PLC Programming Course

Lesson 1 • PLC Hardware Architecture

Examines CPU, power supply, I/O modules, and backplane. Understanding hardware is prerequisite to configuring and programming any PLC system.

Lesson 2 • Input and Output Fundamentals

Covers how field devices connect to PLC inputs and outputs. Students map real-world signals to PLC terminals for accurate program design.

Lesson 3 • Safety and Industrial Standards

Introduces electrical safety practices and relevant automation standards. Safe work habits established here apply throughout all lab and field exercises.

Lesson 4 • What Is a PLC

Defines PLCs, their origin, and how they replaced relay-based control. Establishes the industrial context that motivates all subsequent programming study.

Lesson 1 • Ladder Diagram Language Overview

Introduces ladder diagram syntax derived from relay schematics. Familiarity with this language is the entry point for all PLC programming work.

Lesson 2 • Addressing and Tag Naming

Explains absolute addressing and tag-based addressing conventions. Consistent naming practices improve program readability and long-term maintainability.

Lesson 3 • Program Verification and Online Monitoring

Teaches online monitoring, forcing, and status indicators for live program verification. These skills are essential for debugging and commissioning ladder programs.

Lesson 4 • Programming Software Environment

Guides students through a professional PLC programming IDE for project creation and program entry. Hands-on navigation skills accelerate all future programming tasks.

Lesson 1 • Practical Counter Applications

Implements counters for part counting, batch control, and position indexing. These applications directly reflect common industrial automation requirements.

Lesson 2 • Counter Instruction Types

Introduces count-up, count-down, and bidirectional counter instructions. Counters enable event tracking, batch control, and production monitoring.

Lesson 3 • Timer Instruction Types

Covers on-delay, off-delay, and retentive timer instructions with their parameters. Timer selection directly determines sequence behavior in automated processes.

Lesson 4 • Troubleshooting Timers and Counters

Diagnoses common timer and counter faults using online monitoring tools. Systematic fault-finding skills reduce downtime in production environments.

Lesson 1 • Comparison Instructions

Teaches EQU, NEQ, GRT, LES, GEQ, and LEQ instructions for conditional logic. Comparisons enable setpoint checking, alarm triggering, and process branching.

Lesson 2 • Scaling and Engineering Unit Conversion

Applies scaling formulas to convert raw analog counts to engineering units. Accurate scaling is critical for process measurement and control accuracy.

Lesson 3 • Arithmetic and Math Instructions

Implements ADD, SUB, MUL, DIV, MOD, and SQR instructions for process calculations. Math instructions support scaling, totalization, and engineering unit conversion.

Lesson 4 • Data Types and Memory Organization

Defines integer, floating-point, Boolean, and string data types used in PLCs. Correct data type selection prevents overflow errors and ensures calculation accuracy.

Lesson 1 • Function Block Diagram Programming

Covers FBD language for graphical representation of signal flow and function blocks. FBD is widely used in process control and motion applications.

Lesson 2 • Task and Program Organization

Explains continuous, periodic, and event-driven task types in modern PLCs. Proper task assignment ensures deterministic execution of time-critical routines.

Lesson 3 • Structured Text Programming Basics

Introduces IEC 61131-3 Structured Text syntax for math-heavy and algorithmic logic. ST complements ladder logic for complex calculations and data processing.

Lesson 4 • Subroutine Design and Reuse

Teaches how to create parameterized subroutines for reusable logic blocks. Modular subroutines reduce code duplication and simplify system-wide updates.

Lesson 1 • Analog I/O Module Configuration

Configures analog input and output modules for voltage and current signals. Correct module setup is prerequisite to accurate process measurement and control.

Lesson 2 • PID Tuning Methods

Applies open-loop step test and Ziegler-Nichols methods to determine PID gains. Systematic tuning achieves stable, responsive control with minimal overshoot.

Lesson 3 • PLC PID Instruction Configuration

Sets up the PID instruction block with all required parameters and modes. Proper configuration prevents windup, oscillation, and unsafe output behavior.

Lesson 4 • Practical PID Loop Applications

Implements PID loops for temperature, pressure, flow, and level control. Real-world examples reinforce parameter selection and loop interaction management.

Lesson 1 • Remote I/O and Distributed Architecture

Designs distributed I/O systems using remote adapter modules over industrial networks. Distributed architecture reduces wiring costs and improves system scalability.

Lesson 2 • Fieldbus and Device-Level Networks

Introduces PROFIBUS, DeviceNet, and AS-Interface for device-level communication. Fieldbus knowledge enables integration of drives, sensors, and actuators.

Lesson 3 • EtherNet/IP and PROFINET Configuration

Configures EtherNet/IP and PROFINET for high-speed PLC-to-device communication. These protocols dominate modern automation and are required for most new installations.

Lesson 4 • PLC-to-HMI Communication

Establishes data exchange between PLCs and human-machine interfaces. Reliable PLC-HMI communication is fundamental to operator control and visualization.

Lesson 1 • Alarm and Diagnostic Programming

Builds alarm detection, latching, and acknowledgment logic within PLC programs. Structured alarm management reduces operator response time and improves safety.

Lesson 2 • Sequential Function Chart Programming

Implements SFC language for step-based sequential process control. SFC provides clear visualization of machine states and transition conditions.

Lesson 3 • Advanced Data Structures and Arrays

Uses arrays, user-defined data types, and structures for complex data management. Advanced data structures enable recipe systems, logging, and flexible program design.

Lesson 4 • Program Documentation and Version Control

Applies commenting, cross-referencing, and version control practices to PLC projects. Thorough documentation is required for maintenance, audits, and future modifications.