PLC Training
1. Introduction to PLCs: PLCs are industrial computers with various inputs and outputs used
to control and monitor industrial equipment based on custom programming. They come in
many different sizes and form factor.
Overview of industrial automation and the role of PLCs.
Industrial automation is the use of control systems, such as computers or
robots, and information technologies for handling different processes and
machineries in an industry to replace a human being. The role of a
Programmable Logic Controller (PLC) in industrial automation is to act as the
physical interfaces between devices on the plant or manufacturing floor and a
SCADA or HMI system. PLCs can communicate, monitor, and control complex
automated processes such as conveyors, temperature control, robot cells, and
many other industrial machines. They are used in a variety of applications in
industrial automation such as in manufacturing processes, material handling
systems, and industrial control systems. PLCs are designed to control and
automate manufacturing processes by carrying out specific tasks such as
monitoring inputs from sensors and other devices and making decisions based
on the programmed logic
Advantages of using PLCs over traditional control systems.
PLCs offer numerous advantages over traditional relay-based control systems. Some
of these advantages include:
Increased flexibility
Reliability
Ease of maintenance
Improved safety
Fast response times
Precise control
Scalability
Low cost
High accuracy
Less wiring
Introduction to the components of a PLC system.
Power supply
Processor
Input/output (I/O) modules
Programming device
Communication interface
2. PLC Hardware:
2.0: Central processing unit (CPU) - The Central Processing Unit (CPU) is
the brain of the PLC. It is responsible for executing the program stored in its
memory and controlling the input/output (I/O) system. The CPU reads the input
signals from the I/O modules, processes them according to the program
instructions, and sends output signals back to the I/O modules. The CPU also
communicates with other devices such as HMIs and SCADA systems .
2.1: Input/output (I/O) system- The Input/output (I/O) system is
responsible for interfacing the PLC with the outside world. It consists of
input modules that receive signals from sensors and other devices, and
output modules that send signals to actuators and other devices. The I/O
system converts the signals from the sensors and other devices into a
format that can be processed by the CPU, and converts the signals from the
CPU into a format that can be used by the actuators and other devices
2.2: Programming device- The Programming Device is used to create
and edit the program that runs on the PLC. It can be a dedicated
programming device or a personal computer running
programming software.
3) Examination of various types of PLCs and their specifications.
PLCs come in different types and specifications depending on the manufacturer
and model. Some of the common types of PLCs include:
Modular PLCs
Compact PLCs
Rack-mounted PLCs
Small-scale PLCs
The specifications of a PLC can vary depending on the application requirements.
Some of the common specifications include:
Number of I/O points
Memory capacity
Processing speed
Communication protocols
Operating temperature range
5) Overview of input/output (I/O) modules and their functions.
Input/output (I/O) modules are used to interface the PLC with the outside world.
The input modules receive signals from sensors and other devices, and the output
modules send signals to actuators and other devices. The I/O modules convert the
signals from the sensors and other devices into a format that can be processed by
the CPU, and convert the signals from the CPU into a format that can be used by
the actuators and other devices.
The functions of I/O modules include:
Signal conditioning
Isolation
Amplification
Filtering
Conversion
6) Power supply and communication interfaces used in PLC systems.
The power supply is used to provide power to the PLC system. It converts the
incoming AC or DC power to the voltage required by the PLC. The power supply
also provides isolation between the incoming power and the PLC system.
The communication interface is used to connect the PLC to other devices such as
HMIs, SCADA systems, and other PLCs. The communication interface can use
various protocols such as Ethernet, Modbus, Profibus, and DeviceNet.
3. PLC Software:
Introduction to programming software used for PLCs (e.g., ladder logic
programming software).
Familiarization with the software interface and tools.
Creating, editing, and managing PLC programs.
Downloading and uploading programs to/from the PLC.
4. Ladder Logic Programming:
Understanding ladder logic diagrams.
Learning basic ladder logic symbols and their functions.
Writing simple ladder logic programs for basic control tasks.
Developing more complex programs using timers, counters, and other
instructions.
5. I/O Modules and Wiring:
Different types of I/O modules and their configuration.
Wiring techniques for connecting field devices to the PLC.
Addressing I/O points for input and output devices.
6. Data Types and Memory:
Understanding different data types used in PLC programming.
Memory organization in a PLC and its types (input memory, output memory, data
memory, etc.).
Working with memory addresses and data manipulation instructions.
7. PLC Instructions:
Overview of various instructions commonly used in PLC programming, such as
timers, counters, arithmetic instructions, comparison instructions, and logical
operators.
Understanding the execution order and scan cycle of a PLC program.
8. HMI Integration:
Introduction to Human-Machine Interface (HMI) systems.
Integrating HMI with PLCs for real-time monitoring and control.
Designing operator interfaces and configuring HMI screens.
9. Troubleshooting and Debugging:
Techniques for identifying and resolving common issues in PLC programs.
Monitoring and troubleshooting hardware connections.
Debugging logic errors and analyzing program execution.
10. Safety Considerations:
Safety standards and best practices in PLC programming and operation.
Implementing safety functions in PLC programs.
Emergency stop systems and safety interlocks.
Please note that the actual content and duration of a PLC Level 1 course may vary
depending on the training provider or institution offering the course. It is recommended
to check the specific course syllabus or contact the training provider for more detailed
information on the course content and structure
