AUT 107

Basic Siemens Programmable Logic Controller (PLC) with TIA Portal;Programming, Troubleshooting & Maintenance for S7-1200 & S7-1500

This course introduces participants to Siemens PLC fundamentals using TIA Portal with hands-on emphasis on programming, wiring, diagnostics, and troubleshooting real-world automation systems.Participants will learn how to configure projects, create PLC programs, download & test logic, and maintain PLC-based control systems in industrial environments.The course blends theory + practical workshops, ensuring participants gain confidence working with Siemens PLC systems safely and effectively.

Duration: 5 days

Prerequisites: Basic PLC programming, Basic Siemens STEP 7 and Electrical / instrumentation fundamentals

Course objectives

Understand PLC system architecture & components
Configure and setup projects in TIA Portal
Create basic PLC programs using Ladder Logic (LAD) and Function Block Diagram (FBD)
Work with Digital Inputs & Outputs, Timers & Counters and Memory tags & data blocks
Perform online monitoring & troubleshooting
Diagnose faults and interpret system diagnostics
Backup, restore & maintain PLC programs
Safely work with PLC-based systems
Perform preventive maintenance checks
Interpret Alarms & Diagnostic Tools
Replace hardware modules confidently

Course content

Day 1 Introduction to Siemens PLC & TIA Portal

Create a new PLC project
Configure S7-1200 / S7-1500 hardware
Establish communication with PLC
Test digital signals
Focus: Foundations & understanding the system
Topics
Introduction to Industrial Automation & PLC concepts
Siemens PLC family overview
S7-1200
S7-1500
PLC hardware components
CPU
Power supply
Communication ports
I/O modules
Wiring basics — Sensors & Actuators
TIA Portal environment overview
Creating a new project
Configuring hardware & device setup
Downloading firmware & connectivity setup

Hands-On Practical:

Day 2 Basics of PLC Programming in TIA Portal

Develop your first PLC program
Control motors, lamps, solenoids (simulated or real)
Monitor & force I/O
Test program online
Focus: Core logic & digital control
Topics
Understanding logic execution cycle (Scan cycle)
Digital Inputs & Outputs
Ladder Logic fundamentals
Boolean operations: AND / OR / NOT
Memory tags & data types
Creating program blocks (OB, FB, FC)
Monitoring logic online

Hands-On Practical:

Day 3 Timers, Counters & Basic Interlocks

Implement motor start-stop circuit
Create delay & sequence control
Use counters in production scenarios
Develop reusable logic blocks
Focus: Control functions & process logic**
Topics
Siemens Timers: TON, TOF, TP
Counters: Up / Down
Set/Reset latch logic
Interlocking concepts
Start-Stop motor control
Safety & fail-safe concepts (basic awareness)
Program structuring with blocks

Hands-On Practical:

Day 4 HMI, Diagnostics & Troubleshooting

Create basic HMI control panel
Configure alarms
Monitor live process data
Practice diagnosing simulated faults
Focus: Operator interface & system maintenance**
Topics
Basic HMI overview (TIA Portal WinCC basics)
Tag communication between PLC & HMI
Creating simple HMI screens:
Start/Stop buttons
Status indicators
Alarms
PLC diagnostic tools
CPU & module diagnostics
Fault codes & message interpretation
Monitoring program execution

Hands-On Practical:

Day 5 Industrial Applications, Maintenance & Assessment

Perform program backup & restore
Troubleshoot real-world fault scenarios
Final programming mini-project
Instructor feedback & improvement coaching
Focus: Real-world application & competence validation**
Topics
Preventive & corrective maintenance practices
Back-up & restore procedures
Uploading & downloading programs
Best practices in documentation
Basic networking introduction (Profinet overview)
Case studies from real industries
Course review & knowledge consolidation

Hands-On Practical: