Lesson 1 Hard Wiring Lesson 2 PLC Troubleshooting and Preventive Maintenance

This document discusses PLC hardwiring and troubleshooting. It contains two lessons: 1. PLC Hardwiring: This lesson covers physical and internal PLC connections, including terminal blocks, relays, and source/sink connections. It also discusses commons which allow more I/O points with fewer connections. 2. PLC Troubleshooting: This lesson will cover troubleshooting PLC errors with safety and accuracy to diagnose problems in the system. The document instructs the reader to carefully read and understand the lessons, complete exercises, and contact instructors with any issues. It aims to teach how to properly hardwire PLC connections and perform troubleshooting.

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Lesson 1 Hard Wiring Lesson 2 PLC Troubleshooting and Preventive Maintenance

Uploaded by

Kurisuchan Wolf

Available Formats

Download as PDF, TXT or read online on Scribd

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MODULE IV

PLC HARDWIRING AND

TROUBLESHOOTING

LESSON 1 HARD WIRING

LESSON 2 PLC TROUBLESHOOTING AND

PREVENTIVE MAINTENANCE

EMTC 135 - Programmable Logic Controller Application -Module IV-

MODULE IV
PLC HARDWIRING AND TROUBLESHOOTING

 INTRODUCTION

In this module you will learn how to hardwire PLC connections and perform
PLC troubleshooting. Using a PLC can reduce the number of wires needed to hardwire
the circuit due to most of the connections are programmed and downloaded in the
memory of the device allowing minimal connections for input and output devices.

PLC troubleshooting can be performed in many different ways and as the

engineer’s experience always plays the major role in successful resolving of such
issues, five methods have been developed.

OBJECTIVES

After reading the module, you should be able to:

1. Hardwire the PLC circuit following the specified program reading and
following the circuit diagram of the control system
2. Troubleshoot the PLC errors with safety and accuracy in diagnosing problems
in the system

 DIRECTIONS/ MODULE ORGANIZER

There are two lessons in the module. Read and understand the lessons
carefully. Answer the exercises and activities given after each lesson then submit
your output to the concern instructor.
You may contact the concern faculty whenever problems arises regarding the
lesson and or discuss the matter with your instructor during face-to-face meeting.

EMTC 135 - Programmable Logic Controller Application -Module IV-

Lesson 1

 PLC HARDWIRING

Physical Connections

Most PLC connections involve connecting to something like the terminal block.

Slide the wires into the slots on the bottom, and using the screws found on
top, you secure the wires. Some connectors are disconnect from the PLC, while
others are fixed to the the PLC.

This kind of connection is common for Inputs, Outputs and power supplies.

Internal Connections

The inputs and outputs of PLCs are connected internally in 1 of 3 ways: Relays,
Source or Sink. PLC manufacturers often produce all 3 versions, so you can select
the version that best fits your application. Below are descriptions of
each variety and what their advantages/disadvantages are.

Let’s go over the symbols that will be used.

DC Power

Switch. It represents an input. Could be as simple as a light switch that

you’re monitoring to see if it’s on or off.

Load. It represents something you’re powering. Could be a light bulb or motor.

Juggling balls Connections. They are the physical connections to the PLC

PLC. This just tells you where the PLC fits into the equation. Everything inside the
dashed box happens inside the PLC.

EMTC 135 - Programmable Logic Controller Application -Module IV-

Power Flow. Shows which direction power flows through the circuit.

Commons

In order to increase IO points on PLCs without increasing the number of

connections, Commons are used. The picture to the right shows an example of what
the wiring of a PLC with 4 inputs would look like. In the picture Without Common,
the green points all lead to the same voltage source. Commons take advantage of
this frequent situation, grouping one side of connections together. In this case we
go from requiring 8 pins to requiring 5 pins, with no loss of functionality (assuming
you wanted them tied to the same sources). Commons are used in Relays, Sink and
Source Circuits.

Relays

Relays are the simplest Connection type. They act like light switches that are
turned on or off by the PLC. They physically connect/disconnect 2 pins on the PLC.

Source & Sink

Source & Sinking is used exclusively with Digital DC circuits. If the common
pin is + polarity, it’s called a sourcing circuit. If it’s – polarity, it’s called a sinking
circuit.