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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 signaling
- 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 organization
- Status LEDs, CPU displays, and module indicators
TIA Portal Project Structure and Device Configuration
- Project views, device management, and network configuration
- Hardware setup and parameterization of devices
- Managing project versions: loading, saving, and comparison
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing schemes
- 24 V DC signal circuits and wiring verification
- Cross-referencing field signals with program logic
Ladder Logic and Core Programming Concepts
- 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 cross-references
- Utilizing symbol tables, tags, and variable naming conventions
- Tracing logical conditions that govern output behavior
Motor Control: Start/Stop Mechanisms
- Start, stop, and latching conditions
- Motor protection and run feedback signals
- Directional control and multi-motor setups
Interlocks, Permissives, and Automated Sequences
- Defining interlock and permissive conditions
- Step sequences and state-based control logic
- Diagnosing sequences halted at specific steps
SIMATIC HMI Configuration and Operation
- Panel screens, tag management, and navigation
- Operating modes and HMI-based control
- Visualizing equipment status and process values
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgment procedures
- System diagnostics and controller alarms
- Monitoring messages based on process and program events
Variable Frequency Drives: Principles and Applications
- Drive operating principles and control strategies
- Interaction between drives, motors, and mechanical loads
- Standard drive configurations in production environments
- Overview of Yaskawa drives and other common brands used in the plant
VFD Configuration and Commissioning
- Parameter groups and access levels
- Motor data entry, auto-tuning, and test runs
- Backing up, restoring, and documenting parameters
VFD Fault Diagnosis and Troubleshooting
- Interpreting fault, alarm, and parameter error codes
- Analyzing fault history and monitoring values
- Diagnosing issues related to drives, motors, cabling, and mechanics
Controlling Drives from the PLC
- Start, stop, and speed reference signals
- Status, readiness, and fault feedback mechanisms
- Resolving discrepancies between PLC state and drive state
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
- Diagnostics buffer and CPU web server features
- Comparing online and offline program states
- Tracing from fault symptoms to root cause
- Performing electrical, mechanical, and control-side inspections
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of Halted Machinery
- Recommended sequence of checks when equipment stops
- Correlating HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring normal operation
Practical Fault Scenario Exercises
- Exercises focusing on sensors, actuators, and I/O signal verification
- Scenarios involving motor, drive, and start/stop faults
- Simulating communication interruptions and interpreting alarms
- Diagnosing interlock and sequence faults that halt machine steps
Implementing Basic Program Modifications
- Adjusting timers, setpoints, and parameters
- Adding or modifying tags and simple logic structures
- Testing, documenting, and reverting changes as needed
Capstone: End-to-End Troubleshooting Case Study
- Comprehensive fault diagnosis on a production line model
- Decision-making regarding repair, adjustment, or escalation
- Individual feedback and development planning
Requirements
- A fundamental grasp of electrical circuits and industrial machinery
- Introductory knowledge of PLC concepts (university-level exposure is sufficient)
- Basic ability to interpret drive or equipment technical documentation
Target Audience
- Maintenance technicians and engineers operating automated production equipment
- Electricians and technical staff transitioning into automation and control roles
- Professionals responsible for diagnosing PLC, HMI, drive, and communication failures
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
