Programmable Logic Controllers (PLC)

Course Code: TELC1403 Course Title: Programmable Logic Controllers Credit Units: 4 (1 hour lecture, 6
hours laboratory Target Audience: 3rd Year Bachelor of Technical Vocational Teacher Education (BTVTE)
students, Major in Electrical Technology

Course Description

This course offers an in-depth examination of Programmable Logic Controllers (PLCs), encompassing
their fundamental principles, hardware components, programming languages (primarily Ladder Logic),
and diverse industrial applications. Emphasizing hands-on experience, students will learn to design,
program, implement, and troubleshoot PLC-based control systems for a wide range of industrial
automation tasks. The course also integrates concepts of Human-Machine Interface (HMI) and basic
industrial networking.

Course Learning Outcomes (CLOs)

Upon successful completion of this course, students will be able to:

1. Understand the fundamental concepts, history, and applications of Programmable Logic

Controllers (PLCs) in industrial automation.

2. Identify and explain the functions of various PLC hardware components, including CPU, I/O
modules, power supplies, and communication interfaces.

3. Develop and implement PLC programs using Ladder Logic for sequential, combinational, and
timing/counting control applications.

4. Analyze and troubleshoot common hardware and software faults in PLC systems.

5. Design and integrate basic Human-Machine Interface (HMI) screens for PLC-controlled
processes.

6. Apply proper safety procedures and programming practices in the context of industrial control
systems.

7. Work effectively in teams to design and implement a comprehensive PLC-based automation

project.

Course Content: Weekly Breakdown

Week 1: Introduction to PLCs

 Lecture (1 hr): Definition of PLC, history, advantages over traditional relay logic, disadvantages,
typical applications in industry. Overview of different PLC brands.

 Laboratory (6 hrs):

o Familiarization with a typical PLC trainer kit (e.g., components, power-up sequence).

o Identifying major hardware components: CPU, I/O modules, and power supply.

o Overview of PLC programming software interface.

 Laboratory Output: A neatly labeled diagram of the PLC trainer kit components with a brief
description of each part.

Week 2: PLC Hardware & Wiring

 Lecture (1 hr): Detailed discussion on PLC hardware: CPU (processor, memory types), input
modules (digital, analog), output modules (relay, transistor, triac), power supply, communication
modules.

 Laboratory (6 hrs):
 o Safe wiring practices for PLC inputs (push buttons, switches) and outputs (indicator
lamps, small relays).

o Verification of input and output status using the PLC software.

 Laboratory Output: A functional wiring diagram showing a PLC connected to a set of digital
inputs and outputs, verified by real-time status indication.

Week 3: Introduction to Ladder Logic Programming

 Lecture (1 hr): Fundamentals of Ladder Logic: Rungs, power rails, contacts (Normally
Open/Closed - NO/NC), coils. Basic instructions: Examine ON (XIC), Examine OFF (XIO), Output
Energize (OTE).

 Laboratory (6 hrs):

o Developing simple ON/OFF control programs for a single lamp using one push button.

o Implementing a basic AND/OR logic for multiple inputs controlling one output.

 Laboratory Output: PLC program to control a lamp using multiple input conditions (e.g., AND
logic for two push buttons, OR logic for two switches).

Week 4: Timers and Counters

 Lecture (1 hr): Types of timers: Timer ON Delay (TON), Timer OFF Delay (TOF), Retentive Timer
(RTO). Types of counters: Count Up (CTU), Count Down (CTD), Up/Down Counter (CTUD).
Programming examples.

 Laboratory (6 hrs):

o Implementing a traffic light simulation using TON timers.

o Designing a system to count products on a conveyor belt using CTU.

 Laboratory Output: PLC program for a simple traffic light sequence (Red-Yellow-Green) and a
program to count 10 items before activating an output.

Week 5: Advanced Ladder Logic Instructions

 Lecture (1 hr): Comparison instructions (EQU, NEQ, GRT, LES, GEQ, LEQ). Math instructions
(ADD, SUB, MUL, DIV). Move (MOV) instruction.

 **Laboratory (6 hrs):</B>

o Developing a program that compares a process value with a setpoint to trigger an alarm.

o Creating a simple batching system that calculates the required amount and mixes
ingredients using math instructions.

 Laboratory Output: PLC program for a material mixing process that uses comparison and math
instructions to control ingredient quantities.

Week 6: Number Systems & Data Types

 Lecture (1 hr): Review of number systems (Binary, Decimal, Hexadecimal, Octal). PLC data types
(Boolean, Integer, Floating Point, BCD). Addressing conventions.

 Laboratory (6 hrs):

o Experiments involving data manipulation: converting data between different formats

within the PLC program.

o Storing and retrieving data from data registers.

  Laboratory Output: PLC program demonstrating conversion between different number systems
(e.g., converting a decimal input to its BCD equivalent for display).

Week 7: PLC Programming Practices & Documentation

 Lecture (1 hr): Importance of good programming practices: modular programming,

subroutines/functions, meaningful tagging, commenting. Program organization.

 Laboratory (6 hrs):

o Debugging pre-written PLC programs containing common errors.

o Revising existing programs to incorporate modularity and extensive documentation.

 Laboratory Output: A fully functional PLC program that controls a process (e.g., an automated
gate) with clear, well-structured logic, descriptive tags, and comprehensive comments.

Week 8: Analog I/O and Scaling

 Lecture (1 hr): Principles of analog signals (0-10V, 4-20mA). Analog input/output modules.
Scaling analog values to engineering units (e.g., temperature from voltage, flow rate from
current).

 Laboratory (6 hrs):

o Connecting an analog sensor (e.g., potentiometer, temperature sensor) to a PLC analog

input module.

o Writing a PLC program to read the analog input and scale it to display a meaningful
engineering unit.

o Controlling an analog output (e.g., a dimmer light or a small motor speed).

 Laboratory Output: PLC program to read and scale a simulated analog temperature sensor and
display the temperature on an integer output register.

Week 9: Human-Machine Interface (HMI) Basics

 Lecture (1 hr): Introduction to HMI: purpose, types, communication with PLC, HMI software
features (buttons, indicators, text displays, trends).

 Laboratory (6 hrs):

o Designing a simple HMI screen using HMI software.

o Establishing communication between the HMI and the PLC.

o Creating basic HMI elements (buttons, indicators, numeric displays) to interact with the
PLC program.

 Laboratory Output: A functional HMI screen that allows starting/stopping a motor and
displaying its status (ON/OFF) and a simulated speed value.

Week 10: Motor Control Applications with PLC

 Lecture (1 hr): Review of industrial motor control basics. Implementing Direct On-Line (DOL)
starters, reversing starters, and Star-Delta starters using PLC. Interlocking for safety.

 **Laboratory (6 hrs):</B>

o Wiring and programming a PLC for a DOL motor starter with overload protection.

o Implementing a reversing motor control with proper interlocking.

 Laboratory Output: Functional PLC program and wiring setup for a reversing motor control
system, including forward, reverse, and stop functions with interlocks.
Week 11: Sequential Control Systems

 Lecture (1 hr): Principles of sequential control. State-transition diagrams. Introduction to

sequencer instructions (SQO, SQI, SQL) or Sequential Function Chart (SFC/Grafcet).

 Laboratory (6 hrs):

o Analyzing a multi-stage sequential process (e.g., bottling plant, material handling).

o Developing a PLC program to control a sequential process using appropriate logic or

sequencer instructions.

 Laboratory Output: PLC program for a 3-stage sequential process, such as a simulated material
handling system that moves an object through three distinct stations.

Week 12: PID Control Introduction

 Lecture (1 hr): Introduction to Proportional-Integral-Derivative (PID) control. Understanding P, I,

and D terms. Basic tuning concepts.

 Laboratory (6 hrs):

o Simulating a temperature or level control system.

o Experimenting with the PLC's built-in PID instruction (if available) or implementing a
simplified PID algorithm using basic math instructions.

 Laboratory Output: PLC program for a basic simulated PID control loop, demonstrating how
setpoint changes affect the output.

Week 13: PLC Networking and Communication

 Lecture (1 hr): Overview of industrial communication protocols (e.g., Ethernet/IP, Modbus

TCP/RTU, Profibus/Profinet). Master-slave and peer-to-peer communication concepts.

 Laboratory (6 hrs):

o Establishing basic network communication between two PLCs or between a PLC and a
supervisory computer (e.g., using an OPC server or SCADA software).

o Exchanging data between networked devices.

 Laboratory Output: A demonstration of data exchange between two simulated or physical PLCs
over a network protocol (e.g., turning on an output on PLC2 from an input on PLC1).

Week 14: Safety Circuits and Emergency Stops

 Lecture (1 hr): Importance of safety in industrial automation. Design of Emergency Stop (E-stop)
Circuits. Integration of safety relays and safety-rated components. Interlocking strategies for
personnel and equipment protection.

 **Laboratory (6 hrs):</B>

o Designing and implementing a hardwired emergency stop circuit for a simulated

machine.

o Integrating the E-stop functionality into the PLC program.

o Testing the E-stop circuit for proper machine shutdown.

 Laboratory Output: A PLC program and physical wiring demonstrating a failsafe emergency stop
circuit that stops all machine operations when activated.

Week 15: Troubleshooting PLC Systems

  Lecture (1 hr): Common PLC hardware faults (e.g., I/O failures, power supply issues) and
software faults (e.g., logic errors, addressing mistakes). Systematic troubleshooting
methodologies. Using diagnostic tools and status indicators.

 **Laboratory (6 hrs):</B>

o Diagnosing and rectifying pre-introduced hardware faults in a PLC trainer.

o Identifying and fixing software errors in faulty PLC programs.

o Using force I/O functions for troubleshooting.

 Laboratory Output: A detailed report documenting the troubleshooting steps taken, the faults
identified, and the solutions implemented for several given PLC system fault scenarios.

Week 16: Final Project Development - Planning & Design

 Lecture (1 hr): Introduction to project management in automation. Project life cycle,

requirement analysis, functional specification, I/O mapping, detailed design documentation
(flowcharts, state diagrams).

 **Laboratory (6 hrs):</B>

o Students form teams (if applicable) and select a final project from a list of predefined
scenarios or propose their own (subject to approval).

o Developing a detailed design document for their chosen project, including I/O list,
functional description, and proposed PLC logic.

 Laboratory Output: A comprehensive design document for the final PLC project, including a
system overview, I/O assignment, and a block diagram/flowchart of the intended control logic.

Week 17: Final Project Development - Implementation

 Lecture (1 hr): Project consultation and Q&A session. Review of common pitfalls in project
implementation.

 **Laboratory (6 hrs):</B>

o Teams work on implementing their final PLC project, including wiring, programming, and
initial testing.

o Faculty guidance and support during the implementation phase.

 Laboratory Output: A partially or fully functional PLC-based automation system based on the
team's design, demonstrating significant progress towards completion.

Week 18: Final Project Presentation & Evaluation

 Lecture (1 hr): Tips for technical presentations.

 **Laboratory (6 hrs):</B>

o Each team presents its final PLC project, demonstrating its functionality and explaining
the design and implementation choices.

o Evaluation of the project's functionality, adherence to design, documentation, and

presentation quality.

 Laboratory Output: A fully functional PLC-based automation system, complete with all required
hardware and software, was demonstrated and presented to the class and faculty.

Grading System

 Laboratory Outputs & Activities (Weekly): 60%

  Quizzes/Midterm Exam: 20%

 Final Project (Design, Implementation, Presentation): 20% Total: 100%

Required Materials and Equipment

 PLC Trainer Kits (with various I/O modules, power supply, push buttons, switches, indicator
lamps, small motors, analog sensors)

 PLC Programming Software (e.g., Rockwell Studio 5000, Siemens TIA Portal, Omron CX-One, or a
suitable simulation software)

 Computers with the necessary software installed

 Hand tools (screwdrivers, wire strippers, multimeters)

 Industrial wiring components (wires, terminal blocks, conduits, etc.)

 Safety PPE (safety glasses, gloves)

References

 Bolton, W. (Latest Edition). Programmable Logic Controllers. Elsevier.

 Stenerson, J. (Latest Edition). Fundamentals of Programmable Logic Controllers and Ladder Logic.
Delmar Cengage Learning.

 Petruzella, F. D. (Latest Edition). Programmable Logic Controllers. McGraw-Hill Education.

 Manufacturer-specific programming manuals and online resources (e.g., Allen-Bradley, Siemens,

Omron websites).