Untitled 1

Question 4
In order to learn PLC programming and perform the exercises necessary for exams in this course, you
must have your own PLC trainer consisting of a working PLC and input switches all wired and ready to use.
PLC
Power
I/O
Input switches
Indicator lamps
All components should be securely mounted to a wood board or some other structure making it easy
to transport and use. You must have a terminal block in between the switches, indicators, and PLC I/O
terminals to allow for easy connection and disconnection of external devices to your PLC without wearing out
the screws on the PLCs terminal block prematurely. Separate terminal blocks are easily replaced, whereas
the terminal block on your PLC is likely much more expensive and inconvenient to replace!
Consult the users manual for your PLC in order to determine how all devices should be wired to the
input and output (I/O) terminals. Note that often there are different types of I/O (AC, DC, sourcing,
sinking) available for the same (or similar) model of PLC. Most PLC users manuals give detailed diagrams
showing how to connect devices to discrete I/O points, so be sure to follow the proper diagram for your
specific PLC model!
Once you have your PLC wired, the next step is to install and run the software used to program your
programmable logic controller (PLC), and try to get the two devices communicating with each other. This,
of course, requires you have a special cable connecting your PC to your PLC, with any necessary drivers
installed on your PC to allow it to communicate. Like all serial-based communications, the PC needs to be
properly configured with regard to bit rate, number of data bits, number of stop bits, and parity in order to
communicate with the PLC. The software you will be using should have an auto detect feature which will
sequentially try various combinations of these parameters until it finds one combination that works. Note: on
Allen-Bradley PLCs, you must first install and run software called RSLinx which manages communications
between your PC and PLC, before you start up the programming software (RSLogix).
After that, your next step is to use programming software (installed in a personal computer) to program
your PLC with some simple function consisting of contact and coil instructions. The purpose of a virtual
contact in a PLC program is to read data bits from memory, while the purpose of a virtual coil in a PLC
program is to write data bits to memory. Thus, you will create programs for the PLC using virtual contacts
to read the states of real-world switches connected to inputs on the PLC, and using virtual coils to control
real-world outputs on the PLC to energize loads such as lamps and solenoids. The interconnections and
arrangements of these virtual contacts and coils determine the logic implemented by the PLC: specifying the
conditions necessary to energize real-world devices based on input conditions.
You will find step-by-step instructional tutorials for both Allen-Bradley MicroLogix and Koyo CLICK
PLCs in your Instrumentation Reference (provided by the instructor). Follow these tutorials to establish
communication between your PC and your PLC, and to write a simple contact-and-coil ladder diagram
program, before attempting the exercises that follow. You will also find much pertinent information for
programming Allen-Bradley MicroLogix PLCs in the RSLogix 500 Getting Results Guide, since the SLC 500
24
line of Allen-Bradley PLCs program so similarly to the MicroLogix line.

This example shows an Allen-Bradley MicroLogix 1000 series PLC (model 1761-L10BWA) wired to two
toggle switches and one LED indicator lamp, complete with a demonstration program. Note that line power
(120 VAC) wire connections to power the PLC have been omitted, so the focus is solely on the I/O wiring:
Toggle switch
24V
DC
COM
I/0
I/1
I/2
I/3
DC
COM
I/4
I/5
DC OUT
Allen-Bradley
Power
Run
MicroLogix
Fault
1000
Force
85-264 VAC
L1
VAC
VDC
L2/N
O/0
VAC
VDC
O/1
VAC
VDC
O/2
VAC
VDC
O/3
LED (with dropping resistor)
Ladder-Diagram program written to PLC:

I:0
I:0
O:0
0
END
Note how Allen-Bradley I/O is labeled in the program: input bits designated by the letter I and output
bits designated by the letter O.
Based on the wiring and program you see for this PLC, identify the switch state combinations resulting
in an energized lamp. Try duplicating this program in your own PLC (even if it is a different brand or model)
and see how it functions. Be sure to activate the color highlighting feature of your programming editor so
you may see the live status of the programs virtual contacts and coil!
25
This example shows a Siemens S7-200 series PLC (model 224XP) wired to two toggle switches and one
LED indicator lamp, complete with a demonstration program:
24 VDC

SIEMENS
Toggle switch
1M
SIMATIC
S7-200
1L+
0.0
0.1
0.2
Q0
SF/DIAG
0.3
0.4
2M
2L+
0.5
0.6
0.7
1.0
1.1
DC
CPU 224XP
Q1
.0 .1 .2 .3 .4 .5 .6 .7
L+
DC/DC/DC
.0 .1
RUN
STOP
.0 .1 .2 .3 .4 .5 .6 .7
I0
1M
Port 1
.0 .1 .2 .3 .4 .5
I1
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
2M
1.0
1.1
1.2
1.3
1.4
1.5
L+
Port 0

I0.0
Q0.0
I0.1
END
Note how Siemens I/O is labeled in the program: input bits designated by the letter I and output bits
designated by the letter Q.
26
This example shows a Koyo CLICK PLC (model C0-02DD1-D) wired to two toggle switches and one
LED indicator lamp, complete with a demonstration program:
C0-02DD1-D
CLICK
Koyo
C1
X1
X2
X3
X4
PWR
RUN
ERR
RUN
C2
STOP
Y1
Y2
Y3
PORT 1
TX1
Y4
RX1
+V
AD1V
TX2
AD1I
RX2
AD2V
PORT 2
AD2I
Toggle switch
ACOM
PORT 3 RS-485
DA1V
DA1I
TX3
RX3
DA2V
LG
DA2I
24V
24 VDC

X1
X2
X2
X1
Y1
END
Note how Koyo I/O is labeled in the program: input bits designated by the letter X and output bits
designated by the letter Y.
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Question 5
The most basic type of real-world input to a PLC is a discrete (on/off) input. Each discrete input
channel on a PLC is associated with a single bit in the PLCs memory. Use the PLC programming software
on your personal computer to connect to your PLC, then locate the facility within this software that allows
you to monitor the status of your PLCs discrete input bits.
Actuate the switches connected to your PLCs discrete input channels while watching the status of the
respective bits. Based on what you see, what does a 1 bit status signify, and what does a 0 bit status
signify?
Suggestions for Socratic discussion
How does your PLC address discrete input bits? In other words, what is the convention it uses to label
these bits, and distinguish them from each other?
How does the programming software for your PLC provide access to discrete input bit status?
PLC comparison:
Allen-Bradley Logix 5000: the Controller Tags folder (typically on the left-hand pane of the
programming window set) lists all the tag names defined for the PLC project, allowing you to view
the real-time status of them all. Discrete inputs do not have specific input channel tag names, as tag
names are user-defined in the Logix5000 PLC series.
Allen-Bradley PLC-5, SLC 500, and MicroLogix: the Data Files listing (typically on the left-hand pane
of the programming window set) lists all the data files within that PLCs memory. Opening a data
file window allows you to view the real-time status of these data points. Discrete inputs are the I file
addresses (e.g. I:0/2, I:3/5, etc.). The letter I represents input, the first number represents the
slot in which the input card is plugged, and the last number represents the bit within that data element
(a 16-bit word) corresponding to the input card.
Siemens S7-200: the Status Chart window allows the user to custom-configure a table showing the realtime values of multiple addresses within the PLCs memory. Discrete inputs are the I memory addresses
(e.g. I0.1, I1.5, etc.).
Koyo (Automation Direct) DirectLogic and CLICK: the Data View window allows the user to customconfigure a table showing the real-time values of multiple addresses within the PLCs memory. Discrete
inputs are the X memory addresses (e.g. X1, X2, etc.).
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Question 6
The most basic type of real-world output from a PLC is a discrete (on/off) output. Each discrete output
channel on a PLC is associated with a single bit in the PLCs memory. Use the PLC programming software
on your personal computer to connect to your PLC, then locate the facility within this software that allows
you to monitor the status of your PLCs discrete output bits.
Use the force utility in the programming software to force different output bits to a 1 status. Based
on what you see, what does a 1 bit status signify, and what does a 0 bit status signify?
Is there any visual indication that bits have been forced from their normal state(s) in your PLC? Note
that forcing causes the PLC to output the values you specify, whether or not the programming in the PLC
wants those bits to have those forced values!
How does your PLC address discrete output bits? In other words, what is the convention it uses to
label these bits, and distinguish them from each other?
How does the programming software for your PLC provide access to discrete output bit status, and the
ability to force them?
Why would anyone ever wish to force an output bit in a PLC, especially if doing so overrides the logic
programmed into the PLC?
PLC comparison:
Allen-Bradley Logix 5000: forces may be applied to specific tag names by right-clicking on the tag (in
the program listing) and selecting the Monitor option. Discrete outputs do not have specific output
channel tag names, as tag names are user-defined in the Logix5000 PLC series.
Allen-Bradley PLC-5, SLC 500, and MicroLogix: the Force Files listing (typically on the left-hand pane
of the programming window set) lists those data files within the PLCs memory liable to forcing by the
user. Opening a force file window allows you to view and set the real-time status of these bits. Discrete
outputs are the O file addresses (e.g. O:0/7, O:6/2, etc.). The letter O represents output, the first
number represents the slot in which the output card is plugged, and the last number represents the bit
within that data element (a 16-bit word) corresponding to the output card.
Siemens S7-200: the Status Chart window allows the user to custom-configure a table showing the realtime values of multiple addresses within the PLCs memory, and enabling the user to force the values
of those addresses. Discrete outputs are the Q memory addresses (e.g. Q0.4, Q1.2, etc.).
Koyo (Automation Direct) DirectLogic and CLICK: the Override View window allows the user to force
variables within the PLCs memory. Discrete outputs are the Y memory addresses (e.g. Y1, Y2, etc.).
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Question 7
All PLCs provide special locations in memory holding values useful to the programmer, such as status
warnings, real-time clock settings, calendar dates, etc. Use the PLC programming software on your personal
computer to connect to your PLC, then locate the facility within this software that allows you to explore
some of these locations in memory.
Identify some of the specific status-related and special memory locations in your PLC, and comment
on those you think might be useful to use in the future. Note the following memory types you may find
associated with these addresses:
Boolean (discrete) = simply on or off (1 or 0)
Integer = whole-numbered values
Floating-point (real) = fractional values

Describe some of the special memory locations you find in your search, and comment on how some
of them might be useful.
One of the useful bits provided by many PLCs is a flashing bit that simply turns on and off at regular
intervals. How many of these bits can you find in your PLCs memory, and how rapidly does each one
oscillate?
PLC comparison:
Allen-Bradley Logix 5000: various system values are accessed via GSV (Get System Value) and SSV
(Save System Value) instructions.
Allen-Bradley PLC-5, SLC 500, and MicroLogix: the Data Files listing (typically on the left-hand pane
of the programming window set) shows file number 2 as the Status file, in which you will find various
system-related bits and registers.
Siemens S7-200: the Special Memory registers contain various system-related bits and registers. These
are the SM memory addresses (e.g. SM0.1, SMB8, SMW22, etc.).
Koyo (Automation Direct) DirectLogic and CLICK: the Special registers contain various system-related
bits and registers. These are the SP memory addresses (e.g. SP1, SP2, SP3, etc.) in the DirectLogic
PLC series, and the SC and SD memory addresses in the CLICK PLC series.
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Question 8
Read and outline the Relating I/O Status to Virtual Elements subsection of the Logic Programming
section of the Programmable Logic Controllers chapter in your Lessons In Industrial Instrumentation
textbook. Note the page numbers where important illustrations, photographs, equations, tables, and other
relevant details are found. Prepare to thoughtfully discuss with your instructor and classmates the concepts
and examples explored in this reading.
The fundamental concept of relating I/O status to program elements is not necessarily easy to
grasp. For this reason, a Process Switches and PLC Circuits worksheet has been placed in the Socratic
Instrumentation practice worksheet collection. Feel free to use this practice worksheet to supplement your
studies on this critically important topic!
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Question 9
Discrete (on/off) I/O for PLCs often works on AC (alternating current) power. AC input circuitry
usually consists of an optocoupler (LED) with rectification and a large dropping resistor to allow 120 volt
AC operation. AC output circuitry usually consists of TRIACs. Explain how both of these technologies
work.
DC I/O for a PLC generally consists of optocoupled LEDs for inputs and bipolar transistors for outputs.
Some examples are shown in the following schematics. Note carefully the different variations:
Discrete input module
Discrete input module
X0
Com
X0
X1
X1
X2
X2
X3
Com
X3
Discrete output module
Discrete output module
Com
Y0
Y0
Y1
Y1
Y2
Y2
Y3
Com
Y3
Determine for each of these input and output module types, whether they would be properly designated
sourcing or sinking.
Determine how real input and output devices (e.g. switches, solenoid coils) would need to be connected
to the I/O terminals of these modules.
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Question 10
Have some fun writing simple exploratory or demonstration ladder-diagram PLC programs to
perform different functions. Feel free to explore the following instruction types:
Counters (up, down, up/down)
Timers (on-delay, off-delay, retentive)
Sequencing instructions
Identify some realistic applications for PLC programs using counters and timers. What sorts of real-life
processes might benefit from a PLC function where something turns on or off after a definite number of
counts applied to the PLC input, or after a certain amount of time has passed?
Note: this simple exercise may seem trivial, but it holds the key to self-instruction on
PLC programming! Having your very own PLC to work with in the classroom is a tremendously powerful
learning tool. Whenever you encounter a new programming instruction (e.g. a timer, a math instruction,
etc.) that you do not yet know how to use, you may explore that instructions properties and behavior
by creating a simple program in your PLC with nothing but that instruction. Your PLCs User Manual
or Instruction Set reference manual will show you the basic syntax of the instruction, which you may copy
verbatim as an example. Once this simple program is loaded into your PLCs memory, you can play with
it to see its live behavior while viewing the program online.
Once you have directly observed how the instruction works, your next step is to add comments to the
program describing how that instruction works in your own words. Be as detailed as possible here, treating
this activity as though you were asked to explain everything to someone who knew absolutely nothing about
the instruction. These comments will serve as notes to yourself later, when you need to refresh your memory
on how a particular instruction functions or what it is used for.
Refer to the Answer section of this question to see some examples of what such a demonstration
program might look like.
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Question 11
Write a PLC program that accepts two discrete input signals (from two switches), and outputs the
following four discrete outputs:
Output channel #1: The status of input switch #1 (simply repeating input #1)
Output channel #2: The Boolean complement (opposite) of input switch #1
Output channel #3: The AND function of switches #1 and #2
Output channel #4: The OR function of switches #1 and #2
Shown here is a generic RLL listing of such a program:
Input_switch_1
Output_1
Input_switch_1
Output_2
Input_switch_1
Input_switch_2
Input_switch_1
Output_3
Output_4
Input_switch_2
Turn on status highlighting within the programming software environment so that you may see the
virtual power flow through the conductive contacts as you test the program.

How are discrete input and output points associated with contacts and coils in the ladder-logic program?
How do you draw vertical connecting lines in the ladder-logic program?
How do you assign alias names to inputs and outputs for easier program readability? For example,
how do you assign an English name to the input I:2/4 (Input channel 4 on card 2) on an Allen-Bradley
SLC 500 PLC so that it reads as Input switch 4 in the program instead of I:2/4 in the programming
softwares display?
Where is the software function (pull-down menu option, button, hot-key, etc.) located that allows you
to turn on contact status highlighting in the PLC programming software?
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Question 12
Suppose we have an Allen-Bradley MicroLogix 1000 PLC connected to three momentary-contact
pushbutton switches as shown in this illustration:
24V
DC
COM
I/0
I/1
I/2
I/3
DC
COM
I/4
I/5
DC OUT
Power
Run
Fault
Force
C
85-264 VAC
L1
L2/N
VAC
VDC
O/0
VAC
VDC
O/1
VAC
VDC
O/2
VAC
VDC
O/3
Determine the bit statuses of I:0/0, I:0/1, and I:0/2 when switch A is unpressed (released), switch
B is unpressed (released), and switch C is pressed.
file i01865
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Question 13
Suppose we have a Siemens S7-200 PLC connected to two process switches as shown in this illustration:
24 VDC
SIEMENS
1M
SIMATIC
S7-200
1L+
0.0
0.1
0.2
Q0
SF/DIAG
0.3
0.4
2M
2L+
0.5
0.6
0.7
1.0
1.1
DC
CPU 224XP
Q1
.0 .1 .2 .3 .4 .5 .6 .7
L+
DC/DC/DC
.0 .1
RUN
STOP
.0 .1 .2 .3 .4 .5 .6 .7
I0
1M
Port 1
.0 .1 .2 .3 .4 .5
I1
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
2M
1.0
1.1
1.2
1.3
1.4
1.5
L+
Port 0
130 oF
12 GPM
Determine the bit statuses of I0.2 and I1.1 when the temperature switch senses 194 o F and the flow
switches senses 19 GPM.
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Question 14
Suppose we have an Allen-Bradley SLC 500 PLC connected to two process switches as shown in this
illustration:
Slot 0
(processor)
Power
supply
120 VAC
power
Processor
Slot 1
Input
0
1
2
3
L1
L2/N
Gnd
Slot 2
Slot 3
(discrete input) (discrete input) (discrete output)
Input
4
5
6
7
0
1
2
3
Output
4
5
6
7
0
1
2
3
IN0
IN0
VAC 1
IN1
IN1
OUT0
IN2
IN2
OUT1
IN3
IN3
OUT2
IN4
IN4
OUT3
IN5
IN5
VAC 2
IN6
IN6
OUT4
IN7
IN7
OUT5
COM
COM
OUT6
COM
COM
OUT7
4
5
6
7
3 feet
37 PSI
88 oF
Determine the process conditions necessary to generate the following input bit statuses in the PLCs
memory:
I:1/3 = 1
I:1/5 = 0
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Question 15
Examine this live display of a Siemens S7-300 PLCs program, and from this determine all bit statuses
represented by the color highlighting in this ladder logic program:
I1.1
I0.5
Q0.1
I0.2
I1.1
Q0.6
I0.2 = ???
I0.5 = ???
I1.1 = ???
Q0.1 = ???
Q0.6 = ???
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Question 16
Suppose we have a Koyo CLICK PLC connected to three momentary-contact pushbutton switches as
shown in this illustration:
C0-02DD1-D
CLICK
Koyo
C1
X1
X2
X3
X4
PWR
RUN
ERR
RUN
C2
STOP
Y1
Y2
Y3
PORT 1
TX1
Y4
RX1
+V
AD1V
TX2
AD1I
RX2
AD2V
PORT 2
AD2I
ACOM
PORT 3 RS-485
DA1V
DA1I
TX3
RX3
DA2V
LG
DA2I
24V
24 VDC
Determine the switch actuation statuses (i.e. pressed versus released) given the live display of the
ladder logic program shown here:
X1
X2
X3
Y1
Also, determine the status of the lamp connected to the PLCs Y1 output.
file i01874
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Question 17
Explain the function of this light-switching circuit, tracing the directions of all currents when the switch
closes:
file i01000
Question 18
A student attempts to build a circuit that will turn a DC motor on and off with a very delicate (low
current rating) pushbutton switch. Unfortunately, there is something wrong with the circuit, because the
motor does not turn on no matter what is done with the switch:
This circuit does not work!
Mtr
Correct the error(s) in this circuit, showing how it must be set up so that the transistor functions as
intended.
file i01001
40
Question 19
Some of the following transistor switch circuits are properly configured, and some are not. Identify
which of these circuits will function properly (i.e. turn on the load when the switch closes) and which of
these circuits are mis-wired:
Circuit 1
Circuit 2
Load
Load
Circuit 3
Circuit 4
Load
Load
file i01002
41
Question 20
Circuit 1
Circuit 2
Load
Load
Circuit 3
Circuit 4
Load
Load
file i01003
42
Question 21
Read and outline the Contacts and Coils subsection of the Ladder Diagram (LD) Programming
section of the Programmable Logic Controllers chapter in your Lessons In Industrial Instrumentation
textbook. Note the page numbers where important illustrations, photographs, equations, tables, and other
relevant details are found. Prepare to thoughtfully discuss with your instructor and classmates the concepts
and examples explored in this reading.
If you have access to your own PLC for experimentation, I urge you to write a simple demonstration
program in your PLC allowing you to explore the behavior of these PLC instructions. The program
doesnt have to do anything useful, but merely demonstrate what each instruction does. First, read
the appropriate section in your PLCs manual or instruction reference to identify the proper syntax for
that instruction (e.g. which types of data it uses, what address ranges are appropriate), then write the
simplest program you can think of to demonstrate that function in isolation. Download this program
to your PLC, then run it and observe how it functions live by noting the color highlighting in your
editing programs display and/or the numerical values manipulated by each instruction. After playing
with your demonstration program and observing its behavior, write comments for each rung of your
program explaining in your own words what each instruction does.
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43
Question 22
Suppose a Siemens 545 PLC has the following input bit states:
X1 = 0
X2 = 1
X3 = 0
Sketch color highlighting for the contacts and coils in the PLCs program given these bit statuses, also
determining the status of output bit Y1:
X1
X2
X2
X1
X3
Y1

PLC training expert Ron Beaufort teaches students to think of a normally-open PLC program contact
instruction as a command to the PLCs processor to Go look for a 1. Conversely, he teaches students
to think of a normally-closed instruction as a command to Go look for a 0. Explain what Mr.
Beaufort means by these phrases, and how this wisdom relates to this particular problem. Incidentally,
Mr. Beauforts excellent instructional videos (available freely on YouTube) are quite valuable to watch!
Identify the significance of the labels X and Y for this PLCs bits. What do you suppose X
signifies? What do you suppose Y signifies?
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44
Question 23
Examine this live display of a Siemens S7-300 PLCs program, and from this determine all bit statuses
represented by the color highlighting in this ladder logic program:
I1.1
I0.7
Q0.1
I0.7
I1.1
Q0.3
I0.7 = ???
I1.1 = ???
Q0.1 = ???
Q0.3 = ???

PLC training expert Ron Beaufort teaches students to think of a normally-open PLC program contact
instruction as a command to the PLCs processor to Go look for a 1. Conversely, he teaches students
to think of a normally-closed instruction as a command to Go look for a 0. Explain what Mr.
Beaufort means by these phrases, and how this wisdom relates to this particular problem. Incidentally,
Mr. Beauforts excellent instructional videos (available freely on YouTube) are quite valuable to watch!
Identify the significance of the labels I and Q for this PLCs bits. What do you suppose I signifies?
What do you suppose Q signifies?
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Question 24
Suppose we have an Allen-Bradley model SLC 500 PLC connected to a pair of momentary-contact
pushbutton switches and light bulbs as shown in this illustration:
Power
supply
Slot 0
Slot 1
Slot 2
Slot 3
(processor)
(discrete input)
(unused)
(discrete output)
Processor
Input
0
1
2
3
L1
120 VAC
power
L2/N
Gnd
Output
0
1
2
3
4
5
6
7
IN0
VAC 1
IN1
OUT0
IN2
OUT1
IN3
OUT2
IN4
OUT3
IN5
VAC 2
IN6
OUT4
IN7
OUT5
COM
OUT6
COM
OUT7
4
5
6
7
Switch A
Lamp Y
Switch B
Lamp Z
Examine the following relay ladder logic (RLL) program for this Allen-Bradley PLC, determining the
statuses of the two lamps provided neither switch A nor switch B is pressed by a human operator:
I:1
I:1
O:3
I:1
I:1
O:3
Finally, draw color highlighting showing how these contact instructions will appear in an online editor
program given the stated input conditions.
Identify the significance of the labels I and O for this PLCs bits.
Identify the significance of the first and second numbers in each bit label (e.g. the numbers 1 and 2
in the bit address I:1/2, for example). What pattern do you see as you compare the I/O connections
with the respective contact instructions in the PLC program?
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46
Question 25
Suppose we have a Siemens S7-200 PLC connected to a pair of momentary-contact pushbutton switches
and light bulbs as shown in this illustration:
24 VDC
SIEMENS
1M
SIMATIC
S7-200
1L+
0.0
0.1
0.2
0.3
2M
2L+
0.5
0.6
0.7
1.0
1.1
.0 .1 .2 .3 .4 .5 .6 .7
L+
DC
CPU 224XP
Q1
Q0
SF/DIAG
0.4
DC/DC/DC
.0 .1
RUN
STOP
.0 .1 .2 .3 .4 .5 .6 .7
1M
Port 1
.0 .1 .2 .3 .4 .5
I1
I0
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
2M
1.0
1.1
1.2
1.3
1.4
1.5
L+
Port 0
Lamp Y
Switch A
Lamp Z
Switch B
Examine the following relay ladder logic (RLL) program for this Siemens PLC, determining the statuses
of the two lamps provided both switches are simultaneously pressed by a human operator:
I1.2
I0.7
Q0.1
I0.7
I1.2
Q0.3
Finally, draw color highlighting showing how these contact instructions will appear in an online editor
program given the stated input conditions.
file i04664
47
Question 26
Suppose we have a Koyo CLICK PLC connected to three momentary-contact pushbutton switches as
shown in this illustration:
C0-02DD1-D
CLICK
Koyo
C1
X1
X2
X3
X4
PWR
RUN
ERR
RUN
C2
STOP
Y1
Y2
Y3
PORT 1
TX1
Y4
RX1
+V
AD1V
TX2
AD1I
RX2
AD2V
PORT 2
AD2I
ACOM
PORT 3 RS-485
DA1V
DA1I
TX3
RX3
DA2V
LG
DA2I
24V
24 VDC
Determine the necessary switch actuation statuses (i.e. pressed versus unpressed) to turn the lamp on
given the following program running in the PLC:
X1
X3
Y1
X2

Identify the significance of the labels X and Y for this PLCs bits. What do you suppose X
signifies? What do you suppose Y signifies?
file i04638
48
Question 27
Suppose we have an Allen-Bradley MicroLogix 1000 controller connected to a pair of momentary-contact
pushbutton switches and contactor controlling power to an electric motor as shown in this illustration:
"Start" switch
24V
DC
COM
I/0
I/1
I/2
I/3
DC
COM
I/4
I/5
DC OUT
"Stop" switch
Power
Run
Fault
Force
OL contact
85-264 VAC
L1
L2/N
VAC
VDC
O/0
VAC
VDC
O/1
VAC
VDC
O/2
VAC
VDC
O/3
Contactor coil
This motor control system has a problem, though: the motor refuses to start when the Start
pushbutton is pressed. Examine the live display of the ladder logic program inside this Allen-Bradley PLC
to determine what the problem is, assuming an operator is continuously pressing the Start pushbutton as
you examine the program:
I:0/3
I:0/2
I:0/0
O:0/2
O:0/2
Identify at least two causes that could account for all you see here.
Identify what your next troubleshooting step would be if you were tasked with solving this problem.
A helpful problem-solving tip is to annotate each contact in the PLC program to show what its realworld function is. For example, contact I:0/3 may be labeled OL because that is the real-world
switch status it senses. Annotate all contacts in this program and explain how this annotation is helpful
in analyzing the program.
Describe the purpose of the contact labeled O:0/2 in this program, explaining why it is often referred
to as a seal-in contact.
49
file i04662
Question 28
Suppose we have an Allen-Bradley SLC 500 controller connected to a pair of momentary-contact
pushbutton switches and contactor controlling power to an electric motor as shown in this illustration:
480 VAC
Power
supply
1
X2
H2
H3
F7
H1
L1
L2/N
F5
F1
F2
F3
Input
0
1
2
3
X1
F6
H4
Processor
Gnd
Output
4
5
6
7
0
1
2
3
Input
4
5
6
7
Start
Analog
IN0
VAC 1
IN 0+
IN 0-
IN1
OUT0
IN2
OUT1
IN3
OUT2
IN4
OUT3
IN5
VAC 2
IN 2+
IN 2-
IN6
OUT4
ANL COM
IN7
OUT5
COM
OUT6
IN 3+
IN 3-
COM
OUT7
ANL COM
IN 1+
IN 1ANL COM
Stop
ANL COM
F4
6
7
8
Contactor
T3 T2 T1
Overload
block
Reset
Motor
This motor control system has a problem, though: the motor refuses to start when the Start
pushbutton is pressed. Closely examine the pictorial diagram, then identify at least two faults that could
account for the motors refusal to start.
A helpful problem-solving tip is to note the PLCs I/O states by examining the LED indicators on each
input and output card on the PLC rack. What do the LED states tell you in this particular example?
file i04069
50
Question 29
Two technicians, Jill and Bob, work on programming Siemens S7-200 PLCs to control the starting and
stopping of electric motors. Both PLCs are wired identically, as shown:
120 VAC
supply
480 VAC 3-
supply
SIEMENS
1M
1L
SIMATIC
S7-200
1L+
0.0
0.1
0.0
0.2
0.1
0.3
0.2
Q0
SF/DIAG
0.3
0.4
2L
0.4
2M
0.5
2L+
0.5
0.6
0.6
0.7
3L
1.0
0.7
1.1
1.0
1.1
N
M
CPU 224XP
Q1
.0 .1 .2 .3 .4 .5 .6 .7
L+
L1 AC
DC
DC/DC/DC
AC/DC/Relay
.0 .1
RUN
STOP
.0 .1 .2 .3 .4 .5 .6 .7
I0
1M
Port 1
.0 .1 .2 .3 .4 .5
I1
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
2M
1.0
1.1
1.2
1.3
1.4
1.5
L+
Port 0
Start
Stop
However, despite being wired identically, the two technicians PLC programs are quite different. Jills
program uses retentive coil instructions (Set and Reset coils) while Bobs uses a seal-in contact
instruction to perform the function of latching the motor on and off:
Jills PLC program
I0.1
Bobs PLC program
Q0.0
I0.1
I0.4
Q0.0
S
I0.4
Q0.0
Q0.0
Explain how both of these PLC programs function properly to control the starting and stopping of the
electric motor.
It is ordinarily a bad thing to assign identical bit addresses to multiple coil instructions in a PLC
program. With Jills retentive coil program, however, this is not only permissible but in fact necessary
for its proper operation. Explain why this is.
A common misconception of students first learning PLC programming is to think that the type of
contact instruction used in the PLC program must match the type of switch contact connected to that
input (e.g. A N.O. PLC instruction must go with a N.O. switch). Explain why this is incorrect.
file i03674
51
Question 30
Programming Challenge and Comparison Conveyor start/stop control with safety switch
Suppose we wish to control the starting and stopping of a large conveyor belt at a factory using a
PLC. This control system will use a Start pushbutton, a Stop pushbutton, and an emergency shut-down
pull-cable allowing anyone along the conveyors length to stop the belt simply by tugging on a steel cable
(this is akin to the stop cable used on public buses for passengers to signal to the driver their intent to
get off at the next stop).
Inputs
Start pushbutton (momentary NO) pushing this button closes the switch to energize the PLC input
Stop pushbutton (momentary NC) pushing this button opens the switch to de-energize the PLC input
Emergency stop cable (latching NC) tugging on the cable opens the switch to de-energize the PLC
input
Outputs
Motor contactor energizing this PLC output starts the conveyor belt motor
Work individually or in teams to write a PLC program performing this function, and demonstrate its
operation using switches connected to its inputs to simulate the discrete inputs in a real application.
When your program is complete and tested, capture a screen-shot of it as it appears on your computer,
and prepare to present your program solution to the class in a review session for everyone to see and critique.
The purpose of this review session is to see multiple solutions to one problem, explore different programming
techniques, and gain experience interpreting PLC programs others have written. When presenting your
program (either individually or as a team), prepare to discuss the following points:
Identify the tag names or nicknames used within your program to label I/O and other bits in
memory
Follow the sequence of operation in your program, simulating the system in action
Identify any special or otherwise non-standard instructions used in your program, and explain why you
decided to take that approach
Show the comments placed in your program, to help explain how and why it works
How you designed the program (i.e. what steps you took to go from a concept to a working program)

How do you keep the motor latched on when the momentary Start switch is released?
Which is simpler: implementing this function using normal program coils, or implementing this function
using retentive coils (set and reset, or latch and unlatch)?
file i02340
52
Question 31
Suppose we have an Allen-Bradley MicroLogix 1000 PLC connected to three momentary-contact
pushbutton switches as shown in this illustration:
24V
DC
COM
I/0
I/1
I/2
I/3
DC
COM
I/4
I/5
DC OUT
Power
Run
Fault
Force
C
85-264 VAC
L1
L2/N
VAC
VDC
O/0
VAC
VDC
O/1
VAC
VDC
O/2
VAC
VDC
O/3
Determine the bit statuses of I:0/0, I:0/1, and I:0/3 when switch A is pressed, switch B is unpressed
(released), and switch C is pressed.
file i04685
53
Question 32
Suppose we have a Siemens S7-200 PLC connected to two process switches as shown in this illustration:
24 VDC
SIEMENS
1M
SIMATIC
S7-200
1L+
0.0
0.1
0.2
Q0
SF/DIAG
0.3
0.4
2M
2L+
0.5
0.6
0.7
1.0
1.1
DC
CPU 224XP
Q1
.0 .1 .2 .3 .4 .5 .6 .7
L+
DC/DC/DC
.0 .1
RUN
STOP
.0 .1 .2 .3 .4 .5 .6 .7
I0
1M
Port 1
.0 .1 .2 .3 .4 .5
I1
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
2M
1.0
1.1
1.2
1.3
1.4
1.5
L+
Port 0
130 oF
12 GPM
Determine the bit statuses of I0.2 and I1.1 when the temperature switch senses 122 o F and the flow
switches senses 15 GPM.
file i04686
54
Question 33
Suppose we have an Allen-Bradley SLC 500 PLC connected to two process switches as shown in this
illustration:
Slot 0
(processor)
Power
supply
120 VAC
power
Processor
Slot 1
Input
0
1
2
3
L1
L2/N
Gnd
Slot 2
Slot 3
(discrete input) (discrete input) (discrete output)
Input
4
5
6
7
0
1
2
3
Output
4
5
6
7
0
1
2
3
IN0
IN0
VAC 1
IN1
IN1
OUT0
IN2
IN2
OUT1
IN3
IN3
OUT2
IN4
IN4
OUT3
IN5
IN5
VAC 2
IN6
IN6
OUT4
IN7
IN7
OUT5
COM
COM
OUT6
COM
COM
OUT7
4
5
6
7
2 feet
37 PSI
Determine the bit statuses of I:1/3 and I:1/5 when the level switch senses 3 feet and the pressure
switch senses 14 PSI.
file i04687
55
Question 34
The following PLC program preforms the function of an alarm annunciator, where a discrete input
signal from an alarm switch (e.g. high temperature alarm) first causes a warning light to blink and a siren
to audibly pulse until a human operator presses an acknowledge pushbutton. If the alarm switch signal is
still activated, the light will remain on (steady) instead of blink and the siren will go silent. The light turns
off as soon as the alarm signal goes back to its safe state. A timing diagram shows how this should work:
Alarm
switch
Warning
light
Warning
siren
Acknowledge
pushbutton
Alarm_input
Blink
Light
Latch
Blink
Latch
Acknowledge_input Alarm_input
Siren
Latch
Latch
Take this generic PLC program and enter it into your own PLC, assigning appropriate addresses to
all instructions, and demonstrating its operation.
Does the PLC program (as written) expect a closed alarm switch contact to trigger the alarm, or an
open alarm switch contact?
file i02342
56
Question 35
Circuit 1
Circuit 2
Circuit 3
Circuit 4
Circuit 5
Circuit 6
file i01004
57
Question 36
In each of the following circuits, the light bulb will energize when the pushbutton switch is actuated.
Assume that the supply voltage in each case is somewhere between 5 and 30 volts DC (with lamps and
resistors appropriately sized):
Circuit 1
Circuit 2
Circuit 3
Circuit 4
Circuit 5
Circuit 6
However, not all of these circuits are properly designed. Some of them will function perfectly, but others
will function only once or twice before their transistors fail. Identify the faulty circuits, and explain why
they are flawed.
file i01005
58
Question 37
Draw the necessary wire connections so that bridging the two contact points with your finger (creating
a high-resistance connection between those points) will turn the light bulb on:
Contact
points
file i01006
Question 38
Choose the right type of bipolar junction transistor for each of these switching applications, drawing
the correct transistor symbol inside each circle:
+V
+V
+V
Load
Switch sourcing current
to transistor
Switch sinking current

from transistor
Transistor sourcing
current to load
Load
file i01007
59
Transistor sinking
current from load
Question 39
Choose the right type of bipolar junction transistor for each of these switching applications, drawing
the correct transistor symbol inside each circle:
+V
+V
+V
Load

to transistor
Transistor sourcing
current to load

from transistor
Transistor sinking
current from load
Load
Also, explain why resistors are necessary in both these circuits for the transistors to function without
being damaged.
file i01008
Question 40
60
Question 41
Suppose we have a Siemens S7-200 PLC connected to a pair of momentary-contact pushbutton switches
and light bulbs as shown in this illustration:
24 VDC
SIEMENS
1M
SIMATIC
S7-200
1L+
0.0
0.1
0.2
0.3
2M
2L+
0.5
0.6
0.7
1.0
1.1
.0 .1 .2 .3 .4 .5 .6 .7
L+
DC
CPU 224XP
Q1
Q0
SF/DIAG
0.4
DC/DC/DC
.0 .1
RUN
STOP
.0 .1 .2 .3 .4 .5 .6 .7
1M
Port 1
.0 .1 .2 .3 .4 .5
I1
I0
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
2M
1.0
1.1
1.2
1.3
1.4
1.5
L+
Port 0
Lamp Y
Switch A
Lamp Z
Switch B
Examine the following relay ladder logic (RLL) program for this Siemens PLC, determining the statuses
of the two lamps provided switch A is pressed by a human operator and switch B is unpressed:
I1.2
I0.7
Q0.1
I0.7
I1.2
Q0.3
Furthermore, determine whether the inputs and outputs of this particular PLC (as shown) are sourcing
or sinking.
file i04170
61
Question 42
Suppose we have a Koyo CLICK PLC connected to three process switches as shown in this illustration:
C0-02DD1-D
CLICK
Koyo
30 PSI
C1
X1
X2
X3
150 oF
X4
PWR
RUN
ERR
RUN
C2
STOP
Y1
4 inches
Y2
Y3
PORT 1
TX1
Y4
RX1
+V
AD1V
TX2
AD1I
RX2
AD2V
PORT 2
AD2I
ACOM
PORT 3 RS-485
DA1V
DA1I
TX3
RX3
DA2V
LG
DA2I
24V
24 VDC
Determine the switch stimuli (i.e. required pressure, temperature, and level) given the live display of
the ladder logic program shown here:
X1
X2
X3
Y1
Identify how you could force the lamp to energize, if your only tool at hand was a screwdriver.
file i04667
62
Question 43
This Koyo CLICK PLC has been programmed to control the starting and stopping of an electric
motor, including a counter instruction to prevent the motor from being started up more than a specified
number of times:
C0-02DD1-D
CLICK
Koyo
Start
Program (inside PLC)
C1
X1
X1
X2
X2
CT1
Y1
Stop
X3
X4
PWR
RUN
RUN
ERR
C2
Y1
STOP
Reset
Y2
PORT 1
Y3
TX1
Y4
RX1
+V
Y1
AD1V
TX2
AD1I
RX2
AD2V
PORT 2
AD2I
ACOM
PORT 3 RS-485
M1
Y1
Contactor
relay coil
Up
DA1V
TX3
DA1I
RX3
DA2V
LG
X3
Counter
CT1
SetPoint
Current
CTD1
CT1
Complete
DA2I
Reset
24V
24 VDC
Identify the counter instruction in the program shown, its input connections, and also how the result
of the counter reaching its pre-set limit forces the motor to stop. Also, determine the maximum number of
times the motor may be started up, assuming the counters current value goes to zero when the Reset button
is pressed.
Finally, determine how to modify this PLC program so that the counter may be manually reset by the
operator without requiring a separate pushbutton labeled Reset.
If an operator presses the Start button multiple times while the motor is already running, do these
button-presses get counted by the counter instruction, or do only the real motor start-up events get
counted?
What do you suppose the label CTD1 represents inside the counter instruction?
Note the number of times the bit Y1 is referenced inside this PLC program: once in a coil instruction
and twice in contact instructions. Is there any limit to how many times a bit address may be used in a
PLC program?
Describe the purpose of the first contact instruction labeled Y1 in this program, explaining why it is
often referred to as a seal-in contact.
file i03589
63
Question 44
Read selected portions of the Siemens SIMATIC S7-200 Programmable Controller System Manual
(document A5E00307987-04, August 2008) and answer the following questions:
Identify the different types of SIMATIC counter instructions.
Identify a practical application for a counter instruction programmed into a PLC.
How high can one of these counter instructions count up to? How low can it count down to? Based on
these values, how many bits do you think are used in the register to store a counter instructions current
value?
Sketch a simple ladder-diagram program for a Siemens S7-200 PLC whereby a switch connected to input
I0.5 causes a counter to increment (count up) and then turn on an alarm light output Q0.3 when the count
reaches a value of 5. Also provide a reset function triggered by a normally-open switch contact at input
I0.0 to force the count value back to zero when pressed.
file i02245
64
Question 45
Read selected portions of the Allen-Bradley Logix5000 Controllers General Instructions reference
manual (publication 1756-RM0031-EN-P, January 2007) and answer the following questions:
Identify the different types of counter instructions offered in the Logix5000 PLC family.
How high can one of these counter instructions count up to? How low can it count down to? Based on
these values, how many bits do you think are used in the register to store a counter instructions current
value?
Unlike the Siemens S7 family of PLCs, the Allen-Bradley counter instruction box symbols do not
provide a place to connect a reset input. How then is it possible to command a counter instruction to reset
back to zero?
Sketch a simple ladder-diagram program for an Allen-Bradley Logix5000 PLC whereby a hightemperature switch input with the tag-name High Motor Temp causes a counter to increment (count up)
every time a motor overheats, and then turn on an alarm light output (tag-name Alarm Lamp) when the
count reaches a value of 5. Also provide a reset function triggered by a normally-open switch contact
(tag-name Alarm Reset) to force the count value back to zero when pressed.
file i02664
65
Question 46
This Siemens S7-200 PLC is supposed to count the number of cars entering a parking garage, using a
pressure-sensitive switch that the cars drive over when entering the garage. The car-count value is sent to
a computer in the main office via a network cable plugged into the PLC. The parking attendant is able to
reset the count to 0 at the end of his shift, using a key-switch:
...
Network cable
to main office display
SIEMENS
1M
SIMATIC
S7-200
1L+
0.0
0.1
0.2
Q0
SF/DIAG
0.3
0.4
2M
2L+
0.5
0.6
0.7
1.0
1.1
DC
CPU 224XP
Q1
.0 .1 .2 .3 .4 .5 .6 .7
L+
DC/DC/DC
.0 .1
RUN
STOP
.0 .1 .2 .3 .4 .5 .6 .7
I0
1M
Port 1
.0 .1 .2 .3 .4 .5
I1
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
2M
1.0
1.1
1.2
1.3
1.4
1.5
L+
Port 0
Drive-over pressure switch

Key
Reset
switch
Unfortunately, there is something wrong with this system. Although it worked just fine yesterday, today
the counters current value as displayed on the main office computer seems to be stuck at 574 no matter
how many more cars drive over the pressure switch and enter the garage. Explain how you would go about
diagnosing the problem in this system, justifying each step you would take.
A useful troubleshooting strategy is to mentally divide this system into three major portions, and try
to determine which portion the problem lies within: (1) the switches and wiring connected to the PLC,
(2) the PLC itself, and (3) the network cable and computer in the main office.
How important is the fact that this system worked fine yesterday? Does this knowledge help you in
your troubleshooting?
Are there any LED indicators on the face of the PLC that might be helpful in providing diagnostic data
for you to pinpoint the location of the problem?
file i03683
66
Question 47
This Siemens S7-200 PLC has been programmed to count the number of people in a room, by
incrementing a counter every time a person enters through the doorway, and decrementing that same
counter whenever someone exits through the same doorway. The two optical switches activate whenever
their respective light beams are broken by someone passing through. Their horizontal separation is just a
couple of inches much less than the girth of a persons torso. The operating status of each switch is that
it energizes the PLC input when the light beam is broken:
Light sources
Entering
Photo-switches
PLC
SIEMENS
1M
SIMATIC
S7-200
1L+
0.0
0.1
0.2
Q0
SF/DIAG
0.3
0.4
2M
2L+
0.5
0.6
0.7
1.0
1.1
L+
DC
CPU 224XP
Q1
.0 .1 .2 .3 .4 .5 .6 .7
DC/DC/DC
.0 .1
RUN
STOP
.0 .1 .2 .3 .4 .5 .6 .7
I0
1M
Port 1
.0 .1 .2 .3 .4 .5
I1
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
2M
1.0
1.1
1.2
1.3
1.4
1.5
L+
Port 0
Examine the program in this PLC for counting people, and determine how it is able to differentiate
between a person entering the room and a person leaving the room:
I1.0
I1.3
P
I1.3
CU
CTUD
I1.0
P
CD
QU
QD
LD
PV
CV

Explain how a timing diagram of the switch states would be helpful in analyzing the operation of this
PLC program.
How are transition (edge-detecting) instructions implemented in Allen-Bradley PLCs?
file i00185
67
Question 48
A PLC is used to count the number of cans traveling by on a conveyor belt in a fish canning factory.
An optical proximity switch detects the passage of each can, sending a discrete (on/off) signal to one of the
PLCs input channels. The PLC then counts the number of pulses to determine the number of cans that
have passed by:
Power
supply
Input
Processor
0
1
2
3
Input
4
5
6
7
DC sourcing
24 VDC
L1
120 VAC
L2/N
Gnd
2
3
4
DC sinking
Output
4
5
6
7
0
1
2
3
DC sinking
IN0
IN0
VDC
IN1
IN1
OUT0
IN2
IN2
OUT1
IN3
IN3
OUT2
IN4
IN4
OUT3
IN5
IN5
OUT4
IN6
IN6
OUT5
IN7
IN7
OUT6
COM
COM
OUT7
COM
COM
COM
TB-20
TB-23
1
0
1
2
3
Grn
4
5
6
7
Cable 45
Red
Blu
Org
Counter
reset
TB-31
Wht
Blk
Red
DC sinking
One day the canning line operator tells you the PLC has stopped counting even though cans continue to
run past the proximity switch as the conveyor belt moves. Identify what you would do to begin diagnosing
this problem, justifying each step you would take.
Identify different areas or components within this system that could possibly be at fault, as a prelude
to identifying specific diagnostic steps.
Are there any ways you could diagnose this problem without the use of test equipment (e.g. multimeter)?
Explain the significance of the sourcing and sinking labels on the I/O cards as well as the proximity
switch.
file i02428
68
Question 49
The manufacturing company you work for installs a PLC control system on its assembly line, counting
the number of components produced every shift. For quite a while, the system works without any problems
whatsoever, and then one day management decides to scrap a run of product mid-shift and start over. This
is when they discover the system integrator they contracted to build and program the PLC system provided
no way to reset the shift production counter except to wait until the shift is over.
An operations manager summons you to reset the counter for them. Identify at least two different ways
you could reset the counter to meet their needs, as quickly as possible.
file i00182
69
Question 50
A PLC is being used to monitor the oil pressure for a steam turbine driving an electrical generator,
shutting steam off to the turbine if ever the oil pressure drops below a 10 PSI limit. The turbines lubrication
oil pump is driven by the turbine shaft itself, supplying itself with pressurized lubricating oil to keep all the
turbine bearings properly lubricated and cooled:
Start
PLC
PSL
Stop
Oil pump
Turbine
Generator
20 PSI
air supply
(vent)
ATO
Steam supply
Another technician programmed the PLC for the start/stop function, but this program has a problem:
Real-world I/O wiring

Discrete input
card
Discrete output
card
"Start" pushbutton
IN_switch_Start
Solenoid coil
OUT_valve
"Stop" pushbutton
IN_switch_Stop
Low oil pressure

IN_oil_press
PLC program
IN_switch_Start
IN_switch_Stop
IN_oil_press
OUT_valve
OUT_valve
Identify what this problem is, and fix it! Hint: the oil pump is driven by the turbine, and as such cannot
generate any oil pressure until the turbine begins to spin.
file i00189
70
Question 51
An important pump in a chemical process is turned by an electric motor, and operators want to have
visual indication in the control room that the pump is indeed turning. There is no way to attach a speed
switch to the pump shaft (that would be too easy!). Instead, someone has installed a proximity switch near
the pump shaft, situated to pick up the passing of a keyway in the shaft with each rotation. Thus, the
proximity switch will output a pulse signal when the pump shaft is spinning:
Motor
Pump
Proximity switch
Signal cable
to PLC input
I:3/2
Pulse signal (when pump is running)
Operators wanted the indicator light in the control room to blink when the pump is running, for an
indication of shaft motion. The problem is, the shaft turns much too fast to directly drive the indicator with
the proximity switch signal, and so an Allen-Bradley PLC was programmed to produce a slower blink using
this program:
I:3/2
CTU
Count Up
Counter
Preset
Accum
C5:0.ACC/13
CU
C5:0
DN
32767
0
O:1/5
C5:0/DN
C5:0
RES
Explain how this program works to fulfill the function of a frequency divider, converting the high-speed
pulse signal of the proximity switch into a low-speed blink for the operator light.
Explain how a frequency divider circuit built out of J-K flip-flop integrated circuits functions, and then
describe how this PLC program is similar in principle.
file i03838
71
Question 52
A NAND logic function may be built up from a regular AND function plus an inverter function (a NOT gate)
on the output:
AND
NAND
NOT
. . . is equivalent to . . .
The same strategy of building a NAND gate may be done in PLC ladder-diagram programming, by
combining a normally-closed contact instruction with two contacts in series.
Examine these two Allen-Bradley PLC programs, and explain why the left-hand program is wasteful
while the right-hand program makes more efficient use of available bits:
Wasteful
I:0/4
I:0/7
O:2/0
Allen-Bradley MicroLogix/SLC
Efficient
O:2/0
I:0/4
O:2/1
B3:0/0
I:0/7
B3:0/0
O:2/1
Examine these two Siemens S7 PLC programs, and explain why the left-hand program is wasteful
while the right-hand program makes more efficient use of available bits in the same ways the Allen-Bradley
example programs were wasteful/efficient:
Siemens Step 7 (S7)

Wasteful
I0.4
Q2.0
I0.7
Efficient
Q2.0
I0.4
Q2.1
M0.0
I0.7
M0.0
Q2.1
Note: many novice PLC programmers commit this error of wasting valuable I/O as they
write their programs!
file i04092
72
Question 53
Programming Challenge and Comparison Mixer motor auto-stop
A batch mixing process in a manufacturing facility uses a mixer motor and a large paddlewheel to
mix liquid ingredients to make a final product. A PLC needs to run this motor for exactly 1500 turns of
the paddlewheel and then automatically stop. The motor needs to be able to start back up if the Start
button is pressed again for the next batch:
Power
cable
Liquid
Prox. switch
Mixing vessel
Sensor
cable (to PLC)
Paddlewheel
Inputs
Start pushbutton (momentary NO) pushing this button closes the switch to energize the PLC input
Stop pushbutton (momentary NC) pushing this button opens the switch to de-energize the PLC input
Proximity switch (NO) one pulse per paddle revolution
Outputs
Motor contactor energizing this PLC output starts the mixing motor
Work individually or in teams to write a PLC program performing this function, and demonstrate its
operation using switches connected to its inputs to simulate the discrete inputs in a real application.
memory

How can you test your programs basic operation without having to flick a switch 1500 times to simulate
the full number of paddle revolutions?
How can we design the program so that pressing the Start button does not influence the count during
a run, but only resets the count after the run has completed?
file i03688
73
Question 54
C0-02DD1-D
CLICK
Koyo
C1
Trip = 135 oF
X1
X2
X3
X4
PWR
RUN
ERR
RUN
C2
STOP
Y1
Trip = 23 inches
Y2
Y3
PORT 1
TX1
Y4
RX1
+V
Trip = 17 PSI
AD1V
TX2
AD1I
RX2
AD2V
PORT 2
AD2I
ACOM
PORT 3 RS-485
DA1V
DA1I
TX3
RX3
DA2V
LG
DA2I
24V
24 VDC
Determine the process conditions (i.e. temperature, level, and pressure values) given the live display
of the ladder logic program shown here:
X1
X2
X3
Y1
file i02144
74
Question 55
C0-02DD1-D
CLICK
Koyo
C1
X1
Trip = 32 PSI
X2
X3
X4
PWR
RUN
ERR
RUN
C2
STOP
Y1
Trip = 10 inches
Y2
PORT 1
Y3
TX1
Y4
RX1
+V
Trip = 99 oF
AD1V
TX2
AD1I
RX2
AD2V
PORT 2
AD2I
ACOM
PORT 3 RS-485
DA1V
DA1I
TX3
RX3
DA2V
LG
DA2I
24V
24 VDC
Determine the process conditions (i.e. temperature, level, and pressure values) given the offline display
of the ladder logic program shown here, knowing that the lamp happens to be energized at the present time:
X1
X2
X3
X2
Y1
file i02145
75
Question 56
Programming Challenge Hour/Minute/Second timer
Many PLCs provide a range of special contacts to the programmer. Among these special contacts is
typically one that cycles on and off at a rate of once per second, like a 1 Hz clock pulse.
Research the special contact for this function in your PLC, then write a PLC program for an
Hour/Minute/Second timer using three counter instructions: one to count seconds (0 to 59), one to count
minutes (0 to 59), and one to count hours.
What is the address of the special contact in your PLC for the 1 Hz clock pulse?
How do you make three counters count in the correct sequence, so that one represents seconds, the next
minutes, and the next hours?
PLC comparison:
Allen-Bradley SLC 500: status bit S:4/0 is a free-running clock pulse with a period of 20 milliseconds,
which may be used to clock a counter instruction up to 50 to make a 1-second pulse (because 50 times
20 ms = 1000 ms = 1 second).
Siemens S7-200: Special Memory bit SM0.5 is a free-running clock pulse with a period of 1 second.
Koyo (Automation Direct) DirectLogic: Special relay SP4 is a free-running clock pulse with a period of
1 second.
file i03691
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Question 57
Programming Challenge Parking garage counter
Suppose we wish to count the number of cars inside a parking garage at any given time, by incrementing
a counter each time a car enters the garage through the entry lane, and decrementing the same counter each
time a car leaves the garage through the exit lane. One discrete input of the PLC will connect to a switch
detecting the passing of each car through the garage entry, and another discrete input of the PLC will
connect to a switch detecting cars passing out the garage exit. The PLC must be equipped with a way to
for the garage attendant to manually reset the counter to zero.
Write a PLC program to perform this function, and demonstrate its operation using switches connected
to its inputs to simulate the discrete inputs in a real application.
What type of switches would you recommend to detect cars driving into the parking garage?
How are you able to view the counter instructions current count value as the program runs?
Is there any way to fool this system so that it does not hold an accurate count of cars inside the
garage?
PLC comparison:
Allen-Bradley Logix 5000: CTUD count-up/down instruction
Allen-Bradley SLC 500: CTU and CTD instructions.
Siemens S7-200: CTUD count-up/down instruction
Koyo (Automation Direct) DirectLogic: UDC counter instruction
file i03684
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Question 58
Question 59
Question 60
Question 61
Suppose we have an Allen-Bradley model SLC 500 PLC connected to a pair of momentary-contact
pushbutton switches and light bulbs as shown in this illustration:
Power
supply
Slot 0
Slot 1
Slot 2
Slot 3
(processor)
(discrete input)
(unused)
(discrete output)
Processor
Input
0
1
2
3
L1
120 VAC
power
L2/N
Gnd
Output
4
5
6
7
0
1
2
3
IN0
VAC 1
IN1
OUT0
IN2
OUT1
IN3
OUT2
IN4
OUT3
IN5
VAC 2
IN6
OUT4
IN7
OUT5
COM
OUT6
COM
OUT7
4
5
6
7
Switch A
Lamp Y
Switch B
Lamp Z
Examine the following relay ladder logic (RLL) program for this Allen-Bradley PLC, determining the
statuses of the two lamps provided switch A is pressed by a human operator and switch B is unpressed:
I:1
I:1
O:3
I:1
I:1
O:3
file i03760
78
Question 62
Suppose we have a PLC connected to two pushbutton switches (momentary NO) as shown in this
illustration:
120 VAC "line" power

L1
X1
L2
L1
L2
X2
Y2
X3
(NO contacts)
X4
Y3
PLC
X5
(NO contacts)
Personal
computer
display
(Ladder Diagram program)
X3
Y4
Y5
X6
Common
Y1
Y6
Programming
port
Source
X3
Y1
X5
Y2
X5
X3
Based on the highlighting you see in the live PLC program display, determine the status of each
pushbutton switch: whether or not each one is being pressed.
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79
Question 63
Read selected portions of the Siemens SIMATIC S7-200 Programmable Controller System Manual
(document A5E00307987-04, August 2008) and answer the following questions:
Identify the different types of SIMATIC timer instructions, explaining how each one functions.
Identify a practical application for a timer instruction programmed into a PLC.
How long can one of these timer instructions time up to? Based on this maximum value, how many bits
do you think are used in the register to store a timer instructions current value?
What is meant by the resolution of a timer instruction? How many different options do the SIMATIC
instructions provide for resolution?
Comment on how a SIMATIC timers value is updated in a PLC program if the resolution is 1 ms, if it
is 10 ms, and if it is 100 ms. The Siemens S7-200 PLC handles each one differently!
Sketch a simple ladder-diagram program for a Siemens S7-200 PLC whereby a switch connected to input
I0.3 causes a timer to increment (count up) and then turn on an alarm light output Q0.9 after 5 seconds.
file i00229
80
Question 64
Read selected portions of the Allen-Bradley MicroLogix 1000 Programmable Controllers (Bulletin 1761
Controllers) user manual (document 1761-6.3, July 1998) and answer the following questions:
Identify the different types of timer instructions available in the MicroLogix 1000 controller, explaining
how each one functions. How do these types compare with those offered in the Siemens S7-200 PLC?
Identify a practical application for a retentive timer instruction programmed into a PLC.
How many different options do the Allen-Bradley MicroLogix timer instructions provide for resolution?
How long can one of these timer instructions time up to? Based on this maximum value, how many bits
do you think are used in the register to store a timer instructions current value?
Sketch a simple ladder-diagram program for an Allen-Bradley MicroLogix 1000 PLC whereby a switch
connected to input I:0/2 causes a timer to increment (count up) and then turn on an alarm light output
O:0/1 after 5 seconds.
file i00247
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Question 65
Suppose we have an Allen-Bradley model SLC 500 PLC connected to a liquid level switch, a selector
switch, and a motor contactor (for a pump) as shown in this illustration:
Slot 0
Slot 1
Slot 2
(processor) (discrete output)
Power
supply
Processor
L2/N
Gnd
(discrete input)
Output
0
1
2
3
L1
120 VAC
power
Slot 3
(unused)
Input
4
5
6
7
0
1
2
3
VAC 1
IN0
OUT0
IN1
OUT1
IN2
OUT2
IN3
OUT3
IN4
VAC 2
IN5
OUT4
IN6
OUT5
IN7
OUT6
COM
OUT7
COM
4
5
6
7
5 feet
Contactor
Left
Right
Explain what conditions must be met for the pump to turn on, based on an analysis of the program
running in the PLC:
I:3/4
TON
Timer On Delay
Timer
I:3/2
EN
T4:3
Time Base
0.1
Preset
250
Accum
T4:3/DN
file i04634
82
O:1/0
DN
Question 66
A gravel-crushing operation uses three long conveyor belts to move rock from the quarry to the crusher.
The belts must be started up in a particular sequence to avoid overloading the electric motors driving them:
Conveyor A
Conveyor B
Conveyor C
Rock from quarry

Rock to crusher
M
PLC
Start
pushbutton
Stop
pushbutton
First, determine a start-up sequence that makes sense: which conveyor belt should start first, next,
and last? What might happen if the sequence were reversed? Why not simply start all conveyor motors
simultaneously?
83
This operation uses a Siemens S7 series PLC to control the three conveyor belts. Analyze this program
and explain how it accomplishes the task of starting up the three conveyors in sequence:
Start
I0.1
Stop
I0.0
Run
M0.0
Run
M0.0
Run
M0.0
T2
+85
IN
TON
PT
100 ms
T3
T2
+85
IN
TON
PT
100 ms
Run
M0.0
Conv_C_motor
Q0.2
T2
Conv_B_motor
Q0.1
T3
Conv_A_motor
Q0.0
Lastly, determine where you might add a contact instruction for an emergency shutoff safety switch, so
that all three conveyors stop simultaneously if ever the safety switch is actuated.
How long is the time delay between conveyor start-ups? How might this time delay be altered if needed?
Suppose a warning siren were added to the system, sounding for a full 15 seconds before the first conveyor
belt starts. How would you modify the PLC program to include this additional functionality?
file i04428
84
Question 67
Suppose we have an Allen-Bradley model SLC 500 PLC connected to switches and a pump contactor
as shown in this illustration:
Slot 0
Slot 1
Slot 2
(processor) (discrete output)
Power
supply
Processor
120 VAC
power
Output
L2/N
Gnd
Slot 3
(discrete input)
Input
0
1
2
3
L1
(unused)
4
5
6
7
0
1
2
3
VAC 1
IN0
OUT0
IN1
OUT1
IN2
OUT2
IN3
OUT3
IN4
VAC 2
IN5
OUT4
IN6
OUT5
IN7
OUT6
COM
OUT7
COM
4
5
6
7
3 feet
Contactor
Left
Right
20 PSI
Identify the necessary conditions for the pump to turn on, based on this program running in the PLC:
I:3
TON
Timer On Delay
Timer
Time Base
I:3
2
I:3
EN
T4:3
Preset
17
Accum
T4:3
DN
1.0
O:1
DN
I:3
T4:3
RES
file i04635
85
Question 68
An Allen-Bradley Logix5000 PLC is used to control the starting and stopping of an air compressor
based on momentary-contact pushbutton switch inputs as well as high and low pressure switches (PSH and
PSL, respectively). Analyze this program and explain how it is supposed to work:
in_start_switch
in_stop_switch
run_enable
run_enable
in_psl
in_psh
run_enable
out_comp_motor
out_comp_motor
out_comp_motor
RTO
Retentive Timer On
Timer
Time Base
Preset
Accum
(continued on next page)
86
run_time
0.001
3600000
0
EN
DN
(continued from previous page)

run_time.dn
CTU
Count Up
Counter
hours.dn
CU
hours
Preset
250
Accum
DN
out_warning_light
in_reset_switch
hours
RES
run_time.dn
run_time
RES
in_reset_switch
In particular, answer these following questions:

Determine the normal electrical statuses of all switches (e.g. NO or NC) connected to the inputs of
this PLC, based on an examination of the respective contact instructions within the PLC program.
Why is is important that a retentive timer instruction be used for the calculation of total run-time?
What is the significance of the maintenance warning light controlled by this PLC?

Note how all instructions in this Logix5000 PLC program are addressed by tagname rather than by
hardware addresses (e.g. I:2/6, O:3/1). How do you suppose the PLC knows which real I/O points
to associate with which instructions in the program?
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87
Question 69
A technician is troubleshooting a problem with a newly-installed PLC and variable-speed motor drive.
One of the discrete (on/off) outputs of the PLC is connected to a discrete input on the drive, to tell the
motor to either turn on or turn off. The PLCs discrete output is a dry contact type, meaning it is nothing
more than an electromechanical relay contact inside the output card. The discrete inputs on the drive (DI0,
DI1, and DI2) are logic gate inputs, internally pulled up with resistors so that the only thing needed to
activate each input is to form a connection between the respective input and the common (Com) terminal
on the drive. The dry contact for PLC output 0 on the right-most output card is supposed to do just that,
telling the drive when to start the motor:
Power
supply
Processor
Digital
inputs
Digital
outputs
Digital
outputs
3-phase AC
power lines
L1
L2/N
Com
Com
Gnd
L1 L2 L3
DI0
DI1
DI2
Com
T1 T2 T3
To 3-phase motor
The problem is, the motor does not start when the PLC tells it to. Now, the motor itself is brand-new,
and the wiring between the motor and the drive is known to be good. A power check at the PLC and drive
power terminals shows 117 volts AC between L1 and L2/N (on the PLC) and 482 volts between each of the
three phases (L1, L2, and L3) on the motor drive. The LED indicator for output 0 on the PLC card is lit,
88
revealing that the PLC program at least is trying to activate the motor drive. This data suggests (but does
not guarantee) that the problem lies either with the PLC hardware or the drive, and not with the power
sources, motor wiring, motor, PLC inputs, or PLC program.
Both the PLC and the motor drive are complex, programmable devices. The technician knows she could
spend quite a bit of time diagnosing either of these devices trying to find a problem. Thus, it would be very
helpful to know which of these devices is at fault so as to not waste troubleshooting time.
Devise a simple test for the technician to perform that will neatly divide the problem in half, telling her
whether the PLC or the drive is at fault, and be sure to explain your reasoning.
Is the PLC output card sourcing curren to or sinking current from the VFD in this system?
If the problem lies within the PLC, where exactly do you think it might be found within the PLC? Do
you think it could be a hardware problem, a software problem, or either?
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Question 70
Programming Challenge and Comparison solenoid valve control with stuck valve alarm
A PLC is used to control the opening and closing of a solenoid-operated valve with a single discrete
output. A pair of normally-open limit switches sense the valves stem position:
PLC
Compressed
air supply
Processor
Input
0
1
2
3
Valve actuator
Input
4
5
6
7
0
1
2
3
Output
4
5
6
7
0
1
2
3
IN0
IN0
VDC
IN1
IN1
OUT0
IN2
IN2
OUT1
IN3
IN3
OUT2
IN4
IN4
OUT3
IN5
OUT4
IN5
IN6
OUT5
IN7
IN7
OUT6
COM
IN6
COM
OUT7
COM
COM
COM
Full-open limit
4
5
6
7
Alarm lamp
Full-closed limit
Toggle switch
Pipe
Pipe
Valve
Work individually or in teams to write a PLC program energizing an alarm lamp if the valve fails to
reach the full-open position within 5 seconds of receiving the open command signal, and energizing the
same alarm lamp if the valve fails to reach the full-closed position within 8 seconds of receiving the close
command signal. Note that the status of both limit switches will be open (off) when the stem is between
its full-open and full-closed positions. The PLC receives the command to open or close the valve from a
hand-operated toggle switch.
Inputs
Open/Close toggle off when commanding valve to shut ; on when commanding valve to open wide
Valve closed limit (NO) closes when valve reaches 0% position
Valve open limit (NO) closes when valve reaches 100% position
Outputs
Valve actuator solenoid energizing this coil opens up the valve
Valve stuck alarm lamp energize if valve does not respond in time
memory
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90
Question 71
Programming Challenge Reversing motor restart delay
A three-phase electric motor drives an air heat exchanger (radiative cooler) in either direction (forward or
reverse), depending on which way operations personnel wish to blow the warm air. During warm weather, the
preferred direction is up, to direct hot air away from process equipment. During cold weather, the preferred
direction is down, to provide warmth in the process equipment area to help guard against liquid-filled pipes
and tubes freezing:
Radiator core
Forward blows air up
Fan blade
Reverse blows air down
Fan blade
3-phase 480 VAC
Motor
Fwd
Rvs
Reset
A reversing start/stop PLC program is easy enough to write, with two momentary-contact Start
pushbuttons (one for Forward, one for Reverse) and one momentary Stop pushbutton; but what we need
here is a reversing program that prevents an immediate re-start of the motor in the opposite direction
following a stop command. This is because the fan blades have a lot of inertia, and take about 30 seconds to
coast to a stop. This restart lockout timer will prevent someone from trying to reverse the motors direction
before the fan has had a chance to fully stop.
Write a PLC program to provide this forward/reverse/restart lockout functionality. Assume the use of
normally-open (NO) pushbutton switches for all pushbutton inputs.
What type of timer instruction is best suited for this application, an on-delay or an off-delay timer?
file i02347
91
Question 72
Programming Challenge Reaction time measurement
Program your PLC to measure a persons reaction time in flipping a switch. The PLC should energize
a light (or simply one of the discrete output indicating LEDs) telling the user when to flip an input switch,
and then the PLC will measure how long it takes for the person to react to the light and flip the switch.
How can you program the PLC to turn on the signaling light in a way that the person being tested
cannot anticipate it?
How must you configure the reaction time timer to count in units appropriate for this very quick time
delay?
What type of timer instruction is best suited for the reaction time timer, a retentive or a non-retentive
timer?
file i02266
92
Question 73
Programming Challenge Alarm event latch and history timers
A normally-closed (NC) high-pressure sensing switch monitors fluid pressure in a chemical reactor vessel,
opening its contacts if the pressure exceeds the trip point. This triggers an alarm lamp to energize in the
control room, and this lamp will latch in the on state until an operator resets it, even if the high-pressure
condition clears and goes back to normal. This is so the operators will know a high-pressure event occurred
even if they were not in the control room to see it when it happened. A PLC implements this latching function
using retentive (set and reset) coils:
Alarm_output
Pressure_switch_high
S
Reset_switch
Alarm_output
R
The system works well, but the operators want more. If they arrive at the control room to see the alarm
light on (latched), they want to know how long the high-pressure condition lasted and also how long its
been since the reactor pressure returned to normal.
Add instructions to this PLC program to provide the desired timing functionality.
Explain why the PLC program contact for the high-pressure switch is normally-closed, and how this
information alone would be enough for us to determine that the high-pressure switch itself had NC
contacts.
What type of timer instruction is best suited for the event duration timer, a retentive or a non-retentive
timer?
How could a counter instruction be added to this PLC program to provide useful functionality?
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93
Question 74
Question 75
Question 76
Question 77
Question 78
Question 79
Question 80
94
Question 81
Suppose we have an Allen-Bradley MicroLogix 1000 PLC connected to a temperature switch and a flow
switch:
Trip = 15 GPM
24V
DC
COM
I/0
I/1
I/2
I/3
DC
COM
I/4
I/5
DC OUT
Power
Trip = 200 oF
Run
Fault
Force
85-264 VAC
L1
L2/N
VAC
VDC
O/0
VAC
VDC
O/1
VAC
VDC
O/2
VAC
VDC
O/3
120 VAC
We wish for the lamp to come on when the temperature is below 200 degrees F and when the flow rate
is below 15 GPM. Write a RLL program for the PLC (complete with correct address labels for each of the
virtual contacts) to fulfill this function:
O:0
file i02375
95
Question 82
Analyze this Allen-Bradley PLC program and explain what it is supposed to do:
Motor
O:1
CTU
Count Up
Counter
CU
C5:2
Preset
17
Accum
Start
I:0
Stop
I:0
C5:2
DN
DN
Motor
O:1
0
Motor
O:1
0
Reset
I:0
C5:2
RES
file i02377
96
Question 83
In relay ladder logic (RLL) programming, it is considered bad practice to have multiple instances of an
identical (standard) relay coil in a program:
Timer_01
Level_low
Pump_run
Switch_hand
OL_contact
Sump_wet
...
...
Identical coils!
Pump_run
Explain why this is considered poor practice in PLC programming. Next, determine the status of the
Pump run output channel given the following bit states:
Timer 01 = 1
Level low = 1
Switch hand = 0
OL contact = 0
Sump wet = 0
file i02376
97
Question 84
Sketch the wires necessary to connect two pressure switches and two relay coils to the following AllenBradley MicroLogix 1000 PLC (model 1761-L10BWA, with 6 discrete DC inputs either sourcing or sinking,
and 4 discrete relay contact outputs). Be sure to wire the two switches so they source current to the PLCs
inputs (the low-pressure switch to I/2 and the high-pressure switch to I/5, normally-open contacts on both)
and wire the relay coils so the PLC sources current to them (O/0 and O/1):
Com
NC
24V
NO
DC
COM
I/0
I/1
I/2
I/3
DC
COM
I/4
I/5
DC OUT
Power
PSH
Run
Fault
Force
Com
NC
NO
85-264 VAC
L1
L2/N
VAC
VDC
O/0
VAC
VDC
O/1
VAC
VDC
PSL
file i02379
98
O/2
VAC
VDC
O/3
Question 85
Analyze this Siemens S7-200 PLC program (for controlling a motor) and explain what it is supposed to
do:
T6
M0.2
+50
Start
I0.4
IN
TON
PT
100 ms
Stop
I0.5
M0.2
M0.2
T6
Low speed
Q0.0
M0.2
T6
High speed
Q0.1
M0.2
Include an explanation of the motor contactor wiring, based on an analysis of the PLC program.
file i02255
99
Question 86
Calculate all voltages, currents, and total power in this balanced Y-Y system:
Source
Load
7
27
580
Eline =
Iline =
Ephase(source) =
Iphase(source) =
Ephase(load) =
Iphase(load) =
Ptotal =
file i02421
100
Question 87
The following circuit senses temperature using a thermistor with a positive temperature coefficient (i.e.
resistance increases as temperature increases):
10 VDC
1k
Cable 1
(80 mA current-limited)
Cable 2
Voltmeter
+To
1k
(at room temp)
First, determine the voltage we should read at the voltmeter with the thermistor at or near room
temperature.
Next, identify the likelihood of each specified fault for this circuit, supposing the voltmeter registers 0
volts with the thermistor at room temperature, and a voltage measurement taken between terminals D and
F registers 10 volts. Consider each fault one at a time (i.e. no multiple faults), determining whether or not
each fault could independently account for all measurements and symptoms in this circuit.
Fault
Thermistor failed open
Fixed resistor failed open
Wire A-D failed open
Wire F-J failed open
Wire E-H failed open
Thermistor failed shorted
Fixed resistor failed shorted
Short between terminals G-H
Short between terminals E-F
Short between terminals D-E
file i02924
101
Possible
Impossible
Question 88
Identify each of the specified voltages in the following circuit, with reference to ground. The subscripts
refer to the specific test points (where the red test lead of the voltmeter touches the circuit):
3 k
C
18 V
5 k
D
1 k
For example, VB means the voltage indicated by a voltmeter with the red test lead touching point B
and the black test lead touching ground.
VA =
VB =
VC =
VD =
VE =
file i02525
102
Question 89
Suppose a single-phase AC load draws a current of 16.5 amps at 237 volts (RMS). If the measured power
factor of this load is 0.85, calculate the true power (P ) dissipated by the load as well as its apparent power
(S). Be sure to include the proper unit of measurement (e.g. VA, VAR, or W) with each answer!
P =
S=
file i02422
103
Question 90
In this 480 volt AC induction motor control circuit (sometimes referred to as a bucket), a three-pole
relay (typically called a contactor) is used to switch power on and off to the motor. The contactor itself is
controlled by a smaller switch, which receives 120 volts AC from a step-down transformer to energize the
contactors magnetic coil. Although this motor control circuit used to work just fine, today the motor refuses
to start.
To 3- , 480 volt power source
L1
L2
L3
L1
L2
L3
Schematic diagram
Fuses
Transformer
X2
H1
H3
H2
H4
X1
Contactor
H1
H3
H2
H4
Transformer
Contactor
A1
X1
A2
A2
motor
Switch
T1 T2
Motor
X2
A1
T3
Switch
T1 T2 T3
Using your AC voltmeter, you measure 476 volts AC between L1 and L2, 477 volts AC between L2 and
L3, and 475 volts AC between L1 and L3. You also measure 477 volts between transformer terminals H1
and H4. With the switch in the on position, you measure 0.5 volts AC between terminals X1 and X2 on
the transformer. From this information, identify the following:
Two components or wires in the circuit that you know cannot be failed either open or shorted, besides
the 480 volt AC source which is obviously operational.
Two different component or wire failures in the circuit, either one of which could account for the problem
and all measured values, and the types of failures they would be (either open or shorted).
file i03174
104
Question 91
Lab Exercise introduction
Your teams task is to construct a system controlled by a PLC. The system you choose to build shall
use (at minimum) discrete input(s), discrete output(s), and either counter or timer functions. This system
will be expanded during the next course to include a three-pole contactor, so designing the system with this
in mind (or simply installing the contactor in this exercise) will save you time later. Project ideas include:
Air compressor control, with high and low air pressure switches
Water sump pump control, with high and low water level switches
Other alternatives? Must be pre-approved by instructor!
In addition to functioning properly, the PLC program must be fully documented and edited for
cleanliness and good programming form. This includes labels (aliases, or symbolic names) for all inputs
and outputs, and comments for each and every rung of logic explaining the rungs functions. Although
there will be only one program submitted by each team, completion of this objective is individual, with each
student explaining (at least) a part of the PLC program to the instructor.
Objective completion table:
Performance objective
Prototype sketch (before building the system!)
Complete I/O list
Prototype PLC program (before programming!)
Final wiring diagram and system inspection
Demonstration of working system
Final PLC program inspection
Lab question: Selection/testing
Lab question: Commissioning
Lab question: Mental math
Lab question: Diagnostics
Grading
mastery
mastery
mastery
mastery
mastery
mastery
proportional
proportional
proportional
proportional
Team
The only proportional scoring in this activity are the lab questions, which are answered by each
student individually in a private session between the instructor and the team. A listing of potential lab
questions are shown at the end of this worksheet question. The lab questions are intended to guide your
labwork as much as they are intended to measure your comprehension, and as such the instructor may ask
these questions of your team day by day, rather than all at once (on a single day).
It is essential that your team plans ahead what to accomplish each day. A short (10
minute) team meeting at the beginning of each lab session is a good way to do this, reviewing
whats already been done, whats left to do, and what assessments you should be ready for.
There is a lot of work involved with building, documenting, and troubleshooting these working
instrument systems!
As you and your team work on this system, you will invariably encounter problems. You should always
attempt to solve these problems as a team before requesting instructor assistance. If you still require
instructor assistance, write your teams color on the lab whiteboard with a brief description of what you
need help on. The instructor will meet with each team in order they appear on the whiteboard to address
these problems.
105
Lab Exercise planning the wiring

One of the most common problems students encounter when building any working system, whether it be
a circuit on a solderless breadboard or an instrument loop spanning an entire room, is properly connecting and
configuring all components. An unfortunate tendency among most students is to simply start connecting
parts together, essentially designing the system as they go. This usually leads to improperly-connected
components and non-functioning systems, sometimes with the result of destroying components due to those
improper connections!
An alternative approach is to plan ahead by designing the system before constructing it. This is easily
done by sketching a diagram showing how all the components should interconnect, then analyzing that
diagram and making changes before connecting anything together. When done as a team, this step ensures
everyone is aware of how the system should work, and how it should go together. The resulting prototype
diagram need not be complex in detail, but it should be detailed enough for anyone to see which component
terminals (and ports) connect to terminals and ports of other devices in the system. For example, your
teams prototype sketch should be clear enough to determine all DC electrical components will have the
correct polarities. If your proposed system contains a significant amount of plumbing (pipes and tubes),
your prototype sketch should show all those connections as well.
Your first step should be selecting a PLC to use for this project. The PLC needs to be one with modular
(add-on) I/O cards to provide sufficient complexity for the project. Monolithic brick PLCs (with no add-on
I/O modules) are not acceptable for this project. An Allen-Bradley SLC 500 PLC would be a good choice,
as well as a Siemens S7 series or an AutomationDirect Productivity 3000.
You will also need to select appropriate field devices (switches, pumps, etc.) for your project. You are
free to use the field devices left over from the relay-based motor control lab if you prefer.
The next step should be finding appropriate documentation for your PLC. All PLC manufacturers
provide manuals and datasheets for their products online. Use this documentation to identify how to properly
wire, power, and program your teams PLC.
PLC equipment manuals always provide sample diagrams showing how external components may
connect to the I/O points. Feel free to use these sample diagrams as templates for your prototype sketch.
This is the most challenging portion of your wiring, so be sure to work with your teammates to get this right!
Your teams prototype sketch is so important that the instructor will demand you provide this plan
before any construction on your teams working system begins. Any team found constructing their system
without a verified plan will be ordered to cease construction and not resume until a prototype plan has been
drafted and approved! Each member on the team should have ready access to this plan (ideally possessing
their own copy of the plan) throughout the construction process. Prototype design sketching is a skill and
a habit you should cultivate in school and take with you in your new career.
Planning a functioning system should take no more than a couple of hours if the
team is working efficiently, and will save you hours of frustration (and possible component
destruction!).
106
Lab Exercise developing an I/O list

It is a good idea when programming any computer system to first identify all the input and output
signals to the system, as well as internal variables if possible, before commencing on the development of the
program itself. In order to reinforce this practice, your team will be required to develop a complete list of
all input and output points on your proposed system along with any tagnames (also known as symbols or
nicknames) identifying the function of each.
Once this list is complete and you are ready to begin developing the PLC program, you can enter all
the tagnames and define the I/O points as your very first programming step. With this data in place, the
writing of your program will be made easier because each I/O tag you reference will already be defined and
labeled, reminding you of their functions within the system.
Here is a sample I/O list for a motor control PLC program:
Hardware I/O terminal
Card 1, terminal IN0
I/O type
24 VDC discrete input
Tagname
START PB
STOP PB
E STOP
4-20 mA analog input
MTR TEMP
Card 3, terminal OUT0
120 VAC discrete output
CONTACTOR
107
Notes
Black pushbutton,
momentary NO contacts
Red pushbutton,
momentary NC contacts
Red pushbutton,
latching NC contacts
Current signal scaled
0 to 150 deg F
To terminal A1
Lab Exercise wiring the system

The Instrumentation lab is set up to facilitate the construction of working systems, with over a
dozen junction boxes, pre-pulled signal cables, and racks set up with 2-inch vertical pipes for mounting
instruments. The only wires you should need to install to build a working system are those connecting the
field instrument to the nearest junction box, and then small jumper cables connecting different pre-installed
cables together within intermediate junction boxes.
Your teams PLC must be installed in a suitable electrical enclosure, with AC power fed to it through
a fuse or circuit breaker (on the hot conductor only), and firmly grounded (the ground conductor of the
power cord securely fastened to the metal frame of the enclosure and the PLC chassis).
All I/O wiring should be neatly loomed together and/or run through wire duct (Panduit). Power to
I/O cards must be routed through their own fuses so that I/O power may be disconnected independently of
power to the PLC processor and rack.
Common mistakes:
Neglecting to consult the manufacturers documentation for field instruments (e.g. how to wire them,
how to calibrate them).
Proceeding with wiring before creating an initial sketch of the circuitry and checking that sketch for
errors.
Mounting the field instrument(s) in awkward positions, making it difficult to reach connection terminals
or to remove covers when installed.
Failing to tug on each and every wire where it terminates to ensure a mechanically sound connection.
Students working on portions of the system in isolation, not sharing with their teammates what they
did and how. It is important that the whole team learns all aspects of their system!
Building a functioning system should take no more than one full lab session (3 hours) if
all components are readily available and the team is working efficiently!
108
Lab Exercise programming the system

Like wiring a control system, programming one is best done with thoughtful planning rather than a
design-as-you-build approach. Each team will work with the instructor to develop a prototype PLC
program, usually on a whiteboard or on paper. Your prototype program should completely address the
following points:
Identify
Identify
Identify
Identify
Identify
all
all
all
all
all
inputs to the PLC, giving each one a sensible tagname

signal outputs from the PLC, giving each one a sensible tagname
major program functions (i.e. What must this program do?)
internal variables necessary for these functions, giving each one a sensible tagname
system variables necessary for these functions (e.g. real-time clock/calendar variables)
The importance of identifying and naming all relevant variables is paramount to clean programming.
This is especially true when an HMI (Human-Machine Interface) is to be connected to the PLC, and all
relevant variables must be named there as well.
A reasonable approach to developing a robust program prototype is to create your prototype in your
own personal (brick) PLC, de-bugging it there with all the switches in place to simulate input signals.
Even if your personal PLC is a different model (or manufacture) than the project PLC, this is a very helpful
exercise. Furthermore, it allows you to continue program development outside of school when you do not
have access to the project PLC.
Only after a prototype program is developed should you begin programming the project PLC. I
recommend the following steps:
Establish communications between PLC and personal computer (PC)

Connect all I/O cards (modules) to the PLC and get them recognized by the processor
Assign tagnames to all relevant variables, beginning with I/O points
Enter a simplified version of the program, running to check for bugs
Diagnose any program problems
Add complexity to the program (e.g. additional features) and run to check for bugs
Repeat last two steps as often as necessary
Add comments to each and every line of the program, explaining how it functions
The final program should be well-documented, clean, and as simple as possible. All members of the
team should have a hand in designing the program, and everyone must thoroughly understand how it works.
Common mistakes:
Waiting too long after writing the program code to insert comments. This is best done immediately,
while everything makes sense and is fresh in your memory!
Insufficient commenting only makes sense to the person who did the programming
Students working on portions of the program in isolation, not sharing with their teammates what they
did and how. It is important that the whole team learns all aspects of their system!
109
Lab Exercise documenting the system

Each student must sketch their own wiring diagram for their teams system, following industry-standard
conventions. Sample diagrams for input and output wiring are shown in the next question in this worksheet.
These wiring diagrams must be comprehensive and detailed, showing every connection, every cable, every
terminal block, etc. The principle to keep in mind here is to make the wiring diagram so complete and
unambiguous that anyone can follow it to see what connects to what, even someone unfamiliar with industrial
instrumentation. In industry, control systems are often constructed by contract personnel with limited
understanding of how the system is supposed to function. The associated diagrams they follow must be so
complete that they will be able to connect everything properly without necessarily understanding how it is
supposed to work.
When your entire team is finished drafting your individual wiring diagrams, call the instructor to do
an inspection of the system. Here, the instructor will have students take turns going through the entire
system, with the other students checking their diagrams for errors and omissions along the way. During this
time the instructor will also inspect the quality of the installation, identifying problems such as frayed wires,
improperly crimped terminals, poor cable routing, missing labels, lack of wire duct covers, etc. The team
must correct all identified errors in order to receive credit for their system.
After successfully passing the inspection, each team member needs to place their wiring diagram in the
diagram holder located in the middle of the lab behind the main control panel. When it comes time to
troubleshoot another teams system, this is where you will go to find a wiring diagram for that system!
Common mistakes:
Forgetting to label all signal wires (see example wiring diagrams).

Forgetting to label all field instruments with their own tag names (e.g. PSL-83).
Forgetting to note all wire colors.
Forgetting to put your name on the wiring diagram!
Basing your diagram off of a team-mates diagram, rather than closely inspecting the system for yourself.
Creating and inspecting accurate wiring diagrams should take no more than one full lab
session (3 hours) if the team is working efficiently!
110
Lab questions (reviewed between instructor and student team in a private session)
Selection and Initial Testing

Explain what is meant by the term sinking with regard to a PLC input card (DC)
Explain what is meant by the term sourcing with regard to a PLC input card (DC)
Explain what is meant by the term sinking with regard to a PLC output card (DC)
Explain what is meant by the term sourcing with regard to a PLC output card (DC)
Explain what a TRIAC PLC output card is, and how it differs from DC output cards
Explain what a relay PLC output card is, and how it differs from sourcing or sinking DC output cards
Commissioning and Documentation

Demonstrate how to isolate potentially hazardous energy in your system (lock-out, tag-out) and also
how to safely verify the energy has been isolated prior to commencing work on the system
Demonstrate how to insert text comments for a rung in a PLC program
Demonstrate how to insert text comments for a single bit (contact or coil) in a PLC program
Demonstrate how to switch between online and offline modes in the PLC programming software
Demonstrate how to transfer a program from the PLC to the programming computer (PC)
Demonstrate how to transfer a program from the programming computer (PC) to the PLC
Mental math (no calculator allowed!)

Convert a binary number into decimal
Convert a binary number into hexadecimal
Convert a decimal number into binary
Convert a hexadecimal number into binary
Convert a hexadecimal number into decimal
Diagnostics
Virtual Troubleshooting referencing their systems diagram(s), students propose diagnostic tests
(e.g. ask the instructor what a meter would measure when connected between specified points; ask the
instructor how the system responds if test points are jumpered) while the instructor replies according
to how the system would behave if it were faulted. Students try to determine the nature and location
of the fault based on the results of their own diagnostic tests.
Demonstrate how to verify a sinking discrete inputs status using a voltmeter
Demonstrate how to verify a sourcing discrete inputs status using a voltmeter
Demonstrate how to verify a sinking discrete outputs status using a voltmeter
Demonstrate how to verify a sourcing discrete outputs status using a voltmeter
Describe how to replace a failed I/O card in a PLC, assuming that card is hot-swappable
Describe how to replace a failed I/O card in a PLC, assuming that card is not hot-swappable
Identify status of a discrete input field device (e.g. switch) by examining the status of its corresponding
contact instruction in the PLC program (colored versus uncolored)
111
Wiring diagram requirements

Wiring diagram
Proper symbols and designations used for all components.
Relay coil and contacts properly named.
Text descriptions
Each instrument documented below (tag number, description, etc.).
Calibration (input and output ranges) given for each instrument, as applicable.
Connection points
All terminal blocks properly labeled.
All terminals shown in proper order on diagram.
All I/O cards and points fully labeled (complete with program addresses).
All wires are numbered.
All electrically-common points in the circuit shall bear the same wire number.
All wire colors shown next to each terminal.
Cables and tubes

Multi-pair cables or pneumatic tube bundles going between junction boxes and/or panels need to have
unique numbers (e.g. Cable 10) as well as numbers for each pair (e.g. Pair 1, Pair 2, etc.).
Energy sources
All power source intensities labeled (e.g. 24 VDC, 120 VAC, 20 PSI)
All shutoff points labeled (e.g. Breaker #5, Valve #7)
file i03655
Question 92
Wiring diagram requirements
Perhaps the most important rule to follow when drafting a wiring diagram is your diagram should be
complete and detailed enough that even someone who is not a technician could understand where every wire
should connect in the system!
Field device symbols
Proper electrical symbols and designations used for all field devices.
Optional: Trip settings written next to each process switch.
PLC I/O cards
All terminals labeled, even if unused in your system.
Model number, I/O type, and PLC slot number should be shown for each and every card.
Connection points
All terminals properly labeled.
All terminal blocks properly labeled.
All junction (field) boxes shown as distinct sections of the loop diagram, and properly labeled.
All control panels shown as distinct sections of the loop diagram, and properly labeled.
All wire colors shown next to each terminal.
All terminals on devices labeled as they appear on the device (so that anyone reading the diagram will
know which device terminal each wire goes to).
Energy sources
All power source intensities labeled (e.g. 24 VDC, 120 VAC, 480 VAC 3-phase)
All shutoff points labeled (e.g. Breaker #5, Valve #7)
112
PB-5
Reset
Trips @ 35 PSI rising
PSH-10
Field
NO
COM
NC
Blk
Red
Blk
Red
Cable PB-5
Cable PSH-10
Blk
Red
Blk
Red
12
11
TB-43
Grn
Gry
Org
Field junction box JB-28
Blu
Blu
Blu
Blu
Blu
Blu
Blu
Blu
113
Gry
Red
Red
24VDC
Power supply
COM
L2
L1
Slot 4
120 VAC
Bkr #3
24VDC sinking
1746-IB8
Discrete input
Red
Blk
COM
IN7
IN6
IN5
IN4
IN3
IN2
IN1
IN0
Red
(1 amp each)
Fuse block
TB-7
PLC cabinet
Sample Input Wiring Diagram
PAH-20
Alarm lamp
Trip solenoid
PY-3
Field
Blk
Red
Cable PAH-20
Blk
Red
Blk
Blk
TB-44
Red
Red
Cable PY-3
Wht
Blk
Blk
Field junction box JB-28
Wht
Blk
Blk
Wht
Blu
Blu
Blu
Blu
TB-11
file i01880
114
Blk
Blk
Blk
Blk
(1 amp each)
Fuse block
OUT7
OUT6
OUT5
OUT4
VAC2
OUT3
OUT2
OUT1
OUT0
VAC1
Wht
Blk
120 VAC
Bkr #1
Slot 1
100-240 VAC TRIAC
1746-OA8
Discrete output
PLC cabinet
Sample Output Wiring Diagram
Question 93
Connect an ice cube relay to one of the outputs on a PLC, so that the PLC can control the energization
of the relay. All electrical connections must be made using a terminal strip (no twisted wires, crimp splices,
wire nuts, spring clips, or alligator clips permitted). Program this PLC to implement a motor start/stop
(latching) control function. In order to ensure your program has not been pre-written in your computer prior
to this assessment, you will be asked to sketch a correct ladder-diagram PLC program on paper to implement
this function prior to using a computer.
You must connect a commutating diode in parallel with the relays coil to prevent the phenomenon
known as inductive kickback, which may otherwise damage the transistor output on a PLC. Note that
incorrectly connecting this diode will present a short-circuit to the PLC, so you must get it right!
This exercise tests your ability to properly interpret the pinout of an electromechanical relay, properly
wire a PLC output channel to control a relays coil, properly polarize a commutating diode to prevent
inductive kickback from damaging the PLC output, and use a terminal strip to organize all electrical
connections. It also tests your ability to program motor start/stop logic using either a seal-in contact
or latching (retentive) coil instructions.
PLC
24V
DC
COM
I/0
I/1
I/2
I/3
Relay socket
DC
COM
I/4
Terminal strip
I/5
DC OUT
Relay
Power
Run
Fault
Force
Diode
85-264 VAC
L1
L2/N
VAC
VDC
O/0
VAC
VDC
O/1
VAC
VDC
O/2
VAC
VDC
O/3
The following components and materials will be available to you during the exam: assorted ice cube
relays with DC-rated coils and matching sockets ; terminal strips ; 1N400X rectifying diodes ; lengths
of hook-up wire. You will be expected to supply your own screwdrivers and multimeter for assembling and
testing the circuit at your desk.
Start switch to input:
PLC program (instructor chooses):
Stop switch to input:

Seal-in contact
file i00127
115
Relay to output:
Retentive coils
Answers
Answer 1
Answer 2
Input register, byte 1, bit 4: I1.4
Output register, byte 0, bit 2: Q0.2
Variable memory double word, starting at byte 105: VD105 (a double-word consisting of 4 bytes, or 32
bits)
Answer 3
Input file, element 1, bit 4: I:1/4
Output file, element 0, bit 2: O:0/2
Timer 6 accumulator word: T4:6.ACC
Answer 4
For the Allen-Bradley MicroLogix example, the lamp will energize only when switch 0 is turned off and
switch 1 is turned on.
For the Siemens S7-200 example, the lamp will energize when switch 0 is turned on or if switch 1 is
turned off, or both conditions occur simultaneously.
For the Koyo example, the lamp will energize according to the Exclusive-OR function with switch 1 and
switch 2. The lamp energizes when switch 1 is on and switch 2 is off, or when switch 1 is off and switch 2 is
on.
Answer 5
Answer 6
Answer 7
Answer 8
Answer 9
116
Answer 10
Demonstration program showing some basic bit instructions in an Allen-Bradley MicroLogix
PLC:
When the switch connected to input 0 is turned on, the input bit I:0/0 goes from 0 to 1, and this contact becomes colored
on my laptop PCs screen. That color is sent to the coil instruction, where it turns on output bit O:0/1. This makes output
channel 1 turn on, energizing the light bulb wired to that output. When I turn off input switch 0, the contact un-colors and
so does the output coil O:0/1. This program rung makes output O:0/1 be the same state as input I:0/0.
I:0/0
O:0/1
When the same switch on input 0 is turned on, the input bit I:0/0 goes from 0 to 1, and this contact becomes un-colored.
This makes the output bit O:0/2 turn off, so that O:0/2 is always the opposite state of I:0/0.
I:0/0
O:0/2
Placing these two contact instruction in "series" with each other makes it so the coil only gets colored if both of the
contacts become colored. O:0/3 turns on only if switch 4 is on and switch 5 is off.
I:0/4
I:0/5
O:0/3
117
Demonstration program showing an up counter instruction in an Allen-Bradley MicroLogix

PLC:
The CTU instruction is a counter that counts in the "up" direction when its input is toggled. When the "Preset" count value
reached, the "Done" bit (DN) activates.
I:0/0
CTU
Count Up
Counter
CU
C5:0
Preset
12
Accum
DN
When the counter C5:0 reaches the "done" condition, the contact C5:0/DN becomes colored, passing color to the coil
O:0/0 to turn on a light bulb connected to output 0.
O:0/0
C5:0/DN
Allen-Bradley counter instructions can only be reset by external commands, in this case a special coil instruction sharing
the same address as the counter instruction (C5:0). Activating the I:0/1 input causes the RES coil to become colored,
which then resets the CTU instructions "Accumulated" value back to zero.
C5:0
I:0/1
RES
118
Demonstration program showing an on-delay timer instruction in an Allen-Bradley MicroLogix

PLC:
The TON instruction is a timer. Its "Accum" value starts at 0 and counts up (1...2...3...4...) whenever the input contact is
colored. When the "Accum" value reaches 5, the DN coil becomes colored. The "Time Base" value of 1.0 means that
each count of the "Accum" is 1.0 seconds worth of time. If I make the "Time Base" something different, the timer will
count faster.
I:0/0
TON
Timer On Delay
Timer
Time Base
Preset
EN
T4:0
DN
1.0
5
Accum
When the timer T4:0 reaches the "done" condition, the contact T4:0/DN becomes colored, passing color to the coil O:0/0
to turn on a light bulb connected to output 0.
T4:0/DN
O:0/0
Answer 11
Answer 12
Bit statuses:
I:0/0 = 1
I:0/1 = 0
I:0/2 = 1
Answer 13
Bit statuses:
I0.2 = 1
I1.1 = 0
Answer 14
L > 3 feet, P > 37 PSI, and T < 88o F
119
Answer 15
I0.2
I0.5
I1.1
Q0.1
Q0.6
=
=
=
=
=
0
1
0
1
0
Answer 16
Switch statuses:
Switch A = released
Switch B = pressed
Switch C = released
The lamp will be energized.
Answer 17
All currents shown using

conventional flow notation
Answer 18
Mtr
120
Answer 19
Circuit 1
This will work!
Circuit 2
Load
Circuit 3
This will work!
Load
This circuit is bad
Circuit 4
This circuit is bad
Load
Load
121
Answer 20
Circuit 1
This circuit is bad
Circuit 2
This will work!
Load
Load
Circuit 3
This circuit is bad
Circuit 4
This will work!
Load
Load
122
Answer 21
Demonstration program showing some basic bit instructions in an Allen-Bradley MicroLogix
PLC:
When the switch connected to input 0 is turned on, the input bit I:0/0 goes from 0 to 1, and this contact becomes colored
on my laptop PCs screen. That color is sent to the coil instruction, where it turns on output bit O:0/1. This makes output
channel 1 turn on, energizing the light bulb wired to that output. When I turn off input switch 0, the contact un-colors and
so does the output coil O:0/1. This program rung makes output O:0/1 be the same state as input I:0/0.
I:0/0
O:0/1
When the same switch on input 0 is turned on, the input bit I:0/0 goes from 0 to 1, and this contact becomes un-colored.
This makes the output bit O:0/2 turn off, so that O:0/2 is always the opposite state of I:0/0.
I:0/0
O:0/2
Placing these two contact instruction in "series" with each other makes it so the coil only gets colored if both of the
contacts become colored. O:0/3 turns on only if switch 4 is on and switch 5 is off.
I:0/4
I:0/5
O:0/3
Note: your own demonstration program should contain some retentive coil instruction as well, in order
for you to be able to observe what these instructions do and how their operation differs from that of regular
coil instructions!
Answer 22
X1
X2
X2
X1
X3
Y1 = 1
123
Y1
Answer 23
I0.7
I1.1
Q0.1
Q0.3
=
=
=
=
0
1
0
1
Answer 24
Neither output will activate to energize either lamp.
Answer 25
Neither output will activate, resulting in both lamps de-energized.
Answer 26
Necessary switch statuses:
Switch A = released or Switch B = pressed
Switch C = pressed
Answer 27
Some possible problems to account for what we are seeing:
Overload contact tripped (open)

Wire connecting OL contact to I:0/3 failed open
Wire connecting Stop switch to OL contact failed open
Input channel I:0/3 defective on the PLC
Answer 28
Answer 29
Answer 30
Answer 31
Bit statuses:
I:0/0 = 0
I:0/1 = 0
I:0/3 = 1
Answer 32
Bit statuses:
I0.2 = 0
I1.1 = 0
Answer 33
Bit statuses:
I:1/3 = 1
I:1/5 = 0
124
Answer 34
Answer 35
Remember that a bipolar transistor requires current through the base-emitter junction in order to turn
on, and thereby let load current pass between collector and emitter.
Circuit 1 This circuit will work!
Circuit 4
This circuit is bad
Circuit 2
This circuit is bad
Circuit 5 This circuit will work!
Circuit 3
This circuit is bad
Circuit 6
This circuit is bad
Circuit #3 is different from the other bad circuits. While the other bad circuits lamps do not energize
at all, the lamp in circuit #3 energizes weakly when the pushbutton switch is open (not actuated). This is
due to the fact that lamp current will naturally pass through the base-collector PN junction as though it
were a simple diode, regardless of the switchs state.
Answer 36
Circuits 3, 5, and 6 are flawed, because the emitter-base junctions of their transistors are overpowered
every time the switch closes.
Hint: draw the respective paths of switch and lamp current for each circuit!
125
Answer 37
Contact
points
126
Answer 38
+V
+V
+V
Load
NPN
to transistor

from transistor
Transistor sourcing
current to load
Transistor sinking
current from load
PNP
Load
Follow-up question: explain why neither of the following transistor circuits will work. When the
pushbutton switch is actuated, the load remains de-energized:
+V
+V
+V
Load
Load
127
Answer 39
+V
+V
from transistor
+V
Load
PNP
Transistor sinking
current from load
Transistor sourcing
current to load
NPN
Load

to transistor
Follow-up question: explain why neither of the following transistor circuits will work. When the
pushbutton switch is actuated, the load remains de-energized:
+V
+V
+V
Load
Load
Answer 40
Answer 41
Answer 42
Switch statuses:
Pressure switch = less than 30 PSI
Temperature switch = cooler than 150 deg F
Level switch = greater than 4 inches
The lamp will be de-energized.
Answer 43
This PLC program allows the motor to start up 7 times. If you thought the correct number of start-ups
was eight, consider the fact that the counters output bit (CT1) gets set when the counters current value
equals the SetPoint value, not when it exceeds the SetPoint value.
128
Answer 44
Answer 45
Answer 46
Answer 47
Hint: the P contact instructions are positive transition instructions, activating whenever their
respective bits transition from 0 to 1, but returning to an inactive state whenever the bit value holds at
either 0 or 1.
Answer 48
Answer 49
Answer 50
This is one possible fix for the problem:
PLC program
IN_switch_Start
OUT_valve
IN_switch_Stop
OUT_valve
IN_oil_press
Answer 51
Hint: the contact address C5:0.ACC/13 refers to the 13th bit of the counters accumulator register,
which is a 16-bit binary number. The 15th bit would be the MSB, while the 0th bit is the LSB.
Answer 52
Each wasteful program uses an output bit as the intermediary bit between the AND and NOT functions
when there is no need.
Answer 53
Answer 54
Temperature = below 135 o F
Level = above 23 inches
Pressure = below 17 PSI
129
Answer 55
If the lamp is energized, we know that the top two virtual contacts (X1 and X2) are colored, and/or the
bottom two virtual contacts (X3 and X2) are colored.
For the top two virtual contacts to be colored, X1 must be 0 and X2 must be 1. This equates to a
pressure less than 32 PSI and a level less than 10 inches.
For the bottom two virtual contacts to be colored, X3 must be 1 and X2 must be 0. This equates to a
temperature greater than 99 o F and a level greater than 10 inches.
Answer 56
Answer 57
Answer 58
Answer 59
Answer 60
Answer 61
Output O:3/4 will activate to energize lamp Y, but the other output (and lamp) will remain off.
Answer 62
Answer 63
Answer 64
Answer 65
The liquid level must exceed 5 feet in height for at least 25 seconds and the selector switch must be in
the right position in order for the pump to turn on.
Answer 66
Although starting all three conveyor motors simultaneously would be very simple, it would be a bad
thing to do because of the inrush current of all three motors placing undue load on the power system.
Answer 67
Necessary conditions to start the pump:
Pressure must be less than 20 PSI for at least 17 seconds
Selector switch must be in the left position
Pushbutton must be released (unpressed) or level more than 3 feet
Answer 68
Input switch electrical normal statuses:
Start = NO
Stop = NC
PSL = NC
PSH = NC
Reset = NO
130
Answer 69
Here is a schematic diagram to help you formulate an answer:
PLC discrete output
Motor drive discrete input

DI0
Program
Vdd
Vdd
Com
Com
Answer 70
Answer 71
Answer 72
Answer 73
Answer 74
Answer 75
Answer 76
Answer 77
Answer 78
Answer 79
Answer 80
Answer 81
This is a graded question no answers or hints given!
Answer 82
Answer 83
Answer 84
Answer 85
131
Answer 86
Answer 87
Answer 88
Answer 89
Answer 90
Answer 91
Answer 92
Your loop diagram will be validated when the instructor inspects the loop with you and the rest of your
team.
Answer 93
132

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Question 4

line of Allen-Bradley PLCs program so similarly to the MicroLogix line.

LED (with dropping resistor)

Ladder-Diagram program written to PLC:

LED (with dropping resistor)

Ladder-Diagram program written to PLC:

LED (with dropping resistor)

Ladder-Diagram program written to PLC:

Suggestions for Socratic discussion

Discrete input module

Discrete input module

Discrete output module

Discrete output module

Suggestions for Socratic discussion

(discrete input) (discrete input) (discrete output)

This circuit does not work!

Suggestions for Socratic discussion

Suggestions for Socratic discussion

Suggestions for Socratic discussion

Bobs PLC program

Suggestions for Socratic discussion

(discrete input) (discrete input) (discrete output)

Switch sinking current

Switch sourcing current

Switch sinking current

Program (inside PLC)

Drive-over pressure switch

Suggestions for Socratic discussion

Real-world I/O wiring

Low oil pressure

Pulse signal (when pump is running)

Siemens Step 7 (S7)

Suggestions for Socratic discussion

120 VAC "line" power

(processor) (discrete output)

Rock from quarry

(processor) (discrete output)

(continued from previous page)

In particular, answer these following questions:

Suggestions for Socratic discussion

Forward blows air up

Reverse blows air down

To 3- , 480 volt power source

Lab Exercise planning the wiring

Lab Exercise developing an I/O list

Card 1, terminal IN1

24 VDC discrete input

Card 1, terminal IN2

24 VDC discrete input

Card 2, terminal IN0

4-20 mA analog input

Card 3, terminal OUT0

120 VAC discrete output

Lab Exercise wiring the system

Lab Exercise programming the system

inputs to the PLC, giving each one a sensible tagname

Establish communications between PLC and personal computer (PC)

Lab Exercise documenting the system

Forgetting to label all signal wires (see example wiring diagrams).