The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to evaluate PLCs and related control system component applications for safety, efficiency and function.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently:

identify and assess compliance with WHS and regulatory requirements, and risk management procedures

review dangers and effects of electricity on humans

identify PLC related systems and components, integrating principles and techniques

assess suitability of programming

investigate sustainability implications of PLC applications

assess and apply basic electrical and electronic, control principles, controller programming principles and techniques, software basic analysis and graphics skills and techniques

evaluate components of applications against application specifications for safety, economy and fitness for purpose

report and document results.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, then a simulated working environment must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of the MEM05 Metal and Engineering Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge.

Assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure correct interpretation and application.

Assessment may be applied under project-related conditions (real or simulated) and require evidence of process.

Assessment must confirm a reasonable inference that competency is not only able to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Assessment may be in conjunction with assessment of other units of competency where required.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

Required skills

Required skills include:

identifying features and functions of PLCs and control systems, including:

components

signal conditioning and power interfacing

networking and system supervision, data acquisition and systems control options

ensuring safe electrical working practice, including use of licensed personnel, where required

investigating sustainability implications of PLC applications

evaluating safety, condition, efficiency and functionality of PLCs and associated applications, including:

controller functions and programming

network and interfacing, including SCADA, communications protocols, standards and network topologies

suitability of HMIs and GUIs

compliance with WHS and regulatory requirements

applying WHS, regulatory and automation safety requirements, risk management and organisational procedures

reporting and documenting results of evaluation, including layouts, programs, flow charts or state diagrams and files

Required knowledge

Required knowledge includes:

features of a range of PLC and related control system component applications used in engineering environments

effects of electricity on humans, dangerous high currents and voltages and automated systems, regulatory requirements related to extra low, low and high voltage applications

relevant compliance requirements of WHS, regulations, codes of practice, standards, and risk assessment requirements for integrated manufacturing systems with particular emphasis on automation safety

hardware functions, options and integration into PLC and related control systems

input devices/sensors

output devices/actuators

PLCs

interfacing and signal conditioning

communications and networking options for devices

HMIs and GUIs

PLC architecture

Input/Output (I/O) functions and arrangements

typical input signals and sensor/transducers

shielding and twisted pairing for noise mitigation

calibration techniques

reading of discrete levels from analog input data (other analog I/O functions not required by this unit)

input signal conditioning

digitally driven output devices and interface requirements power supply

programming techniques and options

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

PLC applications

PLC applications may include:

industrial (e.g. motor controllers, fault detectors and power controllers)

multi-axis machine control

process automation

packaging, shrink-wrapping, labelling and palletising

utilities, water treatment and effluent treatment

industrial distributed control system

amusement rides

agricultural machine and irrigation controllers

military and aerospace automation (except aircraft systems)

mineral and chemical, and petroleum processing

PLC software

PLC software and programming language may cover:

ladder diagram (LD) – graphical

function block diagram (FBD) – graphical

structured text (ST) – textual

instruction list (IL) – textual

sequential function chart (SFC) – elements to organise programs for sequential and parallel control processing

PLC programming language standards may comply with IEC 61131-3 or other standards

Appropriate technical and professional assistance

Appropriate technical and professional assistance may include:

technical support and advice relating to elements which have intrinsic dangers, such as:

high pressure

energised fluid vessels

high temperatures and heat energy capacity

wiring with high current control voltages above extra low voltage

professional support for technologies may include:

specialist electric motor drives and controllers

specialist materials, plastics, metal alloys and nano materials

special processes, foundry, alloy welding, heat treatment, sealing and fastening

WHS, regulatory requirements and enterprise procedures

WHS, regulatory requirements and enterprise procedures may include:

WHS Acts and regulations

relevant standards

codes of practice from Australian and overseas engineering and technical associations and societies

risk assessments

registration requirements

safe work practices

state and territory regulatory requirements

Standards and codes

Standards and codes refer to all relevant Australian and international standards and codes applicable to a particular PLC related task

Automation safety

Automation safety refers to the reliance on emergency stop, failsafe design, redundancy, system interlocks and data integrity. Standards apply to general plant design and use as well as the ‘functional safety of safety-related electrical, electronic and programmable electronic control systems’

Data and communications protocols and standards

Data and communications protocols and current standards may include:

layered communications and networking protocols, such as Open Systems Interconnection Model (OSI Model) – 7 layers

TCP/IP Internet Protocol Suite {Transmission Control Protocol (TCP) and the Internet Protocol (IP)} – 4 or 5 layers

IEEE 802 Wireless PAN, LAN, MAN and WPAN standards

interface standards, such as RS232 and RS485, Fieldbus, Modbus and DNP3.0

Network topologies

Network topologies may include:

daisy-chain, star, ring, branch, linear and tree

wired and wireless options

Sustainability

Sustainability is used to mean the entire sustainable performance of the organisation/plant, including:

meeting all regulatory requirements

conforming to all industry covenants, protocols and best practice guides

minimising ecological and environmental footprint of process, plant and product

maximising economic benefit of process plant and product to the organisation and the community

minimising the negative WHS impact on employees, community and customer