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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: [email protected] or [email protected]
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
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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