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Basic PLC: Programming, Troubleshooting & Maintenance – Siemens TIA(S7-1200)

Course Overview

The PLC Programming, Troubleshooting, & Maintenance course using Siemens TIA Portal focuses on the S7-1200 /1500 PLC series. This training provides a comprehensive understanding of programming, maintaining, and troubleshooting PLCs in industrial environments. Participants will gain hands-on experience with TIA Portal software, including logic development, hardware diagnostics, and network communication, ensuring readiness to handle real-world automation challenges efficiently.

Course Objectives

By the end of this course, participants will:

  1. Understand the architecture and features of Siemens S7-1200/1500 PLCs.
  2. Navigate and utilize Siemens TIA Portal software effectively.
  3. Program S7-1200 PLCs using Ladder Logic, FBD, and STL.
  4. Configure and troubleshoot hardware components and I/O modules.
  5. Implement advanced control strategies such as timers, counters, and PID loops.
  6. Diagnose and resolve system faults using TIA Portal diagnostic tools.
  7. Establish and manage communication networks (e.g., PROFINET) for system integration.
  8. Perform routine maintenance and backup/restore operations for S7-1200/1500 PLC systems.

Target group: Operation, Installation and Maintenance of PLC control systems technician/Engineers.

Prerequisites: Basic Knowledge in electrical/electronics

Duration: Five (5) days

Methodology: Lectures complemented by hands-on exercises using Siemens S7 PLC Hardware & Simulators/Software.

Contents

Module 1: Introduction to TIA Portal and S7-1200/1500 PLC

  • Introduction to S7-1200/1500 and TIA Portal
  • Overview of S7-1200/1500 hardware and its applications.
  • Key features of the TIA Portal (Totally Integrated Automation) environment.
  • Components of an automation system: HMI, PLC, and network.
  • Hardware Overview and Assembly
  • Identifying S7-1200/1500 components: CPU, power supply, communication ports, and I/O modules.
  • Wiring and assembly of the S7-1200/1500 system.
  • Getting Started with TIA Portal
  • Creating a new project in TIA Portal.
  • Configuring hardware and communication settings.
  • Downloading and testing configurations.
  • Practical Session: Assembling and powering an S7-1200/1500 PLC system.
  • Practical Session: Configuring hardware and establishing communication with TIA Portal.

Module 2: Basic Programming Concepts

  • Programming Basics in TIA Portal
  • Overview of programming languages: Ladder Logic (LAD), Function Block Diagram (FBD), and Structured Control Language (SCL).
  • Understanding organizational blocks (OB), function blocks (FB), and data blocks (DB).
  • Binary operations: AND, OR, XOR, NOT.
  • Timers and Counters; Up and down counters.
  • Configuring and using on-delay (TON), off-delay (TOF), and pulse timers (TP).
  • Practical applications in industrial automation.
  • Memory Management
  • Use of markers, inputs, outputs, and data registers.
  • Introduction to arrays and structures in data blocks.
  • Practical Session: Writing and simulating basic ladder logic programs.
  • Practical Session: Implementing timer and counter functions in a program.

Module 3: Advanced Programming and Troubleshooting Techniques

  • Advanced Programming Techniques
  • Structuring programs with reusable function blocks (FC/FB).
  • Analog signal processing: Scaling and normalization.
  • Logical interlocks and safety conditions.
  • Introduction to alarms and diagnostics.
  • Troubleshooting Basics
  • Using TIA Portal diagnostic tools: online monitoring, watch tables, and force commands.
  • Understanding PLC error codes and fault handling.
  • Practical troubleshooting methods for common issues.
  • Practical Session: Writing and testing structured programs with reusable blocks.
  • Practical Session: Simulating and troubleshooting common programming errors.

Module 4: Communication and Networking

  • Introduction to Industrial Communication
  • Overview of PROFINET and Ethernet communication protocols.
  • S7-1200/1500 communication options and applications.
  • Configuring PROFINET Networks
  • Setting up and configuring PROFINET devices in TIA Portal.
  • Communication between multiple PLCs (PLC-to-PLC communication).
  • HMI Integration with S7-1200/1500
  • Basics of HMI configuration in TIA Portal.
  • Creating simple HMI screens for monitoring and control.
  • Practical Session: Configuring a PROFINET network and testing device communication.
  • Practical Session: Integrating an HMI with S7-1200/1500 and programming basic control screens.

Module 5: Maintenance, Troubleshooting, and Real-World Applications

  • Maintenance Strategies for S7-1200 PLC
  • Routine checks and maintenance schedules.
  • Firmware updates and backups.
  • Safe replacement of modules and restoring configurations.
  • Advanced Troubleshooting
  • Advanced diagnostic tools in TIA Portal.
  • Handling real-time system errors.
  • Remote troubleshooting and maintenance techniques.
  • Final Project and Real-World Applications