Systems Integrator Training Path

A first look at each layer of a machine: choosing an actuator, control power, torque and speed, how a plant network is stacked, what a guard is for and how a P&ID reads. Every unit is free.

• FreeChoosing the actuator (15 min)
• FreeControl power: 24 V DC or mains (10 min)
• FreeForce, torque and work in plain language (14 min)
• FreeThe plant-floor network stack (12 min)
• FreeWhy machines are guarded (12 min)
• FreeWhat a P&ID is, and what it is not (14 min)

The scan cycle, formal ladder patterns, state machines, a full motor starter, a three-step sequence and a sortation diverter that coordinates several outputs.

• FreeThe scan cycle (5 min)
• ProLadder Logic Basics (15 min)
• ProState Machines in Ladder Logic (30 min)
• FreeMotor Start/Stop & Fault Monitoring (30 min)
• ProSeq 01 — Fill, mix, drain (15 min)
• ProSortation Diverter (25 min)

Fieldbus against Ethernet, Modbus, EtherNet/IP, PROFINET and OPC UA, then the security side: zones and conduits, a zoning lab and an alarm flood to triage.

• FreeFieldbus versus industrial Ethernet (14 min)
• FreeModbus RTU and TCP refresher (12 min)
• ProEtherNet/IP and CIP (14 min)
• ProPROFINET: names, roles and GSDML (13 min)
• ProOPC UA: servers, nodes and subscriptions (16 min)
• ProOT cyber-security basics (18 min)
• ProLab: network zones and conduits (20 min)
• FreeLab: alarm flood triage (15 min)

Dual-channel E-stops, light curtains and safety relays, performance levels, guarding and interlocks, and the PLC safety scenarios for reset, two-hand control and a safety mat.

• FreeE-stop circuits (15 min)
• FreeLab: dual-channel E-stop into a safety relay (14 min)
• ProSafety relays and light curtains (16 min)
• ProPerformance levels and SIL, introduced (16 min)
• ProMachine guarding and interlocks (15 min)
• ProSafe PLC programming practices (14 min)
• ProE-Stop & Safety Reset (15 min)
• ProTwo-Hand Control (Safety) (10 min)

The four drawing types, labels and cross-references, tag-to-terminal loop diagrams and I/O lists, program documentation, and the FAT, SAT and as-built paperwork.

• ProFour drawings of the same circuit (12 min)
• ProLabels, terminals and cross-references (14 min)
• ProFrom P&ID tag to PLC address to terminal (18 min)
• ProDocumenting the PLC program: names, comments, structure (16 min)
• ProCommissioning documents: FAT, SAT, punch lists and as-built drawings (14 min)

A safe pre-power and commissioning sequence, troubleshooting from drawings, and graded fault labs on a welded safety output, an open drive safe-torque-off channel and an RS-485 line with no termination.

• ProPre-power and commissioning safety checks (15 min)
• FreeThe half-split troubleshooting method (15 min)
• ProTroubleshooting from drawings: where do you measure? (18 min)
• ProFault 12: Welded safety output contact (14 min)
• ProFault 17: VFD STO channel 1 open (14 min)
• ProFault 16: RS-485 terminator disconnected (12 min)

A robot-to-PLC handshake, a weld cell cycle, a pallet cell with several stations, and a cylinder sequence confirmed by its sensors. The robot programming path is a separate course and is not counted here.

• ProRobot PLC Handshake (20 min)
• ProWeld Cell Cycle (20 min)
• ProPalletizer (Simple) (20 min)
• ProPneu 02 — Cylinder sequence (15 min)

One carton sorter cell, five graded steps that join mechanics, motion, pneumatics, electrical, safety and the PLC: the drive, the pusher and supply, the safeguard, the cycle and the commissioning.

• FreeCapstone 1: size the conveyor drive (15 min)
• ProCapstone 2: size the pusher and the electrical supply (20 min)
• ProCapstone 3: safeguard the pusher station (18 min)
• ProCapstone 4: write and test the PLC cycle (25 min)
• ProCapstone 5: commission and document the cell (20 min)