Department of Electrical Engineering

Government Polytechnic, Pune.

Programmable Logic Controller (P.L.C.) & H.M.I
programming Training- Certificate Course
PLC-Curriculum
Course Duration: Modular (Module 1 is compulsory & Remaining Modules are optional)

Module-1:A) Fundamentals Of P.L.C. (Compulsory)

B)

(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 as per IEC:61131-3
Advantages of PLC
Block diagram And Architecture of 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
PLC Hardware
Communication protocols & cables 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 software
PLC Vs PC
PLC Manufacturers
PLC Installations, Troubleshooting and Maintenance:
(3 hrs)
Environmental factors to be considered while Installing PLC
Electrical factors and protection of electrical circuit
Troubleshooting of PLC
PLC maintenance
Factors to be considered while selecting PLC

Module-2:Messung (NEXGEN 5000) PLC & HMI Programming:

Features of NEXGEN5000, Technical specification of PLC

Features CoDeSys Software (This is as per IEC 61131-3)
Structure of project, POUs: Program, Function & Function Block
Creating New Project in Ladder Diagram editor/ language
Data types, PLC or I/O Configuration & Addressing system of PLC
Visualization Features of CoDeSys
Memory mapping & memory addressing
System components of PLC, wiring of PLC modules & I/O devices

(45 hrs)

 PLC function blocks and programming:

1. Timer, Types of timer & programming on timer applications
2. Counter & types of counters & programming on counter/ timer application
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
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, Specification, Installation and Connection to PLC
2. Creating screen, multiple screens, navigating screen, buttons, Tags
3. Touch Screen: Creating soft keys & function user keys, Turn ON bit / Toggle bit
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

Module-3:Allen Bradley PLC& RSLogix 500 Software:

(25 hrs)

Product Overview :ABS PLC

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 timer /counter 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

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 conducted 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:
J.G. Momin Mobile: 9096907127
Prof. D. A. Katare (HOD Electrical Dept.) Mobile: 9403684437

Fee Structure:
Module 1
Period
20hrs
Fees
Rs 2000/-

Module 2
45 hrs
Rs 5000/-

Module 3
25 hrs
Rs 3000/-

Module 4
40 hrs
Rs 4500/-

Module 5
15 hrs
Rs 1500/-

Total
145 hrs
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) Gents 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 mentioned on certificate.
Co-ordinator,
HOD
P.L.C. Course.
Department of Electrical Engineering.
Government Polytechnic, Pune.