fieldprog said:
I found something interresting: When I´m downloading the program to the controller, it is overtaking the offline - values of my variables. That was fun, because another programmer loaded up the program while my line was running. Then loaded this one later, and I was wondering first why the hell my whole machines with no external start - signal moved when this happend.
Forget your recipies for a while. First, you need to go through that program, and any like it, and make sure that on S:FS (System First Scan), you manually unlatch, reset, turn off any outputs that can cause motion when the PLC powers up, goes from Program to Run mode, or goes to Run from a Download.
PanelView + terminals always read the 'Device' values from the controller (PLC). Unless you have macros programmed in the terminal, it will always just show the values in the PLC. If you download a new program (or an updated one), then you will most likely have different values than those on the terminal.
You can use the Tag Upload/Download tool, but it's important to remember that even then, if you use LATCHING (OTL) 'Run' bits, then if you upload the tag database from the controller while it is running, download a new (updated) program, and then download the tags again, you could still end up with a dangerous situation. And, that tool will most likely at least partially fail if you have changed the structure of a UDT in Logix.
Depending on how well-designed the rest of the control system is, I suppose you could cheat a little, and have the PLC drop out a relay in the machine E-STOP circuit, requiring a manual reset and start command to proceed, but that is highly dependent on your system.
A good general rule to follow, is "All Un-Commanded Motion is Dangerous", that is, if an operator does not initiate motion, either with a start button, or a go button, or something similar, nothing should move no matter how many times the PLC power is cycled or transitioned to and from run mode.