While this course is ideal for engineers who are new to PLCs, much of the contents and additional material in the extensive manual will be of value to those who already have the basic skills, but need a wider perspective for larger and more challenging tasks ahead.

The information contained in this course advances from the basics to challenge even the most experienced engineer in the industry today.

The course is supported by Video demonstrating PLC Programming techniques.

This course aims to enable the participants to:

• Identify and explain the main design characteristics, internal architecture and operating principles of programmable logic controllers.
• Describe and identify the characteristics of commonly used input and output devices. 
• Explain the processing of inputs and outputs by PLCs. 
• Describe communication links involved with PLC systems, the protocols and networking methods.
• Develop ladder and function programming for the logic functions AND, OR, NOR, NAND, NOT and XOR. 
• Develop ladder programs involving internal relays, timers, counters, shift registers, sequencers and data handling.
• Identify the parts of an electrical machine control diagram including rungs, branches, rails, contacts, and loads.
• Correctly design and draw a simple electrical machine control diagram.
• Recognize the difference between an electronic diagram and an electrical machine diagram.
• Understand the more common machine control terminology.
• Identify safety issues with PLC systems. 
• Identify methods used for fault diagnosis, testing and debugging.

This course is designed for:

•  New engineers/tech.
•  Senior engineers/tech.
• Process engineers/tech.
• Instrumentation engineers/tech.
• Electrical engineers/tech.

Day 1

Chapter 1: INTRODUCTION TO PROGRAMMABLE CONTROLLERS

• Definition
• A Historical Background
• Principles of Operation
• PLCs Versus Other Types of Controls
• Advantages of PLCs

Number Systems and Codes

• Number Systems
• Number Conversions
• One’s and Two’s Complement
• Binary Codes
• Register Word Formats

Chapter 2: PLC COMPONENTS AND SYSTEMS

Processors, the Power Supply, and Programming Devices

• Processors
• Processor Scan
• Error Checking and Diagnostics
• The System Power Supply
• Programming Devices

The Memory System and I/O Interaction

• Memory Overview
• Memory Types
• Memory Structure and Capacity
• Memory Organization and I/O Interaction
• Configuring the PLC Memory—I/O Addressing
• Memory Considerations

The Input / Output System

• I/O Rack Enclosures and Table Mapping
• Remote I/O Systems
• PLC Instructions for Discrete Inputs
• Types of Discrete Inputs
• PLC Instructions for Discrete Outputs
• Discrete Outputs
• Discrete Bypass/Control Stations
• Analog Input/ output Connections
• Instructions for Analog Input/ Output Modules
• Analog Input/ Output Data Representation & Handling

Day 2

Chapter 3: PLC PROGRAMMING

Programming Languages

• Types of PLC Languages
• Ladder Diagram Format
• Ladder Relay Instructions
• Ladder Relay Programming
• Timers and Counters
• Timer Instructions
• Counter Instructions
• Program/Flow Control Instructions
• Arithmetic Instructions
• Data Manipulation Instructions
• Data Transfer Instructions
• Special Function Instructions
• Network Communication Instructions
• Boolean Mnemonics

The IEC 1131 Standard and Programming Language

• IEC 1131-3 Programming Languages
• Sequential Function Chart Programming
• Types of Step Actions
• IEC 1131-3 Software Systems

Day 3

System Programming and Implementation

• Control Task Definition
• Control Strategy
• Implementation Guidelines
• Programming Organization and Implementation
• Discrete I/O Control Programming
• Analog I/O Control Programming
• Short Programming Examples

PLC System Documentation

• Steps for Documentation
• PLC Documentation Systems

Case Studies “Siemens S7 & Allen Bradley”

Day 4

Chapter 4: PLC COMMUNICATION & NETWORKS

Local Area Networks

• Principles of Local Area Networks
• Network Topologies
• Network Access Methods
• Communication Media
• Understanding Network Specifications
• Network Protocols
• Network Testing and Troubleshooting

I/O Bus Networks

• Types of I/O Bus Networks
• Advantages of I/O Bus Networks
• Device Bus Networks
• Process Bus Networks
• I/O Bus Installation and Wiring Connections

Case Studies “Siemens S7 & Allen Bradley”

Chapter 5: PLC Installation, Start-up, Troubleshooting and Maintenance

PLC Start-Up and Maintenance

• PLC System Layout
• Power Requirements and Safety Circuitry
• Noise, Heat, and Voltage Considerations
• I/O Installation, Wiring, and Precautions
• PLC Start-Up and Checking Procedures
• PLC System Maintenance
• Troubleshooting the PLC System

System Selection Guidelines

• PLC Sizes and Scopes of Applications
• Process Control System Definition
• Other Considerations

Case Studies “Siemens S7 & Allen Bradley”

Day 5

Chapter 6: PLC Programming Application Exercises

• Normally closed contact in series connection
• Block in parallel connection
• Rising-edge pulse output for one scan cycle
• Falling-edge pulse output for one scan cycle
• Latching control circuit
• Automatic parameter initialization when powered-up
• Common latched circuit and SET/RST instructions application
• Alternate output circuit (with latched function)
• Conditional control circuit
• Fist-in Priority circuit
• Entry-Exit control of the underground car park
• Forward/ Reverse control for 3-phase asynchronous motor
• Selective execution of programs
• MC/MCR- Manual/Auto control
• Product Mass Packing
• Daily production record programs
• Delay-ON & Delay-OFF programs
• Sequential Delay output programs
• Star-delta reducing voltage starter control
• Automatic liquids mixing control system

Case Studies “Siemens S7 & Allen Bradley”