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BasicPLCTroubleshooting

BriantLam 07/01/2010

TopicsCovered
SystemsOverview
KlystronSolenoid AlcoveMCOR Gallery 6575Modulator SPEAR3/PEPHVPS ALineSPANGBendPS

BasicIndicators ModuleReplacement SystemSpecificRepair MoreInformation

SystemOverview KlystronSolenoid
S21PSRack CompactLogix PLC

OnePLCpersector,uptoeightpowersupplies Monitorsinterlocksforpowersupplies ProvidesinterlockstatustoMKSU DoesNOTcontrolpowersupplies

SystemOverview AlcovePLC
AlcoveRack1 FlexLogix PLC

OnePLCperMCORcrateandbulkpower supply InterlockstheMCORsonbulkps voltage andgroundfault. RemotecontrolforbulkandMCORreset

SystemOverview GalleryPLC
GalleryRack ControlLogix PLC

OnePLCforupto3bulkpowersupplies InterlocksMCORsonbulkps voltage andgroundfault InterlocksIntermediatepowersupplies Remotecontrolofbulkpowersupplies andMCORreset

SystemOverview 6575ModPLC
6575Modulator CompactLogix PLC

MonitorsinterlocksandprovidesstatustoMKSU Controlsmodulatorandvarioussubsystems

SystemOverview SPEAR3HVPS
ControlEnclosure SLC5/03PLC

Monitorsandprovidesinterlocksto/fromHVPSandKlystron ControlstheHVPS

SystemOverview AlineBendPS
SPANGPS SLC5/03PLC

Monitorsinterlocks Controlsthepowersupply

BasicIndicators

BasicIndicators
Processor(everythingshouldbegreen)
Run solidgreentobeinRUNmode
OtherwiseputinRUNmodeusingkeyswitch

I/O solidgreenmeansgoodmodules
OtherwiselookforabsenceofgreenOKLEDonmodule NotethatsomemodulesdonothaveOKLED

Force off,wedonotuseforces! RS232 solidorflashinggreen,communicatingwith touchpanel BAT shouldbegreen,butgenerallyisnotcritical OK mustbesolidgreen!Anyredmeansweneedto goonlinetoseewhattheproblemis.Apowercycle willprobablyfixit,butwewillloseanyinformationon whatcausedthefault.

BasicIndicators
PowerSupply
OK green

NetworkModule
Link green,goodlinktoswitch Net flashinggreen,Ethernettraffic OK green,moduleisgood ModuleontheControlLogix CardontheFlexLogix BuiltinontheCompactLogix

ModuleReplacement
Processor
Mayneedtoreprogram,unlesspreprogrammed spareavailable
CurrentlyonlyGalleryandAlcovePLCs

I/OModule
Directreplacement,nofurtheractionneeded

EthernetModule
Mayneedtoconfigure,unlesspreconfigured spareisavailable
CurrentlyonlyGalleryandAlcovePLCs

SystemSpecificRepair
KlystronSolenoid
Sparechassisinteststand Processorwillneedreprogramming/configuring

AlcovePLC
SparechassisinB127 InstallappropriateEthernetcardintotheprocessor beforeusing Allprogramsareidentical

GalleryPLC
SpareChassisinR127 InstallappropriateprocessorandEthernetmodule,if replacingchassis Allprogramsareunique

SystemSpecificRepair
6575ModulatorPLC
Identifyandreplaceproblematicmodule Sparesnotyetavailable,partsareavailableifneeded Allprogramswill(hopefully)beidentical

SPEAR3HVPSPLC
Identifyandreplacetheproblematicmodule SpareslocatedinB127

SPANGBendPS
Identifyandreplacetheproblematicmodule Sparesunknown

MoreInformation
DonothesitatetocallEngineeringonPLCproblems HowToDocumentation
http://lclsdev/tikiindex.php?page=How to+Download+PLC+Ladder+Logic http://lclsdev/tikiindex.php?page=How to+Configure+PLC+Ethernet+Communications

Manuals
http://literature.rockwellautomation.com/idc/groups/literature/ documents/in/1756in101_enp.pdf http://literature.rockwellautomation.com/idc/groups/literature/ documents/in/1769in020_enp.pdf http://literature.rockwellautomation.com/idc/groups/literature/ documents/in/1794in002_enp.pdf

PLCPrograms
V:\ESD\PCD\PLC

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