In the OP it wasn't clear if this PLC/microcontroller problem was caused by or co-incidental with the mechanical problem you mentioned. The filler has to have black start capability and if the PLC and connected controllers are all live and communicating, it has to be a synchronization issue. Some transducer is out of sync.
Just a thought.
P.S. I'm assuming it was running previously, and I know you should never assume anything.:thumb:
You are not far off . (and no , it does not have 'black start'!!) ((Sheeeesh))
Now that it's fixed , I can tell you the exact failure tree.
:thumb:WWWOOOOOOOOOOOOOHOOOOOOOOOOOOOO IT"S FIXED !!
The magic was only partially mine , but we have avoided the 10,000$ step !!!
So this will be a wall of text but I can now explain.
When a bottle enters the filler , basically a 'gear' (called a starwheel) feeds a bottle onto a bottle sized platform on the filler....this platform then pushes the bottle up to a rubber 'bell housing"....this actually centers the bottle in relation to the fill tube , which comes down into the bottle from the top.
The issue we had on Monday was that the rubber bell bell housing stuck up , so the bottle was not centered.The fill tube then came down , and managed to exactly jam on the lip of the bottle.The machine then hard stopped , with all valves stuck in current position.
This allowed beer to leave the bowl (holding tank) and co2 to openly jet through the now empty top of the bowl.
The co2 cooled the top bowl temperature gauge past it's limit (low range error)
At this point the serial interface module for that sensor lost it's mind.
It corrupted every single device down the Ethernet chain , right into the PLC.
What a week , I'm getting drunk right efffing now !