Course Outline for Electronic Systems Technology 57
PLCs & Process Control Systems

Effective: Spring 2021
SLO Rev: 04/30/2020
Catalog Description:

ESYS 57 - PLCs & Process Control Systems

3.00 Units

Programmable logic control systems; function, interrelationship, and troubleshooting of systems components. PLC input/output systems and requirements. Ladder logic and SCADA programming using basic I/O instructions, logic instructions, timers, counters, and comparison functions.
Strongly Recommended: ESYS 50.
0934.00 - Electronics and Electric Technology*
Letter Grade Only
Type Units Inside of Class Hours Outside of Class Hours Total Student Learning Hours
Lecture 2.00 36.00 72.00 108.00
Laboratory 1.00 54.00 0.00 54.00
Total 3.00 90.00 72.00 162.00
Measurable Objectives:
Upon completion of this course, the student should be able to:
  1. describe the functions and operations of a process control system at the block level;
  2. implement a basic functional control system using ladder-logic programming;
  3. develop and execute a troubleshooting plan for process control systems;
  4. select sensors, controllers, and actuators appropriate for a given task;
  5. program a controller to execute a sequential task;
  6. program a PID control loop for optimized operation;
  7. develop and execute a troubleshooting plan for process control systems.
Course Content:
Course Content, Lecture
  1. Overview of programmable logic control systems
    1. Basic Relay Circuits vs advantages of PLCs (programmable logic controllers)
    2. Functional parts of a PLC
    3. Operation of a PLC
    4. PLCs as industrial compared to personal computers
  2. PLC Hardware
    1. I/O, Inputs vs Output Sections
    2. CPU (central processing unit)
    3. Memory
    4. Power Supply
    5. Analog vs Digital I/O Modules
    6. Programming Interfaces: PCs vs HMI (human machine interface)
  3. Numbering Systems: decimal, binary, octal, hexadecimal
  4. Basic Logic Gates: AND Gate, OR Gate, and NOT Gate
  5. Other Logic Gates: NAND, XOR and XNOR Gates
  6. PLC Programming
    1. Program scan cycle
    2. PLC programming languages
    3. Ladder Logic Programming
  7. PLC I/O Devices
    1. Sensors, switches, actuators, motor starters, control relays
  8. PLC Timers
    1. Mechanical relay timers
    2. Timer instructions
    3. On-Delay Timer function
    4. Off-Delay Timer function
    5. Retentive and cascading timers
  9. PLC Counters
    1. Counter instructions
    2. Up Counters vs Down Counters
    3. Cascading counters
  10. SMC IPC 200 Industrial Process Control Trainer System
    1. SCADA Supervisory Control and Data Acquisition software
    2. IPC 201 Production Station for fluid processing
      1. Temperature control and mixing control
      2. Level control between 3 fluid storage tanks
      3. Pressure control
      4. Control of flow rate
    3. IPC 202 Bottling Station for containerizing the fluids
      1. Container hopper
      2. Container filling station
      3. Container capping station
      4. Container transfer to IPC 203 Palletizing Station
    4. IPC 203 Palletizing Station for sorting the storage of filled containers
Course Content, Laboratory:
  1. Overview of programmable logic control systems
    1. Basic Relay Circuits vs advantages of PLCs (programmable logic controllers)
    2. Functional parts of a PLC
    3. Operation of a PLC
    4. PLCs as industrial compared to personal computers
  2. PLC Hardware
    1. I/O, Inputs vs Output Sections
    2. CPU (central processing unit)
    3. Memory
    4. Power Supply
    5. Analog vs Digital I/O Modules
    6. Programming Interfaces: PCs vs HMI (human machine interface)
  3. Numbering Systems: decimal, binary, octal, hexadecimal
  4. Basic Logic Gates: AND Gate, OR Gate, and NOT Gate
  5. Other Logic Gates: NAND, XOR and XNOR Gates
  6. PLC Programming
    1. Program scan cycle
    2. PLC programming languages
    3. Ladder Logic Programming
  7. PLC I/O Devices
    1. Sensors, switches, actuators, motor starters, control relays
  8. PLC Timers
    1. Mechanical relay timers
    2. Timer instructions
    3. On-Delay Timer function
    4. Off-Delay Timer function
    5. Retentive and cascading timers
  9. PLC Counters
    1. Counter instructions
    2. Up Counters vs Down Counters
    3. Cascading counters
  10. SMC IPC 200 Industrial Process Control Trainer System
    1. SCADA Supervisory Control and Data Acquisition software
    2. IPC 201 Production Station for fluid processing
      1. Temperature control and mixing control
      2. Level control between 3 fluid storage tanks
      3. Pressure control
      4. Control of flow rate
    3. IPC 202 Bottling Station for containerizing the fluids
      1. Container hopper
      2. Container filling station
      3. Container capping station
      4. Container transfer to IPC 203 Palletizing Station
    4. IPC 203 Palletizing Station for sorting the storage of filled containers
  11. Semester PLC Project
    1. Team formation
    2. Team proposals for review and authorization
    3. ePortfolio documentation of project scope and process
    4. Team Presentation of PLC Project
Methods of Instruction:
  1. Lecture/Discussion
  2. Laboratory
  3. Online Assignments
  4. Distance Education
Assignments and Methods of Evaluating Student Progress:
  1. Program and PLC controller for a specified operation.
  2. Develop and execute a troubleshooting plan for a malfunctioning PLC system.
  3. Describe the expected operation of a PLC system from a ladder logic diagram.
  4. Describe the interaction between a temperature sensor and a heater in a closed-loop temperature control system.
  5. Troubleshoot a given PID motor speed control circuit.
  1. Exams/Tests
  2. Quizzes
  3. Papers
  4. Class Participation
  5. Homework
  6. Lab Activities
  7. Final Examination or Project
Upon the completion of this course, the student should be able to:
  1. describe the functions and operations of a process control system at the block level;
  2. implement and troubleshoot a basic functional control system using ladder-logic programming;
  3. build a PLC project that encompasses inputs and outputs, programming for repetitive function, modifying that programming for cause and effect. The project will culminate with a verbal demonstration presentation to the class and constructing an e-portfolio to showcase the project on the Internet.
Textbooks (Typical):
  1. Petruzella, Frank (2016). Programmable Logic Controllers (5th). McGraw-Hill.
  1. Lessons in Electric Circuits, Vol. 1 & 2, Kuphaldt, T., 2015, open source, hosted on ibiblio.org.
  • Computer with Internet access
Abbreviated Class Schedule Description:
Programmable logic control systems. PLC input/output systems and requirements. Ladder logic and SCADA programming using basic instructions for input/output, logic, timers, counters, and comparison functions.
Strongly Recommended: ESYS 50.