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Level 2 - Advanced Troubleshooting the Allen-Bradley Family of Programmable Logic Controllers

Scope
This hands-on course is designed to continue where the Level 1 course left off. Essential information from the Level 1 course will be discussed at the beginning of this course. The results of the pre-test will be used to determine what information that your particular group needs to have reviewed. The focus of this course will be the advanced instructions typically used when programming a PLC-5 processor. The instructor has used his over thirty years of practical maintenance, control, and teaching experience to provide real world examples for each of the various instructions. You will do many practical exercises and practice problems to help you understand the complex subjects of word to file, file to file and file to word manipulation, file logic and math, file search, and file diagnostic instructions. You will have the opportunity to program the various program control instructions to be able to see the effect that these instructions have on the scanning sequence. You will be able to program, analyze, and troubleshoot the different types of synchronous and asynchronous word and bit shift registers.

The gathering of data is essential for many of today’s processes. The data is usually transferred into and out of a PLC-5 based control system by way of analog sensors and output devices. To be able to effectively troubleshoot these data dominant systems, you will be instructed in both block transfer and Data Highway Plus instructions. You will be given hands-on opportunity to install, program, and troubleshoot a "mini-highway" containing various types of I/O modules and PLC-5 processors.

Even though relay logic diagrams have been the dominant language of programmable logic controllers since their invention in 1969 many programmers have started to migrate into higher level languages. You will learn how to enter, edit and troubleshoot Sequential Function Chart programs, Allen-Bradley’s first introduction to a transitional higher level language.

The final part of the course will introduce you to installing and troubleshooting ControlNet, Allen-Bradley’s new generation of automation and control networks. A discussion of this "non-proprietary" communication hierarchy will be presented.

Prerequisites: Successful completion of the Level 1 - Troubleshooting the Allen-Bradley Family of Programmable Logic Controllers or equivalent knowledge.

 

Learning Outcomes

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

  • Install, Set-up, and Configure a PLC-5 family Data Highway.
  • Write programs to both read and write information from one station to another on the Data Highway.
  • Identify, Isolate, and Correct the most common field and systems faults on the Data Highway.
  • Given industrial applications, write and troubleshoot programs incorporating the Advanced Instructions for the Allen-Bradley PLC-5 family processors.
  • Troubleshoot systems containing Sequential Function Chart programs.

Outline

  • Course Introduction
    • Layout of Course
    • Pre-test
  • Review of Level 1 Course
  • File Instructions
    • Concepts of File Instructions
    • File Transfer
      • File to File
      • Word to File
      • File to Word
    • File Arithmetic
    • File Logic
    • File Conversions
    • File Search and Compare
    • File Copy
    • File Fill
    • Diagnostic Instructions
      • File Bit Comparison
      • Diagnostic Detect
      • Data Transitional
  • Shift Registers
    • Synchronous Instructions
      • Bit Shift Left
      • Bit Shift Right
      • Sequencer Instructions
        • Sequencer Input
        • Sequencer Output
        • Sequencer Load
    • Asynchronous Instructions
      • First In-First Out
      • Last In-Last Out
  • Program Control Instructions
    • Master Control Resets
    • Jump and Label
    • For Next Loop and Break
    • Subroutines
      • Jump
      • Subroutine
      • Return
    • Additional Instructions
      • Temporary End
      • Always False
      • User Interrupt Disable
      • User Interrupt Enable
  • The Transfer of Data
    • Block Transfers
      • Concepts
      • Block Transfer Read
      • Block Transfer Write
    • Data Highway
      • Concepts
      • Message Instruction
  • Sequential Function Chart Programming
    • Concepts
    • SFC Building Blocks
      • Step
      • Transition
      • Selection Branch
      • Simultaneous Branch
      • Goto and label
  • Introduction to ControlNet
    • Concepts
    • Hardware
      • Interface Cards
      • Physical Link
    • Terminology
  • Course Conclusion
    • Course Review
    • Post-Test
    • Course Evaluation

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