Software revision v9.
Skillet Controller Functionality Document
Overview ........................................................................................................................... 1
Sequence of station communications ............................................................................... 2
PLC display window .......................................................................................................... 2
Fault Table ........................................................................................................................ 4
Fault Recovery Procedures............................................................................................... 4
Encoder Offset Setup Procedure ...................................................................................... 6
Skillet Carrier Number Setup Procedure ........................................................................... 6
Skillet Diagnostic Mode Procedure ................................................................................... 7
Data Table Edit ................................................................................................................. 7
Procedure to adjust values to the data table N10 ............................................................. 8
Procedure to Adjust Default Values of the IFM Laser Encoder....................................... 11
Laptop configuration........................................................................................................ 12
Overview
Skillet PLC’s communicate to the System PLC via Optical Data Transfer (ODT)
devices only at predefined stations determined by production build requirements.
The height table is sent to each skillet based on Vehicle Style (6 styles
available).
Skillet
On Board ODT
Off Board ODT
Height Actuator
Magnet (Entry
of next FP)
ODT positioned
to communicate System Dnet
at the 300mm of
footprint.
Skillet signals MCP signals
Fault
Codes
Height, Style or
Vehicle Carrier Number
Style Request
Acknowledge
At Height Fault Reset
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Sequence of station communications
1. Skillet will receive the GO signal from a system ODT nearing FPS.
2. Skillet will send fault data, if it exists, and style information. System will
report the fault with its location (footprint).
3. The style information is used by the system to load the correct height
(bottom of rocker) at the station. (6 possible styles are available).
4. System ODT will send the height data for the next footprint(s). Foot print
height tables are displayed on the HMI and are editable based on the rocker
height (BOR). This information is scaled to the scissor lift motion (0-
1060mm).
5. The skillet will send a “Good data received” acknowledge.
Note: If the skillet is faulted, except fault 7, or the height has not been
acknowledged, skillets are stopped at FPS. An HMI fault reset will be able to reset
most faults (Not all faults can be reset by HMI).
Skillet ODT Inputs Skillet ODT Outputs
0 1 -103 Used for Height Data 0
multiple value by 10. System Reserved for carrier faults (See
1 1
PLC will add (1mm) to the fault table)
2 2
data sent (ex. System PLC
3 sent 70, this is translated to 3 1-6 Vehicle style, Used by
4 690mm) 4 system PLC to send correct
5 5 height table
120 Used for Carrier #
Request
Acknowledge for Data transfer,
122-127 Used for setting 20 good reads
6 Vehicle style 6
7 Fault Reset 7 Lift at height
PLC display window
Display window will display one of the five modes of controller operation: Automatic,
Manual, Maintenance, Setup, and Faulted.
Key positions: Automatic, Manual, and Maintenance. The maintenance position enables
the safety relay when the (2) height enable magnetic switches are not actuated by the
magnet or there is a slack belt condition.
ActBOR – Actual Bottom of Rocker position. This display is in 100ths of an inch. 1268
12.68”
PrgBOR – Programmed Bottom of Rocker position. Desired height received from the
system PLC. This display is in 100ths of an inch. 1268 12.68”
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Automatic
(Switch in Automatic position)
The AUTO will flash when the skillet is in position and communicating to the system
ODT. Style is shown as S=1 (Style 1).
Manual
(Switch in Automatic position)
Manual mode can be used when:
1. (Switch in Manual position when magnetic switches are enabled) Skillet lift can
only travel to the raised or lowered software limit (0mm – 1060mm).
Maintenance
(Switch in Maintenance position)
DANGER!!! MAINTENANCE MODE IS UNRESTRICTED (BYPASSING SLACK BELT
SWITCHES), PERMANENT DAMAGE CAN AND WILL OCCUR IF THE WRONG
DIRECTION PUSH BUTTON IS PRESSED!!! IF PRESSURE SWITCH IS TRIPPED,
MAINTENANCE WILL ALLOW TO RAISE. IF UPPER OVERTRAVEL IS TRIPPED,
MAINTENACE WILL ALLOW TO LOWER.
Maintenance position will also display the Carrier Number (CAR1).
Faulted
See fault code table below
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Fault Table
ODT Fault ODT Fault Description (System SKILLET
Actual Fault LCD Display
Code HMI) BIT
E402S CONTROLLER IS NOT IN AUTOMATIC B3:4/2 MANUAL
1 Skillet Not in Automatic
F230S PENDANT SWITCH MISMATCH B3:3/1 PEND SWITCH
E401SRM SAFETY RELAY FAILED ON B3:2/2 E401FLT ON
2 Skillet Safety Relay Fault E401SRM SAFETY RELAY FAILED OFF B3:2/3 E401FLT OFF
E401SRM SAFETY RELAY FUSE NOT OK B3:2/4 E401FUSE FLT
S04 SKILLET SCISSOR LIFT OVERTRAVELED B3:2/5 RAISED OT
3 Skillet Safety Hardware Fault E426/430CR SCISSOR LIFT BELTS NOT OK B3:2/6 SLACK BELT
S03 PRESSURE SWITCH TRIPPED B3:2/7 PRESSURE FLT
F166CR ENABLE RELAY FAILED ON B3:2/8 F166FLT ON
F166CR ENABLE RELAY FAILED OFF B3:2/9 F166FLT OFF
4 Skillet Relay or Contactor Fault
F174C OK TO RUN CONTACTOR FAILED ON B3:2/12 F174FLT ON
F174C OK TO RUN CONTACTOR FAILED OFF B3:2/13 F174FLT OFF
SKILLET NOT AT HEIGHT FAULT B3:3/0 NOT AT HGHT
VERTICAL POSITION ENCODER FAILURE B3:3/4 ENCODER FLT
5 Skillet Encoder or Position Fault
NO MOTION FAILURE B3:3/6 NO MOTIONFLT
DIRECTION FAILURE B3:3/7 DIRCTN FLT
6 Skillet Brake Not Releasing SKILLET BRAKE NOT RELEASING B3:3/8 BRAKE NOT RL
7 Skillet PLC Battery Low PLC BATTERY POWER LOW S:5/11 BATTERY LOW
Fault Recovery Procedures
Fault 1 (Skillet Not in Automatic)
MANUAL: Place the Pendant key switch into the automatic position.
PEND SWITCH: Place the skillet controller pendant bypass key switch (F230S) into the
correct position based on the pendant being plugged in or not.
Fault 2 (Skillet Safety Relay Fault)
E401FLT ON, E401FLT OFF and E401FUSE FLT: Cycle power to the control panel
and press “RESET”. If the fault is not cleared, open control panel and check the safety
relay for power. If the relay does not have power, replace it.
Not On and Off Faults can be caused by the magnets not properly actuating the
switches properly. Or caused by the slack belt switches not adjusted correctly. There is
a mismatch between the software and hardware contacts.
Fault 3 (Skillet Safety Hardware Fault)
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RAISED OT: DANGER!!! MAINTENANCE MODE IS UNRESTRICTED (BYPASSING
SLACK BELT DETECTION), PERMANENT DAMAGE CAN AND WILL OCCUR IF
THE WRONG DIRECTION PUSH BUTTON IS PRESSED!!! Switch to Maintenance
Mode and Press the “LOWER” PB then reset.
SLACK BELT: DANGER!!! MAINTENANCE MODE IS UNRESTRICTED (BYPASSING
SLACK BELT DETECTION), PERMANENT DAMAGE CAN AND WILL OCCUR IF
THE WRONG DIRECTION PUSH BUTTON IS PRESSED!!! Remove Vehicle and
direct Skillet into Repair. Once in repair, Switch to Maintenance Mode to investigate
reason for faulting
PRESSURE FLT: DANGER!!! MAINTENANCE MODE IS UNRESTRICTED
(BYPASSING SLACK BELT DETECTION), PERMANENT DAMAGE CAN AND WILL
OCCUR IF THE WRONG DIRECTION PUSH BUTTON IS PRESSED!!! Switch to
Maintenance Mode and Press the “RAISE” PB to relieve pressure on the anti-fall device
then reset.
Fault 4 (Skillet Relay or Contactor Fault)
F166FLT ON, F166FLT OFF, F174FLT ON, F174FLT OFF: Press “RESET”. If the
fault is not cleared, examine the Contactor / Relay for failure. Replace if necessary.
Fault 5 (Skillet Encoder or Position Fault)
NOT AT HGHT: Skillet did not reach the programmed height while in automatic and no
faults are present. The controller will display a fault, but the programmed and actual
heights values will be different. Manually move the skillet lift table to the correct position
or reset the fault and examine the motion.
ENCODER FLT: Press “RESET”. If the fault is not cleared, turn the key switch to
manual mode and examine the display of the actual height (actBOR) while raising and
lowering. If this value is erratic, replace the encoder.
NO MOTIONFLT: Power was provided to the motor and movement did not occur.
Press “RESET”, attempt to move lift in manual mode while cautiously examining lift table
for motion.
DIRCTN FLT: Movement was detected in the opposite direct than commanded. Press
“RESET”, attempt to move lift in manual mode while cautiously examining lift table for
motion.
Fault 6 (Skillet Brake Not Releasing)
BRAKE NOT RL: Skillet did not release the brake when a move command was given.
Press “RESET”. If the fault re-occurs, examine the brake in the repair area.
Fault 7 (Skillet PLC Battery Low)
BATTERY LOW: Skillet Controller PLC Battery is Low. Replace battery in the
processor. If the battery does not get changed, there is a possibility of losing the
program in the skillet in buffer areas where there is no rail power.
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Encoder Offset Setup Procedure
Each skillet encoder requires a setup process to determine and compensate for lift table
variations.
Steps to set the encoder offset:
1. Turn the key switch to manual mode, press and hold the “RESET” PB for 5
seconds. This will change the controller to Setup Mode.
2. Ensure the Lift Enable switches are actuated. Press and hold the “LOWER” PB
until the lift stops on the lower hard stops and SETUP mode Disappears and
displays MANUAL. (Approx. 4-5 Seconds after hitting the hard stop).
3. Exit the Setup mode (If No changes are needed) by pressing and holding the
“RESET” PB (for 5 seconds) until the display changes to manual mode.
4. If Slack Belt occurs when using the Setup Procedure. Switch to Maintenance
Mode and press “RAISE” to raise the lift off of the hard stop switch. Press
“RESET”. Return the key switch to manual or auto.
Skillet Carrier Number Setup Procedure
Each skillet controller requires a setup process to set the carrier number.
Steps to set the carrier number:
1. Turn the key switch to maintenance mode and hold, press and hold the “RESET”
PB for 5 seconds. This will change the controller to Carrier Number Setup Mode.
(CAR will flash while in Setup Mode).
2. Press the “LOWER” or “RAISE” PB multiple times until the carrier number
matches the number on the skillet.
3. Exit the Setup mode by releasing the maintenance mode switch.
4. Carrier Number can also be edited from a laptop connected to the MicroLogix or
by editing the Data Table by using the Data Table Edit procedure.
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Skillet Diagnostic Mode Procedure
Each skillet can access a diagnostic mode. This helps to diagnose faults for a carrier.
The skillet will log the last 25 faults the carrier had. The data can be recalled using the
pendant.
Steps to access the Fault Log:
1. Turn the key switch to Automatic mode, press and hold the “RESET” PB for 15
seconds. This will change the controller to Skillet Diagnostic Mode. The reset
will need to be held as long as you want to view this mode.
Diagnostic Mode will display the faults that are listed in the Fault Table above.
(Exception:E401FLT ON will display other varieties based on what switches are
on or off.)
401ONS06OFF - E401SRM Faulted On and S06 magnet switch was off.
401ONS07OFF - E401SRM Faulted On and S07 magnet switch was off.
401ON426OFF - E401SRM Faulted On and E426CR Relay was off.
401ON430OFF - E401SRM Faulted On and E430CR Relay was off.
2. Press the “LOWER” or “RAISE” PB multiple times to scroll through the fault
listings. (Fault #0 – 24).
3. If there is no faults logged, it will not show anything.
4. To reset/clear the log, press the “LOWER” and “RAISE” PB at the same time.
5. Exit the Diagnostic mode by releasing the “RESET” PB.
Data Table Edit
Each skillet controller has ten data fields that can be edited.
N10:0 – (Program Height Adjust) Procedure to write the actual height (ActBOR) to the
programmed height (PrgBOR).
If the programmed height is not correct (PrgBOR) and the skillet is beyond the ODT,
then the lift table height can be physically adjusted and actual height rewritten to the
controller.
Note: The height enable actuator must be enabled or use maintenance mode to raise or
lower lift table to desired height. The programmed height cannot be overwritten while
the skillet is communicating to the station ODT.
1. Place the key switch in manual / maintenance and adjust lift table to the desired
height (ActBOR).
2. Switch the display mode to monitor (see procedure to adjust values to the data
table N10 below) and change the value of N10:0 from 0 to 1. The value will return
to 0 when the programmed height is overwritten.
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N10:1 – (Offset Height Adjust) Encoder offset adjust.
Each encoder has been adjusted to offset the zero position from the hard stops. If a
physical difference exists to a particular skillet lift, then this value can be adjusted.
Lowering the number will raise the lift position and increasing this value will lower the lift
height.
N10:2 – (Lower Position Limit) Lowering position tolerance window
Value is set at 2mm and this value should not be adjusted.
N10:3 – (Upper Position Limit) Raising position tolerance window
Value is set at 2mm and this value should not be adjusted.
N10:4 – (Decel Lower Position Limit) Raising Decel position tolerance window
Value is set at 50mm and this value should not be adjusted.
N10:5 – (Decel Upper Position Limit) Lowering Decel position tolerance window
Value is set at 55mm and this value should not be adjusted.
N10:8 – (Lower Position Limit - Enlarged) In Position Tolerance Changes to this after
reaching narrow window. Lowering position tolerance window
Value is set at 4mm and this value should not be adjusted.
N10:9 – (Upper Position Limit - Enlarged) In Position Tolerance Changes to this after
reaching narrow window. Raising position tolerance window
Value is set at 4mm and this value should not be adjusted.
N10:10 – (Edit Carrier Number) Changing this values will change the carrier number
stored in the MicroLogix.
N10:11 – (Lift Down Plunger Delay) Delay (100ths of a second), from when the carrier
detects the down plunger switch and the drive stops when moving in the down direction.
Value is set at 150 100ths.
Procedure to adjust values to the data table N10
The follow procedure (steps 1-10) were taken directly from the (Rockwell manual
Publication 1763-UM001D-EN-P - March 2011 - Using the LCD pg104) and references
Data table N7. The Spring Hill Monitoring will adjust value in the Data Table N10.
1. Press esc on the LCD keypad for 3 seconds. On the Main Menu screen, select
Monitoring by using the Up and Down keys on the LCD keypad.
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2. Then, press the OK key on the LCD keypad. The Bit/Integer File
Select screen is displayed, as shown below.
3. If Integer is selected, as shown in step 2, press the OK key.
If not selected, press the Down key to select it and then press the OK key.
4. The current data value (ON) of the N10:0 word is displayed, as shown below. Note
that the target word “0”, which is right to “N10:” is flashing, which means the cursor is at
the target word position.
5. For this exercise we will change the data value of the N10:0 word to the negative
decimal value -1300. First, press OK to move the cursor to the data value position. Then,
the last digit of “+00000” will be flashing, which means the cursor is at the data value
position.
6. Press the Left key twice. Then, the cursor will position at the third digit. Press the Up
key three times to change the third digit to 3.
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7. Press the Left key once. Then, press the Up key once. The second digit will change to
“1”. Note that “1” is still flashing, which means the cursor is still at the data value
position.
8. Press the Left key once. Then, press the Down key once. The sign digit will change to
“-”, as shown below. Note that “-” is still flashing, which means the cursor is still at the
data value position.
9. Press OK to apply the changes. Then, the new value -1300 is applied. Note that the
target word “0”, which is right to “N10:” is flashing. The cursor is moved automatically to
the target word position.
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10. Press Esc to navigate to the main menu. Scroll down to the user display and press
OK to change back to the user display.
Procedure to Adjust Default Values of the IFM Laser Encoder
The two values that need to be adjusted from default are ASP(Analog Start Point) and
AEP(Analog End Point). These values are as follows. ASP=210 and AEP=1350
1. Press [MODE/ENTER] until ASP is Displayed and Change to the above values.
Repeat for AEP. Following is from the manual to show the change process.
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Laptop configuration
The skillet controller program was created using RS Logix 500 ver 8.3.
All controller IP addresses are set to 10.2.3.13
Subnet mask 255.255.255.0
The computer’s IP address should be configured using a static IP, as shown below.
(Note the address must be different than the skillet controller address).
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