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.

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

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.

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.

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

Electrical and instrumentation technicians

Maintenance and automation personnel

Junior control and electrical engineers

Engineering students and technical graduates

Individuals beginning a career in industrial automation