Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within a production plant
- 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, grounding, and control panel layout
- Status LEDs, CPU displays, and module indicators
TIA Portal Project Structure and Device Configuration
- Project views, device management, and network settings
- Hardware configuration and device parameter settings
- Managing project versions: loading, saving, and comparing
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog signal addressing
- 24 V DC signal circuits and wiring verification
- Validating field signals against program logic
Ladder Logic and Fundamental Programming
- Contacts, coils, and set/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
- Understanding symbol tables, tags, and variable naming conventions
- Tracing logical conditions that govern output behavior
Motor Control: Start and Stop Mechanisms
- Start, stop, and latching conditions
- Motor protection circuits 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 mechanisms
- Diagnosing sequences blocked at specific steps
SIMATIC HMI Configuration and Operation
- Panel screens, tag assignment, and navigation flows
- Operating modes and control via the HMI
- Displaying equipment status and real-time process values
HMI Alarms and PLC Diagnostics Messages
- Alarm classes, priorities, and acknowledgement procedures
- System diagnostics and controller-level alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Principles and Applications
- Drive principles and various control methods
- Interaction between drives, motors, and mechanical loads
- Typical drive configurations found in production equipment
- Yaskawa drives and other common drive brands in industrial settings
VFD Configuration and Commissioning
- Parameter groups and user access levels
- Motor data entry, auto-tuning, and test runs
- Backup, restoration, and parameter documentation
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm, and parameter error code analysis
- Reviewing fault history and monitoring values
- Diagnosing drive, motor, cable, and mechanical faults
PLC-Driven Control of VFDs
- Start, stop, and speed reference signals
- Status, ready, and fault feedback signals
- 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 resolving communication faults
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch tables
- Utilizing the diagnostics buffer and CPU web server
- Comparing online versus offline program states
- Progressing from fault symptoms to root cause identification
- Performing electrical, mechanical, and control-side checks
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of Stopped Machines
- 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 in sensor, actuator, and I/O signal verification
- Simulating motor, drive, and start/stop fault scenarios
- Addressing communication interruptions and interpreting alarms
- Resolving interlock and sequence faults that block machine steps
Implementing Basic Program Modifications
- Adjusting timers, setpoints, and operational parameters
- Adding or modifying tags and simple logic structures
- Testing, documenting, and reverting changes as necessary
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a production line model
- Decision-making: repair, adjustment, or escalation
- Individual feedback sessions and improvement planning
Requirements
- A foundational understanding of electrical circuits and industrial machinery.
- Introductory knowledge of PLC concepts (equivalent to university-level exposure is sufficient).
- Basic proficiency in reading technical manuals for drives and equipment.
Target Audience
- Maintenance technicians and engineers specializing in automated production systems.
- Electricians and technical staff transitioning into automation and control roles.
- Professionals responsible for diagnosing PLC, HMI, drive, and communication issues.
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
