Upgrading your PLC is one of the most important things you can do to maintain your industrial system’s performance long-term. However, when it comes to switching out your older model and installing a new one, there’s a lot that can go wrong. Setting out to minimize errors is the key to ensuring a successful transition. As such, you’ll want to know what specifically to steer clear of throughout the process. Here are five mistakes to avoid when installing a new PLC.
Failing To Reference Older Code
When you’re changing out one PLC for another, it’s vital that you program your new one in a similar manner. Your older code possesses the groundwork necessary to classify the different pieces of equipment and define each function to your PLC. This doesn’t change simply because you’re installing a different model of PLC. So, make sure you keep a record of your older code and continue to reference it throughout the programming stage. This way, you know you’re creating something that works.
Writing Original Code
You shouldn’t need to write your new PLC’s code from scratch. If the product is compatible with your system, it will run even if you transferred the old code from your previous PLC. Writing new code takes a lot of time, causing you to waste precious minutes that your equipment could use to produce more products. For this reason, don’t hesitate to copy your older code into the program and test it. Should it run as intended, you save yourself a lot of time. If it doesn’t, address the issue with smaller pieces of targeted code.
Creating an Unorganized System Structure
Failing to maintain an organized system structure is also a mistake you should avoid when installing a new PLC. For your new model to operate correctly, it needs to have a clear understanding of which components to control and when. Making recognizable labels for each part can greatly help with readability and reduce the number of potential performance issues later.
Using Code Redundancies
Likewise, try to steer away from coding redundancies, such as leaving in several lines that give the same order or creating several labels for the same equipment part. These things can slow down the processing rate of your PLC and hinder its overall performance.
Forgetting About Version Control
Make sure you’re implementing version control procedures as well. You may write several different pieces of code for this new PLC. Each will send a different order to your machines depending on the specific task you want it to perform. Keeping everything separate and properly tagged will make it easier for your team to select the right one for the project. Otherwise, you risk a manufacturing error.
Whether you’re searching for a newer PLC for your system or simply need advice for installation, PLC Direct can help. We carry a wide range of Allen Bradley and Omron PLC parts, all featuring premium customization and performance capabilities. We offer transparent availability and if you have any questions about our inventory, feel free to reach out to our customer service team.