I am working on the PCin software provided by you.If i am succesful what is next.Do you have something else in your mind?

Got more questions for you:

After you download the plc program to the plc with your pg, do you go to the plc functions in your pg and ask for a plc start?

What happens when you ask for the plc status pb1 to be displayed in your pg?

Can you get in line with your plc status at all?

Thanks for the PCin software.There is still something wrong because it downloads NC parameter to PC but does not load back to Machine.So I have started doing it manually.

I have entered the parameter manually.One thing which has changed the menu bar at the bottom changes its color to green previously.But this time this didnt happen.
Pg is connected successufully and all te program is loaded (each block one by one).
Yes we get with Plc in line all the time.We have also checked the status of
PB1 on line.

I have entered the parameter manually.One thing which has changed the menu bar at the bottom changes its color to green previously.But this time this didnt happen.
Pg is connected successufully and all te program is loaded (each block one by one).
Yes we get with Plc in line all the time.We have also checked the status of
PB1 on line.
The 43 is still there.The red and green LED s on the PLC cpu remain ON.

After you download the plc program to the plc with your pg, do you go to the plc functions in your pg and ask for a plc start?

Yes I have done this .The system led s turns OFF and ON on the Plc cpu ,NC cpu and com cpu and in the end we get Green and red LEDs on the PLC cpu with 43 error code on the screen.

Why don't you take a picture of your I-STACK screen(s), now that you have done the whole re-initialization? It should point out anything still being wrong.

I have send you picture of my I-STACK sceen on 6-10-09.They are empty.How to fix it?

I have send you the picture of I-STACK before the status is same as before.what I have do know.

...I'm thinking...

I have been checking the system hardware like cards etc. one of my colleague thinks that there is some problem in the back plane of the controller.

What do you mean by "A back plane of the controller"? Do you mean the mother board? If so, you can dissasemble the whole box to look for bended pins or cold solder joints, but I don't believe that would be the problem, these are pretty good quality equipment, anyway you can give it a try, you got nothing to lose.

One other thing I was thinking of is this:

Now that you know how to remove and reload again all the information, we can try to write a new and short plc program (Just for testing purposes) and see what happens, there is a pretty small chance that your plc backup program has been missing something like a final in-site tune-up.

I will look over your actual program and see what I can do.

I dont know about step 5 programming.I will be looking forward for a short PLC test program from you.I hope you have checked the PLC program.

When you were doing the overall reset process, do you remember looking at an option in the screen that said something like "load basic plc program"?

Let me explain this a little bit:

Back in those years Siemens used to preload a sample plc program, that is, when you were comissioning your new Sinumerik, after the format memory process, you could call this plc sample program (for testing purposes), then you could set the plc status in "run" by means of the PG function and the plc would RUN, altough the machine remained in emergency status for safety reasons and being just a sample program, you could actually notice it was being processed.

But I'm not sure if your machine has this in the plc side of your control.

If you remember seeing this option we can try it as a test, if you don't, then we´ll have to write a new different sample program.

I dont have the sample program in my machine. I think you can help me by writing one.

When can I expect a sample program from you.

Been a little too busy last few days but almost ready now, do you happen to have a list of inputs/outputs for your machine?

I guess the plc program that you uploaded the last time doesn't include any text regarding I/O's.

Please see the attached file of inputs and outputs.

Attached Files

New Microsoft Word Document.doc (131.5 KB, 8 views)

Ok I've got it, let me work on it and will get back to you in a couple of days with a simple, very small test program for your machine.

Attached Thumbnails

 

Ok, here is the first test program, download it, unzip it and have it ready to be transferred. When transferring it, you will be asked if you want to overwrite the existing program, answer yes. (you already have a plc program backup). After the transfer process, please request a plc RUN command from your PG.

This is a very small program wich contains only 2 blocks, OB1 and PB1.

OB1 is an unconditional order for your Sinumerik to process whatever is written into PB1.

PB1 are basically 2 ladder segments, wich I wrote according to your I/O list:

1.- When you press and hold the spindle jog CW pushbutton (I2.0), the chip conveyor (Q8.2) will start working.

2.-When you press and hold the spindle jog CCW pushbutton (I2.1), the machine worklight (Q64.0) will turn on.

I think your Sinumerik should be able to process this small program, if it doesn't then we'll have to try some other things.

Attached Files

C880T.zip (1.2 KB, 12 views)

I have tried the program as described by you and then ist cold start from the PG.As before all the LEDs turned OFF first and then turned On with the same alarm i.e 43 and green and red LEDs ON on the PLC CPU.I have also tried warm start but system goes OFF LIne.I have also checked the PB and OB block on the Controller and they are as you have send.I have also send these blocks one by one and without any problem.

What I have to do know.The program loaded sucessfully.But the alarm didnt go.The controller will work only if the alarms are gone.

Looking forward for your comments.

Last week I did an overall reset process to a Sinumerik 820 that was "frozen" as yours and it responded well right after the first steps of erasing and formatting the memory, it was also in STOP mode but it accepted the plc START request and then it got into RUN status without any problem.

I don't understand why your machine is not responding to anything.

Is it possible for you to post pictures of this control, from the operator panel front and rear and from the part where the Eprom modules are?

What version of PCIN were you using before, the one that you said was corrupted, what number is it?

I am attaching picture of 880 T controller

one more picture.

Attached Thumbnails

 

Another thing, after you downloaded the plc program and the % files to the Sinumerik, I hope you connected everything at the machine, this model of Sinumerik needs to be connected, otherwise it won't get rid of the stop status, In other words, you can not hope that the red led will go off without connecting everything first.

You can not request a "plc start" command from your pg when everything is disconnected, it will never RUN.

I still need you to tell me what version of PCIN you were working with.

Version of PCIN software is 2.0.