kaiser_will

Is this an application for FTViewSE or FTViewME?

Isolate the problem - break the system down into pieces and verify each piece the best you can (KF2 module, KF2-DCS comm wiring, DCS comm port).  The communication link is just 2 devices, the processor and the Bailey DCS, correct? This setup is a PLC-5 I/O rack without a processor and a KF2 communication module?  Does the KF2 give you diagnostics as to the problem? Since the KF2 module flashes RED once in awhile, this module is telling you there is a problem.  Can you obtain the fault information from the KF2 module?  Refer to pg 7-1. http://www.ideadigitalcontent.com/files/11994/1770-um521_-en-p.pdf Try to string up a temporary communication cable from the KF2 to the DCS to rule out comm wiring. The glaringly obvious we should ask...when was the last time the DCS program was edited?

This is familiar; it has been a number of years, but this thread should help.  The drive assumes the index command is for Preset 0 if Preset Input 0 is OFF (Preset 1 if Preset Input 0 is ON). http://forums.mrplc.com/index.php?/topic/23928-ultra3000-indexing/

The objectives...Multiple machines; Micro 850 PLC and PV800 each machine; same program each PLC and HMI but with different IP addresses. From what I know, changing the PV800 IP address is device-level and independent of the HMI application. Trying to push the PLC IP address from the HMI is not possible, that I know of, as the Ethernet/IP socket connection from the HMI would drop off at some point as the IP address is changed from Address 1 to Address 2. However, a Plan C could be to use a managed Ethernet switch and alias all of the devices to unique IP addresses.  I have done this when converting a control network IP address to have a plant network IP address.  Most managed Ethernet switches have a lookup table that aliases IP #1 to IP #2.  You would have to research further if this is possible with multiple same IP addresses (possibly there is a managed switch that uses unique MAC addresses).

What is the business justification for this upgrade project?   I have been in your shoes before.  On one hand, upgrading to the latest technology is a lot of fun, but the path will be difficult and the end result is you are taking a running, mature process and giving it a brain transplant.   You might find CompactLogix processors to be a better fit than ControlLogix (and more cost effective); I suggest breaking down every system separately and pulling together data on what you have today (gather I/O count, I/O type, motor specifications, motor drive part number, PLC communication protocols). You noted "no PLC code will be added".  When migrating from I/O-based processors like the SLCs to tag-based processors like the ControlLogix, all of the code will not be a load and go process.  Anticipate problems and be ready to respond.   An option to consider...just replacing the processors but keeping some/all of the I/O and racks.  If you have ample spare parts, keeping the I/O and turning into remote I/O and adding new remote processors may afford your project many of your objectives.  It is possible to keep a SLC rack, add a remote RIO module, add a new ControlLogix processor, and port the code over.  Keeping your rack I/O leads to very little panel/wiring changes.  Pull out a SLC rack and put in a ControlLogix rack, there is going to be alot of panel wiring changes.

To upload from or download to this family of HMI, one will need Allen-Bradley/Rockwell PanelBuilder 32 software (which is obsolete and no longer sold). http://ab.rockwellautomation.com/graphic-terminals/2711-panelbuilder32-software#overview Call your local Allen-Bradley/Rockwell distributor and ask if they can provide support.  If your organization has a Rockwell support contract or are a recent Rockwell customer, the distributor may see it to drop by and upload the project out of the running but dim HMI and into your spare. You can also put out a feeler to Mr. PLC forum members that may be in your geographic area, to see if someone would be willing to assist. Keep in mind...you are taking an obsolete (Silver Series) & failing HMI, and replacing it with an obsolete HMI.  If unplanned downtime is expensive for this process, upgrading is suggested.

The PanelView 32 utilized PanelBuilder 32 software (legacy software, Win32 operating system). This model is a CRT unit, similar to an old tube television (not old old vacuum tube).  There is a brightness (contrast) adjustment on the rear. http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2711-um011_-en-p.pdf Generally, weak brightness is an indicator of premature failure. This HMI line was obsolete (i.e., Silver Series) a number of years ago.  There similar replacement models, but would require newer software. Since it is obsolete, there are a number of USED units on the market (eBay, Amazon, CraigsList).  Buying a "mint" replacement is not likely at all, but not impossible. 

The Micro1100 1761-L32BWA, with a 1761-NET-ENI module, has the ability to send email messages via SMTP protocol; refer to page 12 http://www.e-applied.com.tw/technology/PLC/Micro%201000/1761%20Technical%20Data.pdf The key to this working is HOW this PLC would connect to the real-world, since the PLC email message would need to traverse your company's network.  This is usually the road block that most users encounter, as most typical process networks are segmented away from the internet.

What OS are you running on your PC? What version of FTView are you running? Is the application a FTView ME or FTView SE application? Is this a FTView application that you have built or did you restore an application someone else built?  If someone else built this FTView application, what version did they use?

Often times, power monitoring devices have to be installed in the switchgear.  Your switchgear may have power monitoring ability already, but may not be networked,  Or, your switchgear may have ability to add the feature to the "buckets".  Vendors will ask these same questions.  Pull together schematics of your switchgear or find someone in your organization who knows it well.  Some companies contract out switchgear support and maintenance due to the substantial risk of harm to unqualified technicians. Also, your electrical utility may be interested in this conversation.  Utilities like large industrial customers that are serious about managing their electrical load, and sometimes would be interested in playing a part in you having the ability to monitor and report on your electrical load.   If you have an electrical contractor that has an engineering group or works with an engineering group, those 2 parties are key to understanding the infrastructure you need to build a system like this, a utility reporting system.  Vendors who sell equipment will sell you a system and may not fully understand the infrastructure needed to make their solution work; contractor/engineer will have experience in applying the vendor solution. Directives often do not take into account what it takes to make a system like this work.

Online Mode...doing online edits on running processes can result in unplanned downtime if you are not 100% sure of the changes you commit to when accepting the online edits.  If you missed a detail, the process be brought immediately to a stop if there is a mistake.  Common mistakes...math over-run (divide by 0) or an array is not dimensioned large enough. Online edits are great in that you do not have to download (and stop the process to do).  But, if you add tags or change a tags attributes, such as modify the dimension, then a download is required. You have a Logix5000 program, went online with the processor, created new tags, but cannot see them - correct?  Did you take the most-recent PLC program, add new tags, then go online without downloading?  

Please post screenshots of your messaging code. How much data are you sharing between the (2) processors? Have you considered produced/consumed tags?  Both processors support produced/consumed tags, and are on the same Ethernet/IP network.

There can be multiple Logix5000 or Studio5000 versions installed on the same PC (when you start Logix/Studio5000, the splash screen will show you all the versions properly installed).   After Ver 20, RSLogix5000 became Studio5000. RSLogix5000 is stable to run on 32-bit and 64-bit operating systems (WinXP, Win7, Win8) Studio5000 is stable to run on mostly on 64-bit operating systems (Win7, Win8, Win10) For me, I would suggest creating separate VirtualMachines...one WinXP 32-bit for Logix5000 and one Win7 for Studio5000.  Keep everyone in their own backyard.

Have you been given a budget?  What is the objective of this system, to only tell you how much energy you are using?  For monitoring power usage, the key aspect needed...voltage and current per leg.  There are a variety of power monitoring equipment and devices, so you need to hone in your specification. Rockwell/Allen-Bradley has a good power monitoring product profile. http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1400-sg001_-en-p.pdf Monitor power, monitor compressed air, monitor chilled water system...this sounds like a great SCADA application with data reporting.  Does your organization use a SCADA or HMI package already?  By going with the same software, you can reduce project cost for not duplicating development licenses. We engineered a similar system some years ago.  Intellution iFix (then migrated to CiTect) SCADA system to give user interface screens and archive data, communicating with Allen-Bradley PLCs for bringing in the data, PTs and CTs for power grid monitoring. I am not aware of a black box solution that will provide all of what you desire.

... ...Unused analog input channels will float unless they are DISABLED...refer to pg. 53

You can only change features of the keypad, such as customizing the limits.  But the visual look...no, what you get is what you get. You can create your own pop-up window and configure it to be your custom keypad.  If you build it into a faceplate, you can use this same custom keypad throughout your application.

Ultra-series servo controllers can be a huge pain to tune.  I have only done a couple of times, but experienced similar non-robust performance.   To tune an Ultra-series, make sure your servo motor is uncoupled from the load.  In some mechanical designs, this is not possible. Follow this instruction.  Hopefully it is of good use. I do not believe Studio5000 will provide different control ability than Ultraware. https://www.machsupport.com/forum/index.php?action=dlattach;topic=21036.0;attach=30916

I believe you can commission/program the Ultra3000 servo controller with Ultraware or RSLogix5000/Studio5000.  Ultraware is also used to program Ultra1500, Ultra5000 and Kinetix 3 servo controllers.   If you have Ultra3000, and a serial cable, plug the servo controller into your PC.  Startup Ultra3000, select CANCEL to having a previous UDB file (unless you have one), Ultraware will scan the PC serial port for connected drives, select YES to running the setup wizard.

Rockwell also has Ultraware software for the Ultra3000 servo controller family; purchased software. http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2098-um001_-en-p.pdf Of note, this servo, Ultra3000 #2098-DSD-150, is to be discontinued in a few weeks, 12/31/2016. http://www.rockwellautomation.com/global/solutions-services/capabilities/migration-solutions/product-search/results.page

Then you want the opposite of what I did.  In my case, HMI pushes date time to PLC via SSV (Set System Variable).  This SETS the system variable, in this case date and time, to what the variable value is.  What you want to do is push the PLC date/time to the HMI.  This can be done with a GSV (Get System Variable).  In my example, there is a HMI event tag (press a button on a protected HMI screen).  That button tag will be mapped in the PLC program to a GSV instruction.  Make sure your HMI application uses your new date/time tags.

Has this system been in operation for some time without issue, or is this a new startup?  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1756-um009_-en-p.pdf Unused analog input channels will float unless they are disabled...refer to pg 53. All analog channels must be configured.  Refer to pg. 193.  0-10V, +/-10V, 0-5V, 4-20mA are your choices.

Have you tuned this servo drive to this servo motor?  With the motor oscillating, it sure sounds like the servo tuning is not holding position very well.  Refer to page 59+. http://literature.rockwellautomation.com/idc/groups/literature/documents/in/2098-in005_-en-p.pdf  

You do not have a support contract, so you probably do not have full software license?   This tool probably still uses RSLinx.  Are you sure you have set your RSLinx and connected to this processor?  I wonder if this tool uses the last RSLinx connection you made.

There are a multitude of ways to accomplish this.  One such way is to push the date/time from the HMI to the PLC (with this method, you can have a secure HMI screen where the date/time can be touched up and pushed to the PLC).  The attached work instruction should guide you through creating new date/time tag array, linking the PLC date/time to the new tag array with a SSV instruction, then setting up the FTViewME global connection. Work_Instruction_-_Allen-Bradley_Synchronize_PLC_date-time_with_PanelViewPlus[1].doc

Rockwell put out this tool some years ago to give users a quick way to update clock settings, Logix5000 Clock Update Tool. http://www.ab.com/en/epub/catalogs/12762/2181376/2416247/360807/1837528/tab2.html https://rockwellautomation.custhelp.com/ci/fattach/get/120196/