Thank you for sending your enquiry! One of our team members will contact you shortly.
Thank you for sending your booking! One of our team members will contact you shortly.
Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within production plants.
- Sensors, actuators, and field signaling.
- Subsystems for transport, feeding, dosing, and packaging.
SIMATIC S7-1500 Hardware and System Design
- CPU families, signal modules, and distributed I/O systems.
- Power supply, grounding, and control panel organization.
- Status LEDs, CPU displays, and module indicators.
TIA Portal Project Management and Device Setup
- Project views, device lists, and network configurations.
- Hardware configuration and device parameter settings.
- Managing, 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.
Analyzing Existing Programs and Control Logic
- Navigating program blocks and using cross-references.
- Symbol tables, tags, and variable naming conventions.
- Tracing logical conditions that drive specific outputs.
Motor Control: Start/Stop Mechanisms
- Start, stop, and latching conditions.
- Motor protection and run feedback signals.
- Direction control and multi-motor setups.
Interlocks, Permissives, and Automation Sequences
- Interlock and permissive conditions.
- Step sequences and state-based control strategies.
- Diagnosing sequences blocked at specific steps.
SIMATIC HMI Configuration and Usage
- Panel screens, tags, and navigation logic.
- Operating modes and HMI-based control.
- Displaying equipment status and process values.
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 Uses
- Drive principles and control methodologies.
- Interaction between drives, motors, and mechanical loads.
- Standard drive configurations on production lines.
- Yaskawa drives and other prevalent drive brands in industrial settings.
VFD Configuration and Commissioning
- Parameter groups and access levels.
- Motor data entry, auto-tuning, and test runs.
- Backing up, restoring, and documenting parameters.
VFD Fault Diagnosis and Resolution
- Fault, alarm, and parameter error codes.
- Fault history and monitoring value analysis.
- Diagnosing drive, motor, cable, and mechanical issues.
PLC-Driven Control
- Start, stop, and speed reference signals.
- Status, ready, and fault feedback mechanisms.
- Diagnosing discrepancies between PLC and drive states.
Industrial Communication and Network Issues
- 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 watch tables.
- Diagnostics buffer and CPU web server usage.
- Comparing online and offline programs.
- Progressing from fault symptoms to root cause identification.
- Electrical, mechanical, and control-side inspections.
- Documenting findings and defining escalation criteria.
Step-by-Step Diagnosis of Stopped Machinery
- 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
- Exercises involving sensor, actuator, and I/O signal checks.
- Motor, drive, and start/stop fault scenarios.
- Communication interruptions and alarm interpretation.
- Interlock and sequence faults impeding machine steps.
Basic Program Modifications
- Adjusting timers, setpoints, and parameters.
- Adding or modifying tags and simple logic.
- Testing, documenting, and reverting changes as needed.
Capstone: End-to-End Troubleshooting Case Study
- Complete fault diagnosis on a production line model.
- Decision-making regarding repair, adjustment, or escalation.
- Individual feedback and development planning.
Requirements
- A foundational understanding of electrical circuits and industrial machinery.
- Introductory knowledge of PLC concepts (university-level exposure is sufficient).
- Basic proficiency in reading technical manuals for drives or equipment.
Target Audience
- Maintenance technicians and engineers responsible for automated production equipment.
- Electricians and technical staff transitioning into automation and control roles.
- Professionals 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
