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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Production plant automation architecture.
- Sensors, actuators, and field signals.
- Subsystems for transport, feeding, dosing, and packaging.
SIMATIC S7-1500 Hardware and System Design
- CPU families, signal modules, and distributed I/O.
- Power supply, grounding, and control panel layouts.
- Status LEDs, CPU displays, and module indicators.
TIA Portal Project Management and Device Setup
- Project view, device management, and network settings.
- Hardware configuration and device parameterization.
- 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 Core Programming
- Contacts, coils, and set/reset operations.
- Timers, counters, and comparison instructions.
- Functions, function blocks, and data blocks.
Analyzing Existing Programs and Control Logic
- Navigating program blocks and cross-references.
- Symbol tables, tags, and variable naming conventions.
- Tracing the logical conditions governing specific outputs.
Motor Control and Start/Stop Mechanisms
- 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 conditions.
- Step sequences and state-based control logic.
- Diagnosing sequences halted at specific steps.
SIMATIC HMI Configuration and Usage
- Panel screens, tag mapping, and navigation.
- Operating modes and HMI-based control.
- Displaying equipment status and process values.
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgement processes.
- System diagnostics and controller alarms.
- Process and program-based monitoring messages.
Variable Frequency Drives: Principles and Applications
- Drive operating principles and control methods.
- Interaction between drive, motor, and mechanical load.
- Typical drive configurations in production settings.
- Yaskawa drives and other common brands found in the plant.
VFD Configuration and Commissioning
- Parameter groups and access levels.
- Motor data entry, auto-tuning, and test runs.
- Backing up, restoring, and documenting parameters.
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm, and parameter error codes.
- Fault history logs and monitoring values.
- Identifying drive, motor, cable, and mechanical issues.
PLC-Driven Control of VFDs
- Start, stop, and speed reference signals.
- Status, ready, and fault feedback loops.
- Resolving discrepancies between PLC and drive states.
Industrial Communication and Network Diagnostics
- PROFINET and Ethernet fundamentals.
- Device naming, IP addressing, and network topology.
- Connection diagnostics and communication fault resolution.
TIA Portal Diagnostics and Systematic Troubleshooting
- Real-time online monitoring and watch tables.
- Diagnostic buffers and the CPU web server.
- Comparing online and offline program versions.
- Progressing from fault symptoms to root cause analysis.
- Electrical, mechanical, and control-side verifications.
- Documenting findings and defining escalation criteria.
Systematic Diagnosis of Stopped Machines
- Recommended order of checks when equipment halts.
- Cross-referencing HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring operation.
Hands-On Fault Scenario Exercises
- Exercises in checking sensors, actuators, and I/O signals.
- Scenarios involving motor, drive, and start/stop faults.
- Communication interruptions and alarm interpretation.
- Interlock and sequence faults that block machine steps.
Basic Program Modifications
- Adjusting timers, setpoints, and parameters.
- Adding or modifying tags and simple logic.
- Testing, documenting, and reverting changes.
Capstone: Comprehensive Troubleshooting Case Study
- End-to-end fault diagnosis on a production line model.
- Deciding between repair, adjustment, or escalation.
- Individual feedback and a personal improvement plan.
Requirements
- Foundational knowledge of electrical circuits and industrial machinery.
- Introductory familiarity with PLC concepts (university-level exposure is sufficient).
- Basic ability to read technical manuals for drives and 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
