# Open Industrial Automation Lab Manual

Version: 2026-07-26
License: CC BY 4.0
Attribution: PLC Simulation Software — https://plcsimulationsoftware.com/industrial-training-exercises

## Delivery model

Each lab starts with a public server-graded run. Learners should predict the result before submission, preserve the returned evidence, explain every failed check, and only then retry. Account and team features may be used for retained history and assignment, but are not required to inspect the public task.

## Lab 1 — Modbus holding-register poll

- Open: https://plcsimulationsoftware.com/modbus-simulator?challenge=read-holding-registers
- Outcome: distinguish reference 40001 from protocol address 0.
- Evidence: request PDU, response PDU and two decoded register values.
- Review question: what does a valid response fail to prove about the physical process?

## Lab 2 — Modbus write and exception diagnosis

- Open: https://plcsimulationsoftware.com/tutorials/modbus-tcp-plc
- Outcome: compare function 06 echo evidence with exception 02.
- Boundary: use a fictional training map; never reuse it as a production device map.

## Lab 3 — PID first-order process

- Open: https://plcsimulationsoftware.com/pid-simulator
- Outcome: compare overshoot, settling time, final error and IAE.
- Review question: why can two different gain sets both be acceptable?

## Lab 4 — 4–20 mA scaling

- Open: https://plcsimulationsoftware.com/industrial-training-exercises/pressure-transmitter-0-10-bar
- Outcome: apply live zero, engineering span and units.
- Extension: repeat a negative-range temperature or vacuum case.

## Lab 5 — Abnormal loop-current diagnosis

- Open: https://plcsimulationsoftware.com/instrumentation-simulator?challenge=diagnose-loop-current
- Outcome: distinguish open-loop, underrange, normal and overrange evidence.
- Boundary: device fault-current thresholds are configuration-specific.

## Lab 6 — 24 VDC measurement plan

- Open: https://plcsimulationsoftware.com/industrial-training-exercises/24vdc-control-supply-voltage
- Outcome: select state, DC-voltage mode, parallel placement and range.
- Safety: the browser exercise never authorises live work.

## Lab 7 — De-energised continuity

- Open: https://plcsimulationsoftware.com/industrial-training-exercises/control-fuse-continuity
- Outcome: require isolation and prove-dead before continuity.
- Review question: how can an in-circuit parallel path mislead the test?

## Lab 8 — Evidence review

- Open: https://plcsimulationsoftware.com/industrial-automation-training-benchmarks
- Outcome: interpret sample size, pass rate, privacy suppression and selection bias.
- Extension: download the aggregate CSV and write one defensible observation and one limitation.

## Suggested rubric

| Criterion | 0 | 1 | 2 |
| --- | --- | --- | --- |
| Prediction | Missing | Result only | Result with reasoning |
| Safety boundary | Unsafe | Partly stated | Correct and explicit |
| Evidence | Missing | Screenshot only | Inputs, checks and result retained |
| Diagnosis | Random change | Names failed check | Uses failed check to choose next action |
| Transfer | Overclaims | Generic note | States simulator and real-work limits |

Maximum: 10 points. The provider remains responsible for practical assessment, accreditation and safe-work procedures.