book

Practical PLC Programming for Beginners: A Hands-On Guide to Learning PLC Programming with CODESYS

Name: Practical PLC Programming for Beginners: A Hands-On Guide to Learning PLC Programming with CODESYS
Author: Dariusz Wrebiak
ISBN: 9798868824302

by Dariusz Wrebiak

May 2026

Beginner to intermediate

567 pages

11h 23m

English

Apress

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Maker Innovations Series
Practical PLC Programming for Beginners
Preface
Introduction
Acknowledgments
Table of Contents
About the Author
About the Technical Reviewer
1. Initiating Your Journey
Downloading the CODESYS Environment from the CODESYS StoreInstalling the CODESYS EnvironmentCreating the First PLC ProjectImplementing Control LogicRunning the SimulatorTesting the First PLC ProgramSummary
2. Exploring PLC Fundamentals
Applications of PLC in Daily LifeManufacturersDescription of PLC Structure and OperationThe Communication with the External WorldSummary

3. Understanding the Automation Pyramid
Levels “Field Level” and “Control Level”Level “Supervisory Level”HMI (Human–Machine Interface)SCADA (Supervisory Control and Data Acquisition)Level “Planning Level”Level “Management Level”Summary
4. Digital IO for Lighting Control
Application ScenarioApplication FunctionsAdditional ElementsApplication ImplementationCreating a New ProjectAdding Global VariablesImplementation of a PLC ProgramEmergency LightingTesting PLC Program in the SimulatorProgram Execution by a PLC ControllerLighting for Area IAutomatic ModeHand ModeImplementation of VisualizationStatusOperational ModeSummary
5. Basic Gate Control in the Production Facility
Application ScenarioProject OrganizationPLC Program ImplementationGlobal Variables DeclarationProgramming Language FBDTask ConfigurationGate1 Opening Control LogicGate1 Closing Control LogicSimulation and TestingSummary
6. Advanced Gate Control in the Production Facility
Implementation of the PLC ProgramTON TimerDefining Gate States in the PLC ProgramRising and Falling EdgesManaging LibrariesError HandlingFinal Optimization of Gate Opening and ClosingImplementation of VisualizationMenu StructureStart Page of VisualizationVisualization of Gate1Organizing the CodeSummary
7. Heating and Cooling Control in the Production Facility
Temperature Measurement in Control SystemsPT100 Sensor: BasicsPT100 Sensors: Two-Wire, Three-Wire, and Four-Wire ConfigurationsWhy Use Three or Four Wires?PT100 vs. PT1000Analog ModuleCalculating Temperature from Digital ValueReading and Scaling Analog Signals in the PLC ProgramBang-Bang ControllerIntroductionOperation PrincipleExamples of ApplicationsHysteresis in Bang-Bang ControllersAdvantages and Disadvantages of Bang-Bang ControllerOfficial Terminology and StandardsSummaryImplementation of the Bang-Bang ControllerFunction BlockFunction vs. Function BlockFunctionFunction BlockStatelessness vs. StatefulnessVisualizationAdditional TaskSummary
8. Trends and Alarms
Installation and Update of the Simulator LibraryStarting the Software PLC ControllerReconfiguring the CODESYS EnvironmentStarting the Temperature Simulator in the PLC ProjectTrendsWhat They Are and How They Are UsedTrend Recording ManagerConfiguring Trends in the Visualization SystemConfiguring the Trend ViewPractical Reinforcement ExerciseAdditional Functions of the Temperature SimulatorAlarmsWhat They Are and How They Are UsedAlarm ConfigurationAlarm ClassesAlarm GroupsAlarm TriggersAlarm TableTrigger Delay for AlarmsPresenting Alarms in the Visualization SystemAcknowledging Alarms in the Visualization SystemTriggering Alarms Using LimitsAdditional TaskSummary
9. Conveyor Control and Product Quality Assurance
Technology and Operation of ConveyorsConveyor QCS-CONV1Conveyor QCS-CONV2Conveyor QCS-CONV3Implementation of the Conveyor Function Block for Conveyor ControlIntroduction to the Conveyor Function BlockGlobal Variable DeclarationCreating a Function Block ConveyorUsing TP TimersImplementation of Conveyor StateSwitching Between LAD and FBD LanguagesCalling and Testing the Conveyor Function BlockCalling the Conveyor Function BlockTesting the Block’s FunctionalityTesting the Conveyor Hold FunctionalityVisualization and Conveyor ControlCreating the Conveyors ViewControl Panel of ConveyorPersonalization of the Control PanelConveyor Speed ControlHAND and AUTO ModeAdding Conveyors QCS-CONV2 and QCS-CONV3 to the Control SystemDeclaration of Variables for Conveyors CONV2 and CONV3Adding Control Logic for ConveyorsCreating Control Panels for CONV2 and CONV3Expansion of the Conveyors View with New ConveyorsAdding a Speed Indicator for CONV1 in the Conveyors ViewPhotoelectric Sensors on the QCS-CONV3 ConveyorIntroductionGlobal Variable DeclarationCounting Products Using the CTU CounterVisualization of the Product CounterDisplaying the Counter StatusHolding the Conveyor After Reaching 10 ProductsResetting the Counter by the OperatorImplementation of a Counter for Products That Failed the Quality Control TestVisualizationResetting the CounterSimulation of Photoelectric SensorsPusher ActuatorDescription of the Pusher Actuator FunctionImplementation of Pusher Actuator Control LogicCreating the Actuator VisualizationPiston Actuator Movement AnimationReaction to Full PalletsNotification of Full PalletImplementation of Notification LogicAnalyzerImplementation of the HOLD Function for the QCS-CONV2 ConveyorDescription of the Product Quality AnalyzerExpansion of Control Logic with AnalyzerVisualization of the Analyzer on the QCS-CONV2 ConveyorQCS-CONV1 ConveyorAutomatic Holding of QCS-CONV1 ConveyorDynamic Speed Control for QCS-CONV1 ConveyorTesting the Application and Observing the Operation of the QCS-CONV1 ConveyorSummary
10. Sequential Function Chart (SFC) Programming for Conveyor and Quality Control Automation
Simulator Library UpdateInstalling the Simulator Library V5.0New Functionality in Version V5.0Issue with the Current Control LogicModifying the PLC Program: Updating the Simulator Function Block CallExpanding the Pusher Actuator Control LogicCreating the Auto SequenceCreating the Sequence: First StepsSequence Implementation: Adding the Run StepSequence Implementation: Step SetAutoSequence Implementation: Step Start_CONV3The Essence of Implementing the Transition Condition to the Next StepImplementation of the Sequence: Steps Start_CONV2, Start_CONV1Sequence Implementation: Step InitStarting the Sequence from VisualizationDip Switch Button Controlling the SequenceSequence State VisualizationSequence Status Implementation in SFCDisplaying the Sequence State on the VisualizationDebugging and Fixing ErrorsFinal Practical TaskSummary
11. Practical Tips and Best Practices
Compilation ErrorCreating a Custom LibraryCreating an RS Flip-FlopImplementing RS LogicInstalling the Library in CODESYSTesting Function BlocksPLC Programming Languages in IEC 61131-3 StandardLAD (Ladder Diagram)FBD (Function Block Diagram)ST (Structured Text)IL (Instruction List)SFC (Sequential Function Chart)CFC (Continuous Function Chart)TraceSimple Program in CFC LanguageTrace ConfigurationTesting TraceTrigger TraceSummary
Epilogue
Index

Content preview from Practical PLC Programming for Beginners: A Hands-On Guide to Learning PLC Programming with CODESYS

D. WrebiakPractical PLC Programming for BeginnersMaker Innovations Serieshttps://doi.org/10.1007/979-8-8688-2430-2_9

9. Conveyor Control and Product Quality Assurance

Dariusz Wrebiak¹

Dariusz Wrebiak

Email: dariusz@wrebiak.net

In the previous chapters, we focused on building automation, implementing tasks such as automated gate and door control, as well as managing heating and cooling systems. Now, it’s time to take the next step – automating production processes in the quality control hall of a factory.

The quality control line we are designing will consist of three conveyors, each playing a critical role in the product transport and inspection process:

First conveyor (QCS-CONV1): Transfers products from ...

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Practical PLC Programming for Beginners: A Hands-On Guide to Learning PLC Programming with CODESYS

by Dariusz Wrebiak

9. Conveyor Control and Product Quality Assurance

Become an O’Reilly member and get unlimited access to this title plus top books and audiobooks from O’Reilly and nearly 200 top publishers, thousands of courses curated by job role, 150+ live events each month,
and much more.