PLC

Troubleshooting
& Maintenance
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 Manual Work

Brain Motion

Senses Energy

Human Lags:
Human
• Cannot Work 24 Hours
• Cannot work with 100% Accuracy &
precision
• Efficiency decreases as energy
decreases
 Automatic Work
Controllers

Actuators

Sensors

Energy
Machine

Advantages: Lags:
• Accuracy • Regular
• No idle Time Troubleshooting &
• More Production Maintenance
 What is Controllers?
Controller is a part of Automatic Control System, which process the
signal from sensors & send it to the actuators

Sensors Controller Actuator

A closed Loop Control System

 This is a PLC Input Terminals

Output Terminals

D/A Card
Programming Cable
A/D Card
RS 485
This is a PLC
Power 24 VDC

Battery

Output Terminals
Input Terminals

Programming Cable
This is a PLC

Output Terminals
Input Terminals

Programming Cable
Power 24 VDC
Understanding PLC
Understanding PLC
 How to Select a PLC?
Step 1:

Selecting the Inputs

- Number of Inputs
- Input Types – NPN or PNP
- Nature of Inputs– Digital or
Analog
- Voltage rating of the
Inputs

Step 2: Step 3:

Selecting the Outputs Length of Program – Big or Small

- Number of Outputs Nature of Program – Ladder
- Nature of Outputs – Digital Logic, SFC, Instruction List, FDB
or Analog
- Voltage rating of the Inputs
 Programming Languages

Ladder Logic

SFC

Instruction List

FDB
PLC Ladder Logic
Common Industrial Hardware
Representing the Binary Concept
Basics of
Machine
Language
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 Basics of Machine Language

Bits – Nibble - Byte –Word

 Unlike English, computers have only two
characters available  1 or 0.
 Each 1 or 0 is called a binary digit or bit.
 Binary is base or radix 2
PLC
Inputs & Outputs
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Digital Inputs & Outputs
Typical Digital Input/ Output Signals

• 12 VDC
• 24 VDC
• 120 VAC
• 240 VAC
 PLC INPUTS & OUTPUTS
Analog Inputs
 Typical analog
signals come from
temperature,
pressure, position,
and motor speed.
 Analog input
modules convert
analog signals to
digital words.
 Analog input
signals are current
or voltage.
Typical Analog input signals

0 to 10 volts DC
-10 to +10 volts DC
0 to 5 or 1 to 5 volts DC
4 to 20 milliamps
0 to 20 milliamps
-20 to +20 milliamps
 PLC INPUTS & OUTPUTS

Connections from Field Devices

Image courtesy of Allen-Bradley, a Rockwell Automation business

 PLC INPUTS & OUTPUTS

Differential Analog Input Connections

Image courtesy of Allen-Bradley, a Rockwell Automation business

 PLC INPUTS & OUTPUTS
Analog Outputs
 Typical analog signals are required
by Servo Valves, VFD’s, Servo Motors,
Meters
 Analog Output modules convert
Digital bits to analog signal.
 Analog Output signals are current or
voltage.

Typical Analog Output signals

0 to 10 volts DC
-10 to +10 volts DC
0 to 5 or 1 to 5 volts DC
4 to 20 milliamps
0 to 20 milliamps
-20 to +20 milliamps
Basics of PLC
Programming
Ladder Logic
PLC Enclosure
& System
Components
NEMA – 12
National Electric Manufacturer
Association, USA
 PLC Enclosure

Prevents:
Dust
Water
Oil
Mostly used for

Indoor applications of automation. Some examples

are
Packaging
Material handling
Non-corrosive process control.

NEMA enclosures are available in sizes from small wall

mounts to multi-door freestanding models.
Enclosure Layout
 Placement of PLC Components

To allow
maximum cooling

All Controller components

should be mounted in a vertical
(upright) position.
 Duck & Wire Layout
Keep AC signals separate from DC Signals

DC Signals -
I/O lines, such as TTL and analog

AC Signals -
Incoming Line Wires

Minimizes the possibility

of electrical noise pickup.
Power
Requirement &
Safety Circuitry
 POWER REQUIREMENTS
Typical Power Requirement
220 VAC
 SAFETY CIRCUITRY
Door Switch

Pull Rope Switch

Emergency Switch Automation Studio

Master or Safety Control
Relays

Automation Studio
PLC FAULT CONTACT
PROTECTION

Automation Studio
PLC
Maintenance
HEAT, DUST & NOISE
REGULATION
 PLC MAINTENANCE
HEAT & DUST REGULATION

Temperature Withstand Range

0 ~ 60°C
 PLC MAINTENANCE

NOISE REGULATION

Shielded Cables for better communication

 PLC MAINTENANCE

NOISE GENERATING DEVICES

MOTOR STARTERS SOLENOIDS

RELAYS AND CONTACTORS VARIABLE FREQUENCY DRIVES

 PLC TROUBLESHOOTING 2

NOISE FROM GROUNDING

PLC
I/O Installation,
Wiring & Precautions
 I/O INSTALLATION, WIRING, AND
PRECAUTIONS
I/O MODULE INSTALLATION
Placement and installation of the I/O modules is simply a
matter of inserting the correct modules in their proper
locations. This procedure involves verifying the type of
module (220 VAC/ 24 VDC output, 220 VDC/ 24 VDC
input, etc.) and the slot address as defined by the I/O
address assignment document. Each terminal in the
module is then wired to the field devices that have
been assigned to that termination address. The user
should remove power to the modules (or rack) before
installing and wiring any module.11
 I/O INSTALLATION, WIRING, AND
PRECAUTIONS

WIRE SIZE CONSIDERATION

WIRING
 I/O INSTALLATION, WIRING, AND
PRECAUTIONS

WIRE SIZE CONSIDERATION

 I/O INSTALLATION, WIRING, AND
PRECAUTIONS
WIRE LABELLING
 I/O INSTALLATION, WIRING, AND
PRECAUTIONS

WIRE BUNDLING
PLC
START-UP & CHECKING
PROCEDURES
 PLC START-UP AND
CHECKING PROCEDURES

Model numbers
Placement

Power Supply
Inspection

Verify Field Wiring

&
I/O comm. cables
 STATIC INPUT/ OUTPUT WIRING
CHECK

Output Terminals
Input Terminals
PLC
PREVENTIVE
MAINTENANCE
PLC
PREVENTIVE MAINTENANCE

Regular Filter Cleaning

Regular Dusting
Dust restricts heat dissipation
Avoid Conductive Dust

I/O Module Check for any

Loose connections

Avoid Noise generating

Equipment close to PLC

Avoid documentation to create

HOT SPOT

Install vibration Detector in

area of high vibration
PLC
PREVENTIVE MAINTENANCE
PLC
TROBLESHOOTING
AREAS
POWER LED IS TURNED OFF
Is Power Indicator Lit?
NO
Is power supply Supply the power
operating?

NO YES
Does the power
YES LED turned on?

Is the voltage within

NO See the power supply within
the rated power? 180 ~ 240 VAC

YES
NO Does the power
YES LED turned on?

Is the fuse YES

Replace the Fuse
blown?

NO YES
Does the power
NO LED turned on?

Is the power NO
Supply cable Connected? Connect the power supply properly

YES
NO Does the power
YES LED turned on?

Over current YES Eliminate excess current &

Device activated? switch power ON/OFF

NO
YES
Write the steps & NO Does the power
Contact customer care LED turned on?

COMPLETE
RUN INDICATOR NOT LIT
RUN Indicator not Lit
YES
NO
Is the ERR/ALM
Indicator Lit?
Is PC mode NO
Displayed on Programming
YES Device?
Determine the cause of the
error with the Programming
device

NO
Is PC mode displayed Turn the power supply
On Programming device? OFF & then ON again

YES

YES
Is a fatal error Identify the error, eliminate
Displayed? its cause, & clear the error.

NO

Switch to RUN or
MONITOR mode

NO
Is the RUN

FATAL ERROR
Indicator lit?

YES Replace the

END CPU Unit
CHECK
 Program cannot be written

PROGRAM CANNOT BE WRITTEN TO PLC

Is the mode setting NO Switch to the remote STOP

Switch set to the remote mode & execute the
stop? program mode

YES

NO After reading error code by

Is ERR LED Blinking? using peripheral device,
correct the content

NO

COMPLETE
Environment Condition Check ENVIRONMENT CONDITION CHECK

Is the ambient NO Consider using a FAN or

temperature below 55 COLLER
degree?

YES
NO
Is the ambient
temperature above Consider using a HEATER
0 degree?

YES

NO
Is the ambient humidity Consider using an air
between 10% ~ 85% conditioner

YES

NO Install surge protectors or other

Is noise being controlled? noise reducing equipment at
noise sources

YES
NO
Is the installation Consider constructing an
environment ok? instrument panel or cabinet

YES

END
ERR/ALM Indicator flashing ERR/ALM INDICATOR FLASHING

Determine the cause of

the error with a
programming device

IS a non fatal error YES Identify the error, eliminates its

Indicated? cause & clear the error

NO

Is the ERR/ALM FLASHING

Indicator flashing?

NO

Replace the
END
CPU Unit

NON- FATAL ERROR

CHECK
 0002 0003
MALFUNCTIONING OF SOL 1
01003
SOL 1
I/O CHECK
01003

Is the IR 01003 output NO

Indicator operating?

YES

Check the voltage at IR Wire correctly Correct the short circuit or Monitor the ON/OFF
01003 terminals limit the connected load status of IR 01003
NO to the specified range with the
Programming
Device
NO
Operation ok? Is the Output wiring
correct?

YES
YES NO
Operation ok?
Is the external power YES

Next slide
supply Shorted or
overload?
YES
NO
Disconnect the external
wires & check the
conductivity of each wire

YES NO
Operation ok?

Replace the CPU Unit,

Check output Expansion Unit, or Expansion
device SOL 1. I/O Unit with the problem
 0002 0003

01003
SOL 1
I/O CHECK
01003

Are the IR 0002 & IR 0003 NO

Input indicators operating
From previous slide

Normally?

Check the voltage at the

YES IR 0002 & IR 0003 terminals
Check the voltage at the
IR 0002 & IR 0003 terminals

YES
Operation ok?

NO
NO
Operation ok?
YES Are the terminals
Is the wiring correct? YES screws loose?
YES
Check operation by using
NO
a dummy input signal to NO
turn the input ON & OFF
Wire Correctly Tighten the
terminal screws
NO
Operation ok?

Replace the CPU Unit,

Expansion Unit, or Check input
Expansion I/O Unit devices LS1 & LS2 Return to Start Replace the CPU Unit,
with the problem Expansion Unit, or Expansion
I/O Unit with the problem
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