Automation & Process control

Participants
SN Training Module Level Days
In a Batch
Programmable Logic Controllers (PLC)
1 Allen Bradley, Siemens, Modicon, GE Fanuc, Basic 3 Up to 12
Mitsubishi, Messung, Omron
Programmable Logic Controllers (PLC)
2 Allen Bradley, Siemens, Modicon, GE Fanuc, Advanced 4 Up to 12
Mitsubishi, Messung, ABB
SCADA (HMI)
3 InTouch, Ifix, WinCC, RS View, Cimplicity, Advanced 3 Up to 12
Citect
Distributed Control System (DCS)
4 Emerson, Siemens, Microverse, Honeywell, Advanced 4 Up to 12
Yokogawa
AC Drive
5 Allen Bradley, Siemens, Schneider, GE Fanuc, Advanced 2 Up to 12
Mitsubishi, Yaskawa, ABB
Servo Drives
6 Advanced 2 Up to 12
Allen Bradley, Siemens
Maximum 10 to 12 Participants for better understanding & good quality of training

Industrial Communication & Networks Training

Participants
SN Training Module Level Days
In a Batch
Industrial Communication & Networks
7 Advanced 7 Up to 12
Training
Maximum 10 to 12 Participants for better understanding & good quality of training
On-site training
It is our opinion that customer training
is considered one of the most important
parts of any project. In line with our
Total Quality Management and
training policies, Prolific is able to
provide a complete customer training
program, which ensures full knowledge
transfer.

Exact training requirements, however,

can vary Considerably from customer to
customer. For this reason, Prolific offers
both standard training courses and
customer specific training programs.

To help you decide which course is more

suitable for you, we have assigned
experienced technical support
professionals to help you with your
training requirements.
Programmable Logic Controllers (PLC)- Basic (Programming & Maintenance)
Duration of the course: 3 days

Hardware covered (any of the given)

Allen Bradley: Micrologix series, SLC 500 Siemens: Series S7 200 and S7 300
Schneider Electric: Modicon TSX Micro and Premium GE Fanuc: Versa Max Series
Mitsubishi: Fx Series Messung Systems: Nextgen

Topics Covered
Introduction to PLC
Topic Mode
Introduction to PLC hardware and role in
automation
Presentation and physical observations
Architectural Evolution of PLC
Introduction to the field devices attached to PLC
PLC Fundamentals - (Block diagram of PLC's)
Detail information about PLC components
o Power supply, CPU, I/Os, Practical demonstration on hardware
Communication bus
Various ranges available in PLC’s
Types of Inputs & outputs / Source Sink Concepts
Practical on PLC’s
Wiring of the I/O devices
Concept of flags
Practical on PLC’s
Scan cycle execution

Operation and Maintenance of PLC

Topic Mode
Setting up PLC’s / Connecting CPU, I/O modules,
Practical – Assembling PLC
Rack, Back plane and Communication bus
Connecting Field devices to PLC’s I/Os Practical -Physical wiring
Installing and to starting the programming
Practical – Installation of software
terminals
Identifying the status of PLC and communication
Practical on PLC’s
bus
Fault detection and error handling Practical on PLC’s
Forcing of the I/O’s Practical on Software
Back up of the programs and reloading Practical on PLC’s
CPU, I/O module replacements Practical on PLC’s

Programming of PLC
Topic Mode
Introduction to PLC programming software Practical – Programming software
Addressing concepts Practical – Programming software
Introduction to bit, byte & word concepts Practical – Programming software
Programming instructions arithmetic and logical
Load /and /or/out / and Read / Write
Compare / Add / Sub /And /Or – Blocks
Leading edge / trailing edge instructions
MOVE block application
Practical – Programming software
Timer and Counter Blocks programming
Advanced instructions
File handling
Comment functions
Master control /set /reset function
Upload, download, Monitoring of programs Practical – Programming software
Monitoring / Modifying data table values Practical – Programming software
Standard procedure to be followed in wiring / Practical – Programming software
writing ladder etc
Troubleshooting and fault diagnostics of PLC Practical – Programming software
Documenting the project Practical – Programming software
Programmable Logic Controllers (PLC)- Advance
Allen Bradley - ControlLogix Systems
Duration of the course - 4 days
Topics Covered

Topic Mode
Introduction to PLC hardware and role in
automation
Presentation and physical observations
Architectural Evolution of PLC
Introduction to the field devices attached to PLC
PLC Fundamentals - (Block diagram of PLC's)
Detail information about PLC components
o Power supply, CPU, I/Os, Practical demonstration on hardware
Communication bus
Various ranges available in PLC’s
Identifying Logix System hardware and software
Practical demonstration on hardware and software
Components
Types of Inputs & outputs / Source Sink Concepts
Practical on PLC’s
Wiring of the I/O devices
Concept of flags
Practical on PLC’s
Scan cycle execution

Operation and Maintenance of PLC

Topic Mode
Setting up PLC’s / Connecting CPU, I/O
modules, Rack, Back plane and Communication Practical – Assembling PLC
bus
Connecting Field devices to PLC’s I/Os
Practical -Physical wiring
Configuring Local 1756-I/O Modules
Connecting a Computer to a Communications
Network
Installing and to starting the programming
terminals
Creating & Modifying an Rslogix new project Practical – Installation of software
Transferring a Project File to a Logix5000
Controller
Identifying the status of PLC and communication
Practical on PLC’s
bus
Creating Tags & Monitoring Data in an Rslogix
5000 Project Practical on Software
Forcing of the I/O’s
Managing Rslogix 5000 Project Files
Practical on PLC’s
Back up of the programs and reloading

Programming / Project Development

Topic Mode
Creating various Tasks
Organizing Data
Entering, Editing, & Verifying Ladder Logic
Configuring Logix5000 Controllers to Share Data Practical – Programming terminal
Configuring a Message
Documenting & Searching for Project
Components
Ladder Logic Programming/Interpretation
Identifying Programming Strategies &
Techniques
Documenting & Searching Ladder Logic
Programming Basic Instructions
Programming Timer & Counter Instructions Practical – Programming terminal
Programming Program Control Instructions
Programming Compare Instructions
Programming Compute & Math Instructions
Programming Move Instructions
Programming with Advance Instruction Set
 Function Block Programming
Creating a Function Block Diagram Practical – Programming terminal
Programming Logical Function Block
Instructions
Programming Timer & Counter Function
Block Instructions
Programming Analog Function Block
Instructions
Programming Timing Modes in a Function
Block Instruction
Programming & Monitoring an RMPS
(Ramp/Soak) Function Block Instruction
Controlling Program Flow Using Function
Block Instructions
Introduction to industrial networking
Identifying Industrial Networks for Use in a Theory session
Logix5000 System
Introduction to DeviceNet, EtherNet & DHRIO
Devicenet configuration & use.
EtherNet configuration & use Practical – Demonstration on network
DHRIO Configuration & use
Messaging over networks
ControlNet Configuration, Scheduling &
Troubleshooting
Basics of networks
Modules & Media
Practical – Demonstration on network
Addressing of nodes
Scheduling
Downloading/ uploading schedule
Troubleshooting

Maintenance and Troubleshooting

Topic Mode
ControlLogix Troubleshooting
Interpreting Project Organization &
Execution
Monitoring Arrays & Tags of User-Defined
Data Types
Editing Ladder Logic Online
Troubleshooting Controller Problems Practical on PLC
Monitoring GSV/SSV Instructions
Forcing I/O & Toggling Bits
Troubleshooting I/O Module Problems
Troubleshooting Power Supply Problems
CPU, I/O module replacements
Fault detection and error handling
Programmable Logic Controllers (PLC)- Advance
Siemens – Step 7 300 and 400 Series PLC’s
Duration of the course - 4 days
Topics Covered

Topic Mode
Introduction to PLC hardware and role in
automation
Presentation and physical observations
Architectural Evolution of PLC
Introduction to the field devices attached to PLC
PLC Fundamentals - (Block diagram of PLC's)
Detail information about PLC components
o Power supply, CPU, I/Os,
Practical demonstration on hardware
Communication bus
Various ranges available in Siemens S7 200 /
300 /400
Types of Inputs & outputs / Source Sink
Concepts Practical on PLC’s
Wiring of the I/O devices
Concept of flags
Practical on PLC’s
Scan cycle execution

Programming / Project Development

Topic Mode
SIMATIC S7 PLC Functionalities
Practical on PLC’s
Setting up Siemens PLC hardware
Programming software
PLC program structure in Siemens
Practical – PLC programming software
The instruction set of STEP 7
Parameters, functions and tools
CPU configuration, setting parameters and
application of several I/O cards using the STEP 7 Practical – PLC programming software
software
Working online / offline
Starting S7 400 system
Cold, Warm, and Hot Restarts
Practical – PLC programming software
Starting Up a PROFIBUS-DP Subnet
Connecting remote I/Os using Profibus
communication
Addressing Concepts in Siemens PLC’s
Detail information about Organizational Blocks,
Practical – PLC programming software
Function Block, Functions, System Function
Block, System Function, Data block
Creating and Editing PLC programs
Practical – PLC programming software
Introduction to Bit Byte and Word Concept
Programming instructions arithmetic and logical
Load /and /or/out / and Read / Write
Compare / Add / Sub /And /Or – Blocks Practical – PLC programming software
Leading edge / trailing edge instructions
MOVE block application
Programming instructions arithmetic and logical
Timer Blocks programming
Counter Block programming
Comment functions Practical – PLC programming software
Comments in the PLC programs
Handling Analog I/Ps
Conversion shift and jump instructions
 Advanced Programmers
Analyse /evaluate of status words
Jump instructions Practical – PLC programming software
Accumulator functions
Extended mathematical functions
Indirect Addressing
Complex Data-Types
Extended S7 Basic communication
PID / Control functions

Siemens Networking
Industrial Data Networks
Industrial Ethernet – General Practical – on PLC’s
Siemens Profibus
Communication via a Multi Point Interface
(MPI)
Programming / Project Development
Troubleshooting and Maintenance procedure
Replacing Digital or Analog Modules
Replacing CPUs
Replacing the Backup Battery Practical – on PLC’s
Replacing a Power Supply Module
Back up and Restoring programs
Fault diagnostics and error handling
Programmable Logic Controllers (PLC)- Advance
Schneider Quantum PLC’s
Duration of the course - 4 days
Topics Covered

Topic Mode
Introduction to PLC hardware and role in
automation
Presentation and physical observations
Architectural Evolution of PLC
Introduction to the field devices attached to PLC
PLC Fundamentals - (Block diagram of PLC's)
Detail information about PLC components
Practical demonstration on hardware
o Power supply, CPU, I/Os,
Communication bus
Types of Inputs & outputs / Source Sink
Concepts Practical on PLC’s
Wiring of the I/O devices to the PLC’s
Concept of flags
Practical on PLC’s
Scan cycle execution

Schenider PLCs

Topic Mode
Introduction to various ranges available in
Presentation
Schneider PLCs
Setting up Schneider hardware system Practical on PLC’s
Configure and layout a Modicon system,
including input/output modules and local and
Practical – PLC programming software
remote input/output systems
Addressing concepts in Modicon
Introduction to PL 7 PLC programming software
Configuration, Program, Variables Practical – PLC programming software
Hardware and Software Configuration
Ladder Programming language and methodology
Creating a new ladder logic program
Practical – PLC programming software
Handing Digital instructions (NO , NC, Rising
Edge, Falling Edge, Coils, Set, Reset)
Working with Timer and Counters
Register, Drum Practical – PLC programming software
Horizontal, Vertical and Operate Block
Scaling and PID instructions
Creating subroutine Practical – PLC programming software
Jump instruction
Introduction to Grafset
Practical – PLC programming software
Creating an application using Grafset
Task and event management
Practical – PLC programming software
Defined function blocks
Safety considerations related to your PLC
Practical – PLC programming software
system
Networking
Industrial Data Networks supported by
Schneider
Practical on PLC’s
Industrial Ethernet – General
Modicon Modbus and Modbus + networking
protocols
Troubleshooting

Topic Mode
PLC trouble shooting techniques
Distinguish between hardware problems,
software problems, and field problems
Practical on PLC’s
Application debugging
Replacing the faulty modules
Fault diagnostics and error handling
Distributed Control Systems (DCS)- Advance
Emerson – Delta V / Yokogawa CS 3000 / ABB Freelance AC800F
Duration of the course: 4 days

Topics Covered

DCS General
Topic Mode
Introduction to various control systems used
Presentation
Applications of DCS system
Architectural evolution for DCS
Hardware architecture of DCS
Processor
Power supply
Presentation
I/O modules
Communication bus
Operator and Engineering station
Redundancy
Comparison between the hardware PLC & DCS Presentation

Practical exposure on DCS System

Practical exposure on DCS system
Overview of the system components and
topologies
Detailed information on
Controllers Practical on DCS
I/O cards
Carriers
System power suppliers
Control networks
Designing DCS based automation solution for
Practical on DCS
the application
Setting up DCS system with PS, Controllers, I/Os
with communication bus system Practical on DCS
Connecting field devises to DCS
Configuring engineering and operator stations Practical on DCS
Application development in DCS system
Graphical User Interface Development
Practical on DCS
Control Modules
Workspace
Alarm and Process History
Sequential Function Charts Practical on DCS
Display Scripting
Users and Securities
Custom Faceplates Practical on DCS
Custom Dynamos
Scripting and programming languages Practical on DCS
Configuring nodes on networks Practical on DCS
Networking technologies in DCS systems Practical on DCS
Redundancy systems available in DCS
CPU redundancy
Power supply redundancy Practical on DCS
Communication redundancy
I/O redundancy
Troubleshooting

Topic Mode
DCS trouble shooting techniques
Distinguish between hardware problems,
software problems, and field problems
Reading the Error status bits
Practical on DCS
Replacing the faulty modules
CPU, I/O Modules / Power supply
Fault diagnostics and error handling
Backup & Restore Procedures and Techniques
Distributed Control Systems (DCS)- Advance
Siemens – PCS 7
Duration of the course: 4 days
Topics Covered

DCS General

Topic Mode
Introduction to various control systems used
Presentation
Applications of DCS system
Architectural evolution for DCS
Hardware architecture of DCS
Processor
Power supply
Presentation
I/O modules
Communication bus
Operator and Engineering station
Redundancy
Comparison between the hardware PLC & DCS Presentation and physical observations

Practical exposure on Siemens PCS 7 System

Practical exposure on Siemens PCS 7 system

Overview of the system components and
topologies
Detailed information on
Controllers Practical on DCS
I/O cards
Carriers
System power suppliers
Control networks
Designing PCS 7 DCS based automation
Practical on DCS
solution for the application
Setting up PCS 7 system DCS system with PS,
Controllers, I/Os with communication bus system Practical on DCS
Connecting field devises to PCS 7 System
Configuring engineering and operator stations Practical on DCS
Operator Station – OS (WinCC HMI)
WinCC Global scripts. Diagnostics,
triggering and examples. Practical on DCS
Alarming
Trending
Application development in DCS system
Graphical User Interface Development
Practical on DCS
Control Modules
Workspace
Alarm and Process History
Sequential Function Charts Practical on DCS
Display Scripting
Users and Securities
Custom Faceplates Practical on DCS
Custom Dynamos
Scripting and programming languages
Continuous Control – CFC
Practical on DCS
Structured Control Language – SCL
Sequential Control – SFC
Configuring nodes on networks Practical on DCS
Networking technologies in PCS 7 systems
Introduction to - Industrial Ethernet Practical on DCS
Introduction to Profibus technology
Redundancy systems available in DCS
CPU redundancy
Power supply redundancy
Communication redundancy Practical on DCS
I/O redundancy
Management of Redundancy
External or Remote SP control
Troubleshooting

Topic Mode
DCS trouble shooting techniques
Distinguish between hardware problems,
software problems, and field problems
Reading the Error status bits
Practical on DCS
Replacing the faulty modules
CPU, I/O Modules / Power supply
Fault diagnostics and error handling
Backup & Restore Procedures and Techniques
Supervisory Control and Data Acquisition Software (SCADA) - Advance
WonderWare InTouch / Siemens Win CC / Allen Bradley RS View /
GE Fanuc Cimplicity / Citect
Duration of the course: 3 days
Objectives
Participants will learn selection, programming, installation, commissioning and troubleshooting of SCADA software

SCADA General

Topic Mode
Applications of SCADA software
Different packages available with I/O
Practical
structure
Features of SCADA software

Practical exposure on SCADA software

Topic Mode
Creating a new SCADA application
Practical – Software
Creating Database of Tags
Creating & Editing graphic display with
animation
Data Entry / Start Stop command
Practical – Software
Analog entry
Sizing, Movement, Blinking, Visibility,
Filling
Trending
Creating & Accessing Real-time and Practical – Software
Historical Trends
Creating Alarms & Events Practical – Software
Writing logic through script Practical – Software
Connectivity with the different hardware
Communication protocols
Communication with PLC Practical – Software
Communication with Data Acquisition
System
Connectivity between software Practical – Software
Concept of DDE, DLL, OPC drivers Practical – Software
Commissioning the network nodes Practical – Software
Troubleshooting the application
Fault diagnostics and error handling Practical – Software
Sorting communication problems
Drives - Advance
Allen Bradley / Schneider / Yaskawa / Siemens / ABB / Delta
Duration of the course: 2 days
Objective
Participants will be able to select, program, install and maintain drives to suit their application.

Topic Mode
Introduction to AC Drives Practical – Drives setup
Selection criteria of the drives for particular
application
Speed /Torque Characteristic Presentation
Frequency converter techniques.
Control techniques of AC drives
Configuration of different motor parameter
for drives
Speed and torque control
Types of braking
Ramp selection
Jog/inch selection
Practical – Drives setup
Flux optimization
No. Of poles
Load equalization
Selection of slip & skip frequencies
Preset speed selection
RPM etc.
Remote and Local operation of Variable
Practical – Drives setup
Speed Drives
Communication with PLCs Practical – Drives setup
Study of different operational methods
PWM method
Flux vector control
Practical – Drives setup
Vector voltage control
Direct torque control etc. on which Variable
Speed Drives work
Troubleshooting Practical – Drives setup
Case study and different applications of
Practical – Drives setup
Drives in the industry
Industrial Communication & Networks Training

Duration of the course: 7 days

Remarks
If a complete group of participants is interested in a specific Communication & Networks application, the course
contents can be adapted accordingly with agreement of the customer. If customers are normally working with specific
Communication & Networks products this will be taken into account while practicing through exercises.

Topics Covered

Industrial Data Networks: 1 Day

Industrial Ethernet – General: 1 Day
Siemens Profibus: 1 Day
Siemens Industrial Ethernet: 1 Day
Rockwell DeviceNet/ControlNet/Ethernet IP: 2 Days
Modicon Modbus: 1 Day
 Detailed Course Contents
Industrial Data Networks

Introduction to Industrial networking

Basic network knowledge, supported by demonstrations and practical assignments;
Data communication and networking used in plants
Serial connections: RS232/RS422/RS485
Sensor and Control-level Networks
Introduction to network equipment, Routing, Switching
Introduction to commonly used networking protocols
Industrial Ethernet – General

Overview of common industrial communication networks.

OSI model
Available networks (Master/Slave, Client/Server and producer/Consumer)
Communication relations (Point to Point, Multicast and Broadcast)
Transmission media (Cables, Wireless)
Network Standards

Common network topologies and media

The history of Ethernet
Standards (IEEE 802.3 and 802.11)
Transmission media and 10BASE-5, 10BASE-2, 1BASE-T, 10BASE-T, 10BASE-F, Fast Ethernet,
Gigabit Ethernet and 10-Gigabit Ethernet
Ethernet and the OSI model
Cables, connectors and Ethernet devices: Repeaters, Hubs, Bridges, Routers, Switches, Gateways,
etc.
Industrial Ethernet and OPC servers
Industrial Ethernet as a fieldbus and its requirements
IP, TCP and UDP ground rules
Industrial Ethernet protocols; Modbus/TCP, ProfiNet, Ethernet/IP, Foundation Fieldbus HSE, IDA
Organizations (IAONA, ODVA and IDA)
Siemens Profibus

Profibus as open fieldbus system – relationship to the ISO/OSI model

Transmission medium: RS485, fibre-glass and/or IEC 1158-2 technology
Physical characteristics and installation details
Profibus services: FDL, DP, FMS and PA
Data link functions: SDA, SRD, SDN and CSRD
Token passing principle: TTH, TTR, TRR parameters…
Addressing: Profibus address (FDL) and Service Access Point (SAP)
Active versus passive Profibus partners
FMS service details:
Client server model
Virtual Field Device (VFD)
Object dictionary (OD)
Communication Relations List (CRL)
Standard and user defined data types

DP service details:
Master slave model
Remote I/O system: distributed peripheral
Multi-DP sub-network on one cable
Siemens Industrial Ethernet

Contents
Overview of common industrial communication networks.
Common network topologies and -media.
Access methods to the network media: token passing, collision detection etc.
Master-Slave, Client-Server and Peer-to-Peer concepts.
The 7 layer OSI model from the ISO.
Historical aspects of the Siemens Industrial Ethernet.
The OSI-stack-profile of the Siemens Industrial Ethernet.
Transport layer ISO-8073 protocol.
Comparison of ISO-8073 and TCP/IP.
The Sinec-AP protocol.
Application of “handling blocks” in the S7program.
Practical demonstration on connecting remote I/Os on ethernet
Rockwell DeviceNet / ControlNet /Ethernet IP
Specific contents
General overview of the various Rockwell networks
Part 1: ControlNet
Familiarizing with ControlNet protocols
Installing ControlNet networks (hardware)
ControlNet network configuration with RSNetworx for ControlNet
Planned and unplanned data-exchange with ControlNet
Downloading and uploading projects
Network diagnostics / trouble shooting
Practical demonstration of connecting devices on control net networks

Part 2: DeviceNet
Familiarizing with DeviceNet protocols
Installing DeviceNet networks (hardware)
DeviceNet network configuration with RSNetworx for DeviceNet
Downloading and uploading projects
Explicit-messaging
Network diagnostics / trouble shooting
Practical demonstration of connecting devices on Device net networks

Part 3: Ethernet IP
Familiarising with Ethernet TCP/IP and EtherNet IP
Installing EtherNet IP networks (hardware)
Data-exchange over EtherNet IP
Data-exchange over measurement and control devices
Network diagnostics / trouble shooting
Practical demonstration of connecting devices on Ethernet IP networks
Modbus
Contain

INTRODUCTION
Overview of Modbus and development
How Modbus fits into the RS-232/ RS-485/Ethernet and TCP/IP Standards
List of typical problems
OVERALL METHODOLOGY
Common symptoms, problems and solutions
How to quickly identify likely causes
Overall basic steps
Communications issues
Grounding/shielding/noise
BASIC STANDARDS
RS-232
• Fundamentals
• Problems: cabling, male/female, DTE/DCE, 9-pin, handshaking, voltages, noise, isolation
• RS-232 Practical Troubleshooting Session
RS-485
• Fundamentals
• Problems: cabling, common mode voltage, converters, isolation, idle state, terminations,
control - Hardware/software
• RS-485 Practical Troubleshooting Session
MODBUS OVER ETHERNET
Modbus over TCP/IP
Modbus-IDA Packet structure
Typical troubleshooting issues
Practical session with Modbus over TCP/IP
INDUSTRIAL AUTOMATION STANDARDS:
Modbus over Serial Communications (such as RS-232/RS-485)
• Fundamentals
• Problems: no response, exception reports, noise, radio interfaces, physical and application
layers
• Modbus troubleshooting session
Modbus Plus
• Fundamentals
• Problems: cabling, grounding, shielding, terminators, token passing