Download Brochure - Intellect Controls

Download Brochure - Intellect Controls
В Hands-On Industrial
Automation Training
for the Maintenance
Troubleshooter
Your Choice:
Training Available On:
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PLC’s
AC & DC Drives
HMI
Fluid Power
Allen-Bradley/Rockwell
Modicon
Fanuc CNC
Process Control &
Instrumentation
Now Offering!
п‚· Automation Training
Assessments
Nov 2014
Bluegrass Industrial Park – 2205 Plantside Drive – Louisville, KY 40299 Call (888) 468‐3591 – (502) 499‐7522 – www.intellectcontrols.com   Training On-Site
or at Our Training
Center
п‚· Practical
п‚· Customized
п‚· Effective
ABOUT US
Intellect Controls Group, Inc. was founded in 1983. We are an independent
training company and our only business is providing hands-on training
programs on factory automation control systems. Since our inception we
have delivered more than one million man-hours of training to Fortune 500
companies, allowing them to streamline their manufacturing processes and
meet and exceed their productivity objectives.
We deliver training on-site at our customer’s manufacturing facilities
throughout the United States and Canada. Our focus is providing practical,
hands-on training programs that allow factory maintenance and engineering
personnel to become better troubleshooters thus reducing both down time
and manufacturing costs. On any given week our shipping crews and
instructors are crisscrossing the country to deliver turnkey, on-site training
solutions to our customers.
Intellect Controls Group provides training to a diverse customer base,
including companies involved in the automobile manufacturing, brewing,
food processing, consumer products, pharmaceutical, petrochemical, utilities
and paper industries.
We chose Louisville, Kentucky as base for our corporate headquarters due to
its central location for our Training Center and on-site shipping operations.
The Kentucky Training Center allows us to offer a schedule of courses
available for individual enrollment when on-site training is not a practical
solution for our customers.
Intellect Controls Group has developed a reputation for excellence over the
last three decades by offering a proven, high quality alternative to
equipment manufacturers, technical colleges and smaller training
companies. We now offer more than thirty-five hands-on training programs
on the most popular industrial control products and related technologies. In
addition to our existing course offerings, we have the staff and resources to
develop customized training on a variety of industrial control systems.
www.intellectcontrols.com
Judge Us By the Company We Keep
Abbott Labs
Alcoa
American Electric Power
Anheuser-Busch InBev
Borg-Warner Automotive
Bridgestone-Firestone Inc.
Caterpillar, Inc.
Chevron USA
Chrysler
Coca-Cola Company
Colgate Palmolive
Cooper Tire Company
Cummins Engine Company
Dana Corporation
Dow Corning Corporation
R.R. Donnelley
Dofasco Steel, Inc.
Domino Sugar
Duracell
Folgers Coffee
Ford Motor Company
General Electric Company
General Motors Corporation
General Motors Canada, Ltd.
Georgia-Pacific Corporation
Goodyear Tire Company
Harley Davidson
Haynes International
Hubbell Power Systems
International Paper
J.M. Smuckers
Jim Beam Brands
John Deere Inc.
Johnson Controls
Johnson & Johnson
Kraft Foods
Lear Corporation
Logan Aluminum
Louisville Gas & Electric
Kimberly Clark Corporation
Libbey-Owens-Ford
Mercedes Benz USA Inc.
Merck & Company
MillerCoors
Nissan Motor Manufacturing
Nucor Steel Corporation
Pepsi Cola
Pfizer, Inc.
PPG Industries
Procter & Gamble
Quaker Oats
Ralcorp
Raytheon Corporation
Reynolds Metals
Rohm & Haas Corporation
Rolls Royce
S.C. Johnson Wax
Toyota Motor Manufacturing
Tropicana Products
U.S. Army Corp. of Engineers
Universal Studios Orlando
Wausau Paper
Weyerhaeuser Company
“If you want to train your employees in maintenance
troubleshooting for industrial automation equipment, come
to the leader in the industry. These companies chose an
organization that specializes in employee training. They
chose Intellect Controls Group.
We customize our courses to fit our individual clients’
specific needs and target our classes to the individuals who
run and maintain the equipment at their locations or at our
Kentucky Training Center.”
Edward Jay,
President
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
1
Use your Intellect. Other industry leaders learned why we are the
best choice.
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Intellect Controls Group, Inc. responds to our customers by delivering practical training to improve
on-the-job productivity.
We offer a turn-key on-site training product, including logistics, materials, equipment and all travel
arrangements.
All of our instructors are highly-skilled product experts.
Training programs are customized to address your manufacturing applications.
Our one-on-one attention helps your people understand the material fully.
“If you’ve been depending on the manufacturers, smaller training companies or local technical colleges to train
your people, we’re offering you a reputable alternative with proven results. We deliver practical, individual
training to improve on-the-job productivity.
The on-site training we offer is completely “turn-key.” All we need is a room in which to set up our hands-on
training lab. In addition, all our instructors have factory troubleshooting experience and go through extensive
continuing education to maintain their expert status. Give us a call at (888) 468-3591 and we’ll explain how we
can customize a class just for your employees.”
Leno Pederson,
Chief Instructor
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
2
Choose training your way… here or there.
ON-SITE TRAINING AT YOUR FACILITY
пѓ� Customized Courses
пѓ� Flexible Schedule
пѓ� Eliminates Travel Costs
Call (888) 468-3591 to talk about your training requirements or visit our web site at
www.intellectcontrols.com for Training Center course schedule’s and tuition information.
This was a great course, very informative, very constructive. The instructor was knowledgeable and funny. He set
the tone and I was very comfortable. I learned a great deal.
(Employee of Georgia Pacific)
CLASSES AT OUR KENTUCKY TRAINING CENTER
пѓ� Individual Enrollment (as many or as few as you like)
пѓ� Schedule Availability
пѓ� Convenient Travel Destination to Louisville, KY
Call 888-468-3591 to talk about your training requirements or visit our web site at
www.intellectcontrols.com for Training Center course schedules and tuition information.
The knowledge instructor has made the class easy to understand as well as keeping up with the course. Great
class!
(Employee of MillerCoors)
HOW TO ENROLL FOR CLASSROOM TRAINING
Call 888-468-3591 to check available course dates or visit us at
www.intellectcontrols.com to view or training center schedule,
download maps and directions.
Enrollments can be confirmed upon receipt of a purchase order or can
be paid for by a credit card.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
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FREQUENTLY ASKED QUESTIONS
What type of qualifications do your instructors have?
We only hire instructors that have significant factory maintenance and troubleshooting experience. We
believe that this is the critical qualification for someone to become an Intellect Controls Group Instructor.
We have a rigorous internal training program that prepares each instructor to communicate effectively
with technicians as well as engineers. Our instructors are subject matter experts on any product on which
they train.
How do you customize your training programs to meet my requirements?
The first step in this process is to have you review a detailed outline of our course and let us know the
critical topic areas for your manufacturing applications. We will produce a customized course outline that
addresses your specific needs. Additionally, we can incorporate examples from your control programs and
applications into the coverage of the course topics.
How many students do I need to have for an on-site course?
The maximum class sizes for our on-site training programs range from 6-12 students. Many of our
customers find that with as few as four students to train, on-site delivery is more economical than sending
students off-site for training.
What type of room and what supplies do I need to provide for an on-site training
program?
A room with seating and tables for the students is all that is required. We transport our complete training
lab to your facility, including hands-on training equipment, computers, controls software, audio-visual
equipment and all necessary classroom materials.
What type of payment is required to order an on-site class or to enroll a student at the
Louisville Training Center?
We need only a purchase order to confirm enrollment in a training program or to order on-site training
services. Our payment terms are Net 30 days from the starting date of any class. We also accept Visa
MasterCard and American Express.
How do I make hotel arrangements for employees I am sending to the Louisville
Training Center?
We will recommend a selection of several hotels that are located very close to our Training Center.
Lodging costs are very reasonable, which is one of the reasons we chose Louisville, Kentucky as the
location of our headquarters and Training Center. The enrollment confirmation letter will contain maps and
directions to our facility.
I am not sure of my employees’ skill levels. Can you assist me in assessing the skills of
my employees so I can develop a training plan?
Intellect Controls Group, Inc. can provide basic placement testing to determine on which level your
employees begin their training. Intellect is now offering hands-on performance assessments that will
provide you with a measurable base line for each employee.
Please see more information regarding Hands-on Performance Assessments on the next page.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
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FREQUENTLY ASKED QUESTIONS
Intellect Controls Group, Inc. is now offering Customized Training assessment services for your
employees. Our approach to assessing your personnel involves Customized Performance Testing. The
components of this performance testing consist of the following:
пѓ� pre-assessment testing
пѓ� classroom lecture and instruction
пѓ� hands-on performance testing
пѓ� one-on-one assessment with instructor
пѓ� instructor evaluation and recommendation
пѓ� a training plan for each person assessed
Having your personnel properly assessed before you start the training process will result in a more
targeted and effective learning experience. Assessment also provides a baseline from which you can
measure progress on specific skills that are important to your operations.
Performance Assessments are available on:
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Please
Basic Electrical
PLC’s
HMI’s
Drives
Hydraulics
Pneumatics
contact us to inquire further about our assessment services at 1-888-468-3591.
Trademark Acknowledgement Statement
PLC, PLC-5, SLC, SLC-500, RSLogix, RSLogix5, RSLogix500, RSLogix5000, GuardLogix, DriveExplorer, DriveExecutive,
PanelView, PanelView Plus, PanelBuilder, ControlNet, RSNetworx, PowerFlex, FactoryTalk View ME, FactoryTalk View
SE, Logix 5000, Kinetix, 1394 GMC and Data Highway are trademarks and/or registered trademarks of Allen-Bradley
Company, Inc. and/or Rockwell International, Inc. All other brand names and product model names mentioned are
trade names, service marks, trademarks or registered trademarks of their respective owners. Intellect Controls Group,
Inc. is not associated with any manufacturer mentioned herein and the use of any product names is for descriptive
purposes only.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
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FUNDAMENTALS
I-100: Introduction to Ladder Logic & Programmable Controllers
COURSE DESCRIPTION
This 16 hour, 2 day training program is designed to present an introduction to electrical control
devices, ladder logic diagramming, and wiring. Application exercises are used throughout the
course to create a hands-on learning environment.
AUDIENCE
This course is designed for plant maintenance personnel and other technicians who need to
broaden their understanding of industrial control fundamentals. I-100 answers the prerequisite
requirements for our PLC Level One courses. NOTE: I-100 is also ideal for anyone who has a need
to familiarize himself/herself with basic control fundamentals.
CEU’s
1.4
OBJECTIVES
Persons successfully completing this course will be able to:
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Identify electrical control components
Interpret ladder logic diagrams
Understand electrical terms and symbols
Troubleshoot control circuits
Design simple electrical control circuits
Identify the components of a programmable controller (system block diagram)
E-100: Introduction to Electrical Control & Electrical Safety
COURSE DESCRIPTION
This 32 hour 4 day training program is designed to familiarize entry-level electricians, equipment
operators and other skilled trades with electrical control fundamentals, electric terminology and
basic troubleshooting techniques.
AUDIENCE
This course is designed for entry-level electricians, equipment operators and other skilled trades
who need to broaden their understanding of industrial control fundamentals. NOTE: E-100 is also
ideal for anyone who has a need to familiarize himself/herself with basic control fundamentals.
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Learn to work safely with electrical components and test equipment.
Understand electrical terms and symbols
Identify electrical control components
Interpret ladder logic diagrams
Troubleshoot control circuits
Design simple electrical control circuits
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
6
ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
A-6000: ALLEN-BRADLEY ControlLogix Programmable Controllers/Level One
Maintenance & Troubleshooting
COURSE DESCRIPTION
This 36 hour, 4.5 day training program provides students with hands-on experience in the
troubleshooting and maintenance of the Allen-Bradley ControlLogix Programmable Controller.
Hardware and software troubleshooting techniques are heavily emphasized throughout the course.
Troubleshooting techniques include interpretation of status indicators, diagnostic messages and use
of the programming terminal to quickly isolate faults and take proper corrective actions. The
instructor will use examples of actual troubleshooting experiences to enhance the learning process.
TOPICAL OUTLINE
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Introduction to Programmable Controllers
Hardware Description
I/O Configurations
Installation
Programming Terminal Operation
Instruction Familiarization: Ladder Diagram, Timer and Counter, Data Manipulation &
Program Control
Use Software Utilities to aid in the troubleshooting Process: Trend Charts, Search, Cross
Reference & Force
Program Editing
Peripheral Operations: Program Loading & Program Printing
Troubleshooting: Hardware & Software
Application Projects Using Industrial Hardware
RSLinx Driver Creation Overview/Hands-on Demonstration
ControlNet, Ethernet or Data Highway Plus Overview (Time Permitting)
PROGRAM SOFTWARE
Training utilizes Rockwell Software RSLogix5000, Microsoft Windows, 2000, XP Software, & System
7.
PREREQUISITE
Intellect Controls Group training program I-100 or a working knowledge of electromechanical
control devices, relay ladder logic and Windows, 2000 or XP Software.
CEU’s
3.3
OBJECTIVES
Persons successfully completing this course will be able to:
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Identify hardware components of a ControlLogix Programmable Controller System.
Configure and install a ControlLogix Programmable Controller System.
Use a programming terminal for entering, editing and troubleshooting programs.
Isolate processor and I/O faults to the module level.
Troubleshoot simple programs using ladder instruction of the ControlLogix Programmable
Controller.
Properly use peripheral devices to store, copy & print programs.
Properly connect and establish communications over a DF1/RS-232 cable
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
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ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
A-6100: ALLEN-BRADLEY ControlLogix 5000 Fundamentals & Troubleshooting
COURSE DESCRIPTION
This 36 hour, 4.5 day training program is designed to challenge technician’s troubleshooting skills.
The training begins with a thorough review of the Logix5000 Hardware, Software, addressing
schemes and basic Ladder Instructions. Following this review is a series of Hands-on
troubleshooting projects using real world interfaces such as conveyors, pick & place robots, remote
I/O communications, Ethernet I/O and 1771 interfaces. The participants are assigned to evaluate
and troubleshoot a series of equipment problems using a variety of scenarios. Each participant will
be challenged to solve hardware problems, software problems, communication conflicts, addressing
conflicts and other issues that arise when troubleshooting PLC related problems.
TOPICAL OUTLINE
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Review of Programmable Controllers
Hardware Description
I/O Configurations
Installation
Programming Terminal Operation
Instruction Familiarization: Ladder Diagram, Timer and Counter, Data Manipulation &
Program Control
Use Software Utilities to aid in the troubleshooting Process: Trend Charts, Search, Cross
Reference & Force
Program Editing
Troubleshooting: Hardware & Software
RSLinx Driver Creation Overview/Hands-on Demonstration
Troubleshooting real world Hardware equipment
PROGRAM SOFTWARE
Training utilizes Rockwell Software RSLogix5000 and Microsoft Windows OS.
PREREQUISITE
Intellect Controls Group training program I-100 or a working knowledge of electromechanical
control devices, relay ladder logic and Windows Operating System.
CEU’s
3.3
OBJECTIVES
Persons successfully completing this course will be able to:
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Identify hardware components of a ControlLogix Programmable Controller System.
Configure and install a ControlLogix Programmable Controller System.
Use a programming terminal for entering, editing and troubleshooting programs.
Isolate processor and I/O faults to the module level.
Troubleshoot simple programs using ladder instruction of the ControlLogix Programmable
Controller.
Properly connect and establish communications over a DF1/RS-232 cable.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
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ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
A-6200: ALLEN-BRADLEY ControlLogix Programmable Controllers/Level Two
Advanced Maintenance & Troubleshooting
COURSE DESCRIPTION
This 36 hour, 4.5 day training program provides students with hands-on experience using the
advanced control and diagnostic capabilities of the Allen-Bradley ControlLogix Programmable
Controller and the RSLogix5000 programming software package. Application troubleshooting
exercises are used throughout the course to give students hands-on experience solving typical
problems encountered in the factory.
TOPICAL OUTLINE
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Review of ControlLogix Hardware and Basic Concepts
Memory Organization Review
Addressing: Direct and Indirect
Instruction Familiarization: File Arithmetic and Logic, File Search and Compare, Bit Shift and
FIFO, Diagnostics, Sequencers in and out
Communications: Data Highway Plus Communications, Remote I/O Communications,
ControlNet Communications, Ethernet Communications & Message Instruction
Overview: PID Instruction
PROGRAM SOFTWARE
Training utilizes Rockwell Software RSLogix5000, Microsoft Windows NT, 2000, XP Software, &
System 7.
PREREQUISITE
Students should have successfully completed Intellect Controls Group training program A-6000 or
have knowledge equivalent to the course description and be familiar with Windows NT, 2000 or XP
software. A-6200 IS NOT INTENDED FOR BASIC LEVEL ENTRY STUDENTS WHO HAVE NOT
ACQUIRED THE BACKGROUND DESCRIBED ABOVE.
CEU’s
3.3
OBJECTIVES
Persons successfully completing this course will be able to:
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Troubleshoot programs utilizing all commonly used instructions of the ControlLogix
Programmable Controller.
Effectively use an IBM compatible terminal for entering, editing, and troubleshooting
programs.
Utilize the diagnostic capabilities of the ControlLogix system to aid in systems
troubleshooting.
Utilize the remote I/O communications capabilities of the ControlLogix Controller.
Properly connect and establish communications over a Data Highway Plus & Ethernet
networks.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
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ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
A-6300: ALLEN-BRADLEY ControlLogix Programmable Controllers/Level Three Advanced Communications: DeviceNet, ControlNet & Ethernet
COURSE DESCRIPTION
This 36 hour, 4.5 day training program provides participants with hands-on experience in the
troubleshooting and maintenance of the Allen-Bradley ControlNet, DeviceNet and Ethernet
communications networks. Hardware and Software troubleshooting techniques are heavily
emphasized throughout the course.
TOPICAL OUTLINE
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Advanced ControlLogix
Instruction Review: Base & Alias Tag Address
Instructions: Array Instruction Concepts & File, Arithmetic and Logic
ControlNet Unscheduled Communications
ControlNet Scheduled Communications
RS Networx Software
DeviceNet Communications: Hardware, Addressing, Mapping & Node Commissioning
Ethernet Communications
Hardware
Message Instruction
PROGRAM SOFTWARE
Training is available utilizing Rockwell Software RSLogix 5000 and RSNetworx for DeviceNet and
ControlNet.
PREREQUISITE
Students should have successfully completed Intellect Controls Group training program A-6000 or
have knowledge equivalent to the course description and be familiar with Windows NT software. A6200 is recommended, but not required. THIS IS NOT AN ENTRY LEVEL TRAINING PROGRAM.
CEU’s
3.3
OBJECTIVES
Persons successfully completing this course will be able to:
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Identify Hardware components of three ControlLogix Communication Networks.
Establish communications and troubleshoot a DeviceNet Network
Establish communications and troubleshoot a ControlNet Network
Establish communications and troubleshoot an Ethernet Network
Work effectively with RS Network Software.
Enjoyed the course. It was very informative for my first time seeing a PLC. The instructor was very
knowledgeable on the subject which really helped.
(Employee of Bridgestone-Firestone)
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
10
ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
A-6400: ALLEN-BRADLEY ControlLogix Motion Control Maintenance &
Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4 day training program will provide the student with the knowledge and skills to
identify, install, configure and troubleshoot a closed loop motion control system in the Logix 5000
architecture. In addition, students will learn specific programming instructions used for motion
control in ControlLogix ladder logic programs. Students will also learn how to interface ControlLogix
5000 system with either Ultra 3000, Kinetix 350, or Kinetix 6000 Servo Drives.
TOPICAL OUTLINE
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Overview of Motion Control Concepts
Hardware Description
Hard wiring of 1756 Motion Components
Configuring an Axis
Tuning and Testing an Axis
Motion Instructions Control Structures
Basic Motion Instructions
Advanced Motion Instructions
Ultra 3000 or Kinetix 6000 or Kinetix 350 Servo Drives
Fault Routines
System Troubleshooting
PROGRAM SOFTWARE
Training utilizes Rockwell Software RSLogix5000, Microsoft Windows XP and System 7 Operating
Systems.
PREREQUISITE
Students should have successfully completed Intellect Controls Group training program A-6000 or
have knowledge equivalent to the course description and be familiar with Microsoft Windows
functions.
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Identify the motion control components of a Control Logic System.
Configure an Axis of a Control Logix System.
Tune and test an Axis of a Control Logix System.
Interpret and edit basic and advanced motion instructions.
Troubleshoot both software and hardware related problems.
Troubleshoot SERCOS interface to Ultra 3000 or Kinetix 6000 Servo Drives
“Instructor is a great instructor who actually cares if his students learn the material. I never doubted his
knowledge of the course material once”.
(Employee of J.M. Smucker)
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
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ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
A-6110: Allen-Bradley GuardLogix Safety I/O Systems Maintenance &
Troubleshooting
COURSE DESCRIPTION
This 16 hour, 2 day training program covers installing and troubleshooting GuardLogix Safety I/O
Systems. Coverage is primarily on DeviceNet, Safety Modules, but Ethernet versions are covered
as well.
TOPICAL OUTLINE
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Safety Level Overview
GuardLogix Safety Modules
Wiring Options
Safety Module LED Indicators
GuardLogix I/O Configuration
DeviceNet Configuration
Safety Signature
Safety Task, Safety Routine
Safety Instructions: ESTOP, LC, ROUT, FPMS, RIN, EN PEN, DIN & THRS
Explicit Messaging
Safety Tag Mapping
GSV/SSV Instructions with Safety Routines
Produced/Consumed Safety Tags
PROGRAM SOFTWARE
RSLogix5000
PREREQUISITE
A-6000, DeviceNet portion of A-6300 or Ethernet portion of A-6300 if using Ethernet Safety
Modules.
CEU’s
1.4
OBJECTIVES
Persons successfully completing this course will be able to:
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Troubleshoot and repair GuardLogix Control Systems
Locate and reset Safety I/O related faults
Replace Safety I/O Modules
Determine a Safety Instruction’s input requirements and output response
Configure Safety I/O Modules
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
12
ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
A-6120: RS-5000 ControlLogix Function Block Diagrams
COURSE DESCRIPTION
This 16 hour, 2 day training program is for those familiar with Allen-Bradley ControlLogix
controllers, but not familiar with Function Block Diagrams. In this course students will learn how to
program, interpret, and troubleshoot ControlLogix programs written with Function Block diagrams.
TOPICAL OUTLINE
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Definition of a Function Block
Function Block Diagrams in ControlLogix
FBD Basic Boolean Functions & Basic Boolean Function Exercise
FBD Timers and Counter Functions & Timer and Counter Exercise
FBD Math Functions & Math Function Exercise
FBD Compare Functions & Entering a Simple LIM Compare Exercise
FBD Filter Functions
FBD Enhanced PIDE Function & PIDE Simulation Exercise
FBD Software Utilities
PROGRAM SOFTWARE
Training utilizes Rockwell Software RSLogix5000, Microsoft Windows NT, 2000, XP Software, &
System 7.
PREREQUISITE
Students should have successfully completed Intellect Controls Group training program A-6��� or
have knowledge equivalent to the course description and be familiar with Windows NT, 2��� or XP
software. It is also recommended that the A-6200 training program be completed as well.
CEU’s
1.4
OBJECTIVES
Persons successfully completing this course will be able to:
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Enter routines using Function Diagram Blocks
Interpret Function Block Diagram Routines
Troubleshoot Function Block Diagrams and I/O associated with them.
“I felt the course was very well constructed and taught. I enjoyed every minute of it!”
(Satisfied Customer)
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
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ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
A-6130: RS-5000 ControlLogix Structured Text
COURSE DESCRIPTION
This 16 hour, 2 day training program is for those familiar with Allen-Bradley ControlLogix
controllers, but not familiar with the Structured Text. In this course students will learn how to
program, interpret, and troubleshoot ControlLogix programs written using Structured Text.
TOPICAL OUTLINE
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Definition of Structured Text
Structured Text Routines in ControlLogix
ST If…Then Construct & If…Then Exercise
ST Case…Of Construct & Case…Of Exercise
ST For…Do Construct & For…Do Exercise
ST While…Do Construct & While…Do Exercise
ST Repeat…Until Construct & Repeat…Until Exercise
Structured Text Instructions & ST Instruction Exercise
ST Software Utilities
PROGRAM SOFTWARE
Training utilizes Rockwell Software RSLogix5000, Microsoft Windows NT, 2000, XP Software, &
System 7
PREREQUISITE
Students should have successfully completed Intellect Controls Group training program A-6000 or
have knowledge equivalent to the course description and be familiar with Windows NT, 2000 or XP
software. It is also recommended that the A-6200 training program be completed as well.
CEU’s
1.4
OBJECTIVES
Persons successfully completing this course will be able to:
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Enter Routines using Structured Text
Interpret Constructs found in Structured Text
Navigate and Troubleshoot Routines using Structured Text
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
14
ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
A-6140: ControlLogix RS-5000 Sequential Function Chart
COURSE DESCRIPTION
This 16 hour, 2 day training program will enable a student to create, enter, and troubleshoot a
Sequential Function Chart. Topics covered include Sequential Chart Layout, Entering and an SFC,
and Troubleshooting and SFC.
TOPICAL OUTLINE
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Definition of a Sequential Function Chart
Sequential Function Chart Routines in ControlLogix
SFC Steps
SFC Actions
SFC Transitions: SFC Step, Action & Transition Exercise
SFC Selective Branches
SFC Simultaneous Branches: SFC Branch Exercise
SFC Features including Stopping, Pausing and Restarting SFC: SFC Stopping, Pausing and
Restarting Exercise
SFC Troubleshooting
SFC Forcing: SFC Troubleshooting & Forcing Exercise
SFC Software Utilities
PROGRAM SOFTWARE
Training utilizes Rockwell Software RSLogix5000, Microsoft Windows NT, 2000 and XP Software.
PREREQUISITE
Students should have successfully completed Intellect Controls Group training program A-6000 or
have knowledge equivalent to the course description and be familiar with Windows NT, 2000 or XP
software. Training program A-6130: Structured Text course would be helpful but not required.
CEU’s
1.4
OBJECTIVES
Persons successfully completing this course will be able to:
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Design a simple SFC based on equipment sequence of operation.
Enter a simple SFC
Troubleshoot equipment controlled by an SFC by locating the active step, and active action
and then the transition condition preventing the sequence from advancing to the next step.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
15
ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
A-6150: RS-5000 ControlLogix Function Block Diagrams, Structured Text &
Sequential Function Chart Programming
COURSE DESCRIPTION
This 5 day, 40-hour training program will enable a student to create, enter, and troubleshoot
Function Block Diagrams, Structured Text programs, and Sequential Function Charts. Topics
covered include the Enhanced PID (PIDE) instruction, structured Text loop Constructs, and
Sequential Function Chart layout and Troubleshooting.
TOPICAL OUTLINE
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Definition of a Function Block
FBD Basic Boolean Functions & Basic Boolean Function Exercise
FBD Timers and Counter Functions & Timer and Counter Exercise
FBD Enhanced PIDE Function & PIDE Simulation Exercise
FBD Software Utilities
Definition of Structured Text
Structured Text Routines in ControlLogix
ST If…Then Construct & If…Then Exercise
ST Case…Of Construct & Case…Of Exercise
ST For…Do Construct & For…Do Exercise
ST While…Do Construct & While…Do Exercise
ST Repeat…Until Construct & Repeat…Until Exercise
ST Software Utilities
Definition of a Sequential Function Chart
SFC Steps, Actions & Transitions & SFC Step, Action & Transition Exercise
SFC Selective Branches
SFC Simultaneous Branches & SFC Branch Exercise
SFC Features including Stopping, Pausing, Restarting SFC & SFC Stopping, Pausing and
Restarting Exercise
SFC Troubleshooting, Forcing & SFC Troubleshooting & Forcing Exercise
SFC Software Utilities
Program Software
Training utilizes Rockwell Software RSLogix5000 and Microsoft Windows
PREREQUISITE
Students should have successfully completed Intellect Controls Group training program A-6000 or
have knowledge equivalent to the course description and be familiar with Windows software.
CEU’s
3.6
OBJECTIVES
Persons successfully completing this course will be able to:
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Enter and Interpret Function Block Diagrams
Troubleshoot FBD’s
Enter and Interpret Structured Text Programs
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
16
ALLEN-BRADLEY CONTROLLOGIX 5000 SERIES
OBJECTIVES - continued
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Interpret Structured Text Constructs
Design a simple SFC based on equipment sequence of operation.
Enter a simple SFC
Troubleshoot equipment controlled by an SFC by locating the active step, and active action
and then the transition condition preventing the sequence from advancing to the next step
“Instructor was very thorough and not only explained what something did, but how you would use it.”
(Employee of Bridgestone Firestone)
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
17
ALLEN-BRADLEY PLC-5
A-510: ALLEN-BRADLEY PLC-5 Family Programmable Controllers/Level One
Maintenance & Troubleshooting
COURSE DESCRIPTION
This 36 hour, 4 day training program provides students with hands-on experience in the
troubleshooting and maintenance of the Allen-Bradley PLC-5 family of programmable controllers.
Hardware and software troubleshooting techniques are heavily emphasized throughout the course.
Troubleshooting techniques include interpretation of status indicators, diagnostic messages and use
of the programming terminal to quickly isolate faults and take proper corrective actions. The
instructor will use examples of actual PLC-5 troubleshooting experiences to enhance the learning
process.
TOPICAL OUTLINE
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Introduction to Programmable Controllers
Hardware Description
I/O Configurations
Installation
Windows Based Programming Terminal Operation
Addressing
Instruction Familiarization: Ladder Diagram, Timer and Counter, Data Manipulation &
Program Control
Use Software Utilities to aid in the Troubleshooting Process (Histograms, Search, Force)
Program Editing
Peripheral Operations: Program Loading & Program Printing
Troubleshooting: Hardware & Software
Application Projects Using Industrial Hardware
Remote I/O Rack & Network Setup
Data Highway Plus Overview/Hands-on Demonstration
ControlNet Overview (Time Permitting)
Program Software
Training is available utilizing Rockwell Software 6200 Series, AI Series, RSLogix5 and other
software products.
PREREQUISITE
Intellect Controls Group, Inc. training program I-100 or a working knowledge of electromechanical
control devices and relay ladder logic.
CEU’s
3.0
OBJECTIVES
Persons successfully completing this course will be able to:
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Identify hardware components of all PLC-5 Family controllers.
Distinguish the features and capabilities of the different PLC-5 products.
Configure and install a PLC-5 system.
Use a Windows based programming terminal for entering, editing and troubleshooting
programs.
Isolate processor and I/O faults to the module level.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
18
ALLEN-BRADLEY PLC-5
OBJECTIVES – cont.
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Troubleshoot simple programs using all ladder instructions of the PLC-5.
Properly use peripheral devices to store, copy and print programs.
Properly connect and establish communications over a Data Highway Plus network.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
19
ALLEN-BRADLEY PLC-5
A-520: ALLEN-BRADLEY PLC-5 Family Programmable Controllers/Level Two
Advanced Maintenance & Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4.5 day training program allows students to gain hands-on experience using the
advanced control & diagnostic capabilities of the PLC-5 programmable controller. Application
troubleshooting exercises are used throughout the course to give students actual hands-on
experience solving typical problems encountered in the factory.
TOPICAL OUTLINE
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Review of PLC-5 Hardware and Basic Concepts
Memory Organization Review
Addressing: Direct, Indirect & Indexed
Instruction Familiarization: File Arithmetic Logical, File Search and Compare, Shift Registers,
Sequencers & BTW and BTR with Analog Module Configuration
Communications: Data Highway Plus Communications, Remote I/O Communications,
Discreet Data Transfer, Block Transfer & Message Instruction
Overview: SFC Overview (Upon Request) & PID Instructions
Peripheral Operations: Program Loading & Program Printing
PROGRAMMING SOFTWARE
Training is available utilizing Rockwell Software 6200 Series, AI Series, RSLogix5 and other
software products.
PREREQUISITE
Students should have successfully completed Intellect Controls Group training program A-510 or
have knowledge equivalent to the course description. A-520 IS NOT INTENDED FOR BASIC LEVEL
ENTRY BY STUDENTS WHO HAVE NOT ACQUIRED THE BACKGROUND DESCRIBED ABOVE.
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Troubleshoot programs utilizing all available instructions of the PLC-5.
Effectively use a programming terminal for entering, editing, and troubleshooting programs.
Utilize the diagnostic capabilities of the PLC-5 system to aid in systems troubleshooting.
Utilize the remote I/O communications capabilities of the PLC-5.
Properly connect and establish communications over a Data Highway Plus network.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
20
ALLEN-BRADLEY PLC-5
A-650: ALLEN-BRADLEY PLC-5/Level Three – Analog I/O and PID Maintenance &
Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4 day training program is designed to provide engineering and maintenance
personnel with a functional understanding of Analog I/O hardware and software and operation of
the PID instruction in the Allen-Bradley PLC-5 programmable logic controller. The course consists
of hands-on experience utilizing the 1771-IFE, 1771-OFE analog modules and the PLC-5
Programmable Controller.
TOPICAL OUTLINE
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Analog Concepts
Intelligent Module Overview
1771-IFE Analog Input Module
1771-IL Isolated Analog Input Module
1771-OFE Analog Output Module
Analog I/O Configuration and Installation
Analog Calibration and Troubleshooting
Block Transfer Programming
PID Control Concepts
PID Parameters and Configuration
PID Operation and Troubleshooting
Overview: N Series Analog I/O Modules
COURSE HARDWARE
Allen-Bradley PLC-5, 1771-IFE, 1771-OFE and N Series Analog Modules.
PREREQUISITE
Students should have successfully completed Intellect course A-510 (PLC-5 Level One) and
Intellect course A-520 (PLC-5 Level Two) or have a working knowledge equivalent to the course
descriptions. This course is not intended for students who do not have the background described
above.
CEU’s
3.0
OBJECTIVES
Persons successfully completing this course will be able to:
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Install and configure analog I/O modules
Access and interpret diagnostic information
Troubleshoot and calibrate analog I/O modules
Understand the use of block transfer instructions
Troubleshoot and tune PID loops
NOTE
The training program includes application projects utilizing industrial hardware and simulators.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
21
ALLEN-BRADLEY DEVICENET COMMUNICATIONS
A-800: ALLEN-BRADLEY DeviceNet Communications
Course Description
This 16 hour, 2 day training program will familiarize personnel with DeviceNet Hardware/Software,
and how they interface to the Allen-Bradley PLC-5. Each student will be required to set up a
network, add devices to the network and troubleshoot these devices using the required software.
Topical Outline
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DeviceNet Hardware
DeviceNet Software
DeviceNet System Troubleshooting
Supported Hardware & Software
This course can be delivered utilizing Allen-Bradley ControlLogix, PLC-5 or SLC-500 programmable
controller hardware platforms. The course can be delivered either RS Networx for DeviceNet or
DeviceNet Manager software.
Prerequisites
Personnel enrolled in this course should have completed our training program A-510: Allen-Bradley
PLC-5/Level One and A-520: PLC-5/Level Two or have equivalent knowledge.
CEU’s
1.4
Objectives
Persons successfully completing this course will be able to:
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Identify hardware components of a DeviceNet System
Identify appropriate taps, connectors, power supplies and cables.
Determine the cause of cable system faults
Connect to the network to configure and troubleshoot devices.
Use RS Networx Software to configure a DeviceNet network.
Verify the proper operation of the network.
Map a 1771 SDN Scanner’s data table.
Interpret and modify scan list.
“Excellent instructor! Highly recommend. Very knowledgeable and enthusiastic about course material.
Thank you for the valuable training”.
(Employee of Toyota)
“Thanks for the great week. I hope to go through more training like this. Great job”.
(Employee of The Dannon Company)
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
22
ALLEN-BRADLEY SLC-500
A-5000: ALLEN-BRADLEY SLC-500 Programmable Controllers/Level One
Maintenance & Troubleshooting
COURSE DESCRIPTION
This 36 hour, 4.5 day training program provides students to gain hands-on experience in the
troubleshooting and maintenance of the Allen-Bradley SLC-500 programmable controller. Hardware
and software troubleshooting techniques are heavily emphasized throughout the course. The
instructor will use example of actual troubleshooting experiences to enhance the learning process.
TOPICAL OUTLINE
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Introduction to Programmable Controllers
Hardware Description/Configuration: CPU Processor Module & Input/Output Modules
Safety Considerations
Programming Terminal Operation
Program Entry and Interpretation: Ladder Diagram Instructions, Timers and Counters, Data
Manipulation Instructions & Program Control Instructions
Use of Software Utilities in Troubleshooting (Force, Search, Histograms)
Program Editing
Troubleshooting: Software & Hardware Components Including Processor and I/O
Peripheral Operations: Program Loading & Program Printing
PROGRAM SOFTWARE
Training is available utilizing Rockwell RSLogix500 software.
PREREQUISITE
This course is designed to meet the needs of both plant maintenance and engineering personnel.
Students should be familiar with relay ladder logic.
CEU’s
3.3
OBJECTIVES
Persons successfully completing this course will be able to:
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Identify the hardware components of the SLC-500 programmable controller.
Configure and install a SLC-500 programmable controller system.
Develop and interpret simple programs utilizing a programming terminal.
Troubleshoot programs and isolate faults within the SLC-500 system.
Properly use peripheral devices to store, copy and print programs.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
23
ALLEN-BRADLEY SLC-500
A-5200: ALLEN-BRADLEY SLC-500 Programmable Controllers/Level Two
Advanced Maintenance & Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4 day training program allows students to gain hands-on experience using the
advanced program instructions and communications features of the Allen-Bradley SLC-500
programmable controller. Application projects emphasizing hardware and software troubleshooting
techniques are used throughout the course to create a hands-on learning environment.
TOPICAL OUTLINE
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Review of SLC-500 Hardware
Advanced Programming Terminal Techniques: Specialized Edit Keys, Documentation &
Utilities
Instruction Familiarization: Indirect Addressing, File Fill, File Copy, FIFO/LIFO, Sequencer &
Bit Shift
Processor Communications
Message (MSG) Instruction
SLC-500 Network Communications: RS 232 Serial, DH 485, DH Plus & Ethernet
Analog I/O: Module Configuration and Scaling
Program Interrupt Instructions: Discrete Input Interrupt & Selectable Timed Interrupt
Overview Topics (Time Permitting): PID Instruction
PROGRAM SOFTWARE
Training is available utilizing Rockwell RSLogix500 software.
PREREQUISITE
Students should have successfully completed Intellect Controls Group course A-5000 or have
knowledge equivalent to the course description. THIS IS NOT AN ENTRY LEVEL TRAINING
PROGRAM.
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Enter and interpret programs utilizing the advanced file instructions of the SLC-500
Troubleshoot control programs utilizing all available instructions of the SLC-500
Troubleshoot hardware, communications and process faults using indicators, message
displays and a programming terminal.
Properly connect and establish communications over a SLC-500 network.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
24
ROCKWELL RSLINX SOFTWARE
RSL-100: Rockwell RSLinx Communications
Course Description
This 8 hour, 1 day training program course allows students to gain hands on experience using
Rockwell software RSLinx software to configure, understanding, and troubleshooting PLC
communications for Allen-Bradley SLC-500, MicroLogix and PLC-5 systems.
Topical Outline
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Introduction to RSLinx
Communication protocols used by processors: RS232, DH+, DH485 & Ethernet
Configuring RSLinx Drivers: RS232, DH+, DH485 & Ethernet
Configuring address and channel communication for Allen-Bradley Processors
Selecting proper cable for driver type
Troubleshooting various communication problems
Hands-on setting up RSLinx drivers and communication with a processor at various stations
setup in classroom
Prerequisites
Students should be familiar with Allen Bradley programmable controllers, and Windows 2000, XP
Software, or System 7. Basic knowledge of RSLogix5 or RSLogix500 software for the particular
programmable controller is desirable. THIS IS NOT AN ENTRY LEVEL TRAINING PROGRAM.
CEU’s
.8
Objectives
Persons successfully completing this course will be able to:
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Understand various network types used with Allen-Bradley processors
Configure and use RSLinx drivers to communicate with Allen-Bradley processors
Troubleshoot RSLinx and associated hardware when communications problems occur.
“The materials, presentation & hands-on were very good, I particularly like having the opportunity to do
hands-on training as it allows me to bring what’s discussed/learned during the lecture into real life.”
(Employee of Procter & Gamble)
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
25
ALLEN-BRADLEY HMI
A-750: ALLEN-BRADLEY PanelView 300 - 1400 Standard Operator Terminal
Editing & Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4 day training program provides students with hands-on experience using AllenBradley PanelView 300, 550, 600, 900, 1000 and 1400 Operator terminals with the PanelBuilder32
windows based software package. Students receive hands-on experience creating fully functional
operator interface applications and downloading the applications to PanelView terminals. Emphasis
is placed on interaction of the PanelView and the PLC in an integrated process environment.
TOPICAL OUTLINE
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Hardware Types and Configuration: PanelView 300 Operator Terminals, PanelView 550
Operator Terminals, PanelView 600 Operator Terminals, PanelView 900 Operator Terminals,
PanelView 1000 Operator Terminals (non-enhanced) & PanelView 1400 Operator Terminals
(non-enhanced)
Configuration Menu Setup
Maintenance Procedures
Establishing DH-485, DH+, RS-232 and Remote I/O Communications, ControlNet, DeviceNet
and Ethernet Communications
Creating Application Files: Tag Editor, Text Editor, Screen Development & Editing
Creating and Addressing Screen Objects
Uploading/Downloading Files
Troubleshooting and Fault Isolation Techniques
Alarm Setup
PREREQUISITE
Students should have successfully completed Intellect Controls course A-510 (PLC-5/Level One), A5000 (SLC-500/Level One), A-6000 (ControlLogix/Level One) or have knowledge equivalent to the
Course description and have basic experience with Microsoft Windows Operating System. THIS IS
NOT AN ENTRY LEVEL TRAINING PROGRAM.
CEU’s
3.0
OBJECTIVES
Persons successfully completing this course will be able to:
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Identify, interconnect and configure the components of a PanelView
300/550/600/900/1000/1400 and PLC system.
Develop, interpret and edit PanelView application programs using the windows based
PanelBuilder32 software package.
Troubleshoot hardware, communications, process and software faults using indicators,
message displays and programming terminal.
Perform hardware maintenance on PanelView 300, 550, 600, 900, 1000 and 1400 operator
terminals.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
26
ALLEN-BRADLEY HMI
A-760: ROCKWELL FactoryTalk View ME HMI Software Maintenance &
Troubleshooting
COURSE DESCRIPTION
This 36 hour, 4 day training program is designed for the maintenance troubleshooter to enable
them to use PanelView Plus terminals, FactoryTalk View ME and FactoryTalk View Studio to assist
in correcting line stoppages and errors. Emphasis is on troubleshooting rather that on
programming, although exposure to the many software features is included. It is assumed that the
technician will be using existing FactoryTalk View ME, Communications, and PLC programs.
TOPICAL OUTLINE
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Saving and Restoring Projects
Adding and Revising Tags in the Database
Configuring Communication
Adding Objects to Graphic displays
Attaching Controls to Graphic displays
Configuring Animation on Graphic Objects
Configuring Events, Alarms & Logging
Creating Macros
Configuring Trends & Project Security
Running a FactoryTalk View ME Project
PREREQUISITE
Students should have a thorough knowledge of Basic Windows Skills, Level One PLC (for specific
PLC they will be using with FactoryTalk ViewME), one of the PanelView families and the
corresponding Panel Builder software as well as knowledge of RSLinx Configuration and
Troubleshooting.
CEU’s
3.3
OBJECTIVES
Persons successfully completing this course will be able to:
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Open FactoryTalk View Studio and select the correct project for the troubleshooting task at
hand.
Trace communications between FactoryTalk View ME objects and tags to and from PLC
programs.
Use RSLinx Enterprise and OPC communications drivers to troubleshoot communications
problems.
Use the Tag Database to add and make minor edits to memory and device tags.
Open the Graphic Display Editor and identify tags associated with objects.
Use the Graphic Display Editor to add and make minor edits to objects.
Open, evaluate, and make minor edits to Expressions used in object dialog boxes.
Track and make minor edits to display Navigation commands.
Use the Alarm Monitor to view and acknowledge alarms.
Use the Alarm Editor to add and make minor edits to alarms.
Setup and edit data Trends.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
27
ALLEN-BRADLEY HMI
A-770: ROCKWELL FactoryTalk View SE HMI Software Maintenance &
Troubleshooting
COURSE DESCRIPTION
This 36 hour, 4.5 day training program is designed for the maintenance troubleshooter to enable
him or her to use FactoryTalk View Studio programs and FactoryTalk View Client to assist in
correcting line stoppages and errors. Emphasis is on troubleshooting rather than programming. It
is assumed the technician will be using existing FactoryTalk View SE projects, Communications and
PLC programs.
TOPICAL OUTLINE
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Saving and Restoring Projects
Adding and Revising Tags in the Database
Configuring Communication
Adding Objects to Graphic displays
Attaching Controls to Graphic displays
Configuring Animation on Graphic Objects
Configuring Events, Alarms, Activity Logs & Data Logging Files
Creating Macros and Symbols
Configuring Trends & Project Security
Running a FactoryTalk View Project
PREREQUISITE
Students should have a thorough knowledge of Basic Windows Skills, Level One PLC (for specific
PLC they will be using with FactoryTalk ViewSE), One of the PanelView families and the
corresponding Panel Builder software as well as the knowledge of RSLinx Configuration and
Troubleshooting.
CEU’s
3.3
OBJECTIVES
Persons successfully completing this course will be able to:
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Open FactoryTalk View Studio and select the correct project for the troubleshooting task at
hand.
Trace communications between FactoryTalk View SE objects and tags to and from PLC
programs.
Use RSLinx Enterprise and OPC communications drivers to troubleshoot communication
problems.
Use the Tag Database to add and make minor edits to memory and device tags.
Open the Graphic Display Editor and identify tags associated with objects.
Use the Graphic Display Editor to add and make minor edits to objects.
Open, evaluate, and make minor edits to Expressions used in object dialog boxes.
Track and make minor edits to display Navigation commands.
Use the Alarm Monitor to view and acknowledge alarms.
Use the Alarm Editor to add and make minor edits to alarms.
Evaluate the effect of Event commands and make minor edits to Events.
Setup and edit data Trends & Use System Tags to help correct problems.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
28
MODICON 984/QUANTUM PLC’S
M-910: Modicon 984/Quantum Family Programmable Controllers/Level One
Maintenance & Troubleshooting
COURSE DESCRIPTION
This 36 hour, 4.5 day training program allows students to gain hands-on experience in the
troubleshooting and maintenance of the Modicon 984 family of programmable controllers.
Hardware and software troubleshooting are heavily emphasized throughout the training program.
Troubleshooting techniques covered include interpretation of status indicators, diagnostic
messages, error codes and use of the programming terminal to quickly isolate faults and take
proper corrective actions.
TOPICAL OUTLINE
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Introduction to Programmable Controllers
984 System Hardware and Troubleshooting
Processor Configurations
Traffic Cop
Segment Scheduler (Overview)
Installation
Programming Terminal Operation
Instruction Entry and Interpretation: Ladder Logic, Relays: NO, NC, Transitional, Timers:
1.0, 0.1, 0.01 sec., Counters: Up, Down, Math: 4-digit, Add, Subtract, Multiply, Divide &
Data Transfer (Overview)
Instruction Editing
Program Searching
Forcing Inputs and Outputs
Troubleshooting: Status Indicators, Diagnostic Messages, Error Codes, I/O Modules, I/O
Racks & Software
Hands-On Troubleshooting Projects: Conveyers, Material Handling Robots, Batch Process
Stations and Simulator Panels are used to give students hands-on experience solving typical
problems encountered in the factory.
Modbus and Modbus Plus
Program Loading, Program Documentation and Printing
PREREQUISITE
Students should have successfully completed Intellect Controls Group course I-100, Introduction to
Ladder Logic and Control, or have a working knowledge of electromechanical control devices and
relay ladder logic.
COURSE HARDWARE
Modicon 984 Models: 385, 485, Quantum
CEU’s
3.3
OBJECTIVES
Persons successfully completing this course will be able to:
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Identify hardware components of a 984 programmable controller system.
Distinguish the features and capabilities of the different 984 processors.
Configure and install a 984 programmable controller system.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
29
MODICON 984/QUANTUM PLC’S
OBJECTIVES – cont.
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Effectively use a programming terminal to isolate processor and I/O faults.
Understand and troubleshoot control programs containing the ladder logic (Level One)
instructions of the 984 programmable controller.
Properly use peripheral devices to load programs and generate/print reports.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
30
MODICON 984/QUANTUM PLC’S
M-920: Modicon 984/Quantum Family Programmable Controllers/Level Two
Maintenance & Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4 day training program provides a thorough introduction to the Advanced instruction
and Enhanced instruction set capabilities of the 984 family of programmable controllers.
Application exercises are used throughout the course to create a hands-on learning environment.
TOPICAL OUTLINE
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Review of Hardware and Basic Instruction
Review of Memory Organization
Introduction to Table Operations: Register to Table, Table to Register, Block Move, First In/
First Out & Search, Status
Matrix Instructions
Logical AND, OR, Exclusive OR: Compliment, Compare, Bit Modify, Bit Sense, Bit Rotate &
ASCII Read and Write Function
Skips
Subroutines
Advanced/Enhanced Instructions: Table to Block, Block to Table, Double Precision Math,
Square Root & Floating Point Math
Communications: Modbus & Modbus Plus
Hands-On Application Projects: Hands-on application exercises utilizing conveyors, material
handling robots, or batch process stations are used to create a hands-on learning
environment.
PREREQUISITE
Students should have successfully completed Intellect Controls Group course M-910 or have
equivalent knowledge to the course description. M-920 IS NOT AN ENTRY LEVEL TRAINING
PROGRAM.
COURSE HARDWARE
Modicon 984 Models: 385, 485, Quantum
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Identify hardware components of a 984 programmable controller system.
Enter and interpret programs that use the Advanced and Enhanced instructions of the 984
Family of programmable controllers.
Troubleshoot hardware and software faults by interpreting control programs using the
advanced capabilities of the 984 Family of programmable controllers.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
31
ALLEN-BRADLEY DRIVES
MC-100: AC and DC Variable Speed Motor Drives Maintenance & Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4 day hands-on training program is designed to provide maintenance electricians
with a thorough understanding of AC and DC motor construction, operation and variable speed
control. Hands-on lab exercises are used throughout the training program to simulate actual plant
conditions. Course hardware will include Variable Frequency AC and DC Motor Drive Workstations,
Circuit Test Workstations, Oscilloscopes and Multimeter test equipment. Hands-on labs will explain
operation and troubleshooting of diodes, transformers, SCR's, transistors and other electrical
control devices.
TOPICAL OUTLINE
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Electrical Review: Voltage, Current, Power, Resistance, Magnetism, Reactance
Motor Fundamentals: Motor Construction and Operation
Variable Speed Drives
Power Module (Converter): Transformer, Rectifiers, SCR’s, Bridge Rectifier
Soft Start
DC Motor Speed Control: Field and Armature Voltage/Current Control
Braking
AC Motor Speed Control: Reading, Setting and Adjusting Parameters & Converters,
Inverters
Six-step, PWM, Vector
Transistors, GTO, IGBT, Darlington
Control Circuits
Troubleshooting
PREREQUISITE
A basic understanding of electrical principles of voltage, power, current and resistance.
AUDIENCE
This course is designed for plant maintenance personnel and other technicians who need to
broaden their understanding of fundamentals of AC & DC motor troubleshooting and operation. MC100 answers the prerequisite requirements of our Drives courses.
CEU’s
2.9
OBJECTIVES
Persons completing this course will be able to:
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Explain basic AC and DC motor operation
Identify motor parts and function
Describe variable speed motor control
Explain main drive units operation and function
Understand basic theory of SCR’s, diodes, transistors, triacs, and other electrical control
devices
Troubleshoot circuits using a multimeter and an oscilloscope
Use prints to isolate drive and motor problems
Read and Set Drive Parameters
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
32
ALLEN-BRADLEY DRIVES
MC-200: Allen-Bradley 1336 Plus/Plus II Variable Frequency Motor Drives
Maintenance & Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4 day training program will provide maintenance electricians and engineers with the
required knowledge and skills to install, start-up and troubleshoot Allen-Bradley 1336 Plus AC Drive
systems. Emphasis is on using the Human Interface Module and Drive Explorer & Drive Executive
software to set and check parameters used in normal operation and for troubleshooting. Students
will locate power, signal and control terminals, monitor drive conditions, clear faults and be able to
troubleshoot drive and motor problems.
TOPICAL OUTLINE
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Introduction to AC Motor Speed Control: Motor Characteristics & Variable Frequency
Inverters
Power and Signal Wiring
Drive Installation/Replacement: Motor Feedback Polarities
Control Options: Interface Modules & Input Modules
Human Interface Module: Control and Display Panel, Operating Modes, Start-up Parameters
& Advanced Parameter Operation
Troubleshooting: Fault Identification and Clearing, Understand Diagnostic Parameters &
Troubleshooting Charts and Corrective Action
PLC Operation: SCANport Communication, Discrete Inputs and Outputs & Block Transfer of
Data
Other Allen-Bradley Drives
Drive Explorer Software
PREREQUISITE
A basic understanding of AC Motor Operation, Electrical Control and Safety, Allen-Bradley PLC
Ladder Logic and Remote I/O.
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Recognize drives in the 1336 family
Identify input and output power, control and signal terminals
Install/Replace and perform initial start-up of the drive system
Monitor and set drive parameters using the Human Interface Module
Troubleshoot control inputs, outputs, drive and motor faults
Correlate Drive-PLC inputs, outputs and data transfer
Use troubleshooting charts to isolate drive problems
Use Drive Explorer software to monitor and set parameters and troubleshoot problems
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
33
ALLEN-BRADLEY DRIVES
MC-700: Allen-Bradley PowerFlex 70/700 Variable Frequency Motor Drives
Maintenance & Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4 day hands-on training program is designed to provide maintenance electricians and
engineers with the required knowledge and skills to install, start-up and troubleshoot Allen-Bradley
PowerFlex 70/700 Variable Frequency AC Drive systems. Emphasis is on using the Human Interface
Module and DriveExplorer software to set and check parameters used in normal operation and for
troubleshooting. Students will locate power, signal and control terminals, monitor drive conditions,
clear faults and be able to troubleshoot drive and motor problems.
TOPICAL OUTLINE
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Introduction to AC Motor Speed Control: Motor Characteristics & Variable Frequency
Inverters
Power and Signal Wiring
Drive Installation/Replacement: Motor Feedback Polarities
Control Options: Interface Modules & Input Modules
Human Interface Module: Control and Display Panel, Operating Modes, Start-up Parameters
& Advanced Parameter Operation
Troubleshooting
Fault Identification and Clearing
Troubleshooting Charts and Corrective Action
PLC Operation
SCANport Communication
Discrete Inputs and Outputs
Block Transfer of Data
Other Allen-Bradley Drives
DriveExplorer Software
DriveExecutive Software
PREREQUISITE
A basic understanding of AC motor operation, electrical control and safety, Allen-Bradley PLC
ladder logic and remote I/O.
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Recognize drives in the PowerFlex 70/700 family
Identify input and output power, control and signal terminals
Install/Replace and perform initial start-up of the drive system
Monitor and set drive parameters using the Human Interface Module
Troubleshoot control inputs, outputs, drive and motor faults
Correlate Drive-PLC inputs, outputs and data transfers
Use troubleshooting charts to isolate drive problems
Use DriveExplorer or DriveExecutive software to monitor and set parameters and
troubleshoot problems
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
34
ALLEN-BRADLEY DRIVES
MC-750: Allen-Bradley PowerFlex 700S AC Drives Maintenance &
Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4 day hands-on training program is designed to provide maintenance electricians and
engineers with the required knowledge and skills to install, start-up and troubleshoot Allen-Bradley
PowerFlex 700S Variable Frequency AC Drive systems. Emphasis is on using the Human Interface
Module and DriveExecutive software to set and check parameters used in normal operation and for
troubleshooting. Students will locate power, signal and control terminals, monitor drive conditions,
clear faults and be able to troubleshoot drive and motor problems.
TOPICAL OUTLINE
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Introduction to AC Motor Speed Control: Motor Characteristics & Variable Frequency
Inverters
Power and Signal Wiring
Drive Installation/Replacement: Motor Feedback Polarities
Control Options: Interface Modules & Input Modules
Human Interface Module: Control and Display Panel, Operating Modes & Start-up
Parameters & Advanced Parameter Operation
Troubleshooting
Fault Identification and Clearing
Troubleshooting Charts and Corrective Action
DriveLogix Operation
SCANport Communication
Discrete Inputs and Outputs
Block Transfer of Data
Other Allen-Bradley Drives
DriveExplorer Software
DriveLogix Interface
PREREQUISITE
A basic understanding of AC motor operation, electrical control and safety, Allen-Bradley PLC
ladder logic and remote I/O.
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Recognize PowerFlex 700S Options
Identify input and output power, control and signal terminals
Install/Replace and perform initial start-up of the drive system
Monitor and set drive parameters using the Human Interface Module
Troubleshoot control inputs, outputs, drive and motor faults
Correlate Drive-PLC inputs, outputs and data transfers
Use troubleshooting charts to isolate drive problems
Use DriveExplorer or DriveExecutive software to monitor and set parameters and
troubleshoot problems
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
35
ALLEN-BRADLEY DRIVES
MC-755: Allen-Bradley PowerFlex 753/755 Variable Frequency Motor Drives
Maintenance & Troubleshooting
COURSE DESCRIPTION
This 32 hour, 4 day hands-on training program is designed to provide maintenance electricians and
engineers with the required knowledge and skills to install, start-up and troubleshoot Allen-Bradley
PowerFlex 750 Series (the 753 & the 755) Variable Frequency AC Drive systems.
Skills to interface with these drives are developed with the use of the Human Interface Module,
DriveExplorer & DriveExecutive software.
In addition to learning how to set up and replace a drive, students will learn how to check & set
parameters for normal operation and for troubleshooting.
Students will locate power, signal and control terminals, monitor drive conditions, clear faults and
be able to troubleshoot drive problems and perform preventative maintenance procedures.
TOPICAL OUTLINE
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Variable Frequency Drive Theory Review
PowerFlex 750 Drive Hardware
Using the A6 H.I.M.
Setting Up Ethernet Communications
Using Drive Software
Troubleshooting PowerFlex 750 Drives
Using Safety Module Options in the PowerFlex 750 Drives
Understanding Control Block Diagrams
PowerFlex 750 Drives Predictive Maintenance Tools
PREREQUISITE
A basic understanding of AC motor operation, electrical control and safety, Allen-Bradley PLC
ladder logic.
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Install or replace a drive
Configure the drive to meet your application needs
Identify and replace hardware components
Diagnose and correct faults and alarms
Perform preventative maintenance on the drive
“Excellent class. I have attended drive classes before and have left with a lot of questions still
unanswered. I do not feel this way after this class. The instructor did an excellent job of teaching and
answering questions. The labs then re-enforced what we went over in class. If we did encounter
problems, the instructor did an excellent job of responding and helping us”.
(Employee of MillerCoors)
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
36
FANUC CNC TRAINING
NC-100: Fanuc CNC Basic Machine Troubleshooting
COURSE DESCRIPTION
This 36 hour, 4.5 day hands-on training program is designed for technicians who will be
troubleshooting Fanuc controlled machinery. It will concentrate on the use of ladder logic and
various diagnostic screens to troubleshoot machine problems. During the course the student will
examine the ladder logic in detail for one machine. During this process we will also cover various
programming techniques used by other machine builders. Multiple circuits, including M-codes,
spindle commands, interlocks and alarms, will be covered.
This class is available on site or at our location. If done on site, the customer will provide a
classroom suitable for training purposes. A 220VAC supply will be needed for the simulator.
TOPICAL OUTLINE
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Terminology used to describe the machine.
Discuss metal cutting and how it affects the machine.
Discuss basic commands such as G, F, M, S and T codes.
Identifying control types, software versions, machine models.
Identify the major components in the control.
Show how the machine control handles movement and I/O.
Observe control screens used to diagnose errors.
Learn to safely test the major components on the machine.
Learn to distinguish between Fanuc and machine alarms.
Use of the diagnostic and ladder logic screens to trace errors.
If you wish to add, remove or concentrate on any of the topics please let us know. We will
accommodate any special requests.
PREREQUISITE
Participants should have a good basic knowledge of electronics and the ability to use test
instruments such as multi-meters.
CEU’s
3.3
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
37
FANUC CNC TRAINING
NC-150: Fanuc CNC Troubleshooting
COURSE DESCRIPTION
This 36 hour 4.5 day hands-on training program is designed for technicians who will be
troubleshooting CNC equipment with Fanuc controls. We will emphasize the importance for
technicians to fully understand how the electronics and mechanics interact in order to troubleshoot
a problem. The course will cover the three primary areas of CNC troubleshooting:
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Electrical: Motors, servos, encoders, ladder logic and diagnostics
Mechanical:В The major components that make up a machine tool
Environmental: Outside factors such as leveling, power, tooling
This class is available on site or at our location. If done on site, the customer will provide a
classroom suitable for training purposes. A 220VAC supply will be needed for the simulator.
TOPICAL OUTLINE
During the course the students will assemble a CNC machine. This includes items such as box and
linear guide rails, gibbs, ballscrews and a lubrication system. Once this is complete, the students
will add the motors, servo drives and all of the necessary wiring. In the next step they will install
the control, operator panel, parameters and ladder logic. As they assemble the machine we will
discuss each component, how to adjust it, and how it can fail.
We will cover the interface between the CNC and the machine tool in detail. After the assembly,
errors will be introduced into the machine. The students will use what they have learned in class to
diagnose the problems. The students will also be presented with various scenarios dealing with
machine failures. They will discuss potential causes for the failure and determine a logical series of
tests in order to quickly isolate the problem.
If you wish to add, remove or concentrate on any of the topics please let us know. We will
accommodate any special requests.
PREREQUISITE
Participants should have a good basic knowledge of electronics and the ability to use test
instruments such as multi-meters.
CEU’s
3.3
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
38
FANUC CNC TRAINING
NC-200: Fanuc CNC Advanced Machine Troubleshooting
COURSE DESCRIPTION
This 36 hour 4.5 day hands-on training program provides the advanced training needed by CNC
service technicians to fully understand the workings of a Fanuc controlled CNC machine. The
students will use a hands on approach to create ladder logic programs, install and remove scale
feedback systems and modify parameter settings. The students will be using a simulator equipped
with a Fanuc i-series control. This is a fully functional machine using alpha series drives, motors
and scale feedback.
In this class the students are divided up into teams. These teams will work together to create
errors that are introduced into the simulator. Each team will then debug the other team’s errors.
All of our classes can be tailored to the specific issues that you wish to address.
This class is available on site or at our location. If done on site, the customer will provide a
classroom suitable for training purposes. A 220VAC supply will be needed for the simulator.
TOPICAL OUTLINE
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Establishing servo parameter settings
Enabling and disabling of scale feedback system
Parameter details
Data Registers
Creating M-Codes, timers and alarms
Adding additional I/O to a Fanuc control
Using ladder logic and diagnostics
Using custom macros for troubleshooting
If you wish to add, remove or concentrate on any of the topics please let us know. We will
accommodate any special requests.
PREREQUISITE
This is an advanced course. The students should have prior experience with troubleshooting CNC
equipment. An advanced understanding of diagnostic procedures is recommended.
CEU’s
3.3
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
39
FANUC CNC TRAINING
NC-300: Using Fanuc Ladder Logic and Diagnostics for Troubleshooting
COURSE DESCRIPTION
This 36 hour, 4.5 day hands-on training program is designed for technicians who will be
troubleshooting Fanuc controlled machinery. It will concentrate on the use of ladder logic and
various diagnostic screens to troubleshoot machine problems. During the course the student will
examine the ladder logic in detail for one machine. During this process we will also cover various
programming techniques used by other machine builders. Multiple circuits, including M-codes,
spindle commands, interlocks and alarms, will be covered.
This class is available on site or at our location. If done on site, the customer will provide a
classroom suitable for training purposes. We can provide a simulator or teach the class on your
equipment. A 220VAC supply will be needed for the simulator.
TOPICAL OUTLINE
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Ladder logic general description
Inputs / Outputs
Fanuc PMC addresses
Function Statements
Alarm Messages
Reverse Engineering Alarms
Ladder display and searching
Trace function, Trigger Function
M-codes
Interlocks
Sub-routines
PMC parameters
Backing up PMC data
PMC Diagnostics
If you wish to add, remove or concentrate on any of the topics please let us know. We will
accommodate any special requests.
PREREQUISITE
Participants should have an understanding of ladder logic and an electrical background. It is also
recommended that they have a general understanding of machine tool operations.
CEU’s
3.3
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
40
FANUC CNC TRAINING
NC-400: Fanuc G Code (Tool Path) Programming
COURSE DESCRIPTION
This 36 hour, 4.5 day hands-on training program teaches the students the fundamentals of basic
programming. Students learn Cartesian Coordinate Systems, G codes, basic M codes, word
address, canned cycles, cutter radius compensation, and sub programs. Participants will be given
many different examples, as well as write many programs. Safety lines and technique will be
covered.
The customer will provide a classroom and access to a machine tool with a Fanuc controller suitable
for training purposes. The instructor will need unlimited access to the machining center for the
duration of the class.
TOPICAL OUTLINE
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Cartesian Systems
Positioning
Absolute Location
Incremental Location
Word Address
G Codes
M Codes
Alpha Codes
Datum’s
Program Structure
Part Zero
Machine Zero
Reference Planes
Work Coordinates
Canned Cycles
Cutter Radius Compensation
Sub Programs
G10 Functions
Programming Examples
Machine Tool Options
If you wish to add, remove or concentrate on any of the topics please let us know.
We will accommodate any special requests.
PREREQUISITE
Participants should have a good basic knowledge of machining practices.
CEU’s
3.3
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
41
FANUC CNC TRAINING
NC-500: Fanuc Macro Options Training
COURSE DESCRIPTION
This 36 hour, 4.5 day hands-on training program will instruct the students in the use of custom
macro programming and special options for Fanuc controls. The students will learn to use these
powerful functions to increase machine efficiency and reduce cycle times. This is a very intense
course with a considerable amount of time spent writing and executing programs.
The customer will provide a classroom and access to a machine tool with a Fanuc controller suitable
for training purposes. The instructor will need unlimited access to the machining center for the
duration of the class.
TOPICAL OUTLINE
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Machine operation procedures
Programming fundamentals
Introduction to macros
Variables
System variables
Call statements
IF, THEN, GOTO statements
Arithmetic functions
Custom M-codes
Custom G-codes
Special options to reduce cycle time
If you wish to add, remove or concentrate on any of the topics please let us know. We will
accommodate any special requests. Note that the options available on the machine tool will vary
depending upon the manufacturers specifications.
PREREQUISITE
Participants should have a good basic knowledge of machining practices and understand basic Gcode programming.
CEU’s
3.3
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
42
FLUID POWER TRAINING
H-100: Troubleshooting Industrial Hydraulics/Level One
COURSE DESCRIPTION
This 32 hour, 4 day training program focuses on industrial hydraulic systems. We place emphasis
on understanding the basic hydraulic fundamentals utilized in all industrial hydraulic systems; the
participant will learn to effectively to setup, adjust and troubleshoot industrial hydraulic systems.
The participant will apply practical hands on exercises for each basic principle covered in the class.
These hands on exercises will be executed utilizing real world hydraulic adjustments and
calibrations as used in actual systems. We focus heavily on teaching proper safety procedures, and
strictly enforce these procedures to assure participants learn and practice safe work habits. ISO
1219 Industrial hydraulic symbology will be taught and used throughout the class. The participant
will utilize this symbology throughout the class, and learn from case history hydraulic prints. Proper
adjustment procedures for pressure, flow, and directional control valves will be emphasized and
applied.
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Demonstrate and identify good safety procedures when working with industrial hydraulic
systems.
Match system components with appropriate ISO 1219 symbols.
Assemble hydraulic circuits and verify their operation in a lab setting.
Determine why certain components are required in specific circuits.
Adjust and calibrate system components in a predetermined sequence.
Understand sources of heat in a hydraulic system.
Understand the different types of flow controls and applications of each.
Understand how to control a suspend load.
Understand the purpose of accumulators and how to properly charge them.
Identify the symptoms, causes, and prevention of shock in a hydraulic circuit.
Diagnose failure of components that affect efficiency, but not operation.
Successful completion of this program should adequately prepare the participant to successfully
pass the written portion of the Fluid Power Societies Industrial Hydraulic Mechanic certification
examination.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
43
FLUID POWER TRAINING
H-200: Troubleshooting Industrial Hydraulics/Level Two
COURSE DESCRIPTION
This 32 hour, 4 day training program focuses on advanced troubleshooting of industrial hydraulic
systems using in-plant schematics. The participant will practice hands on troubleshooting skills on
our industrial hydraulic trainers. This course is designed to raise the skill level of the hydraulic
mechanic to the hydraulic technician level. The participant will calculate proper sizing of hydraulic
pumps, actuators, valves, and piping. Hydraulic servo and proportional valve function, operation,
terminology, and setting procedures will be covered; a background in electronics is not necessary.
Topics covered will also include; pressure intensifiers, air-over-oil, and pressure compensated
pumps. ISO 1219 Industrial hydraulic symbology will be used and reinforced. Course can be
customized to meet specific client needs, ie; researching in-plant equipment specs, updating inplant schematics, hands on testing preparation, basic electronic control of hydraulic systems, or
covering plant specific topics or equipment.
Prerequisite
Successful completion of H-100 Troubleshooting Industrial Hydraulic/Level One
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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Demonstrate and identify good safety procedures when working with industrial hydraulic
systems.
Calculate proper hydraulic component sizing.
Understand the operation and adjustment of servo and proportional hydraulic valves.
Understand the operation and setting of pressure compensated pumps.
Troubleshoot in-plant hydraulic systems with schematic diagrams.
Successful completion of this program and review of the International Fluid Power Society (IFPS)
study guide should adequately prepare the participant to pass the written portion of the IFPS
“Industrial Hydraulic Technician” certification examination. For more information visit
http://ifps.org/
“I had the same instructor for the basic hydraulics class and I was hoping he would be back. He’s is a
very good teacher”.
(Employee of Logan Aluminum)
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
44
FLUID POWER TRAINING
PN-100: Introduction to Industrial Pneumatics & Air Logic
COURSE DESCRIPTION
This 32 hour, 4 day training program focuses on industrial pneumatics systems. We use proven
troubleshooting methods in this course. This course will teach the student to troubleshoot down to
the component level. Course does not cover individual component repair.
This course provides an introduction to air logic in the forms of; attached Symbology (logic
symbols) and detached Symbology (ladder logic).
Students are welcome to bring schematics into the class for coverage. Please have them provide
schematics on 8 ВЅ x 11 paper if possible so copies can be made for the entire class and to provide
a transparency for the instructor.
CEU’s
2.9
OBJECTIVES
Persons successfully completing this course will be able to:
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To effectively troubleshoot pneumatic equipment, and controls.
To properly build common pneumatic circuits.
To identify and read typical pneumatic schematics.
To identify and understand the operation of pneumatic components.
To use proper pneumatic terminology.
To identify safety related issues relating to pneumatics including safety circuits and the
dangers of misapplication.
The do’s and don’ts of pneumatics.
About oilless pneumatic components.
The importance of clean air and preventive maintenance.
The proper precautions to be taken when removing, repairing, or replacing pneumatic
components.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
45
PROCESS MEASUREMENT & CONTROL
FUNDAMENTALS
PCI-100: Understanding Industrial Process Control/Level One Process
Measurement & Control Fundamentals
COURSE DESCRIPTION
This 36 hour, 4.5 day training program uses a hands-on approach providing students with a
fundamental understanding of industrial process measurement & control systems. Participants will
learn the basic measurement & control principles, terminology, symbols & documentation
standards. In addition students will perform hands-on exercises with actual industrial temperature,
pressure, flow &level measurement & control devices to gain experience in how to set up &
troubleshoot a control system.
TOPICAL OUTLINE
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Introduction to ISA documentation standards: Process Flow Diagrams (PFD’s), Piping &
Instrument Diagrams (P&ID’s), Loop Diagrams, Location Plans & Installation Details
Test Equipment: Calibrators, Digital Multimeters & Power Supplies
Signals: Analog – voltage & milliamps, Digital - on/off & digital data, Wiring basics
Elements of a Process Control Loop: PV-Process Variable, MV-Manipulated Variable & CController
Temperature Measurement: Thermocouples, RTDs, Thermometers, Infrared, Characteristics,
Thermowell & Transmitters
Pressure Measurement: Gauges, Transmitters & Block & Bleed Valves
Flow Measurement: DP Meters, Turbine Meters, Pd Meters & Variable Area Meters
Level Measurement: Float Gauges, Static Head Gauges & Sounding Gauges
Control Valves: Types, Accessories, Sizing & Basic Troubleshooting
PREREQUISITE
This is an entry level course & requires only that participants be familiar with industrial
manufacturing processes.
CEU’s
3.3
OBJECTIVES
Persons successfully completing this course will be able to:
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Construct a block diagram of a closed loop control system utilizing feedback.
List the four most common process variables found in industry.
List and describe the three modes of control.
List the units of measurement of pressure, temperature, level, and flow.
Convert from one unit to another.
List and describe the terms that are common to all closed loop feedback control systems.
List various methods used to measure pressure, temperature, level, and flow.
Determine the action of a controller to obtain if given the characteristics of the other devices
in a control loop.
Describe the operation of the transmitters used to measure the process variables.
List the requirements for stability in a closed loop control system.
Describe the proper procedure for calibrating measurement transmitters.
Explain the procedures for tuning a controller using either closed loop or open loop testing.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
46
PROCESS MEASUREMENT & CONTROL
FUNDAMENTALS
OBJECTIVES – Continued
пѓ� Configure a microprocessor based controller to specifications given by the instructor.
пѓ� List the three common inherent characteristics of control valves.
пѓ� Explain the difference between inherent and installed characteristics of control valves
пѓ� Determine whether a control loop is utilizing cascade, ratio, or feedforward schemes, if
given a block diagram of the control loop.
пѓ� Calculate the Cv rating of a valve if given the maximum flow rate, the specific gravity of the
liquid, and the differential pressure across the valve.
пѓ� Trace the electrical and pneumatic connections of the lab process plant.
пѓ� Explain the difference between direct and reverse acting actuators.
пѓ� Tune a controller to obtain good control, which will be determined by the instructor.
пѓ� Calibrate various types of transmitters.
пѓ� Construct basic temperature transmitters using thermocouples.
пѓ� Identify analytical equipment and their applications.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
47
PROCESS MEASUREMENT & CONTROL
FUNDAMENTALS
PCI-200: Understanding Industrial Process Control/Level Two Advanced Process
Measurement & Control Fundamentals
COURSE DESCRIPTION
This 36 hour, 4.5 day training program uses a hands-on approach providing students an in-depth
understanding of industrial process measurement & control systems. Participants will learn to apply
more comprehensive measurement & control principles, terminology, symbols & documentation
standards. In addition students will perform hands-on exercises in which they will build, test, tune
& troubleshoot temperature, pressure, flow & level control systems.
TOPICAL OUTLINE
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Application of ISA documentation standards
Elements of a Process Control Loop: PV-Process Variable, MV-Manipulated Variable & CController
Other Process Measurements: Weight, pH, Density, Viscosity, Moisture & Others
Process Dynamics: Open Loop Response, Process Gain, Process Time Constant & Process
Dead Time
Control Methods: Open Loop control (Self-regulating), Manual control, ON/OFF control,
Feedback control, Feedforward control & Cascade control
Control Tuning: Open vs. Closed loop methods, Stability vs. responsiveness, Вј decay ratio,
Simplex tuning method, Zeigler-Nichols tuning method & Auto-tuning
Special Cases: pH control & Nonlinear systems
Control Valve Selection & Sizing: Valve types (Globe, Ball, Butterfly & Gate), Valve
Characteristic (Quick opening, Linear, Equal Percentage) & Other Control Valve Topics
(Positioners, Materials, Configuration, Actuators & Accessories)
Installation Best Practices: Wiring, Shielding & Isolation
Control System Troubleshooting: Experience Based & Trial & Error
PREREQUISITE
PCI-100: Understanding Industrial Process Control/Level One Process Measurement & Control
Fundamentals or a fundamental understanding of industrial process measurement & control system
design & operation.
CEU’s
3.3
OBJECTIVES
Persons successfully completing this course will be able to:
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Create the documents used to define instruments & control systems.
Apply the principles, equipment & techniques for the primary industrial process
measurements of temperature, pressure, level & flow.
Understand & process response & how it affects controller operation.
Know & apply the proper controller tuning method.
Select & size the proper control valve.
Build, test, operate tune & troubleshoot a various feedback control loops.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
48
TRAINING SIMULATORS
PLC’s - Allen-Bradley ControlLogix Programmable Controllers
A-6000: Allen-Bradley
ControlLogix Level One
A-6100: Allen-Bradley
ControlLogix 5000
Fundamentals &
Troubleshooting
A-6200: Allen-Bradley
ControlLogix & Two
A-6300: Allen-Bradley ControlLogix/Level Three
Advanced Communications: DeviceNet, ControlNet &
Ethernet
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
49
TRAINING SIMULATORS
A-6400: Allen-Bradley ControlLogix Motion Control
Maintenance & Troubleshooting
GUARDLOGIX - Allen-Bradley GuardLogix
A-6110: Allen-Bradley GuardLogix Maintenance & Troubleshooting
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
50
TRAINING SIMULATORS
ROCKWELL RS-5000 - RS-5000 ControlLogix Function Block Diagrams
A-6120: RS-5000
ControlLogix Function Block
Diagrams
A-6130: RS-5000
ControlLogix Structured Text
A-6140: ControlLogix RS5000 Sequential Function
Chart
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
51
TRAINING SIMULATORS
SLC–500 - Allen-Bradley SLC-500 Programmable Controllers
A-5000: Allen-Bradley
SLC-500 Programmable
Controllers/Level One
Maintenance &
Troubleshooting
A-5200 Allen-Bradley
SLC-500 Programmable
Controllers/Level Two
Advanced Maintenance &
Troubleshooting
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
52
TRAINING SIMULATORS
FACTORYTALK VIEW - Allen-Bradley FactoryTalk View ME & SE
A-760: Rockwell
FactoryTalk View ME
Maintenance &
Troubleshooting
A-770: Rockwell
FactoryTalk View SE
Maintenance &
Troubleshooting
DRIVES - Allen-Bradley PowerFlex 70/700
MC-700: Allen-Bradley PowerFlex 70/700
Variable Frequency Motor Drives
Maintenance & Troubleshooting
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
53
TRAINING SIMULATORS
Allen-Bradley PowerFlex 700S
MC-750: Allen-Bradley
PowerFlex 700S AC Drives
Maintenance &
Troubleshooting
Allen-Bradley PowerFlex 755
MC-755: Allen-Bradley
PowerFlex 753/755 Variable
Frequency Motor Drives
Maintenance &
Troubleshooting
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
54
TRAINING SIMULATORS
FLUID POWER - Troubleshooting Industrial Hydraulics
H-100 & H-200:
Troubleshooting Industrial
Hydraulics Level One &
Level Two
Hydraulic trainers
need a minimum of
3 circuits. Each
Hydraulic trainer
weighs
approximately
700lbs and is 5’4”H
x 5’5”L x 2’4”D. A
total of five trainers
are delivered with
each on-site training
session.
Introduction to Pneumatics & Air Logic
PN-100:
Introduction to
Industrial
Pneumatics & Air
Logic Level One
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
55
TRAINING SIMULATORS
FANUC CNC - Fanuc CNC Machine Troubleshooting
NC-100, NC-150 &
NC-200: Fanuc CNC
Basic, Troubleshooting &
Advanced
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
56
TRAINING SIMULATORS
PROCESS CONTROL - Understanding Industrial Process Control
PCI-100 & PCI-200:
Industrial Process Control
Level One & Level Two
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
57
IDEAL CLASSROOM
SETUP
Typical Classroom set-up for 10 students
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Total of 6 foot tables needed is 6
Intellect will supply an Infocus if training location does not have one.
Room should be wired: 110 vac with a minimum of 2 circuits.
Exception: Hydraulic trainers need a minimum of 3 circuits. Each Hydraulic trainer weighs
approximately 700lbs and is 5’4”H x 5’5”L x 2’4”D. A total of five trainers are delivered with
each on-site training session.
Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
58
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12
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12
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Tues Wed
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13
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14
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8
15
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9
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3
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Intellect Controls Group, Inc. в—Џ www.intellectcontrols.com в—Џ Call (888) 468-3591
Rev 11/14
59
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