TUTORIAL 4 INDUSTRIAL CONTROL

1. Explain stages of Programmable Logic Controller (PLC) operation execution.

Stage 1: Check Input Status

First the PLC takes a look at each input to determine if it is on or off.
Stage 2: Execute Program
Next the PLC executes your program one instruction at a time.
Stage 3: Update Output Status
Finally, the PLC updates the status of the outputs. It updates the outputs based on which
inputs were on during the first step and the results of executing your program during the
second step.

2. Explain phases of Analog to Digital Converter (ADC) process in analog sensor measurement.

ADC consists of three (3) phases:

 Phase 1 (Sampling): converts the continuous signal into a series of discrete analog signals
at periodic intervals.
 Phase 2 (Quantization): each discrete analog is converted into one of a finite number of
(previously defined) discrete amplitude levels.
 Phase 3 (Encoding): discrete amplitude levels are converted into digital code.
 3. Voltage output range for an radar sensor is from 1 Volt to 5 Volt and connected to AI 2 MAD42
PLC module. Resolution setting of OMRON PLC is 8000. Predict and calculate item as below:

RADAR SENSOR

100 % (15 Meter) HIGH LEVEL

SWITCH

LIQUID STORAGE
TANK

LOW LEVEL
SWITCH
PUMP 1 L

0 % (0 Meter)
PUMP 2

TO
UTILITY PLANT

(i) Lower and upper range value (hex) setting at MAD42 PLC module.
Answer:
Lower range: 0000 hex Upper range: 1F40

(ii) Memory address location to configure answer at (i).

Answer:
Lower range: 20029 Upper range: 20030

(iii) Address location for AI 2 channel.

Answer:
Address AI2: 2006

(iv) Value (hex) read by AI 2 channel at 2 meter.

Answer:
2 / 15 meter = 1067 / 8000 decimal
AI2 = 42B (hex)

(v) Value (hex) read by AI 2 channel at 9 meter.

Answer:
9 / 15 meter = 4800 / 8000 decimal
AI2 = 12C0 (hex)
4. Resolution setting of OMRON PLC is 4000. Analog input range is from 1 Volt to 5 Volt. Predict
and explain the condition of the following PLC ladder diagram instruction when:

(i) Analog input channel used.

Answer:
Channel AI4

(ii) THREE (3) voltage input value at COMPARE instruction.

Answer:
2.5 Volt, 3.2 Volt and 4.8 Volt

(iii) Voltage input at 3.5 Volt, observe all output status and value (hex) at memory 2008.
Answer:
L1 & L2 (ON), L3 (OFF), 2006 (9C4 hex)

(iv) Voltage input at 2.4 Volt, observe all output status and value (hex) at memory 2008.
Answer:
L1, L2 & L3 (OFF), 2006 (578 hex)