James Fillmore

Here's what I found. Just for reference this was the initial commissioning of the machine. 1) We are using the 460V Kinetix connected right to plant power. No isolation transformer. The jumper in the IAM was in the default "grounded" position. I moved to "ungrounded". 2) The above didn't fix the problem. So I searched for any loose grounds in the machine and i found not only loose grounds but everything was loose on the wiring on the power filter. The stak-ons were the wrong size for the wire, bad crimps on the stak-ons and loose nuts on the studs on the of the electrical connections on the filter!?!?! I replaced all the stak-ons with the correct size. I tightened all the connections. Now it works perfectly.

Anyone ever come up with a solution? I have started 100 Kinetix systems and have this exact same issue. First drive (of 3) goes to 4. Other 2 E75 error.

Does Studio 5000 support the earlier firmwares like V18, 19 and 20? If so then how? I can't find that info anywhere?

I've done 100 single axis AB units now and always used the auto tune and then tweaked the parameters. I’ve been dealt a new application; lifting a 2000lb plate to multiple positions with 2 AB MPL430 servo mounted to 24" Exlar actuators. I can't autotune this since the 2 servos are MECHANICALLY coupled, one on each side. It looks to me like a bad mechanical design. I suggested like a scissor lift in the middle but this is what I have now and customer is on his way. IS this a bad servo application? Mechanically coupling 2 servos? Do you ever see applications like this? How the hell would I tune this? What parameters would I use for each motor if I just did the calculations by hand?

Why does that instruction work no matter what I put for the Length (tried 1, 4, 6) all worked? Also what is the math behind 4 SINT's representing a REAL?

Found the info right here on MrPLC. COP (Copy File) Source: SINT[0] Dest: REAL Length: 4

If I can get help converting the (4) SINT's to a DINT then I think i can just MOV the DINT to a REAL. Thanks

Happened, as shown in the above picture, while editing a rung comment. I just installed about a week ago on a brand new Dell laptop. Win7 32bit. Happens nearly every time I use the program. 1/2 the time it saves a copy of the program with my recent edits. Can't just be me. Now the other guys in the office don't want to upgrade. Can't say I blame them.

Anyone else had this problem. Here's one screen shot (sorry - cell phone pic)

Great info guys. Quick question. How do you address these in Compact or ControLogix? I mean what do you put on the prints for your guys? I would probably just have a 32pt input module (I:01/00-31) and a 32pt output module (O:02/.00-31) old school I/O in the control panel. Then 3 or 4 AENT's and associated digital I/O out on a simple 5 station conveyor line. One station has approx 46 part detection inputs along with (7) color sensors each requiring 5inputs and 1 output. So thats approx 90 inputs and and 10 outputs at one of the stations. The other stations only have a few I/O. Would I have to invent some tag based I/O numbering. Like Station 1 would be EI01_01/00-08 E=Ethernet I=Input 01_=Sta01 or AENT01 01/=Module01 00-08=the bit on the module. Thanks again! Jim Fillmore

About a year ago I looked at all the options and it looks like Beckhoff has the most well rounded product. It looks like Turck has brand labeled their product and called it Piconet. They are small, pico ports, have a cost effective subnet and have a wide variety of modules (analog, rs232, etc). My managment has been "sold" by a salesguy so now it's a mandate. Problem is I see more of the worked pushed to my side to implement, investigate, document, troubleshoot and SERVICE compared to old school I/O. We don't build large conveyor lines. Just smaller 100 I/O stand alone machines. I'm definitely not anti technology. I already use Exlar Tritex Ethernet I/P servos, Gefran Ethernet to modbus power controllers, etc. Just in the Detroit area there are 2 problems; 1) lack of controls people and 2) the new "MORE WITH LESS" business philosophy. And we are severely understaffed (so if anyone in the Detroit area with decades of AB experience that can hit the ground running and are looking for a job, contact me). What are others using? FYI The sales guy who swayed management is pushing centralized Ethernet I/O on SMV valve pack (EX600). Looks cool but wouldn't solve all situations. Then he had Balluf which had a nice, LARGE block that you could connect sub blocks to but to take full advantage of the I/O you'd need splitters on each port. I could see THAT being a wiring/troubleshooting problem. Plus they were large. We build smallish machines.

Our company is designing a machine to lift a fairly heavy steel fixture (approx 900lbs). It's riding up and down an THK rails and bearings on all 4 corners. I suggested a servo driven ballscrew (we use AB Kineetix 6XXX and I have about 100+ axis of experience using these over the past 5 years) on one side and a counterbalance cylinder on the other side. A SALES GUY convinced management to NOT do this but to instead use 2 servo actuators. I THINK with the THK rails that the fixture isn't going to deflect lifting it on one side with a servo because of the rails and liner bearings. it would be the same as lifting a cantilevered fixture. PLUS with the counterbalance air cylinder, regulated to a PSI where the fixture weighed basically nothing when not moving, would further help. I personally like a counterbalance cylinder on all my vertical servo axis'. It allow me to use smaller servo motors. Easier on the brakes. A safety device if a servo belt or coupling fails. On our machines were we enter light curtains and have to disable the axis every cycle, if I just count on the servo actuators brake, the axis usually drops a few thousandths every time the light curtain is interrupted and the brake has to hang onto the ballscrew. Do this a dozen times and the axis has drifted 50 or 100 thou. With a counterbalance cyl this doesn't happen or only moves a few thou. Anyone he with empirical knowledge on this or suggestions? Thanks, Jim Fillmore

Just got back from this ongoing problem. Looks like excessive mechanical slop/backlash give E19 Position Error and E64 Feedback Noise faults. We are driving a heavy load on a beltdrive actuator (yuck), through undersized cheap jaw type couplings without keys (ugh), through a 25:1 gearbox (added backlash), through another cheap jaw type coupling [rolling eyes] finally connected to the MPLB330P AB motor. I was seeing about 10 degrees of slop at the beltdrive pulley end. So the MOTOR was seeing about 250 degrees of slop. Apparently (tounge in cheek) thats too much. Bet we have $50k plus invested in this problem! And now were investing about another, geez, $10k in hardware and probably $10k in a 2 person, multi-day service trip again. Oh, and the big band aid I put on the machine to make to stabilize it till we swap in another slide, I upped the "jerk" setting to 90%. This REALLY softened up the move but added a couple seconds. BOTTOMLINE, when the servo gives a NOISE FAULT it can be related to mechanical! I HATE having to go outta town to prove the mechaincal is not up to snuff though. Jim Fillmore

I've been fighting E64 issues in a 3 axis Kinetix 6000 system also. It's only on one axis in the system. We paid an AB expert $6000 and still unresolved. at this point I'm thinking it's mechanical in nature. Think some system resonance or excessive slopiness is causing what looks like to the encoder to be "noise". Just an FYI and for others. Jim Fillmore

I saw that unit. Looks like they have 3 flavors. I'd only need the lowest end one (without the built in HMI and webserver capabilities) but according to the literature I don't think I can datalog to the CF card with the low end one. It appears that one ($500 list) is just a gateway. Looks like I have to go to the $900 list unit to get datalogging. Am I correct? Also how do you like this unit and how are you using it?