Safety Module Fault

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1

petal.zip (1.2 MB)

Downloads.zip (49.8 KB)

The on-site equipment is a blow molding machine using a B&R PLC and X20SL8100 safety module. Several yellow safety modules were installed behind the X20BC0083. The equipment had been operating normally for two years before the fault began on August 4th.

Please see the attached video for the fault scenario. please see petal.zip

When the equipment is simply powered on, all modules, including the safety module, are normal. At the sixth second in the video, the equipment starts production, and the safety module light turns red, returning to normal after a few seconds. The X20 module also displays an abnormal light, causing the equipment to stop operating.

This fault has occurred multiple times. I have replaced the X20BC0083 and the PLK cable between the X20SL8100 and X20BC0083, but the fault persists.

Also, I have captured loggers for reference. please see Downloads.zip.

What steps can we take to identify the source of the problem and what should be done next?

4

Hello Hougang Deng,

If the machine has been working for two years, and only started to fail recently, quite often can caused external factor, such as material wearing out. I have taken a look at the logger, and I saw quite a few instance powerfail message and “input error state has changed“–> in AS help it recommend to check the 24V of power supply.

I think check the power supply for both IO and safe PLC could be a good start to check the problem.

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