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Duration 35 hours
Course Outline
Industrial Automation and Control Fundamentals
- Automation architecture within a production facility.
- Sensors, actuators, and field signal handling.
- Subsystems for transport, feeding, dosing, and packaging.
SIMATIC S7-1500 Hardware and System Architecture
- Overview of CPU families, signal modules, and distributed I/O.
- Power supply management, grounding, and control panel layout.
- Interpreting status LEDs, CPU displays, and module indicators.
TIA Portal Project Structure and Device Configuration
- Exploring the project view, devices, and network components.
- Configuring hardware and adjusting device parameters.
- Managing project versions through loading, saving, and comparison.
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog address schemes.
- 24 V DC signal circuits and essential wiring checks.
- Validating field signals against program logic.
Ladder Logic and Basic Programming
- Working with contacts, coils, set, and reset operations.
- Implementing timers, counters, and comparison instructions.
- Utilizing functions, function blocks, and data blocks.
Interpreting Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references.
- Understanding symbol tables, tags, and variable naming conventions.
- Tracing the logical conditions that govern output behavior.
Motors and Motor Start/Stop Control
- Managing start, stop, and latching conditions.
- Motor protection mechanisms and run feedback signals.
- Direction control and configuring multi-motor setups.
Interlocks, Permissives, and Automatic Sequences
- Defining interlock and permissive conditions.
- Implementing step sequences and state-based control.
- Diagnosing sequences that are blocked at a specific step.
SIMATIC HMI Configuration and Operation
- Setting up panel screens, tags, and navigation flows.
- Managing operating modes and executing control via the HMI.
- Displaying real-time equipment status and process values.
HMI Alarms and PLC Diagnostics Messages
- Alarm classes, priority levels, and acknowledgment procedures.
- System diagnostics and controller-level alarms.
- Monitoring messages based on process and program logic.
Variable Frequency Drives: Fundamentals and Applications
- Core drive principles and control methodologies.
- Interaction between the drive, motor, and mechanical load.
- Standard drive configurations on production equipment.
- Overview of Yaskawa drives and other common brands in the plant.
VFD Configuration and Commissioning
- Navigating parameter groups and access levels.
- Motor data entry, auto-tuning, and conducting test runs.
- Backing up, restoring, and documenting parameters.
VFD Fault Diagnosis and Troubleshooting
- Understanding fault, alarm, and parameter error codes.
- Reviewing fault history and monitoring values.
- Diagnosing issues related to the drive, motor, cabling, and mechanics.
Drive Control from the PLC
- Managing start, stop, and speed reference signals.
- Processing status, ready, and fault feedback.
- 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 resolving communication faults.
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and using watch tables.
- Utilizing the diagnostics buffer and CPU web server.
- Comparing online and offline program versions.
- Tracing from fault symptom to root cause.
- Performing 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 halts.
- Cross-referencing HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring normal operation.
Practical Fault Scenario Exercises
- Exercises focused 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.
Making Basic Program Modifications
- Adjusting timers, setpoints, and system parameters.
- Adding or modifying tags and simple logic structures.
- Testing, documenting, and reverting program changes.
Capstone: End-to-End Troubleshooting Case
- Complete fault diagnosis on a simulated production line.
- Decision-making between repair, adjustment, and escalation.
- Receiving individual feedback and a personal improvement plan.
Requirements
- A fundamental grasp of electrical circuits and industrial machinery.
- Introductory familiarity with PLC concepts (university-level knowledge is sufficient).
- Basic competence in reading technical manuals for drives and equipment.
Target Audience
- Maintenance technicians and engineers working with automated production assets.
- Electricians and technical staff transitioning into automation and control roles.
- Personnel tasked with 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
