How can transient faults in PLC-controlled systems be reliably detected?

Transient faults can only be identified through high-resolution, continuous data acquisition. ibaPDA-PLC-Xplorer enables symbolic acquisition of PLC signals with short sampling rates (e.g. 10 ms). This makes even very short-lived signal changes visible over time. Combined with trend visualization, cause-and-effect relationships can be clearly identified.

How can fast ad-hoc troubleshooting be implemented in complex automation systems?

Efficient ad-hoc analysis requires rapid integration into existing PLC structures. ibaPDA-PLC-Xplorer allows direct access to S7 programs via symbolic variables without complex configuration. This enables immediate monitoring of relevant input and output signals. As a result, time to root cause identification is significantly reduced.

How can cause-and-effect relationships in signal dropouts be analyzed in real time?

Signal dropouts can be analyzed through synchronous recording of all relevant digital and analog signals. ibaPDA ensures continuous acquisition and aligns all signals within the same time context. This makes it possible to identify which actions directly trigger signal loss. Such correlations are often not detectable with conventional SCADA systems.

What are the benefits of high-resolution Ethernet-based data acquisition for troubleshooting?

Ethernet-based data acquisition enables short cycle times and flexible integration into existing networks. ibaPDA-PLC-Xplorer allows high-resolution signal capture without additional fieldbus hardware. This makes it possible to analyze very fast events with precision. It is particularly valuable for diagnosing complex sequence-related faults.

How can data-driven analysis help reduce unplanned downtime?

Rapid identification of root causes significantly reduces or eliminates downtime. ibaPDA provides the required data transparency for in-depth analysis. In combination with ibaAnalyzer, recorded data can be evaluated in detail. This enables sustainable problem resolution and minimizes production losses.

Troubleshooting at a Minesite

The Challenge

After a scheduled maintenance shutdown in an Ore Processing Plant, the start-up of a particular Sequence came to a grinding halt whenever a certain step in the Sequence was reached.

The Plant operators could not determine the root cause of the problem, as their SCADA system was flooded with seemingly unrelated Alarm messages when this Sequence Stop occurred. A quick initial online monitoring of the S7 PLC logic by the site Engineer also yielded no meaningful clue to the source of the problem.

Quick and easy ad-hoc setup

for any S7 PLC related troubleshooting and optimisation tasks

Ethernet based

high speed acquisition

Recording

long term continuous as well as trigger/event based

The Solution

As an iba user, the site Engineer quickly realised that it was time to get serious and to start up their ibaPDA-PLC-Xplorer.

Thanks to symbol based S7 program integration, setup of the digital inputs and outputs that required monitoring was a cinch. The Ethernet based acquisition times was then set to 10ms to get a high resolution capture of the seemingly fleeting event. A short few minutes later, the Plant Operators were asked to attempt another Sequence start. As soon as the Sequence crash occurred, the Engineer took one look at the live data on his ibaPDA trend screen and immediately realised the root cause of the problem. The trend clearly showed that all previously active 24V digital inputs dropped to zero a mere 150ms after the Sequence program gave the command to activate a particular digital output.

A close-up, abstract of layered rock with striking blue-green and earthy brown striations.

This “loss” of all the 24V digital inputs led to the Alarm flooding on the SCADA system as well as the PLC program immediately aborting the Sequence. Since this sequence stops also led to a deactivation of any associated digital outputs (including the one that “drained” the 24V supply), all inputs became healthy again some 50ms later. As all of this happened in the blink of eye, it was impossible to observe it via traditional SCADA or S7 PLC online monitoring means.

Based on the data acquired with ibaPDA though, the root cause was obvious and fixed a short time afterwards. As it turns the digital output in question activated a Solenoid valve which had been immersed in water during maintenance work. This now created a partial short circuit which drained the 24V supply.

All up, the identification of this rather simple problem was made possible by the power of ibaPDA-PLC-Xplorer capability for high speed Ethernet based data acquisition, trending and analysis capability.

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In this particular instance, the ROI (Return On Investment) was measured in minutes. It is estimated that the usage of ibaPDA-PLC-Xplorer saved many hours of unscheduled downtime and associated production loss.

Fritz Woller
System Engineer, iba Oceania

Used Functions

The following functions of the iba system are used in this success story.

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Frequently Asked Questions (FAQ)

How can transient faults in PLC-controlled systems be reliably detected?: Transient faults can only be identified through high-resolution, continuous data acquisition. ibaPDA-PLC-Xplorer enables symbolic acquisition of PLC signals with short sampling rates (e.g. 10 ms). This makes even very short-lived signal changes visible over time. Combined with trend visualization, cause-and-effect relationships can be clearly identified.
How can fast ad-hoc troubleshooting be implemented in complex automation systems?: Efficient ad-hoc analysis requires rapid integration into existing PLC structures. ibaPDA-PLC-Xplorer allows direct access to S7 programs via symbolic variables without complex configuration. This enables immediate monitoring of relevant input and output signals. As a result, time to root cause identification is significantly reduced.
How can cause-and-effect relationships in signal dropouts be analyzed in real time?: Signal dropouts can be analyzed through synchronous recording of all relevant digital and analog signals. ibaPDA ensures continuous acquisition and aligns all signals within the same time context. This makes it possible to identify which actions directly trigger signal loss. Such correlations are often not detectable with conventional SCADA systems.
What are the benefits of high-resolution Ethernet-based data acquisition for troubleshooting?: Ethernet-based data acquisition enables short cycle times and flexible integration into existing networks. ibaPDA-PLC-Xplorer allows high-resolution signal capture without additional fieldbus hardware. This makes it possible to analyze very fast events with precision. It is particularly valuable for diagnosing complex sequence-related faults.
How can data-driven analysis help reduce unplanned downtime?: Rapid identification of root causes significantly reduces or eliminates downtime. ibaPDA provides the required data transparency for in-depth analysis. In combination with ibaAnalyzer, recorded data can be evaluated in detail. This enables sustainable problem resolution and minimizes production losses.