Basic PLC Troubleshooting

7/27/2019 Basic PLC Troubleshooting

1/15

BasicPLCTroubleshooting

BriantLam

07/01/2010


2/15

TopicsCovered

SystemsOverview

KlystronSolenoid

AlcoveMCOR

Gallery

6575Modulator

SPEAR3/PEPHVPS

ALineSPANGBendPS

BasicIndicators

ModuleReplacement

SystemSpecificRepair

More

Information


3/15

SystemOverview KlystronSolenoid

S21PSRack CompactLogix PLC

OnePLCpersector,uptoeightpowersupplies

Monitorsinterlocksforpowersupplies

ProvidesinterlockstatustoMKSU

DoesNOTcontrolpowersupplies


4/15

SystemOverview AlcovePLC

AlcoveRack1 FlexLogix PLC

OnePLC

per

MCOR

crate

and

bulk

power

supply

InterlockstheMCORsonbulkps voltage

andground

fault.

RemotecontrolforbulkandMCORreset


5/15

SystemOverview GalleryPLC

GalleryRack ControlLogix PLC

One

PLC

for

up

to

3bulk

power

supplies

InterlocksMCORsonbulkps voltage

andgroundfault

Interlocks

Intermediate

power

suppliesRemotecontrolofbulkpowersupplies

andMCORreset


6/15

SystemOverview 6575ModPLC6575Modulator CompactLogix PLC

Monitorsinterlocks

and

provides

status

to

MKSU

Controlsmodulatorandvarioussubsystems


7/15

SystemOverview SPEAR3HVPS

ControlEnclosure SLC5/03PLC

Monitorsandprovidesinterlocksto/fromHVPSandKlystron

ControlstheHVPS


8/15

SystemOverview AlineBendPSSPANGPS SLC5/03PLC

Monitorsinterlocks

Controlsthepowersupply


9/15

BasicIndicators


10/15

BasicIndicators

Processor(everything

should

be

green)

Run solidgreentobeinRUNmode OtherwiseputinRUNmodeusingkeyswitch

I/O

solid

green

means

good

modules

OtherwiselookforabsenceofgreenOKLEDonmodule

NotethatsomemodulesdonothaveOKLED

Force off,wedonotuseforces!

RS232 solidorflashinggreen,communicatingwithtouchpanel

BAT shouldbegreen,butgenerallyisnotcritical

OK must

be

solid

green!

Any

red

means

we

need

to

goonlinetoseewhattheproblemis.Apowercyclewillprobablyfixit,butwewillloseanyinformationon

what

caused

the

fault.


11/15

BasicIndicators

PowerSupply

OK green

NetworkModule

Link green,goodlinktoswitch

Net flashinggreen,Ethernettraffic

OK green,moduleisgood

ModuleontheControlLogix

Cardon

the

FlexLogix

BuiltinontheCompactLogix


12/15

ModuleReplacement

Processor Mayneedtoreprogram,unlesspreprogrammed

spare

available CurrentlyonlyGalleryandAlcovePLCs

I/OModule

Directreplacement,

no

further

action

needed

EthernetModule

Mayneed

to

configure,

unless

pre

configured

spareisavailable

CurrentlyonlyGalleryandAlcovePLCs


13/15


KlystronSolenoid

Sparechassisinteststand

Processorwillneedreprogramming/configuring

AlcovePLC

SparechassisinB127

InstallappropriateEthernetcardintotheprocessor

beforeusing

Allprogramsareidentical

GalleryPLC

SpareChassis

in

R127

InstallappropriateprocessorandEthernetmodule,ifreplacingchassis

Allprograms

are

unique


14/15


6575Modulator

PLC

Identifyandreplaceproblematicmodule

Sparesnotyetavailable,partsareavailableifneeded

Allprogramswill(hopefully)beidentical

SPEAR3HVPSPLC

Identifyand

replace

the

problematic

module

SpareslocatedinB127

SPANG

Bend

PS

Identifyandreplacetheproblematicmodule

Sparesunknown


15/15

MoreInformation

Do

not

hesitate

to

call

Engineering

on

PLC

problems

HowToDocumentation http://lclsdev/tikiindex.php?page=How

to+Download+PLC+Ladder+Logic

http://lclsdev/tiki

index.php?page=How

to+Configure+PLC+Ethernet+Communications

Manuals

http://literature.rockwellautomation.com/idc/groups/literature/documents/in/1756in101_enp.pdf



PLCPrograms V:\ESD\PCD\PLC
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Basic PLC Troubleshooting

Documents

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