By the end of this chapter, you will be able to:
Mastering these skills will help you confidently handle PLC programming tasks in real industrial settings.
Industrial Mechatronics Technology professionals in Kenya rely heavily on Programmable Logic Controllers (PLCs) for automation and control tasks in manufacturing, processing plants, and other industrial settings. Programming these PLCs requires specialized software tailored to different brands and models. This chapter delves into the installation of key PLC programming software packages widely used within the Kenyan industrial landscape, enabling technicians and engineers to configure, monitor, and troubleshoot PLC systems effectively.
The installation of PLC programming software is a foundational step for any mechatronics engineer tasked with maintaining or developing PLC-based control systems. Proper installation ensures compatibility with PLC hardware, facilitates communication between the PC and PLC, and enables the use of advanced programming features. In Kenya, where industries range from agro-processing to manufacturing, the ability to install and configure these software packages is critical for operational continuity and efficiency.
RS Logix is a prominent PLC programming software developed by Rockwell Automation, commonly used with Allen-Bradley PLCs. Its installation process must be carefully managed to align with system requirements and hardware compatibility.
At a Nairobi-based beverage processing plant, RS Logix enables technicians to program Allen-Bradley ControlLogix PLCs for automated bottling lines. Proper installation ensures rapid response to faults and efficient system upgrades, minimizing downtime.
Logosoft is Siemens’ software designed for programming their LOGO! series PLCs, popular in small-scale industrial and commercial automation projects across Kenya.
Logosoft provides a user-friendly graphical interface for ladder logic programming, ideal for simple automation tasks such as lighting control at hotels or irrigation systems on farms.
At a county government office in Kisumu, Logosoft is used to program LOGO! PLCs controlling access gates and lighting, demonstrating its suitability for small-scale automation that enhances security and energy efficiency.
Gx Works is Mitsubishi Electric’s programming software for their MELSEC PLC range, extensively used in Kenyan manufacturing and packaging industries.
Gx Works supports ladder, structured text, and function block programming, catering to diverse automation needs. It is compatible with Windows 7, 8, and 10, requiring moderate system resources.
At a dairy processing plant in Eldoret, Gx Works enables engineers to program MELSEC PLCs that automate pasteurization and packaging, improving product consistency and operational safety.
Step 5 Micro WIN is Siemens’ legacy programming software for the S7-200 series PLCs, still prevalent in many Kenyan industries despite newer alternatives.
Step 5 Micro WIN offers ladder logic programming in a simple interface but lacks some modern features found in newer Siemens software like TIA Portal, making it suitable for maintenance of existing S7-200 installations.
A manufacturing workshop in Nakuru still maintains S7-200 PLCs programmed with Step 5 Micro WIN, emphasizing the need to support legacy software for uninterrupted industrial operations.
Step 7 Simatic Manager is Siemens’ advanced programming environment for S7-300 and S7-400 PLCs, widely used in complex industrial automation projects in Kenya.
Simatic Manager supports multiple programming languages, hardware configuration, and diagnostics. It is modular, allowing integration with other Siemens tools.
At a textile factory in Thika, Step 7 Simatic Manager is used to program S7-300 PLCs controlling conveyor systems, enhancing production line automation and fault detection.
Totally Integrated Automation (TIA) Portal represents Siemens’ latest integrated engineering framework combining programming, configuration, and diagnostics in one environment, increasingly adopted in Kenyan industries.
TIA Portal unifies Step 7, WinCC, and other Siemens software, allowing seamless project management for S7-1200, S7-1500 PLCs, and HMI devices. Its modern interface supports multi-language programming and simulation.
A large agribusiness in Meru uses TIA Portal to integrate automation across planting, irrigation, and harvesting machinery, streamlining operations and improving yield through precise control.
Explain the key system requirements necessary for installing RS Logix software on a workstation. (10 marks)
Describe the installation steps of Logosoft software and identify why USB driver installation is crucial. (10 marks)
Compare the installation prerequisites of Gx Works and Step 7 Simatic Manager software. (10 marks)
Outline the challenges faced when installing Step 5 Micro WIN on modern operating systems and how to address them. (10 marks)
Discuss how TIA Portal integrates different Siemens software tools and the benefits this brings to industrial automation. (10 marks)
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Create a free accountThis chapter provides a comprehensive overview of programming programmable logic controllers (PLCs) starting with the installation of various PLC programming software such as RS Logix, Logosoft, Gx Works, Step 5-Micro Wins, Step 7-Simatic Manager, and TIA Portal. It then covers the configuration of both PLC software and hardware to ensure proper system integration. The chapter explains the use of flow diagrams including cross-functional and swim lane flow diagrams for process visualization. Various PLC programming languages are introduced, including ladder logic, functional block diagrams, structured text, sequential flow charts, and instruction lists, highlighting their applications. Guidance on creating PLC and input/output schedules is provided to facilitate organized programming. The structure of PLC programs and the role of program rungs are detailed to build a functional understanding. Simulation techniques for testing PLC programs precede troubleshooting methods addressing faults such as I/O module failure, power supply issues, corrupted memory, and voltage supply problems. The chapter also discusses the reconfiguration of PLC software, different PLC operation modes, establishing PLC communication, and clearing PLC memory. Finally, it concludes with the process of downloading programs to PLC hardware and practical exercises on developing and debugging PLC programs to consolidate learning.
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Computer station (Windows 10 or later) | RS Logix 5000 software installation media |
| PLC programming cable | Logosoft software installation media |
| External USB drive | Gx Works software installation media |
| Set of basic IT tools | Step 5 MicroWin software installation media |
| Step 7 Simatic Manager software installation media | |
| TIA Portal software installation media |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Computer station (Windows 10 or later) | 1 Pc per Candidate |
| 2 | RS Logix 5000 software installation media | 1 Set per Candidate |
| 3 | Logosoft software installation media | 1 Set per Candidate |
| 4 | Gx Works software installation media | 1 Set per Candidate |
| 5 | Step 5 MicroWin software installation media | 1 Set per Candidate |
| 6 | Step 7 Simatic Manager software installation media | 1 Set per Candidate |
| 7 | TIA Portal software installation media | 1 Set per Candidate |
| 8 | PLC programming cable (USB or Serial, compatible with software) | 1 Pc per Candidate |
| 9 | External USB drive for software backup | 1 Pc per Candidate |
| 10 | Set of basic IT tools (e.g. screwdrivers, USB extension cables) | 1 Set shared per 3 Candidates |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Installation Preparation and PPE | |||
| Wore personal protective equipment (PPE) including dust coat and safety boots (Award 1 mark for each worn PPE item; 2x1=2 Marks) | 2 | ||
| Sub-Total | 2 | ||
| TASK 2: Software Installation | |||
| Inserted and accessed each software installation media correctly (Award 2 marks for correct access and preparation for each software set) | 2 | ||
| Installed RS Logix 5000 software successfully (Award 3 marks for full correct installation without errors) | 3 | ||
| Installed Logosoft software successfully (Award 3 marks for full correct installation without errors) | 3 | ||
| Installed Gx Works software successfully (Award 3 marks for full correct installation without errors) | 3 | ||
| Installed Step 5 MicroWin software successfully (Award 3 marks for full correct installation without errors) | 3 | ||
| Installed Step 7 Simatic Manager software successfully (Award 3 marks for full correct installation without errors) | 3 | ||
| Installed TIA Portal software successfully (Award 3 marks for full correct installation without errors) | 3 | ||
| Sub-Total | 20 | ||
| TASK 3: Verification and Backup | |||
| Verified successful launch of each installed software without errors (Award 1 mark per successful software launch x 6 = 6 Marks) | 6 | ||
| Connected PLC programming cable correctly to the computer (Award 2 marks for correct connection and device recognition) | 2 | ||
| Backed up installation files and configuration on external USB drive (Award 3 marks for proper backup without data loss) | 3 | ||
| Sub-Total | 11 | ||
| TASK 4: Housekeeping and System Shutdown | |||
| Closed all software properly and shut down the computer station safely (Award 2 marks for correct shutdown procedure) | 2 | ||
| Returned all tools and materials to their designated storage areas (Award 2 marks for neat and complete storage) | 2 | ||
| Performed general housekeeping of the workstation area (Award 2 marks for clean and organized workspace) | 2 | ||
| Sub-Total | 6 | ||
| PRODUCT CHECKLIST | |||
| All six PLC programming software packages installed and launching correctly (Award full 20 marks if all software are installed and run without errors; otherwise 0) | 20 | ||
| Sub-Total | 20 | ||
| GRAND TOTAL | 59 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Computer station with Siemens TIA Portal | Push button switches 24V DC |
| PLC programming cable | Indicator lamps 24V DC |
| Digital multimeter | Capacitive sensor 24V DC |
| Set of hand tools | PLC module Siemens S7-1200 or equivalent |
| Connecting wires 1mm | |
| Power supply 24V DC | |
| Masking tape |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Push button switches 24V DC | 2 Pcs per Candidate |
| 2 | Indicator lamps 24V DC | 3 Pcs per Candidate |
| 3 | Capacitive sensor 24V DC | 1 Pc per Candidate |
| 4 | PLC module Siemens S7-1200 or equivalent | 1 Pc per Candidate |
| 5 | Computer station with Siemens TIA Portal installed | 1 Pc per Candidate |
| 6 | PLC programming cable compatible with Siemens S7-1200 | 1 Pc per Candidate |
| 7 | Digital multimeter | 1 Pc per 3 Candidates |
| 8 | Connecting wires 1mm | 10 meters per Candidate |
| 9 | Power supply 24V DC | 1 Pc per Candidate |
| 10 | Set of hand tools (screwdrivers, side cutter, stripping knife) | 1 set per Candidate |
| 11 | Masking tape | 1 roll per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Configure PLC Hardware Modules and Software Settings | |||
| Wore personal protective equipment: overall/dust coat and safety boots (Award 1 mark for each correct PPE worn) | 2 | ||
| Identified and prepared all required hardware components for configuration (Award full marks for correct identification and preparation) | 2 | ||
| Connected push button switches and capacitive sensor correctly to the PLC input modules (Award 1 mark each for correct wiring of each input device) | 3 | ||
| Connected indicator lamps correctly to the PLC output modules (Award 1 mark each for correct wiring of each output device) | 3 | ||
| Configured the PLC software communication settings for correct connection between the computer and PLC (Award full marks for correct IP addressing, port settings and driver selection) | 4 | ||
| Set the hardware configuration in the PLC software matching the connected physical modules (Award full marks for correct module selection, slot assignment and addressing) | 4 | ||
| Tested the hardware connections using the software diagnostics and multimeter (Award full marks for correct testing and fault identification if any) | 4 | ||
| Powered the PLC system safely and verified power supply connections (Award full marks for correct power connection and safety compliance) | 2 | ||
| Sub-Total | 24 | ||
| PRODUCT CHECKLIST | |||
| PLC hardware modules configured correctly matching software settings and wiring (push buttons, sensor, lamps) (Award full marks for correct hardware and software alignment) | 4 | ||
| PLC software communication settings correctly configured enabling successful connection to the PLC (Award full marks for verified communication link) | 4 | ||
| All wiring connections are neat, secure, and labelled using masking tape (Award marks for neatness, security and correct labelling) | 3 | ||
| System powered on without faults and ready for programming (Award full marks for successful power-up and readiness confirmation) | 5 | ||
| Sub-Total | 16 | ||
| GRAND TOTAL | 40 | ||
At the start of this chapter we promised you would be able to:
Tick each one you can genuinely do.
So, are you there yet?
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