Checklist: commissioning of PLC-controlled system
The steps that ensure the system runs correctly the first time it goes into operation
Use this checklist when an installation with new or modified PLC control is to be commissioned. The order is important: never skip the safety tests even if everything else seems to be working.
§1 — Before power is applied
- 01Check mechanical assembly: everything is bolted tight and correctly adjusted
- 02Check electrical diagram against physical installation
- 03Check that all cables and terminals are correctly connected and labelled
- 04Check that safety circuits (emergency stop, door contacts) are connected as the diagram shows
§2 — Input and output testing (I/O test)
- 01Test each individual input by itself: physically trigger the sensor and check the signal in the controller
- 02Test each individual output by itself: activate in the program and check that the right component responds
- 03Note any deviations and correct them before proceeding
§3 — Safety functions test
- 01Test emergency stop from each position: the system must stop immediately and remain stopped until manual reset
- 02Test door contacts and shielding: the system must not be able to run with the access open
- 03Check that the system does not restart automatically after a power outage
§4 — Functional test of the entire process
- 01Run the system through a complete cycle under supervision, preferably in slow or manual mode first
- 02Check regulations (e.g. temperature, speed, position) against expected values
- 03Test relevant error situations deliberately — what happens if a sensor doesn't report back?
§5 — Delivery and documentation
- 01Update electrical and control diagrams to match the actual installation
- 02Save the final program version with clear version number and date
- 03Deliver documentation and any deviations from original design to the person responsible for operation