PLC Troubleshooting - RSLogix 500 SLC MicroLogix Mathematical Overflow Fault Code Finding Techniques
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The ability to effectively troubleshoot control systems comes from practice. By going through the steps, again and again, an experienced electrician, technician or engineer, will develop an eye for how to fix most problems. By practicing this skill, the individual will take less time on future problems they encounter. That being said, what is an effective starting process? Which steps would we typically take?
Step 1 - Resetting the Fault
It's important to note that in production, every minute of downtime is expensive. Therefore, unless a potential problem of doing so is apparent, the first step is often to reset the PLC and set it back to "Run". An intermittent fault may have been caused by a deadlock in the software, an electrical malfunction or a glimpse in the system. These aren't common, but they do occur.
Step 2 - Using the Error Description Functionality
Every Programmable Logic Controller that throws a fault will present the user with a certain description. In RSLogix 500, this description may be accessed through the fault menu in the top left corner.
Once the menu is opened, it's important to take note of the fault. This description will aid in the following steps of the process and may give the programmer a good idea of what the problem is.
Step 3 - Fault Research
Fault codes may be typed directly into Google. Chances are, someone has already encountered the same fault you're seeing. The top results within the search engine are very good at resolving the fault of our experience. Note that some of these resources could be from a forum, blog post or another user-created resource. Other times, the fault code along with an extensive troubleshooting guide will be available from an OEM document such as a datasheet. Do not disregard user-generated content as end-users may often encounter faults that aren't always known by the OEMs.
Step 4 - Technical Support Channels
If none of the above methods worked, it's time to reach out for professional help. If you have access to paid channels such as Rockwell Tech Connect, it's time to make a phone call. You'll be connected with an expert from the company who should be able to guide you toward a resolution of the problem. If this isn't available to you, it's often possible to obtain help from a local system integration company. If you've purchased equipment from a local distributor, they may be of assistance as well.
Step 5 - New Fault Documentation
If you're still stuck, it's advised to post your fault with as many details as possible on an end-user community forum. As mentioned above, it's highly unlikely that you've encountered an issue that has never been seen before. Create a post with as many details as possible on the following forum: SolisPLC Forums
Full Tutorial:
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