PLC Fundamentals (Level I)

This course will give a person with no prior experience the basic tools necessary to create a PLC program from scratch. By the end of this course, you will be able to create a PLC program from scratch.

You will Learn

  • Introduction
    3 lectures • 21min
  • Course Intro: Curriculum / Objectives
  • Preview
    04:39
    Software and Course Notes
  • 13:34
    Contacting Your Instructor
  • 02:33
  • PLC Programming Overview
    5 lectures • 19min
    Section Objectives
  • 1 page
    PLC Automation
  • 03:54
    RSLogix 500 Environment
  • 07:11
    Basic Functionality of a Program (Inputs, Outputs, Conversion)
  • 05:18
    PLC Programming Overview Quiz
    4 questions
    Section Wrap-up
  • 02:51
  • IO (Inputs and Outputs)
    6 lectures • 11min
    Section Objectives
  • 1 page
    IO Overview
  • 02:05
    Digital IO
  • 02:38
    Analog IO
  • 01:49
    IO Modules
  • 02:34
    IO (Inputs and Outputs) Quiz
    4 questions
    Section Wrap-up
  • 01:42
  • Programming Fundamentals
    18 lectures • 1hr 59min
    Section Objectives
  • 1 page
    Data Management
  • 07:20
    A Bit More on Addresses
  • 01:41
    Rungs and Branches
  • 04:43
    Conditions and Outputs (Left to Right)
  • 09:03
    XIO, XIC, OTE
  • 12:06
    OTL, OTU
  • 09:18
    ONS, OSR, OSF
  • 12:53
    TON, TOF, RTO
  • 14:19
    CTU, RES
  • 05:23
    Comparators
  • 08:37
    Mathematical Operators, CPT
  • 04:07
    SCP
  • 05:04
    A Bit More on Analog Scaling
  • 02:16
    MOV
  • 04:38
    JMP, LBL
  • 04:29
    PID (Proportional Integral Derivative) Control Loops
  • 09:15
    Programming Fundamentals Quiz
    10 questions
    Section Wrap-up
  • 03:29
  • Program Setup
    7 lectures • 38min
    Section Objectives
  • 1 page
    Setup Program / Processor
    05:32
    Module Configurations
    10:23
    Scaling / Resolution
    08:32
    Function Files
    06:15
    Program Files
    05:13
    Program Setup Quiz
    7 questions
    Section Wrap-up
  • 01:54
  • IO Programming
    6 lectures • 46min
    Section Objectives
  • 1 page
    Programming Digital IO
    17:47
    A Bit More on Digital Control Logic
    00:53
    Programming Analog IO
    18:15
    Analog Process Control (LL, L, H, HH)
    06:53
    IO Programming Quiz
    5 questions
    Section Wrap-up
  • 02:20
  • Process Logic
    8 lectures • 1hr 29min
    Section Objectives
  • 1 page
    Process Programming Overview
    04:22
    Blower HOA (Hand / Off / Auto) Control
    21:11
    A Bit More on HOA Controls
    00:42
  • Digital Tank / Pump Control
    Preview
    21:43
    Analog Tank / Pump Control
    07:39
    PID Heater Control
    31:09
    Process Logic Quiz
    4 questions
    Section Wrap-up
  • 02:14
  • Alarms and Notifications
    6 lectures • 1hr 1min
    Section Objectives
  • 1 page
    Alarms Overview
    02:00
    Considerations
    05:39
    Dual-bit Alarm / Notification Programming
    42:36
    Setpoints
    07:32
    Alarms and Notifications Quiz
    7 questions
    Section Wrap-up
  • 03:15
  • HMI (Human Machine Interface)
    8 lectures • 1hr 6min
    Section Objectives
  • 1 page
    HMI Overview
    03:40
    HMI Alternatives
    03:24
    Basic Flow of an HMI Program
    22:32
    Setting Up a Screen
    18:10
    Alarms / Events / Notifications
    04:41
    Permissions
    08:43
    HMI (Human Machine Interface) Quiz
    6 questions
    Section Wrap-up
  • 04:29
  • Communications
    3 lectures • 15min
    Section Objectives
  • 1 page
    Communications Overview
    12:39
    Communications Quiz
    3 questions
    Section Wrap-up
  • 02:46
  • Program Walkthru (Line by Line)
    12 lectures • 1hr 14min
    Section Objectives
  • 1 page
    Overview
    02:28
    Main
    10:00
    D Input
    04:25
    D Output
    02:03
    A Input
    07:47
    A Output
    05:14
    Controls
    19:59
    Alarms
    16:54
    Display
    02:14
    DemoTest Program Report
  • 30 pages
    Section Wrap-up
  • 03:14
  • Shakedown / Debugging
    9 lectures • 52min
    Section Objectives
  • 1 page
    Emulation
    07:26
  • Dry Run
    Preview
    10:04
    Forcing IO
    15:51
    Electromechanical Checks
    03:01
    Full-function Test
    03:31
    Troubleshooting Methodology
    06:31
    Consequences
    02:57
    Shakedown / Debugging Quiz
    7 questions
    Section Wrap-up
  • 02:43
  • Supplemental Material for Further Study
    5 lectures • 1min
    Sample1 (Chemical Process System) Program Report
    527 pages
    Sample1 Cause and Effect Matrix
    1 page
    Sample2 (Water Filtration) Program Report
    75 pages
    Sample2 Control Description
    17 pages
    Program Archive
    00:12
  • Conclusion
    3 lectures • 14min

This course (only ten dollars on PLC Dojo) is designed to equip the novice with no prior PLC programming experience with the basic tools necessary to create a complete PLC program using ladder logic common to most current platforms. 

Using the Rockwell software RSLogix 500 and FactoryTalk View Studio, we will be covering such topics as general controls, digital and analog IO, ladder logic programming, alarm / notification handling, HMI, emulation, best practices and more. 

In the end, we will go through an entire, working PLC program and HMI line by line to solidify comprehension of the learning objectives.

What’s covered in each of the five PLC courses I teach here and on my own PLC Dojo site?

This course, (PLC Fundamentals) teaches you how to program with the focus on ladder logic, which is the most popular PLC programming language.  The goal is to teach you everything you need to know to make a PLC do what you want it to do.  You are also given all the software necessary to both CREATE and RUN your own programs live – right on your own computer. For some people, that’s all they really need.

But for the people who want to really master PLC programming, they have the option of continuing into the advanced material with me.

Applied Logic (Level 2) forces you to take what you’ve learned and solve problem after progressively harder problem unassisted.  You get a spec and are told simply: “Make it work, and don’t progress until you have.”  After, you get to watch me solve each one as well.  By the end, you don’t just know how to program – you are a PROGRAMMER.

Process Visualization (Level 3) gives you both knowledge and experience in FIVE different HMI / SCADA development environments.  By the end, you’ve created several COMPLETE visualization (screen) projects that you can actually run on your own computer (and SHOW PEOPLE in an interview) with no additional hardware.

IEC Paradigms (Level 4) is only for the heavyweights.  This course teaches you how to program using all five IEC programming languages (plus one more) in multiple environments.  There are projects as well, so by the end, you have seen it all and DONE it all as well.  There won’t be anything anybody can show you that you won’t already be familiar with.

TIA Portal Master Project (Level 5) is the culmination of everything. In that course, you’ll program an entire power plant using all five PLC programming languages (in PARALLEL!) with a full HMI. It’s a massive and complex project that really showcases your talents in an interview!

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