Practical Troubleshooting and

Problem Solving of
PLCs and SCADA systems

You will learn how to:

• Quickly interpret, isolate and fix common hardware problems

related to PLC input/outputs
• Troubleshoot PLC software (especially ladderlogic)
• Identify typical SCADA problems and fix them
• Safely make changes to a system without overriding machine
safety or personnel safety programming
• Make temporary fixes to a program to test out new components
or ideas
• Identify and fix electrical noise, earthing and power problems
• Identify and fix PLC/SCADA data communications problems
• Network with your peers on their automation troubleshooting

WHO SHOULD ATTEND:

• Operators
• Electricians
• Instrumentation technicians
• Trades staff working with PLCs
• Electrical, control and instrumentation engineers
• Design engineers
• Project engineers
• IT technicians and IT staff
• Plant engineers
And those who want to achieve a good proficiency in
troubleshooting their PLC and SCADA systems.

5.1
 The Workshop The Program
The objective of this workshop is to help you Day One • Leaky inputs and outputs
troubleshoot, and identify, prevent and fix • Isolation problems
common PLC and SCADA problems. The • You have located the problem - what
Introduction to PLCs and
emphasis is on practical hard hitting
information that goes beyond typical theory,
SCADA Systems to do now?
focusing unerringly on providing you with • PLC block diagram of components • Tracking down intermittent problems
the necessary skills to solve your problems • PLC processor module and memory Practical Session
whether it is a PLC, SCADA system, or organisation
indeed communications system linking the Troubleshooting PLC Analog
• PLC input/output modules
two together. The automation system on Input/Outputs
• SCADA hardware
your plant underpins your entire operation. • Isolated and non-isolated inputs
• Power supplies
It is thus critical that you have the knowledge • Ranges of analog inputs
and tools to quickly identify and fix problems • Good installation practice
• Forcing analog output ranges
as they occur to ensure you have a safe, Practical Session
• Filtering and isolation issues
secure and productive system. No
compromise is obviously possible here. This Fundamentals of PLC Practical Session
workshop distils all the tips and tricks learnt Software
over many years. • Methods of representing logic Day TWO
If you have worked in industry, you are • Boolean algebra
probably familiar with PLCs and SCADA • Instruction code Miscellaneous Hardware
systems and understand their basic • Graphical representation: functional logic Issues
operation. However, an increasing need diagrams and ladderlogic • Processor problems
today is to also understand how to
• Ladderlogic instruction set (coils and • What to do if you don't have the right
troubleshoot the typical problems that occur
contacts/timers/counters) replacement
from time to time with your PLC and SCADA
based equipment. You want to be able to • Advanced instructions (program flow/ • Are you sure you have the right problem?!
quickly diagnose problems using your PLC arithmetic/data transfer and PID) • Confirmation that the system is indeed
software; know how to connect to the right • Start-up/shutdown and fault routines operating correctly
PLC processor online, make minor changes • Good programming habits • Other troubleshooting tips and tricks
to get the machine running and have the • Comparison of different manufacturers Practical Session
know-how to test new ideas and hardware
Practical Session
components. In addition, you want to be PLC Software issues
able to do troubleshooting and problem SCADA Software • How to return the program to its original
solving of your associated SCADA system. state
• Communication architectures, HMI
The first step in PLC troubleshooting is to interface, SCADA software blocks, SCADA • Modifying an existing program
decide if the problem is internal to the Alarm management • Modifying a program to trap problems
processor or in the I/O system. Experience
Practical Session Practical Session
shows that more than 80% of all PLC
malfunctions come back to problems with Industrial Data SCADA Troubleshooting Road
I/O modules or field equipment (or indeed Communications System Map
wiring). Problems that can be traced back to
• Roadmap of different standards, RS-232/ • Review of the key SCADA troubleshooting
an I/O module (and specific input) or usually
RS-485, Profibus and DeviceNet, industrial issues, SCADA system troubleshooting,
external field components; whilst internal
PLC problems often result in large scale Ethernet, TCP/IP, Modbus PLC/SCADA interfacing problems
failure or erratic behaviour on the part of the Practical Session Practical Session
PLC.
Basics of Troubleshooting Human Machine Interface (HMI)
This workshop is designed to benefit you and Diagnosing Equipment
with hard-hitting practical up-to-date • Configuration of database points
• Common symptoms, problems and • Troubleshooting I/O database
information on the application of PLCs for
solutions
the automation and process control of plants
and factories. It aims to give practical advice • How to quickly identify likely causes SCADA Alarm Configuration
from experts in the field, to assist you with • Overall basic steps Issues
your troubleshooting of your PLC and • Communications issues • Configuration of alarms
SCADA systems. • Earthing, shielding and noise SCADA to PLC Interface Issues
The content of the workshop brings everyone Practical Session • Drivers, protocols and throughput issues
up to date by briefly reviewing PLC and
SCADA systems and then examining in a PLC Troubleshooting Road Map Key Industrial Data
logical step-by-step fashion with hands-on • Review of the key PLC troubleshooting Communications Problems
exercises (both PLCs and simulation software issues and Troubleshooting
to get to the problems quickly) PLCs and Practical Session
SCADA systems. The key industrial • Cabling and hardware (switches/routers/
communications problems are briefly converters), fibre optics, noise and
PLCs Power and Earth
covered. interference, RS-485 issues, industrial
• Visual inspection, measuring voltages, Ethernet, TCP/IP and Modbus
The accompanying manual is detailed with power supply test, AC ripple on DC power
contributions from a number of experts who Practical Session
supplies, Batteries testing, EMI/RFI
have presented this course over many years impacts, earthing and screening/shielding Installation and
and will become a valuable reference in Practical Session Commissioning
your work.
• Control room, MCC requirements,
Troubleshooting PLC Inputs/
installation of equipment, loop testing
Outputs
Practical Session
Practical Sessions • Internal memory status against the field
activity Toolkit summary of key
This is a practical hands-on workshop
• Digital input status problems to look for
enabling you to work through twelve (12) • Output modules and power supply • 23 common problems with PLCs and
practical exercises which reinforce the • Fuses SCADA systems
concepts discussed. • Forcing outputs ON and OFF • What to do and how to fix them

idc@idc-online .com • www.idc-online .com