A complete course in PLC systems for the maintenance technician who already knows a panel, a meter and a down machine. It runs from relay logic to troubleshooting, maintaining and protecting PLC systems on Allen-Bradley, Siemens and Schneider Electric platforms.
71 chapters in 16 Parts289 diagrams284 Knowledge Checks236 Review Questions195 worked solutions289 Final Assessment questions in the pool
Edition 1.0, September 2026.
Read the free sample (4 chapters)
Who it is for
Maintenance technicians who know their way around a panel, a meter and a down machine, and who want the PLC knowledge to find the problem when it lives in the controls.
What you will learn
- Foundations: relay logic to PLCs, how a PLC works, hardware, electrical fundamentals and safety in PLC work
- Digital and analog I/O, process control and instrumentation
- PLC programming fundamentals, including the IEC 61131-3 languages
- Communication networks and protocols
- Platform deep dives: Allen-Bradley (SLC 500, MicroLogix, PLC-5, ControlLogix, CompactLogix, Micro800), Siemens (S7-300, S7-400, S7-1200, S7-1500) and Schneider Electric (M340, M580, Quantum)
- HMI systems, drives and motion control from the PLC side, and safety systems
- Troubleshooting and diagnostics, preventive maintenance and program management
- Cybersecurity and remote access, career growth, and a capstone project: Build, Break, and Fix
How the course works
- Hands-on exercises with worked solutions, so you can check your own work
- A Final Assessment you can take in practice or full mode, with a Course Completion Document for your own records
- A recommended four-semester study plan (about 390 hours), or an accelerated two-semester option
- A skills sign-off sheet in the capstone, for the hands-on part a book cannot test
- Read online on any device, with your place and answers saved to your account
Table of contents
Part I - Foundations: From Relay Logic to PLCs6 chapters
- Ch 1The Birth of Industrial Control: Relay Logic and Hardwired Systems
- Ch 2The Invention of the PLC and the Revolution It Started
- Ch 3How a PLC Works: Architecture and Operating Principles
- Ch 4PLC Hardware: Racks, Backplanes, Power Supplies, and Modules
- Ch 5Electrical Fundamentals for PLC Systems
- Ch 6Safety in PLC Work: Electrical Hazards, LOTO, and Arc Flash
Part II - Digital and Analog I/O Systems5 chapters
- Ch 7Digital Inputs: Wiring, Sensors, and Diagnostics
- Ch 8Digital Outputs: Wiring, Loads, and Troubleshooting
- Ch 9Analog Inputs: Signals, Scaling, and Calibration
- Ch 10Analog Outputs: Driving Actuators and Control Devices
- Ch 11Specialty I/O: Thermocouples, RTDs, High-Speed Counters, and Pulse Outputs
Part III - PLC Programming Fundamentals11 chapters
- Ch 12Introduction to PLC Programming: Languages and Concepts
- Ch 13Ladder Logic: The Foundation
- Ch 14Timers: TON, TOF, RTO, and Practical Applications
- Ch 15Counters: CTU, CTD, and Practical Applications
- Ch 16Comparison and Math Instructions
- Ch 17Data Handling: Move, Copy, and Conversion Instructions
- Ch 18Program Flow: Subroutines, Jumps, and Program Organization
- Ch 19Sequencers and State Machines
- Ch 20Function Block Diagrams (FBD)
- Ch 21Structured Text (ST)
- Ch 22Sequential Function Chart (SFC) and Instruction List (IL)
Part IV - Process Control and Instrumentation3 chapters
- Ch 23Process Control Fundamentals: Feedback Loops and Control Theory
- Ch 24PID Control in PLCs: Configuration, Tuning, and Troubleshooting
- Ch 25Instrumentation for PLC Systems
Part V - Communication Networks and Protocols4 chapters
- Ch 26Industrial Networking Fundamentals
- Ch 27EtherNet/IP: Allen-Bradley's Network of Choice
- Ch 28PROFINET and PROFIBUS: Siemens Networks
- Ch 29Modbus, DeviceNet, ControlNet, and Other Protocols
Part VI - Allen-Bradley Platform Deep Dives11 chapters
- Ch 30The Allen-Bradley Ecosystem: Overview and History
- Ch 31PLC-5 and RSLogix 5
- Ch 32SLC 500 and RSLogix 500
- Ch 33MicroLogix 1100 and 1400 with RSLogix 500
- Ch 34ControlLogix 5570: The Proven Workhorse
- Ch 35ControlLogix 5580: The High-Performance Generation
- Ch 36CompactLogix 5370: The Mid-Range Workhorse
- Ch 37CompactLogix 5380: The Newer Mid-Range
- Ch 38Micro800 Series (820/850/870) and Connected Components Workbench
- Ch 39Studio 5000 Mastery: The Complete Walkthrough
- Ch 40RSLogix 500 Mastery: Navigating Legacy Software
Part VII - Siemens Platform Deep Dives5 chapters
- Ch 41The Siemens Ecosystem: Overview and History
- Ch 42Siemens S7-300 and S7-400 with STEP 7 Classic
- Ch 43Siemens S7-1200 and TIA Portal Basic
- Ch 44Siemens S7-1500 and TIA Portal Professional
- Ch 45TIA Portal Mastery: The Complete Walkthrough
Part VIII - Schneider Electric Platform Deep Dives3 chapters
- Ch 46The Schneider Electric Ecosystem: Overview and History
- Ch 47Modicon Quantum and Concept/Unity Pro
- Ch 48Modicon M340 and M580 with EcoStruxure Control Expert
Part IX - HMI Systems4 chapters
- Ch 49HMI Fundamentals: What They Do and How They Connect
- Ch 50Allen-Bradley PanelView and FactoryTalk View
- Ch 51Siemens HMI Panels and WinCC
- Ch 52Schneider Magelis and Other Common HMIs
Part X - Drives, Motion Control, and PLC Integration2 chapters
- Ch 53VFD Fundamentals and PLC Integration
- Ch 54Servo and Motion Control via PLC
Part XI - Safety Systems2 chapters
- Ch 55Safety PLCs, Safety I/O, and SIL-Rated Systems
- Ch 56Safety Network Protocols: CIP Safety and PROFIsafe
Part XII - Troubleshooting and Diagnostics6 chapters
- Ch 57Systematic PLC Troubleshooting Methodology
- Ch 58Fault Codes, Diagnostic Buffers, and Status Registers
- Ch 59I/O Forcing: When It's Safe, When It's Dangerous
- Ch 60Communication Troubleshooting
- Ch 61Power Quality and Its Impact on PLC Systems
- Ch 62Intermittent Faults: The Hardest Problems in PLC Maintenance
Part XIII - Preventive Maintenance and Program Management4 chapters
- Ch 63PLC Preventive Maintenance Programs
- Ch 64Program Backup, Version Control, and Change Management
- Ch 65Spare Parts Strategy and Lifecycle Management
- Ch 66Documentation Practices for the PLC Professional
Part XIV - Cybersecurity and Remote Access2 chapters
- Ch 67Industrial Cybersecurity Fundamentals
- Ch 68Remote Access: VPN, Cloud Gateways, and Secure Connections
Part XV - Career Development and Professional Growth2 chapters
- Ch 69Career Pathways: From Maintenance Tech to PLC SME and Beyond
- Ch 70Building Your PLC Lab and Continuing Education
Part XVI - Capstone1 chapters
- Ch 71Capstone: Build, Break, and Fix
Appendices4
- PLC Platform Quick Reference
- Terms, Acronyms, and Abbreviations
- Troubleshooting Quick Reference Tables
- Other PLC Brands You Will Meet