Course Offerings

This course provides a comprehensive introduction to Programmable Logic Controllers (PLCs), covering essential skills and knowledge required for PLC operation, configuration, and troubleshooting. Students will learn to start up and shut down PLC systems, identify key components, and describe basic operation principles. The course includes hands-on practice in configuring Ethernet/IP and USB serial communication networks, transferring programs between PLCs and PCs, and designing ladder logic programs. Advanced topics include PLC motor control sequences, math instructions, and comparison logic, as well as Human Machine Interface (HMI) configuration. Students will also gain experience troubleshooting PLC systems, including power distribution, processor faults, and multi-step sequence programs. By the end of the course, participants will be able to confidently operate, monitor, and troubleshoot PLCs in various industrial applications.

Course Objectives

Start up and shut down a PLC system


Power up and perform a normal shutdown of a PLC system

Identify the parts of a PLC

Describe the basic operation of a programmable controller (PLC)

Describe the component functions of a PLC

Describe the operation of the PLC power supply circuit

Configure an Ethernet/IP Driver

Configure an Ethernet/IP Driver to permit PLC to PC communications

Describe the function of Ethernet/IP driver software

Transfer programs between a PLC and a PC via point-to-point Ethernet

Connect and configure a point-to-point PLC Ethernet network

Download a PLC project from a PC via point-to-point Ethernet

Upload a PLC project to a PC via point-to-point Ethernet

Describe the basic operation of a point-to-point Ethernet network

Describe the Ethernet IP address system for point-to-point

Describe the basic operation of PLC programming software

Connect and configure a point-to-point PLC serial network

Download a PLC project from a PC via point-to-point USB serial

Upload a PLC project to a PC via point-to-point USB serial

Describe the basic operation of USB serial communications

Describe the USB configuration using PLC programming software

Change PLC operation mode to "Run" or "Program"

Monitor PLC status using I/O indicators and software

Describe the functions of PLC operation modes

Connect and configure a human machine interface (HMI) panel with Ethernet network

Download a project to an HMI panel via an Ethernet network

Operate a basic HMI panel project with Ethernet network

Describe the operation of an HMI panel

Transfer programs between a PLC and a PC via USB serial

Operate and monitor a PLC

Connect, configure and operate an HMI panel with Ethernet

Describe basic functions of an HMI panel project

Configure PLC discrete I/O

Identify a discrete I/O terminal given a tag

Describe the memory organization of a typical PLC

Describe types of discrete PLC I/O modules

Describe how discrete I/O devices are interfaced to a PLC

Describe the format of PLC instruction and I/O addresses

Interpret a tag

Interpret a basic PLC ladder logic program

Interpret a basic PLC I/O diagram

Interpret a basic PLC power diagram

Design and test a basic PLC ladder program

Describe the operation of basic PLC logic instructions: normally-open, normally-closed, output coil, internal coils, timers and up/down counters

Describe the symbolic, absolute discrete I/O address system

Create a PLC project

Enter and operate a PLC logic program

Edit a PLC project

Describe the elements of a PLC project

Configure PLC discrete I/O

Program and operate a basic PLC logic program

Create a PLC project

Program and operate a PLC logic program that uses comparison instructions

Interpret a PLC logic program that uses comparison instructions

Enter and operate a PLC logic program that uses comparison instructions

Interpret the operation of a PLC logic program that uses comparison instructions

Describe the operation of PLC comparison instructions

Interpret a PLC logic program that uses basic math instructions: add, subtract, multiply and divide

Enter and operate a PLC program that uses basic math instructions

Interpret a PLC logic program that uses a "Compute" instruction

Enter and operate a PLC program that uses a "Compute" instruction

Design and test a PLC program that uses math instructions

Describe the operation and applications of basic PLC math instructions

Describe the operation and applications of PLC "Compute" instruction

Interpret the operation of PLC motor control sequence program

Design and test the operation of a PLC motor control sequence program

Describe the operation of a seal-in logic program

Describe the operation of a PLC-controlled motor control circuit

Describe the operation of a reversing motor control

Interpret the operation of an event-driven two-step PLC sequence program

Interpret the operation of a time-driven two-step PLC sequence program

Design and test a basic event-driven PLC sequence program

Design and test a time-driven PLC sequence program

Describe the operation of an event-driven PLC sequence program

Describe the operation of a time-driven PLC sequence program

Use status and diagnostic indicators to troubleshoot a PLC

Describe two levels of troubleshooting and give an application of each

Describe types of PLC faults

Troubleshoot PLC inputs and outputs

Force on a PLC output

Troubleshoot PLC inputs and outputs

Describe the function/applications of forcing outputs

Describe types of input/output module and field device faults

Describe methods of troubleshooting inputs and outputs

Troubleshoot PLC power distribution system

Troubleshoot power distribution faults

Describe the operation of a PLC power distribution system

Describe types of power distribution faults

Describe methods of troubleshooting power distribution faults

Troubleshoot a PLC processor

Describe types of processor faults

Describe methods of troubleshooting processor faults

Troubleshoot a PLC system with discrete I/O

Describe methods of systems troubleshooting

Describe a six-step PLC systems troubleshooting process

Interpret the operation of a multi-step, event-driven PLC sequence program

Interpret the operation of a multi-step, time-driven PLC sequence program

Design and test a multi-step PLC sequence program

Describe the operation of multi-step, event-driven and time-driven PLC sequence programs

Describe types of PLC documentation: truth table and sequence of operation

Describe how to interpret a multi-step PLC sequence program

Troubleshoot a multi-step PLC sequence program with event-driven and time-driven steps

Describe how to troubleshoot PLC sequence programs

Outline of Instruction

PLC Workplace Safety
Demonstrate proper use of personal protective equipment (PPE) when working with PLC systems. Students show how to apply PPE in various PLC troubleshooting scenarios and understand under what circumstances each type is required.

Safety Procedures in PLC Operations
Demonstrate the use of tools and equipment specific to PLC installation and maintenance. Students display proper lifting methods for heavy PLC hardware and components. Demonstrate the use of checklists prior to operating or troubleshooting PLC equipment. Students generate PLC-specific safety checklists.

PLC Ladder Logic Programming
Learn the fundamentals of creating logic using PLC ladder diagrams. Students practice designing and interpreting ladder logic programs used in PLCs for various control applications.

Electrical Concepts in PLC Systems
Review basic electrical safety in the context of PLC systems. Demonstrate how to use a digital volt/ohmmeter (VOM) to read resistance, continuity, voltage and current in PLC circuits. Students wire simple series and parallel control circuits connected to PLC inputs and outputs and verify their proper function.

Introduction to PLC Hardware and Software
Students identify common PLC hardware components and describe the function of each. Students practice programming using relay ladder logic. Students review PLC safety procedures, wire a PLC system, verify inputs and outputs, load pre-written code and confirm system functionality. They then make simple modifications to existing code, save changes, download to the PLC and verify the updated function.

PLC Control of Pneumatic Systems
Review pneumatic safety with a focus on PLC-controlled pneumatic systems. Students build a pneumatic circuit integrated with a PLC, verify the inputs and outputs and ensure the system operates as intended.

PLC Applications in Industrial Automation
Describe how PLCs are utilized in industrial automation processes, including material handling systems, material identification systems and manufacturing execution systems. Students explore PLC integration with robotic components such as servomotors, robotic arms, end effectors, grippers and encoders. They demonstrate methods for axis control using PLC programming and describe various types of end effectors and grippers and their applications.

PLC Integration with Sensors
Describe various types of sensors used in PLC systems and their applications and limitations. Students demonstrate the use of sensors within a PLC-controlled robotic system, including implementing emergency stop functions and safety interlocks to halt robot motion in emergencies.

Interfacing PLCs with Robotic Systems
Identify the terminology used in specifying safeguarding systems for PLC-controlled robots. Distinguish between pneumatic and electric drives as controlled by PLCs. Demonstrate and have students perform lockout/tagout procedures on PLC and robotic equipment. Review relevant safety guidelines and standards for PLC and robotic system integration.

Advanced PLC Programming and Troubleshooting
Students demonstrate a basic understanding of advanced PLC programming methods, using teach pendants in "teach mode" to program PLC-controlled robotic systems. Students practice "walk-through" and "lead-through" programming techniques and discuss the advantages and disadvantages of online versus offline PLC programming. They describe the role of PLCs in computer-integrated manufacturing, identify common coordinate systems used in PLC-controlled robotics and distinguish between different types of program codes. Finally, students explain the importance of maintaining current backups of all PLC programs and configurations to aid in troubleshooting and system recovery.

Contact Hours

132

CEUs

No

Industry Standard, State or National Certification

Certification

Smart Automation Certification Alliance (Programmable Controller Systems 1 (C-207) and Programmable Controller Troubleshooting (C-208))

Website

saca.org

Certification Learning Outcomes/Requirements

PLC workplace safety, safety procedures in PLC operations, PLC ladder logic programming, electrical concepts in PLC systems, introduction to PLC hardware and software, PLC control of pneumatic systems, PLC applications in industrial automation, PLC integration with sensors, interfacing PLCs with robotic systems and advanced PLC programming and troubleshooting

CE or CU Articulation

No

Prerequisites

High School Graduate or GED; at least 18 years of age; reading level of 10th grade or higher. Basic math and general computer skills.

Learning Supplies Needed

PLCs, Programmable Devices (laptops)

Clinical Site/Special Facilities

Advanced Manufacturing Center

Requirements for Successful Completion

90% attendance
Completion of all modules with a minimum score of 75% for each module

Accreditation/Special Approval Requirements

N/A

Intended Audience

Specific Industry or Business Support Needs

Controls Technician, and/or Tech Level I, II, or III

Wake County Need for Industry Positions

This is a skills gap area for light manufacturing in Wake County that is dependent on skilled
robotics operators to keep manufacturing systems operating.

Industry or Job Titles Related to Training Outcomes for Employment

Controls Technician

Controls Technician Level I

Controls Technician Level II

Controls Technician Level III

Related Courses

MEC-3010K1

Course Contact Information