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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within a production plant.
- 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, grounding, and control panel layout standards.
- Status LEDs, CPU displays, and module indicators.
TIA Portal Project Structure and Device Configuration
- Managing the project view, devices, and network connections.
- Hardware configuration and device parameter settings.
- Loading, saving, and comparing different project versions.
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing concepts.
- 24 V DC signal circuits and wiring verification.
- Validating field signals against the control program.
Ladder Logic and Basic 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 specific outputs.
Motor Control: Start, Stop, and Operation
- Start, stop, and latching conditions.
- Motor protection mechanisms and run feedback signals.
- Direction control and multi-motor configurations.
Interlocks, Permissives, and Automatic Sequences
- Defining interlock and permissive conditions.
- Step sequences and state-based control logic.
- Diagnosing sequences blocked at specific steps.
SIMATIC HMI Configuration and Operation
- Panel screens, tags, and navigation flows.
- Operating modes and control execution 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.
- Process and program-based monitoring messages.
Variable Frequency Drives: Fundamentals and Applications
- Drive operating principles and control methods.
- Interaction between drive, motor, and mechanical load.
- Typical drive configurations in production environments.
- Yaskawa drives and other common drive brands used in the plant.
VFD Configuration and Commissioning
- Parameter groups and access level management.
- 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 faults related to drives, motors, cables, and mechanics.
Drive Control from the PLC
- Start, stop, and speed reference signals.
- Status, ready, and fault feedback signals.
- Resolving discrepancies between PLC and drive states.
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals.
- Device naming, IP addresses, and network topology.
- Connection diagnostics and communication fault 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 states.
- Tracing from fault symptoms to root cause.
- Conducting electrical, mechanical, and control-side checks.
- Documenting findings and defining escalation criteria.
Step-by-Step Diagnosis of a Stopped Machine
- Systematic order of checks when equipment halts.
- Cross-referencing HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring operation.
Practical Fault Scenario Exercises
- Exercises covering sensors, actuators, and I/O signals.
- Scenarios involving motors, drives, and start/stop faults.
- Handling communication interruptions and interpreting alarms.
- Resolving interlock and sequence faults that block machine steps.
Basic Program Modifications
- Adjusting timers, setpoints, and system parameters.
- Adding or modifying tags and simple logic structures.
- 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 personal improvement planning.
Requirements
- A fundamental grasp of electrical circuits and industrial equipment operations.
- Introductory exposure to PLC concepts (university-level knowledge is sufficient).
- Basic ability to read and interpret technical manuals for drives or equipment.
Target Audience
- Maintenance technicians and engineers working with automated production systems.
- Electricians and technical staff transitioning into automation and control roles.
- Personnel 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
