Advanced PLCs

Course Description

This combined lecture and laboratory course (ETS2544C) provides an advanced study of Programmable Logic Controller (PLC) systems with an emphasis on complex programming techniques, industrial networking, Human-Machine Interface (HMI) integration, and Supervisory Control and Data Acquisition (SCADA) systems. Building on foundational PLC skills, students apply advanced ladder logic, function block diagrams, sequential function charts, and data manipulation instructions to real-world industrial automation scenarios. Laboratory activities mirror industry environments and reinforce theoretical concepts through hands-on programming, wiring, and troubleshooting exercises. This course is part of the Engineering Technologies > Specialty Engineering Technology taxonomy in Florida's Statewide Course Numbering System (SCNS).

Learning Outcomes

Required Outcomes

Upon successful completion of this course, students will be able to:

• Design and implement advanced ladder logic programs incorporating data manipulation, math, and comparison instructions.
• Program and configure function block diagrams (FBD) and sequential function charts (SFC) in compliance with IEC 61131-3 standards.
• Configure and troubleshoot analog and discrete I/O modules, including scaling and signal conditioning for process control applications.
• Design and configure Human-Machine Interface (HMI) screens, including operator displays, alarm management, and data visualization.
• Integrate PLC systems with SCADA platforms for real-time data monitoring, historical logging, and supervisory control.
• Apply industrial communication protocols (e.g., Ethernet/IP, Modbus TCP, DeviceNet) to network PLCs, HMIs, and distributed I/O devices.
• Perform systematic troubleshooting and diagnostics on PLC hardware and software faults to minimize industrial downtime.
• Demonstrate safe work practices consistent with OSHA standards when installing, wiring, and maintaining PLC-based control systems.

Optional Outcomes

The following outcomes may be addressed depending on institutional emphasis and available equipment:

• Develop process control loops (PID) using PLC instructions for closed-loop industrial applications.
• Explore motion control programming concepts including drive configuration and axis control.
• Investigate Industrial Internet of Things (IIoT) and Industry 4.0 integration with PLC and SCADA environments.
• Utilize emulation and simulation software (e.g., RSLogix 5000/Studio 5000, TIA Portal) for program testing and validation prior to deployment.
• Analyze cybersecurity considerations for Operational Technology (OT) and Industrial Control Systems (ICS) environments.

Major Topics

Required Topics

1. Review of PLC Fundamentals — CPU architecture, scan cycle, I/O addressing, and basic ladder logic; bridge from introductory PLC coursework.
2. Advanced Ladder Logic Programming — Data manipulation instructions (MOV, COP), math functions (ADD, SUB, MUL, DIV, SQR), comparison instructions (EQU, LES, GRT, LIM), and indirect addressing.
3. IEC 61131-3 Programming Languages — Function Block Diagram (FBD), Sequential Function Chart (SFC), Structured Text (ST), and Instruction List (IL) in addition to Ladder Diagram (LD).
4. Analog I/O and Process Control — Analog input/output module configuration, signal scaling, resolution, and introduction to PID control loops.
5. HMI Design and Integration — Creating operator interface screens, configuring tags, alarm management, data visualization, and linking HMI to PLC programs.
6. SCADA Systems — SCADA architecture, data acquisition, real-time monitoring, historical data analysis, reporting, and integration with PLC networks.
7. Industrial Networking and Communications — Ethernet/IP, Modbus, Modbus TCP, Profibus, and DeviceNet protocols; peer-to-peer and distributed I/O architectures; network configuration and troubleshooting.
8. PLC Troubleshooting and Maintenance — Diagnostic tools, fault identification, hardware failure analysis, preventive and corrective maintenance strategies, and minimizing system downtime.
9. Safety and Compliance — Electrical safety, OSHA standards, safety-rated I/O, and safe installation practices for industrial control panels.

Optional Topics

• PID and Closed-Loop Process Control — Tuning proportional, integral, and derivative parameters; applications in temperature, pressure, and flow control.
• Motion Control Fundamentals — Variable frequency drives (VFDs), servo drive configuration, and axis control instructions.
• Advanced Data Handling — File/array manipulation, recipe management, and data logging within PLC programs.
• Emulation and Simulation — Using software simulators (e.g., PLCLogix 5000, Studio 5000 Logix Designer, Siemens TIA Portal) for offline programming and testing.
• IIoT and Industry 4.0 — Cloud connectivity, edge computing concepts, remote monitoring, and integration of PLC/SCADA with modern digital factory platforms.
• OT Cybersecurity Awareness — Common vulnerabilities in ICS environments, network segmentation, and best practices for securing industrial automation systems.

Resources & Tools

• PLC Hardware Platforms: Allen-Bradley (Rockwell Automation) MicroLogix / CompactLogix / ControlLogix series; Siemens S7-1200 / S7-1500 series (platform varies by institution).
• Programming Software: Rockwell Studio 5000 / RSLogix 5000, RSLogix 500, Siemens TIA Portal, or equivalent vendor software.
• HMI Software: Rockwell FactoryTalk View, Siemens WinCC, or equivalent HMI configuration platform.
• SCADA Software: Ignition by Inductive Automation, FactoryTalk, or equivalent SCADA platform used in laboratory exercises.
• Simulation Tools: PLCLogix 5000 emulator or vendor-provided simulation environments for offline program validation.
• Lab Equipment: PLC trainer panels with discrete/analog I/O, HMI touchscreens, industrial sensors (proximity, photoelectric, pressure, temperature), variable frequency drives, and industrial network switches.
• Reference Texts: Petruzella, Programmable Logic Controllers (McGraw-Hill); Rockwell Automation and Siemens vendor documentation; NFPA 79 Electrical Standard for Industrial Machinery.

Career Pathways

Completion of this course supports employment and advancement in high-demand automation and industrial technology fields. Applicable career pathways include:

• PLC / Automation Technician — Programs, maintains, and troubleshoots PLC-based control systems in manufacturing and industrial facilities.
• Controls Engineer / Technologist — Designs and implements automated control solutions using PLCs, HMIs, and SCADA systems.
• Industrial Maintenance Technician — Performs preventive and corrective maintenance on automated manufacturing equipment.
• SCADA / Systems Integrator — Integrates PLC, HMI, and SCADA platforms into cohesive industrial automation solutions.
• Process Control Technician — Monitors and adjusts automated process control systems in industries such as chemical processing, water treatment, oil & gas, and food production.
• Field Service Engineer — Installs, commissions, and supports PLC-based systems for equipment manufacturers (OEMs) and end users.

Special Information

Certification Preparation

The content of this course supports preparation for nationally recognized industry credentials in automation and industrial technology, including:

• NIMS (National Institute for Metalworking Skills) — Industrial Technology Maintenance credentials related to electrical systems and automation.
• Rockwell Automation Certification — Course content aligns with the knowledge domains for Rockwell's Certified Automation Professional (CAP) pathway and vendor-specific ControlLogix/CompactLogix credentials.
• ISA Certified Automation Professional (CAP) — Administered by the International Society of Automation; this course addresses several competency areas in the CAP Body of Knowledge including control systems design, HMI/SCADA, and networking.
• OSHA 10 / OSHA 30 (General Industry) — Safety content covered throughout the course supports OSHA general industry safety standards applicable to industrial automation environments.

Students are encouraged to consult their institution's program advisor regarding certificate or degree program requirements and available industry certification exam vouchers or partnerships.