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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 signals.
- Transport, feeding, dosing, and packaging subsystems.
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 the control program.
Ladder Logic and Fundamental 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 logical conditions that govern specific outputs.
Motor Control: Start/Stop Operations
- 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 Diagnostic 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 operating principles and control methods.
- Interaction between drives, motors, and mechanical loads.
- Typical drive configurations in production settings.
- Yaskawa drives and other common drive brands used on-site.
VFD Configuration and Commissioning
- Parameter groups and access levels.
- Motor data entry, auto-tuning, and test runs.
- Parameter backup, restoration, and documentation.
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 via PLC
- Start, stop, and speed reference signals.
- Status, ready, and fault feedback mechanisms.
- Identifying discrepancies between PLC state and drive status.
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 tables.
- Utilizing the diagnostics buffer and CPU web server.
- Comparing online and offline program versions.
- Transitioning from fault symptom to root cause analysis.
- Performing electrical, mechanical, and control-side checks.
- Documenting findings and establishing escalation criteria.
Step-by-Step Diagnosis of Stopped Machinery
- Systematic order of checks when equipment halts.
- Correlating HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring operation.
Practical Fault Scenario Exercises
- Exercises focusing on sensor, actuator, and I/O signal checks.
- Motor, drive, and start/stop fault simulations.
- Handling communication interruptions and interpreting alarms.
- Resolving interlock and sequence faults that block machine steps.
Implementing 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.
- Making decisions between repair, adjustment, and escalation.
- Receiving individual feedback and an improvement plan.
Requirements
- A solid 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 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 faults.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
