Tuesday, November 24, 2015

The 4 Important Steps Commissioning a PLC Based Control System Guide in the Automation Industry

The process of setting and installation of control systems with PLC requires process steps must be followed by determining the procedure of commissioning and testing system. This commissioning and testing of the system  determine the specifications readings and operating module analog I / O in the PLC to operate PLC as industrial automation control system. Please ensure to what system I / O Analog to be used and consists of an analog input signal, analog input data representation, principles of analog input readings, and Analog Input Connection. This process including PLC communication system, Area Memory, supporting instruction, Component Network, and Controller Area Network.

PLC Hardware in Panel

In general, the commissioning stage includes four main processes including:

Step 1: How to check the hardware properly

Check the hardware is the first stage of the commissioning process that was done by ensuring each sensor, switches and buttons are connected to a particular input and each actuator to output. Make sure that when the process of commissioning the process address and cables should not be mixed. In addition to the sensors and actuators must be in the proper automated system.

Before starting the commissioning process make sure the output is set in the test mode while the actuator must function properly and if there are changes, the documentation (register allocation, pictures, etc.) must also be updated so that the commissioning process can run well.

The next stage is to make sure to check the hardware input device, for example switch should be on the contacts open and closed conditions and the corresponding LED on the module inputs are observed. If there is a failure the LED is not lit check back improper cable connections to the input module, the input device is not supported properly or input module LED or damaged, make sure the push button has been installed so that each output can be tested.

Step 2: Transferring and testing the software to make sure there are no errors program

Check process controller program can use virtual testing tools for example, assays in STEP 7 as subprogram S7-PLCSIM to find error program. The program is able to simulate the work of the PLC (virtual PLC) and allows the user to write a PLC program to be tested prior to commissioning. Make sure all devices are at the off-line.

An important stage test of this program is to simulate changes in the input signal and verify how the outputs react to it. One method that is used directly is the entire program executed in the PLC without any real input and output are connected. The output data for the PLC must be done properly with the support of the physical PLC I / Os so that it can eliminate the risk of damaging the machine or parts of the system.

Step 3: Optimization of the software

After check transfer process and ensure the software runs smoothly the next commissioning process is optimization software. It aims to ensure the program can always be improved after the first test run. Any corrections or modifications are made not only in the PLC user program, but also taken into account in the documentation to facilitate the next stage of the commissioning process.

Step 4: Commissioning of the entire system

This stage is the final circuit testing and optimization of the system control program. Users are advised to do the documentation of all functions of the controller (in accordance with task automation) that has been carried out step-by-step until the final status of the PLC user program is established. Before handing over control to the customer's system, the personal commissioning must ensure no errors occur by the entire system commissioning.


In order to believe that the design of control systems in industrial automation are completely safe to be operated, then the required inspection and testing or called Testing and Commissioning. This process is a series of inspection activities and testing of control systems that have been completed and going to be operated. With the results of inspection and testing is good, it is believed that the design of safety systems at the time of operation. The above procedure should be run with the discipline to produce a control system that has high performance.


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