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Duration 35 hours
Course Outline
Industrial Automation and Control Fundamentals
- Automation architecture within a production plant
- Sensors, actuators and field signal handling
- 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 displays and module indicators
TIA Portal Project Structure and Device Configuration
- Project views, devices and network structures
- Hardware configuration and device parameterisation
- Loading, saving and comparing project versions
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing methods
- 24 V DC signal circuits and wiring verification
- Verifying field signals against program logic
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 conventions
- Tracing logical conditions that govern output states
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 logic conditions
- Step sequences and state-based control strategies
- Diagnosing sequences blocked at specific steps
SIMATIC HMI Configuration and Operation
- Panel screens, tag assignments and navigation
- Operating modes and HMI-based control
- Displaying equipment status and process values
HMI Alarms and PLC Diagnostics Messages
- Alarm classes, priorities and acknowledgement procedures
- System diagnostics and controller alarms
- Process and program-based monitoring messages
Variable Frequency Drives: Fundamentals and Applications
- Drive principles and control methodologies
- 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 level management
- Motor data entry, auto-tuning and test runs
- Backup, restore and parameter documentation
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm and parameter error codes
- Fault history analysis 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 mechanisms
- 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 fault resolution
TIA Portal Diagnostics and Structured Troubleshooting
- Real-time online monitoring and watch tables
- Diagnostics buffer and CPU web server utilisation
- Comparing online and offline program states
- Tracing from fault symptom to root cause
- Electrical, mechanical and control-side inspections
- Documenting findings and defining escalation criteria
Step-by-Step Diagnosis of a Stopped Machine
- Systematic order of checks when equipment halts
- Cross-checking HMI alarms, PLC logic and drive status
- Identifying blocking conditions and restoring operation
Practical Fault Scenario Exercises
- Sensor, actuator and I/O signal verification exercises
- Motor, drive and start/stop fault scenarios
- Communication interruptions and alarm interpretation
- Interlock and sequence faults blocking machine steps
Making Basic Program Modifications
- Adjusting timers, setpoints and operational 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
- Decision-making regarding repair, adjustment and escalation
- Individual feedback and personal improvement planning
Requirements
- A foundational understanding of electrical circuits and industrial machinery
- Introductory exposure to PLC concepts (university-level knowledge is sufficient)
- Basic familiarity with interpreting drive or equipment technical documentation
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-related faults
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
