Programmable Controllers Theory and Implementation [L.A. Bryan & E.A. Bryan].PDF

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Programmable Controllers
Theory and Implementation
Second Edition
L.A. Bryan
E.A. Bryan
PROGRAMMABLE
CONTROLLERS
T
HEORY
AND
I
MPLEMENTATION
Second Edition
L. A. Bryan
E. A. Bryan
An Industrial Text Company Publication
Atlanta • Georgia • USA
© 1988, 1997 by Industrial Text Company
Published by Industrial Text Company
All rights reserved
First edition 1988. Second edition 1997
Printed and bound in the United States of America
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Reproduction or translation of any part of this work beyond
that permitted by Sections 107 and 108 of the 1976 United
States Copyright act are unlawful.
Requests for permission, accompanying workbooks, or
further information should be addressed to:
Industrial Text and Video Company
1950 Spectrum Circle
Tower A-First Floor
Marietta, Georgia 30067
(770) 240-2200
(800) PLC-TEXT
Library
of Congress Cataloging-in-Publication Data
Bryan, L.A.
Programmable controllers: theory and implementation/L.A. Bryan,
E.A. Bryan.—2nd ed.
p.
cm.
Includes index.
ISBN 0-944107-32-X
1. Programmable controllers.
I. Bryan, E.A.
II. Title.
TJ223.P76B795 1997
629.8'9—dc21
96-49350
CIP
Due to the nature of this publication and because of the different applications of
programmable controllers, the readers or users and those responsible for applying the
information herein contained must satisfy themselves to the acceptability of each
application and the use of equipment therein mentioned. In no event shall the publisher
and others involved in this publication be liable for direct, indirect, or consequential
damages resulting from the use of any technique or equipment herein mentioned.
The illustrations, charts, and examples in this book are intended solely to illustrate the
methods used in each application example. The publisher and others involved in this
publication cannot assume responsibility or liability for actual use based on the
illustrative uses and applications.
No patent liability is assumed with respect to use of information, circuits, illustrations,
equipment, or software described in this text.
Industrial Text & Video Company
1-800-752-8398
www.industrialtext.com
Contents
C
ONTENTS
Preface ..................................................................................................... ix
About the Authors .................................................................................... x
How to Use this Book ............................................................................. xi
S
ECTION
1 I
NTRODUCTORY
C
ONCEPTS
Chapter 1
1-1
1-2
1-3
1-4
1-5
1-6
1-7
Chapter 2
2-1
2-2
2-3
2-4
2-5
Chapter 3
3-1
3-2
3-3
3-4
Introduction to Programmable Controllers
Definition ................................................................................................. 4
A Historical Background .......................................................................... 5
Principles of Operation ........................................................................... 10
PLCs Versus Other Types of Controls ................................................... 13
PLC Product Application Ranges .......................................................... 22
Ladder Diagrams and the PLC ............................................................... 24
Advantages of PLCs ............................................................................... 26
Number Systems and Codes
Number Systems .................................................................................... 34
Number Conversions .............................................................................. 41
One’s and Two’s Complement ............................................................... 43
Binary Codes .......................................................................................... 46
Register Word Formats .......................................................................... 50
Logic Concepts
The Binary Concept ............................................................................... 56
Logic Functions ...................................................................................... 57
Principles of Boolean Algebra and Logic .............................................. 64
PLC Circuits and Logic Contact Symbology ......................................... 68
S
ECTION
2 C
OMPONENTS AND
S
YSTEMS
Chapter 4
4-1
4-2
4-3
4-4
4-5
4-6
Chapter 5
5-1
5-2
5-3
5-4
Processors, the Power Supply, and Programming Devices
Introduction ............................................................................................ 82
Processors ............................................................................................... 84
Processor Scan ........................................................................................ 86
Error Checking and Diagnostics ............................................................ 92
The System Power Supply ..................................................................... 98
Programming Devices .......................................................................... 104
The Memory System and I/O Interaction
Memory Overview ............................................................................... 110
Memory Types ..................................................................................... 111
Memory Structure and Capacity .......................................................... 115
Memory Organization and I/O Interaction ........................................... 119
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Contents
5-5 Configuring the PLC Memory—I/O Addressing ................................. 127
5-6 Summary of Memory, Scanning, and I/O Interaction .......................... 132
5-7 Memory Considerations ....................................................................... 133
Chapter 6
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
Chapter 7
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
7-9
7-10
7-11
Chapter 8
8-1
8-2
8-3
8-4
8-5
8-6
8-7
The Discrete Input/Output System
Introduction to Discrete I/O Systems ................................................... 138
I/O Rack Enclosures and Table Mapping ............................................ 139
Remote I/O Systems ............................................................................. 146
PLC Instructions for Discrete Inputs .................................................... 147
Types of Discrete Inputs ...................................................................... 150
PLC Instructions for Discrete Outputs ................................................. 162
Discrete Outputs ................................................................................... 165
Discrete Bypass/Control Stations ......................................................... 177
Interpreting I/O Specifications ............................................................. 178
Summary of Discrete I/O ..................................................................... 182
The Analog Input/Output System
Overview of Analog Input Signals ....................................................... 186
Instructions for Analog Input Modules ................................................ 187
Analog Input Data Representation ....................................................... 189
Analog Input Data Handling ................................................................ 196
Analog Input Connections .................................................................... 199
Overview of Analog Output Signals .................................................... 201
Instructions for Analog Output Modules ............................................. 201
Analog Output Data Representation .................................................... 203
Analog Output Data Handling .............................................................. 207
Analog Output Connections ................................................................. 213
Analog Output Bypass/Control Stations .............................................. 214
Special Function I/O and Serial Communication Interfacing
Introduction to Special I/O Modules .................................................... 218
Special Discrete Interfaces ................................................................... 220
Special Analog, Temperature, and PID Interfaces ............................... 224
Positioning Interfaces ........................................................................... 233
ASCII, Computer, and Network Interfaces .......................................... 248
Fuzzy Logic Interfaces ......................................................................... 255
Peripheral Interfacing ........................................................................... 260
S
ECTION
3 PLC P
ROGRAMMING
Chapter 9
9-1
9-2
9-3
9-4
9-5
9-6
9-7
Programming Languages
Introduction to Programming Languages ............................................. 276
Types of PLC Languages ..................................................................... 276
Ladder Diagram Format ....................................................................... 282
Ladder Relay Instructions .................................................................... 289
Ladder Relay Programming ................................................................. 298
Timers and Counters ............................................................................ 306
Timer Instructions ................................................................................ 308
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