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This exam evaluates fundamental PLC concepts including ladder logic programming, input/output modules, memory addressing, scan cycles, and basic troubleshooting. Learners interpret PLC wiring diagrams, configure simple automation routines, and diagnose controller faults.
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Question 1. Which of the following is the primary purpose of a Lockout/Tagout (LOTO) procedure when working on PLC-controlled equipment? A) To speed up maintenance tasks B) To ensure the equipment remains powered while serviced C) To prevent accidental energization of the machine D) To document the maintenance schedule Answer: C Explanation: LOTO isolates energy sources and prevents accidental start-up, protecting personnel from hazardous energy. Question 2. In a typical PLC system, which component supplies the regulated DC voltage needed for the CPU and I/O modules? A) Processor Module B) Power Supply C) Backplane D) Programming Device Answer: B Explanation: The Power Supply converts AC mains to the DC voltages required by the CPU and modules. Question 3. Which PLC operating mode allows the processor to execute the user program while also permitting edits to the ladder logic? A) Run Mode B) Program Mode C) Remote Mode D) Test Mode Answer: B
Explanation: Program Mode (sometimes called Edit Mode) lets the user edit the program while the PLC is halted; Run Mode executes the program. Question 4. When configuring a point-to-point Ethernet/IP connection, which of the following correctly identifies the four octets of an IPv4 address? A) 192- 168 - 1 - 0 B) 255- 255 - 255 - 0 C) 10- 0 - 0 - 1 D) All of the above Answer: D Explanation: IPv4 addresses consist of four octets (0-255). All listed examples follow that format. Question 5. Which indicator LED on a PLC typically flashes to show that the processor is in RUN mode? A) Power LED B) RUN/STOP LED C) COMM LED D) ERROR LED Answer: B Explanation: The RUN/STOP LED indicates the current processor mode; flashing usually denotes RUN. Question 6. In ladder logic, what does a Normally-Closed (XIO) contact do when the associated input bit is TRUE? A) It closes the circuit B) It opens the circuit C) It toggles the output coil D) It has no effect
C) P-Space (Processor/Program Memory) D) M-Space (Marker/Flag Memory) Answer: C Explanation: P-Space holds the compiled program code (ladder rungs, function blocks, etc.). Question 10. Which of the following best describes the purpose of a “latching” circuit in motor control? A) To stop the motor instantly B) To hold the motor ON after the start button is released C) To reverse motor direction automatically D) To provide a safety interlock Answer: B Explanation: A latch (seal-in) circuit keeps the motor run coil energized after the start pushbutton is released. Question 11. When downloading a program from a PC to a PLC, which of the following steps must be performed first? A) Put the PLC in RUN mode B) Put the PLC in PROGRAM mode C) Disconnect the Ethernet cable D) Power off the PLC Answer: B Explanation: The PLC must be placed in PROGRAM (or STOP) mode to accept a new program download. Question 12. Which RS-232 signal line carries data from the PC to the PLC? A) RTS (Request to Send)
B) DTR (Data Terminal Ready) C) TXD (Transmit Data) D) RXD (Receive Data) Answer: C Explanation: TXD is the transmit line from the PC; the PLC’s RXD receives this data. Question 13. In a PLC ladder diagram, what does the instruction “OTE Y0.0” accomplish? A) Reads the status of output Y0. B) Forces output Y0.0 to ON when the rung is true C) Toggles output Y0.0 each scan D) Resets output Y0.0 to OFF Answer: B Explanation: OTE (Output Energize) energizes the specified output coil when the rung evaluates true. Question 14. Which type of discrete output module uses semiconductor devices to switch loads without mechanical contacts? A) Relay Output Module B) Solid-State Output Module C) Pneumatic Output Module D) Hydraulic Output Module Answer: B Explanation: Solid-State modules employ transistors, SCRs, or MOSFETs, providing silent, fast switching. Question 15. A PLC program uses the instruction “CTU C5,10”. What does the “10” represent?
Question 18. In a PLC scan cycle, which of the following steps occurs first? A) Update outputs B) Execute user program logic C) Examine inputs D) Communicate with HMI Answer: C Explanation: The scan cycle begins with reading the physical input states into the input image table. Question 19. Which of the following is a valid reason to use a “Remote” mode on a PLC processor? A) To edit the program locally only B) To allow a PC to monitor and control the PLC over a network while it runs C) To disable all I/O modules D) To reset the PLC to factory defaults Answer: B Explanation: Remote mode enables external devices (e.g., PC) to interact with the running PLC for monitoring/control. Question 20. What does the PLC instruction “GRT D0,100” evaluate? A) If data register D0 is greater than 100 B) If data register D0 is equal to 100 C) If data register D0 is less than 100 D) If data register D0 is not a number Answer: A Explanation: GRT (Greater Than) compares the first operand to the second; true when D0 > 100.
Question 21. Which safety rule mandates that an energized PLC rack must be de-energized before any wiring changes are made? A) PPE (Personal Protective Equipment) rule B) LOTO (Lockout/Tagout) rule C) Ground Fault rule D) Signal Isolation rule Answer: B Explanation: LOTO requires de-energizing and securing the source before work on electrical equipment. Question 22. In a PLC I/O addressing scheme, what does the prefix “I” typically denote? A) Internal bit B) Input point C) Output point D) Index register Answer: B Explanation: “I” (or “IN”) designates discrete input addresses in many PLC families. Question 23. Which of the following statements about a “Timer OFF-Delay” (TOF) is correct? A) The output energizes after the preset time elapses B) The output de-energizes after the preset time once the input goes FALSE C) The timer counts up while the input is FALSE D) The timer resets automatically when the input goes TRUE Answer: B Explanation: TOF maintains its output true while the input is true; once input goes false, the timer starts counting and de-energizes the output after the preset.
Explanation: A defective input module will not reflect the actual state of field devices, causing static input bits. Question 27. In ladder logic, the instruction “ADD N7:0,N7:1,N7:2” performs which operation? A) Subtracts N7:1 from N7:0 and stores result in N7: B) Multiplies N7:0 and N7:1 and stores result in N7: C) Adds N7:0 and N7:1 and stores result in N7: D) Divides N7:0 by N7:1 and stores result in N7: Answer: C Explanation: ADD adds the two source operands and places the sum in the destination register. Question 28. Which of the following best describes an “Emergency Stop” (E-Stop) on an HMI panel? A) A soft-reset of the PLC program B) A hard-wired circuit that immediately removes power to the machine C) A software command that pauses the PLC scan cycle D) A toggle that switches the PLC to PROGRAM mode Answer: B Explanation: An E-Stop is a safety device that cuts power or disables the drive to stop machinery instantly. Question 29. When using a serial RS-232 connection, what is the typical default baud rate for many PLC programming tools? A) 9600 bps B) 19200 bps C) 38400 bps D) 115200 bps
Answer: A Explanation: 9600 bps is a common default for PLC-PC serial communication, though it can be changed. Question 30. Which component of a PLC is responsible for executing the compiled ladder logic instructions? A) Power Supply B) Processor (CPU) C) Input Module D) Programming Device Answer: B Explanation: The CPU fetches, decodes, and executes the program instructions during each scan. Question 31. In a PLC, what does the term “scan time” refer to? A) The time taken to download a program B) The duration of one complete input-process-output cycle C) The time needed to start the PLC after power-up D) The communication latency with the HMI Answer: B Explanation: Scan time is the interval required for the PLC to read inputs, execute logic, and update outputs once. Question 32. Which of the following is a valid reason to use a “Solid-State Relay” (SSR) output module instead of a mechanical relay module? A) To control high-current inductive loads without contact wear B) To provide audible click feedback for operators C) To reduce electromagnetic interference (EMI) caused by switching
B) A wiring fault causing a short on an input channel C) The output module is overloaded D) The HMI screen is frozen Answer: B Explanation: Input Scan Errors typically arise from electrical issues on the input side, such as shorts or open circuits. Question 36. Which instruction would you use to create a rung that turns on an output only while a pushbutton is held down? A) XIC (Normally Open) contact of the pushbutton feeding an OTE coil B) XIO (Normally Closed) contact of the pushbutton feeding an OTE coil C) Latch (OTL) followed by an unlatch (OTU) D) Timer instruction Answer: A Explanation: A normally open (XIC) contact passes power only while the button is pressed, directly energizing the coil. Question 37. In PLC programming software, what is the purpose of the “Watch Table” (or “Watch Window”)? A) To edit ladder logic diagrams B) To monitor real-time values of tags/addresses during RUN mode C) To configure Ethernet/IP settings D) To compile the project into machine code Answer: B Explanation: The Watch Table displays live values of selected variables, aiding debugging.
Question 38. Which of the following best describes a “Marker” (M) address in PLC memory? A) Stores physical input states B) Holds temporary or intermediate results within the program C) Represents a physical output point D) Contains the PLC’s firmware Answer: B Explanation: Marker bits are user-defined internal bits used for flags, latches, or temporary storage. Question 39. When configuring a PLC’s Ethernet/IP address, which subnet mask would allow communication with devices on the same 192.168.1.x network? A) 255.255.255. B) 255.255.0. C) 255.0.0. D) 255.255.255. Answer: A Explanation: 255.255.255.0 defines a /24 subnet, grouping all 192.168.1.* addresses together. Question 40. Which of the following statements about a “Counter Down” (CTD) instruction is true? A) It increments the count each time the rung is true B) It decrements the count each time the rung transitions from false to true C) It resets the count to zero when the preset is reached D) It only works in Program mode Answer: B
Answer: C Explanation: With a constant TRUE input, the TON timer receives a true condition each scan, causing it to count continuously until the preset is reached. Question 44. Which of the following best explains why a PLC’s power supply should be grounded? A) To increase processing speed B) To protect against electrical noise and provide a reference point for safety C) To enable wireless communication D) To allow the PLC to operate on battery power Answer: B Explanation: Grounding reduces electromagnetic interference and ensures safety by providing a low-impedance path for fault currents. Question 45. A PLC program uses the instruction “LIM D5,10,20”. What condition will cause the rung to be true? A) D5 equals 10 or 20 B) D5 is between 10 and 20 inclusive C) D5 is less than 10 or greater than 20 D) D5 is exactly 15 Answer: B Explanation: LIM (Limit) tests whether the source value lies within the low and high limits (inclusive). Question 46. Which of the following is a common method to verify that a newly installed input module is functioning correctly? A) Observe the PLC’s RUN LED B) Use a multimeter to inject a known voltage and verify the corresponding input bit changes in the software
C) Check the Ethernet cable continuity D) Reset the PLC to factory defaults Answer: B Explanation: Applying a known voltage to the input and confirming the software reflects the change validates the module’s operation. Question 47. In PLC terminology, what does “I/O scanning” refer to? A) The process of loading a new program into the CPU B) The periodic reading of input states and writing of output states during each scan cycle C) The diagnostic routine for detecting faulty modules D) The communication handshake with an HMI Answer: B Explanation: I/O scanning is the part of the PLC scan where physical inputs are sampled and outputs are refreshed. Question 48. Which of the following is a correct IPv4 address for a PLC that must be reachable from a subnet 10.0.0.0/8? A) 10.5.12. B) 192.168.0. C) 172.16.0. D) 255.255.255. Answer: A Explanation: 10.5.12.250 falls within the 10.0.0.0/8 network. Question 49. When a PLC’s “COMM” LED is blinking slowly, what does this usually indicate? A) The PLC is in RUN mode
A) To reduce the number of Ethernet cables required B) To place I/O physically closer to distributed field devices, minimizing wiring length C) To increase the PLC’s processing speed D) To eliminate the need for a backplane Answer: B Explanation: Remote I/O racks extend the I/O bus, allowing modules to be situated near sensors/actuators. Question 53. Which PLC instruction is used to reset a counter to zero? A) CTU (Count Up) with preset = 0 B) RES (Reset) instruction applied to the counter address C) TON timer with preset = 0 D) EQU instruction Answer: B Explanation: The RES (Reset) instruction clears the accumulator of a counter or timer. **Question 54. In ladder logic, what does the “OTU” (Output Unlatch) instruction do? ** A) Forces the associated output coil ON B) Forces the associated output coil OFF regardless of rung conditions C) Toggles the output each scan D) Latches the output until a separate unlatch condition is met Answer: B Explanation: OTU clears (turns OFF) the coil, overriding any rung logic that might otherwise set it.
Question 55. When configuring a PLC project, which file format is typically used to import/export tag definitions in Rockwell Automation software? A) .CSV B) .L5X C) .TXT D) .XML Answer: D Explanation: While .L5X is the project file, tag import/export often uses .XML for portability. Question 56. Which of the following is the correct sequence for a typical “Start/Stop” motor control circuit using a latch? A) Start button → XIC → OTE (Motor) → Stop button → XIO → OTU (Motor) B) Start button → XIC → OTL (Motor) → Stop button → XIO → OTU (Motor) C) Start button → XIO → OTL (Motor) → Stop button → XIC → OTU (Motor) D) Start button → XIC → OTL (Motor) → Stop button → XIO → OTE (Motor) Answer: B Explanation: XIC start energizes OTL (seal-in); XIO stop de-energizes the latch via OTU. Question 57. Which of the following best describes the function of a “Program Counter” (PC) inside a PLC CPU? A) Stores the current scan time B) Holds the address of the next instruction to execute C) Counts the number of inputs scanned per cycle D) Manages Ethernet/IP packets Answer: B