Programmable Logic Controllers

Course Description

This upper-division course provides an advanced study of Programmable Logic Controllers (PLCs) within the context of industrial automation and control systems. Students examine PLC hardware architecture, advanced programming techniques, process control integration, Human-Machine Interface (HMI) design, SCADA connectivity, and industrial networking protocols. Emphasis is placed on hands-on laboratory work using industry-standard PLC platforms (e.g., Allen-Bradley, Siemens) to design, program, commission, and troubleshoot PLC-based control systems in realistic manufacturing and process control scenarios. This course is offered within the Engineering Technologies taxonomy — Specialty Engineering Technology — and satisfies requirements for the Engineering Technology A.S. degree and related College Credit Certificates in mechatronics and industrial automation.

Learning Outcomes

Required Learning Outcomes

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

• Describe the architecture and operating principles of a PLC system, including the CPU, power supply, I/O modules, and memory organization.
• Write, edit, download, and monitor PLC programs using ladder logic (LD) in conformance with the IEC 61131-3 standard.
• Apply timer and counter instructions to solve sequential and time-based industrial control problems.
• Implement data manipulation, arithmetic, and comparison instructions within PLC programs.
• Configure and wire discrete and analog I/O modules, including proper addressing and signal conditioning.
• Develop program control instructions such as jump, subroutine call, and Master Control Reset (MCR).
• Design and test start/stop motor control circuits, latching, and interlocking logic using PLC programming.
• Troubleshoot and diagnose faults in PLC-controlled systems using software diagnostics, I/O force functions, and test equipment.
• Apply electrical safety practices, lockout/tagout (LOTO) procedures, and NFPA 70E standards in a PLC lab environment.
• Demonstrate knowledge of industrial communication networks including Ethernet/IP, Modbus, and DeviceNet as used in PLC systems.

Optional Learning Outcomes

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

• Design and configure a basic Human-Machine Interface (HMI) project including graphics, animations, alarms, and tag databases using FactoryTalk View Studio or equivalent software.
• Implement PID (Proportional-Integral-Derivative) control loops for analog process control applications.
• Apply Sequential Function Chart (SFC) and Function Block Diagram (FBD) IEC 61131-3 languages to appropriate control tasks.
• Integrate PLC systems with SCADA (Supervisory Control and Data Acquisition) platforms for remote monitoring, alarm management, and data logging.
• Configure Variable Frequency Drive (VFD) interfaces and motion control instructions within a PLC program.
• Explain emerging Industry 4.0 and Industrial IoT (IIoT) concepts and their impact on PLC-based automation systems.
• Develop a capstone PLC project that integrates sensors, actuators, HMI, and networking to solve an applied industrial automation problem.

Major Topics

Required Topics

• PLC System Architecture — CPU, power supply, I/O modules, opto-isolation, memory map, scan cycle, and I/O update process
• IEC 61131-3 Programming Standard — Overview of all five languages; primary focus on Ladder Diagram (LD)
• Ladder Logic Programming — Fundamentals — Normally open/closed contacts, output coils, branching, combinational logic, rung conditions
• Ladder Logic Programming — Advanced — Latching instructions (OTL/OTU), transitional contacts, S/R instructions, seal-in circuits, MCR
• Timers and Counters — TON, TOF, RTO timers; CTU, CTD, CTUD counters; timing diagrams and industrial application examples
• Data Manipulation and Math Instructions — MOV, arithmetic (ADD, SUB, MUL, DIV), comparison (EQU, GRT, LES), scaling of analog values
• Program Control Instructions — Jump (JMP/LBL), subroutine calls (JSR/RET), Master Control Reset, Immediate I/O instructions
• Discrete I/O Configuration and Wiring — Sourcing vs. sinking, field device interfacing, I/O addressing conventions (Allen-Bradley and/or Siemens)
• Analog I/O Modules — Configuration, signal types (4–20 mA, 0–10 VDC), scaling, and programming examples
• Shift Registers and Sequencers — BSL/BSR bit shift instructions, SQO/SQI/SQL sequencer instructions for automated machine sequences
• Industrial Sensors and Actuators — Limit switches, proximity sensors, photoelectric sensors, pressure/temperature transducers, solenoid valves, motor starters
• Fault Diagnostics and Troubleshooting — PLC status indicators, I/O forcing, fault routines, interrupt service routines, systematic troubleshooting methods
• Control Panel Standards — NEC/NFPA 79 panel construction, wire labeling, component layout, grounding, and safety interlocks
• Electrical Safety — NFPA 70E arc flash awareness, lockout/tagout procedures, PPE requirements in industrial environments
• Industrial Communication Networks — Ethernet/IP, Modbus RTU/TCP, DeviceNet; network topology, node addressing, and basic configuration

Optional Topics

• HMI Development — Screen design, tag configuration, alarming, data logging, and animated graphics using FactoryTalk View Studio, Studio 5000, or equivalent
• PID Process Control — Open/closed-loop concepts, PID instruction configuration, tuning parameters, and analog process loop applications
• SCADA Systems Integration — SCADA architecture, OPC connectivity, real-time monitoring, alarm management, and historian data
• Sequential Function Chart (SFC) and Function Block Diagram (FBD) — IEC 61131-3 alternative languages for batch and process control applications
• Variable Frequency Drives (VFD) — PLC-to-VFD interfacing, parameter configuration, speed reference via analog/network commands
• Industry 4.0 / IIoT Integration — IoT-enabled PLCs, cloud connectivity, remote monitoring, and cybersecurity basics for OT/ICS environments
• Motion Control Fundamentals — Servo drive integration with PLCs, motion control instructions, and basic axis configuration
• Capstone PLC Project — End-to-end design, programming, wiring, commissioning, and documentation of a student-selected automation system

Resources & Tools

• PLC Hardware Platforms: Allen-Bradley CompactLogix / MicroLogix (Rockwell Automation) and/or Siemens S7-1200 / S7-300 series; lab trainer stations with discrete and analog I/O
• Programming Software: Rockwell Studio 5000 Logix Designer, RSLogix 500/Micro, Siemens TIA Portal; LogixPro 500 PLC simulator for off-hardware practice
• HMI/SCADA Software: FactoryTalk View Studio (ME/SE), Ignition by Inductive Automation (free trial), or equivalent SCADA development environment
• Textbook (commonly adopted): Programmable Logic Controllers by Frank D. Petruzella (McGraw-Hill); Programmable Logic Controllers by James A. Rehg & Glenn Sartori (Pearson)
• Standards References: IEC 61131-3 (PLC Programming Languages), NFPA 79 (Electrical Standard for Industrial Machinery), NFPA 70E (Electrical Safety in the Workplace)
• Test Equipment: Digital multimeter (DMM), clamp meter, oscilloscope, laptop with USB/Ethernet connectivity to PLC
• Online Resources: Rockwell Automation PartnerNetwork training materials; Siemens Industry Online Support; PLCS.net community forums

Career Pathways

Graduates who complete ETS3543 are prepared to pursue roles in manufacturing, utilities, defense, and process industries across Florida and nationally. Common entry-level and mid-level positions include:

• PLC Programmer / Controls Technician — Programs and maintains PLC systems on production lines and process equipment
• Automation Engineer Technician — Supports automation engineers in design, integration, and commissioning of control systems
• Industrial Maintenance Technician — Diagnoses and repairs PLC-controlled machinery in manufacturing facilities
• SCADA / Controls Technician — Operates and maintains SCADA systems in utilities (water, power, oil & gas)
• Field Service Engineer (Automation) — Installs and services automated equipment at customer sites
• Mechatronics Technician — Integrates mechanical, electrical, and PLC-based control systems in advanced manufacturing environments

This course supports advancement in Florida's high-demand manufacturing and industrial sectors and aligns with the state's goals for workforce development in engineering technology as outlined by the Florida Department of Education.

Special Information

Certification Preparation

Coursework in ETS3543 provides foundational preparation for the following industry-recognized credentials:

• NFPA 70E Electrical Safety Awareness — Safe work practices and LOTO compliance covered throughout the course
• Rockwell Automation Certified Programmer (Studio 5000 / Logix) — Course content aligns with Rockwell's CompactLogix and ControlLogix competency framework
• Siemens Certified Automation Technician — TIA Portal and S7-series instruction content supports Siemens credentialing pathways
• AMATROL / MSSC Smart Manufacturing credentials — PLC programming and industrial automation skills align with MSSC Certified Production Technician Plus (CPT+) and AMATROL-based assessments used at many Florida colleges
• ISA Certified Control Systems Technician (CCST) — Advanced PLC, process control, and instrumentation content provides preparation toward the ISA CCST Level I/II examination

Lab & Safety Requirements

Students working in the PLC laboratory must follow all posted electrical safety procedures. Personal Protective Equipment (PPE) is required during live wiring activities. Students must complete a lab safety orientation before accessing live trainer stations. Some institutions may require a background check for internship or co-op placements in regulated industries (e.g., water treatment, power generation).