PLC I - PLCs for Non-Programmers

" ...detailed - but easy to understand"
Robert Bostick - Journeyman Electrician - Basic Energy Services

"This was a huge bang for the buck!"
David Younker - Aetna Bearing Company

Purpose of Seminar:

This seminar converts the seemingly complex world of automation and Programmable Logic Controllers ( PLCs ) into practical lessons the average maintenance person can understand. We've taken information from thousands of pages of manufacturers' technical manuals (Allen Bradley, GE, Siemens, Omron, Modicon, Mitsubishi, Honeywell …), combined it with twenty years of experience and a practical real world philosophy to give you simple, clear, and concise solutions to your everyday PLC problems.

This course is perfect for multi-craft maintenance technicians, electricians, or other non-programmers who need a general understanding of PLCs. And because we know time is money, this seminar is designed to have immediate impact so that you can start saving maintenance dollars on costly repairs and service calls today!

Who should take this course?

This course is created specifically for maintenance personnel and electricians working in industrial plants, public facilities, and commercial buildings. Attendees come from a wide variety of industries, skill-levels, company sizes, and job titles, so if you're not sure you'll fit in or benefit from this class, don't worry - you will! - as long as you have an interest in learning to troubleshoot and repair your PLCs, including.....

All maintenance personnel in:

• Manufacturing Plants
• Commercial Buildings
• Hospitals
• Waste Water Facilities
• Schools
• Government Buildings
• Research Facilities
• Shopping Centers
• Airports

Including:

• Apprentice and Experienced Electricians
• Instrumentation Technicians
• All Building Maintenance Personnel
• All Plant & Facility Maintenance Technicians
• Building Engineers
• Building Managers & Superintendents
• Plant & Facility Managers
• Multi-craft & Cross Training Personnel
• Mechanical Engineers
• Any person needing a basic course in PLC basics & maintenance!

What will you learn?

Attendees will learn to:

1. Speak the PLC language
2. Read and interpret PLC ladder logic
3. Troubleshoot PLC systems and components
4. Relate PLC programming to "real world" applications
5. Fix PLC problems on their own….before calling an outside service contractor!
   

Training Outcomes

Upon completion of this course, students will receive a training certificate with 1.6 American Trainco Continuing Education Units indicating that the student has learned to:

1. Identify PLC components
2. Read and interpret Ladder Logic
3. Understand function and purpose of basic programming instructions
4. Configure a PLC-based control system
5. Relate actual PLC and PID instructions to "real world" applications
6. Troubleshoot and correct PLC problems by identifying and isolating most common system faults
   

Course Outline / Agenda

Studies have indicated that 80% of the faults associated with a PLC-based control systems involve either I/O (Input/Output) devices or field wiring. During this seminar you will learn how to use both hardware and software to find these faults quickly. Students will learn how to use a systematic approach to troubleshooting; how to set up and configure Input/Output modules using various slot addressing techniques; what to understand about program and data table file organization, number systems and processor information flow; and how basic, relay type instructions, timers, and counters, and data manipulation instructions can be used to achieve the automation and PLC solution you want.

The other 20% of faults can also be quickly found using software tools that usually remain hidden to all but the most experienced troubleshooting professional. But, in this American Trainco seminar, we will unlock these tools, dispel the myths, and provide you aids that you can take back to your workplace for easy future reference. At American Trainco, we provide real world training for your real world needs!

I. SPEAKING THE LANGUAGE OF PLCs

A. Hardware Focus

B. How PLCs Work

1. Past
2. Present
3. Future
   

C. PLC Terminology, PID

D. Parts of a PLC

1. Input Interfaces
2. Processor
3. Output Interfaces
4. Power Supplies
5. Programming Terminals
   

E. System Configurations

1. Local
2. Remote
3. Hierarchical
4. Distributive
   

F. Hardware Considerations

1. Field Wiring
2. Master Control Relay
3. Isolation Transformers
4. Four Basic Types of Grounding

II. READING PLC LADDER LOGIC

A. Organization and Function of Ladder Logic

B. Ladder Logic Data Table Organization

1. Numbering Systems
2. Data Table Files
3. Bit, Word and File Addressing
   

C. Introduction to Programming

D. Common PLC & PID Instructions

1. Basic Relay
2. Counters and Timers
3. Data Transfer
   

E. Organization

1. Subroutine Files
2. Selectable Timed Interrupt (STI) Files
3. Jumps and MCR Instructions
4. Fault Routines
   

F. Relating the PLC to "Real World" Applications

III. TROUBLESHOOTING PLC SYSTEMS & COMPONENTS

A. Safety

B. Forcing of Input Data Table & Output Devices

C. Identifying I/O Field Device Faults

D. Identifying I/O Module Faults

E. Identifying System Faults

F. Using the Data Monitor Screen

G. Using the Processor Status and I/O Status Screen

IV. FIND & FIX THE 10 MOST COMMON PLC PROBLEMS

A. The "Ultimate PLC Troubleshooting Flowchart"

B. Using Troubleshooting Tools

C. Using Software Tools

D. "Real World" Case Studies

What You Will Take Home

• American Trainco Seminar Manual - detailing all PLCs for Non-Programmers material covered in the class.

• Personalized Programmable Logic Controllers ( PLCs ) for Non-Programmers Training Certificate with 1.6 American Trainco Continuing Education Units approved by the MTAA and ACE.

• All the information you need from asking our instructors specific questions about your PLC questions including specific questions about your PLC brand (Allen Bradley, GE, Siemens, Omron, Modicon, Mitsubishi, Honeywell, Rockwell, A- …) or ladder logic questions.

CEUs, Testing & College Credit

CEUs
After completion of the PLCs for Non-Programmers class, students will receive a Certificate of Completion and 1.6CEUs (Continuing Education Units) for both days of training approved by the Maintenance Training Association of the Americas and The American Council on Education.

Both Days

1.6 CEUs

College Credit Recommendations

This course qualifies for 1 hour of college credit recommendation by the American Council on Education. Those seeking college credit recommendations must attend both days of this course and successfully pass the MTAA Certification test. Transcripts are available through American Trainco.