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Everything posted by ElectronGuru

  1. Powerflex 755

    There are only two jumpers that I know of on the MCB for the PowerFlex 755 drive; Safety and Enable for frames 1...7, and Enable for frames 8...10. So if this is possible, I don't think that jumpers would be involved. It might be possible to find the two or three tabs on the plug part of the MCB that are for power, hook power to them, then program while communicating via the Ethernet or serial ports. But without an adapter made for that purpose, I would be really warry of trying that. Again, if anyone else knows of a safe and effective method of doing this, please jump into the thread.  @VFD Guy, you ever hear of this? Question for @MTPControl; Why do you need to configure the MCB outside of the drive?
  2. Powerflex 755

    Not that I'm aware of. The main control board (MCB) is plugged into and powered through the backplane. I don't know of any safe means of attempting to power the MCB inside or outside of the drive without line power applied to the drive. If anyone else has a method for this, I'd like to hear it. If you have drive tools software, such as Drive Executive of Connected Components Workbench, you can configure your drive offline and then download the project to the drive once you're ready for power. If you're using ControlLogix, you can configure the drive in Studio5000 and once all the power and networks are up and running, the controller will take over the drive for you.  
  3. "No Project" displayed on the PLC

    This means that you have an L7 or L8 controller with the digital, scrolling display, and that display is currently saying "No Project". If so, you are correct that the controller literally has no project. This happens only under a few conditions: You have purchased a new controller that has never had a project downloaded to it. For a few moments when performing a download. (One of the first download steps is deleting the current project), When the controller has a major non-recoverable fault. Is there also a red fault light activated on the front of the controller? If so, this means the controller experienced a major non-recoverable fault, and has cleared its own project. This is generally considered a hardware failure and as often as not means the controller will need to be replaced. You can try downloading a project to the controller and see if it starts running normally. If it doesn't, you may try to flash the firmware on the controller and then download. And if that doesn't work, replace the controller. 
  4. PF527 Bus undervoltage user limit

    Thanks @VFD Guy! I've never needed to adjust or even look at those settings in an AC drive and only knew (as I said) that most drives don't allow it. Point of interest: though DC drives are a bit of dying art, the Allen Bradley PowerFlex DC drive allow line voltage max/min threshold settings as part of its normal parameters settings. 
  5. PF527 Bus undervoltage user limit

    I'm not an expert on this drive but I do know that most PowerFlex drives do not allow you to adjust the bus voltage thresholds. You can only program (on some drives) what happens when a bus over- or under-voltage condition occurs. As you likely already know, the bus voltage will typically go low for one of two reasons: The incoming power is low There's a problem with the axis motor or wiring that's pulling the voltage down. I've attached a link to the PF527 user manual, and Technical Specifications on bus voltage voltages can be found in Appendix A on page 137. I would check the specs against your specific drive, check the actual bus voltage with a meter at the DC+ and DC- terminals on the power terminal, and work from there.  https://lvmcc-pubs.rockwellautomation.com/pubs/520-UM002C-EN-E.PDF  
  6. Transfer parameters powerflex 525

    Sorry, @VFD Guy, I miss-spoke (-typed) myself. The firmware is fine; it's the EDS that's a pain. As most of us know, the EDS is just a text file that shows information about the device, does a couple of minor background things, and mostly just shows a pretty pic of the device in RSLinx. Typically, when you have a new profile your laptop hasn't seen before and you get that yellow question mark in RSLinx, you can just upload the EDS for that new profile from that device via RSLinx and be done with it. You can still right-click and upload the PowerFlex 520-series drives' EDS from RSLinx, but it's a few hundred files across several folders, and you have to use the EDS Hardware Installation Tool to install and get the EDS running. For anyone who's not used to the EDS installation tool, I've attached a short doc specific to the PF525 EDS download and installation. If anyone has a better, quicker way, please share! EDS.pdf
  7. Transfer parameters powerflex 525

    Not sure. Even though the release note says it was first noticed in V4.x, I know for a fact I had six PF525 drives with V3.x that the USB ("MainsFree Programming") feature wouldn't work on. That's the first time I complained about it, around three-ish years ago. This last January I had another batch of 525s come through and thought I'd re-check since the customer wanted to use that feature and sure enough, they'd finally fixed it. BTW, flashing the firmware is as easy as it can be. Getting it downloaded and installed on your laptop, not so much.
  8. Transfer parameters powerflex 525

    @RobinEriksen it should transfer the values for all the changed parameters for the drive. In your OP you said the drives aren't networked, so you shouldn't have to worry about duplicating node addresses on multiple drives. Once the transfer is complete, aside from auto-tuning (if needed) you should be able to "plug-and-play".   @VFD Guy From the release notes for PF525 latest firmware revision, V7, released Dec 2020: "USB connection is unresponsive on Windows 8 and 10 (PCBANOM-1471) Corrected Anomaly with Firmware Revision 7.001 Known Anomaly first identified as of Firmware Revision 4.001 Catalog Number: 25B PowerFlex® 525 with firmware revision 7.001 and later supports the USB application with Windows® 8 and 10."   Full release notes here: https://compatibility.rockwellautomation.com/GeneratedReleaseNote.aspx?v1=59671&v2=59671&o=&pdf=0
  9. Transfer parameters powerflex 525

    With the power off, remove the control module from the front of the drive and look in upper left-hand corner to find a USB port. Plug that into a laptop and a new device icon should pop up on the laptop. Click on it and follow the prompts to upload the parameters to the laptop, then reverse the process to download to the other drive.  One thing to be aware of is this procedure doesn't work well with Windows 10 unless both drives have firmware revision 7. If they have a lower version, just use a Windows 7 laptop or VM. No other software will be needed. You can also download Connected Components Workbench (CCW) free from the Rockwell website, here:  https://compatibility.rockwellautomation.com/Pages/MultiProductSelector.aspx?crumb=111
  10. Analog Card 1769-OF2/B Revision Upgrade

    Your Logix controller is looking at five different things to make sure I/O can is compatible for use: vendor, product type, product code, major firmware, and minor firmware. There is what's stored in the Logix profile, and there's what's actually on the I/O card. Electronic keying is making the comparison to see if the physical I/O card "fits" into the stored profile.  There are three possible configurations for electronic keying: Exact Match - All five categories must match exactly. Compatible Match - First three categories match but whatever firmware is in the physical I/O card must be the same or higher as the firmware stored in the ControlLogix profile. Disabled - doesn't matter what type of card it is or what firmware, Logix will try to use it. (Never do this). So if it's telling you that your problem is firmware revision, you're either set to exact match and they don't, or you're set for compatible match and the physical card has a lower firmware than the Logix profile. If you're set for exact and the process (including safety and company policies) allow for it, change it to compatible. Otherwise you may have to flash the card to the desired, matching firmware revision. 
  11. Data Types for MAM instruction

    @panic mode that's what I thought, but appreciate you making the effort to be sure I hadn't misunderstood. 
  12. Data Types for MAM instruction

    @Joe E. I didn't intend to misrepresent your remarks. I, too, would've used the word gibberish to describe data that I can't use because the formatting is incorrect, and I believe that's what you were saying. When teaching I often describe COP colloquially as "a more powerful MOV". I had responded above to @VFD Guy that since COP is used to move arrays of data around, I don't understand how it's used to convert Float or REAL to DINT and have meaningful results. My question to @VFD Guy and @panic mode remains; how do you use COP to successfully convert a REAL to a DINT and have the result be useful, since the resulting data looks nothing like what we'd want it to? I've also run into the decimal point thing with PowerFlex drives and have always just used the MUL to get rid of the decimal point so the drive will respond as desired.   Are you using the COP in lieu of MUL? If so, is that the only application for this method, or is it something can be used anywhere you're converting REAL to DINT? Or is the drive truly taking a controller's REAL value of 45.5Hz COP'd to the DINT value 1110835200 and converting it back to REAL? I hate to sound like I'm slitting hairs or beating a dead horse, but I feel like there's something fundamental I might be missing here.  
  13. Data Types for MAM instruction

    Getting back to the OP's question: Sending a DINT to a REAL (or vice versa) via a MOV instruction is ok if you're not worried about losing the fractional value (anything to the right of the decimal point) of the data. REAL to DINT, the DINT truncates the decimal data and rounds. DINT to REAL adds the decimal point, but the fractional value is 0. @panic mode  If that's the case, in a practical sense, how is the COP data then useful in controller code? If it is the correct value that is merely displayed incorrectly due to formatting, will a controller or drive still respond correctly to that value in that format?  Let's say I COP a REAL value of 45.5Hz from controller to drive via Ethernet. The COP instruction is going to send 1110835200, yes? I don't have a drive available to test this, but I'd be blown away if it actually went to 45.5Hz. Have I been missing the bigger picture this whole time? If so, please show us the magic worm hole that would allow skipping the additional code I'm currently having to write to re-scale and drop decimal points whenever I'm forced to mix and match data types. 
  14. There are only about a million things that could cause this. The PF755 gets it's speed command via a parameter called "Speed Reference A" or "-B". When troubleshooting speed problems the first two things I ask myself are: What is the speed reference? What is its value? So is the speed reference coming from the HIM? From ControlLogix? From an analog input? Once you've identified that, figure out what the value is and determine whether the drive is responding correctly. You said the commanded speed ref is 60 but it's only producing 40. Are you sure there's not a preset speed that's been activated? Has an input been programmed and activated to make the drive switch to Speed Ref B? That's the most obvious stuff to start with, and I imagine you've already checked.  Use Connected Components Workbench (CCW) or the older Drive Executive to go online with the drive while it's running and view parameters 935 and 936, Drive Status 1 and 2. This will tell you at a glance what the drive thinks it's doing. So if @BobLfoot is correct and you've hit a current limit, it should jump off the page at you in P935. In no particular order, here are some other ideas; Are these drives new, or have been installed for a while and just started doing this? If new, it's likely in the drive configuration. If this is a new problem on an existing system that was previously working, starting looking into what changed. Did someone screw with the parameters? Was someone digging around in a control cabinet and knock a wire loose? Etc Don't forget to check for obvious things outside of the drive like mechanical binding, bad motor bearings, etc. Do all four drives do the same thing? If so, use Drive Executive or Connected CCW to run a compare tool against a working drive to see what's different. CCW has a feature that allows you to view only the parameters that have been changes from their default values. The is a really helpful tool is you suspect programming. Continuing in that same line of thought, particularly on new installations, mis-programmed parameters are the likely cause of drives not responding correctly. If the motor name plate says max speed is 1200RPM but you don't want your process to run more than 900, then set the motor name plate parameter value to 900, that will give you a lot of scaling / speed control issues. (Proper to set name plate parameter to 1200, and the separate "Max FWD Speed" parameter to 900). Are you sending a signal that you think calls for 60Hz but the drive is programmed for RPM? The same thing applies to encoder programming, if you're using one. Leaving the encoder resolution at the default value of 1024PPR when you actually have a 3K will cause issues. 
  15. Data Types for MAM instruction

    @VFD Guy according to Rockwell literature and my personal experience, mixing and matching data-types always carries the possibility of rounding or truncating errors. So while moving a a DINT value of 60 into a REAL will produce a REAL value of 60.0, moving a REAL value of 60.5 into a DINT will produce 60. When a rounding error occurs, ControlLogix tends to round to the nearest even number, just like the manuals say it will. If you're always dealing in whole numbers and never going outside of data type value boundaries, you can get away with a lot. Unfortunately, my life has not been quite so sheltered, lol. I'm not sure how COP applies to this situation, since in ControlLogix the COP instruction is used to move a contiguous array of data, not a single value. Can you COP a single value with a length of 1 and get a conversion? If so, please explain how. I've just now tried it and got some crazy results. 
  16. Data Types for MAM instruction

    There are several different operands in a MAM instruction and depending on the controller, the data types for the various operands can be DINT, REAL, UINT, AXIS_CIP, AXIS_VIRTUAL, etc. Within the code, if you right click on the instruction and click on Instruction Help, it'll lay out exactly which data type goes with which operand within the instruction.  If somewhere in your code the original programmer is moving DINT values into a REAL data type, or vice versa, you might have some rounding or truncating going on, but it could still be workable. Mixing and matching data types is never ideal but if a programmer has no choice, they can often account for those decimal point issues by offsets, buffering, or other tricks of the code writing trade. I've had to play with this myself when I realized the REAL 60.0Hz my controller was sending was being read by the drive as 60, since the drive only had INT available and apparently didn't recognize decimal points. 
  17. AB Studio 5000 Lite

    In addition to @VFD Guy's suggestion, I would look up the release notes for the specific version of Studio5000 Lite you have and see if there's anything in there that might answer the question. 
  18. Communication

    @VFD Guy This would have to be done offline and then downloaded, or in the program mode. Of course the process would have to be stopped; about 1/2 the drives out there will not let you change the speed reference while the drive is running. I've never figured out how they go about deciding which drives they'll allow a speed reference change while running, but there it is. There are at least a dozen different ways this can be done. But whichever method is used, I would never want to make a major change like this to a running process. You'd want to have the time to safely and thoroughly test the changes before releasing the process back to production.  Yes, speed reference data can be sent from the Micro to the Compact but if done over a network, it would almost certainly have to be via a MSG instruction, and that's time and scan consuming. I don't know how responsive the OP's system has to be, but that might make for sluggish performance, depending on how much network traffic they already have. He could also hardwire the analog output from Micro to Compact and go from there, but he stated earlier he wants the analog input direct to the drive from the Micro.   
  19. 1756-IF8 rev 1.5 Input tags freeze

    @der0492 Thanks for sharing the Tech note because though we're always on the lookout for EMI, I didn't know that was a possible anomaly for the IF8. And we use quite a few of them. To add to @BobLfoot's comments, when you have to hotswap, (Allen Bradley calls it RIUP, for Removal and Insert Under Power) I'm a big fan of placing the controller in the program mode, if possible. If the process is dependent on these inputs for control, and you remove the card in the run mode...... well, use your imagination, lol. Bad things could happen to your process. In any case, the card's configuration is held in the controller and written to the new card so yes, all your scaling, etc, will immediately be written to the new I/O card when it powers up. But there's a catch or two: The new card must be a direct replacement card for the one coming out. If the "Electronic Keying" setting in the card's properties is the default "Compatible", the firmware on the new card must be the same or higher than what's saved in the controller. If the keying is set to "Exact Match", the firmware and everything else on the new card must match exactly what the old card was. Hope this helps, even though you hopefully were able to locate and remove an EMI issue and not have to replace parts. Let us know how it goes, please.
  20. Fault Reset on powerflex

    @PaulKim1003 which specific model of PowerFlex are you using? As you've seen from the previous responses, the answer to your question may vary from drive to drive. The physical Stop button on the front of all PF drives can also be used to clear drive faults. However, within the logic of the drives, some PowerFlex drives' Stop and Clear Fault are always the same input (PF70), and on other PF drives they can be separate inputs (PF755). As @Dev Shrivastav showed above, when they can be on the same digital input, you will almost certainly have to program separate logic instructions. 
  21. Communication

    So reading through the thread again, are these the desired operating conditions? The CompactLogix starts and stops the drive. Never control that from anywhere else. The MicroLogix controls the speed of the drive. Never control that from anywhere else. If so, this is what I would do: Check to see if the PF drive has been added to Compact's I/O configuration. (If it's currently receiving instruction via Ethernet, I guarantee it has).  Go into that configuration (within the CompactLogix controller, NOT in the drive) and change the speed reference (parameter 38) from "Comm Port" to either "0-10V Input" or "4-20mA Input", whichever you have available on the Micro. This step will ensure that the PF drive is always looking at the analog input for speed reference. It shouldn't care that start/stop and other commands come over eNet.  Hardwire an analog output from the Micro to the appropriate input on the PF drive. Write the code in the Micro to scale and control the analog output for speed.  If you have to make any other adjustments to the PF drive parameters (such as Min/Max frequency, etc) do so in the CompactLogix, not the drive itself.  This should work for you and minimize system complexity for this unusual control situation you're in. I would also add rung comments in both controllers, and parameter descriptions on the PF (again, within the CompactLogix I/O tree Device Definition) to explain the setup to anyone else working on the system.
  22. Hey guys, I did a quick search here and didn't come up with anything, so hoping I'm not asking something that has already been answered. I'm looking at automating an existing plant which currently has zero controls, so starting from scratch. The process isn't complicated but the equipment is a bit spread out over a two story facility. We're thinking about using a CompactLogix 1769-L32, physically located as central as possible, with ten four-slot 1734 Point I/O blocks. My concern is that many Allen Bradley controllers limit the number of I/O modules you can add to the project. Like some 1756 controllers are limited to 30 local and remote I/O modules, CompactLogix controllers may be limited to 16 local and who knows how many remotes, etc. I can't find anything that spells it out explicitly in the Design Considerations Manual. The CompactLogix 5370 User Manual only says it supports, "a limited number of Point I/O modules that can be used as local modules". Nothing about networked modules. The CompactLogix Selection Guide clearly defines the number of network nodes, but nothing about the number of modules. Does anyone have any direct experience with this much Point I/O in a CompactLogix environment? I'm thinking that we're in an age of counting nodes, rather than modules but don't want to order the hardware without being 100% sure.
  23. FactoryTalk View Studio Runtime issue

    That sounds pretty bad. If it's working from the FT application, I'd just open and test/run projects from there, and not launch directly from the .mer icon. Otherwise, the only thing coming to my mind is re-installing FT Studio. Were there any recent changes to your laptop? Any updates or installs that a system restore might take care of? 
  24. PanelView Windows screen

    The original post was keeping me up at night, because I knew there was a way to reset that password without flashing the PanelView. I just tested this procedure and it works on my PanelView 7+. -          Plug a keyboard into a USB port and hold F1 while the HMI is rebooting, and this will bring up the Maintenance Mode. -          Use the touch screen (arrow keys, if on keyboard) to select “Special BOOT Action”. -          Use Right/Left arrows to select “Clear All Data”. o   This will clear everything except the firmware. -          Select “Continue booting with selected options” -          During the rest of the BOOT process you will be prompted to create a Windows CE access password. Using this procedure, you will lose any applications within the PanelView, but not have to flash the firmware.
  25. FactoryTalk View Studio Runtime issue

    Since the .mer can only be run in the PanelView, I assume you're running the test mode from your laptop, where FT sets up a temporary .mer-like runtime on the laptop, and mimics the PanelView while being connected to the controller. If so, are you using a shutdown or goto configure button within the FT project, or typing "X" to stop running the test mode? Or is this a problem with shutting down the FT Studio application, itself?