PLC Course

Lesson 1 • Safety and Workplace Standards

Introduces electrical safety practices and industry standards relevant to PLC installation and operation. Establishes safe habits before students handle any hardware.

Lesson 2 • PLC Families and Form Factors

Surveys micro, modular, and rack-based PLC families and their appropriate applications. Helps students match hardware selection to project scale and requirements.

Lesson 3 • Introduction to Industrial Automation

Covers the evolution from manual and relay-based control to programmable automation. Provides context for why PLCs became the standard control solution in industry.

Lesson 4 • PLC Hardware Architecture

Examines the physical components of a PLC system including the CPU, power supply, and I/O modules. Connects hardware knowledge to system design decisions.

Lesson 1 • Bit-Level Instructions

Covers examine-if-closed, examine-if-open, and output energise instructions used to control discrete I/O. These are the building blocks of all ladder logic programmes.

Lesson 2 • Introduction to Ladder Logic

Introduces the graphical structure of ladder logic, including rungs, rails, and contacts. Connects ladder notation directly to its relay logic origins for intuitive understanding.

Lesson 3 • Timer Instructions

Teaches TON, TOF, and RTO timer instructions including their accumulator and preset values. Timers are fundamental to sequencing and delay-based control logic.

Lesson 4 • Counter Instructions

Covers CTU, CTD, and RES counter instructions for counting events and controlling sequences. Counters complement timers in building complete process control programmes.

Lesson 1 • Sequential Function Chart Programming

Introduces SFC for programming step-based sequential processes with transitions and actions. SFC is the preferred language for machine sequencing and batch control.

Lesson 2 • Overview of IEC 61131-3 Standard

Introduces the five standard PLC languages and the programme organisation units that structure them. Establishes a common framework used across modern PLC platforms.

Lesson 3 • Structured Text Programming

Teaches the high-level, Pascal-like Structured Text language for complex calculations and logic. ST is ideal for maths-intensive and algorithm-driven control tasks.

Lesson 4 • Function Block Diagram Programming

Covers the graphical FBD language using interconnected function blocks for signal flow. FBD is widely used in process control and continuous signal applications.

Lesson 1 • Analogue I/O Wiring and Scaling

Teaches wiring of 4–20 mA and 0–10 V analogue signals and scaling raw counts to engineering units. Analogue I/O is essential for process variable measurement and control.

Lesson 2 • Output Devices and Actuator Wiring

Covers wiring of solenoids, motor starters, relays, and variable frequency drives to PLC outputs. Proper actuator wiring ensures safe and accurate machine response.

Lesson 3 • I/O Troubleshooting Techniques

Introduces systematic methods for diagnosing wiring faults, blown fuses, and failed I/O points. Troubleshooting skills reduce downtime and are critical for maintenance roles.

Lesson 4 • Sensor Types and Selection

Surveys proximity, photoelectric, temperature, pressure, and flow sensors used with PLCs. Sensor selection directly affects I/O module type and programme logic design.

Lesson 1 • Comparison Instructions

Covers EQU, NEQ, LES, GRT, LEQ, and GEQ instructions for evaluating numeric conditions. Comparison instructions enable data-driven branching in ladder logic programs.

Lesson 2 • Data Move and Copy Instructions

Covers MOV, COP, FLL, and MVM instructions for transferring data between memory locations. Data move instructions are fundamental to recipe management and data logging.

Lesson 3 • Logical and Bit Shift Instructions

Covers AND, OR, XOR, NOT, BSL, and BSR instructions for bitwise operations and shift registers. Bit shift registers are widely used in conveyor tracking and sequencing applications.

Lesson 4 • Program Control Instructions

Introduces JSR, RET, JMP, LBL, MCR, and SBR instructions for controlling program execution flow. These instructions enable modular, maintainable program architecture.

Lesson 1 • EtherNet/IP and Modbus TCP

Teaches EtherNet/IP implicit and explicit messaging and Modbus TCP for Ethernet-based PLC communication. These are the dominant protocols in modern industrial automation networks.

Lesson 2 • Industrial Network Fundamentals

Introduces OSI model concepts, network topologies, and the role of industrial Ethernet in automation. Provides the foundation needed to understand all PLC communication protocols.

Lesson 3 • Serial Communication Protocols

Covers RS-232, RS-485, and Modbus RTU protocols used for point-to-point and multi-drop PLC communication. Serial protocols remain common in legacy and cost-sensitive applications.

Lesson 4 • PROFIBUS and PROFINET

Covers PROFIBUS DP fieldbus and PROFINET real-time Ethernet for device-level communication. These protocols are dominant in European and global manufacturing environments.

Lesson 1 • Alarm and Interlock Design

Covers designing process alarms, safety interlocks, and emergency stop logic per industry standards. Proper alarm design protects equipment, product quality, and personnel safety.

Lesson 2 • Modular Programme Architecture

Teaches organizing PLC programs into tasks, programs, and reusable routines or function blocks. Modular design improves readability, reuse, and long-term maintainability.

Lesson 3 • Program Documentation Standards

Establishes best practices for rung comments, tag descriptions, and as-built documentation. Good documentation reduces troubleshooting time and supports future modifications.

Lesson 4 • Control System Specification

Covers translating customer requirements into a functional specification and I/O list. A clear specification prevents scope creep and drives all subsequent design decisions.

Lesson 1 • Online Program Editing and Monitoring

Covers making live program changes, forcing tags, and monitoring data tables while the PLC is running. Online editing skills are essential for minimizing production interruptions.

Lesson 2 • Fault Diagnosis Methodology

Teaches a structured fault-finding process using PLC diagnostics, fault logs, and online monitoring. A systematic approach reduces mean time to repair in production environments.

Lesson 3 • Backup, Restore, and Firmware Management

Establishes procedures for backing up programs, restoring after failure, and managing firmware updates. Reliable backup practices are the foundation of PLC disaster recovery.

Lesson 4 • Preventive Maintenance Planning

Covers scheduled maintenance tasks including battery replacement, module inspection, and environmental checks. Preventive maintenance extends hardware life and prevents unplanned outages.