Course Content
To fault find a system you need to know EXACTLY how it works HOW EXACTLY DOES A PLC WORK? -
Am I getting the input to the PLC? -
The Led on the output card means i am getting voltage out right? does it? -
What exactly happens in between? ,theres more than just a program in the CPU -
How exactly does it scan the program? -
What is this Watchdog Timer? Is it that important? -
Can I use the same output twice? That's bad programming isn't it? -
A PLC is a logic controller, so use a logical approach to fault find it. -
What are the 8 simple test points to check? -
The PLC is in RUN, that means theres a program right? does it? -
FORCING a bit and toggling a bit is pretty much the same yeah? depends on which PLC Then you need to Know the specifics HOW DO I DO THE FOLLOWING? (some straight forward some not so) - Check power is ON and PLC is in right mode (RUN or Program)
- Check LEDs for fault definition
- Check and Change Modules if required (with spares and without spares)
- Removing modules with power ON
- Establish link to PLC (RSLinx, a major problem area these days)
- Link to CPU via RS232 port or Ethernet
- Create a blank project and take a backup (just in case I mess up)
- Open the correct project Off Line and link to PLC
- Interrogate errors in Controller Properties, common faults
- Identify if it is a hardware or software fault?
- Identify if it is a PLC or Comms fault
- Access fault information about I/O cards
- Change the battery, with power ON of course
- Check all settings against a template, Node Address etc.
- Check Hardware Configuration, I/O errors
- Clear Memory and Download program
- Monitor program
- Searching for specific operands and instructions
- Using Bookmark function
- Changing timer, counter values On Line
- Making minor mods Off Line and On line
- Creat a Trend to trend address status or values
- Altering timer, counter and other values if required
- Force a parameter if required
- Toggling addresses to move program on in sequence
- Call up documentation to assist with software diagnostics
- Printing Cross Reference / Program Listings etc.
Background information also covered Understanding of the following: - Number formats, bits,words,double words
- Binary, Real, Integer, DINT,
- Tasks, Programs and Routines
- How to monitor various blocks
- Understand basic Ladder programs
- Basic Instructions, contacts, Latch, Unlatch etc.
- Timers, Counters
- Comparators, Maths
- Altering values in Tag tables
- Toggling v Forcing
- Back tracking through a program to establish where power flow stops
- Fault finding tips
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