Ebook programmable logic controllers (fifth edition) part 1

PROGRAMMABLE LOGIC CONTROLLERS, FIFTH EDITIONPublished by McGraw-Hill Education, 2 Penn Plaza, New York, NY 10121.. vi ContentsWiring Diagrams and Ladder Logic Programs 98 6.1 Electroma

Trang 2

Programmable Logic Controllers

Trang 3

This page intentionally left blank

Trang 4

Programmable Logic Controllers

Frank D Petruzella

Fifth Edition

Trang 5

PROGRAMMABLE LOGIC CONTROLLERS, FIFTH EDITION

1998 No part of this publication may be reproduced or distributed in any form or by any means, or stored in a

database or retrieval system, without the prior written consent of McGraw-Hill Education, including, but not

limited to, in any network or other electronic storage or transmission, or broadcast for distance learning.

Some ancillaries, including electronic and print components, may not be available to customers outside the

United States.

This book is printed on acid-free paper

1 2 3 4 5 6 7 8 9 0 RMN/RMN 1 0 9 8 7 6

ISBN 978-0-07-337384-3

MHID 0-07-337384-2

Senior Vice President, Products & Markets: Kurt L Strand

Vice President, General Manager, Products & Markets: Marty Lange

Vice President, Content Design & Delivery: Kimberly Meriwether David

Managing Director: Thomas Timp

Global Brand Manager: Raghu Srinivasan

Director, Product Development: Rose Koos

Product Developer: Vincent Bradshaw

Marketing Manager: Nick McFadden

Digital Product Developer: Amy Bumbaco, Ph.D.

Director, Content Design & Delivery: Linda Avenarius

Executive Program Manager: Faye M Herrig

Content Project Managers: Jessica Portz, Tammy Juran, Sandra Schnee

Buyer: Laura M Fuller

Content Licensing Specialist: Lorraine Buczek

Compositor: MPS Limited

Printer: R R Donnelley

All credits appearing on page or at the end of the book are considered to be an extension of the copyright page.

Library of Congress Cataloging-in-Publication Data

Petruzella, Frank D., author.

Programmable logic controllers / Frank D Petruzella.—Fifth edition.

pages cm

Includes index.

ISBN 978-0-07-337384-3 (alk paper)—ISBN 0-07-337384-2 (alk paper) 1 Programmable

controllers I Title.

TJ223.P76P48 2017

629.8’95—dc23

2015035302

The Internet addresses listed in the text were accurate at the time of publication The inclusion of a website

does not indicate an endorsement by the authors or McGraw-Hill Education, and McGraw-Hill Education does

not guarantee the accuracy of the information presented at these sites.

mheducation.com/highered

Trang 6

3.8 ASCII Code 54

3.9 Parity Bit 54

3.10 Binary Arithmetic 55

3.11 Floating Point Arithmetic 57

Review Questions 59

Problems 60

Chapter 4 Fundamentals of Logic 61 4.1 The Binary Concept 62

4.2 AND, OR, and NOT Functions 62

The AND Function 62

The OR Function 63

The NOT Function 64

The Exclusive-OR (XOR) Function 65

4.3 Boolean Algebra 65

4.4 Developing Logic Gate Circuits from Boolean Expressions 66

4.5 Producing the Boolean Equation for a Given Logic Gate Circuit 66

4.6 Hardwired Logic versus Programmed Logic 67 4.7 Programming Word Level Logic Instructions 70 Review Questions 72

Problems 72

Chapter 5 Basics of PLC Programming 74 5.1 Processor Memory Organization 75

Program Files 75

Data Files 75

5.2 Program Scan 78

5.3 PLC Programming Languages 81

5.4 Bit-Level Logic Instructions 83

5.5 Instruction Addressing 86

5.6 Branch Instructions 87

5.7 Internal Relay Instructions 89

5.8 Programming Examine If Closed and Examine If Open Instructions 90

5.9 Entering the Ladder Diagram 91

5.10 Modes of Operation 93

5.11 Connecting with Analog Devices 93

Review Questions 95

Problems 96

Preface viii

Acknowledgments xi

About the Author xii

Chapter 1 Programmable Logic Controllers (PLCs): An Overview 1 1.1 Programmable Logic Controllers 2

1.2 Parts of a PLC 4

1.3 Principles of Operation 8

1.4 Modifying the Operation 11

1.5 PLCs versus Computers 11

1.6 PLC Size and Application 12

Review Questions 15

Problems 16

Chapter 2 PLC Hardware Components 17 2.1 The I/O Section 18

2.2 Discrete I/O Modules 22

2.3 Analog I/O Modules 27

2.4 Special I/O Modules 31

2.5 I/O Specifications 33

Typical Discrete I/O Module Specifications 33

Typical Analog I/O Module Specifications 34

2.6 The Central Processing Unit (CPU) 35

2.7 Memory Design 36

2.8 Memory Types 37

2.9 Programming Terminal Devices 39

2.10 Recording and Retrieving Data 39

2.11 Human Machine Interfaces (HMIs) 39

Review Questions 43

Problems 45

Chapter 3 Number Systems and Codes 46 3.1 Decimal System 47

3.2 Binary System 47

3.3 Negative Numbers 49

3.4 Octal System 49

3.5 Hexadecimal System 50

3.6 Binary Coded Decimal (BCD) System 51

3.7 Gray Code 53

v

Trang 7

vi Contents

Wiring Diagrams and Ladder Logic Programs 98

6.1 Electromagnetic Control Relays 99

6.2 Contactors 100

6.3 Motor Starters 101

6.4 Manually Operated Switches 102

6.5 Mechanically Operated Switches 103

6.6 Sensors 104

Proximity Sensor 104

Magnetic Reed Switch 107

Light Sensors 107

Ultrasonic Sensors 109

Strain/Weight Sensors 110

Temperature Sensors 110

Flow Measurement 111

Velocity and Position Sensors 111

6.7 Output Control Devices 112

6.8 Seal-In Circuits 114

6.9 Electrical Interlocking Circuits 115

6.10 Latching Relays 116

6.11 Converting Relay Schematics into PLC Ladder Programs 121

6.12 Writing a Ladder Logic Program Directly from a Narrative Description 124

6.13 Instrumentation 127

Review Questions 128

Problems 129

Chapter 7 Programming Timers 131 7.1 Mechanical Timing Relays 132

7.2 Timer Instructions 134

7.3 On-Delay Timer Instruction 135

7.4 Off-Delay Timer Instruction 140

7.5 Retentive Timer 144

7.6 Cascading Timers 147

Problems 151

Chapter 8 Programming Counters 156 8.1 Counter Instructions 157

8.2 Up-Counter 159

One-Shot Instruction 162

8.3 Down-Counter 166

8.4 Cascading Counters 170

8.5 Incremental Encoder-Counter Applications 173 8.6 Combining Counter and Timer Functions 174

8.7 High-Speed Counters 177

Problems 179

Chapter 9 Program Control Instructions 184 9.1 Program Control 185

9.2 Master Control Reset Instruction 185

9.3 Jump Instruction 188

9.4 Subroutine Functions 190

9.5 Immediate Input and Immediate Output Instructions 193

9.6 Forcing External I/O Addresses 195

9.7 Safety Circuitry 197

9.8 Selectable Timed Interrupt 200

9.9 Fault Routine 201

9.10 Temporary End Instruction 201

9.11 Suspend Instruction 202

Problems 203

Chapter 10 Data Manipulation Instructions 207 10.1 Data Manipulation 208

10.2 Data Transfer Operations 208

10.3 Data Compare Instructions 216

10.4 Data Manipulation Programs 221

10.5 Numerical Data I/O Interfaces 224

10.6 Closed-Loop Control 226

Problems 231

Chapter 11 Math Instructions 234 11.1 Math Instructions 235

11.2 Addition Instruction 236

11.3 Subtraction Instruction 238

11.4 Multiplication Instruction 239

11.5 Division Instruction 240

11.6 Other Word-Level Math Instructions 242

11.7 File Arithmetic Operations 245

Problems 248

Chapter 12 Sequencer and Shift Register Instructions 252 12.1 Mechanical Sequencers 253

12.2 Sequencer Instructions 255

12.3 Sequencer Programs 259

12.4 Bit Shift Registers 264

12.5 Word Shift Operations 272

Problems 277

Trang 8

Chapter 13 PLC Installation Practices,

Editing, and Troubleshooting 281

13.1 PLC Enclosures 282

13.2 Electrical Noise 284

13.3 Leaky Inputs and Outputs 285

13.4 Grounding 285

13.5 Voltage Variations and Surges 287

13.6 Program Editing and Commissioning 288

13.7 Programming and Monitoring 289

13.8 Preventive Maintenance 291

13.9 Troubleshooting 292

Processor Module 292

Input Malfunctions 292

Output Malfunctions 294

Ladder Logic Program 294

13.10 PLC Programming Software 299

Problems 302

Chapter 14 Process Control, Network Systems, and SCADA 305 14.1 Types of Processes 306

14.2 Structure of Control Systems 308

14.3 On/Off Control 310

14.4 PID Control 311

14.5 Motion Control 315

14.6 Data Communications 316

Data Highway 322

Serial Communication 322

DeviceNet 322

ControlNet 325

EtherNet/IP 325

Modbus 326

Fieldbus 326

PROFIBUS-DP 326

14.7 Supervisory Control and Data Acquisition (SCADA) 328

Problems 332

Chapter 15 ControlLogix Controllers 333 Part 1 Memory and Project Organization 334

Memory Layout 334

Configuration 334

Project 335

Tasks 336

Programs 336

Routines 337

Tags 337

Structures 340

Creating Tags 341

Monitoring and Editing Tags 342

Array 342

Part 2 Bit-Level Programming 345

Program Scan 345

Creating Ladder Logic 346

Tag-Based Addressing 347

Adding Ladder Logic to the Main Routine 348

Internal Relay Instructions 350

Latch and Unlatch Instructions 352

One-Shot Instruction 353

Problems 356

Part 3 Programming Timers 358

Timer Predefined Structure 358

On-Delay Timer (TON) 359

Off-Delay Timer (TOF) 362

Retentive Timer On (RTO) 364

Cascading of Timers 365

Problems 367

Part 4 Programming Counters 368

Counters 368

Count-Up (CTU) Counter 369

Count-Down (CTD) Counter 371

Combining Counter and Timer Functions 372

Problems 373

Part 5 Math, Comparison, and Move Instructions 374

Math Instructions 374

Comparison Instructions 376

Move Instructions 379

Combining Math, Comparison, and Move Instructions 380

Problems 383

Part 6 Function Block Programming 384

Function Block Diagram (FBD) 384

FBD Programming 388

Problems 394

Glossary 395

Index 407

Trang 9

Preface

Programmable logic controllers (PLCs) continue to evolve

as new technologies are added to their capabilities As

PLC technology has advanced, so have programming

lan-guages and communications capabilities Today’s PLCs

offer faster scan times, space efficient high-density input/

output systems, and special interfaces to allow

non-traditional devices to be attached directly to the PLC

Now in its Fifth Edition, changes made to the content

of the text have been made solely based on reviews from

current instructors and include:

• material that should be added or deleted from

chapters

• topics requiring more in-depth coverage

• increased integration of the ControlLogix platform

of controllers

• chapter modifications require to meet current

cur-riculum needs

The primary source of information for a particular PLC

is always the accompanying user manuals provided by

the manufacturer This textbook is not intended to replace

the vendor’s reference material, but rather to

comple-ment, clarify, and expand on this information The text

covers the basics of programmable logic controllers in a

manner that complements instruction with a SLC-500 or

ControlLogix platform The underlying PLC principles

and concepts covered in the text are common to most

manufacturers They serve to maximize the knowledge

gained through on-the-job training and programs offered

by different vendors

The text is written in an easy-to-read style that is

de-signed for students with no prior PLC experience For

example, when the operation of a program is called for,

a bulleted list is used to summarize its execution The

bulled list replaces a lengthy paragraph and is especially helpful when covering the different steps related to the execution of a program

Each chapter begins with a brief introduction outlin-ing chapter coverage and learnoutlin-ing objectives When ap-plicable, the relay equivalent of the virtual programmed instruction is explained first, followed by the appropriate PLC instruction Chapters conclude with a set of review questions and problems The review questions are closely related to the chapter objectives and require students to recall and apply information covered in the chapter The problems range from easy to difficult, thus challenging students at various levels of competence

Features new to the Fifth Edition include:

• Key concepts and terms are highlighted in bold the

first time they appear

• New/updated photos and line art for every chapter

• New topics for every chapter as requested by

reviewers

• Addition review questions for new topics.

• Updated instructor PowerPoint lessons

• More than 175 SLC-500 and ControlLogix program simulation videos tied directly to the programs

studied in the text

In addition, students who are using McGraw-Hill’s Connect can watch simulated, step-by-step execution of numerous ladder logic programming

examples They’re guided by an audio

commen-tary that explains what to look for as the program

is executed The videos are part of the Student Resources section of Connect

Trang 10

Preface ix

Chapter changes in this edition include:

Chapter 1

• Testing of field devices

• Extended coverage of scan cycle sequence

• Additional test bank questions

• Program video simulations

• New and modified line diagrams and photos

Chapter 2

• ControlLogix Base and Alias addressing

• Extended coverage of DC module Sinking and

Sourcing

• Analog module input sensor 2-, 3-, and 4-wire

connections

• Scaling of PLC analog inputs and outputs

• Extended coverage of Human Machine Interfaces

(HMIs)

• Additional chapter review questions

Chapter 3

• 16 bit 2’s complement

• Floating point arithmetic

• Additional chapter problems

Chapter 4

• Modification to hardwired programming examples

Chapter 5

• Electrical versus logical continuity

• Evaluating XIO and XIC bit instructions

• Rack-based versus tag-based addressing

• Connecting with analog devices

Chapter 6

• Magnetic reed float switch

• Resistance temperature detectors (RTDs)

• Electrical interlocking circuits

• Process instrumentation

Chapter 7

• Extended coverage of timer instructions

• ControlLogix timer instruction

• Reciprocating timers

• TON timer bit table

• TOF timer bit table

Chapter 8

• ControlLogix counter instruction

• Extended coverage of CTD instruction

• Additional information on incremental encoders

• New section on High-Speed Counter instruction

Chapter 9

• Extended coverage of MCR instruction

• Extended coverage of Jump instruction

• Extended coverage of Immediate Input and Output instructions

• ControlLogix Immediate Output instruction

Tiêu đề	Programmable Logic Controllers Fifth Edition
Tác giả	Frank D. Petruzella
Trường học	McGraw-Hill Education
Chuyên ngành	Automation and Control Engineering
Thể loại	Textbook
Năm xuất bản	2017
Thành phố	New York

Định dạng
Số trang	20
Dung lượng	3,17 MB