Regulation – 2016
Programme (s) Semester Course Code (s) Course Title
B.E VII 16EE415 PLC AND AUTOMATION
COURSE OUTCOMES
C415.1 Gain knowledge about the architecture of PLC and I/O modules
C415.2 Understand the basic building blocks of PLC Programming and apply it into practical
issues
C415.3 Understand the necessity of HMI in automation and its panel types.
C415.4 Recognise the Installation and maintenance procedures and networking for PLC.
C415.5 Understand the architecture and demonstrate basic programming of SCADA.
C415.6 Understand the Principle of communication protocols
PART A - 2 Marks BT CO
1. Outline the necessity of Industrial Automation. U C415.1
2. List the control elements in industrial automation. R C415.1
3. Interpret the advantages of PLC system over conventional systems
● Increased Reliability.
● More Flexibility.
● Lower Cost U C415.1
● Communications Capability
● Faster Response Time
● Easier to Troubleshoot
4. Distinguish between relay logic and programmable logic.
A C415.1
5. What are the components of PLC? R C415.1
These components are
● the central processing unit (CPU).
● the input/output [I/OJ section,
● the power supply. and
● the programming device.
6. Define Scan cycle in PLC. U C415.1
The scan cycle is the cycle of which the PLC gathers the inputs, runs your PLC
program and then updates the outputs. This will take some amount of time often
measured in milliseconds or ms. The amount of time it takes for the PLC to make
one scan cycle is called the scan time of the PLC.
7. Infer the advantages of PLC? U C415.1
Advantages:
● Small physical size & shorter project time.
● Cost effective for controlling complex system.
● Reliability.
● Less and simple wiring.
● Faster response.
● Remote control capability.
● More flexibility.
● Ease of maintenance / troubleshooting.
8. What are the functions of PLC I/O module? R C415.1
The purpose of this interface is to condition the various signals
received from or sent to external field devices.
9. Explain the principle of interlock relay panels. U C415.2
10. List the PLC Programming languages . R C415.2
The three most common language structures are ladder diagram
language. Boolean language. and function chart.
11. Distinguish on-delay timer from off-delay timer. A C415.2
In On Delay Timer -After The Input Is Turned On There Is A Delay Before The Output Is Turned
On.
For an On-delay timer two different types of contact.
● NOTC - Normally opened,timed -closed.
● NCTO - Normally-Closed,Timed -Open
While
In Off Delay Timer —After The Input Is Turned Off There Is A Delay Before The Output Is Turned
Off.
● NOTO (Normally Open,Timed Open) -
● NCTC - Normally Closed,Timed Closed Contacts
12. Build a ladder logic program for NAND operation. AP C415.2
13. Create a ladder logic diagram a motor control circuit with two stop
buttons. When the start button is pressed, the motor runs. By sealing, it
continues to run when the start button is released. The stop buttons
stop the motor when they are depressed.
C C415.2
14. Briefly explain the function proximity sensor. Give some example.
A proximity sensor is a sensor able to detect the presence of nearby objects without any
physical contact. A proximity sensor often emits an electromagnetic field or a beam of
electromagnetic radiation (infrared, for instance), and looks for changes in the field or return U C415.1
signal.
For example, a capacitive proximity sensor or photoelectric sensor might be suitable for a
plastic target; an inductive proximity sensor always requires a metal target.
15. Build a Ladder logic for the following expression
C C415.2
Distributive Law A(B + C) = (AB) + (AC)
16. Build a Ladder logic for the expression Y=AB+CD
A C415.2
17. Create a Ladder diagram for two limit switches connected in series
with each other and in parallel with a third limit switch and used to
control a warning horn.
C C415.2
18. Compare the two data transfer instructions in PLC. U C415.2
1. LIM (Limit test) —Tests whether one value is within the limit range of two other
values.
2. MEQ (Masked Comparison for Equal) —Tests portions of two values to see
whether they are equal. Compares 16-bit data of a source address to 16-bit data at a
reference address through a mask.
3. EQU (Equal) —Tests whether two values are equal.
4. NEQ (Not Equal) —Tests whether one value is not equal to a second value.
5. LES (Less Than) —Tests whether one value is less than a second value.
6. GRT (Greater Than) —Tests whether one value is greater than a second value.
7. LEQ (Less Than or Equal) —Tests whether one value is less than or equal to a
second value.
8. GEQ (Greater Than or Equal) —Tests whether one value is greater than or equal
to a second value.
19. Illustrate the functional block of any two data compare instruction. U C415.2
https://www.plcacademy.com/function-block-diagram-programming
/
20. Construct a ladder logic using to count the number of people in a store AP C415.3
till 100, where people being entering and leaving continuously.
21. Build a ladder logic for continuous operation of a motor in forward AP C415.3
and reverse direction each 10 sec.
22. Build a ladder rung for the Boolean expression for Y=A(BC+D) AP C415.3
23. Explain the necessity of networking and interfacing in Industrial U C415.4
Automation.
24. Design a ladder diagram that will control a stepper motor so that it
rotates 10 steps forward, waits for 20 seconds and then cause the motor
to rotate 10 steps in the reverse direction.
C C415.4
25. What is HMI and Different types of interfaces in HMI? R C415.4
A Human-Machine Interface (HMI) is a user interface or dashboard that
connects a person to a machine, system, or device. While the term can
technically be applied to any screen that allows a user to interact with a
device, HMI is most commonly used in the context of an industrial process.
There are three basic types of HMIs: the pushbutton replacer, the data handler,
and the overseer.
26. Identify the benefits of an HMI over a desktop?
❏ Converting hardware to software.
U C415.3
❏ Eliminating the need for mouse and keyboard, and allowing
kinesthetic computer/human interaction.
27. Infer the functions of Client and server in HMI. U C415.4
28. Explain the functionalities in operator panel of HMI. U C415.4
29. List few maintenance guidelines for PLC R C415.4
● Any filters that have been installed in enclosures should be cleaned or replaced to
ensure that clear air circulation is present inside the enclosure.
● Keep a master copy of operating programs used.
● Dust and dirt accumulated in the PLC panel and circuit board should be cleaned. If
conductive dust reaches the electronic boards, a short circuit could result and cause
permanent damage to the circuit board. Ensuring that the enclosure door is kept
closed will prevent the rapid buildup of these contaminants.
● Connections to the I/O modules should be checked for tightness to ensure that all
plugs, sockets, terminal strips, and module connections are making connections and
that the module is installed securely. Loose connections may result not only in
improper function of the controller but also in damage to the components of the
system.
● All field I/O devices should be inspected to ensure that they are adjusted properly.
● Circuit cards that deal with process control analogs should be calibrated every 6
months. Other devices, such as sensors, should receive service monthly.
● Heavy noise or heat generating machines and instruments should not place close to
the PLC.
● Check the state of the battery that supports the RAM memory in the CPU. Most CPUs
have a status indicator that shows whether the battery voltage is sufficient to back up
the memory stored in the PLC. If a battery module is to be replaced, it must be
replaced with the same type of battery module.
30. Explain troubleshooting of a ground loop. U C415.4
To check for a ground loop, disconnect the ground wire at the ground termination and
measure the resistance from the wire to the termination point where it is connected
(see Figure below). The meter should read a large ohm value. If a low ohm value
occurs across this gap, circuit continuity exists,
meaning that the system has at least one ground loop.
31. Illustrate the role of servo motor in Manufacturing system.
A C415.4
32. What is SCADA? R C415.5
Supervisory Control and Data Acquisition (SCADA) is a control system architecture
that uses computers, networked data communications and graphical user interfaces
for high-level process supervisory management, but uses other peripheral devices
such as programmable logic controller (PLC) and discrete PID controllers to interface
with the process plant or machinery. The use of SCADA has been also considered for
management and operations of project-driven-process in construction
33. Classify the types of tag available in SCADA. U C415.5
· Internal Tag
· Virtual Tags
● A Data Point Tag stores a single process value, for example the state of a
pump, or a temperature.
● An Alarm Tag represents an abnormal condition.
● A Graphic Page Tag contains a visual representation of a process or
equipment.
● A Trend Page Tag shows how process values vary over time.
● A Program Tag runs an IEC-61131-3 program.
● A PLC Device Tag represents a programmable logic controller or similar
device.
● A Channel Tag represents a communication channel to a program logic
controller device.
Digital Tag – Represents two states ON/OFF.
34. Design alarm tag using digital tag. AP C415.5
35. Tell the functions of trend in SCADA R C415.5
36. List few applications of SCADA R C415.5
37. Explain OPC. U C415.6
OPC = OLE for Process Control
OPC is a software interface standard that allows Windows programs to
communicate with industrial hardware device. Open Platform Communications
(OPC) specifies the communication of real-time plant data between control devices
from different manufacturers.
38. Summarize the advantages of OLE over DDE? U C415.6
Object Linking & Embedding (OLE) is a proprietary technology developed by Microsoft that
allows embedding and linking to documents and other objects. It is an evolution of the original
Dynamic Data Exchange (DDE) concept that Microsoft developed for earlier versions of
Windows. While DDE was limited to transferring limited amounts of data between two
running applications, OLE was capable of maintaining active links between two documents or
even embedding one type of document within another.
The main benefit of using OLE, next to reduced file size, is the ability to create a
master file.
OLE
Object Linking & Embedding (OLE) is a proprietary technology developed by Microsoft that
allows embedding and linking to documents and other objects. OLE allows an editing
application to export part of a document to another editing application and then import it with
additional content. OLE is also used for transferring data between different applications using
drag and drop and clipboard operations.
DDE
Dynamic Data Exchange (DDE) is an interprocess communication system which
allows data to be communicated or shared between the applications in operating systems such
as Windows. Dynamic Data Exchange makes use of shared memory and a set of commands,
message formats and protocols for communication and sharing. DDE allowed programs to
manipulate objects provided by other programs and respond to user actions affecting those
objects.
39. List few open protocols used in SCADA R C415.6
● Legacy SCADA protocols include Modbus RTU, RP-570, Profibus and Conitel.
● Standard protocols are IEC 60870-5-101 or 104, IEC 61850 and DNP3
40. What does DDE stands for? And explain its function? U C415.6
Dynamic Data Exchange (DDE) is an interprocess communication system which allows data to
be communicated or shared between the applications in operating systems such as Windows.
Dynamic Data Exchange makes use of shared memory and a set of commands, message
formats and protocols for communication and sharing. DDE allowed programs to manipulate
objects provided by other programs and respond to user actions affecting those objects.
PART B - 16 Marks BT CO Mark
Questions can be either one division with 16 Marks or (10+6) Marks or (8+8) s
Marks
1. (i) Define automation? Describe the historical development of R C415.1 10
automation?
(ii) in the elements of automation. R C415.1 6
2. (i) Illustrate the architecture of PLC showing the main functional
items and how buses link them, explaining the functions of each U C415.1 16
block. B : 16-20
3. (i) Discuss the different I/O modules of PLC. P : 33-45 U C415.1 10
(ii) List out the advantages of PLC. P:15-17 U C415.1 6
4. Design suitable block diagram and describe the various
components of Programmable Logic Controller. P : 17-21 & U C415.1 16
B: 14-16
5. i) Construct a PLC program to illustrate the bottle filling process
C C415.2 10
with neat diagram P: 174,B : 279
ii) Draw the Logical AND, OR and EXOR operation in Ladder logic
program P : AND & OR - 94, XOR - 96
C415.2
C 6
B : AND & OR - 95-97, XOR - 100-101
6. (i) Explain any two data handling function of PLC with suitable U C415.2 8
example
https://automationforum.co/data-handling-instructions-for-plc/
https://www.wisdomjobs.com/e-university/programmable-logi
c-controllers-tutorial-523/data-handling-14736.html
(ii) Explain in details counter function of PLC U C415.2 8
https://www.plcacademy.com/plc-counters/
7. i) Enumerate in detail about various applications of PLC. Explain in
brief about PLC advantages and disadvantages. P:26,15-17
Advantages:
● Small physical size & shorter project time.
● Cost effective for controlling complex system.
● Reliability.
● Less and simple wiring. U C415.1 8
● Faster response.
● Remote control capability.
● More flexibility.
● Ease of maintenance / troubleshooting.
Disadvantages:
● Fixed circuit operation.
● PLCs manufacturers offer only closed loop architecture.
● PLCs are propitiatory, which means software and parts one manufacturer can’t
be easily used in combination with part of another manufacturer.
● Number of optional modules must be added to maximize flexibility and
performance.
ii) Analyze the role of sensors in PLC and Explain the principle and
A C415.1
working of Proximity Sensor. P : 149-153 8
8. (i) In an automatic car parking system, entry and exit of a car is
detected by sensors. A PLC will keep a record of number of cars
enter and exit. Maximum 50 numbers of cars in the parking area. AP C415.3 16
An entry gate (controlled by electric motor) will be kept open only
when number of cars in the parking area is less than 50. Design a
ladder diagram to control the operation of the entry gate of the car
parking system.
9. Construct a ladder diagram for a three motor system having the
(i) following conditions: Motor 1(M1) starts as soon as the start AP C415.3 16
switch is ON, after 10seconds M1 goes OFF and M2 starts. After 5
seconds M2 goes OFF andM3 comes ON. After 10 seconds M3
goes OFF and M2 comes ON. And After 5 seconds M2 goes OFF
and M1 comes ON ,and cycle is repeated
Refer :
https://instrumentationtools.com/plc-program-for-sequential-m
otor-control/
10. A motorized overhead garage door is to be operated
(i)
automatically to preset open and closed positions. The field
devices include one of each of the following:
• Reversing motor contactor for the up and down directions
• Normally closed down limit switch to sense when the door is
fully closed
• Normally closed up limit switch to sense when the door is fully
C C415.2 16
opened
• Normally open door up button for the up direction
• Normally open door down button for the down direction
• Normally closed door stop button for stopping the door
• Red door ajar light to signal when the door is partially open
• Green door open light to signal when the door is fully open
• Yellow door closed light to signal when the door is fully closed
P : 173
11. (i)
Illustrate ON delay timer instruction of PLC with timing diagram
and suitable ladder logic example. P: 187-193 AP C415.3 8
(ii) Explain different jump operations with PLC ladder diagram U C415.3 8
P : 252-259, B : 165-168
12. (i) List and explain different data comparison instructions in PLC R, C415.2 8
programming U
https://automationforum.co/comparison-instructions-of-plc/
(ii) Summarize the main features of data handling instructions U C415.3 8
https://automationforum.co/data-handling-instructions-for-plc/
13. (i) Develop the equivalent ladder diagram of AND, OR and NOT AP C415.3 8
gates. P : 94
(ii) When the lights are turned off in a building, an exit door light is
to AP C415.3 8
remain on for an additional 2 min, and the parking lot lights are to
remain on for an additional 3 min after the door light goes out.
Write a ladder program to manipulate this process.
14. (i) Illustrate the characteristics of PLC, functions and its classification AP C415.4 8
(ii) Explain the Alarm logging and Tag logging in SCADA. - U C415.5 8
https://cache.industry.siemens.com/dl/files/270/1145270/att_3
6311/v1/Confm1_e.pdf - 216(Alarm logging)
15. (i) Illustrate the Installation and maintenance procedures and
AP C415.4
Troubleshooting techniques of PLC P:376-386 8
Explain the concept of Human Machine Interface and working of
U C415.3 8
Touch panels and Integrated displays.Refer:sent pdf
16. (i) Analyze the functionality of HMI in PLC based automation with A C415.4 16
an example Refer: sent pdf
17. (i) Explain the architecture of SCADA with a neat sketch. U C415.5 10
https://electricalfundablog.com/scada-system-components-archi
tecture/
https://www.elprocus.com/scada-systems-work/
(ii) Show the functions of SCADA and summarize the functions U C415.5 6
performed by SCADA components.
https://automationforum.co/how-a-scada-works-and-functions-
of-scada/
18. (i) Demonstrate the process of DDE server configuration AP C415.6 10
Refer: sent pdf or
https://www.promotic.eu/en/pmdoc/Subsystems/Comm/DD
E/DDE.htm
(ii) Explain OPC protocol with respect to SCADA.Refer: sent pdf U C415.5 6
https://www.matrikonopc.com/opc-drivers/302/base-driver-de
tails.aspx
19. (i) Explain the process of interfacing SCADA and PLC with an U C415.6 16
example
20. (i) Explain the principle and working of Pressure Sensor. B : 39-40 U
C415.1 8
(ii) Explain principle and working of Temperature Sensor. B: 35-56 U
C415.1
8
