Advanced PLC Programming
and Application
02 – 06 June 2025
Sandton Centre, Johannesburg South Africa
Register Now! Limited Seats Available!
R19, 999.00 Per Delegate
Course overview:
In today’s rapidly evolving industrial landscape, automation and control systems form the backbone of operational efficiency and precision. Programmable Logic Controllers (PLCs) are at the heart of this transformation, enabling intelligent control of complex machinery and systems.
This Advanced PLC Programming and Application Training course is designed to provide in-depth knowledge and hands-on experience in programming, troubleshooting, and deploying advanced PLC systems. It builds on basic PLC skills to tackle real-world automation challenges using sophisticated programming structures, communication protocols, and integration techniques with HMI and SCADA systems.
Participants will explore the practical applications of PLCs in process control, manufacturing, utilities, and other industrial environments, enabling them to design, develop, and maintain highly efficient and reliable automation systems.
Course Objectives
By the end of this course, participants will be able to:
1. Develop Advanced PLC Programs using Ladder Logic, Structured Text, and Function Block Diagram (FBD) in compliance with IEC 61131-3 standards.
2. Configure and Implement Analog I/O and PID Control Loops for process automation such as temperature, pressure, and flow control.
3. Integrate PLCs with HMI and SCADA Systems to create interactive, real-time control and monitoring solutions.
4. Apply Industrial Communication Protocols like Modbus, Profibus, Profinet, and Ethernet/IP for PLC-to-PLC and PLC-to-HMI networking.
5. Troubleshoot and Debug Complex Automation Systems, identify faults, and implement robust fail-safe mechanisms.
6. Design Structured and Modular Code for scalable, maintainable automation projects.
7. Capture and Log Operational Data, and interface PLCs with external databases or IIoT systems.
8. Develop and Document Complete Automation Projects from system design to deployment.
Who Should Attend:
• Automation Engineers
• Control Systems Engineers
• Electrical and Instrumentation Engineers
• Maintenance and Field Technicians
• Mechatronics Engineers
• SCADA and HMI Developers
• Industrial System Integrators
• Technical Trainers and Supervisors
• Engineering Students/Graduates (with basic PLC knowledge)
Course Outline:
PLC Hardware and Architecture Review
• Recap of CPU, I/O Modules, Power Supplies
• Differences between Compact, Modular, and Rack-mounted PLCs
• Specialty modules (e.g., analog, motion control, safety)
• Scan cycle and memory structure
Advanced Ladder Logic Programming
• Recap of basic instructions (AND, OR, TIM, CNT, MOV, etc.)
• Advanced instructions:
o Arithmetic operations
o Comparison and logical operations
o Shift registers and sequencers (SQO/SQC)
o Indirect addressing and indexing
• Subroutines and jump instructions
• Troubleshooting and debugging techniques
Analog I/O and PID Control
• Working with analog sensors and actuators
• Scaling analog inputs and outputs
• Understanding PID control theory
• PID auto-tuning and manual tuning
• Implementing PID in PLCs for process control (temperature, pressure, flow, etc.)
HMI and SCADA Integration
• Overview of HMI/SCADA systems
• Configuring PLC-HMI communication
• Designing dynamic HMI screens (alarms, trends, animations)
• Setting up user permissions and security
• Data logging and historical trend displays
Industrial Communication Protocols
• Network basics (IP addressing, topology, switches)
• Common protocols:
o Modbus RTU/TCP
o Ethernet/IP
o Profibus, Profinet
o OPC/UA
• PLC-to-PLC communication
• Remote monitoring and access
Structured and Modular Programming
• Best practices for structured code development
• Use of function blocks and custom libraries
• Project documentation and version control
• Code reusability and scalability
Fault Detection and Redundancy
• Programming for fault-tolerant systems
• Diagnosing hardware and logic faults
• Redundant I/O and CPU systems
• Watchdog timers, heartbeat signals, and self-diagnostics
Data Logging and Industrial IoT (IIoT) Basics
• Data acquisition and logging into CSV or SQL databases
• Using SD cards, USB, and network storage
• Connecting PLCs to the cloud
• Basics of IIoT for smart manufacturing
Capstone Project / Hands-On Application
• Design and programming of a complete system (e.g., bottling plant, HVAC, pump station)
• Integration of HMI, PID, and communication
• Documentation: Electrical diagrams, flowcharts, and logic explanation
• Presentation and troubleshooting
End of the workshop
IN HOUSE AND ONLINE TRAINING
While both In-House and Online training can present with cost-effectiveness and time-efficacy, there are some very specific differences between in-house courses and those based online.
The demand for additional courses by individuals or groups of people is increasing. Still, it depends entirely on the preferences of a person what type of training he or she wants to receive. Online courses and in-house training carry some similarities but they are considered to exhibit some very pivotal differences too. Despite that, both types of learning can be really beneficial for attendees.
For Registration and other Training arrangements,
contact us on the detail below.
SOUTH AFRICA : +27 11 057 6001
TANZANIA Cell: +255 769 688 544
WhatsApp +27 79 574 0389
info@bmktraining.co.za / www.bmktraining.com
