Day 1 lays the groundwork for working with WAGO PLCs and the CODESYS. It’s designed to equip you with the essential knowledge you need to work confidently with industrial automation systems.

Key topics and skills covered include:

• Introduction to PLCs and WAGO Hardware
  • Understanding the role of PLCs in industry.
  • Overview of WAGO PLC hardware, including CPUs, power supplies, memory cards, and input/output cards.
  • Exploring wiring configurations (NPN and PNP) and how modular systems are constructed and expanded.
  • Tips for selecting the right PLC model and using WAGO part numbers effectively.
  • Using the WAGO software tools to setup your PLC and update firmwares

• Building Technical Foundations
  • Learning numbering systems (binary, decimal, hexadecimal) and how to convert between them.
  • Understanding the importance of memory areas, PLC scan cycles, and logic gates (AND, OR, etc.).
  • Gaining insights into industrial networks for process control.

• Safety Circuits and Standards
  • Working with E-Stops and Safety Circuits and integrating them into your programs.
  • Understanding the differences between standard PLCs and safety PLCs.
  • Exploring SIL (Safety Integrity Levels) and IEC Safety Standards for control systems.

• Getting Started with CODESYS
  • Integrating WAGO PLC hardware catalogues into CODESYS
  • Navigating the CODESYS interface and creating your first project.
  • Setting up hardware configurations and communication between devices.
  • Safely downloading programs to the PLC to avoid production disruptions.

• Practical Programming
  • Creating basic programming routines.
  • Organising your projects with labels and comments for better clarity.
  • Working with control latches and identifying alarm signals.
  • Learning about downloading to the PLC and online editing and understanding the associated risks.

Through a mix of foundational knowledge and hands-on practice, you’ll finish the first day with a firm grasp of WAGO PLCs and the confidence to start working in the CODESYS software package.

Building on the foundation of Day 1, Day 2 dives deeper into PLC programming concepts, preparing you to tackle more complex challenges with confidence. This session combines theoretical understanding with practical application to enhance your technical expertise.

Key topics and skills covered include:

• Understand Common PLC Instructions
  • Using timers and counters effectively for various industrial applications.
  • Incorporating Move instructions for precise data handling.
  • Using CODESYS bit logic instructions, including One Shot Pulse (Rising and Falling), for event-driven control.
  • Implementing Set and Reset instructions cautiously to prevent misfires in the system.

• Handling Program Backups and Uploads
  • Discovering how to handle program backups once we have them in our systems.
  • Understanding uploading from the PLC and the dangers of doing so when working on live systems.

• Best-practice Programming
  • Learning essential safety practices to avoid accidents when working with PLCs.

From understanding programming standards and logic, you’ll leave Day 2 equipped with the knowledge and skills of the most commonly used PLC instructions to help us know what we are looking at when troubleshooting programs.

Day 3 builds upon your programming foundation, focusing on the implementation of advanced techniques to elevate your skill set. Through practical exercises and detailed insights, you’ll learn how to enhance your control systems and tackle complex programming scenarios.

Key topics and skills covered include:

• Structuring Data and Logic
  • Understanding and working with structured data using CODESYS global and local tags.
  • Developing Function Blocks and Functions for structuring programs and consistent programming and troubleshooting
  • Understanding the different Organisational Blocks used in CODESYS programs and why we use them.
  • Explore the use of logic instructions for efficient control system implementation.

• Troubleshooting Techniques
  • Using Cross-references to help navigate and troubleshoot with large PLC programs.
  • 50:50 split-testing to assist in locating failures within an input or output device.
  • Understanding Assignment within CODESYS allow us to identify available and used addressing.
  • Utilising Call Structures to understand which programming blocks are being used and which ones aren’t.
  • Working with Diagnostics to locate faults within the hardware and software of the WAGO PLC.
  • Creating System and Clock Memory for use when removing signals or control routines in programs.

• Adopting Robust Testing Practices
  • Enhancing your approach to online editing while avoiding common pitfalls.
  • Verifying program changes to ensure seamless integration into live systems.
  • Completing IO testing used during commissioning.
  • Understanding the dangers associated with modifying and forcing IO signals.

By Day 3, you’ll have acquired the expertise to troubleshoot WAGO PLCs using the tools available to you inside the CODESYS software package.

On Day 4, you’ll progress to advanced-level skills, focusing on fault resolution, system maintenance, and safety concepts. This day is packed with hands-on practice and real-world scenarios to help you confidently address key industrial challenges.

Key topics and skills covered include:

• Fault Management and Hardware Replacement
  • Identifying different types of CPU faults and resolving them effectively.
  • Replacing PLC batteries correctly on the shop floor.
  • Safely replacing faulty input/output cards and CPUs, including on live PLC systems.
  • Understanding the dangers of erratic signalling and strategies to mitigate risks.

• Understanding Common Programming Routines
  • Using maths instructions and functions for advanced calculations and data handling.
  • Implementing cycle stop routines and sequencers to optimise program efficiency and reduce downtime.
  • Applying comparators to monitor and enforce process safety limits.
  • Understanding the importance of alarms and signal management for critical processes.

• Industrial Best Practices
  • Learning best practice programming methods for robust, future-proof systems.
  • Reading and using PLC electrical schematics and I/O schedules during commissioning.
  • Identifying and preventing faults in industrial programs to enhance reliability.
  • Adopting preventative maintenance techniques for long-term system performance.
  • Making program changes safely on live industrial systems without compromising control.

By the end of Day 4, you’ll have a solid understanding of how to handle hardware failures within the PLC, safety protocols, and best practices. You’ll leave the course equipped to resolve critical issues and confidently handle live industrial environments.

We offer weekly courses at our training centre in Alderley Park. Demand is high, so we advise booking your place at least two months in advance to secure your spot.

Our IMFFP® training focuses on one PLC software package to ensure you receive in-depth and comprehensive training. If you work with multiple PLCs or want to expand your skills across different platforms, we offer a 2-day Bolt-on course for those who have successfully completed IMFFP® 1&2.

Absolutely! Our courses are open to everyone, whether you’re sponsored by a company or joining as an individual. They’re especially popular with people looking to switch careers or enhance their CV with new skills.

When you join one of our training courses, you’ll have your own dedicated training station complete with a computer, PLC programming software, and a SCADA system.

You’ll also receive a Scantime workbook to track your progress throughout the course. This detailed resource is yours to keep, making it an excellent reference tool long after training is complete.

Yes, the course includes two assessments, one for each module, designed to ensure you’ve understood the material. You’ll receive your results on the same day after completing each assessment.

Pass Marks and Points Available:

• Module 1
  • Pass Mark: 180
  • Points Available: 300

• Module 2
• • • Pass Mark: 210
    • Points Available: 300

Absolutely. We’ll give you a City & Guilds certificate, and a digital credential when you successfully complete any of our IMFFP® course modules.