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Duration 35 hours
Course Outline
Industrial Automation and Control Fundamentals
- Production plant automation architecture
- Sensors, actuators, and field signal management
- 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 considerations
- Interpreting status LEDs, CPU displays, and module indicators
TIA Portal Project Structure and Device Configuration
- Managing project views, devices, and network settings
- Hardware configuration and device parameter adjustment
- Loading, 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 Basic Programming
- Working with contacts, coils, set and reset operations
- Utilizing timers, counters, and comparison instructions
- Creating and managing functions, function blocks, and data blocks
Interpreting Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references
- Understanding symbol tables, tags, and variable naming conventions
- Tracing logical conditions that govern output behavior
Motors and Motor Start/Stop Control
- Configuring start, stop, and latching conditions
- Implementing motor protection and run feedback signals
- Direction control and managing multi-motor configurations
Interlocks, Permissives, and Automatic Sequences
- Defining interlock and permissive conditions
- Designing step sequences and state-based control logic
- Diagnosing sequences that are blocked at specific steps
SIMATIC HMI Configuration and Operation
- Managing panel screens, tags, and navigation structures
- Operating modes and executing control actions via HMI
- Displaying equipment status and real-time process values
HMI Alarms and PLC Diagnostics Messages
- Alarm classes, priority levels, and acknowledgement procedures
- System diagnostics and controller alarm management
- Monitoring process and program-based messages
Variable Frequency Drives: Fundamentals and Applications
- Core drive principles and control methodologies
- Interaction between drives, motors, and mechanical loads
- Typical drive configurations in production environments
- Overview of Yaskawa drives and other common brands used on-site
VFD Configuration and Commissioning
- Parameter groups and access level management
- Motor data entry, auto-tuning, and test run procedures
- Backing up, restoring, and documenting drive 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
Drive Control from the PLC
- Managing start, stop, and speed reference signals
- Monitoring status, readiness, and fault feedback
- Resolving discrepancies between PLC and drive states
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals
- Managing device names, IP addresses, and network topology
- Diagnosing connection issues and communication faults
TIA Portal Diagnostics and Structured Troubleshooting
- Using real-time online monitoring and watch tables
- Accessing the diagnostics buffer and CPU web server
- Comparing online and offline program versions
- Tracing from fault symptoms to root causes
- Performing electrical, mechanical, and control-side inspections
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of a Stopped Machine
- Recommended order of checks when equipment halts
- Cross-referencing HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring normal operation
Practical Fault Scenario Exercises
- Exercises for checking sensors, actuators, and I/O signals
- Scenarios involving motor, drive, and start/stop faults
- Addressing communication interruptions and interpreting alarms
- Resolving interlock and sequence faults that block machine steps
Making Basic Program Modifications
- Adjusting timers, setpoints, and parameters
- Adding or modifying tags and simple logic structures
- Testing, documenting, and reverting program changes
Capstone: End-to-End Troubleshooting Case
- Conducting full fault diagnosis on a production line model
- Deciding between repair, adjustment, or escalation
- Receiving individual feedback and developing an improvement plan
Requirements
- Basic understanding of electrical circuits and industrial equipment
- Introductory exposure to PLC concepts (university-level knowledge is sufficient)
- Basic familiarity with reading technical manuals for drives or equipment
Audience
- Maintenance technicians and engineers working with automated production equipment
- Electricians and technical staff transitioning into automation and control roles
- Personnel responsible for diagnosing PLC, HMI, drive, and communication faults
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
