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Duration 35 hours
Course Outline
Industrial Automation and Control Fundamentals
- Automation architecture in production plants
- Sensors, actuators, and field signals
- 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 view, devices, and networks
- Hardware configuration and device parameters
- 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 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 cross-references
- Symbol tables, tags, and variable naming conventions
- Tracing logical conditions that govern specific outputs
Motors and Motor Start/Stop Control
- Start, stop, and latching conditions
- Motor protection and run feedback signals
- Direction control and multi-motor setups
Interlocks, Permissives and Automatic Sequences
- Interlock and permissive condition logic
- Step sequences and state-based control
- Diagnosing sequences blocked at specific steps
SIMATIC HMI Configuration and Operation
- Panel screens, tags, and navigation structures
- Operating modes and HMI-based control
- Displaying equipment status and process values
HMI Alarms and PLC Diagnostics Messages
- Alarm classes, priorities, and acknowledgement procedures
- System diagnostics and controller alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Fundamentals and Applications
- Drive principles and control methods
- Interaction between drives, motors, and mechanical loads
- Common drive configurations on production equipment
- Yaskawa drives and other prevalent drive brands in the plant
VFD Configuration and Commissioning
- Parameter groups and access levels
- Motor data, auto-tuning, and test runs
- Backup, restoration, and parameter documentation
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm, and parameter error codes
- Reviewing fault history and monitoring values
- Diagnosing drive, motor, cable, and mechanical issues
Drive Control from the PLC
- Start, stop, and speed reference signals
- Status, ready, and fault feedback mechanisms
- Resolving discrepancies between PLC and drive states
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals
- Device names, IP addresses, 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 utilities
- Comparing online and offline program states
- Progressing from fault symptoms to root cause analysis
- Conducting electrical, mechanical, and control-side checks
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of a Stopped Machine
- Sequence of checks when equipment halts
- Cross-verifying HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring operation
Practical Fault Scenario Exercises
- Exercises involving sensor, actuator, and I/O signal checks
- Scenarios covering motor, drive, and start/stop faults
- Handling 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 changes as needed
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a production line model
- Decision-making on repair, adjustment, or escalation
- Providing individual feedback and developing an improvement plan
Requirements
- A fundamental 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.
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 faults.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
