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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture in production plants
- Sensors, actuators, and field signals
- Transport, feeding, dosing, and packaging subsystems
SIMATIC S7-1500 Hardware and System Design
- 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 Organization and Device Setup
- Project view, devices, and networks
- Hardware configuration and device parameter settings
- Loading, saving, and comparing project versions
PLC I\/O: Signals and Addressing
- Digital and analog addressing schemes
- 24 V DC signal circuits and wiring verification
- Validating field signals against program logic
Ladder Logic and Basic Programming
- Contacts, coils, and set/reset operations
- Timers, counters, and comparison instructions
- Functions, function blocks, and data blocks
Reading Existing Programs and Control Logic
- Navigating program blocks and cross-references
- Symbol tables, tags, and variable naming conventions
- Tracing logical conditions that control specific outputs
Motor Control: Start and Stop Mechanisms
- Start, stop, and latching conditions
- Motor protection and run feedback signals
- Direction control and multi-motor configurations
Interlocks, Permissives, and Automated Sequences
- Interlock and permissive condition logic
- Step sequences and state-based control methods
- Diagnosing sequences that are blocked at specific steps
SIMATIC HMI Setup and Operation
- Panel screens, tags, and navigation structure
- Operating modes and HMI-based control
- Displaying equipment status and process variables
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgment procedures
- System diagnostics and controller alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Basics and Use Cases
- Drive operating principles and control methods
- Interaction between drives, motors, and mechanical loads
- Common drive configurations in production equipment
- Yaskawa drives and other prevalent drive brands
VFD Configuration and Commissioning
- Parameter groups and access levels
- Motor data entry, auto-tuning, and test runs
- Parameter backup, restoration, and documentation
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm, and parameter error codes
- Fault history logs and monitoring values
- Diagnosing issues related to drives, motors, cabling, and mechanics
PLC-Based Drive Control
- Start, stop, and speed reference signals
- Status, ready, and fault feedback signals
- Resolving discrepancies between PLC and drive states
Industrial Communications and Network Diagnostics
- PROFINET and Ethernet basics
- Device naming, IP addressing, and network topology
- Connection diagnostics and resolving communication faults
TIA Portal Diagnostics and Systematic Troubleshooting
- Real-time online monitoring and watch tables
- Diagnostics buffer and CPU web server features
- Comparing online and offline program versions
- Tracing from fault symptom to root cause
- Electrical, mechanical, and control-side inspections
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of Stopped Equipment
- Sequence of checks when equipment halts
- Cross-verifying HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring operation
Practical Fault Scenario Exercises
- Exercises on sensor, actuator, and I\/O signal verification
- Motor, drive, and start/stop fault scenarios
- Communication interruptions and alarm interpretation
- Interlock and sequence faults hindering machine progression
Implementing Basic Program Changes
- Adjusting timers, setpoints, and parameters
- Adding or modifying tags and simple logic
- Testing, documenting, and reverting changes
Capstone: Comprehensive Troubleshooting Case
- Complete fault diagnosis on a production line model
- Determining whether to repair, adjust, or escalate
- Individual feedback and personal improvement planning
Requirements
- A fundamental understanding of electrical circuits and industrial machinery
- Introductory exposure to PLC concepts (university-level knowledge is sufficient)
- Basic proficiency in reading technical manuals for drives or equipment
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 issues
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
