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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Understanding the automation architecture of a production facility.
- Overview of sensors, actuators, and field-level signals.
- Subsystems involved in transport, feeding, dosing, and packaging.
SIMATIC S7-1500 Hardware and System Design
- Exploring CPU families, signal modules, and distributed I/O.
- Power supply considerations, grounding, and control panel organization.
- Interpreting status LEDs, CPU displays, and module indicators.
TIA Portal Project Setup and Device Configuration
- Navigating the project view, devices, and network structures.
- Configuring hardware and defining device parameters.
- Managing project versions through loading, saving, and comparison.
PLC Inputs and Outputs: Signal Management and Addressing
- Addressing schemes for digital and analog signals.
- 24 V DC signal circuit analysis and wiring verification.
- Validating field signals against the control program.
Ladder Logic and Core Programming Techniques
- Working with contacts, coils, and set/reset operations.
- Utilizing timers, counters, and comparison instructions.
- Constructing functions, function blocks, and data blocks.
Decoding Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references.
- Understanding symbol tables, tags, and variable naming conventions.
- Tracing the logical conditions that drive specific outputs.
Motor Control: Start/Stop Mechanisms
- Defining start, stop, and latching conditions.
- Implementing motor protection and run feedback signals.
- Managing direction control and multi-motor setups.
Interlocks, Permissives, and Automated Sequences
- Establishing interlock and permissive logic.
- Designing step sequences and state-based controls.
- Troubleshooting sequences that are blocked at specific steps.
SIMATIC HMI Setup and Operation
- Managing panel screens, tags, and navigation paths.
- Controlling systems via different operating modes on the HMI.
- Visualizing equipment status and process variables.
HMI Alarms and PLC Diagnostic Messages
- Understanding alarm classes, priorities, and acknowledgement procedures.
- Reviewing system diagnostics and controller alarms.
- Monitoring process and program-based messages.
Variable Frequency Drives: Basics and Practical Use
- Core drive principles and control methodologies.
- Interaction between drives, motors, and mechanical loads.
- Typical drive configurations found in production equipment.
- Handling Yaskawa drives and other prevalent drive brands in the plant.
VFD Setup and Commissioning
- Managing parameter groups and access levels.
- Configuring motor data, performing auto-tuning, and test runs.
- Documenting parameters and managing backups and restores.
VFD Fault Analysis and Troubleshooting
- Deciphering 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
- Managing start, stop, and speed reference signals.
- Monitoring status, ready, and fault feedback.
- Resolving discrepancies between PLC state and drive state.
Industrial Communications and Network Diagnostics
- Basics of PROFINET and Ethernet.
- Understanding device names, IP addressing, and network topology.
- Performing connection diagnostics and resolving communication faults.
TIA Portal Diagnostics and Systematic Troubleshooting
- Using real-time online monitoring and watch tables.
- Leveraging the diagnostics buffer and CPU web server.
- Comparing online and offline program versions.
- Progressing from fault symptoms to root cause identification.
- Conducting electrical, mechanical, and control-side inspections.
- Documenting findings and defining escalation criteria.
Step-by-Step Diagnosis of Stopped Equipment
- Establishing a logical order of checks when equipment halts.
- Cross-referencing HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring normal operation.
Hands-On Fault Scenario Practice
- Exercises focusing on sensor, actuator, and I/O signal checks.
- Scenarios involving motor, drive, and start/stop faults.
- Handling communication interruptions and interpreting alarms.
- Resolving interlock and sequence faults that block machine steps.
Implementing Basic Program Changes
- Adjusting timers, setpoints, and operational parameters.
- Adding or modifying tags and simple logic structures.
- Testing, documenting, and reverting program changes as needed.
Capstone: Comprehensive Troubleshooting Case Study
- Conducting full fault diagnosis on a production line model.
- Deciding between repair, adjustment, or escalation strategies.
- Receiving individual feedback and a personalized improvement plan.
Requirements
- Fundamental knowledge of electrical circuits and industrial machinery.
- Introductory familiarity with PLC concepts (university-level understanding is adequate).
- Basic ability to read 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.
- 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
