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1. PLC
Troubleshooting
& Maintenance
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2. Manual Work
Brain
Motion
Senses
Human Lags:
• Cannot Work 24 Hours
• Cannot work with 100% Accuracy &
precision
• Efficiency decreases as energy
decreases
Energy
Human

3. Automatic Work
Controllers
Actuators
Sensors
Machine
Advantages:
• Accuracy
• No idle Time
• More Production
Energy
Lags:
• Regular
Troubleshooting &
Maintenance

4. What is Controllers?
Controller is a part of Automatic Control System, which process the
signal from sensors & send it to the actuators
Sensors
Controller
A closed Loop Control System
Actuator

5. This is a PLC
Input Terminals
Output Terminals
D/A Card
Programming Cable
A/D Card
RS 485

6. This is a PLC
Power 24 VDC
Battery
Input Terminals
Programming Cable
Output Terminals

7. This is a PLC
Input Terminals
Programming Cable
Output Terminals
Power 24 VDC

8. Understanding PLC

9. Understanding PLC

10. 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:
Step 3:
Selecting the Outputs
- Number of Outputs
- Nature of Outputs – Digital
or Analog
- Voltage rating of the Inputs
Length of Program – Big or Small
Nature of Program – Ladder
Logic, SFC, Instruction List, FDB

11. Programming Languages
Ladder Logic
SFC
Instruction List
FDB

12. PLC Ladder Logic

13. Common Industrial Hardware
Representing the Binary Concept

14. Basics of
Machine
Language
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15. Basics of Machine Language
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

16. PLC
Inputs & Outputs
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17. Digital Inputs & Outputs
Typical Digital Input/ Output Signals
•
•
•
•
12 VDC
24 VDC
120 VAC
240 VAC

18. 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.
PLC INPUTS & OUTPUTS
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

19. PLC INPUTS & OUTPUTS
Connections from Field Devices
Image courtesy of Allen-Bradley, a Rockwell Automation business

20. PLC INPUTS & OUTPUTS
Differential Analog Input Connections
Image courtesy of Allen-Bradley, a Rockwell Automation business

21. Analog Outputs



PLC INPUTS & 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 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

22. Basics of PLC
Programming
Ladder Logic

23. PLC Enclosure
& System
Components
NEMA – 12
National Electric Manufacturer
Association, USA

24. 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.

25. Enclosure Layout

26. Placement of PLC Components
To allow
maximum cooling
All Controller components
should be mounted in a vertical
(upright) position.

27. Duck & Wire Layout
Keep 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.

28. Power
Requirement &
Safety Circuitry

29. POWER REQUIREMENTS
Typical Power Requirement
220 VAC

30. SAFETY CIRCUITRY
Door Switch
Pull Rope Switch
Emergency Switch
Automation Studio

31. Master or Safety Control
Relays
Automation Studio

32. PLC FAULT CONTACT
PROTECTION
Automation Studio

33. PLC
Maintenance
HEAT, DUST & NOISE
REGULATION

34. PLC MAINTENANCE
HEAT & DUST REGULATION
Temperature Withstand Range
0 ~ 60°C

35. PLC MAINTENANCE
NOISE REGULATION
Shielded Cables for better communication

36. PLC MAINTENANCE
NOISE GENERATING DEVICES
MOTOR STARTERS
SOLENOIDS
RELAYS AND CONTACTORS
VARIABLE FREQUENCY DRIVES

37. PLC TROUBLESHOOTING 2
NOISE FROM GROUNDING

38. PLC
I/O Installation,
Wiring & Precautions

39. I/O INSTALLATION, WIRING, AND
PRECAUTIONS
I/O MODULE INSTALLATION
Placement 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

40. I/O INSTALLATION, WIRING, AND
PRECAUTIONS
WIRE SIZE CONSIDERATION
WIRING

41. I/O INSTALLATION, WIRING, AND
PRECAUTIONS
WIRE SIZE CONSIDERATION

42. WIRE LABELLING
I/O INSTALLATION, WIRING, AND
PRECAUTIONS

43. I/O INSTALLATION, WIRING, AND
PRECAUTIONS
WIRE BUNDLING

44. PLC
START-UP & CHECKING
PROCEDURES

45. PLC START-UP AND
CHECKING PROCEDURES
Model numbers
Placement
Power Supply
Inspection
Verify Field Wiring
&
I/O comm. cables

46. STATIC INPUT/ OUTPUT WIRING
CHECK
Input Terminals
Output Terminals

47. PLC
PREVENTIVE
MAINTENANCE

48. PLC
PREVENTIVE MAINTENANCE
Regular Filter Cleaning
Regular Dusting
Dust restricts heat dissipation
Avoid Conductive Dust
I/O Module Check for any
Loose connections
Avoid Noise generating
Equipment close to PLC
Avoid documentation to create
HOT SPOT
Install vibration Detector in
area of high vibration

49. PLC
PREVENTIVE MAINTENANCE

50. PLC
TROBLESHOOTING
AREAS

51. POWER LED IS TURNED OFF
Is Power Indicator Lit?
NO
Is power supply
operating?
Supply the power
NO
YES
NO
Is the voltage within
the rated power?
Is the fuse
blown?
Does the power
LED turned on?
YES
NO
NO
YES
Does the power
LED turned on?
YES
Does the power
LED turned on?
Eliminate excess current &
switch power ON/OFF
NO
Write the steps &
Contact customer care
YES
Connect the power supply properly
NO
YES
Over current
Device activated?
YES
Replace the Fuse
NO
Is the power
Supply cable Connected?
YES
See the power supply within
180 ~ 240 VAC
NO
YES
Does the power
LED turned on?
NO
Does the power
LED turned on?
YES
COMPLETE

52. RUN Indicator not Lit
RUN INDICATOR NOT LIT
NO
YES
Is the ERR/ALM
Indicator Lit?
Is PC mode
Displayed on Programming
Device?
YES
NO
Determine the cause of the
error with the Programming
device
Is PC mode displayed
On Programming device?
NO
Turn the power supply
OFF & then ON again
YES
Is a fatal error
Displayed?
YES
Identify the error, eliminate
its cause, & clear the error.
NO
Switch to RUN or
MONITOR mode
Is the RUN
Indicator lit?
YES
END
NO
Replace the
CPU Unit
FATAL ERROR
CHECK

53. Program cannot be written
PROGRAM CANNOT BE WRITTEN TO PLC
Is the mode setting
Switch set to the remote
stop?
NO
Switch to the remote STOP
mode & execute the
program mode
YES
NO
Is ERR LED Blinking?
NO
COMPLETE
After reading error code by
using peripheral device,
correct the content

54. Environment Condition Check
Is the ambient
temperature below 55
degree?
NO
ENVIRONMENT CONDITION CHECK
Consider using a FAN or
COLLER
YES
Is the ambient
temperature above
0 degree?
NO
Consider using a HEATER
YES
Is the ambient humidity
between 10% ~ 85%
NO
Consider using an air
conditioner
YES
NO
Is noise being controlled?
Install surge protectors or other
noise reducing equipment at
noise sources
YES
NO
Is the installation
environment ok?
YES
END
Consider constructing an
instrument panel or cabinet

55. ERR/ALM INDICATOR FLASHING
ERR/ALM Indicator flashing
Determine the cause of
the error with a
programming device
IS a non fatal error
Indicated?
YES
Identify the error, eliminates its
cause & clear the error
NO
Is the ERR/ALM
Indicator flashing?
FLASHING
NO
Replace the
CPU Unit
END
NON- FATAL ERROR
CHECK

56. 0002
MALFUNCTIONING OF SOL 1
0003
01003
SOL 1
I/O CHECK
01003
NO
Is the IR 01003 output
Indicator operating?
YES
Wire correctly
Operation ok?
Correct the short circuit or
limit the connected load
to the specified range
NO
NO
Monitor the ON/OFF
status of IR 01003
with the
Programming
Device
Is the Output wiring
correct?
YES
YES
Is the external power
supply Shorted or
overload?
YES
Operation ok?
YES
NO
Disconnect the external
wires & check the
conductivity of each wire
YES
Check output
device SOL 1.
Operation ok?
NO
Replace the CPU Unit,
Expansion Unit, or Expansion
I/O Unit with the problem
NO
Next slide
Check the voltage at IR
01003 terminals

57. 0002
0003
01003
SOL 1
I/O CHECK
From previous slide
01003
Are the IR 0002 & IR 0003
Input indicators operating
Normally?
NO
Check the voltage at the
IR 0002 & IR 0003 terminals
YES
Check the voltage at the
IR 0002 & IR 0003 terminals
Operation ok?
Operation ok?
YES
NO
NO
YES
Check operation by using
a dummy input signal to
turn the input ON & OFF
YES
Is the wiring correct?
YES
Are the terminals
screws loose?
NO
NO
Wire Correctly
Tighten the
terminal screws
NO
Operation ok?
Replace the CPU Unit,
Expansion Unit, or
Expansion I/O Unit
with the problem
Check input
devices LS1 & LS2
Return to Start
Replace the CPU Unit,
Expansion Unit, or Expansion
I/O Unit with the problem

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nfi Learn 4 PLC’s in a Day
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Delta DVP 14 SS + 16 SP
• 100+ PLC Video Tutorials
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60. Thanks
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