Advanced PLC Hardware and Programming

A comprehensive treatment on the topic of PLC (Programmable Logic Controller) hardware and software. It concentrates primarily on the Allen-Bradley and Siemens PLC platforms, but includes examples from many other brands.

The first section covers PLCs from a generic perspective, discussing features that are common to all platforms along with their differences. This section also has a history of computers and computing devices along with the evolution of the PLC. The book explains many of the mathematical and data concepts that are necessary for programming PLCs, and describes the five IEC61131 PLC languages with examples of each. It explains the ladder logic programming instructions common to PLC platforms and includes 12 exercises, complete with answers in the back of the book.

The second section covers advanced PLC topics including planning and organizing PLC code. It discusses common subroutine types including System, Input and Output routines, Auto Sequences, Faults and Alarms. Examples of PLC code are included from several platforms. An overview of training hardware is included along with a lab exercise to write a complete hardware-based program for a training model. A full program solution is included in the back of the book.

The third section covers the Allen-Bradley PLC brand, including the SLC/Micrologix RSLogix500 platform and the CompactLogix/ControlLogix RSLogix5000 platform. It also covers the Siemens PLC brand, including the S7-300/S7-400 Step 7 platform, and the Siemens S7-1200/S7-1500 TIA Portal platform. Hardware model descriptions, instruction sets, and examples of creating and programming the four types of PLC are included, with information on platform specific languages including Siemens STL.

Frank Lamb is an industrial automation consultant and advanced PLC programming trainer with more than 30 years of experience in controls and machine automation. From 1996 to 2006, Frank owned and operated Automation Consulting Services, Inc. (ACS), a panel building and machine integration company in Knoxville, TN. From 2006 to 2011, he worked as a senior-level project engineer for Wright Industries in Nashville, TN, where he led the design and implementation of large, complex systems and custom machines for multinational corporations and government agencies. In December 2011, Frank re-established Automation Consulting, LLC with a new vision: to use his experience in the field of industrial automation - from electrical, mechanical and controls engineering to project management, training, and machine documentation - to provide expert consulting and training services to manufacturers. Frank is the president and owner of Automation Consulting, LLC in Nashville, TN. He is a United States Air Force veteran, received his BSEE in Electrical and Computer Engineering from the University of Tennessee, and has a Green Belt in Lean Manufacturing/Six Sigma from Purdue University. He is a contributing editor and on the editorial board of Control Engineering magazine, published by CFE Media.