Technician’s Guide to Programmable Controllers

by Cox, Richard A.

• ISBN13: 9781401890070
• ISBN10: 1401890075
• Edition: 5th
• Format: Paperback
• Copyright: 2006-05-16
• Publisher: CENGAGE Delmar Learning

Summary

Hailed as the most comprehensive introduction to PLCs on the market today, this newly updated 5th Edition covers theory, hardware, instructions, programming, installation, startup, and troubleshooting in a way that is easy to understand and apply. New material has been added to explain communication networks, basic control signals, linear scaling of analog process signals, and Proportional Integral Derivative (PID) instructions used by many PLC applications. Supplementary programming examples utilizing the PLC instructions in the book impart a better understanding of the various instructions and how they can be combined to create simple yet effective control logic solutions for today's world.

Author Biography

Richard A. Cox is the Executive Director of COXCO Training and Consulting in Spokane, Washington and is a retired member of the Electrical/Robotics Department at Spokane Community College Terry Borden is the Chairman of the Electrical Maintenance and Automation Department at Spokane Community College in Spokane, Washington

Table of Contents

Preface	p. x
What is a Programmable Logic Controller (PLC)?	p. 1
Chapter Summary	p. 9
Review Questions	p. 9
Understanding the Input/Output (I/O) Section	p. 10
I/O Section	p. 10
Fixed I/O	p. 11
Modular I/O	p. 12
Discrete I/O Modules	p. 15
Discrete Input Module	p. 15
AC Discrete Input Module	p. 16
DC Discrete Input Module	p. 20
Fast-Responding DC Input Modules	p. 21
Discrete Output Modules	p. 22
AC Output Module	p. 23
Output Fuses	p. 25
Status Lights	p. 26
Module Keying	p. 27
DC Output Modules	p. 28
Sourcing and Sinking	p. 29
Contact Output Modules	p. 31
Interposing Relay	p. 31
Reed Relay Output Module	p. 31
Transistor-Transistor Logic (TTL) I/O Modules	p. 31
Analog I/O Modules	p. 32
Safety Circuit	p. 34
Rack Installation	p. 35
Electrical Noise (Surge Suppression)	p. 37
Grounding	p. 39
I/O Shielding	p. 40
Chapter Summary	p. 42
Review Questions	p. 43
Processor Unit	p. 45
The Processor	p. 46
Memory Types	p. 50
Memory Size	p. 53
Guarding Against Electrostatic Discharge (ESD)	p. 53
Memory Structure	p. 55
Peripherals	p. 56
Chapter Summary	p. 57
Review Questions	p. 57
Programming Devices (Programmers)	p. 59
Programming Devices	p. 59
Hand-Held Programmers	p. 60
Computer Programmers	p. 60
Hand-Held Programmers	p. 64
Advantages	p. 64
Disadvantages	p. 64
Personal Computer Programmers	p. 64
Advantages	p. 64
Disadvantages	p. 64
Chapter Summary	p. 64
Review Questions	p. 65
Memory Organization	p. 66
Memory Words and Word Locations	p. 66
SLC 500 and MicroLogix 1000 and 1500 Addressing Scheme	p. 72
Modicon 984 Addressing Scheme	p. 80
Memory Organization	p. 81
Storage Memory	p. 81
User Memory	p. 82
Allen-Bradley PLC-5 File Structure	p. 83
SLC 500 and MicroLogix File Structure	p. 85
Chapter Summary	p. 90
Review Questions	p. 90
Numbering Systems	p. 91
Decimal System	p. 91
Binary System	p. 93
2s Complement	p. 94
Octal System	p. 103
Hexadecimal System	p. 105
BCD System	p. 108
Using Numbering Systems	p. 109
Chapter Summary	p. 111
Review Questions	p. 112
Understanding and Using Ladder Diagrams	p. 114
Wiring Diagrams	p. 114
Ladder Diagrams	p. 115
Ladder Diagram Rules	p. 116
Basic STOP/START Circuit	p. 118
Sequenced Motor Starting	p. 120
Digital Logic Gates	p. 121
Chapter Summary	p. 129
Review Questions	p. 129
Relay Type Instructions	p. 132
Programming Contacts	p. 133
Examine On	p. 136
Examine Off	p. 137
Clarifying Examine On and Examine Off	p. 143
Chapter Summary	p. 147
Review Questions	p. 147
Programming a PLC	p. 149
Programming with a Computer	p. 150
Programming Using Mnemonic Strings	p. 170
Peripherals	p. 174
Chapter Summary	p. 175
Review Questions	p. 175
Programming Considerations	p. 176
Network Limitations	p. 176
Programming Restrictions	p. 179
Program Scanning	p. 182
Programming Stop Buttons	p. 186
Logical Holding Instructions	p. 187
Discrete Holding Contacts	p. 187
Overload Contacts	p. 187
Chapter Summary	p. 191
Review Questions	p. 191
Program Control Instructions	p. 193
Master Control Relay Instructions	p. 193
Allen-Bradley PLC-5, SLC 500, and MicroLogix MCR Instruction	p. 194
Latching Relay Instructions	p. 195
Safety Circuit	p. 198
Immediate Input Instruction	p. 199
Immediate Output Instruction	p. 200
Jump and Label Instructions	p. 201
Jump to Subroutine, Subroutine, and Return Instructions	p. 202
Temporary End Instruction	p. 202
Always False Instruction	p. 203
One-Shot Instruction	p. 203
Chapter Summary	p. 204
Review Questions	p. 204
Programming Timers	p. 206
Pneumatic Timers (General)	p. 206
Allen-Bradley PLC-5, SLC 500, and MicroLogix Timers	p. 212
Modicon Inc. Timers	p. 218
Cascading Timers	p. 221
Chapter Summary	p. 222
Review Questions	p. 222
Programming Counters	p. 224
Allen-Bradley PLC-5, SLC 500, and MicroLogix Counters	p. 224
Modicon 984 Counters	p. 230
Combining Timers and Counters	p. 232
Chapter Summary	p. 233
Review Questions	p. 234
Data Manipulation	p. 236
Data Transfer	p. 236
Allen-Bradley PLC-5, SLC 500, and MicroLogix Data Transfer Instructions	p. 237
Modicon PLC	p. 241
Data Compare	p. 241
Allen-Bradley PLC-5, SLC 500, and MicroLogix Data Compare Instructions	p. 242
Chapter Summary	p. 251
Review Questions	p. 252
Math Functions	p. 253
Using Math Functions	p. 253
Allen-Bradley PLC-5, SLC 500, and MicroLogix Math Instructions	p. 253
Combining Math Functions	p. 258
Gould 984 Arithmetic (Math) Instruction	p. 260
Chapter Summary	p. 264
Review Questions	p. 264
Word and File Moves	p. 265
Words	p. 265
Synchronous Shift Register	p. 265
Allen-Bradley PLC-5, SLC 500, and MicroLogix Bit Shift Instructions	p. 267
File Moves	p. 272
Word-to-File Instruction	p. 272
File-to-Word Instruction	p. 273
File-to-File Instruction	p. 274
Allen-Bradley PLC-5, SLC 500, and MicroLogix File Copy Instruction	p. 275
Gould Data Transfer Instructions	p. 276
Asynchronous Shift Register (FIFO)	p. 280
Allen-Bradley PLC-5, SLC 500, and MicroLogix FIFO Instruction	p. 281
Last-In First-Out (LIFO) Instructions	p. 283
Gould First In Function Block	p. 284
Chapter Summary	p. 286
Review Questions	p. 286
Sequencers	p. 288
Masks	p. 291
Allen-Bradley PLC-5, SLC 500, and MicroLogix 1000 Sequencer Instruction	p. 292
Chapter Summary	p. 297
Review Questions	p. 297
Process Control Signals, Scaling, and PID Instructions	p. 299
Process Control Signals and Scaling	p. 299
Allen-Bradley SLC 500 Scale (SCL) Instruction	p. 308
Allen-Bradley SLC 500 Scale with Parameters (SCP) Instruction	p. 310
Allen-Bradley SLC 500 PID Instruction	p. 312
PID Tuning Parameters	p. 318
PID Input Parameters	p. 321
PID Output Parameters	p. 321
PID Status & Control Flags	p. 322
PID Program Example	p. 323
PID Loop Tuning	p. 331
Loop Tuning Techniques	p. 332
Chapter Summary	p. 339
Review Questions	p. 339
Programming with Boolean	p. 341
Boolean Algebra	p. 341
Programming in Boolean	p. 345
Terms	p. 354
Chapter Summary	p. 355
Review Questions	p. 355
Understanding Communication Networks	p. 358
History	p. 358
Networking Principles	p. 359
Network Categories	p. 360
Network Configurations	p. 362
Network Media	p. 364
Twisted-Pair Cable	p. 365
Coaxial Cable	p. 367
Fiber Optic Cable	p. 369
Reducing Electromagnetic Interference	p. 371
Network Addressing	p. 372
Network Access Methods (Access Protocols)	p. 374
Network Protocols	p. 375
Network Messages	p. 376
Network Communication Instructions	p. 379
Industrial Communication Networks	p. 380
I/O and Device Networks	p. 380
Control Networks	p. 382
Information Networks	p. 383
Industrial Protocols	p. 383
DeviceNet	p. 383
Foundation Fieldbus	p. 383
Profibus	p. 386
Modbus Plus	p. 386
Data Highway Plus	p. 386
ControlNet	p. 386
Ethernet	p. 387
Chapter Summary	p. 391
Review Questions	p. 392
Start Up and Troubleshooting	p. 393
Start Up	p. 393
Testing Inputs	p. 395
Testing Outputs	p. 396
Final System Checkout	p. 398
Troubleshooting	p. 399
Chapter Summary	p. 404
Review Questions	p. 404
PLC Programming Examples	p. 405
Push ON/Push OFF Circuit	p. 406
1/2 Second Pilot Light Flasher Circuit	p. 407
Motor Starter Fault Monitoring Logic	p. 408
Three-Wire Motor Control Logic with Fault Monitoring, Pilot Light, and Flasher Circuit	p. 410
Time-Based Events	p. 410
Analog Signal Filter Algorithm	p. 413
Parts Conveyor Tracking Logic	p. 416
Tracking Example One	p. 416
Tracking Example Two	p. 420
Chapter Summary	p. 423
Review Questions	p. 423
Glossary	p. 425
Index	p. 441
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