MAINTENANCE Of MACHINES

Jagdish Singh/J.E/M.A. I A.S Sinha/J.E./Tool Room M.K.Singh/J.E./Inspection/Engine

WELOME
TO

DIESEL LOCOMOTIVE WORKS

(ISO 9001 , 14001 , & OHSAS 18001 ORGANISATION )

Combination of any actions carried out to retain an item or restore it to an acceptable condition. It is not mere repair activity or troubleshooting of the system.
OBJECTIVES :1. To maximize availability and reliability of Machinery & Equipment 2. To extend useful life of assets by minimizing wear & tear and deterioration and 3. To ensure safety of personnel using facilities. SPECIFICATION:-is a detailed description of the required characteristic of the system. It may include: type and family, brief description and intended application; outline drawing showing dimension ; most important electrical characteristic and absolute maximum rate value of voltage; current & power; including figure, graphs and characteristic curves; detailed of manufacturing inspection;

MAINTENANCE ?

RELIABILITY and FAILURE

Reliability is the ability of an item to perform a required function without failure) under stated conditions for a stated period of time. Failure is the termination of the ability of an item to perform its required function. FAILURE RATE (FR) is the ratio of no. of failures to no. of component hours. BATH-TUB CURVE
EARLY FAILURE USEFUL LIFE SEAR-OUT PERIOD

FR

TIME

 EEFECTS OF BREAKDOWN 1. Loss in production time 2. Rescheduling of production 3.Spoilt materials 4.Failure to recover overheads 5. Sub-contracting 6. Temporary work shortages

CAUSES OF DOWN TIME :1. Defective design 2. Operating fault 3. Non- availability of spares 4. Inadequate skill 5. Improper maintenance infrastructure A SIX STEP APPROACH TO MAINTENANCE :1. Collect the evidence 2. Analyze the evidence 3. Locate the fault 4. Identify the real cause 5. Repair the fault 6. And test the system

MAINTENANCE OF MACHINE
1.ELECTRICAL MAINTENANCE 2.MECHNICAL MAINTENANCE

TYPES OF MAINTENANCE
1.PREVENTIVE MAINTENANCE 2.BREAKDOWN MAINTENANCE

OBJECTIVES OF P.M.
TO ACHIEVE:
1. 2. 3. 4. 5.

MAXIMUM AVAILBILITY OF PLANT PROPER CONDITION OF PLANTQUALITY PRODUCT HIGH ASSET VALUE OF PLANT SAFETY OF WORKER HIGH EFFICIENCY OF PLANT

ADVANTAGES OF P.M.
REDUTION IN PRODUCTION DOWN TIME LESSER O.T. PAY LESSER NUMBER OF STANDBY EQUIPMENT ARE NEEDED LESS EXPENDITURE OF REPAIR LESSER SPARE PARTS ARE NEEDED GREATER SAFETY OF EMPLOYEES

TYPES OF PREVENTIVE MAINTENANCE

1.

MINOR PREVENTIVE MAINTENANCE MAJOR PREVENTIVE MAINTENANCE

2.

MINOR PREVENTIVE MAINTENANCE

CHECKS: DURATION--ONE DAY/08 HOURS 1. CLEAN WITH DUSTER/BRUSH/VACUUM CLEANER (a) ALL MOTOR (b) CONTROL PANEL 2. MOTOR TERMINALS FOR LOOSENESS 3. MAIN SWITCHES,RELAYS,OVERLOADS,TIMERS,MCB,MPCB,FUSES 4. POWER AND CONTROL CABLES CONNECTION 5. BRAKES FUNCTIONING 6. AIR FILTER 7. CONTRAST AND BRIGHTNESS OF CRT 8. AIR TIGHTNESS OF CONTROL PANEL

MAJOR PREVENTIVE MAINTENANCE

CHECKS: DURATION: TWO DAYS/16 HOURS 1. MOTORS(SPINDLE & FEED),CABINET FANS FOR ABNORMAL SOUND/EXCESSIVE HEATING/DIRECTION 2. REPLACE AIR FILTER 3. ELECTROMAGNETIC CLUTCHES & BRAKES 4. OVERLOADS/MCB/MPCB 5. POWER AND CONTROL SUPPLY 6. TIGHTNESS & CONTINUITY OF EARTH CONNECTION 7. HARNESSING & WIRE MARKING 8. IR VALUE OF MOTORS(>1M OHMS),EARTH RESISTANCE (<2.4 OHMS) 9. COMMUTATORS & CARBON BRUSHES

MECHANICAL CHECKS
Belt tension Oil level/LEAKAGE

(HYD-HLP 32,46,SS 68,LUBE-SS 32.GREESE ON GUIDEWAYS POINT 2-3 SHOTS)

Cleaning Abnormal sound Backlash Filter cleaning Coolant tank cleaning (Yearly) Hyd.oil change (yearly) Cooling gas leakage

BREAKDOWN MAINTENANCE
1. 2.

UNPREDICTABLE FAILURE OF COMPONENTS GRADUAL WEAR AND TEAR OF THE PARTS, WHICH CAN BE ELIMINATED BY P.M.

Spare Parts & Inventory

Machine system dependent spares Machine system independent spares Inventory control by ABC analysis A-class=hyd pumps, ball screw & nut, clutches, drives, power supply etc. B-class=bearings, wipers, solenoid valves, contactors, etc. C-class=o-rings, springs, glass fuses ,push buttons, relays, etc.

SERVO MOTORS
They are also called control motors and have high torque capabilities. Unlike large industrial motors, they are not used for continuous energy conversion but only for precise speed and precise position control at high torque. Of course, their basic principal of operation is the same as that of other electromagnetic motors. However, their construction, design and mode of operation are different. Their power rating vary from a fraction of watt up to a few 100 W. Due to their low inertia, they have high speed of response. That is why they are smaller in diameter but longer in length. They generally operate at very low speeds or some time zero speed. They find wide application in radar tracking and guidance system, process controller, computers and machine tools. Both dc and ac (2 phase & 3 phase ) servo motors are used at present.

SPECIAL FEATURES
Servo motors differ in application capabilities from large industrial motors in the following respect: They produce high torque at all speed including zero speed. They are capable of holding a static (i.e. no motion) position. They do not overheat at standstill or lower speeds. Due to low inertia, they are able to reverse directions quickly. They are able to accelerate and de-accelerate quickly. They are able to return to a given position without any drift.

CONSTRUCTIONAL FEATURES

Two primary windings mutually displaced by 90 degree electrical from one another in magnetic position. Low inertia high resistance rotor. Speed-torque curve substantially linear from no load to standstill. Constant voltage is applied to the fixed reference field winding. An adjustable voltage on variable control field winding to vary the speed of the rotor. May be operated from either a two phase or a single phase source of power. In case of single phase operation a capacitor is connected in series with the fixed phase and then connected to a constant voltage. The fixed phase is usually with two leads. The control phase may be a two-lead winding, a centre tapped winding or a four-lead winding in two section. If the voltage on both windings are varied, the torque at any slip varies as the square of the voltage. If the voltage on only one phase (i.e.) control phase is varied, the torque at any slip varies as the first power of the voltage. In case of single phase power the torque varies approximately as the first power of the voltage applied to the control winding, at any slip.

COMPARITION BETWEEN CONVENTIONAL & SERVO MOTORS

Open loop operation. Speed is not programmable; hence need gearing for speed change. Poor speed regulation, sensitive to external disturbance like load, power supply voltage & frequency variation. No control over acceleration/deceleration characteristics. Regenerative braking is not possible. Protection is limited ,protection by bimetal overload relay. Closed loop operation. Speed is programmable. Good speed regulation, insensitive to external disturbance. Acceleration/deceleration can be set to make the drive smooth. Regenerative braking is possible. Protection like current limit ,over speed protection can be provided by the controller.

DC SHUNT MOTOR
The DC shunt motor has two windings namely (a) armature winding and (b) field winding. The armature is a rotating part, whose current carrying winding are connected a part called commentator made of many copper bars shaped into a cylinder. The smooth, curved surface of the commutator slides beneath carbon brushes, through these brushes the direct current flows into or out of the armature. A series winding may be used in optional cases, which carries the same current as the armature. But the shunt field is normally preferred . It carries comparatively smaller current separate from armature. The speed of dc motor is increased either by increasing the voltage across the armature or by decreasing the voltage across the shunt field. The FR is the field rheostat and T is the rheostat in series with the armature. The motor speed equation is given byN=(V-Ia.Ra)/K where, N = rpm V = voltage across armature Ia = armature current Ra = armature resistance K = a constant for a given motor = magnetic flux produced by field current

ELECTRONIC CONTROL OF A DC MOTOR A variable speed dc motor may receive power from an ac feeder by using SCRs. SCRs rectify the output of transformer and apply a pulsating dc voltage to the armature while diodes supply a similar voltage to the motor field. SCR can controlled by a phase delay network so as to vary the average amount of voltage applied to the motor armature and thereby to change its speed. Such phase control may also provide a smoother starting .SCR firing is done very late in each half cycle and then slowly the firing angle is reduced towards zero degree which increase the current through the armature in turn increasing the speed of the motor.

MAINTENANCE ASPECTS OF DC MOTOR

These motor have cartridge type brush holders. After about 1000 hours of motor operation ,remove the holder and check the brushes. check the commutator through the brush holder opening. If scoring or burn burn mark on the surface of the commutator can no longer be removed with fine emery cloth, the commutator must be resurfaced. Replace the brushes when they have worn-down to about 10 mm from their normal length of about 25 mm. Replaced the brushes of tacho-generator as a set when they have worn down to about 7 mm. Use brush of the same grade.

MAINTENANCE ASPECT OF AC SERVO MOTOR The ac servo motor has not wearing parts (brushes). So simple daily inspection is sufficient. Inspection schedule for the motor is as : 1.Vibration 2. Noise 3. Exterior cleaning 4. Insulation resistance->10 mega ohms (must be after disconnecting the motor from control) 5. Oil seal after every 5000 hours. 6. The servo motor is generally not water proof. If cutting oil, lube oil etc permeate into the inside of the motor, it may cause4 insulation failure and short circuit of the windings. 7. Axial load on the shaft should be avoided to prevent damage to the precise detector with in the motor.

AC DRIVES
The operating speed of an induction motor can be varied: By changing the voltage impressed on the windings, thereby changing the slip at any given load. By auto transformer (older method). By solid state device such as TRIAC. By changing the speed of the rotating field itself, this is achieved by changing the supply frequency by means of a solid-state inverter. (PWM drive and six step drive)

AC DRIVE CONCEPT

Fundamental formula: Ns= 120f/p where, Ns=synchronous speed in RPM f=stator supply frequency in Hz p=number of motor poles The shaft speed or rotor speed is N=Ns-s, where, s=slip of the motor

HYDRAULIC SYSTEM
A hydraulic system requires a liquid to operate. A pump is used to draw the fluid from the tank and to deliver it at the required pressure. The basic actuator is a cylinder with a movable piston. With the fluid pumped from the storage tank to one side of the piston and returned from the other side of the piston to the tank. Some form of pressure regulation is required to spill excess fluid back to the tank. Cylinder movements are usually controlled by a three position changeover valve.

ELECTRICAL SYSTEM
With an electrical system we have three basic choice: a solenoid, a dc motor and the ac induction motor. Of these, the solenoid produces a limited linear stroke directly. Both DC & AC motors are rotary devices. The choice of motor depends largely on the speed control requirements. A dc motor fitted with a tacho and driven by a thyrister can give excellent speed control, but has high maintenance requirements for brushes and commutator. An ac motor is virtually maintenance free, but is essentially a fixed speed device.

PNEUMATIC SYSTEM
The basic actuator is a cylinder. Operating pressures in pneumatic system are generally much lower than those in hydraulic systems. Air is drawn from the atmosphere through an air filter and raised to the required pressure (ideally 6 bar) by an air compressor usually driven by an ac motor. A pressure switch starts the compressor motor when pressure falls and stops it again when pressure reaches to the required level. The air temperature is raised considerably by the compressor. Air also contains a significant amount solid contaminants and water vapor. Before air can be used it must be cooled, filtered and dried to remove unwanted contaminants. Compressibility of a gas makes it necessary to store a volume of pressurized gas in a reservoir, to be drawn on by the load. Many factories produced compressed air at one central station and distribute an air ring main to all places on the site. The final air treatment consists of steps to remove moisture and dirt and the introduction of a fine oil mist to aid lubrication. This is accomplished by an FRL consisting of Filter, Regulator and Lubricator.

INSTALLATION OF CNC MACHINE

Environment condition :-Dust free, oil moist free, corrosive gas free, air cooled/ air-conditioned atmosphere. Not near any heavy machinery:- likes-presses, compressors, vibration generating equipments. Power supply:- must be stable, balanced and perfectly drawn from a star connected secondary of transformer, separate grounding, Foundation:- should be planed depending on solid conditions (may be isolated).

WARNING,FAULT,ALARM

WARNING:-Only a fault code will flash intermittently on the display, whereas part programmed may be continued. FAULT:-Axes and spindle motion stop smoothly, immediately or at the end of a current block. In a situation like this, machining can not be continued till the fault is cleared. however, the slides could be jogged off manually. ALARM:-For serious faults, the machine tool is shut down immediately, but the CNC display remains active to indicate the fault.

CNC SYSTEM BLOCK DIAGRAM

CPU
KEYBOARD
KEYBOARD/DISPLAY INTERFACE

DISPLAY

POWER SUPPLY

DRIVES
MEMORY

M
E

AXIS INTERFACE

I/O INTERFACE

SCHEMATIC DIAGRAM OF A CNC MACHINE TOOL

CNC SYSTEM COMMAND VALUE SERVO MOTOR

PLC

CNC

SERVO DRIVES

SM

LEAD SCREW

ENCODER

TACHO GENERATOR

VELOCITY FEEDBACK POSITION FEEDBACK

Operator panel

Inputs

Machine element

Outputs

FANUC SYSTEM
MACHINE TOOL 9Miscellaneous and Auxiliary function ) Inputs from limits switches, proximity switches, push buttons, selector switches. ON/OFF control of solenoids, induction Motors, indication lamps etc. Movement of turret etc.

(Sequence Co-coordinator)

PLC/PMC

FANUC CNC SYSTEM

MACHINE TOOL (Axis movement and speed control ) X,Z axis movement Spindle speed control Position feedback like Axis pulse coder, spindle encoder.

The spindle drive and feed drive are collectively responsible and quality production. The accuracy in positioning is primarily achieved by the feedback control system.

FEEDBACK SYSTEM

OPEN LOOP CONTROL SYSTEM CLOSED LOOP CONTROL SYSTEM

ERROR DETECTOR

FORWARD PATH ELEMENT

OUTPUT

COMMAND

FEEDBACK PATH

REQUIREMENT :-HIGH RESOLUTION,REPEATABILITY,ACCURACY,HIGH SIGNAL TO NOISE

RATIO,LESS MAINTENANCE.

FEEDBACK DEVICES :- 1.

ROTARY MEASURING DEVICES

2. LINEAR MEASURING DEVICES

RELATED PROBLEMS :-AXIS MOVING WITHOUT COMMAND,AXIS STOPPING DUE TO EXCESSIVE

LAG,UNDERSHOOTING/OVERSGOOTING OF DESIRED POSITION,AXIS MOVING IN ONE DIRECTION ONLY,HOMING DOES NOT TAKE PLACE,HOMING POSIOTION DISTURBED,JERKY MOVEMENTS,LARGE DEVIATIONS IN POSITIONING,TRANDUSER ERROR,INTERMITTENT FEEDBACK,CONTAMINATION SIGNAL,COMPLIMENTARY SIGNAL FAULT.

Positioning system are distinguished according to physical principles, measuring method, measured value capture.

POSITIONING SYSTEM

PHOTO ELECTRIC PRINCIPLE:-POSITON ENCODERS,MAIN SPINDLE ENCODERS, LINEAR SCALES. INDUCTIVE PRINCIPLE :-INDUCTOSYN,RESOLVER GEAR BOXES. INCREMENTAL MEASURING SYSTEM :-PULSE GENERATOR,POSITION ENCODER, SPINDLE ENCODER,LINEAR SCALES. ABSOLUTE MEASURING SYSTEM :-INDUCTOSYN,RESOLVER GEAR BOXES. ANALOG MEASURING SYSTEM :-RESOLVER DIGITAL MEASRUING SYSTEM :-ENCODERS,DIGITIZERS,AND INDUCTOSYN. DIRECT MEASURING SYSTEM :-LINEAR SCALES,INDUCTOSYN. INDIRECY MEASURING SYSTEM :-ROTARY INDUCTOSYN,RESOLVERS,ROTARY ENCODER.

FEEDBACK DEVICES ANALOG DIGITAL ABSOLUTE

DIRECT INDIRECT

INCREMENTAL

DIRECT INDIRECT

DIRECT INDIRECT

Emergency stop alarms and how to troubleshooting machine E-stop .

Machine Emergency stop checks and troubleshooting ?

1. 2. 3. 4. 5. 6. 7. 8.

Conveyor plug,cables,dummy plug. Emergency stop push-buttons. Gantry,High pressure units,Barfeeder. Fuses in control cabinet. Axes overtravels (series interlock) Door interlock DC power supplies Shorting in control wiringvoltage drop.

Questions to ask when troubleshooting machine alarms.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

12.
13. 14.

Did the alarm get worse the last few days ? Does it alarm in a cut ? Alarm in the same tool ? How do you clear the alarm ? What is the alarm on the drive ? What direction was the axis moving ? Does the problem occur when cutting the same part ? Does the problem occur with the same tool ? Does it alarm only while cutting ? Does it alarm on all three shifts ? Does it happens on hotter days ? Can you make the alarm occur ? Test program ? During tool change, pallet change, or other operation ? Is it at the end of a rapid move ?

How to troubleshooting Automatic Tool Changer (ATC) for the CNC machine tool Determine the sequence for an ATC.
1.
2. 3. 4.

5.
6. 7. 8.

9.
10. 11.

Axes moves to tool change position. Spindle orients to align for tool change. Tool change door open. Magazine pot moves down or in to position. ATC arm moves 30 degrees to engage onto tool in spindle. Spindle unclamp tool. ATC arm lower tool from spindle. ATC arm rotates 180 degrees and put tool in to spindle. Spindle clamps the tool. Arm rotates back 60 degrees. Tool change door closes.

Troubleshooting a Low Voltage condition at the device. (contactor, coil, relay ,brake etc.)

Example: Voltage from A1 to A2 of contactor coil=15vdc, should be 24vdc.

Check the power supply from +24vdc to 0vdc. Check the input power of power supply. Check the over loading of power supply. Loose connection/bad contact in the device. Terminal crimping on insulation of wire for new machine tool. Check entire circuit with multimeter & test each point.

How to troubleshoot an electrical short to ground, blown fuse or a power supply.

Electrical shorts---Fuse blown
---Power supply voltage pull down. ---Ground fault.

Checks: 1.Fuse terminal

2.Power supply feeds 3.Rasistance of each terminal w.r.t. ground 4.Moving cables, cable carriers & chips contamination. 5.Use process of elimination to determine which wire is causing the drop-in ohm (short, 0---3 ohms) 6.Then follow that cable and remove the cause.

Door interlock circuit and safety interlock module troubleshooting and tips.
What you should check in your safety circuit ? 1. All door interlock. 2. LED indication on interlock module. 3. Interlock release key should be in proper position. 4. Connection should be tighten on module & switches. 5. Biggest contactor for vibration due to loose connection.

Machine chuck will not clamp or unclamp ?

Chuck/Actuator troubleshooting procedure.
1. 2. 3. 4. 5. 6. 7.

Hydraulic pump. Hydraulic pressure. Foot switches (Input). Output to solenoid (Lack of logic requirement). If in MDI it is OK then check foot switches. Electrical connection to solenoid coil. Check the draw tube, hydraulic cylinder, any internal wedge.

Fanuc Parameter Backup Procedure

There are two types of parameter to backup on Fanuc Control. 1.NC (control side) parameter 2.PMC (manufacturer side)parameter

NC parameter backup 16/18/21 and 16i/18i/21i

4.

5.
6. 7. 8. 9.

Set communications parameters on computer to match machine if not already done so. Select the EDIT key. Press the (system hard) key. Press the (OPRT) soft key below screen. Press the right arrow soft key. Press the (PUNCH) soft key. Press the (EXEC) soft key. Output should flash in bottom right corner. When output stops fleshing load complete.

CNC machine tool troubleshooting

Electrical,servo,and mechanical problems.
1.

2.
3. 4. 5. 6. 7. 8. 9. 10.

Troubleshooting tips Alarms codes Servo and drives problems Electrical fault PLC ladder troubleshooting Fixture setup Parameter issues Common procedures Hydraulics and Pneumatics Door and safety interlocks.

LUBE PUMP PROBLEMS & SOLUTION

PROBLEMS :1. POSOTIONING/REPEATABILITY PROBLEM
2. NOISE IN AXIS WHEN MOVING 3. AXIS MOTOR OVERLOAD ALARMS

CHECKS :

1.LUBE OIL LEVEL

2. LEAKAGE IN PIPE LINE 3. LUBE PUMP 4.FILTER ON SUCTION SIDE 5.LINE FILTER MAY BE CLOGGED 6. WRONG OIL

RELAY BOARD REPAIRS/TROUBLESHOOTING

WORKING :
I/P(24VDC/LOWER)

RELAY

24VDC/110VAC

Basically each relay converts an I/P signal which is typically 24vdc or lower into a signal that is typically 24vdcor 110 v ac ,as high loads or amperage causes by pulling in solenoids contactors or other devices. By using relay control can be fully isolate. The power from the output cards turns on the LED. The power pulls in a coil on the relay. The coil closes the contact and output 110 v ac or some other voltage through the contact and send it to a load.

REPAIR:

Relay boards can be repaired as normally as other PCB. Traces get burnt new wire solder Relay burnt replace it Spare relay should be use.

TESTING OF PROXMITY SWITCHES

PUT THE MACHINE IN E-STOP..UNCONTROL MOTIONLADDER LOGIC Proximity switches testing:PNP:-2-wire-positive voltage inpositive out to machine input 3-wire-positive and negative from power supply inpositive out to machine input NPN:-2-wire-positive voltage inpositive voltage out to machine input 3-wire-negative and positive in from the power supply negative is out to machine input TESTING:- 1.By given proper I/P supply and measuring the O/P Voltage by multimeter (when proximity is activated). 2. Indicating LED on the switch does not always means the switch is good.

COMMON HYDRAULIC SYMPTOMS PROBLEM & TROUBLESHOOTING

(A)

Noise pump:-

(B)

Oil heating up:-

(C) Hydraulic pump not responding :-quickly enough or not enough flow present. (D) Oil foaming, air in oil :(white color)

1.Hydraulic pump may be cavitations and getting air in to the system. 2. Low oil 3. To heavy of oil 4.Cold oil 5. Suction filter clogged or suction line undersized if new system. 1. Contaminations stuck in relief valve 2.To light of oil 3. Oil cooler if equipped dirty or fan not running 4. Dirty oil 5.Low oil level 6. Excessive pump wear 7. Relief valve set to low 1.Relief valve pressure set improperly or relief failing 2. Low oil supply 3. Hydraulic pump is worn or damaged 4. Valve not shifting all the way 5. Clogged flow control if present -1. Air leak in hydraulic pump suction side 2. oil level low 3. Wrong oil put in tank 4. Pump shaft seal or access plates could be drawing air in to the system

PULSE CODER ALARMS TROUBLESHOOTING APC-Absolute pulse coder SPC-Serial pulse coder
CAUSES OF ALARMS:1. Faulty pulse coder 2. Cable 3. Drive 4. Improper setting of parameter 5. Load in the axis Warning:--If an APC is used, you will have to reset home position if the cable is disconnected. Tool change or pallet change position could also be affected if the zero return position is set improperly. Also if not set properly the axis could be moved beyond its allowable stroke causing severe damage to the way covers ,ball screw and much more. Basic encoder troubleshooting:1. Coolant contamination in plug-check both side of each plug connector. 2. Wires all connected to the pins. 3. Drive plug connected. 4. Encoder cable shield thumb screw snug. 5. Pins seated in plug. 6. Extra ckt board, junction block or plug between motor and drive. 7. Check inside encoder cap.

8.While powered up tap on the connector with the back of screw driver to check for movement or vibration problem. 9.Move encoder cables around to see if it is alarms. 10.Inspect any wires that move in cable tracks for damage. 11.Megaohm the motor to see if there is a slight short to ground.

Advanced techniques:- 1.Swap sides of the drive.

2.Swap the drive completely. There may be parameters stored in the drive and not in the control. Ex. Drive of tool magazine, tool changer, turret or pallet changer.

Questions:-Does it come in---- rapid movement, vibration in m/c, same point of

program, same m/c position, on no motion, hotter days, certain shift, parameter change recently.

DC MOTOR TROUBLESHOOTING
1.

2. 3. 4. 5.

6.
7.

BEFORE REMOVING DC MOTOR BRUSHES-ALWAYS PUT THE BRUSH BACK IN THE SAME HOLE.THEY PROVIDED THE MOST SURFACE CONTACT SINCE THEY ARE WORN IN. CHECK THE BRUSH MOVEMENT. SPRING TENSION FOR ALL BRUSHES. BRUSHES SURFACE FOR SHINING. BRUSH LENGTH. CHECK COMMUTATOR FOR BUILD UP, BLACK RESIDUE ON THE GROOVES/SEGMENTS,POLISH IT. CHACK FOR WEAR GROOVES ON THE COMMUTAOR FROM THE BRUSHES RUBBING. CONSIDER REPLACEMENT IF EXTREMELY WORN OR PITTED.

HOW TO TROUBLESHOOT LIKE AN EXPERT

5 STEPS TROUBLESHOOTING APPROACH: APPROACH MUST BE LOGICAL,SYSTEMATIC AND MAY BE DIFFERS AS SYMPTOMS FOUND. PREPARATION STEP 1-Observation Step 2-Define problem area Step 3-Identify possible causes Step 4-Determine most probable causes Step 5-Test and repair FOLLOW UP

MACHINE VERTICAL AXIS BRAKE SYSTEM

POSSIBLE CAUSES: 1. Adjuster screws and jam nutsloosen/screwed down 2. Square piece in the brake puck 3. Loss of power 4. Brake deterioration 5. Oil/dirt/coolant on the brake disk 6. Disk /plate worn EARLY SYMPTOMS: When power is cut off/E-stop is pushed the head will drop a noticeable amount. Usually if brake is working well we can not see the head drop. CHECKING THE BRAKE GAP: Warning: Use extreme caution when working on an axis brake. Spindle head and turrets will drop like a rock causing serious injury and severe damage to machine. Check with a feeler gauge .oo4 between the brake disk and top plate. It should be even and not more than .008 (.004-.006) ELECTRICAL TESTING: 1. Check power at the brake terminal (24vdc/110vac) 2. Check brake coil (10-100 ohms)

WHAT IS THE DIFFERENCE BETWEEN A 2.5 & 3 AXIS M/C ?

An axis is a direction of motion controlled by the CNC machine control. It can be linear (motion along a straight line) or circular (a rotary motion ).The number of axis a machine has determine it's machining capabilities. A 2.5 axis machine really has three moving axis ,but only two axis can move together most machines sold today are full three axis machines). For machining centers, a three axes machine will have three linear axis. A four /five axis machine will have three linear axes as well as one or two rotary axes. Note that 2.5 versus 3 axes has yet another context.2.5 axis machining requires that the machine have three axes ,but only two axes must be moving simultaneously at any one time. On the other 3-axes machining requires that all three axes be moving at the same time.

THE CNC PROGRAM

SERIES OF STEP- BY STEP INSTRUCTIONS. A CNC PROGRAM IS ANOTHER KIND OF INSTRUCTIONS SET. ITS WRITTEN IN SENTENCE LIKE FORMAT AND THE CONTROL WILL EXECUTE IT IN SEQUENTIAL ORDER,STEP- BY-STEP. A SPECIAL SERIES OF CNC WORDS ARE USED TO COMMUNICATE WHAT THE MACHINE IS INTENDED TO DO.CNC WORDS BEGIN WITH LATTER ADDRESS (LIKE F FOR FEEDRATE, S FOR SPINDLE,AND X,Y,Z FOR AXIS MOTION ) WHEN PLACED TOGETHER A LOGICAL METHOD ,A GROUP OF CNC WORDS MAKE A COMMAND THAT RESEMBLE A SENTENCE. FOR ANY GIVEN CNC MACHINE TYPE, THEIR WILL ONLY 40 50 WORDS USES ON A REGULAR BASIS. SO IF YOU CAN COMPARE LEARNING TO WRITE A CNC PROGRAM TO LEARNING A FOREGION LANGUAGE HAVING ONLY 50 WORDS.

STRUCTURE OF A PART PROGRAM

N
Address of block Number Block number Preparatory function Transient information Spindle speed function Miscellaneous function Feed function Tool function Compensation function End of block

1234 G__ X__Y__Z__S__M__F__T__D__LF

DIFFERENT TYPES OF ELETRONIC DEVICES

DIODES:LED,LCD,SIGNAL DIODES,RECTIFIERDIODES,REGULATORDIODES,PHOTOSENSITIVE DIODES.

BIPOLAR JUNCTION TRANSISTERS (BJT):PNP,NPNIN AMPLIFIER,OSCILLATORS,SWITCHING CUIRCUITS , REGULATORS ,SMPS.

FIELD-EFFECT TRANSISTOR (FET):P-CANNEL & N-CHANNEL,-- IN HIGH INPUT IMPEDENCE & SENSITIVITY REQUREMENTS.

METAL-OXIDE SEMICONDUCTOR FET (MOSFET) :THYRISTORS :- SCR,TRIAC,DIAC,UJTIN HEAT CONTROL,MOTOR SPEED

CONTROL,WELDING CONTROL ETC.

DIGITAL ELECTRONICS :-ANALOG/DIGITAL CKT,GATES,FLIP-FLOPS,TIMERS COUNTERS,DAC

,ADC,LOW &HIGH LEVEL LOGICS,COMBINATIONAL AND SEQUNTIAL CIRCUITS,MICRO-PROCESSOR (INPUTS/OUTPUTS UNIT,MEMORY,CONTROL UNITS).

ELECTRICAL POWER
This is the PRIME SOURCE of control and driving to the Electrical Equipments. Kinds of line disturbances: Under voltage Over voltage Sags Surges Transient impulses/spikes Blackouts/Brownouts Noise/EMI interference Harmonics Floating Neutral & bad ground

UNDER VOLTAGE & OVER VOLTAGE

This is RMS voltage decrease below certain limits. CAUSE: In-adequate power generation, over burdened transmission and distribution network, over loaded transformers, due to excessive demand at peak time, due to sudden switch on of large load. EFFECTS: Erratic behavior of the equipments, system hanging, data loss, unwanted system resets ,ac contractors drops out.

Sudden increase in RMS voltage above certain limits. CAUSE: Due to poor line regulation, due to sudden switch off of large loads. EFFECTS: over heating of equipments.

SAGS & SURGES

A short term decrease in voltage or a short term under voltage condition existing below 2.5 seconds. CAUSE: Due to momentary switch on of heavy loads like large motors, heavy furnaces etc. EFFECTS: It can cause HAVOC to sensitive electronic components. It may get the keyboard locked. A short term increase in voltage lasting for a fraction of a second less than 2.5 seconds. CAUSE: These are caused by heavy loads in the same line, caused by disconnection of these loads, can be caused by lightening. EFFECTS: Computer/CNC memory data loss, BIT error in data transmission, power supply/ components damages, failure of CRT/monitors, malfunctioning of dc drives.

TRANSIENT IMPULSES/SPKIES GLITCHES Deviation from an ideal sine wave. CAUSE: Due to sudden dramatic increase in voltage. It exists only for a short duration of the order of micro- second. typically caused by lightening. A supply line switched on after a long shutdown. Caused by connecting/disconnecting heavy loads, inching of heavy duty cranes/power factor compensating capacitors. EFFECTS: Damage of semiconductors. can destroy power supply module, scrambled data transmission.

BLACKOUTS/BROWNOUTS
Totally powerless. Short term decrease in voltage like SAG. CAUSE: By tripping due to excessive demand on the utility, due to unannounced shutdowns, loads shedding/power cuts, tripping of utility breakers. EFFECTS: Data loss in RAM memory, certain parameter may be corrupted, can corrupt digital data manipulation, can cause fuse blowing/device failure in drive circuits, hard disk crash on a PC may be possible.

NOISE/EMI INTERFERENCE
This is an electrical interference which corrupts the smooth sine wave shape of the ac power. CAUSE: By a variety of disturbance in the vicinity effect of switching of a drill gun/ mixie/ scooter), sources of noise, power line disturbances. EFFECTS: Can cause data corruption, the glitches can trigger wrong circuit also, harmonics may be produce, unnecessary heating of ckts, ac relay may operate slower.

NEUTRAL FLOATING & BAD GROUND Poor grounding causes more noise problems. Most logic circuits use ground level potential as zero potential. Hence a floating or bad ground may carry noise. It can corrupt the data transmission. The practice of grounding neutral other than at the power entrance causes the earth conductor to sink the unbalanced current in the system.

PROGRAMABLE LOGIC CONTROLLER (PLC)

A digitally operating electronic system, designed for use in an industrial environment, whishes uses a programmable memory for the internal storage of user oriented instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic, to control, through digital or analog inputs and outputs and various types of machines or processes. Both the PC and its associated peripherals are designed so that they can be easily integrated into an industrial control system and easily used in all their integrated functions.

HARD WIRED CONTROL SYSTEM

A hard wire control system is constructed only after its program has been defined. Hard wire controls are difficult to modify.
+24 v dc Input section PB-1 PB-2

Processing section
K1 K2

Lamp

output section

RELAY CONTROL
1. 2. 3.

The relay control can be divided in to three parts : Input section switches & sensors ( A/D ). Processing section Relay coils and contacts. Output section solenoids, lamps or motors (A/D).

PLC CONTROL SYSTEM

PLC replaces the function of the relay portion of the hard wired control .
+ 24 v dc PB-1 PB-2 TO PG UNIT

Program IF I 1 AND I 2 THEN SET Q 1 OTHER WISE RESET Q 1

Q1 + _ Lamp

TYPES OF PLC
1. FIXED I/P AND O/P TYPE ANALOG MODULE

2. MODULAR DESIGN (PLC/CPU SPECIFIC)

DIGITAL MODULE

MAKES : Allen Bradley, Siemens, Mitsubishi, Genera Electric , Omron , ABB, Fanuc etc.

COMPARISION
CHARACTERISTIC PLC RELAY

CONSTRUCTION
CAPABLE OF COMPLICATED OPERATION EASE OF CHANGING THE COMTROL PROGRAM PHYSICAL SIZE MAINTENANCE

EASY TO PROGRAM
YES

TIME CONSUMING
NO

VERY SIMPLE

VERY DIFFICULT

VERY COMPACT EXCELLENT, PLCs RARELY FAIL

BULKY POOR, IF LARGE NUMBER OF CONTACT AND COILS HAVE TO BE MAINTAINED

Hardware : Actual devices-PCBs , ICs , Battery , Housing etc. Firmware : software supplied and installed by manufacturer-OS (ROM/EPROM) Software : User program written by PLC user (RAM )
Data bus

A PLC is essentially a micro computer with hardware, firmware and software. Bus system : Address Bus, Data Bus, Control Bus.

STRUCTURE OF PLC

ROM

RAM Input Module Output Module

Microprocessor CPU

Operating system Address Bus

Program and Data

Control Bus

SYSTEM COMPONENTS
BLOCK DIAGRAM :
Programming Devices

PLC
Power supply

Program Memory
Final Control Elements

Acknowledge Ments (Limits Switches,& sensor) Control Element (Push Buttons & switches )

Input modules

Central Processing Unit

Output Modules

Relay, Solenoids, Valve, Lamps, etc,.

POWER SUPPLY

120/230 V AC

POWER SUPPLY

24 V DC FOR PROCESSOR & I/P MODULE

The power supply can be a separate unit or an integral part the processor depending on the manufacturer. PS307---2A/5A/10A---24 VDC---120VAC/230VAC

INPUT & OUTPUT SECTION

(0-24 V DC) OR (120-240 V AC )

Input Module

Low level DC voltage (5 V )

Low level DC signal

Output Module

(120-240 V AC) or 24 V DC

INPUT MODULE

INPUT SIGNAL

Error voltage detection

SIGNAL DELAY

Opto -coupler

DIDIGITAL INPUT (321) AIANALOG INPUT (331)

OUTPUT MODULE

SIGNAL FROM THE CPU

Opto- coupler

Amplifier

Short-circuit monitoring

Output signal

DODIGITAL OUTPUT (322) AO---ANALOG OUTPUT (332)

CENTRAL PROCESSING UNIT

DATA BUS

ALU

CONTROL BUS

Command Register

COTROL BUS

Accumulator Arithmetic unit

ADDRESS BUS

Program counter

Control unit

MEMORY
RAM ( Ram Access Memory ): Read/write, Volatile ( back up by battery/accumulator ) EPROM (Erasable Programmable Read Only Memory ): Readable only. non-volatile ,ultra-violet eraser, reprogrammable EEPROM (Electrically Erasable Programmable Read Only Memory ) :Erased electrically by the proper signal at erase pin, it is used primarily as a non-volatile back up for user program RAM, used as application memory in PLCs. Flash RAM : Its can be erased more quickly.

WORD : 8/16/32 BitsPLC specific, stored binary data in form of BITS (Binary digiTS )0/1.

Requirement of inputs/outputs/program memory compact modules or as plug in electronic card (8/16-Inputs/Outputs)

Power supply Processor SM SM SM SM

MODULAR PLCs

To PG Unit

Programming device cable

Power supply

Processor

SM

SM

SM

SM

PROFIBUS (Process Field BUS )

SOFTWARE
The user program can be written with the programming software suitable for the specific PLC. For example STEP 5 & STEP 7--------Siemens PLCs RS LOGIX 500 -------Allen Bradley PLCs STEP 7 Three method of representation can be used to translate a program in to user program. Ladder Diagram (LAD)Graphical representation of control task using relay Symbology. Function Block Diagram (FBD) : Graphical representation of control task using logic boxes familiar from Boolean algebra. Statement List (STL): Textual representation of control task using mnemonic abbreviations

PLC STANDARD
Since 1992, an international standard IEC 1131 exists for programming logic controllers and associated peripheral devices. The purpose of the new standard was to define and standardize the design and functionality of a PLC and the languages required for programming to the extent where users were able to operate using different PLC system without any difficulties. IEC 1131 standard consists of 5 parts: Part 1: General Information Part 2: Equipment requirement & test Part 3: Programming Languages Part 4: User guidelines Part 5: Messaging service specification

SIMATICHARDWARE+SOGTWARE SIEMENS PROGRAMMING CONTROLLER OF S5 FAMILY.

SIEMENS PLCs

SIMATIC S7:--THREE TYPES OF PROGRAMMING LOGIC CONTROLLER SIMATIC S7 200 : Compact micro plc for lowest performance range. SIMATIC S7 300 : Modular mini controller for intermediate performance range. SIMATIC S7 400 : For high performance range.

SIMATIC S 7 300 CONFIGURATION IM 365-Up to o1 meter between racks IM 360 and IM 361-Up to 10 meter between racks
Allotted 08 nos.

Rack 0
(IT MAY BE IN NCU )

PS CPU IM
SM SM
Slot 2 Slot 1 SLOT 3

SM

SM

SM

SM

SM

SM

IM(S) If not used ,then it is free

Rack 1

PS

IM

SM
Slot 1 Slot 2

SM

SM

SM

SM

SM

SM

SM

IM(R)

DATA TYPES
Type & size Description (bits)
BOOL BYTE 1 8

format options

Range & numeric representation

BOOLIAN TEXT TRUE/FALSE HEXADECIMAL B16#0 to b16#FF NUMBER WORD 16 HEXADECIMAL W#16#0 to W#16#FFFF NUMBER DWORD 32 HEXADECIMAL DW#16#0000-0000 to NUMBER DW#16#FFFF-FFFF CHAR 8 ASCII CHARACTER A, B etc TIME-OF-DAY 32 TIME IN STEP OF 1ms TOD#0:0:0:0 to TOD#23:59:59:999 S5TIME 16 S7 TIME IN STEP OF 10 ms S5T#0H-0M-OS-10MS to S5T#2H-46M-30S-OMS ABBREVIATION: INPUTS---I, OUTPUTS---Q, BIT MEMORY---M, TIMERS---T, COUNTER---C, TEMPORARY LOCAL DATA---L

STEP 7 PROGRAMMING SOFTWARE

STEP 7 IS THE PROGRAMMING SOFTWARE FOR THE SIMATIC S7 STEP 7 PROVIDE THE ENTIRE FUNCTIONALITY REQUIRED FOR CONFIGURING,PROGRAMMING,AND ASSIGNING PARAMETERS TO S7-300 STEP 7 RUNS UNDER MICROSOFT WINDOWS 95 OR HIGHER STEP 7 WORKS WITH OBJECT-ORIENTED CONCEPT. THE STEP 7 OBJECTS INCLUDE STATIONS,MODULES,AND PROGRAMS.ALL OBJECT ARE REPRESENTED BY SYMBOLE ON THE GRAPHICAL USER INTERFACE. STEP 7 HAS A USER FRIENDLY,CONTEXT-SENSITIVE ONLINE HELP FUNCTION THAT GIVES VALUABLE INFORMATION AND TIPS. THE SIMATIC MANAGER IS THE CENTRAL WINDOW WHICH IS ACTIVE WHEN STEP 7 IS STARTED.

CREATING A PROGRAM IN OB1 Opening the LAD/STL/FBD Program Window Choosing Ladder logic, Statement List or Function Block Diagram
LADDER LOGIC :
+ 24 V DC I 2.0 I 2.1 RUNG Q 4.0 0V

STATEMENT LIST : A A = I 2.0 I 2.1 Q 4.0

FUNCTION BLOCK DIAGRAM : Q 4.0 I 2.0 I 2.1

&

PB 1---I 2.0, PB 2---I 2.1,

LAMP----- Q 4.0

BASIC FUNCTION Binary logic operation, Memory function, Move function , Timers , Counters.
1.
2. 3. 4. 5. 6. 7.

NO CONTACT NC CONTACT SINGLE COIL SERIAL AND PARALLEL CIRCUIT NEGATING THE RLO SET AND RESET COIL MEMORY BOX ( SR BOX )

NOT
S S R SR

,
Q

1.

EDGE EVALUATION

--- POSITIVE EDGE IN POWER FLOW _____(P)______ NEGATIVE EDGE IN POWER FLOW _____(N)______

TIMERS
WITH
SP S_PULSE

START TIMER AS
PULSE TIMER

SE S_PEXT

EXTENDED PULSE TIMER

SD ON DELAY TIMER S_OD SF OFF DELAY TIMER S_OFFDT SS RETENTIVE ON DELAY S_ODTS TIMER

REPRESENTATION OF A TIMER
T1
S S_ODT Q

BI TV BCD

S-- BOOLSTART INPUT TVS5TIMEPRESET TIME VALU E R BOOL---RESET INPUT BIWORD---REMAINING TTIME VALUE, INTEGER FORMAT BCDWORDREMAINING TIME VALUE IN BCD FORMAT Q--- BOOL---TIMER STATUS

COUNTER
ITS LOCATED IN SYSTEM MEMORY,PLC SPECIFIC,

1. 2. 3. 4. 5. 6.

UP-DOWN COUNTER (S_CUD) UP COUNTER (S_CU) DOWN COUNTER (S_CD) SET COUNTER COIL UP COUNTER DOWN COUNTER COIL

REPRESENTATION OF A COUNTER
COUNTER OPERAND
CU S_C U D Q

CD

CV

CV BCD

PV R

CUBOOLUP COUNT INPUT CDBOOLDN COUNT INPUT S-- BOOLSET INPUT PVWORDPRESET VALU E R BOOL---RESET INPU CVWORD---CURRENT VALUE IN BINARY CV_BCDWORD---CURRENT VALUE IN BCD Q--- BOOL---COUNTER STATUS

MOVE (Assign a value)

I 0.0
EN MOVE ENO

Q4.0

MW10 IN

OUT DBW12

The instruction is executed if I 0.0 is 1.The content of MW10 is copied to the word 12 of the currently open DB. Q4.0 is 1 if the instruction is executed.

IN1 AND IN2 ARE COMPARED ACCORDING TO THE TYPE OF COMPARISON WE CHOOSE.

COMPARISON INSTRUCTIONS

== IN1 is equal to IN2 <> IN1 is not equal to IN2 > IN1 is greater than IN2 < IN1 is less than IN2 >= IN1 is greater than or equal to IN2 <= IN1 is less than or equal to IN2 If the comparison is true, the RLO of the function is 1.It behave like a normally open contact. The following comparison instructions are available: CMP ? I Compare integer CMP ? D Compare Double integer CMP ? R Compare Real

COMPARE INTEGER/DOUBLE INTEGER/REAL

IN1 IN2 CMP ==I IN1 IN2 CMP ==D IN1 IN2 CMP ==R

EXAMPLE: IO.O I0.1 MW0 MW2 IN1 IN2 CMP >= I Q4.0

Output Q 4.0 is set if the following condition exist: There is a signal state of 1 at inputs I0.0 and at I0.1 AND MWO>=MW2

CONVERTER
1. 2.

BCD_I

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

BCD_I I _BCD BCD _DI DI_BCD I_DINT DI_REAL INV_I INV_DI NEG_I NEG_DI NEG_R ROUND TRUNC CEIL FLOOR

EN ENO BCD to Integer Integer to BCD MW10 IN MW12 OUT BCD to Double Integer Double Integer to BCD Integer to Double Integer Double Integer to Floating Point 1,s compliment Integer 1,s compliment Double Integer 2,s compliment Integer 2,s compliment Double Integer Negate Floating Point Number Round the Double Integer Turncate Double Integer number Floating point number to double integer Round to +infinity Floating point number to double integer Round to - infinity

INTEGER MATH INSTRUCTIONS

ADD_I SUB_I MUL_I DIV_I ADD_DI SUB_DI MUL_DI DIV_DI MOD_DI

Add integer Subtract integer Multiply Integer MW0 Divide integer MW2 Add double integer Subtract double integer Multiply Double Integer Divide double integer Return fraction Double Integer

ADD_I EN IN1 IN2 ENO OUT

MW10

CPUs

CPUs are capable of handling 85 K statements and 256 K data the main memory up to 512 KB. Various CPUs provide up to 8192 bit memories,512 timers, and 512 counter. Smaller CPUs can be expanded up to 256 DI/DO or 64AI/AO. Larger CPUs can be expanded up to 1024 DI/DO or 256 AI/AO. Up-down counters acquire pulses up to 10 kHz. With a frequency measurement up to 10 kHz motor speed can be accurately measured. For application involving controller of pressure, temperature or flow rates the integrated PID controllers can e parameterized. The most powerful S7-300 CPU is also available with an integrated PROFIBUS-DP interface.

CPUs--- control & display elements

STATUS AND FAULT DISPLEYS:
SF.RED BATFRED DC5V.....GREEN FRCE..YELLOW RUN...GREEN STOP..YELLOW HARDWARE OR SOFTWARE FAULTS BATTERY FAULT 5 VDC SUPPLY FOR CPU AND S7-300 BUS IS OK. FORCE REQUEST IS ACTIVE. CPU IN RUN; LED FLASHES AT START-UP WITH 1 HZ. CPU IN STOP OR HOLD OR START-UP.

MODE SELECTOR SWITCH:

RUN-P RUN mode STOP mode MRES mode The CPU scans the user program. The key can not be removed. The CPU scans the user key can be removed. The CPU does not scan user program. The key can be removed to prevent anyone from changing the operating mode. Resetting the memory using the mode selector requires a special sequence of operations.

PLC SELECTION CRITERIA

NUMBER OF INPUTSDIGITAL / ANALOG NUMBER OF OUTPUTSDIGITAL/ANALOG MEMORY PROCESSING SPEED OF CPU. CPU CAPABILITIES/SYSTEM FUNCTIONS/SYSTEM FUNCTION BLOCKS. NO. OF TIMERS,COUNTERS & SIZE OF BIT MEMORY,FLAGS(MARKERS). NEED OF SPECIAL FUNCTION MODULES SUCH AS HIGH SPEED COUNTERS,CLOSED LOOP CONTROL ETC. NEED OF INTERFACE MODULE. NETWORKING AND COMMUNICATION CAPABILITIES.

CYCLIC PROGRAM EXECUTION

Start-up block (OB100)execute once. Start the cycle monitoring time. Reading the signal states from the modules and saving the data in the PII (Process Image Inputs). Execution of the program in OB1(cyclic execution).events, time of the day, hardware interrupts etc., call others OBs , FBs , FCs / PBs etc. Writing the process image output (PIQ) to the output modules. PII OB1 PIQ

SOETWARE & VERSION

S5STEP 5 PLCS5 90U S5 100U S5 115 S5 135 S5 155 S7 SERIES S-7 200 ----- 214,215,224,226 etc. S-7 300 ----- 314,315,317 etc. S-7 400 . SOFTWARE : S7 200---Microwin 32,Programming Tool 802. S7 300---Simatic Managerversion 5.0,5.1,5.2,5.3,5.4 S7 400--- ----do----

ABBREVIATION

IFM--- INTEGRATED FUNCTION MODULES MPI--- MULTIPOINT INTERFACE (9-PINS)-SERIES COMMUNICATION ,BAUD RATE-187.5 KBPS OPI---BAUD RATE---1.5 MBPS IM(S)--- INTERFACE MODULES (SENDER) IN(R)--- INTERFACE MODULES (RECIEVER) PROFIBUS--- PROCESS FIELD BUS BAUD RATE12 MBPS NCU--- NUMERICAL CONTROL UNIT (NC+PLC CPU+IM) IN 840D/810D STL--- STATEMENT LIST---HIGH LEVEL LANGUAGE LAD--- LADDER LANGUAGE--- LOW LEVEL LANGUAGE INDUSTRIAL ETHERNET---BAUD RATE---100 MBPS NMI---NON-MASKABLE INTERRUPT. PCU---PROCESS CONTROL UNIT--PCU 20--NO HARD DISK-FLASH DRIVE PCU 50WITH HARD DISK PCU 70WITH HARD DISK OP---OPARATION PANELOP10,OP10C,10S,OP12,OP15 TWISTED PAIR-TO PREVENT EXTERNAL INTERFERENCE

STEP 7 BLOCKS
1.

USER PROGRAMMABLE BLOCK-----1.ORGANISATION BLOCK (OB)

2.FUNCTIONS (FCs) 3.FUNCTION BLOCK (FBs)

2.

DATA BLOCK(DB) ----1. SHARED BLOCK

2. INSTANT BLOCK

3.

PROGRAMMED READY TO USE BLOCK-----IN S7 LIBRARY IN CPUSYSTEM FUNCTION

1. SFC 2. SFB

NOTE:

USER CAN CALL FC & FB THROUGH PROGRAM OB1 ONLY CALLED BY CPU

STRUCTURED PROGRAMMING/LINEAR PROGRAMMING

OB1 ------Call FB1,DB1 ------Call FC1 ---Call FC2 ------------BE
NESTING DEPTH: MAX. DEPTH FOR S7-300 = 8 MAX. DEPTH FOR S7-400 = 16
DB1 FB1

BE

FC1

BE FC3

FC2 =Q4.0 CCFC3 BE

BE

OB 1 Network 1 ----------------------Network 2 ---------------------------------Network 3 --------------------------------------------BE

INSTRUCTION OF BLOCK END

BE------ BLOCK END BEU-----BLOCK END UNCONDITIONAL (WITH IN A BLOCK) BEC-----BLOCK END CONDITIONAL (DEPEND ON THE RLO) RET-----BLOCK END IN THE LADDER PROGRAMMING

ANALOG SIGNAL PROCESSING

TEMP. PRESSURE FLOW LEVEL -------------

SENSOR

ELECTRICAL SIGNAL

STANDARD PROCESSABLE SIGNAL

MEASURING RANGE MODULE (MR)

D/A

PROCESS IMAGE WEIGHT (PIW)

CPU