Common problems and solutions in the maintenance process of Omron PLC

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

1. CPU abnormality:

When the CPU is abnormally alarmed, check all the devices connected to the internal bus of the CPU unit. The specific method is to replace the units that may have problems in turn, find out the problem units, and deal with them accordingly

2. Memory abnormality:

If the memory is abnormally alarmed, if it is a problem with the program memory, the problem will be reproduced after being programmed from scratch. This situation may be caused by noise disturbance causing a change in the program, otherwise the memory should be replaced.

3. Abnormal input/output unit and abnormal expansion unit:

When this kind of alarm occurs, you should first check the penetration status and cable connection status of the connector of the input/output unit and the expansion unit, and then replace the unit after determining the occurrence of a certain unit.

IV. Non-performance Procedure:

In general, it can be viewed according to the process of performing ——- output according to the input ——- program

(1) Input viewing is identified by the input LED indicator or by the input monitor composed of a writer. When the input LED is not lit, you can start to conclude that it is a fault with the external input system, and then cooperate with the multimeter to check. If the output voltage is abnormal, it can be concluded that the input unit is faulty. When the LED is on but the internal monitor is not visible, it can be considered to be a fault with the input unit, CPU unit, or expansion unit.

(2) Program fulfillment viewing is viewed by a monitor on the writer. When the contact status of the ladder diagram is inconsistent with the result, it is a program error (such as the use of two layers of internal relays, etc.), or the operation part is faulty.

(3) Output view: Identification can be identified by output LED indicator. When the calculation result is correct and the output LED indication is wrong, it can be considered as a fault of the CPU unit and 1/0 interface unit. When the output LED is bright but there is no output, it can be determined that the output unit is faulty, or the external load system is faulty.

In addition, due to the different PLC models, the connection method of 1/0 and LED is different (some are connected to the interface of the 1/0 unit, and some are connected to the 1/0 unit). Therefore, the scale of the problem according to the LED judgment is also different.

5. Failure to perform some procedures:

The viewing method is the same as in the previous item

However, if the input time of the counter, step controller, etc. is too short, there will be no echo problem, then the input time should be checked whether the input time is large enough, and the verification can be carried out according to the maximum echo time of the input unit at the input time + the time of operation and sweep multiplied by 2.

6. If the power supply is powered off for a short time, the program content will also disappear:

(1) In this case, in addition to checking the battery, check as follows

(2) After repeatedly turning on and off the power supply of the PLC itself. In order for the microprocessor to start up correctly, the PLC is equipped with a circuit for the initial reset point and a circuit for saving the program when the power supply is disconnected. When this circuit fails, the program cannot be saved. Therefore, you can check the power supply on and off.

(3) If the battery abnormality alarm persists after the battery is replaced, it can be determined that the abnormal increase in leakage current in the memory or external circuit is caused.

(4) The on/off of the power supply is always synchronized with the machine system, and the noise impact of the machine system can be viewed. Because the disconnection of the power supply is often caused by the same time as the machine system, most of them are caused by the strong noise of the motor or winding.

7. PROM does not work:

Check to see if the PROM penetration is good, and then determine if the chip needs to be replaced

8. After the power supply is put in or reset from the beginning, the action stops:

This problem can be thought to be caused by noise disturbance or poor contact within the PLC. The cause of noise is generally caused by the reduction of small capacitor capacity on the circuit board or the poor function of the components. Also look at the penetration of cables and adapters.
Common problems and solutions in the maintenance process of Omron PLC

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