kaiser_will

When you say "the motor has no problem", how have you verified?  If your electrician ohmed the motor windings to find no shorted legs, and the drive still faults, that motor may still be the root-cause of failure.  Especially if the Siemens motor protector is tripping.  Please have the motor meggered to verify the motor health. If the motor passes the megger test, then consider replacing the Siemens motor protector.  These have a simple purpose in life...open when the motor temperature is above a setpoint.  Has the motor protector temperature setpoint changed (or should it be changed)?  Has your process changed?  Has the motor wiring from the panel to the motor been damaged?

There is a way to remotely make program changes.  It only requires a PC with an Internet-connection at the machine-site (that machine-site PC must have your A-B software on it).  I prefer to use TeamViewer.  Email or DropBox the project archives to the machine-site resource; walk them through downloading and installing TeamViewer; work out the logistics for the resource to allow you to remotely connect.

For me, when I run into situations in which devices do not want to work properly, take good notes and grab screenshots.  If you stick with this, you can develop useful work instructions as you go. It also to helps walk your way back to find the fix to your woes.

Ethernet/IP is a very common protocol for Allen-Bradley/Rockwell, and is built into the CompactLogix 5370 L2 processor.  http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1769-sg001_-en-p.pdf To understand the built-in and optional communication protocols for the Allen-Bradley CompactLogix 5370 L2 series PLCs, refer to the users manual, page 119 http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1769-um021_-en-p.pdf 5370 L2 processors support DeviceNet with addition of 1769-SDN module.  http://literature.rockwellautomation.com/idc/groups/literature/documents/qs/iasimp-qs025_-en-p.pdf Modbus TCP over Ethernet is supported.  Modbus RTU would require a special communication module.  Ethernet/IP is built in; suggestion is made to research if Ethernet/IP is supported by your SCADA package.

This part is finicky, when deciding how far to drill down into a Logix rack for setting the FTView communications.  I am going off of memory...when FTView Studio can see the IP address of the PLC rack, that is far enough (as you have shown). Select COPY FROM DESIGN TO RUNTIME to copy the communication link settings; select OK to commit the communication link changes. Incidentally, the FTView Studio lower pane gives step-by-step progress of the application changes as well as diagnostics when things do not progress properly.  If you do not have success, expand the bottom pane and post screenshots of the information.

The details are sketchy.  Your friend has an original Rockwell installation disc.  What installation disc and what form is the media in?

What versions are you running...Studio5000, Connected Components Workbench (CCW), ControlFlash? I ran into a very similar issue a few years ago.  Programmed new PF 525 drive via CCW, downloaded program, but PLC could not match the drive. After alot of reading tech notes, talking with A-B...PLC was EXPECTING a different firmware version than what the drive shipped with. Refer to last section of attached work instruction. Work Instruction - Allen-Bradley PowerFlex 525 VFD Startup.doc

If the HMI application developer added a Go To Configuration Mode button, typically on a security-level screen, that is all you need.  Press the button to exit the application and lead you to the configuration menu. If you have a keypad terminal, with hard keys on the HMI face...one would press and hold the left and right arrow keys at the same time; refer to page 72  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2711-um014_-en-p.pdf If you have a touch terminal, with no hard keys on the HMI face...when you power up the HMI, there will be a small white box in the lower-right corner (it will only be visible for a brief time); press the white box on power-up to halt the program application startup and navigate you to the configuration menu  http://www.plctalk.net/qanda/showthread.php?t=2329  If you miss the opportunity to press the white box, cycle power to the HMI and do it again.

Is your development PC connected to the PLC at the time of project development?   FTView is barking at you about the RSLinx Runtime and Design information not matching.  Most of us have run into this. Refer to Step (7)  https://theautomationblog.com/seven-things-you-need-to-know-before-using-the-panelview-plus/ Page 127/150 also will walk you through configuration Design-Local and Runtime-Target communication tabs.  https://mail.nelson-electric.com/webshare/LABS/On%20Tour%202016%20-%20L16%20-%20FactoryTalk-%C2%AB%20View%20Machine%20Edition%20and%20PanelViewG%C3%A4%C3%B3%20Plus%20Features%20for%20Improving%20Efficiency%20-%20Lab%20Manual.pdf

What version of FTView SE are you running?  This screenshot appears to be an older Rev. Is this a 21 CFR Part 11 application, common in the pharmaceutical industry?   Are these tag-based alarms (i.e., tag state triggers alarm message to be displayed)?  Page 186 has instructions for tag-based alarms.  http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/ftae-rm001_-en-e.pdf  

You should be good to go with the MAPC instruction to drive a pair of PF 527 VFDs as a group. Page 162 has detail about the MAPC command; Master Reference would be the speed command.  http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/motion-rm002_-en-p.pdf Page 170 has detail about status/control bits.  Make sure your logic properly controls the state of these bits as you can exhibit an astable condition if these bits are not in the proper state.   If you command the MAPC block to do something and nothing happens, there is a good bet that your control bits are not in the proper state. http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/motion-rm002_-en-p.pdf

Please post screenshots of your issue.  The more detail you provide, the better chance of getting a concise solution.

Page 100 starts a lab example of (2) PF drives, setup as master-slave, with a MAPC block controlling them.  https://www.rockwellautomation.com/resources/downloads/rockwellautomation/pdf/events/raotm/sessions/manuals/L15-IntegratedMotion.pdf What is your speed command feedback to the 1st VFD?

Rockwell does make finding FTView SE files difficult.  Open a Windows Explorer and drill to C:\Documents and Settings\All Users\Shared Documents\RSView Enterprise\SE I do not have my system in front of me, so going off of old notes.  I do know for a fact that the project file, a very small file (the client) that FTView SE starts as the application, lives in C:\Documents and Settings\All Users\Shared Documents\RSView Enterprise\SE\Client I suspect there is a Project folder in that location

For this new PLC application, total I/O count is (4) analog inputs.  Allen-Bradley CompactLogix 5370 L2 processors (1769-L24ER-QBFC1B  &  1769-L27ERM-QBFC1B) both have (4 each) universal analog inputs.  Refer to pg 12/40.  http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1769-sg001_-en-p.pdf http://apac.rockwellautomation.com/oem/docs/motion/india_CompactLogix_5370_L2.pdf And you need Modbus communication ability.  Would that be Modbus TCP over Ethernet, or Modbus RTU?  The 5370 L2 Ethernet port supports open-socket protocol for utilization of Modbus TCP. I have little experience with Modbus via serial.  http://literature.rockwellautomation.com/idc/groups/literature/documents/ap/cig-ap129_-en-p.pdf

Another PLC-related forum...http://www.plctalk.net/qanda/

MicroLogix 1400 communication ports => Channel 0 (RS-232/485) & Channel 2 (RS-232); page 19/404  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1766-um001_-en-p.pdf When you say "sending exactly information's to COM port", which communication port are you referring to?  COM 0 or COM 2. Identify the PLC communication port you desire to use; identify the communication parameters your external device requires (baud rate, handshake control, parity, etc.). After you have the com port selected, the communication parameters selected, then a base program will need to be loaded in the PLC to setup the communication port, load in the PLC program, put program in RUN mode.  At that point, your communication port is configured and ready for action. You want to send ASCII data out of the serial port of MicroLogix 1400  => you will need this document as well. http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1766-rm001_-en-p.pdf

Define "inexpensive".  Cost is relative. If you want the vision camera's decision making to also control reject control, you may need a PLC.  Depending on the business constraints of "what if" an incorrect product makes it out the factory door, the camera's "Go or No Go" decision will most likely not be adequate for controlling your business constraints. Is it feasible?  Yes.  You will need a PC plugged into the vision system, at least during debug phase, so plan accordingly. Consider how the camera will be told to process an image.  Is your conveyor line continuous motion, or indexed?  If continuous motion, you may need a cam signal or a photoswitch to trigger the camera to take and process an image. Will your process run (1) product or multiple products?  If multiple products are to be run, you will have to consider a vision systems that supports multiple setups and your line controller will have to instruct and interrogate the vision system (command and feedback). Many PLCs or controllers, like Fanuc robot controllers, already have integration configured to network in a vision controller.  Cognex is the big dog in the market.  Mitsubishi has a PDF for integrating a Cognex vision system in with one of their PLCs.  https://www.cognex.com/support/downloads/ns/1/11/93/Vision%20System%20Connection%20Guide%20(COGNEX%20SLMP%20Connection).pdf Overall, most vision systems look for pixels (i.e., Blob tool) or color.  Users configure identifying characteristics for the vision system to look for. The 3 biggest factors that affect performance of a vision system:  (a) lighting [one may have to add lighting to insure the vision system sees a repeatable light level], (b) product presentation control [labels on rotating product may require 360-degree camera or multiple cameras or product escapement to control product placement for inspection], (c) speed [perform due diligence to understand the limitations of all parts of the process]

Offline project...offline.  Unless you updated the OFFLINE tag database after you made edits, your PC (where the OFFLINE tag database probably resides), does not know about the changes you made.  Point the offline tag database to the latest version of the program. Offline, Refresh...this will update the off line tag database with the latest tag additions/deletions.  Refer to page 33.  https://www.rockwellautomation.com/resources/downloads/rockwellautomation/pdf/events/raotm/sessions/manuals/L06-FactoryTalkView.pdf

When selecting an Allen-Bradley PLC, data you need to compile:  types of I/O (i.e., discrete, analog, relay output, isolated, etc. - this will identify the I/O module types needed), quantity of I/O (this will identify the number of I/O modules needed), CIP motion axes (number of integrated motion devices, such as VFDs or Servos), software (what do you have). If you need no I/O, need no motion axes, and just need an A-B PLC...a CompactLogix PLC is good the place to start (5370 L1, requires Studio5000 software) or a MicroLogix 800 (requires Connected Components Workbench software). http://literature.rockwellautomation.com/idc/groups/literature/documents/pp/1769-pp012_-en-e.pdf http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1769-sg001_-en-p.pdf http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1761-sg001_-en-p.pdf http://literature.rockwellautomation.com/idc/groups/literature/documents/br/2080-br001_-en-p.pdf If you want to save money, you can purchase a surplus PLC (used, or new-old stock [NOS]).  Amazon and eBay are great resources.

http://www.automation-interface.com/pdfs/EH04803007E.pdf

Big differences between the 2 platforms in my opinion...local I/O modules that can be used, CPU specs (i.e., number of CIP axes, number of tasks, etc.). 1769 GuardLogix (i.e., 5370 GuardLogix) can utilize 1769 (i.e., CompactLogix) I/O modules in local rack.  http://literature.rockwellautomation.com/idc/groups/literature/documents/pp/1769-pp014_-en-p.pdf 1756 GuardLogix is a two-PLC solution with a primary processor and a safety processor that utilizes 1756 (ControlLogix) I/O modules in local rack.  http://literature.rockwellautomation.com/idc/groups/literature/documents/td/1756-td001_-en-p.pdf As a machine designer, the deciding factors between the two will be PLC power [(simple machine, few motion axes) vs. (extensive I/O, many motion axes)] or I/O module family desired.

This lab example, page 55, should detail the process for you.  https://www.rockwellautomation.com/resources/downloads/rockwellautomation/pdf/events/raotm/sessions/manuals/L04-BasicPLCProgramming.pdf

Suggestion...surplus industrial electronics.  In cases where you have a failed HMI that is obsolete, and you have no replacement spare, your options are (a) upgrade [and live through the headache of software, operating systems, cables, etc.] or (b) purchase a surplus obsolete spare.  There are many companies that sell NOS (new old-stock, unopened or opened box) or used.  Many of these NOS or used items can be found easily on Amazon or eBay or whomever (Surplus Traders is an option).  https://www.surplustraders.net/industrial-equipment/allen-bradley Note...most Rockwell/Allen-Bradley applications utilize RSLinx for the device communication layer.  There is just no way around not using it.  FactoryTalk View is finicky with the RSLinx (communication) settings.  Imagine the scenario...a PanelView project was built on PC #1 with specific RSLinx settings; open the project on PC #2 but it expects to see the same RSLinx settings.  Refer to this recent thread.  http://forums.mrplc.com/index.php?/topic/32065-restoring-pv-600-plus-communications/#comment-151985 Open the new project in FTView Studio; open the RSLinx settings; update the Design link to the correct PLC; copy the Design settings to the Runtime tab; save; download

(a) New PLC may have no IP address and DHCP is on; in that case, use Allen-Bradley's BootP or similar program to set a fixed IP address and turn of DHCP (b) PLC is addressed; in that case, use WireShark (free IP sniffing utility), turn of all PC ports (except the LAN port connected to the PLC), and sniff away