Table of Contents

Notes to the Instructor ..........................................................................................Viii

Chapter 1
Introduction to the PLC .......................................................................................... 1
1.1
1.2
1.3
1.4
1.5
1.6

Introduction
Basic Block Diagram
Size of the PLC System
Components of the PLC Systems
PLC and Process Interaction
Number Systems and Codes

Chapter 2
Processors, Power Supply and Programming Devices ........................................ 15
2.1
2.2
2.3
2.4

Introduction To The PLC Hardwar

Processors (CPU)
PLC Power Supply
Programming Device

Chapter 3
Memory Systems and I/O Interaction ................................................................... 23
3.1
3.2
3.3

Memory Systems
Digital I/O Interaction
Analog I/O Interaction

Chapter 4
Digital Input/Output Systems................................................................................ 31
4.1
4.2
4.3
4.4

Basic Types Of Discrete I/O Systems

Types Of Discrete field Devices
Types Of Discrete Input Modules
Types Of Discrete Output Modules

Chapter 5
Analog Input/ Output Systems.............................................................................. 41
5.1
5.2
5.3
5.4

Basic Of Analog I/O Systems

Types Of Analog Field Devices
Types Of Analog Input Devices
Types Of Analog Output Modules

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Chapter 6
Special Function I/O and Serial Communication Interfacing ................................ 55
6.1
6.2
6.3
6.4

Introduction
Fast Response Input Module
Counter Module
Stepper Motor Positioning Module

Chapter 7
Good Installation Practices................................................................................... 69
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10

Introduction
PLC Modules
PLC Rack
PLC Panel Internal Wiring
PLC Panel Power Supply
Cabling Between PLC And Field Devices
Cabling PLC And Control Room Computers
PLC Earthing
Specific PLC Requirement
Control Room Requirement

Chapter 8
Fundamentals of PLC Programming .................................................................... 89
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9

Introduction
PLC Programming Steps
Programming Languages
Basic Logic Instruction
Timers
Counters
Program Flow Control Instructions
Data Load Transfer Instruction
Arithmetic Or Math Instructions

Chapter 9
Data Acquisition ................................................................................................. 127
9.1
9.2
9.3
9.4

Introduction
A Typical Data Acquisition System
Aliasing And The Sampling Theorem
Data Coding System

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Chapter 10
Analog and Digital Control.................................................................................. 139
10.1
10.2
10.3
10.4
10.5
10.6

Introduction
Analog Inputs
Signal Filtering
Analog Display
Analog Control application Of PID Control
Alternative Forms Of Analog Control

Chapter 11
Fault Tolerance - Spreading the Risk ................................................................. 151
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
11.14
11.15
11.16

How Reliable Is Our Equipment

Project Planning
Key Questions
Two Key Strategies
The People!
Primary Loop Control and Interlocking
The Field Devices
Communications
DCS Structure
PLC System Options
The Costs
Utilities
Spare PLCs
I/O Allocation
Backing up Current Plant Data
Power Supplies

Chapter 12
Peripheral Equipment......................................................................................... 159
12.1
12.2
12.3
12.4

Future Directions with Smart Instruments

Highway Addressable Remote Transducer (HART)
ASCII Communications Devices
Intelligent Communications Devices

Chapter 13
Data Communications ........................................................................................ 165
13.1
13.2
13.3
13.4

Introduction
RS-232
RS-485
Modbus Serial

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Chapter 14
Ethernet and TCP/IP .......................................................................................... 189
14.1
14.2
14.2
14.3
14.5
14.6
14.7
14.8
14.9
14.10

Ethernet
Introduction
10 Mbps Ethernet
100 Mbps Ethernet (Fast Ethernet)
Gigabit Ethernet
Industrial Ethernet
IP (Internet Protocol)
ARP and RARP
TCP
UDP

Chapter15
Field buses......................................................................................................... 223
15.0
15.1
15.2
15.3
15.4
15.5

Background
Plant Automation Hierarchies
HART
DeviceNet
Profibus
Foundation Fieldbus

Chapter 16
Operator Interfaces ............................................................................................ 249
16.1
16.2

Introduction
Ergonomic Considerations

Chapter 17
High Security PLC Systems ............................................................................... 257
17.1
17.2
17.3
17.4
17.5
17.6
17.7
17.8
17.9
17.10
17.11
17.12
17.13

Introduction and Terminology

Background To Safety Control Systems
Safety Systems Concepts
Resistance To Random Hardware Failures
Architectures For Safety PLCs
Objections To Standard PLCs Used For Safety
Characteristics Of Safety PLCs
Hardware Characteristics Of A Safety PLC
Software Characteristics Of A Safety PLC
Design Safety PLCs
Redundant Architectures For PLCs- High Availability With High Integrity
Conclusion Of Safety PLCs
Application Software

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17.14
17.15
17.16

Safe Networking
Classifications And Certification
Summary Of High Security PLCs

Chapter 18
Simulation and Testing Of Systems .................................................................. 293
18.1
18.2
18.3

Introduction
System Testing
Testing Equipment

Chapter 19
Best Documentation Practice ............................................................................. 309
19.1
19.2
19.3
19.4
19.5

What Is a Manual?
Types of Manuals
Planning the Manual
Drafting the Manual
Reviewing the Manual

Chapter 20
HMI (Human Machine Interface) ........................................................................ 329
20.1
20.2
20.3
20.4

Introduction
Design Consideration Of HMI
Hardware Interface Between PLC And HMI
Software Interface Between PLC And HMI

Chapter 21
Electrical Design and Construction..................................................................... 341
21.1
21.2
21.3
21.4

Introduction
PLC Closure
Panel Layout
Electrical Wiring Of Panel guidelines For Panel Electrical Design

Chapter22
Functional Specification of the System............................................................... 351
22.1
22.2
22.3
22.4
22.5

Introduction
The Clients Budget
Function Specification Of The System
Selection Of The System
Testing Of The System

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Chapter 23
Fuzzy Logic ........................................................................................................ 407
23.1
23.2
23.3
23.4

Introduction
Understanding Fuzzy Logic
Fuzzy Logic Example Using Rules And Patches
The Achilles Heel Of The Fuzzy Logic

Chapter24
Configuration of the System ............................................................................... 415
24.1
24.2
24.3
24.4

Initial Concepts
Training on the System
Input/Output Database Creation
General Database Design Tips

Chapter 25
Installation and Commissioning.......................................................................... 427
25.1
25.2
25.3
25.4
25.5
25.6
25.7
25.8

Introduction
Control Room MCC Requirements
Installation of Equipment
Loop Testing
Manual Control
Automatic Control
System Handover
Maintenance and Training

Chapter 26
Working Example of PLC Programs................................................................... 431
26.1
26.2
26.3
26.4

Introduction
Control Philosophy
Typical PLC For Drives
Understanding Advanced Programming Techniques

Bibliography ....................................................................................................... 449

Appendices
Appendix A
Glossary ........................................................................................................... 453
Appendix B
ASCII Table........................................................................................................ 469

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Appendix C
Number Systems................................................................................................ 471
Appendix D
Logic Fundamentals ........................................................................................... 485
Appendix E
Practicals: Part 1 ............................................................................................... 491
Appendix F
Basic Program.................................................................................................... 497
Appendix G
Functional Logic Diagram................................................................................... 509
Appendix H
Practical: Part 2.................................................................................................. 517
Appendix I
Review of PLC Instruction Sets.......................................................................... 559

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viii

Lecturers Notes
I have included a CD in the kit, which will allow the instructor to reset the licensing on each
PC that the kit is used for. I have written the instructions down on the CD itself. You still
need to use the key stiffies, but my software allows the keys to be re-loaded onto the stiffies
over and over, without having to transfer the licenses back and forth from each computer that
is used. (although we own the rights to use the software, it is illegal, but we have no other
solution, as the kit is used all over the world, and sometimes the keys are not re-loaded back
onto the stiffies by the instructor, as was the case when I first got the kit). I make a point of
resetting the stiffies at the end of each course, so that they are ready for the next instructor.
You need to just put the CD in your machine, go to Windows Explorer, and run the EXE file
from the CD itself. The programme will then sort out the licensing for the 500 range, via your
stiffy connection (and as you are aware, the license can only be on a stiffy).
PLCs & Simulators
Of the six PLCs, one (clearly marked) is not operational and will need to be repaired. Of the
simulators, only the very large ammeter on one of the units does not work, but I unfortunately
cannot get a spare in my city (this is not crucial, as the other small ammeter on the same
simulator is still fully functional). Likewise, on one of the PLC's (marked as such), the
analogue I/O card only allows the two inputs to measure from 0 - 9000 (instead of 0 - 27000).
Once again, this is not a train smash, as you can put a multiplier (x 3 works best in the ladder
logic itself) on the analogue input being measured, and send this to the output to get a full
scale deflection. Due to the status of the card, you can only multiply one of the inputs, and
not both, for some or other reason. IDC head office would probably need to consider the
option of replacing this card on that side, as they are probably hopelessly out priced in this
part of the world. The kit still has a good few years of service left in it, so we need to nurse it
as much as possible. I have checked every single input / output, as well as all the wiring.
Where lamps were blown, I could not get the same replacements, but installed LEDs with
series resistors. They give the same effect, and are hardly noticeable (apart from switching on
much quicker). All the broken switches and push buttons have been replaced. There should
also be a spare in the bottom of the box, just in case
Software (in case you need to refresh)
Just for the sake of getting up and running as quickly as possible, here are my installation
guidelines:
Step 1 - The computers must have serial ports. (They can run on modern laptops, using USB
to serial converters, but you then need to select an appropriate port (e.g. port 6 or 7)).
Step 2 - Insert the CD, and let the installation start automatically. Do the licensing installation
when prompted (inserting the stiffies).
Step 3 - You will be asked to do the Linx Lite installation. Do this. You will then be asked to
do a second Linx Lite installation a few minutes later. Do NOT do the second installation.
(Also do not worry about installing the Linx Lite disks found amongst the licensing stiffies).
Step 4 - Go to the linx lite, and select the "RS-232 DF1 Devices" driver, and double click it.
Connect up a PLC, do the "auto config" and you will be running in next to no time at all.
Step 5 - Minimise the Linx software, run the RS Logix 500 programme, select Page New,
select the 1747-Ls32 5/03 CPU 16 kmeg processor.
Step 6 - Double click I/O on the left hand side, and do an auto detection from the PLC
connected to the PC. At this point, you are ready to programme. Have a great course.
Thanking You
Rodney Jacobs