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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- 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 Architecture
- CPU families, signal modules, and distributed I/O configurations.
- Power supply management, grounding, and control panel layout.
- Status LEDs, CPU displays, and module indicator interpretation.
TIA Portal Project Structure and Device Configuration
- Navigating the project view, devices, and networks.
- Hardware configuration and setting device parameters.
- 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 Techniques
- Contacts, coils, set, and reset operations.
- Timers, counters, and comparison instructions.
- Functions, function blocks, and data blocks.
Analyzing 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 specific outputs.
Motor Control and Start/Stop Mechanisms
- Start, stop, and latching conditions.
- Motor protection circuits and run feedback signals.
- Direction control and multi-motor configurations.
Interlocks, Permissives, and Automatic Sequences
- Defining interlock and permissive conditions.
- Step sequences and state-based control strategies.
- Diagnosing sequences blocked at specific steps.
SIMATIC HMI Configuration and Operation
- Panel screen design, tags, and navigation flows.
- Operating modes and HMI-based control interactions.
- Displaying equipment status and real-time process values.
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgement protocols.
- System diagnostics and controller alarm management.
- Process and program-based monitoring messages.
Variable Frequency Drives: Principles and Applications
- Drive operating principles and control methods.
- Interaction between drives, motors, and mechanical loads.
- Standard drive configurations on production equipment.
- Yaskawa drives and other prevalent drive brands in industrial plants.
VFD Configuration and Commissioning
- Parameter groups and access level management.
- 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 drive, motor, cable, and mechanical issues.
PLC-Based Drive Control
- Start, stop, and speed reference signal management.
- Status, ready, and fault feedback interpretation.
- Resolving discrepancies between PLC and drive states.
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals.
- Device naming, IP addressing, and network topology.
- Connection diagnostics and resolving communication faults.
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch table usage.
- Utilizing the diagnostics buffer and CPU web server.
- Comparing online and offline program versions.
- Tracing 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 Stopped Machines
- 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.
- Handling communication interruptions and interpreting alarms.
- Addressing interlock and sequence faults that block machine steps.
Executing Basic Program Modifications
- Adjusting timers, setpoints, and operational parameters.
- Adding or modifying tags and simple logic structures.
- Testing, documenting, and reverting changes as necessary.
Capstone: End-to-End Troubleshooting Case Study
- Complete fault diagnosis on a production line model.
- Decision-making between repair, adjustment, and escalation.
- Individual feedback and personalized improvement planning.
Requirements
- A foundational understanding of electrical circuits and industrial machinery.
- Introductory exposure to PLC concepts (university-level knowledge is sufficient).
- Basic proficiency in reading technical manuals for drives and equipment.
Target Audience
- Maintenance technicians and engineers working with automated production lines.
- Electricians and technical staff transitioning into automation and control roles.
- Professionals responsible for diagnosing issues related to PLCs, HMIs, drives, and communications.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
