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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within production plants.
- Sensors, actuators, and field signal management.
- Subsystems for transport, feeding, dosing, and packaging.
SIMATIC S7-1500 Hardware and System Architecture
- CPU families, signal modules, and distributed I/O systems.
- Power supply, grounding, and control panel layout considerations.
- Interpreting status LEDs, CPU displays, and module indicators.
TIA Portal Project Structure and Device Configuration
- Navigating project views, devices, and networks.
- Hardware configuration and device parameter settings.
- Managing project versions through loading, saving, and comparison.
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing schemes.
- 24 V DC signal circuits and wiring verification techniques.
- Validating field signals against program logic.
Ladder Logic and Fundamental Programming
- Using contacts, coils, and set/reset operations.
- Implementing timers, counters, and comparison instructions.
- Working with functions, function blocks, and data blocks.
Analyzing Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references.
- Understanding symbol tables, tags, and variable naming conventions.
- Tracing logical conditions that govern output actions.
Motor Control: Start and Stop Mechanisms
- Managing start, stop, and latching conditions.
- Motor protection circuits and run feedback signals.
- Direction control and multi-motor system configurations.
Interlocks, Permissives, and Automatic Sequences
- Defining interlock and permissive conditions.
- Creating step sequences and state-based control logic.
- Diagnosing sequences that are blocked at a specific step.
SIMATIC HMI Configuration and Operation
- Panel screens, tag assignment, and navigation flows.
- Operating modes and HMI-based control interactions.
- Displaying real-time equipment status and process values.
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priority levels, and acknowledgement procedures.
- System diagnostics and controller alarm handling.
- Process and program-based monitoring messages.
Variable Frequency Drives: Principles and Applications
- Core drive principles and control methodologies.
- Interaction between drives, motors, and mechanical loads.
- Typical drive setups found on production equipment.
- Yaskawa drives and other prevalent drive brands in industrial settings.
VFD Configuration and Commissioning
- Parameter groups and access level management.
- Motor data entry, auto-tuning, and test run procedures.
- Backing up, restoring, and documenting drive parameters.
VFD Fault Diagnosis and Troubleshooting
- Interpreting fault, alarm, and parameter error codes.
- Reviewing fault history and monitoring values.
- Diagnosing faults related to drives, motors, cabling, and mechanics.
PLC Control of Drives
- Managing start, stop, and speed reference signals.
- Monitoring status, ready states, and fault feedback.
- Resolving discrepancies between PLC and drive states.
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamental concepts.
- 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 table usage.
- Utilizing the diagnostics buffer and CPU web server.
- Comparing online and offline program states.
- Tracing from fault symptoms to root causes.
- Performing electrical, mechanical, and control-side inspections.
- Documenting findings and establishing escalation criteria.
Step-by-Step Diagnosis of Stopped Machines
- Establishing the correct order of checks during equipment stoppages.
- Cross-referencing HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring normal operation.
Practical Fault Scenario Exercises
- Exercises focusing on sensor, actuator, and I/O signal checks.
- Simulating motor, drive, and start/stop fault scenarios.
- Analyzing communication interruptions and interpreting alarms.
- Resolving interlock and sequence faults that block machine steps.
Implementing Basic Program Modifications
- Adjusting timers, setpoints, and operational parameters.
- Adding or modifying tags and simple logic structures.
- Testing changes, documenting updates, and reverting when necessary.
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a simulated production line.
- Decision-making processes for repair, adjustment, or escalation.
- Individual performance feedback and personal improvement planning.
Requirements
- A foundational understanding of electrical circuits and industrial machinery.
- Introductory knowledge of PLC concepts (university-level exposure is adequate).
- Basic familiarity with reading technical manuals for drives and equipment.
Target Audience
- Maintenance technicians and engineers supporting automated production lines.
- Electricians and technical staff transitioning into automation and control roles.
- Personnel responsible for diagnosing issues related to 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
