COMMUNITY COLLEGE OF ALLEGHENY CAMPUS

SOUTH CAMPUS

Programmable Logic Controllers

RBT-235-SC61

SYLLABUS AND COURSE NOTES January 22, 2016, Revision #1

D. Joseph Wolf

Syllabus_RBT235_16_Weeks_Rev1_S16.DOC

Rev 1 Page 1

TABLE OF CONTENTS

COURSE INTRODUCTION: ................................................................................................................................................................. 2

LISTED TOPICS: .................................................................................................................................................................................... 3

SYLLABUS: RBT235-SC61; PROGRAMMABLE LOGIC CONTROLLERS ................................................................................ 4

GRADING SPECIFICS FOR MIT-103 ................................................................................................................................................. 5

WEEKLY AGENDA (UPDATED 1/7/2016): ........................................................................................................................................ 6

LAB REPORT GRADING: .................................................................................................................................................................... 8

MISC. ASSIGNMENTS, EXTRA CREDIT, AND REVIEW MATERIAL ..................................................................................... 10

SUMMARY TABLES ........................................................................................................................................................................... 11

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COURSE INTRODUCTION:

This is a course providing a working knowledge of programmable logic

controllers (PLCs). Topics include terminology, basic and advanced relay

logic programming, and connection and control of input/output devices.

Emphasis is placed on interfacing, operating, and the programming of

robotic and industrial automation devices.

The course Programmable Logic Controllers is designed to introduce the

engineering technology student to the modern uses of the computer in an

industrial setting. The programmable logic controller or PLC is used by

industry to control a number of processes. Sequential control is one of

the most common uses of the PLC and will be emphasized in this class. The

laboratory will involve projects designed to introduce features and

techniques useful to PLC work. In doing this the Allen Bradley line of

PLCs will be used. These units are representative of the units used in

industry, but are not necessarily the exact units a student might encounter

in a specific company. Although the purpose of the course is to teach the

concepts and not to train on a specific manufacturer and model of PLC,

sufficient experience will be gained on the Micrologix 1500 to list that

experience on resumes.

A series of lab and shop activities will be completed and all work must be

approved by the instructor before power is applied. In this course we will

work with voltages from 12 V DC to 120 VAC. Neat and correct wiring

techniques will be stressed! It is suggested that a three ring binder be

used to record and keep the results of all projects.

In addition to the traditional technical topics, this course will also

explore non-technical topics that are essential to success in industry.

These topics include documentation of your work, planning, estimating,

reporting, and people and social skills in the workplace.

Prerequisites: None

LEARNING OUTCOMES:

1. The student should be able to read, modify, and input a ladder logic program.

2. The student should be able to create the ladder program for a simple sequential control project involving up to 8 inputs and outputs.

3. The student will troubleshoot the wiring and programming of a programmable logic controller to secure proper operation.

4. The student will demonstrate teamwork and leadership in the laboratory/shop environment.

5. The student will demonstrate acceptable documentation techniques as provided in the course handouts.

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LISTED TOPICS:

I. Introduction

A. Controllers

B. Number systems

C. Logic concepts

II. Component Parts of Controller

A. Power Supply

B. Processor

C. Memory Systems

D. Input/Output systems

III. Languages

A. Ladder Diagrams

B. Timers

C. Communications

D. Special Functions

IV. Sensors

A. Thermal

B. Optical

C. Pressure

D. Flow

E. Position

F. motion

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SYLLABUS: RBT235-SC61; Programmable Logic Controllers

LOCATION: Mondays, 6:00-10:20pm

INSTRUCTOR: Daniel J. Wolf

PHONE: 412-657-4561 (text messages preferred)

EMAIL: dwolf@ccac.edu or dan.wolf.danwolf@gmail.com

WEBSITE: http://web.acd.ccac.edu/~dwolf

SUPPLIES: You will need one USB Memory Stick (512M or larger preferred)

TEXT: Programmable Logic Controllers by P. Cunningham, W. Erevelles,

and A. Simons

CLASS ATTENDANCE:

Attendance will be graded. Advance notice must be provided if you will miss

a class and you are still responsible for missed material, handouts, etc.

Cell phones shall not be used during the class lecture period.

GRADING:

The final grade will be based on exams and the lab assignments. Pages 2 and

3 describe, in greater detail, the grading requirements.

Late assignments will be down-graded by ten points per week. Failure to

take an exam without prior notification, will earn an 'F' (0%) for the exam.

Incomplete grades will not (normally) be given without a good excuse.

TENTATIVE SCHEDULE:

Jan. 25 First Class

Mar. 14 Exam #1 (Week #8)

Mar. 21-27 Spring Break – No Class

May 9 Review; All Programs and work due (Week #15)

May 16 Final Exam (Week #16)

MISC:

Questions are expected and welcome. The questions that you ask are my clues to

your understanding of the course material. I will tailor the course content and

pace to your responses so you must inform me if you do not understand something.

Class break times are limited. Please do not stretch a five-minute break out to

20 minutes. We will normally take a short break halfway through the lecture

period - please let me know if you need extra time. During the lab period, you

may take a break whenever you choose.

CCAC recognizes its role in providing Services for Students with disabilities.

If you think you have a disability that may impact your performance in this

class, please contact your instructor or the Office of Services for Students with

Disabilities (412-469-6215).

The CCAC Honors Program is an opportunity for interested students to work

interactively with the instructor on a course project of your choosing.

The program provides you with an honors designation on your transcript as

well as work related project experience. Please see me if you are

interested in the CCAC Honors Program.

Hint: Sit towards the front of the classroom, not the back. Pay attention

during class and do not work on the PCs while the instructor is teaching.

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GRADING SPECIFICS FOR MIT-103

FINAL GRADE:

A) Participation.........................................10%

This is based on attendance, quality/quantity of

your responses, questions/comments to the

instructor, interest & enthusiasm for the material

and whether your overall interactions would be an

asset to a corporation. The weighting of these

guidelines is at the instructor’s discretion.

B) Completion of eight labs (no lab report)..............10%

There are eight labs that must be completed but do

not require a lab report. You will be required to

answer questions or submit a printout or screen

dump of your work.

Weeks #2-4, 6, 7, 9-11

C) Three formal lab reports..............................30%

Vat Mix Report Week #7

Robot Pallet Report Week #12

Project (TBD or waived) Week #14

D) Mini-Quiz Assignments.................................10%

Ladder & Wiring Diagrams Week 3

PLC Programming Week 5

Latches, Counters, Timers Week 7

I/O & Math Week 9

Course Review Week 12

E) Comprehensive Mid-Term Exam Week #8...................20%

F) Comprehensive Final Exam Week #14.....................20%

------

100%

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WEEKLY AGENDA (Updated 1/7/2016):

Week Module Pages Activity

1

1/25/16

Pg 1 to 12 (Sections 1.1 to 1.2.2)

Module 1 - Intro and Wiring Do all explorations and applications.

2

2/1/16

Pg 13 to 45 (Sections 1.2.2 to 1.3.8)

Module 1 - Wiring and PLC Intro Simple electrical control, ladder diagrams and circuits PLC components Informal Lab Material to be submitted:

Section 1.2.5 – Three PPS sheets Section 1.3.8 – PPS sheet

3

2/8/16

Pg 46 to pg 64 (Sections 1.4 to 1.4.6B)

Module 1 - PLC Demo and Try-out Connecting the PLC Informal Lab Material to be submitted

Section 1.4.6.A – PPS sheet Section 1.4.6.B – PPS sheet

Mini-Quiz

4

2/15/16

Pg 65 to 75 (Sections 1.4.7 to 1.5.4)

Module 1 - Inputs and Outputs, Reset logic Application of PMC and benefits of a PLC Informal Lab Material to be submitted

Section 1.4.7 – PPS sheet Section 1.4.8 – PPS sheet Section 1.4.10 – PPS sheet Section 1.5.2 – PLC Table Section 1.5.4 – Applications 1 to 3

5

2/22/16

Pg 76 to 90 (Sections 2.1 to 2.2.4)

Module 2 Latches and Bits Informal Lab Material to be submitted

Section 2.1.1 – PPS sheet Section 2.1.5 – PPS sheet Section 2.2.2 – PPS sheet Section 2.2.4 – PPS sheet

Mini-Quiz

6

2/29/16

Pg 91 to 102 (Sections 2.3 to 2.3.4)

Module 2 Timers Informal Lab Material to be submitted

Section 2.3.4 – PPS sheet

7

3/7/16

Pg 103 to 112 (Sections 2.3.5 to 2.3.9)

Module 2 Counters Informal Lab Material to be submitted

Section 2.3.7 – PPS sheet Formal Vat Mixer Report Section 2.3.8 Mini-Quiz

8

3/14/16

Pg 113 to 121 (Sections 3.1 to 3.1.1)

Module 3 Analog Input Informal Lab Material to be submitted

Section 3.1.1 – Six Questions Answered

Mid-term exam

4/21/16 No class Spring Break

9

3/28/16

Pg 122 to 135 (Sections 3.1.1.Part 2 to 3.2.3)

Module 3 Math Instructions, EQU, LES,GRT, ADD, SUB Informal Lab Material to be submitted

Section 3.1.3 – PPS sheet Section 3.2.1 – Two graphs & four questions Section 3.2.3 – PPS sheet

Mini-Quiz

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Week Module Pages Activity

10

4/4/16

Pg. 136 to 145 (Sections 3.2.4 to 3.2.7)

Module 3 Process Control Informal Lab Material to be submitted

Section 3.2.4 – Temperature table Section 3.2.5 – Table, Graph, and questions Section 3.2.7 – PPS sheet

11

4/11/16

Pg 146 to 161 (Sections 3.3 to 3.3.4)

Module 3 Sequences Informal Lab Material to be submitted

Section 3.3.1 – PPS sheet & questions Section 3.3.3 – PPS sheet Section 3.3.4 – PPS sheet

12

4/18/16

Pg 162 to 176 (Sections 3.3.5 to 3.3.9)

Module 3 Complete sequence project Informal Lab Material to be submitted

Section 3.3.6 – PPS sheet Formal Robot Pallet Report – Section 3.3.9 Mini-Quiz

13

4/25/16

Project work Module 4 Course Review

Formal Report: topic is TBD (possible group project)

14

5/2/16

Tbd tbd

15

5/9/16

tbd Tbd

16

5/16/16

Final Exam Final Exam All Assignments are Due

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LAB REPORT GRADING:

Individual lab reports are graded (whenever possible) after the entire

class has turned them in. This provides the most grading consistency.

General Concepts:

1. Each lab write-up should include the following sections:

INTRODUCTION - Explain the newly introduced concepts of the lab.

BODY - Discuss the lab itself.

Label and explain each of the experiments.

Include program listings and flowcharts when appropriate.

Include any tables, calculations, data, or results.

CONCLUSION – This is your summary. Explain what you learned.

If something did not work then explain why you think it did not work.

An explanation of why something did not work may be worth more than

something that DID work. This section is rather important.

2. LABEL the Introduction, Body, and Conclusion sections as well as each

experiment. The listings may be appended to the end of the lab and

referenced within the text. I.e. See Listing 4.

3. Labs are partially graded against the rest of the class. In other

words, one student may turn in a thick lab with great detail and

another student turns in a smaller lab with less detail. Even if both

labs are excellent, the more detailed lab will get more points.

4. The lab write-up must convince me that you understand the concepts of

the course. It is a fact that you may understand the material very

well and still not receive an 'A' if you are unable to convince me

that you know the material.

5. The lab WORK may be a combined effort between lab partners however the

actual program coding and lab write-up is to be an individual effort.

Copying another program will result in a less-than-optimum grade.

6. All program printouts must include your name and date on the first

line as a comment statement.

6. Lab reports not turned in will receive a 0%. This significantly hurts your average. It is much better to turn in something!

7. Use the Microsoft Word spelling and grammar checker. Ask the instructor for help if you do not know how to use it.

How to 'pass' the lab (D or C grade):

1. Complete every lab and turn in all of the write-ups. Do the minimum.

How to get an 'A" lab grade:

1. Do the optional experiments and/or ADD ON TO THE LABS IN SOME FASHION.

I am constantly encouraging students to modify and enhance the labs.

2. There are many topics/concepts covered (and not covered) in this

course. Try everything at least once. This shows me that you have

the deeper understanding of the material that the 'A" grade

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represents. I will be 'volunteering' techniques and lab options

throughout the course. Try them.

3. Discuss as many of the subtle issues within the lab as possible.

Relate the class discussions to the labs. Explain WHY things are so.

Explain alternate ways of programming the lab.

4. If you do not do anything extra or optional to a lab, it is rather

unlikely that it will receive an “A" grade.

5. Format your lab report so that the sections are clearly identified and

easy to understand.

6. It is true: neatness and readability really can affect your grade. I don't check spelling and grammar but continued, incorrect spelling and

poor sentence structure will eventually decrease my understanding of

your work. A very good grammar book, The Elements of Style by William

Strunk, Jr., can be found on-line at

http://www.bartleby.com/141/index.html. This book is only about 40

pages and can be printed or read quickly on-line.

7. Labs should be typed on a computer. The “Write” or “WordPad” programs that come with Windows are more than adequate for this class. If you

use a word processor like MS-Word, don’t forget to make use of larger

fonts and bolding for titles. MS-Word is more powerful and should be

used if it is available. HINT: The MS-Word spelling and grammar

checker should ALWAYS be used. If you want to use MS-Word and don’t

have it, see me – there are very good free clones available (Open-

Office). Ask me for help.

8. Make the effort to interact with the instructor and other students. Do not hesitate to ask for help and/or comment on the material /

class. In industry, your interactions with your co-workers and

managers will significantly determine your success and opportunities.

A very smart engineer who lacks people skills and/or social

interactions will usually be at a disadvantage.

9. Arrive on time to class each night. Work on the class material during class time. Leave when you are done but do not rush/skim a lab and

then be the first student to leave. If you finish the allocated lab

material early, work on options for a while.

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MISC. ASSIGNMENTS, EXTRA CREDIT, AND REVIEW MATERIAL

1. INFORMATION SHARING

In order to encourage the sharing of information:

Acquire the following information from another student.

1. Name of other student 2. Name of dog, cat, or pet. If no pet, then hobby or interest. 3. Place of work. If no current work, then place of last

employment.

4. How valuable do they think this class material will be to them? 5. What would they change to make the class more meaningful?

You must select a student that you do not know.

You may not select a student that sits on either side of you.

You should select a student on the other side of the room.

2. EMAIL STRATEGY and ETIQUITE

You are the lead person on a software project with four other

engineers and you work closely with the hardware and manuals groups.

The hardware group must support your team by helping to debug the

hardware as you write the software. On the other hand, the manuals

group is responsible for writing the software users manual and your

team must support them by explaining how the software will be used.

You realize that, if you get either group upset, they will not be as

responsive to your requests for help.

Your team must be done with the final testing and ready for the big

factory test by the end of next month. You feel that you are not

going to make the due date. You also realize that part of the work

slippage has been that your team has made a few mistakes and had to

rework code.

In addition, the hardware group has another major project and has not

been helping you as much as you feel is necessary – your team is

complaining to you about this but your efforts to get more hardware

support have not helped. As if that is not enough, the manuals group

has assigned an entry-level technical writer to their effort. He is a

good person but he doesn’t understand any part of the product and is

constantly directing questions to your team members – the

interruptions are preventing them from hitting their targets and

causing them to make mistakes in their own work.

You must do something. Write an email to your boss (your instructor)

and say whatever you feel is necessary.

Note: There are different ways to deal with this problem. I will

review these, critique them, and distribute some or all of them to the

class. The idea is to observe the different ways of dealing with this

(very common) situation.

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SUMMARY TABLES

FUNCTION BIT EXAMPLE LADDER LOGIC DIAGRAM PLC DIAGRAM

O0 - Output 0 O:0.0/0

OTE – Output Energize

1 O:0.0/1

L

OTL – Output Latch

2 O:0.0/2 U

OUT – Output Unlatch

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FUNCTION BIT EXAMPLE LADDER LOGIC DIAGRAM PLC DIAGRAM

I1 – Input 0 I:0.0/0

N.O. Pushbutton Switch

SW = Released = Open = 0

XIC SW = Pressed = Closed = 1

I:0

1

Button #1

N.O. Switch #1

1 I:0.0/1

N.O. Pushbutton Switch

SW = Released = Open = 1

XIO SW = Pressed = Closed = 0

I:0

3

Button #3

N.C. Switch #3

2 I:0.0/2

N.C. Pushbutton Switch

SW = Released = Closed = 1

XIC SW = Pressed = Open = 0

3 I:0.0/3

N.C. Pushbutton Switch

SW = Released = Closed = 0

XIO SW = Pressed = Open = 1

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FUNCTION BIT EXAMPLE NOTES PLC DIAGRAM

S2 – Status

B3 – Binary B3:2/0

File: B3, Memory Location: 2,

Bit: 0

Bits 0 to 15 allowed

Note the lack of the colon

after the B

B3:2

15

File3, Location2,

Bit15

B3:0/1

B3:1/12

OSROne Shot Rising

Storage Bit B3:2/14

Output Bit B3:2/15

OSR

OSR – One-shot Rising

T4 – Timer

T4:0

T4:0/EN

T4:0/TT

T4:0/DN

Note the lack of the colon

after the T

EN

DN

TONTimer On Delay

Timer T4:8

Time Base 1.0

Preset 5 <

Accum 0 <

TON

TON – Timer On-Delay

T4:1

T4:0/PRE

T4:0/ACC

EN

DN

TOFTimer Off Delay

Timer T4:8

Time Base 1.0

Preset 5

Accum 0

TOF

TOF – Timer Off-Delay

T4:2

EN

DN

RTORetentive Timer On

Timer T4:8

Time Base 1.0

Preset 5

Accum 0

RTO

RTO – Retentive Timer

T4:8

Rev 1 Page 14

FUNCTION BIT EXAMPLE NOTES PLC DIAGRAM

C5 –

Counter

C5:0

C5:0/CU

C5:0/CD

C5:2/DN

C5:2/OV

C5:1/UN

C5:1/UA

C5:0.PRE

C5:0.ACC

There are 84 counters available

on this PLC.

Note the lack of the colon

after the C

CU

DN

CTUCount Up

Counter C5:2

Preset 5 <

Accum 0 <

CTU

CTU – Count Up

CD

DN

CTDCount Down

Counter C5:2

Preset 5 <

Accum 0 <

CTD

CTD – Count Down

RESC5:2

RES - Reset

R6 –

Control R6:0/EN

N7 –

Integer N7:0

R8 –

Reserved