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Chapter 10
Troubleshooting Principles and Test Instruments
Troubleshooting Troubleshooting Methods Measurement Precautions Meter Abbreviations, Symbols, and Ratings Troubleshooting with Test Instruments
Chapter 10 Troubleshooting Principles and Test Instruments
PLCs provide a centralized location for input device and output component wiring. PLCs are the logical place to start the troubleshooting process.
Chapter 10 Troubleshooting Principles and Test Instruments
Troubleshooting by knowledge and experience is improved when standard maintenance practices are followed.
Chapter 10 Troubleshooting Principles and Test Instruments
Facility (plant) procedures are specific to the system or process used by an individual company.
Chapter 10 Troubleshooting Principles and Test Instruments
Manufacturer procedures vary from facility procedures in that manufacturer procedures are shorter and generally refer to a specific piece of equipment or part.
Chapter 10 Troubleshooting Principles and Test Instruments
PLC status indicator lights (LEDs) provide a visual display of operating conditions.
Chapter 10 Troubleshooting Principles and Test Instruments
Flowcharts use symbols and interconnecting lines to provide a troubleshooter with a logical path to problem solving.
Chapter 10 Troubleshooting Principles and Test Instruments
PLC Error codes indicate problems such as memory errors, processor and software incompatibility, power failure, an empty address slot in a rack, or a module being inserted while the power is ON.
Chapter 10 Troubleshooting Principles and Test Instruments
The users manual for a test instrument details specifications and features, proper operating procedures, safety precautions, warnings, and allowed applications.
Chapter 10 Troubleshooting Principles and Test Instruments
Several precautions must be taken when using test instruments on a PLC-controlled system.
Chapter 10 Troubleshooting Principles and Test Instruments
Abbreviations are used individually or in combination with prefixes.
Chapter 10 Troubleshooting Principles and Test Instruments
Symbols provide quick recognition and interpretation regardless of the language spoken.
Chapter 10 Troubleshooting Principles and Test Instruments
Test instruments are used to measure electrical quantities. A technician should be able to recognize both the unit of measurement and the abbreviation used to represent the quantity.
Chapter 10 Troubleshooting Principles and Test Instruments
The IEC 1010 standard classifies the applications in which test instruments and meters can be used into four overvoltage installation categories.
Chapter 10 Troubleshooting Principles and Test Instruments
Test lights provide a visual indication when voltage is present in non PLC circuits but do not indicate the amount of voltage.
Chapter 10 Troubleshooting Principles and Test Instruments
Voltage testers indicate the approximate voltage amount and type of voltage (AC or DC) in a circuit.
Chapter 10 Troubleshooting Principles and Test Instruments
A specific procedure is followed when using a voltage tester to take measurements.
Chapter 10 Troubleshooting Principles and Test Instruments
DMMs are portable test instruments that measure two or more electrical properties and display the measured properties as numerical values.
Chapter 10 Troubleshooting Principles and Test Instruments
When the voltage is DC at the test point, the two measured values will be the same, but one will have a negative () reading and the other a positive (+) reading.
Chapter 10 Troubleshooting Principles and Test Instruments
When the two measured voltage values do not indicate a DC voltage, the meter should be set to measure AC and the measurements should be retaken.
Chapter 10 Troubleshooting Principles and Test Instruments
A true-rms DMM must be used when taking AC voltage measurements in a PLC circuit or system.
Chapter 10 Troubleshooting Principles and Test Instruments
PLC input devices are typically powered by DC voltages such as 24 VDC.
Chapter 10 Troubleshooting Principles and Test Instruments
Continuity testers are simple test instruments that test de-energized circuits or components for a complete path for current.
Chapter 10 Troubleshooting Principles and Test Instruments
A continuity test can be used to check the operation of a photoelectric switch.
Chapter 10 Troubleshooting Principles and Test Instruments
Ohmmeters measure the amount of resistance (in ohms) in de-energized circuits, devices, or components.
Chapter 10 Troubleshooting Principles and Test Instruments
Technicians must always verify that circuits, devices, or components do not have voltage before taking any resistance measurements.
Chapter 10 Troubleshooting Principles and Test Instruments
Current measurements are typically measured using clamp-on ammeters or multimeters with clamp-on current probe accessories. In low-current applications, in-line ammeters can be used.
Chapter 10 Troubleshooting Principles and Test Instruments
Current measurements are taken using standard procedures.
Chapter 10 Troubleshooting Principles and Test Instruments
Current measurements for both AC and DC can be taken with in-line ammeters.
Chapter 10 Troubleshooting Principles and Test Instruments
Noncontact temperature instruments measure heat by measuring the infrared energy emitted by a material.
Chapter 10 Troubleshooting Principles and Test Instruments
Infrared temperature measurements prevent problems by locating unwanted heat in electrical equipment enclosures before the heat can cause PLC or equipment failure.
