plc troubleshooting & maintenance

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PLC Troubleshooting & Maintenance www.nfiautomation.org nfi

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Learn 5 PLC's in a Day full Course 155+ PLC Video Tutorials of Allen Bradley, Siemens, Delta, Omron & Schneider with FREE PLC Simulators and NFI Support Course Fee: $49 , Lifetime Validity | Limited Coupons only| Course url: https://www.udemy.com/nfi-plc-online-leaning/?couponCode=slideshare For LIVE Sessions and combo offers please visit: www.nfiautomation.org Connect us at: Facebook: https://www.facebook.com/nfiinnovation Website: http://www.nfiautomation.org Google Plus: https://plus.google.com/+RajvirSinghNFIAutomation E-mail: [email protected]

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Page 1: PLC Troubleshooting & Maintenance

PLC

Troubleshooting

& Maintenancewww.nfiautomation.org

nfi

Page 2: PLC Troubleshooting & Maintenance

Senses

Brain Motion

Energy

Manual Work

Human Lags:

• Cannot Work 24 Hours

• Cannot work with 100% Accuracy &

precision

• Efficiency decreases as energy

decreases

Human

Page 3: PLC Troubleshooting & Maintenance

Sensors

Controllers

Actuators

Energy

Automatic Work

Machine

Advantages:• Accuracy

• No idle Time

• More Production

Lags:• Regular

Troubleshooting &

Maintenance

Page 4: PLC Troubleshooting & Maintenance

What is Controllers?

Controller

A closed Loop Control System

Controller is a part of Automatic Control System, which process the

signal from sensors & send it to the actuators

Sensors Actuator

Page 5: PLC Troubleshooting & Maintenance

This is a PLC Input Terminals

Output Terminals

Programming Cable

A/D Card

D/A Card

RS 485

Page 6: PLC Troubleshooting & Maintenance

This is a PLC

Output Terminals

Programming Cable

Power 24 VDC

Battery

Input Terminals

Page 7: PLC Troubleshooting & Maintenance

Output Terminals

Programming Cable Power 24 VDC

Input Terminals

This is a PLC

Page 8: PLC Troubleshooting & Maintenance

Understanding PLC

Page 9: PLC Troubleshooting & Maintenance

Understanding PLC

Page 10: PLC Troubleshooting & Maintenance

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:

Selecting the Outputs

- Number of Outputs

- Nature of Outputs – Digital

or Analog

- Voltage rating of the Inputs

Step 3:

Length of Program – Big or Small

Nature of Program – Ladder

Logic, SFC, Instruction List, FDB

Page 11: PLC Troubleshooting & Maintenance

Programming Languages

Ladder Logic

SFC

Instruction List

FDB

Page 12: PLC Troubleshooting & Maintenance

PLC Ladder Logic

Page 13: PLC Troubleshooting & Maintenance

Common Industrial Hardware

Representing the Binary Concept

Page 14: PLC Troubleshooting & Maintenance

Basics of

Machine

Languagewww.nfiautomation.org

nfi

Page 15: PLC Troubleshooting & Maintenance

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

Basics of Machine Language

Page 16: PLC Troubleshooting & Maintenance

PLC Inputs & Outputswww.nfiautomation.org

nfi

Page 17: PLC Troubleshooting & Maintenance

Digital Inputs & OutputsTypical Digital Input/ Output Signals

• 12 VDC

• 24 VDC

• 120 VAC

• 240 VAC

Page 18: PLC Troubleshooting & Maintenance

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

Page 19: PLC Troubleshooting & Maintenance

Connections from Field Devices

Image courtesy of Allen-Bradley, a Rockwell Automation business

PLC INPUTS & OUTPUTS

Page 20: PLC Troubleshooting & Maintenance

Differential Analog Input Connections

Image courtesy of Allen-Bradley, a Rockwell Automation business

PLC INPUTS & OUTPUTS

Page 21: PLC Troubleshooting & Maintenance

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 signals0 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

Page 22: PLC Troubleshooting & Maintenance

Basics of PLC

ProgrammingLadder Logic

Page 23: PLC Troubleshooting & Maintenance

PLC Enclosure

& System

ComponentsNEMA – 12

National Electric Manufacturer

Association, USA

Page 24: PLC Troubleshooting & Maintenance

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.

Page 25: PLC Troubleshooting & Maintenance

Enclosure Layout

Page 26: PLC Troubleshooting & Maintenance

Placement of PLC Components

All Controller components

should be mounted in a vertical

(upright) position.

To allow

maximum cooling

Page 27: PLC Troubleshooting & Maintenance

Duck & Wire LayoutKeep 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.

Page 28: PLC Troubleshooting & Maintenance

Power

Requirement &

Safety Circuitry

Page 29: PLC Troubleshooting & Maintenance

POWER REQUIREMENTS

Typical Power Requirement

220 VAC

Page 30: PLC Troubleshooting & Maintenance

SAFETY CIRCUITRY

Pull Rope Switch

Door Switch

Emergency Switch Automation Studio

Page 31: PLC Troubleshooting & Maintenance

Master or Safety Control Relays

Automation Studio

Page 32: PLC Troubleshooting & Maintenance

PLC FAULT CONTACT

PROTECTION

Automation Studio

Page 33: PLC Troubleshooting & Maintenance

PLC

MaintenanceHEAT, DUST & NOISE REGULATION

Page 34: PLC Troubleshooting & Maintenance

HEAT & DUST REGULATION

Temperature Withstand Range

0 ~ 60°C

PLC MAINTENANCE

Page 35: PLC Troubleshooting & Maintenance

NOISE REGULATION

Shielded Cables for better communication

PLC MAINTENANCE

Page 36: PLC Troubleshooting & Maintenance

NOISE GENERATING DEVICES

VARIABLE FREQUENCY DRIVES

MOTOR STARTERS

RELAYS AND CONTACTORS

SOLENOIDS

PLC MAINTENANCE

Page 37: PLC Troubleshooting & Maintenance

NOISE FROM GROUNDING

PLC TROUBLESHOOTING 2

Page 38: PLC Troubleshooting & Maintenance

PLC I/O Installation,

Wiring & Precautions

Page 39: PLC Troubleshooting & Maintenance

I/O INSTALLATION, WIRING, AND

PRECAUTIONS

I/O MODULE INSTALLATIONPlacement 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

Page 40: PLC Troubleshooting & Maintenance

I/O INSTALLATION, WIRING, AND

PRECAUTIONS

WIRING

WIRE SIZE CONSIDERATION

Page 41: PLC Troubleshooting & Maintenance

I/O INSTALLATION, WIRING, AND

PRECAUTIONS

WIRE SIZE CONSIDERATION

Page 42: PLC Troubleshooting & Maintenance

I/O INSTALLATION, WIRING, AND

PRECAUTIONS

WIRE LABELLING

Page 43: PLC Troubleshooting & Maintenance

I/O INSTALLATION, WIRING, AND

PRECAUTIONS

WIRE BUNDLING

Page 44: PLC Troubleshooting & Maintenance

PLC START-UP & CHECKING

PROCEDURES

Page 45: PLC Troubleshooting & Maintenance

PLC START-UP AND

CHECKING PROCEDURES

Model numbers

Placement

Power Supply

Inspection

Verify Field Wiring

&

I/O comm. cables

Page 46: PLC Troubleshooting & Maintenance

STATIC INPUT/ OUTPUT WIRING

CHECK

Output Terminals Input Terminals

Page 47: PLC Troubleshooting & Maintenance

PLC PREVENTIVE

MAINTENANCE

Page 48: PLC Troubleshooting & Maintenance

PLC PREVENTIVE MAINTENANCE

Regular Filter Cleaning

Regular DustingDust restricts heat dissipationAvoid Conductive Dust

I/O Module Check for any Loose connections

Avoid Noise generating

Equipment close to PLC

Avoid documentation to createHOT SPOT

Install vibration Detector in area of high vibration

Page 49: PLC Troubleshooting & Maintenance

PLC PREVENTIVE MAINTENANCE

Page 50: PLC Troubleshooting & Maintenance

PLC TROBLESHOOTING

AREAS

Page 51: PLC Troubleshooting & Maintenance

Is Power Indicator Lit?POWER LED IS TURNED OFF

Is power supply operating?

Supply the power

Does the power

LED turned on?

Is the fuse

blown?

Is the power

Supply cable Connected?

Is the voltage within

the rated power?

Over current

Device activated?

Does the power

LED turned on?

Does the power

LED turned on?

Does the power

LED turned on?

See the power supply within

180 ~ 240 VAC

Replace the Fuse

Connect the power supply properly

Eliminate excess current &

switch power ON/OFF

Does the power

LED turned on?Write the steps &

Contact customer care

COMPLETE

NOYES

YES

YES

NO

NO

NO

NO

NO

NO

YES

NO

NO

NO

YES

YES

YES

YES

YES

YES

Page 52: PLC Troubleshooting & Maintenance

RUN Indicator not LitRUN INDICATOR NOT LIT

Is the ERR/ALM

Indicator Lit?

Turn the power supply

OFF & then ON again

Is a fatal error

Displayed?

Is PC mode displayed

On Programming device?

Is the RUN

Indicator lit?

Determine the cause of the

error with the Programming

device

Switch to RUN or

MONITOR mode

Identify the error, eliminate

its cause, & clear the error.

Replace the CPU Unit

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

Is PC mode

Displayed on Programming

Device?

END

FATAL ERROR

CHECK

Page 53: PLC Troubleshooting & Maintenance

Program cannot be written

PROGRAM CANNOT BE WRITTEN TO PLC

Is the mode setting

Switch set to the remote

stop?

Switch to the remote STOP mode & execute the

program mode

Is ERR LED Blinking?

After reading error code by using peripheral device,

correct the content

COMPLETE

NO

NO

YES

NO

Page 54: PLC Troubleshooting & Maintenance

ENVIRONMENT CONDITION CHECKEnvironment Condition Check

Is the ambient

temperature below 55

degree?

Consider using a FAN or COLLER

Is the ambient temperature above

0 degree?

Consider using a HEATER

END

Is the ambient humidity between 10% ~ 85%

Consider using an air conditioner

Is noise being controlled?

Install surge protectors or other noise reducing equipment at

noise sources

Is the installation environment ok?

Consider constructing an instrument panel or cabinet

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

Page 55: PLC Troubleshooting & Maintenance

ERR/ALM INDICATOR FLASHINGERR/ALM Indicator flashing

Determine the cause of the error with a

programming device

IS a non fatal errorIndicated?

Identify the error, eliminates its cause & clear the error

Replace the

CPU Unit

NO

NO

YES

NON- FATAL ERROR

CHECK

Is the ERR/ALMIndicator flashing?

END

FLASHING

Page 56: PLC Troubleshooting & Maintenance

I/O CHECKMALFUNCTIONING OF SOL 1

Check the voltage at IR 01003 terminals

Is the Output wiring

correct?

Check output

device SOL 1.

Operation ok?

Replace the CPU Unit,

Expansion Unit, or Expansion

I/O Unit with the problem

Is the IR 01003 output Indicator operating?

Wire correctly Correct the short circuit or limit the connected load

to the specified range

Monitor the ON/OFF status of IR 01003

with the Programming

Device

Is the external powersupply Shorted or

overload?

Disconnect the external wires & check the

conductivity of each wire

Operation ok?

Operation ok?

NO

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

0002 0003

SOL 101003

01003

Ne

xt

slid

e

Page 57: PLC Troubleshooting & Maintenance

I/O CHECK

Check the voltage at the IR 0002 & IR 0003 terminals

Operation ok?

Replace the CPU Unit,

Expansion Unit, or Expansion

I/O Unit with the problem

Are the IR 0002 & IR 0003Input indicators operating

Normally?

Is the wiring correct?

Wire Correctly

Operation ok?

Are the terminals screws loose?

NO

YES

0002 0003

SOL 101003

01003

Replace the CPU Unit,

Expansion Unit, or

Expansion I/O Unit

with the problem

Check operation by using a dummy input signal to turn the input ON & OFF

Check input devices LS1 & LS2

Check the voltage at the IR 0002 & IR 0003 terminals

Operation ok?

Return to Start

Tighten the terminal screws

Fro

m p

rev

iou

s sl

ide

NO

NO

NO

NO

NO

YES

YES

YES

YES

Page 58: PLC Troubleshooting & Maintenance

Learn 4 PLC’s in a Day100+ Video Tutorials

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For more courses visit www.nfiautomation.org

Course Outline

• 100+ PLC Video Tutorials

• Doubt Clearing Complementary LIVE Sessions on Team Viewer

• Ladder Logic Programming

• PLC Presentations, PLC Circuits, PLC Codes

• FREE PLC Simulation Software for Practice

PLC – Programmable Logic Controller

Delta DVP 14 SS + 16 SP

Allen Bradley M1000

Siemens S7 200

Schneider

Analog Cards Programming

04 AD – Analog to Digital

04DA- Digital to Analog

Page 59: PLC Troubleshooting & Maintenance

PLC & VFD Advanced

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Course Highlights:

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Course Link:http://www.wiziq.com/course/28882-plc-and-ac-drives-online-certificate-trainaing-course

Page 60: PLC Troubleshooting & Maintenance

Thankswww.nfiautomation.org

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