2012 IEEE 8th International Colloquium on Signal Processing and its Applications
Design and Fabrication of Programmable
Logic Controller Kit with Multiple Output
Module for Teaching and Learning Purposes
I. Burhan1
S. Talib
Aircraft Maintenance Engineering Department,
Politeknik Sultan Salahuddin Abdul Aziz Shah,
Shah Alam, Selangor
1
bibrahim@psa.edu.my
Abstract – Programmable Logic Controller (PLC) Kit for
teaching and learning is developed based on the existing
PLC Trainer that is not able to achieve the objective and
learning outcome in enhancing the hands on skill aspect
through circuit designing, installation and trouble
shooting. The existing PLC trainer board comes with a
casing where students have the difficulty in observing
and understanding the connection between the input
module, PLC controller and output modules. The
development of PLC Kit has been designed and
improved by increasing the number of input and output
components, cost reduction and it is also user friendly.
This PLC Kit is embedded with I/O module such as
normally open push buttons, 24VDC motor, 24VDC
relay, 24VDC solenoid cylinder and 24VDC lamp. This
PLC Kit can be interfaced to various types of PLC
controller such as Omron, Siemens and Panasonic
(NAIS). Based on students Lab Practical Assessment
record, it is found that there is 39% improvement of
knowledge and hands on skill when students use the PLC
Kit.
Keyword- Programmable Logic Controller Kit, Multiple
Output, Teaching and Learning
I. INTRODUCTION
A Programmable Logic Controller (PLC) is a
digital computer used in automation industries such as
controlling of machineries on factory assembly line.
PLC is designed for multiple input and multiple output
arrangement. PLCs have been gaining popularity on
the factory floor and will probably remain
predominant for some time in future. Most of this is
because of the benefits that PLCs can offer: effective
in cost, flexible, reliable, etc.
A small PLC has a fixed number of connections
build in for input and output. It can be expanded if the
base model does not have sufficient I/O. These PLC
programs are typically written in a special application
called Ladder Diagram that can be downloaded from a
978-1-4673-0961-5/12/$31.00 ©2012 IEEE
A.A Azman
Electrical Engineering Department,
Politeknik Sultan Salahuddin Abdul Aziz Shah
Shah Alam, Selangor
aftas@psa.edu.my
personal computer or PLC handheld over a cable. The
PLC can be reprogrammed for several times, thus
making it adaptable to the process changes required by
the end user/company [1].
In line with polytechnic objective of producing
semi-professional workforce in technical field, trade
and hospitality, the teaching process and practical
skills become one of the important elements towards
achieving the objective. In accordance to that,
equipment and trainers should be able to deliver the
practical aspects and they become a necessity.
The role of PLC-programming in automation
engineering education in polytechnic is quite
significant. Automation technicians and engineers are
normally trained in automation technology study
programs where the Electrical Engineering
Department, Polytechnic Sultan Salahuddin Abdul
Aziz Shah (PSA) offer three programmes namely
Diploma in Electronic Engineering (Control), Diploma
in Electronic Engineering and Diploma in Electronic
Engineering (Medical). Engineering students should
receive hands-on experience with PLC devices as a
component in instrumentation courses. Understanding
of control and PLC principles is anticipated to provide
more job opportunities and good performance for
engineering graduates [2].
Existing equipment only use toggle switch as the
input module where it is not suitable for practical
aspect and the output module only show light displays.
This development of PLC Kit trainer also will
focus more on students taking Programmable Logic
Controller course that are offered in other programmes
such as Programmable Logic Controller &
Automation module in Diploma in Electrical
Engineering, Diploma in Electronic Engineering
(Optoelectronic) and Diploma in Electronic
Engineering (Control), other modules that include the
teaching of PLC are Industrial Automation,
14
 2012 IEEE 8th International Colloquium on Signal Processing and its Applications

Instrumentation & Control module that are offered in Using male and
Diploma in Mechanical Engineering, Diploma in 03 female connector
Mechanical Engineering (Plastic), Diploma in wire (banana jack).
Mechanical Engineering (Packaging), Diploma in
Only Lamp as the
Mechanical Engineering (Materials), and Year : 2007
Unit: 11 output module.
Programmable Logic Controller module in Diploma
in Mechatronic Engineering that is offered in all 04 Structure from plastic
Malaysian polytechnics [3]. casing.
Various output
components such as
II. HISTORY OF PLCs TRAINER BOARD motor, solenoid
DEVELOPMENT cylinder, relay and
PLC-programming is learned best by practising Year: 2011 lamp.
with real devices, machines or an automation system Need to connect PLC
to I/O module.
[4]. During the establishment of Sultan Salahuddin
Abdul Aziz Shah Polytechnic in 1997, the only ready
made device that was prepared for teaching and
learning is shown in Figure 1. III. PROBLEM STATEMENT
The development of this trainer kit is based on the
problems faced by the lecturers and also the students
at Electrical Engineering Department, Sultan
Salahuddin Abdul Aziz Shah Polytechnic. Learning
PLC-programming is best by applying with the
practical lab work. The existing facilities at Electrical
Engineering Department do not meet the practical
requirement in the syllabus. With regard to this,
lecturers often face problems in complying with the
Figure 1: PLC- NAIS FP1-C24
syllabus requirement.
There is no I/O module to show the function of this The existing facility also does not enhance the
PLC. Due to this constraint, a simple PLC trainer students’ wiring skills. Polytechnics as an educational
board has been developed as in Table 2. institution that produce semi skill workers to the
industry also require the students to carry out the
Table 1: Previous PLC Trainer Board wiring between the I/O component to the PLC. The
use of PLC in teaching is considered vital as the
Ver- Previous PLC Trainer Board Problem Finding existing equipments limit the skills gained by the
sion
students. In addition, the lectures are also facing
Complex connection
01 and takes longer time
problems in drawing the suitable specification to meet
for practical. the syllabus. Moreover, most equipment in the market
Loose terminal screw hardly meet the syllabus requirement [5]-[11].
due to wear and tear. The existing component at the trainer is also
Difficult for trouble unsuitable for teaching and learning, for example the
Year : 2000 shooting due the use of toggle switch at the trainer which is only has
Unit: 10 structure made from normally close contact. The toggle switch is best
wood. replaced by push button where it will have close
02 Problems with the contact when being pushed and open contact when
plug in terminal.
released as shown in Figure 2.
Cable terminal Thus, there is a great need to reform teaching
always break due to methods and assessment tools, laboratory equipment
regular application. and experiments, enhancing students’ practical skills
and practical ability, laying a good foundation for job
Year:2004 Output module shown and improving their social competitiveness and the
Unit:10 through relay and quality of personnel training [12].
lamp only.

15
 2012 IEEE 8th International Colloquium on Signal Processing and its Applications

B. Hardware and Software

Toggle Switch
Figure 2: Existing PLC Trainer Kit with Toggle Switch
During hands on practical, three separate modules
have to be placed together on the table (Program
Module, PLC Module and I/O Module). This situation
is quite messy. The PLC improves this situation
because all components are presented in a kit.
IV. OBJECTIVE
There are two main objectives:
i) To enhance the students psychomotor skills
for PLC courses.
ii) Various types of output components
especially at Output Module
This objective is aligned with the Malaysia
Ministry of Higher Education in producing competent
graduates to meet the needs of national and
international employment.
V. UPGRADING STAGES
A. Design of the System
The PLCs provide analogue and digital series
input/ output that can be used to control the output
module. Figure 3 shows the block diagram of PLC Kit.
It consists of PLC Module, Input Module, Output
Module, Power Supply unit and common for Input and
Output.
COMMON
INPUT
POWER SUPPLY UNIT
24VDC
The hardware required for this project is:
• PLC: NAIS FP1-C24 manufacturer by
Panasonic formerly known as Matsushita
shown in Figure 4, has been selected for this
project. The advantages of using this controller
are it is inexpensive, easy to program and
configure the I/O channels. This PLC has 16
input(I) and 8 output(O) build-in I/O channels.
The input to the PLCs is 240V and will
produce 24 VDC for the output [13].
• Handheld used for downloading the
programming to the PLC through the
peripheral cable.
• 24 VDC External Power Supply as power to
the output channel supplied from the PLCs.
• 24 VDC Motor will start to turn once supplied
with power.
• 24 VDC Solenoid Cylinder that will be
energized once power been supplied.
• 14 pin / 24 VDC Relay with base. The coil
will energized once it connected to power
supply. This relay has four Normally Open
contact and four Normally Close contact.
• Normally Open Push Button is suitable to be
used in this PLC Kit trainer due to it will
disconnect once the button been release. Push
Button is suitable for trainer compared to other
type switches in PLCs application.
• 24VDC Green Lamp as indicator for the
output modules.
OUTPUT PORT
COMMUNICATION
PORT PLC CONTROL
INPUT PORT
PERIPHERAL
COMMON
OUTPUT

INPUT OUTPUT
MODULE MODULE HAND HELD
5 UNIT 2UNIT
PUSH DC MOTOR
BUTTON
NORMALY 3 UNIT
OPEN DC LAMP Figure 4: PLCs Controller and the handheld
PLC MODULE 1 UNIT
RELAY
A relay coil of 24 VDC and contact of 220 V AC is
1 UNIT
SOLENOID utilised to connect to any electrical motor or other
CYLINDER
electrical equipments and also can become an input
module when connected to the sensor (e.g. limit
Figure 3: Block Diagram for PLC Kit switches, temperature indicator or photoelectric
sensors).

16
 2012 IEEE 8th International Colloquium on Signal Processing and its Applications

VI. BUILDING THE PLCs KIT The PLC Section is basically the 8 input and 8
Figure 5 shows the internal wiring diagram for the output connection from the PLC Module which is
PLC Kit. The wiring starts from the 240 VAC power transferred to the front panel. It also consists of the
supply to the PLC. RUN/PROG switch. RUN is used to execute the
program and when switched to PROGRAM is for
write or download the program from Programming
240 VAC, 3 pin plug Console to PLC via peripheral cable. This section also
consists of Input and Output Common and +24 VDC
3 core cable supply to power up the I/O Section.
Input/Output Section consists of five Normally
L N 240 VAC, Open pushbuttons with female connector, three green
PLC Supply lamps with female connector, two units of 24 VDC
E
motor with female connector, one unit 24 VDC relay
Figure 5: 240VAC Supply Power Connection with female connector and one unit of 24 VDC
solenoid cylinder with female connector.
The fabrication of this PLC Kit is set to three The programming section is the place where
segments: the casing that is made of aluminium steel programming console will be in place for the purpose
with 350 slanting panel, PLC Module and 24VDC of downloading the program via the peripheral cable to
Power Supply as in Figure 6. the PLC Module.
Figure 8 represents the wiring connection block
diagram for PLC Kit. Common connection of the +24
VDC will be connected to the input and output devices
and also will be connected to PLC module port. In
order to make a complete circuit, the PLC module port
will also be connected to the -24 VDC supply.

2 UNIT 2 UNIT 1 UNIT 5 UNIT

+24VDC
MOTOR RELAY SOLENOID LAMP
COMMON
OUTPUT
24VDC PLC Casing Wiring
Power Supply Module
PLC
Figure 6: Hardware for PLC Kit OUTPUT
EXTERNAL PLC MODULE
±24VDC
The aluminium steel as the front panel is divided POWER
PLC INPUT
into three sections: PLC Section, I/O Section and SUPPLY
PORT
Programming Section as in Figure 7.

+24VDC 5 UNIT
COMMON PUSH BUTTON
INPUT (NORMALLY OPEN)

Figure 8: Wiring Connection Block Diagram

VI. IMPLEMANTATION AND MEASUREMENT

STAGES
The complete structure of PLC Kit show in Figure
9 has been used as the practical trainer instrument in
conducting practical lesson for teaching modules
related to PLC such as Programmable Logic
PLC Input/Output Programming Controller module, Automatic System Control module
Section Section Section and Basic Control 1 to the Electrical Engineering
Figure 7: Front Panel View of PLC Kit students in the polytechnic.

17
 2012 IEEE 8th International Colloquium on Signal Processing and its Applications

Table 4: Students Achievement Using PLC Kit

LAB PRACTICAL ASSESMENT ITEM FOR E4800: PROGRAMMABLE LOGIC CONTROLLER
USING PLC KIT
CLASS Attandance (5 Wiring Skill Programming Discussion (30 Conclution (20 Total
%) (25 %) (20 %) %) %) (100 %) % IMPROVEMENT

DJK 5A 5% 22% 19% 28% 17% 89% 39%

DJK 5B 5% 24% 19% 28% 18% 93% 40%
DJK 5 int 5% 22% 19% 28% 17% 91% 39%

In order to assess the wiring skill, it base on rubric

standard for Laboratory Evaluation.

Figure 9: Overall view of PLC Kit V. CONCLUSION

In order to measure the enhancement of Through this PLC Kit trainer, it helps the students
psychomotor skills, three classes from the Electrical to achieve the objective and learning outcome in
Engineering Department were asked to use the enhancing the hands on skill aspect through circuit
existing PLC Trainer for their E4800 lab module. To designing, installation and trouble shooting. The
measure psychomotor skills, the students were development of PLC Kit has been designed and
assessed based on their wiring skills. After the improved by increasing the number of input and
students carried out a practical task, they were output components, cost reduction and also it is user
required to submit a report to their lecturer. Again, friendly whereby the three separate modules are
they were asked to carry out the same task, but this attached to this PLC Kit. PLC Kit is now embedded
time the PLC Kit was used. Once they completed the with normally open push buttons, 24 VDC motor, 24
practical task, the students were also required to VDC relay, 24 VDC solenoid cylinder and 24 VDC
submit a report. Based on Table 2, a total number of lamp. This PLC Kit also can be interfaced to other
92 students were involved in the task. By following a various types of PLC controller such as Omron,
similar routine, the students were continuously Siemens and Panasonic (NAIS). This is supported by
assessed throughout the Jun 2011 semester.. the Lab Practical Assessment record which shows that
students have improved by 39% on knowledge and
Table 2: Total Number of students
wiring skills.
Class No Of Students REFERENCES
DJK 5A 31
DJK 5B 21 [1] L. Xiaolong, M. Sairam, A.Z. Qing, ”Design and
DJK 5I Implementation of a Wirelwss Programmable Logic
(Integration) 40 Controller System,” IEEE International Conference on
Electrical and Control Engineering, pp. 3138-3141, 2010.
TOTAL 92 [2] A.F. Kheiralla, O.Siddig, A.A Elhaj Mokhtar. M. Esameldeen,
O Abdalla, ”Design and development of a Low Cost
Table 3 and Table 4 compare the students’ results programmable Logic Controller Workbench for education
based on identical practical tasks assigned using the Purposes,” Internationl Conference on Engineering
Education -ICEE, 2007.
existing PLC Trainer as well as the PLC Kit. On the [3] Curriculum Development and Evaluation Division (2011),
average, the students score 52% when using the PLC Curriculum Document, Department of Polytechnic Education,
Trainer as compared to 91% when using the PLC Kit. Ministry of Higher Education, Malaysia.
This indicates that there is a significant improvement [4] V. Matti, H. Jussi, K. Juha, ”Virtual Learning Environment
Concept for PLC-programming-Case: Building Automation,’
of 39% in their marks when using the PLC Kit. Table IEEE International Conference on education Technology and
4 also shows that the score on their psychomotor skills Computer, pp.173-176, 2010.
(wiring skills) also increases at an average of 23%. [5] http://www.juravic.com.my/PLC.htm
Since items for programming, discussion and [6] http://www.retronic.com.my/product.htm
[7] http://www.omron-
conclusion (Table 3 and Table 4) are not relevant for ap.com.my/product_info/CP1E/training_kit.asp
assessing their psychomotor skills, the findings will [8] http://www.limkimhai.com.sg/precicon/Home/
not be discussed in this paper. Control/PLCSystem/CompactPLCs/OmronCP1TrainingKit/ta
bid/1188/Default.aspx
Table 3: Students Achievement Using Existing Trainer [9] http://www.unitechscales.org/measurement-trainer.html
[10] http://elegantautomation.com/?page_id=209
LAB PRACTICAL ASSESMENT ITEM FOR E4800: PROGRAMMABLE LOGIC CONTROLLER [11] http://www.indiamart.com/advanced-electronic-
USING OLD VERSION OF PLC TRAINER
systems/microprocessor-trainer-kit.html
CLASS Attandance Wiring Skill Programming Discussion (30 Conclution (20 Total [12] R. Zen, H.Meng, X.Wu, J. Li and S. Liu,” Exploration on a
(5 %) (25 %) (20 %) %) %) (100 %)
New System of PLC Three-dimentional Teaching,” Advance
DJK 5A 5% 0% 19% 12% 16% 50%
Material Research Vols. 271-273, pp.1231-1234, 2011
DJK 5B 5% 0% 19% 13% 16% 53%
[13] Matsushita manual for NAIS Programmable Controller FP
DJK 5 int 5% 0% 19% 12% 16% 52%
Series (FP1) hardware

18