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Another option is to install a 1747-BAS add on card, that you will use for your LED display. Not very user friendly, but plenty of samples on how to set it up floating in the web. That will free up your RS232 communications port and will let you with an additional RS232 port in the BASIC card as it has two ports. You need to set up the card with a BASIC program for serial port configuration, if you need I can provide some samples. We still use a lot of these card in a lot of our old machines. Once they are set up, vey reliable.    https://literature.rockwellautomation.com/idc/groups/literature/documents/um/1746-um004_-en-p.pdf

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A little late, hope this helps someone. http://help.cognex.com/Content/KB_Topics/In-Sight/Communication/4131.htm Here you will find where to find your GSD files in InSight Explorer installation folder, depending on your version:  C:\Program Files (x86)\Cognex\In-Sight\In-Sight Explorer 5.x.x\Factory Protocol Description\GSD Cognex does provide an excel template so you can generate your tags depending on the designated addresses, please see attached file with it, and instructions Word file, it works for InSight and Dataman devices. For programming, search in Cognex site for "Industrial_Protocols_Manual". TIA Portal Integration Guide for In-Sight and Dataman.zip

Maybe this? https://www.prosoft-technology.com/Products/Rockwell-Automation-In-chassis/Platform/SLC/EtherNet-IP-Client-Server-Network-Interface-Module-for-SLC

You can always use a USB mouse if the touch screen is unresponsive, and copy the project to a flash card, or if you have an USB hub, then connect the mouse and USB thumbdrive at the same time. Also, you can get "ME transfer utility" as standalone (I've got it before), but usually AB requires licence to download its software, even the free one... Getting the project out of the HMI should be your top priority. You can always install FactoryTalk View as trial, open your project (you can recompile the runtime into a project if the HMI Factorytalk edition is 5 or higher) and see all the controls so you can create a new project in the brand you like. Just remember the trial has a limit in days, so get hurry to fetch all the information you need. I would do this in your situation. Just make sure before you buy a new HMI that is come with DH+ as I can see you serial port is already used, because the serial port to communicate with the HMI would be the "easy and cheap" solution. DH+ is much more uncommon to still have it as an option, and usually expensiver.

Doesn't the AB PLC support Modbus TCP? I think that would be the ideal solution, requiring nothing else than just programming. It will depend on how much and type of data you want to move, even though Modbus doesn't support strings or other types of complex variables, you can always find a work around.

Ok, what I know is that Zebras use ZPL language, it is used by serial, USB or Ethernet port, it's the exac same ascii data you send no matter what protocol, and that includes all the data needed to trigger the printer to print. Sometimes the hard part is just get the correct configuration to start transmiting the buffer data, once you got that, then printing is not that difficult, just have to use the ZPL programming languaje user manual and you will get what ever you need done. Easier if you've got an example to learn from, that's how I did it. I have only modified prints over Ethernet in a PLC, but not created one from the beggining, so I toughth I was missing something when you mentioned the print trigger circuit.   @mark papoI have not used an AB PLC to print from it, only Siemens, but should be very similar. Not sure if what you are saying is that you have two PLCs and one printer or two separate printers, one for each PLC. If you only have one, maybe thats the problem as you may have port interference issues. If you have two printers, then check that all the printer configurations are exactly the same as the first one, by the exception of the IP address.

BobLfoot, what is the print trigger circuit? I've worked before with Zebras but haven't hear that term. I'm no expert, so that is why I'm asking.

Did you try to run the PLC without the HMI for a long period? This will rule out the HMI if it fails again.

I can confirm Advanced HMI is what you are looking for. I have created data exchange systems with it for AB and Siemens PLCs, using DF1, Ethernet/IP and Modbus TCP (this one for Siemens) and it works great. It's really easy to use, they have a forum with a great community and Archie (the creator) provides the best support directly in the forums, for real. And all for free. Been using it since 2013 and helped me to develop my programming skills with VB.NET, it really helps that AHMI is event driven already, it takes out a lot effort of having to code events yourself compared with other paid drivers. To be honest, it is not just a driver, but the whole VB.NET or C# solution what you use to start from. Try it, really.

I just started with Siemens but have years working with AB, which usually requires a termination character to know the transmission is over. Usually CR or LF, which in Honeywell scanners have to be set up manually to be added at the end of the string. Hope this helps.

Each PLC firmware version requires the same version of Studio 5000/RSLogix 5000. You can upgrade also the PLC firmware, but there is usually a version limit. What you will end up doing is install every version of Studio/Logix you need depending on the PLC firmware version available.

I have written some applications in VB.net, not exactly like yours, but data logging into an access database. VB is not hard to learn, there are plenty of tutorials and help over the internet (I've learn this way) to learn whatever you need exactly. I would not use excel as a database, as is risky (anyone can read/modify it) but a simple database like access can help a lot on this, and much easier to use when you learn the basics. To communicate VB with AB PLCs I have used Advanced HMI. It's a free semi-open source project as you download a VB project with a big quantity of already developed visual controls and use it to start writing your program from there. You can connect to several PLCs (there is actually no limit) by Ethernet, serial, modbus, OPC, etc. and read variables from them, it has several drivers to use. Like object oriented languages, it has "events" so you can monitor your string in the PLC whenever it changes and start a procedure after that. https://www.advancedhmi.com/ Edit: Forgot to tell AHMI it's based on VB, but you can use also C#.  

Usually, this is an option in HMI software, to force password changes on a certain period. See your desing software, usually in security options or user management, and you will find some option like "force password chage after X months".

You do not need an OPC. There are several drivers and projects to use from ranges of simple excel files to programming languages. I find very easy to use and develop in VB with Advanced HMI https://www.advancedhmi.com/ beacuse its very simple to code in Visual Basic, and the project is also designed to minimize the need of VB knowledge. It not only a driver but has several visual and non visual controls to choose from, communication its very reliable as I've used it in more than eigth projects where some of them are connected to six PLCs monitoring variables and interacting with an access database. There is even ways to make it run as a service, so you can make sure it will be always running in the background.