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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within production plants.
- Sensors, actuators, and field signal handling.
- Subsystems for transport, feeding, dosing, and packaging.
SIMATIC S7-1500 Hardware and System Design
- CPU series, signal modules, and distributed I/O.
- Power supply, grounding, and control panel organization.
- Interpreting status LEDs, CPU displays, and module indicators.
TIA Portal Project Management and Device Setup
- Navigating project views, devices, and networks.
- Configuring hardware and device parameters.
- Managing project versions through loading, saving, and comparison.
PLC Inputs and Outputs: Signal Handling and Addressing
- Digital and analog signal addressing.
- 24 V DC signal circuits and wiring verification.
- Cross-referencing field signals with the control program.
Ladder Logic and Core Programming
- Working with contacts, coils, set, and reset operations.
- Utilizing timers, counters, and comparison instructions.
- Understanding functions, function blocks, and data blocks.
Analyzing Existing Programs and Control Logic
- Navigating program blocks and using cross-references.
- Managing symbol tables, tags, and variable naming conventions.
- Tracing the logical conditions governing specific outputs.
Motor Control: Start/Stop Operations
- Start, stop, and latching logic.
- Motor protection mechanisms and run feedback signals.
- Directional control and multi-motor setups.
Interlocks, Permissives, and Automated Sequences
- Defining interlock and permissive conditions.
- Implementing step sequences and state-based controls.
- Diagnosing sequences blocked at specific steps.
SIMATIC HMI Setup and Operations
- Managing panel screens, tags, and navigation paths.
- Operating modes and HMI-driven controls.
- Displaying equipment status and process variables.
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priority levels, and acknowledgement procedures.
- System diagnostics and controller-specific alarms.
- Monitoring process and program-based messages.
Variable Frequency Drives: Core Concepts and Use Cases
- Drive operating principles and control strategies.
- Interaction between drives, motors, and mechanical loads.
- Standard drive configurations on production equipment.
- Working with Yaskawa drives and other common plant brands.
VFD Configuration and Commissioning
- Understanding 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.
- Reviewing fault history and monitoring values.
- Diagnosing issues related to drives, motors, cables, or mechanics.
Drive Control via PLC
- Managing start, stop, and speed reference signals.
- Monitoring status, ready, and fault feedback.
- Resolving mismatches between PLC and drive states.
Industrial Communication and Network Diagnostics
- PROFINET and Ethernet fundamentals.
- Configuring device names, IP addresses, and network topology.
- Diagnosing connection issues and communication faults.
TIA Portal Diagnostics and Systematic Troubleshooting
- Real-time online monitoring and watch tables.
- Using the diagnostics buffer and CPU web server.
- Comparing online and offline program states.
- Transitioning from fault symptoms to root cause analysis.
- Performing electrical, mechanical, and control-side inspections.
- Documenting findings and determining escalation paths.
Step-by-Step Diagnosis of Halted Machines
- Establishing the correct order of checks when equipment stops.
- 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 failures.
- Addressing communication interruptions and interpreting alarms.
- Diagnosing interlocks and sequence faults that halt machine steps.
Implementing Basic Program Adjustments
- Modifying timers, setpoints, and parameters.
- Adding or altering tags and simple logic structures.
- Testing, documenting, and reverting changes as needed.
Capstone: Comprehensive Troubleshooting Case
- End-to-end fault diagnosis on a production line simulation.
- Decision-making between repair, adjustment, and escalation.
- Receiving individual feedback and developing an improvement plan.
Requirements
- A solid grasp of electrical circuits and industrial machinery.
- Introductory knowledge of PLC concepts (university-level familiarity is adequate).
- Basic ability to read and interpret technical manuals for drives or equipment.
Target Audience
- Maintenance technicians and engineers managing automated production lines.
- Electricians and technical staff transitioning into automation and control roles.
- Professionals responsible for diagnosing issues with PLCs, HMIs, drives, and communication systems.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
