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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Automation architecture in production plants.
- Overview of sensors, actuators, and field signals.
- Subsystems for transport, feeding, dosing, and packaging.
SIMATIC S7-1500 Hardware and System Design
- CPU families, signal modules, and distributed I/O architecture.
- Power supply management, grounding, and control panel layout.
- Interpreting status LEDs, CPU displays, and module indicators.
TIA Portal Project Organization and Device Setup
- Navigating the project view, device hierarchy, and network structures.
- Configuring hardware and setting device parameters.
- 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
- Working with contacts, coils, set, and reset operations.
- Utilizing timers, counters, and comparison instructions.
- Implementing functions, function blocks, and data blocks.
Reading Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references.
- Understanding symbol tables, tags, and variable naming conventions.
- Tracing logical conditions that dictate output behavior.
Motor Control and Start/Stop Operations
- Managing start, stop, and latching conditions.
- Motor protection mechanisms and run feedback signals.
- Direction control and multi-motor configurations.
Interlocks, Permissives, and Automatic Sequences
- Defining interlock and permissive conditions.
- Designing step sequences and state-based controls.
- Diagnosing sequences blocked at specific steps.
SIMATIC HMI Configuration and Usage
- Setting up panel screens, tags, and navigation flows.
- Managing operating modes and HMI-based control.
- Displaying equipment status and process values.
HMI Alarms and PLC Diagnostic Messages
- Understanding alarm classes, priorities, and acknowledgement.
- Analyzing system diagnostics and controller alarms.
- Interpreting process and program-based monitoring messages.
Variable Frequency Drives: Principles and Applications
- Drive operating principles and control methodologies.
- Interaction between drives, motors, and mechanical loads.
- Common drive configurations in production equipment.
- Yaskawa drives and other prevalent drive brands in industrial settings.
VFD Configuration and Commissioning
- Managing parameter groups and access levels.
- Inputting motor data, auto-tuning, and performing test runs.
- Backing up, restoring, and documenting parameters.
VFD Fault Diagnosis and Troubleshooting
- Decoding fault, alarm, and parameter error codes.
- Reviewing fault history and monitoring values.
- Diagnosing issues related to drives, motors, cables, and mechanics.
PLC-Driven Drive Control
- Managing start, stop, and speed reference signals.
- Monitoring status, ready, and fault feedback.
- Resolving discrepancies between PLC states and drive conditions.
Industrial Communication and Network Diagnostics
- PROFINET and Ethernet basics.
- Managing device names, IP addresses, and network topology.
- Diagnosing connections and communication failures.
TIA Portal Diagnostics and Systematic Troubleshooting
- Utilizing real-time online monitoring and watch tables.
- Accessing the diagnostics buffer and CPU web server.
- Comparing online and offline program versions.
- Moving from fault symptoms to root cause analysis.
- Performing electrical, mechanical, and control-side inspections.
- Documenting findings and defining escalation criteria.
Step-by-Step Diagnosis of Halted Equipment
- 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
- Drills for checking sensors, actuators, and I/O signals.
- Scenarios involving motor, drive, and start/stop faults.
- Handling communication interruptions and interpreting alarms.
- Resolving interlock and sequence faults that block machine steps.
Executing Basic Program Modifications
- Adjusting timers, setpoints, and parameters.
- Adding or modifying tags and simple logic structures.
- Testing, documenting, and reverting changes as needed.
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a production line model.
- Decision-making on repair, adjustment, or escalation.
- Providing individual feedback and improvement plans.
Requirements
- A foundational grasp of electrical circuits and industrial machinery.
- Introductory knowledge of PLC concepts (university-level understanding is adequate).
- Basic proficiency in reading technical manuals for drives or equipment.
Target Audience
- Maintenance technicians and engineers responsible for automated production lines.
- Electricians and technical staff transitioning into automation and control roles.
- Professionals 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
