HARARE INSTITUTE OF TECHNOLOGY
DEPARTMENT OF ELECTRONIC ENGINEERING
EEE 220: PROGRAMMABLE LOGIC CONTROLLERS
SEMESTER 2 2018/2019
LECTURER: T. MARONGEDZE
Email: [email protected]
Cell: 0772807023
INTRODUCTION
Every aspect of industry—from power generation to automobile painting to food packaging—
uses programmable controllers to expand and enhance production. In this course, we learn
about all aspects of these powerful and versatile tools. The basics of programmable
controllers—from their operation to their vast range of applications are covered in the course.
The origin, revolution and advanced concepts of programmable logic controllers from by
different manufacturers are covered as well as the different programming languages. The
course comprises of theory supported by a series of practical’s both software based using
simulators and real process control in the PLC laboratory were Siemens PLCs are used.
COURSE GOAL
To develop an understanding of Programmable Logic Controllers (PLC) and their applicability
in the modern industry.
COURSE OBJECTIVES
1. To develop an understanding of the fundamental laws and elements of Programmable
Logic Controllers (PLC).
2. To develop the ability to apply knowledge of Programmable Logic Controllers on
industrial systems, processes and perform system integration.
3. To develop an understanding of industrial data networks and their relevance in the
industry with regards to Programmable Logic Controllers (PLC).
4. Developing an understanding of industrial controllers such PI, PD, PID , ON and OFF
controller etc.
OUTCOMES
1. Ability to design an automated system for an industrial process
2. Ability to perform system integration on existing industrial system
3. Ability to program and interface Programmable Logic Controllers (PLC) with external
peripheral
4. Ability to apply digital electronics, number systems and Logic in industrial system
TEACHING METHODOLOGY
The course is conducted through lectures, tutorials, and student presentations. Lab sessions are
done as part of the practical work for practice purposes for students to familiarize with the
circuit design and simulation. Student understanding of the subject will be examined through
quiz, assignments and tests. Handouts will be provided in certain areas of the course but each
student is expected to read widely to enhance understanding of the material covered.
ASSESSMENT:
Students shall be assessed on:
Theoretical Coursework will be made up of three assignments and three tests
Assignment 1 (due week 3)
Assignment 2 (due week 6)
Assignment 3 (due week 9)
Test 1 (week 4)
Test 2 (week 8)
Test 3 (week 11)
Practical Coursework will be made up of weekly LAB Sessions An
examination – one three-hour paper.
COURSE CONTENT:
UNIT 1: PLC OVERVIEW AND HARDWARE COMPONENTS
Section 1: Programmable Logic Controllers (PLCs) And Overview
Programmable Logic Controller, Parts of a PLC, Principles of Operation, Modifying the
Operation, PLC versus Computers, PLC Size versus Application
Section 2: PLC Hardware Components
The I/O Section, Discrete I/O Modules, Analog I/O Modules, Special I/O Modules,
I/O Specifications
Typical Discrete I/O Module Specifications
Typical Analog I/O Module Specifications
The Central Processing Unit (CPU), Memory Design, Memory Types, Programming Terminal
Devices, Recording and Retrieving Data, Human Machine Interfaces (HMIs).
UNIT 2: NUMBER SYSTEMS AND FUNDAMENTALS OF LOGIC
Section 3: Number Systems and Codes
Decimal System, Binary System, Negative Numbers, Octal System, Hexadecimal, Binary
Coded Decimal (BCD) System, Gray Code, ASCII Code, Parity Bit, Binary Arithmetic
Section 4: Fundamentals of Logic
The Binary Concept
AND, OR and NOT Functions
The AND Function
The OR Function
The NOT Function
The Exclusive-OR (XOR) Function
Boolean Algebra, Developing Logic Gate Circuit from Boolean Expressions, Producing the
Boolean Equation for a Given Logic Gate Circuit, Hardwired Logic versus Programmed Logic,
Programming Word Level Logic Instructions
UNIT 3: SENSORS AND INTERFACE
Section 5: Basics of PLC Programming
Processor Memory Organization.
Program Files
Data Files
Program Scan, PLC Programming Languages, Relay-Type Instructions, Instruction
Addressing, Branch Instructions, Internal Relay Instructions, Programming Examine If Closed
and Examine If Open Instructions, Entering the Ladder Diagram, Modes of Operation.
Section 6: Developing Fundamental PLC Wiring Diagrams and Ladder Logic Programs
Electromagnetic Control Relays, Contactors, Motor Starters, Manually Operated Switches,
Mechanical Operated Switches
Sensors
Proximity Sensor
Magnetic Reed Sensor
Light Sensor
Ultrasonic
Strain/ Weight Sensors
Temperature Sensors
Flow Measurement
Velocity and Position Sensors
Output Control Devices, Seal-In Circuits, Latching Relays, Converting Relay Schematics into
PLC Ladder Programs, Writing a Ladder Program Directly from a Narrative Description
UNIT 4: PROGRAMMING
Section 7: Programming Timers
Mechanical Timing Relays, Timer Instructions, On-Delay Timer Instruction, Off-Delay Timer
Instruction, Retentive Timer, Cascading Timers
Section 8: Programming Counters
Counter Instructions
Up-Counter
One-Shot Instruction
Down-Counter, Cascading Counters, Incremental Encoder- Counter Applications, Combining
Counter and Timer Functions.
Section 9: Control Instructions
Master Control Reset Instruction, Jumper Instruction, Subroutine Functions, Immediate Input
and Immediate Output, Instructions, Forcing External I/O Addresses, Safety Circuitry,
Selectable Timed Interrupt, Fault Route, Temporary End Instruction, Suspend Instruction.
Section 10: Data Manipulation Instructions
Data Manipulation, Data Transfer Operations, Data Compare Instructions, Data Manipulation
Programs, Numerical Data I/O Interfaces, Closed-Loop Control.
Section 11: Math Instructions
Math Instructions, Addition Instructions, Subtraction Instructions, Multiplication Instructions,
Division Instructions, Other Word-Level Math Instructions, File Arithmetic Operations.
Section 12: Sequencer and Shift Register Instructions
Mechanical Sequencers, Sequencer Instructions, Sequencer Programs, Bit Shift Registers
Word Shift Operations.
Section 13: PLC Installation Practices, Editing, and Troubleshooting
PLC Enclosures, Electrical Noise, Leaky Inputs and Outputs, Grounding, Voltage Variations
and Surges, Program Editing and Commissioning, Programming and Monitoring, Preventive
Maintenance.
Troubleshooting
Processor Module
Input Malfunctions
Output Malfunctions
Ladder Logic Program
PLC Programming Software
UNIT 5: INDUSTRIAL CONTROL AND DATA NETWORKS
Section 14: Process Control, Network Systems, and SCADA
Types of Processes, Structure of Control Systems, On/Off Control, PID Control, Motion
Control. Supervisory Control and Data Acquisition (SCADA)
Data Communication
Data Highway
Serial Communication
DeviceNet
ControlNet
EtherNet/IP
Modbus
Fieldbus
PROFIBUS-DP
UNIT 6: PROGRAMMING AND SIEMENS SOFTWARE DEVELOPING
ENVIRONMENT
Section 15: Siemens Controllers
Part 1: Memory and Project Organization
Memory Layout, Configuration, Project, Tasks, Programs, Routines, Tags, Structures,
Creating Tags, Monitoring and Editing, Array
Part 2: Bit-Level Programming
Program Scan, Creating Ladder Logic, Tag-Based Addressing, Adding Ladder Logic to the
Main Routine, Internal Relay Instructions, Latch and Unlatch, Instructions, One-Shot
Instruction.
Part 3: Programming Timers
Timers Predefined Structure,
On-Delay Timer (TON)
OFF-Delay Timer(TOF)
Retentive Timer On (RTO).
Part 4: Programming Counters
Counters
Count-Up (CTU)
Count-Down (CTD)
Part 5: Math, Comparison, and Move Instructions
Math Instructions.
Comparison Instructions
Move Instructions
Part 6: Function Block Programming
Function Block Diagram (FBD
FBD Programming
Tool and Software
TIA portal
Siemens Step 7
Rockwell logixpro.
Automation Studio
References
1. Programmable logic controllers 4th edition by Frank D Petruzella.
2. Programmable logic controllers- theory and implementation 2nd edition: L. A. Bryan
E. A. Bryan; Industrial Text Company Publication; 1997.
3. Automating Manufacturing Systems with PLCs: Hugh Jack; 2002
4. Programmable Logic Controllers 4th edition: W. Bolton; Elsevier 2006.
5. Programmable logic controllers: 5th edition: JW Webb, A. Reiss; PHI
6. Programmable logic controllers- programming and applications; JR Hackworth, F.D
Hackworth; Pearson 2004.
