CERM Counter System troubleshooting

CERM Counter System troubleshooting - pg. 1/9

CERM Counter System troubleshooting

In this document, we will try to clarify different solutions for problems with the CERM Counter System after installation.

Contents

Hardware modules (in the gray box) .................................................................................................................................... 2

Inside the gray box (version 1) ......................................................................................................................................... 2

Checks ..............................................................................................................................................................................4

Check if the sensor receiver receives signals .................................................................................................................4

Check if the counter is started .......................................................................................................................................4

Check the fuses ............................................................................................................................................................. 5

Check the network connection ....................................................................................................................................... 6

Check the network connection – Newer PLC modules .................................................................................................... 6

Voltage differences – ONLY U.S...................................................................................................................................... 7

Check if there is a magnetic device in the sensor neighborhood ..................................................................................... 7

UPS Fuse ....................................................................................................................................................................... 7

Damage to sensors ........................................................................................................................................................ 8

Connection of the PLC Modules...................................................................................................................................... 8

‘SF’ LED lights up on PLC module .................................................................................................................................... 9

Good/Bad Wiring ............................................................................................................................................................ 9


Hardware modules (in the gray box) The gray box contains 4 principal modules:

• PLC module ▪ Sensor receiver ▪ Counter ▪ Network connector

• Power module ▪ Transformer ▪ Power indicator ▪ UPS

• Fuse module • Cageclamp module(s)

The gray box, somewhere on a wall in

your company

Inside the gray box (version 1)


In the second version of the gray box, the Power Module looks slightly different, but has exactly the same components:

Power Indicator UPS Transformator

Also, the fuse module looks slightly different in the 2nd version, especially the black fuses:

Fuse Module (Complete) Fuse Module (Black fuses removed)

Cabling has changed here compared to the first version of the gray box. Only 1 wire arrives, and 2 wires leave from the fuse holders. The fuse holders are connected with a red connector, which you can see on the right picture.

RED CONNECTOR


Checks Do all these hardware checks before calling CERM! This are basic hardware checks that we can’t do remote.

Check if the sensor receiver receives signals

Step 1: Connect one end with a + clamp Step 2: Connect the other end with the

pulse clamp Result: A green LED lights up on the sensor receiver

Check if the counter is started

The counter can be started or stopped. When the counter is stopped, an orange LED lights up.

The counter is STARTED The counter is STOPPED


Check the fuses

There are 3 fuses in the gray box.

• General fuse The main fuse has to be turned ON. When the main fuse is turned OFF, the gray box could still be working. This is because the power indicator changes his source of electricity to the UPS. But this will work only for a few hours.

Turned OFF Turned ON

• Counter fuse and network connector fuse

Next to the main fuse, there are 2 small fuses. One for the sensor receiver and one for the network connector and counter in the PLC module. Known issues: ▪ A red LED lights up

→ a fuse is broken → change it with a new fuse.(*)

▪ Everything works, except the counter and network connector OR the sensor receiver doesn’t work → A wrapping isn’t properly fixed → push on top of the wrapping.

Normal fuses One broken fuse You can find the fuse here The fuse

(*)Type of the fuse: Check the number on the bottom of the wrapping. 50F14: 500mA 50F17, 3 or less cageclamps (20 counters): 500mA 50F17, 4 cageclamps (30 counters): 1A ‘Fast-acting’ fuses are required.


Check the network connection

If there is something wrong with the network connection, the ‘BF’ red LED lights up on the network connector. The green LED ‘RxTx’ lights up when there is a network connection.

Known issues:

• No network connection → Check network connection on both sides of the cable. The cable has to be in the same physical network as the datacap, only the IP range is different.

No network connection Check network cable

on network connector

Check the network connection – Newer PLC modules

To check the connection on newer PLC modules, the black cover with the inscription “SIMATIC S7-1500” needs to be opened gently.

Gently open the black cover with the inscription

“SIMATIC S7-1500” The orange LINK LED lights up when there is a

network connection.


Voltage differences – ONLY U.S.

There is a slider on top of the transformator to change the input voltage from 230V to 110V.

Check if there is a magnetic device in the sensor neighborhood

If you have one of these problems:

• At random moments you don’t receive counter data • The counter data is not correct

Check if there is a magnetic device (radio, electronic engine,…) in the sensor neighborhood. The sensor is an induction sensor, a magnetic field can disturb the signal.

UPS Fuse

There is a small UPS inside the counter box. This UPS also has a fuse. If a red led lights up (see picture below),the fuse is broken. However, this should not influence the functionality of the counter system as long as there is power.

This led lights up when the UPS fuse is broken You can find the UPS fuse here


Damage to sensors

Check your sensors, there shouldn’t be damage to the sensors. This is what we call a broken sensor:

The damage can be hidden behind the nuts.

Connection of the PLC Modules

The PLC modules are connected with a connector at the back of the modules.

One connector not connected 2 connecters correctly connected

To check these connectors, the PLC modules can be loosened by loosening a screw at the bottom of the modules


‘SF’ LED lights up on PLC module

The SF Indicator means ‘System Failure’. You will need to contact Cerm to solve this.

Good/Bad Wiring

When a Good/Bad switch is used, cabling need to be done like in the picture below. When for a press no Good/Bad signal is necessary (for example Press 3 in the picture), the port for the Good/Bad wire need to stay open. The port cannot be used for other purposes!

Documents

CERM Counter System troubleshooting