PLC Programming Training

Lesson 1 • PLC Hardware Architecture

Examines CPU, power supply, I/O modules, and backplane communication. Students map physical components to functional roles within a PLC chassis.

Lesson 2 • Input and Output Signal Types

Differentiates discrete, analog, and specialty signal types used in field devices. Connects signal understanding to correct module selection and wiring.

Lesson 3 • Safety and Electrical Fundamentals

Reviews electrical safety practices and basic circuit concepts required for PLC work. Ensures safe lab and field practices throughout the course.

Lesson 4 • Introduction to Industrial Automation

Covers the evolution from relay-based to programmable control and the role PLCs play in modern manufacturing. Establishes context for all subsequent programming concepts.

Lesson 1 • Series and Parallel Logic Circuits

Translates AND, OR, and NOT Boolean logic into ladder rung configurations. Students convert truth tables into working ladder diagrams.

Lesson 2 • Bit-Level Instructions

Covers examine-if-closed, examine-if-open, and output energize instructions in detail. These bit instructions form the core logic of nearly every PLC program.

Lesson 3 • Ladder Diagram Structure and Syntax

Introduces rungs, rails, contacts, and coils as the building blocks of ladder logic. Establishes correct syntax habits before more complex instructions are introduced.

Lesson 4 • Addressing and Tag-Based Programming

Explains file-based and tag-based addressing schemes used across PLC platforms. Correct addressing prevents data conflicts and simplifies program maintenance.

Lesson 1 • Comparison Instructions

Introduces EQU, NEQ, LES, GRT, LEQ, and GEQ instructions for numeric decision-making. Comparison instructions connect data values to discrete output control.

Lesson 2 • Math and Data Move Instructions

Covers ADD, SUB, MUL, DIV, MOV, and COPY instructions for arithmetic and data transfer. These instructions enable scaling, calculation, and register management.

Lesson 3 • Timer Instructions

Covers TON, TOF, and RTO timer types including preset, accumulated, and status bits. Timers are foundational to sequencing, delays, and process interlocks.

Lesson 4 • Counter Instructions

Explains CTU, CTD, and RES instructions for event counting and count-based control. Counters enable production tracking, batch control, and position indexing.

Lesson 1 • Tasks, Programs, and Routines

Explains the hierarchical relationship between tasks, programs, and routines in modern PLC platforms. Proper hierarchy reduces scan time and improves code readability.

Lesson 2 • Subroutine and Jump Instructions

Covers JSR, RET, JMP, and LBL instructions for modular and conditional program flow. Subroutines reduce code duplication and simplify troubleshooting.

Lesson 3 • Modular Program Design Principles

Applies modular design by separating I/O mapping, control logic, and HMI data into distinct routines. Modularity enables reuse and simplifies future modifications.

Lesson 4 • Data Organization and Structures

Introduces arrays, user-defined data types (UDTs), and structured tag organization. Well-organized data reduces errors and accelerates program development.

Lesson 1 • Sequential Function Chart Programming

Explains SFC steps, transitions, and actions for sequential machine control. SFC provides a clear visual representation of multi-step process sequences.

Lesson 2 • Selecting the Right Language

Provides decision criteria for choosing ladder, FBD, ST, or SFC based on application type. Matching language to task improves readability and reduces development time.

Lesson 3 • Function Block Diagram Programming

Introduces FBD graphical language for signal flow and continuous process control applications. FBD complements ladder logic for analog and PID-based control strategies.

Lesson 4 • Advanced Ladder Instructions

Covers shift registers, sequencers, file arithmetic, and indirect addressing instructions. These instructions solve complex indexing and data manipulation challenges.

Lesson 1 • Integrating Drives and Smart Devices

Connects variable frequency drives, servo drives, and smart sensors via industrial networks. Students configure device parameters and map drive data to PLC tags.

Lesson 2 • PLC-to-PLC Communication

Configures produced/consumed tags and MSG instructions for peer-to-peer PLC data exchange. Enables distributed control architectures and coordinated multi-PLC systems.

Lesson 3 • SCADA and HMI Data Exchange

Establishes OPC-UA and direct tag server connections between PLCs and SCADA or HMI systems. Proper data exchange configuration ensures accurate real-time visualization.

Lesson 4 • Industrial Network Fundamentals

Reviews OSI model layers relevant to industrial networks and common topology types. Provides the networking foundation required for protocol configuration tasks.

Lesson 1 • Hardware Fault Diagnosis

Diagnoses field wiring faults, blown fuses, failed I/O modules, and power supply issues. Hardware diagnosis skills prevent misdiagnosis of field problems as program errors.

Lesson 2 • Fault Types and Diagnostic Tools

Categorizes major, minor, and I/O faults and introduces built-in diagnostic tools available in programming software. Understanding fault categories accelerates root-cause identification.

Lesson 3 • Online Monitoring and Forcing

Uses online monitoring, cross-reference tools, and I/O forcing to isolate faults in live systems. These techniques minimize downtime during production troubleshooting.

Lesson 4 • Systematic Troubleshooting Methodology

Applies a structured divide-and-conquer approach to fault isolation in ladder programs. A repeatable methodology reduces mean time to repair across all fault scenarios.

Lesson 1 • Functional and Sequence Testing

Executes functional test procedures to verify each control sequence operates per specification. Test results are recorded and deviations are resolved before acceptance.

Lesson 2 • Handover Documentation and Training

Prepares as-built drawings, program backups, and operator training materials for project handover. Complete documentation ensures long-term maintainability and operator competence.

Lesson 3 • Pre-Commissioning Preparation

Covers design review, I/O list verification, and panel inspection before power-up. Thorough preparation prevents costly errors during live commissioning activities.

Lesson 4 • I/O Checkout Procedures

Performs point-by-point I/O verification to confirm correct wiring and signal integrity. I/O checkout is the first live step and validates hardware before program testing.