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FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

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Page 1: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.1 Process and controller.

Curtis JohnsonProcess Control Instrumentation Technology, 8e]

Copyright ©2006 by Pearson Education, Inc.Upper Saddle River, New Jersey 07458

All rights reserved.

Page 2: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.2 Refrigerator/freezer system inputs and outputs.

Curtis JohnsonProcess Control Instrumentation Technology, 8e]

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Page 3: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.3 Continuous control of level.

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Page 4: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.4 Discrete control of level.

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Page 5: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.5 Composite continuous and discrete control.

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Page 6: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.6 Objectives and subobjectives of a process.

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Page 7: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.7 A discrete-control process.

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Page 8: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.8 Completion of the initialization phase of the process shown in FIGURE 8.7.

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Page 9: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.9 Basic flowchart symbols.

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Page 10: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.10 Part of the initialization flowchart for FIGURE 8.7.

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Page 11: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.11 Tank process for Example 8.4.

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Page 12: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.12 Oven system for discrete control.

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Page 13: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.13 Use of a relay and switch to start a motor.

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Page 14: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.14 Use of momentary push-button switches and a relay to implement a latch.

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Page 15: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.15 Symbols of input devices used in ladder diagrams.

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Page 16: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.16 Symbols of output devices used in ladder diagrams.

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Page 17: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.17 Symbols for switches used in ladder diagrams.

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Page 18: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.18 Ladder diagram to control two lights.

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Page 19: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.19 Elevator system for Example 8.6.

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Page 20: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.20 Initialization to move platform down when the START button is pushed for Example 8.6.

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Page 21: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.21 Ladder diagram for the STOP sequence of Example 8.6.

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Page 22: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.22 The complete ladder diagram for Example 8.6.

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Page 23: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.23 A simplified ladder diagram for Example 8.6.

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Page 24: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.24 Solution for Example 8.7.

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Page 25: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.25 Basic structure of the programmable logic controller (PLC).

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Page 26: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.26 Typical wiring to a PLC input module.

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Page 27: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.27 Typical wiring to a PLC output module.

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Page 28: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.28 PLC scan time puts restrictions on the speed of events.

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Page 29: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.28 (continued) PLC scan time puts restrictions on the speed of events.

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Page 30: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.29 Hand-held PLC programming unit.

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Page 31: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.30 Desktop terminal PLC programming unit.

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Page 32: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.31 Using an NC switch to turn on a light with relay logic and with PLC programming: (a) Wrong, the button turns the light OFF; (b) with relay logic, the button turns the light ON; and (c) with a PLC program, the button turns the light ON.

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Page 33: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.32 Physical connections to the PLC (a) and the programmed ladder diagram (b) for a motor start/stop system.

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Page 34: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.32 (continued) Physical connections to the PLC (a) and the programmed ladder diagram (b) for a motor start/stop system.

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Page 35: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.33 Physical elements for Example 8.9.

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Page 36: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.34 Wiring and program solution for Example 8.9.

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Page 37: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.35 The basic PLC counter.

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Page 38: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.36 Program and timing solution to Example 8.10.

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Page 39: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.37 PLC timer functions: (a) simple timer, (b) accumulating timer.

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Page 40: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.38 Solution to Example 8.11.

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Page 41: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.39 Chemical system for Example 8.12.

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Page 42: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.40 PLC program solution for Example 8.12.

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Page 43: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.41 Tank system for Example 8.13.

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Page 44: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.42 Physical ladder diagram for Example 8.13.

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Page 45: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.43 Programmed ladder diagram for Example 8.13.

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Page 46: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.44 System for use in Problems 8.8 and 8.14.

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Page 47: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.45 Process for Problems 8.11 and 8.16.

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Page 48: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.46 Motor and switches for Problem 8.15.

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Page 49: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.47 System for Problems S8.1, S8.2, and S8.3.

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Page 50: FIGURE 8.1 Process and controller. Curtis Johnson Process Control Instrumentation Technology, 8e] Copyright ©2006 by Pearson Education, Inc. Upper Saddle

FIGURE 8.48 Hydroponic system for Problem S8.4.

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