PLC Interview Questions and Answers
1. Basics
Q: What is a PLC?
A: A Programmable Logic Controller (PLC) is an industrial computer used for automation of
electromechanical processes. It is designed to withstand harsh conditions and execute control tasks.
Q: What are the main components of a PLC?
A: The main components include:
- CPU (Central Processing Unit)
- Input/Output (I/O) Modules
- Power Supply
- Programming Device
Q: Why is PLC preferred over traditional control systems?
A: PLCs offer flexibility, reliability, scalability, and ease of programming compared to hardwired relay
systems.
2. Programming
Q: What are the common programming languages used in PLCs?
A: The most common languages include:
- Ladder Logic (LD)
- Function Block Diagram (FBD)
- Structured Text (ST)
- Sequential Function Chart (SFC)
- Instruction List (IL)
Q: Can you give an example of Ladder Logic?
A: Ladder Logic uses graphical symbols to represent the control logic. Example:
- | --[ ]--( )-- |
This represents a normally open contact controlling an output.
Q: How do you ensure efficient PLC programming?
A: By following these steps:
- Use modular programming.
- Properly document the code.
- Simulate and test the logic before deployment.
3. Practical Applications
Q: Where are PLCs commonly used?
A: PLCs are used in:
- Manufacturing and assembly lines
- Process industries (chemical, oil, gas)
- Robotics and motion control
- HVAC systems
Q: How do you approach designing a PLC-based system?
A: Steps include:
- Define the requirements.
- Select appropriate hardware.
- Develop and test the control logic.
- Install and commission the system.
4. Troubleshooting
Q: What are common PLC issues and how do you troubleshoot them?
A:
- Problem: No power to PLC
Solution: Check the power supply and connections.
- Problem: Inputs not detected
Solution: Verify wiring and sensor functionality.
- Problem: Outputs not functioning
Solution: Check program logic and output devices.
Q: What tools are helpful for PLC troubleshooting?
A: Tools include:
- Multimeter
- PLC programming software (for diagnostics)
- Oscilloscope (in advanced cases)
5. General Questions
Q: What is the difference between PLC and DCS (Distributed Control System)?
A: PLC is used for discrete control, while DCS is used for process control. PLCs are faster and
suitable for real-time applications, whereas DCS is better for complex processes.
Q: How does redundancy work in PLC systems?
A: Redundancy ensures system reliability by using backup CPUs, power supplies, or communication
modules to take over in case of failure.
