General

1. What is Automation? Automation is delegation of human control functions to technical equipment for increasing productivity, better quality, reduced cost & increased in safety working conditions. 2. What are the different components used in automation? The components of automation system include Sensors for sensing the input parameters ( T!, Thermocouple, "ressure, #low, $eve% etc& Transmitters for transmitting the raw signal in electrical form 'ontrol system which includes "$', !'S & "(! controllers )utput devices * actuators like drives, control valves. 3. What are the different control systems used in Automation? "(! 'ontroller based control system "$' based control system !'S based 'ontrol system "' +ased automation system

4. Explain PI !ased control system. "(! ("roportional (ntegral !erivative& is the algorithm widely used in closed loop control. The "(! controller takes care of closed loop control in plant. A number of "(! controller with single or multiple loop can be taken on network. "(! 'ontrollers are widely for independent loops. Although some logic can be implemented but not much of sequential logic can be implemented in "(!s. ". ifference !et#een P$% & 'elay ? "$' can be programmed whereas a relay cannot. "$' works for analog (*)s such as "(! loops etc. whereas a relay cannot "$' is much more advanced as compared to relay. ,odifications in relay base circuit is difficult compared to "$'s

(. ifference !et#een P$% & %) ? %)- The system uses multiple processors, has a central database and the functionality is distributed. That is the controller sub system performs the control functions, the history node connects the data, the (,S node gives reports, the operator station gives a good .,(, the engineering station allows engineering changes to be made. P$%- The system has processor & (*)/s and some functional units like basic modules, communication modules and so on. 0ses a S'A!A for visuali1ation. 2enerally the S'A!A does not use a central database. !'S is often used in the big plants where the redundancy level needed is more and the analog input used are high. *. What is P% !ased control system ? (n "' based control system, the '"0 of computer acts as processor, the "'( based cards are used for connecting (nput and )utput. The A, acts as memory. .ard disk is used as storage device. 'urrently this systems are very useful when the large data is to be proceed with very high speed. (n many cases for greater accuracy we can use the real3time operating system.

+. What is Encoder ? A feedback device which converts mechanical motion into electronic signals. 0sually 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. ,. Which are the leadin- P$% pro.iders ? The leading "$' providers include ockwell Automation - Allen +radley (,icrologi4, S$', "$', 'ontrol $ogi4& Siemens ( S5 677, S5 877 , S5 977& 2rouppe Schneider - ,odicon ( :ano, ,icro, "remium, ;uantum& 2< #anuc - =ersa, Series >7387, >7357 ,essung - :e4tgen 1/. Which are the leadin- %) pro.iders ? The leading !'S providers include ?okogawa - 'S 8777 , 'S @777 (<arlier 'entum <4cel, ,icro <4cel& .oneywell - T!' 8777 #isher 3 osemant 3 !elta = A++ 3 #reelance 6777 ,oore 3 A"A'S #o4 boro 3 (*A series 11. Which are the leadin- )%A A soft#are 0 11I pro.iders ? The leading S'A!A software * ,,( providers include Aonderware - (nTouch (ntellution i#i4 (<arlier #i4!,A'S& Siemens - Ain'' Allen +radley - S =iew ( <arlier 'ontrol =iew& B"(T - Astra

Instrumentation )ystem
12. What types of sensors are used for measurin- different parameters? Temperature sensors C T!, Thermocouple, Thermister "ressure Sensor C +orden Tube, +ellows, Strain gauge #low sensor C "itot tube $evel, 'onductivity, !ensity, "h

13. What is transmitter? A transmitter is an electronic device that is generally mounted in the field in close pro4imity to a sensor. The sensor (also known as a transducer& measures a physical variable such as temperature or pressure and outputs a very low level electronic signal. The basic function of the transmitter is to provide the correct electrical power to turn on (or e4cite& the sensor then to read the low level sensor signal, amplify it to a higher level electrical signal and send that signal a long distance to a control or read3out device. Since low3level 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 form the transmitter is 9367 mA or 73D7 = 14. Why 422/ mA preferred o.er /21/ 3 si-nal ? The 73D7 = signal has tendency to drop because of line resistance. (f the distance between sensor and input card is more the signal will not properly represent the field value. The 9367 mA will travel a long distance without dropping signal value. 1". Why 422/ mA preferred o.er /22/ mA si-nal ? Aith 73 67 mA you can not distinguish between minimum field value and connection break. Aith 9367 mA, internal circuit can distinguish between connection break of minimum value. :ormally when the value is minimum the transmitter will give you 9 mA while in case of connection breakage it will give 7 mA. 1(. ifference !et#een 2 #ire4 3 #ire and 4 #ire transmitter. (n 6 wire transmitter the power and signal are transmitted through same cable. (n 8 wire transmitter the data signal and power are with respect to common ground. (n 9 wire transmitter two wires for power supply and two for signals. )nly current transmitters can be used as 6 wire transmitters. 1*. What is a 5)mart6 7ransmitter ?. A ESmartE transmitter is a transmitter that uses a microprocessor as the heart of the electronics. (n addition, a ESmartE transmitter will output some type of remote digital communications allowing you to read and set3up the device from a remote position. 1+. What is 8ield !us ?. #ieldbus is a general term for a digital only, high speed communications protocol. The key attribute to #ieldbus communications is higher speed communications with the possibility of addressing multiple transmitters all on the same field wiring. The #oundation #ieldbus is a specific digital protocol that is often shortened to Fust be called #ieldbus. )ther digital only communications such as "rofibus are also #ieldbus protocols 1,. What is Actuator ?. (n a closed3loop control system, the part of the final control element that translates the control signal into action by the control device.

2/. Explain Wor9in- of '7 s esistance Temperature !evice 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 T! esistance vs Temp characteristic to detect temperature. Typical elements used for T! are :ickel, 'opper and "latinum. "latinum is widely used in T!s because of accuracy. "T D77 means at 7 deg temp D77 ohms resistance. A typical T! consists of a fine platinum wire wrapped around a mandrel and covered with a protective coating (glass or ceramic&. 21. 7emperature measurement ran-e supported !y '7 s? The T! work on temperature range betweenC6@7 to G@7 deg '. 22. Explain Wor9in- of 7hermocouple Thermocouple consists of two strips or wires made up of different metals and Foined at one end. The temperature at that Functure induces an electromotive force (emf& between the other ends. 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. !ifferent metallurgies produce different outputs. The different metallurgies and different lineararities result in different thermocou7le designations such as EHE, EB,E, E:E, E$E, etc. 23. What is %old :unction compensation? The industry accepted standard for the temperature at open end is 7 deg '. Therefore most tables and chart make the assumption that the temp at open end is 7 deg '. (n industry the open ends are always at actual room temperature and not 7 deg '. The emf adFustment because of difference between the actual temp and 7 deg ' is referred as 'old Hunction 'orrection ('H 'orrection& 24. 7emperature measurement ran-e supported !y thermocouple ? The thermocouple work on broad temperature range ie C657 to 6877. 2". %an I split my one 70% si-nal to t#o separate instruments? :o. The T*' signal is a very low3level millivolt signal, and should only be connected to one device. Splitting to two devices may result in bad readings or loss of signal. The solution is to use a IdualJ T*' probe, or convert one T*' output to a 9367 mA signal by using a transmitter or signal conditioner% then the new signal can be sent to more than one instrument 2(. What are the flo# measurin- instruments used in 8lo# measurement ? !ifferential pressure meters "ositive displacement =elocity meters

2*. Explain #or9in- of differential pressure measurement ? Suitable restriction placed in flow stream causes a differential pressure across it. As flow depends upon differential pressure (.ead& & area, so any of them or both can be varied for varying flow. 2+. What are the components of differential flo# sensor ? #or creating differential pressure - )rifice plate, =enturi Tube, #low :o11le , pitot tube

#or measuring pressure - 03Tube ,anometers, ingC+alance ,anometer, !.". 'ell 2,. What type of pressure sensors used in pressure measurement? ,anometers +ourdon tubes +ellow elements !iaphragm elements !" transmitters

3/. Explain #or9in- of differential pressure transmitters. "rocess 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 ma4imum deflection of7.779 inch (7.D7 mm&, is proportional to the applied pressure. 'apacitor plates on both sides of the sensing diaphragm detect the position of the diaphragm. The transmitter electronics convert the differential capacitance between the sensing diaphragm and the capacitor plates into a two3wire, 9367 mA dc signal and a digital output signal. 31. What is %ontrol 3al.es ? 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, regulating the flow. 32. What type of control .al.es used in the industry ? ): 3 )## S< =('<S -3 2ate, +all, !iaphragm, "lug, +utterfly valves. T. )TT$(:2 S< =('<S -3 2lobe, +utterfly, !iaphragm, "inch valves. :): 3 <=< S< #$)A -3 'heck valves.

33. What are the specifications of the control .al.e ? #ollowing specifications are used for control valve #low medium and operating temperature #low rate kg*hr or :m8*hr ,a4*,in*:ormal (nlet and )utlet pressure - kg*cm6 ,a4*,in*:ormal ,a4. allowable diff. "ressure - kg*cm6 !ensity of medium - kg*m8 =iscosity 'v - =alve #low 'oefficient 34. What are the components of control .al.e ? Actuator, +ody, Trim, !iaphragm, !iaphragm plate, Actuator stem Actuator spring, Seat, Travel (ndicator, =alve stem, 2askets, ?oke, .and wheel

3". What is flo# coefficient ? (t is the flow of water (2KD, TK L to 89 deg. '& through the valve at full lift in 0.S gallon per minute with a pressure drop across the valve of D psi.

)uper.isory %ontrol And ata Ac;uisition )oft#are < Wonder#are In7ouch

3(. What is )%A A ? 'ole of 11I0=1I )%A A in Industrial Automation S'A!A - Supervisory control and data acquisition ,,( - ,an ,achine (nterface .,( - .uman machine (nterface 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 real3time trends, alarms and reports. The operator can give commands to control hardware for opening the valve, change the set point, start the pump etc.. 3*. What are 8eatures of )%A A soft#are ? The common features of S'A!A include !ynamic process mimic, Trends, Alarm, 'onnectivity with hardware, ecipe management etc. 3+. Applications of )%A A. S'A!A systems has many applications right from industrial automation, power distribution to water management. 3,. )ome of the leadin- leadin- )%A A companies (nvensys Aonderware (nTouch Siemens Ain'' (<arlier ') )S& Allen +radley S =iew (<arlier 'ontrol =iew& (ntellution i#i4 (<arlier #i4 !,A'S& 2< #anuc Simplicity

4/.

7ypes of Wonder#are )%A A pac9a-es :o. of (*)s C Aondeware (nTouch comes is L9, D6G, 6@L, D777 and L9,777 tags package. !evelopment M untime M :etwork (! :& * untime M :etwork ( M:& and =iew :ode >'>? < Aith this package development and editing of the application is possible, untime monitoring and control of the plant is possible and :etworking is possible. Aith this package development and editing of the application is :)T possible, and control of the plant is possible and :etworking is possible.
'>? < 8actory 8ocus

untime monitoring

< Aith this package development and editing of the application is :)T possible, untime monitoring is possible but control of the plant is :)T possible and :etworking is possible. This package is used a view node 41. What type of licensin- patterns used in the )%A A soft#are Typically two types of licenses are used in the S'A!A software !ongle Bey - (t is a hardware lock which can be put on the communication port of the "'. Software $ock - .ere the software code is the license. Typically you can put the code while installation or transfer the code from #loppy to hard3disk. 42. 3arious E@E files used in In7ouch )oft#are and there role In7ouch - (t is an application manager. 0sing this you can create new application. ,ove between various applications. 3ie# < Aindowviewer. This will start untime application. #rom this you can monitor and control the plant.

W1 < A,.N< is Aindow maker. This will start the development package in (nTouch. 0sing this you can you can develop the application. 43. 7ypes of Windo# ? 'eplace < Automatically closes any window(s& it intersects when it appears on the screen including popup other replace type windows. A.erlay - Appears on top of currently displayed window(s& and can be larger than the window(s& it is overlaying. Ahen an overlay window is closed, any window(s& that were hidden behind it will reappear. 'licking on any visible portion of a window behind an overlay window will bring that window to the foreground as the active window. Popup - Similar to an overlay window e4cept, it always stays on top of all other open windows (even if another window is clicked&. "opup windows usually require a response from the user in order to be removed. 44. What is )ym!ol 8actory ? Symbol #actory contains symbols which can be readily used in the application. The symbols is contains include various Tanks, eactor, "ipes, (cons, #lags. 4". What type of user input used in In7ouch ? 0ser inputs include data entry !iscrete, Analog, String*,essage, Sliders and pushbuttons. 4(. What type of animation can !e -i.en in In7ouch ? 'olour #ill, O #ill, +linking, Si1e 'ontrol, $ocation, )rientation, =isibility, Action, .ide Show Aindow 4*. What are trends ? Trends means graphical representation of data. E eal3timeE and E.istorical. ?ou can configure both trend obFects to display graphical representations of multiple tagnames over time. eal3time trends allow you to chart up to four pens (data values&, while .istorical trends allow you to chart up to eight pens. eal3time trends are dynamic. They are updated continuously during runtime with whatever time span given in configuration. ?ou can not scroll the real3time trends to see previous data. .istorical trends provide you with a EsnapshotE of data from a time and date in the past. They are not dynamic. 0nlike real3time trends, historical trends are only updated when they are instructed to do so either through the e4ecution of a ;uickScript or an action by the operator, for e4ample, clicking a button. ?ou can 1oom in * 1oom out the trends. ?ou can also access the previous data. 4+. What are Alarm and E.ents in In7ouch? Alarms and <vents are the notifications used to inform operators 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 e4ceeds a user3defined limit. (nTouch uses for types of alasm $)$), $), .( and .(.(. <vents represent normal system status messages, and do not require an operator response. A typical event is triggered when a certain system condition takes place, such as an operator logging into (nTouch.

4,. )ecurity mana-ement 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 Elogging onE to the application and entering a E0ser :ameE and E"assword.E (The application developer sets up each operator with a E0ser :ame,E a pre3assigned E"asswordE and an EAccess $evelE via the Special*Security*'onfigure 0sers..command either in Aindow,aker or Aindow=iewer.& Ahen a new application is created, the default E0ser :ameE is EAdministratorE with an access level of >>>> (which allows access to all security commands&. "/. What is the use of )cripts in In7ouch ? (s a way of writing logic in (nTouch. (nTouch has its own instructions and way of writing program. Application - $inked to the entire application. Aindow - $inked to a specific window. Bey - $inked to a specific key or key combination on the keyboard. 'ondition - $inked to a discrete tagname or e4pression. !ata 'hange - $inked to a tagname and*or tagname.field only. "1. What is dri.er ? A software which allows a computer to access the e4ternal devices using com ports or communication cards. "2. What is E? !ynamic !ata <4change is the facility developed by ,icrosoft for e4changing the data between various programs. !!< has three important settings Application * Server name , Topic :ame and (tem :ame "3. %ommunication #ith soft#are BExcelC !!< settings for <4cel App. :ame 3 <4cel, Topic :ame C Pbook.4lsQsheetD (tem :ame C 'ell Address ie ( D'D& !!< settings for (nTouch App. :ame C =iew Topic :ame C TA2:A,< (tem :ame C :ame of tag "4. =o# to monitor the data from In7ouch to Excel ? ie Ane #ay communication from In7ouch to Excel. (n <4cel worksheet write a formula ie K=iewRTA2:A,<SAD AD is name of tag in (nTouch "". =o# to ha.e t#o #ay communication !et#een Excel and In7ouch ? 'reate a (*) Tag :ame with following detail Application name - <4cel Topic :ame - PNNNN.4lsQsheetD ie NNNN.4ls is actual e4cel file used in application. Sheet D is the spreadsheet where the data is kept. (tem :ame - D'D ie Actual Address of the 'ell where the data is kept.

Pro-ramma!le $o-ic %ontroller 2 General

"(. What is P$%? "$' means "rogrammable $ogic 'ontroller. (t is a class of industrially hardened devices that provides hardware interface for input sensors and output control element. The field (*p include element like limit switches, sensors, push button and the final control elements like actuator, solenoid*control valves, drives, hooters etc "$' Senses the input through (*" modules, "rocesses the logic through '"0 and memory and gives output through output module. "*. Applications of P$% "$' can be used in almost all industrial application solutions right from small machine to large manufacturing plants. <ven it caters applications of redundant systems at critical process plants. "+. 'ole of P$% in Automation ? "$' plays most important role in automation. All the monitoring as well as the control actions are taken by "$'s. "$' Senses the input through (*" modules, "rocesses the logic through '"0 and memory and gives output through output module. ",. 'ole of %PD ? This component act as a brain of the system. '"0 consist of Arithmetic $ogic 0nit, "rogram memory, "rocess image memory, (nternal timers and counters, flags (t receives information from (*" device, makes decisions depending upon the information and logic written and sends information through the )*" devices. The '"0/s are distinguished with following features ,emory capacity, (nstruction set supported, communication option, time required to e4ecute the control program. (/. 'ole of Po#er supply in P$% system ? "ower supply provides system power requirement to processor, (*) and communication modules. Typically the power supply has input voltage D67 = C 687 = A' or 69 = !' and back plane output current 6 A to @ A at @ = !' (1. 'ole of 'ac9 or %hassis in P$% system ? A hardware assembly, which houses the processor, communication and (*) modules. (t does following functions. "ower distribution 'ontainment of (*) modules 'ommunication path between (*) module and '"0 The chassis are available in different slots in various "$' systems. Additional chassis can be connected using chassis interconnecting cable.

(2. What is role of I0A modules ? <lectronic plug in units used for interfacing the i*p and o*p device in the machine or process to be controlled. (*" module receives data from i*p devices ("ushbutton, Switches, Transmitters& and send it to processor. The )*" module receives data from processor and send it to output device ( elay, =alves&. !igital*!iscrete -3 Sends and eceives )n*)ff signal Analog -3 Sends and receives variable input or output signals (3. 'ole of EEP'A1 memory module? This module is inserted into processor system for maintaining a copy of proFect ("$' program&. This is helpful in case of memory corruption or <4tended power loss. (4. %ommunication module 'ommunication modules are used either for communication between e4ternal hardware or software. The hardware can be "$'s (same or other make&, 'ontroller, (*) module, smart transmitters. The software can be S'A!A software, ,(S system or programming software. (". ifference Eet#een 8ixed and 1odular P$%s ? (n non modular "$'s the processor will have inbuilt power supply and (*)s in one unit. The modular "$', will have separate slots for components like "ower supply, (*) modules. ?ou can select the (*)s or power supply as per the need. ((. What are the 7ypes of I0As ? $ocal C These are the (*)s placed in the "$' main rack containing '"0. These (*)s are connected to '"0 through backplane. !istributed 3 These are the (*) placed at remote location from the main rack containing the '"0. These (*)/s are to be connected on communication bus like control net, device net or #(" (*). (*. What is meanin- of resolution in I0A cards in P$%s ? (t is the minimum change in i*p parameter which can sensed by the i*p card. As far as !igital (*) is concerned it takes only one bit for operation. (n case of analog input the resolution determines how much bits are used for input or output. #or e4ample a D6 bit resolution card means the input will come as 7 to 97>@ count (6TD6&. #or DL bit data the counts will be from 7 C L@@8L(6TDL&. ,ore the resolution the data will be more accurate (+. What is an Analo- Input 1odule ? An (*) module that contains circuits that convert analog input signals to digital values that can be manipulated by the processor. The signals for pressure, flow, level, temperature transmitters are connected to this module. Typically the input signal is 9367 mA, 73D7 = (,. What is Analo- Autput 1odule ? An (*) module that contains circuits that output an analog dc signal proportional to a digital value transferred to the module from the processor. +y implication, these analog outputs are usually direct (i.e., a data table value directly controls the analog signal value&. */. What is meanin- of uni.ersal analo- input card ? :ormally there are different cards for different signals. +ut in universal input card the same channels can be configured for T!, Thermocouple, 'urrent or voltage input.

*1.

Gi.e examples of I0P and Autput connected to P$%s !igital (*" ("ushbutton, Switches & Analog (*" (Temp, "ressure, #low, $evel& !igital )*" (Solenoids valves, 'ontactors& Analog )*" ('ontrol =alves, Speed&

*2. Explain )ource and )in9 %oncept ? Sinking Source type modules gives out the current to the field digital devices while sink type modules draw current when the device is in high state Sinking C Ahen active the output allows the current to flow to a common ground. Sourcing C Ahen active, current flows from a supply, through the output device and to ground. *3. What is forcin- of I0A ? #orcing the (*)s means making the desired status of (*) in "$'s irrespective of its status coming from the field. (n certain cases when there is problem in receiving field input *output, we can force the i*)s so that the logic takes desired state. *4. )can cycle of P$%
"$'/s scan cycle follows following path Scan cycle of "$' (nput (mage 0pdation "rocess $ogic <4ecution )utput 0pdation

*". What is meanin- of scan time in P$% ? Scan time is the Time required to read the (*", "rocess the logic and update the output in one cycle. *(. What is typical scan time in P$%s ? What effects scan time ? Typically it is less than D7 ms. (t depends on the comple4ity of logic, "(! algorithm etc. **. =o# to pro-ram P$%s ? <very "$' manufacturer have their own software for programming the "$'. #or e4ample Siemens uses Simantic S5 ,anager, Allen +radley uses S $ogi4 and ,odicon uses "$' pro programming software. The programming language used is $adder $ogic ($!&, Statement $ist (ST$&, #unctional +lock !iagram (#+!&, Sequential #unction 'hart (S#'&, (nstruction $ist (($& etc *+. What is ladder dia-ram ? This is a programming language, which e4presses a program as a series of EcoilsE and EcontactsE, simulating the operation of electromechanical relays. The resultant program is the equivalent of an equation, which is e4ecuted continuously in a combinatorial manner. The advantage of this language is the familiarity many electricians have with the simple operation of relays. !isadvantages include the comple4ity of large, cross3 connected programs, and the difficulty of e4pressing such non3binary functions as motion control and analog (*). *,. What is redundancy ? The capacity to switch from primary equipment to standby equipment automatically without affecting the process under control. edundancy means provision for standby module. (n case of failure of one module is running process, the standby module takes over. .ot redundancy means the changeover of control from active processor to standby processor in less than D scan time

+/. ?eed of redundancy (n critical processes, it is important to run the plant without failure. (n such case it is important to have redundancy so that even if one system fails the redundant system can take care without affecting plant. +1. 7ypes of redundancy '"0 redundancy - (n case of '"0 failure the standby '"0 takes care of the plant "ower Supply redundancy - (n case the power supply fails the standby power supply takes control of the situation. 'ommunication - ,ultiple communication channels are provided to take care of communication failure (*) edundancy - ,ultiple (*) channels are provided to take care of input or output failure. +2. What are components of redundant P$% system ? Typical component on Schneider edundant "$'s The backplane used is either 9 slot oL L slot with "ower Supply 'ontroller with built3in ,odbus "lus and ,odbus ports )ptional dual cable ,odbus "lus )ptional fiber optic ,odbus "lus '.S .ot Standby module !ual cable emote (*) .ead The master and Standby configuration must be identical +3. %ommonly used Instructions in P$%s
<4amines if the bit is in ): condition. (f the bit is ): the instruction is true <4amines if the bit is in )## condition. (f the bit is )## the instruction is true Ahen the conditions preceding the instruction is true, makes the rung run for one program scan

Examine if %losed B@I%C < 22F F 22 Examine if Apen B@IAC < 22F0F 22 Ane shot risin- BA)'C < 22GA)'H22

?ot retenti.e Autput instruction Autput Ener-ies BA7EC < 22B C222

(f the rung is true, it turns on the bit. (f the rung goes or a power cycle occurs the bit turns off.

'etenti.e Autput instruction Autput $atch BA7$C < 22B$ C222 Autput $atch BA7DC < 22BD C222

(f the rung is true, turns ): a bit. The bit stays ): until the rung containing an )T0 with the same address goes true. (f the rung is true, turns )## a bit. The bit stays )## until the rung containing an )T$ with the same address goes true.

+4. 7imers Timer and 'ounter are used to control operation based on time or number of events
7ypes of timers 7A? I B7imer A? delayC 7A8 I B7imer A88 delayC '7A 2 B'etenti.e 7imerC An output instruction that can be used to turn an output ): or )## after the timer has been timing for a preset time interval An output instruction used to turn an output ): or )## after its rung has been off for a preset time interval. An output instruction that can be used to turn an output ): or )## after the timer has been timing for a preset time interval. )nce it has begin timing, it holds the count of time

even when the rung continuity is lost. 7imer )tatus Eit .E? - (enable& Specifies whether or not the timer instruction is enabled . ? - (!one& Specifies whether or not the accumulated value of the timer timer.

equals to the preset value of the

"rogramming instruction (Advance& ,' , 'ompute, "(!, ST(, Sequencer, egister, T'

Pro-ramma!le $o-ic %ontroller I Allen Eradley

+". What are the P$% ran-es a.aila!le in 'oc9#ell ? "ico - :on modular small "$'s ,icrologi4 D777, D677 and D@77 Series S$' - S$' @*7D, @*76, @*78 U. 'ontrol $ogi4 #le4 $ogic and Soft "$'

+(. What are the soft#are Dsed #ith AE ? #or "ico soft for "ico "$' programming S $ogi4 @77 for ,icrologi4 and S$' "$'s programming S $ogi4 @777 for 'ontrol $ogi4 "$'s programming S'A!A 3 S =iew earlier 'ontrol =iew +*. What is use of ') $inx soft#are ? S $in4 software is used to perform following tasks. 'onfigure communication drivers =iew configured drivers and active nodes <nable communication tasks such as uploading, downloading, going online, updating firmware and sending messages. ++. What is use of ') $o-ix soft#are ? S $ogi4 is a "$' programming software. (t contains all the instructions needed for "$' programming. Ae can develop the program, down load * upload the program, work on line * off line and force the (*)s using the software. S $ogi4 @77 is used for ,icrologi4 and S$'s S $ogi4 @777 is used for 'ontrol $ogi4 "$'s +,. What file -ets created in P% for ') $o-ix P$% pro-ram ? The e4tension of the file will be .rss. So if you create an application with I elianceJ name the file created will be I eliance.rssJ. +y default it will be stored in Ic-V"rogram #ilesV ockwell Software* S $ogi4 @77 <ng location. ,/. =o# to creatin- lin9a-e !et#een P$%s and P$% pro-rammin- soft#are ? The S $in4 software is used for linking the "$' and software <ither you can manually configuration the communication settings or +y using Auto 'onfigure facility the software will detect the communication settings automatically. ,1. =ard#are confi-uration BP$% and I0AsC ,anual configuration Auto detect

,2. What is the meanin- of Dpload and o#nload ? 0pload means transferring the program data from "$' to "' !ownload means transferring the program data from "' to "$'

,3. What are the .arious communication interfaces supported !y AE ? The commonly used communication protocon in A+ includes !.M, !.9G@, <T., ,odbus, !evice :et and 'ontrol :et. ,4. Gi.e information a!out =4 %ontrol ?et4 e.ice?et and Ethernet protocol.

ata =i-h#ay - The proprietary data network used by Allen +radley "$'s to communicate information to and from other "$'s on the network or to and from host computers attached to the network. %ontrol?et < A real3time, control3layer network providing high3speed transport of both time3critical () data and messaging data, including upload*download of programming and configuration data and peer3to3peer messaging, on a single physical media link e.ice?et < A low3cost communication link that connects industrial devices to a network. (t is based on broadcast3oriented communication protocol 3 the 'ontroller Area :etwork ('A:&. Ethernet < The standard for local communications networks developed Fointly by !igital <quipment 'orp., Nero4, and (ntel. <thernet baseband coa4ial cable transmits data at speeds up to D7 megabits per second. <thernet is used as the underlying transport vehicle by several upper3level protocols, including T'"*(". ,". What is latency in communication ? The delay time between the end of one communication and the start of another. !uring this time, the processes associated with the communication are hung up and cannot continue. The latency has to be minimum. ,(. =o# the communication protocols are distin-uished ? The protocols are distinguished with following specifications :o. of nodes supported, total network length , Speed of communication . ,*. %omparison !et#een .arious Protocols used #ith AE
=4+" D>.6 kbit*s 86 D.6 km e.ice ?et @77 kbit*s L9 7.9G5 km %ontrol net @ ,bit*s >> 87 km

=> +aud rate ma4 687.9 kbits*s :o. of ma4. L9 nodes :etwork $ength 8.79G km

Pro-ramma!le $o-ic %ontroller I )iemens

,+. What are the .arious P$% system in )I1A7I% )* ran-e ? Siemens has broadly 8 "$' ranges ie Siemens S5 677 , 877 and 977 ,,. What are the soft#are used #ith )iemens ? #or S5 677 "$' programming ,icrowin #or S5 877 and 977 system - Simantic S5 manager The S'A!A software used by Siemens is Ain ''.. <arlier Siemens use to supply ') )S $S*+ 1//. %omponents of )iemens )* 3// )eries P$% system ? '"0s (8D6 (#,, 8D8, 8D9, (#,, 8D9, 8D@, 8D@36!", 8DL36!", 8DG Signal ,odules (S,&, !igital (*) (S,86D*866*868&, Analog (*) (S,88D*886*889& #unction modules (#,& e4 "ositioning modules, 'losed $oop 'ommunication "rocessor e4 '" 8963@ !" for "rofibus (nterface module C #or interconnecting individual racks ((, 8L7* 8LD, (,8L@ S * & 1/1. Explain the )ystem Eits a.aila!le in )*22// P$% )pecial 1emory area ? Special ,emory +yte 7 (S,7.7 3 S,7.5& provides eight bits that are updated by the S53677 '"0 at the end of each scan cycle. ?our program can read the status of these bits and then make decisions based on a bit/s value. AlwaysW)n #irstWScanW)n subroutine. S,7.7 This bit is always ):. S,7.D This bit is ): for the first scan cycle only. )ne use is to call an initiali1ation

etentiveW$ost S,7.6 This bit is turned ): for one scan cycle if retentive data was lost. This bit can be used as either an error memory bit or as a mechanism to invoke a special startup sequence. 0:W"owerW0p S,7.8 This bit is turned ): for one scan cycle when 0: mode is entered from a power3up condition. This bit can be used to provide machine warm3up time before starting an operation. 'lockWL7s S,7.9 This bit provides a clock pulse that is )## for 87 seconds and ): for 87 seconds, for a cycle time of D3minute. (t provides an easy3to3use delay or a D3minute clock pulse. 'lockWDs S,7.@ This bit provides a clock pulse that is )## for 7.@ seconds and then ): for 7.@ seconds for a cycle time of D second. (t provides an easy3to3use delay or a D3second clock pulse. 'lockWScan S,7.L This bit is a scan cycle clock that is ): for one scan and then )## for the ne4t scan. This bit can be used as a scan counter input. ,odeWSwitch S,7.5 This bit indicates the current position of the ,ode switch ()##KT< , position and ):K 0: position&. ?ou can use this bit to enable #reeport mode only when the switch is in the 0: position. :ormal communication with the "'*programming device can be re3enabled by switching to the T< , position.

1/2. Explain the 7ime )tamp a.aila!le in )*22// P$% ? This warning message indicates that the timestamps for the proFect do not match the timestamps for the program in the "$'. This may indicate that the programs are different, in which case it would be dangerous to continue the current operation. .owever, the programs may be functionally identical and still have different timestamps. 1/3. What are the 7ime )tamps a.aila!le in )*22// P$% ? <ach program contains two distinct timestamps% the E'reatedE timestamp and the E$ast ,odifiedE timestamp. The created timestamp is set when the proFect is created by the :ew "roFect option. The 'reated timestamp is not affected by any user edits or program compilation. The $ast ,odified timestamp is used to indicate when the user last modified the program. There are many conditions that cause the $ast ,odified timestamp to be set, it includes <dit of instructions or operands in the program, Adding, deleting, or modifying a $ocal or 2lobal Symbol, Adding or deleting a ")0, 'ompiling the program block and !ownloading the program block (this automatically compiles the program block and therefore sets the last modified timestamp&. 1/4. =o# to chec9 #hether the proJect and pro-ram in the P$% is same ? ST<" 53,icro*A(: 86 provides the I'ompareJ option, to allow you to determine whether the programs are same or different. 1/". What are 8atal errors in )iemens )* 2// P$% ? #atal errors cause the "$' to stop the e4ecution of your program. !epending on the severity of the error, a fatal error can render the "$' incapable of performing any or all functions. 1/(. What happens to P$% #hen it -oes to 8atal error ? The "$' performs the following tasks when a fatal error is detected. X 'hanges to ST)" mode X Turns on both the System #ault $<! and the Stop $<! X Turns off the outputs The "$' remains in this condition until the fatal error is corrected. 1/*. What are ?on 2 8atal errors a.aila!le in )iemens P$%s? 'ompile and run3time errors are non3fatal errors. :on3fatal errors can degrade some aspect of the performance of your "$', but do not render the "$' incapable of e4ecuting the user program or updating the (*). 'un2time errors are non3fatal errors detected in 0: mode, and reflected in special memory (S,& bits that your program can monitor and evaluate. At startup, the "$' reads the (*) configuration and stores this information in the S, memory. !uring normal operation, the (*) status is periodically updated and stored in the S, memory. (f the "$' detects a difference in the (*) configuration, it sets the configuration3changed bit of the module3error byte% the (*) module will not be updated until this bit is reset. #or the "$' to reset this bit, the module (*) must once again match the (*) configuration stored in the system data memory. 'un2time pro-rammin- errors are non3fatal error conditions created by you or your program while the program is being e4ecuted. An e4ample of this is an indirect3address pointer, which was valid when the program compiled, modified by program e4ecution to point to an out3of3range address. 0se the "$' Y (nformationU command to determine what type of error has occurred.

?ou can correct run3time programming errors only by modifying the user program. The run3time programming errors are cleared at the ne4t transition from ST)" to 0: mode. %ompile errors Bor pro-ram2compile errorsC are detected at download as the "$' compiles the program. (f there is a compile error, the compile halts, and the previous program (which is known to be valid since it previously compiled& is retrieved. All of these steps occur while the "$' is in ST)" mode. 'ompile errors can be displayed using the "$' Y (nformationU command. 1/+. =o# 7o Writin- and 8orcin- Autputs in )*22// P$% )7AP 1ode ? To enable Arite and #orce functions while in ST)" mode, choose the !ebug Y Arite3#orce )utputs in ST)" menu command. The S53677 "$'s support writing and forcing outputs (both analog and digital& while the "$' is in ST)" mode. As a safety precaution, you must specifically request this functionality to be enabled in ST<" 53 ,icro*A(: 86. The menu option !ebugYArite3#orce )utputs in ST)" enables you to Arite or #orce outputs while the "$' is in ST)" mode. Aarning (f the S53677 "$' is connected to equipment when you write or force an output, these changes may be transmitted to the equipment. This could result in unanticipated activity in the equipment, which could also cause death or serious inFury to personnel, and* or damage to equipment. <ach time ST<" 53,icro*A(: 86 is opened, the menu option defaults to unchecked, and you are prevented from writing or forcing outputs while the "$' is in ST)" mode. 'hecking the menu option enables writing and forcing for the current editing session with the current proFect. Ahen a different proFect is opened, the menu option returns to its default state and you are prevented from either writing or forcing output addresses while the "$' is in ST)" mode. 1/,. =o# 7A Write the )7$ Pro-ram in )*22// P$% ? The e4ample program below shows formatting in the ST$ editor according to the guidelines given in .ow to <nter a Statement in ST$. ?ou might want to set up your program similarly, by having the network comments give a general overview of the function of the network and the statement comments identify the function of the statement. :ote that the sample is written with symbolic addresses. (f you would like to see this program (in either ST$ or $A!& in ST<" 53,icro*A(: 86, select #ileY)pen, browse to the ST<" 53,icroA(:VSamplesV<nglish directory, highlight the sample program and click the )pen button. Sample "rogram for a "aint ,i4er :<TA) B D **#ill the tank with ingredient D and monitor tank level. **,aintain "ump Status if Start Switch )pens. $! ) StartWD **$oad value of StartWD (7.7. "umpWD **)r with "umpWD ;7.7 value.

A A: K

StopWD **And with StopWD (7.6. .ighW$evel **And :ot with .ighW$evel (7.9. "umpWD **Assign result to "umpWD ;7.7.

:<TA) B 6 **#ill the tank with paint ingredient 6 and monitor tank. **level. ,aintain "ump Status if Start Switch )pens. $! StartW6 **$oad value of StartW6 (7.D. ) "umpW6 **)r with "umpW6 ;7.D value. A StopW6 **And with StopW6 (7.8. A: .ighW$evel **And :ot with .ighW$evel (7.9. K "umpW6 **Assign result to "umpW6 ;7.D. :<TA) B 8 **Set memory bit if .igh $evel is reached. $! .ighW$evel **$oad value of .ighW$evel (7.9. S .ighW$evW eached, D**Set .ighW$evW eached ,7.D to D (on&. :<TA) B 9 **Start Timer if .igh $evel is reached. $! .ighW$evW eached **$oad value of .ighW$evelW eached ,7.D. T): ,i4WTimer, MD77 **Timer 85, "reset K D77 (Z7.D s&. :<TA) B @ **Turn on ,i4er ,otor. $!: ,i4WTimer **$oad :ot value of ,i4WTimer T85. A .ighW$evW eached **And with .ighW$evW eached ,7.D. K ,i4erW,otor **Assign result to ,i4erW,otor ;7.6. K SteamW=alve **Assign result to SteamW=alve ;7.8. :<TA) B L **!rain mi4ing tank. $! ,i4WTimer **$oad value of ,i4WTimer T85. A: $owW$evel **And :ot with $owW$evel (7.@. K !rainW=alve **Assign result to !rainW=alve ;7.9. K !rainW"ump **Assign result to !rainW"ump ;7.@. :<TA) B 5 **'ount each cycle. $! $owW$evel **$oad value of $owW$evel (7.@. A ,i4WTimer **And value of ,i4WTimer T85. $! eset **$oad value of eset (7.5. 'T0 'ycleW'ounter, MD6 **'ounter 87, "reset K D6. :<TA) B G ** eset memory bit if $ow $evel reached and Timer **timed out. $! $owW$evel **$oad value of $owW$evel (7.@. A ,i4WTimer **And value of ,i4WTimer T85. .ighW$evW eached, D** eset value of .ighW$evW eached ,7.D to 7. 11/. What is the Protocol used in the in )*22// P$% and =o# many station %an Ee Possi!le in the )*22// ?et#or9? A. "rotocol used in the in S53677 "$' is ""( "rotocol +. 86 station 'an +e "ossible in the S53677 :etwork

)* 3// 111. What is A!solute and )ym!olic Addressin- I? )*K3// P$%? (n a ST<" 5 program you work with addresses such as (*) signals, bit memory, counters, timers, data blocks, and function blocks. ?ou can access these addresses in your program absolutely, but your programs will be much easier to read if you use symbols for the addresses (for e4ample, ,otorWAW)n, or other identifiers according to the code system used within your company or industry&. An address in your user program can then be accessed via this symbol. A!solute Addresses An absolute address comprises an address identifier and a memory location (for e4ample, ; 9.7, ( D.D, , 6.7, #+6D& . )ym!olic Addresses ?ou can make your program easier to read and simplify troubleshooting if you assign symbolic names to the absolute addresses. ST<" 5 can translate the symbolic names into the required absolute addresses automatically. (f you would prefer to access A A?s, ST 0'Ts, data blocks, local data, logic blocks, and user3defined data types using symbolic names, you must first assign symbolic names to the absolute addresses before you can address the data symbolically. ?ou can, for e4ample, assign the symbolic name ,)T) W): to the address ; 9.7 and then use ,)T) W): as an address in a program statement. 0sing symbolic addresses it is easier to recogni1e to what e4tent the elements in the program match the components of your process control proFect.

112. What is meanin- !y Instance data !loc9 in )*K3// P$%? An instance data block is assigned to every function block call that transfers parameters. The actual parameters and the static data of the #+ are saved in the instance !+. The variables declared in the #+ determine the structure of the instance data block. (nstance means a function block call. (f, for e4ample, a function block is called five times in the S5 user program, there are five instances of this block. %reatin- an Instance E +efore you create an instance data block, the corresponding #+ must already e4ist. ?ou specify the number of the #+ when you create the instance data block. Ane Instance E for Each )eparate Instance (f you assign several instance data blocks to a function block (#+& that controls a motor, you can use this #+ to control different motors.

The data for each specific motor (for e4ample, speed, runup time, total operating time& are saved in different data blocks. The !+ associated with the #+ when it is called determines which motor is controlled. Aith this technique, only one function block is necessary for several motors 113. What are )ystem 8unction are in )*K3// P$%? )ystem 8unctions A system function is a preprogrammed function that is integrated on the S5 '"0. ?ou can call the S#' in your program. S#'s are part of the operating system and are not loaded as part of the program. $ike #'s, S#'s are blocks Jwithout memory.E S5 '"0s provide S#'s for the following functions 'opying and block functions 'hecking the program .andling the clock and runtime meters Transferring data sets Transferring events from a '"0 to all other '"0s in multicomputing mode .andling timeofday and timedelay interrupts .andling synchronous errors, interrupts, and asynchronous errors (nformation on static and dynamic system data, for e4ample, diagnostics "rocess image updating and bit field processing Addressing modules !istributed (*) 2lobal data communication 'ommunication via nonconfigured connections 2enerating blockrelated messages 114. ifferences !et#een Instance ata Eloc9s and )hared ata Eloc9s A shared data block is not assigned to a logic block. (t contains values required by the plant or machine and can be called directly at any point in the program. An instance data block is a block that is assigned directly to a logic block, such as a function block. The instance data block contains the data that were stored in a function block in the variable declaration table. 11". =o# to Exchan-in-0)#appin- 1odules in the %onfi-uration 7a!le in )*23// (f you using .A 'onfig to revise a station configuration and you want to e4change a module for one with a new order number for e4ample, proceed as followsD. 0se a drag3and3drop operation to drag the module from the .ardware 'atalog window over the old module that is already placed. 6. !rop the new module. To the e4tent possible, the new module assumes the parameters of the one that was already inserted. This procedure is faster than e4changing modules by deleting the old module and then inserting the new one and assigning parameters to it. ?ou can turn this function on or off in .A 'onfig by means of the menu command Aptions L )ettin-s (E<nable ,odule SwappingE& 11(. What is 1eant !y %omplex ata 7ypes 'omple4 data types define data groups that are larger than 86 bits or data groups consisting of other data types.

The following table describes the comple4 data types. ?ou define structures and arrays either in the variable declaration of the logic block or in a data block. ata 7ype escription
!AT<WA:!WT(,< !T ST (:2 A A?
!efines an area with L9 bits (G bytes&. This data type saves in binary coded decimal format!efines a group with a ma4imum of 6@9 characters (data type '.A &. The standard area reserved for a character string is 6@L bytes long. This is the space required to save 6@9 characters and a header of 6 bytes. ?ou can reduce the memory required for a string by defining the number of characters that will be stored in the character string (for e4ample- stringP>Q [Siemens[&. !efines a multidimensional grouping of one data type (either elementary or comple4&. #or e4ample- JA A? PD..6,D..8Q )# (:TE defines an array in the format 6 4 8 consisting of integers. ?ou access the data stored in an array using the (nde4 (JP6,6QE&. ?ou can define up to a ma4imum of L dimensions in one array. The inde4 can be any integer (3865LG to 865L5&. !efines a grouping of any combination of data types. ?ou can, for e4ample, define an array of structures or a structure of structures and arrays. Simplifies the structuring of large quantities of data and entering data types when creating data blocks or declaring variables in the variable declaration. (n ST<" 5, you can combine comple4 and elementary data types to create your own JuserdefinedE data type. 0!Ts have their own name and can therefore be used more than once. ?ou determine the structure of the assigned instance data block and allow the transfer of instance data for several #+ calls in one instance !+.

ST 0'T 0!T #+, S#+

Structured data types are saved in accordance with word limits (A) ! aligned&. 11*. What meant !y Dser2 efined ata 7ypes BD 7C 0ser3defined data types are special data structures you create yourself that you can use in the whole S5 program once they have been defined. 0ser3defined data types can be used like elementary data types or comple4 data types in the variable declaration of logic blocks (#', #+, )+& or as a data type for variables in a data block (!+&. ?ou then have the advantage that you only need to define a special data structure once to be able to use it as many times as you wish and assign it any number of variables. 0ser3defined data types can be used as a template for creating data blocks with the same data structure, meaning you create the structure once and then create the required data blocks by simply assigning the user3defined data type (<4ample- ecipes- The structure of the data block is always the same, only the amounts used are different.& 0ser3defined data types are created in the S(,AT(' ,anager or the incremental editor Fust like other blocks. 11+. What you mean !y 1emory %ompressin-? B'A1C When it can !e? After deleting and reloading blocks, gaps can occur in the user memory (load and work memory& and reduce the usable memory area. Aith the compress function, the e4isting blocks are rearranged in the user memory without gaps, and a continuous free memory is created. Al#ays 7ry to %ompress the 1emory in )7AP 1ode )nly if you compress the memory in EST)"E mode are all the gaps closed up. (n the 0:" mode (mode selector setting&, the blocks currently being processed cannot be shifted since they are open. The compress function does not work in the 0: mode (mode selector setting& (write protectionS&. 11,. What are the %ommunication Protocol used in )iemens 3// ?
1ulti2Point Interface B 1PI C <

!ata Transfer C DG5.@ kbits to D@ ,bit*s, !istance C @7 m without S 9G@ repeater * D7 Bm with repeater :umber of nodes C up to 86

Profi!us

!ata Transfer C D6 ,bit*s, !istance C 68 Bm with fibre optic cable :umber of nodes C up to D6@ 12/. What are the !loc9s used in )iemens ? Simantic S5 manager uses !+, )+, #', "+ and #+ )+s - !etermine the structure of the user program
ata Eloc9 - These are the blocks used by logic blocks in '"0 program for storing the data. !+/s doesnot contain any instructions and it take up space in the user memory. The user program can access a data block with bit, byte, word or double word operations. Global data block - These contains information that can be accessed by all the logic block in the user program. Instance data block - These !+s are always assigned to a particular #+.

- (t is a logic block without memory. An #' is always e4ecuted by calling in another block. #' is used either for returning a function value to a calling function or e4ecuting a technological function. Temporary variable belonging to #' are saved in local stack and this data is lost when the #' has been e4ecuted.
8% 8unctions

A function block is block with a memory. A #+ contains a program that is always e4ecuted when a different logic block calls the #+. #+ make it much easier to program frequently occurring comple4 functions.
8unction Eloc9s B8EsC <

121. What are )8%s and )8Es ? S#+s and S#'s are integrated in the S5 '"0 and allow you access to some important system functions. 122. What is )tatement $ist? Statement $ist (ST$& is a te4tual programming language that can be used to create the code section of logic blocks. (ts synta4 for statements is similar to assembler language and consists of instructions followed by addresses on which the instructions acts.