How to reset a roll forming machines PLC controller

Resetting a roll forming machine's PLC (Programmable Logic Controller) depends on the type of PLC, the manufacturer, and the specific system used. However,

1. Identify the Type of PLC

• Determine the make and model of the PLC. This information is usually found on the controller or in the machine’s manual. Common brands include Siemens, Allen-Bradley, Mitsubishi, and Omron.

2. Consult the Machine’s Manual

• The machine manual often provides detailed instructions for resetting the PLC controller. Each manufacturer may have different steps, so it’s essential to consult the manual for specific instructions related to your machine.

3. Access the PLC Interface

• Most PLC controllers can be reset through their Human-Machine Interface (HMI) or control panel. Depending on your system, this could involve accessing the PLC through:
  • A touch screen
  • A physical control panel on the machine
  • A computer or laptop connected to the PLC via communication software.

4. Perform a Soft Reset (Reboot)

• If the machine is simply frozen or stuck, a soft reset can often fix the issue without erasing any programmed data. Here’s how:
  • Power Cycle: Turn off the machine or PLC controller. Wait for 30 seconds to 1 minute and then turn it back on.
  • HMI or Control Panel: Navigate to the "Reset" or "Reboot" option from the control screen, if available.

5. Perform a Hard Reset (Factory Reset)

• A hard reset will erase the program and restore the PLC to its factory settings. This should only be done if absolutely necessary, as you’ll lose all programmed instructions.
• Method:
  • Use the software: Many PLCs require connection to a programming tool or software (like TIA Portal for Siemens or RSLogix for Allen-Bradley). The reset function is often found in the software’s maintenance or troubleshooting section.
  • Physical Reset Button: Some PLCs have a physical reset button. Hold the button for a specified time (e.g., 5–10 seconds) to reset the system.
  • Power On Reset Sequence: In some cases, you’ll need to hold specific buttons or switches on the control panel while powering the machine back on.

6. Verify and Test After Reset

• After performing a reset, verify that the machine's PLC is functioning correctly. This may involve:
  • Re-downloading the PLC program from a backup or manually reprogramming it.
  • Running test operations on the roll forming machine to ensure all processes are functioning as expected.

7. Consult a Technician

• If you’re unsure about resetting the PLC or face issues after the reset, it’s advisable to contact a technician or the machine manufacturer for guidance.