Table of Contents
Chapter 1 Programmable Logic Controller (PLC) Overview 2
1.1 PLC History and Development 4
1.2 PLC Block Diagram 5
1.3 Central Processing Unit 6
1.4 Memory Devices 7
1.5 Address Decoder Circuit 10
1.6 Peripheral Chips 10
1.7 Discrete Input Modules 10
1.8 Discrete Output Modules 11
1.9 Analog Input/Output Modules 12
1.10 PLC Power Supply 12
1.11 Allen-Bradley Programmable Controllers 12
1.12 Allen-Bradley Programmable Logic Controllers 13
1.13 Commonly Used Industrial Controllers 14
1.14 Communication with Intelligent Industrial Controllers 16
Chapter 2 PLC Selection, Components, and Communication 20
2.1 PLC Selection 22
2.2 Allen-Bradley SLC 500 Components 22
2.3 PLC Memory Expansion and Usage 29
2.4 PLC Communication Systems 30
2.5 Programming Modules 32
2.6 Introduction to the LogixPro Simulator Software 34
2.7 The Allen-Bradley ControlLogix Family of Controllers 34
2.8 Comparison of RSLogix 5000 and RSLogix 500 36
2.9 The Industrial Control Design Process 37
2.10 Use of HMI in Industrial Control Systems 39
Chapter 3 Number Systems and Codes 44
3.1 Decimal Number System 46
3.2 Binary Number System 47
3.3 Binary-to-Decimal Conversion 47
3.4 Decimal-to-Binary Conversion 48
3.5 Binary Addition 49
3.6 Binary Subtraction 50
3.7 Binary Multiplication 51
3.8 Binary Division 52
3.9 Hexadecimal Number System 52
3.10 Octal Number System 53
3.11 Binary Coded Decimal System 53
3.12 Gray Code 54
3.13 Alphanumeric Code 55
Chapter 4 Input/Output Devices and Motor Controls 60
4.1 Pushbuttons and Switches 62
4.2 Sensors 65
4.3 Indicators 74
4.4 Relays, Contactors, and Solenoids 74
4.5 Motor Control Devices 77
Chapter 5 Creating Relay Logic Diagrams 82
5.1 Relay Logic Diagrams 83
5.2 Rules for Drawing Relay Logic Diagrams 84
5.3 Creating Relay Logic Diagrams for Industrial Control Circuits 88
Chapter 6 PLC Programming 94
6.1 Creating PLC Ladder Logic Diagrams from Relay Logic Diagrams 96
6.2 Programming Ladder Logic Diagrams with Normally Open and Normally Closed Switches 98
6.3 Programming Ladder Logic Diagrams with Normally Open and Normally Closed Contacts 100
6.4 PLC Program Scan Time 103
6.5 PLC Program and Data Files 104
6.6 Programming Ladder Logic Diagrams with Latch and Unlatch Instructions 106
6.7 Loading and Troubleshooting PLC Ladder Diagrams in Run Mode 107
6.8 Using the PLC Force Instruction for Troubleshooting 110
6.9 Creating and Printing PLC Program Reports 112
6.10 Using Utility Instructions to Save and Retrieve PLC Programs 116
6.11 Using the LogixPro Simulator to Create Ladder Logic Diagrams 118
Chapter 7 Programming Logic Gate Functions in PLCs 136
7.1 Combinational and Sequential Logic Gate Circuits 138
7.2 Boolean Expressions, Truth Tables, and Logic Gate Circuits 139
7.3 NOT Gates (Inverters) 139
7.4 AND Gates 140
7.5 OR Gates 141
7.6 NAND Gates 142
7.7 NOR Gates 144
7.8 XOR Gates 145
7.9 XNOR Gates 146
7.10 Simplifying Boolean Expressions 149
7.11 Creating PLC Ladder Logic Diagrams from Logic Gate Circuits 155
7.12 Creating PLC Ladder Logic Diagrams from Boolean Expressions 159
7.13 Creating Logic Gate Circuits from PLC Ladder Logic Diagrams 161
7.14 LogixPro Simulator Examples 163
Chapter 8 PLC Timer Instructions 174
8.1 Timer Instructions 176
8.2 PLC Timer Instruction Registers 178
8.3 Fixed Preset Value Non-Retentive ON-Delay Timer Instructions 179
8.4 Variable Preset Value Non-Retentive ON-Delay Timer Instructions 181
8.5 Retentive ON-Delay Timer Instructions 183
8.6 OFF-Delay Timer Instructions 185
8.7 Interlocking Timers 186
8.8 Cascading Timers to Increase the Timing Value 187
8.9 LogixPro Simulator Examples 188
Chapter 9 PLC Counter Instructions 198
9.1 PLC Counter Instructions 199
9.2 PLC Counter Instruction Registers 199
9.3 PLC Count Up Instructions 200
9.4 PLC Count Down Instructions 202
9.5 Connecting PLC Counter Instructions 203
9.6 Cascading Counters 205
9.7 Creating PLC Ladder Logic Diagrams with Counters and Timers 206
9.8 LogixPro Simulator Examples 206
Chapter 110 PLC Math Instructions 218
10.1 Addition 219
10.2 Subtraction 221
10.3 Multiplication 223
10.4 Division 225
10.5 Advanced Math Instructions 227
10.6 LogixPro Simulator Examples 229
Chapter 11 PLC Compare, Jump, and MCR Instructions 236
11.1 Compare Instructions 238
11.2 Unconditional Jump 242
11.3 Conditional Jump 242
11.4 Master Control Reset (MCR) 244
11.5 LogixPro Simulator Examples 244
Chapter 12 PLC Subroutine Functions 256
12.1 Subroutine Concept 258
12.2 Jump to Subroutine 259
12.3 Return from Subroutine 260
12.4 Subroutine Applications 261
12.5 Interrupt Routines 264
12.6 LogixPro Simulator Example 264
Chapter 13 PLC Logic and Bit Shift Instructions 272
13.1 Logic Gate Instructions 274
13.2 Shift Left Instruction 277
13.3 Shift Right Instruction 280
13.4 LogixPro Simulator Examples 282
Chapter 14 Data Handling Instructions 292
14.1 Move, Indexed Move, and Masked Move 294
14.2 First-In-First-Out (FIFO) and Last-In-First-Out (LIFO) 295
14.3 Copy File and Fill File Instructions 298
14.4 Data/Unit Conversion 300
14.5 LogixPro Simulator Examples 301
Chapter 15 Sequencer Instructions 312
15.1 Sequencer Concept 314
15.2 Sequencer Output Instruction 316
15.3 Sequencer Compare Instruction 321
15.4 Sequencer Load Instruction 323
15.5 Cascading Sequencers 324
15.6 Parallel Sequencers 325
15.7 LogixPro Simulator Examples 326
Chapter 16 Troubleshooting and Servicing the PLC System 338
16.1 Routine Maintenance 339
16.2 Hardware 340
16.3 Software Error Detection 342
16.4 LogixPro Simulator Examples 344
Chapter 17 PLC Networks in Manufacturing 354
17.1 Transmission Media 356
17.2 Network Topologies 361
17.3 Network Access Control 362
17.4 PLC Networks 363
17.5 DH-485 Network Software Configurations 370
17.6 SVC and MSG Instructions 374
Chapter 18 PLC Programming with RSLogix 5000 Software 384
18.1 Project Organization Area 386
18.2 Ultraviolet Water Purification Process Example 386
18.3 Planning the CompactLogix Input/Output Modules 392
18.4 Creating the RSLogix 5000 Project 393
18.5 Overall System Appearance and Functions 411
18.6 Comparing the RSLogix 5000 and RSLogix 500 Software 412
18.7 PLCLogix Simulator Examples 415
Appendix A Electromechanical Devices 423
Appendix B Conversion Tables 431
Appendix C Natural Trigonometric Functions and Binary Systems 437
Appendix D SLC 500 Reference 441
Glossary 443
Index 456
