Course Outline
Foundations of Industrial Automation and Control
- Overview of automation architecture in production plants
- Understanding sensors, actuators, and field signals
- Review of transport, feeding, dosing, and packaging subsystems
SIMATIC S7-1500 Hardware and System Design
- Exploring CPU families, signal modules, and distributed I/O
- Best practices for power supply, grounding, and control panel layout
- Interpreting status LEDs, CPU displays, and module indicators
TIA Portal Project Setup and Device Configuration
- Navigating project views, devices, and networks
- Configuring hardware and defining device parameters
- Managing project versions: loading, saving, and comparing
PLC I/O: Signals and Addressing Strategies
- Managing digital and analog addressing
- Checking 24 V DC signal circuits and wiring integrity
- Validating field signals against program logic
Ladder Logic and Core Programming Concepts
- Working with contacts, coils, set, and reset operations
- Utilizing timers, counters, and comparison instructions
- Applying functions, function blocks, and data blocks
Analyzing Existing Programs and Control Logic
- Navigating program blocks and utilizing cross-references
- Understanding symbol tables, tags, and variable naming conventions
- Tracing logical conditions that govern specific outputs
Motor Control: Start/Stop Operations
- Managing start, stop, and latching conditions
- Implementing motor protection and run feedback signals
- Handling direction control and multi-motor setups
Interlocks, Permissives, and Automated Sequences
- Defining interlock and permissive conditions
- Designing step sequences and state-based controls
- Diagnosing sequences that are stuck at a specific step
SIMATIC HMI Setup and User Interaction
- Configuring panel screens, tags, and navigation paths
- Operating modes and controlling processes via HMI
- Displaying equipment status and real-time process values
HMI Alarms and PLC Diagnostic Messages
- Understanding alarm classes, priorities, and acknowledgments
- Reviewing system diagnostics and controller alarms
- Monitoring process and program-based messages
Variable Frequency Drives: Core Concepts and Uses
- Basic drive principles and control methodologies
- Interactions between drives, motors, and mechanical loads
- Common drive configurations on production lines
- Overview of Yaskawa drives and other prevalent brands
VFD Setup and Commissioning Processes
- Navigating parameter groups and access levels
- Entering motor data, auto-tuning, and conducting test runs
- Backing up, restoring, and documenting parameters
VFD Fault Analysis and Troubleshooting
- Decoding fault, alarm, and parameter error codes
- Analyzing 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
- Processing status, ready, and fault feedback
- Resolving discrepancies between PLC and drive states
Industrial Communication and Network Diagnostics
- Fundamentals of PROFINET and Ethernet
- Managing device names, IP addresses, and network topology
- Diagnosing connections and communication faults
TIA Portal Diagnostics and Systematic Troubleshooting
- Using real-time online monitoring and watch tables
- Accessing the diagnostics buffer and CPU web server
- Comparing online and offline program states
- Moving from symptom identification to root cause analysis
- Performing checks on electrical, mechanical, and control sides
- Documenting findings and determining escalation paths
Step-by-Step Diagnosis of Stalled Machinery
- Establishing the correct order of checks when equipment halts
- Cross-referencing HMI alarms, PLC logic, and drive status
- Identifying blocking conditions and restoring normal operation
Hands-On Fault Scenario Practice
- Exercises in checking sensors, actuators, and I/O signals
- Scenarios involving motor, drive, and start/stop failures
- Handling communication interruptions and interpreting alarms
- Resolving interlock and sequence faults that block machine steps
Implementing Basic Program Changes
- Modifying timers, setpoints, and parameters
- Adding or adjusting tags and simple logic structures
- Testing, documenting, and reverting changes as needed
Capstone Project: Comprehensive Troubleshooting Case
- Full fault diagnosis simulation on a production line model
- Making informed decisions on repair, adjustment, or escalation
- Receiving individual feedback and a personal improvement plan
Requirements
- Foundational knowledge of electrical circuits and industrial machinery
- Introductory exposure to PLC concepts (university-level understanding is sufficient)
- Basic ability to read technical manuals for drives or equipment
Target Audience
- Maintenance technicians and engineers working with automated production systems
- 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 7250 € + VAT*
Contact us for an exact quote and to hear our latest promotions
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
