I would like to discuss a breakdown in my plant. The PLC system of a stamping machine is giving me a lot of pain. It broke down twoo weeks ago, but somehow recovered and started good operation from the next day. We never got any clue about what went wrong. So it's no surprize that it went down again three days ago.
I posted another message in this forum, and got many useful advices. I thank everyone for their time. I. however, made some mistakes in observation and emphasized on a misleading clue (EtherNet card). This time I'm documenting the problem in full details, and with corrections.
Description of the PLC.
I'm handicapped, because we do not have RSLinx/RSLogix/RSNetworx. Sad situation, I know. We're in the process of buying those expensive packages. They less expensive than the present breakdown. It would have been nice to get the OEM co-operation. But their expert cannot arrive within a week from now at least.
Any advice is welcome. Thanks in advance.
Yeasir Rahul
I posted another message in this forum, and got many useful advices. I thank everyone for their time. I. however, made some mistakes in observation and emphasized on a misleading clue (EtherNet card). This time I'm documenting the problem in full details, and with corrections.
Description of the PLC.
- Power supply
- CPU ControlLogix 5555 (slot 0, catalog 1756-L55 A)
- 2-Axis servo controller (slot 1, catalog 1756-M02AE/A)
- DC Input card (slot 5, catalog 1756-IB32)
- DC Output card (slot 7, catalog 1756-OB32)
- EtherNet/IP communication bridge (slot 8, catalog 1756-ENBT A) can be replaced with an ENET card without any problem.
- DeviceNet card (slot 9, catalog 1756-DNB)
- The serial port on the CPU is connected to a custom-made PCB that controls three glue-sprayers.
- The servo controller is connected to a servo drive (Parker Automation SPD), which drives the stamping motor (Parker Automation SBC).
- The DeviceNet card is connected to a bus coupler (Beckhoff BK5200), and then on the same bus connected to an HMI (PanelView 600).
- The Ethernet card is not connected to anything at all. And the system doesn't really care about its presence.
- CPU starts up. "OK" and "RUN" LEDS glow right. "I/O" LED blinks.
- Servo controller - "OK" LED blinks. "FDBK" and "DRIVE" LEDs for both channels blink. Seems normal.
- DC Input card - "OK" glows green steadily. But blinks red after a while.
- DC Output card - "OK" blinks in green.
- EtherNet/IP card - "OK" on. "NET" blinks. "Link" off. Scrolling display says "Link Lost". Seems ok. When replaced with a spare ENET card, "Ok" is on, "TxD", "RxD" off, and that's expected.
- DeviceNet card - "OK" blinks, "I/O" blinks, "MOD/NET" on.
- Bus coupler "RUN" and "I/O" leds on.
- HMI starts up, cannot read any param from the PLC. Shows "Error 4".
- Servo drive is OK.
- Glue sprayer PCB blinks green. We don't know the meaning, possibly "no link".
I'm handicapped, because we do not have RSLinx/RSLogix/RSNetworx. Sad situation, I know. We're in the process of buying those expensive packages. They less expensive than the present breakdown. It would have been nice to get the OEM co-operation. But their expert cannot arrive within a week from now at least.
Any advice is welcome. Thanks in advance.
Yeasir Rahul