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Programmable Logic Controller

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    • An- Najah National University

      Engineering college

      Electrical Engineering Department

      Course name: Programmable Logic Controller  

      Course number:63428

      Instructor:Dr. Kamel Saleh

      Textbook: Frank D.Petrezulla. Programmable logic controller , fourth Edition, Mc Graw Hill 2011

      Online references :https://plcs.net    &   https://www.wisc-online.com/

      ____________________________________________________________

      Course Contents

      PLC architecture, PLC programming procedures, selecting suitable PLC, basic PLC programming, ladder diagrams, basic PLC functions (register. timers. counter), PLC arithmetic functions, data handling functions, Engineering applications, PLC installation and troubleshooting and maintenance.

       

      Learning outcomes and competences:

      After finishing the course, a student should be able to:
      • Install the PLC, edit and troubleshooting it. 
      • Develop ladder program to control different physical systems.
      • Install and wire PLC with different input and output device 

      to read full outline Click here

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      simulator File
    • assign icon
      Assignment
      HW Assignment
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      Ch 14 File

  • Topic 1

    Chapter one:Programmable Logic controller overview.

    • Introduction:

      This chapter gives a brief history of the evolution of the programmable logic controller, or PLC.The reasons for changing from relay control systems to PLCs are discussed. You will learn thebasic parts of a PLC, how a PLC is used to control a process, and the different kinds of PLCsand their applications. The ladder logic language,which was developed to simplify the task of programming PLCs, is introduced 


    • Objectives:

      After completing this chapter, student will be able to:

      1. Define what a programmable logic controller (PLC) is and list its advantages over relay systems 
      2. Identify the main parts of a PLC and describe their functions
      3. Outline the basic sequence of operation for a PLC
      4. Identify the general classifications of PLCs

    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      Chapter1_Programmable Logic_overview File

    • Second :      Watch the following video for       What is a PLC? and Basics of PLCs, featuring.

  • Topic 2

    Chapter two :PLC Hardware Components.

    • Introduction:

      This chapter exposes you to the details of PLC hardware and modules that make up a PLC control system. The chapter’s illustrations show the various subparts of a PLC as well as general connection paths. In this chapter we discuss the CPU and memory hardware components,including the various types of memory that are available, and we describe the hardware of the input/output section, including the difference between the discrete and analog types of modules


    • Objectives:

      After completing this chapter, student will be able to:

      1. List and describe the function of the hardware components used in PLC systems 
      2. Describe the basic circuitry and applications for discrete and analog I/O modules, and interpret typical I/O and CPU specifications
      3. Explain I/O addressing
      4. Describe the general classes and types of PLC memory devices
      5. List and describe the different types of PLC peripheral support devices available

    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      Chapter2_PLC Hardware Components.pdf File
    •   
      Second :Study the following animation to learn I/O modules in PLC ..
    • resource icon
      File
      PLC output modules File
    • resource icon
      File
      PLC input modules File

  • Topic 3

    Chapter three : Number systems and codes.

    • Introduction:

      Using PLCs requires us to become familiar with other number systems besides decimal. Some PLC models and individual PLC functions use other numbering systems. This chapter deals with some of these numbering systems, including binary, octal, hexadecimal, BCD, Gray, and ASCII. The basics of each system, as well as conversion from one system to another, are explained.


    • Objectives:

      After completing this chapter, student will be able to:

      1. Define the decimal, binary, octal, and hexadecimal numbering systems and be able to convert from one numbering or coding system to another

      2. Explain the BCD, Gray, and ASCII code systems

      3. Define the terms bit, byte, word, least signifi cant bit (LSB), and most signifi cant bit (MSB) as they apply to binary memory locations

      4. Define  add, subtract, multiply, and divide binary numbers


    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter3_Number systems and codes.pdf File
    •  
      Second :Study the following animation to learn how converting between Gray and Binary codes.
    • resource icon
      File
      Gray and Binary codes. File
    •    
      Third : Use this animation for doing conversion .
    • resource icon
      File
      Conversion File
    • Fourth: Use this animation to define the terms bit, byte, word, least signifi cant bit (LSB), and most signifi cant bit (MSB) as they apply to binary memory locations.

  • Topic 4

    Chapter four : Fundamentals of Logic.

    • Introduction:

      This chapter gives an overview of digital logic gates and illustrates how to duplicate this type of control on a PLC. Boolean algebra, which is a shorthand way of writing digital gate diagrams, is discussed briefl y. Some small hand-held programmers have digital logic keys, such as AND, OR, and NOT, and are programmed using Boolean expressions.

    • Objectives:

      After completing this chapter, student will be able to:

      1. Describe the binary concept and the functions of gates
      2. Draw the logic symbol, construct a truth table, and state the Boolean equation for the AND, OR, and NOT functions
      3. Construct circuits from Boolean expressions and derive Boolean equations for given logic circuits
      4. Convert relay ladder schematics to ladder logic programs
      5. Develop elementary programs based on logic gate functions
      6. Program instructions that perform logical operations


    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter4_Fundamentals of Logic.pdf File

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      Second :In this animated object, learners examine how to use a programmable logic controller as an alternative to hardwiring a ladder logic circuit.
    • resource icon
      File
      PLC Software Circuit Capabilities File

  • Topic 5

    Chapter five : Basics of PLC Programming.

    • Introduction:

      Each input and output PLC module terminal is identifi ed by a unique address. In PLCs, the internal symbol for any input is a contact. Similarly, in most cases, the internal PLC symbol for all outputs is a coil. This chapter shows how these contact/coil functions are used to program a PLC for circuit operation. This chapter covers only the basic set of instructions that perform functions similar to relay functions. You will also learn more about the program scan cycle and the scan time of a PLC.


    • Objectives:

      After completing this chapter, student will be able to:

      1. Defi ne and identify the functions of a PLC memory map
      2. Describe input and output image table fi les and types of data fi les
      3. Describe the PLC program scan sequence
      4. Understand how ladder diagram language, Boolean language, and function chart programming language are used to communicate information to the PLC
      5. Defi ne and identify the function of internal relay instructions
      6. Identify the common operating modes found in PLCs
      7. Write and enter ladder logic programs


    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter5_Basics of PLC Programming.pdf File
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      Second :In this animated learning object, students examine the addresses of PLC elements and how they pertain to I/O connections and internal memory files.
    • resource icon
      File
      The Relationship of Data File Addresses to I/O Modules

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      Third:Learners examine the functions of the three types of memory used by an Allen-Bradley SLC-500 programmable logic controller: the Executive ROM, Scratch Pad, and Processor File.
    • resource icon
      File
      AB SLC-500 Memory Structure File

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      Fourth:Learners examine the elements of a data file memory of an Allen-Bradley SLC-500 programmable controller. A quiz completes the activity.
    • resource icon
      File
      SLC-500 Data File Elements

  • Topic 6

    Chapter six : Developing Fundamental PLC Wiring Diagrams and Ladder Logic Programs.

    • Introduction:

      For ease of understanding, ladder logic programs can be compared to relay schematics. This chapter gives examples of how traditional relay schematics are converted into PLC ladder logic programs. You will learn more about the wide variety of fi eld devices commonly used in connection with the I/O modules.


    • Objectives:

      After completing this chapter, student will be able to:

      1. Identify the functions of electromagnetic control relays, contactors, and motor starters
      2. Identify switches commonly found in PLC installations
      3. Explain the operation of sensors commonly found in PLC installations
      4. Explain the operation of output control devices commonly found in PLC installations
      5. Describe the operation of an electromagnetic latching relay and the PLC-programmed LATCH/UNLATCH instruction
      6. Compare sequential and combination control processes
      7. Convert fundamental relay ladder diagrams to PLC ladder logic programs Write PLC programs directly from a narrative description

    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter6_Developing Fundamental PLC Wiring Diagrams and Ladder Logic Programs.pdf File


    • Second :Study the following animation examples which help you to understand the chapter.

    • Example #1 ( Latch ):

      Here we are using 2 momentary push button switches. One is physically connected to input 0000 while the other is physically connected to input 0001. When the operator pushes switch 0000 the instruction "set 0500" will become true and output 0500 physically turns on. Even after the operator stops pushing the switch, the output (0500) will remain on. It is latched on. The only way to turn off output 0500 is turn on input 0001. This will cause the instruction "res 0500" to become true thereby unlatching or resetting output 0500.

    •  

      Third:This interactive object is designed to help learners memorize the schematic symbols used in ladder logic diagrams. Learners quiz themselves using electronic flashcards.
    • resource icon
      File
      Ladder Logic Schematic Symbol Flashcards File

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      Fourth :In this animated object, learners examine how to use a programmable logic controller as an alternative to hardwiring a ladder logic circuit.
    • resource icon
      File
      PLC Software Circuit Capabilities File

  • Topic 7

    Chapter seven : Programming Timers.

    • Introduction:

      The most commonly used PLC instruction, after coils and contacts, is the timer. This chapter deals with how timers time intervals and the way in which they can control outputs. We discuss the basic PLC on-delay timer function, as well as other timing functions derived from it, and typical industrial timing tasks.


    • Objectives:

      After completing this chapter, student will be able to:

      1. Describe the operation of pneumatic on-delay and off-delay timers
      2. Describe PLC timer instruction and differentiate between a nonretentive and retentive timer
      3. Convert fundamental timer relay schematic diagrams to PLC ladder logic programs
      4. Analyze and interpret typical PLC timer ladder logic programs
      5. Program the control of outputs using the timer instruction control bits


    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter7_Programming Timers.pdf File


    • Second :Study the following animation examples which help you to understand the chapter.

    • Example #1 :

      In the example above, when the operator pushes button 0001 the timer starts ticking. When the accumulated value reaches 0 the timer contacts (T000) will close and output 0500 becomes true. When the operator releases the button (0001) the accumulated value changes back to the preset value
    •  
      Third:Learners examine the animated Timer-On Delay instruction and the Timer-Off Delay instruction of a PLC timer. A brief quiz completes the activity.
    • resource icon
      File
      PLC Timer Instructions File

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      Fourth:In this animated object, learners examine the types of information to enter, and the sequence of steps required, to program a programmable logic controller (PLC) timer.
    • resource icon
      File
      Programming a PLC Timer File

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      Fifth:Learners study the method of cascading two or more PLC timers to extend their time capacity.
    • resource icon
      File
      Cascading Timers File

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      Sixth :Learners study the descriptions of the three words in a PLC timer: EN, DN, and TT. They then test their knowledge in a brief quiz.
    • resource icon
      File
      The Timer 3-Word Element File

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      Seventh :To gain your experience in  designing  ladder diagram.do the assignment .
    • assign icon
      Assignment
      Timer_Assignment

  • Topic 8

    Chapter eight : Programming Counters.

    • Introduction:

      All PLCs include both up-counters and downcounters.Counter instructions and their functionin ladder logic are explained in this chapter. Typical examples of PLC counters include the following: straight counting in a process, two counters used to give the sum of two counts, and two counters used to give the difference between two counts.


    • Objectives:

      After completing this chapter, student will be able to:

      1. List and describe the functions of PLC counter instructions
      2. Describe the operating principle of a transitional, or one-shot, contact
      3. Analyze and interpret typical PLC counter ladder logic programs
      4. Apply the PLC counter function and associated circuitry to control systems
      5. Apply combinations of counters and timers to control Systems


    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter8_Programming Counters .pdf File


    • Second :Study the following animation examples which help you to understand the chapter.
    • Counter example :

      In the example above, each time the operator pushes button 0001 the counter accumulated value increases by one. Note that it increases only when the button first turns on. (i.e. the off to on transition). When the accumulated value equals the preset value(i.e. 5), the C000 contacts turn on and output 0500 becomes true. When the operator pushes the reset button (0002) the accumulated value changes back to 0000.

    • One-shots example :


    •  
      Third :Learners study an animated PLC counting operation and examine how the count is automatically reset.
    • resource icon
      File
      Automatic PLC Counting File

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      Fourth:In this animated object, learners examine the operation of up-counters and down-counters for a programmable controller. A brief quiz completes the activity.
    • resource icon
      File
      PLC Counter Instructions File

    •  

      Fifth:Learners examine the two methods used by programmable logic controllers to perform a counting operation using addition or counter instructions. A brief quiz completes the activity.
    • resource icon
      File
      PLC Counter Operation File
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      Sixth:Learners observe how to cascade PLC counters to extend the maximum count of one counter.
    • resource icon
      File
      Cascading Counters File

    •  

      Seventh:In this animated object, learners examine the proper way to reset a counter instruction in a programmable controller.
    • resource icon
      File
      How to Reset a Counter File
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      Eightth:Learners examine the counter-reset function of a programmable controller and how it is used.
    • resource icon
      File
      The Counter-Reset Function File
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      Ninth:In this animated object, learners examine how PLC up/Down-counters are used to control an automated parking lot gate.
    • resource icon
      File
      Up/Down-Counter Application File

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      Tenth :To gain your experience in  designing  ladder diagram.do the assignment .
    • assign icon
      Assignment
      Counter_Assignment

  • Topic 9

  • Topic 10

    Chapter nine : Program Control Instructions.

    • Introduction:

      The program control instructions covered in this chapter are used to alter the program scan from its normal sequence. The use of program control instructions can shorten the time required to complete a program scan. Portions of the program not being utilized at any particular time can be jumped over, and outputs in specifi c zones in the program can be left in their desired states. Typical industrial program control applications are explained.


    • Objectives:

      After completing this chapter, student will be able to:

      1. State the purpose of program control instructions
      2. Describe the operation of the master control resetn instruction and develop an elementary program illustrating its use
      3. Describe the operation of the jump instruction and the label instruction
      4. Explain the function of subroutines
      5. Describe the immediate input and output instructions function
      6. Describe the forcing capability of the PLC
      7. Describe safety considerations built into PLCs and programmed into a PLC installation
      8. Explain the differences between standard and safety PLCs
      9. Describe the function of the selectable timed interrupt and fault routine fi les
      10. Explain how the temporary end instruction


    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter 9_Program Control Instructions.pdf File


    • Second: To evaluate students abilities in PLC Programming we make aQuiz. 
    • quiz icon
      Quiz
      Quiz

    • Third :PLC JMP LBL Command tutorial 

    •  

      Fourth:PLC JSR Jump to Subroutine tutorial 

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      Fifth :To gain your experience in  designing  ladder diagram.do the assignment .
    • assign icon
      Assignment
      Data Transmission and Comparison Design_Assignment

  • Topic 11

    Chapter ten : Data Manipulation.

    • Introduction:

      Data manipulation involves transferring data and operating on data with math functions, data conversions, data comparison, and logical operations. This chapter covers both data manipulation instructions that operate on word data and those that operate on fi le data, which involve multiple words. Data manipulations are performed internally in a manner similar to that used in microcomputers. Examples of processes that need these operations on a fast and continuous basis are studied


    • Objectives:

      After completing this chapter, student will be able to:

      1. Execute data transfer of word and fi le level instructions from one memory location to another

      2. Interpret data transfer and data compare instructions as they apply to a PLC program

      3. Compare the operation of discrete I/Os with that of multibit and analog types

      4. Understand the basic operation of PLC closed-loop control systemsv


    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter 10_Data Manipulation.pdf File


    • Second :Study the following animation examples which help you to understand Moving Data.


    • In the example above, data memory 200 (DM200) initially holds the constant (number) 0000. Each time the operator pushes button 0000 the difu instruction will turn on (become true)FOR ONE SCAN. When this happens we load the constant(number) 2222 and move it into data memory 200(DM200). Not a very useful application by itself but it should show what the instruction pair does.


    • Third :Study the following animation examples which help you to understand Data Compare Instructions.
    • resource icon
      File
      Data Compare Instructions File

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      Fourth :To gain your experience in  designing  ladder diagram.do the assignment .
    • assign icon
      Assignment
      Loop_Assignment

  • Topic 12

    Chapter eleven: Math instruction.

    • Introduction:

      Most PLCs have arithmetic function capabilities.Basic PLC math instructions include add, subtract,multiply and divide to calculate the sum,difference, product, and quotient of the content of word registers. The PLC is capable of doing many arithmetic operations per scan period for fast updating of data. This chapter covers the basic mathematical instructions performed by PLCs and their applications.

       

    • Objectives:

      After completing this chapter, student will be able to:

      1. Analyze and interpret math instructions as they apply to a PLC program

      2. Create PLC programs involving math instructions

      3. Apply combinations of PLC arithmetic functions to Processes


    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter 11_math instruction.pdf File


    • Second :Study the following animation examples which help you to understand Add instruction


    • In the example above, data memory 102 (DM102) initially holds the constant (number) 0000. Each time the operator pushes button 0000 the difu instruction will turn on (become true)FOR ONE SCAN. When this happens we load the value(number) in DM100(100) and add it to the value(number) in DM101(200). The result, 300 in this example (100+200=300) is then stored in DM102(300).

    •   

      Third :Math instruction Definition .
    • resource icon
      File
      Math instruction Definition File

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      Fourth :Tutorial on Basic Math Instructions .


    • Seventh: To evaluate students abilities in PLC Programming we make aQuiz. 
    • quiz icon
      Quiz
      Quiz
    •   
      Eighth :Suggest a Ladder diagram and sequential  function chart program to control dishwasher in  Dishwasher machine Forum
    • forum icon
      Forum
      Dishwasher machine Forum

  • Topic 13

  • Topic 14

    Chapter twelve: Sequencer and Shift.

    • Introduction:

      This chapter explains how the PLC sequencer and shift register functions operate and how they can be applied to control problems. The sequencer instruction evolved from the mechanical drum switch, and it can handle complex sequencing control problems more easily than does the drum switch. Shift registers are often used to track parts on automated manufacturing lines by shifting either status or values through data fi les.

    • Objectives:

      After completing this chapter, student will be able to:

      1. Identify and describe the various forms of mechanical sequencers and explain the basic operation of each
      2. Interpret and explain information associated with PLC sequencer output, compare, and load instructions
      3. Compare the operation of an event-driven and a timedriven sequencer
      4. Describe the operation of bit and word shift registers
      5. Interpret and develop programs that use shift registers


    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      sequencer and shift register File


    • Second :see the following video  "PLC Programming Tutorial for Shift Registers - Using The BSR And BSL Bit Shift Instructions "to understanding the shift registers.

    		•

    •  

      Third:In this animated activity, learners study how a PLC performs a shift operation. The learning object covers data movement, data entry, PLC wiring, PLC shift register introductions, and programming for a paint can operation.
    • resource icon
      File
      PLC Shift Registers File


    • Fourth :To gain experience in  designing  ladder diagram using logic counter and timer to control different physical systems.do the follwing project.
    • assign icon
      Assignment
      Evaluation Project Assignment

  • Topic 15

    Chapter thirteen: PLC Installation Practices,Editing, and Troubleshooting.

    • Introduction:

      This chapter discusses guidelines for the installation, maintenance, and troubleshooting of a PLC-controlled system. The chapter gives you information on proper grounding that ensures personal safety as well as correct operation of equipment. Unique troubleshooting  procedures that apply specifi cally to PLCs are listed and explained.


    • Objectives:

      After completing this chapter, student will be able to:

      1. Outline and describe requirements for a PLC enclosure
      2. Identify and describe noise reduction techniques
      3. Describe proper grounding practices and preventive maintenance tasks associated with PLC systems
      4. List and describe specifi c PLC troubleshooting Procedures


    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter 13_PLC Installation Practices,Editing, and Troubleshooting.pdf File
    •  
      Second:Learners consider the correct type of pushbutton to use as a Stop button, the way the Stop button should be hard wired, and the PLC input instruction to use. This animated object includes a short quiz. It is recommended that learners review the learning object “The PLC Examine-Off Instruction” before beginning this object.
    • resource icon
      File
      Stop-Button Wiring to a PLC File

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      Third :In this animated object, learners examine the operation and programming requirements of a PLC Examine-Off instruction. A brief quiz completes the activity.
    • resource icon
      File
      The PLC Examine-Off Instruction File

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      Fourth: Programmable logic controllers from Siemens and Allen Bradley PLC ...

    • url icon
      URL
      Allen Bradley PLC ... URL
    • url icon
      URL
      Programmable logic controllers from Siemens URL

    •  

      Fifth:To gain your experience in  designing  ladder diagram.do the assignment .
    • assign icon
      Assignment
      Rotation and Shift Design _Assignment

    •  

      Sixth :Suggest  a sequential function chart program to control the level of water in a storage tank using the Sequential Function forum.

    • forum icon
      Forum
      Sequential Function Forum

  • Topic 16

    Highlighted

    Chapter fourteen: Process Control, Network Systems, and SCADA.

    • Introduction:

      This chapter introduces the kinds of industrial processes that can be PLC controlled. SCADA is such a process. Different types of control systems are used for complex processes. These control systems may be PLCs, but other controllers include robots, data terminals, and computers. For these controllers to work together, they must communicate. This chapter will discuss the different kinds of industrial processes and the means by which they communicate


    • Objectives:

      After completing this chapter, student will be able to:

      1. Discuss the operation of continuous process, batch production, and discrete manufacturing processes
      2. Compare individual, centralized, and distributive control systems
      3. Explain the functions of the major components of aprocess control system
      4. Describe the various functions of electronic HMI screens
      5. Recognize and explain the functions of the control elements of a closed-loop control system
      6. Explain how on/off control works
      7. Explain how PID control works 

    • Plan:

      First :Study the chapter presentation .
    • resource icon
      File
      chapter 14_Process Control, Network Systems, and SCADA.pdf File

  • Topic 17

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