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Duration 35 hours
Course Outline
Industrial Automation and Control Basics
- Automation architecture within a production plant.
- Sensors, actuators, and field signal handling.
- Subsystems for transport, feeding, dosing, and packaging.
SIMATIC S7-1500 Hardware and System Design
- CPU families, signal modules, and distributed I/O systems.
- Power supply units, grounding, and control panel layouts.
- Status LEDs, CPU displays, and module indicators.
TIA Portal Project Structure and Device Setup
- Project views, devices, and network configurations.
- Hardware configuration and device parameter settings.
- Loading, saving, and comparing different 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 Fundamental Programming
- Contacts, coils, set, and reset operations.
- Timers, counters, and comparison instructions.
- Functions, function blocks, and data blocks.
Reading Existing Programs and Control Logic
- Navigating program blocks and cross-references.
- Symbol tables, tags, and variable naming conventions.
- Tracing logical conditions that govern output states.
Motor and Start/Stop Control
- Start, stop, and latching conditions.
- Motor protection mechanisms 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 strategies.
- Diagnosing sequences blocked at specific steps.
SIMATIC HMI Configuration and Use
- Panel screens, tags, and navigation structures.
- Operating modes and control actions via HMI.
- Displaying equipment status and process values.
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgement procedures.
- System diagnostics and controller alarms.
- Process and program-based monitoring messages.
Variable Frequency Drives: Principles and Uses
- Drive operating principles and control methods.
- Interaction between drives, motors, and mechanical loads.
- Common drive configurations on production lines.
- Yaskawa drives and other prevalent drive brands in plants.
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 and monitoring values.
- Diagnosing issues related to drives, motors, cables, and mechanics.
Controlling Drives from the PLC
- Start, stop, and speed reference signals.
- Status, ready, and fault feedback mechanisms.
- Diagnosing 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 communication fault resolution.
TIA Portal Diagnostics and Systematic Troubleshooting
- Real-time online monitoring and watch tables.
- Diagnostics buffers and CPU web server features.
- Comparing online and offline programs.
- Tracing from fault symptoms to root causes.
- Checking electrical, mechanical, and control sides.
- Documenting findings and defining escalation criteria.
Step-by-Step Diagnosis of Stopped Machines
- Priority order of checks when equipment stops.
- Cross-verifying HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring operation.
Practical Fault Scenario Exercises
- Exercises covering 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 parameters.
- Adding or modifying tags and simple logic blocks.
- Testing, documenting, and reverting changes as needed.
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a production line model.
- Deciding between repair, adjustment, or escalation.
- Receiving individual feedback and an improvement plan.
Requirements
- A solid grasp of electrical circuits and industrial machinery.
- Introductory knowledge of PLC concepts (university-level exposure is adequate).
- Basic proficiency in reading 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
