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輸入回路檢修
判斷某只按扭、限位、線路等輸入回路的好壞，可在PLC通電情況下(在非運(yùn)行狀態(tài)，以防設(shè)備誤動(dòng)作)，按下按扭(或其他輸入接點(diǎn))，這時(shí)對(duì)應(yīng)的PLC輸入點(diǎn)端子與公共端被短接，按扭所對(duì)應(yīng)的PLC輸入指示燈亮，說明此按扭及線路正常。燈不亮，可能按扭壞、線路接觸不良或者斷線。若進(jìn)一步判斷，按扭如果是好的，那么用萬用表的一根表筆，一頭接PLC輸入端的公共端，另一頭接觸所對(duì)應(yīng)的PLC輸入點(diǎn)(上述操作要小心，千萬不要碰到220V或110V輸入端子上)。此時(shí)指示燈亮，說明線路存在故障。指示燈不亮，說明此PLC輸入點(diǎn)已損壞(此情況少見，一般強(qiáng)電入侵所致)。
輸出回路檢修
對(duì)于PLC輸出點(diǎn)(這里僅談繼電器輸出型)，若動(dòng)作對(duì)象所對(duì)應(yīng)的指示燈不亮，在確定PLC在運(yùn)行狀態(tài)下，那么說明此動(dòng)作對(duì)象的PLC輸入輸出邏輯功能沒有滿足，也就是說輸入回路出故障，按前面講的，檢查輸入回路。若所對(duì)應(yīng)的指示燈亮，但所對(duì)應(yīng)的執(zhí)行元件如電磁閥、接觸器不動(dòng)作，先查電磁閥控制電源及保險(xiǎn)器，zui簡(jiǎn)便的方法，用電筆去量所對(duì)應(yīng)PLC輸出點(diǎn)的公共端子。電筆不亮，可能對(duì)應(yīng)保險(xiǎn)絲熔斷等電源故障。電筆亮，說明電源是好的，所對(duì)應(yīng)的電磁閥、接觸器、線路出故障。排除電磁閥、接觸器、線路等故障后，仍不正常，就利用萬用表一只表筆，一頭接對(duì)應(yīng)的輸出公共端子，另一頭接觸所對(duì)應(yīng)的PLC輸出點(diǎn)，這時(shí)電磁閥等仍不動(dòng)作，說明輸出線路出故障。
如果這時(shí)電磁閥動(dòng)作，那么問題在PLC輸出點(diǎn)上。由于電筆有時(shí)會(huì)虛報(bào)，可用另一種方法分析，用萬用表電壓檔量PLC輸出點(diǎn)與公共端的電壓，電壓為零或接近零，說明PLC輸出點(diǎn)正常，故障點(diǎn)在外圍。若電壓較高，說明此觸點(diǎn)接觸電阻太大，已損壞。另外，當(dāng)指示燈不亮，但對(duì)應(yīng)的電磁閥、接觸器等動(dòng)作，這可能此輸出點(diǎn)因過載或短路燒牢。這時(shí)應(yīng)把此輸出點(diǎn)的外接線拆下來，再用萬用表電阻檔去量輸出點(diǎn)與公共端的電阻，若電阻較小，說明此觸點(diǎn)已壞，若電阻無窮大，說明此觸點(diǎn)是好的，應(yīng) 是所對(duì)應(yīng)的輸出指示燈已壞。
程序邏輯推斷
現(xiàn)在工業(yè)上經(jīng)常使用的PLC種類繁多，對(duì)于低端的PLC而言，梯形圖指令大同小異，對(duì)于中機(jī)，如S7-300，許多程序是用語言表編的。實(shí)用的梯形圖必須有中文符號(hào)注解，否則閱讀很困難，看梯形圖前如能大概了解設(shè)備工藝或操作過程 ，看起來比較容易。若進(jìn)行電氣故障分析，一般是應(yīng)用反查法或稱反推法，即根據(jù)輸入輸出對(duì)應(yīng)表，從故障點(diǎn)找到對(duì)應(yīng)PLC的輸出繼電器，開始反查滿足其動(dòng)作的邏輯關(guān)系。經(jīng)驗(yàn)表明，查到一處問題，故障基本可以排除，因?yàn)樵O(shè)備同時(shí)發(fā)生兩起及兩起以上的故障點(diǎn)是不多的。
輸入回路檢修
判斷某只按扭、限位、線路等輸入回路的好壞，可在PLC通電情況下(在非運(yùn)行狀態(tài)，以防設(shè)備誤動(dòng)作)，按下按扭(或其他輸入接點(diǎn))，這時(shí)對(duì)應(yīng)的PLC輸入點(diǎn)端子與公共端被短接，按扭所對(duì)應(yīng)的PLC輸入指示燈亮，說明此按扭及線路正常。燈不亮，可能按扭壞、線路接觸不良或者斷線。若進(jìn)一步判斷，按扭如果是好的，那么用萬用表的一根表筆，一頭接PLC輸入端的公共端，另一頭接觸所對(duì)應(yīng)的PLC輸入點(diǎn)(上述操作要小心，千萬不要碰到220V或110V輸入端子上)。此時(shí)指示燈亮，說明線路存在故障。指示燈不亮，說明此PLC輸入點(diǎn)已損壞(此情況少見，一般強(qiáng)電入侵所致)。
輸出回路檢修
對(duì)于PLC輸出點(diǎn)(這里僅談繼電器輸出型)，若動(dòng)作對(duì)象所對(duì)應(yīng)的指示燈不亮，在確定PLC在運(yùn)行狀態(tài)下，那么說明此動(dòng)作對(duì)象的PLC輸入輸出邏輯功能沒有滿足，也就是說輸入回路出故障，按前面講的，檢查輸入回路。若所對(duì)應(yīng)的指示燈亮，但所對(duì)應(yīng)的執(zhí)行元件如電磁閥、接觸器不動(dòng)作，先查電磁閥控制電源及保險(xiǎn)器，zui簡(jiǎn)便的方法，用電筆去量所對(duì)應(yīng)PLC輸出點(diǎn)的公共端子。電筆不亮，可能對(duì)應(yīng)保險(xiǎn)絲熔斷等電源故障。電筆亮，說明電源是好的，所對(duì)應(yīng)的電磁閥、接觸器、線路出故障。排除電磁閥、接觸器、線路等故障后，仍不正常，就利用萬用表一只表筆，一頭接對(duì)應(yīng)的輸出公共端子，另一頭接觸所對(duì)應(yīng)的PLC輸出點(diǎn)，這時(shí)電磁閥等仍不動(dòng)作，說明輸出線路出故障。
如果這時(shí)電磁閥動(dòng)作，那么問題在PLC輸出點(diǎn)上。由于電筆有時(shí)會(huì)虛報(bào)，可用另一種方法分析，用萬用表電壓檔量PLC輸出點(diǎn)與公共端的電壓，電壓為零或接近零，說明PLC輸出點(diǎn)正常，故障點(diǎn)在外圍。若電壓較高，說明此觸點(diǎn)接觸電阻太大，已損壞。另外，當(dāng)指示燈不亮，但對(duì)應(yīng)的電磁閥、接觸器等動(dòng)作，這可能此輸出點(diǎn)因過載或短路燒牢。這時(shí)應(yīng)把此輸出點(diǎn)的外接線拆下來，再用萬用表電阻檔去量輸出點(diǎn)與公共端的電阻，若電阻較小，說明此觸點(diǎn)已壞，若電阻無窮大，說明此觸點(diǎn)是好的，應(yīng) 是所對(duì)應(yīng)的輸出指示燈已壞。
程序邏輯推斷
現(xiàn)在工業(yè)上經(jīng)常使用的PLC種類繁多，對(duì)于低端的PLC而言，梯形圖指令大同小異，對(duì)于中機(jī)，如S7-300，許多程序是用語言表編的。實(shí)用的梯形圖必須有中文符號(hào)注解，否則閱讀很困難，看梯形圖前如能大概了解設(shè)備工藝或操作過程 ，看起來比較容易。若進(jìn)行電氣故障分析，一般是應(yīng)用反查法或稱反推法，即根據(jù)輸入輸出對(duì)應(yīng)表，從故障點(diǎn)找到對(duì)應(yīng)PLC的輸出繼電器，開始反查滿足其動(dòng)作的邏輯關(guān)系。經(jīng)驗(yàn)表明，查到一處問題，故障基本可以排除，因?yàn)樵O(shè)備同時(shí)發(fā)生兩起及兩起以上的故障點(diǎn)是不多的。
AMK Servo Motor DV5-4-4-I0F 1,2kW 6000r/min 3,3A Lüfter DV5-4-4-IOF
AMK KW 40 Amkasyn KW40 40kVA 66A 46264
AMK Amkasyn AW 25/38-3
AMK AN 20F Power Supply AN20F
AMK AW 4/8-3 Servo Drive Amkasyn + AW R02
AMK Servomotor DV5-2-4-I00 0,83kW max. 1000/6000
AMK Amkasyn AW 2/4-345620-9746-547696 AW-R02
AMK AMKASYN AW 4,5/945415 0-800Hz
AMK AZ-PS4 REV.01.08AZ-MC1-1.00
AMK AMKASYN AW 3/6 44624-9519-625
AMK AMKASYN 46303-0336-887338 KW 5 KW5 +KW-R03 + KW-EA2
AMK AW 25/38-3
AMK AMKASYN KWD 2 +2x KW-R03P
AMK Double Servo Drive AMKASYN KWD2 + 2xKW-R04
AMK Amkasyn KWF 1-0N
AMK Amkasyn KWD 1 Servo Drive KWD1 2x KW-R04 46773
AMK AMKASYN Servo Drive KW 2 + 1x KW-R04
AMK AN 20F
AMK AMKASYN AW 1,5/3AW1,5/3 Servo Drive44623 1,5kVA
AMK DT5-5-10-E00 2.00 Servomotor 1,2kW max.3500/6000
AMK AMKASYN Servo Drive KW2 KW 2 + 1x KW-R03
AMK AN 20 Power Supply AN20
B&R IPC5000 5C5001.01 KBA 5D5500.06 ID C0028031 5P5000:V1038
B&R Power Panel 3004PP320.1505-31
B&R Power Panel B&R5C2002.02 Rev. H0
B&R Panel PC 5C5601.11 IPC5600 5P56 Panel 5D5601.10
B&R Panel PC IPC 2001 5C2001.21
B&R Touchpanel 400 4PP420.1043-75 Rev.F0
B&R CP 260 3CP260.60-1 CPU Module REV.G0
B&R Industrial Automation NC352 3NC352.6
B&R Servomotor 8JSA65.EB025D000-0 max. 2500
B&R Power Panel 3004PP320.0571-35 Rev.F0
B&R NC154 3NC154.60-2 Axis Controller REV. F0
B&R IP151 3IP151.60-2 Rev. E0
B&R Power Panel PP220 LC-Display 4PP220.0571-45 Rev. L0 + IF772
B&R Power Panel 4PP120.0571-21
B&R Power Panel 4004PP420.0571-45 Rev.D0 + IF771
B&R Panel 5C5001.32IPC5000
B&R 5AP980.1505-K15
B&R Power Panel PP 41 4P3040.00-490
B&R NC154 3NC154.60-2 Axis
B&R CP 360 3CP360.60-1 CPU
B&R Panel Front 4D1166.00-590 Rev.C0 + 4C2200.01-510
B&R Servomotor 8MSA4L.E3-X4 max. 4500
B&R Acopos 1180 Servo Drive 8V1180.00-2Acopos1180
B&R Panel PC 5PC720.1214-00
B&R Power Panel 5005PP520.0573-00 REV A2 5PP5:463148.001-00
B&R Power Panel PP414P3040.01-490
B&R Power Panel 3005PP320.0571-39
B&R Power Panel 5005PP520.0573-00 REV B0 5PP5:463148.001-00
B&R Acopos 1180 Servo Drive 8V1180.00-2Acopos1180
B&R Power Panel 5 5PP220.0571-K01 Krones0-900-18-325-0
B&R Panel PC 5PC720.1214-00
AMK Servo Motor DV5-4-4-I0F 1,2kW 6000r/min 3,3A Lüfter DV5-4-4-IOF
AMK KW 40 Amkasyn KW40 40kVA 66A 46264
AMK Amkasyn AW 25/38-3
AMK AN 20F Power Supply AN20F
AMK AW 4/8-3 Servo Drive Amkasyn + AW R02
AMK Servomotor DV5-2-4-I00 0,83kW max. 1000/6000
AMK Amkasyn AW 2/4-345620-9746-547696 AW-R02
AMK AMKASYN AW 4,5/945415 0-800Hz
AMK AZ-PS4 REV.01.08AZ-MC1-1.00
AMK AMKASYN AW 3/6 44624-9519-625
AMK AMKASYN 46303-0336-887338 KW 5 KW5 +KW-R03 + KW-EA2
AMK AW 25/38-3
AMK AMKASYN KWD 2 +2x KW-R03P
AMK Double Servo Drive AMKASYN KWD2 + 2xKW-R04
AMK Amkasyn KWF 1-0N
AMK Amkasyn KWD 1 Servo Drive KWD1 2x KW-R04 46773
AMK AMKASYN Servo Drive KW 2 + 1x KW-R04
AMK AN 20F
AMK AMKASYN AW 1,5/3AW1,5/3 Servo Drive44623 1,5kVA
AMK DT5-5-10-E00 2.00 Servomotor 1,2kW max.3500/6000
AMK AMKASYN Servo Drive KW2 KW 2 + 1x KW-R03
AMK AN 20 Power Supply AN20
B&R IPC5000 5C5001.01 KBA 5D5500.06 ID C0028031 5P5000:V1038
B&R Power Panel 3004PP320.1505-31
B&R Power Panel B&R5C2002.02 Rev. H0
B&R Panel PC 5C5601.11 IPC5600 5P56 Panel 5D5601.10
B&R Panel PC IPC 2001 5C2001.21
B&R Touchpanel 400 4PP420.1043-75 Rev.F0
B&R CP 260 3CP260.60-1 CPU Module REV.G0
B&R Industrial Automation NC352 3NC352.6
B&R Servomotor 8JSA65.EB025D000-0 max. 2500
B&R Power Panel 3004PP320.0571-35 Rev.F0
B&R NC154 3NC154.60-2 Axis Controller REV. F0
B&R IP151 3IP151.60-2 Rev. E0
B&R Power Panel PP220 LC-Display 4PP220.0571-45 Rev. L0 + IF772
B&R Power Panel 4PP120.0571-21
B&R Power Panel 4004PP420.0571-45 Rev.D0 + IF771
B&R Panel 5C5001.32IPC5000
B&R 5AP980.1505-K15
B&R Power Panel PP 41 4P3040.00-490
B&R NC154 3NC154.60-2 Axis
B&R CP 360 3CP360.60-1 CPU
B&R Panel Front 4D1166.00-590 Rev.C0 + 4C2200.01-510
B&R Servomotor 8MSA4L.E3-X4 max. 4500
B&R Acopos 1180 Servo Drive 8V1180.00-2Acopos1180
B&R Panel PC 5PC720.1214-00
B&R Power Panel 5005PP520.0573-00 REV A2 5PP5:463148.001-00
B&R Power Panel PP414P3040.01-490
B&R Power Panel 3005PP320.0571-39
B&R Power Panel 5005PP520.0573-00 REV B0 5PP5:463148.001-00
B&R Acopos 1180 Servo Drive 8V1180.00-2Acopos1180
B&R Power Panel 5 5PP220.0571-K01 Krones0-900-18-325-0
B&R Panel PC 5PC720.1214-00
AMK Servo Motor DV5-4-4-I0F 1,2kW 6000r/min 3,3A Lüfter DV5-4-4-IOF
AMK KW 40 Amkasyn KW40 40kVA 66A 46264
AMK Amkasyn AW 25/38-3
AMK AN 20F Power Supply AN20F
AMK AW 4/8-3 Servo Drive Amkasyn + AW R02
AMK Servomotor DV5-2-4-I00 0,83kW max. 1000/6000
AMK Amkasyn AW 2/4-345620-9746-547696 AW-R02
AMK AMKASYN AW 4,5/945415 0-800Hz
AMK AZ-PS4 REV.01.08AZ-MC1-1.00
AMK AMKASYN AW 3/6 44624-9519-625
AMK AMKASYN 46303-0336-887338 KW 5 KW5 +KW-R03 + KW-EA2
AMK AW 25/38-3
AMK AMKASYN KWD 2 +2x KW-R03P
AMK Double Servo Drive AMKASYN KWD2 + 2xKW-R04
AMK Amkasyn KWF 1-0N
AMK Amkasyn KWD 1 Servo Drive KWD1 2x KW-R04 46773
AMK AMKASYN Servo Drive KW 2 + 1x KW-R04
AMK AN 20F
AMK AMKASYN AW 1,5/3AW1,5/3 Servo Drive44623 1,5kVA
AMK DT5-5-10-E00 2.00 Servomotor 1,2kW max.3500/6000
AMK AMKASYN Servo Drive KW2 KW 2 + 1x KW-R03
AMK AN 20 Power Supply AN20
B&R IPC5000 5C5001.01 KBA 5D5500.06 ID C0028031 5P5000:V1038
B&R Power Panel 3004PP320.1505-31
B&R Power Panel B&R5C2002.02 Rev. H0
B&R Panel PC 5C5601.11 IPC5600 5P56 Panel 5D5601.10
B&R Panel PC IPC 2001 5C2001.21
B&R Touchpanel 400 4PP420.1043-75 Rev.F0
B&R CP 260 3CP260.60-1 CPU Module REV.G0
B&R Industrial Automation NC352 3NC352.6
B&R Servomotor 8JSA65.EB025D000-0 max. 2500
B&R Power Panel 3004PP320.0571-35 Rev.F0
B&R NC154 3NC154.60-2 Axis Controller REV. F0
B&R IP151 3IP151.60-2 Rev. E0
B&R Power Panel PP220 LC-Display 4PP220.0571-45 Rev. L0 + IF772
B&R Power Panel 4PP120.0571-21
B&R Power Panel 4004PP420.0571-45 Rev.D0 + IF771
B&R Panel 5C5001.32IPC5000
B&R 5AP980.1505-K15
B&R Power Panel PP 41 4P3040.00-490
B&R NC154 3NC154.60-2 Axis
B&R CP 360 3CP360.60-1 CPU
B&R Panel Front 4D1166.00-590 Rev.C0 + 4C2200.01-510
B&R Servomotor 8MSA4L.E3-X4 max. 4500
B&R Acopos 1180 Servo Drive 8V1180.00-2Acopos1180
B&R Panel PC 5PC720.1214-00
B&R Power Panel 5005PP520.0573-00 REV A2 5PP5:463148.001-00
B&R Power Panel PP414P3040.01-490
B&R Power Panel 3005PP320.0571-39
B&R Power Panel 5005PP520.0573-00 REV B0 5PP5:463148.001-00
B&R Acopos 1180 Servo Drive 8V1180.00-2Acopos1180
B&R Power Panel 5 5PP220.0571-K01 Krones0-900-18-325-0
B&R Panel PC 5PC720.1214-00
AMK Servo Motor DV5-4-4-I0F 1,2kW 6000r/min 3,3A Lüfter DV5-4-4-IOF
AMK KW 40 Amkasyn KW40 40kVA 66A 46264
AMK Amkasyn AW 25/38-3
AMK AN 20F Power Supply AN20F
AMK AW 4/8-3 Servo Drive Amkasyn + AW R02
AMK Servomotor DV5-2-4-I00 0,83kW max. 1000/6000
AMK Amkasyn AW 2/4-345620-9746-547696 AW-R02
AMK AMKASYN AW 4,5/945415 0-800Hz
AMK AZ-PS4 REV.01.08AZ-MC1-1.00
AMK AMKASYN AW 3/6 44624-9519-625
AMK AMKASYN 46303-0336-887338 KW 5 KW5 +KW-R03 + KW-EA2
AMK AW 25/38-3
AMK AMKASYN KWD 2 +2x KW-R03P
AMK Double Servo Drive AMKASYN KWD2 + 2xKW-R04
AMK Amkasyn KWF 1-0N
AMK Amkasyn KWD 1 Servo Drive KWD1 2x KW-R04 46773
AMK AMKASYN Servo Drive KW 2 + 1x KW-R04
AMK AN 20F
AMK AMKASYN AW 1,5/3AW1,5/3 Servo Drive44623 1,5kVA
AMK DT5-5-10-E00 2.00 Servomotor 1,2kW max.3500/6000
AMK AMKASYN Servo Drive KW2 KW 2 + 1x KW-R03
AMK AN 20 Power Supply AN20
B&R IPC5000 5C5001.01 KBA 5D5500.06 ID C0028031 5P5000:V1038
B&R Power Panel 3004PP320.1505-31
B&R Power Panel B&R5C2002.02 Rev. H0
B&R Panel PC 5C5601.11 IPC5600 5P56 Panel 5D5601.10
B&R Panel PC IPC 2001 5C2001.21
B&R Touchpanel 400 4PP420.1043-75 Rev.F0
B&R CP 260 3CP260.60-1 CPU Module REV.G0
B&R Industrial Automation NC352 3NC352.6
B&R Servomotor 8JSA65.EB025D000-0 max. 2500
B&R Power Panel 3004PP320.0571-35 Rev.F0
B&R NC154 3NC154.60-2 Axis Controller REV. F0
B&R IP151 3IP151.60-2 Rev. E0
B&R Power Panel PP220 LC-Display 4PP220.0571-45 Rev. L0 + IF772
B&R Power Panel 4PP120.0571-21
B&R Power Panel 4004PP420.0571-45 Rev.D0 + IF771
B&R Panel 5C5001.32IPC5000
B&R 5AP980.1505-K15
B&R Power Panel PP 41 4P3040.00-490
B&R NC154 3NC154.60-2 Axis
B&R CP 360 3CP360.60-1 CPU
B&R Panel Front 4D1166.00-590 Rev.C0 + 4C2200.01-510
B&R Servomotor 8MSA4L.E3-X4 max. 4500
B&R Acopos 1180 Servo Drive 8V1180.00-2Acopos1180
B&R Panel PC 5PC720.1214-00
B&R Power Panel 5005PP520.0573-00 REV A2 5PP5:463148.001-00
B&R Power Panel PP414P3040.01-490
B&R Power Panel 3005PP320.0571-39
B&R Power Panel 5005PP520.0573-00 REV B0 5PP5:463148.001-00
B&R Acopos 1180 Servo Drive 8V1180.00-2Acopos1180
B&R Power Panel 5 5PP220.0571-K01 Krones0-900-18-325-0
B&R Panel PC 5PC720.1214-00
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