PLC Bootcamp

Master the fundamentals of industrial automation through intensive, hands-on training that bridges the gap between theory and real-world engineering. This accelerated course equips you with the practical programming, wiring, and troubleshooting skills needed to confidently build and maintain modern PLC systems.

Age: Recommended minimum age is 16 years.
Education: Basic secondary education or equivalent is recommended. Prior study in mathematics, physics, electrical technology or a related technical subject is beneficial.
Experience: No prior industrial experience is essential for entry; however, basic electrical or technical workshop exposure is advantageous.
Health & Safety: Learners should be able to follow workshop safety instructions and use personal protective equipment appropriate to supervised electrical practical activities.
Language & Numeracy: Sufficient English communication and basic numeracy skills are recommended for understanding technical instructions, calculations, drawings and assessment tasks.

Course Code	Curriculum Title	Credit	DLH
INNOQ5416169-1	Electrical Fundamentals, Safety and Test Instruments	15	150
INNOQ5416169-2	Industrial Wiring, Installation and Distribution Systems	15	150
INNOQ5416169-3	Three-Phase Motors, Starters and Motor Control	15	150
INNOQ5416169-4	Industrial Protection, Earthing and Power Quality	12	120
INNOQ5416169-5	PLC Fundamentals, Sensors and Industrial Control	12	120
INNOQ5416169-6	Preventive Maintenance, Fault Finding and Industrial Troubleshooting	12	120

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,LIMITMOVE 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
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

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 subroutin
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 graphical 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

Sematic Manager for S7-300 PLC
Module 10: DCS Siemens PCS7

Aspiring industrial electricians and electrical technicians seeking structured practical training.
Electrical helpers, maintenance assistants and workshop personnel who want to strengthen industrial electrical skills.
Technical and vocational learners preparing for roles in factories, plants, facilities and maintenance departments.
Existing electricians transitioning from domestic/commercial work toward industrial systems and motor control.
Maintenance personnel who need stronger knowledge of electrical safety, controls and troubleshooting.

Assessment should combine knowledge checks with practical evidence so that learners demonstrate both understanding and safe performance. Recommended evidence includes written or oral questions, workshop observations, wiring and motor-control tasks, instrument-use exercises, fault-finding scenarios, maintenance documentation and a final practical assessment.

A learner should be considered successful only when the required learning outcomes and practical assessment criteria have been met with authentic, sufficient and verifiable evidence. Safety-critical tasks must be completed in accordance with the training centre’s approved procedures and under appropriate supervision.

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