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Advanced PLC: Programmable Logic Controller(Siemens S7 300 & 400)

Course Overview

The Advanced Siemens S7-300 PLC Training Program focuses on enhancing participants’ skills in programming and managing complex automation systems, with a strong emphasis on analog input/output systems. The course covers advanced programming techniques, PID control, data handling, and communication protocols. Through practical exercises and real-world scenarios, participants will master the integration of analog systems into industrial automation solutions using Siemens S7-300 PLCs and STEP 7 software.

Course Objectives

By the end of this course, participants will:

    1. Understand the role and fundamentals of analog systems in industrial automation.
    2. Understand advanced hardware configurations and analog I/O module setup for S7-300 PLCs
    3. Program and manage analog signals, including scaling and signal conversion.
    4. Design and implement PID control loops for process automation.
    5. Utilize data blocks for managing complex data structures.
    6. Implement communication protocols (e.g., PROFIBUS, MPI) for system integration.
    7. Consolidate learning through troubleshooting exercises and application development.
    8. Optimize PLC performance using advanced diagnostic and troubleshooting tools.
    9. Develop and test real-world automation projects involving analog systems.

      Target group: Operation, Installation and Maintenance of PLC control systems technician/Engineers.

      Prerequisites: Basic Knowledge in electrical/electronics

      Duration: Five (5) days

      Methodology: Lectures complemented by hands-on exercises using Siemens S7 PLC Hardware & Simulators/Software.

      Contents

      Module 1: Overview of Analog Systems in Automation

      • Introduction to Analog Systems and difference between analog and digital signals.
      • Common analog signals: Voltage (0-10V), Current (4-20mA), Temperature, Pressure, etc.
      • Real-world examples of analog systems in industrial automation.
      • Analog Modules in S7-300
      • Overview of Siemens S7-300 analog input (AI) and output (AO) modules.
      • Understanding module specifications (resolution, sampling rate, accuracy).
      • Wiring and configuration of analog modules.
      • Signal Conditioning and Importance of signal scaling, linearization, and filtering.
      • Role of transducers and transmitters in analog systems.
      • Practical Session: Connecting analog sensors (e.g., temperature, pressure) to the S7-300.
      • Verifying signal input/output using diagnostic tools.

      Module 2: Configuring Analog Modules and Scaling Data

      • Hardware Configuration in Step 7
      • Adding and configuring analog modules in hardware configuration.
      • Assigning input/output addresses to analog channels.
      • Analog Signal Scaling
      • Raw value interpretation (e.g., 0-27648 for 0-10V signals).
      • Scaling raw values to engineering units using math instructions.
      • Unscaled output generation for analog actuators.
      • Practical Session: Configuring analog modules in Step 7.
      • Writing and testing scaling programs to process analog signals.

      Module 3: Advanced Programming with Analog Systems

      Data Blocks for Analog Systems

      • Use of Data Blocks (DBs) for analog signal processing.
      • Managing real-time data with reusable function blocks.
      • Analog Alarms and Interlocks
      • Configuring threshold-based alarms for analog values.
      • Designing safety interlocks based on analog parameters.
      • Practical Session: Creating a reusable analog processing function block.
      • Writing alarm and interlock logic for analog applications.

      Module 4: PID Control and Analog System Optimization

      • Introduction to PID Control; Basics of Proportional, Integral, and Derivative control.
      • Applications of PID control in process automation (e.g., temperature control, level control).
      • PID Configuration in Step 7
      • Using Siemens PID control function blocks (FB41, FB42).
      • Tuning PID parameters for optimal performance.
      • System Optimization
      • Analyzing system performance using trend monitoring.
      • Advanced analog signal processing (e.g., filters, averaging).
      • Practical Session: Implementing a PID control loop for a tank level/temp.  control application.
      • Tuning PID parameters for stability and accuracy.

      Module 5: Troubleshooting and Real-World Applications

      • Diagnosing analog module faults using Step 7 diagnostic tools.
      • Online monitoring of analog signals.
      • Real-World Applications
      • Case study: Process control systems using analog signals.
      • Designing a complete analog control application (e.g., HVAC control, water treatment).
      • Final Project:
      • Participants design and implement an analog system using S7-300.
      • Debugging and performance testing