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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 2008

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 12 printed pages including this page.


IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

Student’s Name :
Student’s I/D No. :
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. A switch or a pushbutton is ____________.

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

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

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

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

4. 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

5. 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

6. The address designation for output byte 5 and bit 5 of an S7-300 PLC is
_______

A. 0055
B. X5.5
C. I5.5
D. Q5.5

7. The main function of a timer is to;

A. Only delay the actuation of any actuator


B. Either delay the actuation or deactuation of any actuator
C. Only delay the actuation of an AC motor
D. Display the time countdown

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

8. The illustration below best describe the operation of ______________. The TV


terminal of the timer function block is set at 10 seconds.

Operand Waveform

I0.0

Q4.0

10s

A. Pulse Timer
B. Extended Pulse Timer
C. On-delay Timer
D. Retentive On-delay Timer

9. Which of the followings list the type/types of counter available in Step7


software?

A. Count Up
B. Count Up and Count Down
C. Count Up, Count Down and Count Up and Down
D. Count Down

10. Which of the following statement correctly describe a comparator in


Siemens PLC?

A. The comparator only accept data from counter to be compared with


the reference data
B. The reference data and the data obtained from the comparator is in
the form of one byte of memory
C. The comparator compare for ‘greater than’ and ‘less than’ cases only
D. If the results of the comparator is true, the output Q will change from
logic ‘LOW’ to logic ‘HIGH’

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

20 MARKS

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.

Rewrite it on the answer sheet.

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

20 MARKS

Section C

Please answer all questions in the answer sheet.

Problem Definition
(Refer to the process schematic to clearly understand the system operation)

A machine is to be used for stamping blank coins.

Initial Condition

• The pusher, ram and ejector is at the full retract position. (S6, S10 and
S8 are ON)
• The die is empty. (SP is OFF)
• The blank coin is in the magazine. (SX is ON)

Process Sequence

1. In order to activate the system, the user must press the start push
button, S1 and key-in a correct 4 digit pass-code numbers at a
numerical setter as shown in the process schematic diagram which is
connected to port IW2 of the PLC.

2. If all the initial conditions are met and the correct pass-code numbers
are set, the pusher extends (actuated by Y1) which at the same time
pushes a blank coin from the magazine into the die as shown in the
process schematic diagram on page 3.

3. Once the blank coin is in the die,

a) The pusher retracts (actuated by Y2) to its initial position.


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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

b) The ram extends (actuated by Y3) to stamp the blank coin. It


stamps for three seconds before it rises up (actuated by Y4) to
its initial position.

4. Then the ejector ejects (actuated by Y6) the finished coin from the die
and at the same time the air jet is activated (actuated by Y5) to blow the
coin into the collecting tray.

5. The blown finished coin is detected by light barrier, B1. This is the end of
the first cycle of the process and the next cycle of the process will proceed
as long as the blank coins are in the magazine.

6. The operation could be stopped at any time by pressing stop push


button, S2.

Indicators

1. Lamp H1 indicates the machine is in operation (from start until the end of
the process).

2. Lamp H2 and buzzer, Z actuate during the three seconds duration of the
stamping.

Process Schematic

1 4 2 7
H1 H2 Z
S1 Numerical Stamping
Operation Buzzer
Start Setter Indicator
Indicator

S10
BLANK COINS Y3
Y5 MAGAZINE (Extend ram)
(On air jet
S11
stream) Y4
(Spring return (Retract ram)
type)* AIR JET RAM
Blank coin
S6 S7 DIE AREA
S
X B1
PUSHER

SPO
S9 COLLECTING
Y1 EJECTOR TRAY
S8
(Extend Pusher)

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Y2
(Retract Pusher)
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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

Y6
(Ejects coin)

(Spring return
type) *

NOTE;

# This schematic shows the position of the components when the pusher has
just push the blank coin into the die.

* Spring return type:

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

Assignment List

INPUTS OUTPUTS
Symb Address Description Symbo Address Description
ol l
S1 I0.0 Start Operation Y1 Q4.0 Solenoid
valve/Pusher
extension
S2 I0.1 Stop Operation Y2 Q4.1 Solenoid
valve/Pusher
retraction
S6 I0.2 Sensor/Sense full Y3 Q4.2 Solenoid valve/Ram
retraction of extension
pusher
S7 I0.3 Sensor/Sense full Y4 Q4.3 Solenoid valve/Ram
extension of retraction
pusher
S8 I0.4 Sensor/Sense full Y5 Q4.4 Solenoid
retraction of valve/Activate air jet
ejector
S9 I0.5 Sensor/Sense full Y6 Q4.5 Solenoid
extension of valve/Activate
ejector Ejector
S10 I0.6 Sensor/Sense full H1 Q4.6 Operation Indicator
retraction of ram
S11 I0.7 Sensor/Sense full H2 Q4.7 Indicate stamping
extension of ram operation (visual)
SP I1.0 Sensor/Sense Z Q5.0 Indicate stamping
blank coin in die operation (sound)
SX I1.1 Sensor/Sense NSET IW2 Numerical Setter
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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

blank coin in
magazine
B1 I1.2 Detect stamped
coin

Correct 4 digit pass-code


numbers

_______
STEP 0
______
_____
SP(OPEN), SX, S6, S8, S10

NS ________________
STEP 1
_______ S ________________

SP
1) Draw the PLC wiring diagram of the above system.
STEP 2 NS ________________
_______ 10 MARKS
NS ________________
2) Complete the Sequence Step Diagram below.
S2 or R
S11

STEP 3 NS ________________
______
_______ NS ________________
_
NS _______________

T1 (Time Expired)
STEP 4 _______________
NS
_____ 9
______
S10
STEP 5 NS ________________
______
_______
NS ________________
_
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German R All ________________
rights reserved.
_____
______
IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

20 MARKS

3) Write the ladder diagram on page 9 to 11 for the system accordingly using
symbolic addressing based on the assignment list and sequence step
diagram from question 1 and 3.

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 5
Diagram
Sequence process programming format 4
Actuation process format 3

System Operation
In order to activate the system the user must press 3
the start push button, S1 and key-in a correct 4
digit pass-code numbers at a numerical setter
which is connected to port IW2 of the PLC.

If all the initial conditions are met, the pusher 3


extends and pushes a blank coin from the
magazine into the die. (2)

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IAT 0912 PROGRAMMABLE LOGIC CONTROLLERS

At the same time indicator H1 indicates the


operation of the machine (2)

Then once the coin blank is in the die,

The pusher retracts to its initial position. (2) 4


The ram extends to stamp the blank coin. It
stamps for three seconds
before it rises up to its initial position. (2)

The ejector ejects the finished coin from the die


and at the same time the air jet is activated to blow 3
the coin into the collecting tray.
The blown finished coin is detected by light barrier,
B1. This is the end of the first cycle of the process 3
and the next cycle of the process will proceed as
long as the blank coins are in the magazine.

Lamp H2 illuminates during stamping 1


Buzzer Z sounds during stamping 1

30 MARKS

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