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MACO Product Training Course Outlines

The Course Outlines for MACO for the Year 2003 are detailed below and are also available as a Download. Please go to the Training Schedules page for information on the class schedules.
 
MACO DS Operation
MACO DS Programming
MACO EM-3 Operations
MACO 4000 Operations
MACO 4000 Programming
MACO 6000 Operations
MACO 6000 Programming
MACO 4000/6000 Regional Operations

 
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M100 - MACO DS Course Outline Download
Operations:

Course Times:

  • 8:00 a.m. to 4:30 p.m. (Classes will end at 11:30 a.m. on Friday)
  • Lunch will be provided from 12:00 p.m. to 1:00 p.m.
  • Breaks 10:00 a.m. and 2:00 p.m.

Recommended Prerequisites:

  • Basic PC knowledge using Windows NT 4.0 or Windows 95/98 Course
  • MACO EM/3, 4000 or 6000 Course

Description:

  • This training is a course designed to teach students the basics of the MACO DS products, and Concept's PLC programming software tools.
  • The purpose of this course is to instill the knowledge necessary to develop applications specific to customer needs. Specific applications such as Extrusion Control, Parison Control and Injection Control are covered in our MACO EM/3, 4000, and 6000 training courses, any or all of which are recommended prerequisites for this course.
  • Barber-Colman will provide MACO DS hardware and computers loaded with InTouch and Concept programming tools to be used throughout the training course.

Course Objectives:

Introduce MACO DS Hardware (Optima PC, ASB's, Terminal I/O)
Review Barber-Colman's Standard Application's for the Extrusion and Blowmolding Markets.
Introduce MBPASB Server (Modbus Plus Server)
Introduce Concept Programming Tools
  • Create a Project
  • Review I/O Mapping
  • Programming in LD (Relay Ladder Diagram)
  • Programming in SFC (Sequential Function Chart)
  • Programming FBD (Function Block Diagram)
  • Programming DFB (Derived Function blocks)
  • Programming in ST (Structured text)
  • Printing Documentation of Concept Applications

Week 1 - MACO DS Operations Schedule
1.1 Course Introductions and Course Overview
1.2 Marketing/Sales Presentation
  • Sales Brochures
  • Data Bulletins
  • Price Sheets

1.3 MACO DS Structure
1.4 Optima PC
  • Hardware Review
  • Adding New Hardware
  • Adding Memory
  • Windows NT Setup
  • Installing New Fonts
  • Flat Panel Display
  • Keyboard Functionality
  • Function Keys
  • Machine Function Keys
  • Hard Drive Configuration
  • Environmental Specifications
  • Troubleshooting/Application Tips
1.5 ASB (Application Specific Blocks)
  • Hardware and Specifications
1.6 I/O Terminal Block, Communication (Modbus/Interbus S) and Option Adapters
  • Hardware and Specifications
1.7 MACO DS Demonstration
  • Review Barber-Colman's Standard Application Sets
1.8 Introduction of Concept
  • System Requirements
  • IEC 1131
  • Hierarchical Structure
  • Programming Languages
  • Functions and Function Blocks
  • Data Declarations
  • Networking (Modbus Plus and Interbus S)
1.9 Security
  • LAB-----Security
1.10 Loader
  • LAB-----Loader
1.11 Concept Development Tools
  • Creating a Project
  • Creating a Section
  • Configurator I/O mapping
  • LAB-----Creating a project and configuring
1.12 Variable Editor and Addressing
  • Review MACO DS Standard Variables and Addressing
  • Creating, Deleting, Revising, and Importing (Excel) Variables
  • LAB-----Variables

1.13 Programming Editors
1.14 32 Bit Simulator
1.15 FBD (Function Block Diagram)
  • LAB-----FBD
1.16 Downloading to PLC
1.17 FBD Scaling
1.18 DFB (Derived Function Block)
  • LAB-----DFB
1.19 DDT (Derived Data Type)
1.20 LD (Relay Ladder Diagram)
  • LAB----- LD
1.21 ST (Structured Text)
  • LAB----- ST
1.22 SFC (Sequential Function Chart)
  • LAB----- SFC

1.23 Code Importing and Exporting
1.24 Converter
1.25 Documentation Descriptions Comments Printing

M101 - MACO DS Course Outline Download
Programming
Course Times:

  • 8:00 a.m. to 4:30 p.m. (Classes will end at 11:30 a.m. on Friday)
  • Lunch will be provided from 12:00 p.m. to 1:00 p.m.
  • Breaks 10:00 a.m. and 2:00 p.m.

Recommended Prerequisites:

  • Basis PC knowledge using Windows NT 4.0 or Windows 95/98 Course
  • MACO DS Operations

Course Obectives:

Introduce InTouch Programming Tools

  • Create and Name an Application
  • Configure WindowMaker
  • Importing of Windows and Scripts from other Applications
  • Use WindowMaker to Create and Manipulate Objects
  • Configure WindowViewer
  • Import, Export, and Define Tagname Dictionary
  • Review ASB Source File Tagnames
  • Implement Application Security
  • Create Animation Links for Objects
  • Increase Application Functionality using Scripting
  • Configure and Create Alarms
  • Introduce and Indirect Tag Reference
  • Create Alarm Summary and History Windows
  • Create Real-Time Historical Chart
  • Configure I/O (DDE) Communications
  • Successfully Save Application and its Components then prepare for Trans
  • Review Mulit Language (keyword) Convention
  • Wizard Generation
  • Printing Documentation of InTouch Applications Components

MACO DS Programming Schedule - Week 2

2.1 Introduction of InTouch
  • System requirements
  • InTouch Components
  • InTouch Application Manager
  • Creating a New Application
2.2 InTouch Development Environment
  • WindowMaker Configuration
  • WindowMaker Elements and Toolbars
  • Creating, Duplicating, Deleting and Saving New Windows
  • Importing Windows and Scripts
  • Creating Text and Objects
  • Creating Symbols and Cells
  • Importing Graphics (*.BMP,*.PCX,*.TGA)
  • Wizard Tools
2.3 InTouch Run Time Environment
  • WindowViewer Configuration
  • LAB-----Windows and Graphics
2.4 Tagname Dictionary
  • Tagname Types
  • Defining a Tagname
  • Creating, Deleting and Revising Tagnames
  • DB Dump Utility using Excel
  • DB Load Utility using Excel
  • Printing Tagname Details
  • Review ASB Source File Tagnames
  • Tagname Browser (Filtering)
  • LAB-----Tagname Exercise
2.5 Indirect Tagname Referencing (Multi-Screen Functionality)
  • LAB-----Indirect Tagname Reference
2.6 Animation Links
  • Animating Text and Objects
  • Creating Touch and Display Links
  • Tagname Dot Fields
  • LAB-----Animations
2.7 Application Security
  • LAB-----Security
2.8 QuickScripts
  • Review all Types of Scripts and their Uses
  • LAB-----QuickScripts Course
2.9 Alarms
  • Configuring Tagname Alarm Attributes
  • Creating a Standard Alarm Display (Summary/Historical)
  • LAB-----Alarming
2.10 Trending Displays
2.11 I/O Communications (DDE)
  • MBPASB Server
  • I/O Tagnames
  • Access Names
  • Review of DDE Server and Setup
  • Establishing I/O Communications
  • LAB-----I/O communications to I/O Terminal Block
2.12 Multi-Language (Keyword) Convention
  • LAB-----Multi-Language

2.13 Saving and Transporting Application Components
2.14 Open Floor for Discussion
2.15 Conclusion and Evaluation

M102 - MACO EM-3 Course Outline

Download

EM-3 Installation and Configuration:

The EM-3 course provides the student with the necessary skills to install, configure and troubleshoot the EM-3 control system. Students are provided an EM-3 system to configure and test.

The course is intended for technicians who are applying the EM-3 into extrusion applications that match the preprogrammed specification of the EM-3. The full two week MACO DS class should taken for technicians who intend to startup applications requiring custom programming.

In order to obtain the greatest benefit from this class, technicians should have a basic understanding of PLCs and extrusion applications.

At the end of this class, technicians should be able to:

  • Specify the appropriate EM-3 blocks to control an extrusion line
  • Create wiring diagrams to install the EM-3 control system
  • Use the programming tools to load the program into the EM-3
  • Enter the necessary setpoints to configure the EM-3 application
  • Interpret diagnostic information to resolve problems

M105 - MACO 4000 Course Outline
Operations		 Download

Week 1 - MACO 4000 Operations Schedule

Course Times

  • 8:00 a.m. to 4:30 p.m (Classes will end at 11:30 a.m. on Friday)
  • Lunch will be provided from 12:00 to 1:00 p.m.
  • Breaks 10:00 a.m. and 2:00 p.m.

Description:

Course Objectives:

Monday
  • 8:15 a.m. Welcome and orientation
  • 8:30 MACO 4000 Hardware - overview of boards
  • 10:00 Break
  • 10:20 Temperature Control Theory
  • 12:00 p.m. Lunch
  • 1:00 Temperature Lab
  • 2:45 Break
  • 3:05 Linear Positioning Control
  • 3:35 Linear Positioning Lab
  • 4:35 Open Discussion
Tuesday
  • 8:00 a.m. Pressure/Flow Control
  • 8:45 Pressure/Flow Lab 10:00 Break
  • 10:20 Introduction to Process Control
  • 12:00 p.m. Lunch
  • 1:00 MACO 4000 closed loop process control
  • 2:30 Break
  • 2:50 Process control Lab
  • 4:15 Open Discussion
Wednesday
  • 8:00 a.m. MACO 4000 Optigrafix Screen Editor Demo
  • 8:45 MACO 4000 Standard User Screens
  • 10:00 Break
  • 10:20 MACO 4000 Standard User Screens (continued)
  • 12:00 p.m. Lunch
  • 1:00 MACO 4000 Standard System & Diagnostic Screens
  • 2:30 Break
  • 2:50 Machine Function Keys
  • 3:50 Printouts
  • 4:20 Open Discussion
Thursday
  • 8:00 a.m. MACO 4000 Control Relays
  • 10:00 Break
  • 10:20 MACO 4000 Control Relays (continued)
  • 11:00 MACO 4000 RLD Editor Demo
  • 12:00 p.m. Lunch
  • 1:00 RLD Exercises
  • 2:30 Break
  • 2:50 Control Relay Access Screen Exercises
  • 3:20 Down Loading Screens & RLD
  • 4:20 Open Discussion
Friday
  • 8:00 a.m. MACO 4000 Statistical Process Control
  • 9:00 SPC set-up and SPC Printouts
  • 10:00 Break
  • 10:20 Final Review and Question/Answers
  • 11:20 Class Evaluation
  • 12:00 p.m. Lunch
  • 1:00 Dismissal or optional individual discussions with plant personnel

M106 - MACO 4000 Course Outline
Programming		 Download

Week 2 - MACO 4000 Programming Class

Course Times:

  • 8:00 a.m. to 4:30 p.m. (Classes will end at 11:30 a.m. on Friday)
  • Lunch will be provided from 12:00 to 1:00 p.m.
  • Breaks 10:00 a.m. and 2:00 p.m.

Description:

Course Objective:

Monday
  • 8:15 a.m. Welcome and orientation
  • 8:30 Control Relay Definitions
  • 10:00 Break
  • 10:20 Control Relay Definitions (continued)
  • 12:00 p.m. Lunch
  • 1:00 Introduction to MACO RLD Editor
  • 1:30 Labels Editor
  • 2:00 Labels Exercise
  • 2:30 Break
  • 2:50 Logic Editor
  • 3:20 Logic Exercise #1
  • 4:20 Questions/Answers
Tuesday
  • 8:00 a.m. Logic Exercise #2
  • 10:00 Break
  • 10:20 Logic Exercise #3
  • 12:00 p.m. Lunch
  • 1:00 Logic Exercise #4
  • 2:30 Break
  • 2:50 Logic Exercise #4 (continued)
  • 4:20 Questions/Answers
Wednesday
  • 8:15 a.m. MACO 4000 Optigrafix Screen Editor
  • 8:30 Installing Optigrafix
  • 9:00 Screen editor functions, control functions, graphs
  • 10:00 Break
  • 10:20 Screen editor functions, control function, graphs (continued)
  • 12:00 p.m. Lunch
  • 1:00 Security Editor
  • 1:30 Message Editor
  • 2:30 Break
  • 2:50 Machine Functions Keys Editor
  • 3:50 Screen Editor Exercise
  • 4:20 Questions/Answers
Thursday
  • 8:15 a.m. Screen Editor Exercise (continued)
  • 10:00 Break
  • 10:20 Screen Editor Exercise (continued)
  • 12:00 p.m. Lunch
  • 1:00 Math Editor
  • 2:30 Break
  • 2:50 Download Screens
  • 4:20 Questions/Answers
Friday
  • 8:15 a.m. Download Screens (continued)
  • 9:00 Printouts
  • 10:00 Break
  • 10:20 Final Review and Question/Answers
  • 11:20 Class Evaluation
  • 12:00 p.m. Lunch
  • 1:00 Dismissal or optional individual discussions with plant personnel

M103 - MACO 6000 Course Outline
Operations		 Download

Week 1 - MACO 6000 Operations Schedule

Course Times:

  • 8:00 a.m. to 4:30 p.m. (Classes will end at 11:30 a.m. on Friday)
  • Lunch will be provided from 12:00 p.m. to 1:00 p.m.
  • Breaks 10:00 a.m. and 2:00 p.m.

Description:

Course Objectives:

Monday
  • 8:15 a.m. Welcome and orientation
  • 8:30 MACO 6000 Hardware - Operator Station
  • 9:00 MACO 6000 Hardware - Controller Card Rack, Power Supply, Data handler, Sequence Hydraulic, Digital Boards
  • 10:00 Break
  • 10:20 Temperature Wiring and Setup
  • 12:00 p.m. Lunch
  • 1:00 Temperature Control Lab
  • 1:45 Analog I/O Card Pressure Flow Setup Linear Postioning Setup
  • 2:30 Break
  • 2:45 Pressure/Flow and Linear Positioning Lab
  • 4:15 Open Discussion
Tuesday
  • 8:00 a.m. Basic Blow Molding Systems
  • 9:00 MACO 6000 Parison Control Card
  • 9:30 MACO 6000 Parison Control
  • 10:00 Break
  • 10:20 MACO 6000 Parison Control (cont)
  • 11:20 MACO 6000 Parison Calibration
  • 12:00 p.m. Lunch
  • 1:00 MACO 6000 Parison Control Lab
  • 2:30 Break
  • 2:50 MACO 6000 Parison Control Lab (cont)
  • 4:15 Open Discussion
Wednesday
  • 8:00 a.m. MACO 6000 Optigrafix Screen Editor
  • 8:30 System Screens
  • 9:00 User Screens
  • 10:00 Break
  • 10:20 MACO 6000 Screen Editor Lab
  • 12:00 p.m. Lunch
  • 1:00 MACO 6000 Screen Editor Lab (cont)
  • 2:30 Break
  • 2:50 Security Editor
  • 3:15 Machine Function Keys
  • 3:45 Printouts
  • 4:15 Open Discussion
Thursday
  • 8:00 a.m. MACO 6000 Control Relays Sequence, Temperature, Hydraulic, Parison, Data Handler
  • 10:00 Break
  • 10:20 MACO 6000 Labels Editor
  • 11:20 MACO 6000 Logic Editor
  • 12:00 p.m. Lunch
  • 1:00 MACO 6000 RLD Exercises
  • 2:30 Break
  • 2:50 MACO 6000 RLD Downloading
  • 3:00 MACO RLD Printouts
  • 4:15 Open Discussion
Friday
  • 8:00 a.m. MACO 6000 Statistical Process Control
  • 8:45 SPC set-up and Lab
  • 9:30 MACO 6000 Recipe and Insta-set Lab
  • 10:00 Break
  • 10:20 MACO 6000 Communications
  • 11:20 Class Evaluation
  • 12:00 p.m. Lunch
  • 1:00 Dismissal or optional individual discussions with plant personnel

M104 - MACO 6000 Course Outline
Programming		 Download

Week 2 - MACO 6000 Programming Class

Course Times:

  • 8:00 a.m. to 4:30 p.m (Classes will end at 11:30 a.m. on Friday)
  • Lunch will be provided from 12:00 p.m. to 1:00 p.m.
  • Breaks 10:00 a.m. and 2:00 p.m.

Description:

Course Objectives:

Monday
  • 8:15 a.m. Welcome and orientation
  • 8:30 Control Relay Definitions
  • 10:00 Break
  • 10:20 Control Relay Definitions (continued)
  • 12:00 p.m. Lunch
  • 1:00 Introduction to MACO RLD Editor
  • 1:30 Labels Editor
  • 2:00 Labels Exercise
  • 2:30 Break
  • 2:50 Logic Editor
  • 3:15 Logic Exercise #1
  • 4:15 Questions/Answers
Tuesday
  • 8:00 a.m. Logic Exercise #2
  • 10:00 Break
  • 10:20 Logic Exercise #3
  • 12:00 p.m. Lunch
  • 1:00 Logic Exercise #4
  • 2:30 Break
  • 2:50 Logic Exercise #4 (continued)
  • 4:15 Questions/Answers
Wednesday
  • 8:15 a.m. MACO 6000 Optigrafix Screen Editor
  • 8:30 Installing Optigrafix
  • 9:00 Screen editor functions, control functions, graphs
  • 10:00 Break
  • 10:20 Screen editor functions, control function, graphs (continued)
  • 12:00 p.m. Lunch
  • 1:00 Security Editor
  • 1:30 Message Editor
  • 2:30 Break
  • 2:50 Machine Functions Keys Editor
  • 3:50 Screen Editor Exercise
  • 4:15 Questions/Answers
Thursday
  • 8:15 a.m. Screen Editor Exercise (continued)
  • 10:00 Break
  • 10:20 Screen Editor Exercise (continued)
  • 12:00 p.m. Lunch
  • 1:00 Math Editor
  • 2:30 Break
  • 2:50 Download Screens
  • 4:15 Questions/Answers
Friday
  • 8:15 a.m. Download Screens (continued)
  • 9:00 Printouts
  • 10:00 Break
  • 10:20 Final Review and Question/Answers
  • 11:20 Class Evaluation
  • 12:00 p.m. Lunch
  • 1:00 Dismissal or optional individual discussions with plant personnel

M107 - MACO 4000/6000 Regional Operating / Maintenance Course Outline Download

MACO 4000 and 6000 Troubleshooting

The MACO 4000 and 6000 Troubleshooting course provides the student with the necessary skills to troubleshoot the MACO 4000 and 6000 control system. Students are provided with MACO control systems to test and configure the system.

The class provides the technician information on how to service MACO assemblies, quickly diagnose application problems and make minor screen and sequence changes.

The full two week MACO 4000 and 6000 class should taken for technicians who intend to create new applications versus modifying existing ones.

In order to obtain the greatest benefit from this class, technicans should have a basic understanding of PLCs and injection or blow molding applications.

At the end of this class, technicians should be able to:

  • Service MACO 4000 and 6000 controllers
  • Install MACO 4000 and 6000 hardware
  • Describe the operation and use Math, Timers, Counters, Switches and Security Levels
  • Modify relay ladder logic programs
  • Modify user screens
  • Understand temperature, parison and injection process control
  • Interpret error codes and determine correct actions
Last Updated Thursday, July 10, 2008

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