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Programmable Logic Controllers

This course will enable a learner to interrogate a PLC system, Allen Bradley or Siemens PLC boards, to determine the cause of equipment faults in modern manufacturing equipment.

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Description

Learner Profile:

Maintenance personnel who would like to enhance their skills by using PLC logic as a means of diagnosing machine faults.

Learner prerequisites:

Learner should have reached the standards of knowledge, skill and competence associated with the preceding level of the National Framework of Qualifications. This may have been achieved through a formal qualification or through relevant life and work experience.

Learning Outcome:

At the end of the course the participants will be able to:

· Navigate the application platform. (Allen Bradley - RSLogix 500) (Siemens - TIA portal) 

· Set-up an Ethernet Interface to Communicate with the PLC, assign an IP address to the PLC 

· Compare Offline files to those in PLC memory 

· Understand the way ladder files are organised 

· Create PLC data files, define data types 

· Use Watch Tables 

· Interrogate Basic Ladder Logic Instructions and how they interact Data Files 

· Use the Cross-Referencing tool to navigate code 

· Learn Program Structure using best practice 

· Track and control sequences with the MOV, EQ and LIM instructions (found commonly in industry) 

· Troubleshoot a robot pick and place sequence with simulated faults in Factory I/

      Course Content:

      Unit 1: Theory


      • Understand the role of PLCs in industrial automation.
      • The advantages of PLCs over traditional relay logic
      • Types of PLCs and their applications.
      • The components of a PLC system - CPU, I/O modules, power supply, etc.
      • Types of input and output devices (sensors, actuators, relays).
      • Panel Diagram and PLC connections.

      Unit 2: PLC Programming Concepts


      • Introduction to PLC programming methods - e.g., ladder logic, Function Block Diagram, structured text.
      • Creating, editing, and saving projects. Downloading and uploading.
      • Online and offline programming.
      • Configuring Analog and Digital inputs and outputs devices.
      • I/O Addressing, data files/tables.
      • Safety considerations.


      Unit 3: PLC Programming


      • Understanding bit level instructions (XIC, XIO, OTE, AND, OR, NOT etc.).
      • Conditional statements (IF, ELSE, etc.)
      • Word and File level instructions- Math and data manipulation instructions.
      • Timers and Counters
      • Sequencers

      Unit 4: Advanced PLC Programming


      • Introduction to Factory simulation software.
      • Programming conveyor sequence
      • Programming sorting system
      • Communication protocols - Modbus, Ethernet/IP, etc.
      • Data logging and storage
      • Integrating PLCs with peripheral devices- HMI design and operation


      Unit 5: Troubleshooting & Debugging


      • Techniques for diagnosing and resolving PLC program errors.
      • Using debugging tools and online monitoring.
      • Common issues and solutions.

      Unit 6: Safety & Best Practise


      • Safety considerations in PLC programming and operation.
      • Best practices for documenting and organizing PLC programs.
      • Firmware updates and backups.

      Duration:

      4 days (2/3 days per week over 2 consecutive weeks, this is flexible per iteration)

      Exam/Continuous Assessment details:

      Skills Demonstration 40% of overall mark


      Portfolio / Collection of Work 20% of overall mark


      Examination – Theory 40% of overall mark


      The pass mark for all assessments is 50%

      Certification / Awarding Body/Credits:

      Certification: QQI Level 6 Minor award in Programmable Logic Controllers


      Awarding Body: QQI


      Credits: 15

      Progression Pathway:

      6M5154 Maintenance Skills Technology Major Award