RS 500 major error fault

[journeyman1963]

Last week we completed a Crown end press conversion and upgrade in our plant. We built and wired the complete electrical system up to NEC and UL standards. The press control panel is using a SLC 5/04 AB processor. We have done several of these type conversions in our facility with great success and each new one we do is basically a repeat of the others to the point where we can copy the program and reuse it. The problem we have run into on this last one is this: The workers for now have been powering the panel down at night and re-powering it up in the morning. Not every time, but about 50% of the time ,the processor faults during boot up. When I go online to clear the fault in the processor status tab/errors it shows a S:1/13 error with a description "module 6 which is required for the user program is detected as missing or removed" Once you clear the major error, it works fine with no apparent problems with card 6 (fast DC/sink 24vdc card). We have reseated that card and checked all connections. Everything in this electrical install is brand new. BACKPLANE?? maybe


any ideas are welcome........thanks

 

[jde777]

I would suggest new chassis and also insure grounding of existing chasis.

 

[journeyman1963]

Right after I posted this an electrical engineer from another company in Ohio we use occasionally stepped into my office. He suggested the same, new backplane (chassis). He claims he has seen a few brand new units not work properly.

thanks JDE, unit is grounded. We'll try another backplane.

 

[panelman]

I try swapping the card out first

 

[jraef]

I have had issues with bizarre processor errors on SLCs, they all turned out to be grounding problems. Something about them makes them hyper-sensitive to intermittent ground connections (or no ground connection).

 

[hillimonster]

I have seen, over the last 20 years, the PLC rack can have some problems with the backplane circuit board. I have had this kind (maybe not exact) of fault, probably twice. The circuit board was "flexed" and I assumed the connections were intermitent.