PLC Fundamentals (Level I) Course

Module 1: Introduction to PLCs & Software Setup

45 minutes

• Overview of PLC hardware: CPUs, I/O modules, power supplies.

• Install and configure the PLC programming environment (e.g., RSLogix, TIA Portal).

• Understand simulation tools and setup a virtual PLC for practice.

Module 2: Ladder Logic Fundamentals

1 hour

• Learn basic ladder elements: contacts, coils, and power rails.

• Create simple on/off control circuits and test in simulator.

• Apply rung organization and commenting for maintainable code.

Module 3: Timers, Counters & Data Handling

1 hour

• Configure on-delay, off-delay, and retentive timers.

• Implement up/down counters and compare operations.

• Use data registers, move instructions, and arithmetic operations.

Module 4: Sequencing & Advanced Instructions

1 hour

• Design multi-step process sequences with state machines.

• Utilize advanced instructions: PID, shift registers, and mask/compare.

• Integrate subroutines and modular function blocks for reuse.

Module 5: HMI Integration & SCADA Basics

1 hour

• Create graphical interfaces: buttons, indicators, and trends.

• Link HMI tags to PLC addresses and simulate operator interaction.

• Understand SCADA architecture and data acquisition fundamentals.

Module 6: Industrial Networking & Protocols

45 minutes

• Explore Modbus RTU/TCP and Ethernet/IP configuration.

• Set up communication between multiple PLCs and HMIs.

• Diagnose network issues using built-in protocol monitors.

Module 7: Hands-On Projects & Case Studies

1 hour

• Build a conveyor belt control system with start/stop sequences.

• Implement safety interlocks and emergency stop logic.

• Review real-world automation scenarios and best practices.

Module 8: Troubleshooting & Maintenance

45 minutes

• Use diagnostic tools: watch windows, force I/O, and error logs.

• Identify and resolve common programming and wiring faults.

• Apply preventive maintenance strategies to ensure uptime.

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