Cleveland State University

Department of Electrical Engineering and Computer Science

EEC447: Programmable Logic Controllers (PLCs)

Catalog Description: EEC447 Programmable Logic Controllers (3-0-3)

Pre-requisite: EEC 315 or EEC 316
An introduction to programmable logic controllers used in
industrial environments including basic concepts, programming,
applications, troubleshooting of ladder logic, and interfacing of
equipment.

Textbook: [Link] (Great resource for IEC 61131-3)

 Petruzella, Frank D. Programmable Logic Controllers,
4th Edition , 2011
o ISBN-13 9780073510880
 Dunning, Gary Programmable Logic Controllers 3rd Edition,
Thompson, 2007 (at bookstore)
o ISBN-13: 978-1-4018-8426-0
o ISBN-10: 1-4018-8426-1

Coordinator: Lucian Fogoros, BSEE, MBA

Course Objectives:
1. Provide senior level students with knowledge of physical
components and software strategies of industrial control systems
(PLC).
2. Demonstrate the various configurations and designs of industrial
factory automation systems.
3. Develop skills to analyze, design, implement and troubleshoot
industrial control systems.
4. Emphasize the “hands on” and “real world” nature of designing
control systems.
5. Extend students 'programming expertise in higher level
languages.

Expected Outcomes: Upon completion of this course, students should be able to:
1. Understand the basic control strategy of industrial control
systems---namely Boolean logic.
2. Recognize and work with the various I/O of PLC control
systems---namely sensors, operator's devices, signal transmitters,
solenoids, motor controllers, and temperature, pressure, and flow
controllers.
3. Understand general control concepts such as sequential scan, I/O
updates, one scan pulses, initializing data, seal ins, latches, timing,
subroutines.
4. Be familiar with typical industrial control strategies such as
sequencers, temperature sampling, ramp/soak profiles, good part/
bad part tracking, alarming routines, closed loop control, recipe
accessing and data retrieval/storage.
 5. Develop algorithms in higher level ladder logic using data
manipulation, bit shifting, mathematics, trig, bit masking, data table
operations.
6. Be familiar with distributive control systems, networking,
messaging. and security.

Prerequisites by Topic:
1. Experience with Blackboard
2. Computer programming
3. Fundamentals of differential and integral calculus
4. Electric circuit analysis
5. Electronics circuit components design and application
Topics:
Weeks
1. Basic concepts and Terminology 1
The hardware of industrial control system hardware: sensors,
operator devices, solenoids, pilot lights, contactors, motor
starters. Boolean logic descriptions of machine operations.
2. Industrial Control Systems Prior to PLC's
Relays and ladder logic 0.5
3. PLC Systems
The PLC hardware components and configuration. I/O wiring,
manuals, troubleshooting the hardware system, indicator
lights. 1
4. PLC Programming Software
“Walking” through the software environment and capabilities.
Toolbars, file operations, print function, online vs offline, run
vs program, editing operations, monitoring the ladder logic,
power flow and forcing. Executing simple machine control
programs as in tutorial. 1.5
5. Midterm Test#1
Hardwired relay ladder logic concepts and applications. 0.5
6. Sequencer
Implementing a machine control application as a sequence of
events, both initiated by event and/or timing. Emphasis on
“sequential scan” nature of PLC control, the concept of a “one
scan” pulse, and latch type coils. 0.5
7. Timers and Counters
Implement machine and process control strategies which
require timing and counters – from simple pick and place
delays (milliseconds) to ramp/soak profiles for furnace
control (hours). 1
8. Data Operations
Working with “values” in the PLC control strategies – both
integer values and floating point values. Applications include
recipe set point storage, timer and counter values, initial
values, stored constants. Strategies include data move, data
compare, data convert, data clear. Implement sequencer using
a counter and compares. 1
 9. Math Operations
PLC control requires scaling, limiting, comparing of analog
values. Applications include averaging, finding the mean,
maximum and minimum values, and incrementing. 1
10. Analog Inputs and Outputs
Working with devices such as speed, pressure, flow,
temperature transmitters and controllers which require DAC
and ADC conversion routines to monitor and control these
parameter values. Includes scaling for engineering units. 1
11. Bit Operations
Bit shifting and bit masking are functions used in many control
algorithms and strategies. Applications include “bad part”
tracking, rotating lights and sequencers. Bit masking using
AND, OR, XOR operations with stored constants are used
machine control applications, such as alarm/acknowledge
routines. 0.5
12. Midterm Test#2
Basic PLC control applications including timing,counting,one
shot pulses,data operations, bit operations, and math. 0.5
13. Modular Programming
Develop sub routines, call and return operations, nesting, jumps
and global variables. Emphasis on divide and conquer” concept
and developing efficient and understandable programs using
subroutines. 0.5
14. Data Manipulations
Source to Table, Table to Destination, Table to Table operations
with indexing and indirect addressing. Applications include
process control for multiple part production, function generator,
sequencer using stored constants to control multiple outputs. 1
15. LAN Communications
Distributive control concept is implemented through Ethernet
network with PLCs sharing data, messages and control
operations. 1
16. IEC 61131 Standard
PLC programming is Structured Text, a universal standard for
control operations. 1
Total 15
Grading Policy
 Assignments& 2 quizzes 70 points
 Demonstrations 50 points
 Midterm Test #1 95 points
 Midterm Test #2 95 points
 Final Examination 190 points
Points 461-500 441-460 421-440 401-420 371-400 351-370 321-350 300-320
Grade A A- B+ B B- C+ C D
Computer Usage:
 PLC assignments are implemented using PLC manufacture's
Windows based programming(development & runtime) software
package. For EEC 447 Section 50 the software is RSLogix5 by
Rockwell Software by General Electric.
 All assignments must include a cover page and project description
in Microsoft Word
 The computers and PLCs are connected in both a network
configuration and proprietary LAN configuration and the students
must understand LAN concepts, Ethernet communications and
TCP/IP addressing in order to download programs, monitor I/O and
implement the distributive control assignment.

Lab Projects:
1. Each of the assignment consists of a PLC application software
design which must be implemented on a physical I/O simulator
system to demonstrate real-time operation of the PLC design.
2. Some assignments will require the use of an oscilloscope, multi-
meter or power supply to demonstrate the real-time operation of the
PLC design.

Prepared by: Donald F Zeller

Date: 2/15/2002