20 Hands-On PLC Training Exercises for Students

Effective PLC training requires more than watching an instructor write ladder logic. Students need repeated cycles of interpreting a requirement, wiring devices, programming the controller, testing the machine, finding faults, and documenting the result.

The following 20 exercises can be adapted for Allen-Bradley Micro800 or CompactLogix, Siemens S7-1200 or S7-1500, and other industrial PLC platforms. Instructors should adjust voltage, guarding, supervision, and operating procedures to match their laboratory equipment and institutional safety requirements.

Foundation exercises

1. Verify the power supply and I/O map

Identify the control voltage, common terminals, input addresses, output addresses, protective devices, and emergency-stop path. Students produce a checked I/O list before programming.

2. Control one indicator with one push button

Wire a momentary input and create a simple output instruction. Verify the physical signal, controller status, and output voltage.

3. Build a start/stop seal-in circuit

Create a maintained run command using separate start and stop inputs. Compare the PLC program with a conventional relay holding circuit.

4. Add an emergency-stop permissive

Use the trainer’s designed safety or control interface to prevent operation when the emergency-stop condition is not healthy. Discuss why standard PLC logic is not a substitute for a required safety system.

5. Program an on-delay and off-delay sequence

Use timers to control two indicators or loads. Monitor timer status and accumulated values online.

6. Count parts and reset the total

Use a sensor or push button as the count input. Add reset logic, a target value, and an indicator when the target is reached.

Sequence and machine-control exercises

7. Create a traffic-light sequence

Program a repeating sequence with defined timing, a stop condition, and a manual reset. Require students to document the state order.

8. Control a pneumatic cylinder

Operate a solenoid valve and confirm cylinder position with sensors. Add timeouts for a missing extend or retract signal.

9. Build a two-cylinder sequence

Create a safe step sequence such as A+ B+ B− A−. Use limit or proximity feedback rather than timing alone.

10. Sort parts on a conveyor

Detect an incoming part, classify it using an available sensor, track its position, and operate a pneumatic pusher. Add counts for accepted and rejected parts.

11. Add manual, setup, and automatic modes

Create mode logic that prevents conflicting commands. In setup mode, allow controlled jogging of individual actuators.

12. Develop an alarm and reset strategy

Detect a missing sensor transition, motor fault, or sequence timeout. Latch the alarm, display its cause, and require the correct reset conditions.

HMI, motor, and analog exercises

13. Build a basic HMI screen

Create start, stop, status, counter, timer, and alarm objects. Confirm that HMI commands do not bypass required PLC permissives.

14. Control a VFD and motor

Practice start/stop, direction where the hardware permits, speed reference, drive status, and fault reset. Compare hardwired and networked control if both are available.

15. Scale an analog input

Convert a raw signal into engineering units such as percent, temperature, pressure, or level. Add reasonable high and low limits.

16. Create a simple PID control exercise

Use a temperature, flow, pressure, or level process. Record the response to setpoint changes and compare conservative and aggressive tuning.

17. Position a stepper or servo axis

Perform homing, jogging, absolute or relative moves, and limit handling. Document position error and recovery after interruption.

Networking and troubleshooting exercises

18. Configure an industrial network device

Connect an HMI, VFD, remote I/O module, or second controller over EtherNet/IP or PROFINET. Verify addressing, connection status, and exchanged data.

19. Diagnose an instructor-inserted fault

Possible faults include an open wire, incorrect common, failed sensor, disabled output, wrong parameter, communication loss, or sequence condition that never becomes true. Students must troubleshoot with a documented test plan rather than random changes.

20. Complete an integrated capstone

Combine PLC logic, HMI, sensors, motor or conveyor control, pneumatics, alarms, production counting, and fault recovery. Require electrical drawings, an I/O list, program comments, an operating procedure, and a commissioning report.

How to assess the exercises

Grade more than whether the machine moves. A practical rubric can include safe setup, drawing interpretation, wiring quality, program structure, comments, test procedure, fault diagnosis, documentation, and the ability to explain why the system behaves as it does.

The desktop PLC conveyor sorting trainer supports sensor, sequence, pneumatic, and troubleshooting projects. The Siemens PLC and VFD motor-control trainer supports drive and motor exercises, while the PLC process-control trainer supports analog scaling and PID work. Browse all PLC training kits or request exercises matched to your course.

Related training guides

Use these exercises alongside What Equipment Does a Mechatronics Lab Need? when planning complete student stations. For programs centered on plant troubleshooting and technician skills, see How to Build an Industrial Maintenance Training Lab.