ELM 4020 - Intermediate PLC Programming

1. Identify the three basic modules of a programmable logic controller.

2. List several applications of a programmable logic controller.

3. Explain the advantages of a programmable logic controller over a hard-wired relay circuit.

4. Define the terms: input device, output device, input module, output module, controller.

1.2- PLC Internal Operations             

1. Describe the operation and use of an opto-isolator.

2. Explain the internal operations of input and output modules.

3. Describe the function of the processor.

4. Describe the sections and functions of memory.

5. Describe the sequence of events for a single program scan.

1.3- Series and Parallel Circuits              

1. Identify and describe the three basic components of a circuit.

2. Explain the difference between AC and DC electrical power.

3. Describe the current flow in a series and a parallel circuit.

4. Design and construct examples of series and parallel circuits.

1.4-Numbering Systems

1. Describe the general origins of numbering systems.

2. Explain the differences between Roman, decimal, binary, octal, and hexadecimal numbering systems.

3. Identify one use of each numbering system.

4. Convert numbers between selected numbering systems.

1.5-Boolean Algebra

1. Explain Boolean Algebra.

2. Explain the AND, OR and NOT logic functions.

3. Develop simple logic equations.

4. Equate a simple electrical circuit to a simple logic equation.

1.6-Ladder Logic              

1. Identify and describe a ladder rung, ladder rail and ladder branch.

2. Identify and describe the elements and symbols used to construct a ladder logic diagram.

3. Explain how AND, OR and NOT circuit logic is represented in a ladder logic diagram.

4. Explain the differences between an internal relay coil and an external relay coil.

5. Write a ladder logic program using internal and external coils.

6. Design and construct ladder logic programs that represent series and parallel electrical circuits.                                    

2.1- SLC 500 PLC Trainer Familiarization                            

1. Locate and identify the components of the Allen-Bradley SLC 500 Programmable Logic Controller trainer.

2. Describe the function of each component of the Allen-Bradley SLC 500 Programmable Logic Controller trainer.

3. Explain and follow safety procedures designed to prevent equipment damage and personal injury when operating the

Allen-Bradley SLC 500 Programmable Logic Controller. 

2.2- Introduction to SLC 500 PLC Programming            

1. Identify and describe the components of the three subsystems that make up the SLC 500 PLC Training System.

2. Explain the function of each component in the three subsystems that make up the SLC 500 PLC Training System.

3. Explain symbols and instructions used to program ladder logic into the SLC 500 PLC Training System.

4. Describe the events occurring during an operating cycle.

5. Identify and describe program and data files.

6. Describe the address structure used when programming the SLC 500 PLC Training System.

7. Enter and edit ladder logic instructions using ICOM software and the subsystems of the SLC 500 PLC Training System. 

2.3- External Input and Output Elements

1. Create ladder logic for using input devices to control output devices.

2. Enter, download and run a simple program which uses external input and output elements. 

2.4-Internal Bits              

1. Use external input elements to energize internal bits.

2. Use internal bits to control multiple output elements.

3. Enter and operate programs which use internal bits. 

2.5-AND, OR, and NOT Gates          

1. Create ladder logic diagrams using AND and AND NOT instructions.

2. Create ladder logic diagrams using OR and OR NOT instructions.

3. Combine AND and OR instructions within a ladder diagram.

4. Enter, download and run simple programs which contain AND and OR instructions. 

2.6-Latching Instructions

1. Use external output elements and internal bits to latch and unlatch program rungs.

2. Use internal latching instructions to latch and unlatch rungs.

3. Enter and run both types of latching instructions.

2.7-Timers

1. Write a program using a non-retentive on-delay timer (TON).

2. Write a program using a non-retentive off-delay timer (TOF).

3. Write a program using a retentive on-delay timer with reset (RTO).

4. Enter and run timer programs.

5. Edit timer preset values.

2.8-Counters

1. Write a program using an up counter (CTU) and a down counter (CTD).

2. Enter and run counter programs.

3. Change the preset value on a counter.

2.9-Cascading Timers

1. Use cascading timers to create an output sequence.

2. Use a timer to activate timer reset instructions.

3. Enter and run a program using cascading timers to operate a pick and place robot arm.

2.10-Move and Convert Instructions

1. Create ladder logic to move data from a source to a destination.

2. Create ladder logic to convert between binary coded decimals (BCD) and decimals.

3. Enter, download, and run simple programs for moving and converting data.

2.11-EQU, NEQ, LES, and GRT Instructions

1. Create ladder logic to compare internal PLC data to values entered through an external input device.

2. Apply proper conversions between BCD and decimal sources and destinations.

3. Enter, download, and run simple comparison programs, including editing programs to change comparison functions.

2.12-LEQ and GEQ Instructions

1. Create ladder logic to compare internal PLC data to values entered through an external input device.

2. Apply proper conversions between BCD and decimal sources and destinations.

3. Enter, download, and run simple comparison programs, including editing programs to change comparison functions.

3.1- Coolant System Application                            

1. Explain the operation of the coolant system.

2. Describe how the coolant system is simulated on the SLC 500 Trainer.

3. Enter and run the coolant system control program.

4. Modify the coolant system program to improve operation.

3.2- Conveyor Application

1. Explain the operation of the conveyor system.

2. Describe how the conveyor system is simulated on the SLC 500 Trainer.

3. Enter and run the conveyor system control program.

4. Modify the quantity of bottles being sent to each packaging machine.

3.3- Batch Process Application

1. Explain the operation of the batch processing system.

2. Describe how the batch processing system is simulated on theSLC 500 Trainer.

3. Enter and run the batch processing control program.

4. Modify the operation of the batch processing program.

3.4-Test Station Application

1. Explain the operation of the testing sequence.

2. Describe how the testing sequence is simulated on the SLC 500 Trainer.

3. Enter and run the test station control program.  

4.1-Arithmetic Instructions          

1. Create ladder logic to execute arithmetic instructions for addition, subtraction, multiplication, and division.

2. Enter, download and run simple programs which use arithmetic instructions.

4.2-JMP, LBL, and MCR Instructions

1. Enter, download and run a simple program which includes jump to label instruction.

2. Enter, download and run a simple program which uses a master control reset instruction.

3. Describe the operation of JMP, LBL, and MCR instructions.

4. Identify the precautions necessary when using JMP and MCR instructions.

4.3-Jump to Subroutine Instructions

1. Create a subroutine file.

2. Enter and run a program which uses a subroutine.

3. Describe the safety precautions needed when using JSR/SBR instructions.

4.4-Bit Shift and File Copy Instructions

1. Enter and run programs using BSL and BSR instructions.

2. Use the file copy instruction to control output devices with an internal bit file.

4.5-Sequencer Instructions

1. Control output devices using the SQO instruction.

2. Explain the use of File and Mask in the SQO instruction.

3. Modify a sequencer program to meet revised operating criteria.

3. Enter, download, and run simple comparison programs, including editing programs to change comparison functions.

5.1- Palletizer Application                          

1. Explain the operation of the palletizer system.

2. Describe how the palletizer system is simulated on the SLC 500 Trainer.

3. Enter and run the palletizer system control program.

4. Modify the palletizer system program to improve operation. 

5.2- Candy Bar Production Line Application

1. Explain the operation of the candy bar production line.

2. Describe how the production line is simulated on the SLC 500 Trainer.

3. Enter and run the production line control program.

4. Create additional recipes and modify instructions to improve program operation. 

5.3- Automated Paint Booth Application

1. Explain the operation of the paint booth system.

2. Describe how the paint booth system is simulated on the SLC 500 Trainer.

3. Enter and run the paint booth control program.

4. Modify the operation of the paint booth program. 

5.4-Pick and Place Robot Application

1. Explain the operation of the robot sequence.

2. Describe how the robot sequence is simulated on the SLC 500 Trainer.

3. Enter and run the robot sequence control program.

4. Create alternative sequences and modify motion control for more efficient operation.