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PLC475

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PLC475: PLC Hardware, Programming and Design

Contact Us Today: info@PiControlSolutions.com, Tel: (832) 495 6436

Duration: Process Control Engineers, PLC Engineers and Technicians, Instrument Engineers.
Prerequisites: Some control room exposure is desirable, but not required.
Course Material: PowerPoint Slides, PLC slides, PLC Simulation Software and Industrial Examples.

Course Description and Objectives: This course teaches you software, hardware and programming skills in using PLCs (programmable logic controllers).  The course is designed to build skills in such a manner that upon completion, the student will have the skills needed to work with any PLC.  This course like other PiControl courses is not vendor specific.  The course starts with basics of PLC, covering both hardware, software and architecture.  It teaches ladder logic, function blocks, input/output cards.  It explains all basic, standard and custom functions and capabilities of a PLC.  With this knowledge, a student will have the skills to design ladder logic, function blocks and safe habits to work in any manufacturing unit.  Various real industrial examples are used to illustrate the concepts and with the incorporation and usage of all commonly used PLC functions.

Learning Outcomes

At the end of this course, students will have strong skills on PLCs.  They will be exposed to hardware, software, ladder logic and function blocks.  They will have learnt all common PLC blocks and schemes.  The course is hands-on and allows students to design and build PLC schemes on their personal computers.  With this knowledge, it is possible to design and build PLC logic and control schemes in an industrial environment.  The course places significant emphasis on safety, reliability and maintenance for the safe and improved operation of any process.  The course covers discrete control, continuous control, adaptive control, safety shutdowns and also the design and implementation of APC inside the PLC.  The following topics are covered in this course:

  • Programmable Logic Controller (PLC) Overview
  • PLC Hardware and Components
  • PLC Communication
  • Number Systems – Binary, Decimal and Hexadecimal
  • PLC Input and Output Cards
  • How to read P&IDs and design control schemes
  • Relays
  • Relay Logic Diagrams
  • PLC Programming
  • Logic Gate Functions
  • Motor Starter Logic
  • Timers
  • Counters
  • Setting up PLC software on personal computers
  • PLC Lab Hands-On Project 1-3
  • PLC Math Blocks and Functions
  • Compare and Jump Instructions
  • PLC Lab Hands-On Project 4-6
  • Subroutines for Repetitious Calculations and Logic
  • Bit Shift Instructions
  • Data Handling Instructions
  • Sequence Design and Implementation
  • Sequence Instructions
  • PLC Lab Hands-On Project 7-10
  • Troubleshooting and Maintenance of PLC systems
  • PLC Networks in Industry
  • Safety Procedures
  • PID and cascade control design inside the PLC
  • Developing APC inside the PLC
  • Starting up APC schemes
  • Safe operating practices and design to avoid making mistakes and process upsets
  • Procedures and practices for improved user interface
  • Designing PLC schemes for improved GUI and assisting the job of the operator
Course Description

PLC475 Question & Answers

PLC475 is a comprehensive course on PLC hardware, programming, and design. It’s ideal for process control engineers, PLC engineers, technicians, and instrument engineers, providing foundational skills in both PLC hardware and software.

While prior exposure to control rooms is helpful, it is not a requirement. The course is designed for beginners and provides hands-on training that builds skills from the ground up.

Upon completing PLC475, students will have strong skills in PLC hardware, software, ladder logic, function blocks, and more. They’ll be able to design and implement PLC control schemes in industrial environments.

The course uses PLC simulation software and PowerPoint slides for comprehensive learning, providing practical experience with industry-standard tools.

Key topics include PLC hardware and components, PLC communication, relay logic diagrams, timers, counters, PLC programming, safety shutdowns, and PID/cascade control design inside PLC systems.

Yes! The course includes hands-on projects that allow you to design, build, and troubleshoot PLC logic and control schemes using your personal computer.

No, PLC475 is not vendor-specific. The course is designed to provide universal PLC knowledge, making it applicable to any PLC system, regardless of the manufacturer.

Ladder logic is a fundamental programming language for PLCs. It enables you to design control schemes for a wide range of industrial applications, and understanding it is crucial for effective PLC operation.

The course includes multiple hands-on projects where students can implement and troubleshoot real-world PLC applications, such as motor starters, relay logic, timers, counters, and data handling instructions.

The course places a significant emphasis on safety practices and reliable PLC system design, ensuring students understand how to avoid mistakes and process upsets while maintaining safe operation in industrial settings.

PID control is a critical element in process control systems. The PLC475 course covers the design and implementation of PID and cascade control, essential for maintaining precise control over industrial processes.

PLC475 offers a unique combination of theoretical and practical knowledge, covering all aspects of PLC hardware, software, and programming, without being vendor-specific, ensuring broader applicability.

The PLC475 course includes detailed instructions for setting up PLC software on personal computers, making it easy for students to get started with hands-on practice from the beginning.

The course covers key safety procedures for working with PLC systems, ensuring students can design systems that are safe for both operators and the entire industrial process.

By gaining expertise in PLC programming, troubleshooting, and maintenance, graduates of the PLC475 course are well-equipped to handle industrial automation projects, making them valuable assets to employers in various industries.

Yes. The course addresses best practices for designing operator-friendly PLC schemes, including guidance on user interface logic and data presentation to improve operator situational awareness.

The course introduces PLC network architectures, data handling instructions, and communication protocols used in multi-PLC systems for distributed control.

Absolutely. PLC475 provides the foundational skills needed for integration into smart manufacturing setups, including real-time control logic, diagnostics, and adaptive logic blocks.

You’ll learn troubleshooting techniques, safe restart procedures, and redundancy strategies that help identify and resolve issues quickly in both test and live environments.

Yes. The course teaches you how to use subroutines and structured logic for repetitive tasks, enabling cleaner, more scalable PLC programs.

Yes. You’ll receive reusable templates and function block examples that can accelerate project deployment and reduce programming errors on the job.

Yes. PiControl offers fully customized corporate training sessions tailored to your plant’s control architecture, devices, and engineering goals.


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