Joe E.

 I just remembered a previous project that we ended up bringing in a contractor to complete. We connected 2 Eurotherm temperature controllers to a ControlLogix PLC. Since the controllers only supported Modbus and not Ethernet, we used the Red Lion G310 HMI that was already present as a gateway. It worked well and easily. If you have (or plan to add) a Red Lion product to the line, it may be able to handle the comms.

You can look in the SLC 5/04 program and the program from any HMI to see how/where those N7 registers are used. That will help you figure out what you need to read from the Honeywell controllers. Since you're starting over from scratch, you may also be able to improve the operation of the system by retrieving more data points than the old PLC was and maybe use the PLC for setpoint changes and such if that's allowed.

Did you swap the 2nd and 3rd drives? If the problem follows the drive (in other words, if drive #2 powers up in the #3 position),  you've isolated the drive itself and not the power supply to it. I don't know about the Kinetix 5500, but the 5300 we just quoted had about a 3 month lead time...

The "2" means it has integrated safety over Ethernet/IP instead of hardwired safety. List price is the same.

I don't know for sure. We had some come in  on a machine but I didn't dig into them too deeply. They also didn't use that jumper system on the main input power. Check this manual: https://literature.rockwellautomation.com/idc/groups/literature/documents/um/2198-um001_-en-p.pdf Page 58 identifies the connectors. If you're not using the separate 24V power connector, then it needs the 480V to light up. You could check the connectors on the top to make sure the 480 is making it to the 3rd drive. Maybe swap it with its neighbor real quick (don't connect anything other than the main and 24V power) and see if the problem stays put.  

I'm pretty sure these have a separate 24VDC control power supply connector. Do you have power on that connector? If so, I would suspect a dead drive.

We all started out clueless with PLCs at some point, so: welcome! I would suggest reaching out to a local integrator with S7-200 experience. Maybe ask your local Siemens distributor for a referral. I would want the integrator to first connect to the PLC and do some diagnostics, including generating a backup of the existing program. I've worked with a bunch of S7-300 and S7-400 processors and a little with the newer 1500s, but never a 200 so I don't know what to tell you to check specifically. Once you have a backup of the program, the integrator should be able to download it to a replacement and, if that's the problem, you'll be back in business. Even if that works, I would seriously consider replacing the controls with a modern system.

While the drive is running, check the display parameters (I don't remember which one) for the output current and see where it is compared to the other units running at the same speed. And maybe confirm the current reading with a clamp-on meter (being aware that the readings won't match since the clamp-on meter is only looking at one phase and they aren't as accurate when reading VFD current). Reducing the speed of a pump will reduce the torque (and therefore the current). Your results make me more suspicious of a mechanical issue in the pump or motor. I know you know this, but production also needs to know that even though it's running without faulting right now you haven't actually fixed anything. If a component (electrical or mechanical) is in the process of failing, you may have bought some time but this problem will almost certainly come back.

So, for data collection I would investigate the Red Lion Data Station. If that will do what you want, I would very seriously consider replacing the DH485 HMI with a Red Lion  HMI because the HMI can do the data stuff too. The Data Station is basically an HMI without the screen. For remote access via RSLogix...that's harder. At my previous location, we had some SLC 5/04s on DH+ that we were able to connect to another machine on the same line that had a DH/RIO module in a ControlLogix rack. If the ControlLogix was networked, we could get to the SLC via the backplane. I don't know of a good way to do that with a SLC 5/03 though. Mickey's suggestion is worth a try and may let you get online with it as well as have a SCADA get data. What were you planning to use for data collection? Do you already have a SCADA system running?

What are you hoping to accomplish with the connection? Gather data, connect with RSLogix, something else?

If you find differences between them, use CCW to backup the current configuration of the drive before making any changes...just in case. If the only differences are in the tuning parameters and the motors are at least nominally identical, I wouldn't change any parameters without investigating a bunch of other things first. I'd check to see if the pump/motor has been replaced recently. We have a machine here where a NEMA Design B motor was replaced with a Design D (or maybe the other way around....) and it kept tripping the overloads. The other nameplate information was identical, so it wasn't obvious at first glance what the problem was. Something like that could cause a tuning issue. But...my first suspicion is still a mechanical issue or damage to the motor or wiring.

Gotcha. For fault 12 HW OverCurrent, the manual (Page 321) says: https://literature.rockwellautomation.com/idc/groups/literature/documents/pm/750-pm001_-en-p.pdf  

Is this a new installation? Is it 4 drives connected to 4 identical motors? If it's an existing system that started showing this fault, I would look at the motor and its coupled load. If it's a new system, the motors may not be perfectly identical enough for identical tuning parameters to work well. In that case, doing the static tune on the problem drive may sort it out.

Have you taken a look at the installation instructions? https://literature.rockwellautomation.com/idc/groups/literature/documents/in/1738-in023_-en-e.pdf They also have a smaller document that just identifies each pin on each connector: https://literature.rockwellautomation.com/idc/groups/literature/documents/wd/1738-wd008_-en-p.pdf  

You will need a PC running the appropriate Siemens programming software to go online and do the hardware diagnostics to find the root of the issues. A few years ago, with an S7-300, I would have said Step 7 for Simatic Manager is what you need, but it could also have used Step 7 for TIA Portal. Do you have a copy of the program? If so, that will tell you which software family to use. If you don't have the software, you will need to get it or someone who does have it to stop by your facility to take a look.

Does the ML1000 show up in RSLinx Classic's RSWho window? After Auto-configuration is successful?

Based on what I've seen in the manual, I wouldn't think you'd need the UIC (it looks like it auto-configures itself for either DH485 or DF1 based on what it's connected to) but you will definitely need a COM Port adapter. Either way, take @IO_Rack's post to heart and verify your RSLinx driver is looking at the right COM port.  

Some additional suggestions... You can get into the configuration mode of the PV+ and transfer the .MER file to a USB flash drive. Starting with version 8 or so, I've found the hassle to be worth it since Ethernet transfers take about 75 years to finish. With older versions, transfers were quick. Once in the configuration mode, check out the startup settings to see which MER file is set to load on startup. There can be several MER files on the PV+ at the same time, which can make it tricky to make sure you get the right one that's running right now. A few links that will be helpful: https://theautomationblog.com/panelview-plus-white-square-missing-or-f1-not-opening-configuration-mode/ https://solconnetwork.com/how-to-access-the-configuration-screen-in-panelview-plus-6-0-or-higher/ https://theautomationblog.com/how-do-i-access-the-panelview-plus-configuration-menu/   Once you have the .MER, you can share it here (if it's small enough) or ask someone local (like your AB distributor) to take a look at it and see if it can be restored. If not, and if this is your only PV+, and if you're planning to replace it anyway, there's not much point in getting FT View Studio. It seems that you're planning to keep the PV+ and add a Citect "copy" of the information, so it probably makes sense to get the software and figure out how to use it. Sure as anything, there will be future updates to make to the PV+ as well. Another option is to contact the OEM who built the machine and ask them for the APA (project archive) and MER files. I've had to do that on occasion when I had trouble getting the MER file out of the PV+.

At a previous employer, we had some SLC 5/04 PLCs using straight digital outputs controlling SSRs off of PID controls. Basically, the Process Variable (PV) of the PID control became a timer preset that set how long the digital output turned on as a portion of a full cycle. I don't remember the exact code, but imagine two timers running in parallel. One has a fixed preset of "x" time while the other has a variable preset based on the PID output. The output turns on when the fixed timer starts and turns off when the variable timer turns off. Then the fixed timer resets itself once it times out. The PID output becomes a share of a full cycle. I don't remember what the fixed time was, but I want to say it was like 10 seconds or something. This was a reasonably stable temperature loop, so that seemed to work. We had others that used an analog output to an analog SSR. Those were simpler to program but used more expensive PLC outputs and more expensive SSRs.

That's probably one of my favorite things about RSLogix (5, 500, 5000)! When "in the groove", I can type in an entire (pretty complicated) rung WAY faster than drag-drop.

I've circled the button used to insert a branch into the logic: Each tab ("User", "Bit", "Timer/Counter",etc.) has more instructions. Use the arrow buttons next to the tabs to scroll through the tabs. Use the arrow buttons next to the instruction icons to scroll through the icons in that tab. If that toolbar isn't visible, go to the "View" menu and make sure "Tabbed Instruction Bar" is checked. If you're not sure what each instruction is, hover your mouse over it and you'll get a tooltip identifying it. To see detailed help, add it to the rung, select it, and hit "F1". The instruction help in RSLogix is actually very solid.  

I'm looking forward to Bob's deeper dive, but I'm not surprised at your symptoms or the solution. I've seen intermittent communication issues after upgrading the FW of a PLC that was talking through an -ENBT that were resolved by also upgrading the -ENBT. It got to where we kept a spare -ENBT standing by with the latest FW that we could set the IP address and do a quick swap in a live machine whenever we made a major change, especially one that required changing the PLC FW or adding any sort of Ethernet I/O devices.

It's been a couple of years since I had access to that software, but I remember there being a keyboard shortcut or a button on the toolbar below the menu that I used to transfer to the HMI. I don't remember using the menu that you're in for transfers, but it may very well be that it's supposed to be there. ...researching... So, Google found this document real quick from Siemens: https://support.industry.siemens.com/cs/document/23800567/how-can-you-transfer-a-wincc-flexible-project-via-ethernet-to-a-windows-based-panel-?dti=0&lc=en-WW If you go to pdf page 21, there's a screenshot showing the toolbar button and an explanation of how to access the command in the "Project" menu. You're definitely on the right track. The fact that the button and menu item are missing from your install is suspicious. Do you have a license for the software properly installed? It's a separate license from Step 7 (in both Simatic Manager and TIA Portal). To check, find your "Automation License Manager" software and see what licenses you have. If that doesn't work, try contacting their tech support. In my experience here in the US, their tech support is free, friendly, and responsive. Unfortunately, they weren't generally able to solve the problems I brought to them, but your problem may be simpler and/or your support better.

Is it a SINT array? In other words, does it say "SINT[x]" in the datatype? What's the value of the "x"? The Logix 5k STRING datatype is actually a compound datatype consisting of a .LEN element (DINT) and a .DAT element which is a SINT[82] array. If Cognex isn't giving you the length automatically, you can find it pretty easily with a loop that looks for the first element of the SINT array that has a value of zero. Or use the FSC. I threw this together real quick, so you'll want to do some limit/error checks to avoid overflows and such. After a single false-to-true rung condition, the .POS member of the Control tag used in the FSC contains the index of the first zero element of the array, which is also the length of the string. The element before that (element [7]) is the last character of the string. To work with it in the PLC, you can COP the SINT array into the .DAT element of a string tag and then update the .LEN element if the string tag with the .POS member of the FSC control tag.

What is the data type of the InspectionResults tag?