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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 signal processing.
- Subsystems for transport, feeding, dosing, and packaging.
SIMATIC S7-1500 Hardware and System Architecture
- CPU families, signal modules, and distributed I/O systems.
- Power supply requirements, grounding, and control panel layout.
- Interpreting status LEDs, CPU displays, and module indicators.
TIA Portal Project Structure and Device Configuration
- Navigating project views, devices, and network configurations.
- Hardware configuration and setting device parameters.
- Managing project versions through loading, saving, and comparison.
PLC Inputs and Outputs: Signal Management 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
- Working with contacts, coils, and set/reset operations.
- Utilizing timers, counters, and comparison instructions.
- Understanding functions, function blocks, and data blocks.
Analyzing Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references.
- Managing symbol tables, tags, and variable naming conventions.
- Tracing logical conditions governing output states.
Motor Control: Start/Stop Mechanisms
- Configuring start, stop, and latching conditions.
- Implementing motor protection and run feedback signals.
- Managing direction control and multi-motor configurations.
Interlocks, Permissives, and Automated Sequences
- Defining interlock and permissive conditions.
- Designing step sequences and state-based control logic.
- Diagnosing sequences halted at specific steps.
SIMATIC HMI Configuration and User Operation
- Managing panel screens, tags, and navigation paths.
- Configuring operating modes and HMI-driven controls.
- Displaying real-time equipment status and process values.
HMI Alarms and PLC Diagnostic Messages
- Understanding alarm classes, priorities, and acknowledgement.
- Reviewing system diagnostics and controller alarms.
- Monitoring process and program-based messages.
Variable Frequency Drives: Core Concepts and Use Cases
- Drive operating principles and control methodologies.
- Interaction between drives, motors, and mechanical loads.
- Common drive configurations on production assets.
- Managing Yaskawa drives and other prevalent brands in the facility.
VFD Configuration and Commissioning
- Navigating parameter groups and access levels.
- Inputting motor data, performing auto-tuning, and test runs.
- Backing up, restoring, and documenting parameters.
VFD Fault Analysis and Resolution
- Interpreting fault, alarm, and parameter error codes.
- Reviewing fault history and monitoring values.
- Diagnosing faults related to drives, motors, cabling, and mechanics.
PLC-Based Drive Control
- Managing start, stop, and speed reference signals.
- Monitoring status, ready, and fault feedback.
- Resolving discrepancies between PLC and drive states.
Industrial Communication and Network Diagnostics
- PROFINET and Ethernet protocol fundamentals.
- Configuring device names, IP addresses, and network topology.
- Performing connection diagnostics and resolving communication faults.
TIA Portal Diagnostics and Systematic Troubleshooting
- Conducting real-time online monitoring and using watch tables.
- Accessing the diagnostics buffer and CPU web server.
- Comparing online and offline program versions.
- Tracing from fault symptoms to root causes.
- Executing electrical, mechanical, and control-side inspections.
- Documenting findings and defining escalation criteria.
Sequential Diagnosis of Stopped Machines
- Establishing the correct order of checks during equipment stoppages.
- Cross-referencing HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring normal operation.
Practical Fault Scenario Drills
- Exercises in verifying sensors, actuators, and I/O signals.
- Scenarios involving motor, drive, and start/stop faults.
- Situations involving communication interruptions and alarm analysis.
- Addressing interlock and sequence faults that block machine steps.
Implementing Basic Program Adjustments
- Modifying timers, setpoints, and parameters.
- Adding or altering tags and simple logic structures.
- Testing, documenting, and reverting changes as needed.
Capstone: Comprehensive Troubleshooting Case Study
- Executing a full fault diagnosis on a production line model.
- Deciding between repair, adjustment, or escalation.
- Receiving individual feedback and a personalized improvement plan.
Requirements
- Fundamental understanding of electrical circuits and industrial machinery.
- Preliminary exposure to PLC concepts (university-level knowledge is sufficient).
- Basic proficiency in reading technical manuals for drives and equipment.
Target Audience
- Maintenance technicians and engineers managing automated production lines.
- Electricians and technical staff transitioning into automation and control roles.
- Professionals responsible for 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
