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About kaiser_will

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  1. Subroutine

    There are solid fundamentals with every control platform that are required to provide working solutions.  A-B has very good literature, in my opinion, that seldom is vague (you might have to hunt for it, but the information is out there and readily available).  Often, the answer is like communicating with an autistic person...it is all in how you phrase the question. A web forum or a video will not replace slowing down, reading the literature, understanding how the system is functioning, taking a FREE online class, going to a FREE on-the-move lab, or attending a paid classroom instruction. One should never expect A results with C effort.
  2. Subroutine

    Logix500-based processors, like the Micro 1400, are I/O-based with a single routine (LAD x) that is the main routine.  Any other routines will need a JMP or JSR to send control to that routine.  If your new routine or the whole program is not functioning as expected, you are encouraged to put Nanny code that will track execution, such as counters with one shot bits. Refer to Chapter 17  http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1766-rm001_-en-p.pdf https://www.courses.psu.edu/e_met/e_met430_jar14/prgflo/jsr.html You have a subroutine that must not send control back to the main program if it does not fully complete.  For myself, a robust control program starts with a concise flowchart.  Chart the process and your inefficiencies should be glaringly obvious.  The system will only do what you tell it to do.
  3. Add pause botton Allen bradly SLC5/03

    "operator needs to get inside the enclosure while the machine is in auto mode".  If there is a potential for the operator to be injured, this approach is not acceptable.  The modern accepted solution is to control harmful energy when an operator enters a work area, such as a physical barrier/guard with a safety interlock switch that disables harmful energy when the interlock switch is opened.  Previously, this was done by running mainline contactors with their coil tied in with the interlock switch (open the gate, mainline contactor drops out and harmful energy is dissipated).  Today, the mainline contactor can be replaced with motor drives/servo controllers that support STO (safe torque off). https://ohsonline.com/Articles/2016/12/01/Protecting-Workers-from-Automated-Machine-Operations.aspx http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/safety-rm001_-en-p.pdf?utm_medium=Email&utm_source=EMEA_NL_ALL_AT_5_Jun16&utm_campaign=Corporate_EMEA_XX_XX_2016_Automation_Today&utm_content=EMEA_NL_Austria_AT_Jun16&s=1284661142&lid=30561&elqTrackId=3c28637972ce4337a8f3d616c96aa311&elq=5b39ebeab0d24a2e82d2482953ac3d66&elqaid=21537&elqat=1 Possibly, for the sake of the class, the instructor and instruction institution are accepting responsibility for unintended injury and just want you to add the buttons. 
  4. 5/04 Rebooting intermittenly

    There are multiple root-causes for a SLC rack to reboot.  Incoming power, poor rack power supply connections, rack slots not seated properly, rack backplane, rack power supply, processor, poor grounding practices.  Many of us have encountered some or all of these over our career. Unplanned restarts would force me to look heavily at the rack backplane and rack power supply.   However, your note that perception that the frequency of events appears to coincide with machine start/stop indicates a possible connection with system power.  If you have access to a power analyzer, such as a Dranetz, I would encourage you to connect to system primary power and analyze with machine running, stopped, and during start/stop events.  It could very well be poor incoming power quality (a power sag at machine start).  If you do not have a power analyzer, do you have an analog oscilloscope?  Meter power and grounding. Go online with the processor to look at the fault history...was there a fault event prior to the restart?
  5. pv plus 400

    Startup Error 31 => refer to page 24, Function Key Failure.  http://literature.rockwellautomation.com/idc/groups/literature/documents/in/2711p-in002_-en-p.pdf Have you experimented with how long you press the F1 key during startup?  You may be leaving depressed too long - PRESS F1 key during startup, do not HOLD F1 key during startup.
  6. pv plus 400

    For the newer PanelView Plus models, the application developer is highly encouraged to embed a "GoTo Configure Mode" button to allow for access to jump out of a running program and get to configuration.  Developers will often hide this button behind a password protected maintenance screen (or forget to add it all together).  This is Plan A. When the PV Plus 400 is powered up, there should be a WHITE box in the lower corner of the screen, lower-left.  Press this white box, which is only displayed for a few seconds after boot-up, to go into configuration mode.  This is Plan B.   Refer to page 218.  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2711p-um001_-en-p.pdf With the production process stopped, pull the HMI power plug and reseat to trigger a reboot.  Be ready to reach around front and press the white box during reboot.
  7. Kinetex 5500 Servo Drive Vertical Load

    Is the brake physically engaging?  Put a multimeter on the brake circuit and verify when it is engaging.  A digital camera and and a partner may be needed. Your stopping action is Decel & Disable, the same action for a number of faults (Lost Controller Connection, Motor Thermal Overload, etc.).  One would expect the stopping action to be correct.  Is it possible that your servo motor is not sized properly to stop and hold the load in the short span of time?  Is your machine design team using Motion Analyzer?
  8. Intermittent Alarms at HMI Start Up?

    When your process demonstrates "bogus" alarm events during startup, a startup inhibit process may need to be added to suppress all alarm events for a brief period during HMI startup.   You could...create a new PLC tag (HMI_Startup); add a HMI startup macro to energize HMI_Startup (this tag will only be ON at HMI power-up via the macro execution); add PLC code one-shot to seal in a startup timer (30 sec) and latch off HMI_Startup; add PLC code to energize new tag HMI_Startup_Disable that is energized when startup timer is timing; add normally-open HMI_Startup_Disable tag to every alarm event to suppress the alarm during startup. http://www.plctalk.net/qanda/archive/index.php/t-80134.html
  9. panelview 550 replacement

    Have  you read the PanelView Standard Migrating Plan?  http://literature.rockwellautomation.com/idc/groups/literature/documents/ap/2711p-ap001_-en-p.pdf Successful conversion of your old Standard application to FactoryTalk View Studio will be a function of how much detail is in the Standard application.  Do you have a new PView Plus 600 and a converted application to test?  Suggestion is made to get a new HMI unit and do a simple conversion and test.  https://www.rockwellautomation.com/resources/downloads/rockwellautomation/pdf/events/raotm/sessions/tech/T101MigratingyourHMIsystem.pdf
  10. Versamax, send datat on modbus rtu network

    VersaMax is a GE PLC platform.  Have you tried to post this in the GE forum here? You have a GE VersaMax PLC, a GE Proficy process SCADA PC, and they all communicate on a Modbus RTU network.  Where do you want to send the coil states on the Modbus RTU network?  Does this location have access from the Proficy SCADA PC?  If so, and if you desire no control other than to share data, then yes I see it possible for the Proficy SCADA PC to perform the function.
  11. Micrologix 1400 - HMI connection

    Refer to the attached Work Instruction for references on RSLinx. Your screenshot of PLC Channel 2 Configuration notes "DF1".  DF1 is a serial-type protocol but is NOT serial protocol; DF1 requires a different cable pinout. - Determine which PLC port you will utilize and configure in RSLogix500 - Cable the configured PLC port into the HMI - Configure RSLinx communication  Work Instruction - Allen-Bradley SLC Communications Setup.doc
  12. Micrologix 1400 - HMI connection

    Post a screenshot of your RSLinx configuration, please. Allen-Bradley/Rockwell utilizes RSLinx as the communication layer control for most of their PLCs.  Logix500/Logix5000/Studio5000 are the PLC programming packages, but all require RSLinx for communication.   MicroLogix 1400 has ports...RS-232 (8-pin mini-DIN), RS-232 (DB-9), Ethernet/IP, DH-485 (with use of 1763-NC01)  http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1761-sg001_-en-p.pdf Beijer iX-T5F-2 HMI has ports...Ethernet, Serial (RS-232, RS-422/485)  http://beijerinc.com/pdf/iX-T5F-2-datasheet.pdf Select your communication protcol based on your hardware => RS-232 is probably the best choice Configure the PLC serial port and the HMI serial port so that they can communicate.  How have you configured the Beijer HMI serial port?  HMI should have connected at COM1 or COM3 for RS-232. On the MicroLogix 1400, Channel 0 is isolated and Channel 2 is non-isolated.  Channel 0 is preferred for serial communication devices, as it is isolated and has driver control integrated.  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1766-um001_-en-p.pdf
  13. panelview 550 replacement

    The PanelView Standard Series, to which the PV550 was a member, went Silver Series (i.e., marked to become obsolete) starting in 2011/2012.  Rockwell/A-B typically phases out a product line over a number of years (Phase 1 - Make the plans known, Phase 2 - Internal components stopped production but can still buy new assemblies, Phase 3 - No new assemblies but will repair and support, Phase 4 - No repair but will support, Phase 5 - You had many years to be on your own). http://www.rockwellautomation.com/global/solutions-services/capabilities/migration-solutions/product-search/results.page A-B suggests migrating PV550-Keypad to PV Plus 600-Keypad & migrating PV550-Touch to PV Plus 600-Touch. Under similar circumstances, we exhausted buying up all surplus new-old-stock or used PV Standard models (Plan A).  Then get cracking on engineering up a migration path, either to the PV Plus 600 or a comparable manufacturer (Plan B).  Overall, there are a many HMI models that have the communication ports you desire. Do you have a concise audit of the models in-use and your spare parts in-house?  Page 11 has a breakdown of the PV550 alphabet soup part numbers and their communication options.  http://literature.rockwellautomation.com/idc/groups/literature/documents/td/2711-td007_-en-p.pdf
  14. Encoder Interrupt Help

    I believe the ML-series high-speed inputs utilize mapping the high-speed inputs into the HSC block which acts similar to the SLC-500 "IIM" (Immediate Input with Mask).  Since you are not using the HSC function, you could utilize the IIM function and get the code to respond to encoder pulse train input change.  Refer to page 229.  http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1762-rm001_-en-p.pdf The early I/O-based processors (SLC-500, PLC-5, early MicroLogix) read inputs, execute logic, update output table.  The IIM function interrupts the typical scan cycle when the designated input changes per the mask (one can mask out low or high bits to not respond to "noise"), executes that logic, then returns to where it was in the read/execute/update scan. With IIM functions, create a new ladder for the IIM code, set the ladder reference in the IIM block of the Settings. Essentially, the high-speed inputs if not utilized through the HSC block does not gain the advantages of high-speed control.  Using a high-speed function, such as the IIM, gets you the fast action you are looking for.
  15. Rockwell/Allen-Bradley has a development software package, Motion Analyzer, that is well suited for this application.  With the software, one can model the mechanics of an application and determine if the servo motor and controller are sized properly, if the VFD can move a load within a time period.  http://ab.rockwellautomation.com/Motion-Control/Motion-Analyzer-Software With A-B systems design, the critical components are servo motor/controller sizing (and if a gearbox is needed) & VFD motor/controller sizing (and if a gearbox is needed), as well as if the PLC controller can handle the motion tasks. One can download for free, trial run period is 30 days without license.  http://www.motion-analyzer.com/download.action Motion Analyzer is a software package developed by Electrical Engineers as a tool really for Mechanical Engineers.  So it ends up being overly complicated and cumbersome until you figure it out.  I have a simple Work Instruction, developed for our Mechanical Engineers to make the software application productive for them.   Work Instruction - Allen-Bradley Motion Analyzer Software.doc