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The syllabus for the subjects PLC course - EE-464

Professor Jack Toporovsky

This course converts complex world of PLCs into practical.
In this course students will be introduced to different process control concepts, learn different PLC
languages based on Allen Bradley and Mitsubishi.
The course is divided into two parts, namely industrial automation and process modeling and control.
In the first part, hydraulic and pneumatic system in industrial automation is introduced and their logic
design is elaborated. Next, Programmable Logic Controllers (PLC) are introduced and their hardware and
software are explained, special attention to ladder programming for industrial
processes are examined through comprehensive examples. Allen Bradley and Mitsubishi PLC's are briefly
introduced here, due to its intensive use in industries. Lab work will be aimed for making different logics
in RS500, RS5000 and GX-Developer (Melsec) languages.
The second part of the course covers modeling of industrial processes through physical principles, and
also identification of them using time and frequency domain techniques. Tuning of industrial controllers
like PID. Finally the controller implementation through pneumatic, electric, electronic hardware as well
as digital implementation is introduced. The student will practice their knowledge of PLC programming
in the LAB. Learn the basic of drive, HMI programming and controlling in close loop with SLC500 PLC.
1. Introduction:
Process to rewind, test, and integrate with extrusion process for wiring and fiber optic industries
Food industry yeast, flour distribution and control
Process Medical equipment Industry Gas analyzer, Leak tester (using CO2), plastic wrapping machines
Mechanical relays versus PLC
2. How PLCs work
2.1 Different types of PLCs Allen-Bradley Micrologix:
ML1000, ML1100, SLC500, CompactLogix, Mitsubishi FX series, HMIs
2.2 Processor and I/O carts
2.3 Introduction to EasyVeep software
3. Sensing devices
3.1 Valves and actuators,
3.2 Position control of hydraulic cylinders,
3.3 Photo eye (sensors)
3.4 Reed switches on the air cylinder.,
3.5 limit switches
3.6 Proximity sensors
Logic from Plastic Assembly System to check the seal of vile
3.7 Timers, counters
3.8 Temperature controllers
3.9 Pressure transducer
3.10 Flow meters
4. Electrical Engineering Documentation
4.1 File organization

4.2 Link between mechanical, electrical and programming documentation

Food industry Yeast distribution system - Example
5. Logic diagrams
5.1 Flip-Flop Logic, M8000, M8001 internal bits interpretation
5.2 Binary code, data table, manipulation and search engine in Mitsubishi
5.3 Communication between PC and PLC
5.4 Communication between PC and HMI, PLC and HMI
Local network
Introduction to SLC500
6. Programming software and applications

6.1 Boolean algebra understanding binary code

6.2 ADD and SUB functions
6.3 UP and Down Counters
6.4 Introduction to k1Y0
6.5 MOV function
6.6 CPR and ZCP functions
6.7 SHWT and SHRD instructions
6.8 Introduction to Absolutely Drum Instruction
7. Allen Bradley PLC
7.1 Introduction to Rockwell Software
7.2 Hardware focus
7.3 Hardware considerations ( Field wiring, Master Control Relay, VFD )
Basic programming applications
Cascade control subroutine
Different programs and detail explanation
8. Programming instructions
8.1 Instructions and binary interpretation:
8.2 Bit Instruction
8.3 Timers and counters
8.4 Comparison instructions
9. Programming Instructions
9.1 Math instructions
9.2 Move and Logical Instructions
9.3 Discussions of programming communications for PLC-Robotic arm
9.4 Exercise of setup and monitoring
Analog and Digital parameters by using SLC5/03-VFD-Panel Mate series 1700

10. Practical Troubleshooting

10.1 Troubleshooting technique
10.2 Control system stability and tuning basics.

Books and helpful material:

Handy manual FX-Series programmable controllers Mitsubishi
MELSEC-F (Stepladder instruction p.61, Model name format p.9)
Micrologix 1000 Programmable Controllers User Manual
Allen-Bradley Advanced Programming Software
Logix5000 Controller Common Procedures
SLC500 User Manuel Cat. No. 1747-KFC15
Midterm 25%
Final 45%
Home works 15%
Attendance 15%

Textbook: Refer to the Blackboard. All manuals and reports are uploaded on Blackboard.

Cheating and Plagiarism: It is students responsibility to familiarize himself or herself with and adhere to the standards set forth in
the policies on cheating and plagiarism as defined in chapter 2 and 5 of the key UB or the appropriate graduate program handbook.