A PLC system is a vital component of many industrial processes, but it also requires regular maintenance and troubleshooting to ensure optimal performance and reliability. How can you keep your PLC system running smoothly and avoid costly downtime and errors? Here are some tips and best practices to follow.
The first step in maintaining a PLC system is to inspect the physical condition of the hardware, such as the power supply, the wiring, the input/output modules, and the communication devices. Look for any signs of damage, corrosion, loose connections, or overheating that could affect the functionality or safety of the system. Clean and replace any faulty or worn-out parts as needed, and make sure the system is properly grounded and protected from electrical surges, dust, moisture, and vibration.
Another important aspect is to make sure the PLC has some kind of ventilation system, a fan, climate control. Depending on the location of the PLC. Wherever it is it will need to be in a cool enviroment or a ventilation system needs to be installed and maintained. They heat up and will do unexpected things.
In my experience Maintaining a PLC system for long-term success requires a comprehensive approach that encompasses regular preventive maintenance, prompt corrective actions, thorough documentation, and continuous improvement o Schedule regular inspections to detect and address potential problems early on o Implement a rapid response system to address PLC system faults and malfunctions promptly o Diagnose and isolate issues accurately to minimize downtime o Identify areas for improvement based on maintenance data and user feedback o Maintain comprehensive PLC system documentation, including: * PLC hardware configuration and wiring diagrams. * PLC software program listings and descriptions
I Suggest First Thing to have complete Maintenance plan , for daily , weekly , monthly , Quarterly and Annualy , These Plans need to have RACI matrix , along with Quality Templates that will be used by Team. You need to ensure that Proper handover done from projects to maintenance team to include list of pending snags, Backups , final AsBuilt Drawings , Operations and Maintenance Manuals , Spare Parts if need to be ordered,....
Bom, para se manter um sistema de controladores funcionando por um longo prazo, é necessário garantir algumas coisas: - Instala??o em rede estabilizada; - Instala??o em painéis que garantam boa veda??o e possuam sistema de refrigera??o; - Realiza??o de inspe??es periódicas, atuando de forma preventiva; - Manter documenta??o e registros atualizados de toda e qualquer altera??o física e lógica; - Realizar backups periódicos; - Possuir componentes de hardware em estoque para trocas rápidas caso necessário; - Manter seus softwares atualizados; Ainda assim, em determinado momento pode ser que seu sistema se torne obsoleto, e seja necessário atualiza??o do mesmo.
PLC's systems are robust and built to last for years provided proper maintenance are kept. For the hardware, keeping them in top shape by providing good ventilation, stable energy for the power modules, good grounding and bonding (good clean earth for the modules). Programs wont easily crash or bugged down even with power outage once in a while. While I/O modules typically last a lifetime of the machine, grounding loop problems would easily shorten their life span.
The second step in maintaining a PLC system is to update the software, such as the firmware, the operating system, and the application program. Updating the software can improve the performance, security, and compatibility of the system, as well as fix any bugs or glitches that could cause errors or malfunctions. Make sure you have a backup of the current software before updating, and follow the manufacturer's instructions and recommendations for the update process. Test the system after updating to verify that everything works as expected.
Most of the time once you buy a PLC system your stuck with that particular software version. I've found that once you learn one system , it soon becomes obselte and you will have to purchase the newer type. Some you can keep, operating, as long as the manufacturer is still selling parts for that system if not upgrade.
Keep backups of the program and the software, also keep track of what version of the software the code is written in, and update as new versions come out, especially useful with Siemens TIA portal were older programs need to be updated in sequence.
This sounds good in theory however real life applications are a bit more complex. Updating only works if you are backed financially as updating usually involves new drivers, new protocols, new software all of which is tedius time consiming and expensive to get right. You would'nt put a Ferrari engine in a old cadillac You'd surely run into issues. Rockwell software is far from being straight forward in terms of simple installation. All revision levels clash with modern pc opperating software. So you run into having to create VM's just to get the different revision levels up to date. Only to find that your system does not communicate due to an upgrade in protocol.
Sw is important. However we should not forget firmware. Often problems are discovered in the firmware that can cause problems with your operation. Always check with plc manufacturers for any updates. Caution must be taken to make sure other units in you system can work if the firmware is updated on only one unit. Usually all firmware should be updated at the same time.
Not really , updating the plc firmware version is done only if you are facing certain issues from beginning.i would not consider this as maintenance schedule at all
The third step in maintaining a PLC system is to monitor the performance, such as the cycle time, the memory usage, the scan rate, and the error logs. Monitoring the performance can help you identify any issues or anomalies that could affect the quality or efficiency of the system, as well as provide valuable data for troubleshooting and optimization. Use the built-in diagnostic tools or external software to collect and analyze the performance data, and adjust the settings or parameters as needed to optimize the system.
Battery management is a big part of maintenance. Check the recommended time between battery changes and if it's critical systems just change them once a year.
*CONTINUACIóN d 1* cuando en realidad esas condiciones en el momento en q se revisan ?no son permanentes!, m refiero a temps mínimas y máximas a lo largo d todo el día/noche, q todos desconocen y son críticas porque ocasionan mal funcionamiento del PLC: y es q X Ej. cualquier bit en una suma/resta/multiplicacn digital mal hecha, hace operar al programa con valores erróneos q lo hacen entrar en estados inimaginados pero válidos para el PLC -ahora imagínense esos errores en la asignac d memoria y/o búsqueda d registros-, es decir, c provocan errores virtuales imperceptibles a la lógica d programac, q hacen trabajar al PLC con valores locos en sus entradas/salidas. Varias veces encontré ese problema en gabinetes colocados en ambiente húmedos.
I would rephrase this step as monitor any alarms or error led on the hardware. Performance of the application would not get affected by time some times if wrong data is input some operational error might come
Make sure to test back up systems such as the backup battery and/or power savers to ensure the performance of the operating system. Have had entire programs dump because of even the shortest length of time passing with no power where in battery backups and powersavers working properly can avoid this.
The fourth step in maintaining a PLC system is to troubleshoot the problems, such as the faults, the alarms, the errors, and the failures. Troubleshooting the problems can help you locate and resolve the root causes of the issues, as well as prevent them from recurring or escalating. Use the troubleshooting methods and techniques that suit your system and situation, such as the ladder logic, the input/output forcing, the online debugging, or the offline simulation. Document and report the problems and solutions for future reference.
In my experience, troubleshooting a PLC system could help you understanding the system better. Also a good method of troubleshooting a PLC is through the led light of the PLC to understand the output signals.
Be sure when troubleshooting to locate the problem in it's entirety and change any components causing malfunction. A plc is not something you want to "make work"! Each system in place serves a necessary function and just because you know how to make the system work without replacing faulty parts does not mean you should. Always replace faulty equipment with new parts bought only from UL licensed sellers, preferably from the the same distributor/supplier you originally purchased the plc system from in order to ensure comparability, performance, functionality, as well as to avoid losing any warranties that may be in place.
The fifth step in maintaining a PLC system is to train the staff, such as the operators, the technicians, the engineers, and the managers. Training the staff can help you ensure that they have the necessary skills and knowledge to operate, maintain, troubleshoot, and improve the system, as well as follow the safety and quality standards and procedures. Provide regular and updated training sessions and materials for the staff, and evaluate their performance and feedback.
Training is the most critical part of maintaining a PLC system. While you may not need to teach the technician to be a programmer, if he doesn't understand programming, how will he troubleshoot it. Troubleshooting hardware such as I/O or power supplies is one phase easily taught as any electrical course would be. The programming must be approached differently. The use of binary code and boolean logic is more easily understood with ladder logic. The technicians should feel comfortable looking around in the code. It is also important to teach early that programs don't change by themselves. So don't try to fix real problems with programming band aids. You can hide issues until they become catastrophic.
Training the staff isn't just a one shot thing, the speed plc's and other automation equipment is evolving it's a constant thing to keep up to date, as well as use the skills you've learnt, no point going on a course to learn a skill and the never putting it into practice.
Make sure that only employees trained in the operation of the plc system perform any maintenace or work on the plc system. As well as make sure there is a clear understanding of who is authorized to troubleshoot ,work on, or replace and components of the system. A person not thoroughly and efficiently trained to work on these systems can potentially hurt themselves, or others and can cause very expensive damage to the system that can be easily avoided by making sure it is understood and clearly stated who is authorized and who is not. I have had many, many problems arise from an unauthorized employee (eg. Maintenance workers), attempting to "Fix Something"!
The sixth step in maintaining a PLC system is to review the system, such as the design, the configuration, the documentation, and the improvement. Reviewing the system can help you assess the effectiveness and efficiency of the system, as well as identify any gaps or opportunities for enhancement. Conduct periodic and systematic reviews of the system, and use the feedback and data from the previous steps to make informed and data-driven decisions for the system.
End Users proactive approach to have regular maintenance on those systems, keep a schedule of Preventive health checks, spares inventory audit, engaging experience systems integrators, technology partners, get support to ensure systems are in good conditions.
Its important to have good relationship with key vendors/distributors. Regular interactions to get better support and stay updated on the installed products as well as understand new technologies/products being introduced, such info can be taken into planning considerations.
Here are some key strategies to maintain a PLC system for long-term success. Regular Backups: Keep master copies and create backups to prevent data loss. Preventive Maintenance: Establish a schedule for inspections, testing, and calibration. Environmental Control: Install PLCs in suitable environments to avoid damage. Cleanliness: Keep components free from dust and debris to prevent malfunctions. Check Connections: Inspect connections, especially I/O modules, for tight fits. Battery Monitoring: Monitor battery indicators and replace promptly when needed. Calibration: Calibrate circuit cards every six months for accuracy. Noise and Heat: Avoid placing equipment generating excess noise or heat nearby.
Keep a list Of device part numbers to make spares and replacements easier to organise. List the required program versions (Siemens S7) so getting the correct software version/program is easier for the maintenance engineers in the field.
Definitely make sure you have a battery backup for the good battery so it saves the program and then just make sure all your equipment is functioning correctly and everything is running properly make sure the program don't have any glitches