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Duration 35 hours
Course Outline
Foundations of Industrial Automation and Control Systems
- Structural overview of automated production facility architectures
- Roles of sensors, actuators, and field-level signaling mechanisms
- Functional components of transport, material feeding, dosing, and packaging units
Siemens SIMATIC S7-1500 Hardware Composition and System Design
- Central processing unit (CPU) categories, I/O modules, and distributed input/output systems
- Power distribution, grounding standards, and control cabinet layout requirements
- Interpretation of status indicators, CPU displays, and module-specific LEDs
TIA Portal Project Framework and Device Setup
- Management of project views, device definitions, and network structures
- Configuration of hardware components and device-specific parameters
- Procedures for loading, saving, and comparing different project iterations
PLC I/O Management: Signal Processing and Addressing
- Addressing schemes for digital and analog signals
- Validation of 24 V DC signal circuits and wiring integrity
- Verification of field device signals against programmed logic
Ladder Logic Principles and Foundational Programming
- Implementation of contacts, coils, and latch/unlatch operations
- Utilization of timers, counters, and comparison logic instructions
- Construction of functions, function blocks, and data structures
Analyzing Existing Control Programs and Logic Flow
- Navigating program blocks and utilizing cross-reference tools
- Management of symbol tables, tags, and variable nomenclature
- Tracing logical pathways that determine output states
Motor Control Systems: Start/Stop Mechanisms
- Configuration of start, stop, and latching logic
- Integration of motor protection circuits and run-status feedback
- Management of directional control and multi-motor assemblies
Control Interlocks, Permissive Conditions, and Automated Sequences
- Definition and application of interlock and permissive logic
- Implementation of step-by-step sequences and state-machine control
- Diagnostic procedures for sequences halted at specific steps
Siemens SIMATIC HMI Setup and Operational Management
- Design and navigation of panel screens, tags, and interface elements
- Management of operating modes and HMI-driven controls
- Visualization of equipment status and real-time process data
HMI Alarm Management and PLC Diagnostic Protocols
- Classification, prioritization, and acknowledgment of alarm events
- Review of system diagnostics and controller-level alarms
- Interpretation of process and program-based monitoring alerts
Variable Frequency Drives (VFDs): Core Concepts and Applications
- Underlying drive principles and control methodologies
- Interaction between drives, motors, and mechanical loads
- Standard drive configurations utilized in production environments
- Overview of Yaskawa drives and other prevalent drive manufacturers
VFD Configuration and Commissioning Procedures
- Navigation of parameter groups and security access levels
- Input of motor data, execution of auto-tuning, and test operations
- Protocols for backing up, restoring, and documenting parameter sets
VFD Fault Analysis and Troubleshooting Strategies
- Interpretation of fault, alarm, and parameter error codes
- Analysis of fault history logs and monitored values
- Diagnostic techniques for electrical, mechanical, and cable-related issues
PLC-Driven Control of VFDs
- Transmission of start, stop, and speed reference commands
- Monitoring of status, readiness, and fault feedback signals
- Resolution of discrepancies between PLC state and drive status
Industrial Network Communications and Fault Isolation
- Fundamentals of PROFINET and industrial Ethernet protocols
- Management of device naming conventions, IP addressing, and topology
- Diagnostic techniques for connection issues and communication failures
TIA Portal Diagnostics and Systematic Troubleshooting
- Utilization of real-time online monitoring and watch tables
- Analysis of diagnostic buffers and CPU web server data
- Comparison of online execution versus offline programming logic
- Methodology for tracing fault symptoms to root causes
- Verification of electrical, mechanical, and control system elements
- Documentation of findings and criteria for escalation
Systematic Diagnosis of Machine Stoppage Events
- Established sequence of checks following an equipment halt
- Correlation of HMI alarms, PLC logic states, and drive status
- Identification of blocking conditions and restoration of operation
Practical Fault Scenario Training Modules
- Exercises focused on sensor, actuator, and I/O signal validation
- Simulation of motor, drive, and start/stop failure scenarios
- Analysis of communication interruptions and alarm interpretation
- Investigation of interlock and sequence faults impeding machine steps
Implementing Basic Program Modifications
- Adjustment of timers, setpoints, and operational parameters
- Creation or modification of tags and basic logic instructions
- Protocols for testing, documenting, and reverting program changes
Capstone Project: Comprehensive Troubleshooting Assessment
- End-to-end fault diagnosis exercise on a production line simulation
- Decision-making framework for repair, adjustment, or escalation
- Individual performance feedback and professional development planning
Requirements
- Fundamental understanding of electrical circuits and industrial equipment operations
- Introductory exposure to PLC concepts (university-level proficiency is sufficient)
- Basic familiarity with reading technical manuals for drives and industrial equipment
Intended Audience
- Maintenance technicians and engineers responsible for automated production equipment
- Electricians and technical staff transitioning into automation and control roles
- Personnel tasked with diagnosing faults in PLC, HMI, drive, and communication systems for government operations
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
