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Educational Videos  PLC Training Video Series (10 DVD Set w/ workbook)

Thanks  : Joe N. for using BIN95.       

Problem : I have an IDC stepper motor w/controller application. I am looking to replace it with an AMCI stepper motor/driver with an AB 1746-HSTP1 stepper motor module. I need help with the 1746-HSTP1 program.

Solution : Assuming you viewed the examples provided at http://www.bin95.com/database.htm for a similar solution below, we offer this further advice.

Use the controller Designed to operate with AMCI's complete line of stepper drives, the 3202 two axis stepper control module. It plugs into the SLC 500 backplane as a stepper controller solution to A-B's ContolLogix platform.
http://www.amcicontrols.com/AMCI/motion.plc_page.htm

This way you will have the combined support of AMC and AB. :>)
If you have a more specific question other than programming example below or alternate solution to the 1746-HSTP1 we provide here, let us know and we will ask our OEM contacts.

Thanks  Yvonne for using BIN95.       

Problem : I am faced a problem that I need to link different type of PLCs (Mitsubishi, Omron, and I-dex) in a network and monitor them by using NAIS PLC. I do not have any idea how to start at all. Since different brand of PLC is having its own protocol, how am I going to let them communicate with each others? Can you please give me some idea in this situation? Or can you please let me know where can I get the related information to solve this problem?

Solution : Part of your solution is dependent on how many PLCs you have from each vendor. We have put together a complete solution page for you, you can view by clicking here. A summary is bellow.

The first step is to get all PLCs of each vendor type on their own respective network. (IE: Mitsubishi's MelsecNet, AB's DeviceNet, Modbus, Omron's HostLink, etc.) If you only have one PLC of a particular vendor, then you might consider an SST X-Link converter for that one PLC or an Ethernet adapter card for that specific PLC. (Example: you have 12-Mitsubishi, 6-Omron, and only 1 I-dex. Get converter for I-dex so it can rest on Mitsubishi network or use Ethernet to run directly to your computer software.)

The next step is connecting all of the networks together, via Ethernet. Depending on the details of how many of what vendors will determine other factors. Such as setting up a "data concentrator" (PLC or bridge computer) for one line or section of the plant. With only a few PLCs, you may decide to run Ethernet to each PLC and avoid the data concentrator.

The third step would be deciding your method of reporting data, accessing all PLCs, etc. Step two above has to be considered while considering this step. You may use Wonderware of some other prepackaged PC software. (More info below)

Bin95 gives you more...

All the resources you will need for the project.

Thanks  Tawatchai of wood factory in Thailand for using BIN95.       

Problem : PLC Omron Sysmac C20 in my wood working machine lights up alarm signal ( blinking ) . The machine can not run. What wrong with the PLC or other component in my machine.

Tried: . I have try to download the PDF manual from the web address you gave, but still not able to view the C20 manual download file. Seemed that the file download is not correctly download. I have try many times but still not work.

Solution : The flashing light on the Omron indicates the battery is dead or disconnected. This fault is a nonfatal error, as it will not interfere with the program running as normal. (Unless someone utilized the internal "battery low" bit.) Insure the battery connection or replace the battery (Type 3G2A9-BAT08), and if your program will still not run, you have most likely lost it.

  • Tip: Replace your batteries and back up programs once a year whether you need to or not. It is surprising how many maintenance departments find out their PLC battery was dead, after lightning or some other voltage spike trashes their program.

If the error light was on solid, the first step of troubleshooting the alarm, would be to read what alarm number/descriptions it is getting. That additional alarm info would guide you to step two.

You will need an Omron Programming Console (3G2A6-PRO15) to access the program, or an Omron Host Link Unit (3G2C7-LK201) to use their software on a PC. This is not only to read alarm, but in case of battery alarm, you will need console to reset. If you do not have a Programming Console, you may be able to buy one cheap on E-Bay. Note: Manuals for the Omron C20s available for download at: http://oeiweb.omron.com/oei/TechManuals-PLC.htm

Since you could not access the large online PDF manual with acrobat 4, we converted just the page concerning Omron C20 battery alarm with acrobat 3.1, and emailed it to you.

Tawatchai: Thank you very much. I really happy to meet you. Well, the battery is 100% damaged. I examined that the battery is burn out as I can pull the wire out of the battery terminal easily. I hope that the program in the ROM still usable after I replace the battery. If all is gone, maybe I'll have to send to OMRON dealer to solve it, I do not own a programming terminal. Again I would like to thank you for very useful PDF sent to me.

Lastly, Thank you again for your kind useful suggestions. Your website is very helpful to everyone.  Regards, Tawatchai

See Also: Our PLC OEM Resources, PLC Manuals, PLC Articles, etc.

EBAY - Business, Office & Industrial:General Equipment:Process Equipment

Thanks  ramansundaram for using BIN95.       

Problem : We are using several types of AB PLC- SLC 5/01...5/04 ETC
I cannot use RSLogix 500 software to go online with SLC 5/01
which is using AI series software though theoretically it is possible. I am able to go online with RSLogix, it reads all the files and finally it gives an error message.

Tried: Off line I have copied the AI series software PLC file and tried to read in RSLogix, but could not.

Solution : It is true, *not just in theory*, you can use RSLogix for SLC 5/01s. First I would ask you what particular error you are getting after reading file online? Second, what error you see when trying to read *.ACH file offline with RSLogix 500?

Occasionally, when original file in PLC was done with AI, I have had problems. I then fallow the same procedures you have, but always with success.
1. Read *.ACH file offline with RSLogix 500.
2. Save file as RSlogix file (importing descriptors with drop down menu, [tools], [database]. But descriptor step is not necessary, just convenient)
3. Download new RSLogix version to PLC with a new name.

I have seen one Techs computer where the Windows file association was set wrong, and when double clicking on *.ACH file in Windows Explorer, windows would try to open file with RSLogix 5 instead of RS 500. To test that, we opened RS 500 first, then used file open command to open *.ACH file. (Later re-associating programs properly.)

Another question, are you trying to open a backed up version of the ACH offline, or did you use AI to upload a current copy of the ladder logic in PLC, and then try opening with RS 500? I mention this as backed up floppy disk laying in the bottom of an electrical cabinet, are prone to corruption. (Another good reason to use WinZip. If the file gets corrupted, WinZip will let you know when opening it.)

If you would like, you can reply to this email with a copy of the AI program to bin95, and we will convert to RSLogix 500 for you. Please WinZip the file up so it is not too large to email. Zipping program up before emailing also insures file integrity.

Thanks  Precision Control Systems for using BIN95.       

Problem : I am trying to get up to speed on controlling 4 stepper motors from an AB SLC 5/04. I am familiar with IDC and Parker but have not had the chance to use the 1746 HSTP1 module. Is there anywhere I can get some example logic so I can jump into this quickly?

Tried: I have been out to Rockwell's (Allen Bradley -Rockwell Automation) website and downloaded the manuals, for a start.

 

Solution :

Beer-B-Gone-done1.RSS (Example of ladder logic with stepper)

step_sequences.txt (Sequence for BBG example above.)

The above examples are from the project: Automated Limited Containment Of Hazardous Organic Liquids

More insight from EPICs project using 1746 HSTP1

 

Thanks  S Rossetti of Austria Heat and Control for the info.       

Problem : I cannot configure an Allen-Bradley PCMK card for DH+ on my new laptop running in Win 2000 professional.  The 'add new hardware' wizard does not recognize the Win95 plug and play driver I have.

Tried: I have contacted my local Allen-Bradley dealer and they seem to think that the Win95 drivers still work (although I am skeptical).  The PCMCIA card shows up on my system (un-configured).

 

Solution : Bin95: Have you tried adding hardware manually? Under control panel, add new hardware. One of the dialog boxes ask you, "Search for hardware?" You select "I would like to pick from list". then go down the categories to the PCMCIA devices, and click. In the list of vendors, you will not see Allen Bradley. You then would insert floppy with AB PCMCIA drivers on it, and click button "Have Disk".

Rossetti: Thanks for the reply - I was able to fix the problem literally minutes after I sent the enquiry to you, how surprising!
Basically the Windows 2000 driver is included with the RSLinx installation
disk - all you have to do is point the Windows hardware installer in the
right direction when it asks you to browse for a driver.  If you use
explorer to view the RSLinx CD, it is not too hard to find the file yourself
prior to installing the card- the CD's folders and file names are pretty
much self-explanatory.
Thanks for your help anyhow!

Thanks  and dheaphy@ongautomation.com for the info.       

Problem : I am trying to access an ABB ACS 600 drive through a device net interface NDNA-02 but I cannot upload all parameters.

Tried: Connections are all correct. DeviceNet software recognizes module so "eds" file correct No fault showing on scanner card.

 

Solution : Rockwell expert: "Are you using RSNetworx for DeviceNet software? Usually when it cannot get or set a parameter correctly it will generate an error message in the Messages field down below the graphical interface; that error message is very helpful in diagnostics. At what stage in the parameter upload does the sequence fail ?"

Dave: Thanks for your reply. I deleted all the "eds" files for the Abb Drives and re installed them one by one. I then reset the network, cycled power to the drive and can now upload parameters. The next task is to configure the drive correctly so I can give it a speed reference.

 

Bin95 gives you more...

Reference: www.abb-drives.com. Also try their US Site or Other US site, it is a new site, as of 8-01 still building it. 

Click here for Additional ABB contacts and here for Device net to drive manual or Device net to drive quick start manual 

Right click below to download...

ACS600 Hardware Manual 601 (1.6 M)
ACS600 Hardware Manual (1.2 M)
ACS600 Manual Supplement 607 (20 K)

Open DeviceNet Vendor Association  All about DeviceNet - specs., training, products and more.

Other source of communicating with drive� 

Ask your ABB vendor for these examples of EDS...

Document

Date

Size

lithvac1.xls

6/20/00 4:42:31 PM GMT

39,936

acs 600 standard limited.eds

8/9/00 6:19:01 PM GMT

13,650

acs 600 pfc limited.eds

8/9/00 6:19:00 PM GMT

13,654

acs 600 csa3_0 limited.eds

8/9/00 6:18:59 PM GMT

13,654

acs 400 limited.eds

8/9/00 6:18:57 PM GMT

13,650

acs 600 general limited.eds

8/9/00 6:18:58 PM GMT

17,140

dacs400a.eds

8/9/00 6:20:20 PM GMT

166,646

acs600 standard v5.x full.eds

8/9/00 6:19:06 PM GMT

205,619

Thanks  and tipar1@hotmail.com for the info.       

Problem : I have a PLC T100MD1616 from Triangle Research Inc. and a stepper driver 5210 from Sigma which one accept input for direction and steps. On my project I have 2 steppers ,they have to load/unload a CD-R writer, so they move in repeated cycles. My problem is how to write this portion of ladder for the stepper drivers. Any examples, or other help will be helpful for me, and I like to thank you for any help.

Solution : Triangle Research Inc.'s T100MD1616 has 2 digital outputs for stepper motors and will work good. 

Sample: Motion Control of Stepper Motor among others�

http://tri.com.sg/demoapp1.zip

Some Samples: viewed online�

http://www.dcitechnologies.com/TriPLC/M/MDapps.htm

For more information see Links-OEM on this site.

Thanks  J SCARLETT and zakria for the info.       

Problem : I have fuji plc model (MICREX-F)(FPB56)and I don't know how can I get the ladder for the plc which installed in a machine I mean, how can I get a tool which I use it to read the program?

Solution : J SCARLETT of INDUSTRIAL WATER ENGINEERING LTD. provides the following...

To handle programs from Fuji controllers on a laptop or desktop PC you need the following :

Software program D25 Emulator 

Hardware adaptor /converter RS232 to Fuji (with appropriate leads)

These items enable you to handle the larger Fujis such as F70, F80, F120 and above. To handle the F56H you need another adaptor designated FTM050 which clips to the front of the PLC to provide the correct signal for the RS232 converter

You connect the RS232 adaptor to the COM1 port of the computer and the software enables you to monitor the program (when running) download to floppy or hard disc for storage, or write/edit complete programs. Also the complete ladder diagram can also be printed out.

We can supply all the above equipment with full instructions for �1150 plus VAT. We also offer tutorials, for which we bring to site several demonstration Fuji and provide instruction in operating the software. (It is wise to become familiar with operation before plugging in to a functioning unit.)

Bin95 Note: No manuals online, but click here for Fuji Web site (American version) Also Mr Noboru Takada is the branch manager of Fuji Electric office in London. 

Thanks idamae1 for the info.       
Problem : I have an Omron Sysmac S6 CPU that I need help programming. My application is simple, but the Omron manual is lacking in information. I can have the PLC do most of what I need but without any consistent results. Here is specifically what I need.

I want to (on input from a limit switch) close output (12) for 15 seconds, pause for 5
seconds (to allow motor to stop) close output (13) for 5 seconds, pause again for 5 and
repeat the entire process until the limit switch breaks.

The PLC is operating a reversing contactor for a blower motor that fills a resin hopper. The
reverse portion is to "blowback" any dust from the filter. The two pause steps are to ensure
the motor has stopped before reversing direction.
Solution : All PLCs should have the ability to program in ladder logic, even PC based systems. Although the acronyms may be slightly different, with the help of a manual, you should be able to convert over Mnemonics for the simple programs. I was able to write the logic for this one using standard timers, with PLC direct software. Click BlowBackPLC.htm to see example of one of many ways to do the Ladder logic/Mnemonics. For manuals please see

http://oeiweb.omron.com/oei/TechManuals/M11W196E12A1198.pdf

http://oeiweb.omron.com/oei/TechManuals/w340-e1-1.pdf

Thanks ghachey for the info.       
Problem : Erratic operation of a A&B plc 2/17 on an acme strapping system. Input and output devices seemed ok. Module indicators and ladder log. indicated everything was ok
Solution : Processor card had vibrated loose from the backplane slot slightly pushed back in and started re-growing the hair I pulled out.

Thanks mheldt for the info.       
Problem : Could not tell if old switch was activating because PLC is sealed away in a box.
Solution : Put indicator, like on modern prox, to tell when switch is activating

Thanks DAVEFo28  for the info.       
Problem : Indiscriminate activation of the written program not in the right sequence that it was written.
Solution : The problem was solved by checking the limit switches that are attached to the pneumatic pistons. If the pistons are in close proximity there is a possibility that the signal given by another piston could be transferred to the next, so causing the program to jump. Or so it would seem. The resolution to this problem is to ensure that all switches are either screened or totally away from any other piston.

Thanks bin95@bin95.com for the info.       
Problem : Gateway Solo users might experience problems where ICOM PLC software will report that the PCMK memory cannot be found, or that the card isn't present at the specified address.
Solution : This is apparently caused by a BIOS problem in the Solo; BIOS version 1.06 may fix the problem, but is currently in beta testing. The latest BIOS (including 1.06 Beta) may be downloaded from Gateway 2000's BBS at 605-232-2224 or from their WEB site. For now, you need to override the address that Windows 95 automatically assigns to the PCMK (the ones we've seen have been at address CA000, which the Solo BIOS mistakenly thinks is unused.) To do this: email me at above address, and I will send you readme file that comes with PCMK Plug and Play driver.

Thanks aton for the info.       
Problem : Do you know if ICOM will work with Windows 2000 using the PCMK driver. I am using a Gateway Solo 9300 notebook and am having a hard time trying to get ICOM to work? The RSLINX works fine though.

Your website is very informative. Thanks
Solution : Thanks for the good comment about our web site :>)

 We have added details about PCMK, as many run into issues. 

So assuming you � 

  1. Compare communication settings in RS Linx, with your settings in ICOM. (I/E: correct pcmk slot, baud matches, etc.) 

  2. Do not have RS links communicating via pcmk, before you try to start up ICOM. Try starting PC in real DOS mode (if win 2000 has real, NT user, need to use RS Linx Lite, maybe winn 2000 users also). 

  3. Check that you have latest pcmk driver for your pcmk card (A or B). See update utility link in download area below, for details to driver/setup needed. (this is a common issue when technicians install old copy of ICOM on a new lap top :>) 

  4. If you want to use rslinx with 6200 you will have to install interchange for windows. 

Commentary: Rockwell advertises full support for their new products with Win 2000. Unfortunately AI came out too early. We have not seen much support for old software with win 2000, (maybe they would rather sell you RS logics :>). Just one of many examples of pcmk/2000 support see control.com message board post. The guys on Tech TV are un-installing win 2000, as it did not pan out. It' back to win98. If you add the complexity of setting up RS Linx Lite + DOS based AI + Win 2000, well you can see the hassles. We heard rumor that Win 2000 DOS is not a real operating system, and causes a lot of head aches too. 

Downloads: 

Alternate Solutions: Of course you could ask Rockwell for updated drivers/software for Win 2000.

Thanks bin95@bin95.com for the info.       
Problem : I have to do a report on PLC's & Process Control. Can anyone help with any info on these subjects. Such as "what is it, what does it do, what it controls, why etc.". Any good web site to locate info. Thanks for any info.
Solution : Do a web search for the people that make PLC's: Allen Bradley, Modicon,GE, Siemens, Koyo, Triconex, Honeywell... (that should be enough to get you started), I am currently looking for subjects to add to our WEB site to increase content. This sounds like a good subject, so in a couple days look at http://www.bin95.com, under news articles.

Thanks bin95@bin95.com for the info.       
Problem : When running Allen Bradley PLC5 software (ICOM), ver. 8.04 or less, my Dell Inspiron 3000 locks up on a BIOS level. (I have to remove power cord and battery to reboot it) This lock up only occurs when going "online".
Solution : This problem occurs because of a memory conflict where BIOS handles power management, and communication to PCMCIA card # 1784-PCMK   series "A" and a modem card. The only solution for now is to run on battery power when online with the PLC and or remove modem card. We are checking into it further and will post a more permanent solution later.

Thanks bin95@bin95.com for the info.       
Problem : If logic to communicate between a PLC 5 and a SLC 500 uses FIFO, can you use that logic to confirm you have a communication problem?
Solution : Yes, you will most likely see that the FIFO pointer is at it's highest position. To confirm that FIFO is being filled up (not emptied by confirmation that each file has been successfully sent), reset pointer to 0 (zero) to see if FIFO fills again. To reset pointer, put cursor on FIFO, and use display/special.

Thanks bin95@bin95.com for the info.       
Problem : What kind of cable is used to connect an Allen Bradley PLC5 RS232 channel zero port to a SLC 500 port?
Solution : When connecting two �Data Terminal� devices together via RS232 for communication, a modem has to be simulated, by swapping wires 2&3. When connecting a �Data Terminal� device to a modem, wires are straight through, pin for pin. Grounds 4&7 connect together also. The PLC5 RS232 port already has wires 2&3 swapped internally, so only a straight through cable is needed.

Thanks bin95@aol.com for the info.       
Problem : I need to find out more about the processor error 83 (watch dog timer fault), in an Allen Bradley PLC.
Solution : This is caused by an error in the programming, such as an infinite loop and can be elusive when caused by jumping to sub-routines. Check the processor status screen for location in program that caused fault.

Thanks ddnakanishi@ra.rockwell.com for the info.       
Problem : After upgrading to SLC500 version 8.14, the "Upload/Download " secondary menu does not appear, when you select "Upload/Download" from the main menu. Also the "Reports" selection from the main menu, does nothing.
Solution : Create a shortcut to the AI500 software. Once the shortcut is created, right mouse click on the icon. Select Properties. In the properties setup window, there is a tab labeled Memory. Select that tab. There is a field that is labeled DPMI memory...it will default to the AUTO setting. Change this setting to 16384. Click on Apply to apply these changes. Click on OK to close out the window.

Thanks bin95@bin95.com for the info.       
Problem : Can't establish communication with Omron controller when I change the baud rate in Omron's "CAPs" software to anything but 9600.
Solution : Must change front switch number 3 on LK201v1 module to match the new baud rate. Email me if you need the data sheet on the LK201v1.

Thanks pentium569@aol.com for the info.

Problem :Thought you would like this handy tip. How do you put a one shot in your ladder logic for a PLC2.

Solution :PLC 2 ONE SHOT Use bit 203/00 SCT in series, there is a bit for leading edge and a bit for trailing edge. (Scan Count Technique)

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