PLC commissioning records: what to check and document
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What should a PLC commissioning record contain?
A commissioning record connects the approved design to the machine that was actually tested. It should show the hardware and program versions, the tests performed and the issues still awaiting resolution.
Establish the starting configuration
Record the CPU and module part numbers, firmware versions, programming-software version and the program backup used for the test. Keep the electrical drawing revision and network configuration with the same record.
Define who can authorize changes and who will accept the results. Arrange safe test conditions before connecting equipment or enabling outputs.
Keep a test sheet for each signal or function
| Record field | What to enter |
|---|---|
| Test reference | The drawing, I/O point or sequence step being checked. |
| Expected behavior | The input, output or machine response required by the design. |
| Observed result | What happened, including any diagnostic message. |
| Correction | The wiring, configuration or program change, with its revision. |
| Retest and acceptance | The result, date and responsible person. |
Scroll the table horizontally to view all columns.
Separate hardware, logic and communication checks
Check installed hardware and field wiring against the drawings. Verify the signal types and module settings. Then test the operating sequence and fault responses under the agreed procedure.
For networked devices, record addresses, communication settings and diagnostics. Successful communication alone does not prove that the program is using the correct data or scaling.
Close out temporary changes
Keep a list of temporary test settings and any authorized forces. Remove them and verify the final operating configuration before handover. Follow the specific hardware manual when replacing modules; hot swapping is not supported by every controller or installation.
Archive the accepted program, drawings and test record together. For fault tracing on an installed machine, see the PLC troubleshooting guide.
Match the hardware in your commissioning record
Send the CPU and module part numbers, firmware or revision requirements, and quantities. Attach label photographs where an existing installation must be matched.
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