CHAPTER 6

SELECTING, MAINTENANCE
AND TROUBLESHOOTING
OF PLC SYSTEM

COURSE LEARNING OUTCOMES (CLO)

Explain clearly blocks, parts, components and

instructions found in the automation systems. (C2)
Handle the troubleshooting and maintenance of
hardwired or PLC automation systems using
appropriate equipment. (P3)

PLC SELECTION PROCEDURE

1. INPUT AND OUTPUT CAPACITY

Input modules provide the interface between the

PLC and external input devices such as proximity
sensors, push buttons, switches, and BCD
thumbwheels.
Output modules provide the interface between
the PLC and external output devices such as
contactors, interposing relays, BCD displays and
indicator lamps.
Capacity means the number of terminal
connections on the input and output unit.
Table 1 show a few of input/output capacity.

INPUT UNIT

TYPE

DC Input

AC Input

MODEL NO.

CAPACITY

CQM1-ID211

8 points

CQM1-ID212

16 points

CQM1-ID213

32 points

CQM1- IA121

8 points

CQM1-IA221

8 points

OUTPUT UNIT
TYPE

MODEL NO.

CAPACITY

Relay Output

CQM1-OC211

8 points

Units

CQM1-OC222

16 points

Transistor

CQM1-OD211

8 points

Output Units

CQM1-OD212

16 points

CQM1-OD213

32 points

CQM1-OD214

16 points

CQM1-OD215

8 points

CQM1-OD221

8 points

AC Output Unit

Table 1: Input / Output Unit Specifications

Example: CPM1A I/O Capacity

The base I/O for the CPU ranges from 10, 20,
30, and 40 I/O points with maximum
expansion to 100 I/O.
Specialized expansion modules include mixed
analog I/O, temperature sensor inputs and
Source: OMRON
serial communications.

CPM1A I/O Capacity

Source: OMRON

2. TYPES OF INPUT AND OUTPUT

Before you use the PLC to control a job, you need to identify
the supply of which will be connected to the input unit
either AC or DC.
Never connect AC supply to DC input unit and vice versa.
Input Device:
Proximity Switches: use inductance, capacitance or light to detect
an object logically.
Switches: mechanical mechanisms will open or close electrical
contacts for a logical signal.
LVDT (linear variable differential transformer): measures linear
displacement continuously using magnetic coupling.

Output device
Normal switching: use Relay
Fast switching: use TRANSISTOR
High-voltage switching: AC type (TRIACS)

3. MEMORY SIZE

The memory system is the area in the PLCs CPU

where all of the sequences of instructions, or
programs, are stored and executed by the
processor to provide the desired control of field
devices.
The memory sections that contain the control
programs can be changed, or reprogrammed, to
adapt to manufacturing line procedure changes
or new system start-up requirements.
Memory size of a PLC is referring to the ability
to save program in your PLC memory system.
Table 2 shows the number of memory size by
CPU type.

No. Model

Memory size

CQM1-CPU11-E 3.2 K-word Program Memory

CQM1-CPU21-E 1K-word Data Memory
CQM1-CPU41-E
CQM1-CPU42-E 7.2 K-word Program Memory
CQM1-CPU43-E 6K-word Data Memory

CQM1-CPU44-E

Table 2: CPU Unit Specifications

Example of memory: ROM,PROM, EPROM

Example: From datasheet

4. TYPES OF SOFTWARE
LANGUAGE
Omron
CX-Programmer.
Syswin.

Mitsubishi.
GX-Developer

Siemens.
Simatic
STEPS 7

NAIS (Panasonic).
Fpwin.

The best way to Designing Programming

the PLC is using the PLC programming
software.

5. FUTURE SYSTEM EXPANSION

Industrial controlEXPANSION
system is undergoing a

transformation from traditional control to

automated control.
PLC is a major agent of this automation system.
Many industries have implemented the
automation-based control system, such as Flexible
Manufacturing System (FMS) and Computer
Integrated Manufacturing (CIM).
During PLC selection, future needs of the industry
must be taken into account so that using PLC
wont cause a drawback to the industry.

 Several types of PLC are design to used the expansion

unit to upgrade the number of I/O and application
device (data logging, temperature unit and etc.).
Example(Omron CJ1W)

 Example (Omron CPM)

6.SUPPORT AND BACKUP

Industrial automated control system requires

support and backup unit.
Backup option is used where you must transfer
the control of the process to a secondary system
without interrupting the machine/process
operation.
To guard against system shutdown, a backup
system must provide:
Equipment with exceptional reliability
Automatic fault isolation.
Minimal disturbance of the process when switching
from the primary to the secondary system

 There are requirement to setup support and

backup system in control system.
Example : CJM-2M-CPU3(Omron)

Requirement
for
support and
backup system

IP PORT( internet )
Serial Gateway.
Serial PLC link.
Fatal error detection.
Backup function.
Remote programming &
monitoring.

CJM-2M-CPU3(Omron)

INSTALLATION TECHNIQUE

1. SITE INSTALLATION CONDITION

CONSIDERATION
To reduce damage to the automation control systems,
serious consideration should be given to the following
during PLC installation and wiring :
Avoid installing PLC at places that has:
Direct exposure to sunlight.
Environment temperature exceeds range of 0C to 55C.
Relative humidity over range 10% to 90% RH.
Condensation occur due to sudden temperature change.
Contains flammable and poisonous gases .
Contains water, oil, chemical dust.
Vibration occurs easily.

 Operating Temperature :Depend on speciation of manufacture.

Omron ( 5 40 C).
Sometimes front panel for plc application 10-15 C
higher then ambient temperature of the room.
Used cooling system for ensure the temperature is
low.
Method of cooling system :

Natural Cooling.
Controlled Ventilation.
Control Circulation.
Room Cooling System.
Higher Temperature malfunction the PLC/ damage

Cooling System

2. PANEL/CABINET INSTALLATION
CONSIDERATION.
Install the PLC in the panel / cabinet with the following
characteristics:
Enough space for air circulation.
Cooling fan.
Device that produces heat is place under the PLC.
Not containing high voltage equipment.
Power line situated approximately 200 mm from the
PLC.

 For safety requirement all

PLC must be installed with
some distance from higher
voltage source.
All panel must be
grounded.

3. WIRING PRECAUTION CONSIDERATION

The input/output signal should be install
separately from power cable (Figure A).

Figure A

 If there are several group of cable in

thesystem, install it in group (Figure B).

Figure B

Types of wiring method.

1. Handing Ducts Wiring Method

2. Floor Ducts Wiring Method

3. Conduit Wiring Method

Power Line

 Follows the wiring instructions as shown below:

Use the cable as short as possible.
Use a single line and do not connect between cables to
extend it. Avoid making sharp curve on the cable.
Distance control system space and control wiring from high
energy wiring.
Separate input wiring, output wiring and other types of
wiring.
Separate AC and DC wiring.
Establish a good grounding for all components.
Ensure the wire is the correct gauge and have proper size to
handle the maximum possible current.
Each field wire and its termination point should be labeled
using a reliable labeling method.
Use wire bundling technique to simplify the connections to
each I/O module. Input, power, and output bundles carrying
the same type of signals should be kept in separate ducts,
when possible, to avoid interference.

4. INSTABLE VOLTAGE AND VOLTAGE SPIKE

PLC contains many active components such as
transistor and integrated circuit.
If surge voltage (resulting from lightning) occurred,
the active components will burn.
This problem can be overcome by:
Ensure that the ground terminal and PLC ground are
grounded by maximum of 100 W.
Make sure that the grounding cable is at least 2 mm2.
Grounding base and the green cable must end at the
cable lug. Cable lug must be screwed and soldered.
Corrosion and paint coatings must be removed from
the ground connection.

 Output Inductive load

 Noise filter for PLC power supply

 Grounding

PLC MAINTENANCE AND

TROUBLESHOOTING
METHODS

 Maintenance
Involves fixing any sort of mechanical or electrical
device should it become out of order or broken
(known as repair, unscheduled or casualty
maintenance).
Preventive maintenance carry out normally for 1
year or 6 month for checking the PLC (I/O device).

Troubleshooting
Problem solving technique.
Applied to repair failed products or processes.

1. PLC EXTERNAL FAULTS

Input/output equipment damage (sensors and
actuator)
Wiring damage
Communication connection damage
Power supply failure

INPUT/OUTPUT EQUIPMENT DAMAGE (Sensors and

Actuator)
60% - 80% damage in the automation control
system usually occurs due to the input and output
devices faulty.
The possibility of this damage is caused by:
Sensor in the cylinder vary from the original
position.
Sensor internal contact failure damage.
Sensor burns due to over current.
Motor coil or solenoid valve burns due to over
current.

WIRING DAMAGE
Likely caused by:
Conductor in the cable disconnected/fault.
Loosen screw; at input and output terminals.
Conductor oxidized.

COMMUNICATION CONNECTION DAMAGE

Can be caused by:
Conductor in the communication cable
disconnected/fault.
Terminal connection pin bent or broken.
Loose pin connection.
Interference occur in the communication cable
caused by motor, coil, high voltage, sloppy
soldering.
Short circuit occurs between conductors in the
communication cable.

POWER SUPPLY FAILURE

Power failure occurred in the automation control
system when the supply voltage dropped below
85% of the rated value.
This situation will cause the PLC to stop
immediately.

2. PLC INTERNAL FAULTS

Can be caused by:
Relay or transistor in the PLC unit/output module
burn.
Optocoupler at the unit/input module not
working.
Fuse burnt .
Weak storage battery.
Micro-electronic component (microprocessor,
RAM, ROM) burnt.
Programming error.

3. METHODS TO MODIFY PROGRAMS

Off Line (using software or console)
ON line ( using mode monitor for OMRON).

4. PROGRAMMING AND MONITORING METHODS.

PLC have a large number of ports for interacting with
analogue systems, sensors, switches, motors, and
various other systems needed to operate, monitor,
and maintain a control system used in industrial
automation applications.
Remote monitoring is used to monitor the system
and to aid in the prevention of problems and to keep
track of the operations of the equipment.
To perform remote monitoring, the software needs
to communicate with the PLC used in the control
systems.

 The system can be monitored through the

ladder logic programming language.
Each rung will be one of two things:
A switch that activates based on an internal
variable or the status of an I/O port (input / output)
An action to take such as changing an internal
variable or switching a motor on via an I/O port

Remote monitoring software retrieves the

values for a range of memory addresses. The
values returned by the PLC can be parsed and
reveal the current status of the control system
at the facility.

Example:
The current electrical usage of a motor being stored in
memory range 0xf489 0xf48c.
To get the information from this memory range, the
remote monitoring software would send a command
packet to request this memory range from the PLC, listen
for a valid response, and interpret/store the returned
information as necessary.

5. PREVENTIVE MAINTENANCE

PLC preventive maintenance can be made as follows:

Making periodic inspections for screw tightness at the input
and output terminals.
Ensure that all components are dust free. PLC cooling system
can not be executed if there is dust on its layer.
Corrosion may occurred in some circumstances. Perform
periodic inspection at the connection terminal for corrosion.
Printed circuit boards and connectors may have corrosion
internally.
Spare parts equipment must be stored well for future use if
any damage arise too the components. Users will suffer
losses if there is no spare parts and they have to wait for a
period of time.
Documentation for program operations and circuit wiring
must be kept safe. It may be needed in case of emergency.

6. STEPS FOR TROUBLESHOOTING PLC SYSTEMS