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Everything posted by kaiser_will

  1. There are (2) tasks at hand...move a cylinder (pneumatic or electric or hydraulic?), move the cylinder to a position.  The 2nd task will require position feedback and closed-loop control.  Both tasks are highly mechanical for specification (the controls guys take care of the programming and wiring).  There is no way to concept the controls with a questionable mechanical concept. What is the specification for position accuracy?  How precise must the cylinder final destination be held to (+/- fractional thousandths, +/- an inch). What is the specification for cylinder speed?  How much time is allowed for the cylinder position to be changed. What is the specification for total load to be moved? Reed switches are often used in cylinders for general cylinder actuation feedback.  However, these buggers are a pain to adjust with high accuracy.  Reed switches are binary...they only tell you if you are at Position A or B.  If you budget is low and the specification is Low Accuracy, a cylinder with multiple reed switches per the customer location is an option. If your budget is higher and the specification is for High Accuracy, a servo cylinder is an option (servo-pneumatic or servo-hydraulic).  Such as a Festo servopneumatic system.   https://www.festo.com/cms/nl-be_be/16425.htm Parker, Festo, IAI...good places to start
  2. Allen-Bradley/Rockwell Compact-series HMI were first marketed with all programming via built-in web browser. Is anyone else providing a HMI with no software needed?
  3. Powerflex 4M

    The dated PowerFlex 4M has an Ethernet-type RJ45 port, but this is a RS-485 port (DSI).  Ethernet/IP was not commonly utilized when the 4M was rolled out. If you can connect to your system without Ethernet/IP, programming is done via the keypad. If you want to physically connect to the drive, you will need either DriveExplorer or DriveExecutive and a serial converter (#22-SCM-232).  Also known as "The Anaconda".   http://literature.rockwellautomation.com/idc/groups/literature/documents/um/22comm-um002_-en-p.pdf You can add a DSI interface module to your panel to convert the 4M RS-485 (DSI) port to Ethernet/IP. http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1769-um013_-en-p.pdf Or you can add an Ethernet/IP communication board to the PowerFlex 4M VFD, the #22-COMM-E.  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/22comm-um004_-en-p.pdf
  4. Allen-Bradley does have a brochure for the PF 755 utilized for material handling/crane applications.  However, the literature does not fully disclose "anti-sway" ability.  If you are talking material handling/anti-sway control, "lower cost" often is a recipe for a problem. http://literature.rockwellautomation.com/idc/groups/literature/documents/br/pflex-br009_-en-p.pdf Magnetek, a material handling controls/equipment manufacturer, does have an anti-sway control solution.  https://www.magnetekmh.com/Products/AC%20Drives/IMPULSE%20AC%20Drives/Sway%20Control%20System%20Series%202 ABB has more of a refined material handling/anti-sway solution.  https://new.abb.com/drives/media/crane-control-solutions
  5. Kinetix 300 Hard Limits

    It has been a few years, but I ran into a situation with the K300 continuously generating an E06-Hardware Overtravel fault that would not go away.  The fix per Rockwell...add 1.5K 2W resistors in parallel with each extreme limit input (stray electrical noise sensed as an extreme limit input ON condition).
  6. Debugging Local O: Data

    Usually, a cross reference will help you find the culprit (like 2 pieces of code controlling the same parameter).  However, with UDTs bundled into an AOI, is is very easy to have this situation.  If anyone has used the open-source PackML template (which Collins may be working with) then you know what I am talking about.  It is very possible to "walk on" a tag within the AOI.  I wrestled with the very same type of situation for a long time, and ended up re-writing the whole program without the pain-in-my-butt PackML template.
  7. Registering EDS Files

    Specifically what piece of hardware are you having an EDS file issue with?  There have been situations that require modification to get the EDS file to work.
  8. Upfront motion application design questions:  How will this master-slave relationship work, overall?  The scope of operation is not defined.  What is your motion resolution accuracy specification?  Resolution accuracy spec may or may not be capable.  How is the hydraulic cylinder controlled?  In order to slave a K300 servo controller, commanded with motion instructions, to a hydraulic cylinder, the cylinder control will need to be via a motion command, also.   Once the scope of operation is known, then research the motion commands needed.  Pull down the Logix/Studio Motion Instructions Reference Manual (Chapter 2, Motion Move Instructions).  From what I read...MAG (motion axis gearing) is probably the ticket.  Master (hydraulic cylinder control output with encoder position feedback input) is slaved to K300 servo motor.  In this fashion, whenever the Master is commanded, the Slave is commanded per the gear ratio. After you have scope and motion figured out, then it is onto determining the encoder feedback.  There are a number of encoder types for different applications.  Refer to the attached. Understanding Encoders.pdf
  9. Factory talk view

    You will need screenshots to fully express your situation.  I suspect your issue is with the scripting of register addresses; your SLC-500 PLC name is what is shown in RSLinx and that is what will be [shortcut] in RSView ME. For migrating a PV550 to a PV700, if the previous PV550 HMI application required operators to acknowledge all alarms (otherwise how would the alarms go away), the new PV700 application should do the same.  Otherwise you will be modifying the behavior of the machine.  
  10. A free TechConnect account will get you to the conversion tool download https://rockwellautomation.custhelp.com/app/answers/detail/a_id/450509
  11. Retrofitting old PLC5

    Ideally, a one-to-one PLC program conversion with identical HMI screen layout/functionality is probably the objective.  Same functionality, updated equipment - no enhancements. Request a drawing of the whole control system.  There could be communication modules that interface with other equipment (remote I/O racks, DeviceNet to VFDs, etc.).  You need to be 100% sure of everything controlled by this PLC. You will need the latest PLC program.  Do you have PLC-5 programming software (i.e., RSLogix 5 or AI)?  The complexity and functions that are in the PLC code will dictate which platform to upgrade to.  A CompactLogix 5370 L1-L2-L3 controller may be a good choice, but features utilized may force you to upgrade to a ControlLogix.
  12. CLX to Fanuc Remote Start

    With Fanuc robots and Ethernet/IP to an external controller, the key is the I/O stack.  The robot may communicate Ethernet/IP (the HOW), but it utilizes a stack of I/O (the WHAT) for the heart of the communications. Work Instruction - Fanuc Robot System Startup.docx Work Instruction - Omron PLC Ethernet-IP With Fanuc Controller.doc
  13. Micrologix and Sick Inspector?

    This is where Sick's literature will drive your configuration, it is not a Rockwell/Allen-Bradley decision.  I have seen Generic Ethernet module configurations of Type INT or SINT; the hardware manufacturer (Sick) will specify what works for them.  Then you need to know the number of input & output words and the instance numbers. I found a Sick blog that suggests...Type-SINT, input instance-105, size-124; output instance-100, size-4; Config instance-1, size-0.  In the Connection tab, turn ON Use Unicast Connection Over Ethernet/IP.  http://sickusablog.com/easily-obtain-inspector-vision-sensor-data-ethernetip/
  14. Stratix Switch Data Type

    Great topic, something I had wondered about using for years but never got around.  Page 28 digs into it; tags configured that you can monitor in your code.  https://www.rockwellautomation.com/resources/downloads/rockwellautomation/noa/RAOTM%20Lab%20Manuals/L02-manual.pdf
  15. Specifically which faults are you getting when trying to energize the VFD?  Let the drive display cycle through ALL existing faults.  Install Connected Components Workbench, get connected to the problem VFD, and go online to dig further into the details of alarm history. Are you getting F041 (Phase U-V) & P042 (Phase U-W) & P043 (Phase V-W)?  If you are not getting all 3 phase shorted faults, the VFD may be telling you that this fan motor has failed.  However, if you are only getting one phase shorted fault, and you have metered the windings and did not find a line-to-line short, then this fan motor needs to be meggered (with a motor megger - tests the motor windings).
  16. A VirtualMachine is highly suggested.  Rockwell/Allen-Bradley is providing their field engineers with virtualized machines.  If you consider the number of hours to configure every new laptop just to get it to perform like the last laptop, then virtualizing your PC and replicating for a new install is the way to go. And being as some Rockwell/Allen-Bradley products do not perform on latest operating systems, virtualizing your PC is the way to go. The biggest struggles with latest operating systems and virtualized PCs, in my opinion...(1) selecting a PC platform that affords to virtualizing [hyper-threading & quad-core, minimum], (2) port sharing [USB requires R&D testing and diligence].  
  17. Have you entered motor nameplate info into drive parameters? Have you tried to auto-tune?  Auto-tune can create more problems than fix. You have metered all 3 legs of fan motor to ground and all 3 are not shorted? You have a Wye-connected 208V 3-phse fan motor on the load-side of the VFD, ground tied to center tertiary of the fan motor? Is the incoming power to the VFD Delta or Wye-connected? What is the Acceleration time set for the VFD to get up to speed (P041)?  Extend P041 time; reduce P044 (max freq); set P039 to 0 (V/Hz mode).  This will help in just getting the VFD to start and stop the fan for now.  With P039 = 0, A530 (Boost Select). How far have you dug into this issue?  This Rockwell A-B tech note will help.  https://rockwellautomation.custhelp.com/app/answers/detail/a_id/1063350
  18. Fault - Phase Short => Fault #F041, F042, F043; the VFD detected one or two of the three legs with more current than the others.  Verify with a multimeter that each leg-to-leg is not shorted.   You need to setup all motor nameplate parameters: P031-Motor Voltage, P032-Motor Hz, P033-Motor Overload Current, P034-Motor Nameplate Full-Load Amps, P035-Motor Number Poles, P036-Motor Max RPM, P038-Motor Voltage Class, P044-Maximum Frequency http://literature.rockwellautomation.com/idc/groups/literature/documents/um/520-um001_-en-e.pdf
  19. DeviceNet and Ethernet/IP are different worlds, so no.  The Ethernet/IP address is set after you disable DHCP and enter the new IP address (and cycle power).  Use a BootP utility to configure Ethernet/IP address and disable DHCP.
  20. This family of drives typically would have a 22-COMM-D DeviceNet adapter board for DeviceNet comms.  Is this communication board installed? PowerFlex drives typically come with DHCP enabled.  Have you disabled DHCP whilst you were configuring the IP address? What version of firmware are the PowerFlex drives running?  Drives often ship with a very early firmware, expecting the user to download and install latest firmware. The PowerFlex 523 and 525 families can be programmed via FREE Connected Components Workbench.  Without having a Rockwell/Allen-Bradley PLC program to reference (which would give you status of all drive internal parameters), you should download and install CCW (requires a FREE Rockwell user account).   The attached work instruction should give you some insight into these tasks.   Work Instruction - Allen-Bradley PowerFlex 525 VFD Startup.doc
  21. AB 1747-HSTP1 homing issue

    Post screenshots of your code.  Get access to an old-school analog scope, monitor the pulse train going out of the stepper module.  Break down the system into parts and try to verify that each part is doing their job...PLC code, stepper module, stepper controller, stepper motor.  The stepper controller should  be queued up and ready to home to limit switch then rotate CW or CCW based on the step pulses commanded.  Right now you are assuming the stepper module is homed properly and the CW or CCW light on should indicate step pulses are being sent to the stepper controller. The 1747 Stepper control is open loop...tossing commands over the wall anticipating the other side will move. Is the stepper module homing properly?
  22. AB 1747-HSTP1 homing issue

    Your issue is with how the axis behaves when homing?  Please specify what the system is doing wrong. According to your notes, you set Bit 4 ON (A Home Limit Switch is used) and you set Bit 5 ON (A Home Proximity Sensor is used).  These should be mutually exclusive...either 4ON-5OFF or 4OFF-5ON.
  23. Micrologix and Sick Inspector?

    MicroLogix 1100 and 1400 both utilize RSLogix500, an I/O-point development package All ComactLogix processors utilize RSLogix/Studio 5000, a tag-based development package Sick Inspector VSPI is an Ethernet/IP-based 2D vision scanner MicroLogix 1100 supports Ethernet/IP networking for peer-to-peer messaging (explicit CIP messaging with MSG block) CompactLogix processors communicate via Ethernet/IP utilizing client/server connections I could not complete the research to verify if the Sick Inspector VSPI supports Modbus TCP over Ethernet.  It appears this vision scanner is Ethernet/IP only; you need a controller that supports Ethernet/IP with implicit messaging.  https://www.rockwellautomation.com/resources/downloads/rockwellautomation/pdf/sales-partners/technology-licensing/eipexp1_2.pdf

    The K300 servo controller has a Web browser built-in for configuration.  This work instruction may be of service.  I added a related instruction for adding pull-up resistors for the extreme limits. Work Instruction - Allen-Bradley Kinetix 300 Servo Pull-Down Resistor Install.docx Work Instruction - Allen-Bradley Kinetix 300 Servo Startup.docx
  25. Panelview Plus 600 problem

    You make a very good point...how the heck to get to Configure Mode when the unit is stuck in Watchdog Error.  Sadly, Rockwell notes for this model...Replace The Terminal.  Do you have the application program archived?  https://rockwellautomation.custhelp.com/app/answers/detail/a_id/766033 There are NOS (new old stock) units still in the supply market.  https://www.amazon.com/gp/offer-listing/B00TT5NX3I/ref=dp_olp_all_mbc?ie=UTF8&condition=all