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 display, and module indicators
TIA Portal Project Structure and Device Configuration
- Project view, devices, and networks
- Hardware configuration and device parameters
- Loading, saving, and comparing project versions
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing
- 24 V DC signal circuits and wiring verification
- Verifying field signals against the program
Ladder Logic and Fundamental Programming
- Contacts, coils, set, and reset operations
- Timers, counters, and comparison instructions
- Functions, function blocks, and data blocks
Interpreting Existing Programs and Control Logic
- Navigating program blocks and cross-references
- Symbol tables, tags, and variable naming conventions
- Tracing the logical conditions that govern an output
Motor and Start/Stop Control
- Start, stop, and latching conditions
- Motor protection 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
- Diagnosing sequences blocked at a specific step
SIMATIC HMI Configuration and Operation
- Panel screens, tags, and navigation
- Operating modes and control via HMI
- Displaying equipment status and process values
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgment
- System diagnostics and controller alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Fundamentals and Applications
- Drive principles and control methods
- Interaction between drive, motor, and mechanical load
- Typical drive configurations on production equipment
- Yaskawa drives and other common drive brands in the plant
VFD Configuration and Commissioning
- Parameter groups and access levels
- Motor data, auto-tuning, and test runs
- Backing up, restoring, and documenting parameters
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm, and parameter error codes
- Fault history and monitoring values
- Diagnosing drive, motor, cable, and mechanical faults
Controlling Drives from the PLC
- Start, stop, and speed reference signals
- Status, ready, and fault feedback
- Diagnosing discrepancies between PLC and drive states
Industrial Communication and Network Troubleshooting
- PROFINET and Ethernet fundamentals
- Device names, IP addresses, and network topology
- Connection diagnostics and communication faults
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch tables
- Diagnostics buffer and CPU web server
- Comparing online and offline programs
- Tracing from fault symptom to root cause
- Electrical, mechanical, and control-side checks
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of a Stopped Machine
- Recommended order of checks when equipment stops
- Cross-checking HMI alarms, PLC logic, and drive status
- Identifying the blocking condition and restoring operation
Practical Fault Scenario Exercises
- Exercises for checking sensors, actuators, and I/O signals
- Motor, drive, and start/stop fault scenarios
- Handling communication interruptions and interpreting alarms
- Interlock and sequence faults that block a machine step
Basic Program Modifications
- Adjusting timers, setpoints, and parameters
- Adding or modifying tags and simple logic
- Testing, documenting, and reverting changes
Capstone: End-to-End Troubleshooting Case
- Comprehensive fault diagnosis on a production line model
- Deciding between repair, adjustment, and escalation
- Individual feedback and development plan
Requirements
- A basic understanding of electrical circuits and industrial equipment
- Introductory exposure to PLC concepts (university-level knowledge is sufficient)
- Familiarity with reading technical manuals for drives and equipment
Audience
- Maintenance technicians and engineers working with automated production equipment
- 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
