PLC QUESTIONS & ANSWERS

1. Explain in depth, the elements (components) of PLC with necessary block

diagram.

Processor section (CPU)

The processor section is brain of PLC which consists of RAM, ROM, logic solver and
user memory. The central processing unit is heart of PLC. CPU controls monitors and
supervises all operation within PLC. The CPU makes decision and executes control
instructions based on the program instruction in memory.
Input and output module
The input module is a mediator between input devices and central processing unit
(CPU) which is used to convert analog signal into digital signal.
The output module is a mediator between output devices and central processing unit
(CPU) which is convert digital signal into analog signal.
Power supply
Power supply is provided to the processor unit, input and output module unit. Power
supply may be integral or separately mounted unit. Most of the PLC operates on 0 volts
DC and 24 volts.
Memory section
The memory section is the area of the CPU in which data and information is stored
and retrieved. Data Memory is used to store numerical data required in math calculation,
bar code data etc. User memory contains user’s application program.

Programming device
Programming devices are dedicated devices used for loading the user program
into the program memory or edit it and to monitor the execution of the program of the
PLC. It is also used to troubleshoot the PLC ladder logic program. Hand held terminal
(HHT) or dedicated terminal or personal computer are programming devices commonly
used in most of the PLCs.

2. Extend the understanding with regard to functioning of dc input module of a PLC

with the necessary block diagram.
The DC input module is an essential component of a PLC (Programmable Logic
Controller) that enables the PLC to receive and process digital input signals from external
devices. It converts the voltage levels of the input signals to a level that can be interpreted
by the PLC's internal circuitry.

Block Diagram of DC Input Module

Input Signal

Opto coupler

Filter

Amplifier

Comparator

Digital Output Signal

1. Input Signal: The input signal is the voltage level received from an external device,
typically a switch, sensor, or other binary device.

2. Opto coupler: The opto coupler electrically isolates the input signal from the PLC's
internal circuitry. This isolation prevents electrical noise or disturbances from affecting the
PLC's operation. The opto coupler consists of a light-emitting diode (LED) and a
phototransistor. When an input signal is present, the LED turns on, illuminating the
phototransistor. The phototransistor then conducts current, generating an electrical signal
that is proportional to the input signal voltage.

3. Filter: The filter removes high-frequency noise from the opto coupler's output signal,
ensuring a clean and stable signal for further processing.

4. Amplifier: The amplifier boosts the signal level to a magnitude suitable for the
comparator's input range.

5. Comparator: The comparator compares the amplified signal to a reference voltage level,
typically half of the supply voltage. If the amplified signal is higher than the reference
voltage, the comparator outputs a HIGH signal; otherwise, it outputs a LOW signal.

6. Digital Output Signal: The digital output signal is the PLC's interpretation of the input
signal. It is a binary signal, either HIGH or LOW, representing the state of the input signal.

Functioning of DC Input Module

The DC input module functions by converting the analog input signal from an
external device into a digital signal that can be processed by the PLC. The input signal is
first isolated and filtered to remove noise, then amplified to a suitable level. The amplified
signal is then compared to a reference voltage, and the resulting comparison is converted
into a digital output signal that represents the state of the input signal.
Applications of DC Input Module

 Reading the state of switches, buttons, and other binary input devices
 Monitoring sensor outputs, such as temperature, pressure, or proximity
sensors
 Interfacing with external logic circuits

3. Explain in detail the working of Discrete output module of PLC with a neat
schematic.

A discrete output module is an essential component of a PLC that enables the PLC
to send control signals to external devices. It converts the digital output signals from the
PLC's internal circuitry into electrical signals that can control various devices, such as
motors, valves, solenoids, and lamps.

PLC Output Signal -> Opto coupler -> Driver -> Output Device
PLC Output Signal:

The PLC output signal is the digital signal generated by the PLC's internal logic,
representing the desired state of the output device.

Opto coupler:

The opto coupler electrically isolates the PLC's output signal from the external
circuitry, preventing electrical noise or disturbances from affecting the output device. The
opto coupler consists of an LED and a phototransistor. When a PLC output signal is
present, the LED turns on, illuminating the phototransistor. The phototransistor then
conducts current, generating an isolated output signal.
Driver:

The driver amplifies the isolated output signal to a level sufficient to control the
output device. The driver typically consists of a transistor or MOSFET that can switch
between high and low voltage states.

Output Device:

The output device is the external device that is controlled by the discrete output
module. It can be a motor, valve, solenoid, or any other electrical or mechanical device
that can be switched on or off.

Functioning of Discrete Output Module

The discrete output module functions by converting the digital output signal from
the PLC's internal circuitry into an electrical signal that can control an external device.
The PLC output signal is first isolated by the optocoupler, ensuring a safe and reliable
connection between the PLC and the output device. The optocoupler's output signal is
then amplified by the driver to a level suitable for controlling the output device. The
amplified signal is applied to the output device, causing it to switch to the desired state.

Applications of Discrete Output Module

 Switching motors on and off

 Opening and closing valves
 Activating solenoids
 Turning on and off lamps
4. Mention in detail the various types of automation.

Fixed Automation

Fixed automation, also known as hard automation, is a type of automation that is

designed to perform a single, specific task. Fixed automation systems are typically used
for high-volume, repetitive processes where there is little need for flexibility.

Examples of fixed automation include:

 Assembly line robots

 Automated welding machines

Programmable Automation

Programmable automation, also known as soft automation, is a type of automation

that can be programmed to perform a variety of tasks. Programmable automation systems
are typically used for more complex processes where there is a need for some flexibility.

Examples of programmable automation include:

 Industrial robots
 Computer numerical control (CNC) machines
 Programmable logic controllers (PLCs)

Flexible Automation

Flexible automation is a type of automation that can be easily adapted to changes

in production requirements. Flexible automation systems are typically used for medium-
volume processes where there is a need for a moderate level of flexibility.
Examples of flexible automation include:

 Flexible manufacturing systems (FMS)

 Automated assembly lines with workstations

Integrated Automation

Integrated automation is the highest level of automation, and it involves the

integration of all aspects of a manufacturing process, from design to delivery. Integrated
automation systems are typically used for high-volume, complex processes where there
is a need for a high level of flexibility and efficiency.

Examples of integrated automation include:

 Smart factories
 Cyber-physical systems
 Industry 4.0

Process Automation

Process automation is the use of technology to control and automate processes in

industries such as manufacturing, oil and gas, and chemicals. Process automation
systems typically use sensors, actuators, and controllers to monitor and control physical
processes.

Examples of process automation include:

 Chemical processing plants

 Power plants
Discrete Automation

Discrete automation is the use of technology to control and automate discrete

manufacturing processes, such as assembly, packaging, and testing. Discrete
automation systems typically use robots, conveyors, and PLCs to move and assemble
products.

Examples of discrete automation include:

 Automotive assembly plants

 Electronics manufacturing plants

5. Explain in detail the PLC processor operating cycle.

Input Scan

During the input scan phase, the PLC processor reads the states of all input
devices connected to the PLC. These input devices can include sensors, switches,
pushbuttons, and other devices that provide information about the current state of the
process or equipment.
Program Scan

Once the input scan is complete, the PLC processor enters the program scan
phase. In this phase, the PLC executes the control program stored in its memory. The
control program consists of a series of instructions that define the logic and control actions
based on the input values.

Output Scan

After executing the control program, the PLC processor enters the output scan
phase. In this phase, the PLC updates the states of all output devices connected to the
PLC. These output devices can include actuators, motors, valves, and other devices that
control the process or equipment based on the control program's instructions.

6. Explain in detail with necessary diagram, the mounting procedures necessary

for PLC.
Mounting Procedure:

 Choose a Suitable Mounting Location:

Select a location that is free from excessive vibration, moisture, direct sunlight,
or extreme temperature fluctuations. The mounting surface should be flat, sturdy, and
capable of supporting the weight of the PLC.

 Attach the Mounting Rails (DIN Rails):

If using DIN rails, ensure they are securely fastened to the mounting surface
using appropriate screws or bolts. Follow the recommended spacing between rails for
proper PLC installation.

 Align the PLC with the Mounting Rails:

Carefully position the PLC on the mounting rails, ensuring it aligns correctly
with the mounting slots or grooves. Check for proper clearance around the PLC to
allow for airflow and cable connections.

 Secure the PLC to the Mounting Rails:

Using the appropriate screws or bolts, securely fasten the PLC to the mounting
rails. Ensure the screws are tightened to the manufacturer's recommended torque
specifications.

 Connect the Grounding Strap:

Connect the grounding strap from the PLC to the grounding point to ensure
proper electrical grounding and prevent electrical hazards.
 Connect Cables and Peripherals:

Connect the necessary cables, such as power supply, communication cables,

and I/O cables, to the PLC according to the manufacturer's instructions. Ensure proper
cable routing and strain relief to prevent damage.

 Verify Installation:

Once the PLC is mounted and connected, carefully inspect the installation for
any loose connections, improperly routed cables, or potential hazards. Apply cable
ties or other securing methods to maintain proper cable organization and prevent
accidental disconnections.

 Power up and Test:

Power up the PLC and connect to it using programming software to verify its
functionality and communication. Test the PLC program and I/O connections to ensure
they are operating as intended.