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Elements and Performance Criteria

1. Identify control system requirements
   • PLC operating functions, parameters and specifications are determined from relevant documentation, electrical drawings or persons to determine the control system scope of work
2. Work health and safety (WHS)/occupational health and safety (OHS) requirements and workplace procedures for a given work area are identified and applied
3. Control system scenario is developed from job specifications of process/plant/machine controlled through consultation with relevant person/s
4. PLC block diagram is developed using industry standard symbols
5. Infotechnology equipment, software and measuring devices needed to carry out the PLC work are obtained and checked for correct operation and safety
6. Installation of PLC is checked for compliance with relevant industry standards, regulations and job specifications
7. Develop control system, enter and test program
   • Established WHS/OHS risk control measures and procedures for carrying out the work are followed.
8. Circuits/machines/plant are checked and isolated in accordance with workplace procedures
9. Control system solutions are developed and documented based on specified control mode and using acceptable methods for designing control systems
10. Developed control system is converted to an appropriate form
11. Program is entered into the PLC using appropriate infotechnology and software
12. Entered instructions and settings are tested in accordance with job specifications by control system scenario
13. Appropriate methods and tools are used to test control system and operating faults and anomalies are identified and rectified
14. Unplanned situations are responded to in accordance with workplace procedures, in a manner that minimises risk to persons and equipment
15. Verify document and report programming activities
    • WHS/OHS work completion risk control measures and procedures are followed
16. Program is transferred from PLC to external medium for storage
17. Control system specification and program are documented in accordance with workplace procedures
18. Work completion is documented and relevant persons notified in accordance with workplace procedures

Range Statement

Range is restricted to essential operating conditions and any other variables essential to the work environment. Non-essential conditions may be found in the UEE Electrotechnology Training Package Companion Volume Implementation Guide.
Developing, entering and verifying programs for PLCs must include at least five (5) of the following functions/controls:	bit shift registers cascading counters cascading timers combining timers and counters constant duty cycle derived timers (off delay) internal relays/flags/markers jump instructions latching relays (set/reset) master control instructions one shot retentive (power fail) functions reversible counters scan time considerations self-resetting simple step sequence instructions

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Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements, performance criteria and range of conditions on at least two separate occasions and include:

applying relevant work health and safety (WHS)/occupational health and safety (OHS) requirements, including identifying programmable logic controller (PLC) risk control measures connecting the PLC correcting programming anomalies dealing with unplanned situations in accordance with workplace procedures in a manner that minimises risk to persons and control equipment developing applications for PLC functions including operation and programming of inputs and outputs developing a control system solution to specified operating functions and parameters developing a PLC block diagram, including identifying industry standard PLC symbols documenting control system and programming identifying PLC modules and applications programming a PLC using industry standard methods such as master control, jump, shift register, step sequencing, timers and counters testing and verify control system inputs and outputs operation transferring programs to PLC documenting control system and programming clearly identifying non-compliance conditions of device installation converting control system to a PLC program entering programming functions and parameters correctly transferring program to external storage.

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Knowledge Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements, performance criteria and range of conditions and include knowledge of: PLC introduction including: evolution of the programmable controller and applications relay control, static logic control and programmable control programmable controller block diagram (inputs and outputs) programmable controller advantages, symbols and functions numbering systems start-up procedures programming inputs and outputs operation of programmable controller inputs PLC operation: scan cycle basic programming types of PLC programs, including: ladder diagrams basic programming program modification ladder diagram development connecting the programmable controller programming timers, including: purpose of timers timer instructions on-delay and off-delay timer instruction programming timers retentive and non-retentive timers cascading timers the self-resetting timer monitoring timers circuit conversion programming counters, including: counter instructions retentive and non-retentive, up/down, programming, self-resetting and cascading counters circuit conversion program storage, including: PLC terms memory the programmable read only memory (PROM) pack printing ladder diagrams PLC input and output modules, including: purpose of modules analogue, dry contact, alternating current (a.c.) and direct current (d.c.) input modules relay, triac, transistor and analogue output modules PLC installation requirements, including: installation precautions safety systems mounting the PLC installation documentation routing signal and power cables earthing requirements master control, including: master control relay master control relay ladder diagram programming master control relays jump function, including: jump function jump function ladder diagram programming jump functions the shift register, including: purpose of registers the shift register shift register operation clock input shift register requirements programming shift registers the step sequencer, including: step sequencers step sequencer operation clock input step sequencer requirements programming step sequencer PLC diagnostics and fault finding, including: PLC fault finding controller status input/output (I/O) faults program faults relevant risk mitigation processes relevant WHS/OHS legislated requirements relevant workplace documentation, including relevant industry standard documentation and regulations related to PLCs relevant workplace policies and procedures.

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