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    PLC Programming Using RSLogix 500 & Industrial Applications: Learn ladder logic step by step with real-world applications
    PLC Programming Using RSLogix 500 & Industrial Applications: Learn ladder logic step by step with real-world applications
    PLC Programming Using RSLogix 500 & Industrial Applications: Learn ladder logic step by step with real-world applications
    Ebook216 pages2 hours

    PLC Programming Using RSLogix 500 & Industrial Applications: Learn ladder logic step by step with real-world applications

    By Charles H Johnson Jr

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    About this ebook

    In this book I provide the foundation you will need to begin writing your first ladder logic program using RSLogix 500. I also provide advanced and practical hands-on training you need to program Programmable Logic Controllers (PLC) with confidence.


    It is simply not enough to have a PLC user guide/manual, or refer to the help c

    LanguageEnglish
    PublisherOjula Technology Innovations
    Release dateAug 9, 2022
    ISBN9781088056325
    PLC Programming Using RSLogix 500 & Industrial Applications: Learn ladder logic step by step with real-world applications
    Author

    Charles H Johnson Jr

    Charles Johnson is control systems engineer and a content creator. He has worked with many clients across business sectors, most of which are in the PLC automation industry. He has more than a decade of experience on designing control systems for industries like refineries, steel, oil, and gas from natural gas compressor stations to cold rolling steel plants.

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    • 5/5
      A very well written and educational book. I learned a lot about PLC in the book.

    Book preview

    PLC Programming Using RSLogix 500 & Industrial Applications - Charles H Johnson Jr

    PLC Programming

    Using RSLogix 500 &

    Industrial Applications

    Learn ladder logic step by step

    with real-world applications

    By

    Charles Johnson

    Ojula Technology Innovations

    PLC Programming Using RSLogix 500 & Industrial Applications

    Copyright © Ojula Technology Innovations

    ISBN: 9786260604134

    Published in the United States

    PLC is a trademark of the Allen-Bradley Company. The following are trademarks of Rockwell Automation Inc. : Allen-Bradley®, MicroLogix™, PanelView™, RSLinx®, RSLogix™, RSLogix™ 500, SLC™ 500.

    The author or the publisher of this book is in no way affiliated with Rockwell Automation, Inc.

    All rights reserved. No part of this book may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, without the prior written permission of the publisher, except in the case of brief quotations embedded in critical articles or reviews. Every effort has been made in the preparation of this book to ensure the accuracy of the information presented. However, the information contained in this book is sold without warranty, either express or implied. The author/publisher, its dealers and distributors will not be held liable for any damages caused or alleged to be caused directly or indirectly by this book. The author/publisher has endeavored to provide trademark information about all of the companies and products mentioned in this book. However, he cannot guarantee the accuracy of this information.

    Table of Contents

    About This Book

    1. Introduction to Programmable Logic Controllers

    1.1. Differences between PLC, Microcontroller & Microprocessor

    1.2. The Main Components of a PLC

    1.3 Understanding the IEC 61131-3 Standard

    1.4 How to Differentiate Between PLCs and PACs

    1.5 I/O Addressing and PLC Memory Mapping

    2. Introduction to Ladder Logic Generic Terms & Techniques

    2.1 The Dialects of PLCs (Rung, XIC, XIO, OTE, OTL, & OTU)

    2.1.2. Summary of the Ladder Logic Generic Terms & Techniques

    2.2. Understanding Ladder Logic Diagrams, Basics and Variables

    2.2.1. How to Draw Equivalent Ladder Logic of the Hard-wired Logic

    2.2.2. The PLC Timers (TON, TOF & RTO)

    2.2.3. Summary of Ladder Logic Diagrams, Basics and Variables

    2.2.4. The PLC Counters (CTU, CTD & RES)

    2.2.5. Data Transfer Instructions: MOV Command

    2.2.6. Arithmetic Commands: ADD Command

    2.2.7. Data Manipulation Instructions: MCR Command

    2.2.8. Program Control Instructions: JSR Command

    2.2.9. Editing & Deleting A Ladder Logic

    2.3 The PLC Scan Operation

    3. Getting Started with RSLogix 500

    3.1. How to Download or Order RSLogix 500

    3.2. How to Download Free Versions of RSLogix 500 & RSLogix Emulate 500

    3.3.1. How to Configure RSLinx

    3.3.2. Summary of How to Order & Download RSLogix 500

    3.4. How to Write Ladder Logic on RSLogix 500 Platform

    3.4.1. AND Logic in Ladder

    3.4.2. OR Logic in Ladder

    3.4.3. NOT Logic in Ladder

    3.4.4. How to Create New Ladder Logic Project in the RSLogix Micro Starter

    3.5. How to Test Your Ladder Logic with RSLogix Emulate 500

    3.6. Real-World Scenario 1

    3.7. Real-World Scenario 2

    4. Real World Applications of PLC Programming

    5. How to Use Allen-Bradley’s RSLogix Format to Write Ladder Logic for Real-World Applications

    5.1. Difference between Generic Ladder Logic Format and the RSLogix’s format

    5.2. RSLogix500 Project Report

    6. Industrial Applications of PLCs

    6.1. The Cement industry

    6.2. Safety PLCs Control access to a Robot Cell with Trapped-key Access

    6.3. SCADA Systems Control and Monitor Industrial Processes

    6.4. Modular PLCs

    6.5. Benefits of Using PLCs in Industrial Applications

    6.10. Application of PLCs to Paper Mill, Coal Kiln, Shaft Kiln and Glass Industries

    6.10.1. How PLCs are Used in Ball Mill

    6.10.2. Coal Kiln

    6.10.3. Shaft Kiln

    6.10.4. Paper Mill

    6.10.5. Glass Industry

    6.10.6. Benefits of PACs and PLCs in Industries

    7. How to Write Valuable Ladder Logic Programs for Automation Industries

    8. Safety PLCs vs Standard PLCs

    8.1. Safety Precautions to Take When Working with PLCs

    9. More Helpful Resources

    9.1. How to Get Further Help

    About This Book

    This book provides the foundation knowledge that you will need to begin writing your first PLC program. It also provides the advanced and practical hands-on knowledge you need to program PLCs with confidence. After reading the book, you will have a good understanding of ladder logic programming. You will also be able to apply it to numerous real-world situations and industrial applications.

    Using real-world situations and industrial applications is the best way to learn PLC programming. This book contains real-world examples and industrial applications that will help you to quickly learn many functions and features of RSLogix 500.

    The methods I present in this book are the ones that are most commonly used in industrial automation. They may be all you ever need. This book is a valuable resource for anyone who is just starting out in PLC programming, as well as any other skilled programmer of PLCs, regardless of their level.

    It is not enough to simply have a PLC user guide, or refer to the help content in order become a skilled PLC programmer. This book is a great resource for learning PLC programming skills. It will give you a head start if this is your first time programming a PLC. It will also teach you advanced techniques that you can use to design, build and program anything on the RSLogix 500 platform.

    One of the most frequent questions I get from beginners is, Where can I download RSLogix 500 for free? Later in this book, I provide links to free versions of RSLogix 500 and RSLogix Emulate 500. So, to learn, run and test your ladder logic programs, you don't need a PLC.

    You will not only learn how to obtain the Rockwell Automation software without any hassle. I also demonstrate with clear screenshots how to configure, navigate, and use them to create ladder logic programs.

    1. Introduction to Programmable Logic Controllers

    Most industrial equipment found in modern manufacturing plants share one thing: control. A control system is a means of controlling a process by monitoring the inputs and, depending on the value, setting or manipulating the outputs.

    It has been many years since control systems cam to existence. Early controllers were made up of hardware that had physical links, such as pipes or wiring. However, no solid-state electronics were involved.

    PLC (Programmable Logic Controller) is the most common controller. It uses a programming language called Ladder Logic.

    Figure 1.1: Different types of Allen Bradley PLCs.

    To make programming easy, especially for people who already understood how relay contacts, switches, and coils work, the ladder logic language was developed. The format of ladder logic is similar to the electrical style of drawing, and is popularly known as the ladder diagram.

    At the onset, there were only a few functions available in the language, but with time, many higher-level functions were introduced. You are going to learn the basic commonly used functions first, and then learn the advanced ones. We have various types of PLCs and also differences among PLCs, but what I discuss here is common to all types. Are you ready to start learning now? Great! Move on.

    1.1. Differences between PLC, Microcontroller & Microprocessor

    Microcontrollers and PLCs have distinct advantages and disadvantages. Microcontrollers are smaller and have fewer ports than PLCs, so they are best for specific applications. As a result, they are more susceptible to failure. Additionally, microcontrollers' chips are more prone to damage. Despite this, they have many advantages over PLCs. Read on to find out how they compare.

    A programmable logic controller is a special purpose computing device used for industrial and manufacturing processes. It has a 16-bit digital input and is programmed using ladder logic language. These controllers can also be used in automobiles and appliances.

    Figure 1.1.1: The Components of a PLC.

    The difference between a Microprocessor and a PLC is that a microprocessor can be used in industrial applications. Microprocessors are commonly found in desktop computers, automobiles, and appliances.

    A microcontroller is an integrated circuit device made up of millions of semiconductors. It usually performs one function. However, sometimes a microcontroller may control multiple functions. For example, a microwave oven might have more than one microcontroller to control different functions. Ultimately, each microcontroller is capable of handling a variety of applications. This is why microcontrollers are the most widely used in embedded systems.

    Both PLCs and Microprocessors have a rich history and different uses. Programmable logic controllers were originally designed to be used by engineers with limited knowledge of computers. They are programmed with ladder programs and logic. However, the PLC is not limited to these applications. The PLC can perform general computation, and other functions can be added to the microprocessor. Its advantages outweigh its disadvantages, and there is

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