PLC Troubleshooting: Troubleshooting Inputs and Outputs

PLC troubleshooting
PLC (Programmable Logic Controllers)

Dec 2018
1/1
Dec 2018
Dec 2018
sivaranjith
Dec '18
To proceed the basics of PLC troubleshooting. it is assumed that the analyzed
PLC system was working correctly at some time in the recent past, so the
problems of debugging the program and wiring errors that are more typical of a
start situation will not be solved.
It is also assumed that the PLC is programmed using some form of ladder logic
and not a higher level language, and the discussion is limited to the most
common types of I / O modules namely, those that support digital inputs and
outputs and analogue.
Troubleshooting inputs and outputs

The most common problem in the solution of input and output problems, the main
objective of solving I/O problems is to find out why the internal state of the PLC
(what the PLC thinks is happening) does not agree with the external situation
(what is really happening).
The first thing to do is to determine the relationship between the physical I / O

modules and the I / O instructions in the PLC program. This is done by using the
addressing scheme for the particular PLC, this scheme differs from one
manufacturer to another.
Once this scheme is understood, each problem can be isolated in a single I / O

module and a program monitoring device (usually a portable unit, terminal or
personal computer) can be used to verify the internal status of the input or exit in
question.
Troubleshooting digital input modules:

plc inputtrblsht.png513×552 22.5 KB
The function of a digital input module is to determine the ON / OFF status of a

signal or signals and communicate that information to the PLC processor. The
digital input modules detect changes in voltage levels and are available with
various AC, DC or universal ratings, and universal modules generally accept a
fairly wide range of AC or DC signals.
There are two types of entries: isolated and not isolated. Problem-solving varies
depending on the type you are dealing with. The isolated input module is
electrically separated from the others and may have a different power source. On
the other hand, one side of each input channel in an uninsulated module is
connected to a common reference.
 If power is present for the input in question, since faults in the wiring and
field devices can burn a fuse, trip a switch or cause another power interruption.
 If there is no input power, determine and rectify the cause of the failure
before continuing. If there is input power, connect a voltmeter through the input.
 Activate the input device in the field and measure the voltage at the input
of the PLC to determine if it changes properly when the field device changes
state.
 If it does not, the field device or wiring are most likely at fault.
 If an adequate voltage change is observed, the power and / or logic
indicators in the module should change when the voltage is applied, and the
location addressed in the PLC, when monitored with the programming device,
should also change state.
 If the indicators do not correctly reflect the status of the input, replace the
input module. If the input module works correctly but the PLC does not register
the input internally, the problem lies in the system used to communicate the input
information of the module to the processor.
Troubleshooting analog input modules

Instead of monitoring the on / off status of an input, the analog inputs measure
the actual value of a voltage or current and communicate it to the processor.
First determine if the input is isolated or not isolated, and determine the source of
energy and verify that it is present. Next, change the voltage or current level
generated by the field device, verify that the change is reflected at the input
module terminals and verify that the address content associated with the input
reflects the change in voltage or current.
There are two additional complications introduced by analog modules, however.

First, there usually is no indication on the module to reflect the level of the input,
so an external meter must be relied upon.
The second is the problem of scale: you must determine what voltage or current
range is designed to measure the module and what numerical scale is
associated with that range in the PLC.
 An input with a 1-5 VDC range may be expected to generate a change

from 0 to 1000 in a PLC register.
 The signal transmitter can be connected directly to the input module, and if
the module does not respond correctly, it must be replaced.
 If it responds correctly, it is most likely that the problem is in the field
device or the wiring. Field wiring can be tested by temporarily replacing the field
device with a signal transmitter and observing the reaction in the PLC to signal
changes.
Troubleshooting digital output modules:
The output modules are designed to cause some change in the external world in
response to an instruction in the PLC processor. The digital outputs will often be
used to perform tasks such as starting engines, turning on indicator lights and
activating solenoid valves.
The energy to control PLC outputs, such as inputs, is not usually supplied by the
module, so it is important to find out where that power comes from.
Faults in field wiring and devices can burn that fuse, so you should check its
condition before continuing. Many modules are equipped with a “blown fuse”
indicator that shows which channel or module has a blown fuse.These fuses may
be accessible from the front of the module, or the module may have to be
removed or even disassembled in order to gain access to them.
 The programming device must be connected to the PLC, and the address
associated with the output in question must be determined. The output can be
“forced” ON or OFF internally in the PLC, and the module can be observed for a
reaction.
 If the indicators in the module do not reflect the forced condition, change
the output module.
 If the indicators are observed to be reacting to the forced state, measure
the voltage across the output device to see that it’s changing as the state of the
output changes.
 If the voltage is changing but the device is not reacting, the problem is in
the output device. If the voltage is not changing, the problem can most likely be
found in the field wiring.
If field wiring is in doubt, it can be temporarily disconnected and a test load can
be connected to the module. If the test load is working correctly, the problem lies
in the field wiring or the field device. It is important that a test load be used
instead of simply disconnecting the field wiring.
Troubleshooting analog output modules:

Analog outputs are used to generate a variable voltage or current that is normally
used to perform tasks such as speeding up a variable speed drive, adjusting the
position of a control valve or driving a panel indicator.
 You must determine what range of voltage or current the module is

designed to produce and what numerical scale is associated with that range in
the PLC. An output with a 4-20 mA DC range may be expected to react to a
change from 0 to 1000 in a PLC
 A good approach to testing analog outputs is to “force” the number in the
PLC register associated with the output in question to minimum, half scale, and
maximum values, and to measure the voltage or current generated at the output.

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PLC troubleshooting

PLC (Programmable Logic Controllers)

Troubleshooting inputs and outputs

The first thing to do is to determine the relationship between the physical I / O

Once this scheme is understood, each problem can be isolated in a single I / O

Troubleshooting digital input modules:

The function of a digital input module is to determine the ON / OFF status of a

Troubleshooting analog input modules

There are two additional complications introduced by analog modules, however.

 An input with a 1-5 VDC range may be expected to generate a change

Troubleshooting analog output modules:

 You must determine what range of voltage or current the module is

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