PLCPanelCheckList

Overallsystemcofigurationchecks

Pass

Fail

Comments

SystemName:

CheckModel,QuanityofthesystemmodulesagainsttherecordinBOM:

VisualInspectionChecks

Checkthesuitabilityofthetestingarea(stagingarea)

DegreeofMechanicalProtection

Cabinettype

Checkterminalstripsfunctionalseparation

checkfusingandfuserating

checkcheckofthewiringseparationofvariousvoltages

checkthefillingducts

checkofthespaceoffutureexpansion

Verifythecontrolandsignalcables

Paintworkfreefromscratches,blemishes,deformities

Eyeboltsfitted

Allmechanicalconnectionsaresecureandfitproperly

DoorsandLock/Keysarefittedsecurely

Nuts/bolts/screws/fastenersaretight

Allhazardouslabelsarefitted(voltage>50V)

Alldevicelabelsarefitted

ThetypetestCertificate(asperIDS)includingtheelectromagnetic
Compatibility,tropicalisationetc.
Checkofinstrumentcalibration(certificatefortheinstrumentsthatwillbe
usedforthetest)

safetygroundingcircuitcheckasperEN610101checkofthesafetyground
insulationtest

AllExteriorcabinetnamepltesarecorrectlylocatedandsquaredtofrontand
rearofcabinetforeasyviewing

PLCPanelCheckList

AllMCBlabelsarefitted

Allterminalblocklablesarefitted

Allearthbarlabelsarefitted

AllrackinterconnectI/Obuscablesarelabled

Randomlycheckcrimpedendsandscrewconnections

AllIOmodulesareincorrectRack/Slot

CheckLocationofeachcomponentagainstGeneralArrangementdrawing

ElectricalChecks

Allcabinetwiringshallbeinspectedpriortopowerup

ControlCabinets:

RandomCabinetpowerwiringvisualorcontinuitycheckedagainstdrawing

Randomferruletaggingvisualcheck,shouldbeclearandreadable

RandomPointtoPoint(resistancetest)

RandomPointtoGround(resistancetest)

Earthbondingtestshallnotexceed0.1ohmsbetweenbondeditemand
appropriateeathbusbar,usemeggertocheckearthing
PowerConnectionChecks
Thefollowingtestistoensureproperpowerfeedisconnectedtothesystem
priortopoweron.Notethatmainprocessorbatteriesshouldberemoved
priortopoweringup.Thismeansthesystemhaspowerbutithasno
appicationcode.
Verifythecorrectnessoftheconnectionwiththesupplysystem,correctpower
connectiontoterminalstrip,neutralandphase
CheckcabinetsareconnectedtoasuitableearthingpointintheFATpremise
Checka230VAC(+5%),50Hz(+1%)supplytoincomingUPSACsupply
terminals
Checka230VAC(+5%),50Hz(+1%)supplytoincomingUtilityACsupply
terminals

PLCPanelCheckList

CheckallMCB'sforthecorrectratingprotection(refertoElectricalPower

SystemPower(230VAC)Up

Check230VACavailableatterminal1&2

Switch'ON'Circuitbreaker'MCB',checkvoltageonitsoutputterminals.

FieldOutputPower(24VDC)Up

Checkthe230VACpowerontheinputterminalsof24VDCpowersupplyunit.

EnsureSystemHealthinessasbelow:

Ensurethemainrackpowersupplydoesnotshowanyalarm

230VACInputfeedVoltage:Current:

24VDCPowersupplyVoltage:Current:

SignalWiringChecks

Distribution&GroundingDrawing)

CheckVoltageonitsoutputterminals;ensuretherespectiveoutputdevices
are'ON'suchasFanunit,PanelLampandFieldPSunits.Ensureallcontrol
systemmodulesarein'ACTIVE'.

Switch'ON'powersupplyandcheckvoltageontheiroutputterminals
respectively.Alsocheckvoltageontheinputsideofthepowerdistribution
terminals(keepingthefusedterminals'OPEN').
Note:Usingatestmetermeasurethepowersupplymodule(offload)and
ensurethatthemeasuredoutputvoltageis24VDC+5%.IftheDCvoltageis
outsideofthespecifiedlimit,adjustpowersupplyoutputinaccordancewith
themanufacturer'sguide.

EnsurenoalarmontheIOmodulesafterpowerupofthe24VDCfieldpower
supply.
PowerConsumption
Foreachtypeofpowerfeeds,measurevoltageandtotalsystemcurrentwith
withsystem"NoLoad"conditionandrecordtheresults

Randomlythesignalwiringshallbeinspectedpriortoloopchecksand
applicationprogram(LogicSimulation)

PLCPanelCheckList

Cabinetwiringvisualorcontinuitycheckedagainstdrawing

Ferruletaggingvisualcheck,shouldbeclearandreadable

PointtoPoint(resistancetest)

PointtoGround(resistancetest)

Randomlycheckthewiringforpropercrimpingandtermination(TugTest)

SystemConfigurationChecks

Verifyexistenceofcontrolprogram

Checkthemoduleconfigurationasper'RackAssignment&I/ODetails'

ChecktheI/Oaddressingforthehardwarepoints100%

ChecktheI/Oaddressingforthesoftwarepoints100%

LoopChecks

Thischeckwillbedoneasperpretestbeforecheckingtheapplicationlogic.

AnalogInputs

Checkconfiguredanalogscalingandanalogalarm/triplevelsarecorrect

CheckconfiguredAlarmsforHMI

Recordresults

DigitalInputs

Note:Earthbondingtestshallnotexceed0.1ohmsbetweenbondeditemand
appropriateearthbusbar

Activateeachoftheanaloginputsbyvaryingthepotentiometeronthe
simulationpanel.
Checkthecurrentatthefieldterminalsusingamultimeter.
Checkthecorrectsystemreferenceaddressisactivatedandthevalueinthe
registervariescorrectly.

Activateeachofthedigitalinputsbytogglingtheswitchesonthesimulation
panel
CheckthecurrentRack/Slot/ChannelLEDilluminatesoninputmoduleand
correspondingHMIdisplayischangingtherespectivedevicecolorasspecified

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intheFDS
CheckconfiguredHMIalarmiscorrect

Recordresults

DigitalOutputs

UsingEngineeringstationforceON(energize)eachoutput

ConfirmthatcorrectRack/Slot/ChannelLEDilluminatesonoutputmodule

ConfirmthatcorrectlamponthesimulationpanelturnsON.

recordresults

Allthechangesinthelogicshallbevisualizedbysimulatorpanel

FieldI/ONormal

Note:AnydiscrepancywillbeinthepunchListandwillbeclearedbefore
startingtheApplicationLogicTest
ApplicationProgramChecks
ThepurposeofthistestistoverifytheLCPApplicationCodesagainstthe
sequenceofoperationasspecifiedintheControlLogicdiagram/FDS.The
simulationcabinetshavebeenwiredtoallowallI/Ogroupstobeoperated
withoutdelay.

Allthedigitalinputsintoitsnormalposition'Open'or'Close'aspernormal
processoperatingconditions
Allanaloginputsintoitsnormalposition'lessthanHighsetpoint'or'more
thanLowsetpoint'aspernormalprocessoperatingconditions
LogicTest
Thelogicsequencewillbetestedexactlyasperthecontrollogicdiagramand
normalplantoperatingconditions,witheachstepsperformedinsequence.
Anycorrectionsrequiredwillbedonethenorattheendofthetestbasedon
thecorrectionrequired.
RedundancyChecks

PLCPanelCheckList

CPURedundancyCheck

CheckchangeoverbetweenCPUA&CPUBandviceversa

PowersupplyRedundancyCheck

CheckchangeoverbetweenPSA&PSBandviceversa

EthernetSwitchRedundancyCheck

RIOBusRedundancyCheck

SpareCapacityChecks

Checkdigitalinputsquarequantityin%

Checkdigitaloutputsquarequantityin%

Checkanaloginputsquarequantityin%

Checkanalogoutputsquarequantityin%

SystemShutdown/RebootFunctionalityChecks

Endtheruntimeprogram,Turnoffpower,forallenclosuresObserveStatus

Switchonpower,forallenclosuresObserveStatus

CheckTestCertificates

Checkthetestcertificateasperdocument

CalibrationTestCertificates
Internaltestreportifany
MaterialTestCertificate
ConformityCertificate