GMI German-Malaysian

Institute

I N D U S T R I A L D I P L O M A P R O G R A M M E

FINAL SEMESTER
EXAMINATION
Academic Period : July 2007

Subject : PROGRAMMABLE LOGIC CONTROLLERS

Code : IAT 0912
Duration : 3 HOURS
Prepared By : SYED NIZAM SYED IDRIS
Total Marks : 100

GENERAL INSTRUCTIONS:

Write down clearly (with capital letters) your name, trade,

group and the date of examination at the bottom of this page.
Do not open this question booklet until you are told to do so by
the invigilator.
Read the specific instructions and questions carefully before
answering.

This question paper consists of 14 printed pages including this page.

Student’s Name :
Student’s I/D No. :
IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

Semester/Trade/
:
Group
Date :

Section A

Answer all questions using the OMR sheet provided.

Please shade your answers clearly on the OMR sheet by using only 2B
pencil or black ball pen.

1. In the following PLC block diagram, item (X) and (Y) represents

Input
Modul (Y)
(X)
e

Programming Operator
Device Interface

A. Central Processing Unit and Output Module

B. Output Module and Central Processing Unit
C. Expansion Module and RAM
D. EEPROM and RAM

2. The component of a PLC which stores and execute the main program is
________.

A. CPU
B. Programming Device
C. Input/Output Module
D. Operator Interface

3. A type of memory which can be read from but not written to is called

A. RAM
B. Read/Write memory
C. ROM
D. EEPROM

4. A switch or a pushbutton is ____________.

A. a digital input device

B. an analog output device
C. a digital output device
D. an analog input device

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

5. __________ is a PLC programming language that uses components

resembling elements used in a control line diagram.

A. Ladder Diagram
B. Statement List
C. Function Block Diagram
D. Process Graph

6. Which of the following is not required when creating or changing a PLC

program?

A. PLC
B. Programming Device
C. Programming Software
D. Printer

7. Which of the followings is not available on Siemens PLC CPU 315-2DP?

A. Status Indicators
B. Mode Switch
C. Programming Port
D. Network Port

8. A digital module for S7-300 PLC can have a maximum of _____ bits of
digital terminal.

A. 32
B. 16
C. 8
D. 4

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

9. For the following ladder diagram, select the most suitable statement
which describe its operation.

A. A continuous signal at contact I0.0 and I0.1 is needed to

continuously on the coil Q0.0
B. With the PLC port I0.1 connected to the normally close
switch, a short pulse of signal at contact I0.0 will latched
coil Q0.0
C. With the PLC port I0.1 connected to the normally open
switch, a short pulse of signal at contact I0.0 will latched
coil Q0.0
D. With the PLC port I0.1 connected to the normally close
switch, a continuously signal at contact I0.0 will latched
coil Q0.0

10. Which of the followings is not a part of a PLC scan?

A. Read inputs
B. Reset all counters and timers
C. Execute program
D. Update outputs

20 MARKS

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

Section B

Complete the following ladder diagram by labelling the correct symbolic

addresses for each contact and output(coil) base on the given symbol
information.

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

20 MARKS

Section C

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

Please answer in the blank space provided below the questions.

Problem Definition

(Refer to the machine diagram to clearly understand the system operation).

• This machine is used to mix 2 types of liquid and then drain it to another
system.

Initial Condition

• Initially, before the start button is pressed, all the valves are closed.
• There should not be any liquid in the tank, TLB1 and TLB2 signal should be
off.
• The stirring motor M, should be stationary, not turning.
• Indicators and buzzers should be turned off.

Process Sequence

1. As the PB1 is pressed, the machine will open valve MV1 and also turn on
the indicator PL to show that the machine is running.
2. When the first liquid into the tank reaches the level sensor TLB2, a timer is
started.
3. When the timer reaches 10 seconds, the valve MV1 closes and valve MV3
opens. Here the second liquid is channeled into the tank. Also at this point
the mixer, stirring motor ‘M’ will start turning.
4. After the combination of both liquids reaches the level sensor TLB1, the
valve MV3 closes and after 5 seconds the valve MV2 opens. Here the mix
liquid is channeled to another system.
5. 10 seconds after the liquid level falls under the level sensor TLB2, the
valve MV2 closes and the stirring motor stops.
6. Next, the valve MV1 opens again and the whole cycle is repeated again for
2 cycle run.
7. After the 2 cycle run, all the valves are closed and the motor stopped, the
indicator PL will be flashing and the buzzer will give a warning pulse of 2
seconds on and 1 second off. This will indicate that the tank need cleaning
before can be used again.
8. By pressing the ‘Stop’ button, the machine will stop all its operation, after
1 cycle is completed.
9. Although in the diagram it is not drawn, please include an ‘Emergency
Stop’ button to stop the operation of the machine immediately.

Indicators

1. Lamp PL indicates the machine is in operation (from start until the end of
the process).

2. Lamp PL flashing and buzzer, indicates that the tank need cleaning
before any further operation.

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

Process Schematic

NOTE;

Valve type:
If current is not flowing through the coil, the valve will CLOSE.
If currently is flowing through the coil, the valve will OPEN.

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

1) Complete the given assignment list/symbol table below.

INPUTS OUTPUTS
Symb Address Description Symbo Address Description
ol l
Start Operation Valve liquid 1
Stop Operation Valve liquid 2
Level Sensor, Valve for drainage
bottom of tank
Level Sensor, top Stirring Motor
of tank
S7 I0.4 Emergency Stop Lamp Indicator
Buzzer

10 MARKS

2) Draw the PLC wiring diagram.

10 MARKS

3) Complete the Sequence Step Diagram below.

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

Initial Condition

_______
STEP 0
S ________________
M1.0
_____ S ________________

_______

NS ________________
STEP 1
______
_ T1 (Time Expired)

R ________________
STEP 2
NS ________________
M1.2
_ S ________________
S2 or R
_______

STEP 3 NS ________________
_____
_______ T2 (Time Expired)
_

STEP 4 _______________
S
M1.4 9
______ TLB2
OFF
STEP 5 NS ________________
M1.5
_______
_ T3 (Time Expired)
R ________________
STEP 6
_____ R ________________
______
NS ________________
C1=3

STEP 7 NS ________________
M1.7
NS ________________
______

20 MARKS

4) Write the ladder diagram for the system accordingly using symbolic
addressing based on the assignment list and sequence step diagram
from question 1 and 3.

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

The assessment for the ladder diagram will be based on the followings;

SPECIFICATION Max. Marks

Marks Awarde
d
Program Structure
Program is develop based on the Sequence Step 4
Diagram
Sequence process programming format 2
Actuation process format 2

System Operation
In order to activate the system it should be in the 2
Initial Condition.

If all the initial conditions are met, and by pressing 2

the start button, MV1 will open.

Then once TLB2 detects the liquid and after 10 3

seconds, MV1 close and MV3 open. Stirring Motor
also turned on.

Then once TLB1 detects the liquid, and after 5

seconds, MV3 close and MV2 open. 2

Then once TLB2 detects the liquid, and after 10 4

seconds, MV2 close, the stirring motor stops and a
counter is triggered.

The cycle will start again for 2 more cycle. 3

When the operator presses the “Stop” button, the

machine will complete 1 cycle before stopping. 2

Lamp PL illuminates during normal running, and 2

starts flashing after 3 cycle run.

Buzzer sounds during after 3 cycle run. 2

30 MARKS

LADDER DIAGRAM FOR Section B, Q4

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