what I am going to do know.How we are going to find out which one is the fault.

PROBLEM

1. “43 1N 1 PLC CPU Fault” on Monitor.
2. Both LEDs on PLC CPU PCB are continuously ON.
3. DW 160 thru 164 of DB1 is 0000000000000000.


ACTION TAKEN

1. We checked all the voltages, cables continuity and earth faults. Then we checked the parameters (eg. % TEA 1, % TEA2) and found correct according to list provided by machine manufacturer.
2. Because both LEDs on PLC CPU are continuously ON, we General Reset the machine according to procedure in manual (Planning Guide of PLC 135WB/WB2/WD 12.93 addition) by Mode Selection Switch located on the PLC CPU. After restarting the machine Alarm 43 reappeared.
3. We replaced the PLC CPU, NC CPU, SERVO CPU and COM CPU Cards with new cards (with old EPROM Modules). After reloading the % TEA1 and % TEA2 through PCIN software no change in the Alarm was observed.
4. We connected the PG 720 P to the port of COM CPU i.e. X 121 connector and checked the PLC USER PROGRAM which was not available in the controller (Message appeared on the screen “Blocks do not exist in PC). Then we loaded the PLC USER PROGRAM i.e. C2431 @ST.S5D. After restarting the machine Alarm 43 reappeared.
5. We checked the Interrupt Stack (I-STACK) at the PG, the status of the I STACK I have already sent to you.




CONCLUSION

In our view the problem may be in the EPROM Modules of PLC CPU Card. Most probably in the User EPROM Module (PLC USER PROGRAM) does not exsist on the ERPROM Module inserted on the Slot 1 of PLC CPU Card). Because Our EPROM Module is not configured in the library of our PG 720 P so we are unable to blow PLC USER Program on EPROM Module.(DO YOU HAVE PROGRAM LIBRARY FOR THIS.)
I am sending you PLC USER PROGRAM PARAMETER (as atttachment) for checking the status of EPROM Modules. I am loading all the parameters in controller using PCIN software.Do you think it doesn’t create problems.

Let's review this whole thing..

First of all I need you to tell me all the following:

a.-How many boards do you have? Cpu, encoder channels, video, etc.

b.-How many firmware EPROMS (white) and program EPROMS (orange)
do you have?

c.-From the firmware EPROMS there is at least one that has a battery, is it ok? Remember, I'm NOT talking about the CPU's battery.

d.-What machine brand and type are we talking about, how many axes?

I hope the EPROM that you are trying to write to is an orange one, the white ones are not supposed to be written by the user.

If it is an orange, I guess you can take it out and try to load your PLC program directly to the CPU, sometimes this can be done when a faulty orange EPROM is avoiding the PLC from working. The program is supported then by the CPU battery while you get a new EPROM.

e.-You said you have all the backup, can you upload a list of all the blocks in your backup, Pb's, Fb's, Ob's, Db's, etc?

f.-Even if your PLC status is off (stopped), have you tried to ask for a block list from it, thru your PG 720, just to compare it with your backup list?

Sometimes when you transfer by selecting "all the blocks" the PG doesn't do it correctly, and you have to compare both lists, and if some of them are missing you have to transfer them one by one, specially those called Organizational blocks "OB's".

g.-This is an obvious question but I still have to do it: When you take the boards/EPROMS in and out, do you first turn the power off?

h.-One other thing I've seen on some Sinumeriks, when you need to transfer NC MD and PLC MD from your PG, you have to change the values of some parameters, in other words, the NC machine data has to be transferred using one communication settings and then when you are done and want to transfer the ladder, you have to change the value of the corresponding parameters, if you don't do it that way, it will keep saying something like "Blocks do not exist in PLC" after you finish.

Can you upload some pictures of your plc, boards, status leds, machine, screens, etc?

You mentioned an attachment, but I can't seem to find it anywhere.

a) For Details of boards/CPU pl. seeattachment.
b) PLC CPU have configuration pl. see attachment.
c) There is no battery on the PCB attached with 1st user EPROM sub-module, operating system EPROM sub module or PLC CPU. There is only one BACK-UP battery on Power supply unit which is healthy i.e3.2V
d) We are talking about CNC lathe machine modle LEONAR – 80/4000, manufactured by M/S SAFOP, Italy equipped with Siemens 880T Sinumerik controller.
Sinumerik 880T AUSF-1
6FC 3191-2AC-Z
F-NR: T238B017-17
Detail of PCB,s of controller is attached . This lathe has following axis
Z, X, C, Y, X1, X2

e) We have loaded in all the Data through PCIN 2.0 software (%TEA1 & %TEA 2).
We connected PG720P and also loaded PLC user program C2431@ST.S5D and transferred the blocks in single GO and also one by one as you suggested. When we download same program that exist on RAM of PLC CPU and then compare it with the backup using step 5 software, it shows no difference and alarm 43 still exist.
When we general RESET the machine all the data is washed out from the RAM of PLC CPU (C2431@ST.S5D).
f) As desired in (e) when we turn ON the controller Machine parameters (% TEA1 & %TEA 2) exists when we connect PG 720 and try to upload machine to PLC CPU RAM.
We download (PG to Machine) user program stay on PLC CPU RAM until machine is switched OFF or general reset is carried out before switching off machine we are able to compare blocks via step 5 and find no difference in the block.
g) We always take out the boards /EPROMS in and out when power is OFF.
I will send you snap shots of the controller very soon.

pl see attachments.

Attached Thumbnails

   

Attached Files

CNC 4.5M.doc (29.0 KB, 4 views)

I already saw a Leonard 80/4000 lathe similar to yours over the internet, pretty large machine.

Please send me your %TEA1 and %TEA2 files, also send me your C2431@ST.S5D, I have the Simatic S5 software in my laptop and want to take a look at all the blocks in your program, since I believe you are missing an OB.

I think it is ok that you use the PCIN software to transfer the %TEA's, I have used it myself with no problems.

I know you have compared your %TEA's after the transfer process, but have you actually seen the parameters at the machine's screens? NC MD, Spindle MD, Servo MD, etc?

You have mentioned a "General reset" several times, does this process involves a sub-process called "Memory format", wich appears at the very beginning, when you press and hold the button that has an eye on it, while you turn your machine on?

If you haven't done the "memory format" prior to re-loading everything, we might still have a chance to wake your machine up.

Don't do it yet, just answer my question.

Attached Images

 

I am sending you all the parameters in winrar format.

Attached Files

Parameters.rar (150.0 KB, 6 views)

I have looked at the information that you uploaded and have already classified all these: PCIN related, machine data (%TEA1, 2 & 3), tool & zero offsets, part programs, R-parameters, setting data and subroutines, everything seems to be there.

But I have not been able to open your main plc program yet, I'm still trying.

Another questions for you would be:

What model of plc do you have, is it 135 or 135WB?

What software version do you have 1/2/3/4/5/6?

yes we have seen the parameters at the machine's screens? NC MD, Spindle MD, Servo MD, etc?



model of plc is 135WB.we are using software version on Pg 6+.

We have done the "memory format" and then enter the default parameters but nothing has happened.

I am reattaching PLC file.
One more answer

we have seen the parameters at the machine's screensand they are O.K .(NC MD, Spindle MD, Servo MD, etc?0

Attached Files

c2431@st.rar (33.5 KB, 5 views)