Module 1 – Introduction to PLC

• Introduction to Programmable Logic Controllers
• Applications of PLCs in industrial automation
• PLC architecture and components
• CPU, memory and power supply
• Input and output modules
• PLC operating cycle
• PLC versus conventional control systems

Module 2 – PLC Hardware and System Configuration

• PLC hardware components
• Digital and analog I/O modules
• Communication modules
• Expansion modules
• Power supply requirements
• PLC rack and system configuration
• Hardware selection concepts

Module 3 – PLC Installation and Wiring

• PLC installation fundamentals
• Input device connections
• Output device connections
• Sensors and switches
• Relays and contactors
• Industrial wiring concepts
• Electrical safety and troubleshooting practices

Module 4 – PLC Programming Fundamentals

• Introduction to PLC programming
• PLC programming languages
• Ladder Logic fundamentals
• Program structure
• Contacts and coils
• Normally Open and Normally Closed logic
• Basic program execution

Module 5 – Digital Inputs and Outputs

• Digital input devices
• Digital output devices
• Push buttons and selector switches
• Proximity and photoelectric sensors
• Lamps, buzzers and relays
• Input/output addressing
• Practical I/O programming

Module 6 – Basic Ladder Logic

• Series and parallel logic
• Start/stop circuits
• Self-holding circuits
• Interlocking logic
• Emergency stop concepts
• Control circuit programming
• Practical ladder logic exercises

Module 7 – Timers and Counters

• Timer fundamentals
• ON-delay timers
• OFF-delay timers
• Retentive timer concepts
• Counter fundamentals
• Up and down counters
• Practical timer and counter applications

Module 8 – Comparisons and Data Handling

• Comparison instructions
• Equal, greater and less-than operations
• Integer and numerical data
• Data registers
• Data movement concepts
• Basic arithmetic operations
• Practical data-handling applications

Module 9 – Analog Input and Output

• Introduction to analog signals
• Voltage and current signals
• Analog input modules
• Analog output modules
• Scaling and signal conversion
• Sensor signal processing
• Practical analog control applications

Module 10 – PLC Control of Motors

• Motor control fundamentals
• Direct-on-line motor control
• Start/stop motor circuits
• Forward and reverse control
• Motor interlocking
• Overload protection concepts
• PLC-based motor automation

Module 11 – Sensors and Actuators

• Industrial sensor fundamentals
• Proximity sensors
• Photoelectric sensors
• Limit switches
• Temperature sensors
• Actuators and solenoid valves
• Integrating sensors with PLC programs

Module 12 – HMI and PLC Communication

• Introduction to HMI
• PLC-HMI communication
• HMI screens and controls
• Push buttons and indicators
• Data display and monitoring
• Basic alarm concepts
• Operator interface design

Module 13 – PLC Communication Networks

• Introduction to industrial communication
• Serial communication concepts
• Ethernet-based PLC communication
• PLC-to-PLC communication
• Communication parameters
• Industrial networking fundamentals
• Troubleshooting communication issues

Module 14 – Industrial Automation Applications

• Automated conveyor systems
• Motorized systems
• Filling and packaging systems
• Material handling automation
• Pump control systems
• Process automation concepts
• Sequence control applications

Module 15 – Advanced PLC Programming

• Program organization
• Subroutines and reusable logic
• Sequencing techniques
• State-based control concepts
• Advanced timers and counters
• Data manipulation
• Program optimization

Module 16 – PLC Troubleshooting and Diagnostics

• PLC fault identification
• Online monitoring
• Input/output status checking
• Program debugging
• Hardware diagnostics
• Communication troubleshooting
• Preventive maintenance concepts

Module 17 – PLC-Based Process Control

• Process control fundamentals
• Temperature control concepts
• Level control
• Flow control
• Pressure control
• Analog signal processing
• Basic PID control concepts

Module 18 – Practical PLC Projects

• Automatic traffic light system
• Conveyor belt automation
• Motor control project
• Automatic water tank control
• Bottle filling system
• Industrial sorting system
• Sensor-based automation project

Module 19 – Advanced Industrial Automation Project

• Complete automated production system
• PLC programming
• Sensor integration
• Motor and actuator control
• HMI monitoring
• Alarm and fault handling
• Testing and debugging

Module 20 – Final PLC Project & Assessment

• Complete PLC automation project
• Hardware and I/O planning
• Ladder logic development
• Sensor and actuator integration
• HMI interface
• Testing and troubleshooting
• Project documentation
• Final project presentation and assessment