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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:

Learners applying for this course should be employed Maintenance Personnel who would like to enhance their skills by using PLC logic as a means of diagnosing machine faults. Learners should possess a QQI Level 5 or equivalent ideally in a related technical area.

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 this course learners will be able to:

· Explain how a PLC controls automated equipment.
· Wire Field devices to a PLC.
· Explain how fault messages are generated.
· Use a PLC I/O interface to narrow a fault down to a specific control loop.
· Backup programs.
· Replace backup batteries.
· Navigate an I/O list to find related control loops.

      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

      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