PROGRAMMABLE

LOGIC CONTROLLERS
FIFTH EDITION

Hardware and Programming

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Max Rabiee, PhD, PE/EE
Electrical Engineering Professor
Electrical and Computer Engineering Technology Program Chair
Electrical Engineering and Computing Systems (EECS) Department
University of Cincinnati
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Publisher
The Goodheart-Willcox Company, Inc.
Tinley Park, IL
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Previous editions copyright 2018, 2013, 2009, 2002

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Foreword
Programmable Logic Controllers: Hardware and Programming is an intro-
ductory text that explores many aspects of PLCs in an easy-to-understand manner.
The key concepts of PLCs are discussed using a comprehensive approach to enhance
learning. The text organization begins with basic concepts and progresses to system
level applications. Applications, testing procedures, and operational aspects of PLC
equipment and systems are discussed. This textbook emphasizes the PLC’s practical
use in industry.
The programmable logic controller was first introduced in the automotive indus-
try in the late sixties. Today, PLCs are found throughout all manufacturing indus-
tries and are increasingly found in commercial building automation systems. Knowl-

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edge of selecting, wiring, and programming PLCs is required in many career fields,
including industrial controls, automation engineering, and industrial maintenance.
This textbook describes the most common programmable logic controller func-
tions and provides examples using the Allen-Bradley Small Logic Controller (SLC
500) series. There are a few software simulators for the SLC 500 for your choosing.
A quick web search can yield results from a variety of suppliers and prices. The
last chapter of the text discusses the next generation RSLogix 5000 software. PLC
theory and PLC selection for various applications are explained. PLC wiring and
programming are also covered with numerous examples.

About the Author

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Max Rabiee earned his PhD in electrical engineering from the University of Kentucky.
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He has taught electrical engineering (EE) and electrical/computer engineering
technology (ECET) courses for over 30 years. Dr. Rabiee is a registered profes-
sional engineer (since 1988) who worked as a control engineer for several years. He
was a senior electrical engineer for over four years in charge of medium and large
industrial control projects.
Dr. Rabiee is a member of the American Society of Engineering Education (ASEE);
the Institute of Electrical and Electronics Engineers (IEEE); the Association of Tech-
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nology, Management, and Applied Engineering (ATMAE); the Eta Kappa Nu

Electrical Engineering Honor Society; and the Tau Beta Pi Engineering Honor Society.
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 Reviewers
The author and publisher wish to thank the following industry and teaching pro-
fessionals for their valuable input into the development of Programmable Logic
Controllers:
Jim Black Martin E. Keane, PE
Ozarks Technical Community College United States Gypsum
Springfield, Missouri Chicago, Illinois
Andrea Blaylock Tom Lockett
Triton College Vatterott College
River Grove, Illinois Quincy, Illinois

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Keith Casey Gholam H. Massiha
Wilkes Community College University of Louisiana at Lafayette
Wilkesboro, North Carolina Lafayette, Louisiana
Robert DeBrecht Melvin L. Roberts
Ozarks Technical Community College Camden County College
Springfield, Missouri Blackwood, New Jersey
Keith Dinwiddie Robert Schwien
Triton College Moraine Valley Community College
River Grove, Illinois
P Palos Hills, Illinois
Wes Gubitz Landon Vinson
Cape Fear Community College Ozarks Technical Community College
Wilmington, North Carolina Springfield, Missouri
David Hartle Jim Wilks
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SUNY Canton Mohawk College
Canton, New York Hamilton, Ontario, Canada
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Acknowledgments
The author and publisher would like to thank the following companies, organiza-
tions, and individuals for their contribution of resource material, images, or other
support in the development of Programmable Logic Controllers.
Energy Concepts, Inc.
Logic Design, Inc., developers of PLCLogix simulator software
Rockwell Automation, Inc.
Siemens

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In addition, the author and publisher wish to thank Bill Simpson of The Learn-
ing Pit, developer of the LogixPro 500 PLC Simulator Software. Many illustrations
and examples found throughout this textbook were created using this software. To
learn more about this software, visit www.thelearningpit.com.

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TOOLS FOR STUDENT AND INSTRUCTOR SUCCESS
Student Tools
Student Text
Programmable Logic Controllers provides a comprehensive
introduction to PLCs and their applications in process and industrial
control systems. Based on the Allen-Bradley RSLogix programming
software, this text begins with basic hardware and programming
concepts before processing to system-level applications. PLC
maintenance, testing, and troubleshooting are also covered. Clear
illustrations and examples are provided in the text to help explain system
functions and complex concepts.

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Lab Manual
The student Lab Manual provides hands-on practice to be completed
in the school lab setting under the guidance of an instructor or trainer.
Aligned with the textbook, the Lab Manual enables students to
demonstrate and apply their learning in a very practical and thoroughly
engaging manner.

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G-W Common Cartridge provides a complete
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When you incorporate G-W content into your courses via Common Cartridge, you have the flexibility to customize and
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Online Instructor Resources
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than ever. Available in one accessible location, the OIR
includes Instructor Resources, Instructor’s Presentations
for PowerPoint®, and Assessment Software with Question
Banks. The OIR is available as a subscription and can be
accessed at school, at home, or on the go.

Instructor Resources One resource provides

instructors with timesaving preparation tools such
as answer keys, editable lesson plans, and other

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teaching aids.

Instructor’s Presentations for

PowerPoint® These fully customizable, richly
illustrated slides help you teach and visually reinforce the
key concepts from each chapter.

ExamView® Assessment Suite Administer and manage assessments to meet your classroom needs. The
ExamView® Assessment Suite allows you to quickly and easily create, administer, and score paper and online tests.
Included in the assessment suite are the ExamView® Test Generator, ExamView® Test Manager, and ExamView®
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creating, managing, administering, and grading tests. You can have the software generate a test for you with randomly
selected questions. You may also choose specific questions from the question banks and, if you wish, add your own
questions to create customized tests to meet your classroom needs.
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G-W Integrated Learning Solution
INSTRUCTIONAL • Knowledge and skills
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• Pedagogically sound

REINFORCEMENT
AND PRACTICE The G-W Integrated Learning Solution
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offers easy-to-use resources that
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assets
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• Projects
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Features of the Textbook
The instructional design of this textbook includes student-focused learning tools to help you succeed. This
visual guide highlights these features.

Chapter Opening Materials

Each chapter opener contains a chapter outline,
a list of learning objectives, and a list of technical
terms. The Chapter Outline summarizes the
topics that will be covered in the chapter.
Learning Objectives clearly identify the knowl-
edge and skills to be gained when the chapter is
completed. Technical Terms list the key words
to be learned in the chapter. Introduction

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provides an overview and preview of the chapter
content. Examples describe real-world PLC pro-
gramming scenarios and solutions.

Illustrations
Illustrations have been designed to clearly and
simply communicate the specific topic. Illustra-
tions have been completely replaced and updated
for this edition. Photographic images have been
updated to show the latest equipment.

End-of-Chapter Content
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End-of-chapter material provides an oppor-
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tunity for review and application of concepts.
A concise Summary provides an additional
review tool and reinforces key learning objec-
tives. This helps you focus on important con-
cepts presented in the text. Know and Under-
stand questions enable you to demonstrate
knowledge, identification, and comprehension
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of chapter material. Apply and Analyze ques-

tions extend learning and develop your abilities
to use learned material in new situations and to
break down material into its component parts.
Critical Thinking questions develop higher-
order thinking and problem solving, personal,
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and workplace skills. Lab Activities at the end

of select chapters provide additional PLC pro-
gramming exercises.

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New to This Edition
The fifth edition of Programmable Logic Controllers includes several updates to reflect the Allen-Bradley
Programmable Logic Controller (PLC) and Programmable Automation Controller (PAC) instructions and
functions. In addition, updated figures and material have been added to the lab manual.
The following details some of the new additions for this fifth edition:
• Updated ladder logic diagrams (LLDs) for the • Updated bit shift instructions and information
Allen-Bradley Controllers in the new textbook on same bit-wise logic available in the new Allen-
and lab manual. Bradley’s Programmable Automation Controllers.
• Added new material for PLC math instructions, • Added new end-of-chapter sections: Know and
including for Programmable Automation Understand, Apply and Analyze, and Critical
Controllers (PACs) in chapters 10 and 16. Thinking to provide more opportunities for
• Added new material on limit test (LIM) and student assessment and comprehension.
masked equal (MEQ) instruction in chapter in
chapter 11.

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 Brief Contents
1 Programmable Logic Controller (PLC) Overview . . . . . . . . . . . 2
2 PLC Selection, Components, and Communication. . . . . . . . . . 20
3 Number Systems and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4 Input/Output Devices and Motor Controls. . . . . . . . . . . . . . . . 60
5 Creating Relay Logic Diagrams. . . . . . . . . . . . . . . . . . . . . . . . 82

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6 PLC Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7 Programming Logic Gate Functions in PLCs. . . . . . . . . . . . 136
8 PLC Timer Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
9 PLC Counter Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
10 PLC Math Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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11 PLC Compare, Jump, and MCR Instructions . . . . . . . . . . . . 236
12 PLC Subroutine Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . 256
13 PLC Logic and Bit Shift Instructions. . . . . . . . . . . . . . . . . . . 272
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14 Data Handling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . 292
15 Sequencer Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
16 Troubleshooting and Servicing the PLC System. . . . . . . . . . 338
17 PLC Networks in Manufacturing. . . . . . . . . . . . . . . . . . . . . . 354
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18 PLC Programming with RSLogix 5000 Software. . . . . . . . . 384

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Contents
CHAP TER 1
Programmable Logic Controller (PLC) Overview. . . . . . . . . . . . . . 2
1.1 PLC History and Development............................................................ 4
1.2 PLC Block Diagram............................................................................. 5
1.3 Central Processing Unit....................................................................... 6
1.4 Memory Devices................................................................................... 7
1.5 Address Decoder Circuit.................................................................... 10

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1.6 Peripheral Chips................................................................................. 10
1.7 Discrete Input Modules...................................................................... 10
1.8 Discrete Output Modules................................................................... 11
1.9 Analog Input/Output Modules........................................................... 12
1.10 PLC Power Supply.............................................................................. 12
1.11 Allen-Bradley Programmable Controllers......................................... 12
1.12 Allen-Bradley Programmable Logic Controllers............................... 13
1.13 Commonly Used Industrial Controllers............................................ 14
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1.14 Communication with Intelligent Industrial Controllers.................. 16

CHAP TER 2
PLC Selection, Components, and Communication. . . . . . . . . . . . 20
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2.1 PLC Selection..................................................................................... 22
2.2 Allen-Bradley SLC 500 Components................................................. 22
2.3 PLC Memory Expansion and Usage.................................................. 29
2.4 PLC Communication Systems........................................................... 30
2.5 Programming Modules...................................................................... 32
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2.6 Introduction to the LogixPro Simulator Software............................ 34

2.7 The Allen-Bradley ControlLogix Family of Controllers................... 34
2.8 Comparison of RSLogix 5000 and RSLogix 500............................... 36
2.9 The Industrial Control Design Process............................................. 37
2.10 Use of HMI in Industrial Control Systems....................................... 39
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CHAP TER 3
Number Systems and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.1 Decimal Number System................................................................... 46
3.2 Binary Number System..................................................................... 47
3.3 Binary-to-Decimal Conversion.......................................................... 47
3.4 Decimal-to-Binary Conversion.......................................................... 48
3.5 Binary Addition.................................................................................. 49
3.6 Binary Subtraction............................................................................. 50
3.7 Binary Multiplication......................................................................... 51

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 3.8 Binary Division.................................................................................. 52
3.9 Hexadecimal Number System........................................................... 52
3.10 Octal Number System........................................................................ 53
3.11 Binary Coded Decimal System.......................................................... 53
3.12 Gray Code........................................................................................... 54
3.13 Alphanumeric Code............................................................................ 55

CHAP TER 4
Input/Output Devices and Motor Controls . . . . . . . . . . . . . . . . . 60
4.1 Pushbuttons and Switches................................................................. 62

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4.2 Sensors................................................................................................ 65
4.3 Indicators............................................................................................ 74
4.4 Relays, Contactors, and Solenoids..................................................... 74
4.5 Motor Control Devices........................................................................ 77

CHAP TER 5
Creating Relay Logic Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.1 Relay Logic Diagrams........................................................................ 83
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5.2 Rules for Drawing Relay Logic Diagrams......................................... 84
5.3 Creating Relay Logic Diagrams for Industrial Control Circuits..... 88

CHAP TER 6
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PLC Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.1 Creating PLC Ladder Logic Diagrams from Relay Logic Diagrams..... 96
6.2 Programming Ladder Logic Diagrams with Normally Open
and Normally Closed Switches.......................................................... 98
6.3 Programming Ladder Logic Diagrams with Normally Open
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and Normally Closed Contacts........................................................ 100

6.4 PLC Program Scan Time................................................................. 103
6.5 PLC Program and Data Files.......................................................... 104
6.6 Programming Ladder Logic Diagrams with Latch
and Unlatch Instructions................................................................. 106
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6.7 Loading and Troubleshooting PLC Ladder Diagrams

in Run Mode..................................................................................... 107
6.8 Using the PLC Force Instruction for Troubleshooting................... 110
6.9 Creating and Printing PLC Program Reports............................... 112
6.10 Using Utility Instructions to Save and Retrieve PLC Programs....... 116
6.11 Using the LogixPro Simulator to Create Ladder Logic Diagrams...... 118

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CHAP TER 7
Programming Logic Gate Functions in PLCs . . . . . . . . . . . . . . . 136
7.1 Combinational and Sequential Logic Gate Circuits....................... 138
7.2 Boolean Expressions, Truth Tables, and Logic Gate Circuits....... 139
7.3 NOT Gates (Inverters)..................................................................... 139
7.4 AND Gates........................................................................................ 140
7.5 OR Gates........................................................................................... 141
7.6 NAND Gates..................................................................................... 142
7.7 NOR Gates........................................................................................ 144
7.8 XOR Gates........................................................................................ 145

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7.9 XNOR Gates..................................................................................... 146
7.10 Simplifying Boolean Expressions.................................................... 149
7.11 Creating PLC Ladder Logic Diagrams
from Logic Gate Circuits.................................................................. 155
7.12 Creating PLC Ladder Logic Diagrams from Boolean Expressions...... 159
7.13 Creating Logic Gate Circuits from PLC Ladder Logic Diagrams........ 161
7.14 LogixPro Simulator Examples......................................................... 163

CHAP TER 8 P
PLC Timer Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.1 Timer Instructions........................................................................... 176
8.2 PLC Timer Instruction Registers.................................................... 178
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8.3 Fixed Preset Value Non-Retentive ON-Delay Timer Instructions..... 179
8.4 Variable Preset Value Non-Retentive ON-Delay
Timer Instructions........................................................................... 181
8.5 Retentive ON-Delay Timer Instructions......................................... 183
8.6 OFF-Delay Timer Instructions........................................................ 185
8.7 Interlocking Timers.......................................................................... 186
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8.8 Cascading Timers to Increase the Timing Value........................... 187

8.9 LogixPro Simulator Examples......................................................... 188

CHAP TER 9
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PLC Counter Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

9.1 PLC Counter Instructions............................................................... 199
9.2 PLC Counter Instruction Registers................................................ 199
9.3 PLC Count Up Instructions............................................................. 200
9.4 PLC Count Down Instructions........................................................ 202
9.5 Connecting PLC Counter Instructions............................................ 203
9.6 Cascading Counters......................................................................... 205
9.7 Creating PLC Ladder Logic Diagrams with Counters
and Timers........................................................................................ 206
9.8 LogixPro Simulator Examples......................................................... 206

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 CHAP TER 10
PLC Math Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
10.1 Addition............................................................................................. 219
10.2 Subtraction....................................................................................... 221
10.3 Multiplication.................................................................................... 223
10.4 Division............................................................................................. 225
10.5 Advanced Math Instructions........................................................... 227
10.6 LogixPro Simulator Examples......................................................... 229

CHAP TER 11

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PLC Compare, Jump, and MCR Instructions . . . . . . . . . . . . . . . 236
11.1 Compare Instructions...................................................................... 238
11.2 Unconditional Jump......................................................................... 242
11.3 Conditional Jump............................................................................. 242
11.4 Master Control Reset (MCR)........................................................... 244
11.5 LogixPro Simulator Examples......................................................... 244

CHAP TER P 12
PLC Subroutine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
12.1 Subroutine Concept.......................................................................... 258
12.2 Jump to Subroutine.......................................................................... 259
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12.3 Return from Subroutine................................................................... 260
12.4 Subroutine Applications................................................................... 261
12.5 Interrupt Routines........................................................................... 264
12.6 LogixPro Simulator Example.......................................................... 264

CHAP TER 13
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PLC Logic and Bit Shift Instructions . . . . . . . . . . . . . . . . . . . . . 272

13.1 Logic Gate Instructions................................................................... 274
13.2 Shift Left Instruction....................................................................... 277
13.3 Shift Right Instruction..................................................................... 280
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13.4 LogixPro Simulator Examples......................................................... 282

CHAP TER 14
Data Handling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
14.1 Move, Indexed Move, and Masked Move......................................... 294
14.2 First-In-First-Out (FIFO) and Last-In-First-Out (LIFO).............. 295
14.3 Copy File and Fill File Instructions................................................ 298
14.4 Data/Unit Conversion...................................................................... 300
14.5 LogixPro Simulator Examples......................................................... 301

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CHAP TER 15
Sequencer Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
15.1 Sequencer Concept........................................................................... 314
15.2 Sequencer Output Instruction......................................................... 316
15.3 Sequencer Compare Instruction...................................................... 321
15.4 Sequencer Load Instruction............................................................. 323
15.5 Cascading Sequencers...................................................................... 324
15.6 Parallel Sequencers.......................................................................... 325
15.7 LogixPro Simulator Examples......................................................... 326

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CHAP TER 16
Troubleshooting and Servicing the PLC System . . . . . . . . . . . . 338
16.1 Routine Maintenance....................................................................... 339
16.2 Hardware.......................................................................................... 340
16.3 Software Error Detection................................................................. 342
16.4 LogixPro Simulator Examples......................................................... 344

CHAP TER 17 P
PLC Networks in Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . 354
17.1 Transmission Media......................................................................... 356
17.2 Network Topologies.......................................................................... 361
17.3 Network Access Control................................................................... 362
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17.4 PLC Networks.................................................................................. 363
17.5 DH-485 Network Software Configurations..................................... 370
17.6 SVC and MSG Instructions............................................................. 374

CHAP TER 18
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PLC Programming with RSLogix 5000 Software. . . . . . . . . . . . 384

18.1 Project Organization Area............................................................... 386
18.2 Ultraviolet Water Purification Process Example............................ 386
18.3 Planning the CompactLogix Input/Output Modules...................... 392
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18.4 Creating the RSLogix 5000 Project................................................. 393

18.5 Overall System Appearance and Functions................................... 411
18.6 Comparing the RSLogix 5000 and RSLogix 500 Software............ 412
18.7 PLCLogix Simulator Examples....................................................... 415

Appendix A: Electromechanical Devices........................................................423

Appendix B: Conversion Tables.....................................................................431
Appendix C: Natural Trigonometric Functions and Binary Systems................437
Appendix D: SLC 500 Reference....................................................................441
Glossary........................................................................................................443
Index.............................................................................................................456
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