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Duration 35 hours
Course Outline
Industrial Automation and Control Fundamentals
- Automation architecture within a production plant.
- Overview of sensors, actuators, and field signals.
- Exploration of transport, feeding, dosing, and packaging subsystems.
SIMATIC S7-1500 Hardware and System Architecture
- Review of CPU families, signal modules, and distributed I/O.
- Power supply requirements, grounding, and control panel layout.
- Interpretation of status LEDs, CPU displays, and module indicators.
TIA Portal Project Structure and Device Configuration
- Navigating project views, devices, and networks.
- Setting up hardware configuration and defining device parameters.
- Managing project versions through loading, saving, and comparison.
PLC Inputs and Outputs: Signals and Addressing
- Understanding digital and analog addressing schemes.
- Checking 24 V DC signal circuits and wiring integrity.
- Verifying field signals against program logic.
Ladder Logic and Basic Programming
- Implementation of contacts, coils, and set/reset operations.
- Utilizing timers, counters, and comparison instructions.
- Working with functions, function blocks, and data blocks.
Interpreting Existing Programs and Control Logic
- Navigation of program blocks and cross-references.
- Understanding symbol tables, tags, and variable naming conventions.
- Tracing logical conditions that govern output behavior.
Motors and Motor Start/Stop Control
- Configuration of start, stop, and latching conditions.
- Integration of motor protection and run feedback signals.
- Managing direction control and multi-motor setups.
Interlocks, Permissives, and Automatic Sequences
- Defining interlock and permissive conditions.
- Designing step sequences and state-based control flows.
- Diagnosing sequences halted at specific steps.
SIMATIC HMI Configuration and Operation
- Setup of panel screens, tags, and navigation paths.
- Managing operating modes and HMI-based controls.
- Displaying equipment status and real-time process values.
HMI Alarms and PLC Diagnostics Messages
- Handling alarm classes, priorities, and acknowledgements.
- Reviewing system diagnostics and controller alarms.
- Interpreting process and program-based monitoring messages.
Variable Frequency Drives: Fundamentals and Applications
- Core drive principles and control methods.
- Interaction between drives, motors, and mechanical loads.
- Typical drive configurations in production environments.
- Overview of Yaskawa drives and other common brands.
VFD Configuration and Commissioning
- Managing parameter groups and access levels.
- Setting motor data, auto-tuning, and conducting test runs.
- Backing up, restoring, and documenting drive parameters.
VFD Fault Diagnosis and Troubleshooting
- Decoding fault, alarm, and parameter error codes.
- Analyzing fault history and monitoring values.
- Diagnosing issues related to drives, motors, cables, and mechanics.
Drive Control from the PLC
- Sending start, stop, and speed reference signals.
- Monitoring status, ready, and fault feedback.
- Resolving discrepancies between PLC and drive states.
Industrial Communication and Network Troubleshooting
- Basics of PROFINET and Ethernet communications.
- Managing device names, IP addresses, and network topology.
- Performing connection diagnostics and resolving communication faults.
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch table usage.
- Accessing diagnostics buffers and the CPU web server.
- Comparing online and offline program versions.
- Root cause analysis from fault symptoms.
- Conducting electrical, mechanical, and control-side inspections.
- Documenting findings and defining escalation criteria.
Step-by-Step Diagnosis of a Stopped Machine
- Establishing the order of checks when equipment stops.
- Correlating HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring operations.
Practical Fault Scenario Exercises
- Exercises involving sensor, actuator, and I/O signal checks.
- Simulating motor, drive, and start/stop fault scenarios.
- Handling communication interruptions and interpreting alarms.
- Resolving interlock and sequence faults blocking machine steps.
Making Basic Program Modifications
- Adjusting timers, setpoints, and operational parameters.
- Adding or modifying tags and simple logic structures.
- Testing, documenting, and reverting program changes.
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a production line model.
- Decision-making regarding repair, adjustment, or escalation.
- Receiving individual feedback and formulating improvement plans.
Requirements
- Fundamental understanding of electrical circuits and industrial equipment.
- Introductory exposure to PLC concepts (university-level knowledge is sufficient).
- Basic proficiency in reading drive or equipment technical manuals.
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-related faults.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
