AutomationDirect DL105 User manual

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DL105 PLC User Manual
Manual Number D1--USER--M

WARNING
Thank you for purchasing automation equipment from Automationdirect.com™, doing business as
AutomationDirect. We want your new automation equipment to operate safely. Anyone who installs or uses this
equipment should read this publication (and any other relevant publications) before installing or operating the
equipment.
To minimize the risk of potential safety problems, you should follow all applicable local and national codes that regulate
the installation and operation of your equipment. These codes vary from area to area and usually change with time. It is
your responsibility to determine which codes should be followed, and to verify that the equipment, installation, and
operation are in compliance with the latest revision of these codes.
At a minimum, you should follow all applicable sections of the National Fire Code, National Electrical Code, and the
codes of the National Electrical Manufacturer’s Association (NEMA). There may be local regulatory or government
offices that can also help determine which codes and standards are necessary for safe installation and operation.
Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and
standards. We do not guarantee the products described in this publication are suitable for your particular application,
nor do we assume any responsibility for your product design, installation, or operation.
Our products are not fault--tolerant and are not designed, manufactured or intended for use or resale as on--line control
equipment 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, or weapons systems, in
which the failure of the product could lead directly to death, personal injury, or severe physical or environmental
damage (”High Risk Activities”). AutomationDirect specifically disclaims any expressed or implied warranty of fitness
for High Risk Activities.
For additional warranty and safety information, see the Terms and Conditions section of our Desk Reference. If you
have any questions concerning the installation or operation of this equipment, or if you need additional information,
please call us at 770--844--4200.
This publication is based on information that was available at the time it was printed. At AutomationDirect we
constantly strive to improve our products and services, so we reserve the right to make changes to the products and/or
publications at any time without notice and without any obligation. This publication may also discuss features that may
not be available in certain revisions of the product.
Trademarks
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company names may be trademarked and are the sole property of their respective owners. AutomationDirect
disclaims any proprietary interest in the marks and names of others.
Copyright 2009, Automationdirect.com™Incorporated
All Rights Reserved
No part of this manual shall be copied, reproduced, or transmitted in any way without the prior, written consent of
Automationdirect.com™Incorporated. AutomationDirect retains the exclusive rights to all information included in
this document.

AVERTISSEMENT
Nous vous remercions d’avoir acheté l’équipement d’automatisation de Automationdirect.comMC, en faisant des affaires
comme AutomationDirect. Nous tenons à ce que votre nouvel équipement d’automatisation fonctionne en toute sécurité.
Toute personne qui installe ou utilise cet équipement doit lire la présente publication (et toutes les autres publications
pertinentes) avant de l’installer ou de l’utiliser.
Afin de réduire au minimum le risque d’éventuels problèmes de sécurité, vous devez respecter tous les codes locaux et
nationaux applicables régissant l’installation et le fonctionnement de votre équipement. Ces codes diffèrent d’une région à
l’autre et, habituellement, évoluent au fil du temps. Il vous incombe de déterminer les codes à respecter et de vous assurer
que l’équipement, l’installation et le fonctionnement sont conformes aux exigences de la version la plus récente de ces
codes.
Vous devez, à tout le moins, respecter toutes les sections applicables du Code national de prévention des incendies, du
Code national de l’électricité et des codes de la National Electrical Manufacturer’s Association (NEMA). Des organismes de
réglementation ou des services gouvernementaux locaux peuvent également vous aider à déterminer les codes ainsi que
les normes à respecter pour assurer une installation et un fonctionnement sûrs.
L’omission de respecter la totalité des codes et des normes applicables peut entraîner des dommages à l’équipement ou
causer de graves blessures au personnel. Nous ne garantissons pas que les produits décrits dans cette publication
conviennent à votre application particulière et nous n’assumons aucune responsabilité à l’égard de la conception, de
l’installation ou du fonctionnement de votre produit.
Nos produits ne sont pas insensibles aux défaillances et ne sont ni conçus ni fabriqués pour l’utilisation ou la revente en tant
qu’équipement de commande en ligne dans des environnements dangereux nécessitant une sécurité absolue, par
exemple, l’exploitation d’installations nucléaires, les systèmes de navigation aérienne ou de communication, le contrôle de
la circulation aérienne, les équipements de survie ou les systèmes d’armes, pour lesquels la défaillance du produit peut
provoquer la mort, des blessures corporelles ou de graves dommages matériels ou environnementaux (”activités à risque
élevé”). La société AutomationDirect nie toute garantie expresse ou implicite d’aptitude à l’emploi en ce qui a trait aux
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conditions de notre documentation. Si vous avez des questions au sujet de l’installation ou du fonctionnement de cet
équipement, ou encore si vous avez besoin de renseignements supplémentaires, n’hésitez pas à nous téléphoner au
770--844--4200.
Cette publication s’appuie sur l’information qui était disponible au moment de l’impression. À la société AutomationDirect,
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désignations des produits et des entreprises peuvent être des marques de commerce et appartiennent exclusivement à
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Copyright 2009, Automationdirect.com Incorporated
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l’égard de tous les renseignements contenus dans le présent document.

1
Manual Revisions
If you contact us in reference to this manual, remember to include the revision number.
Title: DL105 Micro PLC User Manual
Manual Number: D 1 -- U S E R -- 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 corrections and a new appendix
3rd Edition 4/10 Updated with corrections and added
Appendix G

1i
Table of Contents
Chapter 1: Getting Started
Introduction 1--2.........................................................................
The Purpose of this Manual 1--2.........................................................
Where to Begin 1--2...................................................................
Supplemental Manuals 1--2.............................................................
Technical Support 1--2.................................................................
Conventions Used 1--3...................................................................
Key Topics for Each Chapter 1--3........................................................
DL105 Micro PLC Components 1--4.......................................................
The DL105 Micro PLC Family 1--4.......................................................
Programming Methods 1--4...............................................................
DirectSOFT Programming for Windows™1--4............................................
Handheld Programmer 1--5.............................................................
I/O Quick Chart Selection 1--5............................................................
Quick Start for PLC Checkout and Programming 1--6.......................................
Step 1: Unpack the Recommended DL105 Equipment 1--6.................................
Step 2: Connect Switches to Input Terminals 1--7..........................................
Step 3: Connect the Power Wiring 1--8...................................................
Step 4: Connect the Programming Device 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 Guidelines 1--10............................................
Step 2: Understand the PLC Setup Procedures 1--10........................................
Step 3: Review the I/O Selection Criteria 1--10.............................................
Step 4: Choose a System Wiring Strategy 1--10............................................
Step 5: Understand the System Operation 1--10............................................
Step 6: Review the Programming Concepts 1--11...........................................
Step 7: Choose the Instructions 1--11.....................................................
Step 8: Understand the Maintenance and Troubleshooting Procedures 1--11...................
Questions and Answers about DL105 Micro PLCs 1--12......................................
Chapter 2: Installation, Wiring, and Specifications
Safety Guidelines 2--2....................................................................
Plan for Safety 2--2....................................................................
Safety Techniques 2--2.................................................................
Three Levels of Protection 2--3..........................................................
Emergency Stops 2--3.................................................................
Emergency Power Disconnect 2--4......................................................
Orderly System Shutdown 2--4..........................................................

ii Table of Contents
DL105 PLC User Manual, 3rd Edition
Class 1, Division 2 Approval 2--4........................................................
Orientation to DL105 Front Panel 2--5.....................................................
Accessing the I/O Terminals 2--5........................................................
Protective Sheet for DL105 Vents 2--6...................................................
Connector Removal 2--6...............................................................
Mounting Guidelines 2--7.................................................................
Unit Dimensions 2--7..................................................................
Enclosures 2--7.......................................................................
Panel Layout & Clearances 2--8.........................................................
Agency Approvals 2--9.................................................................
Environmental Specifications 2--9.......................................................
Using Mounting Rails 2--10..............................................................
Wiring Guidelines 2--11...................................................................
Power Input Wiring 2--11................................................................
Fuse Protection for Input Power 2--11.....................................................
External Power Source 2--12.............................................................
Planning the Wiring Routes 2--13.........................................................
Fuse Protection for Input and Output Circuits 2--13..........................................
I/O Point Numbering 2--13...............................................................
System Wiring Strategies 2--14............................................................
PLC Isolation Boundaries 2--14..........................................................
Powering I/O Circuits with the Auxiliary Supply 2--15........................................
Powering I/O Circuits Using Separate Supplies 2--16........................................
Connecting Operator 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 Sensors 2--20..........................................................
Solid State Output Loads 2--20...........................................................
Relay Output Wiring Methods 2--22.......................................................
Surge Suppresion For Inductive Loads 2--23...............................................
Prolonging Relay Contact Life 2--24.......................................................
DC Input Wiring Methods 2--25...........................................................
DC Output Wiring Methods 2--26.........................................................
High-Speed I/O Wiring Methods 2--27.....................................................
F1--04SIM Input Simulator Wiring 2--28....................................................
Wiring Diagrams and Specifications 2--29..................................................
F1--130AR I/O Wiring Diagram 2--29......................................................
F1--130AR General Specifications 2--30...................................................
F1--130DR/F1--130DR--CE I/O Wiring Diagram 2--31........................................
F1--130DR/F1--130DR--CE General Specifications 2--32.....................................
F1--130AD I/O Wiring Diagram 2--33......................................................
F1--130AD General Specifications 2--34...................................................
F1--130DD/F1--130DD--CE I/O Wiring Diagram 2--35........................................
F1--130DD/F130--DD--CE General Specifications 2--36
......................................
F1--130AA I/O Wiring Diagram 2--37......................................................
F1--130AA General Specifications 2--38...................................................
F1--130DA I/O Wiring Diagram 2--39......................................................
F1--130DA General Specifications 2--40...................................................

iii
Table of Contents
DL105 PLC User Manual, 3rd Edition
F1--130DR--D I/O Wiring Diagram 2--41...................................................
F1--130DR--D General Specifications 2--42................................................
F1--130DD--D I/O Wiring Diagram 2--43...................................................
F1--130DD--D General Specifications 2--44................................................
Glossary of Specification Terms 2--45......................................................
Chapter 3: High-Speed Input and Pulse Output Features
Introduction 3--2.........................................................................
Built-in Motion Control Solution 3--2......................................................
Availability of HSIO Features 3--2........................................................
Dedicated High-Speed I/O Circuit 3--3...................................................
Wiring Diagrams for Each HSIO Mode 3--3...............................................
Choosing the HSIO Operating Mode 3--4..................................................
Understanding the Six Modes 3--4.......................................................
Default Mode 3--4.....................................................................
Configuring the HSIO Mode 3--5........................................................
Configuring Inputs X0 -- X3 3--5.........................................................
Mode 10: High-Speed Counter 3--6........................................................
Purpose 3--6..........................................................................
Functional Block Diagram 3--6..........................................................
Wiring Diagram 3--7...................................................................
Interfacing 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 Values 3--10......................................................
X Input Configuration 3--10..............................................................
Writing Your Control Program 3--11.......................................................
Program Example: Counter Without Preset 3--11...........................................
Program Example Cont’d 3--12...........................................................
Counter With Presets Program Example 3--13..............................................
Counter With Preload Program Example 3--15.............................................
Troubleshooting Guide for Mode 10 3--16..................................................
Mode 20: Quadrature Counter 3--17........................................................
Purpose 3--17..........................................................................
Functional Block Diagram 3--17..........................................................
Quadrature Encoder Signals 3--17........................................................
Wiring Diagram 3--18...................................................................
Interfacing to Encoder Outputs 3--18......................................................
Setup for Mode 20 3--19.................................................................
X Input Configuration 3--19..............................................................
Writing Your Control Program 3--20.......................................................
Quadrature Counter w/Preload Program Example 3--20.....................................
Program Example Cont’d 3--21...........................................................
Counter Preload Program Example 3--22..................................................
Troubleshooting Guide for Mode 20 3--22..................................................
Mode 30: Pulse Output 3--23...............................................................

iv Table of Contents
DL105 PLC User Manual, 3rd Edition
Purpose 3--23..........................................................................
Functional Block Diagram 3--24..........................................................
Wiring Diagram 3--25...................................................................
Interfacing to Drive Inputs 3--25..........................................................
Motion Profile Specifications 3--26........................................................
Physical I/O Configuration 3--26..........................................................
Logical I/O Functions 3--26..............................................................
Setup for Mode 30 3--27.................................................................
Profile / Velocity Select Register 3--27.....................................................
Profile Parameter Table 3--28............................................................
Trapezoidal Profile 3--28................................................................
Registration Profile 3--28................................................................
Velocity Profile 3--28....................................................................
Choosing the Profile Type 3--29..........................................................
Trapezoidal Profile Defined 3--29.........................................................
Registration and Home Search Profiles Defined 3--29.......................................
Velocity Profile Defined 3--29............................................................
Trapezoidal Profile Operation 3--30.......................................................
Trapezoidal Profile Applications 3--30.....................................................
Trapezoidal Profile Program Example 3--31................................................
Program Example Cont’d 3--32...........................................................
Preload Position Value 3--32.............................................................
Registration 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...........................................................
Velocity Profile Applications 3--38.........................................................
Velocity Profile Program Example 3--39...................................................
Program Example Cont’d 3--40...........................................................
Pulse Output Error Codes 3--41..........................................................
Troubleshooting Guide for Mode 30 3--41..................................................
Mode 40: High-Speed Interrupts 3--43......................................................
Purpose 3--43..........................................................................
Functional Block Diagram 3--43..........................................................
Setup for Mode 40 3--44.................................................................
Interrupts and the Ladder Program 3--44..................................................
External Interrupt Timing Parameters 3--45................................................
Timed Interrupt Parameters 3--45.........................................................
X Input / Timed INT Configuration 3--45...................................................
External Interrupt Program Example 3--46.................................................
Timed Interrupt Program Example 3--47...................................................
Mode 50: Pulse Catch Input 3--48..........................................................
Purpose 3--48..........................................................................
Functional Block Diagram 3--48..........................................................
Pulse Catch Timing Parameters 3--48.....................................................
Setup for Mode 50 3--49.................................................................
X Input Configuration 3--49..............................................................
Pulse Catch Program Example 3--50......................................................
Mode 60: Discrete Inputs with Filter 3--51...................................................

v
Table of Contents
DL105 PLC User Manual, 3rd Edition
Purpose 3--51..........................................................................
Functional Block Diagram 3--51..........................................................
Input Filter Timing Parameters 3--51......................................................
Setup for Mode 60 3--52.................................................................
X Input Configuration 3--52..............................................................
Filtered Inputs Program Example 3--53....................................................
Chapter 4: CPU Specifications and Operation
Introduction 4--2.........................................................................
DL105 CPU Features 4--2..............................................................
CPU Specifications 4--3..................................................................
CPU Hardware Setup 4--4................................................................
Communication Port Pinout Diagrams 4--4................................................
Connecting the Programming Devices 4--5...............................................
CPU Setup Information 4--5............................................................
CPU Modes 4--6......................................................................
Mode of Operation at Power-up 4--6.....................................................
Changing Modes in the DL105 PLC 4--6..................................................
Setting Bits in V7633 4--7..............................................................
Auxiliary Functions 4--8................................................................
Clearing an Existing Program 4--9.......................................................
Initializing System Memory 4--9.........................................................
Setting Retentive Memory Ranges 4--9...................................................
UsingaPassword 4--10.................................................................
CPU Operation 4--11......................................................................
CPU Operating System 4--11............................................................
Program Mode 4--12....................................................................
Run Mode 4--12........................................................................
Read Inputs 4--13......................................................................
Service Peripherals and Force I/O 4--13...................................................
Update Special Relays and Special Registers 4--13.........................................
Solve Application Program 4--14.........................................................
Write Outputs 4--14.....................................................................
Diagnostics 4--14.......................................................................
I/O Response Time 4--15..................................................................
Is Timing Important for Your Application? 4--15.............................................
Normal Minimum I/O Response 4--15.....................................................
Normal Maximum I/O Response 4--16.....................................................
Improving Response Time 4--17..........................................................
CPU Scan Time Considerations 4--18......................................................
Reading Inputs 4--18....................................................................
Writing Outputs 4--18...................................................................
Application Program Execution 4--19......................................................
PLC Numbering Systems 4--20............................................................
PLC Resources 4--20...................................................................
V--Memory 4--21.......................................................................
Binary-Coded Decimal Numbers 4--21....................................................
Hexadecimal Numbers 4--21.............................................................

vi Table of Contents
DL105 PLC User Manual, 3rd Edition
Memory Map 4--22........................................................................
Octal Numbering System 4--22...........................................................
Discrete and Word Locations 4--22.......................................................
V--Memory Locations for Discrete Memory Areas 4--22......................................
Input Points (X Data Type) 4--23..........................................................
Output Points (Y Data Type) 4--23........................................................
Control Relays (C Data Type) 4--23.......................................................
Timers and Timer Status Bits (T Data type) 4--23...........................................
Timer Current Values (V Data Type) 4--24.................................................
Counters and Counter Status Bits (CT Data type) 4--24......................................
Counter Current Values (V Data Type) 4--24...............................................
Word Memory (V Data Type) 4--25........................................................
Stages (S Data type) 4--25..............................................................
Special Relays (SP Data Type) 4--25......................................................
DL105 System V-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 / Status Bit Map 4--31........................................................
Timer Status Bit Map 4--31................................................................
Counter Status Bit Map 4--31..............................................................
Chapter 5: Standard RLL Instructions
Introduction 5--2.........................................................................
Using Boolean Instructions 5--3..........................................................
END Statement 5--3...................................................................
Simple Rungs 5--3.....................................................................
Normally Closed Contact 5--4...........................................................
Contacts in Series 5--4.................................................................
Midline Outputs 5--4...................................................................
Parallel Elements 5--5.................................................................
Joining Series Branches in Parallel 5--5..................................................
Joining Parallel Branches in Series 5--5..................................................
Combination Networks 5--6.............................................................
Comparative Boolean 5--6..............................................................
Boolean Stack 5--7....................................................................
Immediate Boolean 5--8................................................................
Boolean Instructions 5--9................................................................
Store (STR) 5--9......................................................................
Store Not (STRN) 5--9.................................................................
Or (OR) 5--10.........................................................................
Or Not (ORN) 5--10....................................................................
And (AND) 5--11.......................................................................

vii
Table of Contents
DL105 PLC User Manual, 3rd Edition
And Not (ANDN) 5--11..................................................................
And Store (AND STR) 5--12.............................................................
Or Store (OR STR) 5--12................................................................
Out (OUT) 5--14........................................................................
Or Out (OR OUT) 5--14.................................................................
Positive Differential (PD) 5--15...........................................................
Set (SET) 5--15........................................................................
Reset (RST) 5--15......................................................................
Set, Reset Instr. Continued 5--16.........................................................
Pause (PAUSE) 5--16...................................................................
Comparative Boolean 5--17................................................................
Store If Equal (STRE) 5--17..............................................................
Store If Not Equal (STRNE) 5--17.........................................................
Or If Equal (ORE) 5--18.................................................................
Or If Not Equal (ORNE) 5--18............................................................
And If Equal (ANDE) 5--19...............................................................
And If Not Equal (ANDNE) 5--19..........................................................
Store (STR) 5--20......................................................................
Store Not (STRN) 5--20.................................................................
Or (OR) 5--21..........................................................................
Or Not (ORN) 5--21.....................................................................
And (AND) 5--22.......................................................................
And Not (ANDN) 5--22..................................................................
Immediate Instructions 5--23..............................................................
Store Immediate (STRI) 5--23............................................................
Store Not Immediate (STRNI) 5--23.......................................................
Or Immediate (ORI) 5--23...............................................................
Or Not Immediate (ORNI) 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 5--27.....................................................................
Timer (TMR) and Timer Fast (TMRF) 5--28................................................
Timer Example Using Discrete Status Bits 5--29............................................
Timer Example Using Comparative Contacts 5--29..........................................
Accumulating Timer (TMRA) Accumulating Fast Timer (TMRAF) 5--30.........................
Accumulating Timer Example using Discrete Status Bits 5--31................................
Accumulator Timer Example Using Comparative Contacts 5--31..............................
Using Counters 5--32...................................................................
Counter (CNT) 5--33....................................................................
Counter Example Using Discrete Status Bits 5--34..........................................
Counter Example Using Comparative Contacts 5--34........................................
Stage Counter (SGCNT) 5--35...........................................................
Stage Counter Example Using Discrete Status Bits 5--36....................................
Stage Counter Example Using Comparative Contacts 5--36..................................
Up Down Counter (UDC) 5--37...........................................................
Up / Down Counter Example Using Discrete Status Bits 5--38................................

viii Table of Contents
DL105 PLC User Manual, 3rd Edition
Up / Down Counter Example Using Comparative Contacts 5--38..............................
Shift Register (SR) 5--39................................................................
Accumulator / Stack Load and Output Data Instructions 5--40................................
Using the Accumulator 5--40.............................................................
Copying Data to the Accumulator 5--40....................................................
Changing the Accumulator Data 5--40.....................................................
Using the Accumulator Stack 5--42.......................................................
Using Pointers 5--43....................................................................
Load (LD) 5--45........................................................................
Load Double (LDD ) 5--46...............................................................
Load Formatted (LDF) 5--47.............................................................
Load Address (LDA) 5--48...............................................................
Out (OUT) 5--49........................................................................
Out Double (OUTD) 5--49...............................................................
Out Formatted (OUTF) 5--50.............................................................
Pop (POP) 5--50.......................................................................
Pop Instruction Continued 5--51..........................................................
Logical Instructions (Accumulator) 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 (ADD) 5--60.......................................................................
Add Double (ADDD) 5--61...............................................................
Subtract (SUB) 5--62....................................................................
Subtract Double (SUBD) 5--63...........................................................
Multiply (MUL) 5--64....................................................................
Divide (DIV) 5--65......................................................................
Increment Binary (INCB) 5--66...........................................................
Decrement Binary (DECB) 5--66..........................................................
Bit Operation Instructions 5--67............................................................
Shift Left (SHFL) 5--67..................................................................
Shift Right (SHFR) 5--68................................................................
Encode (ENCO) 5--69...................................................................
Decode (DECO) 5--70..................................................................
Number Conversion Instructions (Accumulator) 5--71.......................................
Binary (BIN) 5--71......................................................................
Binary Coded Decimal (BCD) 5--72.......................................................
Invert (INV) 5--73.......................................................................
Table Instructions 5--74...................................................................
Move (MOV) 5--74......................................................................
Move Memory Cartridge / Load Label (MOVMC), (LDLBL) 5--75..............................
Copy Data From a Data Label Area to V--Memory 5--76.....................................
CPU Control Instructions 5--77............................................................

ix
Table of Contents
DL105 PLC User Manual, 3rd Edition
No Operation (NOP) 5--77...............................................................
End (END) 5--77.......................................................................
Stop (STOP) 5--77......................................................................
Program Control Instructions 5--78........................................................
Master Line Set (MLS) 5--78.............................................................
Master Line Reset (MLR) 5--78...........................................................
Understanding Master Control Relays 5--78................................................
MLS/MLR Example 5--79................................................................
Interrupt Instructions 5--80................................................................
Interrupt (INT) 5--80....................................................................
Interrupt Return (IRT) 5--80..............................................................
Enable Interrupts (ENI) 5--80.............................................................
Disable Interrupts (DISI) 5--80............................................................
External Interrupt Program Example 5--81.................................................
Timed Interrupt Program Example 5--82...................................................
Message Instructions 5--83................................................................
Fault (FAULT) 5--83.....................................................................
Fault Example 5--83....................................................................
Data Label (DLBL) 5--84................................................................
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.........................................................
Output Sequences 6--3................................................................
Step Transitions 6--4.....................................................................
Drum Instruction Parameters 6--4.......................................................
Timer-Only Transitions 6--4.............................................................
Timer and Event Transitions 6--5........................................................
Event-Only Transitions 6--6.............................................................
Counter Assignments 6--6..............................................................
Last Step Completion 6--7..............................................................
Overview of Drum Operation 6--8.........................................................
Drum Instruction Block Diagram 6--8.....................................................
Powerup State of Drum Registers 6--9...................................................
Drum Control Techniques 6--10............................................................
Drum Control Inputs 6--10...............................................................
Self-Resetting Drum 6--11...............................................................
Initializing Drum Outputs 6--11...........................................................
Using Complex Event Step Transitions 6--11...............................................
Drum Instruction 6--12....................................................................
Event Drum (EDRUM) 6--12.............................................................
Handheld Programer Drum Mnemonics 6--14..............................................

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DL105 PLC User Manual, 3rd Edition
Chapter 7: RLLPLUS Stage Programming
Introduction to Stage Programming 7--2...................................................
Overcoming “Stage Fright” 7--2.........................................................
Learning to Draw State Transition Diagrams 7--3...........................................
Introduction to Process States 7--3......................................................
The Need for State Diagrams 7--3.......................................................
A 2--State Process 7--3................................................................
RLL Equivalent 7--4...................................................................
Stage Equivalent 7--4..................................................................
Let’s Compare 7--5....................................................................
Initial Stages 7--5......................................................................
What Stage Bits Do 7--6................................................................
Stage Instruction Characteristics 7--6....................................................
Using the Stage Jump Instruction for State Transitions 7--7.................................
Stage Jump, Set, and Reset Instructions 7--7.............................................
Stage Program Example: Toggle On/Off Lamp Controller 7--8...............................
A 4--State Process 7--8................................................................
Four Steps to 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...........................................................
Modify the Block Diagram and State Diagram 7--12.........................................
UsingaTimerInsideaStage 7--13.......................................................
Add Emergency Stop Feature 7--14.......................................................
Exclusive Transitions 7--14..............................................................
Stage Program Design Considerations 7--15................................................
Stage Program Organization 7--15........................................................
How Instructions Work Inside Stages 7--16................................................
Using a Stage as a Supervisory Process 7--17.............................................
Stage Counter 7--17....................................................................
Power Flow Transition Technique 7--18....................................................
Stage View in DirectSOFT 7--18..........................................................
RLLPLUS Stage Instructions 7--19...........................................................
Stage (SG) 7--19.......................................................................
Initial Stage (ISG) 7--20.................................................................
JUMP (JMP) 7--20......................................................................
Questions and Answers about Stage Programming 7--21....................................
Chapter 8: Maintenance and Troubleshooting
Hardware System Maintenance 8--2.......................................................
Diagnostics 8--2.........................................................................
CPU Indicators 8--6......................................................................

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Communications Problems 8--7..........................................................
I/O Point Troubleshooting 8--8............................................................
Noise Troubleshooting 8--10...............................................................
Machine Startup and Program Troubleshooting 8--11........................................
Appendix A: Auxiliary Functions
Introduction A--2.........................................................................
Purpose of Auxiliary Functions A--2......................................................
Accessing AUX Functions via DirectSOFT A--3............................................
Accessing AUX Functions via the Handheld Programmer A--3...............................
AUX 2* — RLL Operations A--4............................................................
AUX 21 Check Program A--4............................................................
AUX 22 Change Reference A--4.........................................................
AUX 23 Clear Ladder Range A--4........................................................
AUX 24 Clear Ladders A--4.............................................................
AUX 3* — V-memory Operations A--4......................................................
AUX 31 Clear V--Memory A--4...........................................................
AUX 4* — I/O Configuration 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 57 Set Retentive Ranges A--5......................................................
AUX 58 Test Operations A--6............................................................
AUX 5B Counter Interface Configuration A--6..............................................
AUX 6* — Handheld Programmer Configuration A--6.......................................
AUX 61 Show Revision Numbers A--6....................................................
AUX 62 Beeper On / Off A--6............................................................
AUX 65 Run Self Diagnostics A--6.......................................................
AUX 7* — EEPROM Operations A--7.......................................................
Transferrable Memory Areas A--7........................................................
AUX 71 CPU to HPP EEPROM A--7.....................................................
AUX 72 HPP EEPROM to CPU A--7.....................................................
AUX 73 Compare HPP EEPROM to CPU A--7.............................................
AUX 74 HPP EEPROM Blank Check A--7.................................................
AUX 75 Erase HPP EEPROM A--7.......................................................
AUX 76 Show EEPROM Type A--7.......................................................
AUX 8* — Password Operations A--8......................................................
AUX 81 Modify Password A--8..........................................................
AUX 82 Unlock CPU A--8...............................................................
AUX 83 Lock CPU A--8.................................................................

xii Table of Contents
DL105 PLC User Manual, 3rd Edition
Appendix B: DL105 Error Codes
DL105 Error Codes B--2................................................................
Appendix C: Instruction Execution Times
Introduction C--2.........................................................................
V-Memory Data Registers C--2..........................................................
V-Memory Bit Registers C--2............................................................
How to Read the Tables C--2............................................................
Instruction Execution Times C--3..........................................................
Boolean Instructions C--3...............................................................
Comparative Boolean Instructions C--3...................................................
Immediate Instructions C--6.............................................................
Timer, Counter, Shift Register, EDRUM Instructions C--6....................................
Accumulator Data Instructions C--7......................................................
Logical Instructions C--8................................................................
Math Instructions C--8..................................................................
Bit Instructions C--9....................................................................
Number Conversion 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...............................................................
Appendix D: Special Relays
DL105 PLC Special Relays D--2...........................................................
Startup and Real-Time Relays D--2......................................................
CPU Status Relays D--2................................................................
System Monitoring D--2................................................................
Accumulator Status D--3................................................................
HSIO Pulse Catch Relay D--3...........................................................
Equal Relays for HSIO Mode 10 Counter Presets D--3......................................
Appendix E: PLC Memory
DL105 PLC Memory E--2..................................................................
Appendix F: European Union Directives (CE)
European Union (EU) Directives F--2......................................................
Member Countries F--2.................................................................
Special Installation Manual F--4.........................................................
Other Sources of Information F--4.......................................................
Basic EMC Installation Guidelines F--5....................................................
Enclosures F--5.......................................................................
AC Mains Filters F--5..................................................................
Suppression and Fusing F--5...........................................................

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Internal Enclosure Grounding F--6.......................................................
Equi--potential Grounding F--6..........................................................
Communications and Shielded Cables F--6...............................................
Analog and RS232 Cables F--7.........................................................
Multidrop Cables F--7..................................................................
Shielded Cables F--7..................................................................
within Enclosures F--7.................................................................
Network Isolation 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 (Floating Point) Numbering System G--6..............................................
BCD/Binary/Decimal/Hex/Octal -- What is the Difference? G--7...............................
Data Type Mismatch G--8.................................................................
Signed vs. Unsigned Integers G--9........................................................
AutomationDirect.com Products and Data Types G--10.......................................
DirectLOGIC PLCs G--10................................................................
C--more/C--more Micro--Graphic Panels G--10..............................................
Index

11
Getting Started
InThisChapter....
— 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

Getting Started
1--2 Getting Started
DL105 PLC User Manual, 3rd Edition
Introduction
Thank you for purchasing a DL105 Micro
PLC. This manual shows you how to
install, program, and maintain all the Micro
PLCs in the DL105 family. It also helps you
understand how to interface them to other
devices in a control system.
This manual contains important
information for personnel who will install
DL105 PLCs, and for the PLC
programmer. If you understand PLC
systems, our manuals will provide all the
information you need to get and keep your
system up and running.
If you already understand the DL105 Micro PLC please read Chapter 2, “Installation,
Wiring, and Specifications”, and proceed on to other chapters as needed. Be sure to
keep this manual handy for reference when you run into questions. If you are a new
DL105 customer, we suggest you read this manual completely so you can
understand the wide variety of features in the DL105 family of products. We believe
you will be pleasantly surprised with how much you can accomplish with
AutomationDirect products.
If you have purchased operator interfaces or DirectSOFT programming software,
you will need to supplement this manual with the manuals that are written for these
products.
We realize that even though we strive to be the best, we may have arranged our
information in such a way you cannot find what you are looking for. First, check these
resources for help in locating the information:
STable of Contents -- chapter and section listing of contents, in the front
of this manual
SAppendices -- reference material for key topics, near the end of this
manual
You can also check our online resources for the latest product support information:
SInternet -- 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.
The Purpose of
this Manual
Where to Begin
Supplemental
Manuals
Technical Support