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

1. Start up and shut down a PLC system
2. Power up and perform a normal shutdown of a PLC system
3. Identify the parts of a PLC
4. Describe the basic operation of a programmable controller (PLC)
5. Describe the component functions of a PLC
6. Describe the operation of the PLC power supply circuit
7. Configure an Ethernet/IP Driver
8. Configure an Ethernet/IP Driver to permit PLC to PC communications
9. Describe the function of Ethernet/IP driver software
10. Transfer programs between a PLC / PC via point-to-point Ethernet
11. Connect and configure a point-to-point PLC Ethernet network
12. Download a PLC project from a PC via point-to-point Ethernet
13. Upload a PLC project to a PC via point-to-point Ethernet
14. Describe the basic operation of a point-to-point Ethernet network
15. Describe the Ethernet IP address system for point-to-point
16. Describe the basic operation of PLC programming software
17. Connect and configure a point-to-point PLC serial network
18. Download a PLC project from a PC via point-to-point USB serial
19. Upload a PLC project to a PC via point-to-point USB serial
20.Describe the basic operation of USB serial communications
21. Describe the USB configuration using PLC programming software
22. Change PLC operation mode to Run or Program
23. Monitor PLC status using I/O indicators and software
24. Describe the functions of PLC operation modes
25. Connect and configure HMI panel with Ethernet network
26. Download a project to an HMI panel via an Ethernet network
27. Operate a basic HMI panel project with Ethernet network
28. Describe the operation of a Human Machine Interface (HMI) panel
29. Transfer programs between a PLC / PC via USB serial
30. Operate and monitor a PLC
31. Connect, configure, and operate an HMI panel with Ethernet
32. Describe basic functions of an HMI panel project
33. Configure PLC discrete I/O
34. Identify a discrete I/O terminal given a tag
35. Describe the memory organization of a typical PLC
36. Describe types of discrete PLC I/O modules
37. Describe how discrete I/O devices are interfaced to a PLC
38. Describe the format of PLC instruction and I/O addresses
39. Interpret a tag
40. Interpret a basic PLC ladder logic program
41. Interpret a basic PLC I/O diagram
42. Interpret a basic PLC power diagram
43. Design and test a basic PLC ladder program
44. Describe the operation of basic PLC logic instructions: normally-open, normally-closed,
output coil, internal coils, timers, and up/down counters
45. Describe the symbolic, absolute discrete I/O address system
46. Create a PLC project
47. Enter and operate a PLC logic program
48. Edit a PLC project
49. Describe the elements of a PLC project
50. Configure PLC discrete I/O
51. Program and operate a basic PLC logic program
52. Create a PLC project
53. Program and operate a PLC logic program that uses comparison instructions
54. Interpret a PLC logic program that uses comparison instructions
55. Enter and operate a PLC logic program that uses comparison instructions
56. Interpret the operation of a PLC logic program that uses comparison instructions
57. Describe the operation of PLC comparison instructions
58. Interpret a PLC logic program that uses basic math instructions: Add, Subtract, Divide, and Multiply
59. Enter and operate a PLC program that uses basic math instructions
60. Interpret a PLC logic program that uses a Compute instruction
61. Enter and operate a PLC program that uses a Compute instruction
62. Design and test a PLC program that uses math instructions
63. Describe the operation and applications of basic PLC math instructions
64. Describe the operation and applications of PLC Compute instruction
65. Interpret the operation of PLC motor control sequence program
66. Design and test the operation of a PLC motor control sequence program
67. Describe the operation of a seal-in logic program
68. Describe the operation of a PLC-controlled motor control circuit
69. Describe the operation of a reversing motor control
70. Interpret the operation of an event-driven 2-step PLC sequence program
71. Interpret the operation of a time-driven 2-step PLC sequence program
72. Design and test a basic event-driven PLC sequence program
73. Design and test a time-driven PLC sequence program
74. Describe the operation of an event-driven PLC sequence program
75. Describe the operation of a time-driven PLC sequence program
76. Use status and diagnostic indicators to troubleshoot a PLC
77. Describe two levels of troubleshooting and give an application of each
78. Describe types of PLC faults
79. Troubleshoot PLC inputs and outputs
80. Force on a PLC output
81. Troubleshoot PLC inputs and outputs
82. Describe the function/applications of forcing outputs
83. Describe types of input/output module and field device faults
84. Describe methods of troubleshooting inputs and outputs
85. Troubleshoot PLC power distribution system
86. Troubleshoot power distribution faults
87. Describe the operation of a PLC power distribution system
88. Describe types of power distribution faults
89. Describe methods of troubleshooting power distribution faults
90. Troubleshoot a PLC processor
91. Describe types of processor faults
92. Describe methods of troubleshooting processor faults
93. Troubleshoot a PLC system with discrete I/O
94. Describe methods of systems troubleshooting
95. Describe a 6-step PLC systems troubleshooting process
96. Interpret the operation of a multi-step event-driven PLC sequence program
97. Interpret the operation of a multi-step time-driven PLC sequence program
98. Design and test a PLC multi-step PLC sequence program
99. Describe the operation of a multi-step event-driven and time-driven PLC sequence programs
100. Describe types of PLC documentation: truth table, sequence of operation
101. Describe how to interpret a multi-step PLC sequence program
102. Troubleshoot a multi-step PLC sequence program with event-driven and time-driven steps
103. Describe how to troubleshoot PLC sequence programs

Outline of instruction

1. PLC Workplace Safety
• Lab: Demonstrate proper use of Personal Protective Equipment (PPE) when working with PLC
systems. Have students show how to apply PPE in various PLC troubleshooting scenarios and understand
under what circumstances each type is required.
2. Safety Procedures in PLC Operations
• Lab: Demonstrate the use of tools and equipment specific to PLC installation and maintenance.
Students will display proper lifting methods for heavy PLC hardware and components. Demonstrate the
use of checklists prior to operating or troubleshooting PLC equipment. Have students generate PLCspecific safety checklists.
3. PLC Ladder Logic Programming
• Lab: Learn the fundamentals of creating logic using PLC ladder diagrams. Students will practice
designing and interpreting ladder logic programs used in PLCs for various control applications.
4. Electrical Concepts in PLC Systems
• Lab: Review basic electrical safety in the context of PLC systems. Demonstrate how to use a
Digital Volt/Ohm Meter (VOM) to read resistance, continuity, voltage, and current in PLC circuits. Students
will wire simple series and parallel control circuits connected to PLC inputs and outputs and verify their
proper function.
5. Introduction to PLC Hardware and Software
• Lab: Have students identify common PLC hardware components and describe the function of
each. Demonstrate and have students practice programming using relay ladder logic. Students will review
PLC safety procedures, wire a PLC system, verify inputs and outputs, load pre-written code, and confirm
system functionality. They will then make simple modifications to existing code, save changes, download
to the PLC, and verify the updated function.
6. PLC Control of Pneumatic Systems
• Lab: Review pneumatic safety with a focus on PLC-controlled pneumatic systems. Students will
build a pneumatic circuit integrated with a PLC, verify the inputs and outputs, and ensure the system
operates as intended.
7. PLC Applications in Industrial Automation
• Lab: Describe how PLCs are utilized in industrial automation processes, including material
handling systems, material identification systems, and manufacturing execution systems. Students will
explore PLC integration with robotic components such as servomotors, robotic arms, end effectors,
grippers, and encoders. They will demonstrate methods for axis control using PLC programming and
describe various types of end effectors and grippers and their applications.
8. PLC Integration with Sensors
• Lab: Describe various types of sensors used in PLC systems, their applications, and limitations.
Students will 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.
9. Interfacing PLCs with Robotic Systems
• Lab: 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.
10. Advanced PLC Programming and Troubleshooting
• Lab: Students will demonstrate a basic understanding of advanced PLC programming methods.
They will use teach pendants in "teach mode" to program PLC-controlled robotic systems. Students will
practice "walk-through" and "lead-through" programming techniques and discuss the advantages and
disadvantages of online versus offline PLC programming. They will 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 will 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

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

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.

Text and 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

Grayson Halstead
919-747-0109
[email protected]