Course Outline
Foundations of Industrial Automation and Control
- Automation architecture within a production facility.
- 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.
- Power supply, grounding, and control panel layouts.
- Status LEDs, CPU displays, and module indicators.
TIA Portal Project Management and Device Setup
- Project views, device lists, and network structures.
- Hardware configuration and device parameterization.
- Managing project versions: loading, saving, and comparison.
PLC I/O: Signals and Addressing Schemes
- Digital and analog addressing techniques.
- 24 V DC signal circuits and wiring verification.
- Cross-referencing field signals with control programs.
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 Logic
- Navigating program blocks and cross-references.
- Managing symbol tables, tags, and variable naming conventions.
- Tracing logical conditions that govern output states.
Motor Control: Start/Stop and Protection
- Start, stop, and latching conditions.
- Motor protection mechanisms and run feedback.
- Direction control and multi-motor arrangements.
Interlocks, Permissives, and Automatic Sequences
- Configuring interlock and permissive conditions.
- Step sequences and state-based control logic.
- Diagnosing sequences blocked at specific steps.
SIMATIC HMI Setup and Operation
- Panel screens, tags, and navigation flows.
- Operating modes and HMI-driven control.
- Displaying equipment status and process values.
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priorities, and acknowledgement procedures.
- System diagnostics and controller-level alarms.
- Process and program-based monitoring alerts.
Variable Frequency Drives: Core Concepts and Uses
- Drive operating principles and control methods.
- Interaction between drives, motors, and mechanical loads.
- Standard drive configurations on production assets.
- Yaskawa drives and other prevalent brands in the plant.
VFD Configuration and Commissioning
- Parameter groups and user access levels.
- Motor data entry, auto-tuning, and test runs.
- Parameter backup, restoration, and documentation.
VFD Fault Diagnosis and Troubleshooting
- Decoding fault, alarm, and parameter error codes.
- Analyzing fault history and monitoring values.
- Diagnosing issues related to drives, motors, cables, and mechanics.
Drive Control via PLC
- Start, stop, and speed reference signaling.
- Feedback for status, ready state, and faults.
- Resolving discrepancies between PLC and drive states.
Industrial Communications and Network Troubleshooting
- PROFINET and Ethernet basics.
- Device naming, IP addressing, and topology.
- Connection diagnostics and communication fault isolation.
TIA Portal Diagnostics and Structured Problem-Solving
- Real-time online monitoring and watch tables.
- Using the diagnostics buffer and CPU web server.
- Comparing online and offline program versions.
- Progressing 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 Stopped Machinery
- Establishing the correct order of checks during a stoppage.
- Correlating HMI alarms, PLC logic, and drive status.
- Identifying blocking conditions and restoring operations.
Practical Fault Scenario Drills
- Exercises in sensor, actuator, and I/O signal verification.
- Simulating motor, drive, and start/stop failures.
- Addressing communication interruptions and interpreting alarms.
- Resolving interlock and sequence faults that halt machine steps.
Basic Program Modifications
- Tuning timers, setpoints, and system parameters.
- Adding or adjusting tags and simple logic sequences.
- Testing, documenting, and reverting changes as needed.
Capstone: End-to-End Troubleshooting Case Study
- Comprehensive fault diagnosis on a production line model.
- Decision-making on repair, adjustment, or escalation.
- Individual feedback and personalized improvement planning.
Requirements
- Foundational understanding of electrical circuits and industrial machinery.
- Basic exposure to PLC concepts (university-level knowledge is sufficient).
- Competence in reading technical manuals for drives and equipment.
Target Audience
- Maintenance technicians and engineers working with automated production lines.
- Electricians and technical staff transitioning into automation and control roles.
- Professionals responsible for diagnosing PLC, HMI, drive, and communication issues.
Custom Corporate Training
Training solutions designed exclusively for businesses.
- Customized Content: We adapt the syllabus and practical exercises to the real goals and needs of your project.
- Flexible Schedule: Dates and times adapted to your team's agenda.
- Format: Online (live), In-company (at your offices), or Hybrid.
Price per private group, online live training, starting from 8000 € + VAT*
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Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
