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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within a production plant.
- Sensors, actuators, and field 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 view, device management, and network setup.
- Hardware configuration and device parameter settings.
- Managing project versions through loading, saving, and comparison.
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 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.
- Managing symbol tables, tags, and variable naming conventions.
- Tracing logical conditions that govern output actions.
Motor Control: Start/Stop Operations
- Start, stop, and latching conditions.
- Motor protection mechanisms and run feedback signals.
- Direction control and configurations for multiple motors.
Interlocks, Permissives, and Automated Sequences
- Defining interlock and permissive conditions.
- Step sequences and state-based control logic.
- Diagnosing sequences blocked at specific steps.
SIMATIC HMI Configuration and Operation
- Panel screens, tag management, and navigation.
- Operating modes and HMI-based control functions.
- Displaying equipment status and process values.
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priority levels, and acknowledgement processes.
- System diagnostics and controller-specific alarms.
- Monitoring messages based on process and program conditions.
Variable Frequency Drives: Principles and Applications
- Drive operating principles and control methods.
- Interaction between drives, motors, and mechanical loads.
- Common drive configurations in production environments.
- Yaskawa drives and other prevalent drive brands.
VFD Configuration and Commissioning
- Parameter groups and access level settings.
- Motor data entry, auto-tuning, and test runs.
- Backing up, restoring, and documenting parameters.
VFD Fault Diagnosis and Troubleshooting
- Fault codes, alarm indicators, and parameter errors.
- Analyzing fault history and monitoring values.
- Diagnosing issues related to drives, motors, cables, and mechanics.
PLC-Based Drive Control
- Start, stop, and speed reference signals.
- Status, readiness, and fault feedback mechanisms.
- Resolving discrepancies between PLC and drive states.
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamental concepts.
- 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 and offline program versions.
- Progressing from fault symptoms to identifying root causes.
- Performing electrical, mechanical, and control-side inspections.
- Documenting findings and establishing escalation criteria.
Step-by-Step Diagnosis of Stopped Machines
- Establishing the order of checks when equipment halts.
- Cross-referencing HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring normal operation.
Practical Fault Scenario Exercises
- Exercises focused on sensor, actuator, and I/O signal verification.
- Scenarios involving motor, drive, and start/stop faults.
- Handling communication interruptions and interpreting alarms.
- Addressing interlock and sequence faults that block machine steps.
Performing Basic Program Modifications
- Adjusting timers, setpoints, and system parameters.
- Adding or modifying tags and simple logic structures.
- Testing, documenting, and reverting program changes.
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a production line model.
- Decision-making regarding repair, adjustment, or escalation.
- Individual feedback and formulation of an improvement plan.
Requirements
- Fundamental understanding of electrical circuits and industrial machinery.
- Introductory familiarity with PLC concepts (university-level knowledge is adequate).
- Basic ability to read 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.
- Personnel responsible for diagnosing faults in PLCs, HMIs, drives, and communications.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
