Rockwell RSLogix 5000 and Allen Bradley Controllogix for PLC platforms
This course is designed to instruct electrical and electronic control professionals on how to successfully integrate PLC into actual day to day industrial electrical processes. It not only deals with the hardware and software, but also surrounding systems that must be compatible to achieve safe and reliable control.
It also helps students keep abreast of the latest PLC techniques and exchange ideas relating to their own applications.

Programmable Logic Controllers (PLCs) for Automation and Process Control
This course is designed to benefit you with practical up-to-date information on the application of PLCs for the automation and process control of plants and factories. It is suitable for people who have little or no exposure to PLCs, but expect to become involved in some or all aspects of PLC installation. It aims to give practical advice from experts in the field, to assist you to correctly plan, program and install a PLC with a shorter learning curve and more confidence. The inventible question is which PLC is being used.
This course will be focusing on the generic PLC and use the open programming IEC 61131-3 standard. The information contained in this course advances from the basics to challenge even the most experienced engineer in the industry today.

 

WHO SHOULD COMPLETE THIS COURSE

• PLC Engineering and Design personnel
• Maintenance and Technical service personnel
• Process and Operations personnel
• Technical and Process Managers
• Electrical consulting Engineers
• Electrical Contractors
• Instrumentation Engineers
• Application  Engineering/Quality  Department Personnel

COURSE OUTLINE

• Rockwell RSLogix 5000 and Allen Bradley Controllogix for PLC platforms

BASIC UNDERSTANDING OF CONTROL SYSTEMS AND LOGIX 5000

• Basics of a Control System
• Why PLC is widely accepted
• Use of PLC and its working
• Main components of Programmable Controller Systems
• Drafting basic Ladder Logic for Rs Logix5000 ladder Routine
• Operating RsLogix5000 Software
• Languages supported by Logix5000           

PROJECT CREATION AND MODIFICATION

• Project Creation- Specifications and components for organization
• Number systems and codes-Conversion and Interpretation
• Tag creation
• PLC addressing                                    

DATA ORGANIZATION AND BASIC LADDER LOGIC DESIGN RULES

• Tasks, programs and routines
• Types of tasks
• Creating and scheduling programs
• Ladder logic routines and Ladder logic Diagram
• Ladder logic Instructions used in Logix5000
• Tag arrays and Tag verification

HARDWARE IDENTIFICATION, MODULE SELECTION AND CONFIGURATION

• Module description and Components
• Digital and Analog modules-Characteristics
• Configuring I/O modules
• Communication formats
• Module connection status
• Module diagnostics
• Local and Remote I/O                          

LADDER LOGIC USING ADVANCED INSTRUCTION TYPES

• Structure of Ladder logic routine
• Ladder logic features
• Various Instruction types
• Mathematical Instructions
• Programming a BTD instruction       

SPECIALIZED INSTRUCTIONS AND COMMUNICATION

• Message Instructions
• Programming with Program Control Instruction
• Use of GSV/SSV Instructions for setting Controller Status values
• Creating User Defined Data type      

DOCUMENTING AND SEARCHING A LOGIX 5000 PROJECT AND DATA SHARING

• Searching and Documenting a program
• Data sharing between controllers    

FAULT FINDING TECHNIQUES

• Troubleshooting by Forcing I/O bits, Toggling
• Fault finding using Trend Chart
• Resolving Controller faults
• Digital and Analog Module faults
• Power Supply Faults                                         

CREATING ADD-ON INSTRUCTIONS AND ON LINE ACTIONS

• Methods to Edit and Enter Ladder Logic
• Creating Add-On Instructions

NETLINX  PHILOSOPHY AND EARTHING  CONSIDERATIONS

• Basics of Netlinx Philosophy
• Netlinx Architecture
• Set up considerations for Devicenet and a typical Network
• Control net Network
• Ethernet I/P Network and Advantages
• Earthing in Control Systems                            

FIRMWARE UPGRADE AND SETTING UP COMMUNICATION MODULES

• Firmware upgrade and procedure
• Ethernet Module set up (Using Rslinx, BootP server, Logix 5000)
• Devicenet Module Setup
• Controlnet  Module Setup                            

INTRODUCTION TO OTHER PROGRAMMING LANGUAGES

• Creation of Function Block Diagram,Structured Text Routine and Sequential Function Chart
• Programmable Logic Controllers (PLCs) for Automation and Process Control

INTRODUCTION TO THE PLC

• Introduction to PLCs
• A brief history of PLCs
• Alternative control systems – where do PLCs fit in?
• Why PLCs have become so widely accepted
• Lingering concerns about PLCs

INTRODUCTION TO IEC61131-3

• Concepts
• Common elements
• Programming languages: structured text
• Function block diagrams
• Ladder diagrams
• Instruction list
• Sequential function chart

OPC

• Introduction to OPC
• What is OPC?
• Architecture

SAFETY PROGRAMMABLE FEATURES

• Why regular PLCs should not be used for safety functions
• Programmable electronic logic solvers
• Safety certification
• Certified programming systems
• Application examples
• Growth of networked safety devices and certified networks
• Integrated safety systems

FUNDAMENTALS OF PLC HARDWARE AND SOFTWARE

• Block diagram of typical PLC

USING LADDERLOGIC FOR A SIMPLE DIGITAL FUNCTION

• The basic rules
• Comparison with relay ladder diagrams
• The concept of the “scan” and how to apply it
• Infinite fan-out
• Contact “normal” states
• Positive and negative logic
• Basic Boolean functions
• The usefulness of De Morgan’s law

PLC PROCESSOR MODULE MEMORY ORGANISATION

• Input/output section – module types
• Power supplies
• Methods of representing logic
• Boolean algebra
• Instruction code
• Graphical presentation: functional logic diagrams, ladder logic
• Fundamental ladder logic instruction set
• Comparison of different manufacturers
• Memory and data representation
• Instruction code

DATA COMMUNICATION

• Interface standards, RS-232, RS-422/423, RS-485
• Protocols, Modbus and DH+
• Local area networks, Ethernet and token bus
• Monitoring communication links and simple watchdog timers

USING REGISTER (WORDS)

• Number systems
• Types of register data
• Timers
• Counters
• Bit shift/rotate
• Table functions
• Register (matrix) logic functions

GOOD PROGRAMMING HABBITS

• Keeping track of addresses and data used
• Looking ahead – how will programs be maintained
• Practical methods to improve program quality
• Organisation of code
• Through documentation
• Simplifying changes

BATCH PROCESSES AND SEQUENTIAL CONTROL

• Remembering the program state
• Creating a “stepper”
• Step advance
• Fault detection and recovery
• Operator intervention
• Multiple recipes or alternate paths
• Sequential function charts

GOOD INSTALLATION PRACTICE

• Location of hardware
• Good wiring practice
• Cable spacing
• Power distribution
• Wire numbering
• Reducing noise and interference
• Screening and shielding
• Earthing and grounding

ADVANCED CONTROL WITH PLC

• The concept of reusable logic - examples: drive logic, alarm handling
• Use of advanced programming functions
• Matrix logic
• Table functions and indirect addressing
• Examples: simple display driver

PID CONTROL

• The importance of timing and scan time
• When PID is not always appropriate:
• Intermittent measurements
• Long transport delays

SYSTEM CHECKOUT AND TESTING

• Development and verification of code
• Factory acceptance testing
• Testing procedures
• Emulating missing hardware
• Emulating process responses