Joe E.

MrPLC Member
 View profile  See their activity

  • Content count

    1600

  • Joined

  • Last visited

Posts posted by Joe E.

  1. Posted

    59 minutes ago, BobLfoot said:

    It's pretty basic, but did you check the thumbwheel settings?

    If the thumbwheel is between 1 & 254 then the device comes up as 192.168.1.X where X comes from the switches.

    No boot-P or dhcp requets are issued.

    I've also in some models connected RSLinx to the 192.168.1.X address and chenged the address to what I want using linx module properties.  Set the switches to 256-989 and cycle power.  It now comes up at the desired address.  Again no need to mess with Bootp/dhcp 

    I've never encountered Point IO before, so I didn't know about the thumbwheels. That has definitely caught me before, I think it was on a 1756-ENBT. That's a good trick that I'll have to try again. I seem to remember trying it once and it failing, but I don't know what device it was or what went wrong exactly.

    If it's not a new module, it's also possible that it's already been set. In that case, you can use Wireshark. Connect your network adapter directly to the device and see what it does. You should see some packets that contain its IP address as the source.

  2. Posted

    I think it's at least partially because of our IT settings, but I've found that I have to disable all network connections other than the one I'm using. In the BootP program, you can select which network interface to use. Then I use a patch cable to connect the network adapter directly to the device. You may have to power cycle the device after it's connected.

  3. Posted

    Theoretically....maybe. I've worked on HMI migrations where I had old and new operating side by side and it went ok...on the bench. But I wouldn't try to do so in the field. Having two devices control the same thing is generally not a good idea.

  5. Posted

    I have almost no experience with ABB drives, but here are my first thoughts as a starting point.

    Does it accelerate more accurately while running on internal or external control? In other words, calculate how long you would expect the motor to take to get to its target speed based on the max acceleration parameter. I would expect the encoder feedback mode to be more accurate. Check also for other parameters that might limit the acceleration. It's possible there are current limits or other parameters that are only active while using encoder feedback.

  6. Posted

    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.

  7. Posted

    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.

  8. Posted

    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.

    3 people like this

  9. Posted

    29 minutes ago, BobLfoot said:

    @Joe E. That PDF is going to be priceless thank you.

    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.

  10. Posted

    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.

  11. Posted

    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

    1 person likes this

  12. Posted

    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.

  13. Posted

     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.

    1 person likes this

  14. Posted

    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.

    1 person likes this

  15. Posted

    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...

  17. Posted

    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.

     

  19. Posted

    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.

  20. Posted

    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.

  21. Posted

    So, for data collection I would investigate the Red Lion Data Station. If that will do what you want, I would very seriously consider replacing the DH485 HMI with a Red Lion  HMI because the HMI can do the data stuff too. The Data Station is basically an HMI without the screen.

    For remote access via RSLogix...that's harder. At my previous location, we had some SLC 5/04s on DH+ that we were able to connect to another machine on the same line that had a DH/RIO module in a ControlLogix rack. If the ControlLogix was networked, we could get to the SLC via the backplane. I don't know of a good way to do that with a SLC 5/03 though. Mickey's suggestion is worth a try and may let you get online with it as well as have a SCADA get data.

    What were you planning to use for data collection? Do you already have a SCADA system running?

  23. Posted

    If you find differences between them, use CCW to backup the current configuration of the drive before making any changes...just in case. If the only differences are in the tuning parameters and the motors are at least nominally identical, I wouldn't change any parameters without investigating a bunch of other things first. I'd check to see if the pump/motor has been replaced recently. We have a machine here where a NEMA Design B motor was replaced with a Design D (or maybe the other way around....) and it kept tripping the overloads. The other nameplate information was identical, so it wasn't obvious at first glance what the problem was. Something like that could cause a tuning issue.

    But...my first suspicion is still a mechanical issue or damage to the motor or wiring.

    1 person likes this

  24. Posted

    Gotcha. For fault 12 HW OverCurrent, the manual (Page 321) says:

    Quote

    The drive output current has exceeded the hardware current
    limit.
    Check the motor and external wiring to the drive output
    terminals for a grounded condition. Check the programming.
    Check for excess load, and other causes of excess current.
    Insulation Resistance (IR” test the wiring to motor.

    https://literature.rockwellautomation.com/idc/groups/literature/documents/pm/750-pm001_-en-p.pdf

     

  25. Posted

    Is this a new installation? Is it 4 drives connected to 4 identical motors?

    If it's an existing system that started showing this fault, I would look at the motor and its coupled load.

    If it's a new system, the motors may not be perfectly identical enough for identical tuning parameters to work well. In that case, doing the static tune on the problem drive may sort it out.