ATMN 160 - Industrial Control Systems-Allen Bradley

4 Credit: (1 lecture, 3 open-lab, 0 clinical) 4 Contact Hours: [Pre- or co-requisite: ATMN 140 ]

This course will emphasize programmable logic controllers (PLC), their use, selection, setup, and servicing. This course is designed to give the industrial technician/electrician a basic understanding of the Allen Bradley PLC using RSLogix software, its logic functions, its installation, and troubleshooting. In addition, a Human Machine Interface (HMI) is introduced.
OFFERED: fall and spring semesters

Course Goals/ Objectives/ Competencies:
Goal 1: Introduction to PLCs.

Open a Processor File using PLC Software.
Download a PLC Processor File using PLC programming software.
Configure a Serial Communications Driver.
Monitor PLC operation using PLC programming software.
Run a PLC Processor File using PLC programming software.
Stop a PLC Processor File using PLC programming software.

Goal 2: Demonstrate basic PLC programming.

Convert between decimal and binary.
Monitor the status of CompactLogix’s Boolean Tags.
Create a CompactLogix project.
Configure the I/O of a CompactLogix PLC.
Enter and run a Basic Routine using RSLogix software.

Goal 3: Demonstrate PLC Motor Control.

Design a PLC program to jog a motor.
Design a PLC program to control the Start/Stop of a bi-directional motor.
Create a BOOL Tag/Array for a CompactLogix project.
Design a PLC program to interlock two motors.
Design a PLC Program that uses a safety interlock to control the operation of a machine.
Develop a Wiring Diagram to Interface a PLC to a Machine Controller.

Goal 4: Create PLC Timer Instructions.

Enter and Edit a PLC Program that Uses an RTO Instruction.
Enter and Edit a PLC Program that Uses a TON Instruction.
Enter and Edit a PLC Program that Uses a TOF Instruction.
Design a PLC Program that Provides Low Voltage Starting of an Electric Motor.
Design a PLC Program that Controls a Centrifugal Air Compressor.

Goal 5: Create PLC Counter Instructions.

Enter and Edit a PLC Program that Uses a Count Up Instruction.
Design a PLC Program to Indicate When Preventive Maintenance Should be performed.
Enter and Edit a PLC Program that Uses an Up/Down Counter Instruction.
Enter a PLC Program that Uses an FRD Instruction.
Enter and Edit a PLC Program that Uses a TOD Instruction.
Design a PLC Program that Controls an Adjustable Counting Station.

Goal 6: Investigate, configurations, forces, and major and minor PLC faults.

Identify and resolve faults indicated by a PLC.
Understand concepts of configuration of local and remote I/O busses.
Explore safe uses of I/O forces.
Create a ladder logic routine utilizing remote analog I/O.
Rewrite a relay logic ladder diagram as a PLC ladder logic routine.

Goal 7: Investigate RSLogix tag based programming.

Understand importance of accurate documentation in tag based programming.
Construct a ladder logic program using tag and alias tag identifiers.
Integrate “compare functions” into a ladder logic routine.
Demonstrate a working ladder logic routine incorporating timers and compare functions.

Goal 8: Evaluate various attributes of, function block, structured text, ladder logic, and sequential function programming.

Review attributes of function block programming.
Review attributes of sequential function programming.
Review attributes of structured text programming.
Demonstrate re-writing a ladder logic program using structured text programming.

Goal 9: Incorporating “add-on” instructions into RSLogix programming.

Investigate, creating, using and importing/exporting “add on” instructions.
Demonstrate using the “add-on” instruction in an advanced PLC routine.

Goal 10: Investigate advanced commands and advanced on-line editing.

Investigate, MOV, MCR, JSR, JMP, and LBL commands.
Demonstrate safely editing a PLC RSLogix program while in use.
Demonstrate a working ladder logic routine incorporating one or more of the commands previously researched.

Goal 11: Correctly wire an input card and an output card on an Allen Bradley Compact Logix PLC.

Implement the proper wiring of a PLC system given a wiring diagram.
Connect and Test a Limit Switch to a Discrete Input Module.
Connect and Test the Operation of an Electronic Sensor to a PLC Input Module.
Connect and Test the Operation of a PLC Input Module to a Robot Output Module.
Connect and Test the Operation of a PLC Discrete Output Module to a Robot Input Module.

Goal 12: Integrate an HMI device into an Allen Bradley Compact Logix PLC.

Revise a ladder logic routine to incorporate an HMI as an input and an output device.