PLC Programming Course for Beginners

Lesson 1 • What Is a PLC?

Defines a PLC, its operating cycle, and its place in modern manufacturing. Establishes the conceptual baseline for all subsequent programming topics.

Lesson 2 • PLC Hardware Components

Identifies CPU, power supply, I/O modules, and communication ports. Understanding hardware prepares students to wire and configure real systems.

Lesson 3 • Types of PLCs and Form Factors

Compares micro, modular, and rack-based PLCs by application size and cost. Students select the appropriate PLC type for a given automation scenario.

Lesson 4 • Safety and Workplace Standards

Covers electrical safety rules, lockout/tagout procedures, and panel wiring standards. Safe work habits are enforced throughout all hands-on activities.

Lesson 1 • Creating and Managing Projects

Covers new project creation, file structure, and version management practices. Organised projects reduce errors during development and maintenance.

Lesson 2 • Connecting to the PLC

Establishes communication between a PC and a PLC via Ethernet or serial links. A live connection enables program download, upload, and online monitoring.

Lesson 3 • Hardware Configuration in Software

Adds PLC modules to the software rack and assigns I/O addresses. Correct configuration ensures the program communicates with physical hardware.

Lesson 4 • Installing and Launching PLC Software

Guides installation of industry-standard programming software and initial setup. A working software environment is required before any programming begins.

Lesson 1 • Basic Logic Instructions

Programmes AND, OR, and NOT logic using series and parallel contact arrangements. These patterns form the foundation of all discrete control logic.

Lesson 2 • Ladder Logic Structure and Syntax

Explains rungs, rails, contacts, and coils as the building blocks of ladder logic. Correct syntax is essential before any executable program can be created.

Lesson 3 • Program Download and Online Testing

Downloads a ladder program, forces I/O bits, and monitors rung status in real time. Live testing validates logic before connecting to field devices.

Lesson 4 • Seal-In and Latching Circuits

Implements self-holding circuits using output feedback contacts and latch coils. Seal-in logic is fundamental to motor start/stop and interlock control.

Lesson 1 • Troubleshooting Timer and Counter Logic

Diagnoses common faults such as incorrect presets, missing resets, and accumulated value errors. Systematic fault-finding skills are applied to timer/counter circuits.

Lesson 2 • Programming Timer Applications

Builds practical timer circuits for conveyor delays, alarm delays, and pulse outputs. Application-based practice reinforces correct timer instruction usage.

Lesson 3 • Timer Instruction Types

Covers TON, TOF, and RTO timer instructions with their enable, done, and timing bits. Each timer type solves a distinct class of time-delay control problems.

Lesson 4 • Counter Instruction Types

Introduces CTU, CTD, and CTUD counter instructions with preset and accumulated values. Counters track discrete events such as parts counted or cycles completed.

Lesson 1 • Arithmetic Instructions

Programmes ADD, SUB, MUL, DIV, and MOD instructions for process calculations. Arithmetic enables scaling, totalisation, and engineering-unit conversion in programmes.

Lesson 2 • Logical and Bit-Shift Instructions

Applies AND, OR, XOR, and shift instructions to manipulate word-level data. Bit-level operations support status word decoding and pattern-based control.

Lesson 3 • Comparison Instructions

Uses EQU, NEQ, GRT, LES, GEQ, and LEQ instructions to trigger outputs based on data values. Comparisons enable setpoint-based control and alarm generation.

Lesson 4 • Move and Copy Instructions

Programmes MOV, COPY, and fill instructions to transfer data between registers. Data movement is the prerequisite for all setpoint and recipe management tasks.

Lesson 1 • Program Documentation Practices

Adds rung comments, tag descriptions, and page titles to improve program readability. Well-documented programmes reduce troubleshooting time and training costs.

Lesson 2 • Program Tasks and Routines

Explains continuous, periodic, and event tasks and how routines are called within them. Task structure determines program execution timing and priority.

Lesson 3 • Add-On Instructions and Function Blocks

Creates custom add-on instructions to encapsulate repeated logic patterns. Reusable function blocks enforce consistency across multiple program instances.

Lesson 4 • Subroutine and JSR/RET Instructions

Programmes jump-to-subroutine and return instructions to call reusable code blocks. Subroutines reduce duplication and simplify program maintenance.

Lesson 1 • PID Tuning and Loop Monitoring

Applies manual and auto-tune methods to achieve stable, responsive loop performance. Loop trend monitoring confirms that tuning meets process requirements.

Lesson 2 • PID Instruction Configuration

Configures the PID instruction with process variable, setpoint, and output parameters. The PID block is the standard method for closed-loop process control in PLCs.

Lesson 3 • Reading and Scaling Analog Values

Programmes scaling calculations to convert raw analog counts to engineering units. Accurate scaling is required before analog data can drive control decisions.

Lesson 4 • Analog Module Configuration

Sets input range, filter settings, and engineering-unit scaling in the module properties. Proper configuration converts raw counts to meaningful process values.

Lesson 1 • Commissioning and Handover Procedures

Runs functional acceptance tests, documents results, and hands over the system to operations. Formal handover ensures operators understand system behaviour and emergency stops.

Lesson 2 • Online Monitoring and Forcing

Uses online monitoring, cross-reference tools, and I/O forcing to isolate logic faults. These tools allow safe diagnosis without interrupting the production process.

Lesson 3 • I/O Wiring and Field Device Faults

Diagnoses open circuits, short circuits, and misconfigured field devices using a multimeter. Field-level faults account for the majority of PLC system failures.

Lesson 4 • Pre-Commissioning Checklist

Executes a structured checklist covering wiring verification, tag mapping, and safety interlocks before first power-up. Checklists prevent costly commissioning errors.