AUTOMATION CONTROL & INSTRUMENTATION SERIES

CORE
INTRODUCTION* ISG-ACCIN-VV
This lesson outlines the functions of the input, decision-making and output 
elements of control systems and defines terms. It distinguishes between 
analog and binary components and functions, and surveys the kinds of 
devices a technician is likely to find. It also introduces open loop, 
feedback and feed forward concepts.

PRINCIPLES OF CONTROL* ISG-ACCO-VV
This lesson focuses on the decision-making part of an automatic control 
system: the controller. It introduces relay logic, solid state logic boards 
and PLCs. It also explains the functions and operation of PID 
controllers. Practical procedures for adjusting, programming and 
troubleshooting both digital and analog controllers are integrated with 
principles.

PRINCIPLES OF CALIBRATION* ISG-ACCA-VV
A trainee will learn how to test, adjust and calibrate the components of a 
control system for optimum process control, as well as what is involved in 
loop calibration. The importance of safety, following plant documentation 
procedures and minimizing the impact on production while calibrating the 
control system is emphasized.

INTRODUCTON TO CONTROL AND DATA SYSTEMS 
ISG-ACCIC-VV
This program describes digital control and data system components and 
their function, including the system architecture, the system network and 
operating software, as well as application software that technicians must 
use to maintain data flow between equipment, controllers, and the business 
database systems. The application software discussion includes: virtual 
instrumentation, PLC control program creation, using graphical objects to 
create the system data structure and Human-Machine Interface screens, 
password hierarchy and the need for security, the functions and 
architecture of the Supervisor control and Data Acquisition system.

THE HUMAN-MACHINE INTERFACE ISG-ACCHM-VV
This program provides a basic introduction to industrial computers for 
production and maintenance students who have little or no experience 
using computers that are interfaced with industrial equipment. Emphasis is 
placed demystifying computers and the mechanics of working with 
computers. Both text-based and graphical-bases interfaces are covered. 
Basic computer tasks are explains as part of logging-on and using a 
CMMS.

BASIC ELECTRICAL TEST EQUIPMENT ISG-ACCBE-VV
The safe operation and use of the following analog and digital test 
equipment is covered: continuity testers, volt/ohm meters, ammeters, 
meggers, and digital low resistance testers. An extensive discussion of 
safety is includes, as well as step-by-step practical instruction in the use of 
these all-important basic-troubleshooting tools.

DIGITAL AND ANALOG OSCILLOSCOPES ISG-ACCDA-VV
This program is basic introduction to the operation and use of analog and 
digital oscilloscopes. These instruments are commonly used when 
diagnosing electrical waveforms created and used in inverter, battery 
charger, generator control system, crane and hoist control, programmable 
logic controller and solid-state protective relay circuits. The program 
covers basic terminology and techniques, including: horizontally and 
vertically setting up the scope, compensating the probes, triggering, 
reading the grid to take voltage and time measurements, and basic test 
techniques. Safety is stressed throughout the program.

CONTINUOUS PROCESS
PRINCIPLES ISG-ACPCR-VV
This program introduces the basic continuous process control algorithms: 
proportional, derivative, and integral. It also covers configuration 
parameters and options that may be offered by process controllers, 
including ramp/soak state, auto-tune, and fuzzy logic. Material covered is 
essential background for technicians who may be called on to tune 
process control loops.

PNEUMATIC CONTROLS* ISG-ACPPC-VV
In this lesson, a trainee is introduced to pneumatic control devices: 
transmitters, receiver-controllers and actuators. How they work is 
explained in the context of inspecting, maintaining, testing and calibrating 
components and pneumatic systems generally. The importance of clean 
air delivered from a correctly maintained and functioning control air supply 
system is emphasized.


FIELD DEVICES - TEMPERATURE, PRESSURE & WEIGHT 
ISG-ACPPT-VV
Theory of operation and descriptions of field input devices that measure 
and report on Level and Flow in modern industrial operations. 
Thermocouples, RTDs, thermistors and the different types of load cells. 
Applications and examples. The emphasis is on smart transmitters-how 
they communicate with controllers, and how to communicate with them for 
setup, calibration, and troubleshooting.

FIELD DEVICES: LEVEL AND FLOW ISG-ACPLF-VV
Theory of operation and descriptions of field input devices that measure 
and report on Level and flow in modern industrial operations. Differential 
pressure, bubbler, capacitance, ultrasonic, radar, laser, weight loss, RF, 
displacer, tuning fork, and nuclear level sensors. Micro Motion, magnetic, 
differential pressure, vortex, pulse turbine, ultrasonic and FCI-temperature 
flow sensors.

FIELD DEVICES: ANALYTICAL ISG-ACPAF-VV
Theory of operations and description of field input devices that measure 
and report on pH, density, conductivity, opacity, opacity, stream current, 
total residual chlorine, turbidity, excess O2, CO, CO2, FTIR, GC, and 
SO2

INTRODUCTION TO DISTRIBUTED CONTROL SYSTEMS 
ISG-ACPID-VV
The program begins the introduction to DCS hardware and architecture 
by quickly reviewing field components and how to identify them from a P 
and I diagram. CDS central components like I/O field termination bus, 
I/O control and processor cards are described, followed by the data 
functions of the systems server, DCS networks, and how PLCs are 
integrated into a DCS system. A brief introduction to DCS tasks such as 
performing basic service operations on a field device, tracing field device 
writing, checking for problems inside processor cabinets and performing 
basic data, parameter and program operations at the user interface.

FIELD DEVICES: ANALOG CONFIGURATION 
ISG-ACPCA-VVI
This program defines “analog” in the context of process control; explains 
the funct8ion of analog field devices and how to calibrate and set the range 
on traditional analog devices. It also explains the use of the common 
4-to-20 milli-Amp signal; defines “smart “ field devices, identifies their 
basic configuration parameters and gives examples of how they are 
configured with portable communicators and laptop PC’s.

FIELD DEVICES: USING PORTABLE COMMUNICATORS 
ISG-ACPFC-VV
This program provides the step-by-step process for setting or changing 
the basic configuration parameters on smart analog field devices, suing the 
four most common communicators: HART, Honeywell SFC, Foxboro 
HHT & Yokogawa BT200.

FIELD DEVICES: CONFIGURING WITH LAPTOP PCs 
ISG-ACPCL-VV
This program presents the step-by-step process for configuring both input 
field devices (e.g., transmitters) and output field devices (e.g, control 
valves, VSDs, dampers), using common software programs.

FIELD DEVICES: DIGITAL CONFIGURATION WITH DCS’s 
ISG-ACPCD-VV
The program defines “digital” in the context of process control; explains 
the function and network structure of a Distributed Control system; 
examines the DCS screens commonly used by Instrument Techs in the 
Honeywell TDC 3000 and Fisher-Rosemount DeltaV DCSs, including the 
various data items and their significance; and provides step-by-step 
processes for configuring smart digital devices with those two systems.

SMART CONTROLLERS ISG-ACPSC-VV
This program uses examples to describe those controllers, and covers 
typical procedures for configuring and programming them. It also surveys 
the kinds of Human-Machine Interface functions a technician may find on 
smart controllers, and the interface logic between smart controllers and the 
supervisory PLC, PC-based, or DCS controllers which may integrate the 
process into larger plant operations.

SINGLE LOOP CONTROL ISG-ACPSL-VV
Single loop control includes any application that includes an input, some 
kind of digital logic or analog control algorithm, and a controlled output. 
The loop may be either open or closed. This program looks at examples 
and typical applications. It concentrates on the kinds of components and 
control logic a technician is likely to find, and the testing and kinds of set 
point and configuration adjustments a technician may have to perform.

MULTIPLE LOOP CONTROL ISG-ACPML-VV
This program looks at cascaded, ratioed, and other types of multiple loop 
logic with the aim of equipping a technician to set up, test, and adjust 
multiple control loop systems.


TROUBLESHOOTING LOOPS ISG-ACPTS-VV
Troubleshooting single loops that rely on a single set point and simple 
digital logic is usually straightforward. Troubleshooting loops with 
complex analog control algorithms and feedback, and/or multiple control 
loops, requires a thorough grounding not only in the principles involved, 
but in systematic troubleshooting methodology. This program steps a 
technician through the procedure from investigating and analyzing 
symptoms to formulating hypotheses, testing, verification and analysis of 
root causes.

TROUBLESHOOTING DCS I/O’S- PROCEDURES 
ISG-ACPTD-VV
The most vulnerable parts of a Distributed Control system are the field 
devices and the cables that carry information to and from them. This 
program covers the procedures for troubleshooting the inputs and outputs 
of a distributed control system. Trainees should be able to identify possible 
causes of problems, test the possible causes, and finish up the 
troubleshooting procedure.

TROUBLESHOOTING DCS I/O’S- PRACTICES ISG-ACPTP-VV
This program will familiarize trainees with some practical applications of 
basic procedures for troubleshooting the inputs and outputs of a 
distributed control system. Trainees should be able to explain how to 
troubleshoot problems in digital I/O devices that are part of a DCS, 
analog I/A devices that are part of a DCS, and miscellaneous I/O 
components of a DCS.

TUNING LOOPS ISG-ACPTL-VV
Tuning loops is part art and part science and is typically the area of 
greatest training need in continuous and batch process industries. Turning 
a loop efficiently and effectively requires that the technician fully 
understand the process being controlled and how it responds to changes in 
operating parameters. The technician must understand the field devices 
monitoring the system, and how to troubleshoot and determine the root 
cause of a process disturbance. Only then can a technician effectively tune 
a loop. This program takes a “systems approach” by bringing together the 
entire Continuous Process curriculum to focus on the process of turning 
process. Technicians following a process will be able to begin practicing 
the science of tuning loops.

NETWORKS
INTRODUCTION* ISG-ACNIN-VV
Basic terms, protocols and topologies are presented. The trend in modern 
control systems is to connect components together on LANs to cut siring 
costs, improve performance and allow both distributed processing and 
system integration. This lesson surveys the performance enhancements 
that networks make possible and introduces the trainee to the electrical 
interface and basic protocol issues, data packaging and addressing 
network topology, message initiation, network speed, etc.

SETTING UP & TROUBLESHOOTING* ISG-ACNST-VV
This lesson introduces trainees to the hardware typically found in LANs 
used for process and manufacturing controls in many plants-wires and 
connectors, as well as the adapters, modules, hubs and smart devices that 
connect on the network. The emphasis is hands-on: funning additional 
network circuits, connecting components, testing the cabling and the 
network and troubleshooting problems.

FIBER OPTIC SYSTEMS* ISG-ACNFO-VV
This lesson displays and discusses the hardware, in addition to illustrating 
how to run, connect and test cables I expansion and troubleshooting 
situation. The basic principles of fiber optics are introduces when 
necessary to explain procedures.


PROGRAMMABLE LOGIC CONTROLLERS (PLCs)
ARCHITECTURE, TYPES AND NETWORKS ISG-ACLAT-VV
Principles of PLC operation and system architecture. Examples are 
drawn from Allen-Bradley, Modicon, Siemens, and others. Modern, 
hierarchical control architectures used in manufacturing cells are discussed, 
and essential terminology is introduced.

NUMERICS ISG-ACLNU-VV
This program introduces the number systems that a technician will 
encounter in working with PLC operations: decimal, binary, hex, BCD, 
and octal, and the conversion of data between these systems. Additional 
topics include the handling, organization, and storage of data with in a 
PLC; registers, stacks, data moves, etc.

LADDER LOGIC & SYMBOLOGY ISG-ACLLL-VV
This program first reviews the roots of ladder logic in relay logic, and build 
on fundamental concepts of binary or Boolean Algebra to present ladder 
logic functionality. It describes the conventions and Symbology of ladder 
logic as found both in control schematic diagrams, and on the screen of 
PLC programming interfaces.

I/O COMMUNICATION ISG-ACLIO-VV
This covers common I/O devices and communication, so the focus in on: 
directly connected and networked I/O modules, field devices, and wiring. 
Discrete bit, word, analog, and intelligent I/O module types are discussed. 
I/O module addressing is shown and common field devices that use the 
different module types are covered. The topics of field wiring, image 
tables, and networked I/O modules are discussed in detail.

INTRODUCTION TO PROGRAMMING ISG-ACLIP-VV
This introduction to PLC programming first reviews the programming 
languages a PLC technician may encounter: ladder logic, C, C++, flow 
chart, and other graphical programming techniques. It also looks at the 
programming differences between some of the main PLC platforms. The 
trainee is stepped through the typical procedure for setting up and 
addressing points, identifying I/O, creating data tables, and entering 
counter and timer parameters.

PROGRAMMING COMMON FUNCTIONS ISG-ACLCF-VV
In this second PLC program dedicated to creating control logic, the 
trainee will be introduced to more advanced techniques for machine 
control, and to the typical applications where functions such as jumps, 
resets, go-to subroutines, and shift registers are useful or necessary. The 
procedures for programming these and other functions are detailed.
HUMAN-MACHINE INTERFACE & TROUBLESHOOTING 
ISG-ACLMT-VV
This program concentrates on the interfaces provided by PLC 
manufacturers for both programmers and operators. Topics include the 
programming of operator interfaces, using examples from Panel View, 
XYCOM, and others. The program emphasizes techniques for 
troubleshooting PLC and machine operation using the operator and 
programming interfaces.

TROUBLESHOOTING HARDWARE ISG-ACLTH-VV
PLC hardware proper – the backplane or rack, I/O, power supply, 
communications, and controller modules – have become very reliable. 
Most PLC hardware problems are associated with I/O and 
communications. This program introduces trainees to the kind of PLC 
hardware problems they are likely to encounter, the typical symptoms, 
causes, and remedies.

TROUBLESHOOTING SOFTWARE AND NETWORKS 
ISG-ACLSN-VV
If a PLC control program is correctly tested and debugged, subsequent 
software problems are rare. The interaction between software and I/O 
hardware, and with the process being controlled, however, is often subtle, 
and operational problems sometimes arise. Also, PLCs are often 
integrated into larger plant information and control systems. 
Communication problems between the PLC and supervisory controllers 
are fairly common. This program discusses typical communication and 
software-related problems and solutions.

INSTALLING AND MAINTAINING ISG-ACLIM-VV
This program provides the procedures, techniques, and tips that a 
technician who installs PLC hardware and maintains PLC system 
operations may need to do his job. It includes a closer look at topics such 
as wire and terminal testing and labeling, circuit wire routing, 
electromagnetic noise in the environment, power supply isolation, UPS 
installation and setup, ventilation, etc.

PROGRAM ENTRY, TESTING, AND MODIFICATION 
ISG-ACLPE-VV
This program is designed to familiarize trainees with the techniques used to 
install, test, and modify a PLC project. After completing this program, the 
trainees should be able to explain how to prepare a system for program 
entry and how to download or enter the program. They should also be 
able to explain how to test and debug the program and make changes to 
the program in various processor modes.

VARIABLE SPEED DRIVES
INTRODUCTION TO VSDs ISG-ACVSD-VV
This program serves as an introduction to DC thyristor, AC inverter, and 
AC Flux Vector Control. In each case, an overview of the types is 
provided; how the drive operates is covered; the drive hardware 
components are described; and basic controller operation is discussed.

APPLICATIONS ISG-ACVDA-VV
Variable Speed Drives must be matched to the required application. That 
means the drive must deliver the required horsepower and torque at the 
specified speeds to fulfill the design specifications. This program is 
designed for maintenance electricians and even engineers who must 
understand VSD operating parameters and how a VSD system works so 
that the technician can choose, install and setup a drive as a replacement 
or as a fresh installation. Common VSD applications are covered, 
including network arrangements. Selections, installation, integration and 
setup, as well as normal maintenance issues are discussed.

SYSTEMS INTEGRATION ISG-ACVSI-VV
This program covers field sensors, motor-mounted sensors, “sensorless” 
feedback, and network control. The field sensors discussion includes 
milliamp and low-voltage DC sensors, as well as the importance of proper 
shielding and grounding. The section on motor-mounted sensors includes 
installing, adjusting and maintaining tachometers, encoders, and resolvers. 
Sensorless feedback operation and how to adjust the control is explained. 
Networked control of VSDs is described, as well as how to integrate a 
drive into an existing drive network.

PROGRAMMING CONTROLLERS ISG-ACVPC-VV
This lesson covers programming DC, AC inverter, and AC Flux Vector 
controls from the perspectives of typical controls options, commands, and 
menu structures. The lesson focuses on typical programming parameters, 
the programming steps for each type of drive in a typical application, and 
then how to re-program each type of controller for a new application.

CONTROLLER TROUBLESHOOTING ISG-ACVCT-KT
This program begins with safety by describing the safe work practices 
needed while troubleshooting the controller and how to select and safely 
use the test equipment required for troubleshooting drives. The topic 
covering troubleshooting FROM the controller includes an introduction to 
controller displays and how to use operations manuals. The program then 
discusses such issues as ground faults and short circuits, overloads, 
intermittent trips, speed fluctuations, torque fluctuations, key test point 
checking, multi-quadrant operations, as well as harmonics and filtering. 
The topic of troubleshooting IN the controller focuses on component and 
board failure within the controller and identifying and correcting problems 
caused by electrical noise.

TROUBLESHOOTING ISG-ACVST-VV
This program covers safe work practices required to troubleshoot the 
VSD system and its various components. Test equipment selection and 
safe use is also discussed. Troubleshooting the motor is covered, 
including motor connections, winding failure, bearing failure and leakage 
currents. Wiring problems are addressed and often show up in the 
connections, shielding/grounding, control system feedback, and 
over-voltage reflections. Electrical supply issues often include the 
connections, voltage imbalances, single phasing and harmonics – which are 
all discussed in this program.

*Titles marked are from the original Automation Control & 
Instrumentation Series and have a series workbook and leaders guide with 
test. All others have separate booklets for each subject.

email: filmo@filmo.com