pturmel

I wouldn't expect a gui to work.  This is something you need the precision of the command line for.  Look at the manpage for mkfs.fat.

Pretty sure Linux could format it with FAT16.  Or take an image of a good one to write back to a device in a crisis.

The installation diagram is pretty clear that the four channels share a pair of connected common terminals.  The channels are not isolated from each other, and the signal terminal must be positive, and the input must be the last device on the loop (internally completed by a precision resistor to common). Also, do you have a diagram for the AO55 that is required for 4-20mA operation?

Please don't double-post.  Follow-up post is here: https://forums.mrplc.com/index.php?/topic/43695-got-simple-series-having-screen-error/  

In the PLC, use GSV to extract the EntryStatus, FaultCode, and FaultInformation into local variables.  Set the local variables to display in Hex format for best results.  In my EtherNet/IP module for Ignition, I format errors the same way, and document the most common codes in my user manual's troubleshooting section.  EntryStatus is purely a Logix creation, which I've tweaked for my own purposes, but FaultCode and FaultInformation are drawn directly from the EtherNet/IP standard's ForwardOpen Response. https://www.automation-pros.com/enip1/UserManual.pdf

Prepare to be disappointed.

Sounds like something you'll regret when the bandwidth bill comes in.  Point I/O is made for "class 1" connections with traffic all the time.  Presumably this is a private cell network space?  As long as your private network routes UDP packets, it should work.  Ping is not a sufficient test.

Normally, you would use a function parameter that the caller provides for any necessary context.

So, the manual for the levelmaster doesn't appear to be the correct one.  It shows Modbus output, not 4-20mA.   Assuming the 4-20mA version is similar, then it is a 4-wire transmitter, not a 2-wire.  You will need to supply power to the transmitter separately from the 4-20mA loop. Then, you will probably need to wire the display into the signal loop as shown in the Vegadis manual, figure 17 in §5.5.  However, that figure shows an isolated PLC input, and your module is not isolated.  You might want to contact Vega for assistance, as they don't show the non-isolated case.  (Their internal arrangement of sensor and power terminals is not clear.)

A "positioner" typically refers to an actuator that has its own internal position sensor, power, and feedback loop (possibly purely mechanical) such that the command signal can be low-power and is expected to be nearly linear with valve % open.  In my ancient (25 years ago), a positioner with 5% hysteresis error would be immediately replaced.  The paper mill I worked at back then expected positioner error to be <1%.  Considering the potentially dangerous conditions you are trying to control, you should consider have the valve/positioner manufacturer examine it. That said, there's no magic to a high-pressure control loop versus any other.  The performance of the components will dictate the overall performance of the system. If you cannot get the gross components to behave sufficiently well, consider adding a parallel, smaller pipe with a smaller control valve.  Configure the small valve as primary control, and program the large valve as a cascade loop with large deadband.  (That is, it would use the smaller valve's control % as its process value, with a permanent setpoint of 50%).

You definitely need to power your devices separately.  Per GE manual GFK-1504N, page 10-39: It also extremely unlike that the wiring for the display is correct, as what you show doesn't have the display and input module in series on the signal lines, as is typically required.  Do you have manuals for the display and the transmitter? (The input module is non-isolated, so it must be the last signal on the current loop.)

Are these devices loop-powered?  Are either non-isolated?  Show your circuit diagram.

That's the kind of fault information that would normally only be decipherable by someone with the source code.  So, contact whoever sells Proficy now-a-days.  Don't be surprised to be told that it is a bug fixed in a newer version, and you need to upgrade.  Or, perhaps, that it might be a bug, but you need to run the latest version to be sure.

Yes.  With a leading edge sensor wired to one of its Z inputs, where that input is configured to "latch and continue". Then, use a high-speed output on the encoder card to stop the analog drive at the target position, with an appropriate (speed-compensated) lead for deceleration.  If deceleration from normal speed is not sufficiently precise for your 3mm tolerance, use additional logic to slow down the drive early, then stop from the slower speed.

I'm not familiar with that particular drive, but the general requirements for the application described are: Capture an encoder count or position value, at the required level of precision, when the leading edge of the material enters the cut zone, and Command the drive to stop at the required ending position, again, to the required level of precision. Drives with positioning modes built in can generally do both of these operations, as long as some leading edge sensor is wired directly to the drive (for high speed capture). If your drive doesn't have any positioning functionality, or lacks the high-speed position capture feature, it all becomes much more complicated.  And possibly requires encoder signals to be brought to the PLC itself.