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2010 • Nantha Kumara a/l Periasamy • Mohd Sani bin Saian • Mat Nizam Bin Ngathinee • Nurul Asikin Bt Saari • Mohammad Jailani Bin A Jamil

TM001: KURSUS TEKNIK MENGAJAR SIRI 5/2010

AHLI KUMPULAN

PEMBANGUNAN LEARNING GUIDE/ PANDUAN PEMBELAJARAN

SUPERVISOR • En. Ahmad bin Abdullah

COURSE MANAGER • En. Ibrahim bin Osman

TM001 : TEKNIK MENGAJAR SIRI 5/2010

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CONTENTS/ ISIKANDUNGAN

TASK CLUSTERING ....................................................................................................................... 3

REVIEW AND REFINE ................................................................................................................... 6

SEQUENCING .................................................................................................................................... 9

TRAINING PATHWAY ................................................................................................................. 10

NOSS MATRIX ................................................................................................................................ 13

LEARNING EXPERIENCE TABLE ........................................................................................... 15

LEARNING EXPERIENCE DETAILED (N0.01-05) ............................................................. 16

COURSE OF STUDY ...................................................................................................................... 23


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TASK CLUSTERING H-176-2 JUNIOR AUTOMATION TECHNICIAN

01.01 Carry Out Mechanical Equipment Condition Check

01.02 Carry out Mechanical Equipment Safety Check

01.03 Troubleshoot Mechanical Equipment Failure

01.04 Carry out Mechanical Parts/Components Failure Repair/Replacement

04.01 Carry Out Tools, Jigs And Fixtures Condition Check

04.02 Carry Out Calibration Of Tools, Jigs and Fixtures

04.03 Carry Out Tools And Jigs Maintenance Activities

04.04 Carry Out Tool And Fixtures Replacement

MECHANICAL EQUIPMENTH-176-2 (MO1)

02.01 Carry Out Electrical Equipment Condition Check

02.02 Carry out Electrical Equipment Safety Check

02.03 Troubleshoot Electrical Equipment Failure

ELECTRICAL EQUIPMENTH-176-2 (MO2)

02.04 Carry Out Electrical Parts/ Components Failure Repair/Replacement


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03.01 Carry Out Electronic Equipment Condition Check

ELECTRONIC EQUIPMENT H-176-2 (MO3)

03.02 Carry out Electronic Equipment Safety Check

03.03 Troubleshoot Electronic Equipment Failure

03.04 Carry Out Electronic Parts/ Components Failure Repair/Replacement

08.01 Troubleshoot Pneumatic System Failure

HYDRAULIC AND PNEUMATICH-176-2 (MO4)

08.02 Troubleshoot Hydraulic System Failure

08.03 Troubleshoot Vacuum/Clean Dry Air (CDA ) Equipment

05.01 Carry Out Programmable Logic Controller (PLC) Functionality Check

PROGRAMMABLE LOGIC CONTROLLER H-176-2 (MO5)

05.02 Carry Out Input / Output (I/O) Maintenance Activities

05.03 Carry Out Programmable Logic Controller (PLC) Integration Check


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06.02 Carry Out Drive And Transmission Maintenance Activities

06.03 Carry Out Drive And Transmission Replacement

07.01 Carry Out Detection System Component Check

09.01 Carry Out Robots Condition Check

09.02 Carry out Robots safety check

07.02 Carry Out Detection System Component Installation

AUTOMATION H-176-2 (MO6)

07.03 Carry Out Detection System Test

07.04 Maintain Detection System Component�

06.01 Carry Out Drive And Transmission Condition Check

06.04 Carry Out Drive And Transmission Equipment Functionality Test

PREVENTIVE MAINTENANCE H-176-2 (MO7)

11.01 Carry out preventive maintenance activities


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REVIEW AND REFINE H-176-2 JUNIOR AUTOMATION TECHNICIAN

MODULE

NO 05 MODULE: PROGRAMMABLE LOGIC CONTROLLER (PLC)

TASK NO

05.01

05.02

05.03

TASK

Carry out Programmable Logic Controller (PLC) functionality check

Carry out Input/output maintenance activities

Carry out Programmable Logic Controller (PLC) integration check

MODULE OBJECTIVE:

(Action, Condition, Criteria)

Carry Out functionality, Input / Output (I/O) and i ntegration of PLC using Manufacturer’s Specification, Operation Manual, Checklist, Special Tools, Hand Tools, Report Forms so that its features are in accordance with Job Specif ication Requirements and Standard Operating Procedures.

New Step

New Enabling Requirement

New Tool, Equipment and

Material

1. Identify Type Of

Programmable Logic Controller (PLC)

Knowledge of: 1.1 Type of Programmable Logic Controller (PLC) 1.2 Type of Input and Output (I/O) 1.3 Functions of Programmable Logic Controller (PLC) Ability to: 1.1 Determine Programmable Logic Controller

(PLC) 1.2 Determine Type of Input and Output (I/O) 1.3 Determine Functionality of Programmable

Logic Controller (PLC) Attitude: - Proactive Safety : - Resourceful

- Manufacturer’s Specification

- Programmable Logic Controller (PLC)

- Program Language

(Ladder Diagram,

Statement List etc)

- Computer System


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2. Install Programmable Logic Controller (PLC) 3. Check Input / Output of Programmable Logic Controller (PLC)

4. Apply Programmable Logic Controller (PLC) Programming

Knowledge of: 2.1 Power supply input 2.2 Mounting Instruction 2.3 Mounting requirements 2.4 Manufacturers Specification Ability to: 2.1 Determine power supply input 2.2 Follow Mounting Instruction 2.3 Determine mounting requirements 2.4 Comply to Manufacturers Specification Attitude : - Resourceful - Observant Safety : - Cautious - Safety conscious Knowledge of: 3.1 Input And Output Terminals 3.2 Application of Programmable Logic

Controller (PLC) 3.3 Method of checking Programmable Logic Controller (PLC) functionality Ability to: 3.1 Determine Input And Output Terminals 3.2 Determine Application of Programmable Logic

Controller (PLC) 3.3 Apply method of checking Programmable Logic Controller (PLC) Functionality Attitude : - Resourceful - Observant Safety : - Cautious - Safety conscious Knowledge of: 4.1 Input / Output devices 4.2 Ladder Diagram 4.3 Input / Output Of Parameters device 4.4 I/O maintenance activities 4.5 Record I/O maintenance status

- Standard Operating Procedure

- Operation Manual

- Checklist - Special Tools - Hand Tools - PLC

Specification - Mounting

Instruction

- Power Supply

- Cables

- Personal Protective

Equipment (PPE)


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5. Perform testing & interfacing

Ability to: 4.1 Apply Input / Output Of Parameters device 4.2 Interpret Ladder Diagram 4.3 Apply Input / Output devices 4.4 Determine I/O maintenance activities 4.5 Apply maintenance status recording. Attitude : - Clarity - Accountable Safety : - Cautious - Safety conscious Knowledge of: 5.1 Program Language (Ladder Diagram, Statement List etc) 5.2 Method Of Connecting Input And Output (I/O) 5.3 Input And Output (I/O) Type and Specification 5.4 Type Of Cables And Sizes Ability to: 5.1 Comply to Program Language (Ladder Diagram, Statement List etc) 5.2 Comply to I/O Type and Specification 5.3 Apply Method Of Connecting Input And Output (I/O) 5.4 Apply Type Of Cables And Sizes Attitude & Safety: - Resourceful - Accountable Safety : - Safety conscious


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SEQUENCING H-176-2 – JUNIOR AUTOMATION TECHNICIAN

START

MECHANICAL EQUIPMENT

H-176-2 (M01) 01.01 01.02 01.03 01.04 04.01 04.02 04.03

ELECTRICAL EQUIPMENT

H-176-2 (M02) 02.01 02.02 02.03 02.04

03.01 03.02 03.03 03.04

PNEUMATIC & HYDRAULIC

H-176-2 (M04) 08.01 08.02 08.03

H-176-2 (M03)

ELECTRONIC EQUIPMENT

PROGRAMMABLE LOGIC CONTROLLER H-176-2 (M05)

05.01 05.02 05.03

07.01 07.02 07.03 07.04 06.01 06.02 06.03 06.04 09.01 09.02

11.01

PREVENTIVE MAINTENANCE H-176-2 (M07)

AUTOMATION

H-176-2 (M06)

END


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TRAINING PATHWAY H-176-2 – JUNIOR AUTOMATION TECHNICIAN

START

MECHANICAL EQUIPMENT

H-176-2 (M01)

Carry Out Mechanical Equipment Condition Check

01.01 1/1 Carry Out Mechanical Equipment Safety Check

01.02 2/1

Troubleshoot Mechanical Equipment Failure

01.03 3/1

Carry Out Tools, Jigs And Fixtures Condition Check

04.01 5/1 Carry Out Calibration Of Tools, Jigs and Fixtures

04.02 6/1

Carry Out Tools and Jigs Maintenance Activities

04.03 7/1

Carry Out Tool and Fixtures Replacement

04.04 8/1

Carry out Mechanical Parts/Components Failure Repair/Replacement

4/1 01.04

ELECTRICAL EQUIPMENT

H-176-2 (M02)

Carry out Electrical Equipment Safety Check

02.02 2/2

Carry Out Electrical Equipment Condition Check

02.01 1/2

Troubleshoot Electrical Equipment Failure

02.03 3/2

Carry Out Electrical Parts / Components Failure Repair/ Replacement

02.04 4/2

A


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H-176-2 (M03)

ELECTRONIC EQUIPMENT

1/3 Carry Out Electronic Equipment Condition Check

03.01

Carry out Electronic Equipment Safety Check 03.02 2/3

Troubleshoot Electronic Equipment Failure 03.03 3/3

Carry Out Electronic Parts / Components Failure Repair/ Replacement

03.04 4/3

A

PNEUMATIC & HYDRAULIC H-176-2 (M04)

Troubleshoot Pneumatic System Failure

08.01 1/4

Troubleshoot Hydraulic System Failure

08.02 2/4

Troubleshoot Vacuum/Clean Dry Air ( CDA ) Equipment

08.03 3/4

PROGRAMMABLE LOGIC CONTROLLER H-176-2 (M05)

Carry Out Programmable Logic Controller (PLC) Functionality Check

05.01 1/5 Carry Out Input / Output (I/O) Maintenance Activities

05.02 2/5

Carry Out Programmable Logic Controller (PLC) Integration Check

05.03 3/5

B


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B

AUTOMATION

H-176-2 (M06)

Carry Out Detection System Component 07.02 2/6

5/6 06.01 Carry Out Drive And Transmission Condition

Carry Out Drive And Transmission Maintenance Activities

06.02 6/6

06.03 7/6 Carry Out Drive and Transmission Replacement

Carry Out Drive and Transmission Equipment Functionality Test 06.04 8/6

Carry Out Robots Safety Check 09.02 10/6

Carry Out Robots Condition Check 09.01 9/6

1/6

Maintain Detection System Component 07.04 4/6

Carry Out Detection System Test 07.03 3/6

Carry Out Detection System Component Check 07.01

Carry Out Preventive Maintenance Activities

11.01 1/7 PREVENTIVE

MAINTENANCE H-176-2 (M07)

END


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NOSS MATRIX : H-176-2 – JUNIOR AUTOMATION TECHNICIAN

MODULE

JOB PROFILE

ME

CH

AN

ICA

L E

QU

IPM

EN

T

ELE

CT

RIC

AL

EQ

UIP

ME

NT

ELE

CT

RO

NIC

EQ

UIP

ME

NT

PN

EU

MA

TIC

AN

D

HY

DR

AU

LIC

PR

OG

RA

MM

AB

LE L

OG

IC C

ON

TR

OLL

ER

(P

LC)

AU

TO

MA

TIO

N

PR

EV

EN

TIV

E M

AIN

TE

NA

NC

E

DUTY NO DUTY TASKS TASK

NO. M01

M02

M03

M04

M05

M06

M07

01

Perform Mechanical Equipment Maintenance

Carry Out Mechanical Equipment Condition Check 01.01 √

Carry out Mechanical Equipment Safety Check 01.02 √

Troubleshoot Mechanical Equipment Failure 01.03 √

Carry out Mechanical Parts/Components Failure Repair/Replacement 01.04 √

02

Perform Electrical Equipment Maintenance

Carry Out Electrical Equipment Condition Check 02.01 √

Carry out Electrical Equipment Safety Check 02.02 √

Troubleshoot Electrical Equipment Failure 02.03 √ Carry Out Electrical Parts / Components Failure Repair/Replacement 02.04

√

03

Perform Electronic Equipment Maintenance

Carry Out Electronic Equipment Condition Check

03.01 √

Carry out Electronic Equipment Safety Check 03.02 √

Troubleshoot Electronic Equipment Failure 03.03 √

Carry Out Electronic Parts / Components Failure Repair/Replacement 03.04

√

04

Perform Tool, Jigs and Fixtures Maintenance

Carry Out Tools, Jigs And Fixtures Condition Check 04.01 √

Carry Out Calibration Of Tools, Jigs and Fixtures

04.02 √

Carry Out Tools And Jigs Maintenance Activities 04.03 √

Carry Out Tool And Fixtures Replacement 04.04 √

05

Perform

Programmable Logic Controller (PLC) Maintenance

Carry Out Programmable Logic Controller (PLC) Functionality Check

05.01

√

Carry Out Input / Output (I/O) Maintenance Activities

05.02

√

Carry Out Programmable Logic Controller (PLC) Integration Check

05.03

√

06

Perform Drive And Transmission Maintenance

Carry Out Drive And Transmission Condition Check 06.01 √

Carry Out Drive And Transmission Maintenance Activities

06.02 √

Carry Out Drive And Transmission Replacement 06.03 √ Carry Out Drive And Transmission Equipment Functionality Test

06.04 √


14

MODULE

JOB PROFILE

M

EC

HA

NIC

AL

EQ

UIP

ME

NT

ELE

CT

RIC

AL

EQ

UIP

ME

NT

ELE

CT

RO

NIC

EQ

UIP

ME

NT

PN

EU

MA

TIC

AN

D

HY

DR

AU

LIC

PR

OG

RA

MM

AB

LE L

OG

IC C

ON

TR

OL

LER

(P

LC)

AU

TO

MA

TIO

N

PR

EV

EN

TIV

E M

AIN

TE

NA

NC

E

DUTY NO

DUTY TASKS TASK NO. M

01

M02

M03

M04

M05

M06

M07

07

Perform Detection System Maintenance

Carry Out Detection System Component Check 07.01

√

Carry Out Detection System Component Installation

07.02

√

Carry Out Detection System Test 07.03 √

Maintain Detection System Component 07.04 √

08 Perform Hydraulic And Pneumatic Maintenance

Troubleshoot Pneumatic System Failure 08.01 √

Troubleshoot Hydraulic System Failure 08.02 √

Troubleshoot Vacuum/Clean Dry Air( CDA ) Equipment

08.03 √

09

Perform Robot Maintenance

Carry Out Robots Condition Check 09.01 √

Carry Out Robots Safety Check 09.02 √

11 Perform Preventive Maintenance

Carry Out Preventive Maintenance Activities 11.01

√


15

LEARNING EXPERIENCE TABLE H-176-2 – JUNIOR AUTOMATION TECHNICIAN

MODULE: M05 – PROGRAMMABLE LOGIC CONTROLLER (PLC)

MODULE OBJECTIVE:

Carry Out functionality, Input / Output (I/O) and integration of PLC using Manufacturer’s Specification, Operation Manual, Checklist, Special Tools, Hand Tools, Report Forms so that its features are in accordance with Job Specification Requirements and Standard Operating Procedures.

LEARNING EXPERIENCE ENABLING REQUIREMENT Identify Type Of Programmable Logic Controller (PLC)

Identify type of Programmable Logic Controller (PLC) by referring manufacturer specification and job requirement so that function and main component of PLC is identified and defined.

Install Programmable Logic Controller (PLC)

Install Programmable Logic Controller (PLC) using appropriate mounting tools and power supply so that mounting instruction, requirements and manufacturer’s specification is fulfilled.

Check Input / Output terminals of Programmable Logic Controller (PLC)

Check input and output terminals of Programmable Logic Controller (PLC) by referring to the circuit diagram and program so that the input and output terminals are Identified and located against the diagram and program.

Apply Programmable Logic Controller (PLC) Programming

Apply Programmable Logic Controller (PLC) programming by referring to Programmer Logic Controller (PLC) program manual so that the program is installed and function according to the user requirement.

Perform testing and interfacing

Perform testing and interfacing by using simulation tools so that the function and operating sequence of the program is identified and defined.


16

LEARNING EXPERIENCE DETAILED (N0.01-05) H-176-2 – JUNIOR AUTOMATION TECHNICIAN (MODUL 05)

OBJEKTIF MEMBOLEH

Identify type of Programmable Logic Controller (PLC) by referring manufacturer specification and job requirement so that function and main component of PLC is identified and defined.

Kenalpasti jenis Programmable Logic Controller (PLC) dengan merujuk kepada spesifikasi pengeluar dan keperluan kerja oleh itu fungsi dan komponen utama PLC dapat ditakrif dan dikenalpasti.

BIL. AKTIVITI PEMBELAJARAN ARAHAN KHAS

1. 2. 3. 4. 5.

Baca Kertas Penerangan H – 176 – 2 /M05/P (1/5) untuk mengetahui jenis Programmable Logic Controller (PLC), jenis input dan output dan fungsi PLC. Untuk maklumat tambahan layari internet di laman web www.omron.com.my Setelah faham sila jawab soalan-soalan yang disertakan dalam Penilaian Pengetahuan Sendiri H – 176 – 2/M05/PS (1/1/5) dan bandingkan jawapan seperti didalam Lampiran A disetiap soalan. Buat latihan dengan pilih komponen input dan output berdasarkan kertas kerja H – 176 – 2/M05/K (1/1/5). Setelah selesai segala tugasan dan dibenarkan, sila teruskan ke PENGALAMAN PEMBELAJARAN NO – 02

• Rujuk Pusat Multimedia

• Rujuk Pengajar

PENGALAMAN PEMBELAJARAN NO. 01 H – 176 – 2 (MODUL 05)

IDENTIFY TYPE OF PROGRAMMABLE LOGIC CONTROLLER (PLC )


17

OBJEKTIF MEMBOLEH Install Programmable Logic Controller (PLC) using appropriate mounting tools and power supply so that mounting instruction, requirements and manufacturer’s specification is fulfilled. Pemasangan Programmable Logic Controller (PLC) dengan menggunakan peralatan mounting dan bekalan kuasa yang sesuai supaya memenuhi spesifikasi pengeluar.

BIL. AKTIVITI PEMBELAJARAN ARAHAN KHAS 1. 2. 3. 4. 5.

Baca Kertas Penerangan H – 176 – 2 /M05/P (2/5) untuk mengetahui cara-cara pemasangan PLC seperti “Panel mounting”dan “Wall mounting”, pendawaian bekalan kuasa mengikut spesifikasi pengeluar.

Untuk maklumat tambahan layari internet di laman web www.samson.de /pdf_en/e55710en.pdf dan www.plcmanual.com . Setelah faham sila jawab soalan-soalan yang disertakan dalam Penilaian Pengetahuan Sendiri H – 176 – 2/M05/PS (2/5) dan bandingkan jawapan seperti didalam Lampiran A disetiap soalan. Buat latihan pemasangan PLC berdasarkan kertas kerja H – 176 – 2/M05/K (2/5). Setelah selesai segala tugasan dan dibenarkan, sila teruskan ke PENGALAMAN PEMBELAJARAN NO – 02


• Rujuk Pengajar

PENGALAMAN PEMBELAJARAN NO. 02 H-176-2 (MODUL 05)

INSTALL PROGRAMMABLE LOGIC CONTROLLER (PLC)


18

OBJEKTIF MEMBOLEH Check input and output terminals of Programmable Logic Controller (PLC) by referring to the circuit diagram and program so that the input and output terminals are Identified and located against the circuit diagram and program. Periksa terminalmasukan/keluaran PLC dengan merujuk kepada gambarajah litar dan program supaya terminal masukan/keluaran dapat dikenalpasti mengikut gambarajah litar dan program.

BIL. AKTIVITI PEMBELAJARAN ARAHAN KHAS 1. 2. 3. 4.

Baca Kertas Penerangan H – 076 – 2 /M05/P (3/5) untuk mengetahui terminal masukan dan keluaran, penggunaan PLC dan kaedah pemeriksaan bagi fungsi PLC. Read information Sheet to gain understanding on input and output terminal, application of PLC and method of checking PLC functionality. Untuk maklumat tambahan layari internet di laman web www.festo.com For additional information, browse to internet address www.festo.com. Setelah faham sila jawab soalan-soalan yang disertakan dalam Penilaian Pengetahuan Sendiri H – 076 – 2/M05/PS (3/5) dan bandingkan jawapan seperti didalam Lampiran A disetiap soalan. Once completed, please proceed by answering questions attached in Self-Review Exercises and compare your answer with Answeer sheet given in Attachment A. Buat latihan periksa terminalmasukan/keluaran PLC berdasarkan kertas kerja H – 076 – 2/M05/K (3/5). Setelah selesai segala tugasan dan dibenarkan, sila teruskan ke PENGALAMAN PEMBELAJARAN NO – 04


• Rujuk Pengajar


PERIKSA TERMNAL MASUKAN/KELUARAN PROGRAMMABLE LOGIC CONTROLLER (PLC)


19

Do exercises on check input and output terminals of Programmable Logic Controller (PLC) by referring to Lab work D-Once finished, please proceed with LEARNING EXPERIENCE NO – 04.


20

OBJEKTIF MEMBOLEH/ ENABLING OBJECTIVE Apply Programmable Logic Controller (PLC) programming by referring to Programmable Logic Controller (PLC)’s manual so that the program is installed and function according to user requirement. Buat PLC programming dengan merujuk kepada Manual Programmable Logic Controller (PLC) supaya program diinstall dan berfungsi mengikut kehendak pengguna.

BIL. AKTIVITI PEMBELAJARAN ARAHAN KHAS 1. 2. 3. 4.

Baca Kertas Penerangan H – 176 – 2 /M05/P (4/5) untuk mengetahui mengenai peranti input/ output, rajah tangga, aktiviti penyelenggaraan I/O, Rekod status penyelenggaraan I/O. Read information Sheet to gain understanding on Input / Output devices, Ladder Diagram, I/O maintenance activities, Record I/O maintenance status. Untuk maklumat tambahan layari internet di laman web www.omron.com For additional information, browse to internet address. Setelah faham sila jawab soalan-soalan yang disertakan dalam Penilaian Pengetahuan Sendiri H – 176 – 2/M05/PS (4/5) dan bandingkan jawapan seperti didalam Lampiran A disetiap soalan. Once completed, please proceed by answering questions attached in Self-Review Exercises and compare your answer with Answer sheet given in Attachment A. Buat latihan Pemprograman PLC berdasarkan kertas kerja H – 176 – 2/M05/K (4/5). Do exercises on PLC Programming by referring to Worksheet H-176-2/M05/K (4/5)

• Rujuk Pusat Multimedia • Refer to Mutimedia Center

• Rujuk Pengajar • Refer to Instructor


BUAT PROGRAMMABLE LOGIC CONTROLLER (PLC) PROGRAMMIN G


21

5.

Setelah selesai segala tugasan dan dibenarkan, sila teruskan ke PENGALAMAN PEMBELAJARAN NO – 05 Do exercises on PLC Programming by referring to Lab work D-Once finished, Please proceed with LEARNING EXPERIENCE NO – 05.


22

OBJEKTIF MEMBOLEH Perform testing and interfacing by using simulation tools so that the function and operating sequence of the program is identified and defined. Buat pengujian dan antaramuka dengan menggunakan alatan simulasi supaya fungsi dan turutan operasi program dapat ditakrif dan dikenalpasti.

BIL. AKTIVITI PEMBELAJARAN ARAHAN KHAS 1. 2. 3. 4. 5.

Baca Kertas Penerangan H – 176 – 2 /M05/P (5/5) untuk mengetahui programming language ( ladder diagram/statement list), kaedah penyambungan input/output, jenis input/output dan spesifikasinya serta jenis dan saiz kabel. Untuk maklumat tambahan layari internet di laman web www.omron.com.my Setelah faham sila jawab soalan-soalan yang disertakan dalam Penilaian Pengetahuan Sendiri H – 176 – 2/M05/PS (1/5/5) dan bandingkan jawapan seperti didalam Lampiran A disetiap soalan. Buat latihan dengan menguji dan membuat antaramuka programming yang disediakan dalam kertas kerja H – 176 – 2/M05/K (1/5/5). Setelah faham dan benar-benar yakin dengan kemampuan anda melakukan kesemua tugasan didalam modul ini, sila maklumkan kepada Pegawai Penilai bagi menjalankan penilaian pengetahuan dan prestasi sebenar.


• Rujuk Pengajar


PERFORM TESTING AND INTERFACING

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