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
- Transport, feeding, dosing, and packaging subsystems
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 Setup and Device Configuration
- Project view, devices, and network structures
- 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 Foundational Programming
- Contacts, coils, set, and 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 behavior
Motor Control: Start/Stop Operations
- 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 condition logic
- Step sequences and state-based control methods
- Diagnosing sequences blocked at specific steps
SIMATIC HMI Configuration and Usage
- 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: Principles and Use Cases
- Drive operating principles and control methods
- Interaction between drive, motor, and mechanical load
- Common drive configurations in production equipment
- Yaskawa drives and other prevalent drive brands in the plant
VFD Configuration and Commissioning
- Parameter groups and access level management
- Motor data entry, auto-tuning, and test runs
- Backing up, restoring, and documenting parameters
VFD Fault Diagnosis and Troubleshooting
- Interpreting fault, alarm, and parameter error codes
- Reviewing fault history and monitoring values
- Diagnosing drive, motor, cable, and mechanical failures
PLC Control of Drives
- Start, stop, and speed reference signals
- Status, ready, and fault feedback mechanisms
- Diagnosing discrepancies between PLC and drive states
Industrial Communication and Network Diagnostics
- PROFINET and Ethernet fundamentals
- Device naming, IP addressing, and network topology
- Connection diagnostics and troubleshooting communication faults
TIA Portal Diagnostics and Systematic Troubleshooting
- Real-time online monitoring and watch tables
- Diagnostics buffer and CPU web server features
- Comparing online and offline program states
- Progressing from fault symptom to root cause analysis
- Performing electrical, mechanical, and control-side checks
- Documenting findings and defining escalation criteria
Methodical Diagnosis of Stopped Machines
- Systematic order of checks when equipment halts
- Correlating 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
- Motor, drive, and start/stop fault scenarios
- Handling communication interruptions and interpreting alarms
- Resolving interlock and sequence faults that block machine steps
Implementing Basic Program Modifications
- Adjusting timers, setpoints, and parameters
- Adding or modifying tags and simple logic
- Testing, documenting, and reverting changes as needed
Capstone: Comprehensive Troubleshooting Case Study
- End-to-end fault diagnosis on a production line model
- Decision-making between repair, adjustment, and escalation
- Individual feedback and personalized improvement planning
Requirements
- Foundational knowledge of electrical circuits and industrial machinery
- Introductory familiarity with PLC concepts (university-level understanding is sufficient)
- Basic ability to read technical manuals for drives and equipment
Target Audience
- Maintenance technicians and engineers managing automated production equipment
- Electricians and technical staff transitioning into automation and control roles
- Personnel tasked with 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
