Maintenance Training

Electrical and PLC

Raymond Maintenance Department

Raymond Corporation Maintenance Training Assessment

Safety
1. When should a power tool or extension cord be taken out of service for worn
or broken insulation?
a. After finishing the current job
b. Next time I need it
c. Immediately
d. None of the above

2. True / False Only perform work in which you are authorized.

3. True / False Electrical panels can be blocked if they are not used very often.

4. True / False It is ok to daisy chain power strips.

5. Junction boxes and pull boxes must have what in place?

a. Stickers
b. Wires
c. Covers
d. None of the above

6. True / False Power tools and extension cords must be inspected every other
time they are used.

7. Severity of the shock depends on _____?

a. Path of current through the body
b. Amount of current flowing through the body
c. Length of time the body is in the circuit.
d. All the above

8. What are some of the electrical hazard protections?

a. Insulation
b. Personal Protective Equipment
c. Safe Work Practices
d. All the above

9. What are 3 direct major electrical injuries?

a. Electrocution, Electrical Shock, Burns
b. Sprain, Strain, Pulled Muscle
c. Falls, Headaches, Backaches
d. All of the above

[Link] wiring should be considered ____?

Raymond Corporation Maintenance Training Assessment

a. De-energized
b. Safe
c. Energized
d. Someone else’s problem

Basic Electrical
1. What does this symbol indicate _____?

e. Resistor
f. Battery
g. Inductor
h. Capacitor

2. Voltage is _____?
a. Pressure from a power source that pushes electrons.
b. The number of electrons passing a given point in one second.
c. Resistance to flow of electrons.
d. Both A & C

3. True / False Resistors are passive circuit elements.

4. Inductance opposes _____?

a. Change in voltage
b. Change in current
c. Change in resistance
d. Change in power

5. The main purpose of capacitance is to _____?

a. Provide additional voltage
b. Provide additional current
c. Provide additional resistance
d. Provide additional energy

6. The current through a wire is 400A. If the voltage on the wire is 120V find the
resistance of the wire.
a. 300 Ω
b. 30 Ω
c. 3000 Ω
d. 0.3 Ω

7. Inductors can be found in _____?

a. Electric motors
Raymond Corporation Maintenance Training Assessment

b. Transformers
c. Relays
d. All the above

8. Power is _____?
a. Rate of doing work.
b. The number of electrons passing a given point in one second.
c. Measured in Watts.
d. Both A & C

9. The resistance of a wire is 30 Ω, and the voltage through the wire is 60V. Find
the current through the wire.
a. 2 A
b. 2.5 A
c. 0.2 A
d. 5 A

[Link] power of a motor is 300 W and the current supplied is 30 A. Find the
voltage across the motor.
a. 100 V
b. 1 V
c. 1000V
d. 10 V

Electrical Wiring
1. A kilowatt hour equals _____?
a. 100 watt hours
b. 10 watt hours
c. 1000 watt hours
d. 10000 watt hours

2. True / False Aluminum and Copper of the same size can carry the same
amount of current.

3. On which wire do you install a switch on in a 120 VAC circuit?

a. Neutral
b. Ground
c. Green
d. Hot

4. The technical term for the neutral wire is called _____?

a. Non-Grounded, Non-Current Carrying Conductor
b. Non-Grounded, Current Carrying Conductor
Raymond Corporation Maintenance Training Assessment

c. Grounded, Current Carrying Conductor

d. Grounding, Non-Current Carrying Conductor

5. How does a GFCI work?

a. Detects unequal current flow
b. Detects bad appliances
c. Detects low voltage
d. Detects unequal voltage

6. True / False An electrical circuit is a path through which electricity will flow.

7. In a typical 120 VAC circuit what are the wires usually referred to?
a. A, B, C
b. Hot, Ground, Hot
c. Hot, Neutral, Ground
d. Neutral, Neutral, Ground

8. A circuit breaker will “trip” when it detects _____?

a. Normal load
b. Overload
c. Under load
d. Balanced load

9. A double pole breaker inside a standard breaker panel attaches to _____?

a. 4 buss bars
b. 3 buss bars
c. 2 buss bars
d. 1 buss bar

[Link] electricity comes from an electrical meter it goes to what _____?

a. Light switch
b. Light bulb
c. Ground
d. Breaker Panel

Electrical Controls
1. A motor starter overload contact is wired in _____ with the coil?
a. Parallel
b. Diagonal
c. Series
d. Any of the above
2. What is the purpose of overload contacts _____?
a. To prevent the motor from overloading.
b. To allow the motor getting hot.
c. To save money on fuses.
d. To prevent the motor from restarting.
Raymond Corporation Maintenance Training Assessment

3. A meter reading of 0.00 Ω indicates _____?

a. Continuity
b. No voltage
c. Meter Defective
d. No Continuity

4. A Megohmmeter (Megger) tests what _____?

a. Insulation
b. Voltage
c. Amperage
d. All of the above

5. The following symbols indicates _____?

a. Single phase motor

b. DC Motor
c. Three phase motor
d. Indicating lamp

6. Continuity means a circuit has a _____?

a. Incomplete path
b. Open path
c. Complete path
d. Both B & C

7. True / False Mechanical limit switches are generally actuated by a moving

device on a machine.

8. True / False Category I multi-meters are unsafe to use closer to high current.

9. The following symbol indicates _____?

Raymond Corporation Maintenance Training Assessment

a. Solenoid Coil
b. Normally Closed Contact
c. Normally Open Contact
d. Time Delay Contact

[Link] relays are used for _____?

a. Delayed switching
b. Instantaneous switching
c. Incremental switching
d. All of the above

Motor
1. Three common motor enclosure types are _____?
a. Fan Cooled Drip Proof, Totally Enclosed Ventilated, Open Fan-Cooled
b. Non-Ventilated Drip Proof, Open Sealed Fan-Cooled, Drip Proof Non-
Ventilated
c. Open Drip Proof, Totally Enclosed Non-Ventilated, Totally Enclosed Fan-
Cooled
d. None of the above

2. True / False The motor name plate is one location to check for motor wiring
connection information.

3. True / False Motor windings should have a low resistance to the motor
frame/housing.

4. True / False Totally enclosed motors are airtight.

5. To change direction of a three-phase motor you must _____?

a. Switch 3 feed wires
b. Switch 1 feed wire
c. Switch 2 feed wires
d. None of the above

6. When ohming out Wye motor windings on a good motor will be _____ when
measuring between T1 & T2, T2 & T3 and T1 & T3.
a. Greatly different
b. No value
c. Approximately the same
d. None of the above

7. When ohming out Wye motor windings on an unknown motor. If T1 & T2 = 40

Ω, T2 & T3 = 20 Ω, T1 & T3 = 40 Ω the motor has _____?
a. Shorted windings
b. Grounded windings
Raymond Corporation Maintenance Training Assessment

c. Open windings
d. Normal windings

8. When ohming out Wye motor windings on an unknown motor. If T1 & T2 =

OL, T2 & T3 = OL, T1 & T3 = 40 Ω the motor has _____?
a. Normal windings
b. Shorted wingings
c. Open windings
d. Grounded windings

9. When ohming out Wye motor windings on an unknown motor. If T1 & T2 = 40

Ω, T2 & T3 = 40 Ω, T1 & T3 = 40 Ω the motor has _____?
a. Open windings
b. Shorted wingings
c. Grounded windings
d. Normal windings

[Link] / False The rotor is the stationary part of the motor.

Variable Frequency Drive

1. True / False SCR’s can be used to control large amounts of current.

2. True / False Meggers use a relatively high current at a low voltage to

determine insulation condition.

3. True / False When a motor is running at base speed it will develop rated
horsepower when the correct voltage is applied.

4. A bridge rectifier will output _____?

a. DC when AC is applied
b. AC when DC is applied
c. Both A & B
d. None of the above

5. A diode _____?
a. Allows current flow in two directions
b. Allows current flow in one direction
c. Does not allow current flow
d. None of the above

6. A SCR will conduct electricity when the gate is _____?

a. Forward biased
b. Reverse biased
c. Side biased
d. Not biased
Raymond Corporation Maintenance Training Assessment

7. True / False A ground fault exists when a winding becomes shorted to the
metal frame of the motor.

8. Select possible motor starting methods _____?

a. Full Voltage Starting
b. Wye-Delta Starting
c. Solid State Starting
d. All of the above

9. Filters in an AC circuit/Rectified circuit consist of these two elements _____?

a. Resistor & Capacitor
b. Capacitor & Inductor
c. Capacitor & Diode
d. SCR & Diode

[Link] open motor winding can be a result of _____?

a. Mechanical stress
b. Running in reverse
c. Overcurrent conditions
d. Either A or C

PLC 1 RSLogix 500

1. An analog signal _____.
a. Can have an infinite number of states
b. Can only be in one of two possible states
c. Varies with time but not magnitude
d. Is Repetitive over a given period of time

2. Either of these symbols in a ladder logic diagram represent a(n) _____.

a. Set of normally open contacts

b. Contact that will seal itself in once it closes
c. Field load or sensing device
d. Imaginary coil that, when energized can close an output interface
contact

3. True / False Scan time may be a concern in low speed operations.

4. The correct Boolean equation for the combination logic gate circuit shown is
_____?
Raymond Corporation Maintenance Training Assessment

a. Y = (A + B) (C + D)
b. Y = ABCD
c. Y = (A B) + (C D)
d. Y = (A B) + (C D)

5. An opto-isolator is used to_____.

a. Rectify AC inputs
b. Control AC outputs
c. Electrically isolate the inputs from the outputs
d. Electrically isolate the processor circuitry from the inputs and outputs

6. True / False The decimal number 7 would be written in binary as 1011.

7. The symbol shown is that of a (an) _____?

a. AND gate
b. Inverter
c. OR gate
d. NAND gate

8. Normally, when power to your PLC system is lost, when power is restored the
counter accumulated value will be _____?
a. Zero
b. Unchanged
c. Whatever it was preset for
d. Maximum

9. Which of the following could cause an output module fuse to blow

repeatedly?
a. Output device short-circuited
b. Module’s output current exceeded
c. Fuse rating incorrect
Raymond Corporation Maintenance Training Assessment

d. All of the above

[Link] _____ bit operates the same as an instantaneous contact on a timer relay.
a. Done
b. Timer-timing
c. Enable
d. Timer number

PLC 2 RSLogix 5000 & Studio

1. True / False The three different types of structures in a control-logix controller
are: predefined, module-defined, and user-defined.

2. True / False The 5 timer structures are: PRE, ACC, EN, OV, and DN.

3. Which routine is configured to execute first _____?

a. Subroutine
b. Fault routine
c. Main routine
d. None of the above

4. True / False A tag is a text-based name for an area of the controller where
data is stored.

5. To reset an RTO timer accumulated value you must use the _____ instruction.
a. OTU
b. ONS
c. RES
d. CLR

6. Internal relays are used to control _____?

a. Internal logic
b. Solenoids
c. Lights
d. All of the above

7. The output latch (OTL) will remain latched until _____?

a. The OTL goes false
b. The OTU goes true
c. The ONS goes true
d. Power is cycled to the controller

8. True / False During a program scan the processor reads all the inputs and
energizes or deenergizes the outputs according to the user program.

9. Which of the following are base types for tag data _____?
Raymond Corporation Maintenance Training Assessment

a. BOOL
b. SINT, DINT, INT
c. REAL
d. All of the above

[Link] does a project contain _____?

a. Controllers Programming
b. Project description
c. Configuration Information
d. Both A & C

HMI
1. True / False Graphical elements can be tied to PLC tags.

2. In which menu item would you find instructions to change pages in the HMI
_____?
a. Indicator
b. User Management
c. Push Button
d. Display Navigation

3. The three basic types of HMI’s are: the push button replacer, the data handler
and _____?
a. The data selector
b. The overseer
c. The feedbacker
d. The data exporter

4. What communication protocols are used with HMI’s

a. RS232
b. RJ-45
c. EtherNet
d. Any of the above

5. What does HMI stand for _____?

a. Hard Memory Input
b. Hard Machine Interface
c. Human Machine Interface
d. Human Machine Input

6. Programming software comes in three main categories _____?

a. Freeware, Open, Closed
b. Proprietary, Hardware independent, Open
c. Hardware independent, Freeware, Open
d. Proprietary, Freeware, Open
Raymond Corporation Maintenance Training Assessment

7. What are advantages of a graphical interface _____?

a. Easing problems of illiteracy
b. Reduce cost of poduct manufacting
c. Pictures and Icons
d. Any of the above

8. How many controllers can be hooked up to one HMI _____?

a. Limited by COM ports
b. 1
c. 2
d. 3

9. True / False HMI is graphical interface to make process interaction easier.

[Link] / False Simple graphical elements can have only one state.

Integration
1. True / False A 0 – 10 V signal has a tendency to weaken over a long distance.

2. Typically, when connecting devices to communicate with the PLC the

following method is used _____?
a. RS232
b. Device Net
c. Ethernet
d. Either A or C

3. True / False Industrial automation systems are usually categorized into 3

types.

4. The new method of coordinating between systems and appliances is called

_____?
a. SCADA
b. IoT
c. VFD
d. SCR

5. When configuring a PLC for a project and it has 5 input modules and 5 output
modules what should be considered _____?
a. Physical size
b. Color of the PLC
c. PLC power supply size
d. Both A & C
Raymond Corporation Maintenance Training Assessment

6. The main reason for system integration is _____?

a. Improve programming
b. Improve networking
c. Both A & B
d. Improve productivity and quality

7. Why is 4-20mA preferred over 0-20mA _____?

a. It’s cheaper
b. A signal cable break would give a high signal
c. A signal cable break would not affect the device
d. A signal cable break would give the same signal as a low signal

8. How many levels of autonomy are there _____?

a. 2
b. 3
c. 4
d. 6

9. Integration is important because _____?

a. Reduce costs
b. Save time
c. Decrease the scale of your manufacturing
d. Both A & B

[Link] / False Uploading means transferring the program data from PC to PLC.