PLC 2 – Applications

Course Content:

Advanced Ladder Logic Programming

• Nested logic structures and program sequencing

• Use of latches, unlatches, and one-shot instructions

• Advanced timer and counter functions (TON, TOF, RTO, CTU, CTD)

Data Handling and Memory Management

• Understanding PLC data types (integers, floating point, Boolean, arrays)

• Use of data registers, word and bit-level manipulation

• File handling and indirect addressing

Analog I/O and Signal Processing

• Introduction to analog sensors and actuators

• Scaling analog signals (e.g., 4-20mA, 0-10V) to engineering units

• Analog input/output configuration and programming

Structured Programming Techniques

• Modular and reusable code development

• Subroutines/functions and program organization

• Tag-based programming and use of UDTs (User Defined Types) in tag-based systems

HMI and SCADA Integration

• Basics of Human-Machine Interface configuration

• Linking PLC data to HMI displays

• Creating alarms, trends, and control interfaces

Industrial Communication Protocols

• Introduction to protocols: Ethernet/IP, Modbus TCP/RTU, Profibus

• Configuring communication between multiple PLCs or with external devices

• Network diagnostics and troubleshooting

Sequencer and State-Based Programming

• Step sequencing using sequencer instructions or logic

• State machine programming for complex control flows

• Batch process automation concepts

Troubleshooting and Diagnostics

• Real-time program monitoring and forcing I/O for testing

• Diagnostic tools and fault codes

• Troubleshooting hardware and logic-related issues

Safety and Reliability in PLC Systems

• Redundancy and fault-tolerant design basics

• Incorporating safety relays and safety PLCs

• Safe start/stop logic and emergency stop programming

Capstone Project or Hands-on Labs

• Design, program, and test an automated control system

• Simulate or implement multi-step machine or process control

• Document and present a fully functional PLC project