COURSE OVERVIEW:

The purpose of this course is to provide practical technical skills for the daily operation, upkeep, and repair of Programmable Logic Controllers (PLCs) in an industrial environment. The PLC is the workhorse of modern automation, and its reliability is essential for continuous production. This program focuses on equipping technical staff with the ability to navigate PLC hardware and software to ensure smooth operation and to rapidly restore service in the event of a failure.

The scope of this training encompasses the hardware components, software interfaces, and diagnostic tools of the leading PLC brands. Participants will explore the mechanics of the PLC scan cycle, the meaning of various status indicators, and the use of programming software as a troubleshooting tool. The curriculum is specifically designed for "hands-on" applications, moving beyond theory to the practical tasks of replacing modules, force-setting variables, and interpreting logic errors.

Coverage includes the systematic identification of faults in I/O systems, power supplies, and communication links. Attendees will learn how to perform safe software backups, manage battery replacements without losing program data, and use online monitoring to isolate field-level issues. By focusing on the practicalities of PLC maintenance, the course ensures that participants can reduce downtime and improve the overall reliability of the plant's automation infrastructure.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Analyze the hardware architecture of modern industrial PLCs.
• Interpret PLC status LEDs to identify CPU and I/O faults.
• Utilize PLC software for online monitoring and diagnostics.
• Identify and troubleshoot faults in Analog and Digital I/O modules.
• Perform safe hardware replacements (Hot-swapping and Cold-start).
• Execute program backups, uploads, and downloads.
• Use "Forcing" and "Toggling" functions responsibly for testing.
• Troubleshoot communication failures between PLCs and HMI/SCADA.
• Manage PLC batteries and memory modules to prevent data loss.
• Interpret Ladder Logic and Function Blocks to isolate process issues.
• Maintain a comprehensive PLC maintenance log and documentation.
• Follow electrical safety protocols when working inside PLC panels.

TARGET AUDIENCE:

This course is intended for Maintenance Electricians, Instrument Technicians, Junior Automation Engineers, and Plant Operators.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.