Hello, I am facing difficulties in getting an old lift gate conveyor, specifically the 5384i Lift Gate, up and running at our smt facility. Despite most of our equipment being controlled by proprietary software, it has been years since I last went online with a processor. Our maintenance department has been struggling to make the conveyor operational, and I recently got involved to assist them. After conducting an assessment, I identified and replaced faulty reset PBs and EStops, as well as secured loose wires in the terminals. Although we managed to get the green stack light to illuminate, the conveyor is not functioning as expected. Signal transmission from upstream and downstream conveyors seems fine, but the board is not transferring onto the lift gate. Over the weekend, a colleague from another plant tried to help by going online with the processor, but encountered challenges due to unannotated addresses in the .rss file. The belt motor now turns on regardless of board availability for transfer, and manual intervention is required to initiate the transfer. Unfortunately, our company does not have extra licenses for software like RSLogix500, so I had to use RSLogix Micro Starter Lite to access the Micrologix 1761-L32BBB processor. Despite resolving some issues, a change in equipment layout on the floor has delayed further troubleshooting for a few days. I am seeking assistance from anyone familiar with ladder logic and willing to review my findings and descriptions. Any help would be greatly appreciated. Thank you.
If you're interested, I can email the extensive operating instructions that are too big to attach even when compressed. Let me know if you'd like a copy.
I am unfamiliar with the concept of a lift gate, but would the enclosed document provide any clarity on the matter?
Managing this project may be a bit challenging with various obfuscations and red herrings to navigate. I have included the .RSS file as a PDF attachment for easy access, eliminating the need for RSLogix 500 or a similar IDE. Additionally, I have made changes to some routines, added comments, and provided descriptions for certain tags to enhance clarity. LAD 3 appears to handle I/O mapping and preprocessing, while routines such as HSC_INT and STI_INT do not seem to be triggered by interrupts. It may be beneficial to provide a more detailed process flow, potentially with sketches or annotated photos, to explain the control mechanism. Including an I/O list and detailed explanations can help readers understand the purpose of the project better. In Program File LAD 13, Rung 0005, there seems to be a sequencer in action. The BSL operation shifts the low eight bits of N7:7 in a circular manner, with specific integer values controlling the process. Understanding the sequence logic and the impact of different integer values is crucial for the functionality of the program. It is worth noting that there may be timers with a .PRE(set) of 0, which adds a layer of complexity to the project. Further clarification on this aspect would be beneficial. Remember, thorough documentation and clear explanations can make a significant difference in successfully completing this project. Good luck!
I understand that the electrical diagram features PLC inputs and outputs. However, when I requested the list, I was also seeking a detailed explanation of each, including their significance in the operational process or sequence.
Have you ever wondered about the significance of N7:2/1 and whether it can have a value of 1? Are there any HMIs capable of writing to this address? Explore the possibilities of N7:2/1 and its functionality with HMI integration.
I'm glad to hear you've been able to resolve some of the issues with the older model's conveyor. It sounds like you've got a good handle on things so far, and I appreciate your thorough problem description — this does sound like quite the challenge! In terms of your RSLogix Micro Starter Lite situation, you might have better luck reaching out to them directly to see if they can provide any guidance considering your constraint of not having extra licenses. As for your issue with the board not transferring, I've had a similar problem occur before and found it to be an issue with the board detection sensor. It might be worth checking whether the board is correctly triggering the sensor or if it needs recalibrating/replacement. Keep going, troubleshooting these issues can be a lengthy but ultimately rewarding process!
Hello! I'm sorry to hear about the trouble you're experiencing with your lift gate conveyor, it must be frustrating. I have some expertise in ladder logic and I'd be happy to review your findings, feel free to send them my way. I would suggest double-checking the sensors that detect the board presence, especially since the motor is now continuously running. It could be a case where they don't sense a board and therefore don't send a signal to start the conveyor. Additionally, look into the addressing scheme for your .rss file, some unannotated addresses might just be placeholders or unused elements. Lastly, even though you mentioned that the signal transmission from the upstream and downstream conveyors seems fine, there might possibly be a logical flaw/bug in the control scheme. Let's have a look at it and see if we can find a solution for your problem. Don't lose hope, we'll figure this out!
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Answer: Answer: Common issues can include faulty reset PBs and EStops, loose wires in terminals, unannotated addresses in the .rss file causing challenges in online connectivity with the processor, and the belt motor turning on regardless of board availability for transfer.
Answer: Answer: It is important to check signal transmission from upstream and downstream conveyors, ensure proper board transfer onto the lift gate, and review the ladder logic programming for any errors or misconfigurations.
Answer: Answer: In the absence of RSLogix500 licenses, RSLogix Micro Starter Lite can be utilized to access the Micrologix 1761-L32BBB processor for troubleshooting and programming tasks.
Answer: Answer: Manual intervention may be necessary if there are issues with the automation process, such as the belt motor turning on regardless of board availability for transfer. Troubleshooting such issues involves checking the ladder logic programming and
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