kaiser_will

Spool of material, different diameter spools, but the spool mandrel should be same/similar?  If that is the case, no matter what spool diameter is run, the stop point will be the same. If stop the process before the spool runs out, will this create scrap?  How quick must the spool detection system react?  Some processes want to utilize as much materials as possible, so triggering to stop with material left on the spool is not acceptable. If you use a non-contact sensor, such as a laser sensor, keep in mind the vision sensor may behave differently for different materials.   How should the system be stopped for low/empty spool?  Some processes cannot be emergency-stopped - a graceful shutdown command may be needed. Once you know the proper shutdown method (E-stop or graceful stop), pull out the machine system electrical drawings and get an understanding of what is the new "spool low/empty" stop command to do?  Drop out the E-stop circuit (to issue an immediate stop such as depressing an E-STOP button) or trigger a graceful stop (such as pressing the red STOP button).

3-phase power, as an engineer or technician, is a very broad subject.  You are aware of the different voltage levels (240V, 480V, etc.)?  You are aware of the impact of 50Hz and 60Hz?  Panic is correct...a VFD creates a simulated 3-phase circuit but is not the real thing. There is a wealth of knowledge on the web on this subject.  My suggestion is that you start to write your own Primer on the subject.  50% of my technical skill set has NOT been built in a classroom, and that I can demonstrate with my own library of Primers.   The NEC dovetails with this subject, as it is the framework of guidelines for design of 1-phase and 3-phase networks.

Whenever a PC display shows the PAST as the PRESENT, that is typically memory leakage and may be indicative of a struggling operating system.  Ironically having the same problem now but that is network related.

I am configuring new Schneider Altivar 630 VFDs to replace mature, obsolete Altivar 61 VFDs.  The drives have a simple function in life...analog input (thermostat scaled through trim pot) running a fan/blower.  If main power is available, VFD is to run to analog input scaling. VFD powers up correctly, but will not auto-start unless the analog input is removed first.  I have not found the parameter in 698 page manual that cures the issue, yet.

I have not personally addressed this same issue, but there are past threads with a fix at the end  http://forums.mrplc.com/index.php?/topic/13704-net-eni-comms-problem/ Have you investigated the Net-ENI firmware revision and what latest is available for download?

Rockwell Software products are purchased through the distributor in your region.  Follow the link and enter your country.  https://locator.rockwellautomation.com/ Avanceon Ltd, Lahore, Pakistan +92 42 111 940 940 A-B/Rockwell has extensive literature easily found on the web to educate you.  Start by learning the different PLC platforms that are offered, then understand the software needed for these platforms. 

This depends on Motor Polarity & Feedback Polarity, an attribute that allows the move polarity to be flipped to match a process direction.  Servo controllers think in terms of target position in relation to actual position per settings configured. I remember needing this same tag some years ago and coding it with timers, storage of position, comparison of buffered and existing position, then energizing CW or CCW status tags.

ML1000 has no clock feature, only a free-running clock; ML1100 has a built-in RTC real-time clock; ML1200 & ML1500 have the optional RTC module. If you have an HMI attached to the network, you would MSG the date/time from HMI into PLC. If no HMI, you could build your own RTC with cascading timers and counters; it will need to be calibrated in some way.

You want a program or ladder file to execute every 4 hours?  If so, which PLC processor are you using.  

cHud is correct...CoDeSys-based PLCs, such as Wago, have internal web servers built in.  You can build HMI webpages that are viewable on your smartphone.  If your cabinet includes a WiFi router, you can easily set up smartphone communication.  

The "sometimes its here, sometimes its not" issue is often classic memory leakage, applications pushing resources past their limit.  How large did you declare your VM to be?  Is your PC a quad-core that supports hyperthreading?  Is hyperthreading enabled in the BIOS? I have a long VM Primer I developed with configuration settings and notes.  If you are interested, message me your email and I will DropBox a download link to you - the file is too large for an attachment.

You desire a cordless screwdriver with a small-diameter shaft so that it can penetrate the small A-B terminal block screws?  Which A-B TB part family are you desiring a solution for?  There is a huge variety.  One will need low-speed, low-torque, small diameter.  What is the budget?  https://www.expressassembly.com/catalog/Inline-Air-Torque-Screwdriver-FL045?gclid=EAIaIQobChMI75q5uKis1wIVSmx-Ch0vgA-iEAkYASABEgIOBfD_BwE Research the screw diameter available, research cordless low-torque screwdrivers with small-diameter shaft.  Old-school ratchet screwdriver may do the trick.  https://www.google.com/search?q=small-diameter+cordless+screwdriver+shaft&source=univ&tbm=shop&tbo=u&sa=X&ved=0ahUKEwirqOueqKzXAhXEZCYKHeTuBScQsxgIJw&biw=1920&bih=900#spd=247312322370454551

Was this a working PanelView prior to attempting download?  Have you gone through the PanelView troubleshooting to verify the hardware is functioning properly?  Is this a PanelView 600 or a PanelView Plus 600?  Refer to the manual and verify the status lights on power-up.  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2711-um014_-en-p.pdf

The PLC and PC Ethernet/IP addresses are not configured to communicate with each other, yet.  Do you know for sure what the Ethernet/IP addresses (and subnet masks) are for the PLC and the PC?  Is DHCP turned ON for either device (i.e., Ethernet/IP is not set and device requests Ethernet/IP be set remotely)? If either/both device has had Ethernet/IP address programmed and you do not know what the address is, that can be dealt with. Post screenshots of the Ethernet/IP address configuration for both the PLC and the PC, please.

Have you read the manual for RSView32?  Post screenshots with the problem or where you are stuck, that will get the best response from the forum. Understand that the project is built for the HMI to communicate with the PLC; if the compiled, downloaded HMI project does not allow the HMI to communicate with the PLC, then the HMI project communication path is not set properly.  Chapter 2 http://literature.rockwellautomation.com/idc/groups/literature/documents/um/vw32-um001_-en-e.pdf

Would this make more sense in a Siemens forum post?  A screenshot of the logic may help more than the cryptic machine code listing.

This subject has been a goal for many for some time. I have not pulled it off yet, but I think the time is near to make it happen. Has anyone had success with putting their HMI view or control on a smart phone or tablet? If so, what software has worked for you?

First with encoders, there are multiple styles of encoder.  Incremental, absolute, single-turn, multi-turn, with different output types (differential line driver, open collector output).  It is not plug and play.  Research what the PLC supports, research what the encoder is, research the wiring required, research the programming required.  Plugging it in is just a part of the task. Understanding Encoders.pdf

Have you consulted the owner's manual, concentrating on the Troubleshooting section, such as checking the Status Indicators (page 21)?  Fault Indicator OFF => Hardware Error (replace HMI); Fault Indicator BLINKING => Hardware Error in Display (replace HMI).  Blinking Red => recoverable; Solid Red => unrecoverable (replace HMI terminal) http://literature.rockwellautomation.com/idc/groups/literature/documents/in/2711p-in002_-en-p.pdf

The ML1500 offers an add-on real time clock module (1764-RTC).  Although I have no experience with such, it appears the ML1500 needs an external clock module to provide date/time functionality into your application.  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1764-um001_-en-p.pdf

This customer has many machines, all with A-B PLCs, and all with a 6181 PC-based FactoryTalk View SE application?  If that is the case, they have much of the tools in-place already.  Each FTView SE application is a full-blown SCADA system, storing data probably in the complimentary Microsoft SQL Server license that comes with every FTView SE license. To clarify...FTView ME (Machine Edition) is for HMI dumb terminals, limited data collection; FTView SE (Site Edition) is for PC-based HMI applications with capability for data & event collection. FTView SE has the capability to store events in a complimentary SQL database.  The customer can run SQL query reports, which they probably have someone who does already, either on command or timed (every day, generate a report for the last 24 hours, email report to list of people).  There are many SQL report generating front-ends on the market. If this is along the line of what you are interested in, message me and I will share a wealth of knowledge on this subject.  The files are too large to mass post here. FTView Studio - Event Data Collection.doc

When you say you tried to replace the new touch, please describe what you did (did you replace the touchscreen front face, did you replace the whole HMI).  Is there an anti-glare membrane on the screen face? The HMI main board is sensing a button is pressed during startup. Do you have a keypad version (with buttons) or a touch version (touchscreen only)?  What happened prior to the failure? http://www.plctalk.net/qanda/showthread.php?t=81606 http://control.com/thread/1466489142 https://www.youtube.com/watch?v=GAovhUoDFb8

Is this for a class project?  

Your choices are Purchase Logix500 for 64-bit OS or Utilize a virtualizing package (such as VMWare Workstation) and create a 32-bit OS then install Logix500 Micro Starter Lite.

This concept should work, pending the solid-state relays have been sized for the load and the PLC controller supports a PID function.