ELECTRICIAN TRAINING
Contents
1. processor o Verify that the processor power switch is turned on and check for voltage at the location where the power cord is connected to the processor See Figure 9 2 p a h N Power Cable N D Connection Figure 9 2 Power Cord Connection on the 984 Processor Electrician Training DUTY K PLC Modicon Skill Development Guide 7 K 09b Troubleshoot Processor eee detected power light is not lit WOvdetected power light is lit proceed to Step 4 110v not detected replace the power supply then proceed to Step 4 4 Check the processor Ready light for illumination O O If the Ready light is off then proceed to Step 5 If the Ready light is on then proceed to Step 6 5 Cycle the PLC power O O O Turn the power off and wait a few seconds Turn the power back on and check the Ready light again If the Ready light comes on then proceed to Step 6 6 Check the Run light on the processor Run light is on proceed to Step 8 Run light is off using proceed to Step 7a P230 Using the P230 using proceed to Step 7b P190 Using the P190 7a Using the P230 O O O O O Start the Modsoft program Select the Combine menu Use the arrow key to select the select program option Select the program from the list The P230 programmer and processor should communicate If the processor fails2. K 09b ELECTRICIAN TRAINING SKILL DEVELOPMENT GUIDE Duty K PLC Modicon K 09b Troubleshoot Processor Issued 01 01 98 Task Preview Troubleshoot Processor At Caterpillar typical PLC problems occur such as a machine shutdown a loss of communication between a controller and the input output I O boards or programmer or no illuminated active lights on the I O boards The Learner must exercise extreme caution when troubleshooting a processor Performing the troubleshooting steps incorrectly could result in sudden machine movement which could injure personnel or damage the machine The Learner must locate the controller needing troubleshooting and check it for voltage Then the Learner must check the power or power OK light the processor run light the active input output I O lights and if the controller has a remote I O the COM active light on remote I O processor The Learner should attempt to communicate with the processor using the P190 or the P230 programmer After a thorough analysis you should determine a corrective action How your skills will be checked The Skill Check will require you to troubleshoot a processor The Evaluator will arrange the availability of all the tools materials and resources you will need to demonstrate the task The Evaluator will verify that your demonstration meets the skill objective by observing or measuring each task standard You must demonstrate safe work practice
3. Program Loader Tape P190 only o Modicon Bus Plus Used with all processors o Wiggy voltage tester Electrician Training DUTY K PLC Modicon Skill Development Guide 4 K 09b Troubleshoot Processor Basic Help Keys available on programmer software o Modsoft Programmer User s Manual GM MSFT 001 Rev F o Modicon P230 Quick Key reference card o Ladder Diagram printout o Modbus Plus Data Highway Chart o Machine print Electrician Training DUTY K PLC Modicon Skill Development Guide 5 K 09b Troubleshoot Processor Troubleshoot Processor Task Steps 1 Locate the processor and the I O boards 2 Observe the lights on the processor and I O boards See Figure 9 1 BATTERY OK POWER RUN ACTIVITY INDICATOR EE POWER ON READY EE RUN fl BATTERY LOW _ MODBUS guy PLUS i EE N 1 EEN 2 EE IN 3 MODBUS Hl MEMORY PROTECT OFF PROGRAMMABLE CONTROLLER Modicon EEN 4 EEN 5 N EEN 6 E7 EEN 8 OUTPUT FAULT OUT 1 HOUT 2 HOUT 3 HOUT 4 MOUTS5 EE OUT 6 EE OUT7 HOUT 8 1 0 BOARD Modicon 984 Figure 9 1 800 Series I O 584 Processor 984 Processor and 800 series I O Boards Electrician Training Skill Development Guide DUTY K PLC Modicon K 09b Troubleshoot Processor o If lights are on then go to Step 4 o If lights are off then go to Step 3 3 Check the voltage to the
4. al or fiber optic cable 9 If the processor still does not work at this point then consult an Electrical Engineer Electrician Training DUTY K PLC Modicon Skill Development Guide 11 K 09b Troubleshoot Processor Troubleshoot Processor Concept Check Answer the following questions to check your understanding of troubleshooting a processor Circle the correct answer in each question Then compare your responses with the answers at the bottom of this page Some of the questions may have more than one correct answer If you have difficulty answering a question review the Skill Development Guide or ask your Trainer for assistance 1 If you detect no voltage then you should replace the processor first a True b False 2 After cycling power and cycling backup battery power if the ready light is still not on then you should a b C d replace the processor replace the power supply start the controller reload the machine program 3 If the Ready light is on but the Run light is off then you should a b g a replace the processor replace the power supply start the controller reload the machine program Electrician Training Skill Development Guide DUTY K PLC Modicon 12 K 09b Troubleshoot Processor 4 When replacing the receiver on a remote I O processor which settings should you check to see are the same as the original receiver a I O boards b jum
5. eck the remote I O processor for fault lights communication lights and the remote I O board for active lights Electrician Training DUTY K PLC Modicon Skill Development Guide 10 K 09b Troubleshoot Processor o If there are no illuminated Active or Fault lights then check the remote power supply o Verify that the Power OK lights are on and the power switch is turned on o Usea Wiggy voltage tester to verify that the processor is getting 110 volts o If the remote power I O boards are not getting power then replace the remote power supply Make sure the power supply is receiving power before replacing the power supply o After replacing the power supply verify that the machine works If it is still not working then check the coaxial or fiber optic cables for connection kinks tears or any abnormality o If the coaxial or fiber optic connections are good and the machine is still not working then replace the receiver with a new one from the crib Note Set the DIP switches on the new receiver to the same as the original receiver o Ifthe processor is still not working then replace the remote I O processor with a new one from the crib Note If the remote I O processor is type S908 then verify that the exec pack is installed o If the machine is still not working then replace the tap o Verify that the machine is working o Ifthe processor is still not working then replace the coaxi
6. pers c fiber optic cable d DIP switches 5 When replacing a remote I O processor that is an S908 type you should remember to install the exec pack a True b False Answers 1 b 2 b 3 c 4 d 5 a Next Step If you are ready to demonstrate the task now ask your Evaluator or Trainer to schedule the Skill Check However if you need to practice some of the steps first continue to the next section Electrician Training DUTY K PLC Modicon Skill Development Guide 13 K 09b Troubleshoot Processor Practice The following practice will help prepare you for the Skill Check Ask your Trainer to set up the practice for you After you complete a practice ask your Trainer to check your work Practice Ask your Trainer to simulate a processor problem so that you can practice troubleshooting the processor Troubleshoot the PLC using the task steps to generate a corrective action Practice Objective You should be able to determine what the Trainer has done to set up the practice by following the task steps You should be able to determine if there is a solution to the PLC problems or if the PLC will need to be replaced If possible get the processor back ONLINE If unable to resolve the problem and you need to replace a part then suggest a corrective action that is viable to your Trainer Next Step Continue to practice until you are ready for the Skill Check When you are ready to demonstrate the task ask your Eval
7. prompt o Verify that the Run light is illuminated o Ifthe Run light fails to illuminate then replace the processor 7b Using the P190 o Insert the tape loader tape or program loader tape o Enter the unit number o Press the lt Attach gt software label key o Press the lt Start Processor gt software label key Electrician Training DUTY K PLC Modicon Skill Development Guide 9 K 09b Troubleshoot Processor o Press the lt Y gt key when prompt displays Confirm start o The programmer will display either an error message or a message that the unit is running o Ifan error message is displayed then verify that the data cord is connected properly If the data cord is connected properlyand the error message continues then replace the processor 8 Check the remote I O processor See Figure 9 4 PROCESSOR I O BOARDS I O BOARDS 1 0 BOARDS I O BOARDS I O BOARDS REMOTE I O PROCESSOR 1 0 BOARDS RECEIVER POWER SUPPLY REMOTE I O BOARD REMOTE I O BOARD REMOTE I O BOARD REMOTE I O BOARD REMOTE I O BOARD REMOTE I O BOARD REMOTE I O BOARD Figure 9 4 Primary Processor Remote Processor and Remote I O Boards o Ch
8. s during the Skill Check Contact your Evaluator whenever you are ready for the Skill Check Electrician Training DUTY K PLC Modicon Skill Development Guide 2 K 09b Troubleshoot Processor Skill Objective Upon notification of a complete machine shutdown no communication between the controller and the I O boards or the programmer or no illuminated Active lights on the I O boards troubleshoot the processor Task Standards 1 You must perform a complete analysis of the processor 2 You must recommend a corrective action 3 Corrective action resolves the processor problem Electrician Training DUTY K PLC Modicon Skill Development Guide 3 K 09b Troubleshoot Processor What You Will Need This section contains the safety information tools and resources you will need before troubleshooting the processor SAFETY FIRST DON T TAKE o Follow all Caterpillar Facility Safety Standards when performing this task in the plant o Use caution when working around the PLC high voltage is present on the inside of the PLC cabinet door and near the I O chassis o Wear safety glasses and hearing protection in assembly and production areas o P190 programmer Typically used with the 184 384 484 584 884 and 984 processors o P230 programmer Used with the 984 processor and the 184 384 484 584 and 884 processors in the P190 emulator mode o PLC communication cable o Tape Loader Tape P190 only o
9. to communicate with the programmer then check the data cord connections Electrician Training DUTY K PLC Modicon Skill Development Guide 8 K 09b Troubleshoot Processor o If the connections are secure and the programmer still fails to communicate with the processor then replace the processor o If communication is established then enter the machine program and select the PlcOps menu F2 See Figure 9 3 Utility PlcOps Commands Editors Config ASCII Save Quit PicOps Start CTRL F51 Stop CTRL F6 TUS DISPLAY Single Sweep Constant Sweep Se Run Edit Mode Optimize Mode 01 Clear Logic PROGRAMMED 02 Store to Prom Flash PROGRAMMED 03 Set Hardware Clock PROGRAMMED PROGRAMMED 17 NOT PROGRAMMED 18 NOT PROGRAMMED 19 NOT PROGRAMMED 20 NOT PROGRAMMED 21 NOT PROGRAMMED 22 NOT PROGRAMMED 23 NOT PROGRAMMED PROGRAMMED Networks Seg SFC Networks 25 NOT PROGRAMMED 26 NOT PROGRAMMED 27 NOT PROGRAMMED 28 NOT PROGRAMMED 29 NOT PROGRAMMED 30 NOT PROGRAMMED 31 NOT PROGRAMMED 32 NOT PROGRAMMED 05 NOT PROGRAMMED 06 NOT PROGRAMMED 07 NOT PROGRAMMED 08 NOT PROGRAMMED 09 NOT PROGRAMMED 10 NOT PROGRAMMED 11 NOT PROGRAMMED PROGRAMMED Press lt ENTER gt to uiew the selected segment Figure 9 3 Segment Status Screen with PlcOps Menu Highlighted o Select the Start lt F1 gt function key o Press lt Y gt at the Start controller
10. uator or Trainer to schedule the Skill Check Electrician Training DUTY K PLC Modicon Skill Development Guide 14 K 09b Troubleshoot Processor
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