Programmable Logic Controller (PLC) Wiring & Troubleshooting I

Overview: At the completion of this course, the participants will clearly see the differences between relay logic and ladder logic, and will be able to “talk through” and troubleshoot the PLC’s ladder logic using the Logix5000 software in order to locate a “real,” faulty input or output device, replace it, and get the process back up and running. It’s all about troubleshooting!

The participant will begin their training by wiring the actual input and output (I/O) devices such as photo-electric sensors, inductive proximity and selector switches, pushbuttons, and outputs such as contactors, indicator lamps, etc., to the PLC’s input/output module.

The participants actually wire their own PLC trainer!

  • A brief overview of relay logic will be given so that the employee will be able to understand the differences between relay logic and ladder logic.
  • The employee will be able to identify “real” and “simulated” I/O in order to troubleshoot the ladder logic.
  • The concept of “tags” will be fully understood and each employee will assign “tags” where appropriate using the Logix5000 software.
  • The troubleshooting tools of “toggling” and “forcing” I/O will be thoroughly examined and applied.
  • Examples of Timer (TON, TOF, RTO) and Counter (CTU, CTD) circuits will be presented.
  • An explanation of “how” and “why” specific instructions such as One-Shot (ONS), First Scan (S:FS), Set Bit if Zero/Negative (S:Z, S:N) are used in a PLC-based system.
  • Several examples using Comparison instructions such as EQU, NEQ, GRT, LES, GEQ, LEQ, LIM, etc will be shown.
  • Project examples that use Math instructions, such as, ADD, SUB, MUL, and DIV will be presented in detail.

NOTE: Numerous hands-on labs utilizing troubleshooting skills are included in all of the above subject matter in order to reinforce the lecture material.