PLC Boot Camp Training Course

Fee: 50,000

Duration: 3 Months

Timing:  9AM-11AM, 11AM-1PM, 1PM-3PM, 3PM-5PM, 5PM-7PM, 7PM-9PM

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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
• Multiuser project and client 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
• Message representation, message logging, message configuring
• 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
• Server-side Scripting
• Client-side Scripting
• Many side scripting
• Database
• Recipes
• 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
• Redundant System
• Fail-Safe PLC System
• OPC UA
• OPC DA
• MQTT
• 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
• Jump and label command
• High speed counters
• 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 subroutines
• Jump and label command
• High speed counters
• Encoder with DELTA PLC

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
• Faceplates for reuse and centralized modification of graphics blocks
• Background processing Global Scripting
• Reinforcement of the content by means of practical exercises on the TIA system model

Module 8

• Introduction to instrumentation and their applications
• Digital and analog
• instrumentation
• Measurement terminologies and
• Principles of different measurement techniques.
• Unit Dimension and Standards
• Fundamental and derived units, electrical units
• Frequency, voltage, current, resistance,
• capacitance and inductance standards
• Types of bridges for
• measurements
• AC and DC Bridges
• Resistance, capacitance and inductance bridges,
• The Wagner ground and commercial RLC bridges
• 3.Transducers
• Types of Transducer
• based on Quantity to be Measured
• Temperature transducers (e.g. a thermocouple)
• Thermistors NTC/PTC
• Resistance Temperature Detectors (RTDs) (pt100)
• Thermocouples j, k,l types
• Semiconductor-Based Sensors
• Pressure transducers
• Strain gauges
• Capacitance Pressure Transducers
• Potentiometric Pressure Transducers
• Resonant Wire Pressure Transducers
• The Barometer:
• The Aneroid Barometer
• The Siphon Barometer
• The Diaphragm Pressure Gauge
• The Bourdon Gauge
• Piezometer or Pressure Tube
• Manometers:
• The U-Tube Manometer (The Double Column Manometer):
• The Inclined Tube Manometer:
• Single Column Manometer:
• Inverted U-Tube Manometer:
• Micro Manometer (U-Tube with Enlarged Ends):
• Displacement/position transducers (e.g. LVDT)
• Potentiometer
• Strain gauge
• Capacitive sensors
• Oscillator Transducer
• Flow transducers
• Differential Pressure Flow Meters
• Positive Displacement Flow Meters
• Velocity Flow Meters
• Mass Flow Meters
• Open Channel Flow Meters
• Vision and Imaging Sensors
• Radiation
• Sensors
• Proximity
• Sensors
• Photoelectric
• Sensors
• Particle
• Sensors
• Motion
• Sensors
• Metal Sensors
• Level Sensors
• Leak Sensors
• Humidity
• Sensors
• Gas and
• Chemical Sensors
• Force Sensors
• Flaw Sensors
• Flame Sensors
• Electrical
• Sensors
• Contact
• Sensors
• Non-Contact
• Sensors
• Types of Transducer based on
• the Principle of Operation
• Photovoltaic (e.g. a solar cell)
• Piezoelectric transducer
• Chemical
• Mutual induction
• Electromagnetic
• Hall effect
• Photoconductors
• Primary & Secondary Transducer
• Analog & Digital Transducer
• Transducer & Inverse Transducer
• Active and passive transducers
• Conditions for selection of Transducer Types
• Dynamic Range
• Repeatability
• Noise
• Hysteresis
• Measuring
• Instruments
• Oscilloscopes
• Signal generators
• Spectrum analyzers
• Network analyzer
• Impedance analyzers
• Logic analyzers
• DC ammeters, DC voltmeters and resistance
• measurements
• DC meter calibration
• AC Indicating Meters
• Energy meters
• Half wave and full wave rectifier meters
• Single phase wattmeter and energy measurement
• meters
• Instrument transformers (CT and PT)
• Analog Electronic Meters:
• The d’Arsonval movement galvanometer
• Transistor voltmeter circuits and operational
• amplifier voltmeter circuits
• Universal Instrumentation
• amplifiers
• AC electronic voltmeters and current and
• Resistance measurement.
• Digital Mustimeters:
• Digital voltmeter, ohm meters and current meter.
• 5.Industrial
• Communication Techniques
• RS232, RS 422, RS 423, RS 485,
• IEEE488 (GPIB)
• Serial, Bus, and Ethernet Technology
• Ethernet or CSMA/CD
• Converters
• Analog to digital converter,
• Types of ADC circuits flash ADCs
• Sigma Delta converters
• Analog to Digital convertors
• types
• Successive approximation
• register (SAR) converters
• Integrating or Dual-slope
• Converters
• Digital to Analog converter and their implementation
• 7.Grounding
• Shielding and Noise
• Different Noise categories
• Signal to noise ratio and noise figure
• Interference and external sources of
• interference
• Grounds, ground faults and ground loops
• Common mode noise
• Shielding and filtering
• 8.Instrumentation
• Signaling and Plant Applications
• Analog or Modulating
• Digital or On/Off
• Real-Time Data Acquisition and Processing
• Systems
• Electronic devices for signal sampling and
• quantification,
• Sampling rate calculation for data acquisition
• systems
• 9.Introduction
• to Statistical Quality Control
• Utilizing Trend charts to determine if a
• process is out of control
• Evaluating and fixing problems utilizing
• Fishbone Diagrams and Pareto Charts