ProgrammableLogicalControllerPLC
ProgrammableLogicalControllerPLC
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Course Title PROGRAMMABLE LOGIC
CONTROLLER (PLC)
Objectives and Employable skills for DAE in Electrical / Electronics through an intensive
Expectations
course on Programmable Logic Controller (PLC)
The course therefore is designed to impart not only technical skills but also
soft skills (i.e interpersonal/communication skills; personal grooming of the
trainees etc) as well as entrepreneurial skills (i.e marketing skills; free lancing
etc). The course also seeks to inculcate work ethics to foster better
citizenship in general and improve the image of Pakistani work force in
particular.
Main Expectations:
In short, the course under reference should be delivered by professional
instructors in such a robust hands- on manner that the trainees are
comfortably able to employ their skills for earning money (through wage/self-
employment) at its conclusion.
This course thus clearly goes beyond the domain of the traditional training
practices in vogue and underscores an expectation that a market centric
approach will be adopted as the main driving force while delivering it. The
instructors should therefore be experienced enough to be able to identify the
training needs for the possible market roles available out there. Moreover,
they should also know the strengths and
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documentaries. Needless to say that if the training provider puts
his heart and soul into these otherwise non-technical components,
the image of Pakistani workforce would undergo a positive
transformation in the local as well as international job markets.
• Success Stories
• Case Studies
These techniques would be employed as an additional training tool wherever
possible (these are explained in the subsequent section on Training
Methodology).
Lastly, evaluation of the competencies acquired by the trainees will be done
objectively at various stages of the training and proper record of the same will
be maintained. Suffice to say that for such evaluations, practical tasks would
be designed by the training providers to gauge the problem solving abilities of
the trainees.
Training Tools/
Methodology
(i) Motivational Lectures
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Trainees Fit so that the situation is actionable by trainees and not
represent a just idealism. Ending Points to persuade the trainees on
changing themselves.
A good motivational lecture should help drive creativity, curiosity and spark
the desire needed for trainees to want to learn more.
Impact of a successful motivational strategy is amongst others commonly
visible in increased class participation ratios. It increases the trainees’
willingness to be engaged on the practical tasks for longer time without
boredom and loss of interest because they can clearly see in their mind's eye
where their hard work would take them in short (1-3 years); medium (3 -10
years) and long term (more than 10 years).
As this tool is expected that the training providers would make arrangements
for regular well planned motivational lectures as part of a coordinated strategy
interspersed throughout the training period as suggested in the weekly lesson
plans in this document.
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Through an audio/ videotaped message (2-3 high quality videos must
be arranged by the training institute)
It is expected that the training provider would collect relevant high quality
success stories for inclusion in the training as suggested in the weekly lesson
plan given in this document.
Suggestive structure and sequence of a sample success story and its various
shapes can be seen at annexure III.
Where a situation allows, case studies can also be presented to the trainees
to widen their understanding of the real life specific problem/situation and to
explore the solutions.
In simple terms, the case study method of teaching uses a real life case
example/a typical case to demonstrate a phenomenon in action and explain
theoretical as well as practical aspects of the knowledge related to the same.
It is an effective way to help the trainees comprehend in depth both the
theoretical and practical aspects of the complex phenomenon in depth with
ease. Case teaching can also stimulate the trainees to participate in
discussions and thereby boost their confidence. It also makes class room
atmosphere interesting thus maintaining the trainee interest in training till the
end of the course. Depending on suitability to the trade, the weekly lesson
plan in this document may suggest case studies to be presented to the
trainees. The trainer may adopt a power point presentation or video format for
such case studies whichever is deemed suitable but it’s important that only
those cases are selected that are relevant and of a learning value. The
Trainees should be required and supervised to carefully analyze the cases.
For the purpose they must be encouraged to inquire and collect specific
information / data, actively participate in the discussions and intended
solutions of the problem / situation.
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i. A good quality trade specific documentary ( At least 2-3
documentaries must be arranged by the training institute)
ii. Health &Safety case studies (2 cases regarding safety and
industrial accidents must be arranged by the training institute)
iii. Field visits( At least one visit to a trade specific major
industry/ site must be arranged by the training institute)
Intake to the Training Since intake level is DAE in Electrical / Electronic so expectations from the
trainees are:
Learning Outcome of After completion of this course, the trainees must be able to demonstrate their
the Course underpinning knowledge of:
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• Translate relay ladder diagram into PLC coding.
• Assign real I/O and internal addresses to inputs and outputs.
• Review machine logic of operation and optimize when possible.
• Understand the actual process or machine function.
• Motor control switchgear and its applications with PLC
• Should be able to interpret manufacturer’s instructional manual in order to
install and connect the PLC system according to the functional diagram
• Knowledge & understanding to install, operate & repair PLC systems.
• Interpretation of circuit diagrams, service manuals, technical sketches,
graphic symbols, wiring diagrams and manufacturer’s specifications etc.
• Can locate/trace and repair/replace the faulty components of PLC system
and also carry out the function tests.
• Trouble shooting of the faults in the PLC system, input/output devices and
PLC based machines
• Common faults in industrial PLC based machines Knowledge of ADC,
DAC and data acquisition systems.
• Must be able to make HMI for industrial control room.
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Companies Offering Most of Pakistani industries are moving their processes to automatic systems
Jobs in the so a person having this knowledge& skill, will have all the industrial
respective trade opportunities at his choice and can secure job with ease. It is expected that
by acquiring sufficient knowledge and skills, the prospects of employability of
passed out graduates increases many folds.
Job Opportunities
• PLC/SCADA Technician in industry (Textile, Leather,
Pharmaceuticals, Food Processing, Automotive, Cement etc.)
PLC/SCADA consultant for industry and commerce.
• Automation trainer for workers and lower management of industries.
No of Students
25
Learning Place
Classroom / Lab / Workshop / Industry
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Scheduled Module Title Days Learning Units Home
Weeks Assignmen
t
Home
Assignmen
t
No. 2
Day 5
K-Map
Success story (For further
detail please see Page No: 5
and Annexure-IV at the end)
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Week 2 Basic Day 1 • Motivational Lecture( For
Components, further detail please see
their symbols Page No: 4)
and • Control Transformer Task No.
Applications 2
Relays & Details
Contactors may be
seen at
Annexur
e-I
Home
Assignment
No. 3
Details
may be
seen at
Annexure-
II
Day 3 • Indicators Task No. 3
Details may
be seen
Relay: at
Annexur
Construction, e-I
Operation/working Principal,
Types & Applications
Monthly
Test 1
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Day 4 • Contactors:
Construction,
Operation/working Principal,
Types & Applications
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Day 2 • Advantages of
Programmable Logic
Controller
• Role of PLC in Automation
• Success story (For further
detail please see Page No: 5
and AnnexureIV at the end)
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Day 4 I/O Addressing and Wiring:
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Week 4 Introduction to Day 1 • Definition.
PLC
• History.
PLC Hardware
• Types.
• Configuration.
Home
Assignmen
t
No. 5
Day 2 • Sizes & Brands. Details
may be
• Applications. seen at
• Advantages. Annexure-
II
• Case Study-2 (For further
detail please see Page No: 6) Monthly
Motivational Lecture( For Test 2
further detail please see Page
No: 4
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Day 3 • Block Diagram of PLC
• Components of PLC
• Analog & Digital I/O Modules
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Week 5 PLC Day 1 • System Requirement
Software
PLC • Installation of PLC Software
Task No. 5
Details
may be
seen at
Day 2 • Configure Software for Desired Annexure-I
Task
• Industrial Simulation (Online Home
Assignment
and Offline)
No. 5
• Success story (For further Details
detail please see Page No: 5 may be
and seen at
Annexure-IV at the end) Annexure-
II
Task No. 6
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Day 4 Hand on experience with
Ladder logic programing
Task No. 7
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Day 2 Logic Gates Ladder Logic Details may be
programing seen at
Annexure-I
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Day 5 Counters Ladder Logic
Programming
Up Counter
Down Counter
Up down Counter
Special Instructions
Online and Offline
Simulation of Above
tasks
Practical industrial
applications
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Day 3 Preparation of midterm exam
Day 4
EEEXAM
Day 5
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Day 2 • Timers Comparison
Programming
• Counters Comparison
Programming
• Data Registers Comparison
Programming
• Online and Offline
Simulation of
Above tasks
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Day 4 • ADC and DAC
• Analog Values Scaling
Related Problems
Case Study-4 (For
further detail please
see Page No:
6)
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Week 9 Analog Day 1 • Analog IOs Programming
Programmin • Applications of Analog
g Programming in Industry
Analog
Sensors II • Online and Offline Simulation
of Analog Programming Task No. 11
Details may
be seen
at
Annexur
e-I
Task No. 12
Details
may be
seen at
Annexur
e-I
Day 2 • Practical industrial scenarios
for Analog I/Os
• Motivational Lecture(For
further detail please see Page
No: 4)
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Day 4 Interfacing Level Sensor with
PLC
Automation of Level
Sensor via
PLCs
Programming for
Automation
Level Sensor
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Day 2 • Planning and designing of
HMIs
• Recipes of HMI
Case Study-5 (For further
detail please see Page No: 6)
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Day 5 future Trends in HMI PLC
A. Advancements in HMI
technology
B. Integration with IoT and
cloud computing
C. Enhanced data analytics
and predictive maintenance
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Day 3 • Commissioning testing etc
Session on Self-
Employment How to
start a Business.
• Requirements ( Capital,
Physical
etc)
Benefits/Advantages of self-
employment
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Week 12 Employable Day 1 • Guidelines to the project
Project/Assi Trainees for selection of
gnment employable project like
(6 weeks i.e. final year project (FYP
21- 26) in
addition of
regular
classes.
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Day 3 Work on FYP
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Weak 13 Entrepreneu Day1 • Fundamentals of Business
r ship and Development
Final To Day
5 • Entrepreneurship Startup
Assessment
in Funding
project • Business Incubation and
Acceleration
• Project
• Business Value Statement completio
• Business Model Canvas n and
• Sales and Marketing Strategies testing/laun
• How to Reach Customers and ching.
Engage CxOs
• Stakeholders Power Grid
• RACI Model, SWOT Analysis,
PEST Final
Analysis
Assess
• SMART Objectives ment
• OKRs
• Cost Management (OPEX,
CAPEX,
ROCE etc.)
• Final Project
Final Assessment
MODULES
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0
Annexure-I
Task
No. Task Description
1 Make an OR & AND circuits.
Make an OR & AND circuit, draw it logic and circuit diagrams, also
draw the truth table for this circuit.
2 Controlling of a lamp/LED
Make a circuit to control one lamp/LED from two different places
from two different places. using SPDT switch and also draw,
Circuit diagram, logic diagram and truth table.
3 Operating lamp/LED & Make a circuit using Relay & Contactor logic to control a lamp &
buzzer using Relay & buzzer in the following way, When the lamp is “ON” the buzzer
Contactor logic. remaining deactivated.
When the lamp turned “OFF” the buzzer circuit is then activated
automatically until the lamp is again operated.
Draw logic, circuit diagrams and truth table.
5 Implement given Boolean Simulate PLC Program to implement the following Boolean functions
Functions with the help of with Don’t Care Condition.
PLC Program.
F(A,B,C,D)=∑m(0,1,5,9,13,14,15) + d(3,4,7,10,11)
6 Using PLC Program to make Run a 3-phase motor in the Forward and Reverse direction with the
Forward- Reverse help of PLC using Ladder Diagram programming language. This
Circuit (with limit switches) for circuit is used to change the direction of rotation of a 3-Phase
a 3-Phase Motor. induction motor (i.e. forward &backward or upward & downward).
Forward-Reverse movement of a 3- Phase motor can be obtained by
changing its phase sequence.
Also draw its electrical and Ladder Logic diagrams.
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8 Operating Seven Segment
Display using PLC Program. Prepare, execute, and demonstrate a PLC Program to displaying 0-9
digits using 7 Segment LED Display interfacing with PLC using
Ladder Diagram programming language.
Task
No. Task Description
11 PLC Program for a Car A parking plot has total capacity of Cars. Number of empty spots are
Parking System displayed on the display outside the Parking Plot and which spots
are available is to be indicated by LEDs. Implement this in PLC using
Ladder Diagram programming language.
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12 Automatic Door Open Close Prepare, execute, and demonstrate a PLC Program to implement
Control System with the logic for the automatic door open & close system using ladder
help of PLC Program. diagram programming language.
13 PLC Program for Heating Implement the process to control Heating and maintaining high and
water in the Tank by low level of water in the tankusing PLC Ladder Diagram programming
Heater using RTD as language.
temperature detector.
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14 PLC Program to Control A feeder drops material on the conveyor which sends the dropped
the Sequence of material to collector through one more conveyor. Conveyor must
Conveyors and start automatically.When material falls on conveyor belt 1, motor 1
Interlocking Them should start, and when material in present on conveyor belt 2, motor
2 remain On.Implement automation of this in PLC using Ladder
Diagram programming language.
Task
No. Task Description
15 PLC Program to Maintain the A classroom has a capacity of maximum 25 students. There are two
Capacity of a Particular doors, one for Entry and the other for Exit. When number of students
Classroom using HMI in the classroom is less than 25, Entry door has a Green light on it
Interface. which remains ON. When number of students in the classroom is 25
or more than that, Red light goes ON turning OFF the Green light
which indicates that the classroom has reached its maximum capacity
and is full.
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Annexure-II
ASSIGNMENTS FOR PROGRAMMABLE LOGIC CONTROLLER
Assign
Assignment
. No.
(PLC)
1 Prepare safety charts. Showing general & Trade specific safety measure (text/pictorial).
Each trainee will prepare different chart.
2
Simplify the following Boolean expression using K-Map, also draw logic diagrams
(Before & after simplification)
f (W,X,Y,Z) = ∑ (1,3,4,6,9,11,12,14)
3 Draw neat & clean sketches (along with their symbols) of various components you
have learnt in this week on drawing sheet(s)/Chart(s).
4
What is the difference between timers & counters? Explain function of Timer &
Counter in PLC, enlist different types of timers and counters and draw their symbols,
also write down its advantages.
5 What do you mean by automation? What are their types? Write down advantages of
Programmable Logic Controller with examples.
6 What is PLC? Enlist different the different sizes & brands of PLC, also write down the
uses and advantages of PLC.
7 What do you mean by physical protocol of communication? What is the difference
between RS232 and 485? How & why we can convert RS232 to 485? Draw the Block
diagram of PLC and Pinout of RS232 & 485 connector (both male, female) on drawing
sheet(s)/Chart(s).
8 Enlist the complete step by step procedure to install PLC software. Also write the
method to configure PLC software for desired task. Evident screenshots is mandatory.
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Annexure-III
Workplace/Institute Ethics Guide
Work Ethics is a standard of conduct and values for job performance. The modern definition of what
constitutes good work ethics often varies. Different businesses have different expectations. Work
ethic is a belief that hard work and diligence have a moral benefit and an inherent ability, virtue or
value to strengthen character and individual abilities. It is a set of values centered on importance of
work and manifested by determination or desire to work hard.
The following ten work ethics are defined as essential for employee’s success:
1. Attendance:
Be at work every day possible, plan your absences don’t abuse leave time. Be punctual every
day.
2. Character:
Honesty is the single most important factor having a direct bearing on the final success of an
individual, corporation, or product. Complete assigned tasks correctly and promptly. Look to
improve your skills.
3. Team Work:
The ability to get along with others including those you don’t necessarily like. The ability to
carry your own weight and help others who are struggling. Recognize when to speak up with
an ideas and when to compromise by blend ideas together.
4. Appearance:
Dress for success, set your best foot forward, personal hygiene, good manner, remember that
the first impression of who you are, can last a life time
5. Attitude:
Listen to suggestions and be positive, accept responsibility. If you make a mistake, admit it.
Values workplace safety rules and precautions for personal and co-worker safety. Avoids
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unnecessary risks. Willing to learn new processes, systems and procedures in light of
changing responsibilities.
6. Productivity:
Do the work correctly, quality and timelines are prized. Get along with fellows, cooperation is
the key to productivity. Help out whenever asked, do extra without being asked. Take pride in
your work, do things the best you know how. Eagerly focuses energy on accomplishing tasks,
also referred to as demonstrating ownership. Takes pride in work.
7. Organizational Skills:
Make an effort to improve, learn ways to better yourself. Time management; utilize time and
resources to get the most out of both. Takes an appropriate approach to social interactions at
work. Maintains focus on work responsibilities.
8. Communication:
Written communication, being able to correctly write reports and memos.
Verbal communications, being able to communicate one on one or to a group.
9. Cooperation:
Follow institute rules and regulations, learn and follow expectations. Get along with fellows,
cooperation is the key to productivity. Able to welcome and adapt to changing workplace
situations and the application of new or different skills.
10. Respect:
Work hard, work to the best of your ability. Carry out orders, do what’s asked the first time.
Show respect, accept and acknowledge an individual’s talents and knowledge. Respects
diversity in the workplace, including showing due respect for different perspectives, opinions
and suggestions.
Annexure-IV
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SUGGESTIVE FORMAT AND SEQUENCE ORDER OF SUCCESS STORY
Note: Success story is a source of motivation for the trainees and can be presented in a
number of ways/forms in a NAVTTC skill development course as under: -
1. To call a passed out successful trainee of institute. He will narrate his success story to
the trainees in his own words and meet trainees as well.
2. To see and listen to a recorded video/clip (5 to 7 minutes) showing a successful trainee
Audio video recording that has to cover the above mentioned points.
3. The teacher displays the picture of a successful trainee (name, trade, institute,
organization, job, earning etc) and narrates his/her story in teacher’s own motivational
words.
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