Advance PLC Training
This
Training provides a foundation to PLCs in manufacturing and includes PLCLogix
500, our lab simulator for the Rockwell Logix 500 series PLC control Software.
Table of Contents
1.
Overview of PLCs
2.
Central Processing Unit
3.
I/O System
4.
Programming Terminals and Peripherals
5.
Installation and Maintenance of PLCs
6.
Relay Logic
7.
Ladder Logic
8.
Timers
9.
Counters
10.
MCR, JUMP, and FORCE Instructions
11.
Sequencers
12.
Data Transfer
13.
Math Functions
14.
Process Control
15.
Data Communication
16.
Number Systems and Codes
17.
Digital Logic
18.
RTUs & PACs
19.
Introduction to Automation
Module 1 – OVERVIEW OF PLCS
This
module provides a general overview of PLCs and their application in industry.
The origins of the PLC and its evolution are
covered
in detail. The advantages of PLCs are also outlined, and the main components
associated with PLC systems are explored.
An
introduction to ladder logic is presented and the most common types of PLC
signals are covered with an emphasis on practical
application.
Learning
Outcomes:
•
Describe the purpose of a control panel.
•
Define programmable logic controllers.
•
List six factors affecting the original design of programmable
controllers.
•
Name three advantages of PLCs compared to relay logic systems.
•
List the three main components in a PLC system.
•
Explain the term ladder logic.
•
Describe the application of PLC signals.
•
Explain the difference between a bit and a word.
Module 2 – CENTRAL PROCESSING UNIT
This module is
intended to familiarize the student with the most important aspects of the
PLC’s central processing unit. Topics
covered in the module
include memory devices and memory storage, as well as an introduction to data
storage and processing. In
addition to covering
memory utilization and memory mapping, the module also provides detailed
information on multiprocessing
and PLC scan
functions.
Learning
Outcomes:
•
Define the term CPU.
•
Explain the purpose of the executive program.
•
Describe the application of buses in a CPU.
•
List two types of CPU diagnostics.
•
Differentiate between fatal and non-fatal errors.
•
Explain the advantage of multiprocessing.
•
Describe the two general classes of memory devices.
•
Name four types of memory.
•
Define memory protect.
•
Explain the purpose of memory utilization and how it applies to
PLC
systems.
•
Describe the scan function.
Module 3 – I/O SYSTEM
This module covers all
aspects of the Input/Output system for PLCs including discrete, analog and data
I/O. In addition, the module
presents an overview
of I/O addressing and an introduction to Allen-Bradley I/O parameters. Module
topics include the principles of
remote I/O and an
introduction to scaling and resolution of analog devices and signals.
Learning
Outcomes:
•
Explain the purpose of the I/O system.
•
Describe how I/O addressing is accomplished.
•
Define discrete inputs.
•
List four tasks performed by an input module.
•
Describe the basic operation of a discrete output.
•
Explain the purpose of data I/O interfaces.
•
Define analog I/O.
•
Describe the resolution of an analog I/O module.
•
List three applications for advanced I/O.
•
Explain the purpose of remote I/O.
Module 4 – PROGRAMMING TERMINALS AND PERIPHERALS
This module is
intended to provide students with an overview of the wide range of programming
terminals currently in use and to
outline some of the
key differences between them. In addition, the module covers topics such as
hand-held programming terminals
and computer-based
software packages. The operation of host computer-based systems is covered as
well as the application of
peripheral devices in
a PLC network.
Learning
Outcomes:
•
Define the term programming terminal.
•
Describe the application of dedicated programming terminals.
•
List the two types of programming terminals.
•
Describe the purpose of mini-programmers.
•
Define computer-based programming terminals.
•
Differentiate between programming software and documentation
software.
• Describe
the function of a host computer-based PLC system.
•
Explain the purpose of peripheral devices.
Module 5 – INSTALLATION AND MAINTENANCE OF PLCS
The purpose of this
module is to provide the student with a thorough coverage of the various safety
precautions, preventative
maintenance, and
troubleshooting techniques associated with a typical PLC system. The module
also covers proper grounding
techniques, sources of
electrical interference and I/O installation techniques. Field checkout and
troubleshooting with an emphasis
on practical
troubleshooting and problem-solving strategies are covered.
Learning
Outcomes:
•
List three safety precautions when installing PLC systems.
•
Define system layout.
•
List three safety measures for PLC installations in control panels.
•
Describe proper grounding techniques for PLCs.
•
Name three precautions to avoid electrical interference.
•
Define cross-talk interference.
•
Explain I/O installation.
•
Describe the need for I/O documentation.
•
Define leakage current and explain the purpose of bleeder resistors.
•
Explain the field checkout of PLC systems.
•
Provide periodic maintenance for a PLC system.
•
Troubleshoot PLCs.
•
Describe redundant PLC architecture.
Module 6 – RELAY LOGIC
This module is
intended to provide an introduction to relay logic and relay logic diagrams.
The basic operating principles of relays
are presented as well
as detailed information regarding sizing and rating of electromagnetic
contactors. Seal-in circuits and
their application in
control systems are discussed as well as an introduction to timing circuits. In
addition, the module covers I/O
devices and their
application in PLC systems.
• Name three
types of mechanical switches and three types of
proximity
switches.
• Define
inductive arcing and explain how it can be prevented.
• Describe the
operating principle of a control relay.
• Explain the
purpose of overload relays.
• Define the
term holding contact.
• Differentiate
between a control relay and a solenoid.
• List three
applications of rotary actuators.
• Name three
types of time-delay relays.
• Define the
term relay logic.
Module 7 – LADDER LOGIC
This module provides
an introduction to ladder logic programming techniques using laboratory
simulation software. The lab
component of the
module provides the student with an opportunity to write ladder logic programs
and test their operation
through PLC
simulation. Topics covered in the module include I/O instructions, safety
circuitry, programming restrictions
and I/O addressing.
•
Define ladder logic.
•
Explain the purpose of I/O addresses.
•
Describe softwiring, branches and rungs.
•
Write a ladder logic program.
•
Run a ladder logic program using lab simulator.
•
Define the terms examine on and examine off.
•
Explain the purpose of a latching relay instruction.
•
Differentiate between an internal output and an actual I/O output.
•
Describe the operation controller scan.
•
Name two programming restrictions.
•
Define nesting.
•
Explain why safety circuitry is important in ladder logic systems.
• List
three types of I/O addressing.
Module 8 – TIMERS
This module is
intended to provide students with an overview of PLC timers and their
application in industrial control circuits.
Allen-Bradley timing
functions such as TON, TOF, and RTO are discussed in detail and the theory is
reinforced through lab projects
using lab simulation
software. In addition, students will learn practical programming techniques for
timers including cascading and
reciprocating timing
circuits.
Learning
Outcomes:
• Name two
types of relay logic timers.
• List the four
basic types of PLC timers.
• Describe the
function of a time-driven circuit.
• Differentiate
between an ON-delay and an OFF-delay instruction.
• Write a
ladder logic program using timers.
• Describe the
operating principle of retentive timers.
• Explain the
purpose of cascading timers.
• Define
reciprocating timers.
Module 9 – COUNTERS
This module provides
students with a broad overview of PLC counters and their application in control
systems. Allen-Bradley
counting functions
such as CTU and CTD are presented in detail and the theory is reinforced
through lab projects using lab
simulation software.
In addition, students will learn practical programming techniques for counters
including cascading counters
and combining counting
and timing circuits.
Learning
Outcomes:
•
Name two types of mechanical counters.
•
Define the two basic types of PLC counters.
•
Write a ladder logic program using CTU, CTD and RES.
•
Explain the terms underflow and overflow.
•
Describe the function of an event-driven circuit.
•
Design an up/down counter.
•
Define cascading counters.
•
Explain the advantages of combining timers and counters.
Module 10 – MCR, JUMP, AND FORCE INSTRUCTIONS
This module is
intended to provide an overview of various zone control techniques and
branching instructions. The principles of
Master Control Relays
are presented with an emphasis on safety considerations and compliance with
safety codes and regulations.
In addition, the
module provides coverage of subroutines and their application and benefit in
complex control problems. Force
instructions are
presented and demonstrated through lab simulation software. The simulation
software also allows the student to
program and observe
branching operations.
Learning
Outcomes:
•
Define master control relay.
•
Explain the purpose of a zone of control.
•
Describe the function of zone control latch.
•
Write a ladder logic program with a subroutine.
•
Describe the purpose of first failure annunciators.
•
Differentiate between a JSR and a JMP.
•
Explain the advantage of using subroutines.
•
Use the FORCE instruction for troubleshooting.
Module 11 – SEQUENCERS
This module is
designed to provide the student with a clear understanding of the purpose and
application of PLC sequencers, both
through the theory of
operation and through the actual demonstration using lab simulation software.
The module will familiarize
the learner with
masking techniques and the various types of sequencers available including SQO
and SQC instructions. In addition,
sequencer charts are
presented with an emphasis on maintenance and recording of sequencer chart
information.
Learning
Outcomes:
•
Explain the operation of a mechanical drum controller.
•
Describe the basic function of a PLC sequencer.
•
Explain how time-driven sequencers operate.
•
Describe the operation of event-driven sequencers.
•
Derive a sequencer chart.
•
Define the term matrix.
•
Explain the purpose of masking.
•
List three types of sequencers.
•
Write a ladder logic program using SQO and SQC.
Module 12 – DATA TRANSFER
This module provides
students with an introduction to the principles of data transfer including
bits, words and files. Using lab
simulation, various
aspects of data transfer will be demonstrated and students will program and
observe transfer instructions such
as MOV. An
introduction to shift registers is also presented with an emphasis on practical
application in industrial control circuits.
Learning
Outcomes:
•
Explain the purpose of a move instruction.
•
List three basic types of registers.
•
Define the term sign bit.
•
Explain the operating characteristics of a register-to-register move.
•
Differentiate between a file-to-word and a word-to-file move.
•
Describe the purpose of a table-to-table move.
•
Explain the operation of a shift register.
•
Write a ladder logic program using MOV.
•
Transfer data between memory locations.
Module 13 – MATH FUNCTIONS
This module provides
an overview of basic mathematical functions found in typical PLCs. It also
provides thorough coverage of data
comparison
instructions such as EQU, LES and GRT. In addition, this module provides a
foundation for more advanced programming
techniques including
analog input and output control. Topics such as combining math functions are
presented with an emphasis on
practical application
and are demonstrated through lab simulation.
Learning
Outcomes:
•
List three types of data comparison.
•
Explain the Addition function.
•
Subtract two numbers using a PLC.
•
Multiply and divide two numbers.
•
Define the terms scaling and ramping.
•
Write a program using LES, GRT and EQU.
•
Use the Square Root instruction.
•
Write a program combining math functions.
•
Describe the purpose of LIM.
Module 14 – PROCESS CONTROL
The purpose of this
module is to provide the student with a thorough understanding of the various
aspects of process control and its
application to PLC
systems. In addition to open-loop and closed-loop systems, the module also
covers advanced closed-loop
techniques including
PID control. Analog I/O devices are presented in detail and tuning parameters
for PID control systems are
demonstrated through
practical examples.
Learning
Outcomes:
•
Define the terms process, process variable and controlled variable.
•
Name four applications for control systems.
•
Explain the advantage of using block diagrams.
•
Describe the function of the setpoint, error signal and measured
value.
•
Differentiate between open-loop control and closed-loop control.
•
List the five basic components in a closed-loop control system.
•
Name the four variables associated with closed-loop control systems.
•
Define dead time.
•
Explain the basic operating principles of On-Off and PID control.
•
Describe the purpose of feedforward control in process systems.
•
Define the terms algorithm and flowchart.
•
Explain the basic principle of fuzzy logic.
Module 15 – DATA COMMUNICATION
This module is
intended to provide the student with an introduction to networking using PLC
systems and peripherals. The principles
of data highways are
discussed using windows platform and Allen-Bradley hardware and programming
software. In addition,
an introduction to
Ethernet and network switching is presented as well as detailed descriptions of
topology and the application of
token passing in a
data highway. The module provides an overview of transmission media including
fiber optic, coaxial and twisted
pair cable.
Learning
Outcomes:
•
Define the term data highway.
•
Describe the term protocol as applied to PLCs.
•
Explain the principle of token passing.
•
Name two types of topology.
•
List four factors affecting transmission media.
•
Describe the two types of bandwidth used in data highway systems.
•
Define response time.
•
Explain proprietary networks.
•
Describe the purpose of Manufacturing Automation Protocol (MAP).
•
Name the seven MAP layers.
•
List three advantages of using Ethernet.
•
Explain the purpose of network switching
Module 16 – NUMBER SYSTEMS AND CODES
This module is
designed to provide the student with a thorough understanding of the various
number systems used by PLCs and
their application in
industrial control. The module covers binary numbers and codes including BCD
Octal and hexadecimal. The
module demonstrates
through lab simulation how number systems are manipulated by the PLC’s
processor. Topics covered include
negative binary
numbers, parity bit, Gray code and ASCII.
Learning
Outcomes:
•
Explain the operation of the binary number system.
•
Express a negative number in binary form.
•
Differentiate between least-significant bit and most-significant bit.
•
Add and subtract binary numbers.
•
Multiply and divide binary numbers.
•
Convert binary numbers to decimal, and decimal numbers to binary.
•
Count using the octal number system.
•
Convert octal numbers to binary and binary numbers to octal.
•
Explain the hexadecimal number system.
•
Write a program using number system conversion.
•
Convert hexadecimal numbers to binary and binary numbers to hex.
•
Differentiate between natural binary and Binary Coded Decimal (BCD).
•
Describe the purpose of parity bit, Gray code and ASCII code.
Module 17 – DIGITAL LOGIC
This module provides a
thorough treatment of digital logic and its application in PLC programming and
control. Boolean algebra and
the theorems
associated with it are presented and demonstrated through a series of
programming examples. In addition, the student
will become adept at
converting digital logic to ladder logic and will apply DeMorgan’s theorem to
increase circuit efficiency
and reduce redundancy.
Learning
Outcomes:
•
Apply truth tables to troubleshooting digital circuits.
•
List five logic gates.
•
Describe the basic operation of an inverter.
•
Explain the purpose of Boolean algebra.
•
Apply logic gate combinations to PLC control.
•
Convert digital logic to ladder logic.
• Name
eight Boolean theorems.
•
Apply DeMorgan’s theorem to ladder logic circuits.
Module 18 – RTUs & PACs
This module is
designed to cover the fundamentals of Remote Terminal Units (RTUs) and
Programmable Automation Controllers
(PACs). The four types
of connections used for interfacing with field devices are demonstrated, with
an emphasis on practical
application. A
discussion of RTU architecture, communications and practical applications is
presented. In addition, an overview of
PACs and a comparison
of PAC and RTU functionality is described and the differences between PLC and
PACs are also highlighted.
The main features of
DNP3 protocols are introduced, and a discussion of alarm management and its
application in RTUs and PACs
is also included.
Learning
Outcomes:
•
Differentiate between an RTU and a PAC.
•
List the four types of RTU connections for interfacing to field devices.
•
Identify 7 specifications for selecting an RTU.
•
Define the communications protocol DNP3.
•
Describe the layers of the Enhanced Performance Architecture.
•
Name four common uses for RTUs in industrial applications.
•
Explain the main differences between RTUs and PLCs.
•
Define Alarm Management and explain its use in RTU systems.
•
Identify the five components in an Intelligent Electronic Device.
•
Name three differences between PACs and PLCs.
•
List the five main characteristics of a PAC.
Module 19 – INTRODUCTION TO AUTOMATION
This module provides a
general overview of automation systems and the role of automation in industry.
It also covers the basic
principles of flexible
automation and flexible manufacturing systems. The advantages of automation are
outlined, and the main
components associated
with automation systems are explored. An introduction to automation simulation
is presented with an
emphasis on practical
application.
Learning
Outcomes:
•
Define the term “automation”.
•
List three advantages of using automation systems.
•
Name six factors affecting the original design of PLCs.
•
Describe the role of automation in industry.
•
Define flexible automation.
•
Differentiate between economy of scale and economy of scope.
•
List three examples of continuous flow processes.
•
Describe the purpose of a flexible manufacturing system.
•
Explain the difference between DCS, RCS, and CCS.
•
Define automation simulation and explain its advantages.
