Joe E.

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About Joe E.

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  1. S7-200 programming/replacement

    A quick Google search says it's part of the older TP family. I don't think I ever used a TP but did use the older MP series. I know the MP series used WinCC Flexible and I'm pretty sure the TP did as well. I agree that you're probably on borrowed time with the HMI; my experience with the longevity of the MPs was not good.
  2. Source Code Security

    Another end user here who insists on access to the source. We have a bunch of machines here (they started buying them before my time) that have Beckhoff PCs and the OEM's custom HMI software. We're locked in to their stuff and can't do much with them. We have another machine builder now who's also using Beckhoff but who has agreed that we will have full ownership of and access to the source code. I kind of understand the impetus as an OEM, but if you lock your code, that's a hard "no" from me. If I have any say in it at all, we won't buy it. I've run into too many machines with locked code and an OEM who was out of business or who had abandoned that product line so we couldn't support it and they wouldn't. The only encryption I would even be a little bit ok with is if it was temporary until the last payment was received and even that would only be if the OEM provided full (free) support during that period. That, of course, would have to be negotiated ahead of time.
  3. PLC Basics

    Personally, I think that the best practice is to write the code in whatever way makes it the clearest to the next person to look at it. I generally prefer rungs be small enough to fit on one screen without scrolling if possible. If you can be clever and write it in one rung but it's difficult to decipher....be less clever and break it up so it's easier to decipher. I'm a fan of avoiding 2AM phone calls. I've been called because "the PLC is the problem" and they stumbled on a piece of code they couldn't understand so it had to be the problem even though it was completely unrelated. I try to write code defensively whenever possible.
  4. Step 7 V5.6 with S7-400 Upload and Monitor

    You're very welcome. Remember, that pdf is based on a particular machine's configuration. If your Profibus settings are different (very likely),  you'll have to change it. There is an "auto" version of the PC adapter driver that works but is slower because it polls the network every time you go online with anything. Buried somewhere in the Set PG/PC Interface dialog is an option to manually poll the bus settings that will tell you the parameters of the network you're connected to. I almost always did that and then set the PC Adapter driver to match. Made for faster connections. If I had the software in front of me (or had done it more recently), I could tell you the exact wording of it, but it's been almost 2.5 years since I touched Simatic Manager so it isn't fresh any more. Ethernet is simpler (as long as you know the subnet), but our IT department did something to our host PCs that kept the Accessible Nodes function from working over Ethernet. It also blocked Rockwell's Ethernet/IP driver so we had to use Ethernet Devices instead. The S7-400s I messed with (a Loooonngg time ago) didn't have Ethernet, so that's probably a moot point in your case.
  5. S7-200 programming/replacement

    My first thought would be that, if they used a signal generator to "simulate" a known good signal from the transducer to the analog input and it didn't read correctly, that the problem is almost certainly the analog input module. But...if they swapped the output module instead of the analog input module, I don't have a lot of confidence they did the test correctly.
  6. Step 7 V5.6 with S7-400 Upload and Monitor

    I could guide you through it pretty easily if I could see your screen...but it's been long enough that I can't remember the details enough to give you a good description and I don't have access to the software myself any more to put something together for you. I wrote some work instructions at my previous location but they were based on having the archive file and knowing the Profibus network parameters ahead of time. I had to make it as easy as possible for the technicians because they weren't used to it but that makes the work instruction so specific it won't help you much here. The hardest part will be getting the PG/PC Interface working. Once that's set up correctly, the upload is pretty straightforward. You won't have any documentation, of course, but I'm sure you're expecting that. WI_GGM01(Pp3-8)_Small.pdf
  7. S7-200 programming/replacement

    That makes more sense. Yes, the analog input module could be bad. I'm a little concerned that a vendor tried replacing an analog module with a digital one. Generally, you have to tell the PLC what module is in which slot, so just moving it to another slot won't work without updating the program inside the PLC. Without having access to the programming software, the next step is probably to replace the analog input module.
  8. Upgrade a SLC 5/04 to ControlLogix

     I just remembered a previous project that we ended up bringing in a contractor to complete. We connected 2 Eurotherm temperature controllers to a ControlLogix PLC. Since the controllers only supported Modbus and not Ethernet, we used the Red Lion G310 HMI that was already present as a gateway. It worked well and easily. If you have (or plan to add) a Red Lion product to the line, it may be able to handle the comms.
  9. Upgrade a SLC 5/04 to ControlLogix

    You can look in the SLC 5/04 program and the program from any HMI to see how/where those N7 registers are used. That will help you figure out what you need to read from the Honeywell controllers. Since you're starting over from scratch, you may also be able to improve the operation of the system by retrieving more data points than the old PLC was and maybe use the PLC for setpoint changes and such if that's allowed.
  10. Kinetix 5500 lost power

    Did you swap the 2nd and 3rd drives? If the problem follows the drive (in other words, if drive #2 powers up in the #3 position),  you've isolated the drive itself and not the power supply to it. I don't know about the Kinetix 5500, but the 5300 we just quoted had about a 3 month lead time...
  11. Kinetix 5500 lost power

    The "2" means it has integrated safety over Ethernet/IP instead of hardwired safety. List price is the same.
  12. Kinetix 5500 lost power

    I don't know for sure. We had some come in  on a machine but I didn't dig into them too deeply. They also didn't use that jumper system on the main input power. Check this manual: https://literature.rockwellautomation.com/idc/groups/literature/documents/um/2198-um001_-en-p.pdf Page 58 identifies the connectors. If you're not using the separate 24V power connector, then it needs the 480V to light up. You could check the connectors on the top to make sure the 480 is making it to the 3rd drive. Maybe swap it with its neighbor real quick (don't connect anything other than the main and 24V power) and see if the problem stays put.  
  13. Kinetix 5500 lost power

    I'm pretty sure these have a separate 24VDC control power supply connector. Do you have power on that connector? If so, I would suspect a dead drive.
  14. S7-200 programming/replacement

    We all started out clueless with PLCs at some point, so: welcome! I would suggest reaching out to a local integrator with S7-200 experience. Maybe ask your local Siemens distributor for a referral. I would want the integrator to first connect to the PLC and do some diagnostics, including generating a backup of the existing program. I've worked with a bunch of S7-300 and S7-400 processors and a little with the newer 1500s, but never a 200 so I don't know what to tell you to check specifically. Once you have a backup of the program, the integrator should be able to download it to a replacement and, if that's the problem, you'll be back in business. Even if that works, I would seriously consider replacing the controls with a modern system.
  15. PowerFlex 755 - Static tune

    While the drive is running, check the display parameters (I don't remember which one) for the output current and see where it is compared to the other units running at the same speed. And maybe confirm the current reading with a clamp-on meter (being aware that the readings won't match since the clamp-on meter is only looking at one phase and they aren't as accurate when reading VFD current). Reducing the speed of a pump will reduce the torque (and therefore the current). Your results make me more suspicious of a mechanical issue in the pump or motor. I know you know this, but production also needs to know that even though it's running without faulting right now you haven't actually fixed anything. If a component (electrical or mechanical) is in the process of failing, you may have bought some time but this problem will almost certainly come back.