kaiser_will

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Posts posted by kaiser_will

  4. Posted

    Which PLC processor do you have?

    COP, as you are having trouble with, Source and Destination must be same type (INT).

    You want to copy/move part of a source into a destination word...Masked Move (MVM) may be your best bet, allowing you to move part of source to destination.

    http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1756-rm003_-en-p.pdf

    The other issue you are going to have is you want to move "32" into bit 7.  Data move instructions are byte-for-byte;  "32" => 0010 0000 (bit 6 is high).  But you want to move "32" into bit 7 => 0100 0000, which is actually "64".

  5. Posted

    What PLCs are at each station?  What communication protocol/networking are you using?  How much "data" do you want to transfer from station to station with the product?  What is the cycle rate of the part?

    For this process, consider developing a flowchart of the process.  Start small and add as much detail.  As you are developing your flowchart, ask yourself how can this step go wrong (i.e., determine all modes).  When you determine all modes of operation, this is helpful for determining what alarms to be displayed.  A good flowchart would like the process and have handshaking (and mode alarms). 

    Without a well thought out sequential process, throwing data over the wall (i.e., daisy chain) often has events in which the system fails.

    If you have Visio, I can provide flowchart examples.

  6. Posted

    Akif I have been in your position, inheriting a DeviceNet mess "that worked".  Working around production, myself and our technicians isolated a DNet connection point, monitored the network to find out where the break was, and took good notes.  It is easy to separate the network and ring out wires.  However it usually means "breaking" the network, which might affect production.

    Dig into the DNet module to find diagnostic history.  Work your way backwards.

  7. Posted

    Micrologix 1400:  D-Sub communication port supports protocols DH-485, DF1-Full, DF1-Half, DF1 Radio, Modbus RTU, ASCII, DNP3 Slave.

    http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1766-um001_-en-p.pdf

    Panasonic GT707 HMI:  D-Sub communication port supports protocols MEWTOCOL & MEWTOCOL7, General purpose serial (for Panasonic dedicated protocol), Modbus RTU, Other.

    https://www.panasonic-electric-works.com/cps/rde/xbcr/pew_eu_en/mn_gt707_hardware_jp_en.pdf

    It appears there is no defined DF1 protocol for the Panasonic HMI to communicate with any Logix PLC.  You do have the ability to configure communication for Modbus RTU.

  12. Posted

    Something has changed to your DeviceNet network and the interface card is letting you know it.  Poor connection, damaged DeviceNet media, one too many nodes attached.  DeviceNet is very rugged and robust, but I have seen many DNet networks show signs of failure and nobody has a definitive schematic of the network.  Do you have a good schematic?  Start going through the network looking for physical signs of failure, pinched trunk or drop lines, poor connections.  We had a similar failure; root-cause - someone pushed the SCADA computer too close to the office wall, shoving the termination resistor to the side and making a poor contact.  Had it not been for the cleaning lady, the problem would have never occurred. 

  13. Posted

    1794-OF4I => Isolated 4-channel analog output module.  In Logix5000, when you add a PLC module, Logix automatically creates read and write configuration words , tags, for you.  If you pull up the Controller Tags list, and drill to the rack and analog output module, there will be input and output words.  Read the literature; these cards can be used in a multitude of ways, so look for your desired example.  You will need to set/reset certain bits to get the desired configuration.  

    http://literature.rockwellautomation.com/idc/groups/literature/documents/in/1794-in037_-en-p.pdf

    http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1794-um008_-en-p.pdf

  14. Posted

    1. Research the PID itself and understand the differences in undershoot, overshoot, unstable conditions, etc.

    2. Break the problem description down into blocks.  Bit-size morsels is how we code.

    3. Learn and understand the PID (or PIDE) function block; it is only 1 block.  A code example for 1 rung and 1 block...probably not going to happen.

    http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1756-rm003_-en-p.pdf

    http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1756-rm006_-en-p.pdf

    http://literature.rockwellautomation.com/idc/groups/literature/documents/wp/logix-wp008_-en-p.pdf

    http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1756-rm094_-en-p.pdf

  18. Posted

    You are trying to restore a FTView 8 backup application with FTView 7 and it does not work.  This is very common.

    If this application came from a supplier and you do not have FTView 8, you could try asking the supplier to save as a FTView 7 application.

    An alternative is to contact your local Allen-Bradley/Rockwell distributor and ask if they can open and back-convert the application to FTView 7.  Being as they are not getting anything for this work, the answer may be "no".

    As noted above, there may be loss of functionality in  your application if it utilized features not in the newer software.

  19. Posted

    Keep in mind (along with JackDempsey's comments)...with indirect addressing, make sure to add limit tests.  If you increment the indexer beyond the dimension of the array, the processor will fault.  Unplanned downtime, scrap product created, late order delivery, your name next to a staff note...been there.

    1 person likes this

  21. Posted

    Joe E raises a good point...legacy equipment with the PIC box likes Win XP but hates other operating systems.  A nifty work-around is a WinXP VirtualMachine loaded on your Win7+ PC; I prefer VMWare Workstation.

    Alot of the older PViews do have (2) ports, but read the fine print...one is often DH-485 and the other is RS-232 for a local printer.

    When you are tasked with getting something up, always research the details.  Assuming a DB-9 port is RS-232 and up for grabs can wind up causing a lot of grief.  A brief sort-of primer on SLC processors is attached; something I created to educate the field techs for this very subject.

    Read the literature, network the devices, add functionality for you to test communication.  HMI status lights tied to PLC addresses; HMI buttons tied to PLC addresses.

    Work_Instruction_-_Allen-Bradley_SLC_Communications_Setup[1].doc

  22. Posted

    MOST AC induction motors are capable of 100Hz continuous-duty operation.  Before you jack up the maximum VFD speed output, gather data on the motor and how much it is loaded already.  If the application is already fully loaded, increasing the speed headroom will do nothing for you.  

    There are a number of questions to answer prior to making the change.  How is the VFD commanded?  It could be a speed pot, an analog output from the HMI via the PLC, an Ethernet/IP register from the PLC.  Pull out the electrical schematics, go through the PLC program, pull out the VFD user manual.

    http://literature.rockwellautomation.com/idc/groups/literature/documents/td/520-td001_-en-e.pdf

    http://literature.rockwellautomation.com/idc/groups/literature/documents/um/520-um001_-en-e.pdf

    PFlex 520 AC VFDs have parameter P044-Max Freq (typical is 60Hz).  Once you have proven that you will not burn up the motor, and once you have insured yourself that the motor is not fully loaded already, with the machine stopped, change parameter P044 and whatever else is needed (for expanding the maximum signal coming into the drive).  

  23. Posted

    Although I haven't worked with the PF527 line, I do believe they offer basic V/Hz control.  I do not have a code example I can share, but this Work Instruction will walk you through using CCW to add the drive to your project, then use RSLinx and Studio5000 to bring the networked drive into your project.  After that, create the safety routine to utilize the STO feature, add motion code and you are set.  

    Work Instruction - Allen-Bradley PowerFlex 525 VFD Startup.doc

  24. Posted

    Have you read through the Mitsubishi drive manual?  You have programmed the drive for the analog input command (i.e., analog current or analog voltage)?

    http://dl.mitsubishielectric.com/dl/fa/document/manual/inv/ib0600366eng/ib0600366engg.pdf

    You will want to add HMI indicator lights mapped to motor drive status registers (i.e., ON, Faulted, Running, Stopped, Speed Command, etc.).  These "idiot lights" come in really helpful with debugging communication.

  25. Posted

    No Rockwell Support Contract (that you know of), No Solenoid Output Snubbers, No washdown-rated electrical panel for the PLC.  You have your work cut out for you.

    To justify to your management a support contract...ask "what is 1 day of production worth?".  The annual support contract value should be a fraction of daily production worth.