Programmable Logic Controllers: Industrial Control

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Programmable Logic Controllers: Industrial Control

Programmable Logic Controllers: Industrial Control

Authors: Khaled Kamel and Eman Kamel

Published: August 2013

eISBN: 9780071810470 0071810471 | ISBN: 9780071810456

Cover

About the Authors

Title Page

Copyright Page

Contents

Preface

1. Introduction to PLC Control Systems and Automation

1.1. Control System Overview

1.1.1. Process Overview

1.1.2. Manual Control Operation

1.1.3. Automated-System Building Blocks

1.2. Hardwired Systems Overview

1.2.1. Conventional Relays

1.2.2. Relay Logic System

1.2.3. Control Relay Application

1.2.4. Motor Magnetic Starters

1.2.5. Latch and Unlatch Control Relay

1.3. PLC Overview

1.3.1. What Is a PLC?

1.3.2. History of PLCs

1.3.3. PLC Architecture

1.3.4. Hardwired System Replacement

1.3.5. PLC Ladder Logic

1.3.6. Manual/Auto Motor Control Operation

1.3.7. S7-1200 Book Training Unit Setup

1.3.8. Process-Control Choices

Homework Problems and Laboratory Projects

Problems

Projects

2. Fundamentals of PLC Logic Programming

2.1. PLC Hardware

2.1.1. S7-1200 Processor

2.1.2. Operating Modes of the CPU

2.1.3. Communication Modules

2.1.4. Signal Boards

2.1.5. Input-Output Modules

2.1.6. Power Supply

2.1.7. S7-1200 PLC Memory Organization/Specifications

2.1.8. Processor Memory Map and Program Organization

2.2. Ladder-Logic Diagrams

2.2.1. PLC Input/Output Terminal Connection

2.2.2. PLC Boolean Instructions

2.2.3. Shift and Rotate Instructions

2.2.4. Program-Control Instructions

2.3. Sequential and Combinational Logic Instructions

2.3.1. The Set-Reset Flip-Flop Instructions

2.3.2. Set and Reset Output Instructions

2.3.3. Positive and Negative Edge Instructions

2.3.4. Logic Gates and Truth Tables

2.3.5. Combinational Logic Instructions

2.3.6. Illustrative Ladder Examples

Homework Problems and Laboratory Projects

Problems

Projects

3. Timers and Counters Programming

3.1. Timer Fundamentals

3.1.1. ON-DELAY Timers (TONs)

3.1.2. OFF-DELAY Timers (TOFs)

3.1.3. Retentive/Time-Accumulator Timers (TONRs)

3.1.4. Implemented Timer Applications

3.2. Counters Fundamentals

3.2.1. Count Up Counters (CTU)

3.2.2. Count Down Counters (CTD)

3.2.3. Count Up and Down Counters (CTUD)

3.2.4. Implemented Counter Applications

3.3. Special Timing Instructions

3.3.1. Pulse Generation/Pulse Timer (TP)

3.3.2. One-Shot Operations

3.3.3. Implemented One-Shot Application

3.3.4. Implemented Counter Applications

Homework Problems and Laboratory Projects

Problems

Projects

4. Math, Move, and Comparison Instructions

4.1. Math Instructions

4.1.1. Numbering Systems

4.1.2. S7-1200 Data and Number Representation

4.1.3. Common Math Instructions

4.1.4. MOVE and TRANSFER Instructions

4.2. Comparison Instructions

4.2.1. Equal, Greater, and Less Than Instructions

4.2.2. IN RANGE and OUT RANGE Instructions

4.3. Implemented Industrial Application

4.3.1. Common Process-Control Tasks

4.3.2. Small Industrial Process-Control Application

Homework Problems and Laboratory Projects

Problems

Projects

5. Device Configuration and the Human-Machine Interface

5.1. Device and PLC/HMI Configuration

5.1.1. Siemens S7-1200 Hardware Arrangement

5.1.2. PLC/HMI Configuration

5.2. Human-Machine Interfacing

5.2.1. Communication Fundamentals

5.2.2. PROFINET and Ethernet Protocol

5.2.3. HMI Programming

5.3. Control and Monitoring

5.3.1. Distributed Control System Process Description

5.3.2. Control System Process I/O Map

5.3.3. Design and Execution of Pump Station Ladder Program

5.3.4. HMI-PLC Application

Homework Problems and Laboratory Projects

Problems

Projects

6. Process-Control Design and Troubleshooting

6.1. Process-Control Overview, Layer 1

6.1.1. Process Descriptions

6.1.2. Level of Control/Automation

6.1.3. Control-System Components

6.2. Process-Control Implementation, Layer 2

6.2.1. I/O Listing

6.2.2. Data-Acquisition and Closed-Loop-Control Tasks

6.2.3. Project Logic Diagrams and Ladder-Function Blocks

6.2.4. Control-System Preliminary Documentation

6.2.5. Program Documentation Using Cross Reference

6.3. Process-Control Checkout and Startup, Layer 3

6.3.1. Checkout Using Forcing Functions

6.3.2. Checkout Using Watch Tables

6.3.3. Checkout Using Cross-Reference, Program Status, and System Diagnostics

6.4. System Checkout and Troubleshooting

6.4.1. Static Checkout

6.4.2. Safety Standards and Precautions

6.5. Safeguard Implementation Examples

Homework Problems and Laboratory Projects

Problems

Projects

7. Instrumentation and Process Control

7.1. Instrumentation Basics

7.1.1. Sensors Basics

7.1.2. Analog Sensors

7.1.3. Digital Sensors

7.2. Process-Control Elements

7.2.1. Basic Measurement System

7.2.2. Process-Control Variables

7.2.3. Signal Conditioning

7.2.4. Signal Transmitters

7.3. Signal Conversion

7.3.1. Analog-to-Digital Conversion

7.3.2. Digital-to-Analog Conversion

7.3.3. Quantification Errors and Resolution

7.4. Process-Control System

7.4.1. Control Process

7.4.2. Controlled Variables

7.4.3. Control Strategy and Types

7.4.4. Process-Control Loop

7.4.5. Control-System Error Quantification

7.4.6. Control-System Transient and Performance Evaluation

7.5. Closed-Loop Process-Control Types

7.5.1. ON/OFF Control Mode

7.5.2. Proportional Control Mode

7.5.3. Composite Control Mode

7.5.4. PLC/Distributed Computer Supervisory Control

Homework Problems and Laboratory Project

Problems

Project

8. Analog Programming and Advanced Control

8.1. Analog I/O Configuration and Programming

8.1.1. Analog I/O Modules

8.1.2. Configuring Analog I/O Modules

8.1.3. Analog I/O Diagnostic Configuration

8.1.4. Analog Input Range and Scaling

8.1.5. Analog I/O Programming

8.2. PID Control Configuration and Programming

8.2.1. Closed-Loop Control System

8.2.2. Control-System Time Response

8.2.3. Control-System Types

8.2.4. Controller Behavior

8.2.5. Selection of the Suitable Controller Structures

8.3. PID Instruction

8.3.1. SIMATIC S7-1200 Tank-Level PID Control

Homework Problems and Laboratory Project

Problems

Projects

9. Comprehensive Case Studies

9.1. Irrigation-Canal Water-Level Control

9.1.1. System Input-Output (I/O) Map

9.1.2. Logic Diagrams

9.1.3. Automated-System Building Blocks

9.2. Irrigation-Canal Ladder Implementation

9.3. Irrigation-Canal HMI Implementation

9.4. Wet-Well Pump-Station Control

9.4.1. System I/O Map

9.4.2. Automated System Building Blocks

9.5. Pumping-Station Ladder Implementation

9.5.1. Pump Alarms

9.6. Pumping-Station HMI Implementation

Homework Problems and Laboratory Project

Problems

Project

Appendix: Siemens Cooperates with Education

1. Load and Re-Store Existing Project

2. WinCC Operator Interface (Fig. A.12)

3. Project Navigation

4. Menu Bar and Buttons

Work Area

Tools

Property Window

Details View

5. Operating Screens and Connections

6. Basic Screen or Start Screen

7. Connections to S7 Controllers

8. Assigning the IP Address

9. Configuring the Basic Screen

10. Function Key F6

11. Configuring the Automatic and Manual Buttons

12. Changes in the Step 7 Program

13. Setting the PG/PC Interface for Run-Time Simulation

Starting the Configuration in Run Time

14. Loading the Configuration to the Panel and Testing It

15. Start and Stop Button

16. Adding Graphics from the Graphics Folder

17. Control Program for Simulating Bottle Movement

18. Activating the Clock Memory and Assigning the MB100

19. Calling FB2 (Simulation) in OB1

20. Configuring Bottle Movement

21. Resetting the Bottle Counter

22. Drawing the Beer Case

23. Drawing the Bottles in the Case

Index