SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 RIGHT WE HAVE A BECKOFF UNIT THIS ONE IS THE A4 RIGHT SIDE, TO SEE ITS NAME DETAILS SELECT ITS PROPERTIES BELOW THE SELECTED DEVICE IS ALL OF ITS IO CARD ADDRESSING, WHICH YOU CAN LOCATE IN THE PROGRAM IMPORTANT: IF Q48.0 IS NOT WORKING, WE CAN SEE IT IS THIS RACK AT PROFIBUS ADDRESS 10 TH AND THE 7 CARD IN THAT RACK 51 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 LOCATING SPARE IO – MARKER BITS – MEMORY WORDS – TIMERS - COUNTERS YOU CAN LOCATE SPARE ADDRESSING IN - ASSIGNMENTS IN SIMATIC MANAGER – CLICK BLOCKS SELECT OPTIONS MENU – REFERENCE DATA - DISPLAY 52 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 SELECT ASSIGNMENT AND CLICK OK NOTE: IF THIS CUSTOMIZE DOES NOT APPEAR, SOMEONE HAS UNCHECKED THE DISPLAY BOX IF YOU SEE THIS WINDOW >>>>>> CLICK THIS BUTTON 53 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 EVERY X IS AN ADDRESS USED IN THE PROGRAM. WE CAN SEE IB2 – IB = INPUT BYTE = 8 BITS THEREFORE, I2.5 AND I3.5 ARE NOT USED AND POSSIBLY NOT WIRED IN IB9 = I9.0 – I9.7 ONLY I9.1 IS USED TIMERS: T4 AND T5 NOT USED, NEITHER ARE ALL TIMERS T100-119. USE ASSIGNMENT WHEN YOU NEED A SPARE ADDRESS – TIMER – COUNTER – MEMORY WORD ETC 54 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 IB = Input Byte - 8 INPUTS QB = Output Byte – 8 OUTPUTS MB0 = Memory Byte 0 – Displays M0.0 – M0.7 An X is placed inside of any box where the address is being used in the program, if no X is inside of the box, it is not being used and is available. Right we see, which MARKER/MEMORY BITS are being used NOTE THE BLUE VERTICAL BAR in one row is a BYTE, so MB5, 6, 7 and 17 are being used as BYTES MB12 + MB13 is being used as MW12 55 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 IMPORTANT: IF YOU SEE A YELLOW FILTER BOX – A FILTER HAS BEEN APPLIED THIS MEANS THAT ONLY CERTAIN AREAS OF THE ADDRESS ARE BEING DISPLAYED TO REMOVE FILTER; CLICK THE PENCIL BUTTON TO THE RIGHT AND SELECT ALL – CLICK OK FILTER IS THEN REMOVED AND ALL ADDRESSING IS BEING DISPLAYED 56 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 FINDING THE ALWAYS ON FLAG APPLYING A SHORT CIRCUIT IN THE PROGRAM – YOU NEED THE ALWAYS ON FLAG IN SIMATIC MANAGER, CLICK BLOCKS AND OPTIONS – REFERENCE DATA – DISPLAY AS WE DID FOR ASSIGNMENT SELECT CROSS – REFERENCES – CLICK OK CLICK THE FILTERED TOOL BUTTON 57 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 DESELECT ALL CHECK BOXES EXCEPT BIT MEMORY CLICK OK THIS APPLIES A FILTER AND ONLY BIT MEMORY WILL APPEAR WE NOW SEE M0.1 (ON) THIS IS THE ALWAYS ON FLAG IN THE PROGRAM TO FIND OUT WHERE THE ROUTINE IS IN THE PROGRAM – EXPAND [+] 58 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 EXPAND [+] LOOK IN THE TYP (TYPE) COLUMN FOR “W” WE CAN SEE THIS IS IN FUNCTION FC1 SEE LOCATION COLUMN NW2 /= THIS IS A COIL DOUBLE CLICK NW2 AND FC1 WILL OPEN IMPORTANT: USE CROSS REFERENCES TO LOCATE ANY SIGNALS IF AN OUTPUT IS OFF THAT SHOULD BE ON, OPEN CROSS REF AND LOCATE THE Q ADDRESS – DOUBLE CLICK “W” NW? TO JUMP TO THAT POINT IN PROGRAM 59 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 TIPS & TRICKS Learn how to make changes to a program for maintenance purposes. WARNING: DO NOT ALTER A PROGRAM UNLESS YOU ARE AUTHORISED AND 100% SURE OF THE EFFECT THE CHANGE WILL MAKE CREATING A SHORT CIRCUIT CREATING A OPEN CIRCUIT SETTING A TRAP 60 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 CREATING A SHORT CIRCUIT REMOVING AN INPUT SIGNAL DO NOT DELETE THE SIGNAL SHORT IT OUT RIGHT INPUT I3.3 HAS BEEN SHORT CIRCUITED WE USE THE ALWAYS ON FLAG AS A SHORT CIRCUIT SAVE AND DOWNLOAD I3.3 WILL NO LONGER AFFECT THIS RUNG 61 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 DISABLING A RUNG - OPEN CIRCUIT DISABLING A RUNG DO NOT DELETE THE RUNG CREATE AN OPEN CIRCUIT YOU CAN USE ALWAYS ON TO A N/C CONTACT AND THIS WILL BE ALWAYS OFF OR IF YOU HAVE AN ALWAYS OFF M BIT USE THIS AS SHOWN 62 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 SETTING A TRAP TO DETECT AN INTERMITTENT SIGNAL THAT IS CAUSING A PROBLEM – SET A TRAP IF A MOTOR IS INTERMITTANTLY STOPPING AND RESTARTING THIS COULD BE ANY OF THE SIGNALS CHANGING STATE BRIEFLY ADD A NEW NETWORK AND USE SET INSTRUCTION TO SPARE M BIT RIGHT WE ARE MONITORING I40.0 IF IT TURNS OFF – SET M65.0 WILL LATCH ON 63 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 IF A MOTOR IS BRIEFLY TURNING ON/OFF, THIS IS BECAUSE EITHER I40.0 OR M3.0 IS TURNING ON TO FIND OUT WHICH: ADD A NEW NETWORK AND USE SET INSTRUCTION TO SPARE M BIT RIGHT WE CREATED 2 NEW NETWORKS, ONE FOR EACH SIGNAL THEN USED N/O CONTACTS TO SET INSTRUCTIONS TO SPARE M BITS M65.1 & M65.2 IF EITHER SIGNAL TURNS ON, THE M BIT WILL LATCH ON 64 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 MACHINE PROGRAM OVERVIEW MACHINE MASTER SLAVE ADDRESSING HARDWARE ADDRESSING CPU SETTINGS IMPORTANT PLC ADDRESSING IMPORTANT PROGRAM BLOCKS PROGRAM GUIDE WARNING SIGNALS 65 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 MACHINE MASTER / SLAVE MPI & DP ADDRESSING This PLC Master and Slave MPI and Profibus communication addressing for the machine. This addressing can be found in NET PRO NAME MODEL/TYPE MPI ADDRESS DP ADDRESS LINE PLC CPU 315-2 DP 2 2 PRESS 2 IM151-7 20 - PRESS 3 IM151-7 18 - PRESS 4 IM151-7 - PRESS 5 IM151-7 - PRESS 6 IM151-7 ROBOT 1 DP501 - 28 ROBOT 2 DP501 - 29 ROBOT 3 DP501 - 30 ROBOT 4 DP511 - 31 ROLAND 1 - 26 66 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 ROLAND 2 PRESS ENCODER TR CE65M DP V4.0 20 BLANK HOLDER TR CE65M DP V4.0 ENCODER SLIDE ENCODER TR CE65M DP V4.0 A4 RH SIDE BK3150 SLAVE RACK IO 10 A10 CROWN BK3150 SLAVE RACK IO A5 RH REAR BK3150 SLAVE RACK IO 12 A11 BASEMENT BK3150 SLAVE RACK IO 67 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 MACHINE HARDWARE ADDRESSING The addressing below can be found in HARDWARE CONFIGURATION NAME MODULE INPUT ADDRESS OUTPUT ADDRESS PSU PS 307 5A LINE PLC CPU 315-2 DP ANALOGUE A02*12 BIT 256 - 259 DIGITAL INPUT D132*DC 24V 0.0 3.7 DIGITAL INPUT D132*DC 24V 4.0 – 7.7 DIGITAL INPUT D132*DC 24V DIGITAL OUTPUT DO16*DC 24V/0.5A 0.0 – 1.7 DIGITAL OUTPUT DO16*DC 24V/0.5A ROBOT 1 DP501 28 - 39 28 - 39 ROBOT 2 DP501 78 - 89 78 - 89 ROBOT 3 DP501 ROBOT 4 DP511 ROLAND 1 260 - 271 260 - 271 68 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 ROLAND 2 PRESS ENCODER TR CE65M DP V4.0 512 - 515 512 - 515 BLANK HOLDER TR CE65M DP V4.0 ENCODER SLIDE ENCODER TR CE65M DP V4.0 A4 RH SIDE BK3150 SLAVE RACK IO 40.0 – 47.7 40.0 – 47.7 49.0 – 55.7 48.0 -52.7 A10 CROWN BK3150 SLAVE RACK IO A5 RH REAR BK3150 SLAVE RACK IO 60.0 – 63.7 60.0 – 63.7 69 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 CPU SETTINGS This area details all the settings for the CPU, there are several important areas that require checking. NAME MODULE LINE PLC CPU 315-2 DP CLOCK MEMORY M BITS: RETENTIVE MEMORY MEMORY BYTES MB0+ NUMBER: S7 TIMERS T0+ NUMBER: S7 COUNTERS C0+ NUMBER: CYCLIC INTERRUPTS OB35 CYCLE TIME: TIME OF DAY INTERRUPTS OB10 TIME: 70 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 IMPORTANT PLC ADDRESSING This area details all the used IO, M Bytes, Timers Counters etc and where you can find each address. It also allows you to identify addressing of M Bits etc that you can use for any modifications. SIMATIC MANAGER > CLICK ON BLOCKS OPTIONS MENU REFERENCE DATA – DISPLAY – CROSS REFERENCES IMPORTANT: WATCH FOR FILTERED INFORMATION IMPORTANT NAME BLOCK ADDRESS ALWAYS ON FC1 ALWAYS OFF FC1 PROFIBUS OK CLOCK PULSES LAMP TEST 71 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 FAULT PRESENT READY FOR AUTO START ALL GATES OK ALL JACKS OK ALL ESTOPS OK ALL SAFETY OK 72 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 IMPORTANT NAME ADDRESS ROBOTS TO PARK START PRESS AUTO ROBOTS TO PARK START PRESS AUTO ROBOTS TO PARK START PRESS AUTO SPARE M BITS SPARE TIMERS 73 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 IMPORTANT PROGRAM BLOCKS Blocks folder holds all the program blocks for the whole machine. Note that NOT all FB/FC Blocks may be used in the program, the unused Blocks can be found in OB1 – CALL STRUCTURE Tab Left Tool Bar. Blocks with a CROSS inside are NOT used [X]. SIMATIC MANAGER > BLOCKS BLOCK DESCRIPTION NOTE ST OB100 1 SCAN BLOCK EMPTY – NOT USED FC1 GENERAL FC2 AUTO CYCLE FC10 MAIN MOTOR 74 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 PROGRAM GUIDE Blocks folder holds all the program blocks for the whole machine. Note that NOT all FB/FC Blocks may be used in the program, the unused Blocks can be found in OB1 – CALL STRUCTURE Tab Left Tool Bar. Blocks with a CROSS inside are NOT used [X]. SIMATIC MANAGER > BLOCKS BLOCK DESCRIPTION NOTE FC15 FROM PLC 2 FC16 TO PLC2 FC401 PRESS FAULTS FC402 ROBOT FAULTS FC403 SAFETY FAULTS FC404 GENERAL FAULTS DB1001 ALARMS 75 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 WARNING SIGNALS The following areas were searched for errors that could cause breakdowns to occur and also programming. NOTE the entries below are those found after a quick analysis, other problems could be in the programming but will need further analysis to identify these. ADDRESS DESCRIPTION REASON BLOCK NETWORKS M4.0 ALL ESTOPS OK DUPLICATION FC4 1, 2, 3 M4.1 ALL GATES OK DUPLICATION FC4 4, 5 76 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
SCANTIME TRAINING - JAGUAR LAND ROVER - HALEWOOD MACHINE PLC MAINTENANCE FAULT FINDIN | SIEMENS S7-300 SERIES eLearning Manual copyright © 2016 PROGRAM GUIDES GUIDES TO HOW ROUTINES WORK 77 Scantime Engineering Ltd. © 2016 | Tel: +44 (800) 7561011 | E-mail: [email protected] | Web: https://www.scantime.co.uk
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