Programmable Logic Controllers: Principles and Applications FM

Glen A. Mazur William J. Weindorf

Programmable Logic Controllers: Principles and Applications contains procedures commonly practiced in industry and the trade. Specific procedures vary with each task and must be performed by a qualified person. For maximum safety, always refer to specific manufacturer recommendations, insurance regulations, specific job-site and plant procedures, applicable federal, state, and local regulations, and any authority having jurisdiction. The material contained herein is intended to be an educational resource for the user. American Technical Publishers assumes no responsibility or liability in connection with this material or its use by any individual or organization.

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Acknowledgments

The authors and publisher are grateful for the technical information and assistance provided by:

Dave McDonald Automation Systems Estimator Integrity Integration Resources

ABB Inc.

Lincoln Electric, Inc.

Advanced Assembly Automation Inc.

Lovejoy, Inc.

Atlas Technologies Inc.

PLC Multipoint

Baldor Electric Company

R.C. Flagman Inc.

Carlo Gavazzi Inc.

Rockwell Automation, Inc

Carrier Corporation

Rockwell Automation, Allen-Bradley Company, Inc.

Cleaver Brooks

Saftronics, Inc.

Dreamsquare/Shutterstock.com

Salisbury

Fluke Corporation

SEW-Eurodrive, Inc.

GE Fanuc Automation

Siemens

Ideal Industries, Inc

Worcester Controls Corporation

Jackson Systems LLC

Table of Contents 1

PROGRAMMABLE LOGIC CONTROLLERS AND CRITICAL SAFETY PRACTICES

2

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 PLC EXERCISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

2

PLC ELECTRICAL PRINCIPLES, RATINGS, AND CIRCUIT CALCULATIONS

72

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 PLC EXERCISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

3

PLC PROGRAMMING SYMBOLS, DIAGRAMS, AND LOGIC FUNCTIONS

118

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 PLC EXERCISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

4

PLC HARDWARE, MEMORY, AND OPERATING CYCLE

156

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 PLC EXERCISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177

5

PLC SYSTEMS, CIRCUITS, AND INTERFACE DEVICES

186

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227 PLC EXERCISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231

6

PLC PROGRAMMING DIAGRAMS, ADDRESSES, AND BIT INSTRUCTIONS

242

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 PLC EXERCISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265

7

PLC PROGRAMMING TIMER AND COUNTER INSTRUCTIONS

274

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293 PLC EXERCISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295

8

PLC ANALOG DEVICE INSTALLATION, PROGRAMMING, AND TROUBLESHOOTING

312

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335 PLC LABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337

9

INSTALLATIONS AND STARTUP

354

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381 PLC LABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .383

10

TROUBLESHOOTING METHODS AND TEST INSTRUMENT OPERATION

396

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .429 PLC LABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431

Table of Contents 11

TESTING AND TROUBLESHOOTING ELECTRICAL DEVICES AND PLC HARDWARE

438

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471 PLC LABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473

12

TROUBLESHOOTING WITH PLC SOFTWARE

482

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .499 PLC LABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501

13

PLC SYSTEM MAINTENANCE

510

CHAPTER REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .527 PLC LABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .529

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545 GLOSSARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573

Learner Resources • • • •

Quick Quizzes® Illustrated Glossary Flash Cards Chapter Activities

• • • •

PLC Components TECO Resources Allen-Bradley® Resources SIEMENS Resources

• Programming Software Tutorial Videos • Internet Resources

Features Objectives identify specific concepts addressed within each chapter.

Industrial application photos facilitate proper safety measures during troubleshooting applications.

QR Codes at the beginning of each chapter enable quick access to Learner Resources.

Caution, Warning, and Danger boxes provide specific safety practices or information for certain electrical applications.

Code Connects provide specific code information from the 2020 NECÂŽ.

Chapter Reviews reinforce comprehension of chapter content.

PLC Tips provide additional information related to topics presented.

PLC Exercises/Labs reinforce developmental skills to program and wire PLC circuits.

Full color photos supplement text and illustrations.

Detailed illustrations show operation of components and PLC circuits.

Learner Resources The Programmable Logic Controllers: Principles and Applications Learner Resources are self-study tools that reinforce the content covered in the book. These online resources can be accessed using either of the following methods: • Key ATPeResources.com/QuickLinks into a web browser and enter QuickLinks™ access code .

• Use a Quick Response (QR) reader app to scan the QR Code with a mobile device.

Programmable Logic Controllers: Principles and Applications includes access to online learner resources that reinforce textbook content and enhance learning. The learner resources include the following: • Quick Quizzes® that provide interactive questions for each chapter, with embedded links to highlighted content with the textbook and to the Illustrated Glossary • Illustrated Glossary that serves as a helpful reference to commonly used terms, with selected terms linked to textbook illustrations • Flash Cards that allow a self-study/review of common terms and their definitions • Chapter Activities that provide PDFs of activities based on corresponding chapter content • PLC Components that list components used to build PLC circuits or trainers • TECO Resources that provide PDFs and weblinks for downloading software and using TECO PLCs • Allen-Bradley® Resources that provide PDFs and weblinks for downloading software and using Allen-Bradley® PLCs • SIEMENS Resources that provide weblinks for purchasing SIEMENS software and PLCs, and a PDF document used to assist in programming SIEMENS Step 7 software • Programming Software Tutorial Videos consisting of procedural videos for programming both TECO and Allen-Bradley® software • Internet Resources that provide access to additional resources to support continued learning