PLC Interview Questions

1. What is the RS LINX software used for?

RS Linx software is generally a communicator between programming devices and the

controllers themselves. It acts as a link between the both and hence it is extremely
useful to pass commands. It can not only configure communication drivers but also view
the already configured drivers and the active nodes. Tasks, which enable
communication, are its forte. RS Linx software is renowned for performing tasks such as
downloading, uploading, updating firmware, going online, sending messages and more.

2. Which programmable languages are used in PLCs?

Each computer or rather, all kinds of software have their own programming language.
These languages are unique and command the computer to produce outputs. These
languages may or may not be same for all computers.
The programming languages used in PLCs are:

 Instruction List Programming

 Structured Text Programming
 Functional Block Programming
 Ladder Logic Programming
 Sequential Functional Chart

3. What is SCAN in PLC? What is scan time?

SCAN is the procedure, which any sequential operation of the program controller must
go through. It is the process of the operation going from the top to the bottom of the
ladder in the ladder diagram. The process results in all updated outputs, which
correspond to the given inputs. The process of SCAN takes place from the left to the
right of each rung in the ladder diagram. Scan time is basically the total time needed to
read the input, process the logic of the program and update the corresponding output in
a single cycle. Generally, the time for SCAN is of the order milliseconds and it is a
continuously running process.

4. Which are leading suppliers of PLCs?

There are 4 main countries, which supply PLCs:

  America
o Allen Bradley
o Texas Instrument
o General Electric
 Europe
o Siemens
o Festo
 Japan
o Toshiba
o Mitshubishi
o Omron
 India
o Messung
o Delta

5. Explain redundancy.

Redundancy translates to the state of non-usefulness. For PLCs, when they are out of
order or when they have certain flaws in them, they cannot be used. They then become
useless and are said to be redundant. This state of PLCs is known as redundancy.

6. Which PLC ranges are available in Rockwell?

The PLC ranges available in Rockwell are as follows:

 Micrologix 1000, 1200 and 1500 Series

 SLC: SLC 5/01, 5/02, 5/03.
 Pico: Non modular small PLCs
 Control Logix Flex Logic and Soft PLC.

7. How are PLCs more advantageous than hard-wired Relay?

In general, PLCs are smaller and cheaper compared to the Relays. They are also
economically more stable than that of relays and they are very useful commercially. The
PLCs are highly reliable and extremely easy to program which is often not the case with
hard-wired relays. In simple words, PLCs can sustain in any kind of robust environment
even with low maintenance but hard-wired relays are extremely specific in use.

8. What is PLC and what is its role in automation?

PLC is a digitalized computer used in industries to manufacture robotic and automobile
devices. It is used in automation of certain electromechanical processes is which is it
used as a device which controls electricity and is like a transducer for converting
electrical energies to mechanical energies. In order to work efficiently and to make the
program easy, the language of PLC is designed logically and their language resembles
to the ladder logic diagrams.

9. Differentiate between PLCs and DCS.

Here are a few considerable differences between the two:

 PLCs were invented much earlier than DCS.

 PLCs are used for electrochemical processors while DCS are used for
Pneumatic/Single Loop Controls.
 PLCs have generally fixed scan time while the scan time for DCS is adjustable.
 PLCs are used for discrete controls and DCS are used for regulatory controls.

10. What are various applications of PLC?

The main application of PLC is in industries but other applications of PLC include:

 Driving Motors
 Light Lamps
 Button Switches
 Traffic Signals
 Water Draining Pumps
 Photo Sensors.

Since all of these have hard and complex machines to convert electric energy in
mechanical energy, the hard machines are now replaced by the PLCs.

11. How Do Fixed PLCs differ from modular PLCs?

Fixed PLCs are mostly designed to perform basic functions, which are to be completed
in the industries. They are small and consist of a power supply and CPU.
On the other hand, modular PLCs have different independent systems and components
and they have numerous I/O systems and they can be repaired easily.
12. Explain Different Components Of PLC In Brief.

Different components of PLC include:

 Input/output Modules: These are basically the modules, which depend on the
input and the output commands given by the user.
 Power Supply: As the name suggest; power supply is the work of supplying
power to be specific supplying DC current, which operates the PLC.
 Central Processing Unit (CPU As it is CPU, it will work as brain of the computer
and will supply and store all the commands and the data given to the computer.
 Co-processor Modules: These are set of different microcomputers, which can
do different programmes. Their main aim is the function PLC more properly and
appropriately.
 Software: As the name suggests, software is the pioneer of PLC which stores
and supplies all the commands and data to the PLC and Co-processors.
 Peripheral Device : The peripheral device works for inputting data and other
equipment which are needed to the monitor.

13. Differentiate between PLCs are Relays

The difference between PLC and Relay is given below:

 PLCs are much cheaper compared to relays.

 The PLCs are more efficient compared to relays.
 They are used more.
 PLCs can be repaired easily but it is hard to repair Relays.

14. Which one would you prefer: 4-20 ma or 0-20 ma? Explain your answer.

Use of a 4-20 ma signal results in easy detection of a cable break by the PLC. This is
because it only returns 0 ma. On using a 0-20 ma signal, the PLC loses its ability to
detect any cable break. Since the return value is 0 ma which is the same as input, the
PLC thinks that the signal is working perfectly. That is why 4-20 ma is preferred over 0-
20 ma.

15. What is an HMI?

The HMI is the Human Machine Interface. It basically allows the operators to interface
or communicate with the system that they are overseeing. The HMI provides a pictorial
overview of the status of the mechanical system as well as its operation’s direct control.
The graphical screens of the HMI can be so programmed as to allow the operator to
view all-important statuses as well as control information. The HMIs make use of
pictures, sounds, icons and solid colors in order to visually exemplify the various
operating conditions. Many HMIs even deploy the advanced touch screen technology to
improve the user’s interaction with the elements displayed on-screen.