The E-stop is reset, the safety relay is closed, every one of the twelve PowerFlex 525s on the accumulation line has S1 and S2 at 24 V again and F059 cleared from its display, and nothing moves. No fault on any drive, no alarm on the HMI, twelve zones with a carton on every eye … Read more
The warehouse system’s report for the night shift said 4,629 cartons sorted, 100% to the lane the order wanted, and the lane 2 pallet had 19 cartons on it that belonged in lane 3 and a picker who found them at 06:40. The sorter had no way to know. Its scanner read the label, its … Read more
Zone 6’s eye came out of stores as a 42EF-P2KBB-F4, went onto the bracket in place of a 42EF-P2JBB-F4, and from the next 600 mm carton on, zone 6 reported occupied while it was empty and empty while a carton stood on it. One letter in the fifth position of the catalogue number, K for … Read more
The takeaway conveyor’s 25B-D010N104, a 480 V PowerFlex 525 on a 4 kW motor, ran all day and tripped F005 OverVoltage on the first stop of every shift, with the PowerFlex 525 decel time at 2.00 s, b005 [DC Bus Voltage] sitting at 812 V in the fault history, and a belt carrying forty cartons … Read more
A first SCL block is two statements long – FC10, for a CPU 1516-3 PN/DP – and the first compile of it comes back with four errors and a warning. Every one of them is a ladder habit typed into a language that reads like Pascal, and the compiler is describing each habit accurately, in … Read more
A CPU 315-2 PN/DP with 6ES7315-2EH14-0AB0 on the label maps to a CPU 1515-2 PN, 6ES7515-2AM01-0AB0, in the Siemens migration guide’s CPU table, and the S7-1500 migration does not happen in one move. It happens in two, the second of which is a right-click on the old CPU in the device view called Migrate to … Read more
A CU240E-2 PN sits on the PROFINET IO system of a CPU 1516-3 PN/DP with G120 telegram 1 in its device view, the PLC is writing 16#047F to the control word and 8192 to the setpoint, and the motor does not move. Bit 6 of the status word is set. That bit is “switching on … Read more
Step 2 of a two-step TIA Portal GRAPH sequencer on a CPU 1515-2 PN has been active for 4 minutes 12 seconds by its own S2.T, the transition below it has been satisfied for the last 40 of those seconds, and the sequencer is still sitting on step 2. The heater that step 2 drives … Read more
Zone 3 of the takeaway conveyor stops about once a shift with “Zone3”.Fault latched, the photo-eye on %I4.3 reads a steady 1 in every watch table anybody has opened, and the CPU 1516-3 PN/DP is turning OB1 over in about 6 ms. Whatever is happening is happening inside one of those 6 ms passes, hours … Read more
A Pt100 RTD input wired two-wire over 22 m of 0.5 mm² cable into channel 0 of a 1756-IR6I reads 104.1 °C in a bath that the reference thermometer says is 100.0 °C, and the same sensor with its third lead landed on RTN-0/C reads 100.0 °C. Lift lead A off the module and the … Read more
A CPU 1516-3 PN/DP in RUN on the filler, a SIMATIC memory card behind its front flap, and no project file on any laptop in the building. An S7-1500 upload – online, Upload device as new station (hardware and software) – and about three minutes later an empty project holds the rack, every block with … Read more
A CTU on the end-of-line eye of a takeaway running 0.500 m/s read 12,480 at the end of a shift in which the palletiser stacked 12,116 cartons, and it had been drifting the same way, 2.6% to 3.4% high, for three weeks. Counting cartons was one contact and a counter, and there was nothing wrong … Read more