A CPU 1515F-2 PN on TIA Portal V17, an ET 200SP station with an F-DI 8x24VDC HF, and channel 2 on it is a guard door. The buffer showed “Channel 2: Short-circuit” last week and the channel passivated; the electrician found a chafed wire in the door loom and repaired it, the buffer now says … Read more
A pycomm3 write of 95.0 to Line4_SP on a CompactLogix comes back to the Raspberry Pi with no error, and the line is now running at 95 % because nothing between the driver and the tag asked whether it should. A read-only logger becomes a control path the first time somebody puts a slider on … Read more
The 1791ES-IB8XOBV4 on the palletiser cell failed on a Sunday, the spare from stores has the same catalogue number and the same three address switches set to 21, and the yellow triangle over it in the I/O tree has not moved in forty minutes. The GuardLogix 5580 project has a safety signature, the module’s Safety … Read more
A 300 mm tote leaving zone 12 at 0.280 m/s onto a metering belt running 0.513 m/s arrives at the scanner 250 mm behind the tote that left in front of it, and a 600 mm carton on the same two belts arrives 499 mm behind its neighbour. Neither number has a timer in it: … Read more
The 440R safety relay on the new guard, a 440R-S12R2, was showing PWR/Fault flashing red four times, IN steady red with the door shut, and the electrician had already swapped it for the spare, which did the same thing within a second of power-up. The guard switch is a single-contact tongue switch, and the link … Read more
The guard on the case packer came off its 440R-S12R2 on a Saturday and went onto a 1791ES-IB8XOBV4 under a GuardLogix 5580, same tongue switch, same two 100S-C09 contactors, and the first time the door was closed the DCS instruction reported Fault Code 16#4000 and would not take a reset. Channel A active, channel B … Read more
Zone 5 is stopped, PE5 is clear, Zone[5].Expecting is 0, and there is a 600 mm carton standing 30 mm short of the beam that no zone on the line is driving. Zone 4 behind it has a carton on its eye, Owns clear, its hold timer done, and every permissive it needs to release … Read more
The infeed conveyor’s GuardLogix 5580 consumes one safety tag from the case packer’s 5580, CP_Safe, and at 02:04 every night for a week CP_Safe.ConnStatus.ConnectionFaulted went to 1 for between two and nine seconds, the consumed data went to zero, the conveyor’s CROUT dropped its contactors, and the shift lead reset it and wrote “network” on … Read more
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