5 Common Issues With PLCs and How To Solve Them

As technology advances and businesses rely more on automation, Programmable Logic Controllers (PLCs) are becoming more important for industrial control systems. Like any technology, PLCs are not immune to issues. Knowing how to identify and address common PLC issues can save warehouse managers and business owners from costly downtime and repairs. We will cover five of the most common PLC issues and how to solve them.

Programming Issues

Incorrect encodings, code errors, and communication faults are some problems PLCs experience. Incorrect programming can lead to improper control of machinery, resulting in wasted materials and reduced productivity. To solve programming issues, carefully review and test the code to ensure it functions correctly. We recommend working with a professional programmer to avoid these problems in the first place.

Electrical Noise

Electromagnetic fields cause electrical noise, which can interfere with the signals between the components of a PLC system. This interference can lead to system errors, wrong measurements, and even equipment damage. Fortunately, installing a noise filter on the electrical system or modifying the wiring can mitigate this problem and ensure the PLCs operate correctly.

Communication and Network Issues

PLCs rely on communication between components to perform. Communication faults can result in missed data, incorrect measurements, and issues with machinery. Check and reconfigure communication settings, replace the communication module, or re-install the communication software to reduce your risk of communication errors.

Hardware and Component Failures

Like any other machinery, PLC systems can suffer from hardware and component failures. Symptoms of such failures include blinking error codes on the PLC display, flashing red lights, and abnormal sounds. Replacing faulty components and performing regular maintenance will help you get ahead of these problems and avoid future issues.

Power Supply Issues

A malfunctioning power supply is another common issue to be aware of with PLCs. The power supply is a vital component of any PLC system. Power outage or overvoltage can cause the system to shut down or lead to equipment damage. Implementing a backup power supply, using surge protectors, and performing regular power quality checks are three effective ways to protect your power supply and keep things running smoothly.

PLC issues can disrupt productivity and business operations, leading to losses. By following these tips, you can minimize PLC issues and save your business money and resources in the long run. Work alongside a reliable supplier like PLC Direct. We offer a diverse collection of products from premium PLC brands, like our line of Omron safety PLCs. By working with us, you gain a partner who will provide you with everything you need to keep your systems performing as they should.