Daily maintenance of PLC and its fault detection - Solutions - Huaqiang

First, ensuring a stable operating environment is crucial for PLCs, as they are precision electronic devices that require long-term reliable operation. The environment must be dust-free, fireproof, waterproof, heat-resistant, and lightning-proof. Typically, the electrical control room is located on the second floor with double-glazed, water-cooled air conditioning. The temperature is usually maintained around 28°C. To prevent dust, the PLC is installed in a cabinet measuring 1M x 2.2M x 0.6M with a metal lock and a glass door. A dust extraction system is also installed on top of the cabinet to help cool it down. Second, daily maintenance tasks include familiarizing yourself with the process and the layout of the PLC modules. It's important to ensure that all testing tools are in good working condition before starting work. Third, routine inspections involve checking the voltage of the CPU battery (normally around 3V), maintaining the UPS, performing manual dust removal, cooling, and backing up the PLC program. Any faulty components should be replaced promptly. Fourth, when diagnosing PLC faults, use the "touch, look, smell, listen, trace, and replace" method. Check the CPU temperature (should not exceed 60°C), inspect indicator lights, detect any burning smells, listen for abnormal noises, and trace the fault using schematics and flow diagrams. If uncertain parts are suspected, replace them one by one to identify the issue. Fifth, if the software isn't functioning properly, check the CPU’s RUN status. If it's not running, reset and re-download the program. For hardware issues, start by checking the power supply voltage, then move on to the power module, input/output terminals, and other components. If there's no power, trace the wiring according to the schematic and layout. Sixth, understanding the CPU's operating mode is essential. If it's in STOP or HOLDUP mode, re-upload the program. If the CPU is faulty, replace it with an identical model. Similarly, if a board is damaged, replace it carefully while ensuring compatibility with the original version. Seventh, check communication cables and LED indicators on each module. For digital output modules, simulate a switch to test each point. If a point is faulty, rewire or replace the module. For analog modules, verify each channel using similar methods, and adjust the software configuration accordingly. Eighth, during normal production, avoid powering off large output modules to prevent relay errors. Contact the on-site operator to manually operate equipment before making any changes. Ninth, test various switches such as relays, proximity switches, and circuit breakers. Depending on whether they are normally open or closed, check their state using a table. Replace any faulty switches. Tenth, use a new communication module to test the existing one. For wiring detection, connect a known good wire to an unknown one and check the continuity. Resistance can be measured either when the battery is charged or when it's not. Finally, most common faults can be resolved through these steps. Always remember to follow safety protocols, especially when dealing with AC 220V and DC 24V systems. Stay updated on electrical safety practices and ensure safe operations at all times.

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