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.
- 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 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.
- Progressing 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
- A 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.
Target 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 faults.
Testimonials (2)
All in general
Daniele Donzelli - ITT ITALIA S.r.l.
Course - CANoe for CAN Compact Training
PLC basic knowledge
