Cairo University MEP 4023

Faculty of Engineering Application of PLC in Automatic Control Systems

Mech. Power Department

2024/3/17 ‫ مطلوب تسليم )ھاردكوبى( لحلول الشيت األحد‬Sheet # (2) –on Lecture 2-PLC's Inputs/Outputs
1- Select True (√) or False (x) for each statement:
# TrueFalse statement
1 T All the field devices of a PLC system are connected to its I/O system through the I/O modules section
2 T The PLC's I/O system is a part of the main CPU to which all of the input devices & actuators are directly connected
3 F PLC's I/O system is what actually physically carries out control commands from the program stored in the main CPU
4 T PLC's I/O system consists of 2 parts: I/O rack & I/O modules; both parts form interface between field devices & PLC
5 T I/O system rack is an enclosure with slots in it. I/O modules are installed into the rack which is connected to the CPU
6 T I/O modules are devices with connection terminals to which the field devices are wired.
7 F The PLC I/O modules must be connected directly to the PLC's main CPU
8 T Each I/O module is both securely wired to its corresponding field devices & securely installed in a slot in the I/O rack
9 T In some small PLCs, the rack & the I/O modules come prepackaged as one unit
10 T Input & output Processing Units are used to protect inner PLC circuits from high voltages& currents or short circuits.

2-The Next figure is for:…Interface circuit for the plc

….I/O System. .....
Write the correct part # in table below:
# Part name # Part name # Part name # Part name
77 Input field devices 5 Input processing circuit 12 Photo sensor in output processing circuit 9 Output electric signals
3 Input electric signals 1 Input signals to CPU 11 Output field devices/actuators 8 Photo transistor in
13 Output processing circuit 2 PLC's CPU unit 10 LED in output processing circuit input processing
6 Output signals from CPU 4 LED in input processing circuit circuit
3- Write the function or the job of each part of the above Figure as given in the next table:
# Part name description of part function or job
LED in input processing Converts electric input signals from all input
1
circuit devices into light emitted signal to prevent direct connection with the CPU.
LED in output Converts CPU electric output signal into light
2
processing circuit emitted signal to prevent direct connection with the output field devices.
Photo transistor in input Converts light signals from LED in input processing circuit into electric signal input to the CPU to execute the
3
processing circuit program.
Photo sensor in output Converts light signals from LED in output processing circuit into electric signal output to the field devices or the
4
processing circuit actuators.
Devices supply electric input signal data to PLC. Examples
5 Input field devices are push buttons, switches, contactors, measurement devices .
Output field devices Devices await a signal data from PLC to perform control
functions. Examples are: Lights, horns, motors, valves, solenoid.
To make electric buffering between input electric
6 Input processing circuit signals & inner PLC circuits to protect PLC from high voltages and the currents or short circuit faults.
To make electric buffering between the inner PLC circuits and the output electric signals
7 Output processing circuit to protect the PLC from any high voltages and currents or short circuit faults.

4- Select True (√) or False (x) for each statement:

# TrueFalse statement
1 T PLC's inputs come from all types of devices that supply electric type signals or data to a PLC unit
2 F The PLC checks all the input signals during both the input & the output scan parts of each scan cycle
3 F Typical examples of PLC's inputs are push buttons, switches, measurement devices, and sound alarms
4 F The PLC checks all the output signals during both the input & the output scan parts of each scan cycle
5 T PLC's outputs are devices or actuators that receive electric signal/data from the PLC to perform their control functions
6 F Typical examples of PLC's outputs are lights, horns, motors, valves, and measurement devices.
7 T Types of Input/output signals that PLCs deal with include: analog signals, digital or discrete signals, and binary signals
8 T Output signals of measurement devices/transducers are analog electric signals (e.g., thermo-couples, potentiometers)
9 T Any analog signal can be converted to digital/discrete signal by sampling it through an Analog/Digital conversion board
10 F Binary/Logical signals has only 2 values (e.g., ON/OFF, High/Low, Yes/No, 1/0) and each signal value is called a Byte
MEP 4023 Applications of PLC in Control Systems Page 1 / 6 Dr. Mohsen Soliman, ACC Manager
5-Next fig. is table that identifies …Input & output designation
- Select True (√) or False (x) for each statement:
# TrueFalse statement
1 st
Group/rack I 1.# is for 1 output group/rack,
F while group/rack Q 1.# is for 1st input group/rack
2 F Group/rack I 1.# is for 1st input group/rack, while group/rack Q 1.# is for 1st output group/rack
3 T Group/rack I 1.# is for 2nd input group/rack, while group/rack Q 1.# is for 2nd output group/rack
4 F Group/rack I 0.# is for 1st output group/rack, while group/rack Q 0.# is for 1st input group/rack
5 T Group/rack I 0.# is for 1st input group/rack, while group/rack Q 0.# is for 1st output group/rack
6 T The label: I 0.0 designates the 1st input to the PLC I/O system
7 F The label: I 0.6 designates the 6th input to the PLC I/O system
8 F The label: I 1.4 designates the 14th input to the PLC I/O system
9 T The label: Q 0.0 designates the 1st output from the PLC I/O system
10 F The label: Q 0.6 designates the 6th output from the PLC I/O system
6-Next figure is for…Binary system
Select True (√) or False (x) for each statement:
# TrueFalse statement
0 1 2 3 4
1 F The Decimal numbering system includes 9 digits, base of 10, and weights powers of 10 (10 , 10 , 10 , 10 , 10 ,…..)
0 1 2 3 4
2 F Binary numbering system includes 3 digits, base of 2,& weights powers of 2 (2 , 2 , 2 , 2 , 2 (1, 2, 4, 8, 16, ...)
3 F The above figure is for 7 bits binary code system
4 In the above binary system, The 1st column has binary weight of 20. It is equivalent to a decimal 1.This is referred to
T as the least significant bit. Number in far left column is referred to as the most significant bit. For 8 bits system, as
shown, the most significant bit has a binary weight of 27. This is equivalent to a decimal 128.
5 In binary system, the 1st column to far right is referred to as the least significant bit & has binary weight of 21. It is
F equivalent to a decimal 1.
6
F In binary system, Number in far left column8is referred to as the most significant bit. For 8 bits system, as shown, the
most significant bit has a binary weight of 2 . This is equivalent to a decimal 128.
7 T For 8 bits binary system, the most significant bit has an equivalent to a decimal 128.
8 T For 8 bits binary system, the binary number 0 0 0 1 1 0 0 0 has an equivalent to a decimal 24
9 T For 8 bits binary system, each binary digit is a bit. Eight bits make up one byte. Two bytes, or 16 bits, makes one word
10 T Binary 1 indicates that signal is present, or switch is On. Binary 0 indicates that signal is not present, or switch is Off.
7-Next figure is for………BCD (Binary coded decimal)…
- Select True (√) or False (x) for each statement:
# TrueFalse statement
1 Binary-Coded Decimal (BCD) are decimal numbers where each digit is represented
T
by four-bit binary number.
2 F Binary-Coded Decimal (BCD) cannot commonly used with input & output devices.
3 T A thumbwheel switch is one example of an input device that uses BCD as shown
4 T 4-digit thumbwheel switch, like the one shown, would control 16 (4 x 4) PLC inputs
5 Hexadecimal number system has 16 digits: the ten digits from 0 to 9 of decimal system. The remaining six digits are
T the 1st six letters of alphabet (i.e, 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, F)
6 T Hexadecimal number system has a base of 16 & weights powers of 16 (e.g, 160,161,162, 163,… = 1, 16, 256, 4096,…)
7
F Hexadecimal system is used in PLCs because it allows status of small number of binary bits to be represented in small
space such as on computer screen or programming device display.
8 T Each hexadecimal digit represents exact status of 4 binary bits.
9 F To convert decimal number to hexadecimal number, decimal number is divided by 10.
10 Decimal number 28 = 1 C hexadecimal number(28 divided by 16=1 with remainder of 12 which is equivalent to C in
T
hexadecimal.
11 T The hexadecimal number 2B is converted to its decimal equivalent of 43
MEP 4023 Applications of PLC in Control Systems Page 2 / 6 Dr. Mohsen Soliman, ACC Manager
8-Complete missing numbers in following table (next table is for help)

111 1111
0001 0010 1000
1FE
1 1111 1111 1FF
0101 0001 0010
10 0000 0001 0101 0001 0011 201
10 0000 0010 0101 0001 0100 202

9- Select True (√) or False (x) for each statement:

# TrueFalse statement
1 Sensors: devices converting physical conditions of controlled system to electrical signals for use by PLC output module
2 Output signals of sensors which to be connected to PLCs input module has to be in the form of some electric signals.
3 Output signals of sensors which to be connected to PLCs input module has to be in the form of analog electric signals.
4 Output signals of sensors which to be connected to PLCs input module has to be in the form of digital electric signals.
5 Sensors are classified into analog or digital types based on type of the physical condition which they are monitoring
6 Sensors are classified into analog or digital types based on type of the output signal which they are generating
7 All digital sensors must generate logical or binary type output signals (e.g., on-off, high-low, No-Yes,….)
8 All analog sensors must generate an analog signal which has a very small current and a voltage higher than 5 volts
9 Both analog or digital sensors must generate an A-C current and an A-C voltage higher than 5 volts
10 Analog or digital sensor may generate any type of A-C or D-C output currents at any voltage based on sensor's circuit.
11 If a sensor generates non-electric output, a sensor's circuit is used to convert its output into an electric signal
plc terminology
10-Next figure is for ….…………………..………...
Write correct part # in table below:
# Part name # Part name # Part name
11Discrete input signal 3 PLC input module 2 Actuator from PLC
9 Discrete output signal 7 CPU unit 5 Motor starter
6 Sensor for PLC input 8 PLC unit 1 Electric motor
4 Pushbutton device 10 PLC output module

11-Write the function of each of the following and complete the last column:
# Sensor's name description of sensor's function or job I/O type: Analog or digital?
Discrete digital input device that is either in ON or OFF condition. In ON condition, input is referred to as logic 1 or
1 Pushbuttons switches logic high volt. In OFF condition, input is referred to as logic 0 or logic low volt. discrete / digital
2 Limit switches discrete / digital
3 Proximity switches discrete / digital
4 Photoelectric switches
5 Pressure switches
Answers are in next page discrete / digital
discrete / digital
6 Temperature switches discrete / digital
7 Encoder switches discrete / digital
8 Potentiometers analog
9 Differential transformers analog
10 Strain gauges analog
11 Thermo-couples
12 Level sensors
13 Flow-meters
14 PLC Internal Relay (flags)
15 Motor starter (actuator)
Solenoids of slide control
16
valves
Sounders and light or
17
visual alarms

MEP 4023 Applications of PLC in Control Systems Page 3 / 6 Dr. Mohsen Soliman, ACC Manager
6-Write each sensor’s or part name in the following table. Write type of its I/O signal in the last column:
# Sensor's or part name description of sensor's or part function or job I/O type: Analog/digital?
Pushbuttons Discrete/digital input device that is either in ON or OFF condition. In ON condition, input is referred to
1 as logic 1 or logic high volt. In OFF condition, input is referred to as logic 0 or logic low volt. Discrete/digital
switches
Discrete/digital input device that is either in ON or OFF condition. We have 2 types of limit
2 Limit switches switches: Normally open & Normally closed. In ON condition, the discrete input is referred to as Discrete/digital
logic 1 or logic high volt. In OFF condition discrete input is referred to as logic 0 or logic low volt.
Proximity switches Discrete/digital input device that is either in ON or OFF condition. The ON condition is when a
3 Discrete/digital
body comes close enough to the switch depending on the type of switch and the type of the body.
Photoelectric Discrete/digital input device that is either in ON or OFF condition. The ON condition is when a body
4 Discrete/digital
switches cuts the photo light beam of the switch circuit.
Discrete/digital input device that is either in ON or OFF condition depending on the set point value of
5 Pressure switches Discrete/digital
the pressure. The switch may connect or disconnect an electric circuit connected to an actuator.
Temperature Discrete/digital input device that is either in ON or OFF condition depending on the set point value of
6 Discrete/digital
Switches the temperature. The switch may connect or disconnect an electric circuit connected to an actuator.
Encoder switches act as position sensor that detects/determine linear position or the angle of a
rotating shaft. Discrete/digital input device that is either in ON or OFF condition depending on set-
7 Encoder Switches point for the linear position or the angle of a rotating shaft. An encoder that detects rotation is Discrete/digital
called a rotary encoder, and an encoder that detects linear displacement is called a linear
encoder.
Analog input sensor. It is3-terminal resistor with a sliding or rotating contact that forms an
8 Potentiometers adjustable voltage divider. If only 2 terminals are used, one end & the wiper, it acts as variable Analog
resistor/rheostat.
Differential
9 Analog input device/sensor. It is used to measure the linear position of an object. Analog
transformers
Analog input sensor used to measure strain on an object. It is a sensor whose resistance varies with
10 Strain gauges applied force; It converts force, pressure, tension, weight, etc., into a change in electrical Analog
resistance which can then be measured.
11 Thermo-couples Analog input sensor used to measure temperature at a point by measuring the volt or e.m.f. produced. Analog
12 Analog Level sensors Analog input sensor used to measure the liquid level in a tank. Analog
Analog input sensors used to measure fluid flow rate. Obstruction flow meters convert flow rate
13 Flow-meters Analog
into pressure difference that can be measured by a pressure transducer.

PLC Internal
14 Discrete/digital
Relay(flags)

Discrete/digital input or output bits. They are parts of PLC internal memory bits. They are used to
carry data. The act as relays, they can be logic 1 or logic 0.
Discrete/digital output device/actuator. It is used to connect electric power to start electric motor.
15Motor starter(actuator) Discrete/digital
It converts electrical signal output from PLC to physical condition.
Solenoids of slide Discrete/digital output device/actuator. It converts electrical signal output from PLC to physical
16 Discrete/digital
control valves condition such as moving the internal spool of a directional control valve.
Sounders and light or
17 Discrete/digital output device/actuator. They can be either in ON or OFF condition. Discrete/digital
visual alarms
12- Select True (√) or False (x) for each statement:
# TrueFalse statement
1 Pushbutton is digital sensor. Electrical signal is sent from it to PLC indicating condition(open/closed) of sensor's contacts
2 Digital or switch type sensors include: limit, proximity, photoelectric, pressure, temperature, and Encoder switches.
3 Analog sensors include: Potentiometer, Differential transformer, strain gauge, thermo-couple,level sensor, flow-meter
4 All Pressure and Temperature transducers are of the digital type sensors
5 All Pressure and Temperature transducers are of the analog type sensors
6 Actuators: convert analog or digital output electrical signals from PLC unit into physical conditions.
7 Actuators are transducers which are connected to PLC output modules.
8 A motor starter is an actuator. Depending on output PLC signal, motor starter will either start or stop the motor.
9 Electric motors are actuators connected to PLC input. Motors include DC-motors, AC-motors, and Stepper motors.
10 Actuators include electric solenoids of slide control valves used for pneumatic or hydraulic cylinders/motors
11 Sounders and light or visual alarms are different types of PLC output and input actuators.
13-Next fig. is for…Various
discrete types of PLC input devices….Write correct part # in table below:
input
common
# Part name & write the value of logic input # Part name & write the value of logic input
99 Normally open pushbutton, logic value =…0… 55 Normally closed pushbutton, logic value =….1…
66 Normally open switch, logic value =……0.… 11 Normally closed switch, logic value =….1.…
44 Normally open contact, logic value =….0… 77 Normally closed contact, logic value =….1.…
33 Normally open limit switch, logic value =...0… 22 Normally closed limit switch, logic value =….1…
88 PLC input module, logic value
14- Select True (√) or False (x) for each statement:
# TrueFalse statement
1 Discrete/digital input sensor or device or element is either in ON or OFF condition (as shown in above figure).
2 Push buttons, toggle switches, limit switches, proximity switches, and contact switches are all non-discrete sensors
which may be connected to discrete/digital input modules.
3 In the OFF condition, a discrete input signal is referred to as logic 1 or logic high volt. In the ON condition, a discrete
input signal is referred to as logic 0 or logic low volt.
4 Many PLCs require a separate power supply to power the input elements.
5 In open state of normally open pushbutton, no voltage is present at PLC input. This is OFF condition (as shown in fig.).
6 When the pushbutton is depressed or is closed, 12 VDC is applied to the PLC input. This is the ON condition
7 An analog input signal is continuous signal that may vary from 0 to 20 milliamps, 4 to 20 milliamps, or 0 to 10 volts.
8 A transmitter that monitors the level of liquid in a tank is a non-analog sensor. Depending on the level transmitter
output signal , the signal input to the PLC can either increase or decrease as level increases or decreases
9 Discrete/digital output sensor or device or element is either in ON or OFF condition (as shown in above figure).
10 Solenoids, contactor coils, lamps are digital actuator devices that may be connected to PLC's discrete output modules.
11 A PLC analog output signal is non-continuous signal that may be as simple as 0-10 VDC level that drives analog meter.
15- Select True (√) or False (x) for each statement:
# TrueFalse statement
1 Examples of devices that may use PLC analog outputs are speed-meters, weight-meters, and temperature-meters.
2 The PLC's output signal may also be used on more complex applications such as a current-to pneumatic transducer
that controls an air-operated flow-control valve
3 PLCs are non-digital devices. Therefore, PLCs cannot process analog signals. PLCs must convert analog signals into digital
4 Expansion module to be used to convert analog signal. PLC analog modules convert standard voltage and current
analog values to 12-bit digital values transferred to the PLC for use in the register or word locations.
5 Output of thermocouple& RTD sensors go to PLC digital module to achieve high accuracy in temperature measurement
6 A weight-meter or scale is analog input device that may be used in PLC output system if it is connected to a load cell.
7 A load cell is a device that takes varying value(i.e., load) and converts it to a variable/analog, 0- 10VDC output voltage
8 The output signal of a load cell depends entirely on the manufactured specifications for the device.
9 A 0 - 10 VDC output load cell is an analog device connected to the input of an analog expansion module of the PLC.
10 A Load station in a conveyor system with a gate to direct packages is an example for PLC system with digital input.
11 Analog outputs may be used as variable reference to pilot-operated control valves, chart recorders, electric motor
drives, analog meters, pressure transducers

MEP 4023 Applications of PLC in Control Systems Page 4 / 6 Dr. Mohsen Soliman, ACC Manager
 PLC input or output
16-Next figure is for ….…………………..………...
Write correct part # in table below:
# Part name # Part name
5 Micro PLC unit 4 PLC input terminal strip
8 Program download port 3 LED status indicators
6 Fixing screws 1 Input simulator unit
7 Power supply point Pre-wired toggle
2 switches
9 Input designation labels
17- Select True (√) or False (x) for each statement:
# TrueFalse statement
1 T PLC output devices, such as relays & sound alarms, are connected to the input terminal strip under micro PLC top cover
2 F When testing a ladder program, it is necessary to connect PLC output terminals to the real output devices.
3 T During ladder program testing, the LED status indicators on output terminals signal &is turned ON if an output is active
4 An optional fan-out connector does not allow for real field wiring connections (for inputs or outputs) to remain fixed
F in place when removing or replacing the PLC unit (as shown in above figure).
5 In some micro PLCs, both the Input and Output terminal strips are removable. This allow real field wiring connections
T
to remain fixed in place when removing or replacing the base PLC unit.
6 F Super capacitor cannot maintain electric charge for long time to protect data stored in RAM in case event of power loss
7 T Based on PLC type, the RAM memory data is typically stored/backed up on the PLC for a long time up to 190 hours
8 T PLC programming port is used to communicate with variety of external devices such as text display unit (TD)
9 The text unit TD displays messages read from PLC, allows adjustment of designated program variables, provides the
T ability to force, and permits setting of the time and date.
10 F The text unit TD cannot be connected to an external power supply nor it can receive its power from PLC base unit.
11 Free port mode of PLC programming port allows the PLC connectivity to various external intelligent sensing devices
T
such as bar code reader & code decoder. Free port mode can be used to connect to external printer
18-Write the function of each of the following parts:
# part name description of part's function or job
1 An input simulator A convenient method of testing a program is to wire toggle switches to the input
2 Fan-out connectors Allows for the real field wiring connection to remain fixed in place.
3 Removable Terminal Strips Allows real field wiring connection to remain fixed in place when removing or replacing the base PLC.
4 Super Capacitor Chip Maintain a charge for a long period of time, protects data stored in RAM in the event of a power loss.
5 PLC programming port Used to communicate with a variety of external devices.
6 Text Display Unit It displays messages read from PLC, allows adjustment of designated program variables, provides the ability to force and permits setting of date and time.

MEP 4023 Applications of PLC in Control Systems Page 5 / 6 Dr. Mohsen Soliman, ACC Manager
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MEP 4023 Applications of PLC in Control Systems Page 6 / 6 Dr. Mohsen Soliman, ACC Manager