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Level 1 - Troubleshooting the Allen-Bradley Family of Programmable Logic Controllers

Scope
This hands-on course is designed to teach you how to properly install, operate, and troubleshoot any of the Allen-Bradley PLC-5 family of programmable logic controllers. This course stresses the practical aspects of troubleshooting these sophisticated and complex programmable controllers. The author/instructor has used his over twenty years of practical control and teaching experience to condense the thousands of pages of technical information from the manufacturer's manuals into clear and concise solutions to your everyday problems. The installation section emphasizes practical examples of how to set-up and configure local, remote, hierarchical and distributive control systems. You also will be given hands-on opportunity to configure I/O modules using the various slot addressing techniques so that you can locate any field termination point. You will do many practical exercises and practice problems to help you understand the complex subjects of program and data table file organization, number systems and processor information flow.

Although this is not specifically a programming course, basic relay type instructions, timers and counters, and data manipulation instructions will be discussed along with the opportunity to perform many practical programming exercises and practice problems. Studies have indicated that eighty percent of the faults associated with a PLC based control system involve either I/O devices or field wiring. You will learn how to use the PLC-5 hardware and software to be able to find these faults quickly. The remaining twenty percent of the faults can also be quickly found using software tools that usually remain hidden to all but the most experienced troubleshooting professional. You will be given the keys to unlock these tools along with job aids that you can take back to your job site for easy future reference.

Prerequisites: A strong working knowledge of Electricity, Electronics, and either Motor Control Basics or Instrumentation is required. In addition it would be very helpful for the participant to have a good general understanding of personal computers.

 

Learning Outcomes

At the conclusion of the course the participant should be able to:

  • Install, Set-up, and Configure a PLC-5 programmable logic controller based control system.
  • Write programs using the Basic Relay Type, Timer and Counter, and Data transfer and manipulate instructions.
  • Identify, Isolate, and Correct the most common field and systems faults.

Outline

  • Installation
    • Parts of a PLC-5 Programmable Logic Controller
      Processor
      • Single channel PLC-5 processors
        • Front panel features
        • Dip switch setting
      • Multiple channel PLC-5 processors
        • Front panel features
        • Dip switch setting
      • Input Interfaces
        • Five section block diagram
        • Internal circuit analysis
      • Output Interfaces
        • Five section block diagram
        • Internal circuit analysis
      • Power Supplies
        • Operation of switching power supplies
        • Front panel features
      • Programming Terminals
        • Communication card installation
        • Software installation
          • Config.sys file
          • Autoexec.bat file
          • On-line configuration screen
    • System Configurations
      • Local
      • Remote
      • Hierarchical
      • Distributive
    • Hardware Considerations
      • Field wiring
      • Master Control Relay
      • Isolation transformers
      • Grounding
    • Hands-on activities
  • Program and data table files
    • Organization and function of various program files
    • Data Table Organization
      • Numbering Systems
        • Decimal
        • Binary
        • Octal
        • Binary Coded Decimal
        • Integer
        • Two’s compliment
      • Data table files
      • Bit, word and file addressing
    • Hands-on activities
  • Introduction to PLC-5 programming
    • The most common PLC-5 instructions
      • Basic relay type instruction
      • Counter and timer instructions
      • Data transfer instructions
    • Entering and editing user programs
    • Organization of ladder diagram programs
      • Subroutine files
      • Selectable timed interrupt (STI) file
      • Jumps and MCR instructions
      • Fault routines
    • Interpretation of logic diagrams
    • Hands-on activities
  • Troubleshooting Activities
    • Safety considerations and forcing of input data table and output devices
    • Identifying input and output field device faults
    • Identifying I/O module faults
    • Identifying system faults
    • Using the data monitor screen to troubleshoot I/O faults
    • Using the processor status and I/O status screen to troubleshoot I/O and system faults
    • Hands-on activities

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