S 7 M A I N T E N A N C E & T R O U B L E S H O O T I N G

S7 Maintenance & Troubleshootin

!LC S"STEM MAINTENANCE
Programmable controllers are designed to be easy to maintain, to ensure
trouble-free operation. Still, several maintenance aspects should be
considered once the system is in place and operational. Certain maintenance
measures, if performed periodically, will minimize the chance of system
malfunction. This section outlines some of the practices that should be
followed to keep the system in good operating condition.
!RE#ENTI#E MAINTENANCE
Preventive maintenance of programmable controller systems includes only a
few basic procedures, which will greatly reduce the failure rate of system
components. Preventive maintenance for the PC system should be
scheduled with the regular machine or e!uipment maintenance, so that the
e!uipment and controller are down for a minimum amount of time.
"owever, the schedule for PC preventive maintenance depends on the
controller#s environment the harsher the environment, the more fre!uent the
maintenance.
The following are guidelines for preventive measures$
Periodically clean or replace any filters that have been installed in
enclosures at a fre!uency dependent on the amount of dust in the area.
%o not wait until the scheduled machine maintenance to check the
filter. This practice will ensure that clean air circulation is present
inside the enclosure.
$
Cha%ter
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%o not allow dirt and dust to accumulate on the PC#s components&
the central processing unit and '() system are not designed to be dust
proof. 'f dust builds up on heat sinks and electronic circuitry, it can
obstruct heat dissipation, causing circuit malfunction. *urthermore, if
conductive dust reaches the electronic boards, it can cause a short
circuit, resulting in possible permanent damage to the circuit board.
Periodically check the connections to the '() modules to ensure that
all plugs, sockets, terminal strips, and modules have good connections.
+lso, check that the module is securely installed. Perform this type of
check more often when the PC system is located in an area that
e,periences constant vibrations, which could loosen terminal
connections.
-nsure that heavy, noise-generating e!uipment is not located too close
to the PC.
.ake sure that unnecessary items are kept away from the e!uipment
inside the enclosure. eaving items, such as drawings, installation
manuals, or other materials, on top of the CP/ rack or other rack
enclosures can obstruct the airflow and create hot spots, which can
cause system malfunction.
'f the PC system enclosure is in an environment that e,hibits
vibration, install a vibration detector that can interface with the PC as
a preventive measure. This way, the programmable controller can
monitor high levels of vibration, which can lead to the loosening of
connections.
S!ARE !ARTS
't is a good idea to keep a stock of replacement parts on hand. This practice
will minimize downtime resulting from component failure. 'n a failure
situation, having the right spare in stock can mean a shutdown of only
minutes, instead of hours or days. +s a rule of thumb, the amount of a spare
part stocked should be 012 of the number of that part used. 'f a part is used
infre!uently, then less than 012 of that particular part can be stocked.
.ain CP/ board components should have one spare each, regardless of how
many CP/s are being used. -ach power supply, whether main or au,iliary,
should also have a backup. Certain applications may re!uire a complete CP/
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S 7 M A I N T E N A N C E & T R O U B L E S H O O T I N G
rack as a standby spare. This e,treme case e,ists when a downed system
must be brought into operation immediately, leaving no time to determine
which CP/ board has failed.
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S 7 M A I N T E N A N C E & T R O U B L E S H O O T I N G
RE!LACEMENT O) I*O MO+ULES
'f a module must be replaced, the user should make sure that the replacement
module being installed is the correct type. Some '() systems allow modules
to be replaced while power is still applied, but others may re!uire that power
be removed. 'f replacing a module solves the problem, but the failure
reoccurs in a relatively short period, the user should check the inductive
loads. The inductive loads may be generating voltage and current spikes, in
which case, e,ternal suppression may be necessary. 'f the module#s fuse
blows again after it is replaced, the problem may be that the module#s output
current limit is being e,ceeded or that the output device is shorted.
SIMATIC S7,-.. an/ M7,-.. Maintenance
Re%lacin the Bac0u% Batter1
0. %ischarge any static charge by touching a grounded metal part of the
S3-411.
5. )pen the cover of the power supply module.
6. /sing the loop7s8, pull the backup battery(batteries out of the battery
compartment.
Figure 5-1 Replacing the Backup Battery
4. 'nsert the new backup battery(batteries in the battery compartment of
the power supply module. -nsure correct polarity of the
battery(batteries.
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9. Switch on battery monitoring with the :+TT ';%'C slide switch.
<. Press the *.= button.
3. Close the cover of the power supply module.
Note
'f you store the batteries for a long period, a passivation layer may form.
Please read Section <.>, 'nserting a :ackup :attery.
Using Backup Batteries
?ou should change the backup battery once a year.
)bserve the usual regulations(guidelines for disposing of lithium
batteries in your country.
:ackup batteries should be stored in a cool, dry place.
:ackup batteries can be stored for ten years. 'f they are stored for a
longer period, however, a passivation layer may form.
Rules for the Care of Backup Batteries
?ou must observe the following rules to avoid hazards in the care of backup
batteries$
Warning
The improper care of backup batteries can result in in@ury and damage.
:ackup batteries can ignite or e,plode if they are heated or damaged.
:ackup batteries must not be
=echarged
"eated
:urned
%rilled into
Crushed
Store the backup batteries in a cool, dry place.
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Re%lacin a !o2er Su%%l1 Mo/ule
Slot Numbering
'f you have provided the modules in your system with slot numbering, you
must remove the number from the old module when replacing it and apply
the number to the new module.
Remoing the !o"ule #ignore steps 1 an" $ %hen using
re"un"ant po%er supply mo"ules&
0. Set the CP/ mode switch to ST)P. Ahen you replace the power
supply module in an -=, the C= may remain in the =/; state,
depending on CP/ programming. ?ou can back up the data in the -=
via the -BT. :+TT. socket of the receive '..
5. 'f you wish to back up the data in the CP/, you can use the -BT.
:+TT. Socket of the CP/ 7see =eference .anual, Chapter 48.
6. Set the standby switch of the power supply module to 71 C output
voltages8.
4. Set the line disconnector to )**.
9. =emove the cover.
<. =emove the backup battery(batteries if applicable.
3. %isconnect the power supply connector from the power supply
module.
>. oosen the mounting screws of the module.
D. Swing the module out.
'nstalling a Ne% !o"ule
0. Check the voltage selector switch.
5. +ttach the new module of the same type and swing it downwards.
6. Screw the module on.
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4. Check that the power disconnector is set to )** and the standby
switch to
.
9. Plug in the power supply connector at the power supply module.
<. 'nsert the backup battery(batteries, if applicable.
3. Close the cover.
>. Set the power disconnector to );.
D. Set the standby switch of the power supply module to ' 7output
voltages at rated value8.
01.Set the CP/ mode switch to =/; if applicable.
(o% the S)-*++ Behaes after ,-changing !o"ules
'f an error occurs after replacing a module, you can read out the cause of the
error from the diagnostic buffer.
Re%lacin C!Us
Slot Numbering
'f you have provided the modules in your system with slot numbering, you
must remove the number from the old module when replacing it and apply
the number to the new module.
Saing the .ata
Save the user program including configuration data.
Remoing the !o"ule
0. Set the CP/ mode switch to ST)P.
5. Set the standby switch of the power supply module to 71 C output
voltages8.
6. =emove the cover of the CP/.
4. %isconnect the .P' connector, if applicable.
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9. %isconnect the connector at the -BT. :+TT. socket, if applicable.
<. =emove the memory card.
3. oosen the mounting screws of the module.
>. Swing the module out.
'nstalling a Ne% !o"ule
0. +ttach the new module of the same type and swing it downwards.
5. Screw the module on.
6. 'f applicable, plug the connector for the e,ternal battery supply into
the socket.
4. Set the CP/ mode switch to ST)P.
9. 'nsert the memory card.
<. Set the standby switch of the power supply module to ' 7output
voltages at rated value8.
The remaining procedure depends on whether you use a *lash
card and whether or not you have configured your system for
networking.
3. Proceed as follows to operate with a *lash card$
Transfer the user and configuration data.
Set the CP/ mode switch to =/;.
Close the cover.
>. 'f your system is not configured for networking, proceed as follows$
Transfer the user and configuration data by means of the
programming device, via the programming device cable 7see
Section <.68.
Set the CP/ mode switch to =/;.
Close the cover.
D. 'f your system is configured for networking, proceed as follows$
Transfer the user and configuration data by means of the
programming device,
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via the programming device cable 7see Section <.68.
Set up your network by plugging in the .P' connector.
Set the CP/ mode switch to =/;.
Close the cover.
(o% the S)-*++ Behaes after ,-changing !o"ules
'f an error occurs after replacing a module, you can read out the cause
of the error from the diagnostic buffer.
Re%lacin +iital or Analo Mo/ules
Slot Numbering
'f you have provided the modules in your system with slot numbering, you
must remove the number from the old module when replacing it and apply
the number to the new module.
'nstalling a !o"ule
0. ?ou can replace analog and digital modules in =/; mode. ?ou
must have taken the appropriate action in your ST-P 3 program
to ensure correct responses from your system.
'f you are not sure whether your program will react correctly,
set the CP/ mode switch to ST)P.
5. oosen the mounting screw of the front connector and pull it off.
6. oosen the mounting screws of the module.
4. Swing the module out.
Remoing the Front Connector Co"ing /ey
:efore fitting the front connector, you must remove 7break off8 the front part
of the coding key, because this part is already fitted in the wired front
connector.
'nstalling a Ne% !o"ule
0. +ttach the new module of the same type at the appropriate slot and
swing it downwards.
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5. Screw the module on with both mounting screws.
6. *it the front connector.
4. 'f you have set the CP/ to ST)P, you must now set it to =/; again.
9. +fter fitting, each programmable module will be reinitialized by the
CP/ with parameters.
(o% the S)-*++ Behaes after ,-changing !o"ules
'f an error occurs after replacing a module, you can read out the cause of the
error from the diagnostic buffer.
,-changing the Front Connector
0. Switch off all load power supplies for the module.
5. oosen the screw of the front connector and pull it off.
6. =emove the labels from the front connector and insert them into the
new front connector.
4. Aire the new front connector.
9. 'nsert the front connector in the module.
<. Screw the front connector on.
3. Switch on the load voltage.
Chanin the )uses in the +iital Mo/ules
!o"ules %ith Fuses
The following modules have fuses which you can change yourself if they are
defective$
%igital output module S. 455& %) 0< , +C 51-051 C(5+ 7<-S3 455-
9-"11-1+:18
%igital output module S. 455&%) > , +C 051(561 C(9+ 7<-S3 455-
0**11-1++18
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%igital output module S. 455&%) 0< , +C 051(561 C(5+ 7<-S3
455-0*"11-1++18
Check the 0lant
Correct the faults which led to the fuses blowing.
Changing the Fuses
To change the fuses in a digital module, you must remove the front
connector from the digital module and remove the module from the rack.
To change the fuses, follow the steps outlined below$
0. ?ou must have taken the appropriate action in your ST-P 3 program
to ensure correct responses from your system. 'f you are not sure
whether your program will react correctly, set the CP/ mode switch to
ST)P.
5. oosen the mounting screw of the front connector and pull it off.
6. oosen the mounting screws of the module.
4. Swing the module out.
9. =emove the covers on the right-hand side of the module by levering
them out with a screwdriver.
<. =eplace the defective fuses with new fuses of the same type.
3. Place the guides on the covers into the appropriate cutouts in the
module casing and close the covers until they click into place.
>. +ttach the module onto its slot and swing it down.
D. Screw the module on with both mounting screws.
01.*it the front connector.
00.'f you have switched the CP/ to ST)P, you must now switch it to
=/; again.
05.+fter fitting, each programmable module will be reinitialized by the
CP/ with parameters.
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(o% the S)-*++ Behaes after Replacing the Fuse
'f an error occurs after replacing a fuse, you can read out the cause of the
error from the diagnostic buffer.
Re%lacin Inter6ace Mo/ules
Slot Numbering
'f you have provided the modules in your system with slot numbering, you
must remove the number from the old module when replacing it and apply
the number to the new module.
Fitting an" Remoing !o"ules .uring 1peration
)bserve the following warning when fitting and removing the interface
modules and the corresponding connecting cables.
Remoing !o"ules 2 ,-changing Cables
0. 'f you wish to back up your data in the CP/, you can do this with a
backup battery or via an e,ternal battery supply at the CP/ 7see
=eference .anual, Chapter 48.
5. Set the CP/ mode switch to ST)P.
6. Set the standby switches of both power supply modules 7in the C= and
the -=8 to 71 C output voltages8.
4. =emove the cover.
9. %isconnect the connecting cables.
<. %isconnect the terminator, if applicable.
3. oosen the mounting screws of the module.
>. Swing the module out.
'nstalling a Ne% !o"ule
0. Set the number of the rack at receive '.s.
5. +ttach the new module of the same type and swing it downwards.
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6. Screw the module on.
4. *it the connecting cables.
9. Plug in the terminator, if applicable.
<. Secure the cover.
3. *irst switch on the power supply module in the -=.
>. Then switch on the power supply module in the C=.
D. Set the CP/ mode switch to =/; mode.
(o% the S)-*++ Behaes after ,-changing !o"ules
'f an error occurs after replacing a module, you can read out the cause of the
error from the diagnostic buffer.
Re%lacin the )use o6 the )an Subasse7bl1
Fuse 3ype
The fuse of the fan subassembly is a standard 9 , 51 mm cartridge fuse to
%'; and not a spare part.
/se the following fuse$
0<1 m+ slow blow if the voltage selector switch is set to 561 C
591 m+ slow blow if the voltage selector switch is set to 051 C
Replacing the Fuse
To replace the fuse of the module, follow the steps outlined below$
0. %isconnect the power cable of the fan subassembly from the supply.
5. /se a screwdriver to unscrew the fuse cap.
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Figure 5-$
6. =emove the blown fuse from the fuse cap.
4. 'nsert the new fuse in the fuse cap and screw the cap into the fan
subassembly.
9. Connect the power cable of the fan subassembly to the supply.
Re%lacin )ans in the )an Subasse7bl1 +urin
O%eration
Remoing the Fans
0. /se a screwdriver to make a !uarter turn counter-clockwise and open
the two !uick-release locks on the front of the fan subassembly.
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5. Erasp the base with both hands, press it down slightly and pull it fully
out of the fan subassembly.
Figure 5-4
6. =elease the fan to be replaced by pressing the fan grip away from the
housing with your thumb.
Figure 5-*
4. Pull out the fan to be replaced.
9. Slide the new fan in until it engages.
<. Slide the base in again and press it up.
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3. /se a screwdriver to make a !uarter turn clockwise and close the two
!uick-release locks.
>. /se a pointed ob@ect to press the =-S-T button. The fault -% will
go off and the fan will start running.
Re%lacin the )ilter )ra7e o6 the )an
Subasse7bl1 +urin O%eration
Replacing the Filter Frame
0. /se a screwdriver to make a !uarter turn counter-clockwise and open
the two !uick-release locks on the front of the fan subassembly.
5. Erasp the base with both hands, press it down slightly, pull it first
fully forward and then up at an angle out of the fan subassembly.
Figure 5-5
6. The filter frame is secured either in the bottom of the base or at its rear
edge with snap hinges and snap catches. The individual filter mats are
@oined with the filter frame.
=emove the filter frame as follows$
F The filter frame is fitted in the bottom of the base$ ;ear the snap
catches, press against the filter frame from below and remove the
filter frame.
F The filter frame is secured at the rear edge of the base$ Aith the
flat of your hand, press the filter frame away from the base of the
fan subassembly. This will release the filter frame from the snap
hinges.
4. *it the new filter frame$
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F *itting the filter frame at the bottom of the base$ 'nsert the filter
frame in the snap hinges at the base cutout and engage it with the
snap catches.
Figure 5-5
F *itting the filter frame at the rear edge of the base$ +t about a right
angle to the base, insert the filter frame in the snap hinges at the
rear edge of the base.
9. Slide the base in again and press it up.
<. /se a screwdriver to make a !uarter turn clockwise and close the two
!uick-release locks.
3. =eplacing the filter frame will not trigger an interrupt. There is
therefore no need to press the =-S-T button.
Re%lacin the !o2er Su%%l1 !CB an/
Monitorin !CB o6 the )an Subasse7bl1
,-changing the !other Boar"
0. %isconnect the power cable of the fan subassembly from the supply.
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5. /se a screwdriver to make a !uarter turn counter-clockwise and open
the two !uick-release locks on the front of the fan subassembly.
6. =emove the base of the fan subassembly.
Shown in the following figure is a front view of the fan subassembly.
?ou can also see the locations of the printed-circuit boards 7PC:s8.
Figure 5-)
4. Pull the faulty PC: forward and out of the fan subassembly.
9. Slide the new PC: in until it engages.
<. Slide the base in again and press it up.
3. /se a screwdriver to make a !uarter turn clockwise and close the two
!uick-release locks.
>. Connect the power cable of the fan subassembly to the supply.
D. /se a pointed ob@ect to press the =-S-T button. The fans will start
running.
TROUBLESHOOTING THE !LC S"STEM
3R1UB6,S(113'N7 7R1UN. 6110S
+s mentioned earlier, a ground loop condition occurs when two or more
electrical paths e,ist in a ground line. *or e,ample, in *igure 9->, the
transducers and transmitter are connected to ground at the chassis 7or device
enclosure8 and connected to an analog input card through a shielded cable.
The shield connects to both chassis grounds, thereby creating a path for
current to flow from one ground to another since both grounds have different
potentials. The current flowing through the shield could be as high as several
amperes, which would induce significant magnetic fields in the signal
transmission. This could create interference that would result in a possible
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misreading of the analog signal. To avoid this problem, the shield should be
connected to ground on only one side of the chassis, preferably the PC side.
'n the e,ample shown in *igure 9->, the shield should only be connected to
ground at the analog input interface.
Figure 5-89 7roun" loop create" by shiel"e" cable groun"e" at both
en"s9
To check for a ground loop, disconnect the ground wire at the ground
termination and measure the resistance from the wire to the termination point
where it is connected 7see *igure 9-D8. The meter should read a large ohm
value. 'f a low ohm value occurs across this gap, circuit continuity e,ists,
meaning that the system has at least one ground loop.
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Figure 5-:9 0roce"ure for i"entifying groun" loops9
.';7N1S3'C 'N.'C;31RS
-% status indicators can provide much information about field devices,
wiring, and '() modules. .ost input(output modules have at least a single
indicatorGinput modules normally have a power indicator, while output
modules normally have a logic indicator.
*or an input module, a lit power -% indicates that the input device is
activated and that its signal is present at the module. This indicator alone
cannot isolate malfunctions to the module, so some manufacturers provide
an additional diagnostic indicator, a logic indicator. +n ); logic -%
indicates that the input signal has been recognized by the logic section of the
input circuit. 'f the logic and power indicators do not match, then the module
is unable to transfer the incoming signal to the processor correctly. This
indicates a module malfunction.
+n output module#s logic indicator functions similarly to an input module#s
logic indicator. Ahen it is );, the logic -% indicates that the module#s
logic circuitry has recognized a command from the processor to turn );. 'n
addition to the logic indicator, some output modules incorporate either a
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S 7 M A I N T E N A N C E & T R O U B L E S H O O T I N G
blown fuse indicator or a power indicator or both. + blown fuse indicator
indicates the status of the protective fuse in the output circuit, while a power
indicator shows that power is being applied to the load. ike the power and
logic indicators in an input module, if both -%s are not ); simultaneously,
the output module is malfunctioning.
-% indicators greatly assist the troubleshooting process. Aith both power
and logic indicators, the user can immediately pinpoint a malfunctioning
module or circuit. -% indicators, however, cannot diagnose all possible
problems& instead, they serve as preliminary signs of system malfunctions.
3R1UB6,S(113'N7 06C 'N0U3S
'f the field device connected to an input module does not seem to turn );, a
problem may e,ist somewhere between the 0 connection and the terminal
connection to the module. +n input module#s status indicators can provide
information about the field device, the module, and the field device#s wiring
to the module that will help pinpoint the problem.
The first step in diagnosing the problem is to place the PC in standby
mode, so that it is not activating the output. This allows the field device to be
manually activated 7e.g., a limit switch can be manually closed8. Ahen the
field device is activated, the module#s power status indicator should turn
);, indicating that power continuity e,ists. 'f the indicator is );, then
wiring is not the cause of the problem.
The ne,t step is to evaluate the PC#s reading of the input module. This can
be accomplished using the PC#s test mode, which reads the inputs and
e,ecutes the program but does not activate the outputs. 'n this mode, the
PC#s display should either show a 0 in the image table bit corresponding to
the activated field device or the contact#s reference instruction should
become highlighted when the device provides continuity 7see *igure 9-018.
'f the PC is reading the device correctly, then the problem is not located in
the input module. 'f it does not read the device correctly, then the module
could be faulty. The logic side of the module may not be operating correctly,
or its optical isolator may be blown. .oreover, one of the module#s
interfacing channels could be faulty. 'n this case, the module must be
replaced.
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Figure 5-1+9 (ighlighte" contact in"icating po%er continuity9
'f the module does not read the field device#s signal, then further tests are
re!uired. :ad wiring, a faulty field device, a faulty module, or an improper
voltage between the field device and the module could be causing the
problem. *irst, close the field device and measure the voltage to the input
module. The meter should display the voltage of the signal 7e.g., 051 volts
+C8. 'f the proper voltage is present, the input module is faulty because it is
not recognizing the signal. 'f the measured voltage is 01F092 below the
proper signal voltage, then the problem lies in the source voltage to the field
device. 'f no voltage is present, then either the wiring or the field device is
the cause of the problem. Check the wiring connection to the module to
ensure that the wire is secured at the terminal or terminal blocks.
To further pinpoint the problem, check that voltage is present at the field
device. Aith the device activated, measure the voltage across the device
using a voltmeter. 'f no voltage is present on the load side of the device 7the
side that connects to the module8, then the input device is faulty. 'f there is
power, then the problem lies in the wiring from the input device to the
module. 'n this case, the wiring must be traced to find the problem.
3R1UB6,S(113'N7 06C 1U30U3S
PC output interfaces also contain status indicators that provide useful
troubleshooting information. ike the troubleshooting of PC inputs, the
first step in troubleshooting outputs is to isolate the problem to either the
module, the field device, or the wiring.
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+t the output module, ensure that the source power for switching the output
is at the correct level. 'n a 051 C+C system, this value should be within 012
of the rated value 7i.e., between 01> and 065 volts +C8. +lso, e,amine the
output module to see if it has a blown fuse. 'f it does have a blown fuse,
check the fuse#s rated value. *urthermore, check the output device#s current
re!uirements to determine if the device is pulling too much current.
'f the output module receives the command to turn ); from the processor
yet the module#s output status does not turn ); accordingly, then the output
module is faulty. 'f the indicator turns ); but the field device does not
energize, check for voltage at the output terminal to ensure that the switching
device is operational. 'f no voltage is present, then the module should be
replaced. 'f voltage is present, then the problem lies in the wiring or the field
device. +t this point, make sure that the field wiring to the module#s terminal
or to the terminal block has a good connection and that no wires are broken.
+fter checking the module, check that the field device is working properly.
.easure the voltage coming to the field device while the output module is
);, making sure that the return line is well connected to the device. 'f there
is power yet the device does not respond, then the field device is faulty.
+nother method for checking the field device is to test it without using the
output module. =emove the output wiring and connect the field device
directly to the power source. 'f the field device does not respond, then it is
faulty. 'f the field device responds, then the problem lies in the wiring
between the device and the output module. Check the wiring, looking for
broken wires along the wire path.
3R1UB6,S(113'N7 3(, C0U
PCs also provide diagnostic indicators that show the status of the PC and
the CP/. Such indicators include power OK, memory OK, and
communications OK conditions. *irst, check that the PC is receiving
enough power from the transformer to supply all the loads. 'f the PC is still
not working, check for voltage supply drop in the control circuit or for blown
fuses. 'f the PC does not come up even with proper power, then the
problem lies in the CP/. The diagnostic indicators on the front of the CP/
will show a fault in either memory or communications. 'f one of these
indicators is lit, the CP/ may need to be replaced.
S7,'.. Troubleshootin Gui/e
'(
S 7 M A I N T E N A N C E & T R O U B L E S H O O T I N G
3able 5-1 S)-$++ 3roubleshooting 7ui"e
'-
S 7 M A I N T E N A N C E & T R O U B L E S H O O T I N G
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