Course Description
This practical course introduces PLC hardware, operating principles, and programming techniques used in industrial automation. Participants learn how to configure inputs and outputs, develop Ladder Logic programs, and apply timers, counters, comparison instructions, and basic arithmetic functions.
Through guided exercises and a final project, participants build control sequences for common industrial applications, such as conveyors, pumps, and tank-level systems. The course also introduces analog signals, Human–Machine Interfaces (HMIs), and systematic troubleshooting.
Overview
Level: Beginner to intermediate
Recommended Duration: 40 training hours
Delivery Method: Instructor-led lessons, demonstrations, and practical laboratory exercises
Prerequisites: Basic electrical knowledge and computer skills; no prior PLC programming experience required
Training Platform: A selected PLC programming environment with simulation software or a training kit
Assessment: Practical exercises, knowledge checks, and a final automation project
Objectives
The course aims to:
Introduce PLC architecture and its role in industrial automation.
Explain the PLC scan cycle and input/output processing.
Develop practical Ladder Logic programming skills.
Apply timers, counters, and data-handling instructions.
Introduce analog signal processing and HMI integration.
Build confidence in testing, documenting, and troubleshooting PLC programs.
Learning Outcomes
By the end of the course, participants will be able to:
Identify the main PLC components and explain their functions.
Interpret basic control requirements and prepare an input/output list.
Create and configure a PLC project in the selected software.
Develop Ladder Logic programs using Boolean logic, timers, and counters.
Implement basic operating sequences, permissives, and process interlocks.
Scale simulated analog signals into engineering units.
Link PLC variables to a basic HMI screen.
Test programs and diagnose common logic and input/output faults.
Document and demonstrate a working automation project.
Course Outline
Module 1: Introduction to PLCs — 3 Hours
Industrial automation fundamentals
PLC applications and advantages
PLC control versus relay-based control
Overview of common programming languages
Module 2: PLC Hardware and Input/Output Systems — 4 Hours
CPU, power supply, memory, and communication interfaces
Digital and analog input/output modules
Sensors, switches, relays, and actuators
Reading basic wiring diagrams and preparing an I/O list
Electrical safety awareness for training equipment
Module 3: Programming Environment and PLC Operation — 4 Hours
Creating and organizing a project
Hardware configuration and addressing
Tags, variables, and basic data types
PLC scan cycle
Program transfer, simulation, and online monitoring
Module 4: Ladder Logic Fundamentals — 6 Hours
Contacts, coils, and logic continuity
AND, OR, and NOT logic
Start/stop circuits and holding logic
Set/reset instructions
Permissives and process interlocks
Practical exercise: Simulated motor-control circuit
Module 5: Timers, Counters, and Data Operations — 5 Hours
On-delay, off-delay, and retentive timers
Up and down counters
Comparison and arithmetic instructions
Data movement
Practical exercise: Product-counting conveyor simulation
Module 6: Sequential Control — 5 Hours
Breaking a process into operating steps
Step transitions and sequence conditions
Manual and automatic modes
Fault handling and restart behavior
Practical exercise: Automated filling sequence
Module 7: Analog Signals and HMI Fundamentals — 5 Hours
Common analog signal types
Raw values and engineering-unit scaling
Thresholds and process alarms
HMI tags, indicators, and operator controls
Practical exercise: Tank-level monitoring interface
Module 8: Testing, Troubleshooting, and Documentation — 4 Hours
Structured program testing
Monitoring logic and variable values
Diagnosing common programming and I/O faults
Program comments, backups, and version management
Distinction between standard control logic and safety-rated control systems
Module 9: Final Practical Project — 4 Hours
Review a small automation requirement
Prepare an I/O list and control sequence
Develop and simulate the PLC program
Test normal operation and selected fault conditions
Present the solution with supporting documentation
