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 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 views, devices, and networks.
- Hardware configuration and device parameter settings.
- Loading, saving, and comparing project versions.
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.
Analyzing Existing Programs and Control Logic
- Navigating program blocks and cross-references.
- Symbol tables, tags, and variable naming conventions.
- Tracing logical conditions that govern output actions.
Motors and Start/Stop Control
- Start, stop, and latching conditions.
- Motor protection mechanisms 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 logic.
- Diagnosing sequences blocked at a specific step.
SIMATIC HMI Configuration and Operation
- Panel screens, tags, and navigation structures.
- Operating modes and HMI-based control.
- Displaying equipment status and process values.
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgement procedures.
- System diagnostics and controller alarms.
- Process and program-based monitoring messages.
Variable Frequency Drives: Core Concepts and Applications
- Drive principles and control methodologies.
- Interaction between drives, motors, and mechanical loads.
- Standard drive configurations on production equipment.
- Yaskawa drives and other common plant drive brands.
VFD Configuration and Commissioning
- Parameter groups and access levels.
- Motor data entry, auto-tuning, and test runs.
- Parameter backup, restoration, and documentation.
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm, and parameter error codes.
- Fault history analysis and monitoring values.
- Diagnosing faults in drives, motors, cables, and mechanics.
PLC-Driven Drive Control
- Start, stop, and speed reference signals.
- Status, ready, and fault feedback signals.
- Resolving discrepancies between PLC and drive states.
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals.
- Device naming, IP addresses, and network topology.
- Connection diagnostics and resolving communication faults.
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch tables.
- Diagnostics buffer analysis and CPU web server usage.
- Comparing online and offline program states.
- Tracing from fault symptoms to root causes.
- Performing electrical, mechanical, and control-side checks.
- Documenting findings and defining escalation criteria.
Step-by-Step Diagnosis of Stopped Machinery
- Establishing the correct order of checks during a stoppage.
- Cross-referencing 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.
- Simulating communication interruptions and interpreting alarms.
- Diagnosing interlock and sequence faults that halt machine steps.
Implementing Basic Program Modifications
- Adjusting timers, setpoints, and parameters.
- Adding or modifying tags and simple logic.
- Testing, documenting, and reverting changes as necessary.
Capstone: End-to-End Troubleshooting Case Study
- Comprehensive fault diagnosis on a production line model.
- Decision-making between repair, adjustment, or escalation.
- Individual feedback and formulation of an improvement plan.
Requirements
- A 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 and 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 PLC, HMI, drive, and communication faults.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
