Programmable Logic Controls

Course Description

ETS2673C — Programmable Logic Controls is a 4-credit combined lecture and laboratory course within the Engineering Technologies > Specialty Engineering Technology taxonomy of Florida's Statewide Course Numbering System (SCNS). The course is intended for students majoring in Electronics Engineering Technology and Advanced Manufacturing. Students learn the principles of PLCs including hardware architecture, programming, and troubleshooting. Students develop advanced working programs and troubleshoot hardware and software communication problems in hands-on lab exercises using industry-standard equipment and software.

The "C" suffix denotes a combined lecture and laboratory course that meets in the same place at the same time, providing integrated theory and hands-on practice throughout the semester.

Learning Outcomes

Required Learning Outcomes

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

• Apply Boolean algebra principles, including number system conversions (binary, decimal, hexadecimal, and octal) to PLC programming tasks.
• Describe and implement basic logical operators (AND, OR, NOT) and simplify Boolean functions using Karnaugh Maps (K-Maps).
• Demonstrate an understanding of basic PLC technology and the industrial control devices used in current automation environments.
• Identify, describe, and interface common electromechanical input devices (toggle switches, push buttons, limit switches, proximity sensors) to a PLC system.
• Identify, describe, and interface common output devices — including solenoids, relays, contactors, and alarms — to a PLC system.
• Design, write, download, and monitor ladder logic programs using industry-standard PLC programming software.
• Implement and troubleshoot timer instructions, including Timer-On Delay (TON) and Timer-Off Delay (TOF), in ladder logic designs.
• Design and troubleshoot counter instructions, including up/down counters and done-bit, enable-bit, and overflow/underflow-bit counters.
• Design, implement, and troubleshoot sequencer instructions in ladder logic, including cascading sequencers with timing.
• Describe the operation of analog sensors (temperature, pressure, flow, and position) and integrate analog I/O modules into PLC programs.
• Troubleshoot hardware and software communication problems in a PLC system, including I/O faults and program errors.

Optional Learning Outcomes

The following outcomes may be covered depending on institutional emphasis and available laboratory resources:

• Develop PLC programs using additional IEC 61131-3 programming languages such as Function Block Diagram (FBD), Sequential Function Chart (SFC), or Structured Text (ST).
• Configure and operate a basic Human-Machine Interface (HMI) connected to a PLC system for monitoring and control.
• Describe the relationship between PLCs and SCADA (Supervisory Control and Data Acquisition) systems in industrial environments.
• Explain the operation of Variable Frequency Drives (VFDs) and their integration with PLC control schemes.
• Apply data manipulation and math instructions within ladder logic programs for process control calculations.
• Describe basic PLC network communications protocols and configure communications for program upload and download.
• Describe industrial applications of Distributed Control Systems (DCS) and how they differ from single-unit PLC installations.

Major Topics

Required Topics

The following content areas are covered at all Florida institutions offering ETS2673C:

• Boolean Algebra and Number Systems — Binary, decimal, hexadecimal, and octal conversions; AND, OR, NOT logical operators; K-Map simplification; truth tables and digital circuit equivalents.
• PLC Hardware Architecture — CPU, power supply, I/O modules, memory types, chassis/rack configuration, and system scan cycle.
• Industrial Input Devices — Manually operated switches (toggle, push button, selector, limit), proximity sensors (inductive, capacitive, photoelectric), and their wiring to PLC input modules.
• Industrial Output Devices — Solenoids, relays, contactors, motor starters, and alarm indicators; wiring and interfacing to PLC output modules.
• Ladder Logic Programming — Normally open (XIC) and normally closed (XIO) contacts, output coil (OTE), branching, series and parallel rung structures.
• Timer Instructions — TON (Timer On-Delay), TOF (Timer Off-Delay), RTO (Retentive Timer); timing diagrams, preset and accumulator values.
• Counter Instructions — CTU (Count Up), CTD (Count Down), RES (Reset); done bit, enable bit, overflow/underflow bits; up/down counter ladder diagrams.
• Sequencer Instructions — Sequencer output (SQO), sequencer input (SQI), sequencer load (SQL); timing with sequencers; cascading sequencers.
• Analog I/O — Analog input and output module configuration; scaling; temperature, pressure, flow, and position sensor types and signal conditioning.
• PLC Troubleshooting — Fault diagnosis, I/O status indicators, program monitoring, forcing I/O, hardware and software communication fault isolation.

Optional Topics

The following topics may be introduced based on available equipment, lab resources, and program emphasis:

• Additional IEC 61131-3 Languages — Function Block Diagram (FBD), Sequential Function Chart (SFC), Structured Text (ST), and Instruction List (IL).
• Human-Machine Interface (HMI) — HMI panel configuration, tag linking to PLC data, basic screen development for monitoring and control.
• SCADA Fundamentals — Role of SCADA software in supervisory control; PLC-to-SCADA communication concepts.
• Variable Frequency Drives (VFDs) — AC motor fundamentals, VFD operating principles, speed control schemes, and PLC integration.
• Data Manipulation and Math Instructions — MOV, COP, ADD, SUB, MUL, DIV instructions; data files and integer/floating-point data types.
• PLC Network Communications — RS-232/RS-485 serial communications; EtherNet/IP and DeviceNet fundamentals; upload/download configuration.
• Program Control Instructions — JSR (Jump to Subroutine), RET (Return), MCR (Master Control Reset), and JMP (Jump) instructions for advanced program structures.

Resources & Tools

• PLC Hardware: Allen-Bradley / Rockwell Automation MicroLogix or CompactLogix series PLCs are the most commonly used platforms in Florida college labs; Siemens S7-1200 and AutomationDirect Click/Do-more PLCs are also encountered.
• Programming Software: RSLogix 500 / RSLogix 5000 (Studio 5000 Logix Designer) for Allen-Bradley platforms; TIA Portal for Siemens platforms; Do-more Designer for AutomationDirect.
• Simulation Tools: RSLogix Micro Starter Lite (free); Factory I/O or FluidSIM for virtual PLC lab simulation when hardware is limited.
• Recommended Textbook: Programmable Logic Controllers by Frank D. Petruzella (McGraw-Hill) — widely adopted across Florida community colleges for this course.
• Supplementary References: Rockwell Automation online documentation and knowledgebase; AutomationDirect learning resources; IEC 61131-3 standard documentation.
• Lab Equipment: PLC trainer stations with input (switches, sensors) and output (lights, solenoids, motor starters) demo panels; digital multimeters; oscilloscopes.

Career Pathways

Completion of ETS2673C supports entry into a broad range of automation and manufacturing roles. Graduates are prepared for positions in industries including packaging, chemical processing, food and beverage, pharmaceutical, power generation, wastewater treatment, and advanced manufacturing.

• PLC Technician / Controls Technician — Programs, maintains, and troubleshoots PLC-based automation equipment on the plant floor.
• Automation Technician — Installs, commissions, and services automated production systems integrating PLCs, sensors, and actuators.
• Electrical/Instrumentation Technician — Maintains and calibrates process instrumentation and control wiring in industrial facilities.
• Controls Engineer (entry-level) — Assists in designing and implementing PLC-based control systems under the supervision of a licensed engineer.
• Systems Integrator Technician — Configures and integrates PLC hardware and software for custom automation solutions across multiple industries.
• Field Service Technician — Services PLC-controlled equipment at customer sites; diagnoses faults and performs repairs and upgrades.

This course is typically part of an Associate in Science (A.S.) in Engineering Technology or an Advanced Manufacturing / Mechatronics College Credit Certificate program, both of which prepare students for engineering technology support positions in high-tech production, manufacturing, and distribution.

Special Information

Certification Preparation

The skills developed in ETS2673C align with several nationally recognized industry credentials that students may pursue after course completion:

• NIMS (National Institute for Metalworking Skills) — Credentials in CNC and automation control relevant to advanced manufacturing pathways.
• ISA Certified Control Systems Technician (CCST) — Entry-level (Level I) credential covering instrumentation, loop calibration, and PLC/DCS fundamentals.
• Rockwell Automation Authorized Academic Partner Credentials — Institutions using Allen-Bradley equipment may prepare students for Rockwell ControlLogix or Studio 5000 micro-credentials.
• MSSC CPT (Manufacturing Skill Standards Council — Certified Production Technician) — The Safety, Quality, Manufacturing Processes, and Maintenance modules align with PLC technician workflows.

Safety Requirements

Students must adhere to OSHA electrical safety standards and laboratory safety protocols when working with live PLC trainer stations, including proper lockout/tagout (LOTO) procedures for industrial control equipment. Personal protective equipment (PPE) requirements are enforced during all lab sessions.

Lab Component

The "C" designation indicates this course integrates lecture and laboratory hours in a combined format. Lab sessions require students to physically wire input and output devices, download programs to live PLC hardware, and monitor real-time program execution — skills essential for workforce readiness in automation and controls careers.