Thank you for sending your enquiry! One of our team members will contact you shortly.
Thank you for sending your booking! One of our team members will contact you shortly.
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 views, devices, and network structures.
- 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 Basic Programming
- Contacts, coils, set, and reset operations.
- Timers, counters, and comparison instructions.
- Functions, function blocks, and data blocks.
Interpreting Existing Programs and Control Logic
- Navigating program blocks and using cross-references.
- Symbol tables, tags, and variable naming conventions.
- Tracing logical conditions that control specific outputs.
Motors and Motor Start/Stop Control
- Start, stop, and latching conditions.
- Motor protection and run feedback signals.
- Direction control and multi-motor configurations.
Interlocks, Permissives, and Automatic Sequences
- Interlock and permissive conditions.
- Step sequences and state-based control logic.
- 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.
- Typical drive configurations on production equipment.
- Yaskawa drives and other common brands used 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 drive, motor, cable, and mechanical faults.
Drive Control 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 Structured Troubleshooting
- Real-time online monitoring and watch tables.
- Diagnostics buffer and CPU web server usage.
- Comparing online and offline programs.
- Progressing from fault symptom to root cause identification.
- Performing electrical, mechanical, and control-side checks.
- Documenting findings and defining escalation criteria.
Step-by-Step Diagnosis of a Stopped Machine
- Recommended order of checks when equipment halts.
- Cross-referencing HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring operation.
Practical Fault Scenario Exercises
- Exercises for checking sensors, actuators, and I/O signals.
- Motor, drive, and start/stop fault scenarios.
- Handling communication interruptions and interpreting alarms.
- Addressing interlock and sequence faults that block machine steps.
Making Basic Program Modifications
- Adjusting timers, setpoints, and parameters.
- Adding or modifying tags and simple logic.
- 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.
- Individual feedback and personal improvement planning.
Requirements
- A foundational 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 equipment.
- 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
