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9780134328812

Programmable Logic Controllers

by ;
  • ISBN13:

    9780134328812

  • ISBN10:

    0134328817

  • Edition: CD
  • Format: Hardcover
  • Copyright: 2007-01-01
  • Publisher: Pearson College Div
  • View Upgraded Edition
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List Price: $115.80

Summary

Emphasizes the Allen Bradley SLC 500 PLC, covers all three Allen Bradley PLCs (PLC 5, SLC 500, and ControlLogix); as a result, it is the most comprehensive PLC book on the market. Numerous Allen Bradley manuals are included on th enclosed CD to support PLC experiments and problems that demonstrate the use of idustrial reference material. The primary focus of this book is ladder logic programming, but chapters on switches, sensors, output actuators, process control, industrial networks, and three other PLC languages (Function Block Diagrams, Structure Text, and Sequential Function Charts) are also included. Operation and programming for two generations of Allen Bradley PLC softwarel rack/slot-based addressing in the PLC 5 and SLC 500 and tag-based addressing in ControlLogix system. Standard ladder logic building blocks are developed for PLC instructions in Chapters 4 through 11, 13, 15 and 16. Troubleshooting is integrated into each chapter. Descriptions of the five IEC 61131 programming languages with example problems for the four supported in Allen Bradley PLCs. This book describes the technology so that readers can learn PLCs with no previous experience in PLCs or discrete and analog system control.

Table of Contents

Part 1 Programmable Logic Controllers---Fundamental Concepts
1(348)
Goal
1(1)
Objectives
1(1)
Career Insight
1(2)
Introduction to Programmable Logic Controllers
3(32)
Goals and Objectives
3(1)
The PLC Industry Today
3(3)
PLC Definitions
4(1)
PC versus PLC
5(1)
Relay Ladder Logic
6(5)
Electromagnetic Relay
6(2)
Relay Control Systems
8(3)
PLC System and Components
11(9)
Backplane
13(1)
Processor and Power Supply
13(1)
Programming Device
13(1)
Input and Output Interface
13(3)
Special Communications Modules and Network Connections
16(4)
PLC Special-Purpose Modules
20(1)
PLC Types
20(2)
Rack/Slot Address Based
20(2)
Tag Based PLCs
22(1)
Soft PLCs or PC-Based Control
22(1)
PLC Ladder Logic Programming
22(6)
PLC Solution
22(2)
Ladder Logic Operation
24(1)
An Alternate Solution
25(1)
PLC Advantages
25(3)
Electrical and PLC Safety
28(4)
Electrical Shock---How the Body Reacts
28(1)
The Nature of Electrical Shock
29(2)
Safe Electrical Practices
31(1)
Response to Shock Victims
32(1)
Web Sites for PLC Manufacturers
32(3)
Problems
34(1)
Input Devices and Output Actuators
35(44)
Goals and Objectives
35(1)
Manually Operated Industrial Switches
35(6)
Toggle Switches
36(2)
Push Button Switches
38(2)
Selector Switches
40(1)
Mechanically Operated Industrial Switches
41(7)
Limit Switches
41(1)
Flow Switches
42(1)
Level Switches
42(2)
Pressure Switches
44(1)
Temperature Switches
45(1)
Control Diagrams
45(3)
Industrial Sensors
48(12)
Proximity Sensors
49(2)
Photoelectric Sensors
51(9)
Interfacing Input Field Devices
60(3)
Powering Input Field Devices
61(1)
Input Wiring
61(1)
Current Sinking and Current Sourcing Devices
62(1)
Electromagnetic Output Actuators
63(8)
Solenoid-Controlled Devices
63(3)
Control Relays
66(3)
Latching Relays
69(1)
Contactors
69(1)
Motor Starters
69(2)
Visual and Audio Output Devices
71(1)
Pilot Lamps
71(1)
Horns and Alarms
71(1)
Interfacing Output Field Devices
72(2)
Powering Output Field Devices
72(1)
Output Wiring
73(1)
Current Sinking and Current Sourcing Devices
73(1)
Troubleshooting Input and Output Devices
74(5)
Troubleshooting Switches
75(1)
Troubleshooting Relays
75(1)
Troubleshooting Proximity Sensors
76(1)
Troubleshooting Photoelectric Sensors
76(2)
Problems
78(1)
Introduction to PLC Programming
79(70)
Goals and Objectives
80(1)
Number Systems
80(4)
Number System Basics
80(1)
Binary System
81(1)
Octal Number System
82(2)
Bits, Bytes, Words, And Memory
84(1)
PLC Memory and Register Structure
85(8)
Allen-Bradley Memory Organization
85(1)
Allen-Bradley PLC 5 Memory Organization
86(1)
Allen-Bradley SLC 500 Memory Organization
87(2)
Allen-Bradley Logix System Memory Organization
89(4)
Input and Output Addressing
93(12)
PLC 5 Rack/Group-Based Addressing
93(3)
SLC 500 Rack/Slot-Based Addressing
96(5)
Other Vendors' Rack/Slot PLC Addressing
101(1)
Tag-Based Addressing
101(4)
Internal Control Relay Bit Addressing
105(5)
PLC 5 and SLC 500 Binary Bit Addressing
106(1)
ControlLogix Binary Bit Addressing
107(2)
Retentive and Non-retentive Memory
109(1)
Status Data Addressing
110(1)
PLC 5 and SLC 500 Status Data Addressing
110(1)
Logix System Status
110(1)
Allen-Bradley Input Instructions and Output Coils
111(7)
Examine if Closed and Examine if Open Instructions
112(3)
Output Energize, Output Latch, and Output Unlatch Instructions
115(3)
Inputs, Outputs, and Scan Time
118(5)
Scan Time
118(1)
Linking Inputs and Outputs
119(1)
Process Tank Application
120(3)
PLC Program Design and Relay Ladder Logic Conversion
123(14)
Examine if Closed and Examine if Open Selection
124(2)
Multiple Inputs
126(2)
Multiple Outputs
128(1)
Empirical Program Design
129(5)
Converting Relay Logic to PLC Solutions
134(3)
Troubleshooting Ladder Logic Control Systems
137(12)
System Troubleshooting Tools
137(4)
Troubleshooting Sequence
141(1)
Troubleshooting Input and Output Modules
142(3)
General Problems
145(1)
PLC 5 Problems
146(1)
SLC 500 Problems
146(1)
Controllogix Problems
146(1)
Challenge Problems
147(2)
Programming Timers
149(42)
Goals and Objectives
149(1)
Mechanical Timing Relays
149(4)
Timed Contacts
150(1)
Instantaneous Contacts
151(1)
Timing Relay Operation
152(1)
Selecting Timing Relays
153(1)
Electronic Timing Relays
153(1)
PLC Timer Instructions
154(1)
Allen-Bradley Timer Instructions
154(7)
Allen-Bradley Timer Symbol and Parameters
154(3)
Allen-Bradley Timer Bits
157(1)
Allen-Bradley TON, TOF, and RTO Instructions
157(4)
Allen-Bradley Timer Parameter and Bit Addressing
161(2)
PLC 5 and SLC 500 Timer Memory Map
161(2)
ControlLogix Timer Addressing
163(1)
Timer Contacts versus PLC Instructions
163(1)
Programming Allen-Bradley TON and TOF Timer Ladder Logic
163(9)
Standard Ladder Logic for Allen-Bradley TON Timers
164(2)
Standard Ladder Logic for Allen-Bradley TOF Timers
166(1)
Allen-Bradley TON and TOF Timer Applications
166(6)
Allen-Bradley Retentive Timers
172(4)
Reset Instruction for RTO Timer and Other Allen-Bradley Instructions
173(3)
Cascaded Timers
176(1)
Empirical Design Process with PLC Timers
176(8)
Adding Timers to the Process
176(8)
Conversion of Relay Logic Timer Ladders to PLC Logic
184(1)
Troubleshooting Ladder Rungs with Timers
184(3)
Troubleshooting Timer Ladder Logic
186(1)
Temporary End Instruction
186(1)
Location of the Instructions
187(4)
General Problems
188(1)
PLC 5 Problems
189(1)
SLC 500 Problems
189(1)
Controllogix Problems
189(1)
Challenge Problems
190(1)
Programming Counters
191(36)
Goals and Objectives
191(1)
Mechanical and Electronic Counters
191(1)
Introduction to Allen-Bradley Counters
192(3)
Counter Output Bits
193(2)
Allen-Bradley Counter and Reset Instructions
195(19)
PLC 5 and SLC 500 Counter and Reset Addressing
195(3)
Logix Counter Instructions
198(2)
Standard Ladder Logic for Counters
200(3)
Allen-Bradley Up Counters
203(6)
Allen-Bradley Down Counters
209(1)
Allen-Bradley Up/Down Counters
209(1)
Allen-Bradley One-Shot Instructions
210(4)
Cascaded Counters
214(1)
Empirical Design Process with PLC Counters
214(5)
Adding Counters to the Process
215(4)
Conversion of Relay Logic Counter Ladders to PLC Logic
219(1)
Troubleshooting Counter Ladder Logic
220(1)
Suspend Instruction
220(1)
Process Speed versus Scan Time
220(1)
Location of the Instructions
221(6)
General Problems
223(1)
PLC 5 Problems
224(1)
SLC 500 Problems
224(1)
Controllogix Problems
225(1)
Challenge Problems
225(2)
Arithmetic and Move Instructions
227(34)
Goals and Objectives
227(1)
Binary Arithmetic
227(2)
Signed Binary Numbers
229(2)
Allen-Bradley Arithmetic Instructions
231(1)
Structure for Arithmetic Instructions
232(1)
Operation of Allen-Bradley Arithmetic and Move Instructions
232(8)
Addition Instruction
234(1)
Subtraction Instruction
235(1)
Multiplication Instruction
235(1)
Division Instruction
235(2)
Square Root Instruction
237(2)
Move Instructions
239(1)
Standard Ladder Logic for Allen-Bradley Math and Move Instructions
240(8)
Empirical Design Process with Math and Move Instructions
248(5)
Adding Math and Move Instructions to the Process
248(5)
Troubleshooting Math and Move Ladder Logic
253(2)
SLC 500 Test Modes
253(2)
Location of the Instructions
255(6)
General Problems
257(1)
PLC 5 Problems
257(1)
SLC 500 Problems
258(1)
Controllogix Problems
258
Challenge Problems
228(33)
Conversion and Comparison Instructions
261(38)
Goals and Objectives
261(1)
Binary Coded Decimal System
261(10)
Allen-Bradley BCD Instructions and Standard Ladder Logic
263(8)
Hexadecimal System
271(1)
Comparison Instruction Structure
271(2)
Allen-Bradly Comparison Instructions
273(7)
Standard Ladder Logic for EQU, NEQ, LES, and GRT Comparison Instructions
273(1)
Standard Ladder Logic for LEQ, GEQ, MEQ, and LIM Comparison Instructions
274(2)
Standard Ladder Logic for Multiple Instructions and Hysteresis
276(4)
Empirical Design Process with BCD Conversion and Comparison Instructions
280(9)
Adding BCD Conversion Instructions to the Process
280(1)
Adding Comparison Instructions to the Process
280(1)
Process Tank Design
281(6)
Pneumatic Robot Design
287(2)
Troubleshooting BCD Conversion and Comparison Ladder Logic
289(3)
Troubleshooting with the Module Indicators
290(2)
Location of the Instructions
292(7)
General Problems
295(1)
PLC 5 Problems
296(1)
SLC 500 Problems
296(1)
Challenge Problems
297(1)
Controllogix Problems
297(2)
Program Control Instructions
299(34)
Goals and Objectives
299(1)
Program Control Instructions
299(1)
Allen-Bradley Program Control Instructions
300(21)
Master Control Reset Instructions
300(3)
Jump and Label Zone Control Instructions
303(3)
Subroutine Instructions
306(1)
PLC 5 and SLC 500 Subroutine Instructions
307(8)
PLC 5 and ControlLogix Options for Subroutine Instructions
315(6)
Allen-Bradley Immediate Input and Output Instructions
321(4)
PLC 5 Immediate Input and Output Instructions
322(1)
SLC 500 Immediate Input and Output Instructions
322(2)
ControlLogix Immediate Output Instruction
324(1)
Empirical Design Process with Program Control Instructions
325(2)
Adding Program Control Instructions to the Process
325(2)
Troubleshooting Program Control Instructions in Ladder Logic
327(1)
Location of the Instructions
327(6)
General Problems
329(2)
PLC 5 Problems
331(1)
SLC 500 Problems
331(1)
ControlLogix Problems
332(1)
Challenge Problems
332(1)
Indirect and Indexed Addressing
333(16)
Goals and Objectives
333(1)
Allen-Bradley Addressing Modes
333(7)
Direct Addressing
334(1)
Indirect Addressing
334(1)
Indexed Addressing
335(1)
Indexed Indirect Addressing
335(1)
PLC 5, SLC 500, and Logix Systems Syntax
335(5)
Empirical Design Process with Indirect and Indexed Addresssing
340(3)
Adding Indirect and Indexed Addressing to the Process
340(3)
Troubleshooting Indirect and Indexed Addressing in Ladder Logic
343(6)
General Problems
346(1)
PLC 5 Problems
346(1)
SLC 500 Problems
346(1)
Controllogix Problems
346(1)
Challenge Problems
347(2)
PART 2 Advanced PLC Instructions and Applications Goals
349(230)
Goal
349(1)
Career Insights
350(1)
Data Handling Instructions and Shift Registers
351(1)
Data Handling Instructions and Shift Register
351(34)
Goals and Objectives
351(1)
Data Handling
352(1)
Bit Patterns in Words
352(1)
Word Patterns in Files
352(1)
Allen-Bradley Data Transfer And Manipulation Instructions
353(24)
AND, OR, and XOR Instructions
353(2)
File-Arithmetic-Logic (FAL) Instruction
355(4)
Shift Registers
359(8)
First In, First Out (FIFO) Function
367(4)
Last In, First Out (LIFO) Function
371(2)
Copy and Fill Instructions
373(4)
Empirical Design Process with Bit and Word Operation Instructions
377(3)
Troubleshooting Data Handling Instructions and Shift Registers in Ladder Logic
380(2)
Location of the Instructions
382(3)
Challenge Problems
384
PLC 5 Problems
383(1)
SLC 500 Problems
384(1)
Controllogix Problems
384
General Problems
383(2)
PLC Sequencer Functions
385(30)
Goals and Objectives
385(1)
Electromechanical Sequencing
385(2)
Basic PLC Sequencer Function
387(1)
Allen-Bradley Sequencer Instructions
387(21)
PLC 5 and SLC 500 SQO and SQC Sequencer Instruction Structure
388(1)
PLC 5 and SLC 500 SQO Instruction Operation
389(1)
ControlLogix SQO Sequencer Instruction
390(7)
PLC 5 and ControlLogix Sequencer Input (SQI) Instruction
397(8)
Sequencer Compare (SQC) Instruction
405(1)
Sequencer Load (SQL) Instruction
406(2)
Cascading Sequencers
408(1)
Empirical Design Process with Sequencer Instructions
408(2)
Adding Sequential Instructions to the Process
409(1)
Troubleshooting Sequencer Instructions
410(1)
Location of the Instructions
410(5)
General Problems
412(1)
PLC 5 Problems
413(1)
SLC 500 Problems
413(1)
Controllogix Problems
413(1)
Challenge Problems
413(2)
Analog Sensors and Control Systems
415(52)
Goals and Objectives
415(1)
Analog Sensors
415(26)
Temperature Sensors
416(3)
Pressure Sensors
419(2)
Flow Sensors
421(9)
Position Sensors
430(1)
Vision Systems
431(7)
Troubleshooting Analog Sensors
438(3)
Analog Modules and Field Devices Interfacing
441(2)
Analog Input and Output Data
442(1)
PLC 5, SLC 500, and Logix Options
443(1)
Closed-Loop Control Systems
443(5)
Direct-Acting and Reverse-Acting Controllers
443(2)
Analysis of Closed-Loop Systems
445(2)
Load Change---Process Disturbance
447(1)
Attributes of an Effective Control System
448(15)
Transient Response
448(1)
Response to Change
448(2)
Controller Response and Damping
450(1)
Transient Response Options
451(1)
Steady-State Response
451(1)
Understanding Steady-State Error
452(4)
Correction for Steady-State Error
456(3)
Controller Gain Side Effects
459(1)
Steady-State Error Correction with Bias
460(1)
Stability
461(2)
Troubleshooting the Proportional Gain Controller
463(4)
Problems
465(2)
PLC Standard IEC 61131-3 Function Block Diagrams
467(26)
Goals and Objectives
467(1)
PLC Standards
467(2)
IEC 61131-3 Standard Languages
468(1)
Function Block Diagram (FBD)
469(8)
Signal Flow Types, Execution Order, and Data Latching
471(2)
Feedback Loops
473(1)
Function Block Diagram Program Development Sequence
474(1)
Allen-Bradley RSLogix 5000 FBD Programming
475(2)
Empirical Design With Function Block Diagrams
477(10)
Standard Function Block Control Solutions
477(10)
Sites for Allen-Bradley Products and Demo Software
487(6)
Controllogix Problems
492(1)
Intermittent and Continuous Process Control
493(32)
Goals And Objectives
493(1)
Process Control
493(1)
Intermittent Controllers
494(6)
On-Off Control
494(2)
Two-Position Control
496(3)
Floating Control
499(1)
Continuous Controllers
500(15)
Proportional Control
501(3)
Proportional Integral (PI) Control
504(3)
Proportional Derivative (PD) Control
507(4)
Proportional Integral and Derivative (PID) Control
511(1)
Fuzzy Control
511(4)
Digital Control
515(5)
Digital Sample and Hold
515(1)
Proportional Control Mode
516(1)
Integral Control Mode
517(2)
Derivative Control Mode
519(1)
Scaling In Process Control
520(1)
Manual Control Mode and Bumpless Transfer
521(1)
Location of the Instructions
521(4)
Controllogix Problems
523(2)
PLC Standard IEC 61131-3 Structured Text Language
525(18)
Goals and Objectives
525(1)
Overview of IEC 61131-3 Text Languages
525(1)
Allen-Bradley IEC 61131 Structured Text Implementation
526(1)
Structure Text Programming
526(9)
Assignment Statements
526(1)
Expressions
527(1)
Operators and Functions
527(1)
Relational Operators
528(1)
Logical Operators and Bitwise Operators
528(2)
Constructs
530(5)
Empirical Design with Structured Text
535(8)
Standard Structured Text Control Solutions
535(2)
Discrete and Process Implementation
537(4)
Problems
541(2)
PLC Standard IEC 61131-3 Sequential Function Chart
543(16)
Goals and Objectives
543(1)
IEC 61131-3 Standard Languages
543(1)
Sequential Function Chart (SFC)
544(12)
Standard SFC Sequences
544(1)
SFC Sequences
545(1)
SFC Step Programming
546(10)
Sites for Allen-Bradley Products and Demo Software
556(3)
Controllogix Problems
558(1)
Industrial Networks and Distributive Control
559(20)
Goals and Objectives
559(1)
PLC Network Architecture
559(2)
Ethernet
561(1)
Ethernet Operation
561(1)
Ethernet Industry Protocol
561(1)
Controlnet
562(1)
ControlNet Operation
562(1)
ControlNet Features
562(1)
Devicenet
563(2)
DeviceNet Operation
563(1)
DeviceNet Features
564(1)
Special Network Interfaces
565(4)
SERCOS Interfaces
565(1)
Smart I/O Interfaces
565(1)
Remote I/O Interfaces
565(1)
Serial Communication Interfaces
566(1)
Wireless Interfaces
567(1)
Human-Machine Interfaces
568(1)
Network Applications
569(3)
Profibus Network
569(1)
Data Highway Networks
570(1)
Modbus Network
570(2)
Troubleshooting Network Systems
572(1)
Distributive Control
573(1)
Distributed I/O
574(1)
In-cabinet I/O
574(1)
On-machine I/O
575(1)
Selecting and Designing Networks
575(3)
Web Sites for Industrial Networks
578(1)
Problems
579

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