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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within a production plant
- Understanding sensors, actuators, and field signals
- Overview of transport, feeding, dosing, and packaging subsystems
SIMATIC S7-1500 Hardware and System Design
- Exploring CPU families, signal modules, and distributed I/O
- Power supply systems, grounding practices, and control panel layouts
- Interpreting status LEDs, CPU displays, and module indicators
TIA Portal Project Management and Device Setup
- Navigating the project view, devices, and network structures
- Configuring hardware and defining device parameters
- Managing project versions through loading, saving, and comparison
PLC I/O Management: Signals and Addressing
- Understanding digital and analog addressing schemes
- Checking 24 V DC signal circuits and wiring integrity
- Validating field signals against program logic
Ladder Logic and Introductory Programming
- Working with contacts, coils, and set/reset operations
- Utilizing timers, counters, and comparison instructions
- Managing functions, function blocks, and data blocks
Decoding Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references
- Understanding symbol tables, tags, and variable naming conventions
- Tracing the logical conditions governing specific outputs
Motor Control: Start/Stop Mechanisms
- Configuring start, stop, and latching conditions
- Implementing motor protection and monitoring run feedback signals
- Managing direction control and multi-motor configurations
Interlocks, Permissives, and Sequential Control
- Defining interlock and permissive conditions
- Designing step sequences and state-based control logic
- Diagnosing sequences halted at specific steps
SIMATIC HMI Setup and User Interaction
- Configuring panel screens, tags, and navigation flows
- Managing operating modes and HMI-based control
- Displaying real-time equipment status and process values
Managing HMI Alarms and PLC Diagnostics
- Understanding alarm classes, priorities, and acknowledgement processes
- Reviewing system diagnostics and controller alarms
- Monitoring process and program-based messages
Variable Frequency Drives: Core Principles and Use Cases
- Fundamentals of drive principles and control methods
- Interaction between drives, motors, and mechanical loads
- Common drive configurations in production settings
- Specific focus on Yaskawa drives and other prevalent plant brands
VFD Setup and Commissioning Process
- Managing parameter groups and access levels
- Executing motor data entry, auto-tuning, and test runs
- Backing up, restoring, and documenting parameter settings
VFD Fault Analysis and Troubleshooting
- Interpreting fault, alarm, and parameter error codes
- Analyzing fault history and monitoring values
- Diagnosing issues related to drives, motors, cabling, and mechanics
Integrating Drive Control with PLC
- Managing start, stop, and speed reference signals
- Monitoring status, ready, and fault feedback
- Resolving discrepancies between PLC and drive states
Industrial Networking and Communication Diagnostics
- Essentials of PROFINET and Ethernet connectivity
- Configuring device names, IP addresses, and network topology
- Performing connection diagnostics and resolving communication faults
TIA Portal Diagnostics and Systematic Troubleshooting
- Using real-time online monitoring and watch tables
- Leveraging the diagnostics buffer and CPU web server
- Comparing online and offline program states
- Tracing from fault symptoms to root causes
- Conducting electrical, mechanical, and control-side inspections
- Documenting findings and establishing escalation criteria
Sequential Diagnosis of Stopped Machinery
- Establishing the order of checks when equipment halts
- Cross-referencing HMI alarms, PLC logic, and drive statuses
- Identifying blocking conditions and restoring normal operation
Practical Fault Scenario Workshops
- Exercises focusing on sensor, actuator, and I/O signal verification
- 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 system parameters
- Adding or modifying tags and simple logic structures
- Testing, documenting, and reverting changes as necessary
Capstone Project: Comprehensive Troubleshooting Case
- Conducting full fault diagnosis on a production line simulation
- Deciding between repair, adjustment, or escalation
- Receiving individual feedback and developing an improvement plan
Requirements
- A solid grasp of electrical circuits and industrial equipment fundamentals
- Introductory exposure to PLC concepts (university-level understanding is adequate)
- Basic proficiency in reading technical manuals for drives or related equipment
Target Audience
- Maintenance technicians and engineers responsible for automated production equipment
- Electricians and technical staff transitioning into automation and control roles
- Personnel tasked with diagnosing PLC, HMI, drive, and communication-related faults
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
