Course Outline
Foundations of Industrial Automation and Control
- Automation architecture in production plants
- Sensors, actuators, and field signaling
- 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 arrangement
- Status LEDs, CPU displays, and module indicators
TIA Portal Project Structure and Device Configuration
- Project view, devices, and network architecture
- Hardware configuration and device parameterization
- Managing project versions: loading, saving, and comparison
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing schemes
- 24 V DC signal circuits and wiring verification
- Cross-referencing field signals with program logic
Ladder Logic and Fundamental Programming
- Contacts, coils, and set/reset operations
- Timers, counters, and comparison instructions
- Functions, function blocks, and data blocks
Interpreting Existing Programs and Control Logic
- Navigating program blocks and cross-references
- Symbol tables, tags, and variable naming conventions
- Tracing logical conditions that drive outputs
Motors and Start/Stop Control
- Start, stop, and latching conditions
- Motor protection 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
- Diagnosing sequences halted at specific steps
SIMATIC HMI Configuration and Operation
- Panel screens, tags, and navigation flows
- Operating modes and HMI-based control
- Displaying equipment status and process values
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgement
- System diagnostics and controller alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Basics and Applications
- Drive principles and control methodologies
- Interaction between drives, motors, and mechanical loads
- Typical drive configurations on production lines
- Yaskawa drives and other prevalent brands in industrial settings
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
- Interpreting fault, alarm, and parameter error codes
- Analyzing fault history and monitoring values
- Diagnosing drive, motor, cable, and mechanical issues
Controlling Drives from the PLC
- Start, stop, and speed reference signals
- Status, ready, and fault feedback signals
- Resolving discrepancies between PLC and drive states
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet basics
- Device naming, IP addressing, and network topology
- Connection diagnostics and communication error 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 program versions
- From symptom to root cause analysis
- Electrical, mechanical, and control-side inspections
- Documenting findings and defining 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 operations
Practical Fault Scenario Exercises
- Checking sensor, actuator, and I/O signals
- Simulating motor, drive, and start/stop failures
- Handling communication interruptions and interpreting alarms
- Resolving interlock and sequence faults that block machine steps
Performing 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 between repair, adjustment, or escalation
- Individual feedback and personal improvement plan
Requirements
- Foundational understanding of electrical circuits and industrial machinery.
- Introductory knowledge of PLC concepts (university-level exposure is acceptable).
- Basic proficiency in reading technical manuals for drives or 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
