INE 4040 - Programmable Logic Controllers (100 hrs)

A. Electro-mechanical to programmable

1. Describe the 3 elements to control a process.

2. Identify the similarities between manual, electro-mechanical, and PLC control.

3. Describe the active and inactive states of contacts.

4. Identify the components of a programmable control system.

5.Describe the role PCs play in an automatic control system.

6.Explain the action of components in a control system in terms of ON or OFF (YES/NO) decisions.

B. Logic circuits and discrete/analog devices

1. Describe how a logic diagram shows the flow of events within an automatically controlled system.

2. Explain the function of logic devices such as: coils, counters, and timers.

3. Explain how power flows through a simple logic circuit.

4. Distinguish between the electrical signals produced by discrete and analog field devices.

5. Explain AND and OR circuits as well as demonstrate the difference between them.

C. Function and wiring of input/output modules

1. Describe the function of simple I/O modules in a PLC system.

2. Describe how the logic section of a PLC uses I/O’s to direct the operation of output devices.

3. Describe the function of I/O addresses and explain why they are necessary in a PLC managed operation.

4. Explain the importance of the user program to the PC’s operation within the system.

5. Identify all discrete inputs in a user program as contacts, and all discrete outputs as coils.

6. Differentiate between normally open and normally closed contacts and explain their use in user program.

D. Memory, logic symbols, timer, and counters

1. Explain what internal logic symbols are and how they function in a PLC user program.

2. Explain why devices which are hard wired must be referenced to Examine open and Examine closed.

3. Describe how a PLC uses input signals, scans a user program in the logic, solves the ladder rungs, and keeps an operation running.

4. Describe the two types of memory found in a controller and show how they enable the PLC to control an operation.

5.Describe a memory register and the part it plays in the PLC’s operation.

6.Explain how counters and timers function in a PLC through the use of registers.

E. File structure and addressing schemes

1. Explain the file structure for PLC’s.

2. Explain the specific addressing scheme that applies to his/her particular PLC trainer.

F. Initial communications setup

1. Demonstrate communications on various PLC’s.

G. Uploading and opening an existing program

1. Demonstrate uploading of an existing project.

2. Demonstrate opening of an existing project.        

H. Creating and downloading a program

1. Explain the difference between electrical continuity and logical continuity.

2. Demonstrate the XIC, XIO, and OTE instructions as they are used in PLC programs.

3. Demonstrate the steps in downloading of a project.

4. Demonstrate the steps in modifying a project.

I. Output latch/unlatch instructions

1. Write a simple program containing an output latch and unlatch instruction.

J. Branch instructions

1. Define and identify a rung branch.

2. Write a simple program containing a rung branch.           

K. Time ON delay, time OFF delay, and retentive time ON timer instructions

1. Define various instructions pertaining to time ON, time OFF, and retentive time ON timers.

2. Write a program using time ON, time OFF, and retentive time ON timers.

L. Count UP and count DOWN counter instructions

1. Write a program using count UP and count DOWN counter instructions.

2. Write a program using count up, count done, and count down bits.

3. Explain how count UP and count DOWN counters work.

4. Explain the count up, count done, and count down bits.

M. Compare instructions

1. Define various terms pertaining to compare instructions.

2. Write a program using all of the compare instructions.

3. Explain how the compare instructions work.        

N. Arithmetic functions, binary, octal, BCD, and hexadecimal

1. Explain and demonstrate arithmetic operations as used in PLC’s.

2. Explain and demonstrate decimal, octal, hexadecimal systems as used in PLC’s.

3. Describe the binary number system and explain why it is important to the operation of a PLC.

4. Describe how the decimal and binary numbering system have been combined to produce the (BCD) binary coded decimal such as thumbwheels and readouts.

5.Explain how the PLC systems use analog voltages and currents and their BCD values to monitor and cause changes within an operation.

O. Procedures in troubleshooting a PLC system

1. Identify the three steps in troubleshooting an operation under PLC control and state each primary objective.

2. Describe some of the safety procedures which must be followed when troubleshooting PLC.

3. Identify the troubleshooting tools which assist in bringing a failed operation back up.

4. Describe some of the indicator lights within a PLC system and explain what they mean.

5. Explain the procedures used to isolate a fault through the process of elimination.

6. Explain how a programming device can be used to assist in a troubleshooting procedure.

P. Procedures in troubleshooting a complex PLC system using forces

1. Describe how the basic troubleshooting steps can be applied to a more complex operation.

2. Explain how accessing a register can help in the troubleshooting of a PLC managed operation.

3. Explain why it is sometimes necessary to force output coils, and the dangers which must be considered.

4. Explain the function and replacement of batteries in a PLC.

Q. Modifying rungs

1. Modify an existing rung.

R. Using search function

1. Locate specific items in a program by using the search.

S. Monitoring data table files

1. Demonstrate how to monitor the data table files.

T. Analog

1. Demonstrate how to use analog input and output signals in a PLC system.

2. Wire up analog devices and make them work.

U. Introduction to robotics

1. Robotic Safety.

2. List and define the fundamentals of robotics.

3. Operate the Robot in a safe operation.

4. Perform Robotic laboratory experiments.

5.Operate robotic axes.