Technician's Guide to Programmable Controllers

Practical and up-to-date, TECHNICIAN'S GUIDE TO PROGRAMMABLE CONTROLLERS, 6th Edition provides readers with the most comprehensive introduction to PLCs available on the market today. Theory, hardware, instructions, programming, installation, startup, and troubleshooting are discussed in detail in a way that is easy to understand and apply. In addition, supplementary programming examples utilizing the PLC instructions in the book give readers 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. Cover 1 Table Of Contents 5 Preface 12 Chapter 1: What is a Programmable Logic Controller (PLC)? 15 Chapter Summary 23 Review Questions 23 Chapter 2: Understanding the Input/Output (I/O) Section 24 I/O Section 24 Discrete I/O Modules 29 Analog I/O Modules 46 Safety Circuit 48 Rack Installation 49 Electrical Noise (Surge Suppression) 51 Grounding 53 I/O Shielding 54 Chapter Summary 55 Review Questions 56 Chapter 3: Processor Unit 58 The Processor 59 Memory Types 63 Memory Size 66 Guarding Against Electrostatic Discharge (ESD) 66 Memory Structure 68 Programming Devices 69 Hand-Held Programmers 69 Computer Programmers 70 Chapter Summary 73 Review Questions 73 Chapter 4: Memory Organization 75 Memory Words And Word Locations 75 SLC 500 And MicroLogix Addressing Scheme 81 Memory Organization 88 Allen-Bradley PLC-5 File Structure 90 SLC 500 And MicroLogix File Structure 92 Logix Memory 95 Chapter Summary 110 Review Questions 110 Chapter 5: Numbering Systems 112 Decimal System 112 Binary System 114 2s Complement 115 Octal System 124 Hexadecimal System 126 BCD System 129 Using Numbering Systems 130 Chapter Summary 132 Review Questions 133 Chapter 6: Understanding and Using Ladder Diagrams 135 Wiring Diagrams 135 Ladder Diagrams 136 Ladder Diagram Rules 137 Basic STOP/START Circuit 139 Sequenced Motor Starting 141 Digital Logic Gates 142 Chapter Summary 150 Review Questions 150 Chapter 7: Relay Type Instructions 153 Programming Contacts 154 Examine On 157 Examine Off 158 Clarifying Examine On And Examine Off 164 Chapter Summary 168 Review Questions 168 Chapter 8: Programming a PLC 170 Programming With A Computer 171 Programing With The Logix5000 Software 190 Chapter Summary 204 Review Questions 205 Chapter 9: Programming Considerations 206 Network Limitations 206 Programming Restrictions 209 Program Scanning 212 Programming Stop Buttons 214 Logical Holding Instructions 215 Discrete Holding Contacts 215 Overload Contacts 216 Chapter Summary 218 Review Questions 219 Chapter 10: Program Control Instructions 221 Master Control Relay Instructions 221 Latching Relay Instructions 223 Safety Circuit 225 Jump And Label Instructions 226 Jump To Subroutine, Subroutine, And Return Instructions 227 Temporary End Instruction 227 Always False Instruction 229 One-Shot Instruction 229 Chapter Summary 230 Review Questions 230 Chapter 11: Programming Timers 231 Pneumatic Timers (General) 231 Allen-Bradley PLC-5, SLC 500, And MicroLogix Timers 237 Allen-Bradley Logix5000 Timers 243 Cascading Timers 245 Chapter Summary 247 Review Questions 247 Chapter 12: Programming Counters 249 Allen-Bradley PLC-5, SLC 500, And MicroLogix Counters 249 Combining Timers And Counters 256 Allen-Bradley Logix5000 Counters 257 Chapter Summary 259 Review Questions 260 Chapter 13: Data Manipulation 262 Data Transfer 262 Allen-Bradley PLC-5, SLC 500, And MicroLogix Data Transfer Instructions 263 Data Compare 267 Allen-Bradley PLC-5, SLC 500, And MicroLogix Data Compare Instructions 268 Allen-Bradley Logix5000 Data Manipulation 277 Chapter Summary 278 Review Questions 278 Chapter 14: Math Functions 279 Using Math Functions 279 Allen-Bradley PLC-5, SLC 500, And MicroLogix Math Instructions 279 Combining Math Functions 284 Allen-Bradley Logix5000 Basic Math Functions 286 Chapter Summary 286 Review Questions 286 Chapter 15: Word and File Moves 288 Words 288 Synchronous Shift Register 288 Allen-Bradley PLC-5, SLC 500, And MicroLogix Bit Shift Instructions 290 File Moves 295 Word-To-File Instruction 295 File-To-Word Instruction 296 File-To-File Instruction 297 Allen-Bradley PLC-5, SLC 500, And MicroLogix File Copy Instruction 298 Asynchronous Shift Register (FIFO) 299 Allen-Bradley PLC -5, SLC 500, And MicroLogix FIFO Instruction 300 Last-In First-Out (LIFO) Instructions 301 Allen-Bradley Logix5000 File (Array) Instructions 302 Chapter Summary 305 Review Questions 305 Chapter 16: Sequencers 307 Masks 310 Allen-Bradley PLC-5, SLC-500, And Micrologix 1000 Sequencer Instruction 311 Allen-Bradley Logix5000 Sequencers 316 Chapter Summary 317 Review Questions 317 Chapter 17: Process Control Signals, Scaling, and PID Instructions 319 Process Control Signals and Scaling 319 Allen-Bradley SLC 500 Scale (SCL) Instruction 328 Allen-Bradley SLC 500 Scale With Parameters (SCP) Instruction 330 Allen-Bradley SLC 500 PID Instruction 332 PID Loop Tuning 350 Chapter Summary 359 Review Questions 359 Chapter 18: Function Block Diagram and Structured Text Programming 361 Function Block Diagram Programming 361 Structured Text Programming 362 Chapter Summary 375 Review Questions 375 Chapter 19: Sequential Function Chart Programming 377 SFC Programming Example 386 Chapter Summary 391 Review Questions 391 Chapter 20: Understanding Communication Networks 392 History 392 Networking Principles 393 Network Categories 394 Network Configurations 396 Network Media 398 Network Addressing 406 Network Access Methods (Access Protocols) 408 Network Protocols 409 Network Messages 410 Network Communication Instructions 413 Industrial Communication Networks 414 Industrial Protocols 417 Chapter Summary 425 Review Questions 426 Chapter 21: Start-Up and Troubleshooting 427 Start Up 427 Testing Inputs 429 Testing Outputs 430 Final System Checkout 432 Troubleshooting 433 Chapter Summary 438 Review Questions 438 Chapter 22: PLC Programming Examples 439 Example 1—Push ON/Push OFF Circuit 440 Example 2—1/2 Second Pilot Light Flasher Circuit 441 Example 3—Motor Starter Fault-Monitoring Logic 442 Example 4—Three-Wire Motor Control Logic With Fault Monitoring, Pilot Light, And Flasher Circuit 444 Example 5—Time-Based Events 444 Example 6—Analog Signal Filter Algorithm 448 Example 7—Parts Conveyor Tracking Logic 449 Chapter Summary 456 Review Questions 457 Glossary 458 Index 474 Offering a comprehensive introduction to PLCs, this title covers theory, hardware, instructions, programming, installation, startup, and troubleshooting. It includes topics such as sequential function chart programming, function block programming, structured text programming, alarm and event programming, and programming information.