Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within a production plant
- Sensors, actuators, and field signals
- Subsystems for transport, feeding, dosing, and packaging
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 networks
- Hardware configuration and device parameters
- Loading, saving, and comparing project versions
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing
- 24 V DC signal circuits and wiring verification
- Validating field signals against the program
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 specific outputs
Motor Control: Start, Stop, and Operation
- 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 conditions
- Step sequences and state-based control
- Diagnosing sequences blocked at a specific step
SIMATIC HMI Configuration and Operation
- Panel screens, tags, and navigation
- Operating modes and HMI-based control
- Displaying equipment status and process values
HMI Alarms and PLC Diagnostics Messages
- Alarm classes, priorities, and acknowledgement
- System diagnostics and controller alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Principles and Applications
- Drive principles and control methods
- Interaction between drives, motors, and mechanical loads
- Typical drive configurations on production equipment
- Yaskawa drives and other common drive brands used in the plant
VFD Configuration and Commissioning
- Parameter groups and access levels
- Motor data, auto-tuning, and test runs
- Backup, restore, and parameter documentation
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm, and parameter error codes
- Fault history and monitoring values
- Diagnosing faults in drives, motors, cables, and mechanical components
Drive Control from the PLC
- Start, stop, and speed reference signals
- Status, ready, and fault feedback
- 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 resolution
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch tables
- Diagnostics buffer and CPU web server
- Comparing online and offline programs
- Tracing from fault symptom to root cause
- Electrical, mechanical, and control-side inspections
- Documenting findings and establishing escalation criteria
Step-by-Step Diagnosis of a Stopped Machine
- Recommended order of checks when equipment halts
- Cross-checking 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
- Scenarios covering motor, drive, and start/stop faults
- Handling communication interruptions and interpreting alarms
- Resolving interlock and sequence faults that block 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
- Complete fault diagnosis on a production line model
- Deciding between repair, adjustment, and escalation
- Individual feedback and development of an improvement plan
Requirements
- Fundamental understanding of electrical circuits and industrial equipment
- Introductory exposure to PLC concepts (university-level knowledge is sufficient)
- Basic familiarity with reading technical manuals for drives or equipment
Target Audience
- Maintenance technicians and engineers working with automated production equipment
- Electricians and technical staff transitioning into automation and control roles
- Personnel responsible for diagnosing PLC, HMI, drive, and communication faults
Custom Corporate Training
Training solutions designed exclusively for businesses.
- Customized Content: We adapt the syllabus and practical exercises to the real goals and needs of your project.
- Flexible Schedule: Dates and times adapted to your team's agenda.
- Format: Online (live), In-company (at your offices), or Hybrid.
Price per private group, online live training, starting from 6500 € + VAT*
Contact us for an exact quote and to hear our latest promotions
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
