JRoss

No problem. That's a common mistake in the Mitsubishi world, particularly with new users. Especially watch out for multiplication and division (16 and 32-bit), that one still gets me if I'm not careful.

That's because you're using a 32-bit instruction on a 16-bit register. Change the instruction from DMOV to MOV.

The settings I'm referring to are hidden by default. To see them, you have to expand the MAM block. There should be a little arrow in the bottom corner. The help manual gives you an idea of what they do. If you post a screenshot of the expanded MAM blocks, I can help you figure out what they're set up to do.

Depends on the parameters of the instruction. IIRC, you can set the move to either take over the axis, add to the axis, or go into the execution buffer pending completion of the previous move.

Didn't even know it existed, I'll have to check it out.

HMI vs SCADA depends on what you want to do with it. Generally speaking, SCADA is more complex to deploy, but gives you a lot more capability, though things have been converging lately. As in HMIs are getting more capable and SCADA is getting easier and cheaper. If you only need a display at one location (especially if that location is on the production floor) and don't need a historian, I'll second (third?) a Red Lion HMI.

+1 on posting the program. If the output light is on, it's almost always on in the program. Yes, there's a slight chance it's hardware, but if you transferred the program to a second PLC and got the same behavior, you've eliminated that possibility.

I haven't really tested it with other HMIs, since the only times I've used a non-AB HMI with an AB PLC are new installations. If I had to guess, I would think that the brand of HMI doesn't really matter. I think the PLC simply recognizes when an outside source accesses a tag and flags it so you can't accidentally delete it. It's not a perfect system, and if anything it's overcautious. It's common to clean out a program and still have a handful of tags that it won't let you delete online just because at some point in the past something tried to access it.

I don't think there is a functional difference between a Jog and a Speed Control mode for something as simple as that.

In RS Logix 5000, open the tag database and select the filters at the top. There is a filter for "unused". I use it all the time to clean out programs. But as Michael said, be aware of tags that may be in the PLC simply for use by the HMI. If you do this online, the software won't let you delete tags that are used by the HMI.

All of AB's software downloads are available at this link: http://compatibility.rockwellautomation.com/Pages/MultiProductDownload.aspx It looks like Panelbuilder32 is not free, but login and see. I have a toolkit, so I get access to everything and can't test it myself. I seem to remember a period of time where it was a available for free from a different location on their website, but they appear to have taken that down.

Another mantra.... save everything. Digital storage is a lot cheaper than all the time spent re-inventing the wheel. I add an "Archive" folder to all my project folders where I put old versions. I create new copies anytime I start making sweeping changes, just in case I want to roll it back. I also create a new copy anytime I make any changes after I've sent the program to a customer. That way I can roll back to the last known working version if my changes don't work out. Has saved me a number of times.

That's the adapter I use. I suspect there is a machine setup screen that lets you select metric versus SAE, and that the default is metric. Unlike AB, in Mitsubishi a saved program doesn't necessarily include data memory, and it doesn't get downloaded by default.