Upon completion of this course, participants will be able to:

• Explain the basic hardware components and the **PLC scan cycle** (I/O, logic, communication).
• Read and interpret basic control logic written in **Ladder Diagram (LD)** and Function Block Diagram (FBD).
• Understand the role and addressing of different **memory areas** (I, Q, M, DB) in the PLC.
• Manage and scale **analog I/O** signals (e.g., 4-20mA, 0-10V) for use by the SCADA system.
• Differentiate between common industrial control concepts: interlocking, sequencing, and PID control.
• Apply best practices for structuring PLC code to ensure clarity and maintainability.
• Explain how the PLC prepares and holds data for communication to the SCADA historian.

• SCADA/HMI Developers and System Integrators
• Control System Engineers (Non-PLC Specialists)
• SCADA System Administrators and Database Managers
• Instrumentation and Field Technicians
• Project Managers overseeing automation projects
• New Control System Programmers

• Hands-on simulation using major vendor PLC software (e.g., Allen-Bradley/Siemens) to read and modify code.
• Group activities involving troubleshooting a pre-faulted piece of Ladder Logic.
• Individual exercises focused on creating and testing an analog scaling function.
• Case studies demonstrating how a PLC programming error caused a SCADA data anomaly.
• Discussions on the common pitfalls in PLC code structure that complicate integration.

Unit 1: PLC Hardware and Basic Architecture

• The role of the Central Processing Unit (CPU) and I/O modules
• The concept of the **I/O Image Table** and data refreshing
• Different types of PLC platforms (e.g., CompactLogix, S7-1500) and their applications

• Detailed breakdown of the **PLC Scan Cycle** (Read Inputs, Execute Logic, Write Outputs)
• The concept of deterministic control and cycle time limitations

Unit 2: Core Programming Fundamentals

• Introduction to **IEC 61131-3** standards and their relevance
• Mastery of **Ladder Diagram (LD)**: contacts, coils, timers, and counters
• Reading and using basic **Function Block Diagram (FBD)** logic

• Understanding data types (Boolean, Integer, Real) and memory word sizes
• Basic principles of data movement and comparison instructions

Unit 3: I/O and Analog Signal Management

• Programming logic for motor starts, valve control, and safety interlocks
• Handling inputs: switches, sensors, and field device status

• The process of converting raw sensor counts to engineering units (e.g., psi, deg C)
• Implementing the **scaling logic** necessary for SCADA data accuracy

Unit 4: Preparation for SCADA Communication

• Structuring data blocks or memory areas specifically for SCADA communication
• Using consistent **Tag Naming Conventions (TNC)** that align with SCADA standards
• Techniques for minimizing the amount of data the SCADA system needs to poll

• Creating "heartbeat" logic and status bits for SCADA connection diagnostics
• Programming data buffers to handle temporary communication loss

Unit 5: Best Practices and Documentation

• Best practices for commenting and documenting PLC code for maintenance
• The importance of testing and verifying code before deployment

• Understanding the difference between process control (PLC) and safety control (SIS)
• Implementing basic failure-safe logic for critical components