Automating Manufacturing Systems - Process Control and ...

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plc wiring - 2.15 2.4 PRACTICE PROBLEMS 1. Give an example of where a PLC could be used. 2. Why would relays be used in place of PLCs? 3. Give a concise description of a PLC. 4. List the advantages of a PLC over relays. 5. A PLC can effectively replace a number of components. Give examples and discuss some good and bad applications of PLCs. 6. Explain why ladder logic outputs are coils? 7. In the figure below, will the power for the output on the first rung normally be on or off? Would the output on the second rung normally be on or off? 8. Write the mnemonic program for the Ladder Logic below. 100 201 101 2.5 PRACTICE PROBLEM SOLUTIONS 1. To control a conveyor system 2. For simple designs 3. A PLC is a computer based controller that uses inputs to monitor a process, and uses outputs to control a processusing a program.
plc wiring - 2.16 4. Less expensive for complex processes, debugging tools, reliable, flexible, easy to expend, etc. 5. A PLC could replace a few relays. In this case the relays might be easier to install and less expensive. To control a more complex system the controller might need timing, counting and other mathematical calculations. In this case a PLC would be a better choice. 6. The ladder logic outputs were modelled on relay logic diagrams. The output in a relay ladder diagram is a relay coil that switches a set of output contacts. 7. off, on 8. LD 100, LD 101, OR, ST 201 2.6 ASSIGNMENT PROBLEMS 1. Explain the trade-offs between relays and PLCs for control applications. 2. Develop a simple ladder logic program that will turn on an output X if inputs A and B, or input C is on.
Page 1 and 2: ST1 B T2 A T1 C*B T3 page 0 ST3 T4
Page 3 and 4: page i 1.1 TODO LIST 1.4 2. PROGRAM
Page 5 and 6: page iii 7.4 PRACTICE PROBLEM SOLUT
Page 7 and 8: page v 14.2 MEMORY ADDRESSES 14.1 1
Page 9 and 10: page vii 20.3 SUMMARY 20.16 20.4 PR
Page 11 and 12: page ix 25.2 CONTROL OF LOGICAL ACT
Page 13 and 14: page xi 30.1 INTRODUCTION 30.1 30.2
Page 15 and 16: page xiii 35.21 U 35.28 35.22 V 35.
Page 17 and 18: plc wiring - 1.2 tougher, and the p
Page 19 and 20: plc wiring - 1.4 This book supports
Page 21 and 22: plc wiring - 2.2 logic diagrams was
Page 23 and 24: plc wiring - 2.4 115VAC wall plug r
Page 25 and 26: plc wiring - 2.6 A B B Note: When A
Page 27 and 28: plc wiring - 2.8 number there. The
Page 29 and 30: plc wiring - 2.10 2.1.3 PLC Connect
Page 31 and 32: plc wiring - 2.12 2.1.5 Ladder Logi
Page 33: plc wiring - 2.14 Solution: There a
Page 37 and 38: plc wiring - 3.2 quantities of I/O
Page 39 and 40: plc wiring - 3.4 5 Vdc (TTL) 200-24
Page 41 and 42: plc wiring - 3.6 There are many tra
Page 43 and 44: plc wiring - 3.8 ASIDE: PLC outputs
Page 45 and 46: plc wiring - 3.10 24 V DC Output Ca
Page 47 and 48: plc wiring - 3.12 put card directly
Page 49 and 50: plc wiring - 3.14 3.4 A CASE STUDY
Page 51 and 52: plc wiring - 3.16 L1 N 010 020 stop
Page 53 and 54: plc wiring - 3.18 disconnect circui
Page 55 and 56: plc wiring - 3.20 Resistor Tapped R
Page 57 and 58: plc wiring - 3.22 program. 200 201
Page 59 and 60: plc wiring - 3.24 3.8 PRACTICE PROB
Page 61 and 62: plc wiring - 3.26 14. 24Vdc + - 1 c
Page 63 and 64: plc wiring - 3.28 button inputs. b)
Page 65 and 66: discrete sensors - 4.2 puts from se
Page 67 and 68: discrete sensors - 4.4 term sourcin
Page 69 and 70: discrete sensors - 4.6 sensor V+ V+
Page 71 and 72: discrete sensors - 4.8 PLC Input Ca
Page 73 and 74: discrete sensors - 4.10 When purcha
Page 75 and 76: discrete sensors - 4.12 4.3.3 Optic
Page 77 and 78: discrete sensors - 4.14 In the figu
Page 79 and 80: discrete sensors - 4.16 effective b
Page 81 and 82: discrete sensors - 4.18 The optical
Page 83 and 84: discrete sensors - 4.20 C Ak = ----
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discrete sensors - 4.22 Material Co
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discrete sensors - 4.24 metal induc
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discrete sensors - 4.26 4.3.8 Fluid
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discrete sensors - 4.28 below. 00 0
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discrete sensors - 4.30 forget to i
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discrete sensors - 4.32 5. A transp
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discrete sensors - 4.34 7. 00 01 02
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discrete sensors - 4.36 9. L1 N sto
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discrete actuators - 5.1 5. LOGICAL
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discrete actuators - 5.3 Valve type
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discrete actuators - 5.5 F advancin
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discrete actuators - 5.7 Hydraulic
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discrete actuators - 5.9 Flow contr
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discrete actuators - 5.11 5.11 PRAC
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discrete actuators - 5.13
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plc boolean - 6.2 Note: By conventi
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plc boolean - 6.4 Idempotent A + A
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plc boolean - 6.6 6.3 LOGIC DESIGN
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plc boolean - 6.8 Ladder Logic for
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plc boolean - 6.10 der logic there
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plc boolean - 6.12 A = B⋅ C ⋅ (
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plc boolean - 6.14 A+ CA = A+ C pro
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plc boolean - 6.16 D1 D2 D3 multipl
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plc boolean - 6.18 Solution: D = A
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plc boolean - 6.20 The inputs and o
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plc boolean - 6.22 A = ( S⋅ M⋅
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plc boolean - 6.24 • Truth tables
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plc boolean - 6.26 b) Simplify the
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plc boolean - 6.28 2. A B D C 3. B
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plc boolean - 6.30 9. a) ( A+ B)
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plc boolean - 6.32 A B C B C D C A
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plc boolean - 6.34 17. D A Y 18. CA
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plc boolean - 6.36 c) A X B A C C A
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plc boolean - 6.38 algebra, and the
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plc karnaugh - 7.1 7. KARNAUGH MAPS
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plc karnaugh - 7.3 expression. The
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plc karnaugh - 7.5 7.3 PRACTICE PRO
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plc karnaugh - 7.7 5. Examine the t
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plc karnaugh - 7.9 Boolean equation
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plc karnaugh - 7.11 13. Consider th
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plc karnaugh - 7.13 5. 00 FG 01 11
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plc karnaugh - 7.15 9. CD AB AB A B
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plc karnaugh - 7.17 12. DA + ACD AB
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plc karnaugh - 7.19 4. Convert the
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plc operation - 8.2 inputs and outp
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plc operation - 8.4 input scan take
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plc operation - 8.6 8.3 PLC STATUS
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plc operation - 8.8 8.7 PRACTICE PR
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plc timers - 9.1 9. LATCHES, TIMERS
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plc timers - 9.3 The operation of t
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plc timers - 9.5 I/0 O/0 I/0 O/1 L
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plc timers - 9.7 oven has been turn
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plc timers - 9.9 value. The timer i
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plc timers - 9.11 I/1 TON T4:1 dela
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plc timers - 9.13 Start Stop Auto A
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plc timers - 9.15 CTU A Counter C5:
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plc timers - 9.17 The program in Fi
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plc timers - 9.19 9.6 INTERNAL RELA
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plc timers - 9.21 Solution: A T4:0/
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plc timers - 9.23 Solution: Motor S
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plc timers - 9.25 Solution: Go Stop
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plc timers - 9.27 Solution: TS1 LS1
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plc timers - 9.29 8. Complete the t
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plc timers - 9.31 17. Design a conv
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plc timers - 9.33 7. A RTF Timer T4
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plc timers - 9.35 9. input TON RTO
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plc timers - 9.37 14. I/1 T4:1/DN T
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plc timers - 9.39 16. left button T
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plc timers - 9.41 18. A T4:0/TT C5:
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plc timers - 9.43 22. GIVE SOLUTION
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plc timers - 9.45 3. Explain what w
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plc design - 10.2 Most control syst
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plc design - 10.4 Description: Step
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plc design - 10.6 step4 bottom LS s
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plc design - 10.8 Description: A ha
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plc design - 10.10 3. The first wra
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plc design - 10.12 3. (for both sol
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plc design - 10.14 (with latches fi
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plc design - 10.16 a) Start in an i
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plc flowchart - 11.1 11. FLOWCHART
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plc flowchart - 11.3 START Open out
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plc flowchart - 11.5 STEP 1: Add la
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plc flowchart - 11.7 STEP 2: Write
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plc flowchart - 11.9 F2 start MCR U
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plc flowchart - 11.11 F6 MCR L outl
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plc flowchart - 11.13 FS F1 F6 T1 T
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plc flowchart - 11.15 11.4 SUMMARY
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plc flowchart - 11.17 2. Start Get
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plc flowchart - 11.19 F3 gas can fu
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plc flowchart - 11.21 first scan L
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plc flowchart - 11.23 ST3 button MC
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plc flowchart - 11.25 ST8 button MC
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plc flowchart - 11.27 3. A welding
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plc states - 12.1 12. STATE BASED D
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plc states - 12.3 be active while c
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plc states - 12.5 Red Yellow Green
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plc states - 12.7 Step 2: Define St
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plc states - 12.9 RESET THE STATES
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plc states - 12.11 FIRST STATE WAIT
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plc states - 12.13 THIRD STATE WAIT
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plc states - 12.15 first scan L STB
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plc states - 12.17 Informally, Stat
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plc states - 12.19 Now, simplify th
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plc states - 12.21 OUTPUT LOGIC FOR
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plc states - 12.23 Each of the alte
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plc states - 12.25 A state diagram
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plc states - 12.27 CALCULATE STATE
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plc states - 12.29 STA T5 B T4 D ST
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plc states - 12.31 4. Given the fol
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plc states - 12.33 24 V AC Power Su
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plc states - 12.35 3. T1 = ST1 •
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plc states - 12.37 5. TA = ST2 ⋅
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plc states - 12.39 first scan MCR L
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plc states - 12.41 state 3 MCR rese
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plc states - 12.43 first scan state
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plc states - 12.45 state 4 remote M
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plc states - 12.47 ST1 remote T1 bu
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plc states - 12.49 12.5 ASSIGNMENT
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plc states - 12.51 6. Implement the
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plc states - 12.53 using an equatio
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plc states - 12.55 INPUTS I/1 - sta
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plc numbers - 13.2 decimal binary o
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plc numbers - 13.4 start with decim
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plc numbers - 13.6 Therearethreemot
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plc numbers - 13.8 decimal binary b
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plc numbers - 13.10 13.2.2 Other Ba
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plc numbers - 13.12 Figure 13.17 AS
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plc numbers - 13.14 An example of a
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plc numbers - 13.16 DATA CHECKSUM 1
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plc numbers - 13.18 a) from base 10
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plc numbers - 13.20 17. Do the foll
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plc numbers - 13.22 14. octal binar
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plc memory - 14.1 14. PLC MEMORY To
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plc memory - 14.3 programs are for
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plc memory - 14.5 Type A-ASCII B -
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plc memory - 14.7 literal data valu
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plc memory - 14.9 A MOV source 130
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plc memory - 14.11 CU - count up bi
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plc memory - 14.13 S2:0/0 carry in
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plc memory - 14.15 • In memory lo
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plc memory - 14.17 9. A B B C MOV S
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plc basic functions - 15.1 15. LADD
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plc basic functions - 15.3 NOTE: I
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plc basic functions - 15.5 A MOV so
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plc basic functions - 15.7 ADD sour
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plc basic functions - 15.9 given as
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plc basic functions - 15.11 FRD Sou
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plc basic functions - 15.13 A AVE F
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plc basic functions - 15.15 A FAL C
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plc basic functions - 15.17 EQU A N
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plc basic functions - 15.19 the hig
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plc basic functions - 15.21 15.3.2
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plc basic functions - 15.23 Solutio
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plc basic functions - 15.25 15.4.4
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plc basic functions - 15.27 6. A th
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plc basic functions - 15.29 3. coun
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plc basic functions - 15.31 first s
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plc basic functions - 15.33 9. NEG
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plc basic functions - 15.35 6. Writ
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plc advanced functions - 16.2 ter i
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plc advanced functions - 16.4 entry
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plc advanced functions - 16.6 16.2.
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plc advanced functions - 16.8 advan
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plc advanced functions - 16.10 16.1
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plc advanced functions - 16.12 A FO
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plc advanced functions - 16.16 prog
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plc advanced functions - 16.18 A X
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plc advanced functions - 16.20 e.g.
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plc advanced functions - 16.24 Prog
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plc advanced functions - 16.28 T4:0
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plc advanced functions - 16.30 8. D
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plc advanced functions - 16.32 B3:0
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plc advanced functions - 16.34 3. I
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plc advanced functions - 16.36 S3 S
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plc advanced functions - 16.38 11.
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plc iec61131 - 17.1 17. OPEN CONTRO
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plc iec61131 - 17.3 Name Type Bits
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plc il - 18.1 18. INSTRUCTION LIST
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plc il - 18.3 LD I:000/0 AND( I:000
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plc il - 18.5 Ladder A X Instructio
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plc il - 18.7 Ladder A X Y Instruct
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plc il - 18.9 Program File 2: Label
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plc st - 19.1 19. STRUCTURED TEXT P
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plc st - 19.3 GOOD BAD *) FUNCTION
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plc st - 19.5 Text Program Line VAR
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plc st - 19.7 Time Value 25ms 5.5ho
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plc st - 19.9 • Functions for Boo
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plc st - 19.11 F8:10 := 0; FOR (N7:
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plc st - 19.13 the delay time for a
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plc st - 19.15 • The list below g
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plc st - 19.17 Function MAX(A,B,...
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plc st - 19.19 .... D := TEST(1.3,
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plc sfc - 20.1 20. SEQUENTIAL FUNCT
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plc sfc - 20.3 selection branch - a
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plc sfc - 20.5 press will then retr
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plc sfc - 20.7 first scan INITIALIZ
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plc sfc - 20.9 transition 5 top lim
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plc sfc - 20.11 step 6 U step 6 L t
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plc sfc - 20.13 Program 3 (for step
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plc sfc - 20.15 ST2 TR8 ST2 TR13 FS
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plc sfc - 20.17 20.4 PRACTICE PROBL
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plc sfc - 20.19 2. Start EW crosswa
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plc sfc - 20.21 4. step 1 step 2 T1
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plc sfc - 20.23 T1 remote L step 3
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plc sfc - 20.25 step 1 step 2 step
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plc fb - 21.2 A FBD program is cons
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plc fb - 21.4 Figure 21.6 shows a d
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plc analog - 22.1 22. ANALOG INPUTS
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plc analog - 22.3 A more realistic
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plc analog - 22.5 R = 2 N = R max -
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plc analog - 22.7 Figure 22.6 Low S
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plc analog - 22.9 ASIDE: This devic
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plc analog - 22.11 (Note: each type
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plc analog - 22.13 important if the
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plc analog - 22.15 Given, Calculate
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plc analog - 22.17 tion will change
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plc analog - 22.19 A t V eff = A A
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plc analog - 22.21 flow. The resist
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plc analog - 22.23 • Analog shiel
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plc analog - 22.25 5. A card with a
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plc analog - 22.27 7. A SIN Source
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plc analog - 22.29 22.8 ASSIGNMENT
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continuous sensors - 23.2 terized w
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continuous sensors - 23.4 θ max V
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continuous sensors - 23.6 sensors r
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continuous sensors - 23.8 Normally
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continuous sensors - 23.10 A rod dr
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continuous sensors - 23.12 on off o
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continuous sensors - 23.14 Sealant
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continuous sensors - 23.16 After th
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continuous sensors - 23.18 stress d
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continuous sensors - 23.20 23.2.5 L
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continuous sensors - 23.22 These se
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continuous sensors - 23.24 result i
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continuous sensors - 23.26 very hig
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continuous sensors - 23.28 mV 80 E
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continuous sensors - 23.30 Thermist
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continuous sensors - 23.32 23.2.9 O
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continuous sensors - 23.34 device +
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continuous sensors - 23.36 The circ
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continuous sensors - 23.38 put is p
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continuous sensors - 23.40 ratio. I
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continuous sensors - 23.42 10. enco
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continuous actuators - 24.1 24. CON
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continuous actuators - 24.3 command
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continuous actuators - 24.5 wear, w
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continuous actuators - 24.7 ASIDE:
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continuous actuators - 24.9 L2 L1 L
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continuous actuators - 24.11 torque
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continuous actuators - 24.13 • Si
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continuous actuators - 24.15 runnin
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continuous actuators - 24.21 cally
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continuous actuators - 24.23 e f =
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continuous actuators - 24.25 24.5 S
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continuous actuators - 24.27 How ma
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plc pid - 25.2 valve a) Water Tank
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plc pid - 25.4 to a process, and tu
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plc pid - 25.6 θ neural desired +
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plc pid - 25.8 next two sections de
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plc pid - 25.10 Figure 25.10 A Comb
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plc pid - 25.12 25.3.4 PID Control
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plc pid - 25.14 PID Control Block:
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plc pid - 25.16 S2:1/15 - first sca
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plc pid - 25.18 SOLUTION Analog Inp
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plc pid - 25.20 BT9:0/DN BT9:2/EN B
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plc pid - 25.22 4. Assume the value
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plc pid - 25.24 7. S2:1/15 - first
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plc pid - 25.26 25.8 ASSIGNMENT PRO
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plc fuzzy - 26.1 26. FUZZY LOGIC T
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plc fuzzy - 26.3 1. If (bucket is f
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plc fuzzy - 26.5 1. If v error is L
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plc fuzzy - 26.7 final motor contro
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plc fuzzy - 26.9 response will be s
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plc serial - 27.2 An example of a n
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plc serial - 27.4 A typical data by
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plc serial - 27.6 Modem Computer co
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plc serial - 27.8 RI - (ring indica
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plc serial - 27.10 ABL(channel, con
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plc serial - 27.12 ACI String ST9:1
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plc serial - 27.14 on many new inst
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plc serial - 27.16 5. Write a progr
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plc serial - 27.18 5. MOV Source F8
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plc network - 28.1 28. NETWORKING
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plc network - 28.3 ... R Repeater R
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plc network - 28.5 that syntax, for
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plc network - 28.7 28.1.4 Control N
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plc network - 28.9 • Data packet
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plc network - 28.11 MG9:0/EN MSG Se
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plc network - 28.13 1bit 11 bits 1b
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plc network - 28.15 46 to 1500 byte
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plc network - 28.17 1 byte 1 byte D
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plc network - 28.19 CMD 00 01 02 05
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plc network - 28.21 Table 1: Networ
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plc network - 28.23 Figure 28.17 A
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plc network - 28.25 2. MG9:0/EN MG9
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plc network - 28.27 b) MG9:0/EN MSG
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plc network - 28.29 to advance a he
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plc internet - 29.2 Aside: Open a D
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plc internet - 29.4 SMTP (Simple Ma
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plc internet - 29.6 Aside: While lo
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plc internet - 29.8 • A client do
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plc internet - 29.10 Windows machin
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plc hmi - 30.1 30. HUMAN MACHINE IN
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plc hmi - 30.3 1. Who needs what in
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plc electrical - 31.1 31. ELECTRICA
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plc electrical - 31.3 terminals pow
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plc electrical - 31.5 L1 L2 L3 star
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plc electrical - 31.7 L1 L2 L3 M M
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plc electrical - 31.9 31.2.2 Ground
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plc electrical - 31.11 Note: Always
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plc electrical - 31.13 31.2.4 Suppr
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plc electrical - 31.15 Dirt - Dust
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plc electrical - 31.17 more sensiti
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plc electrical - 31.19 • Use NO b
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plc electrical - 31.21 4. Why are n
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plc software - 32.2 Sabotage - For
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plc software - 32.4 provides good t
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plc software - 32.6 Table 1: ANSI/I
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plc software - 32.8 orifice plate m
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plc software - 32.10 Each block in
Page 737 and 738:
plc software - 32.12 2. A basic mod
Page 739 and 740:
plc software - 32.14 Project Notes
Page 741 and 742:
plc software - 32.16 Application No
Page 743 and 744:
plc software - 32.18 Internal Locat
Page 745 and 746:
plc software - 32.20 These design s
Page 747 and 748:
plc selection - 33.1 33. SELECTING
Page 749 and 750:
plc selection - 33.3 PLC MEMORY TIM
Page 751 and 752:
plc selection - 33.5 Typical values
Page 753 and 754:
plc selection - 33.7 FEATURE PLC Si
Page 755 and 756:
plc selection - 33.9 - when a speci
Page 757 and 758:
plc function ref - 34.1 34. FUNCTIO
Page 759 and 760:
plc function ref - 34.3 XIC, XIO, O
Page 761 and 762:
plc function ref - 34.5 OSR, OSF -
Page 763 and 764:
plc function ref - 34.7 CTU - CounT
Page 765 and 766:
plc function ref - 34.9 TON - Timer
Page 767 and 768:
plc function ref - 34.11 DTR - Data
Page 769 and 770:
plc function ref - 34.13 LIM - LIMi
Page 771 and 772:
plc function ref - 34.15 ADD, DIV,
Page 773 and 774:
plc function ref - 34.17 CLR - CLea
Page 775 and 776:
plc function ref - 34.19 SRT - SoRT
Page 777 and 778:
plc function ref - 34.21 34.1.7 Mov
Page 779 and 780:
plc function ref - 34.23 COP - file
Page 781 and 782:
plc function ref - 34.25 FLL - file
Page 783 and 784:
plc function ref - 34.27 34.1.9 Lis
Page 785 and 786:
plc function ref - 34.29 SQI - SeQu
Page 787 and 788:
plc function ref - 34.31 FOR, NXT,
Page 789 and 790:
plc function ref - 34.33 SFR - Sequ
Page 791 and 792:
plc function ref - 34.35 MSG - MeSs
Page 793 and 794:
plc function ref - 34.37 34.1.12 St
Page 795 and 796:
plc function ref - 34.39 AEX - Asci
Page 797 and 798:
plc function ref - 34.41 ASC - Asci
Page 799 and 800:
plc function ref - 34.43 Table 1: I
Page 801 and 802:
plc function ref - 34.45 BSR BTD BT
Page 803 and 804:
plc function ref - 34.47 Table 1: I
Page 805 and 806:
plc glossary - 35.1 35. COMBINED GL
Page 807 and 808:
plc glossary - 35.3 background supp
Page 809 and 810:
plc glossary - 35.5 bottom-up desig
Page 811 and 812:
plc glossary - 35.7 noise immunity.
Page 813 and 814:
plc glossary - 35.9 35.4 D daisy ch
Page 815 and 816:
plc glossary - 35.11 DTR (Data Term
Page 817 and 818:
plc glossary - 35.13 flow chart - a
Page 819 and 820:
plc glossary - 35.15 impedance - In
Page 821 and 822:
plc glossary - 35.17 ladder diagram
Page 823 and 824:
plc glossary - 35.19 motion detect
Page 825 and 826:
plc glossary - 35.21 OSF (Open Soft
Page 827 and 828:
plc glossary - 35.23 used to pull i
Page 829 and 830:
plc glossary - 35.25 but at the cos
Page 831 and 832:
plc glossary - 35.27 step response
Page 833 and 834:
plc glossary - 35.29 operating syst
Page 835 and 836:
plc references - 36.1 36. PLC REFER
Page 837 and 838:
plc references - 36.3 Table 1: Auth
Page 839 and 840:
plc references - 36.5 *Ridley, J.E.
Page 841 and 842:
gfdl - 37.2 ical or political posit
Page 843 and 844:
gfdl - 37.4 * A. Use in the Title P
Page 845 and 846:
gfdl - 37.6 37.8 AGGREGATION WITH I
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