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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Overview of automation architecture in production plants.
- Understanding 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 considerations, grounding, and control panel layout.
- Interpreting status LEDs, CPU displays, and module indicators.
TIA Portal Project Structure and Device Configuration
- Navigating project views, devices, and networks.
- Configuring hardware and defining device parameters.
- Managing project versions: loading, saving, and comparing.
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 Core Programming
- Contacts, coils, set, and 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 output states.
Motor Control and Start/Stop Logic
- Start, stop, and latching conditions.
- Motor protection and run feedback signals.
- Direction control and multi-motor configurations.
Interlocks, Permissives, and Automatic Sequences
- Defining interlock and permissive conditions.
- Step sequences and state-based control logic.
- Diagnosing sequences halted 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 processes.
- System diagnostics and controller alarms.
- Monitoring messages based on process and program logic.
Variable Frequency Drives: Basics and Applications
- Drive principles and control methodologies.
- Interactions between drives, motors, and mechanical loads.
- Standard drive configurations on production lines.
- Yaskawa drives and other prevalent drive brands in industrial settings.
VFD Configuration and Commissioning
- Parameter groups and access security levels.
- Motor data entry, auto-tuning, and test runs.
- Backing up, restoring, and documenting parameters.
VFD Fault Diagnosis and Troubleshooting
- Decoding fault, alarm, and parameter error codes.
- Reviewing fault history and monitoring values.
- Identifying faults in drives, motors, cabling, and mechanics.
PLC-Based Drive Control
- Start, stop, and speed reference signals.
- Status, ready, and fault feedback mechanisms.
- Resolving discrepancies between PLC and drive states.
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals.
- Device naming, IP addressing, and network topology.
- Connection diagnostics and resolving communication issues.
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch tables.
- Diagnostics buffer and CPU web server utilities.
- Comparing online and offline program versions.
- Tracing from fault symptoms to root causes.
- Electrical, mechanical, and control-side inspections.
- Documenting findings and defining escalation criteria.
Step-by-Step Diagnosis of Stalled Machines
- Recommended sequence of checks when equipment stops.
- Correlating HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring operations.
Practical Fault Scenario Exercises
- Exercises in checking sensors, actuators, and I/O signals.
- Scenarios involving motor, drive, and start/stop faults.
- Handling communication interruptions and interpreting alarms.
- Debugging interlocks and sequence faults that block machine steps.
Basic Program Modifications
- Adjusting timers, setpoints, and parameters.
- Adding or altering tags and simple logic blocks.
- 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 development of an improvement plan.
Requirements
- Foundational understanding of electrical circuits and industrial machinery.
- Introductory knowledge of PLC concepts (university-level familiarity is sufficient).
- Basic ability to read and interpret technical manuals for drives or equipment.
Target Audience
- Maintenance technicians and engineers operating automated production equipment.
- Electricians and technical staff transitioning into automation and control roles.
- Professionals responsible for diagnosing faults in PLCs, HMIs, drives, and communications.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
