PLC

Troubleshooting

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 PLC
Troubleshooting
Troubleshooting consist of three activities-
 Understanding how the application (control system)
operates
 Finding the problem and
 Correcting it.

Before troubleshooting any control system

technician must understand how the system works and
how the various components interact. 2
 PLC
Troubleshooting
1) Finding the problem:
 If the control system has been operating, the
technician should be confident of the accuracy of the
program logic. In this case malfunctioning of field
devices or loose wiring associated with the field
devices cause most errors. For a control system that
has never worked, programming errors should also be
considered

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 PLC
Troubleshooting
2)Troubleshooting the PLC:
 A) PLC Troubleshooting.
 B) Output Troubleshooting.
 C) Input Troubleshooting.
 D) Program Troubleshooting.

Cont.
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 PLC
Troubleshooting
A)PLC Troubleshooting
 If the PLC is running properly, its power and RUN
LED should be on. And there should be no fault
indication. If the fault LED is on use HHP or PC
running PLC running software to determine the cause
of the fault. Then consult the user manual to
determine the possible causes and corrective action.

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Cont.
 PLC
Troubleshooting
 If all LED’s are off verify that PLC has proper power
with the voltmeter. If a power problem exist , verify that
all wiring connections are good and that there are no
broken wires. Check the power from circuit breaker or
fuse block. After verifying PLC power, check
communication with the controller, using HHP or PC
running PLC software. If communication is possible
assume that PLC is running properly and investigate
field devices, field wiring and field power.

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 PLC
Troubleshooting
B&C)Troubleshooting input/ output:
 Most technician start troubleshooting at the output’s
and work backwards. This usually quickest and most
efficient procedure. Typically operator or technicians
first notice a problem when an action fails to occur.

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Cont.
 PLC
Troubleshooting
Begin troubleshooting by examining the output
LED’s.:
a)
 If there is a power at output terminal, the PLC is
functioning.
 If the output LED is on and the output device is not
on, test for power at the suspected output terminal.
 If power is not present on PLC output terminal, the
PLC has failed and must be replaced .
Cont. 8
 PLC
Troubleshooting
b) Next test for power at non functioning output device.
 If there is a power at the output terminal then the
device is faulty and should be fixed or replaced.
 If there is no power at device , then there is a blown
fuse in the field wiring or another wiring fault between
the PLC and the device.
 If the PLC and the output device are functional,
examine the program and look at the rungs with not
functioning outputs. Determine what condition
instruction needs to be true to enable activation of the
outputs. And start tracing them to find out which
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conditions are not satisfied. Cont.
 PLC
Troubleshooting
c)If input device is supposedly on but corresponding
input LED is not on. Use HHP or voltmeter to check for
a signal at the input terminal.
 If there is no signal, examines wire connections
between the terminal and the field devices and tighten
the or repair wiring as necessary.
 Check the devices for proper power and see if the
field devices are broken.

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Cont.
 A) Flow Chart – Troubleshooting PLC
Start

All LED’S are off Check Power LED is on.Fault

the PLC LED is on.

Check and verify Power and LED.S

Fault occur in PLC
PLC power
No power
With voltmeter Power and Use HHP or PC running
problem Power Power problem
LED is on Run LED is PLC software to determine
exist
on. Fault LED
Verify that all wiring connections the cause of the fault
is off,
are good and that there is no
broken wires. Check the power PLC is running Consult the user manual
from circuit breaker & fuse block Properly to determine the possible
causes and corrective
Check the action.
Communication
PLC communication is not ok
With controller Using HHP
Or PC running Check the communication
software Cable is ok.
PLC communication is ok Check the driver configure in
PLC is running properly 11
RS Linx.
B)-Output Troubleshooting

Begin Troubleshooting
by examining
the output LED’s.
Output LED is on
Output device is not on.

Test for There is no power

Power at at output terminal
the suspected PLC has failed and
output terminal must be replaced.
There is power at
output terminal

PLC is functioning. 12
Cont.
 B)-Output Troubleshooting

PLC is functioning
PLC and output There is no power at
device is functional the output device

Test for
Examine the program Power at There is blown fuse
and look at the rungs the non functioning in the field wiring or
with not functioning Output device. another wiring fault
outputs between the PLC
There is and Device.
power
The device is faulty
and should be fixed 13
or replaced..
 C)-Input Troubleshooting

I/P device is on but

corresponding input
LED is not on.

Use HHP
or voltmeter to
Check for signal
at input
terminal
Examine the connections
between the terminal and the Check the devices for proper
field devices. power and see if the field
Tighten the wiring or repair devices are broken.
wiring as necessary. 14
 D)- Program Troubleshooting
Program troubleshooting:
 For a system that has working but has stopped,
suspect the program, only after checking the PLC and
verifying the integrity of field devices and associated
wiring. However procedure is same to debug the new
existing program.
Typical logical errors include-
 Programming a normally open instruction, instead
of normally closed instruction. (or vice versa)
 Using an incorrect address in the program.

Cont.

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 PLC Troubleshooting

Faults:
 Fault messages are displayed on HHP or
programming software for easier problem
identification. Error messages coupled with
information from the PLC user manual, help locate the
fault determine its cause and suggest corrective
action.
 Most common causes of faults include memory
errors, data corruption errors, watchdog timer errors,
momentary power problems.
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Cont.
 PLC Troubleshooting

Safety:
 After identifying the problem and determining the
appropriate corrective measures, consider the
following safety measures when repairing the system:
 Disconnect the power to the whole system while
making repairs and make sure that there is no chance
of someone inadvertently reconnecting the power.
 Make sure that no system element can be harmed
it when the system is restored to working order.
 Some application requires all system components
(fixed devices) to be in “start position” 17
Cont.
 PLC Troubleshooting

Safety:
 After making repairs ensure that the system works
properly to the extent

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