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The Leading Causes Of Plc Control System Failure

The Control System is the heart of a Delta PLC. It is responsible for processing the data that comes into it, making decisions and sending signals to various devices or functions within the factory. If the Control System fails, then you will have to replace it with a new one. 

This can be expensive and time-consuming. In order to save time and money, let's look at some of the most common reasons why PLC control systems fail:

Ground Integrity

Ground integrity testing is a method for ensuring that the ground connection between your Delta PLC and other equipment, such as sensors and operator terminals, is working properly. The ground connection represents a small resistance value in series with other components in the control system. 

If this resistance decreases to zero or becomes non-functional, it can cause a variety of problems ranging from warning lights not turning on to actual damage taking place to components in the system.

Dealing with Interference

The most common causes of interference are other devices on the network and devices in close proximity to the PLC. 

For example, harmonics produced by motors or transformers can produce interference that can be mistaken for a data packet from the PLC.

Data corruption is a result of interference, which can occur in two ways:

Delta PLC

Data Corruption – A bit in the I/O device’s memory cell is flipped so that it reads opposite to what was originally intended by its user. 

For example, if you attempt to send 0x55 but instead receive 0xAA as an output from your I/O device via Ethernet communication (which would signify an error), then this means that one or more bits have been flipped somewhere between your computer and your I/O device (perhaps during transmission). The same thing would happen if both computers were sending 1's rather than 0's since they could easily end up as 2's instead thanks just to how computers work internally! 

Network and Communications

Network and communication issues are the most common cause of PLC control system failure. This may come as a surprise to some since there are many other potential causes such as hardware issues, software bugs, human error and more. But network communication is a big factor in industrial automation setups.

Network problems can have many causes: lack of redundancy in the network infrastructure is one major factor, but faulty hardware or poorly designed software can also lead to problems with systems integration. 

If you're looking at how to reduce risk when it comes to your PLC control systems, consider adding redundancy where appropriate—and checking for any other possible trouble spots too!

It’s worth noting that Delta PLC offers a range of products specifically designed for maximum reliability and uptime at all times; if you want peace of mind from your automated machinery then look no further than Delta PLC!

Conclusion

The power industry is always evolving, and so must its control systems. The good news is that there are many ways to make your PLC system more reliable and resilient, ensuring that your plant can stay on line when it counts the most.

Source: The Leading Causes Of Plc Control System Failure

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