Course Outline
Industrial Automation and Control Fundamentals
- Automation architecture of 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 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 checks
- Verifying field signals against the program
Ladder Logic and Basic 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
- Tracing the logical conditions that control an output
Motors and Motor 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 a sequence blocked at a step
SIMATIC HMI Configuration and Operation
- Panel screens, tags and navigation
- Operating modes and control from the HMI
- Displaying equipment status and process values
HMI Alarms and PLC Diagnostics Messages
- Alarm classes, priorities and acknowledgement
- System diagnostics and controller alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Fundamentals and Applications
- Drive principles and control methods
- Drive, motor and mechanical load interaction
- 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
- Backup, restore and documentation of parameters
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm and parameter error codes
- Fault history and monitoring values
- Diagnosing drive, motor, cable and mechanical faults
Drive Control from the PLC
- Start, stop and speed reference signals
- Status, ready and fault feedback
- Diagnosing discrepancies between PLC and drive state
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
- From fault symptom to root cause
- Electrical, mechanical and control-side checks
- Documenting findings and escalation criteria
Step-by-Step Diagnosis of a Stopped Machine
- 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
- Sensor, actuator and I/O signal check exercises
- Motor, drive and start/stop fault scenarios
- Communication interruptions and alarm interpretation
- Interlock and sequence faults blocking a machine step
Making 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
- Full fault diagnosis on a production line model
- Deciding between repair, adjustment and escalation
- Individual feedback and improvement plan
Requirements
- Basic understanding of electrical circuits and industrial equipment
- Introductory exposure to PLC concepts (university level is sufficient)
- Basic familiarity with reading drive or equipment technical manuals
Audience
- Maintenance technicians and maintenance engineers working with automated production equipment
- Electricians and technical staff moving 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
