Siemens PLC SCADA Day 01–20
Handwritten Manual

Step 1. Purpose and use of Siemens TIA Selection Tool for real automation project planning.

Step 2. Selection workflow for S7-1500 CPU based on IO count, communication ports, memory and application requirement.

Step 3. Selection of power supply, digital input, digital output, analog input and analog output modules.

Step 4. Selection of ET200 remote IO station, interface module and distributed IO architecture.

Step 5. Selection of memory card, front connector, communication module and required accessories.

Step 6. Selection of HMI, SCADA, VFD and network components as per plant requirement.

Step 7. Preparation of complete hardware BOM with order numbers, quantity and spare consideration.

Step 8. Understanding compatibility between CPU, firmware, TIA Portal version and module family.

Step 9. Practical exercise: prepare one small machine control system using TIA Selection Tool.

Step 10. Daily assignment: create project hardware list for PLC panel with CPU, IO, power supply and remote IO.

Step 1. Purpose of PLC memory architecture in Siemens S7-1200 / S7-1500 automation projects.

Step 2. Understanding BOOL, BYTE, WORD, DWORD, INT, DINT, REAL, TIME and STRING data types.

Step 3. Difference between input area, output area, memory area, timer, counter and data block storage.

Step 4. Absolute addressing concept: I, Q, M, DB, byte, bit, word and double word format.

Step 5. Symbolic addressing concept and why professional projects use tag names instead of raw addresses.

Step 6. PLC tag table creation with comments, engineering units and meaningful naming standard.

Step 7. Understanding DB, global DB, instance DB and retentive / non-retentive data.

Step 8. Practical exercise: create tags for push button, sensor, motor, valve, alarm and analog values.

Step 9. Common mistakes in addressing such as wrong byte, overlapping word and mismatch data type.

Step 10. Daily assignment: prepare a clean tag list with data type, address, comment and purpose.

Step 1. Create a new TIA Portal project and add Siemens S7-1500 / S7-1200 CPU.

Step 2. Configure device view, rack, power supply, DI, DO, AI and AO modules.

Step 3. Add ET200 remote IO station and configure Profinet interface module.

Step 4. Set PLC IP address, device name, subnet and Profinet network connection.

Step 5. Check hardware catalog, module article number, firmware version and compatibility.

Step 6. Configure input and output addresses according to module slot and process requirement.

Step 7. Compile hardware configuration and understand common compile warnings/errors.

Step 8. Download hardware configuration to PLC and verify online connection.

Step 9. Use accessible devices, online diagnostics and module status for hardware verification.

Step 10. Daily assignment: create complete hardware configuration for one machine panel with CPU and remote IO.

Step 1. Purpose of IO testing before machine logic development and commissioning.

Step 2. Testing digital inputs using push buttons, sensors, limit switches and selector switches.

Step 3. Testing digital outputs using lamps, relays, contactors, solenoids and interposing relays.

Step 4. Understanding PNP/NPN input wiring, source/sink concept and common wiring mistakes.

Step 5. Testing analog input signals such as 0-10V, 4-20mA, temperature or pressure transmitter values.

Step 6. Testing analog output signals for VFD speed reference, valve command or actuator control.

Step 7. Use online monitoring table and watch table for live input-output status verification.

Step 8. Use forcing carefully for commissioning and understand safety precautions before forcing outputs.

Step 9. Troubleshooting loose wiring, wrong address, module fault, common supply and field device issue.

Step 10. Daily assignment: prepare IO test checklist with actual status, expected status and remarks.

Step 1. Purpose of professional IO mapping in real PLC panel and machine automation projects.

Step 2. Prepare master IO list with device tag, description, signal type, PLC address and field location.

Step 3. Map physical IO addresses to symbolic PLC tags with standard naming convention.

Step 4. Create separate mapping for digital inputs, digital outputs, analog inputs and analog outputs.

Step 5. Create alarm mapping, motor feedback mapping, valve feedback mapping and sensor status mapping.

Step 6. Use comments, network titles and tag descriptions for maintenance-friendly programming.

Step 7. Understand cross reference and tag usage checking before starting logic development.

Step 8. Prepare IO mapping structure for machine modules such as station, zone, conveyor or furnace segment.

Step 9. Documentation output: IO list, tag list, address list, panel wiring reference and commissioning checklist.

Step 10. Daily assignment: prepare complete IO mapping sheet for one industrial machine section.

Step 1. Purpose of Timers and Counters in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for TON, TOF and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for ton, tof, tp timers, ctu/ctd counters and industrial timing applications.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply TP and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on Timers and Counters.

Step 1. Purpose of Motor Control Logic in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for Motor Start, Feedback and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for dol motor start-stop, feedback, overload, permissive and local/remote command logic.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Overload and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on Motor Control Logic.

Step 1. Purpose of Star Delta and Reversing Logic in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for Star-Delta, Forward/Reverse and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for forward-reverse, star-delta sequence, contactor interlock and timer-based changeover.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Contactor and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on Star Delta and Reversing Logic.

Step 1. Purpose of Analog Signal Scaling in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for 4-20 mA, 0-10 V and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for 4-20 ma, 0-10 v, raw count conversion, engineering units and alarm limits.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Raw Count and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on Analog Signal Scaling.

Step 1. Purpose of ET200 Distributed IO Configuration in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for ET200SP, Remote IO and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for et200sp/et200s remote io configuration, profinet device name and io testing.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply PROFINET and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on ET200 Distributed IO Configuration.

Step 1. Purpose of PROFINET Communication in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for PROFINET, IP Address and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for network topology, ip address, device name, topology view and communication diagnosis.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Device Name and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on PROFINET Communication.

Step 1. Purpose of Modbus RTU TCP Basics in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for Modbus RTU, Modbus TCP and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for modbus registers, function codes, rtu/tcp concept and device communication planning.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Registers and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on Modbus RTU TCP Basics.

Step 1. Purpose of SINAMICS G120 VFD Overview in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for G120 Drive, CU Module and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for drive hardware, cu/pm module, motor data, wiring and safe commissioning practice.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Power Module and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on SINAMICS G120 VFD Overview.

Step 1. Purpose of VFD Parameterization in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for Motor Parameters, Ramp Time and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for motor parameter entry, ramp time, speed reference, command source and drive protection.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Speed Reference and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on VFD Parameterization.

Step 1. Purpose of PLC to VFD Communication in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for Control Word, Status Word and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for plc control word, status word, speed setpoint and drive feedback using fieldbus.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Speed Setpoint and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on PLC to VFD Communication.

Step 1. Purpose of Fault Diagnostics in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for PLC Fault, Module Fault and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for plc fault, module fault, network fault, drive fault and online troubleshooting method.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Network Fault and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on Fault Diagnostics.

Step 1. Purpose of HMI Basic Interface Preparation in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for HMI Tags, Command Bits and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for hmi tag planning, command bits, status bits, setpoints and animation values.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Status Bits and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on HMI Basic Interface Preparation.

Step 1. Purpose of Mini Project Machine Logic in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for Mini Project, Sequence and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for create a small machine control project with inputs, outputs, motor, alarms and sequence.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Alarms and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on Mini Project Machine Logic.

Step 1. Purpose of Project Testing and Backup in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for Watch Table, Force Table and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for online monitoring, force table, watch table, backup, archive and version control practice.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply Archive and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on Project Testing and Backup.

Step 1. Purpose of Level 01 Final Practical in real Siemens PLC, panel and machine automation projects.

Step 2. Required hardware/software checklist for Final Practical, PLC + ET200 and related field devices.

Step 3. Step-by-step TIA Portal configuration or wiring preparation for complete plc, et200 and vfd final practical with documentation and viva preparation.

Step 4. Industrial naming standard for PLC tags, IO addresses, comments and project folders.

Step 5. Hands-on practical activity to apply VFD Control and verify it with online monitoring.

Step 6. Machine example using motor, sensor, VFD, valve, alarm or remote IO as applicable to this day.

Step 7. Safety and commissioning precautions before download, wiring change or live testing.

Step 8. Troubleshooting method for wrong address, loose wiring, module fault or communication issue.

Step 9. Documentation output: IO list, tag list, wiring note, parameter sheet or test checklist.

Step 10. Daily practice assignment with viva questions focused on Level 01 Final Practical.