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-level signals
- Subsystems for transport, feeding, dosing, and packaging
SIMATIC S7-1500 Hardware and System Design
- CPU families, signal modules, and distributed I/O
- Power supply units, grounding, and control panel layouts
- Status LEDs, CPU displays, and module indicators
TIA Portal Project Setup and Device Configuration
- Project views, device lists, and network structures
- Hardware setup and device parameterization
- Loading, saving, and comparing project versions
PLC Inputs/Outputs: Signals and Addressing
- Digital and analog addressing schemes
- 24 V DC signal circuits and wiring verification
- Cross-referencing field signals with program logic
Ladder Logic and Fundamental Programming
- Contacts, coils, set/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 governing specific outputs
Motor Control: Start/Stop Mechanisms
- Start, stop, and latching conditions
- Motor protection features and run feedback signals
- Direction control and multi-motor setups
Interlocks, Permissives, and Automatic Sequences
- Interlock and permissive condition logic
- Step sequences and state-based control strategies
- Diagnosing sequences stalled at specific steps
SIMATIC HMI Setup and Operations
- Panel screens, tag management, and navigation
- Operating modes and HMI-driven control
- Displaying equipment status and process values
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgment processes
- System diagnostics and controller alarms
- Monitoring messages based on process and program states
Variable Frequency Drives: Principles and Uses
- Drive operating principles and control methodologies
- Interactions between drives, motors, and mechanical loads
- Typical drive configurations on production lines
- Yaskawa drives and other prevalent drive brands in the facility
VFD Configuration and Commissioning
- Parameter groups and access hierarchies
- Motor data entry, auto-tuning, and test operations
- Backing up, restoring, and documenting parameters
VFD Fault Diagnosis and Troubleshooting
- Fault codes, alarms, and parameter errors
- Fault history logs and monitoring values
- Diagnosing issues related to drives, motors, cabling, and mechanics
Controlling Drives from the PLC
- Start/stop commands and speed reference signals
- Status, ready, and fault feedback loops
- Resolving discrepancies between PLC and drive states
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet basics
- Device naming, IP addressing, and network topology
- Connection diagnostics and communication error resolution
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch tables
- Diagnostics buffer analysis and CPU web server usage
- Comparing online vs. offline program states
- Transitioning from fault symptoms to root causes
- Checks across electrical, mechanical, and control domains
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of Halted Machinery
- Sequential checks when equipment stops
- Cross-verifying HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring operation
Practical Fault Scenario Exercises
- Exercises for checking sensors, actuators, and I/O signals
- Scenarios involving motor, drive, and start/stop failures
- Handling communication interruptions and interpreting alarms
- Resolving interlock and sequence faults blocking 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
- Comprehensive fault diagnosis on a production line model
- Decision-making regarding repair, adjustment, or escalation
- Individual feedback and improvement planning
Requirements
- Fundamental comprehension of electrical circuits and industrial machinery
- Preliminary exposure to PLC concepts (university-level knowledge is acceptable)
- Basic proficiency in interpreting technical manuals for drives or equipment
Target Audience
- Maintenance technicians and engineers managing automated production assets
- Electricians and technical staff transitioning into automation and control roles
- Personnel 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
