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Courses & Training

Zeenni Technology Center for Engineering and Industrial Research

PLC & Industrial Automation

This module aims at explaining all about the installation, commissioning and programming of MPS stations (Distribution, Buffer, Separating, Processing, Handling, Packaging, In/out) and PMS PA stations (Filtration station, Mixing station, Reactor station, Bottling station).
It starts from the point where the station has been set-up mechanically all the way till it reaches the communication between the stations.
It also focuses on the configuration of PROFIBUS-DP with STEP 7 and explains various possibilities of data exchange with the User end and gives wise advice for commissioning and troubleshooting. It is designed specifically to help all those who are responsible for the planning, configuration or programming of PROFIBUS.
TP301- Basic of PLC (Siemens Step7)
Prerequisites: Technical Understanding
Automating with a PLC
Introduction - areas of application of a PLC - basic design of a PLC - the new PLC standard
The decimal number system - binary number system - BCD code
The hexadecimal number system
Signed binary numbers - Real numbers
Generation of binary and digital signals
Boolean operations
Basic logic functions - further logic operations - establishing switching functions
Simplification of logic functions - Karnaugh-Veitch diagram
Design and mode of operation of a PLC
Systematic solution finding - structuring resources - programming languages
Common elements of programming languages
Resources of a PLC - variables and data types - Program
Ladder diagram
Elements of ladder diagram - functions and function blocks - evaluation of current rungs
Instruction list
Instructions – operators - functions and function blocks
Structured text
Expressions - Selection statements - Iteration statements
Sequential function chart
Introduction - elements of sequential function chart – transitions - steps
Logic control systems
What is a logic control system - logic control systems without latching properties
Logic control systems with memory function - edge evaluation
Introduction - pulse timer - switch-on signal delay - switch-off signal delay
Counter functions - incremental counter - decremental counter
Incremental/decremental counter
Sequence control systems
What is a sequence control system
Commissioning and operational safety of a PLC
TP302- Programming, MPS Station (Digital)
Prerequisites: TP301
Set-up of the station - Mechanical set-up - Electrical connections - Pneumatic connection
Installation of Step 7 - Download example project to the PLC
Adjustment of mechanical components - Adjustment of pneumatic actuators
Adjustment of sensors
Test the project
Project preparation - Delete the contents of the CPU - Hardware configuration of the PLC
Definition of the input addresses - Definition of the output addresses
Edit the Symbol Table - Structural programming
Programming projects - Project descriptions - Project solutions
Industrial communication
Basics of I/O communication - I/O connection of the stations - Test the I/O communication
Material- and signal flow through the system
Trouble Shooting
Basics of Trouble Shooting - Simulate broken wires - List of possible errors in the station
TP303- Programming, PMS PA Station (Analog)
Prerequisites: TP302
Fundamentals of closed-loop control technology
What is a system
Open and closed-loop control technology - Basic terminology of closed-loop control technology
Controlled systems -
Identification of the controlled system - Dynamic behavior
Characteristic of the response behavior
Order of a system - Time constant - The inflectional tangent model
The controller
Control response -The two-position controller - The time response of a controller -
Technical details of controllers
Mode of operation of various controller types
The P-controller - The PI controller - The PD controller - The PID controller
Optimization method for controller settings
Manual tuning of control parameters without knowledge of the system behavior
Tuning rules according to Ziegler/Nichols - Tuning rules according to Chien/Hrones/Reswick
Tuning method according to the rate of rise 
TP400- Communication via MPI/Industrial Ethernet Bus Technology (AS- Interface)
Prerequisites: TP301 & TP302
Hierarchy Level in Automations Technology
Field Bus Systems
The Multipoint - Interface (MPI)
Technical data for the MPI, Configuration of a MPI network,
Commissioning of a MPI network
Commissioning of an Operator Station on a MPI network
Commissioning of a program device / PC on a MPI network
Global data communication with MPI, Functionality of a cyclic data exchange
Reaction time and transmission security, Global data configuration
The AS- Interface
Technical data for the AS- Interface, Configuration of an AS- Interface
Basic components of an AS- Interface configuration,
Bus access process, Data transmission and transmission security
Commissioning of the AS- Interface
AS-I binary values exchange with standard A slaves
AS-I binary values exchange with B slaves, Transmitting AS-I analog values
The Profibus
Profibus- FMS, Profibus- PA, Profibus- DP
Technical data for the Profibus-DP, Configuration of the Profibus-DP
System configuration, Bus access process, Frame configuration, Data transmission and transmission security
Time response of the Profibus-DP, Protection mechanisms, Commissioning of the Profibus-DP
Checkpoint – Learning Outcomes
Upon completion of this training, the participant will be able to:
  • Configure and commission a Simatic S7 controller
  • Create and change hardware configurations
  • Create and commission PLC programs with logic operations and sequences
  • Combine various program modules into structured programs
  • Isolate and eliminate faults and errors
  • Design, program and implement basic automation tasks
  • Select appropriate languages for specific tasks and combines them to a complete project
  • Create and use different kinds of variables (local, global)
  • Create a basic simulation based on the internal SoftPLC and test programs
  • Create a basic visualization (for example, of a belt or distribution station)
  • Program the sequence of the MPS Distribution Station using a language or combination of languages
  • Use debugging tools to simulate, test and trace
  • Troubleshoot effectively