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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within production facilities
- Sensors, actuators, and field-level signaling
- Subsystems for transport, feeding, dosing, and packaging
SIMATIC S7-1500 Hardware and System Architecture
- CPU series, signal modules, and distributed I/O systems
- Power supply distribution, grounding, and control panel design
- Status LEDs, CPU displays, and module indicator lights
TIA Portal Project Organization and Device Setup
- Project navigation, device lists, and network views
- Hardware configuration and parameter adjustments
- Managing project versions: loading, saving, and comparison
PLC Inputs and Outputs: Signaling and Addressing
- Digital and analog addressing schemes
- 24 V DC signal circuits and wiring verification
- Validating field signals against program logic
Ladder Logic and Fundamental Programming
- Contacts, coils, set, and reset operations
- Timers, counters, and comparison instructions
- Functions, function blocks, and data blocks
Analyzing Existing Programs and Control Logic
- Navigating program blocks and using cross-references
- Symbol tables, tag definitions, and variable naming conventions
- Tracing logical conditions that trigger specific outputs
Motor Control: Start and Stop Mechanisms
- Start, stop, and latching conditions
- Motor protection features and run feedback signals
- Direction control and multi-motor setups
Interlocks, Permissives, and Automated Sequences
- Understanding interlock and permissive logic
- Step-by-step sequences and state-based control strategies
- Diagnosing sequences halted at specific steps
SIMATIC HMI Setup and Operational Use
- Panel screens, tag mapping, and navigation flows
- Operational modes and HMI-based controls
- Displaying equipment status and process data
HMI Alarms and PLC Diagnostic Messages
- Alarm classification, priority levels, and acknowledgment
- System diagnostics and controller-specific alarms
- Process and program-based monitoring alerts
Variable Frequency Drives: Core Concepts and Uses
- Drive operating principles and control techniques
- Interaction between drives, motors, and mechanical loads
- Common drive configurations in production environments
- Yaskawa drives and other prevalent drive brands
VFD Configuration and Commissioning Processes
- Parameter groups and access permissions
- Motor data entry, auto-tuning, and test runs
- Backing up, restoring, and documenting parameters
VFD Fault Diagnosis and Troubleshooting Strategies
- Interpreting fault, alarm, and parameter error codes
- Reviewing fault history and monitoring values
- Diagnosing issues related to drives, motors, cables, or mechanics
PLC-Driven Control of VFDs
- Start, stop, and speed reference signaling
- Status, ready, and fault feedback mechanisms
- Resolving discrepancies between PLC states and drive conditions
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals
- Device naming, IP addressing, and network topology
- Connection diagnostics and communication error resolution
TIA Portal Diagnostics and Systematic Troubleshooting
- Real-time online monitoring and watch table usage
- Diagnostics buffers and CPU web server access
- Comparing online versus offline program versions
- Tracing from fault symptoms to root causes
- Performing electrical, mechanical, and control-side inspections
- Documenting findings and defining escalation criteria
Methodical Diagnosis of Stalled Machinery
- Recommended order of checks when equipment halts
- Cross-referencing HMI alarms, PLC logic, and drive statuses
- Identifying blocking conditions and restoring normal operation
Practical Fault Scenario Exercises
- Exercises covering sensor, actuator, and I/O signal checks
- Scenarios involving motor, drive, and start/stop failures
- Handling communication interruptions and interpreting alarms
- Resolving interlock and sequence faults that block machine steps
Executing Basic Program Adjustments
- Modifying timers, setpoints, and system parameters
- Adding or refining tags and simple logic structures
- Testing, documenting, and reverting changes as needed
Capstone: Comprehensive Troubleshooting Case Study
- End-to-end fault diagnosis on a production line simulation
- Decision-making regarding repair, adjustment, or escalation
- Individual feedback sessions and development plans
Requirements
- Foundational knowledge of electrical circuits and industrial hardware
- Introductory familiarity with PLC concepts (university-level understanding is adequate)
- Basic ability to read technical manuals for drives or equipment
Target Audience
- Maintenance technicians and engineers responsible for automated production systems
- Electricians and technical staff transitioning into automation and control roles
- Professionals tasked with diagnosing PLC, HMI, drive, and communication issues
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
