This unit involves the skills and knowledge required to develop, enter and verify word/text and analogue control programs for programmable logic controllers (PLCs).

It includes identifying, developing and entering industrial control system programs, as well as monitoring, verifying and documenting programming activities. It also includes installing and testing programs for an industrial system requiring advanced control functions using structure logic and acceptable design techniques.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Identifyindustrial control system

1.1

Work health and safety (WHS)/occupational health and safety (OHS) requirements and workplace procedures are identified and applied

1.2

Hazards are identified, risks are assessed and control measures implemented

1.3

Mode of operation of control system is determined from job specifications and consultations with relevant person/s

1.4

Equipment, software and testing devices for work are obtained in accordance with workplace procedures and checked for correct operation and safety

1.5

Installation of programmable controller is checked for compliance with regulations, relevant industry standards and job specifications

2

Develop and enter programs for industrial control system

2.1

WHS/OHS risk control measures and procedures for carrying out the work are followed

2.2

Control solutions are developed and documented based on operational mode and using acceptable methods for designing control system containing numeric variables and values

2.3

Control solution is entered using information technology and appropriate software

2.4

Programming elements are written and used to manipulate word data

2.5

Program control values are assigned using applicable numbering systems and codes

2.6

Programs are written to read and write analogue signals

2.7

Arithmetic functions are used to scale analogue inputs to a specified input range

2.8

Arithmetic functions are used to un-scale an engineering value to drive an analogue output

2.9

Unplanned situations are responded to in accordance with workplace procedures in a manner that minimises risk to personnel and equipment

3

Monitor, verify and document programming activities

3.1

Device operation is tested in accordance with workplace procedures and manufacturer specifications

3.2

Programming is tested in accordance with specified control mode requirements

3.3

Operating anomalies are identified and corrected in accordance with workplace procedures

3.4

WHS/OHS work completion risk control measures and procedures are followed

3.5

Control system specifications and programs are documented in accordance with workplace procedures

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

consulting with relevant person/s

correcting programming anomalies

dealing with unplanned events/situations in accordance with workplace procedures in a manner that minimises risk to personnel and equipment

determining modes of operation from job specifications

developing and entering programs for industrial control systems

developing control solutions

developing control systems to required operating functions and parameters

documenting control system and programming clearly

entering programming functions and parameters

identifying industrial control systems/programs

installing programmable controllers

monitoring, verifying and documenting programming activities

obtaining relevant equipment, software and testing devices

testing and verifying device operations

using arithmetic functions to scale and un-scale engineering values

using word data, numbering systems and codes.

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:

numbering systems and codes, including:

types of numbering systems

codes

application of codes

conversion between codes and numbering systems

use programmable logic controller (PLC) software, including:

install programming software

memory mapping

computer software

manufacturer's instruction manuals

PLC hardware, including selection, installation, configuration, signals and resolution

analogue modules, including:

comparison of signals

resolution of analogue signals

connection of analogue field

programming

loop fault

data manipulation, including:

IEC data types

word structure

select bits transfer

move

block transfer

compare

block compare

and words

mask

maths function

scaling and un-scaling

special registers

shift register

multiplexing

sequencer, including:

application

event and time driven

programming application

languages including:

ladder

code structure format (CSF)

state logic (STL)

diagnostics, including:

special register

software diagnostics

edits

rung scan faults

complex industrial process, including:

describe process

write program

edit program

connect and run program

documentation

analogue and word programming

analogue modules

control systems and programmable controllers

job safety assessments or risk mitigation processes

numbering systems and codes

relevant arithmetic functions

relevant equipment, software and testing devices

relevant manufacturer specifications

relevant WHS/OHS legislated requirements

relevant workplace documentation

relevant workplace policies and procedures.

Assessors must hold credentials specified within the Standards for Registered Training Organisations current at the time of assessment.

Assessment must satisfy the Principles of Assessment and Rules of Evidence and all regulatory requirements included within the Standards for Registered Training Organisations current at the time of assessment.

Assessment must occur in workplace operational situations where it is appropriate to do so; where this is not appropriate, assessment must occur in simulated workplace operational situations that replicate workplace conditions.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Resources for assessment must include access to:

a range of relevant exercises, case studies and/or other simulations

relevant and appropriate materials, tools, equipment and personal protective equipment (PPE) currently used in industry

applicable documentation, including workplace procedures, equipment specifications, regulations, codes of practice and operation manuals.

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

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 word/text and analogue control programs for PLCs must include at least five of the following:

hardware configuration

software configuration

number systems

converting between systems

basic diagnostics

binary word structure

integer (INT), double integer (DINT) and REAL arithmetic operations

scaling and un-scaling engineering units

Electrotechnology

Instrumentation & Control