PLC

Syllabus

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 Syllabus
Course Title: PLC

Course Code: N/A

Course Followers:
Students of Mechatronics Department in 1st semester of 2nd year

Course Meeting Times

Lectures: 1 session / week, 2 hours / session
Tutorial: 1 session / week, 2 hours / session
Labs: 1 session / week, 3 hours / session

Course Credits: 4

Course Introduction
This course gives Mechatronics department students necessary knowledge and understanding of
Siemens or Mitsubishi PLC (Programmable Logic Controller) that are widely used in the industrial
field. This course deals with some fundamentals of PLC-based control systems without which
Mechatronics technicians‟ field, namely factory automation domain cannot exist. This PLC course is
designed to equip the novice with no prior PLC programming experience with the basic tools
required to create a complete PLC program using ladder logic common to most current platforms.
Using Siemens or Mitsubishi PLC software, we will be covering such topics as general controls,
digital and analog IO, ladder logic programming, alarm/notification handling, emulation, best
practices and more. The student will write, enter, and execute application programs using the

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programmable controllers. The use of the PLC Lab equipment will give the student practical
programming and troubleshooting skills used in the maintenance of automated systems.

Course Objectives
Main objective:
The main objective is learning PLC operation and programming.

Learning objectives:
1. Characteristics of a PLC
2. Know general PLC issues
3. Understanding of PLC programming, ladder logic.
4. Understand and design basic input and output wiring
5. Analysis and classification of the process control
6. Interlocking process control
7. Sequential process control
8. Random process control
9. Understand the operation of a PLC
10. Understanding of Siemens or Mitsubishi PLC hardware units and utilizing them.

Learning Outcomes
By the end of this practice, mechatronics department students will be able to:
1. Describe typical components of a Programmable Logic Controller.
2. Explain the basic concepts of a Programmable Logic Controller.
3. State basic PLC terminology and their meanings.
4. Explain and apply the concept of electrical ladder logic, its history, and its relationship to
programmed PLC instruction.
5. Use ladder language programming for real cases.
6. Explain the concept of basic digital electronics and data manipulation.
7. Learn the difference between digital and analog signals and how to bring them into a PLC,
process them, and send them back out.

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8. Use latch, timer, counter, and other intermediate programming functions.
9. Design and program basic PLC circuits for entry-level PLC applications.
10. Design and program a small, automated industrial production line.
11. Explore basic, standard controls techniques for all process control which classified into Interlock
control, Sequential control, and Random control.
12. By the end of this practice, students will be able to create a PLC program from scratch and find
some solutions for real-time industrial automation problems.

Prerequisites / Reference Courses

Classic control
Digital signaling
Microprocessor and microcontroller
Sensors in Technology
System Network in Technology

Textbooks
The course textbooks are:
1. Mano, M. Morris. Digital logic and computer design. Pearson Education India, 2017.
2. Kamel, Khaled, and Eman Kamel. Programmable logic controllers: Industrial control.
McGraw Hill Professional, 2013.
3. Handbook, P. L. C. "Practical Guide to Programmable Logic Controllers."
AutomationDirect. com.
4. Jack, Hugh. Automating manufacturing systems with PLCs. Lulu. com, 2010.
5. CHUNGPA, “User’s Manual :Universal PLC Training System CPS-3580U”, English
ver1, 2020.
6. Egyptian Company for the Development of Technical Education (ECDTE), PLC Kit
Manual: ECDTE 1000.1 Laboratory Manual, 2018.

Homework
∙ Homework will be issued in lectures and collected a week later in recitation.
∙ Corrected homework with solutions will be returned in labs the week after it is collected. You are
welcome and encouraged to discuss the homework among your colleagues. However, the final
formulation and write up of your homework answers must be your own.

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∙ Submitting homework copied from someone else is a breach of ethics, and will be handled by the
Committee on Discipline. More importantly, although homework counts for only 5 percent of the
grade, they are critical to learning the material and to doing well on the quizzes and final
exam. One homework problem will appear in each of the tests, and homework performance will
be taken into account during grade assignment for cases that are on letter-grade boundaries.

∙ Late homework will not be accepted for grading. However, total homework grades will be based
on the best nine out of eleven individual homework grades. Thus, with one exception, two
homework assignments may be missed without a grading penalty.

∙ All homework will be graded on a coarse scale of 0 to 3 points. 3 points if all or nearly all problems
are correct, 2 points if homework is approximately half correct, 1 point if mostly incorrect, and 0
points if late or not submitted.

Labs (or Tutorials/Exercise, Workshop)

∙ Labs will be conducted during the weeks shown in the schedule. Each lab assignment involves one
or more accomplishments which must be checked off by an instructor in the lab. The instructor will
be available for help and lab check-off during those weeks in which a lab is in progress.
∙ No written work will be due for the last lab.
∙ You are welcome and encouraged to discuss the labs among your colleagues. You are also welcome
to team up in pairs to execute a lab. However, the write up of your lab must be done on your own.
Skipping the lab and submitting work copied from someone else is a serious breach of ethics and
will be handled by the Committee on Discipline.
∙ Lab assignments will be graded on a scale of 0 to 3 (3: lab complete, works, good job on pre- and
post-lab; 2: lab mostly complete, reasonable job on pre and post lab; 1: lab partially done, marginal
to poor job on pre- and post-lab; 0: lab not done, poor job on pre- and post-lab).

Lab Books
∙ You must obtain the contents of a few pages for every lab (from Lab #1 to lab #15) for recording
measurements, observations and graphs of data taken during the in-lab exercises.

∙ Written pre-lab and post-lab exercises are also to be completed in your own papers.

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Midterm Exam
∙ One closed-book midterm exam will be given in this term. The exam will take place few days after
Lab #7 for a two-hour duration.

∙ There will be no lecture or lab on the day. You may bring one two-sided sheet of notes written
by your own hands to the exam. You may also bring a calculator, eraser, pencil or ball pens.

Final Exam
∙ A three-hour final exam will be given during the end-of-term exam week. Timing and room
assignments will be announced later. You may bring three two-sided sheets of notes written by
your own hands to the exam.

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Calendar
The calendar provides information on the course's lecture class (L), lab (Lab #), and exam (E)
sessions.

SES # TOPICS KEY DATES

Introduction to Logic Circuit: Logic Gates,

L1 Homework #1 in
Numbering System.

Lab #1 Introduction to PLC lab Lab report #1 in

Homework #1 out
Interfacing Peripheral Chips: F.F., Registers, Tristate
L2 Homework #2 in
Buffers, Latches, Decoders, Memory.

Lab report #1 out

Lab #2 Configuration and Software Install
Lab report #2 in

Introduction to PLC: Microprocessor, I/O Ports,

Homework #2 out
L3 Isolation, Filters, Drivers, Microcontrollers/DSP,
Homework #3 in
PLC/DDC.

Lab report #2 out

Lab #3 Monitoring and Simulation
Lab report #3 in

PLC Construction: What is a PLC, Why preferring

PLC, PLC Memories, PLC I/O, PLC Programming, Homework #3 out
L4
introduction to PLC Ladder, PLC Special I/O, PLC Homework #4 in
Types.

Lab report #3 out

Lab #4 Ladder Logic
Lab report #4 in

PLC Basic Instructions: PLC Ladder Language,

Ladder/Instruction List, PLC Basic Instructions, Homework #4 out
L5
Basic Examples (Start Stop Rung, Entry/Reset Homework #5 in
Rung).

Lab report #4 out

Lab #5 Logic Design with Siemens (TIA Portal)
Lab report #5 in

Process Control Problems Classification: Types of

Homework #5 out
L6 Process Control, Interlock control definition,
Homework #6 in
Sequential control definition, Random control

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 SES # TOPICS KEY DATES

definition, Interlock control examples.

Lab report #5 out

Lab #6 Logic Design with Mitsubishi (GX-Works2)
Lab report #6 in

Homework #6 out
L7 Timers and Counters: Timers, Counters, Examples.
Homework #7 in

Lab report #6 out

Lab #7 Timers and Counters
Lab report #7 in

E1 Midterm Exam

Word and Branching Instruction: Data Handling

Instruction, Arithmetic Instruction, PLC Internal Homework #7 out
L8
Facilities, Logic Instruction, I/O Instruction, Program Homework #8 in
Control Instruction.

Experiments Classification and Simple Programming Lab report #7 out

Lab #8
Exercises Lab report #8 in

Homework #8 out
L9 Sensors, Switches, Solid State Relays.
Homework #9 in

Lab report #8 out

Lab #9 Solving Interlock Problems
Lab report #9 in

Sequential Process Control: Sequential control, Homework #9 out

L10
Sequential control examples. Homework #10 in

Lab report #9 out

Lab #10 Solving Basic Sequential Problems
Lab report #10 in

Application Examples of Sequential Industrial Homework #10 out

L11
Problem Homework #11 in

Lab report #10 out

Lab #11 Traffic Control
Lab report #11 in

Homework #11 out

L12 Application Examples of Production Lines
Homework #12 in

Lab report #11 out

Lab #12 Conveyor Control
Lab report #12 in

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 SES # TOPICS KEY DATES

Homework #12 out

L13 Application Examples
Homework #13 in

Lab report #12 out

Lab #13 Stepper Motor Control
Lab report #13 in

Random Process Control: Random control, Random Homework #13 out

L14
control examples. Homework #14 in

Lab report #13 out

Lab #14 CNC Machine Control
Lab report #14 in

Homework #14 out

L15 Application Examples
Homework #15 in

Lab report #14 out

Lab #15 Random Experiment: Elevator Control
Lab report #15 in

E2 Final Exam

Grading (or Assessment) Policy

Initial grading will be based on the following weighting:

ACTIVITIES PERCENTAGES

Homework 5%

Labs (performance & reports) 35%

Midterm 30%

Final exam 30%

 Lab assignments will be graded on a scale of 0 to 3

i) 3: lab complete, works, good job on pre- and post-lab;
ii) 2: lab mostly complete, reasonable job on pre and post lab;
iii) 1: lab partially done, marginal to poor job on pre- and post-lab;

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 iv) 0: lab not done, poor job on pre- and post-lab.

 All homework will be graded on a coarse scale of 0 to 3 points,

i) 3 points if all or nearly all problems are correct,
ii) 2 points if homework is approximately half correct,
iii) 1 point if mostly incorrect, and
iv) 0 points if late or not submitted.

∙ This will be followed by considerable discussion among the entire teaching staff to factor in your
diligence on the homework and labs, and your participation in class and labs. This discussion can
affect your letter grade for the course, particularly if your initial grade is on a letter-grade boundary.
∙ Furthermore, failure to complete the labs in this subject will result in an overall grade that is one
letter grade lower (not an Incomplete).
∙ This subject has been designed so that lectures, homework and labs are integral and essential parts
of the learning process. Although there is no specific reward for participation, there is a clearly
defined penalty for not participating. Students who consistently miss lectures, homework and labs
will not be included in the grading discussions.

Lecture notes
This section contains lecture notes from some chapters of the following books,
I) Mano, M. Morris. Digital logic and computer design. Pearson Education India, 2017.
II) Kamel, Khaled, and Eman Kamel. Programmable logic controllers: Industrial control.
McGraw Hill Professional, 2013.
III) Handbook, P. L. C. "Practical Guide to Programmable Logic Controllers."
AutomationDirect. com.
IV) Jack, Hugh. Automating manufacturing systems with PLCs. Lulu. com, 2010.
V) CHUNGPA, “User’s Manual :Universal PLC Training System CPS-3580U”, English
ver1, 2020.
VI) Egyptian Company for the Development of Technical Education (ECDTE), PLC Kit
Manual: ECDTE 1000.1 Laboratory Manual, 2018.

LEC # TOPICS LECTURE NOTES

BOOK I
Introduction to Logic Circuit: Logic Gates,
L1 Chapter 1: Binary Systems
Numbering System.
Chapter 2: Boolean Algebra

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LEC # TOPICS LECTURE NOTES

and Logic Gates

BOOK I
Chapter 6: Synchronous
Interfacing Peripheral Chips: F.F., Registers, Sequential Logic
L2
Tristate Buffers, Latches, Decoders, Memory. Chapter 7: Registers,
Counters and the Memory
Unit

BOOK II
Chapter 1: Introduction to
Introduction to PLC: Microprocessor, I/O Ports,
PLC Control Systems and
L3 Isolation, Filters, Drivers, Microcontrollers/DSP,
Automation
PLC/DDC.
Chapter 2: Fundamentals of
PLC Logic Programming

BOOK II
Chapter 1: Introduction to
PLC Control Systems and
PLC Construction: What is a PLC, Why
L4 Automation
preferring PLC, PLC Memories, PLC I/O,
BOOK III
Chapter 1: What is a PLC
Chapter 5: PLC Software

PLC Basic Instructions: PLC Ladder Language, BOOK IV

Ladder/Instruction List, PLC Basic Instructions, Chapter 1: Introduction
L5
Basic Examples (Start Stop Rung, Entry/Reset Chapter 14: Ladder Logic
Rung). Functions

Process Control Problems Classification: Types

of Process Control, Interlock control definition, BOOK VI
L6
Sequential control definition, Random control Chapter 4: Experiments
definition, Interlock control examples.

BOOK IV
Timers and Counters: Timers, Counters,
L7 Chapter 8: Latches, Timers,
Examples.
Counters and more.

Word and Branching Instruction: Data Handling

BOOK IV
Instruction, Arithmetic Instruction, PLC Internal
L8 Chapter 14: Ladder Logic
Facilities, Logic Instruction, I/O Instruction,
Functions
Program Control Instruction.

L9 Sensors, Switches, Solid State Relays. BOOK IV

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 LEC # TOPICS LECTURE NOTES

Chapter 3: Logical Sensors

Sequential Process Control: Sequential control, BOOK VI

L10
Sequential control examples. Chapter 4: Experiments

Application Examples of Sequential Industrial BOOK VI

L11
Problem Chapter 4: Experiments

Application Examples of Production Lines BOOK VI

L12
Chapter 4: Experiments

Application Examples BOOK VI

L13
Chapter 4: Experiments

Random Process Control BOOK VI

L14
Chapter 4: Experiments

Application Examples BOOK VI

L15
Chapter 4: Experiments

Lab notes (or Practice Manual)

This section contains lab notes from every chapter of the practice manual, “M. Kang and Amir
Yassin, PLC, (Practice Manual), 2020.”

LAB NOTES
LAB # TOPICS (PRACTICE MANUAL
CHAPTER)

Lab #1 Introduction to PLC lab Module 1: Chapter 1

Lab #2 Configuration and Software Install Module 1: Chapter 2

Lab #3 Monitoring and Simulation Module 1: Chapter 3

Lab #4 Ladder Logic Module 2: Chapter 4

Lab #5 Logic Design with Siemens (TIA Portal) Module 2: Chapter 5

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 LAB NOTES
LAB # TOPICS (PRACTICE MANUAL
CHAPTER)

Logic Design with Mitsubishi (GX-

Lab #6 Module 2: Chapter 6
Works2)

Lab #7 Timers and Counters Module 3: Chapter 7

Experiments Classification and Simple

Lab #8 Module 4: Chapter 8
Programming Exercises

Lab #9 Solving Interlock Problems Module 4: Chapter 9

Lab #10 Solving Basic Sequential Problems Module 5: Chapter 10

Lab #11 Traffic Control Module 5: Chapter 11

Lab #12 Conveyor Control Module 5: Chapter 12

Lab #13 Stepper Motor Control Module 5: Chapter 13

Lab #14 CNC Machine Control Module 5: Chapter 14

Lab #15 Random Experiment: Elevator Control Module 6: Chapter 15

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