Multi Conveyor Upgrade Manual

Neil Kane January 2014

Back Conveyor Control System


Overview of system The new system is based on an Siemens S7-300 PLC using remote I/O communicating on a Profibus system. The HMI utilises Win CC Advanced software to run the operating system on a standard desktop PC . The PLC and PC communicates via the MPI port on the PLC connected to a S7 USB adaptor. Profibus The main PLC is located in the desk ext to dock 3. It is connected via profibus to two lots of remote I/O.

□ Node 5 is located in a small panel above the Main electrical Panel. □ Node 10 is located in panel next to Dock 1.

Hardware Config:


IM 153 -1 – Located in small panel above main back conveyor electrical panel Node 5

ET 200 - Located in the panel next to insert lines Node 10

PLC Ladder Below are the details of blocks used in the S7 software to control the back conveyor system.


Starting the Back conveyor Dashboard HMI software with Winn CC runtime If there is a power cut or the PC locks up the Winn CC runtime will need to be restarted from the PC that controls and monitors the back conveyor system.

1) Click on the Win CC flexible runtime icon on the desktop.

2) Click yes to the following message:


3) Select the following project

The file can be found in the following directory


Once you have selected the correct program the software will load up. It will take a few seconds for the PLC and the PC to establish communications.

Comms faults If power is removed to one of the remote slaves on the profibus, or the profibus becomes un plugged the PLC will come up with a Comms fault that may need resetting. Fails safe, BF 1 or BF 2 error lights may be illuminated depending on the problem Ensure power is established to all devices. Momentarily put the run switch to the MRES position. If this doesn’t reset the fault. Power down the CPU for a few seconds and then restart the system. It will take approximately 20 seconds to fully establish all communications once power has been switched back on. Pushers stuck out If a pusher is stuck out to retract it you must select the effected dock. (This is because the system works on the logic that if a dock is not selected then the associated ladder logic will not be

Accessing S7 PLC software

□ From Desktop open up the Simatic Manager software

□ Expand the main PLC icon until it is as displayed below showing a list of blocks in the RHS column.


□ Ensure that the view button as highlighted is selected in order that you can see the description of

each block.

□ Double clicking on a block will open up it so that you can view the ladder logic or statement list etc.

□ Click the icon to monitor the ladder. Inputs Old identification New Identification Description X0 I 0.0 EMS Healthy X1 I 0.1 Start of line Push Button


Note Inputs X2 – X16 on old PLC (dock Selection) are replaced by HMi X17 I 0.2 Remote Stops X20 I 0.3 A line bundle hold (PS1) X21 I 0.4 AA Line con hold (PS2) X22 I 0.5 Dock 4 pusher sensor (PS3) X23 I 0.6 Dock 4 pusher sensor (PS5) X24 I 0.7 Dock 4 pusher extend (PS4) X25 I 1.0 Dock 3 - A pusher sensor (PS6) X26 I 1.2 By pass dock 4 (CS1) X27 I 1.3 Dock 3 pusher extend (PS7) X30 I 1.4 Dock 3 - B pusher sensor (PS9) X31 I 1.5 Dock 3 pusher extend (PS8) X32 I 1.6 Bundle Hold ( A,AA) (PS10) X33 I 1.7 B Line Hold (PS11) X34 I 2.0 BB Line Hold (PS12) X35 I 2.1 Dock 2 pusher sensor (PS13) X36 I 2.2 Dock 2 pusher sensor (PS15) X37 I 2.3 Dock 2 pusher extend (PS14) X40 I 2.4 Bundle Hold ( A, AA, B) (PS16) X41 I 2.5 BB Line hold (PS17 X42 I 2.6 Dock 1 pusher sensor (PS19) X43 I 2.7 Dock 1 pusher extend (PS18) X44 I 3.0 Motor Overloads Inputs in E200 module in panel next to insert lines I 4.0 Motor overloads


I 4.1 Sensor PS 20 I 4.2 24v link (Comms ok) I 4.3 Estop button 5 I 4.4 Estop button 6 I 4.5 Estop button 7 I 4.6 Estop button 8 Outputs Y0 Q 0.0 Dock 4 pusher extend Y2 Q 0.1 Dock 3 pusher extend Y4 Q 0.2 Dock 3 pusher extend Y6 Q 0.3 Dock 2 pusher extend Y10 Q 0.4 Dock 1 pusher extend Y20 Q 0.5 A Line Motor (M1) Y21 Q 0.6 A line back conveyor (M2) Y22 Q 0.7 AA Line Motor (M3) Y23 Q 1.0 Back conveyor (M4) Y24 Q 1.1 Back conveyor REV (M4) Y25 Q 1.2 Back conveyor (M5) Y26 Q 1.3 Back conveyor REV (M5) Y27 Q 1.4 B Line Motor (M6) Y30 Q 1.5 Back conveyor (M7) Y31 Q 1.6 Back conveyor REV (M7) Y32 Q 1.7 BB Line Motor (M8)


Y33 Q 2.0 Back conveyor (M9) Y34 Q 2.1 Back conveyor REV (M9) Y46 Q 2.3 Lamp Y47 Q 2.4 Lamp NEW Q 2.2 Piltz relay reset New Q 2.5 Inserting line conveyor (M10) NEW Q 2.6 Conveyor Start buzzer/lamp NEW Q 2.7 Boom loader delay Outputs in E200 module in panel next to insert lines Q 4.0 Motor 10 Q 4.1 Motor 11 Q 4.2 Motor 12 Tags Identification Tag Bit Address Indication info Sets HMI start Tag 1 bit 1 M101.1 Tag 2 M103.0 HMI stop reset Tag 1 Bit 2 M101.2 N/A N/A HMI stop Tag 1 Bit 3 M101.3 Tag 3 M105.0 A Line HMI Start Tag 1 Bit 4 M101.4 Tag 4 M107.0 A Line HMI Stop Tag 1 Bit 5 M101.5 Tag 6 M111.0 AA Line HMI Start Tag 1 Bit 6 M101.6 Tag 5 M109.0 AA Line HMI Stop Tag 1 Bit 7 M101.7 Tag 7 M113.0 B Line HMI Start Tag 8 Bit 0 M116.0 Tag 9 M117.0


B Line HMI Stop Tag 8 Bit 1 M116.1 Tag 10 M119.0 BB Line HMI Start Tag 8 Bit 2 M116.2 Tag 11 M121.0 BB Line HMI Stop Tag 8 Bit 3 M116.3 Tag 12 M123.0 Dock Selection: A – D4 Tag 13 Bit 0 M126.0 Tag 14 M127.0 M801.0 A – D3 Tag 13 Bit 1 M126.1 Tag 15 M129.0 M801.1 A – D2 Tag 13 Bit 2 M126.2 Tag 16 M131.0 M801.2 A – D1 Tag 13 Bit 3 M126.3 Tag 17 M133.0 M801.3 B – D4 Tag 13 Bit 4 M126.4 Tag 18 M135.0 M801.4 B – D3 Tag 13 Bit 5 M126.5 Tag 19 M137.0 M801.5 B – D2 Tag 13 Bit 6 M126.6 Tag 20 M139.0 M801.6 B – D1 Tag 13 Bit 7 M126.7 Tag 21 M141.0 M801.7 BB – D1 Tag 22 Bit 0 M144.0 Tag 25 M149.0 M802.0 A Reset Tag 22 Bit 1 M144.1 N/A N/A B Reset Tag 22 Bit 2 M144.2 N/A N/A Insert D1 Tag 22 Bit 3 M144.3 Tag 26 M151.0 M900.0 Insert D2 Tag 22 Bit 4 M144.4 Tag 27 M153.0 M900.1 Insert D3 Tag 22 Bit 5 M144.5 Tag 28 M155.0 M900.2 Insert D4 Tag 22 Bit 6 M144.6 Tag 29 M157.0 M900.3 Insert Stop Tag 22 Bit 7 M144.7 Tag 30 M159.0 Indication Arrows for Direction of conveyors on HMI: M4 FWD Tag 23 bit 2 M146.2 M4 REV Tag 23 bit 3 M146.3 M5 FWD Tag 23 bit 4 M146.4


M5 REV Tag 23 bit 5 M146.5 M7 FWD Tag 23 bit 6 M146.6 M7 REV Tag 23 bit 7 M146.7 M9 FWD Tag 24 bit 0 M148.0 M9 REV Tag 24 bit 1 M148.1 M10 INS Tag 24 bit 2 M148.2 Alarms Alarm 1 E stop not Healthy Alarm 2 Motor Overloads Tripped Alarm 3 No Dock Selected Alarm 4 Remote stop PB Fault Alarm 5 Dock 1 Pusher stuck out Alarm 6 Dock 2 Pusher stuck out Alarm 7 Dock 3B Pusher stuck out Alarm 8 Dock 3A Pusher stuck out Alarm 9 Dock 4 Pusher stuck out Alarm 10 Boom Loaders Timed out Alarm 11 A Line E stop not healthy Alarm 12 AA Line E stop not healthy Alarm 13 B Line E stop not healthy Alarm 14 BB Line E stop not healthy Timers


Using S5T#2S format where 2 = value of timer T1 OB1 fb execution T2 OB1 fb execution T3 OB1 fb execution T4 OB1 fb execution T5 OB1 fb execution T6 OB1 fb execution T7 OB1 fb execution T8 OB1 fb execution T9 Dock 1 pusher T10 A – Dock 2 Pusher delay T11 A – Dock 3pusher delay T12 A – Dock 4 pusher delay T13 B – Dock 2 pusher delay T14 B – Dock 3 pusher delay T15 B – Dock 4 pusher delay T16 BB Line to Dock 3 delay T17 Insert to Cock 1 Delay T 18 AA line Bundle collision delay T19 AA 2 Bundle Delay T20 Insert to Dock D2 T21 Insert to Dock D1 T22 B Bundle Delay 1 T23 B Bundle Delay 2


T24 boom Loader switch off T25 BB Bundle Delay 1 T26 BB Bundle Delay 2 T27 B- D1 conveyor start delay T28 Buzzer T29 B - D2 conveyor start delay T30 B – D3 conveyor start delay T31 B – D4 conveyor start delay T32 A – D1 conveyor start delay T33 A – D2 conveyor start delay T34 A – D3 conveyor start delay T35 A – D4 conveyor start delay T36 Insert - D1 conveyor start delay T37 Insert – D2 conveyor start delay T38 Insert conveyor delay Tasks Left to Complete

□ Remove large contactor for boom loader

□ Dock Count

□ Stacker Count

Despatch Dashboard HMI – User guide


1) Check alarms screen to see if any stops are in or any other faults. 2) If stop has been in press the “Reset back conveyor button” This mimics the push button on the old panel which can still be used. 3) Start system via start/stop push buttons on console. When system is on LED is illuminated. 4) Start the conveyors up between the 3rd strap machine and the back conveyor by using the “start BB line” etc etc. 5) Select the chosen dock for each press. Once selected the button will be illuminated blue on the HMI. 6) Each dock has a counter on the mimic, this count can be reset by pressing the “Reset dock count” button. 7) The Good copy count for B News grip can be found under the copy count tab. This has been modified to count to a higher value.

8) If a pusher sticks in the out position, go to the “Copy count page” and press the button “Retract

dock Pushers” This will remove the voltage from the coil of the solenoid.


Trinity Mirror Printing Newcastle LtdNOT TO SCALE

1/2

DOCK 1 DOCK 2 DOCK 3 DOCK 4

MOTOR OUTPUTS

VALVE OUTPUTS

SENSOR INPUTS

LIFT UPGATE MICROSWITCH

BBB AA A

M1

M7

M6

M5 M4

M3

M2

M8

M9

MS1MS4 MS3 MS2

SV1SV4 SV3 SV2

PS1

PS4

PS5 PS3

PS2

SV5

PS9

PS8 PS7

PS6

PS11

PS10PS12

PS14

PS13PS15

PS17

PS16

PS18

DATE

SHEET NO.

2/1/2014

DRAWING

MACHINE

BACK CONVEYOR LAYOUT

PS19PS20

M10

New inserting

conveyor

CC

M12

C

M11

E Stop button

Cable for extra stop buttons Core 1 Piltz Estop 1 In Core 2 Piltz Estop 2 In Core 3 Piltz Estop 1 Out Core 4 Piltz Estop 2 out Core 5 24 v dc Core 6 input to PLC for Mimic Core 7 Reverting to old system in the event of an emergency

□ Switch off CB 2 located in the small panel on top of back conveyor panel □ Switch on CB4 located in the old back conveyor panel. □ Selected the designated dock from the rotary switches on A desk or the rotary switches in the

main desk that are inside the panel.

Date post:	16-Apr-2017
Category:	Documents
Upload:	neil-kane
View:	142 times
Download:	1 times

Multi Conveyor Upgrade Manual

Documents