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Duration 35 hours
Course Outline
Industrial Automation and Control Essentials
- Automation architecture within production facilities.
- Sensors, actuators, and field-level signals.
- Transport, feeding, dosing, and packaging subsystems.
SIMATIC S7-1500 Hardware and System Architecture
- CPU families, signal modules, and distributed I/O systems.
- Power supply requirements, grounding, and control panel layout.
- Status LEDs, CPU displays, and module indicators.
TIA Portal Project Structure and Device Setup
- Project views, device management, and network configuration.
- Hardware configuration and parameter assignment.
- 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.
- Validating field signals against program logic.
Ladder Logic and Core 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 utilizing cross-references.
- Symbol tables, tag management, and variable naming conventions.
- Tracing logical conditions governing specific outputs.
Motor Control: Start/Stop Mechanisms
- 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 logic conditions.
- Step sequences and state-based control mechanisms.
- Diagnosing sequences blocked at specific steps.
SIMATIC HMI Configuration and Usage
- Panel screens, tag associations, and navigation structures.
- Operating modes and HMI-based control actions.
- Displaying equipment status and process variables.
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgement procedures.
- System diagnostics and controller alarms.
- Process-based and program-based monitoring messages.
Variable Frequency Drives: Basics and Applications
- Drive principles and control methodologies.
- Interaction between drives, motors, and mechanical loads.
- Standard drive configurations in production environments.
- Yaskawa drives and other common drive brands used in the plant.
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 drive, motor, cable, and mechanical faults.
PLC-Controlled Drive Operation
- Start, stop, and speed reference signals.
- Status, ready, and fault feedback mechanisms.
- Diagnosing discrepancies between PLC state and drive state.
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals.
- Device naming, IP addressing, and network topology.
- Connection diagnostics and communication fault analysis.
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch tables.
- Diagnostics buffer and CPU web server utilization.
- Comparing online and offline program states.
- Progressing from fault symptoms to root cause analysis.
- Electrical, mechanical, and control-side verification checks.
- Documenting findings and defining escalation criteria.
Step-by-Step Diagnosis of Stopped Equipment
- Recommended 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 involving sensor, actuator, and I/O signal verification.
- Motor, drive, and start/stop fault simulations.
- Communication interruption analysis and alarm interpretation.
- Interlock and sequence faults halting machine steps.
Basic Program Modifications
- Adjusting timers, setpoints, and system parameters.
- Adding or modifying tags and simple logic structures.
- Testing, documenting, and reverting changes as necessary.
Capstone: Comprehensive Troubleshooting Case
- End-to-end fault diagnosis on a production line model.
- Decision-making regarding repair, adjustment, or escalation.
- Individual feedback and personal improvement planning.
Requirements
- A foundational understanding of electrical circuits and industrial machinery.
- Introductory familiarity with PLC concepts (university-level knowledge is sufficient).
- Basic proficiency in reading technical manuals for drives and equipment.
Target Audience
- Maintenance technicians and engineers managing automated production equipment.
- 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
