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.
To fault find a system you need to know EXACTLY how it works
Am I getting the input to the PLC?
The Led on the output card means i am getting voltage out right? does it?
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?
The PLC is in RUN, that means theres a program right? does it?
FORCING a bit and toggling a bit is pretty much the same yeah? depends on which PLC
Then you need to know the specifics
Level 1 Elements
- Check power is ON and PLC is in right mode (RUN or Program)
- Check LEDs for fault definition (what exactly does the LED tell me)
- Check and Change Modules if required (with spares and without spares)
- Removing modules with power ON (will I blow anything up)
- Establish link to PLC (RSLinx)
- Link to CPU via RS232 port, Ethernet or DH+ module
- Checking Ethernet connections using PING instruction (very useful)
- Create a blank project and take a backup (just in case I mess up)
- Open the correct project Off Line 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 I/O cards
- Change the battery, (with power ON of course)
- Working with CPUs with Non Volatile (EEPROM) memory
- Check all settings against a template, Node Address etc.
- Check Hardware Configuration, I/O errors
- Clear Memory and Download program
- Monitor program
- Is it Latched or Unlatched I’m never quite sure?
- 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 On Line
- Making minor mods Off Line and On line
- 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 Input and output cards
- Use of Diagnostics Input and output 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 Excel
- Programming Tips and Trick
- DeviceNet, configuration, programming and troubleshooting
- ControlNet, configuration, programming and troubleshooting
- EtherNet, configuration, programming and troubleshooting
Background information also covered
Understanding of 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, Counters
- Comparators, Maths
- Fault finding tips
- Allen Bradley ControlLogix Filofax
Course Equipment (per delegate)
- Allen Bradley PLC (systems designated to suit delegates requirements)
- ControlLogix, CompactLogix or FlexLogix
- PC or Laptop
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Excellent course. Would highly recommend, especially for any engineers leaving the forces and going in to a maintenance role
- Steven Meldrum (December 18, 2020)
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Fantastic course, covering everything in the title and more. Highly recommended.
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Attended the training course as above, From enquiring the staff were most helpful, learned a lot on the course, information and equipment was excellent.
Would recommend to anybody.
- Jack Cameron (November 27, 2020)
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I had a fantastic week with Rob learning all about Siemens S7 1200 and HMI. I learned a lot and Rob was a great host… would 100 percent recommend.
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This is a great course which covered a great range of the Siemens plc program. Both instructors were very knowledgeable and friendly. I would highly recommend.
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