Industrial Automation (Advance)

Unit-03 : Installation and maintenance of PLC

systems

By : Er. Shivam Choudhary

PLC enclosure

 PLC enclosures are cabinets used for in-house industrial control

panels and CPUs.

 They preserve PLC and other sensitive electronics in excellent

conditions.

 This enclosure protects technicians from contact with energized

parts.

 They are designed to operate well in both indoor and outdoor

applications, and are commonly used in manufacturing lines,
conveyor systems, oil refineries, and indoor and outdoor
automation.
PLC Enclosures Protects Electronics From:

 high temperatures

 Moisture

 Humidity

 dust, water, oil

 shock and vibrations

 mechanical forces

 corrosive environments.
 Grounding requirements

 Proper grounding is an important safety measure in all electrical

installations. Grounding or earthing is referred as connecting the
electrical equipment body with earth.

 The National Electrical Code is the authoritative source on

grounding requirements for a PLC installation.

 It specifies the types of conductors, color codes, and connections

necessary for safe grounding of electrical components.

 A properly installed grounding system will provide a low-

impedance path to earth ground
Noise generating inductive devices

 Noise is an unwanted electrical signal that provides undesirable effects

and hence disrupts the control system.

 Inductive loads generally induce noise in the PLCs.

 Devices that are potential noise generators include relays, solenoids,

motors, and motor starters, especially when operated by hard contacts,
such as push buttons and selector switches.

 To increase the operating noise margin, the controller must be

installed away from noise-generating devices such as large AC motors
and high-frequency welding machines. Also, all inductive loads must
be suppressed.
Leaky inputs and outputs

Leaky inputs and outputs can cause problems in PLCs.

A leaky input 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.

These connections include leaky inputs, inductive loads, output

fusing, and shielded cable.
Techniques to reduce electrical noise and leakage

There are several techniques to reduce electrical noise and leakage in PLCs.

 These include proper placement of sensors and cables, routing cables away
from large motors or control cabinets with transformers and other inductors,
using shielded cables for sensors, digital communications, and even load
wiring.

 Properly grounding your equipment can also help reduce electrical noise.

 Conducted noise is usually best reduced by adding filtering to the cables where
the noise is entering the system.

 Using an LC filter for power supply is a great way to reduce unwanted circuit
noise and ensure your design is functioning optimally.
Introduction to PLC Troubleshooting and maintenance

o PLC troubleshooting is the process of identifying and fixing

problems in a programmable logic controller system.

Some common methods and steps for PLC troubleshooting are

 Checking the PLC power supply for any loose connections,

burnt/ blown fuses, or low voltage supply in the control circuit.

 Checking if the emergency push button is pressed.

 Checking the status monitoring LED indicators on the CPU
module of the PLC, which include “BATT”

 “ALARM” (ALM), and “ERROR” (ERR) LEDs.

 Verifying the PLC program with the master program.

 Checking if the PLC memory is corrupted

 It is also important to keep your system up-to-date with the

latest firmware and software updates.

 Regular maintenance can help prevent problems before they

occur.
 Hardware Faults

 The hardware faults mostly occurred in the field with your

physical field devices and it is Caused by:

 Invalid wiring connection of your instruments and control

devices.

 Failure in the instrument or in the PLC itself due to many

reasons.
Software Faults

The software faults have two main reasons:

 Programming mistakes that is mainly because of some wrong

instruction into your code that do not meet the process
requirements.

 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 itself. These faults related to the compiling of your
code.
 Troubleshooting software involves discovering which problem is
causing the issue. Generally speaking, software issues are
consistent, but which program is causing the problem, you start
with the:

 Windows

 Hardware drivers

 Programs and applications that you run.

Diagnostic LED Indicators in PLCs

 LED indicators are used in PLCs to give relevant information about the
system’s status.

 The CPU module of the PLC hosts several status monitoring LEDs such
as “BATT”, “ALARM” (ALM), and “ERROR” (ERR), which indicate
an internal problem.

 The RUN light should be green, indicating that the PLC is in RUN
mode.

 If the BATT light is red, the battery needs to be replaced. LED

indicators greatly assist the troubleshooting process, but cannot diagnose
all possible problems
Common Problems Encountered in PLC Control Systems

 Technical problems that may be encountered in properly

programmed and wired PLC control systems can be
classified as internal, environmental, or external.

Internal PLC Problems

Internal problems in a PLC system refer to the technical faults

pertaining(संबंधित) to the PLC processor, memory, and power
supply. The possible causes of these internal problems
include:
 Faulty Power and Ground Connections: The
main issues with power circuits and ground
connections could be looseness, breaks in wiring,
corrosion, and carbon deposits due to sparking.

 Check if the Emergency Push Button is

pressed: Pressing this button usually shuts down
the PLC-based control system, which could be the
reason why the PLC is not in operation.
 Power Supply Failure: Like any other electronic device, a PLC requires
a steady and uninterrupted supply of power so as to function properly and
effectively. In case of sudden power loss due to grid failure, regional
blackouts, loose connections, burnt fuse, or deteriorated cables, the
electrical shock to the PLC system is usually huge and may result in data
loss.

 Battery Failure: The most effective way to avoid PLC problems

associated with sudden power loss is to install backup power sources
which activate when the primary power supply becomes unavailable.
Many PLC control systems include a battery whose purpose is to prolong
the supply of power in the event of an outage, so as to secure the PLC
program stored in RAM. But if the battery is not regularly checked or
replaced as specified by its manufacturer, it could fail to provide adequate
voltage for retaining the processor’s non-volatile memory during power
outages.
 Electrical Noise Interference: Foreign signals resulting from
either Radio Frequency Interference (RFI) or Electromagnetic
Interference (EMI) can greatly affect the performance and service
life of a PLC. The use of antennas, transmitters, and handheld
radios in close proximity to the PLC system can result in RFI.

 Verify the PLC Program with the Master Program. Check if the
program in the PLC memory matches the backed up original
copies, and reload the program if you encounter any problems. You
can use the DEBUG feature in the PLC Program to match the
running program with the initially loaded master program. Also,
after verifying the PLC program ensure that the backup copies are
up-to-date and keep them safely, away from extreme temperatures,
and high humidity; so that they remain usable.
Corrupted PLC Memory: External factors such as the
Radio Frequency and Electromagnetic Interference as well
as power supply disruptions can corrupt the PLC memory.
When this happens, the programs and functions stored
within the PLC memory may become unreadable, or the
PLC processor may not be able to execute the program
properly when booted up from an unintended shutdown.
External PLC Problems

Problems pertaining to communication modules, network connections, and specific I/O

modules are referred to as external PLC problems. Various PLC tools, as well as status-
indicating LEDs on the CPU and I/O modules, can be used to localize the external faults.

 Input/output Module Failure: Once a PLC control system is properly wired and
programmed, more than 80% of the problems affecting such a system are related to
I/O modules and field I/O devices. For example, whenever a PLC controlled process
or machine stops, it’s almost invariably that a faulty field input/output device or I/O
module has caused the shutdown.

 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. Because if the connection was to fail, the connected devices
cannot perform their functions as per the PLC program, which could result in
downtime of the system or process being controlled by the PLC.
Environmental Problems

 PLC control systems must operate throughout within the working

environmental conditions recommended by the manufacturers, in
order to avoid system failures and malfunctioning. In this context,
factors like humidity, temperature, dust, corrosion, noise level,
mechanical vibrations, and exposure to corrosive or non-corrosive
gases and liquids need to be critically monitored.
Troubleshooting(समस्या निवारण) of Specific Components of the PLC
System

Power Supply Troubleshooting

 When troubleshooting the power supply module of a PLC, the first thing to
check is the integrity of the voltage source and grounding.

 Thus, visually inspect the power circuit and ground wiring for loose, corroded,
or other faulty connections.

 Then, use a digital multimeter or voltmeter set on the lowest scale possible to
check the electrical integrity of the ground voltage, by measuring the voltage
between the PLC ground terminal and a reference ground.

 The meter readings should be zero for both AC and DC voltages.

Flowchart for
Troubleshooting PLC Power
Supply Faults
I/O Modules Troubleshooting

 Troubleshooting the PLC output and input units requires checking whether the
status monitoring LEDs on those units are “ON” or “OFF”, to be able to
localize the problem.

 The primary focus for troubleshooting I/O module failure is to establish the
disconnect between the internal diagnosis (what the PLC processor thinks is
happening) and the external diagnosis (what’s actually happening).

 This process requires the operator to examine the relation between the I/O
instructions within the PLC program stored in RAM and the physical I/O
modules.

 Once the relation has been established, the faulty I/O module can then be
isolated and its internal status checked using a program monitoring device.
Troubleshooting PLC Program Errors

 When no abnormality is found with the PLC CPU, its power

supply, the I/O modules, and corresponding field I/O devices, you
should confirm that the program in the PLC RAM memory is the
same as the backed-up master program.

 Also, check if there are any communication problems between the

I/O modules and the PLC processor.

 The flowchart illustrated below provides the procedure for

examining the PLC program and CPU communications.
Flowchart for Troubleshooting the PLC
program
Troubleshooting the Working Environment of
a PLC

To check the environmental conditions of a PLC

system in operation, you can follow the
procedure outlined in the flowchart:
Flowchart for Checking the
Working Environmental
conditions of a PLC
Replacement of CPU
 If the diagnostic LED indicators on the front of the CPU module
show no fault in either memory, battery, or communications.

 The power supply, field input, and output devices, as well as the
I/O modules, check OK. And the program in the PLC memory
matches with the master program and all the working
environmental conditions are as recommended by the PLC
manufacturer. But the PLC system still doesn’t come up even
with proper powering, then the problem lies in the CPU circuitry,
and the CPU may need to be replaced.
PLC Troubleshooting Flowchart
Main PLC Troubleshooting Flowchart
PLC maintenance checklist
Here is a checklist(जााँच सच
ू ी) for PLC maintenance:

 Back up your PLC program before preventive maintenance.

 Check LED indicators for battery replacement.

 Check the power supply regularly.

 Check the battery backup regularly.

 Check the wiring and connections regularly.

 Keep the software up-to-date.

 Regularly back up your programs and data.

Preventive maintenance procedure

Here is a procedure for preventive(निवारक) maintenance of PLC:

 Back up your PLC program prior to getting your hands dirty (it’s also a good idea to
always keep a master copy of operating programs on hand).

 Follow proper lockout/tagout procedures.

 Remove power from the system.

 Check environmental factors/operating conditions.

 Clear debris(मलबा ), dust from your units.

 Clean or replace all filters installed in enclosures.

 Check all your connections for a tight fit, especially I/O modules.

 Inspect I/O devices for proper adjustments.

 Check LED battery indicators on the RAM memory module in the CPU.

 Check the power and battery LED indicators that back up the RAM memory
in the CPU.

 Check the environment temperature, humidity and other factors satisfy the
PLC operating conditions.

 Clear dust.

 Audit parts in use.

Maintenance plan for the PLC system

 A preventive maintenance plan for the PLC system should be

scheduled with the regular machine or equipment maintenance so
that the equipment and controller are down for a minimum amount of
time.

 The schedule for PLC preventive maintenance depends on the

controller’s environment – the harsher the environment, the more
frequent the maintenance.

Here are some steps that can be followed to keep the system in good
operating condition:

 Check environmental factors/operating conditions.

 Clear debris, dust from your units.

 Clean or replace all filters installed in enclosures.

 Check all your connections for a tight fit, especially I/O

modules.

 Inspect I/O devices for proper adjustments.

 Check LED battery indicators on the RAM memory

module in the CPU
Safety procedure

 Safety in PLCs is an important aspect of industrial automation.

 A Safety PLC is one of the 3 parts of a Safety Instrumented

System (SIS).

 The SIS can also be referred to as the Safety Shutdown

System.

 Stated simply, the SIS monitors the equipment or process and

if an unacceptable condition or risk, or an unsafe condition
occurs it reacts by the shutdown of the equipment or process.
Safety equipment

 Safety PLCs are designed for safety-related applications.

 They are one of the parts of a Safety Instrumented System (SIS) that
monitors and shuts down the equipment or process if an unsafe condition
occurs.

 A safety PLC can control and automate pieces of industrial equipment, as

well as safety systems.

 A safety PLC has internal, diverse, redundant processors that cross check
all safety functions and initiate a safe shutdown if they detect a failure.

 A safety PLC can achieve a high safety integrity level (SIL) rating and
meet standards like IEC 61511 and IEC 61508.