Joe E.

It looks like that's the embedded I/O that's built into the processor, but it can still be affected by the end cap or bad connections on the Compact Bus. Try pturmel's suggestion and disconnect/re-connect all of the modules and the end cap. With power off, of course... Here's a tech note (access level: TechConnect): https://rockwellautomation.custhelp.com/app/answers/answer_view/a_id/466339/loc/en_US When you downloaded the new program, did you keep the same firmware version? I saw a Tech Note about an anomaly in v20.11-20.12 with these processors and their embedded I/O acting funny with firmware change (access level: Everyone): https://rockwellautomation.custhelp.com/app/answers/answer_view/a_id/498109/loc/en_US There's another anomaly caused by sending a "reset" command via the AOP or MSG instruction in v20.13 and earlier (access level : everyone): https://rockwellautomation.custhelp.com/app/answers/answer_view/a_id/519749/loc/en_US  

It may not apply to you guys, but there's a tech note (access level: TechConnect) about "1756-IB16ISOE Modules Randomly get 16#0204 on Power up and Download": https://rockwellautomation.custhelp.com/app/answers/answer_view/a_id/602867/loc/en_US#__highlight It's not a very well-edited tech note with some run-ons and incomplete sentences, but the gist is to flash the firmware of the modules to a different version. I'd check the release notes for the different FW versions of your modules to see if this issue is mentioned and which FW version it starts with. Then choose an older version (or a newer one if it's been fixed...).

I'm not aware of any such products. I know they go through a lot of testing and certification to be allowed for safety applications. For what you're doing, you might reach out to the safety relay's manufacturer representative to see if they could work out something like an open frame model that could attach to your board, but I would be really surprised if they did that unless your volume is really high.

Since you have to replace the CPU anyway, consider the 1747-AENTR. That would turn the SLC chassis into an EtherNet/IP node that the CLX can reach pretty easily. I've never used it in the real world, but when you put the 1747-AENTR into the ControlLogix project, you can set the chassis size up to 31, which is what the extended SLC chassis maxes out at. You can then populate the SLC chassis with its modules. Not sure how well that would work out, but see if you can configure it offline. You may need to search the "secondary market" for modules, though, especially for the -ASB which was discontinued back in 2013. The -AENTR is still made, but it's "Active Mature" and list price is VERY high. What SLC PLCs are in the racks? If they're 5/05s, you could turn them into IO processors of sorts and have the CLX use MSG instructions to read/write IO with the code running in the CLX. That's far less ideal a solution, but could work without having to buy expensive hardware that you're going to replace anyway. I did a migration from PLC-5 to ControlLogix and we ended up just replacing all the IO in one fell swoop since the changes to the system were so extensive already. I'd seriously consider that option as well if it's at all possible. It may be that you can get your hands on the COMMS modules easier than the new IO modules, especially analog ones. Those things are really hard to get over here.

I've used the IBH gateway before and it worked reasonably well but initial setup was a bit involved and it was expensive. I don't know how the price compares to an in-chassis module, but it does simplify things in that it isn't added to the PLC's hardware configuration.

Hmmmm....that's interesting. I've done serial to a PLC5 but not what you're proposing. I wouldn't have even thought it possible if you hadn't found the tech note. Have you been able to ask Red Lion support directly? If there's an HMI out there that could do that, Red Lion is probably it.

Hehe, wedding of the rabbit and the carp. I'm going to have to remember that one! I'm pretty sure that there are Modbus examples available for the S7, but I've never used them. I looked into them a little when I was testing Advanced HMI. As I recall, though, those examples were Modbus over Ethernet, not RS485. It's been a few years, though, so my memory may be faulty. Does the manufacturer of the power meter have any documentation or support for connecting to an S7?

One thing I've learned with FT View Studio is to reboot the PC. That sorts out a lot of bugs. It's not directly related to your issue, but I took a working project and made a change to it, recompiled and downloaded the runtime, and communications didn't work. I banged on it for an hour before rebooting and recompiling the mer. That's all I did: reboot and recompile. Then it worked fine. I'm sure you've done that by now, but reboot the PC and see if anything is different. Another thing to double check is your tag syntax in the display objects. To do that, create a blank display and add just a single indicator light or numeric display. While connected to the PLC, go to the connections tab of the object properties. Click the "..." button under "Tag" next to the "Value" field. The Tag Browser will open. Expand the PLC shortcut name and then "Online". Click "Refresh All Folders". If you don't have stuff there, then there's an issue. If you do...pick an appropriate tag and "OK". Then test the display with just that object. If that works, then you can double check the syntax of the other objects and verify they're correct. Edited to add: I should have asked earlier. Is this a new project or an existing one that you're editing?

When simulating/testing from  your PC, it uses the "Design (Local)" shortcut path. Have you set that?

In general, i/o tags in the Logix 5000 world that are marked "Input" are written by the field device and read by the PLC. Tags marked "Output" are written by the PLC and read by the field device.

So, I had a really long post underway, but it looks like you got it figured out. A few general tips: I generally use a NAT adapter for most things with VMs. I have a USB network adapter that I keep manually configured to connect to our automation devices. This frees up the built in network adapter for the office LAN. When I have to set up a device using BOOTP, I connect the USB NIC to the VM and use BOOTP inside the VM. I only use AB's BOOTP as a last resort. I've found IPAssign from Phoenix Contact to be better in general but it won't work with a few things. I've used NMap to do a ping scan when I know the subnet but not the actual IP address. I've used WireShark to find the IP address when I don't know the subnet. This works when the device is connecting to something else.

I haven't worked with this module before, but I have used other Flex IO Analog modules, so here's what I suggest. First, it's really...interesting...that the latest installation instructions are from 2022 while the latest user manual is from 1996. Anyway... Once you add the module to the I/O Configuration, double-click on it to open its Properties and go to the "Channels" section. Did you set that correctly? Looking at the module specifications sheet, I don't see a direct match to your RTD as far as temperature ranges, so you may be able to choose the closest. I wouldn't really expect that to work too well, though. Page 20 of the module specifications says it can handle 1 to 433Ω. Does your RTD fall within that range? The literature talks about using high-accuracy resistors to do a calibration. Based on that, here's how I would proceed: 1) Set the channel configuration to "Resistance" since none of the RTD options seem to match yours. 2) Note the resistance values of the RTD at the extremes of its range (use the spec sheet for the RTD to find those) 3) Get your hands on some resistors with those values. **If you can't find 2 matching resistors, get some that are within that range, as close to the ends as possible and calculate the temperature that corresponds to each resistor** 4) Connect the low-temperature resistance to the input and note the value in the Ch*Data tag. *Refer to the user manual and/or installation instructions for connection information, especially the difference between 2-wire and 3-wire connections*. This raw value becomes the Input_Low value for your scaling function. 5) Change to the high-temperature resistance and note the value in the Ch*Data tag. This raw value becomes the Input_High value for your scaling function. 6) Your Output_Low and Output_High values are the temperature values that correspond to the respective input resistances. 7) In previous versions of RSLogix, I'd say use an SCP instruction, but AB didn't include that in 5000. I've written an AOI that does it and I think AB has one as well that you can download. Or, you can write your own scaling code. Here's what I do, broken down into steps to make it easier to see what's happening: A) Input_SPAN = Input_High - Input_Low *Limit check your Input_SPAN to make sure it is not zero (so you don't fault the processor)* B) Output_SPAN = Output_High - Output_Low C) Input_PART = Input - Input_Low D) Input_RATIO = Input_PART / Input_SPAN E) Output_PART = Input_RATIO * Output_SPAN F) Output = Output_LOW + Output_PART That can mostly be combined into a CPT instruction as long as  you make sure the Input_SPAN isn't zero ahead of time. Let us know how you make out...

For accumulating timers like that, I generally use a high priority periodic task with its interval set appropriately. Put an ADD instruction behind whatever conditions you're checking for. It'll accumulate a LONG time with a DINT tag. If I want to track how long the machine was in different modes, I just put an XIC with the bit for that mode in front of the ADD instruction. You can log the time or do whatever you need to with it at the end of the day. If the same code in other PLCs works to get the system time but not this one...but this one works fine otherwise...I'm not sure what to say. What PLCs do the other machines have? When you go online with the processor and go to the Date/Time tab of the Controller Properties, are the date and time correct? What goes wrong when you try the GSV instruction? Do you just get bad data back or does the instruction fail?

I wish.... I haven't used one in a while, but I remember the built in alarm displays were too small and lo-res to be useful. Couldn't even read the captions on the buttons. I only used it to display information and a couple of pushbuttons, not data entry, so I didn't see how small the keypad was. I just poked around in FT View Studio and I don't see a way to change the keypad. You may be able to edit the alarm banner, though.

I don't have access to the software any more, so I'm going from memory here...and it's been about 2.5 years since I worked with it. Inside the "Set PG/PC Interface" dialog, there's a place somewhere to select the USB PC adapter instead of RS-232. Make sure you've selected the right one. When you're picking the driver, make sure you pick one that's "<Active>" too. When you're in the settings area, there's a button to "detect network settings" or similar. That will tell you the configuration of the network that the PC adapter is connected to. Write them down (or take a screenshot) and then manually set the PC adapter to those settings. I've found that setting it to Auto usually works but it's slower because it has to query the network every time there's a demand for a connection (like switching from offline to online inside the FB/FC viewer). As I recall, the detect network settings button is behind the properties of the PC Adapter.Auto driver...but I could be off on that. I'd also verify a few other things. 1) Can you connect to another PLC with the PC adapter? If so, you know your hardware is good. Remember, though, that the network settings could very well be different between PLCs. 2) Are you connecting directly to the PLC or to the pass-through DE9 connector on the back of a Profibus connector? If you're connecting to the pass-through port, try connecting directly to the PLC. 3) Verify that there aren't any other adapters (like a miniature null modem...ask me how I know!) already connected to the PLC. If there is (or was) a null modem adapter plugged in and you accidentally plugged your PC adapter into it, you just fried your PC adapter and will need to replace it. Try the PLC's other DP port as well.

Hmm...it's been a while since I worked with a PV Standard so I pulled up the manual. They do have a battery for the RTC, but the manual says it's not used for application backup. The memory card is optional.  The manual says that the application is stored on EEPROM flash memory, so it shouldn't just lose it like that. The help for fault 1110 ("No valid application") is simply to download the application to the terminal. Interestingly, there's a Tech Note (access level: TechConnect for some unknown reason) that repeats the exact wording in the user manual. Was the machine operational when it was shut down? It seems weird for it to lose its program like that. I'm not finding any other Tech Notes on it.

Check this out: https://www.plccable.com/ge-quickpanel-quickdesigner-proficy-me-view-gp-propb-hmi-proface-usb-gpw-cb03-a/ I've actually used it at my previous location for some old GE/Proface/QuickPanel HMIs. It worked well.

Check parameters d007, d008, and d009 for the 3 most recent fault codes, with d007 being the most recent. Refer to the user manual too: https://literature.rockwellautomation.com/idc/groups/literature/documents/um/22b-um001_-en-e.pdf You may also be able to use DriveTools/DriveExecutive/DriveObserver to do some diagnostics too. It's been a long time since I opened those programs, so I can't help you much there. I seem to remember, though, that the software would give you more fault history than the parameters. I could be mis-remembering that, though.

Yes, you can. It will be an SSV instruction. Use the Class Name "Module", Instance Name of the module, Attribute Name "Mode". For "Source", use a tag with bit 2 set. For more info, put an SSV instruction in your program, highlight it, and hit "F1" to open the help. Then scroll down to the bottom and select "GSV/SSV Objects" and then scroll down to click the link "Module". Here's a screenshot of two SSV instructions that inhibit and un-inhibit a module: There should be rung conditions to enable it as needed, of course. Probably couple the SSV with a GSV to verify it has changed state so you can disable the SSV instruction. That's all based on v32 of Logix Designer.

Here you go. Two versions: Portrait and Landscape. 4875v001.pdf 4875v001_L.pdf

It's been about 7 years for me since I set up a Prosoft PLX31-EIP-PND module to communicate between a ControlLogix and an S7-300. The software was free and easy (on the AB side). I had to get Prosoft support involved to get the Siemens side working (their instructions and samples were in TIA Portal while our system was Simatic Manager), but it worked very well once it was going. Be aware that it will work with an S7-300 with onboard Profinet but the add-on network module has 2 versions. One will work with this while the other won't. I don't remember the catalog numbers or have the ability to look them up, but the cheaper one didn't support I/O and that's how the Prosoft module shows up to the S7. The more expensive one was supposed to work but we didn't have any to test. This is all in the S7-300 world. I don't know how it would work to use it in Portal.

So, a quick followup. I opened up my Win10 VM again this morning and tried to connect to the 5/05 but RSLinx couldn't get the COM port, said it was busy. The Keyspan utility showed it bouncing between idle and busy about every second. I ended up having to delete the driver in RSLinx and set it up again from scratch. Even so, auto-configure took several tries to work. I fired up my Win7 VM (same Win10 host) and it connected and worked out of the box with no issues. There may be an issue with the Keyspan driver (I'm using the latest one) or with how Windows 10 is handling things. I'll definitely be keeping my Win7 VM...

My go-to USB-serial adapter has been the Keyspan (Tripplite) USA-19HS for over a decade. This thread made me realize that I'd never tested it in Windows 10, so I just did. It took a reboot and a few tries in RSLinx Classic, but I did get it to  connect to a SLC 5/05's serial port. I've used it in the past to connect to a Watlow F4 as well, but using Windows 7 on a different laptop. My software is in a Windows 10 virtual machine running on a Windows 10 host. The last time I used a Watlow controller was with Windows 7 VM on a Windows 7 host.  

I would suggest a PowerFlex 525 with encoder option module...but they're probably not any easier get. Is it going to be a stand-alone drive or integrated into a Logix project?

Interesting, and I agree to an extent. It depends on the speed of the movement and how busy the network is. One of the places I've used one was on a dancer arm riding on bimetallic strip to detect delamination and ripple. The dancer mechanism wasn't the greatest but the encoder did really well. The network had a ControlLogix PLC, 7 remote IO racks, 5 HMIs, 5 or 6 drives (VFD, DC), a PC (doing servo control), another PC doing data logging, and a SCADA PC. The strip was only running at about 40 ft/min, though, so it wasn't a super high speed thing. In a true motion control setting, I don't think I'd use them either. In your customer's application, the issue with 0-10V signal may just be inability to get an analog input module for the PLC. The last time I had a 5069 analog module quoted, the lead time was long and fluid.