EAL Siemens STEP7 and TIA Portal Maintenance & Fault Finding PLC Training Course

EAL Siemens Industrial Maintenance & Fault Finding Professional


Hands-on Siemens PLC Training using TIA Portal or STEP7 Professional.

Our PLC Industrial Maintenance & Fault Finding Professional courses are training courses with a difference. Recognised by EAL, we aim to help you become more proactive and confident in working with PLCs safely and efficiently in day-to-day operations and fault finding situations to reduce downtime and increase profitability.

We have been working closely with EAL who is the specialist awarding organisation for the engineering, manufacturing and professional trades sectors, to help develop the first EAL recognised Industrial Maintenance & Fault Finding Professional courses that are essential for anyone who intends to be working at an industrial level with machines and processes controlled by PLCs (Programmable Logic Controllers).

Experience Required: 

No previous experience or knowledge is required before attending this course however, an understanding of electrical principles is useful.

Duration and Times

5 Days (4 Days is available upon request)

09.00 – 17.00 (Monday - Thursday)

09.00 - 15.30 (Friday)

Recognised Training Supported by Blue-chips Companies including : 

Jaguar Land Rover | Toyota | UK Royal Mail | Wellstream International | British Engines

What You'll Learn

This training course is for anyone who is interested in working with PLCs on the shop-floor while being able to fault find, make modifications and maintain the machinery/production line.

Upon completing this course, you will able to work with live PLC's in industrial environments while not compromising safety or increasing production downtime when working on the shop-floor. Based around STEP7 Professional or TIA Portal, we will walk through the software and the majority of its available programming instructions that are most used throughout programs on the shop-floor. You will learn how to read industrial programs and incorporate instructions into Organizational Blocks, Function Blocks, and Functions. We will explain the Standard Operating Procedures for working on the shop-floor with PLC’s, ensuring you are working safely and efficiently. Fault Finding methods and techniques are then demonstrated and practiced, making you more pro-active when working on processes/machinery, increasing production efficiency and reducing downtime.

At the end of the course, you are expected to have a detailed understanding of the most used instructions and routines in programming, as well as being confident in approaching, maintaining and fault finding with the PLC in all situations.

Day 1 Topics

  1. Background to the PLC
  2. PLCs in Industry and where they are used
  3. Understanding what PACs are and the differences between a PAC and a PLC
  4. Understanding PLC Numbering Systems and converting between them (Binary, Decimal, Hexadecimal, Octal)
  5. Understanding the Siemens PLC Range
  6. Understanding the differences between Modular, Compact and Rack-based PLCs
  7. How to select a model of PLC for a control system
  8. How to use the Siemens website and locate important areas
  9. Understanding what a Siemens PSU is
  10. Understanding the Siemens CPU and its features
  11. Understanding the Siemens CPU LED indication and error displays
  12. Understanding how to use the CPU Mode Selector
  13. What is a PLC Battery and why is it important
  14. Understanding the Siemens Digital Input and Output Cards
  15. The importance of the Siemens Part Numbers
  16. Understanding the Siemens SD Memory Cards
  17. How to wire the Siemens PSU, CPU and Input/Output Cards
  18. Understanding the differences between NPN and PNP wiring
  19. Understanding how Modular PLCs are constructed and expanded
  20. Increasing process control via Networking
  21. Understanding the use of Bus and Ring Networks
  22. Understanding basic PLC components
  23. Understanding the differences between Steps, Rungs and Networks
  24. Understanding Logic terminology (AND, OR, ANDN, ORN, EOR)
  25. Understanding the Siemens PLC hardware and internal addressing
  26. Understanding the unique Siemens Memory Area and how to manage it correctly
  27. The importance of the PLC Scan and how it can be increased
  28. Understanding what PC/Laptop Operating System you should use for STEP7 Professional/TIA Portal
  29. Understanding the STEP7 Professional/TIA Portal environment
  30. Creating your first project
  31. Setting up communications between your Laptop and PC
  32. Setting up Hardware Configuration and why its important
  33. How to download safely to the PLC without accidentally shutting down production
  34. Introduction to Siemens Programming Blocks (OB's, FB's, FC's, DB's)
  35. Using STEP7 Professional/TIA Portal to create your first programming routines
  36. Labelling your project with Symbols and Comments and the benefits of doing so
  37. Understanding Online Editing and the dangers
  38. Understanding the differences between Control Latches and Alarm Latches and their important signals
  39. Understanding the dangers of duplication
  40. Using STEP7 Professional/TIA Portal to create Timer delay routines using the variations of Siemens Timers available

Day 2 Topics

  1. Understanding the differences between PLC programming languages and the positives and negatives of each<
  2. Understanding the IEC 61131-3 Programming Standards and why we adhere to these standards
  3. Understanding Siemens Counters and what we can use them for
  4. How to use programming instructions to monitor system equipment for maintenance
  5. Understanding what downtime is and how to prevent downtime on the shop-floor
  6. Undertaking an Upload and how to do so correctly
  7. Understanding the dangers of the PLC scan and how it can affect your programs
  8. Understanding the dangers of when working with PLCs and how to work with them safely to prevent accidents in industry
  9. Understanding data handling with the Move instruction
  10. How the PLC works with negative values and 2's complement
  11. Understanding Analogue values and how they are inputted to the PLC
  12. How to convert Analogue signalling from Raw to Engineering and Engineering to Raw
  13. Understanding the common Bit Logic instructions in the Siemens catalog
  14. How to use the One Shot Pulse (Rising and Falling) instructions correctly inside of the Siemens PLC
  15. Using Set and Reset inside of the PLC and why it can be dangerous when used incorrectly

Day 3 Topics

  1. How to undertake a PLC IO Test at the start of commissioning and installing a program
  2. Understanding the use of clock memory of the Siemens PLC
  3. Adopting practices to help reducing downtime when fault finding on a PLC
  4. Using Siemens Cross-References to navigate through your program when fault finding
  5. Using the Siemens Assignment List to locate free addressing inside of the Siemens PLC
  6. Understanding the Siemens Call Structure
  7. Using verification to ensure accurate backups are available
  8. Understanding the affects that Modifying and Forcing I/O has on the PLC
  9. Understanding the dangers of Forcing Inputs and Outputs in your program
  10. Adopting advanced backup procedures
  11. Using VAT Tables to monitor your programs more effectively
  12. How to locate intermittent faults in a program
  13. Using the Always On and Always Off flags effectively
  14. Using Siemens PLC diagnostics to locate problems in the PLC 
  15. Using Safety Interlocking to help increase the integrity of your programs
  16. Understanding interrupts and background routines
  17. Understanding the use of Data Blocks inside of your program
  18. How to create Function Blocks to further increase your program control
  19. How to create Alarms inside of the PLC and how to manage these within your program

Day 4 Topics

  1. Understanding the different types of CPU Faults
  2. Understanding how to replace a PLC battery on the shop-floor correctly
  3. Understanding how to replace faulty Input/Output cards
  4. Understanding how to replace a PLC memory card on the shop-floor correctly
  5. Understanding how to work with E-Stops and Safety Circuits and implement these inside of your program
  6. Understanding the differences between standard PLCs and safety PLCs
  7. Using Maths instructions inside of the PLC
  8. Using Functions for calculations and data handling giving you further control of your program
  9. Understanding the PLC electrical schematics and IO schedules and why we use these when commissioning and installing programs
  10. Practice fault finding techniques by working with a real industrial program which is currently being used on the shop-floor with the help of your tutor
  11. Understanding the use of sequencers inside of programs and how they can reduce downtime
  12. Understanding the use of a cycle stop routine inside of a program
  13. Using Comparators to monitor process safety limits

Day 5 Topics

  1. Understanding the further differences between PACs and PLCs
  2. Understanding preventative maintenance techniques to be used with the PLC
  3. Learn how to replace an Input/Output Card on a Live PLC System
  4. How to protect your career when working with PLCs
  5. Understanding SIL levels when working with a control system
  6. Understanding IEC Safety Standards when working with a control system
  7. Understanding the dangers of erratic signalling
  8. Identifying faults inside of real industrial programs and how they can be prevented
  9. Understanding best practice programming
  10. Learn how to replace a CPU on a Live PLC System
  11. Make changes to a real industrial program safely without affecting the control system

EAL Certification

This training course includes examination periods throughout each day of training. We will also be including additional training time should anyone request further explanation of any topics covered.

Upon completion of this course you will receive an Official EAL Training Certificate, this is proof that the learner has successfully completed a recognised training course at a Recognised EAL Training Centre and has passed all of the assessments for the training course.

COVID-19 Policy

Training at Scantime has been changed to protect our Staff and Learners due to the COVID-19 pandemic.

Our staff have been trained in new procedures when delivering Training at our Centre and when delivering Training Onsite.

To view what changes have been made, click here.

Location & Hotels

Training Centre Information

When arriving at our Training Centre, please sign in at the reception desk and then proceed to the onsite restaurant where you can order food and drink, please mention Scantime Training at the till for the order to be added to our account.

A member of staff will then be along shortly after to collect you for your induction.

Hotel Information

There are several hotels near to Scantime, all are within 15 minutes walking distance from our training centre. We highly recommend staying at the Holiday Inn Express which is located 0.9 miles from our training centre and is also situated opposite restaurants and within walking distance to the Metro Centre shopping and entertainment complex, alternatively, we also recommend the Premier Inn which is located 1.3 miles from our training centre.

Holiday Inn Express

Metro Centre
Clasper Way
Newcastle Upon Tyne,
NE16 3BE

Click here.

Premier Inn

Metro Centre
Derwenthaugh Rd
Newcastle Upon Tyne,
NE16 3BL

Click here.

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