Unit VI

PLC Installation Practices, Editing, and Troubleshooting

Voltage Variations and Surges

Power Supply Design:

• The PLC system's power supply is designed to withstand normal line voltage
fluctuations and continue operating within its specified range.
• If voltage fluctuations exceed the operating range, a system shutdown may occur to
prevent damage.
• Constant Voltage (CV) Transformer: In areas prone to excessive voltage variation
or brownouts, a CV transformer may be required to prevent PLC shutdowns.

Isolation Transformers:

• Purpose: These transformers isolate the PLC from electrical disturbances caused by
other equipment connected to the power distribution system.
• Isolation transformers are often used to place the PLC power supply and I/O devices
on a separate transformer, which can also serve as a step-down transformer for
reducing incoming voltage.

Inductive Load Interruption:

• When an inductive load (like relays, solenoids, or motors) is interrupted, it generates a

high-voltage spike.
• Suppression Techniques:
o Output modules controlling inductive loads often have built-in suppression
circuits.
o Additional external suppression devices may be necessary to control inductive
devices and prevent high-voltage transients.

Suppression of Inductive Loads:

• Diode Suppression for DC Loads (Refer to Fig. 13-11):

o A diode is connected in reverse-bias across an inductive load, like a solenoid.
o In normal operation, current flows through the solenoid, but not through the
diode.
o When the solenoid is switched off, the collapsing magnetic field generates a
voltage of opposite polarity, which causes a current to flow through the diode,
dissipating the high-voltage spike.
 • RC (Resistor-Capacitor) Snubber Circuit for AC Loads (Refer to Fig. 13-12):
o The RC circuit suppresses voltage peaks by slowing the rate of rise of the
transient voltage.
o The capacitor prevents the voltage from changing instantaneously, causing a
transient current flow that softens the voltage spike when the circuit is opened.

Metal Oxide Varistor (MOV) Surge Suppressor:

• The MOV is a popular surge protection device and works similarly to two zener
diodes connected back-to-back.
• Operation (Refer to Fig. 13-13):
o The MOV acts as an open circuit until the voltage across it exceeds its rated
value.
o Once the voltage surpasses the threshold, the MOV becomes a short circuit,
redirecting the excess voltage away from sensitive components, protecting the
circuit from surges.
 Program Editing in PLC:

Editing a PLC program refers to making changes to an existing ladder logic program. This
can involve adding or removing instructions, modifying rung elements, or updating
addresses. Most modern PLC programming environments are user-friendly and based on
graphical interfaces (e.g., Microsoft Windows), which simplifies the editing process.

Key Editing Functions:

1. Adding or Deleting Instructions and Rungs:

o You can insert new instructions into your ladder logic or remove existing
ones.
o Rungs (the horizontal lines in ladder logic) can be added or deleted depending
on your control logic needs.
2. Modifying Data, Addresses, and Bits:
o You may need to change the address (location of input/output) or modify data
values like timers, counters, or other parameters associated with the
instructions.
o Bits represent the status of inputs or outputs (ON/OFF) and can also be
updated in the program.

Editing Process:

1. Selecting Instructions or Rungs:

o In most PLC programming software (Windows-based), you interact with the
ladder diagram using your mouse.
o Left-click: Selects an instruction or rung on the ladder logic diagram.
o Double left-click: Allows you to edit the address or value associated with the
selected instruction.
2. Right-click Menu:
o Right-clicking on an instruction or rung brings up a pop-up menu of available
commands.
o This menu typically includes options like "Edit", "Add", "Delete", "Cut",
"Copy", "Paste", etc.
 oFor example, you can right-click a rung number to add comments or
descriptions.
3. Adding Comments:
o You can include additional information, such as address descriptions (labels
or identifiers for devices) or rung comments (explanations of what a rung
does).
o Address descriptions are placed directly above the symbol in the ladder
diagram.
o To add a rung comment, right-click the rung number and select "Add
Comment" from the menu.

Example Scenario:

• You need to add a timer in the middle of an existing rung:

1. Left-click to select the point where you want to insert the timer.
2. Right-click and choose "Insert Instruction".
3. Select the timer instruction from the menu and define its address and preset
value.
• If you want to modify a specific address (e.g., changing an input from I:0/0 to I:0/1):
1. Double-click on the existing instruction.
2. Edit the address to reflect the new value (I:0/1).
• To remove an unwanted instruction:
1. Select the instruction by left-clicking it.
2. Right-click and choose "Delete".

Commissioning

Commissioning is the process of testing and verifying that a PLC system, including the
hardware, ladder logic program, and I/O devices (inputs and outputs), functions as intended
before putting it into full operation. This process ensures that the system is safe, reliable, and
ready to control the equipment it’s designed for.

General Steps for Commissioning a PLC System:

1. Safety First – Isolate Output Devices:

o Before applying power to the system, disconnect or isolate any output
devices that could cause harm or damage if activated unexpectedly. These
devices include motors, valves, or anything that moves.
o This step is important for safety because outputs might get activated during
testing, which could result in accidents.
2. Apply Power to the PLC and Input Devices:
o Power up the PLC and the input devices (sensors, switches, etc.).
o Measure the voltage to ensure that the correct voltage is being supplied to the
system (typically 24V DC or 120V AC, depending on your PLC).
3. Check PLC Status Indicators:
o Examine the PLC’s status indicator lights:
▪ Power indicator: It should be ON to confirm power is applied.
▪ Fault indicator: There should be NO fault lights on. If there are fault
lights, check for errors.
 o If the PLC doesn't power up properly, the PLC hardware might be faulty.
However, PLC failures are rare and usually occur only when the PLC is first
powered on.
4. Establish Communication with the PLC:
o Use your programming device (PC or laptop running PLC programming
software) to connect to the PLC.
o Verify communication between the PLC and the programming device by
opening the programming software and ensuring it can "talk" to the PLC.
5. Set PLC to a Safe Operating Mode:
o Before testing, set the PLC to a mode where the output circuits won’t be
energized. This prevents unintentional activation of devices like motors or
pumps.
o Depending on the PLC model, this mode might be called:
▪ Disable mode
▪ Continuous test mode
▪ Single-scan mode (runs one cycle of the program without activating
outputs)
o This allows you to monitor inputs, test the program, and ensure that the output
signals behave correctly, but without actually powering the outputs.
6. Verify Inputs:
o Manually activate each input device (such as switches, sensors, buttons,
etc.), one at a time.
o Check the PLC’s input status lights: Each input should turn the
corresponding light ON or OFF as expected.
o Monitor the ladder logic program on your programming device to confirm
that the input changes are being registered correctly in the program.
o For example, if you press a push button, the corresponding contact in the
program should change from open to closed.
7. Test Outputs Manually:
o After verifying inputs, test the output devices:
▪ Manually apply power to the output terminals where field devices
(such as motors, relays, solenoids) are connected.
▪ This will verify that the field devices are correctly wired and
functioning properly.
▪ Ensure that when the program logic sends a signal, the correct output
device responds as expected.
8. Validate Program Settings:
o Check the preset values for all timers, counters, and other important
parameters in the program.
o Ensure the timers are set for the correct duration, counters have the right
setpoints, and any other variable parameters are properly configured.
9. Reconnect Outputs and Place PLC in Run Mode:
o Reconnect any output devices that were isolated during testing (such as
motors or valves).
o Set the PLC to Run mode to activate the system and execute the program.
o In Run mode, the PLC will read the inputs, execute the control logic, and
energize the outputs accordingly.
10. Final Testing:
o Test emergency stop buttons and other critical safety features to ensure they
function properly and can immediately stop the system if necessary.
 o Observe the entire system’s operation: Verify that all inputs, outputs, and
program logic function as designed. Watch for any unexpected behaviors or
errors in the process.
o If everything works correctly, the commissioning is successful, and the PLC is
ready for use.

Programming and Monitoring

1. Programming a PLC

When programming a PLC, you generally use a personal computer with specialized
programming software provided by the PLC manufacturer. This software allows you to:

• Write, edit, and store PLC programs.

• Download and upload programs between the computer and the PLC.
• Monitor the PLC’s performance and make real-time adjustments if necessary.

Programming Modes:

• Offline Programming:
o In this mode, you write and edit the program on your computer without being
connected to the PLC.
o Once the program is ready, you can download it to the PLC later.
o This is a safer way to program because changes don't affect the running
system until explicitly uploaded to the PLC.
• Online Programming:
o In this mode, you are directly connected to the PLC, and any changes you
make are immediately implemented.
o You can modify, test, and either accept or reject changes while the PLC is
running.
o While convenient, online programming requires caution because changes take
effect immediately and can affect the process being controlled.
o It is generally advised to use online programming only if you fully understand
the system and the effects of your changes.

Test Modes:

• Continuous Test Mode:

o This mode allows the PLC to execute the program without energizing any
outputs.
o It is useful for debugging the program logic without affecting the connected
equipment.
• Single-Scan Mode:
o This mode runs the program one scan at a time, meaning the PLC executes
one cycle of the user program and then stops.
o It is useful for troubleshooting specific parts of the program, allowing step-
by-step observation of how the control logic behaves.

2. Monitoring Tools:
Monitoring is critical for observing how the PLC operates, detecting issues, and making
adjustments. Most PLC programming environments offer two key tools for monitoring: Data
Monitor and Cross Reference.

Data Monitor:

The data monitor feature allows you to observe and manipulate real-time data from the
program. It can be used to:

• View data values within specific instructions (such as timer values or counter
positions).
• Set or reset values for debugging purposes (e.g., force an input or output bit on/off).
• Change the data format (such as converting between binary, decimal, or
hexadecimal).
• Monitor and modify specific variables during testing and debugging.

For example, in the Allen-Bradley SLC 500 and RSLogix software, you can monitor data
like the status of I/O files, timers, counters, and other system variables. Changes made
through the data monitor can affect the operation of the system, so use this feature cautiously.

Cross Reference Function:

The cross reference function helps you locate where a specific address or data point is used
throughout the program. It provides a report that includes:

• All occurrences of an address (e.g., an output coil, input contact, etc.).

• The rung numbers and program files where the address appears.
• The type of instruction associated with the address.

This is helpful when troubleshooting or trying to understand how a particular input/output is

being used throughout the program.

Contact Histogram:

The contact histogram function allows you to track the on/off states of data table values over
time. It records:

• How long a bit remains in an on or off state.

• The total time the program has been running.
• The time difference between changes in state (delta time).

This tool is particularly useful for detecting intermittent problems, either in hardware or
program logic. For instance, if a sensor is failing intermittently, the histogram will show the
exact moments it fails, making it easier to diagnose.

3. Uploading and Downloading Programs:

• Uploading: When you upload a program, you copy it from the PLC to the
programming device (your computer). This is useful for backing up the program
currently running on the PLC.
 • Downloading: When you download a program, you transfer it from the programming
device to the PLC. This is how you load new or modified programs onto the PLC.

Preventive Maintenance of PLC Systems

Preventive maintenance is crucial for minimizing system faults and ensuring reliable
operation of PLCs (Programmable Logic Controllers). While PLCs are designed to require
minimal maintenance, certain preventive measures help prolong their lifespan and prevent
costly downtime.

Key Preventive Maintenance Practices:

1. Power Removal and Lockout/Tagout Procedures:

o Always disconnect electrical power before performing maintenance.
o De-energize all other sources of power (e.g., pneumatic, hydraulic) to prevent
accidental activation of equipment.
o Implement lockout and tagout procedures to secure power sources. Only the
person who applied the lock and tag should remove them to ensure safety.
2. Spare Parts Stocking:
o Stock commonly used spare parts, especially input and output modules, as
these components tend to fail more frequently.
o Keeping spares on hand ensures quicker recovery from component failures,
reducing downtime.
3. Maintaining Backup Programs:
o Keep a master copy of all operating programs used in the PLC.
o Regularly update these backups to reflect any changes made to the system,
ensuring quick restoration in case of memory or system failure.
4. Regular Equipment Inspections During Short Shutdowns:
o Clean or replace filters: Ensure proper airflow in enclosures to avoid
overheating of components.
o Clean dust or dirt from PLC circuit boards: Dust buildup on heat sinks or
circuitry can cause heat dissipation issues and short circuits if conductive dust
reaches the electronics. Keep the enclosure door closed to minimize dust
accumulation.
o Check and tighten all connections: Inspect the I/O module plugs, sockets,
and terminal strips to ensure secure connections. Loose connections can lead
to improper function or damage to the system.
o Inspect field I/O devices: Sensors, actuators, and other devices should be
adjusted and serviced regularly. Circuit boards for analog process control
should be calibrated every six months, while other devices should undergo
monthly checks.
o Ensure that noise- or heat-generating equipment is kept at a safe distance
from the PLC to avoid interference or overheating issues.
5. Battery Maintenance:
o Regularly check the condition of the battery that backs up the RAM memory
in the CPU.
o Most PLC CPUs have a battery status indicator that shows whether the
voltage is sufficient. If the voltage is low, replace the battery with the exact
type required to avoid memory loss
 Troubleshooting PLC Systems

When a PLC system experiences faults, employing a methodical troubleshooting approach is

key to diagnosing and resolving issues. PLCs are relatively easy to troubleshoot, as the
control program can be monitored in real-time, which allows observation of program
execution and system behavior. Below are key troubleshooting strategies for different PLC
components:

1. Identifying the Source of the Problem

Start by identifying the problem and its potential source. The issue could stem from various
components, such as:

• Processor Module
• I/O Hardware
• Wiring
• Machine Inputs or Outputs
• Ladder Logic Program

2. Troubleshooting the Processor Module

The processor performs self-diagnostics and provides status information through indicators
(LEDs). You can also access more detailed diagnostics through the programming software.
Key indicators on the processor include:

• RUN (Green LED): Indicates the processor mode.

o On steady: The PLC is in RUN mode.
o Flashing: Program transfer from RAM to memory module.
o Off: The processor is in another mode (not RUN).
• FLT (Red LED): Indicates fault conditions.
o Flashing at power-up: Processor not configured.
o Flashing during operation: Major error in processor, chassis, or memory.
o On steady: Fatal error, no communication.
o Off: No errors.
• BATT (Red LED): Monitors the backup battery.
o On steady: Battery voltage is low or missing.
o Off: Battery is functional.

Watchdog Timer: This function ensures that the CPU completes its scan within a set time. If
the CPU takes too long, a major error will be declared, signaling a processor issue.

3. Input Malfunctions

If the PLC is in RUN mode but outputs are not functioning as expected, the issue may lie
with:

• Input/output wiring
• Field devices or their power supplies
• Input sensors and output actuators
• PLC I/O modules
 • Processor

Steps for Troubleshooting Input Malfunctions:

1. Check the Input Module's Status Indicator: If it doesn't illuminate when the input
device (e.g., a pushbutton or sensor) is activated, check the voltage across the input
terminal.
2. Measure the Voltage: If correct voltage is present but the status indicator remains
off, the input module may be faulty and needs replacement.
3. Verify Input Module Conversion: If the status indicator illuminates but the
programming monitor shows incorrect logic status, the input module may not be
converting signals correctly.

If replacing the input module does not resolve the issue, the problem may lie in the wiring,
I/O rack, communication cable, or processor.

4. Output Malfunctions

Output malfunctions may be related to blown fuses, faulty modules, or wiring issues. Most
output modules include a blown fuse indicator and a power indicator:

• Blown Fuse Indicator: Shows when the protective fuse in the output circuit has
blown.
• Power Indicator: Confirms that power is applied to the load.

Steps for Troubleshooting Output Malfunctions:

1. Check the Blown Fuse Indicator: If illuminated, replace the fuse and fix the cause
of the malfunction.
2. Verify Output Status Indicator: If the logic status indicator is on but the output
device isn’t responding, inspect the wiring and the output device itself.
3. Check Voltage: If the programming device monitor shows the output is commanded
to turn on but the status indicator is off, the output module or processor could be
faulty.

5. Additional Tools for Troubleshooting

• Programming Software: Modern PLCs allow you to monitor the system in real-time,
providing tools such as data monitors, cross-reference functions, and fault logs to help
trace errors.
• Data Monitor: Displays the real-time status of variables, instructions, and data
values, making it easier to locate faults.
• Cross-Reference Function: Helps identify all instances where a specific address is
used in the program, making it easier to trace and debug specific components.

6. Ladder Logic Programs in PLCs

While the ladder logic program itself is generally reliable, it can sometimes fail due to
programming errors or unexpected process states. Many software tools, like RSLogix 500,
offer verification features to check for program errors before deployment.
Key Steps for Troubleshooting Ladder Logic Programs:

a) Verify the Ladder Logic Program:

o Use verification tools in software (e.g., RSLogix 500) to check for
programming errors.
o Error messages help identify issues such as missing instructions or addressing
errors.
b) Common Logic Errors:
o Incorrect Instruction Type: Using an "Examine If Closed" (XIC) instead of
an "Examine If Open" (XIO), or vice versa.
o Incorrect Addressing: Assigning the wrong address to an instruction.

These can lead to unexpected behavior, especially in previously unconsidered process

states. Modify the program to account for these new conditions.

c) Tracing Faulty Outputs:

o Identify which outputs are malfunctioning, then trace back through the ladder
logic.
o Check the logic preceding the output to pinpoint why it isn't energizing.
d) Force Instructions for Testing:
o Force On/Off: This function lets you override the program and turn bits or
outputs on or off manually.
▪ Example: Forcing a solenoid valve on can help determine if the
solenoid is functional (hardware issue) or if the problem lies within the
software.
e) Temporary End (TND) Instruction:
o This instruction allows partial scans of the program for debugging. It halts the
program at the TND instruction to prevent the processor from scanning
further.
o By placing TNDs in different parts of the program, you can debug sections
sequentially.
f) Suspend (SUS) Instruction:
o SUS is used to halt the controller in a specific condition, helping to trap and
identify program issues.
o The instruction stores information such as the ID and location of the rung
where it was triggered.

Common Issues in Ladder Logic:

• Address Conflicts: One common issue is assigning the same address to multiple coil
instructions. This creates conflicting commands, where later instructions override
earlier ones, causing malfunctioning outputs.
o Example: If two rungs are controlling the same output (O:2/1), but one rung is
false, it will prevent the output from energizing even if an earlier rung sets the
condition to true.
Input Troubleshooting Guide:

Output Troubleshooting Guide: