Unit – 03

Installation and maintenance of PLC systems

PLC Enclosure

PLC enclosures are used in a variety of applications and are the go-to option for different industries. The
enclosures are designed to perform well both indoors and outdoors. They come in handy when working
with larger electrical equipment and controls, whether they are for electric power distribution or
engineering1. PLC enclosures are designed to feature a lot of space that allows them to cater to large PCB
(printed circuit board) systems.

Grounding Requirements

Grounding or Earthing Scheme in DCS or PLC Systems is crucial. Whenever the DCS or PLC systems are
grounded, they still not connected to the earth. The system has a ground bus bar inside located at an
appropriate place to which all internal grounding connection is returned. Once the final ground bus bar is
connected to an actual-earth pit or earth grid that the system finally earthed. Improper earthing or
grounding of Distributed Control System (DCS) or Programmable Logic Controller (PLC) may result in either
mal-operation of the control system or a controller or failure of electronic cards or sometimes even
embedded software gets erased.

Noise Generating Inductive Devices

Devices such as relays, solenoids, motors, and motor starters can generate electrical noise that can interfere
with the operation of the PLC. Noise usually enters a system through input, output, and power supply lines.
Noise may also be coupled into these lines electrostatically through the capacitance between them and the
noise signal carrier lines.

Leaky Inputs and Outputs

Leaky inputs can be corrected by placing a bleeding (or loading) resistor across the input. A bleeding resistor
introduces resistance into the circuit, causing the voltage to drop on the line between the leaky field device
and the input circuit. This causes a shunt on the input’s terminals

Techniques to Reduce Electrical Noise and Leakage

There are several techniques to reduce electrical noise and leakage in PLC systems:
• Use of shielded cables: Proper use of shielded cables will help minimize common mode electrostatic
noise5.
• Use of twisted pair cables: Twisted pair cables can help reduce electromagnetic interference5.
• Signal isolation: Signal isolation can help reduce noise by isolating the signal path from other paths
that might introduce noise5.
• Differential measurements: Differential measurements can help reduce noise by measuring the
difference between two signals rather than absolute values5.
• Grounding: Proper grounding can help reduce electrical noise by providing a path for noise currents
to flow back to their source5.
• Wire routing: Proper wire routing can help reduce noise by keeping wires carrying sensitive signals
away from wires carrying high current or high voltage signals5.
 • Anti-aliasing filters: Anti-aliasing filters can help reduce noise by filtering out high-frequency
components that might alias into lower frequencies5.

Introduction to PLC Troubleshooting and Maintenance

PLC troubleshooting and maintenance is a critical skill for automation engineers. PLCs are essential
components in modern control systems, and understanding the basic components of a PLC is crucial when it
comes to troubleshooting and maintaining these systems1. When a problem occurs, the first step in the
troubleshooting procedure is to identify the problem and its source2. The source of a problem can generally
be narrowed down to the processor module, I/O hardware, wiring, machine inputs or outputs, or ladder
logic program3.

Troubleshooting of Hardware and Software in PLC Systems

Hardware faults in PLC systems can occur due to invalid wiring connections of your instruments and control
devices or failure in the instrument or in the PLC itself due to many reasons4. Software faults have two main
reasons: Programming mistakes that do not meet the process requirements and software debugs or system
errors that may happen if the PLC exceeds the scan cycle time or it can push your PLC to go in the STOP
mode by itself4. These faults related to the compiling of your code4.

Troubleshooting tools like ControlFLASH™ and RSLogix 5000™ can help diagnose software-related issues.
Unexpected fault conditions can also be a frequent concern with PLCs. These can arise from various
sources, such as power supply failures, I/O module issues, or even software bugs.

Diagnostic LED Indicators in PLCs

Diagnostic LED indicators on a PLC provide visual feedback about the status of the system. They can indicate
power status, network communication status, error conditions, and more1. Here are some common types of
LED indicators you might see on a PLC:

1. Power LED: This light indicates whether the PLC is receiving power. If this light is off, it means the PLC is
not receiving power1.

2. Run LED: This light indicates whether the PLC is in Run mode. If this light is on, it means the PLC is
running its program1.

3. Error/Fault LED: This light indicates whether there are any errors or faults in the PLC system. If this light is
on, it means there is an error or fault that needs to be addressed2.

4. I/O Status LEDs: These lights indicate the status of the individual I/O modules. They can help identify
specific problems or statuses1.

5. Network Communication LEDs: These lights indicate the status of network communication. They can
help identify issues with network connectivity1.

In addition to these, some PLCs may have other specific LEDs for functions like battery status, module
status, etc3. The exact meaning of each LED can vary between different PLC models and manufacturers, so
it’s always a good idea to refer to the specific PLC’s manual for accurate information.
Internal Problems in PLC

1. PLC Power Supply The power supply provides the appropriate voltage levels required to power on the
PLC and its internal components. It accomplishes this by converting a line voltage, mainly 120V or 240V AC
(Alternating Current), into the required DC (Direct Current), normally 24V DC1.
2. Emergency Push Button An emergency push button is a safety device that is used to shut down a
machine or a process in an industrial setting. It is typically red and is usually a large, conspicuous button
designed to be easily accessible2. When pressed, it should halt the operation of the machine or process as
quickly as possible in a controlled manner3.
3. Power Supply Failure Power supply issues are common causes of PLC control system failures. PLC control
systems require a steady stream of power or electricity to function as designed. When power is lost or
fluctuates, the PLC can no longer function properly, and such frequent interruptions can cause complete
system failure4.
4. Battery Failure PLC configuration settings, Process set points, PLC logic, and Real-Time clock are stored in
the EPROM (Erasable Programmable Read-Only Memory), and the battery powers the EPROM1. The battery
continues to power the EPROM, in case the PLC’s power supply is isolated for maintenance or when a
power failure occurs1. The lifespan of the PLC batteries can be affected negatively by frequent power
outages, high operating temperatures, and powering off the system for long durations1.
5. Electrical Noise Interference Electrical noise interference can have a large impact on the PLC control
system. This typically occurs when there is foreign signal interference from electromagnetic interference
(EMI) or radio frequency interference (RFI). To avoid electrical noise interference, be sure to store any large
motors or similar machines far from the PLC system5.
6. Verifying the PLC Program with the Master Program Verifying the PLC program with the master program
is an important step in ensuring that the PLC is functioning correctly. This involves comparing the current
program running on the PLC with a known good version (the master program). Any discrepancies between
these two programs could indicate an issue with the PLC’s programming that needs to be addressed.
7. Corrupted PLC Memory Corrupted memory in a PLC can occur due to external factors such as electrical
noise interference and power disruptions. When this happens, the code within the PLC may become
unreadable, or the PLC may not be able to read properly when it’s booted up from an unintentional
shutdown6. The safest and most efficient way to deal with this problem is to ensure all data is copied to a
redundant storage device that is kept away from interference, high temperatures and humidity6.

External Problems in PLC

1. Power failure Power supply issues are common causes of PLC control system failures. PLC control systems
require a steady stream of power or electricity to function as designed. When power is lost or fluctuates,
the PLC can no longer function properly, and such frequent interruptions can cause complete system
failure12. Power failures can be avoided using a backup power source to ensure a constant flow of power to
the PLC32.

2. Faulty grounding A good grounding of the PLC system is essential for the safety of the system and
personnel. Ground wires must be fully intact4. Improper earthing or grounding of Distributed Control
System (DCS) or Programmable Logic Controller (PLC) may result in either mal-operation of the control
system or a controller or failure of electronic cards or sometimes even embedded software gets erased5.

3. Electrical noise interference (RFI or EMI) Electrical noise interference can have a large impact on the PLC
control system. This typically occurs when there is foreign signal interference from electromagnetic
interference (EMI) or radio frequency interference (RFI). To avoid electrical noise interference, be sure to
store any large motors or similar machines far from the PLC system62.
4. Status of the Output Modules and their associated Circuitry Output signals are generated by the PLC’s
computer circuitry activating a switching device (transistor, TRIAC, or even an electromechanical relay),
connecting the “Source” terminal to any of the “Y-” labeled output terminals7. The “Source” terminal,
correspondingly, is usually connected to the L1 side of the 120 VAC power source7.

5. Status of the Input Modules and their associated Circuitry Input devices provide data and control signals
to an information processing system (IPS). Some examples of input devices include: Switches and push
buttons, Sensing devices, Limit switches, Proximity sensors, Photoelectric Sensors, Condition sensors8. The
input device provides a signal to an input module. This input module is connected with the CPU for the
initial automated processes9.

6. Field Input and Output Devices Field devices are all controlled by Programmable Logic Controllers (PLCs).
They are all connected to the PLC and provide an interface between them and the CPU10. Input devices can
be either start and stop pushbuttons, switches, etc and output devices can be an electric heater, valves,
relays, etc11.

7. Communication Issues To function properly, PLC systems should be in constant communication with field
input and output devices, and other peripheral devices like Human-Machine Interfaces (HMIs). These
communications are facilitated via cables like Ethernet, RS-232 serial, and USB cables, and they require safe,
consistent, and stable connections.

Environmental Conditions for PLC

1. Checking for Humidity in PLC Systems Humidity can have a significant impact on the performance and
lifespan of a PLC system. High humidity can lead to condensation, which can cause short circuits and
corrosion in the PLC’s electronic components1. Therefore, it’s important to monitor the humidity levels in
the environment where the PLC is operating. This can be done using humidity sensors that measure both
temperature and humidity at the same time1. The measured values are stored in the PLC and displayed on a
Human-Machine Interface (HMI) for monitoring1.

2. Checking for Temperature in PLC Systems Temperature is another critical factor for PLC systems. If the
temperature in the environment where the PLC is operating gets too high, it can cause overheating, which
can lead to reduced performance or even damage to the PLC2. Therefore, it’s important to monitor the
temperature levels in the environment where the PLC is operating. This can be done using temperature
sensors that are connected to the PLC2. The PLC reads the voltage from these sensors to determine the
temperature2.

3. Checking for Vibration in PLC Systems Vibration can also affect the performance and lifespan of a PLC
system. Excessive vibration can cause mechanical stress and wear on the PLC’s components, leading to
premature failure3. Therefore, it’s important to monitor vibration levels in the environment where the PLC is
operating. This can be done using vibration sensors that are connected to the PLC3. The PLC reads signals
from these sensors to monitor vibration levels3.

4. Checking for Noise-Level Limits in PLC Systems Electrical noise can interfere with the operation of a PLC
system, causing errors and reducing performance4. Therefore, it’s important to monitor noise levels in the
environment where the PLC is operating. This can be done using noise measurement devices that are
connected to the PLC4. The PLC reads signals from these devices to monitor noise levels4.
Troubleshooting of Specific Components of the PLC System

1. Power Supply Troubleshooting The power supply provides the appropriate voltage levels required to
power on the PLC and its internal components. It accomplishes this by converting a line voltage, mainly
120V or 240V AC (Alternating Current), into the required DC (Direct Current), normally 24V DC1. If the PLC is
still not working, check for voltage supply drop in the control circuit or for blown fuses1. When many parts
of a system, such as the sensors on a machine, or an entire PLC, go dead, that might indicate faulty power
supply2.

2. I/O Modules Troubleshooting Input/Output (I/O) modules are responsible for communicating with the
external devices in a control system. Input modules receive digital or analog signals from sensors and
convert them into a format that the processor can understand3. Conversely, output modules receive digital
or analog signals from the processor and convert them into signals that can control devices such as motors
or valves3. The primary goal of I/O troubleshooting is to find out why the internal status of the PLC (what
the PLC thinks is happening) does not agree with the external situation (what is actually happening)4.

3. Troubleshooting PLC Program Errors PLC programming errors can occur for a variety of reasons, such as
incorrect programming, wiring errors, or hardware malfunctions5. These errors can cause the PLC to behave
unpredictably, leading to incorrect outputs or even system failures5. Troubleshooting these errors requires a
systematic approach that involves identifying the root cause of the problem and then taking the necessary
steps to fix it5.

4. Troubleshooting the Working Environment of a PLC The working environment of a PLC includes factors
like temperature, humidity, vibration, and noise levels. These factors can significantly impact the
performance and lifespan of a PLC system6. For example, high temperatures can lead to overheating, which
can reduce performance or even damage the PLC6. Therefore, it’s important to monitor these
environmental conditions and ensure they are consistently within the range specified by the manufacturer.

5. Replacement of CPU The CPU is the brain of the PLC and is responsible for processing the logic and
making output decisions based on the inputs received7. If there’s an issue with the CPU, it may need to be
replaced. Some PLCs have a simple conversion kit as it’s very low risk and requires little downtime8. It’s not
necessary to do any rewiring, and existing swing arms will fit directly onto the conversion modules8.

PLC trouble shooting flowchart

A PLC troubleshooting flowchart is a step-by-step guide to diagnosing and resolving common PLC problems.
Here’s a general procedure outlined in a flowchart1:

1. Check the PLC Power Supply: Look for any loose connections, burnt/blown fuses, or low voltage
supply in the control circuit1.

2. Check the Emergency Push Button: Ensure it hasn’t been accidentally pressed1.

3. Check the Status Monitoring LED Indicators on the CPU module of the PLC: These include “BATT”,
“ALARM” (ALM), and “ERROR” (ERR) LEDs1. These indicators can provide valuable information about
the status of the PLC.

4. Verify the PLC Program with the Master Program: Compare the current program running on the
PLC with a known good version (the master program). Any discrepancies between these two
programs could indicate an issue with the PLC’s programming that needs to be addressed1.
 5. Check if the PLC Memory is Corrupted: Corrupted memory in a PLC can occur due to external
factors such as electrical noise interference and power disruptions. When this happens, the code
within the PLC may become unreadable, or the PLC may not be able to read properly when it’s
booted up from an unintentional shutdown1.

PLC Maintenance Checklist

A PLC maintenance checklist is a list of tasks that need to be completed to ensure the PLC system is
maintained properly. Here are some items that might be included on a PLC maintenance checklist123:
• Backup PLC Program: Save a copy of your PLC program during routine maintenance to ensure a
fairly up-to-date backup1.
• Check LED Indicators: Check the power and battery LED indicators1.
• Replace the Battery: If the Battery OK light is flickering or on, it is time to change the battery1.
• Check Operating Environment: Check temperature, humidity and other environmental factors1.
• Check Operating Voltage: Check the input voltage that is powering your PLC1.
• Check Program Functionality: During routine maintenance, check the functionality to make sure the
system or equipment that is being controlled is operating as intended1.
• Look For Indications Of Overheated Components: Check the CPU and modules for distorted,
warped, or discolored cases and burnt odors1.
• Clear Dust And Check Venting: Do not allow dirt and dust to accumulate on the PLC’s components1.
• Inspect Battery Status: Check battery and replace if necessary1.
• Check Connections: Make sure that all communication cables, plugs, sockets, terminal strips, wiring
and modules are connected properly1.

Preventive Maintenance Procedure

Preventive maintenance involves regularly scheduled inspections, updates, and repairs to prevent potential
failures or breakdowns. Here are some preventive maintenance procedures for a PLC system23:
• Regularly clean or replace any filters that have been installed in enclosures at a frequency
dependent on the amount of dust in the area3.
• Do not allow dirt and dust to accumulate on the PLC’s components; if dust builds up on heat sinks
and electronic circuitry, it can obstruct heat dissipation, causing circuit malfunction3.
• Periodically check the connections to the I/O modules to ensure that all plugs, sockets, terminal
strips, and modules have good connections3.
• Ensure that heavy, noise-generating equipment is not located too close to the PLC3.

Maintenance Plan for the PLC System

A maintenance plan for a PLC system outlines the tasks and schedule for maintaining the system. It includes
regular inspections of hardware and software components, updates to software as needed, and
replacement of parts as they wear out or fail. The plan should also include regular backups of PLC programs
and data. The frequency of these tasks will depend on factors such as the age of the system, its operating
environment, and how critical it is to operations2.
Safety Procedures in PLC Systems

Safety procedures are a set of guidelines that are followed to ensure the safe operation and maintenance of
PLC systems. Here are some key safety procedures123:

1. Emergency Stop: An emergency stop is used to stop the system suddenly when an operator presses
this button1.
2. Power Supply: The power supply must be designed properly to ensure safe operation of the PLC
system2.
3. Earthing: Proper earthing is required to pass any leakage current to the ground. This prevents
electric shock, noise, and electromagnetic interference2.
4. Critical Digital Input Signals: Every PLC system must have critical inputs like emergency stop, panel
power failure, and air pressure. Also, all these signals must be connected in NC (normally closed)
format2.
5. Disable Mode: The PLC must be put in a mode that prevents it from sending an output voltage or
current to the output devices. This can either be called “Disable” or “Continuous test” mode
depending on the PLC manufacturer4.

Safety Equipment in PLC Systems

Safety equipment refers to the devices and systems used to ensure the safe operation of a PLC system. Here
are some key safety equipment used in PLC systems56:

1. Safety PLCs: Safety PLCs are constantly guarding against plant failures which could result in harm to
people, equipment, or the environment5.
2. Emergency Stops: Emergency stops are devices that provide a means of stopping machinery during
an emergency situation where there is a risk of injury or damage1.
3. Safety Relays: Safety relays are devices that implement safety functions. In a safety-related control
system, they monitor variables such as position switches, ropes, light barriers, etc., and allow for
safe switching of higher loads6.
4. Safety Sensors: Safety sensors are used to monitor the position of guards or to create a monitored
protective field. They provide non-contact protection of people and machinery6.