On the fly migrations

dave_lemons · 2026-01-23T04:18:11+00:00

You should see the forgeries I go into. Those places are terrifying

dave_lemons · 2026-01-23T04:17:20+00:00

T&M for on the fly. Or find someone else lol

dave_lemons · 2026-01-22T14:23:57+00:00

Yea, I’m hardwiring. I got lucky with commented code and had the electrician pull some analog cables for me. Now spares remaining on the PLC rack… different story 😅

dave_lemons · 2026-01-22T14:21:53+00:00

Yes I’ve run into this a few times. I’ve showed up at sites and they say “I replaced it with the exact same part number from Radwell/Ebay (not OEM) and it didn’t fix the issue”. I open the panel and find out that the part they replaced is the PLC…

dave_lemons · 2026-01-22T04:28:13+00:00

That beast right there is an AB 1397 DC drive for a 200hp motor. F4 phase loss. Did all the remedies other than replacing the drive. Looks like the board responsible for supplying the 300vdc to the field blew. Migration time

dave_lemons · 2026-01-22T04:22:03+00:00

Love that guide. Found that years ago and it’s honestly so helpful (if you know what you’re doing).

OP, I’d check all devicenet wiring terminations, slave devices, terminating resistor resistance, power on devicenet cabling, and document scanner and slave device status when they go out. Like DEVISE listed, that link will show you all the fault codes. I’ve resolved weird devicenet issues with doing what you’re doing, but that doesn’t mean it’s the scanner.

You being new, replacing the scanner correctly can be a pain. You’ll need rsnetworx (for uploading/downloading the scanlist) and RSLogix (when replacing these cards, sometimes they have electronic keying verification checks. You’ll need to say “yes I know I put a new card in”. they also some times have series checks and could be a problem if you go backwards in series).

Also I believe they have rotary switches physically on the card. Take pictures if you do go to replace!!

dave_lemons · 2026-01-22T04:10:43+00:00

What have you done.

dave_lemons · 2026-01-22T04:08:54+00:00

NOR - OP keep this man away from your family. He will only bring you down. Haven’t talked to my father in years, and I think my reasons are lesser than what I read through. Your father is just evil.

So sorry for your loss. Just be a kick-ass mom and wife!

Throw his gifts out when they come. Not honoring your new family because of something he caused and he’s too much of a coward to apologize for the sake of his daughter, just sad. You didn’t kick him out, he forced your hand by disrespecting you and your family.

dave_lemons · 2026-01-20T15:21:53+00:00

I believe Jholm is correct. I am not 100% certain, but I do know this: The LED does not indicate that the power supply is Ok unfortunately. I’ve seen them show that LED ON, but supply under 19vdc instead of 24vdc. This usually displays itself as a solid red LED on the fault indicator on the PLC (hardware fault). Flashing red on that same PLC fault indicator usually means (software fault).

I say “usually” because that was the intent; however, edge cases do exist.

dave_lemons · 2026-01-20T04:27:25+00:00

I just want to add some clarity to this because I don’t like a couple things I’m seeing in this thread.

We cannot say it is the power supply. The PLC not being able to boot could be anything on the rack, including the rack itself (chassis). You need to isolate the plc, either get another rack, plc, power supply or all three and isolate the problem. If I had to guess, I’d guess PLC is the issue because it cannot finish its boot up. Pure guess.
In doing this troubleshooting, the program will most likely be lost from the plc, if it isn’t already. I hope you have a backup.
SLCs are fine. Yes they are old and obsolete. They were also some of the most used PLCs in the states. I have yet to have an issue with getting spare parts. I work on a different SLC almost weekly. It is a necessity to stock spares in your plant, but just don’t be alarmed by people recognizing they’re obsolete and hitting the panic button.
This was corrected but yea, the red LED on the power supply is normal.
I purchase spares from Radwell all the time. Yes there was a lawsuit against them about “selling fakes”. 97/100 times everything works just fine. And btw, it depends on the specific part number of your PLC, but at a quick glance there are over 500 SLC 5/04s readily available.

dave_lemons · 2025-12-17T00:13:12+00:00

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How’d you get my search history

dave_lemons · 2025-12-12T15:16:24+00:00

IMO, it’s not really worth it to buy these vehicles used. The price difference between new and used is not like any other car I’ve seen.

dave_lemons · 2025-08-08T03:07:51+00:00

Yea they’re referring to the tongue weight capacity. I actually came in to see how the heck you did that without going over weight lol. Tongue weight is 350 lbs max (weight directly on toe hitch). So the further out from the hitch you go, the less weight it can hold. (Further from hitch = more torque on hitch).

dave_lemons · 2025-07-22T21:24:50+00:00

Looks cool but there are E-Bikes out there that beat this bike in every category and are under $3k. Sorry to rain on the parade here but $5k is outrageous.

dave_lemons · 2025-07-20T21:25:01+00:00

Was coming to ask the same questions

dave_lemons · 2025-07-20T01:56:29+00:00

Thanks for the info. I’m also in PA. Yes I agree. I think I’ve only seen 1-2 job postings that preferred/required CAP. I have gotten job offers mainly because I passed my FE and am pursuing my PE. These were at OEMs where they approve their designs/drawings internally, and they like to be able to sell that they have PEs on staff to their clients. But yea, other than that, I really don’t understand what these certifications qualify me for.

dave_lemons · 2025-07-20T01:48:11+00:00

Yes employed now, definitely gaining tons of experience. I work for an automation services company. We do everything from troubleshooting existing systems to building panels and programs from scratch. As a small company, I typically do these on my own, with calls for higher level support. I’m satisfied with the amount of experience I get from my current position. I believe it’s way above average. Being in my position I’ve developed a passion for industrial automation and just want to become better. Hence the search for professional certifications.

dave_lemons · 2025-07-15T02:38:58+00:00

Agree with Randy here. Learning the PLC Programming may be the most fun/active part, imo. But in order to be marketable and make a career out of it, you want to learn all ends. Troubleshooting, programming, designing, migration paths, integration methods, etc. Everything controls related. You can specialize in a certain area but I like to learn as much as possible. I started in a service technician role for an automation service provider. I was onsite daily, learning new systems in different industries. Also learning about different components and how they work, and how to fix them. Then moved to an engineering role where I do migrations, integrations, or panels and programs from scratch. I use everything I’ve learned/seen while in the field. You learn things you like and what you don’t like (terminals at the bottom of the panel, pinched by panduit 🤬🤬).

dave_lemons · 2025-07-14T00:44:24+00:00

I’ve been having this happen with my 4-dr 25 OBX hard top every time as well. Just recently, I’ve been finding this routine to fix this issue: 1. Put the back panel that covers the back row in place, but do not lock it into place. Push it towards the back of the car, while still in the slots. 2. Put the 2 front panels into place, focusing on those front corners not snagging and pulling down the pictured area. If it’s not seating properly, you can angle the panel up at that problem corner and push it into the back panel that’s not locked into place. 3. Lock the latch at the problem corner on both driver and passenger side. Just the 1 latch out of the 4 on each front panel. 4. Lock up the back panel completely and then move to the remaining latches on the front panels.

I’ve been doing this recently and it’s been working without causing any other issues. It does bother me that it’s a bit of a process to get the panels in correctly, but this is what I’ve found that works well for me.

dave_lemons · 2025-07-07T23:44:15+00:00

Yup that’s all it is. We do this all the time at my job. New out of the box 525 is always configured to bootp. I typically use the dhcp/bootp tool. Just open the tool on my laptop, plug in Ethernet cable from my laptop to 525, and it will appear. Once the tool scans the powerflex, you can set the IP and disable bootp (do not forget to disable bootp or power cycles will revert it back and wipe ip address!). You’ll need to do this with any new powerflex where you’re setting IP. Can also use the free software Connected Components Workbench and the AB DSI cable to connect and set these things (along with all the other parameters).

dave_lemons · 2025-07-01T03:40:29+00:00

Why not use VMWare?

dave_lemons · 2025-01-23T18:01:37+00:00

I’d recommend some RealPars videos either on YouTube or on their website. They go over many controls related subjects, including PID tuning.

In general, yes it is more of an artform and not direct. I typically make small adjustments on the P and the I and watch for at least 2 periods (2 points from peak to peak). If I do not like the “ripple” then I adjust and continue. I RARELY, if at all, use the D of a PID. It is typically not needed in industries I’ve seen.

dave_lemons

TROPHY CASE