PLC Laboratory

When conducting training in the field of programming, diagnostics and communication of Siemens SIMATIC S7 – 300/400/1200/1500 logic controllers in the STEP 7 and TIA Portal environment as well as training in Safety Integrated safe controllers, we use modern logic controllers, PROFIBUS, AS-Interface, PROFINET network modules and components, diagnostic analyzers, operator panels, and the latest software used in industrial automation - these are the basic elements of the equipment of this laboratory.

The laboratory is also equipped with HMI operator panels and SCADA software enabling training on modern visualization systems. Another strong point among our training stations are electric drives, which allow us to conduct training on modern methods of controlling electric motors and introduce the concepts of economics and energy efficiency to the control field.

See what our PLC training looks like:

Each training participant has access to a personalized training station designed for learning industrial tasks and solutions based on the Siemens S7-300/400, S7-1200, and S7-200 controllers. The training station consists of a controller equipped with digital and analog input/output modules, connected to a digital and analog input and output signal simulator. Additionally, each controller is connected to an executive station containing a valve terminal, a manipulator, a set of actuator end-position sensors, and pulse buttons.

The training station includes:

• air preparation system,
• valve island with 4 electropneumatic valves 3/2, 5/2,
• an executive system based on two actuators and a gripper,
• reed sensors informing about the status of the actuators' extreme positions,
• digital input/output system,
• ON/OFF pulse switch,
• light signal,
• safety switch,
• binary signal simulator,
• analog input and output signal simulators (0-10V) with electronic voltage indicators,
• Siemens S7 PLC control unit,
• computer with STEP 7, TIA Portal V13, MicroWin software

The stations are equipped with various sensor sets (optical, inductive, capacitive, pressure, and flow) as well as frequency converters and electric motors. They enable exercises based on real-world components used in industrial automation.

Each participant has access to a personalized training station designed for learning industrial tasks and solutions based on PLCs. The training station consists of a controller equipped with digital input/output modules and input and output signal simulators, and a computer with STEP 7 software connected to the PLC.

Each participant of the training courses also has at their disposal an innovative training station containing:

• air preparation system,
• valve island with 2 electropneumatic valves 5/2,
• two double-acting pneumatic cylinders,
• reed sensors informing about the status of the actuators' extreme positions,
• electronic proportional controller,
• stepper motor,
• angle encoder,
• PT100 temperature sensor with 0-10V transducer,
• inverter,
• servo motor with permanent magnets,
• binary signal simulator,
• analog input and output signal simulators (0-10V) with electronic voltage indicators,
• Siemens S7 PLC control unit,
• computer with STEP 7 and TIA Portal software.

The stations are equipped with various sensor sets (optical, inductive, capacitive, pressure, and flow) as well as frequency converters and electric motors. They enable exercises based on real-world components used in industrial automation.

Participants in the Programming and Designing with Distributed Safety course in Simatic Safety Integrated controllers have at their disposal: individual training stations equipped with various production equipment:

• traditional PLC solutions – CPU 315F 2PN/DP and input/output modules from the family S7-300 in the edition FAIL-SAFE
• CPU 315F 2PN/DP connected via the Profinet communication network with input/output modules from the family ET-200S in the edition FAIL-SAFE
• comprehensive solutions based on the ET-200S CPU family in the F edition

Additional elements of each set also include real performance equipment:

• optical barriers with a moving product (forcing the barrier to turn off while the product is passing – so-called muting)
• "mini door" equipped with safety limit switches
• two-handed button sets
• security "mushrooms" with double contacts
• ignition with key
• double – “safe” contactors executive

Training, except for the driver PLC-F and real executive elements, also uses OP operator panels for the presentation of alarms related to the security system and a mechanism for confirming security system errors via the panel in question.

An important executive element is also frequency converter (Sinamics G120) controlling an asynchronous motor equipped with built-in safety functions triggered both via its digital inputs and via the communication network.

Our laboratories have modern equipment based on industrial-grade devices supplied by renowned manufacturers.

The following devices are available during the TIA1500-1 training:

Siemens SIMATIC S7-1500 controller, with a controller containing:

• 8 buttons for input signals
• potentiometer adjusting the analog input voltage range
• displays of input and analog output voltage values

Basic executive position:

• air preparation system
• valve island with 4 electropneumatic valves 3/2, 5/2, 5/3
• an executive system based on two actuators and a gripper
• reed sensors informing about the status of the actuators' extreme positions
• digital input/output system
• ON/OFF pulse switch
• light signal
• safety switch

Advanced Executive Station:

• air preparation system
• valve island with 2 electropneumatic valves 5/2
• two double-acting pneumatic cylinders
• reed sensors informing about the status of the actuators' extreme positions
• electronic proportional controller
• stepper motor
• angle encoder
• PT100 temperature sensor with 0-10V transducer
• frequency converter
• electric motor with permanent magnets

Each training participant has access to a training station designed for learning sequential programming based on the S7-300/400 controller. The training station consists of a controller equipped with digital and analog input/output modules, connected to a digital, analog input, and output signal simulator.

Additionally, each controller is connected to a basic or advanced execution station that contains real elements found in the industry.

Training station for each course participant:

SIEMENS S7-300 controller

• 128 KB working memory
• 24 digital inputs
• 16 digital outputs
• 4 analog inputs
• 2 analog outputs

Additionally, the controller is equipped with a controller containing:

• 8 buttons for input signals
• potentiometer adjusting the analog input voltage range
• analog input voltage value display
• analog output voltage value display

Each participant has access to a dedicated training station designed for diagnostics, analysis, and servicing of S7-300/400 controllers. The training is conducted on a station consisting of a SIEMENS SIMATIC S7-300 CPU313C controller with an attached analog input module with diagnostic functionality. The station is configured to enable participants to generate PLC diagnostic situations: cutting power to the field portion of digital and analog modules, and generating hardware interrupts supported by binary and analog signals. The training station also includes an execution station, whose main advantage is its stepper motor and encoder.

The training program focuses on controller diagnostics. The following exercises are taught:

• use of tools for analyzing the running program
• diagnosis of CPU error causes
• diagnosis of the causes of CPU stoppage and programmatic handling of this event
• diagnosis of signal module errors and the use of hardware interrupts

Participants in industrial network training, in particular PROFIBUS and PROFINET, have at their disposal multi-element sets that create an extensive network allowing them to perform tasks and exercises on a wide range of topics.

The main element of the station is a controller equipped with an appropriate communication port.

PROFIBUS and PROFINET in STEP V5.x

• SIEMENS SIMATIC S7-300 CPU314C-2PN/DP
• PROFIBUS CP 342-5 communication processor
• PROFINET CP 343-1 Advanced communication processor
• IE/PB LIBK PN IO

PROFINET in TIA

• SIEMENS SIMATIC S7-1500 CPU1511TF and
• SIEMENS SIMATIC S7-1200 + HMI panel

Other SIEMENS elements include:

• IM151 modules for PROFIBUS and PROFINET with digital inputs and outputs (ET200S)
• SCALANCE X204IRT industrial switches
• SINAMICS G120 drives equipped with CU240E-2 DP and CU240E-2 PN modules
• SIEMENS OP177B operator panels
• RS485 diagnostic repeater

Modules from other manufacturers for PROFIBUS and PROFINET networks:

• INDU-SOL repeaters (2-channel and 5-channel)
• Distributed I/O TURCK BL67 and BL20
• Distributed I/O and I/O Link Balluff type BNI 302, BNI 502, BNI 507
• Valve island PNEUMAX OPTYMA S
• Lumberg Automation LioN-S series modules type 940 and 970
• Lumberg Automation LioN-Link series modules type 940 and 980
• Encoders with PROFIBUS protocol

Other elements of the stand:

• analog position and rotation sensors
• a set of different types of Balluff sensors
• Parker, TURCK, PNEUMAX Optyma valve islands
• pneumatic actuator sets with Parker and PNEUMAX position sensors
• binary signal generator
• analog input signal simulator (0-10V) with electronic voltage indicator
• NO, NC and E-Stop buttons

The uniqueness of EMT-Systems network training lies in the number of diagnostic tools available to students. To quickly and efficiently diagnose faults and restore networks to proper functioning, training must be conducted using the most popular and best equipment available on the market.

Handheld Network Analyzer:

• Profitrace (Procentec)
• PB-Q One (Indu-Sol)
• PROFIBUS Tester 4 (Softing)

Stationary network analyzer:

• PROFIBUS NT Inspector (Indium-sol)
• FG-110 FF (Softing)

Other tools:

• PROFtest II XL cable tester (Indu-Sol)
• Clamps for measuring current flow in the EMCheck LSMZ screen (Indu-Sol)
• EMCheck MWMZ II shielding effectiveness measurement tool (Indu-Sol)

Training is conducted in a modern industrial sensor laboratory, where participants have the opportunity to familiarize themselves with and commission industrial sensors and monitors from various manufacturers. Our wide range of automation equipment allows for individual work on theoretical problems, so each participant can independently connect and commission:

• inductive sensors,
• capacitive,
• magnetic,
• optical,
• flow monitors,
• temperature,
• the presence of liquid and gaseous media,
• color sensors

and many others found in our workshop. Thanks to this approach, participants reach many conclusions independently and, together with the trainer, translate their acquired knowledge into practical skills.

To course participants We offer training stations designed for learning industrial tasks and solutions based on electric drives using frequency converters. Each station consists of a frequency converter equipped with a digital and analog signal simulator. Each converter is connected to an asynchronous electric motor.

There are two types of stations available, based on different repeaters:

Parker AC 890 SD

• power 0,55 kW
• 7 digital inputs
• 3 digital outputs
• 4 analog inputs
• 2 analog outputs
• communication interfaces: PROFIBUS, PROFINET

SEW Movitrac B 07

• power 0,25 kW
• 6 digital inputs
• 3 digital outputs
• 1 analog input
• communication interfaces: PROFIBUS

Parameters of Siemens electric motors:

• power supply: 50 Hz, 230/400 V
• power: 0,18 kW
• revolutions 1350/min
• current: 0,97/0,56 A

Parameters of SEW electric motors:

• power supply: 50 Hz, 230/400 V
• power: 0,25 kW
• speed 1300/405 rpm (engine with gearbox)
• current: 1,27/0,73 A

During the training, two additional Parker inverters (the larger of which is 11 kW) driving hydraulic power unit pumps can also be demonstrated. The installation can be loaded, allowing the operator to observe the drive system in real-world conditions.

The stations enable the implementation of exercises based on real elements used in industrial automation.

Siemens Sinamics G120/Siemens Micromaster M440

Siemens Sinamics S120/Siemens Simotion

Parker AC 890 SD and SEW Movitrac B 07

In addition to individual stations, the training also includes access to a hydraulics laboratory where frequency converters are used to drive hydraulic power unit pumps, allowing you to observe their operation and characteristics under real industrial loads.

The use of electric motors today has gone far beyond simply powering machines. Flexibility, control, and management are key, often without the aid of additional devices (such as a PLC). Optimizing energy consumption during nominal operation, as well as regenerating energy back into the grid when the equipment is decelerating, has also become crucial. Our training courses on drive technology cover all these aspects – from selecting drive system components, through commissioning and diagnostics, to optimization and economic considerations.