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Operator PLC System

This document provides a syllabus for an apprenticeship training scheme for the trade of Operator PLC System. The training will last 2 years and cover topics like programming PLC systems, wiring, fault finding, pneumatic and hydraulic systems, sensors, drives, HMIs, SCADA, robotics, and a required multi-week project. The syllabus also lists members of the trade committee from various organizations that developed the syllabus.

Uploaded by

Nisar Ahmed
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© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
264 views

Operator PLC System

This document provides a syllabus for an apprenticeship training scheme for the trade of Operator PLC System. The training will last 2 years and cover topics like programming PLC systems, wiring, fault finding, pneumatic and hydraulic systems, sensors, drives, HMIs, SCADA, robotics, and a required multi-week project. The syllabus also lists members of the trade committee from various organizations that developed the syllabus.

Uploaded by

Nisar Ahmed
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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SYLLABUS

For the trade of


OPERATOR PLC System

Under
Apprenticeship Training Scheme

Government of India
Ministry of Labour & Employment
Directorate General of Employment & Training
New Delhi-110001

GENERAL INFORMATION

Name of the Trade

CNC Programmer cum Operator

N.C.O. Code No.

8211.90

Entry Qualification

Passed 10th class examination under


10+2 system of education or
its
equivalent.

Duration of the Apprenticeship Training

02 years

Rebate allowed in Apprenticeship Training

One year and six months for trainees


completed Broad Based Basic Training
in Production and Manufacturing Sector
under Centre of Excellence Scheme and
Advanced module of Centre of
Excellence Scheme in PLC and
Automation.

Ratio of apprentices to workers other than


unskilled workers

1:2

Terminal Behavior

: On completion of training, the trainee is


able to design & develop PLC Programs

Course Outline :
The training shall comprise ofa) On the job training
The actual training shall be depended on the facilities available in the
establishments with an idea to expose the trainees to as many activities as
possible. The trainee shall maintain a daily work for a job training, which shall
be periodically authenticated by the supervisor.
b) Project
Each apprentice shall under take a project in any of the areas
depending on his/her interest and facilities available in the establishment. The
duration of the project shall be two Weeks.

Syllabus for the trade of Operator PLC System


under
Apprenticeship Training Scheme

List of the members present in trade committee meeting held on 13th January 2007 at
ITI, Aundh, Pune, Maharashtra

S.No. Name and Designation


Organisation
1.
Shri Rajendra Gaikwad, Specialist Engineer, R & Force Motors Ltd., Pune
D-HCV
2.
Shri B.U.Bhandari, Works manager
TATA Motors, Pune
3.
Col. U.G.Umrani, G.M.
Maruti Suzuki

Syllabus for trade of Operator PLC System

SR.NO.
1
2
3
4
5
6

8.

9.

10.

11

12.
13.
14.
15.

16.
17.

SHOPFLOOR TRAINING
Single & double actuator circuits (Pneumatics)
Programming as per application
Wiring of PLC, connecting relay logic with PLC
Replacement of burnt relays, contactors etc.
Checking the configuration of PLC as per Hardware
Crimping/soldering of communication cables
Fault finding of Pneumatic multi actuator circuits, checking the sequence.
Repairing the valves replacement of seals, maintenance of pneumatic
system i.e. valves, cylinders etc.
Simple ladder development using PLC like Siemens, ABB, Allen Bradley,
Fanuc, Mitsubishi, Omron, Messung etc.
Installation of Programming Software
Configuration of Driver
Multiple ladder development using PLC
Siemens, ABB, Allen Bradley, Fanuc, Mitsubishi, Omron, Messung etc.
Multiple ladder development
Use of timers in circuit. TON, TOF, RTO
Application of timer in ladder logic time base, preset value, accumulator
value (online checking)
Multiple ladder development
Use of Counters in circuit
CTU, CTD counting mechanism, sensors/LIMIT Switches used for counting
the production.
Connecting the sensor in PLC circuits
Installation of sensors
Replacement of damaged sensors
Speed control, types of attachment required for conveyer system., Belt
tightening, adjustments of speed as per production, maintenance etc.
Basic parameter setting of drives. (Programming) like Siemens, ABB,
ALLEN Bradley, DELTA DANFOSE, B&R, Mitsubishi etc.
Basic parameter setting of drives. (Programming) like Siemens, ABB,
ALLEN Bradley, DELTA DANFOSE, B&R, Mitsubishi etc.
Advanced parameter setting of drives by using keypad (programming) like
Siemens, ABB, ALLEN BRADLEY , DELTA, DANFOSE, B & R, Mitsubishi
etc.
Setting & checking the parameters by using HMI, ON-OFF CONTROL etc.
Controlling the devices by using HMI
Start & stop, DATA setting etc.

18.

Maintenance & servicing of hydraulic valves, power pack maintenance etc.

19.

Causes & remedies of different faults occurred in components rectification


of faults, replacement of valve/part, repairing etc.
Compressor maintenance. Dryer maintenance & servicing
Replacement of piston rings etc., attachments used with pneumatic
cylinders, accurate setting of attachments.
Connection of PT 100/RTD, pressure sensors, load cell, configuring
sensors as per output. Voltage/current input or output configuring it in
software as per voltage or current.
Checking of parameters by using of SCADA, data recording, parameter
setting/checking by using SCADA.
Checking of parameters by using of SCADA. Report generation

20.

21

22
23.
24.
25

Concept of Robotic operation


Welding, pick & place Robot Operation Sequence
Preparation of project

26

Preparation of project.

Related Instructions
1.

Introduction of Pneumatic & Hydraulic components


Introduction of PLC types of PLC (Revision)

2.

Industrial wiring diagram of PLC


Wiring diagram & fault finding & labeling of PLC

3.

Panel board wiring with PLC


Relay logic, relays used in panel board, isolation of PLC circuit & power circuit by
using relays.

4.

Configuration of PLC system available in shop floor

5.

Communication system, type of communication, RS232, DH+, DH485, TCPIP etc.


Data transfer

6.

Multi actuator circuits, operation & sequencing, displacement diagram


Fault finding of Pneumatic multi actuator circuits, checking the sequence. Repairing
the valves replacement of seals etc.

7.

Addressing method of PLC Siemens, ABB, Allen-Bradley, Fanaque, Mitsubishi,


Omron and Messung etc. Simple ladder development using PLC, installation of
programming software, configuration of driver.

8.

Multiple ladder development


Use of flags in circuit. Application of Multiple ladder programming
Case study addressing method of PLC. Siemens, ABB, Allen-Bradley, Fanaque,
Mitsubishi, Omron, Messung etc. Multiple ladder development using PLC.

9.

Multiple ladder development. Use of timers in circuit


Application of timer in ladder logic time base, present value, accumulator value
(online checking)

10.

Multiple ladder development


use of counters in circuits. Counting mechanism, sensors, used for counting the
production

11.

Sensors & types. Two wire, three wire etc.. Inductive, capacitive, optical etc.

12.

Industrial application of sensors, Pressure, temperature, speed, flow, level etc.


Analog programming (I/P, O/P)

13.

Conveyers & types of conveyers. Conveyer system application, speed control, types
of attachment required for conveyer system.

14.

Introduction of A.C. drives. Basic parameter setting of drives (programming)

15.

Single phase & three phase A.C. drives, Difference & application.

16.

Introduction to Human Machine Interface (HMI). Setting & checking the parameters
by using HMI

17.

Simple programming by using HMI, selection of PLC while programming

18.

Application of PLC in hydraulic system. Case study.

19.

Concept of low cost automation & applications

20.

Application of PLC in food industry, engineering industry, refinery, beverages etc.


preparation of air for food packing, pharmaceutical packing.

21.

RTD/PT 100 type sensors, importance, voltage/current types difference. Connection


of PT 100/RTD, pressure sensors, load cell, configuring sensors as per output.

22.

Introduction of SCADA. Checking of parameters by using of SCADA. Connecting


SCADA with PLC by using PC.

23.

Preparation of project on case study of industry

24.

Basic Robotics

25.

Concept of project

26.

Concept of project

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