Syllabus - Programmable Logic Controllers: The Human, Machine and Power Distribution Interface

This training will prepare the industrial maintenance technician or electrician to perform common tasks on PLC control systems in order to commission, test and troubleshoot. It focuses on presenting information to “non-programmers” and seeks to make the often confusing world of PLC control systems safer and more understandable to the ordinary technician or electrician. It is presented in two parts which may be taken together or separately. Each part culminates with a written and or performance test.

Part 1 – Two Days or 16 Hours


Section 1 – The Fundamentals

1.       What the PLC is and how it works

2.       Loads usually controlled by the PLC

3.       Output configurations normally found in the PLC system

4.       PLCs: State-of-the-art versus what you will find in the field

5.       The NEC and the PLC

Section 2 – Making the Connection

1.       The PLC enclosure

2.       Requirements for supplying power to the PLC enclosure

3.       Control transformers

4.       Bonding and grounding

5.       Supplying loads controlled by the PLC

6.       Over current protection and contactors

7.       Motor starters

8.       Motor Drives, Inverters or Variable Frequency Drives

9.       Safety considerations

10.   Arc Flash and PPE

Section 3 – Commissioning

1.       Phasing of AC loads

2.       I/O (Input/Output) testing

3.       Continuity testing

4.       Confirming the operation of the PLC both with and without a personal computer interface

5.       The HMI (the Human-Machine Interface) or “the display”

 


Section 4 – Common Programming Techniques

1.       Allen-Bradley – Rockwell Software

2.       Siemens – Step 7

3.       Others

Section 5 – Communications

1.       Connecting to the PLC with a PC and the appropriate software

2.       Multiple controllers

3.       Remote I/O

4.       Controlling devices (loads) over an intranet

5.       Other communication methods

Section 6 – Troubleshooting techniques

1.       Troubleshooting the PLC controlled system without the aid of a PCI (personal computer interface)

2.       Troubleshooting with a PCI

3.       Inputs

4.       Outputs

5.       Motor controls

6.       Safety relays and associated circuits

7.       Interlocks and by-passes

8.       Signal substitution and “forcing”

9.       Trouble with the controller

10.   Trouble with the modular parts of the “rack”

 

 

Part 1 – Two Days or 16 Hours (continued)


Section 7 – Performing repair work on a control system

1.       Safety considerations – LOTO and HIRA

2.       “What’s hot and what’s not”

3.       Over current protection devices

4.       Control transformers

5.       Contactors and starters

6.       Terminations

7.       Changing parts

8.       Testing, tuning and reprogramming

9.       Documentation

 

Part 2 – One Day or 8 Hours

 


Section 8 – Connecting to the PLC

1.       Software and cables or wireless connections

2.       The GUI – Graphical User Interface and the Portable Programming Device

3.       Locating the controller on an intranet

4.       Controller modes of operation

5.       Controller status and history

 

Section 9 – Examination of the PLC programs

1.       Transferring instructions from (uploading) and to (downloading) the PLC

2.       The main routine

3.       Subroutines

4.       Inserting “breaks” and monitoring values

5.       Commenting and identification

6.       The HMI and its program

7.       Drive software

8.       Analog inputs and outputs

9.       Digital inputs and outputs

10.   Forces and “shorted rungs”

 

Section 10 – Programming basics

1.       Memory management within the PLC

2.       Locating bits of information

3.       Ladder Logic, Functional Block and Structured Text

4.       Simple programming examples

5.       Remote I/O

6.       Multiple controllers

 

Registration

                Contact Russell Olson Phone 256-312-0969 (russell@fsiir.com)

or

Glenn Gould 256-546-1681 extension 112 (glenn@fsiir.com)

 

Location

the FSI Facility – 104 College St. Glencoe AL

 

Schedule A - Weekdays (Class 1 tentative upon class making of at least 6 people)

                Part 1 - August 26 and 27, 2013 

                              8:00 AM to 4:30 PM

                Part 2 - August 28 , 2013 

                              8:00 AM to 4:30 PM

 

Schedule B – Saturday Only (Class 2 tentative upon class making of at least 6 people)

                Part 1 - August 24 and 31, 2013 

                              8:00 AM to 4:30 PM

                Part 2 – September 7 , 2013 

                              8:00 AM to 4:30 PM

 

Price

                Part 1 -  $98

                Part 2 -  $49

 

Items to bring

Your calculators, computers or other devices

Your Code Book and your Ugly Book

Notebooks and writing utensils you prefer