PLC Boot Camp Training Course

PLC Boot Camp Course Outline

Module 1

• Introduction and History
• Introduction to TIA portal and its installation
• Programming languages stl , fbd, ladder.
• Making Simple Program in TIA
• Add remove PLC controllers IN TIA program
• Going online with s7-1200 PLC via TIA
• Connecting s7-1200 via Ethernet
• Topology, network and device views
• Upload /download program in PLCs
• Working with different type of simulators like PLCSIM and s7-plsim simulating modules
• Integration of simulator with TIA and their offline control
• Monitoring of PLC program while online
• Checking and setting the CPU /CONTROLLER and module properties
• Create tags for the I/O of the CPU.
• Create a simple network in your user program
• Use the PLC tags in the tag table for addressing the instructions
• Inserting new networks and deleting them
• Adding empty box, open and close branch as well as inserting inputs
• Program blocks and main OB
• Bit Logic Instructions NO, NC, COIL
• Word Logic Operations, AND, OR NOT, NAND, XOR, XNOR
• Assignments and negative assignments
• Set/reset coil with flip-flops
• Timers TP, TON, TOFF and time accumulators
• Counters UP, DOWN, UP/DOWN
• Range and validity functions
• Comparator Like equal to, not equal to, less than, greater than etc.(= ,> ,< ,>= ,<= )
• Arithmetic Functions like add sub,MUL,DIV,MOD,NEG,INC,DEC,ABS ,MIN,MAX,LIMIT
• MOVE Block FIELDREAD, FIELD WRITE etc.
• Advance Functions like SWAP, CONVERT, CEIL, FLOOR
• Special Functions
• Plc tags and adding new tag table
• Plc data types, int, float, double, byte etch and how to add them
• Plc trouble shooting and maintenance
• Watch and force table and how to add them in project
• Introduction to analog and digital sensors
• PT100, opt electrical, limit switches
• 38. Integration of sensors with plc and taking values in TIA
• Calibrating analog sensors RTD and Thermocouple
• Reading analog sensor value from TIA portal
• Going online problems and theirs solutions
• WinCC Runtime Advanced
• Implement PLC Programming in Factory Environment
• Intro to VFD and frequency drives
• VFD parameter setting in FUJI
• Connect VFD with PLC and control by current change
• HMI (Human Machine Interface) Section
• Learn to Program WIENTEK HMI
• Learn to design in Utility manager
• Creating tags in HMI in utility manager
• Adding buttons ,lamps , numeric inputs and outputs
• Connect HMI with plc
• Download program in HMI as well as online and offline simulations
• Hmi and plc connection problems and solutions
• Reading senor value at HMI
• Controlling motors from HMI
• WinCC Runtime Advanced
• Programming with Factory I/O
• Introduction to SCADA

Module 2

• Quick Review of PLC HMI SCADA Level 1 Course.
• Jump and Label instruction in TIA Portal S7 1200/300/400 PLC
• How to make Functions (FC) in TIA Portal
• What is Cross Reference?
• FCs calling in Main (OB)
• Difference between FC and FB
• How to make FB in TIA and How to call it
• Introduction to Factory I/O
• Factory I/O Environment
• Understand industrial automation components on Factory I/O
• Configure and program Factory I/O Applications
• Understand and develop logic on real time applications
• Create and program your own automation applications
• Understand uses of sensors, switches, actuators and conveyors
• Interface & Configure different PLC Programming Software with Factory I/O
• RTUs concept using Profibus
• Motor Control with VFD
• Parameters setting of Analog IO’s in VFD from control terminals
• Connections of Analog IO’s (0-10V or 4-20mA)
• Forward Reverse of Motor using keypad
• Forward reverse of Motor from external signal
• Controlling the Motor Acceleration and Deceleration time
• Frequency setting range up to 120Hz
• PLC wiring of Analog IO’s with VFD
• Motor Speed control using VFD through PLC Motor Speed control from thermocouple through temperature.
• Read and Write major parameter of VFD on HMI (weintek) via MODBUS RTU using RS485
• Two VFD’s/Motors Operate with their feedback (Master Slave VFDs
• Introduction to SCADA
• SCADA system application( Oil GAS / factory /Metro/ Solar Power Plant /Steel Plant )
• System overview TIA Portal,
• WINCC Explorer Professional
• Creating a WINCC Explorer Professional project
• Configuring the connection to the WINCC Explorer automation system
• Structuring the operator interface
• Data & Communications
• Project overview
• Project Management
• Running the Project
• WINCC Explorer SCADA Graphic Designing
• WINCC Explorer SCADA Reporting
• WINCC Explorer SCADA connection with SQL Database by taking value of temperature/pressure/flow/level etc.
• Alarm Logging
• Tag logging & Trend display
• Gauges, sliders, motors, pipes, tanks and other object designing on
• WINCC Explorer SCADA.
• Fundamentals of creating graphics displays for human machine interfacing
• Navigating through the plant displays
• User administration
• Variable logging, trend configuring and trend plotting
• Trend plotting, and message representation including logging of data in the database
• Graphical Animation
• Slider Movement
• Visibility
• More Animations
• Introduction to Kepserver
• SCADA direct Communication with PLC
• SCADA to PLC Communication via Kepserver
• SCADA to PLC Communication via Kepserver and Modbus

Module 3

• Quick Review of Level 1 Level 2
• WINCC FLEXIBLE RUNTIME
• DB Block in Detail
• FB Block in Detail
• FC Block in Detail
• ARRAYS
• UDTS
• PID
• PLC Safety Circuit
• Web Server
• MCR

Module 4

• S7-Communication
• PUT/GET Instruction
• PLC to PLC Communication
• Master Slave Communication
• Concept of Redundant System
• Concept of Fail-Safe PLC System
• OPC
• Real-time Plant Project

Module 5

• Introduction
• Difference between Servo and Stepper Motor
• Overview of PLC based motion
• HSC and PTO in S7-1200
• How to generate PTO in S7-1200
• Hardware wiring of Motor and Driver
• Configuration Of Positioning Axis
• Commissioning Of Axis
• Programming of basic motion control functions
• Axis Power and Axis Reset
• Axis JOG Operation
• Axis Homming Operation
• Axis MoveRelative Motion Control
• MC_MoveAbsolute
• Difference between MC_Relative and MC_MoveAbsolute
• Axis MC_MoveVelocity
• Axis MC_Halt

Module 6

ALLEN BRADLY

• Intro to AB PLC
• Intro to micrologix 1000
• Installing micrologix 1000 and RS linkx
• Learn to download and upload program in micrologix 1000
• Use of  emulator in AB
• AB plc wiring sink/source
• Sensor wiring
• NO ,NC and OUT commands
• Timers TON, TOFF AND retentive  in AB
• Counters and compare commands
• Data registers
• Increment and decrement operations
• Arithmetic commands
• Connect and programing  HMI with micrologix 1000
•  

MITSUBISHI

• Intro to MITAUBISHI PLC
• Intro to GX works 2
• Installing GX works 2
• Learn to download and upload program in GX works 2
• Use of  emulator in GX works 2
• MITAUBISHI plc wiring
• GX Works 2 Requirement & Setup/Installation
• GX Works 2 Screen Configuration
• Create a project and sample program in GX works 2
• MITAUBISHI PLC wiring sink/source
• Sensor wiring with  MITAUBISHI PLC
• Latch and Timer MITAUBISHI PLC
• Counter
• Turn Off Simulation
• Rising Pulse & Falling Pulse
• How to use Data Register
• MOVE Instruction
• Math Instruction
• Compare command in GX works
• Connect and programing  HMI with MITAUBISHI PLC

DELTA

• Intro to DELTA PLC DVP24ES
• Intro to WPLsoft
• Installing WPLsoft
• Going online with DELTA Plc
• Learn to download and upload program with WPLsoft
• Use of  emulator in WPLsoft
• DELTA plc wiring
• Making PLC Sink/Source
• Connecting NPN and PNP sensors with PLC
• LD,LDI  and OUT commands
• Commenting and labeling in WPLsoft
• Types of timers in DELTA plc
• Counters and compare commands
• Data registers
• Increment and decrement operations
• Arithmetic commands ADD,AUB,MUL,DIV
• Call subroutine

FATEK

• Intro to FATEK PLC
• Intro to Winproladder
• Going online with FATEK Plc
• Learn to download and upload program in winproladder
• Use of  emulator in Winproladder
• FATEK plc wiring sink/source
• Connecting NPN and PNP sensors with PLC
• Sensor wring and its types
• NO ,NC and OUT commands
• Commenting and labeling in Winproladder
• Timers TON, TOFF AND retentive  in AB
• Counters and compare commands
• Data registers In FATEK
• Increment and decrement operations
• Arithmetic commands
• Jump and label command
• High speed counters
• Encoder with FATEK
• Motor control with FATEK

Module 7

• Industrial Automation Basics
• Basic Knowledge
• Programmable Logic Controllers (PLC)
• Quick Review of PLC HMI SCADA
• SCADA system application(Oil GAS / factory /Metro/ Solar Power Plant /Steel Plant)
• System overview TIA Portal, Wonderware Intouch Professional
• Creating a Wonderware Intouch Professional project
• Configuring the connection to the Wonderware Intouch automation system
• Structuring the operator interface
• Data & Communications
• Project overview
• Project Management
• Running the Project
• Wonderware Intouch SCADA Graphic Designing
• Wonderware Intouch SCADA Reporting
• Alarm Logging
• Tag logging & Trend display
• Gauges, sliders, motors, pipes, tanks and other object designing on Wonderware Intouch SCADA.
• Fundamentals of creating graphics displays for human machine interfacing
• Navigating through the plant displays
• Variable logging, trend configuring and trend plotting
• Trend plotting, and message representation including logging of data in the database
• Graphical Animation
• Web Buttons
• Slider Movement
• Visibility
• More Animations
• Reinforcement of the content by means of practical exercises on the TIA system model

Module 8

It Covers the Instrumentation used in the industrial Process.

Module: 9

 Simatic Manager for S7-300 PLC

Module 10: DCS Siemens PCS7