN R ISG U ORST M 0 A ENT After entering the EDRUM mnemonic as above the handheld programmer creates an input form for all the drum parameters The input form consists of approximately fifty...

Page 260: ...0 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 DEF 0000 Outputs DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 DE...

Page 261: ...K0000 DEF K0000 DEF K0000 DEF K0000 DEF K0000 step 1 pattern 0000 Last rung Events 6 G 1 16 NEXT SHFT MLS Y 4 E NEXT SHFT SET X 1 B NEXT SHFT SET X 2 C NEXT SHFT 2 C 0 A NEXT SHFT 2 C NEXT 1 B SHFT S...

Page 262: ...tion Diagrams Using the Stage Jump Instruction for State Transitions Stage Program Example Toggle On Off Lamp Controller Four Steps to Writing a Stage Program Stage Program Example A Garage Door Opene...

Page 263: ...disadvantages as well S Large programs can become almost unmanageable because of a lack of structure S In RLL latches must be tediously created from self latching relays S When a process gets stuck i...

Page 264: ...thinking toward the states of the process we need to identify Clear thinking and concise analysis of an application gives us the best chance at writing efficient bug free programs State diagrams are j...

Page 265: ...off X1 X0 OUT C0 OUT Y0 C0 Set Reset Latch Output Latch The stage program solution is shown to the right The two inline stage boxes S0 and S1 correspond to the two states OFF and ON The ladder rung s...

Page 266: ...ay to get started because rungs are not scanned unless their stage is active Assume that we want to always begin in the Off state motor off which is how the RLL program works The Initial Stage ISG is...

Page 267: ...s equivalent operation is shown on the right When S0 is true the two rungs have power flow S If Stage bit S0 0 its ladder rungs are not scanned executed S If stage bit S0 1 its ladder rungs are scanne...

Page 268: ...ction when executed Here s how it works S The jump instruction resets the stage bit of the stage in which it occurs All rungs in the stage still finish executing during the current scan even if there...

Page 269: ...he state diagram at top speed If implemented in stage this solution would flash the light on or off each scan obviously undesirable The solution is to make the the push and the release of the pushbutt...

Page 270: ...ess S Assign I O point numbers X and Y to physical inputs and outputs 3 Draw the State Transition Diagram The state transition diagram describes the central function of the block diagram reading input...

Page 271: ...t and a down limit switch Each limit switch closes only when the door has reach the end of travel in the corresponding direction In the middle of travel neither limit switch is closed The motor has tw...

Page 272: ...emains active until the door control pushbutton activates Then we transition JMP to Push UP stage S1 A push release cycle of the pushbutton takes us through stage S1 to the RAISE stage S2 We use the a...

Page 273: ...utput In the diagram below we add an additional state called LIGHT Whenever the garage owner presses the door control switch and releases the RAISE or LOWER state is active and the LIGHT state is simu...

Page 274: ...it is not required that s good because our two locations for the Set S6 instruction make that impossible Stage numbers and how they are used determines the transition paths In stage S6 we turn on the...

Page 275: ...Y2 one scan to turn off before the Raise output Y1 energizes Ladder Program Inputs Outputs Toggle X0 Y1 Raise Y2 Lower Up limit X1 Down limit X2 Y3 Light Obstruction X3 X0 Push UP UP Push DOWN DOWN X0...

Page 276: ...ge contains ladder rung tasks done just once at powerup Its last rung resets the stage so this stage is only active for one scan or only as many scans that are required S Main Process this stage seque...

Page 277: ...stages to have a logical OR control of an output One Shot or PD coils Use care if you must use a Positive Differential coil in a stage Remember that the input to the coil must make a 0 1 transition I...

Page 278: ...ge as shown above to watch the main process The counter inside the supervisor stage uses the stage bit S1 of the main process as its count input Stage bits used as a contact let us monitor a process N...

Page 279: ...e will precede it The power flow transition method is also achievable on the handheld programmer by simply following the transition condition with the stage instruction for the next stage The power fl...

Page 280: ...reset stage instruction is executed Operand Data Type DL130 Range aaa Stage S 0 377 The following example is a simple RLLPLUS Stage program This program utilizes an initial stage and jump instructions...

Page 281: ...sition from an active stage containing the jump instruction to another stage specified in the instruction The jump occurs when the input logic is true The active stage containing the Jump will deactiv...

Page 282: ...ster representing the active inactive status of the stage in real time For example the bit for Stage 0 is referenced as S0 If S0 0 then the ladder rungs in Stage 0 are bypassed not executed on each CP...

Page 283: ...or Reset Stage Bit A These instructions are used according to the state diagram topology you have derived S Use a stage JMP instruction for a state transition moving from one state to another S Use a...

Page 284: ...nce and Troubleshooting In This Chapter Hardware System Maintenance Diagnostics CPU Indicators Communications Problems I O Point Troubleshooting Noise Troubleshooting Machine Startup and Program Troub...

Page 285: ...errors which may cause the system to function improperly perhaps introducing a safety problem The CPU will automatically switch to Program Mode if it is in Run Mode Remember in Program Mode all outpu...

Page 286: ...lay table also includes status indicators which can indicate errors For a more detailed description of each of these special relays refer to Appendix D CPU Status Relays SP12 Terminal Run mode SP16 Te...

Page 287: ...E210 Power fault E312 Communications error 2 E313 Communications error 3 E316 Communications error 6 E320 Time out E321 Communications error E501 Bad entry E502 Bad address E503 Bad command E504 Bad r...

Page 288: ...e error codes Error Code Description E4 No Program in CPU E401 Missing END statement E402 Missing LBL E406 Missing IRT E421 Duplicate stage reference E422 Duplicate SBR LBL reference E431 Invalid ISG...

Page 289: ...orrect the problem WARNING To minimize the risk of electrical shock always disconnect the system power before inspecting the physical wiring 1 First disconnect the external power 2 Verify that all ext...

Page 290: ...r clears you should monitor the system and determine what caused the problem You will find this problem is sometimes caused by high frequency electrical noise introduced into the CPU from an outside s...

Page 291: ...S The I O point status indicators are logic side indicators This means the LED which indicates the on or off status reflects the status of the point with respect to the CPU On an output point the sta...

Page 292: ...o set turn on or off the points you wish to test 7 When you finish testing I O points delete the END statement at address 0 WARNING Depending on your application forcing I O points may cause unpredict...

Page 293: ...d it can be reduced to a level that will not affect the system S Most noise problems result from improper grounding of the system A good earth ground can be the single most effective way to correct no...

Page 294: ...AUX 21 CHECK PROGRAM to check the program syntax from a Handheld Programmer or you can use the PLC Diagnostics menu option within DirectSOFT This check will find a wide variety of programming errors T...

Page 295: ...other logic to operate while disabling selected outputs The output image register is still updated but the output circuits are not For example you could make this conditional by adding an input contac...

Page 296: ...T The following example shows how to perform the duplicate reference check with a Handheld Programmer DUP COIL REF 00024 E471 One of two displays will appear NO DUP REFS Error Display example Syntax O...

Page 297: ...ed off with a programming device 3 Input point changes are not acknowledged during Run Time Edits So if you re using a high speed operation and a critical input comes on the CPU may not see the change...

Page 298: ...EDIT MODE CHANGE Use the MODE key to select Run Time Edits RUNTIME EDITS MODE CHANGE Press ENT to confirm the Run Time Edits MODE ENT ENT NEXT 00000 STR X0 Find the instruction you want to change X0...

Page 299: ...s stored in the image register The forced value will be valid until the CPU writes to the image register location during the next scan This is useful you just need to force a bit on to trigger another...

Page 300: ...ons In This Appendix Introduction AUX 2 RLL Operations AUX 3 V memory Operations AUX 4 I O Configuration AUX 5 CPU Configuration AUX 6 Handheld Programmer Configuration AUX 7 EEPROM Operations AUX 8 P...

Page 301: ...e of programming device Note the Handheld Programmer may have additional AUX functions that are not supported with the DL105 PLCs AUX Function and Description DL105 AUX 2 RLL Operations 21 Check Progr...

Page 302: ...ctions are only available from the Handheld Sometimes the AUX name or description cannot fit on one display If you want to see the complete description just press the arrow keys to scroll left and rig...

Page 303: ...to change an I O address reference or control relay reference AUX 22 allows you to quickly and easily change all occurrences within an address range of a specific instruction For example you can repl...

Page 304: ...these changes are stored NOTE You may never have to use this feature unless you have made changes that affect system memory Usually you ll only need to initialize the system memory if you are changin...

Page 305: ...onfiguration You can choose the type of counter set the counter parameters etc See Chapter 3 for a complete description of how to select the various counter features AUX 6 Handheld Programmer Configur...

Page 306: ...n the previous table AUX 72 copies information from the EEPROM installed in the Handheld Programmer to CPU memory in the DL105 You can copy different portions of EEPROM HP memory to the CPU memory as...

Page 307: ...r modify a password from within DirectSOFT by using the PLC Password sub menu This feature works slightly differently in DirectSOFT Once you ve entered a password the CPU is automatically locked when...

Page 308: ...1B DL105 Error Codes In This Appendix Error Code Table...

Page 309: ...length exceeds the amount of available CPU RAM this error will occur SP52 will be on and the error code will be stored in V7755 Reduce the size of the application program E151 BAD COMMAND A parity err...

Page 310: ...ctive Power cycle the system and if the error continues replace the CPU first and then the handheld programmer if necessary E4 NO PROGRAM A syntax error exists in the application program The most comm...

Page 311: ...ottom E452 X AS COIL An X data type is being used as a coil output E453 MISSING T C A timer or counter contact is being used where the associated timer or counter does not exist E454 BAD TMRA One of t...

Page 312: ...the handheld programmer E520 BAD OP RUN An operation which is invalid in the RUN mode was attempted by the handheld programmer E524 BAD OP PGM An operation which is invalid in the PROGRAM mode was att...

Page 313: ...nction was requested with an EEPROM in the handheld programmer which contains V memory data only E625 PROGRAM ONLY A function was requested with an EEPROM in the handheld programmer which contains pro...

Page 314: ...1C Instruction Execution Times In This Appendix Introduction Instruction Execution Times...

Page 315: ...2000 V2377 V4000 V4177 You may recall that some of the discrete points such as X Y C etc are automatically mapped into V memory see Appendix E The following bit registers contain this data Bit Registe...

Page 316: ...X Y C S N pt 17 4 s 12 0 s 5 4 sxN 6 8 s 6 8 s RST 1st T CT 2nd T CT N pt 31 6 s 17 s 14 6 sxN 6 8 s 6 8 s PAUSE 1wd Y 2wd Y N points 19 0 s 15 s 4 s x N 19 0 s 15 s 4 s x N RST 1st X Y C S 2nd X Y C...

Page 317: ...Data Reg V Bit Reg K Constant 75 s 158 s 55 s 158 s 239 s 137 s 12 0 s 12 0 s 12 0 s 12 0 s 12 0 s 12 0 s ANDNE 1st 2nd V Data Reg V Data Reg V Bit Reg K Constant V Bit Reg V Data Reg V Bit Reg K Con...

Page 318: ...0 s 12 0 s 12 0 s 1st 2nd V Data Reg V Data Reg V Bit Reg K Constant V Bit Reg V Data Reg V Bit Reg K Constant 75 s 158 s 55 s 158 s 240 s 137 s 12 0 s 12 0 s 12 0 s 12 0 s 12 0 s 12 0 s AND 1st 2nd...

Page 319: ...Register and Drum Instructions DL105 Instruction Legal Data Types Execute Not Execute TMR 1st 2nd T V Data Reg V Bit Reg K Constant 75 s 158 s 66 s 31 s 31 s 31 s TMRF 1st 2nd T V Data Reg V Bit Reg...

Page 320: ...ot Execute LD V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 68 s 149 s 62 s 169 s 256 s 8 4 s 8 4 s 8 4 s 8 4 s 8 4 s LDD V Data Reg V Bit Reg K Constant P Indir Data P Indir Bit 72 s 266 s...

Page 321: ...g V Bit Reg K Constant 63 s 257 s 54 s 8 4 s 8 4 s 8 4 s Math Instructions Accumulator DL105 Instruction Legal Data Types Execute Not Execute ADD V Data Reg V Bit Reg 198 s 397 s 10 6 s 10 6 s ADDD V...

Page 322: ...s Number Conversion Instructions Accumulator DL105 Instruction Legal Data Types Execute Not Execute BIN None 359 s 7 2 s BCD None 403 s 7 2 s INV None 27 s 5 0 s Table Instructions DL105 Instruction...

Page 323: ...N Interrupt Instructions DL105 Instruction Legal Data Types Execute Not Execute ENI None 9 s 5 s DISI None 8 s 5 s INT O0 0 s 0 s IRT None 1 6 s Message Instructions DL105 Instruction Legal Data Types...

Page 324: ...1D Special Relays In This Appendix DL105 PLC Special Relays...

Page 325: ...ck on for 0 5 second and off for 0 5 second SP5 100 ms clock on for 50 ms and off for 50 ms SP6 50 ms clock on for 25 ms and off for 25 ms SP7 Alternate scan on every other scan SP12 Terminal run mode...

Page 326: ...rent target value on when the counter current value equals the value in V2330 SP545 Current target value on when the counter current value equals the value in V2332 SP546 Current target value on when...

Page 327: ...1E PLC Memory In This Appendix DL105 PLC Memory...

Page 328: ...ained by the internal power supply 5VDC only while the PLC is powered by an external source normally 120VAC When power to the PLC is turned off the contents of RAM are maintained by a Super Capacitor...

Page 329: ...1F European Union Directives CE In This Appendix European Union EU Directives Basic EMC Installation Guidelines...

Page 330: ...ngdom Iceland Liechtenstein and Norway together with the EU members make up the European Economic Area EEA and all are covered by the Directives There are several Directives that apply to our products...

Page 331: ...stry EN50082 2 Generic immunity standard for industrial environment S Low Voltage Directive Standard Applicable to PLCs EN61010 1 Safety requirements for electrical equipment for measurement control a...

Page 332: ...e additional requirements it is recommended that the following publications be purchased and used as guidelines S BSI publication TH 42073 February 1996 covers the safety and electrical aspects of the...

Page 333: ...sor To AC Input Circuitry Schaffner FN2010 L N NOTE Very few mains filters can reduce problem emissions to neglegible levels In some cases filters may increase conducted emissions if not properly matc...

Page 334: ...bicles that contain I O devices remote I O racks or have inter system communications with the primary PLC system enclosure An equi potential bond wire must be provided alongside all serial communicati...

Page 335: ...ires To account for non European installations using single end earth grounds and sites with far from ideal earth ground characteristics we recommend the addition of 100 ohm resistors at each 0V link...

Page 336: ...Hexadecimal Numbering System Octal Numbering System Binary Coded Decimal BCD Numbering System Real Floating Point Numbering System BCD Binary Decimal Hex Octal What is the Difference Data Type Mismatc...

Page 337: ...nd one or off and on respectively You would think that it would be hard to have a numbering system built on Base 2 with only two possible values but the secret is by encoding using several digits Each...

Page 338: ...in the two representations For example consider the hex number D8AF To evaluate this hex number use the same method used to write decimal numbers Each digit in a decimal number represents a multiple o...

Page 339: ...cimal Octal Decimal 0 0 20 16 1 1 21 17 2 2 22 18 3 3 23 19 4 4 24 20 5 5 25 21 6 6 26 22 7 7 27 23 10 8 30 24 11 9 31 25 12 10 32 26 13 11 33 27 14 12 34 28 15 13 35 29 16 14 36 30 17 15 37 31 Table...

Page 340: ...this reason numbers cannot be coded as efficiently using the BCD system For example a byte can represent a maximum of 256 different numbers i e 0 255 using normal binary whereas only 100 distinct numb...

Page 341: ...9 8 7 6 5 4 3 2 1 0 Mantissa continues from above Table 6 Floating point numbers which DirectLOGIC PLCs use have three basic components sign exponent and mantissa The 32 bit word required for the IEE...

Page 342: ...1 0 2 4 5 1 2 2 5 6 1 2 8 6 4 3 2 1 6 8 4 2 1 Max Value 65535 Hexidecimal Bit Pattern Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Decimal Bit Value 8 4 2 1 8 4 2 1 8 4 2 1 8 4 2 1 Max Value F F F F BCD...

Page 343: ...to jump six digits by when viewing it as the BCD With larger numbers the error multiplies Binary values from 10 to 15 Decimal are actually invalid for the BCD data type Looking at a larger number suc...

Page 344: ...itude It is general convention to use the most significant bit MSB as the sign bit a 1 will indicate a negative and a 0 a positive number Thus a 16 bit word allows numbers in the range 32767 The follo...

Page 345: ...To change from BCD to a real number use a BIN and a BTOR instruction box When using Math instructions the data types must match For example a BCD or decimal binary number cannot be added to a real nu...

Page 346: ...Cables operator interfaces 2 17 programming 1 11 programming devices 2 17 4 5 Common terminals 2 19 Communications port 4 4 Compare instruction 5 58 Connectors common terminals 2 19 removal 2 6 Counte...

Page 347: ...tion 7 20 Initial Stages 7 5 Input simulator 1 7 2 28 Installation grounding 2 8 panel design specifications 2 8 Instructions accumulator stack Load 5 40 bit operations 5 67 boolean 5 3 5 9 comparativ...

Page 348: ...rd 4 10 A 8 Pause instruction 5 16 Pop instruction 5 50 Positive Differential instruction 5 15 Power wiring 1 8 Presets 3 8 3 10 Program control instructions 5 78 Program mode 4 12 Programming concept...

Page 349: ...instruction 5 23 Store instruction 5 9 5 20 Store Not Immediate instruction 5 23 Store Not instruction 5 9 5 20 Subtract double instruction 5 63 Subtract instruction 5 62 System panel design specific...

Page 350: ...uipment Have surplus equipment taking up shelf space We ll give it a new home Learn more Visit us at artisantg com for more info on price quotes drivers technical specifications manuals and documentat...

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