Fundamentais of Programmable Logic Controllers, Sensors, and Communications Second Edition Jon Stenerson Fox Valley Technical College Prentice Hall Upper Saddle River, New Jersey Columbus, Ohio
Contents Preface vi Acknowledgements viii Chapter 1: Overview of Programmable Logic Controllers 1 HistoryofPLCs 2 PLC Components 7 Allen-Bradley Memory Organization and I/O Addressing 30 Logical Addressing 31 I/O addressing 32 GE Fanuc Memory Organization and I/O Addressing 33 PLC Applications 35 Questions 39 Chapter 2: Overview of Number Systems 43 Decimal 44 Binary Numbering System 45 Binary Coded Decimal System 47 Octal 48 Hexadecimal 49 Questions 54 Chapter 3: Fundamentals of Programming 57 Ladder Logic 58 Allen-Bradley Contacts 59 Coüs 59 Allen-Bradley Coils 60 Ladder Diagrams 60 Allen-Bradley SLC File Organization and I/O Numbering 65 Allen-Bradley Normally Closed Contacts 72 Multiple Contacts 73 Brandung 75 V
Special Contacts 79 Program Flow Instructions 83 GE Fanuc Program Flow functions 86 GE Fanuc Subroutine Instructions 87 PLC Scanning and Scan Time 88 Questions 91 Chapter 4: Timers and Counters 95 Timers 96 Allen-Bradley PLC-5, SLC 500, and MicroLogix 1000 Timers 101 GE Fanuc Timers 105 Gould Modicon Timers 108 Omron Timers 108 Square D Timers 111 Texas Instruments and PLC Direct Timers 112 Cascading Timers 114 Counters 115 Allen-Bradley PLC-5, SLC 500, and MicroLogix 1000 Counters... 118 GE Fanuc Counters 121 Gould Modicon Counters 122 Omron Counters 123 Square D Counters 124 Texas Instruments and PLC Direct Counters 126 Programming Hints 127 Questions 131 Chapter 5: Industrial Sensors 137 The Need For Sensors 138 Sensor Types 138 Digital Sensors 140 Electronic Field Sensors (Field Sensors) 152 Sensor Wiring 157 Sourcing and Sinking Sensors 160 Analog Sensors 161 Installation Considerations 178 Typical Applications 180 Questions 188 vi
Chapter 6: Input/Output Modules and Wiring 189 I/O Modules 190 Digital (Discrete) Modules 190 Analog Modules 199 Remote I/O Modules 202 Communication Modules 203 Position Control Modules 205 Vision Modules 208 Bar-Code Modules 210 Proportional, Integral and Derivative Modules (PID) 210 Fuzzy Logic Modules 217 Radio-Frequency Modules 218 Operator Input/Output Devices 219 Questions 223 Chapter 7: Arithmetic Instructions 225 Introduction 226 Allen-Bradley Instructions 227 GE Fanuc Functions 250 Gould Modicon Instructions 261 Omron Arithmetic Instructions 264 Square D Arithmetic Instructions 269 Texas Instruments and PLC Direct Arithmetic Instructions 274 Questions 277 Chapter 8: Advanced Programming 279 Sequential Control 280 Sequencer Instructions 282 Shift Resister Programming 285 Stage Programming 286 Step Programming 291 Fuzzy Logic 294 State Logic 302 Questions 307 vii
Chapter 9: IEC 1131-3 Programming 309 Overview of IEC 1131-3 310 Structured Text Programming 312 Function Block Diagram Programming 317 Ladder Diagramming 320 Instruction List Programming 322 Sequential Function Chart Programming 325 Questions 337 Chapter 10: Overview of Plant Floor Communication 339 Introduction 340 Levels of Plant Communication 340 Questions 364 Chapter 11: Industrial Networks 367 Overview of Industrial Networks 368 Types of Industrial Buses 371 ProcessBus Standards 372 Device Buses 372 Process Buses 383 CONTROLNETtm 386 Integrating Networks 389 Questions 392 Chapter 12: Supervisory Control and Data Acquisition 393 Overview Of Supervisory Control and Data Acquisition (SCADA) 394 Sample Application 397 Application Development 410 Questions 430 Chapter 13: PC-Based Control 431 Introduction to PC-Based Control 432 Flowchart Programming 436 Application Development 438 Gello 446 IOworks 454 VIII
SoftPLC 456 Questions 459 Chapter 14: Industrial Automation Controllers 461 Overview of Industrial Automation Controllers 462 Industrial Automation Controller Hardware 471 Questions 479 Chapter 15: Single-Board Controllers 481 Overview 482 Single-Board Controllers 482 Simple Tank Application 490 Indexing, Sealing and Perforating Application 493 Questions 506 Chapter 16: Lockout/Tagout 507 Overview of Lockout/Tagout 508 Lockout 510 Tagout 511 Training 511 Requirements for Lockout/Tagout Devices 512 Application of Control 514 Sample Lockout Procedure 517 Sample Lockout/Tagout Checklist 520 Questions 521 Chapter 17: Installation and Troubleshooting 523 Installation and Troubleshooting 524 Installation 524 Industrial Controller Maintenance 536 PLC Troubleshooting 537 Questions 542 Appendix A: Internet Addresses 543 Appendix B: Common Electrical Symbols 545 Glossary 547