76
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-
77
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-
78
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-
79
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.
EMTC 135 - Programmable Logic Controller Application -Module IV-
80
THINK!
Draw the PLC hardwiring diagram of a Start-Stop Control System.
Start button address is I0.0, stop button address is I0.1, and Coil
address is Q0.0
EMTC 135 - Programmable Logic Controller Application -Module IV-
