Logo

PLC, HMI and SCADA Industrial Automation

Introduction

PLC, HMI and SCADA Industrial Automation

Course Objective

• Practise and use standard STEP 7 tools and methods
• Testing, Diagnosing, and correcting hardware & software issues in a running program
• Operate, Monitor, Control and Maintain components of a typical SIMATIC TIA system
• Establish PLC communication with multiple technologies
• Retrieve, Archive, and Download S7 programs
• Address and wire signal modules, perform start-up procedures for S7 automation system hardware and software
• Configure and parameterize S7-1500 Hardware utilizing S7 Software tools
• Backup and document executed program changes
• Create and manage WinCC Projects
• Integrate components between WinCC and TIA Portal
• Make WinCC tags in STEP 7 symbol table
• Establish communications with the PLC
• Design a complex graphic
• Configure internal and external tags
• Define & Administer User Security
• Set and assess the WinCC Alarms and Messages
• Configure, archive and display Trends & Tables
• Configure, preview and print reports
• Advanced competency in system integration and digital plant automation for career growth
• Expertise in troubleshooting and fault detection for reduced costly downtimes
• Enhanced understanding of simulation-based learning and real industrial scenario application
• Skills in predictive maintenance implementation and process optimization
• Proficiency in future-proof automation technologies and continuous learning methodologies

Who Should Attend?

PLC, HMI and SCADA Industrial Automation Training Course would be suitable for:

• Programmers
• Commissioning engineers
• Configuring engineers
• Service personnel
• Maintenance personnel
• Operators
• Automation technicians and control system specialists
• Plant engineers and production supervisors
• Electrical engineers and instrumentation professionals

Course Outline

MODULE 1: Course Overview

• Course goals
• Course project overview
• Training equipment
• Create course project
• Introduction to industrial automation principles and control system fundamentals
• Overview of PLC, HMI, and SCADA system integration in modern manufacturing
• Training equipment setup including Siemens S7-1500 and TIA Portal software
• Project-based learning approach and hands-on laboratory exercises

MODULE 2: System Overview

• S7-1200, S7-300, S7-400, and S7-1500 Function Comparison
• Communications
• Comparison of Siemens PLC models including hardware specifications and applications
• Industrial communication protocols including Profibus, Profinet, and Ethernet/IP
• System architecture and integration considerations for different automation levels
• Selection criteria for appropriate PLC systems based on application requirements

MODULE 3: Introduction: Engineering Software “TIA Portal”

• Comparison STEP 7 Basic/ Professional
• Portal-View
• Project View
• Windows arrangement
• Online Help
• Settings: Download, Project path
• TIA Portal installation, configuration, and navigation fundamentals
• Project creation and management within TIA Portal software environment
• Software licensing, updates, and version compatibility considerations
• Integration capabilities with other Siemens automation software packages

MODULE 4: PLC Installation & Maintenance

• S7-1500 Hardware Components & Installation
• Remote I/O Hardware Components & Installation
• Signal Module Wiring, Removal, & Installation
• Hardware installation procedures and safety considerations
• Power supply calculations and electrical connection requirements
• Maintenance scheduling and preventive maintenance practices
• Troubleshooting hardware faults and diagnostic procedures

MODULE 5: Device and Network

• Hardware-Editor
• Hardware-Catalog / Device-View
• Creating a Configuration
• Reading Configurations
• Network-View
• Configuring devices on the Network
• Network topology design and implementation strategies
• Device addressing schemes and communication parameter configuration
• Network diagnostics and performance optimization techniques
• Integration of distributed I/O systems and remote monitoring capabilities

MODULE 6: Tag Table

• Tag Names
• PLC-Tag / User-Parameter / System Parameter
• Introduction to Symbol Table Editor
• Local and Global symbols
• Watching Global Symbols in PLC Tag Table
• Using Excel to create Symbol Tables
• Data organization and naming conventions for industrial applications
• Global and local variable management strategies
• Data type selection and memory optimization techniques
• Integration with external databases and Excel-based tag management

MODULE 7: Hardware Commissioning

• Hardware LED Indicator Descriptions & Troubleshooting
• Clearing the PLC memory
• Testing & Troubleshooting I/O
• Calling the “Watch Table” Tool
• Monitoring and Modifying Variables
• System startup procedures and commissioning checklists
• I/O testing methodologies and signal verification techniques
• Online monitoring and real-time variable modification
• Fault diagnosis using built-in diagnostic tools and indicators

MODULE 8: Program Blocks

• S7 Block Types
• Structured programming
• Process Image Inputs/Outputs
• Cyclic Program processing
• Ladder Logic and Function Block Diagram
• Using the Block Editor
• Program Testing & Troubleshooting by operating the “Monitor Block” function
• Function blocks (FB), function calls (FC), and data blocks (DB) programming
• Structured programming methodologies and code organization
• Program execution cycles and scan time optimization
• Advanced programming techniques including arrays and user-defined data types

MODULE 9: Binary Operations

• S7 Block Types
• Distinct variations between “real” connected NC contacts and NO contacts and programmed symbols
• Programming basic binary logic operations
• Logic gate implementation including AND, OR, NOT, NAND, NOR, XOR operations
• Contact and coil programming techniques in ladder logic
• Interlocking and safety circuit design principles
• Boolean algebra applications in industrial control logic

MODULE 10: Digital Operations

• Data Types
• SIMATIC Counter & Timer Functionality
• Data Blocks
• IEC Counter & Timer Functionality
• Timer operations including TON, TOF, TP, and TONR instructions
• Counter functions including CTU, CTD, and CTUD applications
• Data handling and manipulation techniques
• Mathematical operations and data conversion methods

MODULE 11: Introduction to HMI & SCADA

• Data Exchange between HMI and PLC
• Commissioning a Comfort Panel Project
• Networking the Comfort Panel
• Troubleshooting an HMI Network
• Creating a SIMATIC WinCC Professional project
• Configuring and aligning the connection to the SIMATIC S7 automation system
• Structuring the operator interface
• Fundamentals of designing graphic displays for human machine interfaces
• Navigating through the plant displays
• User administration
• Message representation, message logging, message configuring
• Variable logging, trend configuring, and trend plotting
• Message representation containing logging of data in the database
• Recipes
• Re-usable faceplates and centralized modification and alteration of graphic blocks
• Global Scripting & Background processing
• SCADA system architecture and component integration
• HMI design principles for operator efficiency and safety
• Real-time data acquisition and historical data management
• Alarm management systems and notification strategies

MODULE 12: Graphics Designer

• Tools & Features for creating a graphic
• Using Object, Styles & other palettes
• Use object properties and events
• Creating a Customized Object
• Using the Object Library
• Advanced graphics design techniques for industrial applications
• Animation and dynamic object behavior programming
• Screen navigation and user interface optimization
• Template creation and standardization for multiple projects

MODULE 13: Making Objects Dynamic

• Direct Connect Interface
• Dynamic Dialog Interface
• Object C/VBS Scripting
• Global Actions
• Script Threading Model
• Advanced scripting techniques for dynamic HMI functionality
• Event-driven programming and conditional logic implementation
• Performance optimization for real-time data updates
• Integration with external systems and databases

MODULE 14: Advanced Functionality

• Tag Prefix / Popup windows
• Creating Faceplates
• Advanced HMI features including popup windows and modal dialogs
• Faceplate development for standardized operator interfaces
• Recipe management and batch processing integration
• Multi-language support and localization techniques

MODULE 15: User Administration & Security

• Groups & Users
• Log on & Log off
• OS Security
• User privilege management and access control systems
• Security policies and industrial cybersecurity best practices
• Audit trails and user activity logging
• Integration with enterprise security systems

MODULE 16: Archiving & Trending

• Archive configuration
• WinCC Online Trend Control
• WinCC Online Table Control
• Historical data management and long-term storage strategies
• Trend analysis and performance monitoring techniques
• Data compression and archiving optimization
• Integration with enterprise historian systems

MODULE 17: Archive Management

• Configuring and arranging archive and backup management for Alarms and Trending
• Backup and disaster recovery planning for SCADA systems
• Data integrity and validation procedures
• Performance monitoring and system optimization
• Regulatory compliance and documentation requirements