Course Title: Develop, enter and verify programs for industrial control systems using high level instructions

National Element Code & Title:

UEENEED009B Develop, enter and verify programs for industrial control systems using high level instructions

Performance Criteria:

2.1 Established OHS risk control measures and procedures for carrying out the work are followed.
2.2 Control solutions are developed and documented based on the operational mode and using acceptable methods for designing control system that contain numeric variables and values.
2.3 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.
2.4 Programming elements are written and used to manipulate word data. (See Note 1)
1. Example of programming elements are loading data from discrete input switches to an internal register; manipulating internal registers using arithmetic, logical and other functions; driving outputs from internal registers; utilizing thumbwheel switches and displays; manipulating double registers with
mathematical operations; loading constants, variables and presets in and out of memory; using masking of registers to obtain desired data; using tables for the storage of data.
2.5 Program control values are assigned using an applicable numbering system and code. (See Note 2)
2. Examples are binary and signed binary, numbering systems and codes such as BCD or ASCII codes
2.6 Programs are written to read and write analog signals offset using applicable software tools.
2.7 Arithmetic functions are used to scale analog inputs to a specified span.
2.8 Program is entered into the programmable control using a personal computer and appropriate software.
2.9 Methods for dealing with unexpected situations are selected on the basis of safety and specified work outcomes.

Performance Criteria:

3.1 Device operation is tested in strict accordance OHS requirements and procedures.
3.2 Entered instructions and settings are tested as meeting those specified for the control mode requirements.
3.3 Appropriate methods and tools are used to test and monitor control programs and operating faults, anomalies are identified and rectified. (See Note 3)
3. Examples of control program testing and monitoring methods and tools are locating status bits (flags); examining and modifying watchdog timer; investigating the implications of rung positioning in relation to scan.
3.4 OHS work completion risk control measures and procedures are followed.
3.5 Control system specification and program are documented in accordance with established procedures.

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 Mode of operation of the control system is determined from job specifications of the process/plant/machine to be controlled, and through consultation with appropriate person(s).
1.4 Equipment, software and testing devices needed to carry out the work are obtained and checked for correct operation and safety.
1.5 Installation of programmable controller is checked for compliance with regulations and job specification.

Discrete control and process control systems. Introduction to IEC 61131 Sequential Function Chart (SFC).

UEENEED009B: 1.1, 1.2, 1.3, 1.4, 1.5, 2.1, 2.2, 2.3, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Floating point arithmetic instructions (add, subtract, multiply, divide, square root) and logical instructions (<, >, =,≠) in LD. Data format conversion in LD.Floating point arithmetic instructions (add, subtract, multiply, divide, square root) and logical instructions (<, >, =,≠) in LD. Data format conversion in LD.

UEENEED009B: 1.3, 2.2, 2.3, 2.8, 2.9, 3.2, 3.3, 3.4, 3.5

Bit-shift and word-shift registers. Omron bit-shift instruction in LD. Typical applications.

UEENEED009B: 1.3, 2.2, 2.3, 2.4, 2.5, 2.7, 2.8, 3.2, 3.3, 3.4, 3.5

Analogue field devices and I/O interfacing (current and voltage signals). Omron analogue input and output modules (resolution, scaling, and signal offset). Scaling analogue input data by programming.

UEENEED009B: 1.1, 1.2, 1.3, 1.4, 1.5, 2.1, 2.2, 2.3

Project MPS distribution machine and MPS testing machine.

Indirect and indexed addressing.

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Project

Open-loop and closed-loop control systems

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

PID control and the PID instruction

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Introduction to industrial communication networks

UEENEED009B: 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.1, 3.2, 3.3, 3.4, 3.5

Programmable logic controllers, James A. Rehg & Glenn J. Sartori.