IAU

Zeal Education Society’s
ZEAL POLYTECHNIC, PUNE.

NARHE │PUNE -41 │ INDIA
THIRD YEAR (TY)

DIPLOMA IN E&TC ENGINEERING
SCHEME: I SEMESTER: V
NAME OF SUBJECT: INDUSTRIAL AUTOMATION

Subject Code: 22534
MSBTE QUESTION PAPERS & MODEL ANSWERS

1. MSBTE SAMPLE QUESTION PAPER
2. MSBTE WINTER-19 EXAMINATION
Page 1 of 10
Scheme - I
Sample Question Paper
Program Name : Electronics Engineering Programme Group

Program Code
Semester
: DE/EJ/ET/EN/EX/EQ/IS/IC
: Fifth
22534
Course Title : Industrial Automation (Elective for DE/EJ/ET/EN/EX/EQ )
Marks : 70 Time: 3 Hrs.
Instructions:
(1) All questions are compulsory.
(2) Illustrate your answers with neat sketches wherever necessary.
(3) Figures to the right indicate full marks.
(4) Assume suitable data if necessary.
(5) Preferably, write the answers in sequential order.
Q.1) Attempt any FIVE of the following. 10 Marks

a) State the benefit of Automation.
b) Compare Fixed and Modular PLC. (any two points)
c) State the I/O Module selection criteria wrt PLC.
d) List different programming languages used with PLC.
e) Give list of any four relay type instructions with their symbols.
f) List the functions of Electrical drives.
g) List different editors used in SCADA.
Q.2) Attempt any THREE of the following. 12 Marks

a) Compare fixed and flexible automation on any four points.
b) With neat sketch explain redundancy in PLC.
c) Draw a neat block diagram of PLC and describe the working of its parts.
d) List different PLC programming languages. Explain any one with suitable example.

a) List any four device & four output devices that can be connected to PLC.
b) Draw a generalized block diagram of Electrical Drives and explain in brief.
c) Compare PLC and SCADA system on any four points.
1
d) Write a PLC ladder program for 24-hour time clock.

a) Draw block diagram of SCADA system and explain its parts.
b) Explain the sinking & sourcing concept in PLC input output module.
c) Describe the working of UP counter with neat diagram and waveform.
d) Compare AC and DC drives on any four points.
e) Draw a symbol of ON delay timer instruction. State the function of following :
i) Enable bit (EN) ii) Done bit (DN) iii) Timer timing bit (TT)
Q.5) Attempt any TWO of the following. 12 Marks

a) Select device that can be used with PLC to control the speed of AC motor. Explain
how?
b) Develop a ladder program for Traffic light control system with following conditions:
i) Red light ON for 30 sec, ii) green light ON for 25 sec, and
iii) Yellow light on for 05 sec. iv) Repeat the sequence until stop push button is
pressed.
c) Draw a neat wiring diagram (interfacing diagram) of following I/O devices with
appropriate PLC module: i) Proximity sensor – 24VDC, ii) Limit switch, iii) Lamp -
24VDC, iv) Fan – 230VAC.
Q.6) Attempt any TWO of the following. 12 Marks

a) Describe the steps involve developing SCADA application for following system.
b) There are four outputs A, B, C, D. Draw the ladder diagram for following condition:
i) A goes off when stop switch is pressed. ii) B goes off 7 seconds after A.
iii) C goes off 6 seconds after B. iv) D goes off 2 seconds after C.
c) Draw Ladder diagram for automatic bottle filling system. Assume suitable system
design for the same.
2
Scheme - I
Sample Test Paper - I

Program Code
Semester
: Fifth
22534
Marks : 20 Time: 1 Hour
Instructions:
.
Q.1 Attempt any FOUR. 08 Marks
a) Define Automation.
b) List different systems used in Industrial Automation.
c) Draw block diagram of Power supply used in PLC.
d) List different speciality I/O module.
e) Give addressing format for me I/P and O/P in PLC.
f) List any four comparison instructions.
Q.2 Attempt any THREE. 12 Marks

a) Draw automation hierarchy and explain.
b) Write functions of following parts of PLC.
c) Give I/O selection criteria for PLC.
d) Write a ladder diagram for traffic light control with following conditions: i) Red light
– 25sec, ii) Green light – 20 sec, iii) Yellow light – 5 sec, iv) Repeat the sequence.
e) List different PLC programming languages. Explain any one with example.
3
Scheme - I
Sample Test Paper - II

Program Code
Semester
: Fifth
22534
Marks : 20 Time: 1 Hour
Instructions:
Q.1 Attempt any FOUR. 08 Marks

a) List types of Electric drives.
b) Define wrt to SCADA: i) Tags, ii) Items.
c) List various elements of SCADA system.
d) Elaborate the term “an OPC”
e) Draw format of following instructions wrt to PLC:
i) Down Counter, ii) ON Delay timer
f) State the function Variable frequency drives.
Q.2 Attempt any THREE. 12 Marks

a) Draw functional block diagram of Electrical drives and explain in brief.
b) Draw basic architecture of SCADA and explain in brief.
c) List different editors in SCADA (any four) and describe the functions of each.
d) Write a PLC ladder diagram for following motor sequence:
i) Start button starts motor M1.
ii) After 10 sec M1 is off and M2 is ON.
iii) After 5 sec motor M2 is off.
iv) Stop push button stops M1, M2, if pressed any time during process.
e) Enlist different specifications of AC drives. (Any eight)
4
11920
22534
3 Hours / 70 Marks Seat No.
Instructions : (1) All Questions are compulsory.

(4) Assume suitable data, if necessary.
Marks
1. Attempt any FIVE of the following : 10

(a) State the need of Automation.
(b) Draw a neat block diagram of PLC power supply.
(c) State the I/O module selection criteria with respect to PLC.
(d) List the types of comparison instruction used in PLC.
(e) Give any two relay type instructions with their symbols.
(f) State the need of electric drives.
(g) List any four applications of SCADA.
2. Attempt any THREE of the following : 12

(a) Compare fixed and programmable automation on any four points.
(b) Explain redundancy in PLC with suitable diagram.
(c) Draw a neat block diagram of PLC and explain the function of CPU and
memory.
(d) Draw a symbol of OFF delay timer instruction. State the function of
following :
(i) Enable bit
(ii) Done bit
(iii) Timer timing bit
[1 of 2] P.T.O.
22534 [2 of 2]
(a) State the function of each block of analog output module with block diagram.
(b) Draw a basic block diagram of electrical drive and explain each block in brief.
(c) Compare PLC and SCADA on any four points.
(d) Explain any four data handling instruction used in PLC.

(a) Draw block diagram of SCADA system and explain its parts.
(b) Describe the steps involved in interfacing of PLC based application to a
SCADA system.
(c) Describe memory organisation of PLC with neat sketch.
(d) Explain (V/f) control method of AC drive with suitable diagram.
(e) Explain how SCADA is used in water distribution system with diagram.
5. Attempt any TWO of the following : 12

(a) Select device that can be used with PLC to control the speed of DC motor.
Explain how.
(b) Draw ladder diagram for stepper motor control in clockwise direction.
(c) Explain special I/O modules used in PLC.
6. Attempt any TWO of the following : 12

(a) Describe the steps involve developing SCADA application with an simple
system.
(b) State the types of programming languages and explain any two.
(c) Draw a ladder diagram for a two motor system having following condition :
(i) Start push button, starts motor M1.
(ii) After 10 sec, motor M1 is OFF and motor M2 is ON.
(iii) After 5 sec motor M2 is OFF.
(iv) STOP push button, stop both motors M1 and M2 if pressed any time
during process.
_______________
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
WINTER-19 EXAMINATION
Subject Name: Industrial Automation Subject Code 22534
Model Answer:
1
Important Instructions to examiners:

1) The answers should be examined by key words and not as word-to-word as given in themodel answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may tryto assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given moreImportance (Not
applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in thefigure. The
figures drawn by candidate and model answer may vary. The examiner may give credit for anyequivalent
figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constantvalues
may vary and there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.
Q. Sub Answers Marking

No. Q. N. Scheme
1 (A) Attempt any FIVE of the following: 10- Total

Marks
(a) State the need of Automation. 2M
Ans: 2M for
Need of Automation in process : correct
a. To fulfill the demand of product at right time. points
b. To reduce the human errors and involvement of human being in
the process.
c. For better productivity.
d. For better control of process.
e. For better quality .
f. For reducing man power.
g. For reducing cost of product.
Note : Any other equivalent points should be considered
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Model Answer:
2
(b) Draw neat block diagram of PLC power supply. 2M
Ans:
Block diagram power supply of PLC :
2M for
correct
diagram
(c) State the I/O module selection criteria with respect to PLC. 2M
Ans: I/O Selection criteria : 2M for

correct
1) Number of analog and digital inputs points
2) Numbers of analog and digital outputs
3) Number AC/DC inputs
4) Number of AC/DC outputs
5) Discrete I/O.
6) Power supply voltage
7) Type of I/O signals –temperature, pressure, speed control etc.
(d) List the types of comparison instruction used in PLC. 2M
Ans: Types of comparison instruction: ½ M for

1)EQU(Value, Value) each
2)NEQ(Value, Value) correct
3)LES(Value, Value) type
4)LEQ(Value, Value)
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Model Answer:
3
5)GRT(Value, Value)
6)GEQ(Value, Value)
e) Give any two relay type instructions with their symbols. 2M
Ans:
Relay type instructions : (Any TWO)

(1M for
1. Normally open (XIC) :
each
correct
Symbol : type)
2. Normally Close (XIO) :
Symbol :
3. One Shot Instruction (OSR) :
Symbol :
4. Output Instruction :
Symbol :
5. Output latch instruction(L) :
Symbol :
6. Output unlatch instruction(U) :
Symbol :
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Model Answer:
4
f) State the need of electric drives. 2M
Ans: Need of Electric drives :
a. The motion control is required in large number of industrial and domestic

applications. These applications include sugar mills, paper mills, textile mills etc.
(1M for
b. The motors need to be operated at different speeds for which an electric drive is correct
needed. point)
c. To meet good overload capacity
d. To improve the energy efficiency
e. For operating in all four quadrants of speed torque plane.
g) List any four applications of SCADA. 2M
Ans: Applications of SCADA: (Any FOUR) ½ M for

each
1.Traffic light control correct
2. Water distribution point
3. Pipeline control
4.Electric power system, operation and control
5. Manufacturing Industries or plants
6. Lift and Elevator controls
7. Telecom and IT based systems

No. Q. N. Scheme
2 Attempt any THREE of the following: 12- Total
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(Autonomous)
Model Answer:
5
Marks
a) Compare fixed and programmable automation on any four points. 4M
Ans:
Sr.
Fixed Automation Programmable Automation
No
Programmable automation is type 1M for

Fixed automation is a type of automation each
Of automation where the automated
1 where the automated application is used correct
Application is used for multiple
for a dedicated fixed purpose or use. point
Purpose Or use.
In Programmable Automation
In Fixed Automation, the number of inputs
, the number of inputs and outputs
and outputs are fixed because I/O
2 are not fixed. Can be added to the
capabilities are decided by the
automated system PLC systems
manufacturer but not by the user.
by the user.
To achieve Programmable
To achieve fixed automation, generally
3 automation Generally , Modular
Fixed PLCs are used.
PLC is used.
Cost wise Fixed automation is relatively Programmable automation is

4
cheaper. Relatively Costlier.
It is used for industrial purpose

It is useful for the smaller applications and
5 and also for future industrial
most suitable for the domestic purpose.
expansion and growth.
b) Explain redundancy in PLC with suitable diagram. 4M
Ans: Description of Redundancy :
a. Redundancy means extra system components or mechanisms added to decrease the 3M for
chance of total system failure. explanat
b. Different types of redundancy are available in PLC like redundancy for a CPU module, ion
power module, bases and communication module is available.
c. CPU redundancy system is composed of separate bases for ideal redundancy structure.
d. In case an error occurs in an active CPU module, a backup module is automatically
converted to active one for continuous operation.
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Model Answer:
6
e. In these cases two processors can be tied into one I/O system and some means is
provided that switches control from the failure CPU to the backup when a failure CPU to the
backup when a failure occurs as shown in Fig.
1M for
diagram
f. The working of total system is reliability of its operation.

g. The safety of critical load is increased by transferring it from a failed power module to an
alternative source of power.
h. Thus, reliability can be increased by selective use of redundancy.
c) Draw a neat block diagram of PLC and explain the function of CPU and memory. 4M
Ans:
2M for
diagram
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(Autonomous)
Model Answer:
7
Function of CPU, Memory :

CPU or the central processing unit is the main part of any PLC. The CPU solves 2M for
the user program logic by using real time input status from input module and explanat
updates the status of output module. ion
The CPU consists of – (i) Processor, (ii) Memory.
The processor is responsible for the complete program scan in a PLC. During
Program scan processor communicate with the memory.
Memory is used in CPU are of two types RAM and ROM. RAM memory is used to
store the data related to input status, output status, timers, counters, internal
bit relay, numerical values etc. ROM memory is to store system program and
user program.
d) Draw a symbol of OFF delay timer instruction. State the function of following: 4M
(i) Enable bit
(ii) Done bit
(iii) Timer timing bit
Ans: Symbol of OFF Delay Timer :
1M for
symbol
Function :
(i) Enable bit : Enabled bit is set when the line is true, indicates that the timer is 3M for
enabled. It is clear when the line is false. The address for these bits is as follows: correct
T #file: #element/EN, for example T4: 0 / EN. explanat
(ii) Done bit : Done bit is set when the accumulated value is equal to the preset value ion
and the timer is disabled. It is clear when the timer is enabled. The address for these
bits is as follows: T #file:#element/DN, for example T4: 0 / DN.
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Model Answer:
8
(iii) Timer timing bit : Timing timer bit is set in the time interval that occurs between the
timer is disabled and when the accumulated value reaches the preset value. The rest
of the time this bit is clear. The address for these bits is as follows:
T #file:#element/TT, for example T4: 0 / TT.

No. Q. N. Scheme
3 Attempt any THREE of the following : 12- Total

Marks
a) State the function of each block of analog output module with block diagram. 4M
Ans: Block diagram of analog output module: 2M
Explanation:
Analog output modules accept 16 bit output status word, which they convert to an analog
value through a digital to analog converter. The converter is a part of the electronics inside
the analog output module. Typical analog signals are 0 to 10 V DC, -10 to 10 V DC, 0 to 5 V
DC, 1 to 5 V DC, 0 to 20 milliamps, -20 to +20 milliamp or 4 to 20 milliamps. Analog output
modules are selected to send out either a varying current or voltage signal. An analog output
sends a 4 to 20 milliamp signal to variable speed drive. The drive will control the speed of a
motor in proportion to the analog signal received from the analog output module.
An analog valve can provide precise control. An analog output module could output a 0 to 10
volt signal to an analog valve to provide the needed control. The output signal can be divided 2M
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Model Answer:
9
into 32,767 increments and represented in a 16-bit word. Output module automatically
converts the 1-bit output word to the proper analog voltage, the programmer only has to
output the desired decimal integer value to the output status file. The above figure shows
value position variations with analog signals and its decimal equivalent.
b) Draw a basic block diagram of electrical drive and explain each block in brief. 4M
Ans: Basic block diagram of electrical drive: 2M
2M
Explanation:
The main parts of the electrical drives are power modulator, motor, controlling
unit and sensing units. Their parts are explained below in detail.
i. Power Modulator :
The power modulator regulates the output power of the source. It controls the
power
from the source to the motor in such a manner that motor transmits the speed -
torque
characteristic required by the load. During the transient operations like starting,
braking and speed reversing the excessive current drawn from the source. This
excessive current drawn from the source may overload it or may cause a voltage
drop. Hence the power modulator restricts the source and motor current. The
power
modulator converts the energy according to the requirement of the motor e.g. if the
source is DC and an induction motor is used then power modulator convert DC into
AC. It also selects the mode of operation of the motor, i.e., motoring or braking.
ii. Control Unit:
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(Autonomous)
Model Answer:
10
The control unit controls the power modulator which operates at small voltage and
power levels. The control unit also operates the power modulator as desired. It
also generates the commands for the protection of power modulator and motor.
An input command signal which adjusts the operating point of the drive, from an
input to the control unit.
iii. Sensing Unit :
It senses the certain drive parameter like motor current and speed. It mainly required
either for protection or for closed loop operation.
c) Compare PLC and SCADA on any four points. 4M
Ans: Sr.N Parameter PLC SCADA 1M Each

o
1 Full form PLC stands for SCADA stands for Supervisory Control and (Any
Programmable logic Data Acquisition four
controller points)
2 Function PLC is a controller SCADA doesn’t have its own controller it
i.e it takes inputs, just monitors one or multiple controllers
executes the through software applications.
program and
generates the
output.
3 Use PLC is a simple SCADA is a visual and easy interface for
programming for automation of the industry.
the automation of
the industry
4 Meaning It is a solid state It is a software. It is used to monitor,
device which control and acquire data from field
controls the output devices even from remote locations.
of the process
through the
program given in
ladder diagrams.
5 Input/Output Input and output Input and output are represented in
are represented in images.
normal open (NO),
normal close (NC)
and coil contacts.
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Model Answer:
11
6 Component/Obj Each component Each object is defined using name.

ect involved are defined
using address.
d) Explain any four data handling instruction used in PLC. 4M
Ans: Data Handling Instructions: 1M

Each
1. MOV (Move):
The move instruction copies a value from a source address to a destination
address. The source can be either a constant value or the address of a memory
location. Figure represents the MOV instruction. The source is N7:0,
and the destination is N7:2.
Symbol of MOV instruction
As shown in figure, the following parameters are used in a MOV

instruction.
 Source: Represents the address from which the instruction reads the
value.
 Destination: Represents the data address to which the data from the
source is to be moved.
The MOV instruction can be used to transfer data between any two words.
This instruction can also used to change the preset values of the timer, and the
preset or accumulated values of counters, to fulfill programming requirements.
The source value remains unchanged.
2. MVM (Masked Moved):

The MVM instruction copies the value from a source address to a destination
address, allowing some portion of the data to be masked. The MVM instruction
transfers data through the mask from the source address to the destination
address. the bits set as 1 in the mask will pass the data from source to
destination. For the bits set as 0 in the mask, the data in the destination
address will remain in its last state. Figure shows the format of MVM
instruction and its illustration.
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Model Answer:
12
Symbol of MVM instruction
As show in the figure

 The source address is B3:0.
 The mask is F0F0 (HEX)
 The destination address is B3:2.
Mask word is F0F0, so bits 4 to 7 and bits 12 to 15 are set to 1. As a result, data get
transferred from the source word to the destination word only in these bits. In the
destination word, bits having 0s in the mask remain unchanged when the MVM instruction
goes true.
3. LIM (Limit Test):
The LIM instruction compares whether a given value lies within a specified range. The high
and low limits are stored in different memory addresses as HIGH LIMIT and LOW LIMIT. The
value to be tested is kept in another memory location, namely TEST. If the value stored in
TEST is greater than or equal to the value in LOW LIMIT, and less than or equal to the value
in HIGH LIMIT, then the rung output becomes TRUE, else the rung output is FALSE. Figure
represents the block format of an LIM instruction.
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Model Answer:
13
Symbol of LIM instruction
4.Convert BCD ,Convert from BCD,Radian to Degree & Degree to Radian:
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Model Answer:
14
No. Q. N. Scheme
4 Attempt any THREE of the following : 12- Total

Marks
(a) Draw block diagram of SCADA system and explain its parts. 4M
Ans: Block diagram of SCADA: 2M
 Master Terminal Unit (MTU)
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(Autonomous)
Model Answer:
15
1M
(Diagra
m
optional
)
Block diagram of MTU
(i) Master terminal unit (MTU) is a system controller , which is sometimes called
'host computer'.
(ii) It can monitor and control the field devices even when the operator
is not present. It does this by means of a built in scheduler that can be
programmed to repeat instructions at set intervals.
(iii) Generally, MTU receives the signal from operator interface and after processing,
this signal will be given to RTU for control of various field devices. It also
receives the signal from RTU, which is received by RTU from field devices. This
received signal is stored and processed by MTU according to program given by
operator.
the general functions of MTU:-
1. Collects the data from different RTU's placed at remote locations.
2. Stores required information into internal and external storage devices.
3. Passes other information on to the associated system.
4. Interfaces with the people which operator the process.
5. Issues commands or control signal to various RTU's.
 Remote Terminal Unit (RTU):

Block diagram of RTU:
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Model Answer:
16
1M(Dia
gram is
optional
)
(i) RTU stands for Remote terminal unit. Modern RTU's are essentially microcomputer
or programmable controllers (PLC) which is interfaced with the MTU and various field
devices.
(ii) RTU gathers information from the field . i.e. analog values, various ON-OFF
status signals etc.It keeps this information in the memory until the MTU asks
for required information, it then codes and transmits the information using
modem through communication link to the MTU.
(i) When master terminal unit sends the control signal, RTU receives that signal and
follows the commands given by MTU. Following diagram shows the various
signals that are entering and leaving the Remote terminal unit.
(b) Describe the steps involved in interfacing of PLC based application to a SCADA system. 4M
Ans: Diagram:
The communication between PLC software and SCADA is achieved through an 2M

OPC DA Server. Open Platform Communications (OPC) is a standard defined for industrial
communication.
The Figure shows the typical connection diagram or interfacing diagram of PLC hardware
with SCADA software. It is cleared from the figure that PLC hardware is operated through a
appropriate PLC software.
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Model Answer:
17
Steps involved in interfacing of PLC based application to a SCADA system:
 PLC is interfaced with OPC DA server.OPC DA server works on the server-client

mechanism, which provides access to the live and historic data of process variables.
2M
OLE for process control (OPC) is a standard that provides interoperability between
the devices of different manufacturers for secure and reliable exchange of data. The
various PLC parameters are acquired in real time in OPC server by configuring OPC
with device, channel and groups. Several tags are defined to indicate PLC input and
output parameters.
 This which is aquired by an OPC is then can be accessed using SCADA application
which acts as client for OPC server.
 SCADA application (HMI screen) is developed that, allows reading and writing data to
and from SCADA to OPC DA server in real time.
(c) Describe memory organization of PLC with neat sketch. 4M
Ans: MEMORY Organisation in PLC: 4M

To understand the organisation of memory in PLC, think of program files and data files like a
two drawer file cabinet, where, program files are in one drawer and data files are in the
other drawer as shown in figure
PLC memory as two drawer cabinet
Program files: The PLC processor stores system information, configuration information and
user program in one group of files called program files. Figures illustrates a grouping of
program files.
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Model Answer:
18
There are 256 program files available per project file. As shown in figure all 256 files (i.e. file
0 to file 255) are orderly arranged in program file folder. Program file consists of following
information in individual files
 File 0 (Sys 0) - Contains system configuration information.
 File 1 (Sys 1) - Contains system configuration information.
 File 2 (LAD 2) - Contains main Ladder program.
 File 3 to _le 255 (LAD 3 to LAD 255) - Contains subroutine
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Model Answer:
19
programs.
Figure:RS logix 500 project tree
Data files: The PLC memory stores data which is required to solve the user program in one
group of files called Data files. Figure illustrates the grouping of data files in a two drawer file
cabinet.
There are 256 data files available per project file. As shown in figure all 256 files (i.e. file 0 to
file 255) are orderly arranged in data file folder. Data file consist of nine (9) default data files
(i.e. file 0 to file 8) and 247 user defined data files (i.e. file 9 to file 255).
(d) Explain (V/f) control method of AC drive with suitable diagram. 4M
Ans: Variable Frequency Drive(VFD): 1M

AC drives are used to drive the AC motor especially three phase induction motors
because these are predominant over other motors in most of the industries. In
industrial terms, AC drive is also called as variable frequency drive (VFD),
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Model Answer:
20
variable speed drive (VSD), or adjustable speed drive (ASD).

Though there are different types of VFDs (or AC drives), all of them work on
same principle that converting fixed incoming voltage and frequency into variable
voltage and frequency output. The frequency of the drive determines the how fast
motor should run while the combination of voltage and frequency decides the amount
of torque that the motor to generate.
A VFD is made up of power electronic converters, Filter, a central control unit (a
1M
microprocessor or microcontroller) and other sensing devices.
The block diagram of a typical VFD
Principle 2M
Operation of Variable Frequency Drive (VFD) :
The speed of an induction motor is proportional to the frequency of the supply
(N = 120f=p)
and by varying the frequency we can obtain the variable speed. But, when the
frequency is decreased, the torque increases and thereby motor draws a heavy current.
This in turn increases the flux in the motor. Also the magnetic field may reach to
the saturation level, if the voltage of the supply is not reduced. Therefore, both the voltage
and frequency have to be changed in a constant ratio in
order to maintain the flux within the working range. Since the torque is proportional
to the magnetic flux, the torque remains constant throughout the operating range
of v/f.
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Model Answer:
21
The figure shows the torque and speed variation of an induction motor for
voltage and frequency control. In the figure, voltage and frequency are changed at
a constant ratio up to the base speed. Thus the flux and thereby torque remain
almost constant up to the base speed. This region is called as a constant torque
region.
Since the supply voltage can be changed up to the rated value only and hence the
speed at rated voltage is the base speed. If the frequency increased, beyond the base
speed, the magnetic flux in the motor decreases and thereby torque begins falling
off. This is calledfl ux weakening or constant power region.
OR
Diagram: 2M
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2M
Explanation:
 Rectifier and Filter section converts the AC power into DC power with
negligible ripples. Mostly, the rectifier section is made with diodes that produce
uncontrollable DC output. The filter section then removes ripples and produces the
fixed DC from pulsating DC. Depends on the type of supply number of diodes is
decided in the rectifier. For example, if it is three phase supply, a minimum of 6
diodes are required and hence it is called as six pulse converter.
 The inverter takes the DC power from the rectifier section and then converts back to
the AC power of variable voltage and variable frequency under the control of
microprocessor or microcontroller. This section is made with series of transistors,
IGBTs, SCRs, or MOSFETs and these are turned ON/OFF by the signals from the
controller. Depends on the turn ON of these power electronic components, the
output and eventually the speed of the motor is determined.
 The controller is made with microprocessor or microcontroller and it takes the input
from sensor (as speed reference) and speed reference from the user and accordingly
triggers the power electronic components in order to vary the frequency of the
supply. It also performs overvoltage and under voltage trip, power factor correction,
temperature control and PC connectivity for real time monitoring.
(e) Explain how SCADA is used in water distribution system with diagram. 4M
Ans: Block Diagram of SCADA in water distribution System: 2M
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Use of SCADA:
The SCADA system assures the acquisition from the transducers of the characteristic
parameters of the functioning of the technological installations within the water distribution
stations, the monitoring and command of the pumps at the local stations level, the taken of
the acquisitioned data, sending the data to the central dispatcher level, monitoring the
2M
stations functioning through the synoptic schemes, elaborating the monitoring bulletin and
stations balance sheets, sending the results to the decision factors. In this way, each station
has its own data acquisition and command local equipment which has associated a local PC
and which communicates with the dispatcher PC. The equipment is questioned at a constant
period of time fixed by the local PC and so all the analogical/digital inputs and outputs are
registered at the level of the local computer. The equipment realizes the drive of the pumps
driving engines within the respective station, through soft- starters/invertors.
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No. Q. N. Scheme
5. Attempt any TWO of the following: 12- Total

Marks
a) Select device that can be used with PLC to control the speed of DC motor. Explain how. 6M
Ans: The device that can be used with PLC to control the speed of DC motor is Electric drive Device :
Four Quadrant Operation of Drives: 1M
Four Quadrant Operation of any drives means that the machine operates in four quadrants. Diagram
They are Forward motoring, Forward braking, Reverse motoring and Reverse braking. A : 2.5 M
motor operates in two modes- Motoring and Breaking. A motor drive capable of operating in
both directions of rotation and of producing both motoring and regeneration is called a Four Explanat
ion:
Quadrant variable speed drive. In motoring mode, the machine works as a motor and
2.5M
converts the electrical
energy int o mechanical energy, supporting its motion. In braking mode, the machine works
as a generator, and converts mechanical energy into electrical energy and as a result, it
opposes the motion. The Motor can work in both, forward and reverse directions, i.e., in
motoring and braking operations. Figure 4.2 shows the four quadrant operation of electric
drive.
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Model Answer:
25
1. First quadrant operation - Forward motoring : In this quadrant the direction of

rotation (speed) is positive and torque is positive so, quadrant power developed is
positive and the machine is working as a ’motor’, supplying mechanical energy.
(Power is positive means power flow is from source to load.)
2. Second quadrant operation - Forward Braking : In this quadrant the direction of
rotation (speed) is positive, but the torque is negative, and thus,the machine
operates as a ’generator’ developing a negative torque, which opposes the motion.
(Power is negative means power flow is from load to source. )
3. Third quadrant operation - Reverse motoring: In this quadrant The motor works in
the reverse direction. Both the direction of rotation (speed) and the torque are
negative, while the power is positive. (Power is positive means power flow is from
source to load.)
4. Fourth quadrant operation - Reverse braking : In this quadrant the motor works in
the reverse direction. In This the direction of rotation (speed) is negative and the
torque is positive, therefore, the power is negative. (Power is negative means power
flow is from load to source.)
b) Draw ladder diagram for stepper motor control in clockwise direction. 6M
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Model Answer:
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Ans:
6M
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Model Answer:
27
(Any other correct programming logic should be given marks )
c) Explain special I/O modules used in PLC. 6M
Ans: Different types of speciality I/O modules: ( 1mark

1) Communication module each
2) RTD input module module
3) High speed encoder explanati
on )
4) Stepper motor control
5) Thermocouple input module
6) Remote I/O sub scanner
1) Communication module: - The communication modules are used to communicate with

programming devices, displays, plant computers, other PLC’s. The four common
communication modules are ASCII modules, local I/O adapter modules, the serial data
modules, network interface modules.
2) RTD input module: - This module interfaces RTD’s to a PLC and other types of resistance
input devices such as potentiometers. It consists of bridge circuit filter, amplifier, and
isolator circuits.
3) High speed encoder:-When input pulses come in faster than a discrete input module can
handle them, a high speed input module is used. High speed counters are also used to
interface encoder to a PLC.
4) Stepper motor control:-A stepper motor module is a intelligent module that resides in a
PLC chassis and provides a digital output pulse train for microstepping stepper motor
applications.
5) Thermocouple input module:- The thermocouple input module converts input from
various thermocouple or millivolt devoces into values that can be input and stored into PLC
data tables.
6) Remote I/O subscanner:-A subscanner scans the remote I/O chassis and the respective I/O
chassis points. After the subscanner has scanned all remote I/O points, their I/O status is
stored in a build in buffer(storage area).

No. Q. N. Scheme
6. Attempt any TWO of the following : 12- Total

Marks
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28
a) Describe the steps involve developing SCADA application with an simple system. 6M
Ans: Steps required to develop a SCADA based application are given as below: Each
• Creating new I/O server and I/O Device: step: 2M
In Citect project editor, communication express wizard is used to create new I/O server
which is linked with KEPServerEX.V4 driver. A new I/O device is created which is linked
with Allen bradley PLC driver. This linking of I/O server and I/O device enables the SCADA
to access the real time data from PLC through OPC server.
• Creating variable tags and graphics:
In Citect project editor a variable tags are created with specific tag name and data types.
These
are linked with an I/O device and I/O server. The variable tags holds real time data
acquired from PLC. To develop a required graphics, Citect SCADA graphic builder platform
is used. The required objects are selected from object library and linked with appropriate
tags already created. The behaviour of individual graphics object in runtime is set by
editing properties of each object.
• Configuring OPC DA:
KEPServerEX is an OPC server, acts as a link between SCADA client and PLC based
application. It serves live data to a SCADA client whom it had acquired from PLC.
KEPServerEX is configured, setting channel, device, groups and tags with appropriate data
type.
b) State the types of programming languages and explain any two. 6M
Ans: State
PLC programming languages:
types:
2marks
This standard specifies five languages divided into two parts namely graphical languages and
text-based languages. Any two
types
A) Graphical languages : explanat
ion :2
i) Ladder Logic Diagram (LD) marks
ii) Function Block Diagram (FBD) each
iii) Sequential Function Chart or Grafcet (SFC)
B) Text-based languages :
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Model Answer:
29
i) Instruction List (IL)

ii) Structured Text (ST)
Explanation of PLC programming languages:
i) Ladder logic diagram(LD):

It is a type of graphical language having the instructions in graphical symbol format. Ladder
program is very similar to electrical wiring diagram, so it is easy to understand. Fig. Ladder
logic diagram
ii) Function Block Diagram (FBD): The primary concept behind FBD is data flow in this
instructions are composed of operational blocks, Each block has one or more inputs and
outputs. Fig. Simple comparison example
iii) Sequential Function Chart or Grafcet (SFC): This language is used for performing
simultaneously operations required for controller in complex machine process
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Model Answer:
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iv) Instruction List (IL): It is similar to assembly language programming, in this low level
computer language like mnemonic codes are used to specify the operation of each rung of
ladder diagram.
v) Structured Text (ST): It is a high level computer type language like Basic or C. It is capable
to perform calculations on values other than binary.
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Model Answer:
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c) Draw a ladder diagram for two motor system having following condition: 6M
(i) Start push button, starts motor M1.
(ii) After 10 sec, motor M1 is OFF and motor M2 is ON.
(iii) After 5 sec motor M2 is OFF.
(iv) STOP push button, stop both motors M1 and M2 if pressed any time during
process.
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Model Answer:
32
Ans: correct
ladder
diagram
: 06
marks
(Any other correct programming logic should be given marks )
Page 32/

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Zeal Education Society’s

ZEAL POLYTECHNIC, PUNE.

THIRD YEAR (TY)

NAME OF SUBJECT: INDUSTRIAL AUTOMATION

MSBTE QUESTION PAPERS & MODEL ANSWERS

Sample Question Paper

Program Name : Electronics Engineering Programme Group

Q.1) Attempt any FIVE of the following. 10 Marks

Q.2) Attempt any THREE of the following. 12 Marks

Q.3) Attempt any THREE of the following. 12 Marks

Q.4) Attempt any THREE of the following. 12 Marks

Q.5) Attempt any TWO of the following. 12 Marks

Q.6) Attempt any TWO of the following. 12 Marks

Sample Test Paper - I

Program Name : Electronics Engineering Programme Group

Q.2 Attempt any THREE. 12 Marks

Sample Test Paper - II

Program Name : Electronics Engineering Programme Group

Q.1 Attempt any FOUR. 08 Marks

Q.2 Attempt any THREE. 12 Marks

Instructions : (1) All Questions are compulsory.

1. Attempt any FIVE of the following : 10

2. Attempt any THREE of the following : 12

4. Attempt any THREE of the following : 12

5. Attempt any TWO of the following : 12

6. Attempt any TWO of the following : 12

Important Instructions to examiners:

Q. Sub Answers Marking

1 (A) Attempt any FIVE of the following: 10- Total

(a) State the need of Automation. 2M

Note : Any other equivalent points should be considered

(b) Draw neat block diagram of PLC power supply. 2M

Ans: I/O Selection criteria : 2M for

(d) List the types of comparison instruction used in PLC. 2M

Ans: Types of comparison instruction: ½ M for

e) Give any two relay type instructions with their symbols. 2M

Relay type instructions : (Any TWO)

2. Normally Close (XIO) :

3. One Shot Instruction (OSR) :

5. Output latch instruction(L) :

6. Output unlatch instruction(U) :

f) State the need of electric drives. 2M

Ans: Need of Electric drives :

a. The motion control is required in large number of industrial and domestic

d. To improve the energy efficiency

e. For operating in all four quadrants of speed torque plane.

g) List any four applications of SCADA. 2M

Ans: Applications of SCADA: (Any FOUR) ½ M for

4.Electric power system, operation and control

5. Manufacturing Industries or plants

6. Lift and Elevator controls

7. Telecom and IT based systems

Q. Sub Answers Marking

2 Attempt any THREE of the following: 12- Total

a) Compare fixed and programmable automation on any four points. 4M

Programmable automation is type 1M for

Cost wise Fixed automation is relatively Programmable automation is

It is used for industrial purpose

Ans: Description of Redundancy :

f. The working of total system is reliability of its operation.