JAYAWANT SHIKSHAN PRASARAK MANDAL’s

Bhivrabai Sawant Polytechnic

(Approved by AICTE, New Delhi, Govt. of Maharashtra, Affiliated to MSBTE Mumbai)
Gat No. 720 (1&2), Wagholi, Pune-Nagar Road, Pune-412207)
Phone: 020 – 65335100 Tele fax: - + 91-020-65335100
E-mail: bspoly@rediffmail.com Website: www.jspm.edu.in

Electronics & Telecommunication Department

Academic Year 2019-20
SAMPLE PAPER SOLUTION
Course: Industrial Automation Course Code: 22534 Semesters: 5th
4 or 6 Marks Questions.
Q.No. Marks Questions
1 4 Draw the Functional Block diagram of Electric Drives and explain in brief.

Marking Draw : 2 Marks , Explain : 2 Marks

Scheme
Block diagram of Electric Drives:

Drive:

A combination of prime mover, transmission equipment and mechanical Working load is

Answer called a drive

Electric drive:

An Electric Drive can be defined as an electromechanical device for converting electrical

energy to mechanical energy to impart motion to different machines and mechanisms for
various kinds of process control.

The aggregate of the electric motor, the energy transmitting shaft and the control equipment
by which the motor characteristics are adjusted and their operating conditions with respect to
mechanical load varied to suit practical requirements is called as electric drive.

Drive system=Drive + load

Load: usually a machinery to accomplish a given task. Eg-fans, pumps, washing

machine etc.
 Power modulator: modulators (adjust or converter) power flow from the source to the
motion
Motor: actual energy converting machine (electrical to mechanical)
Source: energy requirement for the operation the system.
Control: adjust motor and load characteristics for the optimal mode.
Power modulators:

Power modulators regulate the power flow from source to the motor to enable the motor to
develop the torque speed characteristics required by the load.

The common function of the power modulator is,

They contain and control the source and motor currents with in permissible limits during
the transient operations such as starting, braking, speed reversal etc.

They convert the input electrical energy into the form as required by the motors.
Adjusts the mode of operation of the motor that is motoring, braking are regenerative.

Power modulators may be classified as,

Converters uses power devices to convert uncontrolled valued to controllable output.

Switching circuits switch mode of operation

Variable impedance

Converters

They provide adjustable voltage/current/frequency to control speed, torque output power of

the motor.

The various type of converters

AC to DC rectifiers

DC to DC choppers
AC to AC choppers
AC to AC –AC voltage controllers (voltage level is controlled)

Cycloconverter (Frequency is controlled)

DC to AC inverters.

Switching circuits

Switching circuits are needed to achieve any one of the following.

Changing motor connection to change its quadrant of operation.

Changing motor circuits parameters in discrete steps for automatic starting and braking
control.
 For operating motors and drives according to a predetermine sequence
To provide inter locking their by preventing maloperation

Disconnect under up normal condition Eg: electromagnetic contacters,

PLC in sequencing and inter locking operation, solid state relays etc.

Variable impedance

Variable resisters are commonly used for AC and DC drives and also needed for
dynamic braking of drives

Semiconductors switch in parallel with a fixed resistance is used where step less
variation is needed. inductors employed to limit starting current of ac motors.

2 4 Draw the Basic architecture of SCADA and explain in brief.

Marking Draw : 2 Marks , Explain : 2 Marks

Scheme
Architecture of SCADA:

Answer

SCADA (Supervisory Control and Data Acquisition) systems are extensively used to control
geographically distributed processes, which are often scattered over thousands of kilometers
and where centralized data acquisition and control is necessary to perform system operation.

Architecture of SCADA
A typical architecture of a SCADA system is shown in below figure which describes the
general configuration and major components of the SCADA. In this, control area or master
station house main server which acts as MTU and communication routers.
Also, the control area includes engineering workstations, HMI stations, data servers, and data
historians, which are all connected by local area network (LAN). The master station is
responsible for monitoring and controlling various remote stations.
Remote stations are equipped with one or more RTUs/ PLCs which performs local monitoring
through sensors (such as voltage, current, temperature and pressure) and local controlling
through actuators (such as pumps, relays, and valves). The field site devices are connected
through WAN network to perform remote diagnostics.
The communication or transferring of information between field sites and control center is
carried through proprietary communication protocols over serial communications using
telemetry techniques such as cable, telephone line and RF.
Components of SCADA or Block Diagram of SCADA:
The major components of SCADA include
Master Terminal Unit (MTU)
It is the heart of the SCADA system, which can be a dedicated computer, a Programmable
Logic Controller (PLC), or a network server that communicates with remote field side RTUs.
It initiates all communication, collects the data, stores the data in database, provides interfaces
to operators and sends the information to other systems.

It allows the users to perform controlling functions on field devices such as breakers, switches
and other actuators depending on the gathered data. It continuously communicates with other
devices in master station so as to facilitate data logging, alarm processing, trending and
reporting, graphical interface and security system.
Remote Terminal Units (RTUs)
RTUs gather the information from various field sites in which they are employed. Each RTU
is connected with various sensors and actuators that manage local process or field equipment.
It collects the information from various sensors and sends the information to the MTU. Also,
it receives the control commands from MTU and correspondingly controls the various
actuators.
Remote Terminal Units
Many RTUs store the data in their database and waits for a request from the MTU to send or
transmit the data. In sophisticated systems, PLCs are used as RTUs which directly transfers
the field data and controls the parameters without a request from the MTU. It uses a local area
network to communication with various field intelligent devices.

Communication Equipment/Network
It provides the link between RTUs (in the field) to MTU (in the control center). The
communication can be wired or wireless or through internet which provides bidirectional and
 uninterrupted communication between RTU and MTU.
SCADA systems can be connected using various communication mediums including twisted
pair cables, coaxial metal cables, fiber optic cables, satellites, high frequency radio, telephone
lines, and microwave radio.
The topology of the SCADA system network depends on the type of system or application it
is intended for. Mostly redundant topology is recommended for critical control applications.
SCADA Software
It is an important aspect of every SCADA system which presents the information to the user
and also allows the user to intervene in the process control. Many SCADA systems use
commercial proprietary software upon which SCADA system is developed.

3 4 Enlist Different Specification of AC Drives. (Any 8)

Marking Each Specification: ½ Marks

Scheme
Different Specification of AC Drives
1. Open loop vector control variable frequency drive
2. Speed or torque control variable frequency drive
3. Speed reference input: 0-10V, 0-20mA, 4-20mA, (-10 to +10V SM-I/O Lite option)
4. 4 digital inputs- World (enable, run forward, run reverse, local/remote)- USA (not
stop, run, jog, local/remote)
5. VFD switching frequency: 3 (default) – 6 – 12– 18 kHz
6. VFD Output frequency 0 to 1500Hz
Answer
7. VFD Accelerate and Decelerate ramps (linear and S type)
8. Positive logic control
9. Serial communication - Modbus RTU RS485 via RJ45 connector- Baud rate 4800,
9600, 19200or 38400 bits per second
10. DC injection braking as standard in the VFD
11. Dynamic braking transistor as standard in the VFD
12. Dynamic motor flux V/Hz for energy saving
13. Quadratic motor flux V/Hz for fan and pump optimization
Explain the following Electrical Drives (Any One)
4 4
a. Group Drive b. Individual Drive c. Multimotor Drive

Marking Draw : 2 Marks , Explain : 2 Marks

Scheme
 Group Drive :

 When one prime mover or motor is used for the number of machine tools on common
shaft then the drive is called as group drive . it is also sometimes called as line shaft drive.
 Cost of group drive is less for given capacity of load. cost of one motors of given capacity
is less than the cost of many motors of the same capacity.
 Total H.P of motor used in group drive may be less than the sum of the H.P of individual
machines since all the machines may not be working at same time.
 Group drive has high overload capacity.
 Speed control of individual machine is very difficult.
Answer
 It does not give good appearances due to use of line shafting pulleys and belts.
 Group drives are less safe to operate.
 Flexibility of layout of the various machines is lost in group drive since machines have to
be installed to suit the layout of the line shafting.
 Extension of the process by installing new machine is limited.
 The breakdown of main motor causes stoppage of all the operations. Considerable power
loss takes place in the energy transmitting system.
 It is used in the process where stoppage of one operation requires the stoppage of
sequence of operations as in case of textile mills.

Individual Drive:
  In individual drive an electric motor used for transmitting motion to various parts or
mechanism belonging to single equipment. For example, such drive are used to rotate the
spindle, moves the feed and with the help of gears imparts motion to lubricating and
cooling pumps in lathe.
 In application, individual drive consist of motor which is specifically designed to form an
integral part of the machine.
 In individual drive, the energy is transmitted to different parts of same mechanism by
means of mechanical parts like gear, pulley, etc. hence occurs some power loss.

Multimotor Drive:

The multimotor drive consists of several individual motor which serve to one of many
motions or mechanism in some production unit. For example, in travelling crane, there are
three motors used.
 One for hoisting, other for long travel motion and third for cross travel motion. Such a
drive is essential in complicated metal cutting machine, paper making machine, rolling
mills, rotary printing machine, etc.

The use of multimotor drive is expanding in modern industries due to their advantage
outweighs increase in capital cost compared to the group drive.

5 4 Compare between PLC & SCADA system in any 4 points

Marking Each points: 01 Marks
Scheme

Features PLC SCADA

It is a solid state device which It is software. It is used to

controls the output of the monitor, control and acquire
What is it?
process through the program data from field devices even
given in ladder diagrams. from remote locations.

Input and output are

represented in normal open
Input/output
(NO), normal close (NC) and Input and output are
coil contacts. represented in images.

Each component involved is Each object is defined using

Answer Component/Object
defined using address. name.

1. Glass industry, 1. Electric power system,

2. Paper Industry, operation and control
3.Cement manufacturing, 2. Manufacturing Industries or
4. Continuous bottle filling plants
system 3. Telecom and IT based
Application 5.Batch mixing system systems
6..stage air conditioning 4. Water and sewage treatment
system plants and supply
7..Traffic control management
5. Traffic controls
6. Lift and Elevator controls
6 4 Compare between AC drive & DC drive.
Marking Each: 01 marks
Scheme

CHARACTERISTIC
AC DRIVES DC DRIVES
S

Supply Run by AC supply Run by DC supply

Maintenance Requires less maintenance. Requires comparatively more and

frequent maintenance.
Answer
Use/ Application Are generally used for AC Are used for DC motors normally.
motors.

Locational use Are used in almost all the are used in very few locations
locations.

Breaking Mechanism Breaking and accelerating Breaking occurs when resistance is

 when supply frequency (F s ) applied at rotor.
changes

Power & Control Power and control circuits Power and control circuits are
Circuitry are difficult and quite simple to design and less expensive
complex in design. s compared to their counter-parts.

Components Have converter and inverter. Have converter and chopping

circuit.

Commutation There is no commutation Because of commutation, they are

which makes AC Drives less more heavy and costly.
bulky and inexpensive.

Rectifier There is no need of rectifier Rectifying circuit is necessary

circuit

Speed Control Sped control is achieved by Speed control is achieved by

changing the frequency armature and field control

Corrosive and Wet Can be used in such Cannot be used because sparks can
Environment environment since their be produced in brushes easily.
operation is spark free

Cost In AC Drives, motors are In DC Drives, motors are

less expensive especially significantly expensive.
squirrel cage motors.

Speed limit There is no upper limit for Speed is limited because of

speed. commutation process.

Harmonics Converters produce Converters do not produce

harmonics in supply as well harmonics
as in load

Motor speed Can reach up to 10000 RPM Can reach up to 2500 RPM

Speed regulation ~1% speed regulation is Not possible to achieve 1 % speed

attainable regulation

Dynamic response Offer high dynamic response Offer low dynamic response

Starting torque Do not produce high starting Produces high starting torque
torque

Battery use Cannot be run directly by Can be run directly through

batteries without using extra batteries without adding an extra
circuitry components

Noise Operation is noisy which is They are not noisy as compared to

highly unfavorable in certain AC Drives
applications

Power consumption Consume less power Consume more power

Brushes life Very high (~10000h) Low (~3000h)

Explain Sinking & Sourcing concept in PLC input & Output Module.
7 4
Marking Draw : 2 Marks , Explain : 2 Marks
Scheme
 When choosing the type of input or output module for your PLC system, it is very important
to have a solid understanding of sinking and sourcing concepts. Use of these terms occurs
frequently in discussion of input or output circuits. It is the goal of this post to make these
concepts easy to understand, so you can make the right choice the first time when selecting
the type of I/O points for your application. This post provides short definitions, followed by
general example circuits.

sinking and sourcing First you will notice that the diagrams on this page are associated with
only DC circuits and not AC, because of the reference to (+) and (-) polarities. Therefore,
sinking and sourcing terminology applies only to DC input and output circuits. Input and
output points that are sinking or sourcing can conduct current in one direction only. This
means it is possible to connect the external supply and field device to the I/O point, with
current trying to flow in the wrong direction, and the circuit will not operate. However, the
supply and field device can be connected every time based on an understanding of sourcing
Answer
and sinking.

The figure below depicts a sinking input. To properly connect the external supply, it must be
connected so the input provides a path to supply common (-). So, start at the PLC input
terminal, follow through the input sensing circuit, exit at the common terminal, and connect
the supply (-) to the common terminal. By adding the switch between the supply (+) and the
input, the circuit is completed. Current flows in the direction of the arrow when the switch is
closed.

Sink/source I/O circuits combine sinking and sourcing capabilities. This means that the I/O
 circuitry in the PLC will allow current to flow in either direction, as shown below. The
common terminal connects to one polarity, and the I/O point connects to the other polarity
(through the field device). This provides flexibility in making connections to your field power
supply. Please note:

 Wire all I/O points with a shared common as either sinking or sourcing.

 Do not use an AC power supply on a DC sink/source I/O point.

8 4 List any four input & Output devices that can be connected to PLC.

Marking Input Devices:2 Mark & Output Devices:2 Mark

Scheme
Input devices that can be connected to PLC:

1. Mechanical Switches
2. Proximity Switches
3. Photoelectric Sensors and Switches
4. Temperature Sensors
5. Position/Displacement Sensors
6. Strain Gauges
7. Pressure Sensors
Answer 8. Liquid-Level Detectors
9. Fluid Flow Measurement
10. Smart Sensors
Output devices that can be connected to PLC:
1. Relay
2. Directional Control Valves
3. Motors- AC / DC Motor
4. Stepper Motor
5. Display Devices
Write a PLC ladder diagram for following motor sequence:
i) Start button starts motor M1.
ii) After 10 sec M1 is off and M2 is ON.
9 4
iii) After 5 sec motor M2 is off.
iv) Stop push button stops M1, M2, if pressed any time during process.

Marking Proper ladder diagram: 4 Mark.

Scheme
 Answer

List different types of language used in PLC.

10 4
Marking Each type: ½ marks
Scheme
PLC programming languages: This standard specifies five languages divided into two parts
namely-graphical languages and text-based languages.

(ii) Function Block Diagram (FBD)

Answer
(iii)Sequential Function Chart or Grafcet (SFC)

-based languages : (i) Instruction List (IL)

(ii) Structured Text (ST)

Compare fixed and flexible automation on any four points.

11 4

Marking Each Point : 1 marks

Scheme
Sr. No. Fixed Automation Flexible Automation

1. Fixed automation is a system in which It is an extension of programmable

Answer
the sequence of processing is fixed by automation
equipment configuration.
 2. The operation sequence are simple. It is flexible automated system which can
accommodate design change of product

3. Higher initial investment of custom High investment initially

equipment.

4. High production capacity Continuous production with Varity of

product.

5. Inflexible to accommodate product Flexibility for verity of product design

changes change over

6. Example : Automated material Example: - CNC m/c tools,

handling & transfer lines & assembly reprogrammable Industrial robots.
equipments.

With neat sketch explain redundancy in PLC.

12 4

Marking Diagram:2 marks, Explain: 2 marks

Scheme
Redundancy : ● Redundancy means extra system components or mechanisms added to
decrease the chance of total system failure. ● Different types of redundancy are available in
PLC like redundancy for a CPU module, power module, bases and communication module is
available. ● CPU redundancy system is composed of separate bases for ideal redundancy
structure. ● In case an error occurs in an active CPU module, a backup module is
automatically converted to active one for continuous operation. ● In these cases two
processors can be tied into one I/O system and some means is provided that switches control
from the failure CPU to the backup when a failure CPU to the backup when a failure occurs as
Answer
shown in Fig.

Draw a neat block diagram of PLC and describe the working of its parts.
13 4

Marking Block Diargam:2 Marks, Explain: 2 Marks.

Scheme
 Explanation:

The Basic PLC structure consists of –

1) Input Module: Input Module works as an interface between the CPU and the real

world input devices attached to input module .The devices connected to input module

are called as input devices. It accepts the incoming signal and converts this signal in
Answer
the form which is compatible with CPU.

2) Output Module: Output module works as an interface or link between the CPU and

the real world devices attached to the output module. The main function of output

module is to take control signal from CPU and based on signal received from CPU it

changes the status of output devices.

3) Central processing unit: The CPU is the main part of any PLC .The CPU solves the

user program logic, by using real time input status from input module and updates the

status of outputs through output module.

4) Power supply: Power supply is the part of PLC which is used to supply required

amount of power to CPU, input module and output module.

5) Programming device: The programming device is used for communication between

user and PLC. The programming device helps the user to enter and modify the required

program into the PLC memory and troubleshoot PLC ladder logic program.
 6) Memory: PLC memory is divided in two part, Data memory and User memory. Data

memory is used to store data associated with instruction address and user memory is

used to store user’s application program.

Write a PLC ladder program for 24-hour time clock.

14 4 or 6

Marking Ladder Diagram: 2 Marks, Problem Definition: 2 Marks.

Scheme
24 Hour clock using Counter PLC Ladder Program
Basic PLC Ladder Programming Training Examples for Beginners. Hi Friends here we are
starting a series of Free Training on PLC Ladder Programming. These PLC Ladder Programs
are important to get basics of Ladder Programs
PLC Ladder Practice Problem:

 Using 3 counters together with the flag of M1013 (1s clock pulse) to operate a 24-
hour clock.

Topics Covered in this example is use of Counter in PLC Program

Number of PLC Counter Required

C0 - count per second

C1- count per minute
Answer C2 - count per hour

Number of PLC internal memory flag Required

M1013 - 1s clock
PLC Ladder Programming:
 PLC Ladder Programming Description:
.
 The key of operating a 24-hour clock is to use M1013 (1s clock pulse). When the

program is executed, C0 will count once per second. When the counted number
reaches 60(1 minute), C0 = ON. C1 will count once, and C0 will be reset at the same
time; similarly, when the counted number in C1 reaches 60(1 hour), C1 = ON. C2 will
count once, and C1 will be reset at the same time. Furthermore, when the present value
in C2 reaches 24, C2 will be reset, and the 24-hour counting process will start again.
 The 24-hour clock operates by using C0 to count “second”, C1 to count “minute” and
C2 to count “hour.” In this clock, the value of “second”, “minute” and “hour” can be
read by C0, C1 and C2 correspondingly. When the set value of C2 is 12, the clock will
be a 12-hour clock.
Describe the working of UP counter with neat diagram and waveform.
15 4

Marking Instruction: 2 marks, Waveform: 2 marks

Scheme
Explain up counter instruction with waveform:

Answer Format of up-counter:

Explanation:

When i/p to count up counter goes true the Acc value will be increased by 1 , not matter how
long the i/p is true. So every true rung condition acc will increment by 1.

When acc value reaches the preset value the counter DN bit will be set.

For example as shown in figure, IN example preset value is 5 , in waveform when /p goes
high then CU bit also goes high and Acc values is incremented by one .

When Next high i/p arises at counter i/p then CU bit also goes high and Acc is incremented by
1. Like this when Acc value becomes equal to preset value then DN bit is set and related o/p
device is ON. This DN bit remains high until counter is reset by reset instruction. When reset
 instruction is executed counter gets reset and DN bit also goes low and Acc also goes to zero.

Waveform:

Draw a symbol of ON delay timer instruction. State the function of following :

16 4
i) Enable bit (EN) ii) Done bit (DN) iii) Timer timing bit (TT)

Marking Ladder Diagram: 1 Marks, Waveform:2 Marks, Explanation: 1 Marks.

Scheme
Explanation of Bits:
1) T4:0 : This bit indicates timer file4,timer 0 ,it stores timer information
2) Time base 1.0: This bit indicates processor increments accumulated values in 1 second
intervals.
3) Preset: It indicates delay for timer
4) Accumulator value gives current value of the timer as 0 which increases up to the preset
value
5) I:010/5 : It is the input to the timer
6) EN : This bit is set ,when input is true
7) TT: This bit is set when timer is running other is reset
8) DN : This bit is set when accumulator value becomes equal to preset value and then
respective output becomes ON Explanation of Bits:
Answer
1) T4:0 : This bit indicates timer file4,timer 0 ,it stores timer information

2) Time base 1.0: This bit indicates processor increments accumulated values in 1 second

intervals.

3) Preset: It indicates delay for timer

4) Accumulator value gives current value of the timer as 0 which increases up to the
preset value
5) I:010/5 : It is the input to the timer

6) EN : This bit is set ,when input is true

7) TT: This bit is set when timer is running other is reset

8) DN : This bit is set when accumulator value becomes equal to preset value and then

respective output becomes ON.

Explanation of Bits:
1) T4:0 : This bit indicates timer file4,timer 0 ,it stores timer information
2) Time base 1.0: This bit indicates processor increments accumulated values in 1 second
intervals.
3) Preset: It indicates delay for timer
4) Accumulator value gives current value of the timer as 0 which increases up to the preset
value
5) I:010/5 : It is the input to the timer
6) EN : This bit is set ,when input is true
7) TT: This bit is set when timer is running other is reset
8) DN : This bit is set when accumulator value becomes equal to preset value and then
respective output becomes ON.
17 4 Draw Automation hierarchy and explain.

Marking Draw: 2 Marks, Explain: 2 Marks.

Scheme

Figure: Automation hierarchy

Answer Figure show the Hierarchy arrangement of the Automation systems consisting of different
layers.
LEVEL 0 (FIELD LEVEL)
This lowest level is where all field devices and hardware stands. All these devices are directly
or indirectly connected to automated control mechanism where they respond to the signals
(outputs) they receive and they generate feedback signals (inputs) that reflect the actual
condition on field. For example devices like motors, pneumatic systems reside at this level
and are activated with output signals from PLCs. Similarly devices like sensors, switches,
instruments reside at this level and generate input signals that are received and processed by
PLCs.

LEVEL 1 (OPERATIONAL LEVEL)

This level is also called automatic control level. PLC and DCS systems are good examples of
this level. Closed loop controls, PID control, SCADA solutions, drives are handled at this
level. This level is where all basic control processes are managed and is crucially important
for the realization of a successful production. Solutions developed at this level are specific to
process type and machine hardware itself. The technology supplier’s know-how is
transformed into production at this level.

LEVEL 2 (SUPERVISORY LEVEL)

This level is the connection between MES system and the ongoing production on shop level.
It resides various functions such as production schedule management, material data
management, product data management, machine/equipment data management, downtime
management, shift data management, recipe data management, process data acquisition,
reporting. These functions make the production activities easier for the shop floor crew.
Besides these basic functions, Level 2 systems may also provide more complicated functions
such as mathematical models, extended recipe management, machine learning and adaptation.
 Especially for some processing lines, these functions are not optional but they are required. In
these cases Level 2 systems are required as well.
As Level 1, Level 2 systems are also specific to process type. The complicated functions of a
Level 2 system given above require a deep process know-how. And each strip processing line
has its own Level 2 system.
In some resources, you may an counter that Level 2 is named as SCADA (Supervisory
Control and Data Acquisition) Level. But the name “Level 2” is mostly used.

LEVEL 3 (PLANT LEVEL)

The software systems that run at this level are called Manufacturing Execution Systems
(MES). This level does not focus only on one production line as lower levels do, but it does
cover all production lines and share information with them. It communicates with all Level 2
systems at all times through bi-directional telegrams.
A Level 3 system may have functions such as production planning, schedule management,
quality control management, material status and material transfer management, downtime
management and custom reporting. But some of these functions can also be handled by and
ERP (Level 4) system as well. At the design phase of all the systems and solutions, the
company will decide how to and where to handle each function.
Level 3 is more focused on production data. It aims to increase the manageability of
production and quality control workflow and to increase the real-time traceability of
production status in every possible detail. In order to achieve (almost) real-time data
acquisition, a Level 3 system may have to communicate with various systems other than
Level 2s, using various methods and protocols.

LEVEL 4 (ENTERPRISE LEVEL)

This level is where ERP (Enterprise Resource Planning) software run at. ERP solutions focus
on the corporate level activities (finance, accounting, human resources, etc.) which are not
directly related to production and shop-floor activities.
Level 4 communicates with Level 3 through bi-directional telegrams. Level 4 does not expect
receiving quick respond about real-time plant data as Level 3 does.

Give I/O selection criteria for PLC.

18 4
Marking 01 mark for each point(four points)
Scheme
Following points must be considered while selecting I/O modules:
1. System Requirement.
2. Application requirement.
3. What input /output capacity is required.
4. What types of input/output are required?
5. Electrical requirements.
Answer
6. Speed of operation.
7. Communication Requirements.
8. Software Requirements.
9. Operator interface requirements.
10. Physical environment.

Write a ladder diagram for traffic light control with following conditions: i) Red light
19 4 – 25sec, ii) Green light – 20 sec, iii) Yellow light – 5 sec, iv) Repeat the sequence.

Marking Correct Ladder Diagram: 4 Marks.

Scheme
 List of Input Devices

I:0/0- Start Button , I:0/1-Stop Button

List of Output Devices

O:0/0- Red Light, O:0/1- Yellow Light. O:0/2- Green Light.

T4:0-TON- Timer 1 for 25 sec T4:1-TON- Timer 2 for 20 sec

T4:0-TON- Timer 3 for 5 sec

25

Answer

20

List different PLC programming languages. Explain any one with example.
20 4

Marking List:2 Marks, Explain: 2 Marks

Scheme
 PLC programming languages: This standard specifies five languages divided into two parts
namely-graphical languages and text-based languages.

dder Logic Diagram (LD)

(ii) Function Block Diagram (FBD)

(iii)Sequential Function Chart or Grafcet (SFC)

-based languages : (i) Instruction List (IL)

(ii) Structured Text (ST)

Explanation of PLC programming languages:

i) Ladder logic diagram (LD): It is a type of graphical language having the instructions
Answer in graphical symbol format. Ladder program is very similar to electrical wiring
diagram, so it is easy to understand.
ii) Function Block Diagram (FBD): The primary concept behind FBD is data flow in
this instructions are composed of operational blocks, Each block has one or more
inputs and outputs.
iii) Sequential Function Chart or Grafcet (SFC): This language is used for performing
simultaneously operations required for controller in complex machine process
iv) Instruction List (IL): It is similar to assembly language programming, in this low
level computer language like mnemonic codes are used to specify the operation of
each rung of ladder diagram.
v) Structured Text (ST): It is a high level computer type language like Basic or C. It is
capable to perform calculations on values other than binary.

List different editors in SCADA (any four) and describe the functions of each.
21 6

Marking List: 2 Marks, Explain: 4 Marks.

Scheme
Four Editors

i. Inkscape SAGE-SCADA Animation Graphic Editor.

ii. Generic Logic

iii. TRACE MODE

Answer iv. UCanCode

i. Inkscape SAGE-SCADA Animation Graphic Editor:

SAGE is an add-on feature for Inkscape to enable real-time mimic graphic animation in SVG
running with IntegraXor SCADA animation engine. Animation effects incorporated such as
"Bar", "Color", "Rotate", "Opacity", "Zoom", "Slider", etc.
 ii. Generic Logic: Generic Logic Inc. is a premier provider of Real-Time Graphics, Data
Visualization, HMI SCADA and custom GIS Solutions for software developers around the
world. Its products are used to visualize and control real-time and mission-critical processes in
a variety of industries, from producing silicon wafers and controlling chemical plants to
launching satellites into space and monitoring airport security.

iii. TRACE MODE:

The overall functionality of TRACE MODE® has already overgrown the traditional
HMI/SCADA software, and nevertheless, HMI is still the most demanded part of the TRACE
MODE. In addition to the standard HMI functionality, TRACE MODE® 6 has a number of
features, which distinguish it from the ordinary HMI/SCADA software.

First of all, TRACE MODE has an integrated development environment (IDE), combining in
itself more than 10 different editors. The IDE has a free version. The HMI features of TRACE
MODE 6 SCADA software are so deeply merged with SOFTLOGIC controllers’
programming tool and with economical modules of T-FACTORY (MES-EAM-HRM), that
one can hardly distinguish them.

iv. UCanCode: UCanCode provides a complete set of services, consisting of design tools
and a software development kit (SDK), for developers who want to create a user interface for
industrial monitoring and process control drawing SCADA applications. These displays
feature highly customized graphical objects that connect to underlying real-world data. E-
XD++ is a complete suite of all VC++ and .NET products for SCADA and HMI applications.

Develop a ladder program for Traffic light control system with following conditions:
i) Red light ON for 30 sec, ii) green light ON for 25 sec, and
22 6 iii) Yellow light on for 05 sec. iv) Repeat the sequence until stop push button is
pressed.

Marking Correct Ladder Diagram: 6 Marks.

Scheme
Same as above Question No.19.
Answer
Select device that can be used with PLC to control the speed of AC motor. Explain how?
23 6

Marking
Scheme Device Selection: 3 marks, Explain:3 Marks
 Answer

Draw a neat wiring diagram (interfacing diagram) of following I/O devices with
appropriate PLC module: i) Proximity sensor – 24VDC, ii) Limit switch, iii) Lamp -
24 6 24VDC, iv) Fan – 230VAC.

Marking Correct wiring diagram : 6 Marks.

Scheme

Answer
There are four outputs A, B, C, D. Draw the ladder diagram for following condition:
i) A goes off when stop switch is pressed. ii) B goes off 7 seconds after A.
25 6 iii) C goes off 6 seconds after B. iv) D goes off 2 seconds after C.

Marking Correct Ladder diagram : 6 Marks.

Scheme

Answer
Draw Ladder diagram for automatic bottle filling system. Assume suitable system
26 6
design for the same.

Marking Design: 3 Marks, Ladder Diagram: 3 Marks.

Scheme
We will implement a control program that detects the position of a bottle via a limit switch
then waits for 0.5 secs, and then fills the bottle until a photodetector detects the filled

Answer condition of the bottle. After the bottle is filled ,the buzzer sounds and the control program
will again wait for 0.7 secs. before moving to the next bottle .Until the limit switch signals
,the feed motor,M1 runs while there are fixed rollers which carries the filled bottles.
Motor,M2 keeps running after the process has been started.

Once the start button is pressed the green light (L1) turns ON and remains ON until stop
button is pressed.As light turns ON out feed motor(M2) starts running.After M2 runs and if
either limit switch(LS) has not signalled or filled bottle condition is fulfilled motor(M1)
starts.After limit switch has signalled timer,T1 gets activated. After T1 gives done (DN)signal
and photo detector (PE) is disabled ,solenoid valve gets in operation.As PE signals solenoid
stops and buzzer(B1) sounds after which timer,T2 gets enabled which stops the process for
0.7 seconds. Once the filled bottle condition is activated the cycle starts again. The ladder
diagram was successfully checked in the PLC simulator and all the prescribed conditions were
observed completely.
 Draw the ladder diagram as shown in Fig. l for elevator system

27 6

Logic
(i) When the start button is pushed the platform is driven to the down position.
(ii) When stop push button is pressed the platform is halted at whatever
position it occupies at that time.
(iii) When up button is pushed, the platform if it is not in down motion is
driven to the up position.
(iii)When the down button is pushed, the platform if it is not in up
motion is driven to down position.
Marking Correct Ladder diagram : 6 Marks.
Scheme

Answer

Explain with diagram types of PLC.

28 4

Marking Types:1 Marks, Diagram: 2 Marks, Explain : 1 Marks.

Scheme
PLC types are as follows:

1. Micro PLC ( Fixed I/O)

2. Modular PLC:

Small PLC- Less than 100 I/O additional can be added (20 Input and 12 outputs mounted
locally with the process)

Medium PLC-4000 to 8000 I /O.

Answer
Large

1. Micro PLC ( Fixed I/O):

Explanation: 1. Limited I/O (32 or less than 32)

2. A fixed PLC consists of a fixed or built in input and output sections.

3. There is one fixed, non-removable screw terminal strip containing all input screw terminals
and another screw containing all output control signal screw terminals.

4. Memory capacity is fixed.

5. Generally digital devices are connected to it.

Modular PLC:

Explanation:

1. A modular PLC does not have a terminal strip built into the processor unit.

2. Modular PLC’S have their I/O points on plug in type, removable units called I/O modules.
3. PLC’s with modular inputs and outputs consists chasis, rack or baseplate where power
supply, CPU and all input, output modules are separate hardware items.

4. The power supply is modular is typically hooked up to line voltage on the chasis.
 Classify the following devices into input and output devices w.r.t. PLC, pressure

switch, Thermocouple, Motor, push button, Relay coil, toggle switch, Stepper
28 6
motor, level switch, Alarm, RTD, Lamp, Sensor.

Marking ½ Marks each

Scheme

Answer

List the different counter instructions ofPLC and explain anyone in detail.
29 4

Marking List : 2 Marks, Explain: 2 Marks.

Scheme
Different Counter instructions:
1. Up Counter
2. Down Counter
3. High Speed Counter
4. Counter Reset

1.Up Counter:

Answer
Waveform:

Explanation:
Up counter instruction is three word instruction.

CU Bit: This status bit is true when UP counter instruction is true.
DN bit: This bit is true when accumulated value is equal to or greater than
the present value of the counter.
OV(Overflow) bit: when counter count value exceeds 32,767,this bit
becomes true.
UN(Underflow):It will go true when counter counts below -32,768.
Reset instruction resets accumulated value to zero.

OR
2.Down counter:

CD Bit: This status bit is true when DOWN counter instruction is true.
DN bit: This bit is true when accumulated value is equal to or greater than the
present value of the counter.
OV(Overflow) bit: when counter count value exceeds 32,767,this bit becomes
true.
UN(Underflow):It will go true when counter counts below -32,768.
Reset instruction resets accumulated value to zero.

3. High Speed Counter:

This counter is similar to the CTU; however the high speed counter
instruction is only enabled by the rung on which resides.
This instruction is used to count pulses that are too fast separately from
normal input points and modules.
Most fixed PLCs will have a high speed set of input points that allow
interface to high speed inputs.
 Signals from an incremental encoder would be a typical high speed input.

4.Counter Reset:

The Reset instruction resets the counter’s accumulated value back to zero
When I:1/6 is pressed C20:7 counter will reset i.e its accumulated value becomes
zero.

30 6 Draw the block diagram of AC input module. State the function of each.
Marking Draw : 3 Marks, function: 3 Marks.
Scheme

Explanation:
Answer Power conversion:The power conversion section usually consists of resistors and
bridge rectifier. The bridge rectifier converts the incoming AC signal to a pulsating
DC level. The DC level is passed through filters and other logic circuits in order to
deliver a clean, denounced, DC input signal. The filtered DC signal goes on to the
threshold detector.
Threshold detection:Threshold detection circuitry detects if the incoming signal has
reached or exceeded a predetermined value for a predetermine time, and whether it
should be classified as valid ON or OFF signal.
 Isolation:Isolation section of the input ckt. Is usually made up of an optical isolator,
or opt coupler. In a 120VAC input module, isolation separates the high voltage,
120VAC input signal from the CPUs low voltage control logic.
Logic section:DC signal from the opto coupler are used by the logic section to pass
the input signal to the module’s input address LED and the CPU and then on to the
input status file.
Draw the ladder diagram to verify the truth table of following logic gates.
(i) AND
31 4 (ii) NOT
(iii) EXOR
(iv) OR
Marking
Scheme

Answer
32 4 State the name of specialityI/0 modules of PLC. Explain anyone.
Marking 2M for listing, 2M for explanation
Scheme
Specialty I/0 modules:
1. Communication module
2. High speed encoder input modules
3. Resistance Temperature Detector (RTD) Input modules
4. Stepper control modules
5. Thermocouple/millivolt input module.
Explanation:
1. Communication module:
ASCII I/O Modules: ASCII I/O modules allow the interfacing of bar code readers,
meters, printers, and data terminals to a PLC. ASCII modules, which accept only
valid ASCII data, are not used as extensively as they once were. Today, the RS-232
module is the module of choice in many applications.
RS-232CInterface Modules: Communication modules are available that reside in a
PLC chassis and enable you to connect a PLC to telephone lines using a modem.
PLCs connected to phone lines allow central control room operators to examine
ladder programs to modify or edit program operation at remote PLC sites. Today
many remote oil, gas, and wastewater applications are unmanned. Remote access by
way of phone lines saves maintenance personnel from driving to remote sites each
time a PLC encounters aproblem or a program change is necessary. .
Answer
OR
2.High-Speed Encoder Input Modules
When input pulses come in faster than a discrete input module can handle them, a highspeed
input module is used. High-speed counters are also used to interface encoders to a PLC.
OR
Resistance Temperature Detector (RTD) lnput Modules
A resistance temperature detector (RTD) input module interfaces a PLC to RTD
temperature-sensing elements and other types of resistance input devices such as
potentiometers. The RTD input module converts analog input signals from a
potentiometer or. RTD into input signals understood by the PLC. These values are
stored in the PLC input table.
OR
Stepper Motor Control Modules
A stepper module is an intelligent module that resides in a PLC chassis and provides
a digital output pulse train for microstepping stepper motor applications.
Thermocouple/Millivolt Input Module
The thermocouple/millivolt input module converts inputs from various thermocouple
or millivolt devices into values that can be input and stored into PLC data tables.
This module greatly enhances the flexibility of a PLC system by interfacing
 thermocouples, thus eliminating expensivethermocouple transmitters.Using an RTD
module ,PLCs can thus be used for interface applications requiring temperature and
measurement control.

Sign of Course Coordinator Sign of Module Coordinator Sign of H.O.D.