| 1 | 1a. Produce off-line programs for programmable logic controller equipment | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Produce computer control programs that contain all the relevant and necessary data for the engineering activity to be carried out |
| 1.3 | Ensure that they apply all of the following checks and practices during the PLC programming activities: • check that all the computer equipment is correctly connected, and is in a safe and usable condition (such as cables undamaged, correctly connected, safely routed) • power up the equipment and activate the programming software • set up the computer system to produce programs • ensure that the correct process input/output and control data to produce programs is obtained and checked for currency and validity • identify and deal with problems (such as information based and/or technical) |
| 1.4 | Produce control programs for a PLC with inputs/outputs from six of the following: • proximity sensors • barcode scanners • optical sensors • colour sensors • counters • hydraulic actuators • safety devices • limit switches • timer switches • temperature sensors • footswitches • pneumatic actuators • optical guard curtains • pressure switches • liquid flow switches • air flow switches • liquid level sensors • other actuator |
| 1.5 | Prove the programmable logic controller program, using six of the following: • single block run • program save/store facilities • search facilities • program override controls • edit facilities • data input facilities • full dry run • graphic displays |
| 1.6 | Produce the control programs in the appropriate formats |
| 1.7 | Prepare, load and prove programs for one of the following types of programmable logic controller: • fixed IO • modular • rack mount |
| 2 | 1b. Produce off-line programs for programmable logic controller equipment (continued) | 2.1 | Make sure that codes and other references used in the programs are applicable to the type of controller used |
| 2.2 | Develop programs which use nine of the following, as applicable to the type of controller: • ladder and logic diagrams • function diagrams • statement lists • communication protocols (such as RS232, IEE 488, RS 422, 20mA) • advanced functions (such as less than, greater than, binary to BCD, calculations, PID control) • high level language (such as BASIC, ‘C’) • Boolean algebra • graphical programming language • networking methods and standards • appropriate letter address codes • all necessary positional information • preparatory commands and process management/auxiliary functions • repetitive programs (sub-routines, canned cycles, labels) • switch/actuator positions • sensor information • failsafe positions (where appropriate) |
| 2.3 | Pass on the programs to the appropriate people, within agreed timescales |
| 2.4 | Save and back up the program detail, and store securely in accordance with organisational requirements |
| 2.5 | Carry out all of the following on completion of the programming activity: • check and review program formats and content • edit programs using the correct procedure (where appropriate) • check that programs are correctly titled and referenced • ensure that programs are saved and stored safely and correctly, in the correct format • ensure that programs have been checked and approved before forwarding to the end user • create a separate back-up copy of the program, in case of file corruption |
| 2.6 | Undertake changes to program details, within agreed control procedures |
| 3 | 2a. Know how to produce off-line programs for programmable logic controller equipment | 3.1 | Describe the specific safety precautions to be taken when working with computer systems (to include safety guidance relating to the use of visual display unit (VDU), equipment and workstation environment (such as lighting, seating, positioning of equipment), repetitive strain injury (RSI); the dangers of trailing leads and cables; how to spot faulty or dangerous electrical leads, plugs and connections) |
| 3.2 | Describe the good housekeeping arrangements (such as cleaning down work surfaces; putting disks, manuals and unwanted items of equipment into safe storage; leaving the work area in a safe and tidy condition) |
| 3.3 | Describe the basic set-up and operation of the computer system, and any peripheral devices that are used |
| 3.4 | Describe the correct start-up and shutdown procedures to be used for the computer system |
| 3.5 | Explain how to access the specific programming software, and the use of manuals and related documents to solve problems and aid the efficient programming of PLCs |
| 3.6 | Describe the importance of protecting the computer system from viruses, and the implications if the correct procedure is not followed |
| 3.7 | Explain how to power up, log on and activate the computer system and programming software correctly |
| 3.8 | Explain how to deal with system problems (such as error messages received, peripherals which do not respond as expected) |
| 3.9 | Describe the checks to be carried out to ensure that peripheral devices are connected correctly |
| 3.10 | Describe the correct procedure to shut down the operating and programming system |
| 3.11 | Explain how to create and structure directories and files correctly (such as importing, copying, transferring, exporting, deleting, backing up and saving files) |
| 3.12 | Describe the different types of storage media that can be used to save program files |
| 3.13 | Describe the offline programming methods used in PLCs (such as linear, structured, ladder, statement lists, logic function blocks) |
| 4 | 2b. Know how to produce off-line programs for programmable logic controller equipment (continued) | 4.1 | Describe the common PLC numbering systems (such as binary, octal, decimal, hexadecimal, binary coded decimal (BCD)) |
| 4.2 | Describe the different programming codes used to identify factors (such as safety interlocks/guards and sensor inputs, actuator and other outputs, process management and auxiliary functions) |
| 4.3 | Describe the main PLC types that are available, and the importance of understanding that a different PLC may use completely different codes for similar functions |
| 4.4 | Describe the information and data required in order to produce complete and accurate PLC programs |
| 4.5 | Explain how to extract and interpret general and technical data and information from different sources (such as drawings, computer models, symbols and conventions, BS or ISO standards) in order to produce the PLC program for process control |
| 4.6 | Describe the factors to be taken into account when producing PLC programs (including, the type of PLC (fixed I/O, modular, rack mounted) and its control capabilities, safety, the product/environment being controlled by the process) |
| 4.7 | Explain how to produce effective and efficient programmes to avoid unnecessary operations (including the use of macro programs and canned cycles, to reduce program size) |
| 4.8 | Describe the methods and procedures used to check that the completed program will control the required parameters safely, accurately and efficiently |
| 4.9 | Explain how to save the completed programs in the appropriate format, and the need to store programs safely and correctly, away from contaminants and electromagnetic sources |
| 4.10 | Explain how to back up completed or edited programs, and the implications if this is not carried out effectively |
| 4.11 | Describe the problems that can occur with the downloading and running of the PLC program, and how these can be overcome |
| 4.12 | Describe the correct procedure to be followed before the program is released to the end user |
| 4.13 | Describe the extent of their own responsibility and to whom they should report if they have any problems that they cannot resolve |
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