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

Part B: Course Detail

Teaching Period: Term1 2011

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:

Verify, document and report programming activities

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)
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)
2.8 Methods for dealing with unexpected situations are selected on the basis of safety and specified work outcomes.

 

Element:

Prepare to develop, enter and verify program

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)
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.

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. 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.
3. Examples of storage mediums are IC storage, hard disks, servers .


Learning Outcomes



Details of Learning Activities


• Tutorial activities to consolidate Safety Engineering concepts, 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 a least 3 hours per week for independent study (in addition to scheduled sessions) to do project research, design, construction, testing and problem solving activities.


Teaching Schedule

WeekSession Details                                                                                      Activity
1Occupational health and safety induction
Introduction to automation and control systems.
Number systems and codes
Lab 1. Risk analysis
Lab 2.Converting numbers
2 PLC system components and arrangement
Status LEDs
CPU memory organisation
Discrete field devices
Pneumatic system components
Lab 3. Opening a project file, compiling and downloading the program to the PLC
Lab 4. Changing PLC modes
Lab 5. Creating a new project
3 EC61131 programming languages(IL, ST, LD,SFC, and FB)
Introduction to the Omron CX-Programmer development environment
Understanding the CX project tree(Symbols table and program sections)
PLC modes of operation (Program, Monitor, and Run modes)
Lab 6. Creating variables in the symbols tables
Lab 7. Monitoring CPU memory
4Introduction to programming concepts
CPU unit operation and cycle time
Review the discrete I/O interface and /O addressing
Lab 8. Configuring the serial port and connecting to the PLC
Lab 9. Setting up the I/O table
5Logic gates
Introduction to Ladder Diagram
Contacts and coils
Lab 10. On-line program editing
6Latching instructionProject 1. Simple motor control application
7Decrementing timer instructions. On-delay, off-delay , and self-resetting implementationsProject 2. Two-cylinder pneumatic machine
8Decrementing and reversible counter instructionsProject 3. Two-cylinder pneumatic machine
9Mid-semester exam  
10Controlling sequential processes
State diagrams and flowcharts for program design
State actions and state transitions
Program development in Ladder Diagram
Project 4. Two-cylinder pneumatic machine
11Adding reset functions to the sequential program flow
Adding timers to the sequential program flow
Project 5. Two-cylinder pneumatic machine
12Adding automatic and manual mode to the sequential program flowProject 6. Two-cylinder pneumatic machine
13Adding counters to the sequential program flowProject 7. Two-cylinder pneumatic machine
14Adding emergency stop to the sequential program flowProject 8. Two-cylinder pneumatic machine
15Introduction to SFCProject 9. Parking gate application
16Final exam  



Learning Resources

Prescribed Texts


References

Rexford,K & Guiliani, P 2004, Electrical Control for Machines, Sixth Edition.  

Rehg, J & Sartori, G 2009, Programmable Logic Controllers, Second Edition.


Other Resources

Omron Industrial Automation. eData DVD May 2010.


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 6 Projects.

Projects 2, 3, 4 completed as scheduled. All specified control functions must be demonstrated. 10 marks.

Mid-semester exam  30 marks.

Projects 6, 7, 8 completed as scheduled. All specified control functions must be demonstrated. 10 marks.

Final exam.  50 marks.


Assessment Matrix

Competency National Code

Competency Title Assessment typeAssignmentProjectProgressive TestIn class Activity/LAb
UEENEED007B
PLC Programming various items            X        X      X

Other Information

Please refer to class information

Course Overview: Access Course Overview