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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Understanding automation architecture in production plants
- Sensors, actuators, and field signal management
- Subsystems for transport, feeding, dosing, and packaging
SIMATIC S7-1500 Hardware and System Architecture
- Overview of CPU families, signal modules, and distributed I/O
- Power supply requirements, grounding, and control panel layout
- Interpreting status LEDs, CPU displays, and module indicators
TIA Portal Project Setup and Device Configuration
- Navigation of project views, devices, and networks
- Hardware configuration and adjustment of device parameters
- Managing project versions: loading, saving, and comparing
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog signal addressing schemes
- 24 V DC signal circuits and wiring verification
- Correlating field signals with program logic
Ladder Logic and Fundamental Programming
- Working with contacts, coils, and set/reset operations
- Utilizing timers, counters, and comparison instructions
- Understanding functions, function blocks, and data blocks
Analyzing Existing Programs and Control Logic
- Navigating program blocks and using cross-references
- Managing symbol tables, tags, and variable naming conventions
- Tracing logical conditions that govern specific outputs
Motor Control: Start, Stop, and Operation
- Defining start, stop, and latching conditions
- Implementing motor protection and run feedback signals
- Managing direction control and multi-motor setups
Interlocks, Permissives, and Automatic Sequences
- Designing interlock and permissive conditions
- Creating step sequences and state-based control logic
- Diagnosing sequences that are blocked at specific steps
SIMATIC HMI Configuration and Usage
- Managing panel screens, tags, and navigation structures
- Setting operating modes and controlling processes via HMI
- Displaying real-time equipment status and process values
HMI Alarms and PLC Diagnostic Messages
- Understanding alarm classes, priorities, and acknowledgement
- Reviewing system diagnostics and controller alarms
- Interpreting process and program-based monitoring messages
Variable Frequency Drives: Core Concepts and Uses
- Drive operating principles and control methodologies
- Interaction between drives, motors, and mechanical loads
- Typical drive configurations in production settings
- Yaskawa drives and other prevalent drive brands in the plant
VFD Setup and Commissioning
- Exploring parameter groups and access levels
- Configuring motor data, performing auto-tuning, and test runs
- Backing up, restoring, and documenting parameters
VFD Fault Diagnosis and Resolution
- Interpreting fault, alarm, and parameter error codes
- Analyzing fault history and monitoring values
- Diagnosing issues related to drives, motors, cables, and mechanics
Controlling Drives from the PLC
- Managing start, stop, and speed reference signals
- Monitoring status, ready, and fault feedback
- Resolving discrepancies between PLC and drive states
Industrial Communication and Network Troubleshooting
- Fundamentals of PROFINET and Ethernet
- Configuring device names, IP addresses, and network topology
- Diagnosing connections and communication faults
TIA Portal Diagnostics and Systematic Troubleshooting
- Using real-time online monitoring and watch tables
- Accessing the diagnostics buffer and CPU web server
- Comparing online and offline program versions
- Transitioning from fault symptoms to root cause analysis
- Performing electrical, mechanical, and control-side checks
- Documenting findings and establishing escalation criteria
Step-by-Step Diagnosis of Stopped Machines
- Establishing the correct order of checks during equipment stoppages
- Cross-referencing HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring normal operation
Practical Fault Scenario Exercises
- Exercises focusing on sensor, actuator, and I/O signal checks
- Scenarios involving motor, drive, and start/stop faults
- Addressing communication interruptions and interpreting alarms
- Resolving interlock and sequence faults that block machine steps
Implementing Basic Program Modifications
- Adjusting timers, setpoints, and system parameters
- Adding or modifying tags and simple logic structures
- Testing, documenting, and reverting program changes
Capstone Project: Comprehensive Troubleshooting Case
- End-to-end fault diagnosis on a simulated production line
- Making informed decisions on repair, adjustment, or escalation
- Receiving individual feedback and creating an improvement plan
Requirements
- A fundamental grasp of electrical circuits and industrial equipment operations.
- Introductory exposure to PLC concepts (university-level knowledge is sufficient).
- Basic familiarity with interpreting technical manuals for drives and equipment.
Target Audience
- Maintenance technicians and engineers working with automated production systems.
- Electricians and technical staff transitioning into automation and control roles.
- Professionals responsible for diagnosing PLC, HMI, drive, and communication-related faults.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
