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 
● Commun​i​cations 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