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PLC Commissioning

The commissioning of a PLC system involves 4 key steps: 1. Checking the hardware by testing inputs and outputs and verifying proper connections. 2. Transferring and testing the software by simulating programs offline and gradually integrating real inputs and outputs. 3. Optimizing the software by improving programs based on initial test runs and ensuring documentation is updated. 4. Commissioning the entire system by executing all controller functions step-by-step to verify proper integration and operation.

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Nijam Jabbar
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239 views2 pages

PLC Commissioning

The commissioning of a PLC system involves 4 key steps: 1. Checking the hardware by testing inputs and outputs and verifying proper connections. 2. Transferring and testing the software by simulating programs offline and gradually integrating real inputs and outputs. 3. Optimizing the software by improving programs based on initial test runs and ensuring documentation is updated. 4. Commissioning the entire system by executing all controller functions step-by-step to verify proper integration and operation.

Uploaded by

Nijam Jabbar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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4 Steps To Follow During Commissioning of

a PLC System
PLC programs are never final…
Yes, PLC programs are never final, it is always possible to make corrections and subsequent adaptations
to new system according the customer requirements. Even during commissioning, program changes are
often necessary. The commissioning of a system can be divided into four steps:

1. Checking the hardware


2. Transferring and testing the software
3. Optimization of the software
4. Commissioning of the entire system

1. Checking the hardware


Each sensor, switch and button is connected to a specific input and each actuator to an output. During
engineering process addresses and wires must not be mixed up. Also, the sensors and actuator placing
should be checked (that they are where they have to be in the automated system).

During checking procedure, the outputs are set in a test mode. The actuators must then meet the
specified requirements (functions). If changes are made, then the documentation (allocation list,
drawings, etc) must also be updated to respond to reality.

1.1 Testing inputs and outputs


Input devices, e.g. switches, can be manipulated to give the open and closed contact conditions and the
corresponding LED on the input module observed. It should be illuminated when the input is closed and
not illuminated when it is open.

Failure of an LED to illuminate could be because the input device is not correctly operating, there are
incorrect wiring connections to the input module, the input device is not correctly powered or the LED or
input module is defective. For output devices that can be safely started, push buttons might have been
installed so that each output can be tested.

2. Transferring and testing of software


Prior to commissioning, all available off-line and virtual PLC program testing tools should be used
intensively to find program faults. For example, such test tool is in STEP 7 as subprogram S7-PLCSIM.
It simulates the work of a PLC (virtual PLC) and allows the user written PLC program to be tested.
Following this, the program is transferred to a central processing unit in the virtual PLC. The entire program is
executed without using the real PLC.

The user has to simulate the input signal changes and verify how the outputs react to it. Some PLCs offer
simulation in a real PLC: the entire program is executed in a PLC without the real inputs and outputs
being connected. Processing of the PLC outputs thus only takes place in the PLC image table. The
physical PLC I/Os are not updated to/from the PLC I/O images.

Therefore this eliminates the risk of damaging machines or system parts.

After this, the individual user program parts and system functions are tested: manual operation, setting,
individual monitoring programs etc. and finally the interaction of the program parts with the help of the
main program.

The system can and should be commissioned step-by-step. Important aspects of commissioning and fault
detection are the test functions of the programming system, such as the single-step mode or the setting of
stop points. The single-step mode in particular is of importance, whereby the program in the PLC
memory is executed line-by-line or step-by-step. In this way, any program faults which may occur in the
program can be immediately localized.

3. Optimization of the software


User programs can almost always be improved after the first test run. It is important that
any corrections or modifications are made not just in the PLC user program, but are also taken into
account in the documentation.

4. Commissioning of the entire system


This already occurs in part during the testing and optimization phase. Once the final status of the PLC
user program and the documentation is established, all the controller functions (in accordance with the
automation task) need to be executed step-by-step again.

If no faults occur by the entire system commissioning, then the system is ready to be handed over to
the customer.

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