Hollysys PLC - Six Fault Types of PLC and Troubleshooting Methods (1-3)

Create Date: 2024-8-30 12:03:23|Source: HollySys/HollySys

First, the type of failure of the PLC.

1. External equipment failure.

External equipment refers to various switches, sensors, actuators, loads, etc., which are directly connected with the PLC operation process. The failure of these equipment will directly affect the control function of the PLC system. Therefore, to repair the PLC, the first thing to identify is the fault of the external equipment or the fault of the PLC itself.

2. System failure.

1) System failure is a global fault that affects the operation of the PLC system.

2) PLC system failures can be divided into fixed faults and occasional faults.

3) After the fault occurs, it can be restarted to restore the system normally, which is an accidental failure. If the reboot does not recover, but requires the replacement of hardware or software for the system to recover normally, it is considered a fixed fault.

3. Hardware failure.

PLC hardware failure mainly refers to the failure caused by the damage of the template and circuit in the PLC system.

4. Software failure.

PLC software failures include software errors, operational errors, etc. PLC software failures can generally be viewed and viewed through the PLC's own self-diagnosis test function or software.

Second, the failure rate of PLC control system.

1) CPU and memory failure rate accounts for 5%.

2) The failure rate of I/O modules accounts for 15%.

3) The failure rate of sensors and switches accounts for 45%.

4) Actuator failure rate accounts for 30%.

5) The failure rate of wiring and other aspects accounts for 5%.

Third, the key parts of PLC failures are frequent.

1) Relays, contactors.

2) Valves, rams.

3) Switches, limit positions, safety maintenance, some components or equipment for on-site operation.

4) Sub-equipment in the PLC system.

5) Sensor, appearance.

6) Noise of power supply, ground wire, and signal wire.
Hollysys PLC - Six Fault Types of PLC and Troubleshooting Methods (1-3)

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