DEPARTMENT OF MECHANICAL ENGINEERING

DJM3072
PROGRAMMABLE LOGIC CONTROLLER

LAB REPORT

Experiment No. : EXPERIMENT 4

PLC SELECTION, INSTALATION AND
Title : MAINTENANCE
1) Mahindra Prakas Rao Ramarao(1070)
2) Kesaven Swaminathan (1099)
3) Kevin Santana Anthony (1119)
4) Manosh Kumaar A/L Kalaimani
Name : Daniel(1157)
Programme : DIPLOMA IN MECHANICAL ENGINEERING
Semester : SEMESTER 5
Date : 16/10/2019
Lecturer : Encik Rama Rao & Pn Noor Liza Wati
 ASSESSMENT RUBRIC

a) LAB SESSION ASSESSMENT RUBRIC

b) LAB REPORT ASSESSMENT RUBRIC

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EXPERIMENT NO:
LAB 4/4

TITLE:

PLC SELECTION,
INSTALATION AND
MAINTENANCE

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1.0 TITLE :COUNTER APPLICATION IN PLC

2.0 EXPERIMENT OBJECTIVES:

-Identify the PLC selection procedure
-Install the PLC module (Brand: Siemens)
-Conduct basic maintenance on PLC
3.0 EQUIPMENTS / MATERIALS:
-Siemens PLC module
-Basic PLC maintenance check list

4.0 THEORY:
PLC selection criteria
System requirements:
The starting point in determining any solution must be to understand what is to be
achieved.
The program design starts with breaking down the task into a number of simple
understandable elements, each of which can be easily described.

Application requirements:
Input and output device requirements. After determining the operation of the system, the
next step is to determine what input and output devices the system requires.
List the function required and identify a specific type of device.
The need for special operations in addition to discrete (On/Off) logic.
List the advanced functions required beside simple discrete logic.

Electrical Requirements:
The electrical requirements for inputs, outputs, and system power; When determining the
electrical requirements of a system, consider three items:
Incoming power (power for the control system);
Input device voltage; and
Output voltage and current.

Speed of Operation:
How fast the control system must operate (speed of operation). When determining speed of
operation, consider these points:

- How fast does the process occur or machine operate?

Are there “time critical” operations or events that must be detected?
In what time frame must the fastest action occur (input device detection to output device
activation)?
Does the control system need to count pulses from an encoder or flow-meter and respond
quickly?

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 Communication:
If the application requires sharing data outside the process, i.e. communication.
Communication involves sharing application data or status with another electronic device,
such as a computer or a monitor in an operator’s station. Communication can take place
locally through a twisted-pair wire, or remotely via telephone or radio modem.

Operator Interface:
If the system needs operator control or interaction. In order to convey information about
machine or process status, or to allow an operator to input data, many applications require
operator interfaces. Traditional operator interfaces include pushbuttons, pilot lights and LED
numeric display. Electronic operator interface devices display messages about machine
status in descriptive text, display part count and track alarms. Also, they can be used for
data input.
Physical Environment:
The physical environment in which the control system will be located. Consider the
environment where the control system will be located. In harsh environments, house the
control system in an appropriate IP-rated enclosure. Remember to consider accessibility for
maintenance, troubleshooting or reprogramming.

5.0 PROCEDURES:

1. Save A copy of PLC program Was saved during routine maintenance to ensure a fairly up-
to-date backup. In the event a PLC becomes inoperable and has to be replaced, this backup
file can be downloaded onto a new PLC.

2. Check the power and battery LED was checked indicators. If the power LED indicator is off
or flickering or if the battery LED indicator is on or flickering this may be a preliminary sign
of a low battery or potential power issues.

3.If the Battery OK light is flickering or on, it is time to change the battery. Avoided
catastrophic problems if were to lose main control power by changing the battery regularly
– it easy – watched these videos to learn more.

4. Checked temperature, humidity and other environmental factors to make sure that your
PLC is operating within the proper conditions. Also make sured there is good airflow in the
cabinet by cleaning filters in the enclosure.

5. Checked the input voltage that is powering PLC to make sure that the voltage is within
the appropriate range and free from power spikes or ‘brown out’ conditions.

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6. During routine maintenance, checked the functionality to make sure the system or
equipment that is being controlled is operating as intended.

7. Checked the CPU and modules for distorted, warped, or discolored cases and burnt odors.

8.Dirt and dust was not allowed to accumulate on the PLC’s components. The central
processing unit and I/O system are not designed to be dust proof. Check to be sure none of
the PLC and module cooling vents are clogged or blocked by dust or debris. Make sure that
there is sufficient heat dissipation space around the PLC. If heat dissipation is obstructed,
circuit malfunction can occur and if conductive dust reaches the electronic boards, it can
cause a short circuit, resulting in possible permanent damage to the circuit board.

9.Battery Was checked and replaced if necessary.

10.all communication cables, plugs, sockets, terminal strips, wiring and modules are
Checked connected properly. If your PLC system is located in an area that experiences
constant vibrations that could possible loosen terminal connections, perform this check
more often and consider installing a vibration detector.

11.any product notices, patches and upgrades and update Was checked as necessary.

12.items such as drawings, installation manuals or other materials was krep3d way from the
PLC system. Leaving these items on top of the CPU rack or other enclosures can obstruct
airflow and create hot spots, ultimately causing a system malfunction.

13.An audit was conducted to check each component of your PLC system and determine if
parts are good or need replacement.

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 14. A stock of replacement parts was keeped on hand to minimize downtime resulting from
component failure. Having the right spare in stock during a failure situation can result in
shutdown for only minutes instead of hours or days.

6.0 RESULT / DATA:

7.0 DISCUSSION:

8.0 CONCLUSION:

9.0 REFERENCES: