INTERVIEW QUESTIONS

1. What is Automation?

Automation, roboticization or industrial automation is the use of control systems such as

computers, PLC, CNC, PID’s etc. to control industrial machinery and Process, reducing the need
for human intervention. A delegation of human control functions to industrial machineries and
equipments for increasing productivity, quality, safe working conditions and to reduce
production cost.

2. Different components used in automation?

The different components of automation system are:-

Sensors for sensing the input parameters like Limit switches, Position sensors.

Transmitters for transmitting the raw physical signal in electrical signals form.

Control system which includes PLC, DCS&PID Controllers

Output devices/actuators like drives, control valves.

3. Different control systems used in Automation?

PID Controller based control system

PLC based control system

PC Based automation system

CNC Based control System

4. Explain PID based Control system.

PID abbreviated as “Proportional Integral Derivative” is the algorithm widely used in

closed loop control systems. The PID controller takes care of closed loop control systems in
plan. PID controllers widely used for independent control loops.

5. Difference between PLC & Relay?

PLC is a Programmable hardware whereas relay is not a programmable device

PLC can work for both digital and analog I/O’s whereas a relay cannot.

PLC is much more advanced as compared to relay.

6. Difference between PLC & DCS?

DCS: A distributed control system(DCS) refers to a control system usually of a manufacturing

system, process or any kind of dynamic system, in which the controller elements are not central
in location (like the brain) but are distributed throughout the system with each component sub-
system controlled by one or more controllers. The entire systems of controllers are connected by
a network for communication and monitoring. DCS is a very broad terms used in a variety of
industries, to monitor and control distributed equipment. DCS are used to control the entire plant
and a process

PLC: In PLC (Programmable Logic Controllers) Based system, the system has processor &
I/O’s and some functional units like basic modules and so on. PLC are usually used for
particular machine automation.

7. What is Encoder?

An encoder is a device used to change a signal (such as a bit stream) or data into a code. An
electronic encoder is a transducer for converting rotary motion or position to a series of
electronic pulses. An encoder is a rotary device that outputs digital pulses which correspond to
incremental angular motion. The encoder consists of a glass or metal wheel with alternating
clear and opaque stripes that are detected by optical sensors to produce the digital outputs. By
converting shaft rotation of a rotating shaft. The encoder’s output pulses are counted and
evaluated by a control unit to determine machine position and velocity, which provides
exceptional accuracy and flexibility when controlling motion.

8. What types of sensors are used for measuring different parameters?

Temperature sensors – RTD, Thermocouple, Thermister

Pressure Sensor - Borden Tube, Bellows, Strain gauge

Flow Sensor – pitot tube, Rotameter.

Level Sensors – Level switches, Optical level sensors, Ultrasonic Level sensor etc.

Position sensors: - Proximity Switches etc.

9. What is transmitter?

The sensor (also known as a transducer) measures a physical variable such as a temperature of
pressure and outputs a very low level electronic signal. The basic function of the transmitter is to
amplify it to a higher level electrical signal and send that signal a long distance to a control or
read out device.

Since low-level electrical signals do not transmit long distances with great accuracy, installing a
transmitter generally gives a tremendous improvement in the accuracy of the information
delivered to a larger control system. Typically the output from the transmitter is a 4-20mA or 0-
10V

10. Why 4-20 mA preferred over 0-10 V signal?

The 0-10 V signal has tendency to drop because of line resistance over long distance
transmissions. As, we know that resistance of a conductor is directly proportional to length of a
conductor. Therefore, the 0-10 V signal received at the controller will not be accurate.

The 4-20 mA signals will travel a long distance without dropping signal value.

11. Why 4-20 mA preferred over 0-20 mA signal?

With 0-20 mA you can not distinguish between minimum field value and connection break.
With 4-20mA, internal circuit can distinguish between connection break and minimum value.
Normally when the value is minimum the transmitter will give you 4 mA while in case of
connection breakage it will give 0mA

12. Difference between 2 wire, 3 wire and 4 wire transmitter.

In 2 wire transmitter the power and signal are transmitted through same cable

In 3 wire transmitter the data signal and power are with respect to common ground.

In 4 wire transmitter two wires for power supply and two for signals.

Only current transmitters can be used as 2 wire transmitters.

13. What is Field bus?

Field bus is generic –term which describes a new digital communication network which will be
used in industry to replace the existing 4 -20mA analogue signal. The network is a digital, bi-
directional, multidrop, serial-bus, communication network use to link isolated field devices, such
as controllers, transducers, actuators and sensors. Each field device has low cost computing
power installed in it, making each device a smart device. Each device will be able to execute
simple function on its

Own such as diagnostic, control, and maintenance functions as well as providing bi-directional
communication capabilities. With these devices not only will the engineer be able to access the
field device, but they are also able to communicate with other field devices . In essence fieldbus
will replace centralized control networks with distributed-control networks. Therefore fieldbus
is much more than a replacement for the 4-20mA analogue standard.

14. What is Actuator?

An actuator is something that converts energy into motion. It can also be used to apply a force.
An actuator typically is a mechanical device that takes energy, usually created by air, electricity,
or liquid, and converts that into some kind of motion. That motion can be anything from
blocking to clam pint to ejecting. Actuators are typically used in manufacturing or industrial
applications and may be used in things like motors, pumps, switches, and valves.

15. Explain working of RTD’s

Resistance Temperature Device works on the principles that the resistance of the material
changes as its temperature changes. Temperature is determined by measuring resistance and
then using the RTD Resistance vs Temp Characteristic to detect temperature. Typical elements
used for RTD are Nicked, copper and Platinum, Platinum is widely used in RTD’s because of
accuracy. PT 100 means at 0deg temp 10ohms resistance. A typical RTD consists of a fine
platinum wire wrapped around a mandrel and covered with a protective coating (glass or
ceramic) RTD has positive temperature coefficient.

16. Temperature measurement range supported by RTDs?

The RTD work on temperature range between -250 to 850dg C.

17. Explain working of thermocouple

Thermocouple consists of two strips or wires made up of different metals and joined at one end.
The temperature at that junction induces an electromotive force (emf) between the other end. As
the temperature goes up the emf also increases. Through standard charts and tables the
corresponding temperature can be found out.

The relationship between the thermocouple output and the temperature is quite non linear.
Different metallurgies produce different outputs. The different metallurgies and different line
arties result in different thermocouple designation as “J” “K” “N” “L” , etc.

18. What is Cold Junction compensation?

Temperature should be measured with the cold junction at 0 C or 32 F When a thermocouple or

its extension wires are connected to the terminals of a device like a thermocouple transmitter the
cold junction is at the room temperature T 1 C. If both temperatures of the hot and the cold
junctions above 0 C. In order to measure the temperature accurately we need to add the emf
value which corresponds to t1 to the measured emf. To add this emf is called cold junction
compensation.

19. Temperature measurement range supported by thermocouple?

The thermocouple work on board temperature range 270 to 2300 deg C.

20. What type of pressure sensors used in pressure measurement?

Manometers
Bourdon tubes
Bellow elements
Diaphram elements
Differential Pressure transmitters.

21. Explain working of different pressure transmitters.

Process pressure is transmitted through isolating diaphragms and oil fill fluid to a sensing
diaphragm. The sensing diaphragm is a stretched spring element that deflects in response to
differential pressure across it. The displacement of the sensing diaphragm, a maximum
deflection of 0.004in (0.10mm), is proportional to the applied pressure, Capacitor plates on both
sides of the sensing diaphragm detect the position of the diaphragm. The transmitter electronics
convert the different capacitance between the sensing diaphragm and the capacitor plates into a
two-wire mA signal and a digital output signal.

22. What is Control Valves?

The control valve commonly named the final control element of control contains a pneumatic
device that converts the control signal from the controller in action and regulate the flow.

23. What type of control valves used in the Industry?

ON-OFF SERVICES:- Gate, Ball, Diaphragm, Plug, Butterfly valves.
THROTTILING SERVICES:- Globe, Butterfly, Diaphragm, Pinch valves.
NON- REVERSE FLOW:- Check valves.
24. What are the components of control valve

Actuator, Body, Trim, Diaphragm Diaphragm plate, Actuator stem

Actuator spring, Seat, Travel Indicator, Valve stem, Gaskets, Yoke. Hand wheel

Supervisory control and data Acquisition Software.

25. What is SCADA? Role of MMI/HMI/SCADA industrial Automation

SCADA : Supervisory control and data acquisition
MMI : Man Machine Interface
HMI : Human Machine Interface
This acts as an operator station. The operator can monitor as well as control the process
parameters from this stations. Apart from online process data the operator will have access to
historical and real-time trends, alarms and reports. The operator can give commands to control
hardware for opening the valve change the set point, stat the pump etc.

26. What are Features of SCADA software?

The common features of SCADA include Dynamic process mimic, Trends, alarm, Connectivity
with hardware, Recipe management etc.

27. Applications of SCADA

SCADA systems has many applications. Few are industrial automation, power distribution and
water management..

28. Some of the leading SCADA companies

Invensys Wonder ware : - In Touch
Siemens :- WinCC (Earlier COROS)
Alien Bradley: - RS View (Earlier Control View)
Intellution :- ifix (Earlier Fix DMACS)
GE Fanuc : - Simplicity
29. What type of licensing patterns used in the SCADA software

Typically two types of licenses are used in the SCADA software

Dongle Key : It is a hardware lock which can be put on the communication port of the PC.

Software Lock : Hare the software code is the license. Typically can put the code while
installation or transfer the code from Floppy to hard-disk.

30. Types of Window?

Replace : automatically closes any window (s) it intersect when it appears on the screen
including popup other type window.

Overlay : Appears on top of currently displayed window (s) and can be larger than the window(s)
it is overlaying. When an overlay window is closed, any window(s) that ware hidden behind it
will reappear.

Clicking on any on visible portion of a window behind an overlay window will bring that winow
to the foreground as the active window.
Popup/On-Top : similar to an overlay window except, it always stays on top of all other open
windows (even if another window is clicked) Popup window usually require a response from the
user in order to be removed.

31. What is Library in Intouch?

Library contains symbols which can be readily used in the application. The symbols include
various Tanks, Reactor, Pipes Icons, buttons and indicators.

32. What are datatypes used in SCADA?

Different data types used are Digital, Analog, String/Message.

33. What type of animation can be given in SCADA?

Colour, %Fill, size Control, Position, Orientation/Rotation, Visibility.

34. What are tends?

Trends mean graphical representation of data.

“Real – time” and “Historical”. You can configure both trend objects to display graphical
representations of multiple tag names over time. Real-time trends allow you to chart up for pens
(datavalues).

Real-time trends are dynamic. They are updated continuously during runtime with whatever
time span given in configuration. You cannot scroll the real –time trends to see previous dat.

Historical trends provide you with a “snapshot” of data from a time and data in the past. They
are not dynamic unlike real-time trends historical trends are only updated when they instructed to
do so either through the execution of a Quick-Script or an action by the operator, for example,
clicking a button. You can zoom in/zoom out the trends. You can also access the pervious data.

35. What are Alarm and Events?

Alarms and Events are the notifications used to inform operator of process activity Alarms
represent warnings of process conditions that could cause problems and require an operator
response. A typical Alarm is triggered when a process value exceeds a user defined limit.
Events represent normal system status message and do not require an operator response. A
typical event is triggered when a certain system condition takes place, such as an operator
logging.
36. Security management

Security provides the ability to control whether or not specific operators are allowed to perform
specific functions within an application. Security is based on the concept of the operator
“logging on” to the application and entering a “user Name” and “Password.” (The application
developer sets up each operator with a “User Name,” a pre-assigned “Password”).

37. What is Driver?

A driver acts like a translator between the device and programs that use the device. Each device
has its own set of specialized commands that only its driver knows. In contrast, most programs
access devices by using generic commands. The driver, therefore, accepts generic commands
from a program and then translates them into specialized commands for the device. A software
which allows a computer to access the external devices using com ports or communication cards.

38. What is DDE

Dynamic Data Exchange is the facility developed by Microsoft for exchanging the data between
various programs.

DDE has three important settings

Application / Server name, Topic Name and Item Name

Programmable Logic Controller – General

39. What is PLC?

PLC mean Programmable Logic Controller. It is a class of industrially hardened devices that
provides hardware interface for input sensors and output control element. The field I/P
include element like limit switches, sensors, push button and the final control elements like
actuator, solenoid control valves, drives, hooters etc.

PLC Senses the input through I/p modules, Processes the logic through CPU and memory
and gives output through output module.

40. Applications of PLC?

PLC can be used in almost all industrial application solutions right from small machine to large
manufacturing plants. Example:-
Power distribution

Water treatment Plant

Packaging Machines

Bottling Line Machines

Chemical Plants

Textile Plants

41. Role of PLC in Automation?

PLC plays most important role in automation. All the monitoring as well as the control actions
are taken by PLC’s. PLC senses the states of input through I/p modules, Processes the logic
through CPU and memory and then gives the states of output through output module.

42. Role of CPU?

This component act as a brain of the system.

CPU consists of Arithmetic Logic Unit, Program memory, Process image memory, internal
timers and counters, flags.

It receives information from I/P device, makes decisions depending upon the information and
logic written and sends information through the O/P devices.

The cpu are distinguished with following features

Memory capacity, instruction set supported, communication option, time required to execute the
control program.

43. Role of Power supply in PLC system?

Power supply provides system power requirement to processor, I/O and communication
modules. Typically the power supply has input voltage 120V – 230 V AC or 214 V DC and
backplane output current 2A to 5A at 5 V DC.

44. Role of Rack or Chassis in PLC System?

A hardware assembly which houses the processor, communication and I/O modules. It does
following functions.

Power distribution to modules.

Containment of I/O modules

Communication path between I/O module and CPU

The chassis are available in different slots in various PLC systems. Additional chassis can be
connected using chassis interconnecting cable.

45. What is role of I/O modules?

Electronic plug in units used for interfacing the i/p and o/p device in the machine or process to be
controlled.

I/P module receive data from i/p devices (Pushbutton, Switches, and Transmitters) and send it to
processor. The O/P module receives data from processor and send it to output device (Rlay,
Valves)(.

Digital/Discrete: - Sends and receives On/Off signal

Analog:- Sends and receives variable input or output signals.

46. Role of EEPROM memory module?

This module is inserted into processor system for maintaining a copy of project (PLC program).
This is helpful in future in case of memory or processor corruption.

47. Communication module

Communication modules are used either for communication between two xternal hardwares or
between a external hardware and a software. The hardware can be PLC’s (same or other make),
I/O module, smart transmitters, Drive etc. The software can be SCADA software, programming
software. A module provides a communication interface for coupling external input and output
(I/O) devices and other remote apparatus to a programmable controller.

48. Difference between fixed and Modular PLC’s?

In non modular PLC, the processor will have inbuilt power supply and I/Os in one unit or on a
single base unit For example : - Micrologix 1000.

The modular PLC is a Power supply, I/O modules. You can select the different I/Os or power
supply as per the need. For example: - SLC 5/03, SLC 5/04 etc.

49. Difference between Local and Distributed I/O’s?

Local – These are the I/Os placed in the PLC main rack containing CPU These I/Os are
connected to CPU through backplane.
Distributed - These are I/O placed at remote location from the main rack containing the CPU.
These i/Os are to be connected on communication bus like control net, device net or FIP I/O.

50. What is meaning of resolution in I/O cards in PLCs?

It is the minimum change in i/p parameter which can sensed by the i/p card. As far as Digital I/O
is concerned it takes only one bit for operation. In case of analog input the resolution determines
how much bits are used for input or output. For example a 12 bit resolution card means the input
will come as 0 to 4095 count (2|12). For 16 bit data the counts will be from 0 65536(2|16).
More the resoluti9on the data will be more accurate.

51. What is an Analog Input Module?

A module containing circuits (A to D converter) that converts analog input signals to digital
values that can be manipulated by the processor. The signals from pressure, flow level,
temperature transmitters are connected to this module Typically the input signal is 4-20 mA, 0-
10Vdc.

52. What is an Analog Output Module?

A module that contains circuits which produces a time continuous output as an analog dc signal
proportional to a digital value transferred to the module from the processor. The analog output
signal is 4-20 mA, 0-10 Vdc, Example to control speed of motor.

53. What is the meaning of universal analog input card?

Normally there are different cards for different signals. But in universal input card the same
channels can be configured for RTD, Thermocouple, Current or voltage input.

54. Give Examples of I/P and Output connected to PLCs

Digital I/P (Pushbutton, Switches)

Analog i/P (Temp, Pressure, Flow, Level)

Digital O/P (Solenoids valves, Contactors)

Analog O/P (Control Valves, Speed)

55. Explain Source and Sink Concept?

When wiring any device to a PLC, it is to be consider that what is direction of the current in the
loop

Sinking - if the direction the current is towards (i.e. entering) the module then this connection is
called as sinking connection. Used with PNP sensors.
Sourcing – if the direction of the current is outwards(i.e. leaving) the module then this
connection is called as sourcing connection. Used with NPN sensors.

We can configure an I/O module as sinking/sourcing as discussed above.

56. What is forcing of I/O?

Forcing the I/Os means making the desired i/O on/off in PLC irrespective of its status in the
field.

In certain cases when there is a problem in receiving field input/output, we can force the I?Os so
that the logic takes desired state.

57. What is meaning of scan time in PLC?

Scan time is the time required to read the I/P, Process the logic and update the output.

58. What is typical scan time in PLC’s? What effects scan time?

Typically it is less than 10ms. It depends on the complexity of logic, PID algorithm etc.

59. How to program PLC’s?

Every PLC manufacturer have their own software for programming the PLC. For example
Siemens uses Simantic s7 Manager, Allen Bradley uses RS LogiX and Modicon uses PLC Pro
Programming software. The programming language used is Ladder logic(LD), Statement
List(STL), Functional Block Diagram
(FBD). Sequential foundation Chart (SFC), Instruction List(IL) etc.

60. What is Ladder Diagram?

This is a programming language, which expresses a program as a series of “colls” and

“contacts”. Simulating the operation of electromechanical relays. The resultant program is the
equivalent of an equation, which is executed continuously in a combinatorial manner. The
advantage of this language is the familiarity many electricians have with the simple operation of
relays. Disadvantages include the complexity of large, cross-connected programs, and difficulty
of expressing such non-binary functions as motion control and analog I/P.

61. What is redundancy?

The capacity to switch from primary equipment to standby equipment automatically without
affecting the process under control. Redundancy means provision for standby module. In case
of failure of one module in running process. The standby module takes over. Hot redundancy;
means the changeover of control from active processor to standby processor in less than 1 scan
time.
62. Need of redundancy/

In critical processes, it is important to run the plant without failure in such case it is important to
have redundancy so that even in one system fails the redundant system can take care without
affecting plant.

63. Types of redundancy

CPU redundancy : In case of CPU failure the standby CPU takes care of the plant. Power supply
redundancy : in case the power supply fails the standb;y bower supply takes control of the
situation.

Network: Multiple Communication channels are provided to take care of network failure.

I/O Redundancy : Multiple I/O Channels are provided to take care of input or output failure.

64. Commonly used Instructions in PLCs

Examine if Closed (XIC) : - | | Examines if the bit is in ON condition. If the bit is

ON the instruction is true.
Examine if Open (XIO) :- |/| - Examines if the bit is in OFF condition. If the bit is
OFF the instruction is True
One short rising (OSR) : - [OSR] When the conditions preceding the instruction is true
makes the rung run for one program scan.

Not retentive Output instruction

Output Energies (OTE) : --( ) If the rung is true, it turns on the output bit.if
rung goes false, the bit turns off.

Retentive Output instruction

Output Latch (OTL) : --(L)-- If the rung is true, turns ON a bit and it
remains ON even the rung gets fals. The bit
stays ON until the rung containing an OUT
with the same address goes true.
Output Latch (OUT)---(U)---- If the rung is true, turns OFF a bit. The bit
stays OFF until the rung containing an OTL
with the same address goes true and the rung
containing OUT with same address remains
false.

65. Timers
Timer and Counter are used to control operation based on time or number of events

Types of timers

TON – (Timer ON delay) An output instruction that can be used to turn

an output ON or OFF after the timer has been
timing for a preset time interval.
TOF – (Timer OFF delay) An output instruction used to turn an output
ON or OFF after its rung has been off for a
preset time interval
RTO – (Retentive Timer An output instruction that can be used to turn
an output ON or OFF after the timer has been
timing for a preset time interval. Once it has
begin timing, it holds the count of time even
when the rung continuity is lost.

66. What are the PLC ranges available in Rockwell?

Pico : Non modular small PLC’s

Micrologix 1000, 1200, 100 and 1500 Series

SLC : SLC 5/01, 5/02, 5/03, 5/04, 5/05.

Compact Logix, Control Logix, Flex Logix and Soft Logix

Diff b/w Micro Logic and SLC

Micrologix SLC

1. Fixed type Rack type

2. Online editing not possible Online editing Possible.

67. What are the software Used with AB Products?

Pico soft for Pico PLC programming

RS Logix 500 for Micrologix and SIC PLCs programming

RS Logix 5000 for Control Logix, Flex logix, Compact logix PLC’s Programming SCADA – RS
View 32

Panel Builder 32 for panel view terminals

68. What is use of RS Link software?

RS Link software is used to perform following tasks.

Configure communication drivers

View configured drivers and active nodes

Enable communication tasks such as uploading, downloading, going online, updating firmware
and sending messages.

69. What is use of RS Logix Software?

RS Logix is a PLC programming software. It contains all the instructions needed for PLC
programming. We can develop the program, download/upload the program, work online /offline
and force the I/Os using the software

RS Logix 500 is used for Micrologix and SLCs

RS Logix 5000 is used for Control Logix etc. PLC’s.

70. What file gets created in PC for RS Logix PLC program/

The extension of the file will be (.RSS), So if you create an application with “Reliance” name
the file created will be “Relianc.RSS”. By default it will be stored in “C:\Program Files\
Rockwell Software/RS Logix 500 Eng location.

The extension of the file created will be “Reliance.ACD”. By Default it will be stored in “C:\
Program Files\Rockwell Software/RSLogix5000/Projects.

71. What is the meaning of upload and Download?

Upload means transferring the program data from PLC to PC

Download means transferring the program data from PC to PLC

72. What are the various communication interfaces supported by AB?

The commonly used communication protocol in AB includes DF1 full duplex, DH+ DH485,
Ethernet, Modbus, Device Net and Control Net.

73. Give Information about DH, Control Net, Device Net and Ethernet protocol.

Data Highway : The proprietary data network used by Allen Bradely PLCs to communicate
information to and from other PLCs on the network or to and from host computers attached to
the network.

ControllNet : A realtime, control layer network providing high speed transport of both time
critical IO data and messaging data, including upload/ download of programming and
configuration data and peer to peer messaging, on a single physical media link.
Device net : The Communications and information Protocol (CIP) is a communications protocol
for transferring automation data between two devices. deviceNet is a combination of the CIP
Protocol and the CAN (Controller area network) Physical Layer. In the CIP Protocol, every
network device represents itself as a series of objects. Each object is simply a grouping of the
related data values in a device. For example, every CIP device is required to make an Identity
object available to the network. The identity object contains related identity data values called
attributes. Attributes for the identity object include the vendor ID, date of manufacture, device
serial number and other identity data. CIP does not specify at all how this object data is
implemented, only what data values, usually called attributes, must be supported and that these
attributes must be available to other CIP devices. The identity object is an example of a required
object.

Ethernet : Ethernet is a network standard of communication using either coaxial or twisted pair
cable. The most used for of LAN communication, Ethernet typically runs at 10 megabytes per
second, though newer systems use 100 mbps. Ethernet is the IEEE standard 802.3. It has
several different flavors, with the original Ethernet designed with 10base5. The “10” stands for
10 megabits per second. Base is the Baseband communicate with. Original Ehernet used coaxial
wiring, while newer versions use twisted pair cablin ther aer several flavors of Ethernet,
including 10Base2 (10Mbps, 200meters), 10BaseT (10 Mbps, 100 meters, twisted-pair), and
100BaseT (100Mbps, 100meter, twisted-pair).

74. What is latency in communication?

The delay time between the end of one communication and the start of another. During this
time, the processes associated with the communication are hung up and cannot continue. The
latency to be minimum.

75. How the communication protocols are distinguished?

The protocols are distinguished with following specifications

No. of nodes supported, total network length, speed of communication.

76. Comparison between various protocols used with AB

Protocols DH+ DH485 Device Net Control Net

Baud rate max 230.4 kbits/s 19.2kbit/s 500kbit/s 5 Mbit/s
No of max nodes 64 32 64 99
Network Length 3.048 Km 1.2 Km 0.487 Km 30 Km
Programmable Logic Controller- Siemens

77. What are the various PLC system in SIMATIC range?

Siemens has broadly 3PLC ranges is Siemens S7 200,300 and 400

78. What are the software used with Siemens?

For S7 200 PLC programming Micro win

For S7 300 and 400 system: Simatic S7 manager

The SCADA software used by Siemens is Win CC. Earlier Siemens use to supply COROS LS /
B

79. What are the Communication Protocol used in Siemens?

Mult - Point interface (MPI):

Data Transfer – 187.5 kbits to 15 Mbit /s

Distance -50 m without RS 485 repeater / 10 Km with repeater

Number of nodes up to 32

Profibus

Data Transfer- 12 Mbit / s.

Distance -23 Km with fiber optic cable

Number of nodes – up to 125

80. What are the blocks used in Siemens?

Simantic S7 manager uses DB, OB, FC, PB and FB

Obs: Determine the structure of the user program

Data Black: These are the blocks used by logic blocks in CPU program for storing the data.
DB’s does not contain any instructions and it take up space in the user memory. The user
program and access a data block with bit, byte, word or double word operations. Global data
block: These contain information that can be accessed by all the logic block in the user program.

Instance data block: these DBs are always assigned to particular FB.

UN : (enable) Specifies whether or not the timer instruction is enabled

DN : (Done) Specifies whether or not the accumulated value of the timer equals to the preset
value of the timer.

FC Functions: It is a logic block without memory. An FC is always executed by calling in

another block. FC is used either for returning a function value to a calling function or executing
a technological function. Temporary variable belonging to FC are saved in local stack and this
data is lost when the FC has been executed.

Function Blocks (FBs) : A function block is block with a memory. A FB contains a program that
is always executed when a different logic block calls the FB. FB make it much easier to program
frequently occurring complex functions.

81. What are SFCs and SFBs?

SFBs and SFCs are integrated in the S7 CPU and allow you access to some important system
functions

82. What is Statement List?

Statement List (STL) is a textual programming language that can be used to create the code
section of logic blocks. Its syntax for statements is similar to assembler language and consists of
instructions followed by addresses on which the instructions act.

83. What is a Tag?

A named area of the controller’s memory where data is stored. It is the basic mechanism for
allocating memory, referencing data from logic and monitoring data.

84. What is a Tag name?

A name you supply to reference a tag instance. It can be a maximum of 40 characters.

85. What is OLE?

Object Linking and Embedding (OLE) is a technology that allows embedding and linking to
documents and other objects developed by Microsoft. For developer, it brought OLE custom
controls (OCX), a way to develop and use custom user interface element, OLE allows an editor
to “farm out” part of a document to another editor and then re-import it. For example, a desktop
publishing system might send some text to a word processor or a picture to a bitmap editor using
OLE. The main benefit of using OLE is to display visualizations of data from other programs
that the host program is not normally able to generate itself (e.g. a pie chart in a text document),
as well as to create a master file. References to data in this file can be made and the master file
can then have changed data which will then take effect in the referenced document. This is
called “linking” (instead of”embeddin”). Its primary use is for managing compound documents,
but it is also used of transferring data between different applications using drag and drop and
clipboard operations. The concept of “embedding” is also central to much use of multimedia in
Web pages, which tend to embed video, animation (including Flash animations), and audio files
within the hypertext markup language (such as HTMLor XHTML) or other structural markup
language used (such as XML or SGML)- Possibly, but not necessarily, using a different
embedding mechanism than OLE.

86. What is OPC?

OLE for Process Control (OPC) which stands for Object Linking and Embedding (OLE) for
Process Control is the original name for standards specification developed in 1996 by an
industrial automation industry task force. The standard specifies the communication of real-time
plant data between control devices from different manufacturers. After the initial release, the
OPC Foundation was created to maintain the standard. Since then, standards have been added
and names have been changed. As of June, 2006, “OPC is a series of standards specification”.
(Seven current standards and two emerging standards.) “The first standard (originally called
simply the OPC Specification”). Is “now called the Data Access Specification” or “OPC Data
Access” or OPC Data Access Specification.

87. What is a communication protocol?

A communication protocol is the set of standard rules for data representation, signaling,
authentication and error detection required to send information over a communications channel.

88. What is difference between Baud rate and Bit rate?

The difference between the two is complicated and intertwining. They are dependent and inter-
related. But the simplest explanation is that a Bit Rate is how many data bits are transmitted per
second. A baud Rate is the measurement of the number of times per second a signal in a
communications channel changes.

89. What is Node and a Channel?

Node - defines the device type and address of a station on the network, or th application and
topic (for DDE).

Channel – define the network on which a tag’s value is accessed.

90. What are the advantages of using PLC?

Increasing productivity, Decrease in cost, High accuracy, Real time operation

91. What are PLC selection criteria for any project?

No. of I/O (Digital+Analog)

Memory size (2,4,8,16,32,64 k - according to process complexity)

Expandable, Non –Expandable (For future expansion)

Instruction set used

Port / Protocol Used.

92. What is open and close loop control system ?

In Open-Loop control, no feedback loop is employed and system variations which cause the
output to deviate from the desired value are not detected or corrected.

A Closed-Loop system utilizes feedback to measure the actual system operating parameter being
controlled such as temperature, pressure, flow, level, or speed. This feedback signal is sent back
to the controller where it is compared with the desired system point. The controller develops an
error signal that initiates corrective action and drives the final output device to the desired value.
In the DC Motor Drive illustrated above, he tachometer provides a feedback voltage which is
proportional to the actual motor speed. Closed loop systems have the following features:

A Reference or Set Point that establishes the desired operatint point around which the system
controls.

The process variable Feedback signal that “tells” the controller at what point the system is
actually operating.

A Controller which compares the system Reference with the system Feedback and generates an
Error signal that represents the difference between the desired operating point and the actual
system operating value.

A Final Control Element or mechanism which responds to the system Error to bring the system
into balance. This may be a pneumatically controlled valve, an electronic positioned, a
positioning motor, an SCR or transistor power inverter, a heating element, or other control
device.

System Tuning Elements which modify the control operation by introducing mathematical
constants that tailor the control to the specific application, provide system stabilization, and
adjust system response time. In process control systems these tuning elements are: Proportional,
Integral, and Derivative (PID) functions. In electrical systems, such a generator voltage
regulators and motor drives, typical tuning adjustments include;

Gain, the amplification factor of the controller error amplifier, which affects both system
stability and response time.
Stability which provides a time-delayed response to feedback variations to prevent oscillations
and reduce

System “Huntin”.

Feedback an adjustment which controls the amplitude of the feedback signal that is balanced
against the

System set-point.

Boost which is used in AC and DC motor drives to provide extra low-end torque: and

IR Compensation which provides a control signal that compensates for the IR

Drop (Voltage Drop) which
Occurs in the armature windings in DC machines due to increased current flow
through the armature.
92. What is Fail-safe system?
Fail-safe or fail-secure describes a device or feature which, in the event of
Failure, responds in a way that will cause no harm or at least a minimum of
Harm to other devices or danger to personnel. Fail-safe components of a
System are distinguished from fail-secure components in that, in the former,
Component failure allows but does not cause or invite a certain improper
System behavior, whereas in the latter, component failure does not allow a
Certain improper system behavior, although some proper behaviors are
impeded. For example, a lock that unlocks at the wrong time has failed, but it
may be considered fail-safe if its failure does not send the door flying open or
attract undue attention to the door’s unlocked state. In contrast, a fail-secure
lock will remain locked during a failure, but cannot be unlocked even by the
correct key.

Electrical or Electronic
Avionics using redundant systems to perform the same computation with
Voting logic to determine the “safe ” result.
Traffic light controllers use a Conflict Monitor Unit to detect faults or
Conflicting signals and switch an intersection to all flashing red, rather than
Displaying potentially dangerous conflicting signals, e.g. showing green in
all directions.
The automatic protection of programs and/ or processing systems when a
hardware or software failure is detected in a computer system. A classic
example is a Watchdog timer. See fail-safe (computer).
A control operation or function that prevents improper system functioning
Of catastrophic degradation in the event of circuit malfunction or operator
Error, for example, the failsafe track circuit used to control railway block
signals.
The iron pellet ballast on the Bathyscaphe is dropped to allow the submarine
to ascend. The ballast is held in place by electromagnets. If electrical power
Fails the ballast is released, and the submarine then ascends to safety.
Inside a modern CPU are implementations to prevent damage through
overheating. In the event of cooling failure, the CPU will throttle then shut
down beyond a critical temperature threshold to avoid damage.

93. what is a drive?

A drive is a system or a device which is used to control the amount of power
Provided to a load without wasting energy.
Motor drives:
1) Saves energy.
2) Controls motor speed.
3) Controls motor direction.
4) Controls motion profile.

94. How Ac drives saves energy? Explain.

Ns = 120 F/P When we reduce F to reduce the speed. Due to V/Hz algorithm
Voltage also reduces then P also reduces. But the efficiency of ac drive is around
80%.
95. What is PWM?

Pulse-width modulation (PWM) of a signal or power source involves the modulation

Of its duty cycle, to either convey information over a communications channel or
Control the amount of power sent to a load.
An example of PWM: the supply voltage (blue) modulated as a series of pulses
Results in a sine-like flux density waveform (red) in a magnetic circuit of
electromagnetic actuator. The smoothness of the resultant waveform can be
controlled by the width and number of modulated impulses (per given cycle).

96. What are different modes of PLC?

Ans. REM Run mode:

Remote run mode during which the processor scans or executes the ladder
Program, monitors input device, energizes output devices, and acts on enabled
I/O forces.

Program mode:
When the controller is not executing the processor file and all
Outputs are de-energized.

Run mode:
When the processor file in the controller is being executed, inputs are read the
Program is scanned and outputs are energized and de-energized
 Plc practical question
Assignment no. 1

1. Draw ladder diagram for the following (2 I/Ps) and 1o/p.

.AND

.OR

.NAND

.XOR

.NOR

2. Make 4 O/Ps high in OR order by using 4O/Ps in AND order.

3. Condition 1,2&3 in AND turn on output A & B.
4. Condition (1 AND 2 AND 3) OR (4 AND 3) turn on output A and
B.
5. Condition 1 OR (2 AND 3) turn on output A, Condition (1AND 4
OR (2 AND 3 AND 4) turn on output B.
6. Condition 1,2,3,4,5 in OR turn on output B.
7. Condition (1 AND 2) OR the state of output A.
8. Condition 1 turn on output A, Condition 1,2,3 &4 in AND turn
on output B condition 1 AND 2 turn on output C.
9. Condition (1AND 2 AND 3) OR (4 AND 2 AND 3) OR (5 AND
6) turn on output B.
10. When Ip0 AND Ip1 are closed turn on Op1.
11. When Ip0 AND Ip2 are closed OR Ip1 is open turn on Op0.
 12. When Ip0 is closed OR Ip1 is open turn on Op2.
13. When Ip1 is closed turn on Op1,Op2,Op3 and Op4.
14. When Ip1 is closed and either Ip1 is open OR Ip2 is closed turn
on Op4 & Op5.

Assignment Sheet …2
TIMER

1. Make the logic using NO PB in such a way, when PB pressed light

get ON after 3 sec.

2. Make a logic in such a way that when NO PB pressed, light 1 will

get on after 5 sec, light remains on until NC PB pressed.

3. Make a logic in such a way when NO PB Pressed after 5 sec light 1

will get on, after 10 sec light-2 will get On and after 5 sec both the
light get off.

4. Make a logic in such a way that when NO PB Pressed light-1 will

get ON after 10 sec, then after 5 sec light-2 will get on for 7 sec
and this cycle will repeat until NC PB pressed.

5. You need to turn the valve for 27 sec after a switch is closed, if
interrupted the valve should close and time should reset to zero.
6. When a switch 1is closed, turn on the motor1, motor2, motor3 ,
at five sec intervals its goes turn off when switch 1 will open.

7. After a product is placed in five sided wooden shipping crate, the

remaining side of the crate is sealed using an industrial adhesive.
The operator initiates the sealing problem by pressing PB6. it
takes 20 sec to apply the adhesive, after the adhesive is applied
the top is held in position for 20 sec by a sense of automated
clamps before it is transferred to the shipping dock.

Assignment Sheet…….3

COUNTER

1. Make a logic using NO PB in such a way when PB pressed counter

will increment its value (counter Preset is 10). Reset the counter
using NO PB.

2. Make the logic using NO PB in such a way when PB pressed

counter will increment its value (counter Preset is 10) when
counter get done light-1 will get on.
3. Make a logic using NO PB in such a way when PB pressed counter
will increment its value =10. When counter current value is 2 light
-1 will get on , when counter current value is 5 light -2 will get on.
 Assignment Sheet…….4

PLC QUESTION

1. ON a lamp with a SWITCH and OFF the same lamp with same
SWITCH.

2.ON a lamp with start push button and OFF the same lamp with

Stop push button.

3.ON 3 lamp with start push button and OFF the same lamp with

Stop push button.

4.ON a lamp with start push button and OFF the same lamp with

Same push button.

5.When START push button is pressed, bulb is switched ON,when

 Run push button is pressed first bulb goes OFF and second bulb
goes ON.When process push button is pressed the second bulb
goes OFF and first goes ON.The system will stop by pressing stop
push button.

6. There are three lamps, first lamp should go ON when start push

button is pressed,when again the same push button is pressed first

lamp should go OFF and second lamp should switch ON,

when again the same push button is pressed the second

lamp should go OFF and third lamp should go ON,when again

the same push button is pressed the third lamp should go OFF

and again first lamp should go ON . The system will stop by

pressing stop push button.

7. When START toggle switch is pressed a lamp should go ON for

10 sec.,after 10 sec. the lamp should go OFF while the start toggle

is switch is ON.
8.THE lamp should go ON after 10 sec. of pressing the start push

button and it will go OFF by pressing the stop push button.

9.A HIGH TO LOW PULSE IS GENERATED AFTER EVERY 10

SEC. OF PRESSING START PUSH BUTTON.

10.There are two lamps,the first lamp should go ON for 10 sec.by

pressing the start push button,after 10 sec. the first bulb should

go OFF and the second lamp should go ON.The ON bulb should

go OFF by pressing the stop push button.

11.There are two lamps,ON pressing the start push button first lamp

should go ON for 10sec.,after 10 sec.the first lamp should off the

and second lamp should go ON for 10 sec.,after 10sec.the second

lamp should go off and first lamp should go ON.The process will

stop by pressing the stop push button.(BLINKING)

12.There are two lamps,on pressing the start push button the first

lamp should ON and when the start push button is pressing again

the first lamp should go OFF and second lamp should go ON .If

any lamp is ON for more than 15 sec.then both lamps will

interchange their status i.e.the ON lamp goes OFF and OFF lamp

goes ON. The process will stop by pressing the stop push button.

13.On pressing the start push button a lamp should go ON, when the

same push button is pressed second time the bulb should go OFF

and remain OFF for next 15 sec.If the start push button is pressed

in between these 15 sec.the lamp should not go ON and it will

only go ON after 15 sec.

 14.By pressing the start push button the value stored in a memory

word will move to another memory word.

15. By pressing the start push button the value stored in a memory

word is between 22 and 27 the lamp should go ON otherwise the

lamp should remain OFF.

16. When start push button is pressed the value in this memory word
is ANDed with another value in another memory word and the result is
stored in third memory word.

17.When start push button is pressed the value in this memory word is

ORed with another value in another memory word and the result is

Stored in third memory word.

18.On pressing the start the value in a memory word is added,

Subtracted,multiplied and divided with another memory word

and the result is stored in a memory other than two.

19.On pressing the start push button a value is to be stored in a

memory word.If the value is greater than the value stored in

another memory word than a lamp should go ON ,and if value

less than MULTIPLY it with value in third memory word,now

if the value is greater than the lamp is switched ON and if the

value is less than lamp is switch ON after 10 sec.

20.A lamp should go ON after 10 input pulses.

21.When start push button is pressed an input pulse should come after

every 5 sec. and a lamp should go after 5 input pulses.

22. There are 6 lamps,when start push button is pressed lamp 0,2 are

ON and others OFF after 5 sec lamps 2,3 are ON and others OFF

After another 5 sec lamps 1,3 are ON others OFF after another 5sec

lamps 0,1 are ON others OFF .The process continues until the
 stop push button is pressed.

23.When a start is depreesed,M goes on.Five second later,N goes on.

When stop is pushed,both M and N go off.In addition,6 second

after M and N go off fan F,which had previously been off,goes on.

F remains on until the start button is again depressed, at which time

it goes off.

24. A wood saw W,a fan F and a lubrication pump P all go on when a

Start button is pressed.Stop button should stop the saw only.The

Fan is to run additional 5 seconds to blow the chip away.Pump

Should remain ON.

.
 INTERLOCKING
Develop ladder logic for the following:-

1) Switch ON and OFF a lamp with a single momentary push button.

2) Switch ON a motor with a Star momentary push button and switch OFF the
same motor with a Stop momentary push button.

3) Switch ON all 3 motors with a Single Start momentary push button. Switch
OFF all with single Stop momentary push button.

4) ON/OFF of a lamp.

Inputs:- Start Momentary P.B. and Stop Momentary P.B.

Outputs:- Lamp.
When start PB is pressed, Lamp should ON and then when stop PB is
pressed, Lamp should get off. (Make logic using Binary Bit as holding).

5) ON/OFF of lamps using 3 Push Buttons. (No holding to be used).

Inputs:- I/P-1, I/P-2, I/P-3.

Outputs:- Lamp.
If any two input Push buttons are pressed simultaneously than only the
Lamp should glow otherwise not.
6) Combinations of switches to ON/OFF a lamp. (NO holding required )
Inputs: - PB1, PB2.

Outputs: - O/P1 Green lamp, O/P2 Blue lamp, O/P3 Red lamp.
a). If PB1 pressed O/P1 and O/P2 glows.
b). If PB1 and PB2 are pressed simultaneously only O/P3 glows.
c). If PB2 is pressed only O/P2 should glows.

7. On/Off of lamps
Inputs:- I/P1 start PB1 for pump1, I/P2 – Stop PB2 for pump1, I/P3-Start PB3 for pump2, I/P4-
stop PB4 for pump2.

Outputs; - O/P1 : Green lamp, O/P2: - Rd lamp, O/P3:- pump1, O/P4:- Pump2.

A). When I/P1 is pressed : - Pump 1 starts and Red lamp glows. Then

b). When I/P3 is pressed: Pump2 starts, Green lamp is on and Red lamp gets off. Then

c). When I/P2 is pressed :- Pump 1 switches off, Red lamp glows with Green lamp off. Then

d). When I/P4 is pressed:- Pump2 switches off and Red lamp also goes off. (as green lamp was
previously of in step3)

8) When start momentary pressed, a motor gets switched ON, when SP2 is momentarily
pressed first motor goes off and second motor switched On. When preset momentary button is
pressed, second motor goes Off and first motor gets ON again. System can be stop by stop
momentary push button at any time.

TIMER

1). Make ladder logic to glow the LED’s in the following pattern. When input (a momentary
Push button ) is ON, the following LEDs glow in the following pattern.

Time(upto) LED1 LED2 LED3 LED4

5 Sec 1 0 0 0
10Sec 1 1 0 0
15Sec 1 1 1 0
20Sec 1 1 1 1

2). An oil pump should start up after pressing start push button and the main motor will start
automatically after 15 sec. After pressing stop push button.
 MOVE, COMPARE, MATH

1. On Press of a start push button, value stored in some memory word should move to some
another memory word.
2. On Press of start push button, value stored in memory word will move to another memory
word. If the value in this memory wired is between 20 to 30, a lamp should go ON,
otherwise the lamp remains off.
3. On press of start push button, value stored in some memory word is logically AND ed
with another value in another memory word and then the result is stored in the third
memory word.
4. On press of a start push button, value stored in some memory word is logically OR ed
with another value in another memory word and then the result is stored in third memory
word.
5. On press of a start push button, value stored in memory word is added with some another
value in another memory word and the resulted value is then multiplied by some another
value in other memory bit.
6. A lamp goes on, only after pressing the momentary input push button exactly 10 times.