jpen_110

Here is my attempt to diagram the machine. Talk Soon.  Machine Diagram.pdf

Hello- I am looking for some existing code to reference to try to troubleshoot an old machine.  It has a Omron Sysmac S6 console and I've been able to get the individual inputs and outputs to activate via the console, but the code that is in the machine seems to not be correct.  I suspect someone got in there and overwrote a bunch of the initial lines of the program.  Again, I can control the machine manually through using the console, but want to now automate it.  I've done the program checks and have a whole host of errors, including double coil errors, a missing IL error and circuit errors.   Ideally, I'd like to see what the code looks like to "start" the machine with a button (input 9) as an example and also see how that input can keep one output "ON" or running constantly (output 27) while then activating several outputs in sequential order, individually for a set period of time or until they activate a certain sensor (as an example input 6).   I've mapped out and am attaching what I believe the process flow to be.   I am also attaching the code as I pulled it off the machine.  Again, I don't believe the code to be correct.  Thank you for reading this. Any help would be greatly appreciated.

Jay has been a real godsend on this.  very thankful  

Thanks.  I think I sent a reply  

Changed those line of code.  Start button, when activated, no longer shuts off output 27.  No other activity occurs, however.

OK.  Looking at this, and if I understand it correctly, make changes to 2 of the steps:  Step 159:  Change to LD NOT 70 Step 163:  Change to OR 70 "70" won't actually do anything, but this keeps the rest of the step numbers the same for referencing. Is that a correct understanding?  Thanks Jay.

All next week, including Tuesday...take care Jay. I changed the code to reflect above changes (step 158 to Out 66 and step 159 to LD NOT KR7). The Start Button is wired separately from the Stop Button - no shared wires The Start Button, when depress, shuts off Output 27 which is the hydraulic motor, once start button is released, Output 27 output on again. We then activated Input 0 and pressed Start Button and the same scenario happened above. Input 1 and Input 20 seem to be linked together.  We can, via manipulation, get that input to come on and off (sensor) Only in the scenario where Inputs 0, 1, 20 are on, when pressing the start button does 27 not shut off. The Stop Button when pressed, does shut down Output 27.  

Ok.  Output 24 is not on either when it is initially powered, when the key is switched to RUN or MONITOR, nor when the Start Button is pushed.  When you push the Start Button, input 9 is activated and then Output 27 shuts off (killing hydraulic motor). I did change out line 158 from OUT 66 to LD NOT KR7 after determining above.  Then retested and it didn't make a difference.

158 is now "OUT 66", so that should be changed to read "LD NOT KR7", right?    

They are good, with really specific directions.  I asked if they were around and if they could check on if output 24 was on.  They responded yes, and I mistook that as in yes it was on.  It was yes, they were around.  

Hold on.  Might have bad info.  Doing this remotely this am.  

output 24 is on when we turn key to RUN or MONITOR  

input 10 is "On" and goes off when the STOP BUTTON is pushed.

Thanks Jay.  I went through the S6 and confirmed each step now matches the attached file.  It is your file with the steps renumbered in a couple of places (there were some duplicated/missing step numbers).  No errors are being reported in the program check!  I was clearly sloppy on my keying in a few places. When I put the key into RUN or MONITOR, output 27 turns on immediately and the Hydraulic Motor begins to run.  Then when I push the "START BUTTON" or input 9, the motor "pauses", but then resumes running once you release the button.  Same thing happens with the "STOP BUTTON" or input 10.  No other action takes place.   If we can assume the code is accurate, what do you think the starting conditions are for stuff to start moving (besides hydraulic motor running)? Footnote:  As I stated before, I am able to "force" an ON setting to each of the outputs and get the independent pieces (auger motor, agitator, main cylinder extend/retract, etc.) to move via the S6 controller.  The one "new condition" is that the PrePress Cylinder Retract no longer retracts when forcing the output 13.  We have to manually hold down, what we believe, is one of the Diverter Solenoids, while forcing output 13.  I don't know if output 13 was "linked" in the original code to another output, and if it was, I don't know how to link it. Code as of 12-27.-JP Numbered.txt

My observation is that after compensating for step 19 being deleted, it seems most of the variance between the ladder diagram and theS6toC2k code numbers occurs in Network 7-Agitator Motor, between lines 031 and 050.  

Here is the code.  I failed to number the lines and was coordinating the number between the 2 documents (the ladder and the S6toC2K file).  Thus, this was throwing me off.  I assumed, wrongly, that the reference numbers on the ladder at each section were referencing steps.  It seems there are 178 lines of code, not 173, so somewhere I messed up.  Thus my reference to line 85 was off. see attached txt.  I left the line 19 in there for now. Revised code as of 12-27.txt

I think I initially misread the line 085 from the written code and thought is was in a different section.  Sending code in a minute.

Here is what I wrote out to make the changes.  It isn't the full code, rather just the changes. Steps to make changes.txt

Thanks Jay.  Great actionable feedback. You are a wiz! Input 0 is when there is material in the hopper.  When it goes OFF, then presumably there is either not enough material in the hopper, or somehow the material has "bound up" and keeps the hopper high sensor on, while a air bubble of sorts gets created below, so again - no material available in the right place to process. Confirming comments above: Step 000:  Change from LD 31 to LD NOT 31 Step 112: Change from LD 75 to LD 76 (clearly a keying error as that is what is should have been) Step 085:  Change from TIM1 to OR LD Step 019:  Will delete this step entirely (this should then adjust all the step numbers I presume, so I will do this last)

Thanks again Jay.  I think I got a little too excited about your progress and went ahead, before seeing this, and wiped the program and keyed in your code from the S6toCK2Code file.  Sorry.   So I have a few questions: Should I just rekey the old code back in and follow the above steps, or better to proceed as is?  IF the answer is proceed as is, my questions are: 1). If better to proceed as is, I ran the diagnostics and it came up with 3 errors: Step 105: Coil Double Out 75 Step 020:  Circuit Error IL END. - When looking at the code, I entered an IL statement at step 7 so I don't understand the IL END. Step 087:  Circuit Error Out 64 2). Also, when keying, I wasn't sure how to keep the command "keep" (step 49).  I keyed it as KR 7.  This occurs again at step 160. 3).  Your above post comments that we should add a LD NOT 31 line into the old code, the "new code" begins with LD 31.  I assume that is OK as the old and new, while doing similar things get there in different ways.  Just wanted to check. 4).  In order for the machine to "run", with your code, can you specify what inputs (sensors) need to be on or maybe better, off? I can't really tell if the status Hopper Full makes it "run" or makes it "stop".  Hopper Full, I think, is a status where the machine should run (meaning there is enough materials in there to begin processing).

Checked machine.  No wires are hooked up to either output 23 or input 31.  I reviewed the 64 and 65, and it doesn't seem to be coded to anything as when I try to force set them to being on, nothing happens. Would it be to bold at this point to: wipe out existing code load up new code into S6, as written Turn key to RUN Press the "start button" (input 9) and see what happens? Thanks again Jay.

WOW JAY.  Incredible.  Thank you for all of this. Let me check on the input 31 and output 23. I do believe they are both open, but given your expertise and my lack of knowledge, I suspect I am missing something.  I also don't see any thing for 64, at least not as a hard output.  I will check this as soon as we get back. I see both the ladder diagram and the S6 file.  I don't see the program code converted into statement code, however.  That will be awesome to have as I am still trying to wrap my head around how this code works. Jay-I am super grateful for what you've done here and would love to get your address. Cheers! James      

Wow.  Great to know. The line with CNT has a 0 and then 002.  Is this what you are asking?  

Here is what I believe the process flow should be, or close to it... Process Flow.pdf

Number Class Description 0 Input Hopper Low Level Sensor 1 Input Hopper High Level Sensor 2 Input Pre-Press Cylinder Down Sensor 3 Input Main Cylinder Retracted Sensor 4 Input Main Cylinder Pressure Sensor 5 Input Pre-Press Cylinder Pressure Switch 6 Input Tool Left Sensor 7 Input Tool Right Sensor 8 Input Main Cylinder Bypass Pressure Switch 9 Input Start Pushbutton Switch 10 Input Stop Pushbutton Switch 11 Input TD-1 12 Output Pre-Press Cylinder Extend 13 Output Pre-Press Cylinder Retract 14 Output Main Cylinder Retract 15 Output Main Cylinder Extend 16 Output Tool Cylinder Left 17 Output Tool Cylinder Right 18 Output Fault Light 19 Output TD-1 20 Output Hopper Full Contact (115 VAC 2 AMP Max) 21 Output Diverter Solenoid Side A 22 Output Diverter Solenoid Side B 23 Output Open 24 Output Main Cylinder Bypass Solenoid 25 Output Auger Motor 26 Output Agitator Motor 27 Output Hydraulic Motor 28 Input Main Cylinder Extended Sensor