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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within a production facility
- Sensors, actuators, and field signal handling
- Subsystems for transport, feeding, dosing, and packaging
SIMATIC S7-1500 Hardware and System Architecture
- CPU families, signal modules, and distributed I/O
- Power supply, grounding, and control panel layout
- Status LEDs, CPU displays, and module indicators
TIA Portal Project Structure and Device Configuration
- Project views, devices, and network integration
- Hardware configuration and device parameterization
- Managing, saving, and comparing 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 Fundamental Programming
- Contacts, coils, and set/reset operations
- Timers, counters, and comparison instructions
- Functions, function blocks, and data blocks
Interpreting Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references
- Symbol tables, tags, and variable naming conventions
- Tracing logical conditions that govern output behavior
Motor Control: Start/Stop and Management
- Start, stop, and latching conditions
- Motor protection and run feedback signals
- Direction control and multi-motor configurations
Interlocks, Permissives, and Automated Sequences
- Interlock and permissive logic conditions
- Step sequences and state-based control strategies
- Diagnosing sequences blocked at specific steps
SIMATIC HMI Configuration and Operation
- Panel screens, tags, and navigation flows
- Operating modes and HMI-driven control
- Displaying equipment status and process variables
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgment procedures
- System diagnostics and controller alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Principles and Applications
- Drive operating principles and control methods
- Interaction between drives, motors, and mechanical loads
- Typical drive configurations in production environments
- Yaskawa drives and other prevalent drive brands
VFD Configuration and Commissioning
- Parameter groups and access level management
- Motor data setup, auto-tuning, and test runs
- Backup, restoration, and parameter documentation
VFD Fault Diagnosis and Troubleshooting
- Interpreting fault, alarm, and parameter error codes
- Analyzing fault history and monitoring values
- Diagnosing drive, motor, cable, and mechanical issues
PLC Control of Drives
- Start, stop, and speed reference signals
- Status, ready, and fault feedback loops
- Resolving discrepancies between PLC and drive states
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals
- Device names, IP addressing, and network topology
- Connection diagnostics and communication failure resolution
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 versions
- Progressing from fault symptoms to root cause analysis
- Electrical, mechanical, and control-side inspections
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of Halted Equipment
- Procedural order of checks during equipment stoppages
- Cross-referencing HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring operations
Practical Fault Scenario Exercises
- Exercises focusing on sensor, actuator, and I/O signal checks
- Motor, drive, and start/stop fault simulations
- Handling communication interruptions and interpreting alarms
- Resolving interlock and sequence faults that halt machine steps
Executing Basic Program Modifications
- Adjusting timers, setpoints, and parameters
- Adding or modifying tags and simple logic elements
- Testing, documenting, and reverting changes as needed
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a production line model
- Decision-making regarding repair, adjustment, or escalation
- Individual feedback and development plan
Requirements
- Foundational understanding of electrical circuits and industrial machinery
- Introductory knowledge of PLC concepts (university-level exposure is adequate)
- Basic proficiency in reading technical manuals for drives and equipment
Target Audience
- Maintenance technicians and engineers managing automated production systems
- Electricians and technical staff transitioning into automation and control roles
- Professionals responsible for 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
