PLC Programming and Applications

• This advanced program is designed for engineers, technicians, and automation professionals who already possess a strong foundation in PLC programming. The course equips participants with advanced programming techniques, industrial networking skills, and HMI development expertise—enabling them to design, implement, and troubleshoot fully integrated automation systems.
   

​Learning Outcomes

By the end of this course, participants will be able to:

• Develop and manage complex PLC projects using structured data types (UDTs), arrays, and efficient tag management.

• Apply modular programming practices with subroutines, POUs, and function blocks.

• Configure and integrate analog/digital modules and VFDs.

• Master advanced communication protocols for distributed automation.

• Design and deploy advanced HMI applications with navigation, alarms, logging, and trends.

• Integrate PLCs, HMIs, and devices for scalable plant-wide automation.

• Apply best practices in documentation, debugging, and validation.

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​Course Content

Module 1: Advanced PLC Programming Techniques

• Structured data handling (UDTs, arrays, structures).

• Modular design with subroutines, POUs, and parameterized function blocks.

• Advanced programming instructions: arithmetic, logical, comparison, jumps, subroutine calls.

• Project organization for scalability and maintainability.
   

Module 2: Device Integration & Process Control

• Configuration and scaling of analog input/output modules.

• Signal conversion, filtering, and data handling.

• Integration and commissioning of Variable Frequency Drives (VFDs).

• Closed-loop process control basics with PLCs.
   

Module 3: Industrial Networking & Communication

• Industrial communication standards: Ethernet/IP, Modbus TCP/IP, Profibus, Profinet, DeviceNet, CC-Link.

• PLC-to-PLC and PLC-to-device communication.

• Network troubleshooting and diagnostics.

• Designing robust, fault-tolerant automation networks.
   

Module 4: HMI Design & Development

• Advanced HMI project creation using FactoryTalk ME/SE, Siemens TIA Portal, Mitsubishi GT Designer.

• Multi-screen navigation and structured project design.

• Data logging, recipe management, and historical trending.

• Advanced alarm handling and event management.

• Designing operator-friendly graphical interfaces.
   

Module 5: System Integration & Best Practices

• PLC–HMI–Device integration for plant-wide automation.

• Testing, validation, and commissioning workflows.

• Documentation and project handover standards.

• Troubleshooting and advanced debugging strategies.

• Reliability, scalability, and maintainability considerations.
   

​Skills Developed

• Proficiency in Rockwell Studio 5000, Siemens TIA Portal, Mitsubishi GX Works3, FactoryTalk, CCW, GT Designer.

• Deployment and troubleshooting of VFDs and analog/digital modules.

• Strong understanding of industrial networks and communications.

• Ability to design and deploy advanced HMIs with real-time functionality.

• Competence in system documentation, debugging, and long-term maintenance.