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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control
- Understanding the automation architecture of production facilities
- Exploring sensors, actuators, and field signal interactions
- Overview of transport, feeding, dosing, and packaging subsystems
SIMATIC S7-1500 Hardware and System Architecture
- CPU families, signal modules, and distributed I/O structures
- Power supply, grounding practices, and control panel layouts
- Interpreting status LEDs, CPU displays, and module indicators
TIA Portal Project Setup and Device Configuration
- Navigating project views, devices, and network structures
- Configuring hardware and defining device parameters
- Managing project versions: loading, saving, and comparing
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing schemes
- 24 V DC signal circuits and wiring verification techniques
- Validating field signals against program expectations
Ladder Logic and Introductory Programming
- Working with contacts, coils, set, and reset operations
- Utilizing timers, counters, and comparison instructions
- Understanding functions, function blocks, and data blocks
Interpreting Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references
- Working with symbol tables, tags, and variable naming conventions
- Tracing the logical conditions governing specific outputs
Motor Control: Start/Stop and Protection
- Start, stop, and latching logic conditions
- Motor protection mechanisms and run feedback signals
- Direction control and multi-motor configuration strategies
Interlocks, Permissives, and Automated Sequences
- Designing interlock and permissive conditions
- Implementing step sequences and state-based control
- Diagnosing sequences halted at specific steps
SIMATIC HMI Configuration and Operation
- Panel screen design, tag management, and navigation
- Managing operating modes and HMI-based control
- Displaying equipment status and real-time process values
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, prioritization, and acknowledgement procedures
- System diagnostics and controller-level alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Principles and Applications
- Core drive principles and control methodologies
- Interaction between drives, motors, and mechanical loads
- Common drive configurations in production settings
- Overview of Yaskawa drives and other prevalent plant brands
VFD Configuration and Commissioning
- Parameter group management and access levels
- Motor data entry, auto-tuning, and test run procedures
- Parameter backup, restoration, and documentation
VFD Fault Diagnosis and Troubleshooting
- Interpreting fault, alarm, and parameter error codes
- Reviewing fault history and monitoring values
- Diagnosing issues related to drives, motors, cables, and mechanics
Controlling Drives from the PLC
- Managing start, stop, and speed reference signals
- Monitoring status, ready, and fault feedback
- Resolving discrepancies between PLC and drive states
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals
- Device naming, IP addressing, and network topology
- Connection diagnostics and resolving communication faults
TIA Portal Diagnostics and Systematic Troubleshooting
- Real-time online monitoring and using watch tables
- Utilizing the diagnostics buffer and CPU web server
- Comparing online and offline program versions
- Tracing from fault symptoms to root causes
- Conducting electrical, mechanical, and control-side inspections
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of Stopped Machines
- Establishing a priority order for checks during equipment stoppages
- Cross-referencing HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring operations
Practical Fault Scenario Exercises
- Exercises focused on sensor, actuator, and I/O signal checks
- Scenarios involving motor, drive, and start/stop faults
- Handling communication interruptions and interpreting alarms
- Resolving interlock and sequence faults that block machine steps
Making Basic Program Modifications
- Adjusting timers, setpoints, and operational parameters
- Adding or modifying tags and implementing simple logic
- Testing, documenting, and reverting program changes
Capstone: End-to-End Troubleshooting Case Study
- Comprehensive fault diagnosis on a production line simulation
- Decision-making between repair, adjustment, or escalation
- Individual feedback and formulation of improvement plans
Requirements
- A foundational grasp of electrical circuits and industrial equipment operations.
- Introductory knowledge of PLC concepts; university-level understanding is sufficient.
- Basic ability to interpret technical manuals for drives and industrial equipment.
Target Audience
- Maintenance technicians and engineers responsible for automated production systems.
- Electricians and technical specialists transitioning into automation and control roles.
- Staff members tasked with diagnosing faults in PLCs, HMIs, drives, and communication networks.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
