You do not need to buy a PLC training kit to learn PLC programming. Free browser simulators, Siemens PLCSIM and Factory I/O can cover logic, HMI and testing. But simulators have real limits: Siemens' own S7-PLCSIM manual says it does not simulate counting, PID control or motion control for S7-1200 CPUs, and hardware teaches wiring, power, comms and faults in a way software cannot. A sensible path starts with a simulator and adds hardware only if you have a specific reason.
What can a PLC simulator do?
A simulator runs your program against a virtual controller so you can test logic without hardware. For learning, that covers a large share of what you need: writing ladder logic, structuring programs, building HMI screens, going online, watching values and forcing inputs.
Siemens' S7-PLCSIM operating manual (V19) describes supporting debugging and validation of PLC programs without actual hardware, with STEP 7 tools such as the watch table, program status and diagnostics. It supports several product families, including S7-1200 and S7-1500. Factory I/O adds a 3D virtual plant, so your program controls conveyors, tanks and pick-and-place cells instead of a row of virtual switches.
What are the options and what do they cost?
The options range from free to hundreds of pounds, with different strengths. Here are the ones I could verify on 21 October 2026. I have not quoted hardware prices because I could not find a reliable current UK price for a specific kit, and listings vary widely between new, grey-market and second-hand.
| Option | What it is | Cost (as checked) | Main limits |
|---|---|---|---|
| Free browser simulators (lab.edwartens.com) | PLC, ladder logic, motor control, wiring and process simulators in the browser | Free, no install | Generic, not Siemens TIA Portal itself |
| Siemens S7-PLCSIM | Simulates S7-1200, S7-1500 and other families for use with STEP 7 in TIA Portal | Siemens software; licence and trial terms not verified here, check Siemens | S7-1200: no counting, PID or motion control simulation, per the V19 manual |
| S7-PLCSIM Advanced | Simulates S7-1500 and ET 200SP family controllers, per Siemens | Siemens page does not state a price | The V19 manual says S7-1200 is only supported as a standard S7-PLCSIM instance |
| Factory I/O | 3D factory simulation; supports Siemens PLCSIM, S7-1200/1500 and Allen-Bradley drivers | 30-day free trial; editions from €40 per year (Starter) to €278 per year (Ultimate), Siemens edition €158 per year or €435 one-time | Extra cost; VAT basis not stated on the page |
| Physical starter kit (e.g. S7-1200) | Real CPU, I/O, power supply, network | Not quoted here; check authorised UK distributors | Cost, wiring risk, firmware and software compatibility |
| In-person course with rigs | Instructor plus equipment | Technique: £1,030 excl. VAT for 5 days; Make UK: £995 plus VAT for 3 days | Travel, fixed dates |
Factory I/O connects to Siemens software rather than replacing it: its page lists S7-PLCSIM and PLCSIM Advanced among the Siemens drivers it supports, so you still need TIA Portal and a PLCSIM on your side.
What can't a simulator teach you?
A simulator cannot teach what depends on physical reality and timing, and Siemens is open about it. The V19 manual says simulated PLCs can behave differently from physical ones, that programs depending on PLC clock times or hardware timing behave differently in a Windows-based simulated PLC, and that timing-dependent programs can be hard to debug in simulation. It also says S7-PLCSIM does not simulate CPU functionality that needs a memory card, such as data logging and recipes, and that some instructions are only partially supported.
For S7-1200 specifically, the manual states S7-PLCSIM does not simulate counting, measurement and position detection, PID control or motion control. Siemens also notes S7-PLCSIM will not simulate PROFIBUS elements, though it simulates the rest of your project.
Beyond the software, hardware teaches things no virtual controller can:
- wiring, terminal numbering and 24 V supplies
- sink and source input types, and what a floating input looks like
- network addressing, cabling and connectivity faults
- reading LEDs, diagnostics buffers and module faults on a real CPU
- how tidy panels are built and why
This 19-minute walkthrough by Marcin Regulski shows how to connect TIA Portal, PLCSIM Advanced and Factory I/O into a simulation environment, which is the most common software-only setup for practising Siemens control of a virtual plant. Remember PLCSIM Advanced targets S7-1500-class controllers, not the S7-1200.
What do employers actually care about?
Employers mostly care about whether you can program, test and fault-find to a standard, not whether you own a rack. They also look for platform familiarity. In the six months to 21 October 2026, ITJobsWatch lists Siemens in 17 of 144 permanent PLC Engineer ads (11.8%) and Rockwell in 8 (5.6%), a small, IT-focused sample in which most ads list neither brand as a skill. Reed adverts show the same range: "Junior Automation Engineer (PLC/Siemens Tia Portal)", "Software Engineer (PLC/Siemens Tia Portal)" and "PLC Programmer (Allen-Bradley / Mitsubishi / Schneider)" all appeared on 21 October 2026.
So the platform matters, but the evidence of working practice matters more. A portfolio with documented projects, test notes and a fault you diagnosed counts for more than a photo of a rack. See trainee PLC jobs: what employers want.
How do you build a portfolio using only simulation?
You can build a credible portfolio entirely in simulation if you document it honestly. Here is a workable approach.
- Choose three projects of rising difficulty. For example a start/stop motor with interlocks, a conveyor sorter in Factory I/O, and a tank-level controller with an alarm and an HMI screen.
- Avoid features your simulator cannot run. On an S7-1200 in S7-PLCSIM, skip projects that depend on counting, PID or motion control, since the manual says they are not simulated. Practise the control theory in the free process control simulator and the free PID control course instead.
- Document each project. Include the specification, an I/O list, screenshots of the program, a test table (what you tested and what happened), and one fault you introduced and fixed.
- Be explicit about the environment. Write "developed and tested in PLCSIM and Factory I/O" on the CV. Employers value honesty, and it avoids awkward interview questions.
A dead-input example shows why hardware still matters. In a simulator you tick a box and the input goes true. On a real panel an input that stays false could be a missing 24 V supply, sink and source wiring mismatched to the sensor, a wrong address in the program or a loose terminal. Learning to check those in order is what a bench setup, a wiring simulator or a site placement teaches, and it is a skill worth mentioning in interviews even if you have only practised it in the PLC electrical troubleshooting course.
Should you buy a kit?
Buy hardware if you have a clear reason; otherwise start with simulation. These are the situations where a kit earns its cost:
- You work in maintenance and want to practise on the model your site uses.
- You want to learn panel wiring and commissioning, not just programming.
- You are applying for roles that explicitly ask for hands-on hardware experience.
- You enjoy building and have the budget for a mistake.
If you do buy, treat it as a project: confirm the CPU model, firmware and your TIA Portal version are compatible, buy from an authorised distributor where possible, and budget for a power supply, Ethernet cable and a way to mount and protect it. I would avoid unknown-origin listings for a first kit because a fault there will cost you more learning time than money saved. If you want to see the Siemens-side options, our Siemens vs Allen-Bradley guide and PLC training UK guide cover choosing a platform.
What is a sensible learning path?
A sensible path moves from free to paid only when you hit a limit.
- Free browser first. Use the PLC simulator, ladder logic simulator and IEC 61131-3 simulator to learn logic. All run in your browser.
- Move to TIA Portal with PLCSIM. Follow the free Siemens TIA Portal course and then the free virtual commissioning with Factory I/O course.
- Add real electrics. The electrical wiring simulator and multimeter simulator help, and a cheap bench exercise with a real relay and contactor adds more.
- Add hardware or an in-person course only if your target role needs it.
You can compare options in PLC training online: live vs self-paced.
How EDWartens can help
The Professional Module is online and simulation-based: you get a TIA Portal and PLCSIM install guide and Factory I/O simulation software to practise with, not a physical rig. It runs five live days with an instructor, then self-paced Basic Engineering modules, and the CPD certificate is not a regulated qualification. If you specifically want a physical rig, an in-person course may suit you better. Details are on the Professional Module page, and you can sign up or try the free labs first.
