AUT 110

SCADA & HMI Development using Siemens WinCC Flexible (Configuration, Operation, Troubleshooting & Maintenance)

This intensive 5-day program equips engineering, maintenance, and automation personnel with the knowledge and hands-on skills required to design, configure, operate, troubleshoot, and maintain SCADA/HMI systems using Siemens WinCC Flexible. Participants will work with real-world industrial case studies, PLC-HMI interfacing, alarms, trends, recipes, and diagnostics to ensure reliable plant monitoring and control.

Duration: 5 days

Prerequisites: Basic knowledge of PLCs (preferably Siemens S7-1200 & 1500), Basic computer & networking skills and Industrial automation/controls background (recommended)

Course objectives

Understand SCADA & HMI architecture and industrial communication principles
Configure and develop HMI projects using Siemens WinCC Flexible
Interface WinCC Flexible with Siemens PLCs (S7-1200, S7-300, S7-400, S7-1500 via gateways)
Create graphical process screens, animations, and control objects
Configure alarms, fault indication, and event logging
Implement user access control and security
Configure data trending, logging, and reporting
Troubleshoot HMI communication and runtime issues
Perform backup, restore, and project migration
Apply best practices for HMI design and maintenance

Course content

Day 1 Fundamentals of SCADA & WinCC Flexible Environment

Introduction to SCADA & HMI systems
Components of SCADA (PLC, HMI, Networks, Sensors, Actuators)
Difference between WinCC Flexible & WinCC Professional
WinCC Flexible versions & licensing
HMI Panels overview (KTP, TP, MP Panels, PC Runtime)
Installing & navigating WinCC Flexible
Project structure and engineering workflow
PLC to HMI communication concepts (PROFIBUS, PROFINET, MPI, Ethernet)
Tag management & data exchange fundamentals

Practical Session:

s
Create a new HMI project
Configure communication to a Siemens PLC
Create HMI tags linked to PLC variables
Build a simple control screen

Day 2 HMI Screen Design & Runtime Configuration

Topics Covered
Screen navigation concepts
Designing operator interface pages
Buttons, switches, lamps, IO fields
Data entry validation
Screen templates & global layouts
Message display objects
Creating multi-language support
Runtime simulation concepts
Downloading projects to panel/runtime PC

Practical Session:

s
Develop multiple process screens
Configure screen navigation menus
Create runtime simulation
Deploy to panel / runtime test

Day 3 Alarms, Events, Trends & Data Logging

Topics Covered
Alarm management strategy
Process alarms vs system alarms
Alarm groups & priorities
Acknowledgement levels
Alarm display configuration
Historical & real-time trending
Data logging concepts
Event logging
Exporting data to CSV format
Operator guidance & fault diagnostics

Practical Session:

s
Configure alarm/event system
Create historical & real-time trends
Log operational data
Simulate plant alarm scenarios

Day 4 Advanced Functions & Security

Topics Covered
Advanced animation techniques
Recipe management & data storage
User authentication & access control
Password security & privilege levels
PLC-HMI diagnostics
System backup & recovery
Project version control
Panel firmware & maintenance
Introduction to WinCC Flexible scripting

Practical Session:

s
Implement recipe control
Configure multi-level user access
Create secure operator roles
Perform backup & restore

Day 5 Troubleshooting, Best Practices & Case Study

Design a complete HMI project
Interface with a PLC
Implement alarms & trends
Apply security
Perform testing & troubleshooting
Topics Covered
Common HMI/SCADA faults
Communication diagnostics
PLC-HMI connectivity troubleshooting
Panel hardware fault handling
Performance optimization
Best practices for industrial HMI design
Documentation & change management
Preventive maintenance planning
Final Capstone ProjectParticipants will: