American Trainco Seminars
TPC Trainco presents

PLC Workshop: From Introduction to Application - 4-Day Hands-On On-Site Training

This on-site training class is also available as Public Schedule Seminar.

This PLC Programming Workshop combines our introductory PLC course with our programming and applications course to provide the student a complete PLC education from a basic introduction on how PLC's work to providing them the knowledge, confidence and ability to modify or create their own PLC programs.

Course Description/Agenda

This PLC Programming Workshop combines our introductory PLC course with our programming and applications course to provide the student a complete PLC education from a basic introduction on how PLCs work to providing them the knowledge, confidence and ability to modify or create their own PLC programs.

The training in this class is practical and geared to cover most of the PLC situations students will run across in the field. The training presented is not manufacturer specific but uses LogixPro 500 simulators so that students can explore the variety of PLC software platforms that they will encounter in their jobs.

Please Note: This four day seminar consists of the two-day “PLCs for Non-Programmers” seminar and the two-day “PLC Programming and Applications” seminar that are offered consecutively to create this workshop.  This seminar is great for students who want a comprehensive training seminar that will immerse them in the world of PLCs.


PLCs For Non-Programmers Workshop Agenda

Using hands-on demonstrations in this PLC training, we convert the seemingly complex world of automation and Programmable Logic Controllers (PLCs) into practical, down to earth lessons the average non-programming person can understand. Students will learn to speak the PLC language, read and interpret PLC ladder logic, troubleshoot PLC systems and components, and fix the most common PLC problems on their own.  

Day One - Discussion Topics

Day One of our PLC training focuses on understanding PLCs; how they work, terminology, and the hardware and software elements that make up a programmable logic controller.  We will begin to examine the primary causes of faults associated with PLC based control systems: Input/Output devices and field wiring.  You will learn to use both hardware and software to find these faults quickly.  Students will learn a systematic approach to troubleshooting; how to set-up and configure local, remote, hierarchical and distributive control systems; how to configure Input/Output modules using various slot addressing techniques; how to understand program and data table file organization, number systems and processor information flow; and how basic relay type instructions, timers and counters, & data manipulation instructions can be used to achieve the PLC solution you want.  This focus during the PLC training will stretch into day two.


  • Hardware Focus
  • How PLCs Work
    • Past
    • Present
    • Future
  • PLC Terminology, PID
  • Parts of a PLC
    • Input Interfaces
    • Processor
    • Output Interfaces
    • Power Supplies
    • Programming Terminals 
  • System Configurations
    • Local
    • Remote
    • Hierarchical
    • Distributive
  • Hardware Considerations
    • Field Wiring
    • Master Control Relay
    • Isolation Transformers
    • Four Basic Types of Grounding

Day Two - Discussion Topics

Day Two will continue to examine I/O and field wiring issues.  We will also look at common troubleshooting techniques and strategies.


  • Organization and Function of Ladder
  • Logic Ladder Logic Data Table Organization
    • Numbering Systems
    • Data Table Files
    • Bit, Word and File Addressing
  • Introduction to Programming
  • Common PLC & PID Instructions
    • Basic Relay
    • Counters and Timers
    • Data Transfer
  • Organization
    • Subroutine Files
    • Selectable Timed Interrupt (STI) Files
    • Jumps and MCR Instructions
    • Fault Routines
  • Relating the PLC to "Real World" Applications


  • Safety
  • Forcing of Input Data Table & Output Devices
  • Identifying I/O Field Device Faults
  • Identifying I/O Module Faults
  • Identifying System Faults Using the Data Monitor Screen
  • Using the Processor Status and I/O Status Screen


  • The "Ultimate PLC Troubleshooting Flowchart"
  • Using Troubleshooting Tools
  • Using Software Tools
  • "Real World" Case Studies


PLC Programming and Applications Workshop Agenda

This two-day “Hands-On” PLC Programming & Applications training program provides a greater depth of PLC knowledge for those who have already taken American Trainco’s introductory course PLCs for Non-Programmers, or have a similar background and experience working with PLCs. It is designed to help maintenance technicians, electricians and others modify and write common PLC programs on their own. It will provide students the comfort and confidence they need to edit or create new PLC solutions for their specific work applications. It will make vendor specific PLC programming manuals understandable. And in addition to a practical, real world PLC programming education, students’ specific needs and concerns are also addressed during the class so that they can go back to their workplace and immediately apply what they’ve learned.

Day One - Discussion Topics

Day one starts with a quick review of PLC basics before moving on to an introduction of the laptops and simulation software the students will be using to learn PLC programming.  Depending on the students’ needs and applications to be discussed in your specific class, the instructor may use RsLogix, Direct Soft 5 and/or Logix Pro500 simulator programs.  The similarities and differences between relay ladder logic and PLC ladder logic are covered next. Then the students begin to write common control programs that demonstrate simple circuit design concepts (like series, parallel, holding, and latching), and then test their programs on a simulator.

PLC Quick Review

  • PLC Block Diagram and Major Components
  • Inputs and Outputs and Sequence of Operation
  • Types of PLC’s and Associated Software
  • Numbering Systems
  • PLC Basic Instructions

Design and Program Selected Exercises Using Logixpro-500 Simulator

  • Introductory Exercise: Relay Logic
  • Applying Relay Logic: Door Simulation
  • Applying Relay Logic to a Process: Silo Simulator
  • Introductory Exercise: PLC Timers
  • Applying Cascading TON Timers: Traffic Control
  • Introductory Exercise: Word Compare
  • Applying Word Compare Instructions: Traffic Control
  • Introductory Exercise: PLC Counters
  • Applying PLC Counter Instructions: Batch Mixing
  • Dual Compressor Exercise: Sharing the Workload
  • Advanced Batch Mixing Exercise: Your choice of instructions
  • Applying Bit Shift Instructions: Bottle Line Simulation
  • Multi Floor Elevator Control: Which Way to Go?
  • Interfacing to 7-Segment Displays: Includes Bottle Line Wiring Details

Day Two - Discussion Topics

Day two moves into more complex programming commands such as timers, counters, and compare functions that students will write and test again.   Following these lessons the student will take a relay ladder logic circuit and convert it to PLC logic and write the program for that circuit using the software of their choice.  Students will now use the cumulative knowledge presented in this class to create programs that are even slightly more complex. These exercises include silo sim, traffic light sim, batch sim, bottle and line sim.

Additional Programming Applications

  • Student Exercises: DirectSoft
  • Discussion of commonly used PLC’s and Programming Applications

Function Block Diagram (FBD) and Programming Exercises

  • Function Block Diagrams Overview: Advantages and Usage
  • FBD Construction
  • Understanding Structured Text and FBD’s
  • Student Exercise: Write FBD Programs Advanced Concepts
  • Scripting
  • Mnemonic Programming Code
  • Smart Relays
  • Pico Controller

Advanced Concepts

  • Scripting
  • Mnemonic Programming Code
  • Smart Relays
  • Pico Controller


More Seminar Information

TPC Trainco
American Trainco Seminars

Delivery Method

On-Site Training On-Site Training

Also Available As

Seminar Seminar

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