In this course the participants will learn about PLC hardware
and how each piece of the PLC contributes to its overall operation and reliability.
Discussions will cover the different numbering systems which form the basis of digital control logic as well as the various types of programming and options available in building a control program.
The course will close with coverage of how to properly install, maintain and troubleshoot the PLC.
Safety is included and will be stressed throughout this course.
This course is mainly targeted to process technicians working in the field as an introduction or refresher.
The course can be applicable to technicians working in other disciplines,
procurement and storage personnel,
job planners and immediate supervisors to the working technicians.
Introduction to Programmable Logic Controllers
The Electromagnetic Relay; Characteristics of Programmable Controllers; Applications of Programmable Controllers; Limitations of Programmable Controllers; Parts of a Programmable Logic Controller System; The Input Side; The Processor; The Output Side; Programming Devices; Power Supplies
Describe an electromagnetic relay and define the terms control circuit, power circuit, NO and NC.
Define programmable logic controller.
Describe the general type of application in which a programmable logic controller would best be used, and give examples.
Define scan time.
Name each of the blocks in a block diagram of a programmable logic controller system and explain how each functions within the system as a whole.
Compare the decimal, binary, octal, and hexadecimal number systems.
Explain the purpose for using each of the following: BCD, Gray code, and ASCII.
Explain what AND, OR, and NOT mean in Boolean logic, and identify the symbols for each.
Identify AND and OR logic circuits in a relay ladder diagram, and construct a truth table for each.
Explain the basic concepts of ladder logic.
Programming the System
PLC Programming; Ladder Logic Programming; Boolean Programming; The AND Instruction; The OR Instruction; The Stack Register
Explain the relationship between a programmable logic controller processor and program.
Define the term scan and explain the basic steps involved in a scan.
Explain the basic concepts of ladder logic programming.
Explain the purpose of a parallel branch in a ladder logic program.
Explain the basic concepts of Boolean programming.
Define stack register and state the stack rule.
Input/Output Devices and Modules
Definition of I/O Devices; Discrete Input Devices; Analog Input Devices; Digital Input Devices; Discrete Output Devices; Analog Output Devices; Sourcing and Sinking; Definition of I/O Modules; Input Modules; Output Modules
Explain the operation of common input and output devices and identify their symbols.
Describe the relationship of an input/output device to a terminal on an input/output module.
Contrast the basic concepts of a sourcing device and a sinking device.
Explain the operation of various input and output modules.
Developing a Programmable Logic Controller System
Before You Begin; Equipment Operation Specifications; Sizing the System; Program Development; Assembling the Documentation Package; Functional Model; Startup and Debugging
Explain the importance of working with accurate information from a specification.
Demonstrate how to size a system.
List the elements in a good documentation package.
Name the steps involved in specifying the hardware and developing the program for a simple control system.
Describe system startup and debugging procedures.
Lesson 6: Maintenance and Troubleshooting
The Importance of Documentation in Maintenance Troubleshooting; Using the Hardware Documentation; The Maintenance Log; Using the Program Documentation; Operational Documentation; Routine Maintenance; Batteries; Troubleshooting; Problems in Troubleshooting; Troubleshooting in Practice
Explain the importance of good documentation.
Tell what type of information can be found in user’s manuals and operations manuals.
Tell what types of logs are kept and why they are necessary.
Explain the major concepts of troubleshooting, including problems sometimes encountered.
Describe routine maintenance procedures required by a programmable controller system.
Practical skills in designing financial models using Excel
The design of financial models for forecasting and decision-making