PLC fault finding method and its countermeasures - Database & Sql Blog Articles

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First, the PLC fault finding flowchart

1. Overall inspection

Following the overall inspection flowchart, you can identify the general direction of the fault and gradually narrow it down to locate the exact issue, as shown in Figure 1.


Figure 1

2. Power failure check

If the power indicator light is off, check the power supply system. The process is outlined in Figure 2.


Figure 2

3. Running fault check

If the power is normal but the running indicator is off, it suggests that the system has stopped due to an abnormal condition. Refer to Figure 3 for the troubleshooting steps.


Figure 3

4. Input and output fault check

The input and output channels are crucial for communication between the PLC and external devices. Issues here may involve not only the input/output units but also factors like wiring, terminal blocks, and fuses. The inspection process is detailed in Figures 4 and 5.


Figure 4


Figure 5

5. Inspection of the external environment

Environmental factors such as temperature, humidity, noise, dust, and corrosive substances can significantly affect the performance of a PLC. It's important to ensure the operating conditions are within acceptable limits.

Second, troubleshooting the input and output units of the programmable controller

Table 1: Troubleshooting the PLC Input Unit

Table 2: Troubleshooting the PLC Output Unit

When dealing with PLC issues, it’s essential to approach the problem systematically. Start with the most basic checks—like power and lights—and work your way through each component. Always refer to the manufacturer's documentation and diagrams for accurate guidance. Keeping a log of symptoms and previous fixes can also help in identifying recurring problems and improving future maintenance procedures.

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