Hands-On PLC Programming with RSLogix 500 and LogixPro / Edition 1

by Eman Kamel, Khaled Kamel

Overview

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Master the art of PLC programming and troubleshooting

Program, debug, and maintain high-performance PLC-based control systems using the detailed information contained in this comprehensive guide. Written by a pair of process automation experts, Hands-On PLC Programming with RSLogix™ 500 and LogixPro® lays out cutting-edge programming methods with a strong focus on practical industrial applications. Homework questions and laboratory projects illustrate important points throughout. A start-to-finish capstone design project at the end of the book illustrates real-world uses for the concepts covered.

Inside:

• Introduction to PLC control systems and automation
• Fundamentals of PLC logic programming
• Timer and counter programming
• Math, move, comparison, and program control instructions
• HMI design and hardware configuration
• Process control design and troubleshooting
• Instrumentation and process control
• Analog programming and advanced control
• Comprehensive case studies

Product Details

ISBN-13:	9781259644344
Publisher:	McGraw Hill LLC
Publication date:	08/26/2016
Edition description:	New Edition
Pages:	432
Product dimensions:	7.30(w) x 9.40(h) x 0.70(d)

About the Author

Eman Kamel teaches in the School of Electronics Technology at ITT Technical Institute. She has more than 15 years of experience in process automation at companies including Dow Chemical, GE Jet Engine, Philip Morris Co., and PLC Automation, and has extensive experience designing and implementing PLC-based automation projects.

Khaled Kamel is a Professor in the Department of Computer Science at Texas Southern University. He was a faculty member and administrator for 22 years at the University of Louisville, where he was a Professor and Chair of the Computer Engineering and Computer Science Department.

Table of Contents

1 Introduction to PLC Control Systems and Automation 1

1.1 Control System Overview 2

1.1.1 Process Overview 2

1.1.2 Manual Control Operation 4

1.1.3 Automated System Building Blocks 5

1.1 A Direct/Reverse Acting Controller 7

1.2 Hardwired Systems Overview 7

1.2.1 Conventional Relays 7

1.2.2 Relay Logic System 9

1.2.3 Control Relay Application 11

1.2.4 Motor Magnetic Starters 12

1.2.5 Latch and Unlatch Control Relay 14

1.3 PLC's Overview 15

1.3.1 What Is a PLC? 15

1.3.2 History of PLCs 17

1.3.3 PLC Architecture 21

1.3.4 Hardwired System Replacement 22

1.3.5 PLC Ladder Logic 25

1.4 Manual/Auto Motor Control Operation 26

1.5 SLC-500 LogixPro Simulator Setup 27

1.5.1 The LogixPro 500 Screen 27

1.5.2 Editing Your Program 28

1.5.3 Debugging Your Program 28

1.5.4 RSLogix Documentation 29

1.5.5 I/O Simulator Screen 29

1.5.6 LogixPro 500 PLC Software 30

1.6 Process Control Choices 31

Chapter 1 Home Work Problems and Laboratory Projects 32

Laboratory 1.1 LogixPro 500 Program Creation 36

Laboratory 1.2 Program Testing 38

Laboratory 1.3 Converting Hardwired Control Relay to PLC Ladder Logic 39

2 Fundamentals of PLC Logic Programming 41

2.1 PLC Hardware 42

2.1.1 SLC-500 Processor 42

2.1.2 Operating Modes of the CPU 44

2.1.3 Communication Modules 45

2.1.4 Input/Output Modules 45

2.1.5 Power Supply 46

2.1.6 SLC-500 Memory Organization/Specifications 46

2.1.7 Processor Memory Map and Program Organization 47

2.2 Ladder Logic Diagrams 49

2.2.1 PLC Input/Output Terminal Connection 50

2.2.2 PLC Boolean Instructions 51

2.2.3 LogixPro 500 Data Files 53

2.3 Combinational Logic 55

2.3.1 Logic Gate Operations 55

2.3.2 LogixPro 500 Implementation Examples 59

2.3.3 I/O Testing Using the Force Function 61

2.4 Combinational Word Logic Operations 64

2.4.1 AND Word Logic Operation 64

2.4.2 OR Word Logic Operation 65

2.4.3 XOR Word Logic Operation 66

2.4.4 NOT Word Instruction 66

2.5 Latch, Unlatch, Subroutine, and One-Shot Instructions 67

2.5.1 Latch and Unlatch Instructions 68

2.5.2 Positive/Negative Edge One-Shot Instruction 68

2.5.3 File shift Instructions 72

2.5.4 JSR Instructions and Subroutine Nesting 73

Chapter 2 Home Work Problems and Laboratory Projects 78

Laboratory 2.1 Programming Combinational Logic 83

Laboratory 2.2 Basic Word Logic Operation Using Structured Programing 84

Laboratory 2.3 Controlling a Conveyor Belt Using Latch and Unlatch Instructions 86

Laboratory 2.4 Conveyor Belt Movement Directions 87

3 Timers and Counters Programming 89

3.1 ON-Delay Timers 90

3.2 Generating a Pulse Timer 93

3.3 OFF-Delay Timers 95

3.4 Retentive Timers-On-Delay 98

3.5 Fundamentals of Counters 100

3.5.1 Count-Up Counters 100

3.5.2 Count-Down Counters 103

Chapter 3 Home Work Problems and Laboratory Projects 107

Laboratory 3.1 Merry-Go-Round 114

Laboratory 3.2 Machine Tool Operation 114

Laboratory 3.3 Pump Fail to Start Alarm 116

Laboratory 3.4 Vertical Gate Monitoring 116

Laboratory 3.5 Cooling System Control 117

Laboratory 3.6 OFF-Delay Control of Three Motors 117

Laboratory 3.7 Pump Start/Stop Control for Predefined Calendar 118

Laboratory 3.8 Conveyor System Control 118

4.1 Math Instructions 122

4.1.1 Numbering Systems 122

4.1.2 SLC-500 Data and Numbers Representation 123

4.1.3 Common Math Instructions 126

4.1.4 Advanced Math Instruction 133

4.1.5 Swap Operation 135

4.1.6 Arithmetic Status Bits 137

4.2 Move and Transfer Instructions 138

4.2.1 Move Instruction 138

4.3 Comparison Instructions 139

4.3.1 Equal Instruction 139

4.3.2 Not Equal Instruction 139

4.3.3 Greater Than or Equal Instruction 139

4.3.4 Less Than or Equal Instruction 142

4.3.5 Greater Than Instruction 142

4.3.6 Less Than Instruction 142

4.3.7 Masked Move Instruction 145

4.4 Program Control Instructions 145

4.4.1 Jump Instruction 145

4.4.2 Subroutine Call 148

4.5 Implemented Industrial Application 149

4.51 Common Process Control Tasks 151

4.5.2 Industrial Control Applications 152

Chapter 4 Home Work Problems and Laboratory Projects 158

Laboratory 4.1 Tank Alarm 164

Laboratory 4.2 Feed Flow Digester Control 165

Laboratory 4.3 Merry-Go-Round Using One Timer 166

Laboratory 4.4 Pumps Alternation Using Structured Programming 166

Laboratory 4.5 Tank Fill/Refill 167

5.1 Allen-Bradley PLC Networking Options 172

5.2 PanelView Plus 600 Graphic Terminal 173

5.3 Door Control Simulator/Monitor 173

5.4 Silo Conveyor Control Operation 181

5.5 Single Batch Mode Operation 185

5.6 One-Way intersection Traffic Light Control 191

5.7 Bottling Assembly Line Control 195

5.8 PLC Trainer and Hardware Configuration 201

5.8.1 Book Training Unit Setup 201

5.8.2 RSLogix500 Software 202

5.8.3 RSLinx and Online Operation 204

5.8.4 Online Application Debugging 207

Chapter 5 Home Work Problems and Laboratory Projects 212

Laboratory 5.1 Garage Door Operation Control 213

Laboratory 5.2 Flashing Light Indicators 215

Laboratory 5.3 BCD I/O Simulator 216

Laboratory 5.4 Batch Process Auto/Manual Operation Modes 217

Laboratory 5.5 Batch Process Chemical Reactor 218

Laboratory 5.6 Structured Program for One-Way Traffic Lights Control 219

Laboratory 5.7 Batch Process Using ON-OFF Level Control 220

Laboratory 5.8 Conveyor Inspection Station Control 220

Laboratory 5.9 Structured Programming for the Bottling Assembly line 222

6 Process Control Design and Troubleshooting 225

6.1 Process Control Overview, Layer 1 226

6.1.1 Process Descriptions 227

6.1.2 Level of Control/Automation 227

6.1.3 Control System Components 228

6.2 Process Control Implementation, Layer 2 229

6.2.1 I/O List 229

6.2.2 Data Acquisition and Closed Loop Control Tasks 230

6.2.3 Project Logic Diagrams and Ladder Function Blocks 231

6.2.4 Control System Preliminary Documentation 231

6.2.5 Program Documentation Using Cross Reference 232

6.3 Process Control Checkout and Startup, Layer 3 232

6.3.1 Debugging Using Find and Replace Function 234

6.3.2 Debugging Using Program Data File 234

6.3.3 Debugging Using Advance Diagnostic 235

6.3.4 Checkout Using Forcing Functions 235

6.3.5 Checkout Using Custom Data Monitors 241

6.4 System Checkout and Troubleshooting 242

6.4.1 Static Checkout 243

6.4.2 Wired Master Control Relay Safety Standards 244

6.4.3 Master Control Reset Instruction Control Zones 246

6.5 Safeguard Implementation Examples 248

Chapter 6 Home Work Problems and Laboratory Projects 250

Laboratory 6.1 Conveyor System Control 252

Laboratory 6.2 Irrigation Canal Sensors, Validation and Calibration 253

7 Instrumentation and Process Control 257

7.1 Instrumentation Basics 258

7.1.1 Sensors Basics 258

7.1.2 Analog Sensors 259

7.1.3 Digital Sensors 259

7.2 Process Control Elements 260

7.2.1 Basic Measurement System 260

7.2.2 Process Control Variables 261

7.2.3 Signal Conditioning 262

7.2.4 Signal Transmitters 263

7.3 Signal Conversion 263

7.3.1 Analog-to-Digital Conversion 263

7.3.2 Digital-to-Analog Conversion 265

7.3.3 Quantification Errors and Resolution 266

7.4 Process Control System 267

7.4.1 Control Process 268

7.4.2 Controlled Variables 268

7.4.3 Control Strategy and Types 269

7.4.4 Process Control Loop 270

7.4.5 Control System Error Quantification 272

7.4.6 Control System Transient and Performance Evaluation 272

7.5 Closed-Loop Process Control Types 273

7.5.1 On/Off Control Mode 275

7.5.2 Proportional Control Mode 275

7.5.3 Composite Control Mode 277

7.5.4 PLC/Distributed Computer Supervisory Control 277

Chapter 7 Home Work Problems and Laboratory Projects 279

Laboratory 7.1 On/Off Temperature Control 281

Laboratory 7.2 Tank Level and Flow Rate Monitoring 284

8 Analog Programming and Advanced Control 285

8.1 Analog Input/Output Configuration and Programming 286

8.1.1 Analog Input/Output Modules 286

8.1.2 Configuring Analog Input/Output Modules 286

8.1.3 Scale Instruction 287

8.1.4 NI04V Composite Module Bit Addressing and Data Conversion 289

8.1.5 .Analog Scaling and Mapping 292

8.2 PID Control Configuration and Programming 296

8.2.1 Closed-Loop Control System 296

8.2.2 Control System Time Response 298

8.2.3 Control System Types 300

8.2.4 Controllers Behavior 302

8.2.5 Selection of the Suitable Controller Structures 304

8.3 FID Instruction 305

8.3.1 SLC-500 FID Control Block 306

8.3.2 SLC-500 Tank Level FID Control 310

8.4 PID Tuning 312

8.4.1 PID Closed-Loop Tuning 313

8.4.2 Manual Tuning 314

8.4.3 Ziegler-Nichols Method 315

8.4.4 Cohen-Coon Tuning Method 315

8.4.5 PID Tuning Software 316

8.4.6 Integral Windup and PI Controllers 317

Chapter 8 Home Work Problems and Laboratory Projects 318

Laboratory 8.1 Tank Level Sensors Measurement Processing and Monitoring 319

Laboratory 8.2 Validating and Monitoring Power Supply Voltage 322

Laboratory 8.3 Simple Closed-Loop PID Control 325

9 Comprehensive Case Studies 327

9.1 Irrigation Canal Water Level Control 328

9.1.1 System I/O Map 329

9.1.2 Logic Diagrams 329

9.1.3 Automated System Building Blocks 332

9.2 Irrigation Canal Ladder Implementation 334

9.3 Wet Wells Pump Station Control 346

9.3.1 System I/O Map 346

9.3.2 Automated System Building Blocks 347

9.4 Pumping Station Ladder Implementation 348

9.4.1 Pump Alarms 348

Chapter 9 Home Work Problems and Laboratory Project 354

Laboratory 9.1 Conveyor System Speed Control Capstone Project 354

Odd-Numbered Home Work Problem Solutions 361

Glossary 393

Index 405