PLC Programming from Beginner to Paid Professional Part 1

 

Learn RSLogix Software & Hardware with Demo Videos

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This short book is part 1 of a 4-part series, which serve as an exhaustive collection of my step-by-step tutorials and demos on PLC programming for beginners and advanced learners alike. You will find this book very helpful if you are an electrician, an instrumentation technician, an automation professional or engineer looking to improve your PLC programming knowledge.

This part 1 has 7 chapters and is accompanied with 53 in-depth HD demo videos. These videos simplify everything you need to understand, and help you speed up your learning of Allen-Bradley’s RSLogix software and hardware. There is also a link in this book for you to download my PLC programs (codes) for your revision.

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Copyright © AB Prominent Publisher

ISBN: 9787177241399

Published in the United States

PLC is a trademark of the Allen-Bradley Company. The following are trademarks of Rockwell Automation Inc.: Allen-Bradley®, MicroLogix™, PanelView™, RSLinx®, RSLogix™, RSLogix™ 500, RSLogix™ 5000, Studio™ 5000, SLC™ 500.

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

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

Table of Contents

About the Author

How this Book can Help You

How to Use the Demo Videos & PLC Programs

1. Software Foundation: Getting Started with PLC Programming

1.1. How to Download Free RSLogix Micro Starter Lite Package from Rockwell Automation

1.2. How to Launch RSLogix 500 for Creating PLC Programs

1.2.1. How to Install & Configure Your RSLogix Micro Starter Lite Platform

1.2.2 How to Configure RSLinx

1.3. Getting Started with RSLogix500 on an Actual MicroLogix 1100 PLC

2. Hardware Foundation: ControlLogix, CompactLogix, MicroLogix & Other Control Systems Hardware

2.1. Introduction to PLC Hardware

2.2. ControlLogix - Chassis & Power Supply Overview

2.3. ControlLogix - PLC 1756-L61 Overview

2.4. ControlLogix - 1756-EN2T EtherNet_IP Adapter Overview

2.5. ControlLogix - Input & Output Modules - Analog, Digital, AC & DC Overview

2.6. ControlLogix - Chassis Assembly & Power ON - Analog, Digital, AC & DC Overview

2.7. CompactLogix - Platform Overview - Analog, Digital, AC & DC Overview

3. Software Development in RSLogix 5000 & Studio 5000 Ladder Logic

3.1. Introduction to Software Development

3.2. How to Download Firmware from Rockwell Compatibility Center

3.3. RSLinx Classic Setup & Drivers

3.4. RSLogix 5000 & Studio 5000 Firmware-Software Revisions

3.5. PLC Firmware Flashing, First Program Creation & Online Connection

3.6. Getting Started with the Basics: Routines in RSLogix 5000

3.7. How to Build Rungs & Understand the Principles of Ladder Logic Structures

3.8. Good Practices of Structuring Rungs: Leaving Rung & Tag Level Comments

3.9. Programming Instructions: XIC & XIO - Examine If Closed & Examine If Opened

3.10. Programming Instructions: OTE - Output Energize

3.11. Practical Challenge 1: 3 Buttons & 3 Lights Control System (Output Latch - OTL & Output Unlatch - OTU)

3.12. Programming Instruction: One Short (ONS)

3.13. Programming Instruction: One Shot Rising (OSR) & One Shot Falling (OSF)

3.14. Programming Instructions: Timer ON (TON)

3.15. Programming Instructions: Timer OFF (TOF)

3.16. Practical Challenge 2: Tank Filling Mini-Project (HMI-PLC Development, Part 1)

3.17. Practical Challenge 2: Tank Filling Mini-Project (HMI-PLC Development, Part 2)

3.18. Practical Challenge 2: Tank Filling Mini-Project (HMI-PLC Development, Part 3)

3.19. Practical Challenge 2: Tank Filling Mini-Project (HMI-PLC Development, Part 4)

3.20. Programming Instructions: Count UP (CTU)

3.21. Programming Instructions: Count Down (CTD)

3.22. Programming Instructions: Retentive Time ON (RTO)

3.23. Programming Instructions: Equals (EQU) & Not Equals (NEQ)

3.24. Programming Instructions: Greater Than (GRT) & Less Than (LES)

3.25. Programming Instructions: Limit Test (LIM)

3.26. Programming Instructions: Addition (ADD) & Subtraction (SUB)

3.27. Programming Instructions: Masked Equals (MEQ) - Part 1

3.28. Programming Instructions: Masked Equals (MEQ) - Part 2

3.29. Programming Instructions: Multiply (MUL) & Divide (DIV)

3.30. Programming Instructions: Modulo (MOD)

3.31. Programming Instructions: Compute (CPT)

3.32. Programming Instructions: Bit Shift Left (BSL) in RSLogix 500

3.33. Programming Instructions: Bit Shift Right (BSR) in RSLogix 500

4. Advanced PLC Programming Topics

4.1. PLC Programming Instructions: FOR Loop Development

4.2. PLC Forces - What you Need to Know

4.3. Implementing Add-On Instructions in Studio 5000

4.4. Input/output Buffering: Best Practices for PLC Inputs & Outputs

5. Large PLC Programming Project - PLC-HMI Street Traffic Light System

5.1. Initial Setup for Green, Yellow & Red Lights Logic - Part 1

5.2. Hand-Shaking Logic & HMI Interface Tags - Part 2

5.3. Initial HMI Screen Development & Animations - Part 3

5.4. HMI Screen Layout & Design - Part 4

5.5. HMI Control System Development - Part 5

5.6. Control System Display Development, Numeric Entries & Displays - Part 6

5.7. Adding Physical Inputs & Outputs for the System Programming Tags to Handle Local I/O - Part 7

5.8. System Fault Handling Implementation - Part 8

6. How to Download the Demo Videos, PLC Programs (Codes) & Demo Editions of RSLogix 5000 / Studio 5000 Logix Designer

7. How to Get Further Help

7.1. More Helpful Resources

About the Author

I am a Control Systems engineer, Systems Integrator and a Content Creator. I have worked with over a thousand clients across business sectors, mostly the PLC automation industry. I have written numerous books, articles, and leadership classes for higher education institutions.

I have over 15 years of experience in Control Systems Engineering. I have had the opportunity to work within world class organizations such as Kraft Heinz, Procter & Gamble, and Post Holdings.

As a Control Systems Engineer, I have worked on several PLC-based systems such as the Allen-Bradley’s RSLogix 5, 500, 5000, Studio 5000 and PACs. I have mastered other great technologies such as Cognex In-Sight Vision Systems & so much more.

Now I live and breathe PLCs (Programmable Logic Controllers). I've invested a lot of money and time into equipping myself with many of the latest PLC hardware in the world. This is because I truly believe that an investment in myself will pay dividends down the road and that the automation industry will only keep growing.

I believe in excellence and I'm highly driven by successful people. I am dedicated to seeing my clients succeed and achieve their goals. I love to create PLC programs and help manufacturing companies grow. I've successfully coached over a thousand business owners and leaders.

I'm proud to boast of extensive experience and a successful company which has been in business for over 15 years.

How this Book can Help You

This short book is part 1 of a 4-part series, which serve as an exhaustive collection of my step-by-step tutorials and demos on PLC programming for beginners and advanced learners alike. You will find this book very helpful if you are an electrician, an instrumentation technician, an automation professional or engineer looking to improve your PLC programming knowledge.

This part 1 has 7 chapters and is accompanied with 53 in-depth HD demo videos. These videos simplify everything you need to understand, and help you speed up your learning of Allen-Bradley’s RSLogix software and hardware. There is also a link in this book for you to download my PLC programs (codes) for your revision.

Since I assume you have little knowledge of PLCs and PLC programming, I prepared this book in such a way that when you read it and study the accompanying demo videos (53 episodes), you will not only have an in-depth knowledge of common Allen-Bradley’s Programmable Logic Controllers, you will also gain a lot of job experience you need to build innovations and earn higher salaries.

This book begins with the fundamental knowledge you need to start writing your very first PLC program. It goes on to teach the advanced topics of PLCs you need to become a paid professional in the field of PLC programming.

So, after studying this book and the demo videos, which are presented in the form of tutorials, you should have a clear understanding of the structure of ladder logic programming and be able to apply it to real world industrial applications.

The best way to master PLC programming is to use real world situations. The real-world scenarios and industrial applications developed in this book and its accompanying video demos will help you learn better and faster many of the functions and features of both the RSLogix 500 and RSLogix 5000 platforms.

The methods presented in the demo videos are those that are usually employed in the real world of industrial automation, and they may be all that you will ever need to learn. The information in this book and the demo videos is very valuable, not only to those who are just starting out, but also to any other skillful PLC programmer, no matter their skill level.

Merely having a PLC user manual or referring to the help contents is far from enough in becoming a skillful PLC programmer. Therefore, this book is extremely useful for building PLC programming skills. First, it will give you a big head start if you have never programmed a PLC before. Then it will teach you more advanced techniques you need to learn, design and build anything from simple to complex programs on the RSLogix 5000 (now called Studio 5000) platform.

One of the questions I get asked often by beginners is, where can I get a free download of RSLogix 500 to practice? I provide later in this book links to a free version of the RSLogix Micro Starter Lite (which is essentially the same programming environment as the RSLogix 500 Pro) and a free version of the RSLogix Emulate 500.

In Chapter 6, I also provide links to download the demo edition of RSLogix 5000 / Studio 5000 Logix Designer to your system. Make sure you create an account at RockwellAutomation.com first. So, you don’t even need to have a full-blown PLC to learn, run and test your ladder logic programs.

I do not only show you how to get these important Rockwell Automation software for free and without hassle, I also show with HD videos how to install, configure, navigate and use them to write ladder logic programs.

However, if you are a complete novice to PLCs or PLC programming, here’s the link to my book you will find very helpful to get started: PLC Programming Using RSLogix 500 & Real World Applications: Learn Ladder Logic Concepts Step by Step with Real Industrial Applications.

Finally, if you have questions or need further help, use the support link I provided in Chapter 7. I will get back to you very quickly.

How to Use the Demo Videos & PLC Programs

You will find the link to download all the 53 demo videos and program codes in Chapter 6 of this book. The serial number and title of the video you should watch is mentioned in the appropriate section of each chapter.

For effective learning and to get good practice, I strongly advise you attempt the challenges and project in this book on your own. Build your own program after you have watched me build mine in each video. Then later you can cross check your programs with mine. Also feel free to use or modify any of the PLC programs you downloaded as you wish.

1. Software Foundation: Getting Started with PLC Programming

In this chapter, you will learn how you can download for free the necessary tools you need to start a PLC programming on your machine without the requirements of expensive hardware. The tools I am talking about are RSLogix Micro Starter Lite (the free version of RSLogix 500), RSLogix 500 Emulate and RSLinx Classic Lite.

That is pretty much the entire kit you might need in order to program within your own machine and get started with some of the instructions I will been teaching in my videos. If you have not already done so, go to Chapter 6 right now to get the download link and download the tutorial videos.

1.1. How to Download Free RSLogix Micro Starter Lite Package from Rockwell Automation

Here’s the link to begin downloading your package: https://compatibility.rockwellautomation.com/.

Now that you have downloaded all your videos, watch the following video:

Video 1: How to download RSLogix package

On the Rockwell Automation site, I recommend going to the “Managed Download” route because it is secure. It verifies the file integrity. However, you can use the “Direct Download” if you like, especially if the Rockwell servers are having a hard time.

1.2. How to Launch RSLogix 500 for Creating PLC Programs

After downloading those three tools mentioned in section 1.1, the next process is of course, to install them. This is very simple to do. All you have to do is double-click the shortcuts and pretty much follow the installation instructions. The RSLogix Micro Starter Lite (the free version of RSLogix 500) is the primary tool you will create your ladder logics in.

You will find MicroLogix 1000 and 1100 in the RSLogix Micro Starter Lite package that Allen-Bradley offers you as a free download. This RSLogix Micro Starter Lite has essentially the same programming environment as RSLogix 500. So, it is ok if you are unable to buy RSLogix 500.

In addition, Allen-Bradley also offers RSLogix Emulate 500 for free so that you don’t even need a PLC to run and test your ladder logic diagrams. RSLogix Emulate 500 can be used to simulate a real PLC.

Now I will give you a hassle-free way to download the two packages for free, and also show you how to set them up. Below are the direct download links.

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