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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within a production facility
- Function of sensors, actuators, and field signals
- Subsystems involved in transport, feeding, dosing, and packaging
SIMATIC S7-1500 Hardware and System Architecture
- CPU families, signal modules, and distributed I/O systems
- Power supply requirements, grounding, and control panel layout
- Interpreting status LEDs, CPU displays, and module indicators
TIA Portal Project Structure and Device Configuration
- Navigation of project views, devices, and networks
- Hardware configuration and device parameter settings
- Managing the loading, saving, and comparison of project versions
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing schemes
- 24 V DC signal circuits and wiring verification
- Validating field signals against program logic
Ladder Logic and Basic Programming
- Contacts, coils, and set/reset operations
- Implementation of timers, counters, and comparison instructions
- Use of functions, function blocks, and data blocks
Interpreting Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references
- Managing symbol tables, tags, and variable naming conventions
- Tracing logical conditions that govern specific outputs
Motors and Motor Start/Stop Control
- Start, stop, and latching conditions
- Motor protection mechanisms and run feedback signals
- Direction control and configurations for multiple motors
Interlocks, Permissives, and Automatic Sequences
- Defining interlock and permissive conditions
- Step sequences and state-based control logic
- Diagnosing sequences that are blocked at a specific step
SIMATIC HMI Configuration and Operation
- Panel screens, tag management, and navigation flows
- Operating modes and direct control via HMI
- Displaying equipment status and real-time process values
HMI Alarms and PLC Diagnostics Messages
- Alarm classes, priorities, and acknowledgement procedures
- System diagnostics and controller-level alarms
- Monitoring messages based on process and program logic
Variable Frequency Drives: Fundamentals and Applications
- Core drive principles and control methodologies
- Interaction between drives, motors, and mechanical loads
- Standard drive configurations in production equipment
- Overview of Yaskawa drives and other common brands in the plant
VFD Configuration and Commissioning
- Parameter groups and access level management
- Motor data entry, auto-tuning, and test runs
- Backup, restoration, and parameter documentation
VFD Fault Diagnosis and Troubleshooting
- Interpretation of fault, alarm, and parameter error codes
- Reviewing fault history and monitoring values
- Diagnosing issues related to drives, motors, cabling, and mechanics
Drive Control from the PLC
- Management of start, stop, and speed reference signals
- Status, ready, and fault feedback mechanisms
- Diagnosing discrepancies between PLC state and drive status
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals
- Device naming, IP addressing, and network topology
- Connection diagnostics and resolving communication faults
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch tables
- Utilizing the diagnostics buffer and CPU web server
- Comparing online and offline program states
- Systematic approach from fault symptom to root cause
- Electrical, mechanical, and control-side verification steps
- Documentation of findings and escalation criteria
Step-by-Step Diagnosis of a Stopped Machine
- Recommended order of checks upon equipment stoppage
- Correlating HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring operation
Practical Fault Scenario Exercises
- Exercises for checking sensors, actuators, and I/O signals
- Scenarios involving motor, drive, and start/stop faults
- Situations with communication interruptions and alarm interpretation
- Interlock and sequence faults that block machine steps
Making Basic Program Modifications
- Adjusting timers, setpoints, and parameters
- Adding or modifying tags and simple logic
- Testing, documenting, and reverting changes as needed
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a production line model
- Decision-making between repair, adjustment, and escalation
- Individual feedback and formulation of an improvement plan
Requirements
- A foundational understanding of electrical circuits and industrial equipment operations
- Introductory familiarity with PLC concepts (university-level exposure is sufficient)
- Basic competence in reading technical manuals for drives and equipment
Target Audience
- Maintenance technicians and engineers managing automated production systems
- Electricians and technical professionals transitioning into automation and control roles
- Staff responsible for diagnosing faults related to PLCs, HMIs, drives, and communications
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
