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Department of Electrical Engineering.

Government Polytechnic, Pune.


Programmable Logic Controller (P.L.C.) & H.M.I
programming Certificate Course.

Course Duration: Modular. (Module 1 is compulsory & Remaining Modules are optional.)
Module: 1 A) Fundamentals Of P.L.C. (Compulsory) (17 hrs)
Logic Gates: AND, OR, AND-OR, OR-AND, NOT, NAND, NOR, EX-OR, EX-NOR.
Electrical logics of all above gates.
Disadvantages of relay & solid state switching devices control panel.
Programmable Logic Controller.
Types of PLC & Programming Languages of PLC.
Advantages of PLC.
Block diagram And Architecture of a PLC:
1. Input devices such as limit switches, proximity switches, float switches, thermostat,
temperature sensors etc.
2. Output devices such as contactors, relay, Solenoid valve etc.
3. Input & Output modules: Types, sink/source concept, connection of I/O devices.
4. Architecture of CPU & Memory of PLC.
5. Input image file (table) & output image file (table).
6. Scan cycle &Watchdog timer.
7. Power supply.
8. Programming devices of PLC.
Hardwire system of PLC system.
Communications protocols & cable such Rs232, Rs422, Rs485, Ethernet, etc.
Ladder diagram development on logic gates & simple applications.
FBD programming concept & programming on it.
Programming on different PLC simulations softwares.
PLC Vs PC.
PLC Manufacturers.
B) PLC Installations, Troubleshooting and Maintenance. (3 hrs)
a. Environmental factors to be considered while PLC Installation.
b. Electrical factors and protection of electrical circuit.
c. Troubleshooting of PLC.
d. PLC maintenance.
e. Factors to be considered while PLC system selections.

Module: 2 Messung (NEXGEN 5000) P.L.C., & HMI Programming. (45 hrs)
Features of NEXGEN5000, Technical specifications of PLC.
Features CoDeSys Software (This is as per IEC 61131-3).
Structure of project, POUs: Program, Function Block & Function.
Creating New Project in Ladder Diagram editor/ language.
Data types, PLC or I/O Configurations & Addressing system of PLC.
Visualization Features of CoDeSys
Memory mapping & memory addressing.
System components of PLC, wiring of PLC modules & I/O devices.
PLC functions blocks and programming:
1. Timer, Types of timer & programming on timer applications.
2. Counter & types of counters & programming on counter/ timer applications.
Advanced programming:
1. Arithmetic functions.
2. Comparison functions & logical functions.
3. Data transfer functions.
4. String handling functions.
5. Data type conversion instructions.
6. Real time clock handling instructions.
7. Subroutine programming (calling user define program& function), Return, Jump &
Label.
8. Export & import of project.
9. Analog programming & Scaling to engineering units.
Programming using structured text (ST) editor.
10. Fundamentals of ST.
11. Operators, Expressions & Evaluation of expressions.
12. Boolean, Arithmetic, Comparison Operators, Bitwise operators and operators like
LIMITALARM, MOVE, and SIZEOF.
13. Selection Operators like LIMIT, MAX, MIN, SEL, and MUX.
14. String Functions and Bitwise operators.
15. Calling function blocks in programming. E.g. timers, counters & other FB etc.
16. IF, IF-ELSE, CASE, FOR, WHILE.
17. Dynamic Variables (Pointers).
18. Programming on industrial applications.
HMI (MMI) Programming on Smart Touch HMI.
1. Introduction of HMI, Specifications, Installation and Connection to PLCs.
2. Creating screen, multiple screens, navigating screen, buttons, Tags.
3. Touch Screen: Creating soft keys & function user keys, Turn ON bit / Toggle bits.
4. Text input & output, Numeric inputs & outputs, date /time display, bitmaps.
5. Create objects such as analog meter, bar graph. Trends & alarm management.
6. Real Time Clock (RTC) Management.
Project on Messung PLC (Only for interested participants.)

Module: 3 Allen Bradley P.L.C. & RSLogix 500 – Software. (25 hrs)
Product Overview AB’s PLCs.
RsLogix 500 software: Features, Controller, Program files, Data files, Force files, User
defined data files etc.
Addressing Methods & Programming of digital I/O instructions on MicroLogix PLC.
PLC I/O Configurations, I/O Modules.
Addressing Methods & Programming of digital I/O instructions on Modular PLC.
Programming on digital I/O and interlocking.
PLC functions and programming:
1. Timer, Types of timer (TON, TOF & TRO) & programming on timers applications.
2. Counter, types of counters (CTU, CTD& Up-Down) & programming on counters.
3. Programming on timers /counters applications.
Advanced programming:
a. Mathematical functions, Comparison functions, logical functions & programming.
b. Data Manipulation functions.
c. Subroutines (Program flow) Instructions & Subroutines programming.
d. Sequencer Instructions & programming on sequencer.
e. Analog programming & scaling functions.
Documentation of PLC System.

Module: 4 B & R P.L.C. and H.M.I. programming. (40 hrs)


Introduction to B&R and product overview.
Hardware Specifications of the Practical Set Up used.
Introduction to Programming Software B&R Automation Studio.
Different Data types & function blocks for conversion of data types.
Different Communication protocol for online communication with PLC like Serial,
Ethernet.
Use of simulation software for Programming.
Programming using Ladder Editor. (Graphical Language).
o Use of different relay contacts in Ladder & variable declarations.
o Use function blocks like Timer, Counter, data type conversion etc.
Programming Using Hardware.
o Creating Compact Flash.
o Inserting of DI,DO,AI,AO,AT
o Linking of Internal flags to Physical Hardware.
Programming using Automation Basic (Text Language)
o Features and fundamentals of Automation Basic.
o Operators like Comparison <> , Mathematical (+ -),Logical (AND , OR , NOT)
o Data type conversion (Implicit & explicit).
o Decision loops such as IF, IF- ELSE, IF-ELSE IF, Nested IF and CASE statements.
o Looping Statements and use of dynamic variables.
o Use of function blocks like timers, counters.
Working with Analog Variables.
o Analog Inputs (0 – 20mA , +/- 10V)
o Analog outputs (0 – 20 mA , +/- 10V)
o Temperature inputs (J type thermocouple)
o Scaling function block for Analog Inputs ( converting analog counts to voltage)
Concept of Multitasking.
Programming diagnostics.
o Watch.
o Trace (Oscilloscope).
o Line Coverage (For text Language).
Visualization (HMI) Programming:
o Basics of Visualization and HMI.
o Creating new project of visualization.
o Creating Pages and use basic controls like Text box, numeric, string, buttons,
virtual keys (Soft key) & function keys,
o Creating Common Layer, Borders & Style sheets, Variables management, Text
group ,Bitmap group, Date & time
PID
o Concept of PID
o Auto tuning of PID with practical set-up.

Project on B&R PLC * (* - Project is only for interested participants.)


Module: 5. Pneumatics and Hydraulics system with PLC Programming. (15 hrs)
Fundamentals & Salient Features of Pneumatics and Hydraulics system.
Components of Pneumatics and Hydraulics system & applications.
Analysis & design of Pneumatics and Hydraulics control circuits.
Simulations of Pneumatic control circuits using simulation software.
Interfacing of pneumatic and Hydraulic systems to PLC & I/O addressing.
Controlling the actuations of pneumatic cylinders by using PLC programming.
Controlling the actuations of hydraulic cylinders by using PLC programming.
Programming on pneumatic and Hydraulic systems.

PLC and HMI Training course is conducting on


 Simulation softwares.
 Allen Bradley PLC.
 Messung PLC and Smart Touch HMI.
 B & R PLC with power panel (i.e. PLC & HMI).
 Pneumatics & hydraulics systems interfaced with PLC.
 One computer in two students.

For contact: Prof: Kalyan Kakade Ph: 9423239163, Miss: Teju Ph: 9881297641
E-mail: plcgppelectrical@gmail.com
Fee Structure:
Module 1 Module 2 Module 3 Module 4 Module 5 Total
Period 20hrs 45 hrs 25 hrs 40 hrs 15 hrs 145 hrs
Fees Rs 2000/- Rs 5000/- Rs 3000/- Rs 4500/- Rs 1500/- Rs 16000/-

Note: 1) Fees for complete package consisting module 1 to 5 will be Rs 14000/-.


2) Fees in installments can be accepted as per module fee structure.
3) Gent’s hostel facility will be available for outstation students.
4) There will be 10% fee concision for group (minimum 5) registration with letter from
industry or sponsoring industry or institute.
5) There will be 50% fee concision for regular students & staffs of Govt. Polytechnics,
Maharashtra State. (Proof or letter from Principal.)
6) Any one fee concision can be availed but not more then one.
**The certificate will be issued after successfully completion of course and end
examination for each module. The examination will be based on objective type test and
practical examination on each PLC.
*** Only successfully completed PLCs & HMI will be mention on certificate.

Co-ordinator.
$ (This is for private circulation only) ( P.L.C. Course.)
Department of Electrical Engineering.
Government Polytechnic, Pune.