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  1. Designer 5000 cannot Auto Module Discovery

    In your original post you said you are using Studio 5000, V32. The L6 controller can not use V32, as it is hard-stopped at V20. It sounds like you're able to get the Select Module Type dialog box for adding modules to open and the Catalog tab is working, but the Module Discovery tab is not working. So let's back up a bit and start with the basics: Are you building a new project, or adding to an existing project? If you are adding to an existing project, go online with the controller and open the Select Module Type dialog box and choose the Module discovery tab. If you are creating a new project, the easiest way I've found to add I/O cards is to create the project selecting only the controller, controller slot number, and firmware. Save and download to the controller, go online with controller, then use auto-discover. If you're using an L6 controller, you will have to use an RS232 cable to plug directly into the controller. On the L8 controller, you can use an EtherNet cable or USB cable, plugged directly into the front of the controller card. A couple of important (if not silly) gotcha's: You must be online with the controller. The I/O cards you're trying to discover must be properly seated in the cassis, with no fault lights on them. Open RSLinx and make sure it can see the I/O cards you're trying to add. If you're trying to discover remote I/O cards, a communication card must be added and configured in both the local and remote chassis beforehand. If you are able to download and/or go online with the controllers and all the above conditions have been met, and you're still not able to use Module Discovery: Close all applications on the laptop. Delete the RSLinx driver(s) you're using to communicate with the controller(s). Close RSLinx by typing "RSLinx Classic Launch Control Panel" in your laptop's search box, open it, and press the stop button. If it warns you the application is still being used, close it anyway. Completely power down and re-start the laptop. For the L8 controller, (assuming a valid Ethernet/IP address has been assigned to the controller) configure a new RSLinx ethernet driver. (If RSLinx is open, an RSLinx USB driver will be auto-configured when a USB cable is plugged into the controller). Go online with the controller and try to use Module Discovery. Hope this helps.
  2. DF1 Polling and PLC Fault

    Just drop an unconditional SVC on the rung below your overflow trap. Use the instruction help if needed. The overflow trap has likely eliminated the code as a possibility for this fault. It's looking more and more like a hardware issue. I'm assuming you've already checked your power (and other, if any) wires for solid, tight connections? The battery (though only used for storage purposes) is good? Are there any expansion cards installed, even if not used in the code?
  3. DF1 Polling and PLC Fault

    Looks like you have set it up for RS232, according to the pic you attached.  Is your laptop going into screen saver while connected to the running PLC? That could cause loss of comms to the controller. Unless you can sit there and stare at it, I'd disconnect the laptop while it's running without the HMI. Sometimes controllers are set up to go into a fault when they lose comms with an I/O card or other peripheral device, such as an HMI. I can't remember if the Micro 1500 has this option but even then, it should be a recoverable fault, not a non-recoverable fault.  Have you put in the math overflow trap and SVC instructions? Post the code (or a pic) if you have, please.
  4. DF1 Polling and PLC Fault

    This means that the PLC can't find a matching file project on the laptop. Have you tried using the Browse button and manually navigating to where you have the offline file stored? If that doesn't work, click on the "Create New File" and you should be able to upload from the PLC to the laptop. In your original post you said you were using RS232 as the communication format. However, I notice in the attached .RSS file that the comms are set up for DataHighway Plus. I can't imagine that would cause an unrecoverable fault, but it's easy thing to eliminate.  What's odd is that according to the indicator light, you're getting a hardware failure, and then you're able to come back from that by cycling the power. How long does the PLC run before the fault occurs? Have you tried putting the PLC in Run mode without the HMI connected and running? We really need to try to catch this in the act and grab a fault code. 
  5. DF1 Polling and PLC Fault

    Dumb question: did you try cycling the operating mode switch? The Micro 1500 should have one under the left door. From run to program and back once or twice should reset the fault. That will reset the controller without having to do another download. Unless the fault condition is still present, and then the fault may occur again as soon as the code scans. If you're moving a bunch of data around with each code scan it's possible that at some point a value larger than 32,767 came up, triggering the math overflow. The suggestions above (OTE with address of S:5/0) should help with that. Also, the code may have tried to write data beyond a file boundary, which will fault the controller. But we have no way of knowing unless we are able to read the fault code(s). When the controller is faulted, if you can see it via RSLinx, you should be able to view the data table from within RSLinx without going online. You'll be most interested in S:6, which is the Major Error Fault Code file. It will give you a numeric fault code that you will have to look up in the manual.
  6. Dint to Real

    DINT to REAL is easy; just about any math instruction will handle that. REAL to DINT is an issue because you will get rounding or truncating errors. But there are only two "rules":  If source A & B are not REALs, then the fractional portion of the result truncates.  If source A or B are REALs, then the fractional portion of the result is rounded. But how it rounds seems to be random. For instance, if the result is -2.5, it rounds up to -2. If the result is 2.5, it rounds down to 2.
  7. Powerflex 525 single phase

    Most drives will take single phase in, three phase out but you must de-rate the drive, typically to 1/3 it's nameplate rating. In fact, some drives even specify which line terminals you use for single phase input.  I'm still not 100% certain the OP is asking about single phase input, three phase output. But if that's the case, on a PowerFlex 525: R, S, & T are the line power inputs on the power terminal block. If you're wanting to run on single phase input, use R & T and de-rate the drive to 1/3 of its nameplate rating.
  8. PowerFlex 755 F12 (HW OverCurrent)

    If they've been in service for quite a while and are just now starting to get these faults, the real question is, what changed? If you have saved and off-line project somewhere in Drive Executive or CCW, I'd run a compare tool first to check the known good files against those on the drives. If you do not have drive tools software, use the HIM on the front of the drive and navigate to the parameters of the main control board. You will see a list that gives options like, "linear list, file groups, changed, access level". Selected changed parameters and this will show all the parameters that have been changed to something other than the default values. Write them down and compare against those in the drive that are not faulting. This will ensure that nobody has changed the parameters pcmccartney referenced above. If this doesn't produce any meaningful results, then you want to work your way through the mechanics of the system to see if you've got an actual excess load (bad bearings, worn gear boxes, etc), loose wires anywhere in the system, excessive environmental temperatures, etc. If you have several drive that have just started doing this, it has to be something that is common to all of those drives.
  9. kinetix 300

    In all Allen Bradley drives the term "reference" usually indicates a parameter that has something to do with how the drive is controlled. So "speed reference" in a VFD would be the data source that commands the speed of the drive. In this case, "ReferenceSource" in your Kinetix servo drive means the type of control being used on the drive, ie velocity control, current control, absolute position control, etc. Each bit in the ReferenceSource word represents a type of control, and the bit that is true is the type of control your drive is using. In the picture you posted bit 2 is true, so this drive is using incremental position control. For future reference: https://literature.rockwellautomation.com/idc/groups/literature/documents/um/2097-um001_-en-p.pdf
  10. Designer 5000 cannot Auto Module Discovery

    The most common reason people have trouble discovering modules is they're not actually online with the controller. You probably already know that Module Discovery feature only works while online but since it's the most obvious thing, I had to ask.  Can you add modules manually? Or does the Select Module Type dialog box fail to open at all? I've run into the manual working but discovery failing a few times with L7 controllers using V28 & V31. The only solution I've found is to completely shut down ALL open studio projects on the laptop, completely shut down RSLinx, and then start over from "hello". In one extreme case a few months ago I had to refresh the FactoryTalk Application Manager and reboot the laptop. If there's a simple something that can be toggled in Studio or RSLinx, I'd love to know what it is, because this happens to me three or four times a year. I haven't ever seen the Select Module Type dialog box completely fail to open and if that's the case, I'd close all the software you have open and reboot the laptop. I know that's a placebo but as often as not, it is effective. 
  11. factorytalk view SE

    Here are some course descriptions that may help you. The first two are for ME & Se; the last is for a remote desktop server called ThinClient that Rockwell is now using for remote monitoring and programming of controls.  https://www.rockwellautomation.com/resources/downloads/rockwellautomation/twn/pdf/CCV204.pdf https://literature.rockwellautomation.com/idc/groups/literature/documents/pp/gmst10-pp241_-en-e.pdf https://literature.rockwellautomation.com/idc/groups/literature/documents/pp/gmst-pp802_-en-p.pdf
  12. Load different programs on power up with compact logix

    Again, the idea would be to have one base PanelView program per machine, that can handle multiple tooling plates on that machine. Here's how the recipe works: You'll have a set of tags that you want to write data to. This is called the "Tag Set". These will be the same tags for ALL of your plates on ALL of your machines. (If you're not using a particular tag with that plate or machine, then it won't be in the subroutines for that plate and will be ignored, regardless of its value). You'll have the data that you're writing to the tags. This is called the "Data Set".  You can write up to 50 data sets to up to 50 tag sets. So that means I can have only one tag set being written to by up to 50 data sets. Or, one set of plate tags receiving data from 50 different data sets. BUT, you are not limited to 50 plates per machine. When you pair a data set with a tag set, you get a "Unit", and you can have up to 2,500 Units per PanelView program. This should be way more than the total number or plates you would ever put on a single machine.
  13. RSLogix 5000 BOOL Base tag not activating output

    DOH! Program vs controller scoped tags. Yet another gotcha! Good call panic!
  14. Load different programs on power up with compact logix

    How many tooling plates do they have that it would consume the entire memory of the controller?! That aside, the customer wants what the customer wants. I assume that you're using the similar data types and tags for each of these tooling plates, and further assume that some plates may have more tags than others. Likely, the majority of the storage you're eating is in the tag data-base, and possibly in some of the nuanced (or major) differences in the way each plate is used in the process. Just guessing, but am I on the right track? If so, have you considered using the recipe function in your PanelView? Factory ME & SE have recipe functions that allow an operator to write data to enormous amounts of tag sets with the touch of a button. Individual tooling plates would have their own recipes, the base project would use a generic code, calling specific sub-routines as needed per plate. Each time a plate is changed, the operator pushes the appropriate touch screen button to load the correct settings to the controller, rather than load a whole new project. I personally don't know of any automated means of downloading from PC to controller but I'm sure someone who was determined enough could come up with something.
  15. RSLogix 5000 BOOL Base tag not activating output

    In addition to what panic mode has suggested, right click on the output tag and cross reference it. This will show you everywhere in the code that tag is use. You're looking for another output instruction with that tag that is scanning that it back to a false condition after you think it should be on.  Make sure you check panic's first suggestion before you do anything else. Verifyt the controller is in the run mode, the routine that contains the instruction is being called, the instruction is not between a set of MCR instructions, etc. These are all simple "gotcha's" that will have you chasing your tail in circles if you don't catch them early.