FAULT-FINDING DEVICE

By: Koen Broekx Xavier Fontanet

Old Fault-Finding Device

Wooden enclosure PLC siemens S5 Conventional switches Plastic shields for the circuits 13 circuits and 13 possible errors Traditional fuses and supply

Why make a new one?

15 years old The measuring points Bad connections Safety Plastic stencils PLC program No labels in the wires Incomplete electric diagrams

New Fault-Finding Device

Select the components Order the components Design the circuits Building the simulator Program the PLC and the TP Test and simulate

Select the components

PLC Siemens S-7 TP 177A PIT es 1.11 E-stop PSENmag 1.1 P20 Safety relays PNOZ X2P Contactors LP4 K0610BW3 Auxiliary relays C2-A20/24VDC Thermal overload relay LR2 K0306 Circuit breaker DX 10 000A Curve C, DE 3000A

Select the components

Power switch VBD-N12 Start push buttons XB4-BA3311 Stop push buttons XB4-BA4322 Supply DR-SPS120W24V Safety Sockets SLB4-G Wire holders DIN rail Enclosure AE 1180/500 Trespa plates

The PLC

14 inputs 40 outputs Features of the CPU’s Price

The Safety relays

The Safety relays

The Contactors

The Contactors

The Supply

DIN rail PLC Safety

Uout = 24V DC Iout = 5A Pout = 120W

Ordering the components

Breva Siemens Multi Contact B.A.G. Plastics nv

Design of the circuits Old simulator circuits:

13 circuits in a soft plastic stencil Structure horizontal and vertical Symbols of the contacts, not professionals Transform symbol in the front.

Design of the circuits

New simulator circuits: 5 circuits in a trespa stencil Structure totally vertical and orthogonal Regulated symbols Supply symbol in the front

Dahlander circuit

642

531

F2F

H2H

H1H

K5MA1

A2A2K3B

A1

A2K1B

A1

K3B

23

24

14K1B

13

32K1B

31

2S1B

1

32K3B

31

32K5B

31

2S2B

1

2S0Q

1

F7F

F6F

F8F

F1F

96 98

95

9896

F2F95

4S1B

3

4S2B

3

14K3B

13

42K1B

41

U2 V2 W2 PE U1 V1 W1 PE

K5M

1

2 4

3

6

5

F1F

1 3 5

2 4 6

K1B

2 4 6

531

K3B

2 4 6

531

K6A

2 4 6

531

F5F F4F F3F

Direct on/off switching

F1F

1

2 4

3

6

5

K1M

1 3 5

2 4 6

642

531

K6A

F5F F4F F3F

A2K1M

A1

H1H

H1H

24K1M

23

14K1M

13

2S0Q

1

F8F

F6F

4S1B

3

9896

F1F95

PEW1V1U1

Pole change-over

PEW1V1U1PEW2V2U2

642

531

F1F

642

531

F1F

642

531

K1M

642

531

K2M

642

531

K6A

F5F F4F F3F

H2H

H1H

A2K2M

A1

A2K1M

A1

24K1M

23

24K2M

23

24K1M

23

14K2M

13

4S1B

3

4S2B

3

2

1

S1BS2B 2

1

32K2M

31

2

1

S1B

32K1M

31

S0Q 2

1

9896

F1F95

9896

F2F95

F8F

F6F

F7F

Sequential circuit

MOTOR 2 MOTOR 1

PEW1V1U1PEW2V2U2

642

531

F1F

642

531

F2F

642

531

K1M

642

531

K2M

642

531

K6A

F5F F4F F3F

A2K1M

A1

A2K2M

A1

H2H

H1H

14K2M

13

34K2M

33

24K2M

23

24K1M

23

34K1M

33

14K1M

13

4

3

S1B

2S1Q

1

2S0Q

1

4S3B

3

F8F

F7F

F6F

9896

F1F95

9896

F2F95

Automatic star delta

PEW1V1U1PEW2V2U2

642

F1F

1 3 5

642

531

K2M

642

531

K1M

642

531

K3M

642

531

K6A

F5F F4F F3F

A2K3M

A1

A2K1M

A1

A2K4A

A1

H2H

H1H

K4A 2

1

32

31K2M

32

31K3M

32

31K1M

K1M14

13

K1M24

23

K3M14

13

F8F

K2M24

23

K2M14

13

S1B 4

3

F6F

F7F

S0Q 2

1

F1F

96

95

98

A2K2M

A1

Construction Mechanical

Construct the mounting plate Hole the door and side of the enclosure Mount the safety sockets, pushbuttons, E-Stop, Power

switch,… Design L-profile for the PSENmag Mount the magnetic safety switch

Construction

Electrical Wire the power circuit Wire the control circuit Wire the PLC

Program PLC program:

New program divided in 9 FC’s: FC1: Safety check

FC2: Circuit Selection

FC3, 4, 5, 6, 7: The different circuits

FC8: Relay outputs and sign lights

FC9: Outputs of the Measuring point

Program

TP program: WinCC program divided in 4 screens:

Screen n°1: Program start Screen n°2: Circuit selection Screen n°3: Error selection Screen n°4: Information

Testing and simulating

Test of the device: Checking inside of the machine

Check all the safety components Check all the connections.

Simulation of the device: Checking outside the machine

Check the Emergency Stop and the magnetic safety switch Check the Push Buttons and the Touch Panel Start the simulation

Conclusions

Improvements compared with the old simulator: Safety More resistant enclosure Stronger stencils Stronger measuring point connections Structured and more understandable PLC

program Updated systems More comfortable working Labelled wires

Conclusions

Usefulness of the Fault-Finding Device:

Improve the knowledge

Faster an more efficient reactions

Thank you for your attention

Dank U well