Thank you for sending your enquiry! One of our team members will contact you shortly.
Thank you for sending your booking! One of our team members will contact you shortly.
Duration 35 hours
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 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 Setup and Device Configuration
- Project overview, device management, and network integration
- Hardware configuration and device parameterisation
- Managing project versions: loading, saving, and comparison
PLC Inputs and Outputs: Signals and Addressing
- Digital and analog addressing schemes
- 24 V DC signal circuits and wiring verification
- Validating field signals against the programme logic
Ladder Logic and Core Programming
- Contacts, coils, set and reset operations
- Timers, counters, and comparison instructions
- Functions, function blocks, and data blocks
Analysing Existing Programmes and Control Logic
- Navigating programme blocks and cross-references
- Symbol tables, tags, and variable naming conventions
- Tracing logical conditions that govern output states
Motor Control: Start and Stop Operations
- Start, stop, and latching conditions
- Motor protection mechanisms and run feedback signals
- Direction control and multi-motor setups
Interlocks, Permissives, and Automatic Sequences
- Interlock and permissive logic
- Step sequences and state-based control strategies
- Diagnosing sequences blocked at specific steps
SIMATIC HMI Setup and Operation
- Panel screens, tags, and navigation structures
- Operating modes and HMI-based control
- Displaying equipment status and process values
HMI Alarms and PLC Diagnostic Messages
- Alarm classes, priority levels, and acknowledgement procedures
- System diagnostics and controller alarms
- Process and programme-based monitoring alerts
Variable Frequency Drives: Principles and Applications
- Drive operating principles and control methodologies
- Interaction between drives, motors, and mechanical loads
- Common drive configurations on production lines
- Yaskawa drives and other prevalent drive brands in industrial settings
VFD Configuration and Commissioning
- Parameter groups and access permissions
- Motor data entry, auto-tuning, and test runs
- Backing up, restoring, and documenting parameters
VFD Fault Diagnosis and Troubleshooting
- Fault, alarm, and parameter error codes
- Reviewing fault history and monitoring values
- Identifying drive, motor, cable, and mechanical faults
PLC-Driven Control of Drives
- Start, stop, and speed reference signals
- Status, ready, and fault feedback loops
- Resolving discrepancies between PLC and drive states
Industrial Communication and Network Diagnostics
- PROFINET and Ethernet basics
- Device naming, IP addressing, and network topology
- Connection diagnostics and resolving communication failures
TIA Portal Diagnostics and Systematic Troubleshooting
- Real-time online monitoring and watch tables
- Diagnostic buffers and the CPU web server
- Comparing online and offline programmes
- Moving from fault symptoms to root cause analysis
- Electrical, mechanical, and control-side inspections
- Documenting findings and defining escalation criteria
Sequential Diagnosis of Stopped Machinery
- Prioritised checklist for when equipment halts
- Cross-referencing HMI alarms, PLC logic, and drive status
- Isolating blocking conditions and restoring operation
Practical Fault Scenario Drills
- Exercises on sensor, actuator, and I/O signal verification
- Scenarios involving motor, drive, and start/stop failures
- Communication interruptions and alarm analysis
- Interlocks and sequence faults hindering machine progress
Basic Programme Adjustments
- Modifying timers, setpoints, and parameters
- Adding or refining tags and simple logic
- Testing, documenting, and reverting changes
Capstone: Comprehensive Troubleshooting Case Study
- End-to-end fault diagnosis on a production line simulation
- Assessing options: repair, adjustment, or escalation
- Individual feedback and personalised improvement plans
Requirements
- A foundational grasp of electrical circuits and industrial machinery
- Introductory familiarity with PLC concepts (university-level exposure is sufficient)
- Basic competency in reading technical manuals for drives and equipment
Target Audience
- Maintenance technicians and engineers responsible for automated production systems
- Electricians and technical personnel transitioning into automation and control roles
- Professionals tasked with diagnosing PLC, HMI, drive, and communication issues
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
