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Descripción: Troubleshooting FortiOS
Troubleshooting PLCs
Troubleshooting PLCs By Steve Mackay
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RH
Welcome to this webinar
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IDC Technologies and EIT
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Troubleshooting PLCs
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EIT MicroCourse Series
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IDC Technologies and EIT
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Troubleshooting PLCs
Objectives • Quic Quickl kly y in inte terp rpre ret, t, isolate and fix common hardware problems related to PLC input/outputs • Tr Trou oubl bles esho hoot ot PLC PLC software • Id Ide enti tify fy data communications problems www.eit.edu.au
Topics • In Intr trod oduc ucti tion on to PL PLC C • Inte Intern rnal al or Ex Exte tern rnal al Problem • In Inte tern rnal al Pr Prob oble lems ms • Exte Extern rnal al Pr Prob oble lems ms I/O and Comms • Appli lica cati tio ons • Conclusion www.eit.edu.au
IDC Technologies and EIT
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Troubleshooting PLCs
Industrial Automation Skills
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Introduction to the PLC
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IDC Technologies and EIT
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Troubleshooting PLCs
Introduction to the PLC
• “PLC” “PLC” means means “Program “Programmabl mable e Logic Logic Controll Controller”. er”. The The word “Programmable” differentiates it from the conventional hard-wired relay logic • The PLC PLC as a unit unit consists consists of a proces processor sor to exec execute ute the control action on the field data provided by input and output modules • In a progra programmin mming g device, device, the the PLC contr control ol logic logic is first first developed and then transferred to the PLC • PAC or Progr Programma ammable ble Autom Automatio ation n Contr Controlle oller r
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What can a PLC do? • It can can perfo perform rm rela relay-s y-swit witchi ching ng tasks tasks.. • It can conduc conductt counting, counting, calcu calculation lation and compar comparison ison of analog analog process values. • It offers offers flexibility flexibility to to modify modify the contro controll logic, logic, whenever whenever require required, d, in the shortest time. • It responds responds to the the changes changes in process process parame parameters ters within fraction of seconds. • It improv improves es the overa overallll control control syst system em reliab reliabili ility. ty. • It is cost cost effectiv effective e for contr controll olling ing compl complex ex system systems. s. • Tro Troubl uble-s e-shoo hootin ting g become becomes s simple simplerr and faster faster.. • An operator operator can can easily easily interact interact with the proce process ss with with the help help of the HMI (Human-Machine Interface) computer.
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IDC Technologies and EIT
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Troubleshooting PLCs
Basic block diagram of the PLC
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Working of a PLC CPU
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IDC Technologies and EIT
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Troubleshooting PLCs
Ladder diagram
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Ladder program execution
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IDC Technologies and EIT
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Troubleshooting PLCs
Internal or External Problem
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Internal or External Problem ? • Over Over 80% of of malfunc malfunctio tions ns are are with with I/O I/O modules and field equipment • Problem Problems s related related to to specific specific I/O module module or or I/O device are external problems • La Large rge grou groups ps of of fail failure ures s – int inter ernal nals s of PLC PLC
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IDC Technologies and EIT
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Troubleshooting PLCs
Internal Problems
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Internal Problems • Chec Check k earthin earthing/g g/groun rounding ding is corr correct ect • Check Check power power suppl supply y to to PLC is with within in correct range and ac ripple on dc supplies is not excessive • Ba Batt tteri eries es on PLC ar are e OK OK • PLC prog program ram hasn hasn't 't been corr corrupt upted ed • Examine Examine inte internal rnal diagno diagnosti stics cs for for a crash crash of PLC program www.eit.edu.au
IDC Technologies and EIT
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Troubleshooting PLCs
External Problems
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Extern Ext ernal al Pr Probl oblems ems – dig digital ital Inputs • Ch Check eck Pow Power er supp supply ly to to modul module e • Look for wher where e power power to digi digital tal Inp Input ut comes from • Ch Check eck fu fuses ses/b /bre reak akers ers • Ade Adequat quate e changes changes of volta voltage ge to to Input Input • Digital Digital inpu inputt fine fine === ===> > PLC pro program gram problem www.eit.edu.au
IDC Technologies and EIT
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Troubleshooting PLCs
Discrete DC input module
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Extern Ext ernal al Pr Probl oblems ems – dig digital ital outputs • Ch Check eck Pow Power er supp supply ly to to modul module e • Ch Check eck pow power er out output put fr from om PLC PLC • Chec eck k fuses • For Force ce digit digital al outp outputs uts on and and off off • Use test test load rat rather her than than open open circu circuit it – why ?
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IDC Technologies and EIT
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Troubleshooting PLCs
Discrete DC output module
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Extern Ext ernal al Pr Probl oblems ems – ana analog log inputs • Move Move fie field ld de devic vice e thr throu ough gh full range range of of current current – 420mA • Hook Hook up up sign signal al tran transmi smitte tterr if if you need to be absolutely sure.
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IDC Technologies and EIT
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Troubleshooting PLCs
Extern Ext ernal al Pr Probl oblems ems – ana analog log outputs • For Force ce output output to to specifi specific c value value and and observe observe • Ch Check eck ext extern ernal al wi wirin ring g
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Applications
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IDC Technologies and EIT
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Troubleshooting PLCs
Remote troubleshooting • Be caref careful ul with with remot remote e trouble troublesho shootin oting g about industrial network security • Ha Hack ckers ers are abo about ut 24 24x7 x7
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Thorny transients • Fi Fibe berr Optic Optics s where where poss possib ible le • Goo Good d earthing earthing/gr /ground ounding ing for for data data comms comms
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IDC Technologies and EIT
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Troubleshooting PLCs
A typical shield
The purpose of the shield is to reduce the magnitude of the noise coupled into the low-level signal circuits by electrostatic or magnetic coupling. This has brushed up the above-mentioned concepts up to some extent www.eit.edu.au
Opto-electric coupler circuit
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IDC Technologies and EIT
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Troubleshooting PLCs
When in doubt -disconnect • Test Test with with dummy dummy equip equipment ment not 1MW ball ball mills
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Thank You For Your Interest If you are interested in further training, please visit: IDC Technologies Short Courses: Two-day Two-day practical courses available availa ble to the public: http://idc-online.com/workshops IDC Technologies Conferences: http://idc-online.com/conferences-main The Engineering Institute of Technologies Online Certificate and Advanced Diploma programs: www.eit.edu.au