Swapped a PowerFlex 525 on the infeed conveyor this morning, the old one had a blown DC bus fuse and we had a spare on the shelf. 1769-L33ER, same cable, same address set on the keypad. Drive powers up fine, no fault on the keypad, LINK light green.
In the I/O tree the drive has a yellow triangle and the Connection tab says (16#0116) Electronic Keying Mismatch: Major and/or Minor Revision Invalid or Incorrect. I did a factory reset on the drive with P053, set the address again and power cycled it twice, same code. The old drive on the same cable never did this.
Is the spare bad? It's never been used, still had the plastic on it. Or is 0116 comparing the drive against something in the tree, could someone explain what it's actually looking at?
Pretty sure the spare's not bad. What firmware is on the old drive and what's on the new one? Keypad, scroll into the display group, the firmware version is in there. Also what's the decel time set to, since you had a bus fuse go. Not the same problem but I'd look while you're in there.
Old one was a 4 point something, new one shows 7.001 on the keypad. Decel is 5 seconds, load is a short belt, not much on it. So the new drive is newer, not sure if that matters to the PLC.
So if I'm reading this right, the PLC expects the exact drive it was set up with and the new one's a different version, so it says no. Is that it?
Yes, that's the whole of it. In the tree, open the drive, Module Properties, General tab, Change next to Module Definition. Electronic Keying will be on Exact Match, it has to be for that code, so the major revision in the project, 4, has to equal the drive, 7. Set it to Compatible Module, which lets the drive decide, and a newer 525 has accepted an older project revision on every one I've done. Then download. Or set the revision to 7 and keep Exact Match, but the next spare bites you again. Which Studio version are you on, out of interest? Someone did a decent article on keying and the other 16#01xx codes: https://plctr.com/utilizing-ethernet-ip-in-plc-communication/
Compatible Module did it. Module Properties, Change, keying dropdown, downloaded on the lunch break, drive went green and the belt ran on the first start. Studio is v32 here.
So the spare came with firmware 7 and the project was on Exact Match at revision 4. Compatible Module and it stopped caring.
What I don't know is whether the other six 525s on the line are set the same way. Guessing yes since the same guy built them. Going to check them while it's quiet.
Thanks vinnie86 and rsdave, and finn21 for putting it in one sentence.