kaiser_will

This counter is being reset on power-up is the issue?  The counter instruction is a CTU?  Please post a screenshot of the counter RESET instruction.  This rung is being executed on startup, and that is your root-cause.  

To find the model number of the module, open the swing door on the front...the A-B part number is on the lower part of the swing door

There is no PLC4 attachment.  (2) solid-state relays for the (2) electric heating elements, and (1) Type-K thermocouple.  Have you considered a simple, off-the-shelf heating controller?

Your PLC program notes that the serial port is configured for DF1 (should be RS-232); RSLinx driver on your PC you noted is configured for RS232-DF1 (correct, but the settings within this driver will need to be set for RS-232 SERIAL not DF1).   DF1 is a Rockwell/A-B protocol that LOOKS like RS-232, but is pinned out differently.  That serial port on the PLC can be configured for DF1 (Allen-Bradley PLC), DH-485, or RS-232.  RSLinx...Driver=RS-232 DF1 driver, Comm Port=COM 0 (if you are 100% sure your PC serial port is COM 0), Device=PLC-CH0 Joe E notes that a standard DF1 serial cable can be converted to serial cable with a null modem.

Have you connected a serial device to this PLC before, or is this the first time?  What are you connecting via serial port to this CompactLogix PLC?  You do understand that a CompactLogix serial port can be configured for RS-232 (typical serial application) or Allen-Bradley DF1 (same DB-9 connector, but different cable pinout and configuration)?  http://www.plctalk.net/qanda/showthread.php?t=40432  http://www.kvc.com.my/StorageAttachment/Kvcsb/datasheet/7/allen-bradley-1756-cp3.pdf

You have a MicroLogix 1200 PLC, model 1762-L40BXB, and it communicates with a HMI.  You "give the setting" through the HMI, "but that is not fix".  Please clarify the setting that is erased?  A screenshot can help both of us, if you have the ability to do so.

Get a preventative maintenance schedule setup for PLC processor batteries.  The first power outage was your wake-up call that this subject may not be properly addressed. 1756 ControlLogix batteries are lithium and derated due to their environment temperature.  Panel temp (106-113F) derates typical battery life to 2 years; (97-104F) derates to 3 years (page 38).  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1756-um001_-en-p.pdf Get a preventative maintenance schedule setup for replacing your spare batteries.  The battery meters out as awesome until you put a load on it, then it cannot handle the load? The 1756-BATM external battery module, if the lithium pack is healthy, will provide longer ride-through and reduce the potential for a similar event.  http://literature.rockwellautomation.com/idc/groups/literature/documents/in/1756-in576_-en-p.pdf It appears that gaps in the PM of the battery and battery storage may be your root-cause, but a faulty rack power supply could pull that reserve ride-through battery down, as Filthy notes.  If you have an old school oscilloscope, meter the bus voltage and battery voltage powered up, powering down, powering up for a few cycles taking notes as you go. Speaking from experience, too

Which Allen-Bradley safety product family are you referring to?  There are many.  http://ab.rockwellautomation.com/Safety/IO http://ab.rockwellautomation.com/IO

Attached is a brief code & process description of a reference MAOC application.  This process was somewhat similar - rotating drum with ejectors that need to come on at a specific position and only for a brief period of time.  The information and code example may be of use in understanding the motion instruction. Primer - Bottle Filler - Cam Profile & Ejectors.doc

The specifications for this output module, page 186, note an output voltage range of +/- 10V.   http://literature.rockwellautomation.com/idc/groups/literature/documents/td/1756-td002_-en-e.pdf

I built this Produced-Consumed Work Instruction some years ago.  It is a technology I haven't referred to in some time. Understand with Produced-Consumed tags, the pair of controllers (and they can be physically in different places but must be able to communicate with each other) update writing to (Produce) and reading from (Consume) tags.  Any lag in your network not being able to successfully read and write these tags will lead to operational problems. Work Instruction - Allen-Bradley 1769-L32E and L35E Produced and Consumed Tag Mapping.doc

You have a CompactLogix 5570 L73 processor, which has (1) Ethernet/IP port and (1) mini-USB port.  You have a Windows 7 64-bit PC running Logix V24. Which model Perle Ethernet-to-Serial converter model are you using? If you have a Win7 PC, what is the purpose of the Ethernet-to-Serial converter?  PLC has Ethernet; Win 7 PC has Ethernet. Can you post screenshots of the problem situation?

Allen-Bradley EDS files are free downloads.  Which specific ControlLogix processor do you have?  What PC operating system version are you using (32-bit or 64-bit)?  What version of RSLinx are you using?  What Ethernet-to-Serial converter are you using?  These are the (4) pieces of the pie. Understand that when you connect the Ethernet-to-Serial converter into your Windows XP PC, that the operating system will create a virtual serial port.  Open Control Panel, Device Manager, and take note of the virtual serial port that is created (the OS will use an unused IRQ port, virtual port number).  This virtual port number is needed when you add a RS-232 DF1 device in RSLinx.  

For the life of me, I cannot understand the topology of this control system you have described.  But it sounds very interesting.  Can you explain the normal operation in more detail? When the XP PC hard drive was replaced, and the operating system was installed, did they install the same 32-bit XP OS, or did they install a 64-bit XP OS?   Did someone document the software and versions of the previous build and build exactly to suit, or did they use what versions they could find? RS Linx is the communication layer of most A-B software products, it is the glue between the hardware layer software (RSLogix or Studio5000) and the hardware (PLCs, HMIs). From your description, I cannot state where the problem lies...within the network or the Windows XP PC.  Have you tried looking at the XP OS Error Reporting?  XP does a good job of documenting when processes take a dump.

If the PLC DHCP is turned off, it will not show up via BootP If the PLC is addressed and you have no idea what the IP address is, and someone was not nice enough to place an IP address sticker on the processor (great suggestion), try using WireShark to sniff it out.  Disable all ports on your development PC except for the port connected to the PLC.  If there are other Ethernet/IP devices on the machine, leave only the PLC connected and your development PC. Let WireShark run, and soon you should see broadcast traffic from the PLC indicating the IP address

What version of Logix500 are you using?  When you say "there is not a setting for SLC500", what do you mean "setting" and where? Understand that RSLinx is the communication layer of Allen-Bradley's programming packages.  One must configure the link within RSLinx in order for the communication layer to link successfully with something hard in the real world. An example work instruction is attached that walks users through the difference in SLC ports, along with setting up a USB-to-Serial communication connection.  Even though you may connect via a different pipeline, the steps are very similar.  Hopefully you get a better understanding of the communication fundamentals. Work Instruction - Allen-Bradley SLC Communications Setup.doc

There are solid fundamentals with every control platform that are required to provide working solutions.  A-B has very good literature, in my opinion, that seldom is vague (you might have to hunt for it, but the information is out there and readily available).  Often, the answer is like communicating with an autistic person...it is all in how you phrase the question. A web forum or a video will not replace slowing down, reading the literature, understanding how the system is functioning, taking a FREE online class, going to a FREE on-the-move lab, or attending a paid classroom instruction. One should never expect A results with C effort.

Logix500-based processors, like the Micro 1400, are I/O-based with a single routine (LAD x) that is the main routine.  Any other routines will need a JMP or JSR to send control to that routine.  If your new routine or the whole program is not functioning as expected, you are encouraged to put Nanny code that will track execution, such as counters with one shot bits. Refer to Chapter 17  http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1766-rm001_-en-p.pdf https://www.courses.psu.edu/e_met/e_met430_jar14/prgflo/jsr.html You have a subroutine that must not send control back to the main program if it does not fully complete.  For myself, a robust control program starts with a concise flowchart.  Chart the process and your inefficiencies should be glaringly obvious.  The system will only do what you tell it to do.

"operator needs to get inside the enclosure while the machine is in auto mode".  If there is a potential for the operator to be injured, this approach is not acceptable.  The modern accepted solution is to control harmful energy when an operator enters a work area, such as a physical barrier/guard with a safety interlock switch that disables harmful energy when the interlock switch is opened.  Previously, this was done by running mainline contactors with their coil tied in with the interlock switch (open the gate, mainline contactor drops out and harmful energy is dissipated).  Today, the mainline contactor can be replaced with motor drives/servo controllers that support STO (safe torque off). https://ohsonline.com/Articles/2016/12/01/Protecting-Workers-from-Automated-Machine-Operations.aspx http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/safety-rm001_-en-p.pdf?utm_medium=Email&utm_source=EMEA_NL_ALL_AT_5_Jun16&utm_campaign=Corporate_EMEA_XX_XX_2016_Automation_Today&utm_content=EMEA_NL_Austria_AT_Jun16&s=1284661142&lid=30561&elqTrackId=3c28637972ce4337a8f3d616c96aa311&elq=5b39ebeab0d24a2e82d2482953ac3d66&elqaid=21537&elqat=1 Possibly, for the sake of the class, the instructor and instruction institution are accepting responsibility for unintended injury and just want you to add the buttons. 

There are multiple root-causes for a SLC rack to reboot.  Incoming power, poor rack power supply connections, rack slots not seated properly, rack backplane, rack power supply, processor, poor grounding practices.  Many of us have encountered some or all of these over our career. Unplanned restarts would force me to look heavily at the rack backplane and rack power supply.   However, your note that perception that the frequency of events appears to coincide with machine start/stop indicates a possible connection with system power.  If you have access to a power analyzer, such as a Dranetz, I would encourage you to connect to system primary power and analyze with machine running, stopped, and during start/stop events.  It could very well be poor incoming power quality (a power sag at machine start).  If you do not have a power analyzer, do you have an analog oscilloscope?  Meter power and grounding. Go online with the processor to look at the fault history...was there a fault event prior to the restart?

Startup Error 31 => refer to page 24, Function Key Failure.  http://literature.rockwellautomation.com/idc/groups/literature/documents/in/2711p-in002_-en-p.pdf Have you experimented with how long you press the F1 key during startup?  You may be leaving depressed too long - PRESS F1 key during startup, do not HOLD F1 key during startup.

For the newer PanelView Plus models, the application developer is highly encouraged to embed a "GoTo Configure Mode" button to allow for access to jump out of a running program and get to configuration.  Developers will often hide this button behind a password protected maintenance screen (or forget to add it all together).  This is Plan A. When the PV Plus 400 is powered up, there should be a WHITE box in the lower corner of the screen, lower-left.  Press this white box, which is only displayed for a few seconds after boot-up, to go into configuration mode.  This is Plan B.   Refer to page 218.  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2711p-um001_-en-p.pdf With the production process stopped, pull the HMI power plug and reseat to trigger a reboot.  Be ready to reach around front and press the white box during reboot.

Is the brake physically engaging?  Put a multimeter on the brake circuit and verify when it is engaging.  A digital camera and and a partner may be needed. Your stopping action is Decel & Disable, the same action for a number of faults (Lost Controller Connection, Motor Thermal Overload, etc.).  One would expect the stopping action to be correct.  Is it possible that your servo motor is not sized properly to stop and hold the load in the short span of time?  Is your machine design team using Motion Analyzer?

When your process demonstrates "bogus" alarm events during startup, a startup inhibit process may need to be added to suppress all alarm events for a brief period during HMI startup.   You could...create a new PLC tag (HMI_Startup); add a HMI startup macro to energize HMI_Startup (this tag will only be ON at HMI power-up via the macro execution); add PLC code one-shot to seal in a startup timer (30 sec) and latch off HMI_Startup; add PLC code to energize new tag HMI_Startup_Disable that is energized when startup timer is timing; add normally-open HMI_Startup_Disable tag to every alarm event to suppress the alarm during startup. http://www.plctalk.net/qanda/archive/index.php/t-80134.html

Have  you read the PanelView Standard Migrating Plan?  http://literature.rockwellautomation.com/idc/groups/literature/documents/ap/2711p-ap001_-en-p.pdf Successful conversion of your old Standard application to FactoryTalk View Studio will be a function of how much detail is in the Standard application.  Do you have a new PView Plus 600 and a converted application to test?  Suggestion is made to get a new HMI unit and do a simple conversion and test.  https://www.rockwellautomation.com/resources/downloads/rockwellautomation/pdf/events/raotm/sessions/tech/T101MigratingyourHMIsystem.pdf