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

Part B: Course Detail

Teaching Period: Term1 2010

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 +613 992 54468
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:

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

Element:

Prepare to develop, enter and verify program

Performance Criteria:

2.1 Established OHS risk control measures and procedures for carrying out the work are followed.
2.2 Circuits/machines/plant are checked as being isolated where necessary in strict accordance OHS requirements and procedures.
2.3 Control solutions are developed and documented based on the specified control mode and using acceptable methods for designing control systems.
2.4 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. (See Note 1)
Note 1. Example of control functions are 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
2.5 Program is entered into the programmable control using a personal computer and appropriate software.
2.6 Entered instructions and settings are tested as meeting those specified in by the control system scenario.
2.7 Appropriate methods and tools are used to test control systems and operating faults and anomalies are identified and rectified. (See Note 2)
Note 2. Examples of control system testing methods and tools are monitor mode as an aid to fault finding, inbuilt hardware/software diagnostics and use of error codes.
2.8 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:

3.1 OHS work completion risk control measures and procedures are followed.
3.2 Program is transferred from a programmable controller to an external medium for storage. (See Note 3)
Note 3. Examples of storage mediums are IC storage, hard disks, servers
3.3 Control system specification and program are documented in accordance with established procedures.
3.4 Work completion is reported and appropriate personnel notified in accordance with established procedures.


Learning Outcomes



Details of Learning Activities

Students will participate face to face in

classroom tutorial activities to consolidate the theory of Fluid Power concepts, PLC operating principles and introduction to circuits designed for linear pneumatic actuators and asynchronous sequential machine control systems.

Practical activities to develop skill in PLC basic programming, design basic logic control and construction of control circuits, test to verify the performance specification, diagnose and debug faults, verify the completion of the commission.

Work performance simulation projects involving the design and construction PLC circuits, development of testing procedure to verify the performance specification, diagnosis of faults in the systems and repair the fault. Specifications will be provided with work simulation (team or individual basis) or may be negotiated to suit a workplace based application
Projects may be undertaken as part of a team or individual basis.

It is expected that students would require approximately 20% of course hours to be allocated for independent study to do project research, design, construction, testing and problem solving activities.


Teaching Schedule

week 1

Course outline and assessment
• Introduction to course guide
• OH&S issues and good practices
• Introduction to PLC Control System
• Demonstration of typical applications

 In class activity 1
Lab/Tutorial
Group discussion, Q&A
OH&S practice in Automation Centre

week 2

PLC System components & arrangement
• PLC Memory area structure
• Manufacture’s installation requirements
• Various type of PLCs
• Basic structure of a PLC
• Operating principles
• PLC I/O configuration
• Basic Logic functions: Yes, Not, AND.OR,

In class activity 2: Lab/Tutorial

program basic logic functions into PLCs and verify the logic performance by using toggle switches to simulate inputs

week 3

Discrete field devices.
• Introduction to fluid power system and components
• industrial switches : push button selector, toggle
• industrial sensors : position, flow, proximity, photoelectric, optical
• actuators: linear and rotating, electromagnetic

 In class activity 3, Lab/Tutorial

Interface PLC with pneumatic actuator

week 4

PLC operation and software
• Modes of operation. Program, Monitor, Run.
• Power up routine.
• OMRON CX-one software
• RS232 serial communications to PLC
• Programming basics with
Ladder Format
• on-line simulation

In class activity 4 , Lab/Tutorial.
Set up serial communications to PLC. Change PLC modes.
Download/upload program
Operate machine

week 5

PLC programming
• Basic control system design concepts
• Process flowchart
• Set up I/O requirements
• IEC61131 programming languages
• Ladder Diagram manipulation
• Scan cycle
Programming monitoring and editing
• Hand out:
Assignment 1-10%
specifications and assessment criteria

in class activity 5: Preparation of work

week 6

PLC programming
• Latching operation. LD latching device.
Memory device, keep relays
• Concepts to design a basic PLC controlled pneumatic system


• Assignment 1, task 1
Demonstration
Acquire Assessor’s approval signature

week 7

PLC programming
• work on assignment 1, task 2, Reciprocation of pneumatic actuator-two actuators
• timers and counters

Assessment:

Assignment 1- task 2
Demonstration , Acquire Assessor’s approval signature

week 8

Working on assignment 1 task 3-applications of timers
Task involve general practice of : Design, programming, commissioning and faults finding leads to final demonstration of working program

Assessment:

Assignment 1- task 3
Demonstration
Acquire Assessor’s approval signature

week 9

Working on assignment 1 task 4-applications of counters
Assignment 1 involve general practice of :

Design, programming, commissioning and faults finding leads to final demonstration of working program

Assessment:

Assignment 1- task 4,
Demonstration ,acquire Assessor’s approval signature

week 10

PLC programming

• Demonstration of assignment 1 all tasks combined
• Revision on all topics

Assessment:

Assignment 1- all tasks combied demonstration, Written report submission 10%

week 11

Progressive test 1 written , open book (reference text book only, no notes allowed) 25% towards the final mark allocated to this course

week 12

PLC programming
• Introduction to sequential control design concepts
• step-action diagrams
• Sequencers. Process driven program flowcharts.
• Hand out Assignment 2-10%
Specifications and assessment criteria

In class activity 6 , Lab/Tutorial

Preparation of works and report requirements

week 13

Working on assignment 2
• Assignment 2 involve general practice of : sequential control design, programming, commissioning and faults finding leads to final demonstration of working program
• Complete task 1-develop flow chart and complete step-action diagram

Assessment:

Assignment 2- task 1, presentation , Acquire Assessor’s approval signature

week 14

Working on assignment 2 completion of task 2-create Ladder diagram using CX-one programmer , run simulator and faults finding and rectify to meet specifications of assignment 2

Assessment:

Assignment 2- task 2, Demonstration , Acquire Assessor’s approval signature

week  15

Working on assignment 2 completion of task 3-application of timers in sequential control design

Assessment:

Assignment 2- task 3, Demonstration , Acquire Assessor’s approval signature

week  16

• Demonstration of assignment 2, all tasks combined

• Revision on all topics covered between week 12 –week 15

Assessment:

Assignment 2-, all tasks combine and demonstration, written report submission 10%

week  17

Progressive test 2 written , open book (reference text book only, no notes allowed) 25% towards to the final mark allocated to this course


week  18

Practice test- project-
Completion of practice test or project

Practice test- project-
Completion of practice test or project

This is runs through various sessions, between week 12-week 17, please make appointment with your teacher
Completion within given time frame 20%

Week 19

catch-up session



Learning Resources

Prescribed Texts


References


Other Resources

Omron on line Manuals

class notes avaliable in s drive


Overview of Assessment

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


Assessment Tasks

Assessment for this course consists of 2 Written Tests and 1 Practical Tests(project) as outlined in the table below.

For the Practical Test you will be given a brief which specifies the requirements of a PLC control system for which you are to create a project in class within a given time limit.

When the time is up, your Assessor will come around to assess you.

Allocation of Marks:

Assignment 1 10%  Due Wk 10
Written Test 1 25 %  Due Wk 11
Assignment 2 10% Due Wk 16 
Written Test 2 25 %  Due Wk 17
Practical Test/Project 20% Self paced , conducted between wk 12-Wk 17
In Class activities 10%  Due at the end of each class session


Assessment Matrix

Competency National Code

Competency Title Assessment typeAssignmentprojectProgressive TestIn class Activity/LAb
UEENEED07B
PLC Programming various items        X    X        X      X

Other Information

Please refer to class information

Course Overview: Access Course Overview