Course Outline
Industrial Automation and Control Fundamentals
- Automation architecture in production plants
- Sensors, actuators, and field signals
- 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 layout
- Status LEDs, CPU displays, and module indicators
TIA Portal Project Structure and Device Configuration
- Project view, devices, and network components
- Hardware configuration and device parameter settings
- Loading, saving, and comparing project versions
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing schemes
- 24 V DC signal circuits and wiring verification
- Verifying field signals against program logic
Ladder Logic and Basic Programming
- Contacts, coils, set, and 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 control outputs
Motors and Motor Start/Stop Control
- Start, stop, and latching conditions
- Motor protection and run feedback signals
- Direction control and multi-motor configurations
Interlocks, Permissives, and Automatic Sequences
- Interlock and permissive condition logic
- Step sequences and state-based control
- Diagnosing sequences blocked 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 Diagnostics Messages
- Alarm classes, priorities, and acknowledgement processes
- System diagnostics and controller alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Fundamentals and Applications
- Drive principles and control methodologies
- Interaction between drives, motors, and mechanical loads
- Typical drive configurations on production equipment
- Yaskawa drives and other common drive brands in plant environments
VFD Configuration and Commissioning
- Parameter groups and access levels
- Motor data entry, auto-tuning, and test runs
- Backup, restore, and parameter documentation
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm, and parameter error codes
- Fault history logs and monitoring values
- Diagnosing drive, motor, cable, and mechanical faults
Drive Control from the PLC
- Start, stop, and speed reference signals
- Status, ready, and fault feedback signals
- Diagnosing discrepancies between PLC and drive states
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals
- Device names, IP addresses, and network topology
- Connection diagnostics and communication fault analysis
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch tables
- Diagnostics buffers and CPU web servers
- Comparing online and offline program versions
- Progressing from fault symptoms to root causes
- Electrical, mechanical, and control-side inspections
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of a Stopped Machine
- Recommended order of checks when equipment halts
- Cross-referencing HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring operation
Practical Fault Scenario Exercises
- Sensor, actuator, and I/O signal verification exercises
- Motor, drive, and start/stop fault scenarios
- Communication interruptions and alarm interpretation drills
- Interlock and sequence faults blocking machine steps
Making Basic Program Modifications
- Adjusting timers, setpoints, and parameters
- Adding or modifying tags and simple logic
- Testing, documenting, and reverting changes
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a production line model
- Decision-making between repair, adjustment, and escalation
- Individual feedback and personalized improvement plans
Requirements
- Fundamental understanding of electrical circuits and industrial machinery.
- Introductory knowledge of PLC concepts (university-level understanding 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.
- Personnel 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
