advanced-industrial-automation-plc-programming-in-simplest-way-with-110-solved-examples-1nbsped comp

Dedicated to my father ‘Shri Raj Kishore Singh’
You have always inspired me to keep moving and not to accept
defeat.

Topics Page
No.
Introduction to controllers 3
PLC history 4
PLC Vs Micro controller 5
PLC block diagram and explanation to each
important part
7
Types of PLC 8
Basics of PLC programming 10
Contact and Coil instruction 15
Truth table trick for basic programming 23
Latch 31
Flag 35
Timer 36
Easy method for programming 41
Important points for programming 49
PLC scan 59
Pulse 63
Counter 83
Set/ Reset 91
Digital inputs 129
Digital output 133
PLC wiring 135
Hydraulic and pneumatic system programming 151
Arithmetic operation 177
Compare instruction 179
Bit/ byte/ word concept of programming 185
Programming without output coil using variable
addresses
187
Move 188
Types of MOVE 194
Jump instruction 196

Master control 197
Subroutine 197
Mitsubishi 198
Time base of a timer 199
Allen Bradley 205
Siemens 207
Auto/ manual operation programming 212
HMI 216
SCADA 233
AC Drive/ VFD 247
Analog input output programming 265
Analog value scaling 271
PID 275
NO/ NC type of push button programming concept 297

Being an engineer or technician our major role in industry is to maintain the
system running without fail. If any machine gets shutdown, we need to
restart it in short time. In today’s industries where production rate and
product demand are very high, machine should not get shutdown. If it is
shutdown then it should be restarted very fast. Now our fist problem is that
from where to start finding the problem in the machine which is very large in
size and spread in large area. Actually, we have not to be worried about the
largeness of the machine as largeness is just a mechanical structure. Often,
we don’t get any problem in structure once machine running trail is checked
OK. So, we have not to be worried about the largeness of machine but we
have to concentrate on three parts i.e.
INPUT CONTROLLER OUTPUT
These three parts of machine are the important parts in terms of finding
problem. Most of time, machines are shutdown because of its input/ output
issues. We find issues in controllers rarely. Now we go to find problem
among inputs and we face another issue i.e., large number of inputs. It can
be 100 or 1000. You can imagine how difficult is it to find problem among
such large number of inputs and it will take time also to do shut
troubleshooting. The same problem we face among outputs. If we have
advanced controller with advance featured software, we can find problem in
5 to 10 minutes.
We shall have a discussion about controller. A controller monitors and
controls any machine system. Initially when industry started it was all manual
operation. Manual means a man was the controller.it was a man/ operator
who used to monitor the system and he/ she was taking decision of
operation too. This manual system was not accurate and was so time taking
system. Very first automatic controller came in industry was relay logic
controller.