Allen Bradley RS Logix 5000 Basics For Mechanical Technicians Manual

Allen Bradley RS Logix 5000 Basics for
MechanicalTechnicians
O-SECUL NIGERIA LIMITED

CHAPTER ONE
Overview of PLC and Control
System

Introduction
• A Programmable Logic Controller (PLC) is a specialized industrial computer
control system used to replace banks of electromagnetic relays in industrial
process control via continuously monitoring the state of input devices and
makes decisions based upon custom program to control the state of output
devices. The PLC is also known as a programmable controller (PC).
• The tile "PC" for programmable controller could be confused in common

usage with "PC" used to mean personal computer. To avoid this confusion, it
is generally referred as programmable controller or programmable logic
controller or PLC.
Introduction
• The programmable logic controller is like a heavy-duty computer system
designed for machine control. Like a general-purpose computer, the PLC is
based on digital logic and can be field-programmed. The programming
language is a bit different because the purpose of the PLC is to control
machines.
• The PLC is used to time and sequence functions that might be required in
assembly lines, robots, and chemical processing. It is designed to deal with
the harsh conditions of the industrial environment. Some of the physical
environment problems could include vibration and shock, dirt and vapors,
and temperature extremes.
• The PLC commonly has to interface with a wide variety of both input and
output devices. Some input devices include limit and pressure switches,
temperature and optical sensors, and analog- to digital converters (ADCs).
Some output devices valves, motors and cylinders, and Digital-to Analog
converts (DAC).nal computer. To avoid this confusion, it is generally referred
as programmable controller or programmable logic controller or PLC.
Introduction
• Before the advent of solid-state logic circuits, logical control systems were
designed and built exclusively around electromechanical relays. Relays are far
from obsolete in modern design, but have been replaced in many of their
former roles as logic-level control devices, relegated most often to those
applications demanding high current and/or high voltage switching.
• Systems and processes requiring "on/off" control abound in modern

commerce and industry, but such control systems are rarely built from either
electromechanical relays or discrete logic gates. Instead, digital computers fill
the need, which may be programmed to do a variety of logical functions.
• In the late 1960's an American company named Bedford Associates released

a computing device they called the MODICON. As an acronym, it meant
Modular Digital Controller, and later became the name of a company division
devoted to the design, manufacture, and sale of these special-purpose
control computers. Other engineering firms developed their own versions of
this device, and it eventually came to be known in non-proprietary terms as a
PLC, or Programmable Logic Controller.
Introduction
• The leading PLC Manufacturers are Siemens, Schneider, Allen Bradley,
Mitsubishi, Omron, ABB, Panasonic, GE Fanuc, LG, Fatek, Delta etc.
• The purpose of a PLC was to directly replace electromechanical relays as logic

elements, substituting instead a solid-state digital computer with a stored
program, able to emulate the interconnection of many relays to perform
certain logical tasks.
• A PLC has many "input" terminals, through which it interprets "high" and
"low" logical states from sensors and switches. It also has many output
terminals, through which it outputs "high" and "low" signals to power lights,
solenoids, contactors, small motors, and other devices lending themselves to
on/off control.
• In an effort to make PLC easy to program, their programming language was

designed to resemble ladder logic diagrams. Thus, an industrial electrician or
electrical engineer accustomed to reading ladder logic schematics would feel
comfortable programming a PLC to perform the same control functions.
Introduction
• PLC are industrial computers, and as such their input and output signals are
typically 230 volts AC, just like the electromechanical control relays they were
designed to replace. Although some PLC has the ability to input and output
low-level DC voltage signals of the magnitude used in logic gate circuits, this
is the exception and not the rule.

What is PLC
• A Programmable Logic Controller (PLC) is an industrial computer control
system that continuously monitors the state of input devices and makes
decisions based upon a custom program to control the state of output
devices.
• Almost any production line, machine function, or process can be greatly

enhanced using this type of control system. However, the biggest benefit in
using a PLC is the ability to change and replicate the operation or process
while collecting and communicating vital information.
• Another advantage of a PLC system is that it is modular. It can mix and match
the different types of Input and Output devices to best suit other industrial
applications.
• According to NEMA (National Electrical Manufacturer Association) “PLC is a

digitally operated electronic system, designed especially for the use in
industrial environment, which use programmable memory for internal
storage of user-oriented instructions for implementing specific function such
What is PLC
as logic, sequencing, timing, counting & arithmetic to control, through

digital & analog inputs & outputs for various types of machines &
processes.”
• Both the PLC & its associated peripherals are designed so that they can be
easily integrated into an industrial control system & easily used in all
intended functions.

History of Programmable Logic Controllers (PLCs)
• 1968 : Design of PLCs developed for General Motors Corporation to
eliminate costly Scrapping or assembly line relays during model
changeovers.
• 1969 : First PLCs manufactured for automotive industry as electronic
equivalents of relays.
• 1971 : First application of PLCs outside the automotive industry.
• 1973 : Introduction of "smart" PLCs for arithmetic operations, printer

control move, Matrix operations, CRT interface etc.
• 1974 : Introduction of analog PID (Proportional, integral, derivative)
control, which Made possible the accessing of thermocouples,
pressure sensors etc.
• 1975 : First use of PLCs in hierarchical configurations as part of an
integrated Manufacturing system.

History of Programmable Logic Controllers (PLCs)
• 1977 : Introduction of very small PLCs based on microprocessor
technology.
• 1978 : PLCs gain wide acceptance, sales approach $ 80 million.
• 1979 : Integration of plant operation through a PLC communication

system.
• 1980 : Introduction of intelligent input and output modules to provide
high speed, accurate control in positioning applications.
• 1981 : Data highways enable users to interconnect many PLCs up
to 15000 feet from Each other. More 16-bit PLCs become
available. Color graphic CRTs are available from several
suppliers.
• 1982 : Larger PLCs with up to 8192 I/O become available.
• 1983 : "Third party" peripherals, including graphic CRTs, operator’s

Types of PLCs
• Programmable logic controllers (PLCs) has several types. PLC divided
into two types: Based on the size of the module and it can be classified
according to its working,
Based on size
• I. Micro PLC or Small PLC: It is the simplest PLC with the Power
Supply module, CPU, I / O modules and communication ports in a
single chassis. This PLC types are usually limited to a few I / O
discrete and can be expanded. There are various micro PLCs are in
the market today.

Types of PLCs
• The vast majority offer analog I /O. with just about any micro PLC, or for that
matter PLC in general, when the application requires the monitoring of
various analog signals, a separate module is required for each signal (voltage,
current, temperature). Examples of this type are CP1H Omron, Siemens S7-
200, Fuji Electric SPB.
• II. Medium PLC or Mini: It is PLC which has CPU module, I / O or

communication port are separately. Each module is connected by connector
or backplane. It has the capacity more than 2000 I / O.
Types of PLCs
• III. Large PLC or Rack: This kind of PLC is nearly equal to the medium one but
it has large I/O capacity and more able to be connected with the higher
control systems.
Classified According to its Output Working:

• I . Relay based: This type of PLC are used for general purpose application.
• II . Transistor based: This type of PLC are used for High speed application.
• III . SCR based: This type of plc are used for heavy load switching.
Functional Description
• A programmable controller manufactured by any company has several
common functional parts. Figure illustrates a generic PLC architecture.

Generic PLC architecture
• An open architecture design allows the system to be connected easily to
devices and programs made by other manufacturers.
• A closed architecture or proprietary system, is one whose design makes it more
difficult to connect devices and programs made by other manufacturers.
NOTE: When working with PLC systems that are proprietary in nature you must be
sure that any generic hardware or software you use is compatible with your
particular PLC.
I/O Configurations
Fixed I/O
• Is typical of small PLCs
• Comes in one package, with no separate removable
units.
• The processor and I/O are packaged together.
• Lower in cost – but lacks flexibility.

Modular I/O
• Is divided by compartments into which separate modules can be plugged.
• This feature greatly increases your

options and the unit’s flexibility.
You can choose from all the
modules available and mix them
in any way you desire.

Modular I/O
When a module slides into the rack,

it makes an electrical connection
with a series of contacts - called
the backplane. The backplane
is located at the rear of the rack.

Power Supply
• Supplies DC power to other modules

that plug into the rack.
• In large PLC systems, this power

supply does not normally supply
power to the field devices.
• In small and micro PLC systems, the

power supply is also used to power
field devices.

Processor (CPU)
• Is the “brain” of the PLC.

• Consists of a microprocessor
for implementing the logic, and
controlling the communications
among the modules.
• Designed so the desired circuit

can be entered in relay ladder
logic form.
• The processor accepts input data

from various sensing devices,
executes the stored user program,
and sends appropriate output commands to
control devices.

I/O Section
Consists of:
• Input modules
• Output modules.

Input Module
• Forms the interface by which input

field devices are connected to the
controller.
• The terms “field” and “real world”are

used to distinguish actual external
devices that exist and must be
physically wired into the system.

I/O Section
Output Module
• Forms the interface by which output

field devices are connected to the
controller.
• PLCs employ an optical isolator which

uses light to electrically isolate the
internal components from the input
and output terminals.

How Do PLCs Work?
• There are many components to a PLC, but most of them can be put in the
following three categories:
• Processor (CPU)
• Inputs
• Outputs
• PLCs are complex and powerful computers. But, we can describe the function of
a PLC in simple terms. The PLC takes inputs, performs logic on the inputs in the
CPU and then turns on or off outputs based on that logic. We will get into more
detail later but for now, think of it like this:
1. The CPU monitors the status of the inputs (ex. switch on, proximity sensor off,
valve 40% open, etc.)
2. The CPU takes the information that it gets from the inputs, performs logic on
the inputs
How Do PLCs Work?
3. The CPU operates the outputs logic (ex. turn off motor, open valve, etc.)
See the flowchart below for a visual representation of the steps above.
PLC Function Flowchart

• Let’s use a familiar example to illustrate how PLCs work. Your dishwasher. Many
dishwashers have microprocessors that function similarly to PLCs. The
dishwasher has inputs, outputs and, of course, a CPU.
• Some of the inputs into the dishwasher controller would be the buttons on the
front, the water sensors and the door switch. Some of the dishwasher outputs
would be the water valves, the heat elements and the pumps. Now let’s think
about how the dishwasher uses those different components.

How Do PLCs Work?
NOTE: Remember, the CPU is the processor in the dishwasher that is programmed
to make all the decisions we will see below. This is just like a PLC processor (CPU)
which makes logical decisions based on input status.
1. User pushes the cycle mode button (input detected)

2. User pushes the start button (input detected)
3. CPU verifies that the door is closed (input detected)
4. Fill valve opens and the dishwasher begins filling
with water (output activated)
5. CPU waits until proper water level is reached
(input detected)
6. Fill valve closes, and water flow stops
(output activated/de-activated)
7. Heating element is turned on (output activated)

How Do PLCs Work?
8. CPU waits until proper water temperature is reached

(input detected)
9. Soap dispenser opens (output activated)
10. Water pump turns on to force water through sprayers
(output activated)
11. CPU begins timing depending on cycle type
(logic timer activated)
12. Water pump turns off (output deactivated)
13. Heating element is turned off (output deactivated)
14. Drain valve opens and the dishwasher begins draining
the dirty water (output activated)
15. CPU waits until it detects the water level to be low
enough (input activated/de-activated)

How Do PLCs Work?
16. Drain valve closes (output activated/deactivated)

17. Fill valve opens again to rinse dishes (output activated)
18. Water pump turns on to force water through sprayers
(output activated)
19. CPU begins timing (logic timer activated)
20. Water pump turns off (output deactivated)
21. Drain valve opens and the dishwasher begins draining
rinse water (output activated)
22. CPU waits until it detects the water level to be low
enough (input activated/de-activated)
23. Drain valve closes (output activated/deactivated)
24. Heating element turns on to heat the air inside the
dishwasher and dry the dishes (output activated)
25. CPU waits until proper interior temperature is reached (input activated)
26. CPU begins timing (logic timer activated)
27. Heating element is turned off (output activated/deactivated)

Introduction of Relay Logic
Basics of Relay Logic (How Relay Works)
Relay Logic Control - Symbols, Working and Examples

• Relay logic basically consists of relays wired up in a particular fashion to
perform the desired switching operations. The circuit incorporates relays along
with other components such as switches, motors, timers, actuators, contactors
etc.
• The relay logic control works efficiently to perform basic ON/OFF operations by
opening or closing the relay contacts but it involves a humongous wiring. Here
we will learn about Relay Logic Control Circuit, its symbols, working and how
they can be used as Digital Logic Gates.
Working of a Relay
• Relay act as switch which is operated by a small amount of current. The relay
has two contacts-
• Normally open (NO)
• Normally Close (NC)
• In the figure given below, you can see there are two sides of a Relay.
• One is primary coil which acts as a electromagnet on passing current
through it and other one is secondary side having NO and NC contacts.
• When the contact position is Normally Open, the switch is Open and
hence the circuit is Open and no current flows through the circuit. When
the contact position is Normally Close, the switch is closed and the circuit
is completed and hence current flows through the circuit.
• This change of state in the contacts occur whenever a small electrical

signal is applied i.e. whenever a small amount of current flows through
the relay, the contact changes. This is explained through the figures
below-

• Above figure shows the switch in NO contact position. In this figure, primary
circuit (coil) is not completed and hence no current flows through the
electromagnetic coil in that circuit.
• Therefore, the connected bulb remains off as the relay contact remains open.

• Now the above figure shows the switch in NC contact position. In this
figure, primary circuit (coil) is closed, so there is some current through
the coil connected in that circuit.
• Due to the current flowing in this electromagnetic coil, a magnetic field is

created in its vicinity and due this magnetic field, the relay is energised
and hence closes its contacts. Therefore, the connected bulb turns ON.

Relay Logic Circuits - Schematic/Symbols
• A relay logic circuit is a schematic diagram which shows various
components, their connections, inputs as well as outputs in a particular
fashion.
• In relay logic circuits, the contacts NO and NC are used to indicate

Normally Open or Normally Close relay circuit. It contains two vertical
lines, one on the extreme left and the other on the extreme right. These
vertical lines are called rails.
• The extreme left rail is at the supply voltage potential and is used as an
input rail. The extreme right rail is at zero potential and is used as the
output rail.
• Particular symbols are used in relay logic circuits to represent different

circuit components. Some of the most common and widely used symbols
are given below-
Relay Logic Circuits - Schematic/Symbols
• 1. NO contact
• The given symbol indicates a Normally Open contact. If the contact is

Normally open, it would not allow any current to pass through it and
hence there will be an Open circuit at this contact.
• 2. NC contact
• This symbol is used to indicate Normally Close contact. This allows the
current to pass through it and acts as a short circuit.Relay Logic Circuit
Push Button ON

3. Push Button (ON)
• This push button allows current to flow through it to the rest of the circuit
as long as it is pressed. If we release the push button, it becomes OFF
and no longer allows the current to flow. This means in order to carry the
current the push button has to remain in the pressed state.
4. Push Button (OFF)

• The OFF push button indicates an open circuit i.e. it does not allow the
flow of current through it. If the push button is not pressed, it stays in
OFF state. It can transit into ON state to carry the current through it once
it is pressed.

5. Relay coil
• The relay coil symbol is used to indicate control relay or motor starter
and sometimes even contactor or timer.
6. Pilot Lamp
• The given symbol denotes Pilot Lamp or simply a bulb. They indicate the
machine operation.

Relay Logic Circuit – Examples and Working
• The working of a relay logic circuit can be
explained through the given figures-
• This figure shows a basic relay logic circuit.
In this circuit,
• Rung 1 contains one Push
button (initially OFF) and one control relay.
• Rung 2 contains one Push button (initially
ON) and one Pilot lamp.
• Rung 3 contains one NO contact and one
Pilot lamp.
• Rung 4 contains one NC contact and one
pilot lamp.

• Rung 5 contains one NO contact, one pilot
lamp and a sub-rung with one NC contact.

• To understand the working of the
given relay logic circuit, consider
below figure
• In rung 1, the push button is Off and hence it does not allow the current
to pass through it. Therefore, there is no
output through rung 1.
• In rung 2, the push button is On and

therefore, current passes from the high
voltage rail to the low voltage rail and the
Pilot Lamp 1 glows.
• In rung 3, the contact is Normally Open,

therefore Pilot lamp 2 remains Off and
there is no flow of current or output through
the rung.

• In rung 4, the contact is normally Close,
thereby allowing the current to pass through
it and giving an output to the low voltage
rung.
• In rung 5, no current flows through the

main rung as the contact is normally Open
but due to the presence of the sub-rung,
which contains a normally close contact,
there is a flow of current and hence the pilot
lamp 4 glows.

Basic Logic Gates Using Relay Logic
• Basic digital logic gates can also be realised using relay logic and have a
simple construction using the contacts as given below-
• 1. OR Gate – Truth table for OR gate is as shown –
This table is realised using the relay logic circuit in the following manner –
• In this, the Pilot lamp will turn On whenever any one of the inputs
becomes one which makes the contact associated with that input
as normally close. Otherwise, the contact remains Normally open.
2. AND Gate – Truth table for AND gate is given as-
Relay logic realisation of AND gate is given by –

The contacts are connected in series for AND gate. This means that the
pilot lamp will turn ON if and only if both the contacts are Normally close i.e.
when both the inputs are 1.
3. NOT Gate – Truth table for NOT gate is given by –
The equivalent relay logic circuit for the given NOT

gate truth table is as follows –

• The pilot lamp lights up when the input is 0 so that the contact remains
normally close. As the input changes to 1, the contact changes to
normally Open and hence the pilot lamp doesn’t light up giving the output
as 0.

4. NAND Gate – The NAND gate truth table is as follows –
The relay logic circuit as realised for the given truth

table is as –
• As two Normally close contacts are connected in parallel, the pilot lamp
lights up when one or both the inputs are 0.
• However, if both the inputs become 1, both the contacts become

Normally Open and hence the output becomes 0 i.e. the pilot lamp
doesn’t light up.

5. NOR Gate – The truth table for NOR gate is given by the following
table –
The given truth table can be implemented using the relay logic
as follows-
Here, two normally close contacts are connected in series

which means the pilot lamp will light up only if both the
inputs are 0.
If any one of the input becomes 1, that contact changes to

normally open and hence the flow of current is interrupted,
thereby causing the pilot lamp not to light up, indicating
0 output.
Disadvantages of RLC over PLC
1. Complex wiring
2. More time to implement
3. Comparatively less accuracy
4. Difficult to maintain
5. Fault detection is hard
6. Provide less flexibility

CHAPTER TWO
Introduction to Allen Bradley
PLC

Introduction to Allen Bradley PLC
• Nearly all control engineers are familiar with the name Rockwell
Automation, or Allen-Bradley. With the company’s long history of
innovation well before the age of modern computer systems, it is
understandable that many early developments in digital automation
happened here.
• Founded in 1903, before the release of the first PLC, Allen-Bradley had
already accumulated extensive experience in the world of electronics,
becoming a worldwide leader in developing new components and
technologies.

• Allen-Bradley is credited with coining the term PLC (Programmable Logic
Controller) when it launched one of the first-ever programmable
controllers in 1970, the 1774 PLC.
• The first Allen-Bradley PLC introduced to the market was the PLC-5
product family. The PLC-2 and PLC-3 were released in the 1980s and
are now obsolete.
• These PLCs were followed by the PLC-5 and is still in use today.
• The PLC-5 family used the 6200 series programing software originally
and then later RSLogix 5 programming software.
SLC series
• In 1991 the SLC500 product line was released.
• This platform was much smaller in size and had a reduced instruction
set.
• SLC was an acronym for Small Logic Controller and the first SLC500
released was an integrated package (commonly referred to as a shoe
block PLC) containing the CPU, power supply, and I/O.

• Later the SLC5/01 was the first racked based SLC series released.
• The 5/02 and 5/03 PLCs had DH485 (Data Highway serial-based
communication) and the SLC5/04 provided a faster communication
called DH+ (Data Highway Plus).
• The SLC5/05 has both DH485 and Ethernet communications.

Micrologix family
• The Micrologix family and SLC 500 PLCs used the RSLogix 500
programming software.
• In 2014, the MicroLogix family was introduced in response to address the
need for a less expensive PLC solution to compete with other
manufactures and the first MicroLogix introduced was MicroLogix 1000
supporting several types of I/O combinations.

ControlLogix family
• The ControlLogix family was introduced in 1997. This platform was
racked-based having much faster scan times (speed) and memory than
the PLC-5 or SLC products. Communication modules supported
Ethernet, DeviceNet, DH485, and ControlNet.
• Servo motor control cards using SERCOS fiber-optics provided

competitiveness in the coordinated system servo market.

CompactLogix family
• The CompactLogix family was released in 2008 as a lower-cost solution
to ControlLogix for competitive reasons.
• And like the MicroLogix, the products do not use a rack-based solution
but instead, use add-on modules to the ends of the power supply or CPU
modules.
• Communications between the RSLogix programming and configuration

software and PLC/PAC is handled using RSLinx software, a separate
software package, that also supports DDE and OPC support.
Allen-Bradley Communication Types and Protocols
• The communication protocol is a set of rules that govern data communication.

• In other words, the communication protocol acts as an agreement between
two or more communicating devices.
• By using the communication protocols, two devices connect and communicate
with each other.
• Without communication protocol, devices can only be connected but not
communicated
• The communication protocols are dependent upon three fundamental
parts such as baud rate, network length, and the number of nodes.
What is the Baud Rate?
• Baud rate is also known as Communication speed.
• The rate of data transmission on the network is called Baud Rate.
The unit of Baud Rate is bits/second (b/s).
• In simple terms, it is calculated as the “number of data transferred per
second”.
Characteristics of PLC Communication Protocols in Table
• When PLC modules are connected over the network, standard
communication protocols are used.
• The different types of standard communication protocols support different
speeds (baud rate), distances (network length), and the number of
connecting devices (nodes).

Which PLC communication protocol you should use?

• If you want to communicate with the more number of nodes with more
speed, Ethernet is the best choice. You can read detail about ethernet
here.
• If your network has a length of more than 25 Kilo-meter, you should use
the Control Net protocol.
Binary Data Type Conversion for Baud Rate
Binary system based on the bit. Bit is either 0 or 1.
• 1 Nibble= 4 Bits
• 1 Byte= 8 Bits
• 1 Word= 2 Bytes = 16 Bits
• 1 Double Word= 4 Bytes= 32 Bits
• Let’s see, binary data representation diagram.
• As the digital revolution as grown, it has ushered in an accelerated need for
improved and evolving control over such devices to handle new capabilities and
new inputs from a data stream that is growing exponentially.
• Even more than a smart home or a connected individual, factories, warehouses,
and supply chains are becoming more and more connected to leverage this
connectivity to add value to their processes and improve competitiveness.
• As a result, the sophistication and capability of the communication types and
protocols used to drive PLCs and other control equipment has grown and
evolved as well. We’ll cover the following communication protocols:
• Ethernet/IP
• DeviceNet
• ControlNet
• Remote I/O
• Serial
• DH+
• DH 485
• Profibus
• ASCII
• Modbus
An Increasingly Busy Intersection
• As connectivity becomes a business imperative driven by initiatives such
as Industry 4.0, different devices and interface types need to be
connected in a way that can be scaled to meet the growing needs.

• They must also be linked efficiently to allow the movement of data and
the proper responses to the equipment they drive.
• There are four basic elements in today’s industrial automation schemes.
These include Programmable Logic Controllers (PLC), Human Machine
Interfaces (HMI), motor control points and the various sensors and
detectors needed to trigger robotic or mechanical functions to complete
tasks.
• These elements are like cars approaching a busy intersection at high
speed. They need accurate, fast, and safe communication protocols to
act as the stop signals, highway signs and traffic cops to ensure safe
interaction at the point of intersection.
• PLC – The PLC is the ubiquitous workhorse of the automation world.
Ranging from a few input/outputs (I/O) to rack mounted versions that can
support hundreds of I/Os, PLCs require a physical layer to connect it
servers, HMIs, and other devices.

• It also requires a shared protocol. This protocol acts as a common
language, so each device understands what the bits of data mean as
they arrive.
• Human Machine Interfaces – In today’s automated environments, HMIs
are the point at which the operator or technician interacts with the
machine, the communication system, and the programmed variables to
complete tasks.
• These command input interfaces are intuitive and often WYSIWYG in
configuration, requiring accurate programming and communication to
translate these commands into actions understood by the other
elements.
• Motor Controls – These are the control points where the motor is
instructed to engage or disengage based on the inputs form the HMI and
instructions from the PLC.s.

• Sensors and Detectors – In an automation network, sensors and
detectors are deployed at the action end of the equipment, instructing
mechanical devices to complete a task.
• This can include devices such as weight scales, light or IR scanners,
temperature sensors and a host of other devices that drive the “limbs” of
the equipment to perform task Different Protocols for Different System
Needs
• With this complex intersection of devices, it is critical that all speak the
same “language” and that the protocols used in reconciling I/Os and the
meaning of the data to manage the traffic and communicate appropriate
instructions.
• However, each automation system is different. They may range from the
simple to the complex depending on end use and industry. They may
also require specific safety levels or redundancies, again differing from
industry to industry.

• As a result, there are different types of communication and protocols
depending on system needs. Many can work in conjunction or they may
stand alone. And each system of controls must be evaluated to
determine which type of communication protocol is required.
• Here are some of the most common communication types and protocols
that are currently available for automation control systems:
Ethernet
• Ethernet is one of the oldest communication systems

used for industrial automation. It is a networking
technology that can be used in both Local Area Networks
(LAN) as well as Wide Area Networks (WAN).
• Ethernet originally consisted of coaxial cable that
ran throughout an operation and connected machines
physically.

• This not only created the possibility of collisions of data traversing the
cable, it also limited bandwidth depending on the number of devices
attempting to communicate at one time.
• As the system matured it was standardized across the control industry
internationally and has continued to evolve. Today, ethernet systems
have a much higher bandwidth and sport better medium access control
(MAC) methods.
• The MAC layer controls the hardware tasked with interacting with wired,
optical, and wireless elements of the system. This evolution also saw
the upgrade from coaxial cable to point-to-point links that are connected
by Ethernet repeaters, or switches.
• Ethernet systems used today are collision free because they use
duplexing capability. This is due to advanced functionality that allows
switches and stations along the network to send and receive data
simultaneously.

• This has also improved utilization of bandwidth for system segments in
the network. Speeds have also improved, moving from a mere 10
megabits per second (Mbps) on the older coaxial configuration to speeds
as high as 1 gigabit per second (Gbps) using twisted pairs.
Using Industrial Ethernet Protocols
• While there are many different Ethernet protocols, one of the most
common used in industrial automation applications today is Ethernet/IP.
• Ethernet/IP is used in both discreet and process automation needs.
Ethernet/IP is part of a group of network systems that utilize the Common
Industrial Protocol (CIP) in its upper layers.
• It is managed by the Open Device Vendors Association (ODVA) and
follows the Open Systems Interconnection (OSI) model.
• Here, the framework for a network is divided into seven layers including
physical, data link, network, transport, session, presentation, and
application.
• By utilizing this hierarchy of layers, functionality of the network can be
defined from physical implementation through user interface.
• The use of Ethernet/IP can be considered as follows: With the Ethernet
acting as the physical networking protocol, that links elements to the
system, Ethernet /IP is specifically an industrial communication protocol
used in industrial automation systems.
• Ethernet networks offer a large and flexible number of nodes. Because
Ethernet/IP uses CIP over the Ethernet, it can establish connections from
one application node to another.
• It can also with a CIP connection using a Transmission Control Protocol
(TCP). It also allows multiple CIP connections with a single TCP
connection.
Advantages of Ethernet/IP
• As a mature networking system, Ethernet/IP has several advantages
over other systems.
These include:
• Common Protocol – Ethernet/IP uses a proven and long used system –
Ethernet – to provide industrial automation. It uses the transport and
control protocols common in a traditional Ethernet structure.
• CIP – Because Ethernet/IP uses CIP as its core, it can align with
DeviceNet and ControlNet devices and allow a wide range of devices to
be accessed via a common mechanism.
• This allows it to work over larger networks without having to reconcile
communication.
• Data Volume – Ethernet allows the transfer of larger amounts of data
compared to other systems. This functionality aligns well with the
proliferation of edge devices and sensors used in the deployment of
Industrial Internet of Things (IIoT) technology which relies on a vast data
stream to leverage the power of AI, deep analytics and machine learning
algorithms.
• Device Compatibility – Because Ethernet/IP is such a common
communication protocol, it allows devices from different manufacturers to
be connected easily.
• In the past, control systems tended to be proprietary and changing
components could be tricky. With the proliferation of Ethernet/IP, device
compatibility is not an issue.
Disadvantages of Ethernet/IP
• Increased Security Concerns – Using Ethernet/IP increases bandwidth
connects the entire manufacturing system to the network. This makes it
critical that automation engineers must take security into account for the
design of the system to ensure system integrity.
• Diagnostics – Ethernet/IP devices do not contain generic diagnostics.
This means that like security, diagnostic capabilities will need to be
included in system design.

• Device Replacement – There is no current SOP for device replacement
for Ethernet/IP. Components used for replacement will have to be
reconfigured as they were in the original build.
DeviceNet
• Like Ethernet/IP, DeviceNet is an open network that uses the Common
Industrial Protocol (CIP) to control, configure
• and collect data used in industrial devices.
• DeviceNet is an application-level communication
• protocol that is often used for industrial
• automation.
• It sits atop the Controller Area Network (CAN)
• and allows connections between simple, usually
• machine level, devices, and higher-level devices
• such as PLCs.

• DeviceNet is limited to a total of 64 nodes and is predominantly used for
discrete applications within manufacturing.
• In DeviceNet, up to 64 devices can be placed on a single node. These
devices usually have simple functionality with low data requirements
such as on/off switches, sensors, and other straightforward control
systems.
• Because its function is I/Os at the machine level, bandwidth
requirements are lower for DeviceNet than Ethernet/IP and Control/Net.
• Depending on end use and application, one key advantage of DeviceNet
is that power and signal are provided in one cable.
• This gives it a cost advantage over other protocols and is highly useful in
the connection of legacy equipment in IIoT deployments when
connectivity is not native to the machine from the OEM.
• DeviceNet also uses a trunk and dropline system allowing devices to be
added to a total of 64.
• This significantly reduces installation time and helps when needing to
add devices to the system. And since DeviceNet routes all 64 devices
through a single node, troubleshooting and maintenance are easier by
comparison.
• DeviceNet has a server/client network with support for peer-to-peer
communications and uses 11-bit identifiers in message headers.
Transmission speeds range from 125 Kbps to 500 Kbps.
• Network length may create a tradeoff in speed depending on total length.
For example, for short runs for 200-300 feet, 500 Kbps can be realized,
while runs up to 1,640 feet will require thick cable and lower speeds of
around 125 Kbps.
Advantages of DeviceNet
• DeviceNet is great for specific applications and best for discreet
environments. This includes industries such as material handling,
packaging, food and beverage machine tools, and others. Advantages
include:
• Reduced Set-Up and Installation Time – Because of the trunk and drop
system, DeviceNet is simple to install.
Safety Applications –
• DeviceNet is often used for safety control and is also excellent for quality
and regulatory monitoring that may impact safety as well.
Maintenance –
• DeviceNet allows the use of smart devices which can save on equipment
and maintenance costs at the machine level. And because of its plug-
and-play capability, DeviceNet is easier to run diagnostics and
troubleshoot.
Node Capacity –
• If an installation requires less than 64 devices, adding new devices to the
system incrementally to add or enhance system performance makes
DeviceNet flexible.

Disadvantages of DeviceNet
• The disadvantages of DeviceNet are due to specific limitations that
generate lower cost and improved flexibility. They are not qualitative as
such but more along the line of disadvantages that should be weighed
when considering deployment options during an assessment of needs for
building or installing a new system.
• Those with higher-level data and control needs will use these
disadvantages to determine the need for other communication protocols
such as Ethernet/IP or ControlNet. Given that qualifier, here are a few of
the disadvantages of DeviceNet:
• Limited Message Size – Messages on DeviceNet are limited to a max of
240 bytes each for transmit/receive.
• Significantly Shorter Cable Distance – Max cable distance is limited to
1640 with the requirement of thick cable.

• Lower Bandwidth – The benefits of signal and power within the same
cable reduce available bandwidth available for complex or large
messages.
• Lower Number of Devices Per Node – While DeviceNet is ideal for
simple data acquisition environments or the beginning of an IIoT digital
transformation to bring legacy equipment into the data stream, it is still
limited to 64 devices on the node.
ControlNet
• The third in a suite of communication protocols that use CIP, ControlNet
is also managed by ODVA and used for industrial automation.
Compared to DeviceNet, ControlNet has a higher skillset of capabilities
available for more complex data needs used for redundant media and
process applications. It is used where the required volume of data is
much higher for use in devices such as robotics, motion sensing, motion
control and visual controls.

• Also, like Ethernet/IP and DeviceNet, ControlNet uses the OSI model on
CIP defining network protocols in seven layers. It implements CIP at the
session layer and higher but adapts CIP to ControlNet specs at the
transportation level and below.
• This allows it to function as a high-speed network to send time-sensitive
I/O that includes configuration data and peer-to-peer data.
• For companies who require advanced automation and IIoT control or
who are scaling their IIoT to a more sophisticated level, ControlNet has
an increased device count of up to 99 devices per node.
• Because advanced robotics, motion controls, visual controls and other
higher-level automated functions require more data and more signal,
ControlNet offers a higher data transfer rate of 5 Mbps on an open
control network for real-time, high throughput applications.
• Both Ethernet/IP and DeviceNet are not deterministic. But the use of
high-level automation and robotics often require deterministic, repeatable

• transfers on all mission-critical control data. With higher data transfer
rates and higher data volumes, ControlNet uses this feature to control
the data flow by setting exact times of transfer to and from.
• In this system, packets no longer one another and software allows the
user to define the timing to manage the bandwidth and ensure data flow
without interruption or corruption.
• Given the increased data requirements, ControlNet cannot allow signal
and power on the same cable. Using fiber optics or coax, ControlNet
can manage both power and data streams effectively. And when using
fiber optics, it is possible to extend the cable run up to 1000 meters
without use of a repeater.
• ControlNet allows connection of PLCs and HMIs at the floor level to
manage beyond simple on/off commands. This higher-level of data
management can be used to program automation functions for robotics,
visual control quality systems, and other advanced machine functions.

• This not only provides operational data. It allows data to be passed to
ERP systems, IIoT software and other enterprise level analytical systems
in real-time to enhance visualization of the manufacturing environment or
to improve decision-making.
Advantages of ControlNet
• Deterministic – ControlNet allows the user to set and manage times for
critical I/O data. This makes process applications repeatable in both
discrete and process applications.
• Safety – It allows intrinsically safe options to meet EU, UL, FM, and other
certifications for use in potentially explosive atmospheres.
• Flexibility – Nodes can be removed and replaced under power and
anywhere on the network.
• Versatile – ControlNet allows for multiple controllers on one wire,
increasing options and allowing better system performance.

Disadvantages of ControlNet
• ControlNet offer a higher level of data but comes with some
disadvantages depending on end use. These include:
• Higher Hardware Costs – The additional capacity, multiple drop options
and use of fiber optic cable result in higher hardware costs overall.
• Maintenance – ControlNet is inherently more difficult to troubleshoot.
• Complex Cabling Requirements – Because it uses one cable for signal
and one for power, cabling is more complicated when deploying
ControlNet. This complexity increases with length of run and the use of
fiber optics over coax.
• ControlNet is better suited to handle the complex communication and
data needs for IIoT deployments compared to DeviceNet.
• These applications often include extremely heavy data stream
requirements to the IIoT software platform and almost instantaneous
inputs to drive the robotics, analytics and automated adjustments that
come from the benefit of AI and ML applications in these systems.
Remote I/O
• Traditional control systems utilized a local I/O
module that were housed in the same cabinet
with PLCs.
• As automation needs grew and solutions
became more sophisticated, remote I/O has
become more common. Additionally, with the
advent of Industry 4.0 and the arrival of IIoT
devices, remote I/Os may soon equal or surpass
local I/O.
Remote I/O devices are in a physically located
distance from the control PLC cabinet.
They use transmission over wired or wireless systems to send and receive
input and output information to a variety of systems such as personal
computers, PLCs, and other control systems.

Remote I/O
• As their popularity and utility has grown, controller manufacturers such
as Allen-Bradley have developed universal remote I/O network devices
as a LAN solution to connect controllers to a remote I/O chassis for
leveraging intelligent devices such as operator interfaces.
• As remote I/O devices have proliferated, vendors have added
capabilities to make them more agile and flexible. Many offer hardened
remote I/Os that can withstand vibration and shock from direct contact
with the machine.
• They have also begun adding onboard logic solving capability to remain
compatible with IIoT software capabilities and they also offer versions
with several different safety certification ratings such as SIL3, Cat. 4 and
PLe.
• Remote I/O devices may use adaptor modules connected to the
controller backplane in the PLC rack. However, there is a growing
capability for wireless and cellular driven remote I/Os as well, making
Remote I/O
them versatile and flexible for industrial automation applications.
Uses for Remote I/O
• Remote I/Os are used for a variety of reasons including:
• Control and Timing – Remote I/Os may send data and receive
instructions to trigger actions at the machine level.
• Device Communication – They can be used to report conditions of the
machine or equipment for maintenance and breakdowns for reporting in
programs for Overall Equipment Effectiveness (OEE).
• Data Buffering – They can be used for data buffering to mitigate issues
with bandwidth and large surges of data so that the system can properly
handle and process output data in the right order.
• Error Detection – They can trigger action or report faults, stops and
other machine related errors as they occur.

Remote I/O
Using Remote I/Os with Communication Types and Protocols
• Because Remote I/Os are simple electronic network devices designed
only to send and receive information, they must use a communication
protocol for interaction between the control cabinet and the device itself.
• Remote I/O devices can work with a variety of communication protocols.
This includes protocols using CIP such as Ethernet/IP, DeviceNet and
ControlNet. In fact, many remote I/O devices have an ethernet port built
into the device if needed.
• Remote I/O can also be used with other communication protocols such
as EtherCat, Profinet, Modbus/TCP, FL-net and DH485 and even ASCII.
• But again, as remote I/Os are designed for sending and receiving
information, they may need an adapter module for any communication
over a network that is not open.

Remote I/O
Benefits of Remote I/O
• There are many reasons and advantages for using remote I/O devices.
These include:
• Add Capabilities to an Existing System – As digitization of the shop floor
continues, many companies look to add capabilities to their existing
system.
• This allows system expansion without excessive reprogramming and
replacement of control panel components depending on the type of
system and number of nodes available.
• Cost Effective – Because they only need an AC power source, remote
I/Os can be added in a cost-effective manner with smaller and shorter
wire runs or using a wireless remote I/O.
• Harsh Environments – There are many environments where temperature
or other harsh conditions prohibit local placement of the control cabinet.
Remote I/O
• Remote I/Os can be ruggedized to address temperature variations, high
particulate presence or high humidity environments including underwater
units when needed.
• Reduction of Signal Conditioning – Often signal conditioning between
sensor and data acquisition unit is required to mitigate noise, eliminate
ground loops, or isolate voltage for chassis mounted I/O systems.
Remote I/Os eliminate this requirement.
• IIoT Scaling – The explosion of devices linking to IIoT software systems
has reached impressive heights.
• Remote I/O. coupled with the inherent analytical, AI and machine
learning capabilities of these software systems mean that even analog
legacy equipment can be retrofitted for data acquisition.

Remote I/O
• These remote I/O devices can operate wired, wireless or on cellular
technology using edge devices to deliver data to the data stream and not
only add control functionality to the system.
• They can also help automate machine operation while addressing legacy
factory layouts and other obstacles that would prohibit traditional cable
runs.
Serial
• Serial communication protocols are used in serial
communication to determine how data is sent.
Serial buses are common elements, especially in
embedded systems, where the interface and
communication needs are simple and linear.
• In serial communication, data is sent in series, one element after another
in a sequence over a data bus or communication channel.
Serial
• Serial communication is the most widely used method for facilitating the
transfer of information between data processing peripherals.
The communication protocol for serial allows for secure and reliable
receipt of data from the host to the receiver.
Transmission Modes
• Serial communication utilizes binary data pulses and the transmission
method will depend on the type of data transmitted and the transfer
needed. There are three modes of transmission in serial communication:
• Simplex – Simplex mode is a one-way method of data transmission.
Only one party can be active at a time, either the sender, or the receiver.
The receiver can only accept data while the sender can only transmit.
• Half Duplex – In half duplex, both sender and receiver can be active but
only one at a time. If the sender is transmitting the receiver can only
transmit and vice versa.

Serial
Full Duplex – In full duplex, both sender and receiver can send and receive
simultaneously.
• In addition to Mode, serial communication can be either as a
synchronous or asynchronous data transfer. The basic definition of this
is based on clock synchronization.
• A synchronous transfer is a point to point connection from server to
client. All devices in the communication line use a single CPU bus for
both data and clock. For data integrity to be maintained, a signal must
be sent for clock synchronization.
• In an asynchronous serial transfer, there is no clock and the transfer of
data must rely on other factors such as data flow control, transmission
control and reception control. The transmitter and receiver then must
rely on their own clock to synchronize the data once received.

Serial
There are several types of serial protocols. They are often used to allow
one bus to interface with several devices simultaneously.
• I2C – I2C stands for Inter-Integrated Circuit. Here, multiple client
devices can be attached to one or more server. It can support up to 3.4
Mbps and requires two bi-directional wires to allow for transmitting and
receiving. It is used for shorter range communication and handles errors
well.
• SPI – SPI, or Serial Peripheral Interface, is also commonly used in short
range embedded systems. The number of servers is limited to one in
SPI, but it can have many clients.
• It can send high speed data and accept continuous data flow. It can
reach up to 1 Mbps data rate but lacks an error check mechanism. A
subset of SPI called Microwire can obtain data rates of up to 3 Mbps and
has a more complex architecture.

Serial
• USB – Universal Serial Bus is the most used synchronous protocol. It
helps to communicate with peripheral devices, multiple devices and
provides power to the device when needed. Data is transmitted in
packet form each consisting of 8 bits.
• CAN – Controller Area Network allows for error control and configuration
for Engine Control Units (ECU) in automotive. It allows communication
between the ECU and various sensors.
Asynchronous Serial Protocols
Asynchronous serial protocols are best for longer distance data transfers.
They include:
• RS232 – Recommended Standard 232 can be used for things such as
monitors and CNCs. It is a point to point system that can go up to 15
meters in length with data transfer of 9600 bps. Data is transmitted in
binary code.

Serial
• RS422 – Recommended Standard 424 is like RS232 but only allows one
transmitting device with up to 10 receiving devices. Transfer speeds can
vary depending on distance with speeds as low as 10kbps over longer
ranges such as 1200 meters and up to 10 Mbps in shorter ranges of
around 10 meters.
• RS485 – Industry Standard 485 is used across many industries and is
the preferred standard for many. This is because of its ability to use 32-
line drivers and 32 receivers. On short ranges of around 10 meters data
transfer can reach 10 Mbps and it can be either half duplex with two
contacts or full duplex with four.
Profibus

Profibus
• Profibus (derived from process field bus) is a serial
communication protocol used in factory automation.
• It is used to link various automation systems with
controllers and factory floor devices such as
sensors, actuators, and encoders.
• The information is exchanged using a single bus cable.
• Profibus is also a smart field-bus technology that can
do more than send and receive automation messages.
• It is capable of self-diagnosis and connection diagnosis as well.
Profibus uses three layers of the OSI Network:
1. The first layer used is the application layer. Here, a variety of message
types can be handled such as cyclic data, acyclic data, exchange,
diagnosis, alarm handling and isochronous messaging.
Profibus
1. The second layer is the data link layer. Profibus uses both server/client
and token-passing schemes. This gives the system flexibility in its data
handling.
2. The final layer is the physical layer. Profibus can use one of three types
of media including twisted-pairs, fiber optics and for situations where
chemical explosion is possible, it can use a safety enhanced system
called Manchester Bus Power (MBP)
• One interesting feature of Profibus is the use of profiles. These are pre-
defined configurations of different functions that can be applied to
specific devices and applications.
• It helps promote interoperability and interchangeability in devices used
on the factory floor. Profiles allow these different devices from different
OEM vendors to act in a standardized way.

Profibus
Messages in Profibus
The Profibus message hierarchy consists of four message types. Each has
an application and fixed build-up. Each begins with a header which is
followed by the data. The four types of messages are:
• SD1 Contact Check

• SD2 Data Transport
• SD4 Token
• SC Short answer
• For access to the network, server stations are the only ones allowed to
send messages on their own. These include communications to
devices such as PLCs and PCs.
• Client stations can only send with permission of a server and are
usually dedicated to discrete functions such as controlling remote I/Os,
sensors, actuators, and limits.
Profibus
• A Profibus network may be made up of many servers. These servers
communicate with their client stations. However, Profibus’ unique
combination of message schemes allows token sharing between server
stations to facilitate communication at high-levels.
Advantages of Using Profibus
As factory automation increases, Profibus has kept pace with the needs and
changes. Because of this, it has many advantages for deployment:
• The single bus allows for connection of all levels of plant operation
• It is intrinsically safe
• It has diagnostic capability for both system and connection
• The use of profiles allows it to be interchangeable with other
technologies.
• It is easy to troubleshoot
• It has a fast configuration time
• Wiring costs are lower compared to other networks
• Interoperability allows the connection of disparate devices
Modbus
• Modbus is a communication protocol that transmits information over a
serial bus line. The requesting device is called the Modbus Server and
the supplying device units are the Modbus clients.
• In standard Modbus networks there can be up to 247 clients for a single
server. Because it is an open protocol, it is a commonly used system in
factory automation.
• Data in a Modbus system is sent in binary code as a voltage. Zeroes are
represented by positive voltage while ones are represented by negative
voltage. There are for data types stored in different tables depending on
response.
1. Discrete Inputs
2. Coils Inputs
3. Input Registers (Data)
4. Holding Registers (Output Data)
• Sending and Receiving Messages
Modbus
• Modbus is a communication protocol that transmits information over a
serial bus line. The requesting device is called the Modbus Server and
the supplying device units are the Modbus clients.
• In standard Modbus networks there can be up to 247 clients for a single
server. Because it is an open protocol, it is a commonly used system in
factory automation.
• Data in a Modbus system is sent in binary code as a voltage. Zeroes are
represented by positive voltage while ones are represented by negative
voltage. There are for data types stored in different tables depending on
response.
1. Discrete Inputs
2. Coils Inputs
3. Input Registers (Data)
4. Holding Registers (Output Data)
• Sending and Receiving Messages
Modbus
Sending and Receiving Messages
• The Modbus Server makes a request to a client device using an
addressed message that instructs the action to be performed. The
request may instruct the device to read holding registers or write to Input
Registers.
• It will also include how many registers the device is to read. There will
also be a code for the client to validate the message before performing
the task.
• In response, the client device echoes the function code in the original
request and includes the data from the task it was instructed to perform.
It is also possible to report an error in the response code as well.
• There are many different Modbus variations. But for this discussion, we
will cover ASCII and RTU mode. Modbus networks can be set up to
communicate using ASCII characters.

Modbus
• In this mode, eight-bit bytes are sent as two ASCII characters. This
allows time intervals of one second before triggering an error. The
messages are coded in Hexadecimal ASCII and use Longitudinal
Redundancy Checks (LRC) for errors.
• In Remote Terminal Unit (RTU) mode, the eight-bit bytes contain
hexadecimal characters that consist of two four bit hexadecimal.
• The larger character set means better data for the same level of signal.
The data is sent in RTU Mode as a continuous stream. The messages
use Cyclical Redundancy Checks (CRC) for error checking.
Communication Media
• Both the RTU and ASCII mode of protocol utilize RS485 single cable
drops. The only node allowed to initiate a command is the server.
All other component devices are clients.
• Some variant Modbus protocols may use Ethernet. In these cases, it is
possible that all devices can act as the server, but this is not common.
Modbus
• There are many devices such as gateways, converters and modems that
can be used with Modbus.
• It is also possible to develop communication over wired, wireless, SMS
and General Packet Radio Service (GPRS) to increase flexibility of
deployment.
Advantages of Modbus
• Open Protocol – As an open protocol, Modbus allows companies to use
it over a wide range of equipment.
• Simplicity – Its simple message structure allows automation for
companies not looking or needing more extensive data capture and
manipulation.
• Scalability – Modbus Servers can be dedicated servers to allow for
monitoring of different device types. It is also possible to find Servers
that do more than client device communication, enhancing any scale

Modbus
efforts and improving flexibility within the system.
• As automation continues to grow in manufacturing, new communication
protocols will emerge.
• But many of the ones listed here have been in service for decades and
have adapted and evolved into powerful systems fully capable of
managing the communication between complex devices in an equally
complex environment.
• The key to any communication protocol will be the assessment of

individual needs that include current system constraints, future growth,
and the emergence of new and even faster devices communication
needs.

PLC Wiring
• In this session, you will learn the wiring in a PLC control panel and the
basic electrical design of a PLC system cabinet.
• Wiring interlocks need a good understanding of the logic to be
implemented as well as the electrical standards that need to be
implemented to fulfill it.
• So, it is said the one who is a master in designing and understanding

electrical wiring logic and interlock can easily write a PLC logic too.
• We will see how to design a PLC system cabinet. In simpler terms,
consider that you are wiring an electrical PLC panel.
PLC Wiring
Wiring in PLC
• Refer to the below image. We will consider a simple panel here, with all
the basic electrical components.
• The PLC panel consists of the main breaker switch, bus bar, circuit
breakers, relays, contactors, PLC, fuses, SMPS, terminal boards, utility
sockets, and earthing points.

PLC Wiring
Main Breaker Switch

• Let us start with the main breaker switch. This is the point where the
main power supply (3 phases) is connected (R, Y, B, N). It is this point
that supplies power to all the components.
• Install the breaker in such a way that the wireman gets a free hand to do
the wiring; because any lag in it can damage the whole system.
Busbar
• In the next step, connect the output of the main breaker switch to the
busbar. The bus bar provides proper electrical distribution.
• So, if there are many components in the panel which requires a single-
phase supply or three-phase supply, then the bus bar is the most efficient
step to do it.
• Distribute all the points from here to the ones which require single phase
or three phase supply. This will help you in easy and efficient power
management.
PLC Wiring
• You cannot just loop the three-phase wires to different components, as it
is a wrong practice and can damage the wiring or the whole electrical
panel in totality.
Circuit Breakers
• Now, suppose there are three circuit breakers in the panel. Connect the
three phase wires from the bus bar to each of the circuit breaker inputs.
• Individual circuit breakers will power individual contactors connected to
their output. This will give proper output control to the contactors.
• Because contactors have a control circuit that is controlled by the PLC;
thus giving individual three-phase control too will give proper electrical
control over the final output.
SMPS
• Now, from the bus bar, connect one point to the SMPS. This will power it
up and give DC output to the cabinet.

PLC Wiring
• If the current rating of SMPS is higher, then you can use a distribution
terminal board too for DC supply. This will properly segregate the DC
supply to all the components requiring it. From this, power the PLC.
• Now, after this, we will see how to wire the PLC IOs.
Digital Inputs
• Firstly, take digital inputs.
According to sink or source wiring,
connect either 24V or 0V to the
PLC common.
• So, for example, if the common
is 24V, connect 0V to all the
respective PLC field inputs in the
terminal board.
• As one board has two pins, one will be used to provide 0V and the other
will be connected to PLC digital input.
PLC Wiring
• For safety, many use fuse terminal boards. This provides additional
safety to the field devices.
Digital Outputs
• Then, coming to digital outputs, the same sink and source theory applies
to it.
• So, for example, if the common is 24V, connect 0V and PLC digital
outputs to all the relays (relay has two pins, so one pin will be 0V and the
other pin will be PLC digital output).
• According to the output you want at relay output (DC or AC), connect the
wiring accordingly.
• For example, if the relay output required is 230V AC, connect the line
wire to the common and connect the NO wire to the contactor’s line
input. Connect the neutral wire to the contactor’s neutral input and thus,
the circuit is complete.

PLC Wiring
• Now, whenever the relay turns on, that particular contactor will turn on
and if its MCB is on, then the three-phase supply will be passed on to the
final output.
Analog Inputs and Outputs
• Now, analog input and analog outputs will be directly routed through
terminal boards with respect to PLC.
• If possible, use fused terminal boards for additional safety.
Terminal Boards
• Coming back to the contactors, the output is connected to terminal
boards where you can connect your final output.
• Note down some general points while designing a PLC panel:
• Have a good understanding of electrical ratings and standards, before
choosing a component; for example, a contactor.

PLC Wiring
• Many times, fuses are connected after the mains breaker switch to
protect the panel from any damage caused by the incoming three-phase
supply.
• Also, transformers are used in many panels to step down a voltage
according to the requirements.
• Fuses are also installed after SMPS for protecting PLC or other sensitive
field devices.
• If three phase devices are used with earth points, ensure to provide
separate earthing (power and instrument) in the panel. Do not mix them
up.
• In this example, I have not shown terminal boards for PLC digital
outputs; but even they are used normally in many applications.
• Because there can be valves in the system which require 24V DC, and
such outputs require terminal wiring in the boards.

PLC Wiring
• Many types of designs are possible in a PLC cabinet. You should know
the basic requirements and have a fair idea of electrical wiring and PLC
wiring, which will help in designing the panel properly.
• .

Sink or Source? Normally Open or Normally Closed?
• We will discuss about concepts of Sink or Source used in electrical
circuits or in PLC wiring. Also we deal with basics of normally open
contact or normally closed contact which are used in relay wiring.
• When it comes to mastering the language of electronics, nothing causes
more confusion than the “sink” or “source” question.
• This area causes problems for those trying to sort out machine
electronics. When ordering parts, we often find ourselves unable to
answer the question “do you need sink or source?”. Questions such as
these often confront automation engineers and technicians:
• If you replace a sinking input with a sourcing input, does it mean that
everything that was “on” will now be “off”, and vice-versa?
• Is “sinking with normally closed” the same as “sourcing with normally
open”?
• If your application call specifically for “sinking” or “sourcing”, does that
mean you need pnp or npn or does it not matter?
• You will be surprised to find out just how easy it is to understand this
concept.
• Take a look at the circuit in Figure 1. This is our most basic circuit. Even
though it is a simple circuit, we can use this circuit to explain sinking and
sourcing.
• The circuit in Figure 1 shows a light bulb that is connected to a battery
with two wires. DC (direct current) flows from the battery, through the
light bulb, and back to the battery.
• That is all it takes to light the bulb.
Connect positive (+) to one side
of the bulb, connect negative (-)
to the other side of the bulb, and
it turns on.
• This circuit contains the basic requirements of a digital system: a power
source (the battery), a device that is turned on and off (the bulb)

and wires to connect them together.
• Now we will add one more feature: suppose you want to turn the light on
and off? You need to add a switch (or two?). Here is the big question:
• Do you add the switch to wire A or do you add switch to wire B? Or do
you add two switches?
• Figure 2 shows two switches installed

in the circuit.
• You probably already know that one

switch will do the job.
• After all, you have been turning lights

on and off all your life with just once
switch.

• So you probably also guessed that it would be foolish to use two
switches where one will do the job.
• But which switch do you choose? Do you install a switch on Wire A as
shown in Figure 3; or do you install a switch on Wire B as shown in
Figure 4.
• Drum roll please… the answer

is: it doesn’t make any difference;
either switch will work fine!
Either switch will break the flow of
current through the circuit.
• Now here is the part that causes
all of the confusion: we need a way to describe using switch 1 vs. switch
2.
• If you examine Figure 3 you will see that switch 1 is installed on the wire
that runs from the negative (-) side of the battery to the light bulb.
• You can see in Figure 4 that switch 2 is installed on the wire that runs
from the positive (+) side of the battery to the light bulb.
• You can see that the final circuit,

which contains just one switch
(either figure 3 or 4), has two
parts: there is an “inactive” part of
the system and also an “active”
part of the system.
Figure 5 shows these two parts.
The bulb, the battery and the wire that runs from the (+) side of the
battery to the bulb are inactive.
• These 3 items sit there all day long and never change. The switch
however, is active. It has two states: it can be either ON or OFF.
Sometimes people refer to this as OPEN or CLOSED; but those are just
different words for the same thing.

• Now consider what is happening from the switches point of view in
Figure 5. As the switch is opened and closed it takes the negative (-)
from the battery and connects or disconnects
it with the bulb.
• In Figure 4, the switch takes the
positive (+) from the battery and
connects it to the bulb.
• Now imagine that you want to tell
someone how to wire a circuit.
• You need to tell them whether they
should wire the circuit as shown in
Figure 3 or as in Figure 4.
• Imagine further that you have lots of people wiring lots of circuits and you
need to give these instructions all day long.
• It’s too much of a mouthful to say “Wire one side of the bulb permanently
to positive and install the switch so it connects and disconnects the
• It’s too much of a mouthful to say “Wire one side of the bulb permanently
to positive and install the switch so it connects and disconnects the
negative from the battery to the bulb.”
• Besides, if you say that, you don’t
sound very sophisticated.
• So someone made up terms to
shorten the instructions and help us
to sound more sophisticated.
• And these terms are…
SINK and SOURCE. I have no idea
why they chose these terms.
• They could have used any two terms: “Sink” and “Swim” would have
worked just fine; or why not “Source” and “Resource”?
• For all we care they can call these two different conditions Moe and
Larry.
• The name is not important, what is important is that when you set up a
DC system to turn something on and off, you will switch either the
positive or the negative and leave the other permanently wired.
• Now, in order to communicate
intelligently, all you need to know is…
which is Sink and which is Source?
• Here is something that may surprise you:
the terms sink and source are NOT
standardized enough across the industry
to be relied on.
• As incredible as it sounds, when one
person refers to what you may call “source”
the other person may picture what you
would call “sink”. So I recommend that
you never use these terms.

• Instead, you can review the wiring diagrams, or say something like
“switch the negative” or “switch the positive”.
• Leave the terms “sink” and “source” for those who are so pressed for
time that they want to optimize their speech while risking wiring the
machine improperly.
• So now you know. Next time you here the words “sink” or “source”, just
ignore the terminology and focus on what you actually have: are you are
switching the positive (+) or the negative (-)? That’s your deciding factor.

NPN And PNP Proximity Sensors
• Proximity sensors are used to detect objects without making physical
contact. There are 2-wire and 3-wire proximity sensors, and 3-wire
proximity sensors are more popular. There are two main types of
proximity sensors based on their output type: NPN and PNP.
• Selecting the correct type of proximity sensor for a particular application

can ensure the correct operation of a system. This session aims to
provide an outline of the two main output types and a guide on how to
connect a proximity sensor to a PLC.

What Is An NPN Proximity Sensor?
• NPN proximity sensors provide an active LOW output. This means that
when an object enters the detecting range of the sensor, the output of
the sensor is connected with the ground. This type of sensor is also
known as ‘sinking’ sensor.
What Is A PNP Proximity Sensor?

• PNP proximity sensors provide an active HIGH output. When an object
enters the detecting range of the sensor, the output of the sensor is
connected with +24V.
• When connected to a PLC input, it detects this as a logic HIGH signal.
PNP proximity sensors are also known as ‘sourcing’ sensors.
A Way To Remember NPN And PNP Sensor Wiring
• To easily remember the wiring of a 3-wire DC proximity sensor, we can
use the following analogy:

• PNP = Switched Positive
• NPN = Switched Negative
• Proximity sensors are digital sensors.
Therefore, they must always be
connected to a 24V power source to
function.
• In the PNP sensor wiring, the load is
always connected to Negative.
• The Positive is switched when the

proximity sensor detects an object.
But, in the NPN sensor wiring, the load
is always connected to Positive, and the
Negative is switched when an object is
detected.

function.

But, in the NPN sensor wiring, the
load is always connected to Positive, and
the Negative is switched when an
object is detected.

function.

But, in the NPN sensor wiring, the
load is always connected to Positive, and
the Negative is switched when an
object is detected.

PNP Vs NPN For 3 Wire Connection Of A Sensor
• Almost all the industrial proximity sensors are solid-state devices,
meaning that they do not have moving parts inside.
• The most popular type of proximity sensor is the 3-wire type. They use
PNP or NPN type transistors to switch the output when an object is
detected.
• Two of the wires are used to provide the sensor with power to operate,
while the other wire is the output from the sensor.
• At this point, t’s worth mentioning that being a PNP or NPN type sensor,
does not imply if the sensor output is normally open (N/O) or normally
closed (N/C).
• This is dependent only on the application. (I.e. a PNP sensor can be
either N/O or N/C as can an NPN be either N/O or N/C)
• Let’s have a look at a relay-type circuit, where a relay is operated directly
by a proximity sensor.
• The difference between the two wirings is that in the PNP type wiring, the
relay is always connected to 0V, and +24V is switched by the sensor.
• But in the NPN type wiring, the relay is always connected to +24V and
the sensor switches the 0V connection. Regardless, the sensor is
connected to +24 and 0V to supply power to it.
How To Connect NPN/PNP Proximity Sensor To PLC
• Warning! Before attempting any wiring, make sure that the system is
powered off to prevent electric shock.
Identifying The Color Code Of A 3-Wire Proximity Sensor
On a 3-wire sensor, the wiring color code is as follows: (Brown: +24V, Blue: 0V,
Black: output)
If your sensor’s wires are differently colored or unsure about the color code, please
refer to its manufacturer’s datasheet.
Wiring An NPN Type 3-Wire Proximity Sensor To A PLC

• Before connecting the sensor to the PLC, make sure that the PLC is
configured to the ‘sourcing’ type. On a Siemens S7-200 PLC, this can be
done by connecting input 1M to +24V.
• This means that the PLC will ‘source current’ out of the input, and the
NPN sensor will ‘sink current’ when it detects an object.

• If the input is fed to the PLC through an input card, it must be a sourcing
type input card, or else a configurable one. The SIMATIC S7-1200,
Digital Input SB 1221 is such a sourcing-type input card.
Wiring A PNP Type 3-Wire Proximity Sensor To A PLC

• For a PNP type sensor, the PLC needs to be configured as a ‘sinking’
type. Connecting the input 1M to 0V will configure the PLC as input
sinking. With this configuration, the sensor can ‘source current’ and the
PLC will ‘sink current’ to detect sensor output.
• For a PNP type proximity sensor, if an input card is used, it must be a

‘sinking’ type card. The S7-1200, Digital Input SM 1221 input card for S7-
1200 PLCs is a sink/source configurable input card and it can interface
with either type of sensor.

How To Choose A PNP Or NPN Sensor?
• Selecting PNP vs NPN depends mostly on the application and the
availability.
• As Arrow Electronics mentions, NPN sensors are more common in the
automation industry in the Asia region. PNP sensors are more popular in
Europe and America.
• NPN sensors are used in high-speed applications because they are
faster than PNP sensors.
• They also find more applications in relay circuits than PLC circuits. PNP
sensors are more popular in PLC circuits as they can prevent false-
positive signals if damaged and shorted with the ground.
How Do I Know If My Proximity Sensor Is NPN Or PNP?
• The easiest way to identify the sensor type is by observing the sticker on
the body of the sensor. This sticker can sometimes have a wiring
diagram printed on it as well.

• If the sensor is not marked an
is installed, a multimeter can
help identify the sensor type.
• Power on the system and
carefully measure the voltage
• between 0V and the black wire.
• If there is a voltage of +24V
when the sensor is active, it is
a PNP-type sensor.
• If there is a 0V reading on the multimeter when the sensor is active, it is
most likely an NPN sensor.

CHAPTER THREE
Download and Install the
Software

CHAPTER THREE
Introduction to Allen Bradley
PLC programming

Basics of RS Logix 5000 Software
• About RSLogix 5000
• Rockwell Automation and its sister company Rockwell Collins are part of an
impressive legacy,
• including the space shuttle program, the Apollo moon landings, P-51 mustang,
the Navstar
• Global Positioning System (GPS) satellites, and the supersonic B-1 Lancer.
• Today, it is a global provider of industrial automation, power, control, and
information solutions under the brands Allen-Bradley and Rockwell Software.
• Rockwell Automation products are extremelypopular in the North American
market and there are references to it being used in almost every industry
vertical.
• RSLogix 5000 is a user-friendly, IEC61131-3-compliant interface for

About RSLogix 5000
• programming the current generation of Rockwell Automation PLCs
(Programmable Logic Controllers). IEC61131-3-
• compliant means that it complies with the International Open Standard for PLC
programming languages, including:
• Ladder Diagram (LD) f Function Block Diagram (FBD) f Structured Text (ST) f
Sequential Function Chart (SFC)
• More information on RSLogix 5000 IEC compliance can be found in the Rockwell
publication
• The RSLogix 5000 platform is compatible with the new generation of Allen-
Bradley controllers, including ControlLogix, CompactLogix, FlexLogix, SoftLogix,
RSLogix Emulate 5000, and GuardLogix.
• RSLogix 5000 is one of several PLC programming environments from Allen-
Bradley, so it is critical to work with Rockwell Automation sales and
About RSLogix 5000
• programming the current generation of Rockwell Automation PLCs
(Programmable Logic Controllers). IEC61131-3-
• compliant means that it complies with the International Open Standard for PLC
programming languages, including:
• Ladder Diagram (LD) f Function Block Diagram (FBD) f Structured Text (ST) f
Sequential Function Chart (SFC)
• More information on RSLogix 5000 IEC compliance can be found in the Rockwell
publication
• The RSLogix 5000 platform is compatible with the new generation of Allen-
Bradley controllers, including ControlLogix, CompactLogix, FlexLogix, SoftLogix,
RSLogix Emulate 5000, and GuardLogix.

Creating a new RSLogix 5000 application
• In this recipe, we will create a new RSLogix 5000 controller program using the
Logix Designer application.
1. First, we will need to open RSLogix 5000 from the drop-down menu and
then navigate to File | New or press Ctrl + N.
2. The New Project window will appear and allow us to give a name to our
new project and configure it for a particular controller and firmware
revision, or the RSLogix Emulate 5000 Controller if a PLC is not available;
but, keep in mind that the hardware may impact your ability to complete
all the exercises in this training.
3. Set the remaining fields to the following values:
Name: FirstProject
Description: This is my first project in RSLogix 5000!
Chassis Type: 4-Slot
Slot: 0

Creating a new RSLogix 5000 application
4. Click on the Browse button to choose a location on your computer on
which to save your project.
How it works...
• We have created a new empty RSLogix 5000 project and specified the PLC that
will be used throughout this book. When you create a new project, it will be
stored on your local computer as an ACD file.
There's more...
• If you have selected the RSLogix Emulate 5000 controller type, you will also
need to configure it using the RSLogix Emulate 5000 program separately to
simulate a PLC on your local computer.

RSLogix Emulate 5000
• RSLogix Emulate 5000 allows you to use your local computer as a Logix
5000 PLC.
• You will need to have RSLogix Emulate 5000 running and configured in
order to test the projects described in this book.
• RSLogix Emulate 5000 is very simple to set up; simply run the RSLogix
Emulate 5000 program and switch between the Run mode and the
Program mode using the All Modules drop-down menu.
• For the purposes of this class, there is no need to configure any
modules.

Configuring I/O modules (Simple)
• In this recipe, we are going to configure an analog input card to monitor
the open position of 4 valves (0 to 100 percent) based on their 4 to 20
ma signals.
Getting ready
• In order to complete this exercise, you will need a Logix 5000-compatible
rack, a PLC, and some compatible controller cards, or run RSLogix
Emulate 5000.
How to do it...
1. At the bottom of the Controller Organizer window, expand the I/O
Configuration folder, right-click on the Backplane node, and select New
Module... from the menu as shown in the following screenshot:

2. Next, we will select the module that will be added to our rack. We will be
adding a basic 8 channel analog input card. Expand the Allen Bradley
Analog category and choose 1756-IF8.
3. Now, we are presented with the New Module window where you can
specify the name and description of the module. We will identify this
module based on its rack and slot position—RACK01_SLOT01 as shown
in the following screenshot:


4. After adding the new module, the Module Properties window is displayed
(or can be opened by double-clicking on the module).
• The Module Properties window will allow us to configure the channel,
calibrate the card, and modify the Requested Packet Interval (RPI) and
alarm information of our analog input module.
5. We will configure our analog input module's first channel (Channel 0)

to be a typical 4 ma to 20 ma input by navigating to the Configuration
tab and selecting an input range of 0 ma to 20 ma from the dropdown.
6. Now, we will set the information in the Scaling group box to the following
values:
High Signal: 20 ma
Low Signal: 4 ma
High Engineering: 100.0
Low Engineering: 0.0

7. This process must be repeated for all the four channels. We can select
and configure the three remaining channels by clicking on the small square
buttons labeled 1, 2, 3, and following the same method.
8. Finally, we will click on the OK button to save our module configuration.
How it works...
• We have configured all four channels on our module to report our valve
open positions from 0 to 100 based on a 4 mA to 20 mA signal. If a valve
signal wire is disconnected, we will see that our channel will drop below
4ma and a channel fault will be reported.
There's more...
Each card type will have its own configuration dialog, so take some time to
learn the available
cards and their configuration options.

Logix 5000 supports a wide variety of third-party add-on modules. Most of
these modules will need to be installed using an installer from the third-party
company; however, in Version 20 of Logix 5000, many popular third-party
modules are built into the product.
Understanding tags (Simple)

RSLogix 5000 Named Associations (text-based memory locations also
known as variables) are used in our PLC application to represent process
values and equipment. In this recipe, we will introduce text-based name
associations used in RSLogix 5000.
We will demonstrate the configuration of tag types Base and Alias. We will
work through a step-by-step guide to creating and associating tags with
inputs, outputs, and memory.
Getting ready
To complete this exercise, you need to have completed the previous
recipes.
How to do it...
1. First, we will create a tag using the New Tag window. You can open the
new tag window by right-clicking on the Controller Tags folder of the
Controller Organizer (to display the Controller Organizer, press Alt + 0)
and selecting New Tag (or by pressing Ctrl + W).
2. The New Tag window allows us to configure several parameters for

our tag. The first tag we will create will be a base tag that will be used
internally in the program and is not directly associated to a card in the
controller.
The first base tag will be the set point for the flow control valve FC1001,
so we will give it a text-based named association of FC1001_SP.

3. Along with the name, setting a description is a recommended best
practice. We will set the description to FLOW CONTROL 1001 SET
POINT. Refer to the upcoming screenshot.
4. Next, we will set the Type dropdown to Base.
5. We will set the Data Type of our base tag to REAL.
6. We will set the value of Scope to FirstController.

7. Setting the scope to Controller level will allow us to use this tag in all the
tasks and programs in the project (Global scope).
8. The External Access field is set to Read/Write so that our operator will be
able to set the value from the HMI.
9. The Style dropdown allows us to modify the way the value is displayed
and the choices vary depending on the data type that is being used.
The following screenshot shows all of these settings:

10. Finally, we will click on OK to finish adding our variable tag to the
project.
11. Now, we will double-click on the Controller Tags leaf of the Controller
Organizer and view our newly added tag in the Controller Scope pane of
our project.
12. Next, we will repeat the same process for an Alias tag that will be
directly associated with the analog output of the flow control valve.
This time, we will use the Controller Tags pane to enter our new tag into
the Tags table. At the bottom of the Controller Tags pane, there is a tab
labeled Edit Tags and, if we click on that tab, we can type a tag into the
bottom row of the table as if we were adding it to a spreadsheet.

13. In the Name column, set the value to FC1001_PV.
14. In the Alias for column, select the data outputted from the analog input
card. We added Local:1:I.Ch0Data as shown in the following
screenshot:
15. Finally, set the description to FLOW CONTROL VALVE 1001 PROCESS
VALUE.

13. In the Name column, set the value to FC1001_PV.
14. In the Alias for column, select the data outputted from the analog input
card. We added Local:1:I.Ch0Data as shown in the following
screenshot:
15. Finally, set the description to FLOW CONTROL VALVE 1001 PROCESS
VALUE.

How it works...
• We have added two new tags to our project as follows:
• A base type tag that is not directly connected to an input or output card
and allows us to specify any data type we wish to use an alias type tag
that is connected to an input or output card value and whose data type is
specified by the card configuration
• RSLogix 5000 uses text-based named associations that can be
referenced by name throughout the project.
• In RSLogix, tags can also be referenced by external sources, such as
HMIs, SCADA, and DCS systems rather than the numeric addresses of
legacy PLC applications.
There's more...
• Text-based named associations is an important concept in RSLogix 5000.
• This recipe describes a few more important aspects of it.

Deleting tags
• Tags can also be deleted from the Edit Tags tab of the Controller Tags
pane. You can delete a tag by right-clicking on the box to the left of the
name and selecting the Delete menu option (or by pressing the Delete key
after selecting a tag).
Understanding tag scope

• The Scope field of the New Tag form represents the area where the tag is
visible within the controller.
• When you specify the scope as the controller itself (FirstController in our
example), the tag is accessible globally, meaning it can be accessed from
all tasks and programs.
• Later, we will create programs and define tags that have a scope for a
particular program and cannot be accessed outside that specific program.

Data Types in RSLogix 5000
• There is a wide range of data types available, which can be seen from the
Data Type dropdown of the New Tag form. Base types, arrays, function
block types, motion control types, and so on can be added to a controller
at any Scope level.
Produced and Consumed tags

• You may have noticed that there were two other options in the Type field
of the New Tag form: Produced and Consumed.
• These tags allow values to be shared between two separate PLCs on a

network. They are limited to a handful of data types. The project that
contains the Produced tag must have the remote-networked PLC mapped
in I/O Configuration of the project.

Building Ladder Diagram programs (Simple)
• Now we will start to create some PLC programs for our newly created
project.
• In this recipe, we will learn how to create Ladder Logic programs in

RSLogix 5000 by drafting a basic Ladder Logic alarm timer routine.
• We are going to add an alarm that will be triggered if the valve position set
point and current analog input position of the valve differ for more than five
seconds.

Getting ready
You will need to have added the cards and tags from the previous recipes to
complete this exercise.
How to do it...
1. Open Controller Organizer and expand the leaf Tasks | Main Tasks |
Main Program. Right-click on Main Program and select New Routine as
shown in the following screenshot:

2. Configure a new Ladder Logic program by setting the following values:
Name: VALVES
Description: Valve Control Program
Type: Ladder Diagram
3. For our newly created routine to be executed with each scan of the PLC,
we will need to add a reference to it in MainRoutine that is executed with
each scan of the MainTask task.
4. Double-click on our MainRoutine program to display the Ladder Logic

contained within it.
5. Next, we will add a Jump To Subroutine (JSR) element that will add our
newly added Ladder Diagram program to the main task and ensure that
it is executed with each scan.

6. Above the Ladder Diagram, there are tab buttons that organize Ladder
Elementsinto Element Groups. Click on the left and right arrows that are on
the left side of Element Groups and find the one labeled Program Control.
After clicking on the Program Control element group, you will see the JSR
element. Click on the JSR element to add it to the current Ladder Logic
Rung in MainRoutine
7. Next, we will make some modifications to the JSR routine so that it calls
our newly added Ladder Diagram. Click on the Routine Name parameter
of
the JSR element and select the VALVES routine from the list as shown in
the following screenshot:

8. There are three additional parameters that we are not using as part of the
JSR element, which can be removed. Select the Input Par parameter and
then click on the Remove Parameter icon in the toolbar above the Ladder
Diagram. This icon looks as shown in the following screenshot:
9. Repeat this process for the other optional parameter: Return Par.
10. Now that we have ensured that our newly added Ladder Logic routine will
be scanned, we can add the elements to our Ladder Logic routine
.
Double-click on our VALVES routine in the Controller Organizer tab under
the MainTask task.
11. Find the Timer/Counter element group and click on the TON (Timer On
Delay) element to add it to our Ladder Diagram.
12. Now we will create the Timer object. Enter the name in the Timer field as
FC1001_TON. Right-click on the TIMER object tag name we just entered
and select New "FC1001_TON" (or press Ctrl + W).
13. In the New Tag form that appears, enter in the description FAULT TIMER
FOR FLOW CONTROL VALVE 1001 and click on OK to create the new
TIMER tag.
14. Next, we will configure our TON element to count to five seconds (5,000
milliseconds). Double-click on the Preset parameter and enter in the
value 5000, which is in milliseconds.
15. Now, we will need to add the condition that will start the TIMER object
. We will be adding a Less Than (LES) element from the Compare element
group. Be sure to add the element to the same Ladder Logic Rung as the
Timer on Delay element.
16. The LES element will compare the valve position with the valve set point
and return true if the values do not match. So set the two parameters of
the LES element to the following:
FC1001_PV
FC1001_SP
and select New "FC1001_TON" (or press Ctrl + W).
13. In the New Tag form that appears, enter in the description FAULT TIMER
FOR FLOW CONTROL VALVE 1001 and click on OK to create the new
TIMER tag.
14. Next, we will configure our TON element to count to five seconds (5,000
milliseconds). Double-click on the Preset parameter and enter in the
value 5000, which is in milliseconds.
15. Now, we will need to add the condition that will start the TIMER object
. We will be adding a Less Than (LES) element from the Compare element
group. Be sure to add the element to the same Ladder Logic Rung as the
Timer on Delay element.
FC1001_PV
FC1001_SP
FC1001_PV
FC1001_SP
17. Now, we will add a second Ladder Logic Rung where a latched fault
alarm is triggered after TIMER reaches five seconds.
18. Right-click under the first Ladder Logic Rung and select Add Rung
(or press Ctrl + R).

19. Find the Favorites element group and select the Examine On icon as
20. Click on ? above the Examine On tab and select the TIMER object's
Done
property, FC1001_TON.DN, as shown in the following screenshot.
Now, once the valve values are not equal, and the TIMER has completed
its count to five seconds, this Ladder Logic Rung will be activated as
21. Next, we will add an Output Latched element to this Ladder Logic Rung.
Click on the Output Latched element from the Favorites element group
with our new rung selected. O-SECUL NIGERIA LIMITED
122. Click on ? above the Output Latched element and type in the name of a
new base tag we are going to add as FC1001_FLT. Press Enter or click
on the element to complete the text entry.
23. Right-click on FC1001_FLT and select New "FC1001_FLT" (or press Ctrl
+ W).
24. Set the following values in the New Tag form that appears:
Description: FLOW CONTROL VALVE 1001 POSITION FAULT
Type: Base
Scope: FirstController
Data Type: Bool
25. Click on OK to add the new tag. Our new tag will look like the following
screenshot:

26. It is considered bad practice to latch a bit without having the code to
unlatch the bit directly below it. Create a new BOOL type tag called
ALARM_RESET with the following properties:
Name: ALARM_RESET
Description: RESET ALARMS
Type: Base
Scope: FirstController
Data Type: BOOL
27. Click on OK to add the new tag. Then add the following coil and OTU to
unlatch the fault when the master alarm reset is triggered.

28. Finally, we will add a comment so that we can see what our Ladder
Diagram is doing at a glance.
29. Right-click in the far-right area of the first Ladder Logic Rung (where the 0
is) and select Edit Rung Comment (Ctrl + D).
30. Enter the following helpful comment:

TRIGGER FAULT IF THE SETPOINT OF THE FLOW CONTROL VALVE
1001 IS NOT EQUAL TO THE VALVE POSITION

How it works...
• We have created our first Ladder Logic Diagram and linked it to the
MainTask task. Now, each time that the task is scanned (executed), our
Ladder Logic routine will be run from left to right and top to bottom.
• Ladder Logic is the most commonly used programming language in
RSLogix 5000. This recipe describes a few more helpful hints to get you
started.
• Understanding Ladder Rung statusesDid you notice the vertical output
eeeeeee on the left-hand side of your Ladder Logic Rung?
• This indicates that an error is present in your Ladder Logic code. After
making changes to your controller project, it is a good practice to Verify
your project using the drop-down menu item Logic | Verify | Controller.
• Once Verify has been run, you will see the error pane appear with any
errors that it has detected.

Element help
You can easily get detailed documentation on Ladder Logic Elements,
Function Block Diagram Elements, Structured Text Code, and other element
types by selecting the object and pressing F1.
Copying and pasting Ladder LogicLadder Logic Rungs and elements can be
copied and pasted within your ladder routine.
Simply select the rung or element you wish to copy and press Ctrl + C. Then,
to paste the rung or element, select the location where you would like to
paste it and press Ctrl + V.
Troubleshooting techniques (Intermediate)

The ability to troubleshoot and properly diagnose faults in Logix 5000 is
extremely valuable.
This recipe will demonstrate a typical troubleshooting process when things go

awry.
Getting ready
This recipe will cover the fundamentals of troubleshooting issues in RSLogix
5000. When there are troubleshooting issues in RSLogix 5000, there are a
few places where you can start.
How to do it...
1. Open Controller Organizer in RSLogix 5000 and find the Controller Module
(or modules for your project). Right-click on the Controller module and
select Properties (or press Alt + Enter).
2. In the Controller Properties window, navigate to the Major Faults tab and
check for any faults that may have occurred.
3. Now, click on the Minor Faults tab and check for any faults that may have
occurred.
4. You can also check to see if there are any errors with the PLC program
itself by navigating to Logic | Verify | Controller.
5. If any errors occur, they will be listed in the Errors Pane that is displayed.
How it works...
RSLogix 5000 allows you to resolve errors in your PLC program quickly and
easily. Often, you can click on the error messages that appear and you will be
taken directly to the area you need to fix.
Downloading explained (Simple)
In this recipe, we will demonstrate how to download your application to a PLC
in a step-by-step process.
Getting ready
To complete this recipe, you will need a PLC or RSLogix Emulate 5000
running.
How to do it...
1. Before we can communicate with our PLC, we will need to set up the
communications path in a separate program called RSLinx that is installed
with RSLogix 5000. Open RSLinx and then, from the drop-down menu,
navigate to Communications | Configure Drivers as shown in the following
screenshot:
2. The Configure Drivers window allows you to add Driver to the Configured
Drivers list.
In the Available Driver Types group box, use the dropdown and select the
EtherNet/IP Driver option, and then click on the Add New… button.
3. Next, a window will appear asking you to specify the name of Driver; use
the default driver name and click on OK.
4. A Configure Driver window will appear next; simply click on OK to accept

the default settings.
5. We have completed our communications driver configuration in RSLinx, so

we can close that application for now and switch back to RSLogix 5000.

6. In order to download our program to the controller, we first need to specify
the communications path. You can see the currently selected
communications Path on Communications Toolbar:
7. Click on the Who Active icon to the right-hand side of Communications

Toolbar and specify the communications path. This icon looks like the
following screenshot:
8. The Who Active window will appear and allow you to specify the path to
your PLC. Expand the AB_ETHIP driver we added using RSLinx, select
your PLC, and then click on the Download button.

9. A version mismatch message may appear; just click on OK to accept and

overwrite the current PLC program.
10. Now that we have downloaded the PLC program to the PLC, if you check
the PLC status pane in the top-left corner of Logix 5000, you will see that
you are now online.
6. In order to download our program to the controller, we first need to specify
the communications path. You can see the currently selected
communications Path on Communications Toolbar:
Uploading explained (Simple)

• In this recipe, we will demonstrate how to upload an application from a
PLC to RSLogix 5000 in a step-by-step process.
Getting ready
• To complete this recipe, you will need to have completed the previous
recipe to configure your RSLinx to communicate with the device you need.

How to do it...
1. Click on the Who Active icon as shown in the following screenshot:
2. The Who Active window will appear. Use the network browser tree to
select
your PLC on the network.

3. Now we are ready to upload the PLC program to our computer. Click on
the Upload button.
4. The Connected To Upload window provides more details about the current
PLC and the program state. Hit the Upload button to start the upload
process.
5. If you have made any changes to the project that you currently have open,
you will see a Save Changes dialog. Click on No.
6. An uploading progress bar will be displayed when the upload process
begins.
7. Once the upload process is complete, you will see that you are now online
on the PLC
How it works...
Now that we have uploaded the current program from the PLC to our local
copy of RSLogix 5000, the PLC program and our local program are an exact
match.
Don't lose your comments and descriptions
• One potential issue you can encounter when uploading a program from a
PLC is that comments are not stored on the PLC. So, it is important to
keep the following in mind when uploading programs on RSLogix 5000:
• If you upload a project from a PLC to a new project, the newly created
project will be missing all comments and descriptions If someone adds
new tags, descriptions, and comments to a program and downloads it to a
PLC and you upload it to your local program that does not have the newly
added tags, descriptions, and comments, your project will be missing the
recently added descriptions and comments
Understanding online changes (Intermediate)

• In this recipe, we will introduce the concept of Online Changes in RSLogix
5000. We are going to make an online modification to our VALVES routine
by adding logic to check for a power-failure event.

3. Now, we are going to add our newly created POWER_FAILURE tag to the
VALVESLadder Logic Routine. Open the VALVES routine by double-
clicking on it from the Controller Organizer tree.
4. Now, the tricky part with an online change in RSLogix 5000 is that we
cannot make modifications to an existing Ladder Logic that is currently
running. However, we can add new Ladder Logic Rungs.
So the workaround for editing rung is to copy and paste an existing rung,
modify it, and then delete the old rung. So, let's copy the existing rung at
position one by right-clicking on it and selecting Copy (or press Ctrl + C).
5. Next, we will paste our rung under the existing rung by right-clicking on it
and selecting Paste (or press Ctrl + V).
6. After pasting the rung, you will notice that iiiii will appear to the left of the
rung indicating that it is pending insertion.

7. Now that we have added the new rung, we can edit and go ahead
delete the old rung. Right-click on the only rung and click on Delete (or
press Delete).
8. After deleting the old rung, you will notice that ddddd appears to the left of
the rung indicating that it is pending deletion.
9. Now we can make our modification to our newly inserted rung. Choose the
rung we have inserted and click on the Examine Off element to add it.
10. Click on ? above the Examine Off element and associate it with the
POWER_FAILURE tag. The following screenshot displays the Examine
Off element with the associated tag.

11. The changes we have made to the routine will not execute until we
finalize our program (or accept, test, and assemble it). From the drop-
down menu, navigate to Logic | Online Edits | Finalize All Edits in
Program (or press Ctrl + Shift + F).
12. A dialog box will appear confirming that you want to finalize all edits to the
program. Click on Yes.
13. After finalizing the edits, you will notice that the iiiii and ddddd indicators
have disappeared and the new logic is now live.

CHAPTER FIVE
Basics HMI

Basics of HMI
• A very common HMI that you all encounter on a regular basis would be
an ATM machine.
• The screen and pushbuttons allow you to operate the machine to
dispense a certain amount of money, or to deposit money.
• An HMI isn’t a particular piece of hardware but rather a screen that allows a user
to interact with a device. HMIs can also be called Operator Terminals, Local

Basics of HMI
• Operator Interface, Graphical User Interface, etc. If some of these names
(OT, LOI, and GUI) sound familiar to you, it’s because you’ve already
used some of them.
• Simply put, HMIs are used for visualization of particular data, for easier
understanding and control.
• The prime modern example of an HMI is a tablet. A tablet is a GUI that
allows you to control various processes.
• If you’re connected to your TV via Bluetooth, you can use your HMI
(tablet or a smartphone) to control it.
• HMIs come in a variety of shapes and sizes – computer monitors and
machines with built-in screens.
• Let’s talk about industrial HMIs now. It would be hard to have a good
automated process in industry without an HMI.

Basics of HMI
• Many times an HMI will be in the form of a screen, kind of like a
computer screen, and more times than not, they are touch screen.
• An operator or maintenance personnel can operate and monitor the
machine from the HMI.
• They may include information like temperature, pressure, process steps,
and material counts. They can also show very precise levels in tanks and
exact positioning of machines.
• Where machine information used to be viewed on multiple indicators can
now be viewed on one screen. The possibilities are only limited to the
software and hardware used.
• For maintenance personnel, many HMIs can also connect to PLC logic
and display it on the screen for troubleshooting purposes. This can save
valuable time compared to connecting a computer or laptop every time.

Basics of HMI
• Another benefit of having a modern HMI is the fact that plants and other
industrial sites can monitor and control multiple machines or other
equipment. A small manufacturing facility could even monitor the entire
plant on one centrally located HMI.
• Water and wastewater facilities have utilized this for years by coupling an
HMI with a PLC. They are able to monitor remote locations, like water
pumps, as well as equipment inside the plant.
• You probably get the idea now that an HMI is the operating panel and
monitoring screen. But how does the HMI actually connect to the
machine to be able to control and monitor it? Let’s take a look.

Basics of HMI
• First, HMIs use special software
so engineers can program them
correctly. Different brands of panels
use different software accordingly.
• The software allows the engineer to
design what the operator will
actually see on the screen, what
they can monitor on the screen, what “buttons” can be pushed, and how
the operator can manipulate the machine.
• For example, an HMI may have a
large tank displayed on the screen
• with the level of a liquid displayed.
• Next to the tank is a pump to lower
• the liquid level.
• An HMI can also have the start and
stop button displayed and usable on the screen next to the pump.
Basics of HMI
• This display would be able to actually turn the pump on and off.
• But, it is not as easy as just placing a button on the screen or a tank with
a level on the screen.
• The person doing the HMI programming has to program each indicator
and button to a specific input or output address of a PLC.
• This brings up another point, the HMI
and PLC need to be compatible.
• This means they need to be able to
“talk” to each other. They do this on
what is called a Protocol. Different
companies use different protocols.
• Common protocols are Modbus,
Ethernet/IP, and Profibus. These are all just industrial networks, kind of
like the network you may have in your home with multiple computers, tv’s
or other devices connected to each other.
Basics of HMI
• Once the PLC and the HMI are “talking” then whatever is programmed
into the HMI can be used to monitor and control PLC functions.
• Engineers can program an HMI to perform almost any function that can
be controlled or information that can be monitored by a PLC.
• HMIs and PLCs work together to monitor and control the machine. This
means they have to be compatible and they also have to speak the same
language so to speak.
• This comes in the form of a Protocol which is just an industrial network
as we earlier discussed.
Developing Trends in HMI Technology
• In the past decade, changing operational and business needs have
instigated interesting developments in HMI technology.
• Now, it’s becoming more common to see evolved forms of HMI such as
high-performance HMIs, touch screens, and mobile devices, along with
more traditional models.
Basics of HMI
• These modernized interfaces are creating more opportunities for
equipment interaction and analysis.
High-Performance HMIs
• Operators and users are increasingly moving toward high-performance
HMI, a method of HMI design that helps ensure fast, effective interaction.
• By only drawing attention to the most necessary or critical indicators on
the interface, this design technique helps the viewer to see and respond
to problems more efficiently, as well as make better-informed decisions.
• Indicators on high-performance HMI are simple, clean, and purposely
cleared of any extraneous graphics or controls.
• Other design elements, like color, size, and placement, are used with
discretion to optimize the user experience. Learn more about designing
high-performance HMIs here.

Basics of HMI
Touch Screens and Mobile Devices
• Touch screens and mobile HMI are two examples of technological
advances that have emerged with the advent of smartphones.
• Instead of buttons and switches, modernized HMIs allow operators to tap
or touch the physical screen to access controls.
• Touch screens are especially important when used with mobile HMI,
which is either deployed through web-based HMI/SCADA or via an
application.
• Mobile HMI offers a variety of advantages to operators, including instant
access to HMI information and remote monitoring.
Remote Monitoring
• Mobile-friendly remote monitoring allows greater flexibility and
accessibility for operators and managers alike.
• With this feature, an offsite control system engineer can, for example,
confirm the temperature of a warehouse on a portable device, eliminating
Basics of HMI
• The need for onsite supervision after working hours. Soon, checking in
on a process on your factory floor while being miles away from the facility
won’t seem like anything out of the ordinary.
Edge-of-Network and Cloud HMIs
• Edge-of-network HMIs are also in high demand because they allow
operators to access data and visualization from field devices.
• Additionally, it is becoming more common to send data from local HMIs
to the cloud, where it can be accessed and analyzed remotely, while
keeping control capabilities local.
Peering into the Future of HMI
• On the horizon, leading engineers are even exploring ways to implement
Augmented Reality (AR) and Virtual Reality (VR) to visualize
manufacturing functions.
• As data takes on an increasingly essential role in manufacturing, the
future looks very bright for HMI. This technology may have come a long
way, but its potential for growth remains virtually limitless.
Basics of HMI
Bonus
What is the Difference Between HMI and SCADA?
• Supervisory Control and Data Acquisition (SCADA) and HMI are closely
related, and often referred to in the same context since they are both part
of a larger industrial control system, but they each offer different
functionality and opportunities.
• While HMIs are focused on visually conveying information to help the

user supervise an industrial process, SCADA systems have a greater
capacity for data collection and control-system operation.
• Unlike SCADA systems, HMIs do not collect and record information or

connect to databases.
• Rather, HMI provides an effective communication tool that functions as

part of, or alongside, a SCADA system

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• The tile "PC" for programmable controller could be confused in common

• Systems and processes requiring "on/off" control abound in modern

• In the late 1960's an American company named Bedford Associates released

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• In an effort to make PLC easy to program, their programming language was

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• Almost any production line, machine function, or process can be greatly

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as logic, sequencing, timing, counting & arithmetic to control, through

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• 1973 : Introduction of "smart" PLCs for arithmetic operations, printer

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• 1979 : Integration of plant operation through a PLC communication

• 1983 : "Third party" peripherals, including graphic CRTs, operator’s

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• II. Medium PLC or Mini: It is PLC which has CPU module, I / O or

Classified According to its Output Working:

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• This feature greatly increases your

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When a module slides into the rack,

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• Supplies DC power to other modules

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• Is the “brain” of the PLC.

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• Forms the interface by which input

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• Forms the interface by which output

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PLC Function Flowchart

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1. User pushes the cycle mode button (input detected)

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8. CPU waits until proper water temperature is reached

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16. Drain valve closes (output activated/deactivated)

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Relay Logic Control - Symbols, Working and Examples

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