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EAL Level 3

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Course Outline

This course meets ELCAS criteria.

To achieve unit certification, candidates must be able to:

  • Demonstrate an understanding of the internal architecture of PLCs, their applications and knowledge of the number systems they use.
  • Demonstrate an understanding of typical input and output devices used with PLCs, their selection and how they are interfaced to the PLC.
  • Investigate and display an understanding of the basic programming techniques used with PLCs.
  • Produce a correctly developed program for a PLC to control a specified process and document the completed program to a satisfactory standard.
  • Demonstrate an understanding of how to monitor PLC operation, force devices and fault find PLC controlled processes.

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Equipment per Delegate

  • Allen-Bradley ControlLogix, CompactLogix or FlexLogix PLC.*
  • PC or laptop.
  • Simulator.

* Systems designated to suit delegates requirements.

Course Content

To fault find a system you need to know exactly how it works.

How exactly does a PLC work?

  • Am I getting the input to the PLC?
  • The LED on the output card means I am getting voltage out right?
  • What exactly happens in-between? Theres more than just a program in the CPU.
  • How exactly does it scan the program?
  • What is this Watchdog Timer? Is it that important?
  • Can I use the same output twice? That's bad programming isn't it?
  • A PLC is a logic controller, so use a logical approach to fault find it.
  • What are the 8 simple test points to check?
  • Is forcing a bit and toggling a bit is pretty much the same?

Level 1 Elements

  • Check power is ON and PLC is in right mode (RUN or Program).
  • Check LEDs for fault definition.
  • Check and change modules if required (with spares and without spares).
  • Removing modules with power on.
  • Establish link to PLC (RSLinx).
  • Link to CPU via RS232 port, ethernet or DH+ module.
  • Checking ethernet connections using PING instruction.
  • Create a blank project and take a backup.
  • Open the correct project offline and link to PLC
  • Interrogate errors in controller properties, common faults.
  • Identify if it is a hardware or software fault.
  • Identify if it is a PLC or comms fault.
  • Access fault information about IO cards.
  • Change the battery with the power on.
  • Working with CPUs with non-volatile (EEPROM) memory.
  • Check all settings against a template, node address, etc.
  • Check hardware configuration, IO errors.
  • Clear memory and download program.
  • Monitor program.
  • Latched/unlatched.
  • Altering values in tag tables
  • Back-tracking through a program to establish where power flow stops.
  • Searching for specific operands and instructions.
  • Using bookmark function.
  • Changing timer, counter values online.
  • Making minor mods offline and online.
  • Create a trend-to-trend address status or values.
  • Altering timer, counter and other values if required.
  • Force a parameter if required.
  • Toggling addresses to move program on in sequence.
  • Call up documentation to assist with software diagnostics.
  • Printing cross reference/program listings, etc.
  • Introduction to DeviceNet.
  • Introduction to ControlNet.
  • Introduction to ethernet.

Level 2 Elements

  • Advanced hardware features
  • Reading and writing data to IO cards.
  • Use of diagnostics IO cards
  • Use of analog cards, PID, scaling etc.
  • Advanced program design and operation.
  • Period and event driven tasks.
  • Controller fault handler.
  • Controller power up handler.
  • Add on instruction (function blocks).
  • Intermediate data types, arrays, UDTs, etc.
  • Intermediate and advanced instructions.
  • Masked MOVE, compute CPT.
  • System value Instructions, GSV, SSV.
  • Systems with multiple CPUs.
  • Communications with SCADA and HMIs.
  • Linking to ControlLogix via the internet.
  • Messaging instructions, MSG.
  • Producer and consumer tags.
  • Move logical instructions masked move, MVM
  • Bit field distribute.
  • File instructions, file fill, FFL, copy COP.
  • Bit shift instructions, BSL, BSR.
  • Program control instructions, JMP, LBL, RET, MCR, SBR, AFI.
  • Parameter passing to subroutines.
  • Software tools.
  • Flash upgrading.
  • Tag data monitor tool.
  • BOOTP DHCP server.
  • Remote monitoring via ethernet.
  • Exporting data to Microsoft Excel.
  • Programming tips and tricks.
  • DeviceNet, configuration, programming and troubleshooting.
  • ControlNet, configuration, programming and troubleshooting.
  • Ethernet, configuration, programming and troubleshooting.

Background information also covered.

Understanding the following

  • Number formats, bits, words, double words.
  • Binary, real, integer, DINT, UDT, arrays.
  • Basic communications, RS232 and ethernet.
  • Network basics.
  • Setting up a simple ethernet network.
  • Tasks, programs and routines.
  • How to monitor various blocks.
  • Understand basic ladder programs.
  • Basic instructions, contacts, latch, unlatch, etc.
  • Timers and counters.
  • Comparators, maths.
  • Fault finding tips.

Booking

Provisional bookings can be made via email, phone or letter. Confirmation in writing with a purchase order number is required four weeks prior to the course start date.

Dates may be offered to other customers after this date.

Joining instructions are sent out approximately two weeks prior to the course start date.

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Course Times

Typical course times are 09:00 to 16:30. Alternative arrangements can be made for customised and on-site courses.

Lunch

A light lunch will be provided when training at our in-house facility.

Payment and Cancellations

Fees are based upon payment being made to confirm course booking. Should you be unable to meet these terms please advise us as we will be able to re-quote on your payment terms.

Prices are quoted exclusive of VAT. New Customers are required to pay pro forma.

Requests for cancellation must be made via email or letter. Cancellation charges may apply.

Course Specifics

PLC

Allen-Bradley

Software

RSLogix 5000

Duration

10 days

Max. Delegates

6

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