Course Title: Develop, enter and verify programs for programmable logic controllers using ladder instruction set

Part B: Course Detail

Teaching Period: Term1 2009

Course Code: EEET6790C

Course Title: Develop, enter and verify programs for programmable logic controllers using ladder instruction set

School: 130T Vocational Engineering

Campus: City Campus

Program: C6085 - Advanced Diploma of Electrical - Technology

Course Contact: Program Manager

Course Contact Phone: +61 3 9925 4468

Course Contact Email: engineering-tafe@rmit.edu.au


Name and Contact Details of All Other Relevant Staff

Zoran Savic
Phone:
zoran.savic@rmit.edu.au

Nominal Hours: 60

Regardless of the mode of delivery, represent a guide to the relative teaching time and student effort required to successfully achieve a particular competency/module. This may include not only scheduled classes or workplace visits but also the amount of effort required to undertake, evaluate and complete all assessment requirements, including any non-classroom activities.

Pre-requisites and Co-requisites

Nil

Course Description

This unit covers development, installation and testing of programs for programmable logic controllers (PLC) for a system requiring extended control functions. It encompasses working safely, applying knowledge of control systems, control system development methods, ladder logic control functions, using ladder instruction set, following written instructions and documenting program development and testing activities.


National Codes, Titles, Elements and Performance Criteria

National Element Code & Title:

UEENEED007B Develop, enter and verify programs for programmable logic controllers using ladder instruction set

Element:

Develop control system and enter and test program

Performance Criteria:

1. OHS procedures for a given work area are identified, obtained and understood through established routines and procedures.
2. Established OHS risk control measures and procedures are followed in preparation for the work.
3. Safety hazards that have not previously been identified are reported and advice on risk control measures is sought from the work supervisor.
4. Control system scenario is determined from job specifications of the process/plant/machine to be controlled, and through consultation with appropriate person(s).
5. Equipment, software and testing devices needed to carry out the work are obtained and checked for correct operation and safety.
6. Installation of programmable controller is checked for compliance with regulations and job specification.

Element:

Prepare to develop, enter and verify program

Performance Criteria:

1. Established OHS risk control measures and procedures for carrying out the work are followed.
2. Circuits/machines/plant are checked as being isolated where necessary in strict accordance OHS requirements and procedures.
3. Control solutions are developed and documented based on the specified control mode and using acceptable methods for designing control systems.
4. Developed control system is converted to an appropriate form, such as flow, state and ladder diagrams, using a personal computer and software applicable to the programmable controller into which the program is to be entered.
5. Program is entered into the programmable control using a personal computer and appropriate software.
6. Entered instructions and settings are tested as meeting those specified in by the control system scenario.
7. Appropriate methods and tools are used to test control systems and operating faults and anomalies are identified and rectified.
8. Methods for dealing with unexpected situations are selected on the basis of safety and specified work outcomes.

Element:

Verify, document and report programming activities

Performance Criteria:

1. OHS work completion risk control measures and procedures are followed.
2. Program is transferred from a programmable controller to an external medium for storage.
3. Control system specification and program are documented in accordance with established procedures.
4. Work completion is reported and appropriate personnel notified in accordance with established procedures.


Learning Outcomes



Details of Learning Activities

The leaning activities include a lecture followed by practical lab/tutorial involving hands-on work with equipment. Note. The machinery, automation equipment and software are only available in the labs and only during the scheduled times as per the timetable. In addition to this, students are expected to do 4 hours per week researching information from technical standards, textbooks, on-line resources and preparing PLC programs for labs.  


Teaching Schedule

Week Number Date (Monday) Topic Delivered Assessment Task
1 The basic legal requirements covering occupational health and safety in the workplace
encompassing:
• General aims and objectives of the relevant state or territory legislation relating to OHS.;
• Employer and employee responsibilities, rights and obligations
• Major functions of safety committees and representatives); and
• Powers give to Occupational Health and Safety Inspectors.
• identifying and reporting potential workplace hazards
• methods of prevention of safety hazards within a typical workplace environment

Lab/Tutorial. Identifying potential workplace hazards assessing risks and suggesting measures for risk reduction.

2 Programmable controller basics
a) Regulatory requirement/limitations
b) Basic control system concepts:
• Input, process and output
• Relay control, static logic control and programmable control.
c) Typical applications of PLCs
d) PLC system components and arrangement

Lab/Tutorial. Introduction to CX Programmer. One actuator control application

3 Programmable controller basics
e) Definitions and terminology:
• PLC input/output (I/O), memory (RAM, ROM, E2PROM), CPU and power supply.
f) Basic PLC operation
• scan cycle
• basic programming rules
• addressing for I/O
• modes monitor/halt/run
g) Connection of input and output devices.

Lab/Tutorial. PLC memory structure and address allocation. One actuator control application

4 - 5 PLC programming basics
a) Basic control system design methods
b) Programming basics encompassing:
• Clearing memory
• Using ladder format
• Working with Boolean statement
c) Programming monitoring and editing basic control functions.

Note.
Examples of basic control functions are Switching Latching, Timing, Counting, and
Master control.

Lab/Tutorial. One actuator control application

6 Test 1 30%
7 - 12 PLC programming
a) Extended control system design methods using ladder logic

b) Advance discrete programming functions and controls encompassing:
• derived timers (off delay,
• self resetting,
• constant duty cycle),
• reversible counters,
• cascading timers,
• cascading counters,
• combining timers and counters,
• internal relays/flags/markers,
• latching relays (set/reset),
• jump instructions,
• master control instructions,
• bit shift registers,
• scan time considerations,
• one shot,
• retentive (power fail) functions,
• simple step sequence instructions

Labs/Tutorials for this period. One actuator control application. Extended control functions

13 Test 2 30%
14-17 Electrical installations, programmable logic controller requirements
a) Performance for safety requirements and regulations encompassing:
• Protection against mechanical movement
• environmental limitations/protection
Note. Safety requirements are describe in Australian Standards (e.g. AS 3000:2000) and adopted IEC Standards.

b) Regulations and manufacturer’s installation requirements encompassing:
• physical positioning of CPU and I/O racks
• routing signal/power cables
• signal/power earthing requirements
c) Selection of related control equipment and devices

18 Test 3 40%


Learning Resources

Prescribed Texts


References


Other Resources

Automation with programmable logic controllers. Peter Rohner.


Overview of Assessment

This course may be assessed through a range of practical exercises, and progressive tests.


Assessment Tasks

The tests involve developing a control system for a machine in accordance with a given specification. 

Assessment task 1: 30%
Practical exercise to demonstrate occupational health and safety in the workplace, and PLC control system development for a single actuator machine.

Assessment task 2 : 30%
Practical exercise to demonstrate occupational health and safety in the workplace, and PLC control system development for a two actuator machine. Includes structured programming in Ladder Diagram language.

Assessment task 3: 40%
Practical exercise to demonstrate occupational health and safety in the workplace and PLC control system development for a two actuator machine. Includes state flow diagram and structured programming in Ladder Diagram language.


Assessment Matrix

Competency National CodeCompetency TitleCluster TitlelabAssignmentProject/
Presentation
TestWIL
UEENEED007BDevelop, enter and verify programs for programmable logic controllers using ladder instruction set X  X 

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