Introduction to Programmable Logic Controllers

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ISBN: 9781401884260 | 1401884261
Cover: Paperback
Copyright: 12/16/2005

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Updated to reflect recent industry developments, this edition features practical information on Rockwell Automation's SLC 500 family of PLCs and includes a no-nonsense introduction to RSLogix software and the new ControlLogix PLC. To assist readers in understanding key concepts, the art program has been modernized to include improved illustrations, current manufacturer-specific photos, and actual RSLogix software screens to visibly illustrate essential principles of PLC operation. New material has been added on ControlNet and DeviceNet, and a new chapter on program flow instructions includes updated references to the SLC 500, MicroLogix, and the PLC 5.

Preface

Acknowledgments

Part I Introduction to PLCs

Welcome to the World of Programmable Logic Controllers

(28)

What Is a PLC?

(1)

Where Did the PLC Come From?

(1)

Why Use a PLC?

(2)

What Makes a PLC Work?

(1)

How Do PLCs Know What They Are Supposed to Do?

(1)

How Do Instructions Get Into the PLC's Memory?

(2)

Innovations Incorporated Into the Programmable Controller

(6)

Introduction to Fixed and Modular PLC Hardware

(7)

The Central Processing Unit

(7)

Micro Programmable Logic Controllers

(28)

Overview of Selected Micro PLCs

(1)

GE Fanuc Automation Versamax Controllers

(3)

GE Fanuc Automation Series 90 Micro PLC

(4)

The Mitsubishi FX2N Super Micro

(4)

Omron's CPM1A Series Micro PLCs

(2)

Rockwell Automation's MicroLogix 1000 Microcontroller

(1)

Rockwell Automation's MicroLogix 1500 Microcontroller

(5)

Siemens Simatic S7-200 Micro PLC

(7)

Programming a Programmable Controller

(42)

Handheld Programming Terminals

(5)

Desktop Personal Computers (PCs) and PLC Programming

(5)

Notebook Personal Computers and PLC Programming

(3)

Windows CE-Based Handheld Personal Computers

(1)

Industrial Computers

(6)

Industrial Monitors

(1)

Open PLC Systems

(1)

The IEC 1131-3 Programming Standard

(13)

Soft PLC or Open-Architecture Control

(1)

One Step Further: Production Data from PLC to Office Databases

(6)

Number Systems

101

(28)

Number System Characteristics

102

(1)

The Decimal Number System

103

(1)

Decimal Place Values

104

(1)

Binary and Binary-Coded Decimal Numbers

105

(11)

The Octal Number System

116

(2)

Valid Octal Numbers

118

(1)

Octal-to-Decimal Conversion

118

(1)

Binary-to-Octal Conversion

118

(2)

Octal-to-Binary Conversion

120

(1)

The Hexadecimal Number System

121

(8)

Introduction to Digital and Analog PLC Interface

129

(40)

The Digital Concept

131

(1)

Binary Data Representation

132

(2)

Correlation of 16-Bit Words to Input Signals

134

(3)

The Input Status File

137

(1)

The Output Status File

138

(3)

Input and Output Status Files and Fixed PLCs

141

(3)

Sixteen-Point I/O Modules with Decimal Addressing

144

(2)

I/O Interaction with the Input and Output Status Files

146

(3)

Fixed PLC I/O Addressing When I/O Is Expanded

149

(1)

Thirty-Two-Bit ControlLogix PLC

150

(1)

Analog I/O Interface to the PLC

151

(10)

The ControlLogix PLC and Analog

161

(8)

Introduction to Logic

169

(30)

Conventional Ladders Versus PLC Ladder Logic

170

(2)

What Is Logic?

172

(1)

Overview of Logic Functions

173

(1)

Series---The AND Logic Function

174

(3)

Three-Input AND Logic

177

(1)

Function Block Diagram AND Logic

178

(2)

Parallel Circuits---The OR Logic Function

180

(3)

NOT Logic

183

(1)

Analysis of Rung #1

184

(1)

Analysis of Rung #2

184

(1)

Parallel NOT Logic

185

(2)

Exclusive OR Logic

187

(1)

Analysis of Exclusive OR Logic

188

(1)

Combinational Logic

189

(1)

Priority of Logic Elements

190

(3)

Function Block Order of Execution

193

(6)

Input Modules

199

(38)

Input Modules

200

(2)

Discrete Input Module

202

(1)

Discrete AC Input Module

202

(3)

AC Input Module Specifications

205

(6)

DC Input Modules

211

(1)

Sinking and Sourcing

212

(4)

DC Input Module Operation

216

(1)

DC Sinking Input Module Specifications

217

(3)

Solid-State Sensor Interface to DC Input Modules

220

(2)

A Final Note on Sinking and Sourcing

222

(1)

Analog Inputs

222

(9)

Specialty Modules

231

(6)

Output Modules

237

(26)

Discrete Output Modules

238

(5)

Transistor-Transistor Logic (TTL) Output Modules

243

(1)

Relay Output Modules

243

(5)

Module Selection Considerations

248

(1)

Choosing the Proper Output Module

249

(1)

Isolated Output Modules

250

(1)

Interposing Relays

251

(1)

Surge Suppression and Output Modules

251

(2)

High-Density I/O Interface

253

(1)

Analog Outputs

253

(2)

Emergency-Stop Switches and PLC Applications

255

(2)

I/O Modules in Hazardous Locations

257

(1)

Hardware Considerations Before Installing PLCs in Class I, Division 2, Areas

258

(5)

Putting Together a Modular PLC

263

(36)

Racks, Chassis, or Baseplates

264

(6)

The Local, or Base, PLC

270

(1)

Local Expansion

270

(1)

Remote I/O Expansion

271

(2)

PLC Networking

273

(1)

Selection and Placement of I/O Modules

273

(2)

Power Supply Selection

275

(11)

I/O Racks and Expansion

286

(6)

Rockwell Automation ControlLogix Family of PLCs

292

(7)

PLC Processors

299

(54)

The Processor's Function

300

(1)

The Processor's Operating System

300

(3)

Processor Scanning

303

(2)

Omron CQM1 Operating Cycle

305

(2)

The Watchdog Timer

307

(2)

Processor Ports

309

(2)

The RS-232C Communication Standard

311

(1)

Serial Communication Between a Personal or Industrial Computer and the PLC

312

(5)

Processor-Operating Modes

317

(3)

On-Line Editing

320

(1)

Battery Backup for the Processor's Volatile Memory

320

(2)

Lithium Battery Handling and Disposal

322

(1)

Nonvolatile Memory: EEPROM

323

(3)

Passwords

326

(2)

The Allen-Bradley SLC 500 Modular Processors

328

(7)

Rockwell Automation's Logix 5550 Controller

335

(1)

The General Electric Series 90-30 Processors

336

(10)

Choosing the Correct Processor for an Application

346

(7)

Introduction to ControlNet and DeviceNet

353

(50)

The ControlNet Network

354

(1)

ControlNet Network Applications

354

(4)

ControlLogix ControlNet Interface Module

358

(2)

Desktop or Industrial Computer Interface Card

360

(2)

ControlNet Cable System

362

(1)

ControlNet Segment

363

(3)

ControlNet and Scheduled and Unscheduled Communications

366

(3)

Network Update Time

369

(1)

Scheduled Maximum Node

369

(1)

Unscheduled Maximum Node

370

(2)

Slot Time

372

(1)

RSNetWorx for ControlNet

372

(1)

Introduction to the DeviceNet Network

373

(4)

Network Power Supplies

377

(1)

Maximum Trunk Line Distance

377

(3)

Cumulative Drop Line Length

380

(1)

DeviceNet Interface

381

(1)

Node Commissioning

381

(2)

RSNetWorx for DeviceNet Software

383

(7)

Electronic Data Sheets

390

(13)

Part II PLC Instructions

Processor Data Organization

403

(24)

SLC 500 Files

404

(2)

Data Files

406

(13)

User-Defined Files

419

(8)

The Basic Relay Instructions

427

(20)

Bit, or Relay, Instructions

428

(1)

The Normally Open Instruction

428

(1)

The Output Instruction

429

(1)

Modular SLC 500 Instruction Addressing

430

(2)

The Normally Closed Instruction

432

(2)

The One-Shot Instruction

434

(3)

The Output-Latching Instruction

437

(2)

The Negated Output Instruction

439

(1)

Internal Bit-Type Instructions

439

(8)

Understanding Relay Instructions and the Programmable Controller Input Modules

447

(20)

Interfacing a Start-Stop Push-Button Station to a Programmable Controller

451

(3)

User Program Development for a Start-Stop Push-Button Interface

454

(7)

Motor Starter Circuits and the Overload Contacts

461

(1)

Special Considerations for PLC Control of Motor Starters

462

(5)

Documenting Your PLC System

467

(24)

Why Add Documentation to Your User Program?

468

(1)

Information to Include in PLC Documentation

468

(4)

Documentation and Software Packages

472

(1)

Types of Documentation

472

(9)

Adding Documentation When Developing a New Application

481

(10)

Timer and Counter Instructions

491

(28)

Timer Instructions

492

(1)

SLC 500 Timers

492

(4)

The On-Delay Timer Instruction

496

(2)

The Off-Delay Timer Instruction

498

(2)

The Retentive Timer Instruction

500

(1)

The Reset Instruction

501

(1)

PLC Counter Instructions

502

(1)

Allen-Bradley Counters

503

(3)

How Counters Work

506

(1)

The Count-Up Instruction

507

(1)

The Count-Down Instruction

508

(2)

The High-Speed Counter Instruction

510

(1)

The Counter Reset Instruction

511

(1)

The Clear Instruction

511

(1)

Combining Timers and Counters

511

(8)

Comparison and Data-Handling Instructions

519

(34)

Comparison Instructions

520

(4)

Data-Handling Instructions

524

(13)

Logical Instructions

537

(16)

Sequencer Instructions

553

(18)

The Sequencer

554

(1)

Sequencer Instructions

554

(1)

The SLC 500 Sequencer Output Instruction

555

(6)

Programming the Sequencer Output Instruction

561

(1)

Multiple Sequencers and File Designation

562

(1)

Applying Hexadecimal Numbers and Masks with SLC 500 Programming Instructions

563

(8)

Program Flow Instructions

571

(24)

Terminology

574

(1)

Subroutines

574

(10)

Jump to Label Instruction

584

(2)

Immediate Input with Mask (IIM) Instruction

586

(2)

The Refresh Instruction

588

(2)

Master Control Reset (MCR) Instruction

590

(5)

Appendix A Instruction Set Reference

595

(6)

Appendix B SLC 500 Status File Overview

601

(4)

Appendix C Applying Hexadecimal Numbers in PLC Masking Applications

605

(4)

Glossary

609

(8)

Index

617

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Introduction to Programmable Logic Controllers

Summary

Table of Contents

Supplemental Materials