Vd 4 4 a 9ff04/2024, 00:4 PLC MARKING SCHEME EXAM -FINAL docx - Google Docs INDUSTRIAL PLC MARCH 2024 Time: 3 HOURS KISII NATIONAL POLYTECHNIC DIPLOMA IN ELECTRICAL AND ELECTRONIC ENGINEERING (POWER OPTION) OPTION) (TELECOMMUNICATION MODULE TWO. INDUSTRIAL PLCS DEEPS22 & DEETS22 3 HOURS INSTRUCTIONS TO CANDIDATES You should have the following for this examination: Answer booklet; - Non programmable scientific calculator; Drawing instruments This paper consists of two sections ; a and b “Answer ALL questions from section A and any avo from section B in the answer booklet provided. Maximum marks for each question are indicated in each question. TURN OVER 1) oe 113 Inips:idocs google.comidocumentid/1 WP TaaF LESPR2dODbXKubidens7QUWiT/edit gy” wor TWP TaaPLF oa — wsSnes PLC MARKING SCHEME EXAM -FINAL docx - Google Docs MARKING SCHEME arks) With the aid of diagram explain a basic process control system. (5 mi Disturbance inputs Pot Comtrotter ica Measurement] Process control consists of monitoring the state of a critical parameter, detecting when it varies from desired state, and taking action to restore it. It involves the process variable, set points and = @ ‘manipulated variable. Most basic process control systems consist of a control loop. This has four main components which are: ‘A measurement of the state or condition of a process A controller calculating an action based on this measured value against a pre-set or desired value (set point) ‘An output signal resulting from the controller calculation which is used to manipulate the process action through some form of actuator The process itself reacts to this signal, and changes its state or condition. Define the following terms, (5 marks) i) PLC -an industrial computer control system that continuously monitors the state of input devices and makes decisions based upon a custom program, to control the state of devices connected as output. They are based on the Boolean logic operations whereas some models use timers and some have continuous control. These devices are computer based and are used to © control various processes and equipment within a facility. PLCs control the components in the DCS and SCADA systems but they are primary/main components in smaller control configurations. ii) SCADA- is a combination of telemetry and data acquisition. It encompasses the collecting of the information, transferring it back to the central site, carrying out any necessary analysis and control and then displaying that information on a number of operator screens or displays. The SCADA is a centralized system and is composed of various subsystems like Remote Telemetry Units, Human Machine Interface, Programmable Logic Controller (PLC) and Communications networks. iii) EMBEDDED CONTROL -In this control system, small components are attached to the industrial computer system with the help of a network and control is exercised. 21 |tps:/idocs.google.com/documentid/1 WP TaaFLFXSPRzdDDbXkubidens7QuWiZ/editON eS pas PLOMARKING SCHEME ExaM WAL coos Google Docs : MARKING SCHEME i wv) TRANSDUCER "m. Thus sensors are often which converts an electrical 2 device that converts a signal from one form to a different physical transducers, but also other devices can be transducers, e.g. a motor ‘input into rotation. y) ss Be STRIAL CONTROL SYSTEM (ICS) -a term that encompasses several types of Acquisition scapay ao esta reduction These include: Supervisory Control and Data ee ) systems, Distributed Control Systems (DCS) and other smaller control 's configuration such as Programmable Logic controllers (PLC). The application for i ues pplication for industrial process control systems are diverse ranging from simple traffic eure fo complex electrical grid, from environmental control system to oil refinery process control. The Intelligence of these automated systems lies in their measurement and control units, Outline the differences between a Programmable Logic Controller and a personal computer (3 marks). . 1. Environment: © PLCs operate in industrial environments with specific automation and control requirements, while PCs are used in general-purpose computing environments. 2. Programming and Software: © PLCs use specialized programming languages and software tools tailored for industrial automation, whereas PCs use general-purpose programming Janguages and software for various applications. 3. Hardware Design: © PLCs are ruggedized, enclosed devices with specific /O capabilities for industrial control, while PCs are open systems designed for flexibility and compatibility with a wide range of peripherals. € 4. Reliability and Durability: © PLCs are designed for high reliability and durability in industrial settings, whereas PCs are optimized for user interaction and versatility in office and consumer environments. Real-time Operation: ‘© PLCs operate in real-time with deterministic response for control applications, Whereas PCs prioritize multitasking and user interaction over real-time determinism. In summary, PLCs are specialized controllers for industrial automation and process control, whereas PCs are general-purpose computing devices used for diverse tasks in office, home, and entertainment settings. Each device is optimized for its specific application domain and operational requirements. 5.: 1ocx - Google Docs 2004/2028, 00:18, LG MARKING SCHEME EXAM -FINAL docx - C000 MARKING SCHEME cture ofa 5 marks) 4, Provide and explain a diagram that shows the internal architecture of a PLC (5 marks) The CPU controls and supervises all operations within the PLC, carrying out programmed instructions stored in the memory. ‘An internal communications highway, or bus system, carries information to the CPU, memory and |/0 units, under control of the CPU. The CPU controls and processes all the operations within the PLC. It is supplied with a clock with «a frequency of between 1 and 8 MHz. This frequency determines the operating speed of the PLC and provides the timing and synchronization for all elements in the systems. The information within the PLC is carried by means of digital signals. The internal paths along digital signal flow are called buses. A bus is just a number of conductors along which electrical signals can flow. The internal structure of the CPU depends on the microprocessor concerned The simplified model consists of five parts ALU, CU, Registers, Buses, and memory. Arithmetic and Logic Unit (ALU) Which is responsible for data manipulation and carrying out arithmetic operations of addition and subtraction and logic operations of AND, OR, NOT and EXCLUSIVE @ OR(X-OR) it receives control signals from the control unit telling it to carry out these operations Control Unit & This controls the movement of instruction in and out of the processor and also controls the operation of ALU. It consists of a decoder, logic circuit and a clock to ensure everything happens at the correct time. It is also responsible for performing the instruction execution cycle. Registers @ located within the microprocessor and used to store information involved in program execution. It is a small amount of internal memory that is used for the quick storage and retrieval of data and instructions. All processors include some common registers 4l hmine:/idocs ocogle com/documentid/WPTeaFLFXSPR2dDDbXkubider sie ina.ee neers SE ee SCHEME EXAK PLC MARKING: MARKING SCHEME arks 4, Provide and explain a diagram that shows the internal architecture of a PLC (5 marks) The CPU controls and supervises all operations within the PLC, carrying out programmed instructions stored in the memory. ‘An internal communications highway, or bus system, carries information to the CPU, memory and I/O units, under control of the CPU. The CPU controls and processes all the operations within the PLC. It is supplied with a clock with «a frequency of between 1 and 8 MHz. This frequency determines the operating speed of the PLC and provides the timing and synchronization for all elements in the systems. The information within the PLC is carried by means of digital signals. The internal paths along digital signal flow are called buses. A bus is just a number of = conductors along which electrical signals can flow. e The internal structure of the CPU depends on the microprocessor concerned The simplified model consists of five parts ALU, CU, Registers, Buses, and memory. Arithmetic and Logic Unit (ALU) Which is responsible for data manipulation and carrying out arithmetic operations of addition and subtraction and logic operations of AND, OR, NOT and EXCLUSIVE ® OR(X-OR) it receives control signals from the control unit telling it to carry out these operations Control Unit @ This controls the movement of instruction in and out of the processor and also controls the operation of ALU. It consists of a decoder, logic circuit and a clock to ensure everything happens at the correct time. It is also responsible for performing the instruction execution cycle. Registers © located within the microprocessor and used to store information involved in program execution. it is a small amount of internal memory that is used for the quick storage and retrieval of data and instructions. All processors include some common registers 4l lle gna al veces 3(2024, 00:15 PL mag Google Do MARKING SCHEME EXAM FINAL do . cx - Google Docs MARKING SCHEME Buses are ‘ the paths used transmitted in binary fore nosed for communication within the PLC. The information is Spitem bus tears group of bits with a bit being o binary digit of 0 or 1. Which caries deta concommunicatin between the YO ports and VO unit tis a cable peel Imunication between the maj jonents of the including the microprocessor. re eer Cont , aaah ee carer the signals relating to the conto and co-ordination of the various frsareinsireey crite wheiioon be sent ‘from the control unit within the CPU. It Beene ey are to receive data from an input or output data Darelnectries the de igr used to synchronize actions. ‘ Jata used in the process carried out by the CPU. It is used for the exchange of data between the processor, memory and peripherals, and is bidirectional. A ‘micro processor termed as being 8-bit has an internal data bus which can handle 8-bit ‘number. Address bus is used to carry the addresses of memory location. It contains the connection between the microprocessor and memory that carry the signals relating to the addresses which the CPU is processing at that time, such as the locations that the CPU is reading from or writing to. Every memory location is given a unique address. Memory: - There are several memory elements in a PLC system. Executive memory or operating system memory which is read only memory (ROM) to give permanent storage for the operating system and fixed data used by the CPU. It is the one that actually does the scanning in the PLC. ‘System memory @ in order for the operating system to function, a section of the memory is allotted for system administration. As the executive program performs its duties, it often requires a place to store intermediate results and information. A section of RAM (Random Access Memory) is installed for this purpose. Data memory @ This is a RAM where information is stored on the status of input and output devices and the values of timers and counters and other internal devices. Data RAM is sometimes referred to as a data table or register table. User program memory @ The final area of memory in a PLC is allocated to the storage of the user program. It is this memory area that the executive program instructs the micro-processor to examine or Qiscan® to find the user: instructions. /0 status memory or 1/0 image table. A portion of RAM is allocated for the storage of current |/O status. Every single /0 module has been assigned to a particular location within the 1/0 image table, The location within the input and output image table/map ‘are identified by addresses, each location has its own unique address. Describe the basic steps of operation of a PLC after it is tuned on, (4 marks). Overall, the basic operation of a PLC involves initializing control program, scanning inputs, communicating with external devices or systems. control industrial processes and machinery effecti programmed logic. operation, but these fundamental steps are common a 5 hardware, loading and executing the ‘executing contro! logic, updating outputs, and optionally This cyclic scanning process enables the PLC to vvely based on real-time input data and Fach PLC manufacturer may have specific variations in the sequence of cross most PLC systems.PLC MARKING SCHEME EXAM -FINAL docx - Google Docs MARKING SCHEME 1. Power On initialization: * When the PLCis powered on, routines © The CPU (Central Processing Unit) and other hardware components (memory, /0 modules) are initialized, The PLC's operatin starts running, Loading the Control Progra ° The PLC's contro! program, stored in non-volatile ‘memory (such as EEPROM or Flash memory), is loaded into the CPU's memory (RAM). * This control program contains the logic written by the programmer using PLC Programming software (e.g,, ladder logic, function block diagrams, structured text) 3. Scanning Process: it performs a series of self-checks and initialization 9 system (RTOS - Real-Time Operating System) boots up and Once the control program is loaded, the PLC starts the scanning process. rOCeSS consists of re The scanning p) eatedly executing the following steps. ©. Input Scan 2? * Reads the current state ofall input devices (sensors, switches, buttons, etc.) connected to the PLC input modules. Updates the corresponding memory locations (input image table) with the status of input devices. © b. Program Execution: * Executes the control program stored in input states. Processes the logic in the control program to determine © ¢. Output Update: © Updates the output devices (actuators, the PLC output modules based on the p Writes the output states to the output 4. Communication and Networking (if applicable): © The PLC may communicate with other Ethernet, Profibus, Modbus) to exch ‘Communication tasks such as sendi requests, or sending status update: 5. Monitoring and Diagnostic © The PLC continuously monitors its own operation, system parameters, * Diagnostics and error handlin. abnormal conditions, * Diagnostic information may be logged or displayed on operator interfaces for troubleshooting and maintenance. 6. Cycle Completion and Repeat: ® After completing the scanning process (input scan, program execution, output Update, communication tasks), the PLC cycle repeats itself. ‘memory based on the current the states of output devices. relays, motors, etc.) connected to rogram execution results. image table, *r devices or systems over a network (e.g., ange data or receive commands. } ing/receiving data packets, responding to ’S are performed during the scanning process. input/output statuses, and 1g routines are executed to detect faults, errors, or 61 si 3 /tpsu/docs googte.com/documentié/I WPTaaF LEXSPRedDDbXkubldens7QuWTiedt i ay ‘TIPS sraDUR spouyreswure saul FOr Wu ¥4¥ rt tr meet ener sinecee eee tee ne ioeK~ Genet: Doss. MARKING SCHEME © The PL ir € continues to scan inputs, execute the control program, update outputs, and, Perform communication tasks in a continuous loop as long as it remains Powered on, A ladder logi ‘adder logic diagram is shown in figure 1 below. Explain what is wrong with this diagram and hence what he happen if it is used.(5 marks) | | ‘Some PLCs remove memory when a battery is removed. Explain why. (3 marks) The phenomenon where some Programmable Logic Controllers (PLCs) lose memory when a battery is removed is primarily due to the way these PLCs store their program and data in volatile memory. Here's a detailed explanation of why this happens: 1, Memory Type: Many PLCs use volatile memory (such as RAM - Random Access Memory) to store the running program, data tables, and other variables during normal operation. ‘© Volatile memory requires continuous power to maintain stored information. When power is removed, the contents of volatile memory are lost. 2. Battery Backup: @ © Toretain program and data in volatile memory when the PLC is powered off (or when the main power supply is disconnected), a battery backup system is used. © The battery provides backup power to specific memory areas (such as RAM) to preserve the contents even when the PLC is not powered externally. 3. Purpose of Battery: ‘© The battery backup system ensures that critical data (such as the PLC program, variable values, and system configuration) is retained during power outages or when the PLCis shut down. Without battery backup, the PLC would lose all stored data and program every time it is powered off or the main power supply is interrupted. 4. Battery Maintenance and Replacement: © Over time, PLC batteries can degrade or lose their charge capacity. ‘© When a battery is removed or fails completely, the backup power to the volatile memory is lost. 7 https //docs, google com/document/d/ WP TaaFLFXSPRzdDDbXkubldens7QuWi7/edit # 3MARKING SCHEME. © Asa result, the contents of volatile memory (including the PLC program and data) are no longer preserved, and the PLC loses its memory. 5. Consequences: i © Ifa PLC loses its memory due to a removed or failed pare ena Gane © The PLC will revert to its default state upon power-up, po! rogram and configuration settings. «Thue il ned to retaad he Pe program and reconfigure the system settings to restore normal operation. é ‘* This can lead to downtime, loss of productivity, and troubleshooting efforts to recover and restore the PLC functionality. In summary, PLCs that lose memory when a battery is removed rely on battery backup to Preserve data in volatile memory. The battery ensures that critical information remains intact during power interruptions or shutdowns. When the battery fails or is removed, the contents of volatile memory are lost, necessitating reprogramming and reconfiguration of the PLC to resume normal operation. Regular maintenance and timely replacement of PLC batteries are essential to © prevent unexpected memory loss and ensure continuous operation of PLC-based control systems. © ib A. state four factors that make programmable logic controllers more suitable for industrial control over conventional computers. (4 marks) Rugged and designed to withstand vibrations, temperature, humidity, and noise. Programming the PLC is easier than wiring the relay control panel. They eliminate the need for hardwired relay logic. They are fast. Ithas supervisory control capability. They have interfacing for inputs and outputs already inside the controller PLCs are modular so they can be plugged into various setups. High reliability and easy maintenance/troubleshooting Its input and output modules can be extended depending upon the requirements They are user friendly and easy to operate. B, draw the ladder symbols of each of the following: (6 marks) . i) normally open contact ii) normally closed contact ii)(a PLO Mars ING SCHEME EXAM FINAL ds 120x- Google Docs MARKING iv) on delay timer ‘SCHEME V) counter Vi) set and reset internal relay C. with the aid of a labeled diagram, state the functions of ple components. (10 marks) Programming device [A Wh The processor unit or central processing unit (CPU) is the unit containing the microprocessor and this interprets the input signals and carries out the control actions, according to the decisions as action signals to the outputs. program stored in its memory, communicating the convert the mains a.c. voltage to the low d.c. voltage (5 V) The power supply unit is needed to ircuits in the input and output interface modules. necessary for the processor and the ci uired program into the memory of the used to enter the req! y unit of The programming device is veloped in the device and then transferred to the memon processor. The program is de the PLC. ot ee eecvepreinDbXkubidens7QuWi7/edit -FINAL doox - Google Doce: = PLC MARKING SCHEME EXAM FINAL MARKING SCHEME ; : t The memory unit is where the program is stored that Is to be use or Me fp be exercised by the microprocessor and data stored from the input for p! output for outputting. : i ermal The input and output sections are where the processor receives information fr On ee devices and communicates information to external devices. Inputs can be from switches, while outputs might be to motor starter cols, solenoid valves, relays etc. The communications interface is used to receive and transmit data on communication networks from or to other remote PLCs. @ 4 A. giving examples describe the following programmable logic controller languages. (6 Z marks) i) ladder diagram Ladder diagram language (tb): It uses a standardized set of ladder programming symbols to o implement control functions. initially programmed with simple contacts that simulated the Opening and closing of relays, ladder logic, programming has extended to include such functions as counters, timers, shift registers and mathematical operations. instruction list Instruction list ~ a low level (assemble like) language that is based on similar instructions list languages found in a wide range of today’s PLCs. Structured text ~A high level text language that encourages structured programming. It has a language structure (syntax) that strongly resembles PASCAL and supports a wide range of standard functions and operations. For example IF (Limit_switch1 AND Workpiece Present) THEN Gate1 :- Open; Gate2 :- Close; Gate1 :- Close; Gate2 :- Open;PLC MARKING SCHEME EXAM -EWAL docx - Google Docs MARKING SCHEME B. desctibe and st ; marks) ‘ate two advantages in each the following ple styles of construction: (8 1 unita ry Unitary PLC Design A Unitary PLC contai directly to the comp Advantages ins all the features of a basic system in one compact unit. They are fitted }onent or machine that they are controlling They are small and compact. They hold all the basic components in one unit They allow portable and easy access. They are usually the cheapest type of PLC. I. modular Modular PLC Design Modular PLC's are a system of modules that can be slotted together to build up a system. Other types of module can be attached as welll as extra input and output modules to increase the capacity or to cope with changes in hardware system. Advantages © The amount of input and output terminals can be expanded to cope with any changes to the hardware system. © (fany feature fails then only that part has to be changed saving on cost. C.explain any three ple maintenance measures. (6 marks) 1. Periodically clean or replace any filters that have been installed in enclosures at a frequency dependent on the amount of dust in the area. 2. Do not allow dirt and dust to accumulate on the PLC’s components; the central processing unit and 1/0 system are not designed to be dust proof. If dust builds up on heat sinks and electronic circuitry, it can obstruct heat dissipation, causing circuit malfunction. 3. Periodically check the connections to the I/O modules to ensure that all plugs, sockets, terminal strips, and modules have good connections. Also, check that the module is securely installed. 4, Ensure that heavy, noise-generating equipment is not located too close to the PLC. 5, Make sure that unnecessary items are kept away from the equipment inside the enclosure. 6. If the PLC system enclosure is in an environment that exhibits vibration, install a vibration detector that can interface with the PLC as a preventive measure. This way, the programmable controller can monitor high levels of vibration, which can lead to the loosening of connections A.state four merits of using ples. (4 marks) i) They are user friendly and easy to operate ii) Rugged and designed to withstand vibrations, temperature, humidity, and noise. iii) Programming the PLC is easier than wiring the relay control panel iv) They eliminate the need for hardwired relay logic ny_ 0104/2024, 00:15 PLC MARKING SCHEME EXAM -FINAL docx - Google Docs MARKING SCHEME v) They are fast vi) It has supervisory control capability vil) They have interfacing for inputs and outputs already inside the controller. vili) PLCs are modular so they can be plugged into various setups ‘x) High reliability and easy maintenance/troubleshooting X)Its input and output modules can be extended depending upon the requirements b. explain each of the following ple fault finding techniques:(8 marks) i) time checks Timing checks ~ The term watching is used for a timing check that is carried out by the PLC to check that some function has been carried out within the normal time. If the function is not carried out within the normal time, then a fault is assumed to have occurred and the watchdog timer trips, setting off an alarm and perhaps closing down the PLC. As part of the internal diagnostic of PLC, watchdog timers are used to detect faults. ii) replication Replication — replication check involves duplication i.e. replication, the PLC system. This could mean that the system repeats every operation twice and if it gets the same result it is assumed there is no fault. This procedure can detect transient faults. Alternatively, is to have duplicate PLC systems and compare the results given by the two systems. In the absence of the fault the two results should be the same, a fault showing up as a difference. iii) expected value checks Expected values checks — Software errors can be detected by checking whether an expected value is obtained when a specific input occurs. If the expected value is not obtained then a fault is assumed to be occurring. iv) last output test. Last output set — This technique involves the use of status lamps to indicate the last output that has been set during a process which has come to a halt. Such lamps are built into the program 0 that as each output occurs a lamp comes on. The lamps thus indicate which outputs are occurring. The program has to be designed to turn off previous status lamps and turn on anew status lamp as each new output is turned on. c. draw a ladder diagram for the following logic gates: (8 marks) i) not, Input A Output 12]es LS" F-Y1—< >4 iy) xor gate,