Joe E.

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About Joe E.

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  1. Help with PLC communication basics

    That's a big task... My suggestion for right now is to get a MicroLogix 1100 instead of the 1400. The 1100 can be programmed with the free version of RSLogix 500. It can communicate to  your data collection software at the same time as the PC running RSLogix, both over Ethernet. There are drivers available from Advanced HMI, Peak HMI, Ingear, and Ignition, to name a few. Advanced HMI is free and will get you going pretty quickly developing programs in Visual Studio to talk to your AB PLC. I don't have any personal experience with the others, though we do have a system on which the OEM used Ingear's software to manage a machine vision system that talks to a ControlLogix PLC. You'll have to figure out which system works best for you, based on the installed base of the clients you plan to work with. For example, if you wanted to run a demo in our facility, we would like to see you connect to: 1) AB ControlLogix/CompactLogix via Ethernet 2) AB MicroLogix 1400 via Ethernet 3) Siemens S7-300 via Ethernet (Profinet) 4) Siemens S7-1200/1500 via Ethernet (Profinet) 5) AB SLC 5/04 via DH+ gateway connected to Ethernet network 6) AB PLC-5 via DH+ gateway connected to Ethernet network 7) Siemens S7-300 via Profibus DP Just the first 4 options (the easiest) may be daunting. And that doesn't include the other models that we know would be too hard or simply impossible. Getting an ML1100 will get you started, but I think you'll need a fairly significant investment in PLC programming software to do this right.
  2. My Model Train Project

    Last year, I had to program a mechanism that would pick up an engine bearing, rotate it, and put it back down. It's a simple sequence with 3 pneumatic cylinders, 2 solenoid coils and 2 sensors per cylinder. I made a simple state diagram flow chart to illustrate the process so it was easier to follow and easier to code. Instead of using a bit for each state, I used an integer register. Each step's completion wrote the next step's value into that register. The value for each step is shown on the flow chart. The text inside the flow chart boxes tells me what state each solenoid valve output needs to be in during that step while the text on the arrows tells me what sensor condition triggers the next step. Facer_07_UnloadRotatorSequence.pdf Note that the flow chart shows how the system works in auto when everything works. I don't have great software for making flowcharts, so even making this was a pain. I didn't have time to add manual transitions and error conditions. Thankfully, I had just enough time with the machine before it went into the line to do some extensive simulation and testing to add code to handle errors and interruptions. At the end of the sequence code, there's a rung controlling an intermediate bit for each output that has a branch for each step in the sequence. This bit is used later to control the PLC output, based on whether the mechanism is in auto or manual. Here are the rungs for the first 2 steps in the sequence (wait for a part, then move down). The "BrgUnldRot_Posxx" bits are controlled elsewhere by looking at the cylinder sensors to determine which position the rotator is in. I use that information in another section of the code to make better transitions between manual and auto modes. I added a timer to each step, so I could slow it down during debug/development. It doesn't need time delays while actually running, so the timer presets are 0. They can be easily changed later if needed.   This rung controls the "auto down" bit, which is used later to control the actual PLC output:   Here's the rung that actually controls the PLC output:
  3. PLC 5 to Compact Logix with a Message?

    Yes, it is possible. We have several places in our plant where a ControlLogix is reading information from a PLC-5 via DH+. Which PLC-5 do you have? Does it have an Ethernet port or just the RIO/DH+ and serial ports?
  4. Panelview plus 1000

    First, what are you trying to accomplish? If you're trying to make a change, it will be FAR easier if you have the project archive (it will be a file with an apa extension). In fact, it may not be possible at all without it. If it's a new HMI, it will have BOOTP enabled, so you can use a BOOTP server to set the IP address. If it's an existing system, and if your application developer was kind, they included a "Shutdown" button somewhere on the HMI, possibly on a password-protected screen. If not, some PV+ HMIs will flash a small white square in a lower corner of the display while it's booting up. If you see that square, touch it. Either method will get you to the operating system of the HMI. Once on the OS screen, the IP address and subnet mask will be displayed in the lower left corner. To change it, go to Terminal Settings -> Networks and Communications -> Network Connections -> Network Adapters. The built-in network adapter will be selected in the list box. Touch the "IP Address" button to open the IP address screen. Push the button next to each cell to change that cell (IP Address, Subnet Mask, Gateway). If you can't get to the shutdown/OS screen, it's a lot harder. Is it connected to a PLC? If so, do you know the IP address of the PLC? You can use Nmap or Zenmap to run a ping scan of the same subnet as the PLC. That should turn up the HMI.
  5. faulted processor

    I ran a block consistency check and it found references to DB49, DB10640, FB49, and FB640 that don't exist in the project. I didn't try to track those down since they are probably unrelated to this issue but you might want to look for them. I also generated a cross-reference and found one place, in FB600, where the x-ref found a reference to "DB?". It looks like it's using pointers, but that's something I've never done in the Siemens world, so I can't decipher that easily. FB600 is called 4 times, once each with instance DBs 1002, 1000, 1006, and 1004. This could get difficult to track down, especially not being online with the machine. For the calls to FB600, the DB numbers are passed in as constants, but either the source or destination word for each CALL is a variable that comes from the calculations preceding each CALL instructions. It's possible that there could be an issue with that calculation causing the block moves inside FB600 to reach out to non-existent locations. Is it ok to stop the PLC during its operation? If so, you could delete OB121 from the PLC and let it fault. You should be able to go right to the problem from there, with the PLC in STOP mode so nothing is changing. I would be careful, though, to make sure the machine won't do bad things if the PLC faults mid-cycle. As an alternative, you can try to add some diagnostic code to OB121 such that it copies its interface area to a global DB that you create and can then monitor. I remember trying that once with mixed results. I also remember the variable names inside OB121 being far more useful than the ones I see in your program. The project has two Simatic stations in it, each with what looks like the same PLC and IM stations but one also has a G120 drive and a DP/DP coupler. Are there 2 PLCs in the machine, or is one of the stations in the project a backup of the other with some edits done?
  6. faulted processor

    Hmmm....I had a few minutes, so I opened up your archive. You don't have a DB260 or DB262 at all. Does your online/offline compare show any discrepancies? Like blocks that are online only?
  7. faulted processor

    I'm not a super-expert on Siemens, but I have worked with them. It looks like you have 2 errors that have shown up in your buffer, twice each, that would involve OB121. Both are talking about access to a global DB, address 260 for one and 262 for the other. The others look like communications faults to various stations may not be related to this. Does your project include a DB260 or DB262? If so, find all of the places where they, or their sub-elements, are called or referenced and verify that the addresses are all valid. If any of the references to a DB use pointers or indirection, trace the calculations of the indirection to verify they're right and limit check them to appropriate values. In the cross-reference, look also at any entries that show as "DB?". That indicates some ambiguity in the individual calls. I've seen a couple of examples of that being done that I can go into in more detail at another time.
  8. faulted processor

    While connected and online with the PLC, open the online blocks folder (select the Blocks folder of the project and click on the "online" button in the toolbar). Make sure OB121 is present in the processor, not just in the project. You can also select the blocks folder in the project tree and do an online/offline compare. It will tell you if OB121 is missing online. Note: OB121 does not fix the actual root problem. You need to find the actual issue and correct it. All the presence of OB121 will do is allow the PLC to keep running, which may NOT be the best and safest outcome in your situation.
  9. How to update FactoryTalk View Studio?

    I would first try the link that says "Download Software" under "General". You may also need the patch roll-up. If you're using View Point, grab that too. I don't know what WIN-911 is, so I can't advise you on that.
  10. Old panelview 1000 needs to be replaced

    We have had good success using a ProSoft AN-X2-AB-DHRIO to connect a PV+7 to a PLC-5 via DH+. The PV+6 are going towards end-of-life and are priced accordingly, so compare the price of a PV+6 with a DH+ module to the PV+7 with the ProSoft gateway. Remember that you won't be able to use the cheaper PV+6 Compact since it doesn't support option boards. For the fun of it, I just configured one of each, a PV+6 standard and a PV+7, both 10" to get list prices. PV+6: 2711P-T10C4D8 (end of life and to be discontinued 9/30/2020), $6,042.74 with 2711P-RN6 DH+/DH-485/RIO comm module (active product), $549.15, total of about $6600 list price. PV+7: 2711P-T10C21D8S (active product), $2678.00, with ProSoft gateway module, about $2,200, total of about $4900 list price.  
  11. Image primitive for Red Lion Crimson 2.0

    What happens when you run that "makepic" command from command prompt? I think I do see a problem. Your source image filenames don't look right. Go to that directory in Windows Explorer. Open the "Organize" menu and select "Folder and search options". On the "View" tab, un-check "Hide extensions for known file types" and click "OK". Look at the filenames of your images. If you see this before showing extensions... ....and this after... ...then I think I see what's wrong. With the "Hide extensions..." option UN-CHECKED, rename the image file Picture1.bmp like this... ...and try this command: makepic C:\MyImages\picture1.bmp 1 NOTE: I have NOT tried any of this, so I don't know if I'm on the right track at all, so YMMV.   I will also say that Red Lion has great support. If you reach out to them they will get it sorted out for you.
  12. Looking for PanelView suggestions

    If you can get away with the HMI only talking to one of the PLCs (which I would think you could since they're using MSG instructions to get the analog information from one to the other) stick with the "standard" PV+7. A 15" Standard lists for about $4300 while the Performance version lists for about $6200.
  13. Looking for PanelView suggestions

    The base model does not. If you get the PV+7, go with the "Performance" model to connect to 2 PLCs at the same time. I've never used a PV+ to transfer data from one PLC to another, so I can't help you get that working (or if it will). Do you need the HMI to talk to both at the same time other than passing information back and forth? If not, the ML1400 supports messaging between the PLCs directly. If you just need more I/O, you can get I/O expansions modules to add to the ML1400. If the additional I/O is in a remote location, however, that won't work since the ML series doesn't support distributed I/O.
  14. Looking for PanelView suggestions

    I've never worked in a washdown environment but we do have our own wastewater treatment system. It's kind of a mess with multiple partial upgrades over the years. Overall control is by a CompactLogix with a Schneider Magellis HMI (not our pick, the subcontractor brought it in without in-plant automation folks having any say or warning ahead of time). There are also 3 MicroLogix 1100 PLCs and a 6" Red Lion G3 HMI, all communicating over Ethernet/IP. The Red Lion and one of the ML1100s are in a cabinet that controls the addition of caustic solution and both have been taken out by caustic that leaked into the cabinet. We were very impressed that the PLC and HMI both still worked for at least 6 months after having caustic in them (we bought new ones to have programmed and ready when they did finally fail since we couldn't get a production window to change them out until they died). With all that said, I will echo what 5618 said about the learning curve with FT View Studio. I developed a STRONG dislike for it on my first project 8 years ago that hasn't fully gone away. There are still "gotcha" bugs and unexplainable software crashes. My early experience with that software crashing and failing is what pushed me to use virtual machines. Other software packages have since reinforced that need, but FTView Studio (RSView Studio back then) was the first one. To be fair, I've had fewer issues since upgrading to v6 a few years ago (we're on 8.2 right now) but there are still issues. I would ask if the customer has a preference for which line of PanelViews; there are several. If the customer asks for a PanelView+, I would suggest the PV+7, just because it's their current product of that class. I generally prefer the screw-type clamps over the cam-types but we haven't had any trouble with the PV+ HMIs with cam clamps. We don't have a lot of PV+7s in service (just a handful, mostly smaller with one 10" and one 9") but they have done well so far. We have 15 or 20 PV+6s in service that have been bullet proof as long as no-one slams a wrench or broom handle into them. I can't say the same for the SIemens MP HMIs... I can't speak to the PV800 line, but if they're anything at all like the PV+ Compacts that were initially released with the MicroLogix 800 PLCs, I would avoid them. We bought a few different versions of the PV Compact as an experiment back then and we were not impressed.
  15. powerflex755

    Try these: Reference Manual: Programming Manual: