Direct Logic PLC Manual

The Direct Logic PLC series is a comprehensive programmable logic controller system featuring modular design, extensive I/O capabilities, ladder logic programming, communication protocols (Ethernet, serial), real-time monitoring, and robust industrial automation functions. Below are key sections for safety, features, installation, programming, operation, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Devices 7. Programming Basics 8. Communication Features 9. Maintenance & Care 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: CPU module, I/O modules, communication ports, programming software interface, power supply unit.

Feature	Description
CPU Module	Central processing unit with memory and processing capabilities
Digital I/O Modules	Input/output modules for digital signals
Analog I/O Modules	Input/output modules for analog signals
Communication Ports	Ethernet, RS-232, RS-485 for network connectivity
Programming Port	For connecting programming device/computer
Power Supply	24V DC or 120/240V AC power input
Status Indicators	RUN, ERROR, COMM status LEDs
Memory Cartridge	For program backup and transfer
Real-time Clock	Time and date functions
Battery Backup	For memory retention during power loss

Installation

Unpack and inspect contents. Mount on DIN rail or panel.

Mount PLC: Secure to DIN rail or mounting panel using appropriate hardware.
Install modules: Slide I/O and special modules into base unit until they click into place.
Connect power: Wire power supply according to voltage requirements (24V DC or AC).
Ground system: Connect ground wire to grounding terminal.

WARNING! Disconnect all power before installation. Ensure proper grounding to prevent electrical shock.

First-Time Setup

Power on PLC; configure basic parameters.

Connect programming device: Use programming cable to connect PC to programming port.
Install software: Load DirectSOFT or compatible programming software.
Configure communication: Set communication parameters (baud rate, protocol).
Create new project: Start new ladder logic program.
Download program: Transfer initial configuration to PLC.

CAUTION! Verify voltage requirements before applying power. Use proper safety equipment.

Specifications

CPU Type: Various models with different memory and speed capabilities
Memory: 8K to 64K words (depending on model)
I/O Capacity: Up to 512 points (model dependent)
Programming Language: Ladder logic
Communication: Ethernet, RS-232, RS-485
Power Supply: 24V DC or 85-264V AC
Operating Temperature: 0°C to 55°C (32°F to 131°F)
Storage Temperature: -25°C to 70°C (-13°F to 158°F)
Humidity: 10-95% non-condensing

Controls and Settings

Access configuration via programming software or front panel controls.

Front Panel: RUN/STOP switch, STATUS LEDs, COMMUNICATION ports.

Software Settings: Ladder logic programming, I/O configuration, communication parameters, timer/counter settings, data registers, system parameters. Status Monitoring: Real-time I/O status, error logging, communication diagnostics.

Connecting Devices

I/O Devices: Connect sensors, switches, actuators to appropriate I/O terminals. Communication: Ethernet for network, RS-232/485 for serial devices.

Turn off power before making connections.
Wire inputs: Connect sensors/switches to input terminals.
Wire outputs: Connect actuators/indicators to output terminals.
Configure communication: Set network parameters in programming software.

Tip: Use shielded cables for analog signals and long cable runs to reduce noise.

Programming Basics

Supports ladder logic programming with contacts, coils, timers, counters.

Create program: Use programming software to develop ladder logic.
Basic instructions: Normally open/closed contacts, output coils.
Timers: On-delay, off-delay, retentive timers.
Counters: Up counters, down counters, combination counters.
Data handling: Move, compare, math operations.
Program control: Jump, subroutine calls, interrupts.
Test program: Use simulation mode to verify logic.
Download: Transfer program to PLC memory.

WARNING! Always test programs in simulation mode before running on live equipment.

Communication Features

Ethernet Communication: TCP/IP protocol for network connectivity. Serial Communication: Modbus RTU, ASCII protocols. Network Configuration: IP address setting, subnet masks, gateway configuration.

Maintenance & Care

Disconnect power before maintenance. Keep clean and dry; inspect periodically for loose connections.

CAUTION! Do not expose to excessive moisture, dust, or temperature extremes. Replace backup battery annually.

Regulatory Information

UL Listed, CE Compliant, RoHS Compliant. Meets industrial control equipment standards. Copyright © AutomationDirect; all rights reserved. For technical support, visit www.automationdirect.com or contact 1-800-633-0405.

Troubleshooting

Symptom	Possible Cause	Corrective Action
PLC not powering on	Power supply/wiring	Check power source; verify wiring; check fuse.
No communication	Cable/configuration	Verify cable connections; check communication settings; restart devices.
Inputs not working	Wiring/sensor power	Check input wiring; verify sensor power supply; test input status.
Outputs not activating	Wiring/fuse	Check output wiring; verify output power; check for blown fuse.
Program errors	Logic/syntax	Review ladder logic; check for syntax errors; verify addressing.

Reset: Use programming software to clear memory and reload program if needed.

Service: 1-800-633-0405; www.automationdirect.com