Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Multi-meter | PLC 24V DC |
| Side Cutter | RS485 Communication Cable |
| Screw Driver Set (Flat and Phillips) | Power Supply 24 V DC |
| External Control System Simulator |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Programmable Logic Controller (PLC) 24V DC | 1 Pc per Candidate |
| 2 | RS485 Communication Cable | 3 m per Candidate |
| 3 | Laptop with PLC Programming Software | 1 Pc per Candidate |
| 4 | External Control System Simulator (SCADA Emulator) | 1 Pc per Candidate |
| 5 | Power Supply 24 V DC | 1 Pc per Candidate |
| 6 | Multi-meter | 1 Pc per Candidate |
| 7 | Side Cutter | 1 Pc per Candidate |
| 8 | Screw Driver Set (Flat and Phillips) | 1 Set per Candidate |
| 9 | Personal Protective Equipment (PPE): Overall/dust coat and Safety boots | 1 Set per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Setup and Wiring | |||
| Wore personal protective gear i. Overall/dust coat ii. Safety boots (Award 1 mark each for PPE worn) | 2 | ||
| Observed electrical safety rules i. Disconnected power before wiring (Award 2 marks if observed, 0 if not) | 2 | ||
| Used correct tools i. Side cutter ii. Screwdrivers (flat and Phillips) (Award 1 mark each for correct tool use) | 3 | ||
| Connected RS485 communication cable correctly between PLC and external control system (Award 4 marks for correct wiring and termination) | 4 | ||
| Connected 24 V DC power supply correctly to PLC (Award 1 mark each for live, neutral, and earth connections) | 3 | ||
| Verified wiring connections with multi-meter (Award 2 marks for correct verification) | 2 | ||
| Powered ON the PLC system correctly (Award 1 mark for correct powering) | 1 | ||
| Sub-Total | 17 | ||
| TASK 2: Programming and Communication Testing | |||
| Opened correct PLC programming software and created new project (Award 2 marks for correct software and project setup) | 2 | ||
| Configured Modbus RTU communication parameters (baud rate, parity, stop bits) (Award 3 marks for correct parameter settings) | 3 | ||
| Developed PLC program to send and receive data via Modbus (Award 6 marks for correct and functional code) | 6 | ||
| Documented program code with comments explaining each communication step (Award 2 marks for clear documentation) | 2 | ||
| Simulated or debugged the program to verify communication (Award 3 marks for effective debugging and simulation) | 3 | ||
| Set PLC to programming mode before downloading program (Award 2 marks for correct procedure) | 2 | ||
| Downloaded program to PLC successfully (Award 3 marks for successful download) | 3 | ||
| Set PLC to running mode after program download (Award 1 mark for correct mode selection) | 1 | ||
| Established communication between PLC and external control system (verified by data exchange) (Award 5 marks for successful communication test) | 5 | ||
| Sub-Total | 27 | ||
| TASK 3: System Operation and Housekeeping | |||
| Operated system to demonstrate data exchange via Modbus i. Sent command from external system ii. PLC responded correctly iii. Data acknowledged (Award 5 marks for correct operation as per instructions) | 5 | ||
| Powered off system safely and disconnected all components as per SOP (Award 1 mark for correct shutdown and disconnection) | 1 | ||
| Stored tools, components, and accessories properly (Award 1 mark for proper storage) | 1 | ||
| Cleaned work area after completion (Award 1 mark for cleanliness) | 1 | ||
| Sub-Total | 8 | ||
| PRODUCT CHECKLIST | |||
| Correct wiring and termination of RS485 communication cable and power connections (Award 4 marks for neat, secure, and correct connections) | 4 | ||
| PLC program correctly implements Modbus communication with documented code (Award 6 marks for fully functional and documented program) | 6 | ||
| Successful communication established and verified between PLC and external control system simulator (Award 5 marks for verified communication and data exchange) | 5 | ||
| Sub-Total | 15 | ||
| GRAND TOTAL | 67 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Side Cutter | N.O Push Button Green |
| Screw Drivers (Flat and Phillips) | N.O Inductive Proximity Sensor |
| Multimeter | Indicator Bulb 75W 240Vac |
| Hammer | Bulb Holder |
| 12/24V DC PLC Controller | |
| Terminal Blocks | |
| DIN Rail 15 cm | |
| Single Core Cable 1.5 mm (Red, Black, Green) | |
| Mini Trunking 1 Length | |
| Power Supply 12/24V DC | |
| Power Supply 240V AC | |
| Installation Board 1m x 0.5m | |
| Equipment Labels | |
| Personal Protective Equipment (Overall/Dust Coat, Safety Boots) |
| S/N | Item | Quantity |
|---|---|---|
| 1 | N.O Push Button Green | 1 Pc per Candidate |
| 2 | N.O Inductive Proximity Sensor | 2 Pcs per Candidate |
| 3 | Indicator Bulb 75W 240Vac | 2 Pcs per Candidate |
| 4 | Bulb Holder | 2 Pcs per Candidate |
| 5 | 12/24V DC PLC Controller | 1 Pc per Candidate |
| 6 | Terminal Blocks | 4 Pcs per Candidate |
| 7 | DIN Rail 15 cm | 1 Pc per Candidate |
| 8 | Single Core Cable 1.5 mm (Red, Black, Green) | 3 meters per Candidate |
| 9 | Mini Trunking 1 Length | 1 Pc per Candidate |
| 10 | Power Supply 12/24V DC | 1 Pc per Candidate |
| 11 | Power Supply 240V AC | 1 Pc per Candidate |
| 12 | Installation Board 1m x 0.5m | 1 Pc per Candidate |
| 13 | Personal Protective Equipment (Overall/Dust Coat, Safety Boots) | 1 Set per Candidate |
| 14 | Side Cutter | 1 Pc per Candidate |
| 15 | Screw Drivers (Flat and Phillips) | 1 Set per Candidate |
| 16 | Multimeter | 1 Pc per Candidate |
| 17 | Hammer | 1 Pc per Candidate |
| 18 | Equipment Labels | 1 Set per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Perform Electrical Connections and Installation | |||
| Wore personal protective equipment: overall/dust coat and safety boots (Award 1 mark each for overall and safety boots) | 2 | ||
| Observed electrical safety by disconnecting from mains before wiring (Award 2 marks for full compliance) | 2 | ||
| Used correct tools appropriately: side cutter, flat and Phillips screwdrivers, multimeter (Award 1 mark each for correct tool usage) | 3 | ||
| Installed components on the installation board firmly and level: PLC controller, push buttons, sensors, bulbs, bulb holders, terminal blocks, DIN rail (Award 1 mark each for correct and firm installation of six components) | 6 | ||
| Correctly terminated cables: proper stripping, folding, and no nicking (Award 2 marks for proper termination) | 2 | ||
| Connected PLC input ports to push buttons and sensors correctly (Award 1 mark each for correct connection of push buttons and two sensors) | 3 | ||
| Connected PLC output ports to indicator bulbs correctly through bulb holders (Award 2 marks for correct output wiring) | 2 | ||
| Connected power supply lines correctly to PLC: live, neutral, earth (Award 1 mark each for live, neutral, earth connection) | 3 | ||
| Installed mini trunking neatly to organize cables (Award 1 mark for neat cable management) | 1 | ||
| Tested for short circuits using multimeter before powering the system (Award 2 marks for correct testing) | 2 | ||
| Sub-Total | 26 | ||
| TASK 2: Program and Upload PLC Program | |||
| Opened correct PLC programming software and created new project (Award 2 marks for correct software and project setup) | 2 | ||
| Developed I/O distribution list for inputs and outputs (Award 2 marks for correct I/O list) | 2 | ||
| Wrote ladder logic program to operate bulbs based on push button and sensor inputs as per specifications (Award 8 marks for functional ladder program) | 8 | ||
| Documented the program with comments explaining each rung (Award 2 marks for clear documentation) | 2 | ||
| Simulated or debugged the program using PLC simulation tools (Award 3 marks for successful debugging/simulation) | 3 | ||
| Set PLC to programming mode before uploading the program (Award 2 marks for correct mode selection) | 2 | ||
| Connected programming cable and established communication with PLC (Award 2 marks for correct connection and communication) | 2 | ||
| Downloaded program to PLC and set PLC to running mode (Award 3 marks for successful download and mode change) | 3 | ||
| Sub-Total | 24 | ||
| TASK 3: Test and Operate the System | |||
| Powered the system correctly (Award 1 mark for correct powering) | 1 | ||
| Tested system functionality as per specifications: push button starts system; sensor 1 turns on indicator bulb 1 for 5 seconds; sensor 2 turns on indicator bulb 2 until object removal (Award 1 mark each for each correct operation) | 5 | ||
| Observed and recorded system behavior during operation (Award 2 marks for accurate observation and recording) | 2 | ||
| Disconnected components safely following standard operating procedures (Award 1 mark for safe disconnection) | 1 | ||
| Properly stored tools, components and cleaned the work area (Award 1 mark for proper housekeeping) | 1 | ||
| Sub-Total | 10 | ||
| PRODUCT CHECKLIST | |||
| Finished installation conforms to schematic: correct wiring, firm fixing, neat cable management (Award 4 marks for complete and neat installation) | 4 | ||
| Program runs as specified: inputs trigger outputs correctly with timing and hold functions (Award 6 marks for program functionality matching requirements) | 6 | ||
| System operates reliably without faults during test (Award 4 marks for stable system operation) | 4 | ||
| Sub-Total | 14 | ||
| GRAND TOTAL | 74 | ||