Chp5 Plant Floor Installation & Configuration

System: AVI Title: AVI Training Manual Chapter 5: Plant Floor Install and Config

Owner: APICS Page 1 of 44 Revision: 1.2

Document: Chp5 Plant Floor Installation & Configuration.doc Revised: 2008 Feb 27

Automatic Vehicle Identification System (AVI)

Training Manual

Chapter 5: Plant Floor Installation & Configuration




TABLE OF CONTENTS

1 PLANT FLOOR DRIVER INSTALLATION AND CONFIGURATION........................4 1.1 OVERVIEW ..............................................................................................................................4

1.2 PLC-5 BACKGROUND INFORMATION - SOFTWARE PACKAGE OF USP .....................................5

1.3 PLC-5 INSTALLATION - EQUIPMENT .......................................................................................6

1.4 PLC-5 INSTALLATION - SOFTWARE ........................................................................................6

1.5 PLC-5 CONFIGURATION - HARDWARE....................................................................................8

1.6 PLC-5 CONFIGURATION - SOFTWARE LOGIC ..........................................................................9

1.7 PLC-5 CONFIGURATION - SOFTWARE DATA VIA UNIFIED SYSTEMS CONFIGURATOR.............9

1.8 PLC-5 CONFIGURATION - SOFTWARE DATA VIA MANUAL CONFIGURATION..........................9

1.9 PLC-5 CONFIGURATION - FIS.................................................................................................9

1.10 PLC-5 STARTING UP ...........................................................................................................9

1.11 PLC-5 AVI SUPERVISOR PLC CONFIGURATION..................................................................9

1.12 CLX BACKGROUND INFORMATION - SOFTWARE PACKAGE ..................................................9

1.13 CLX INSTALLATION - EQUIPMENT .......................................................................................9

1.14 CLX INSTALLATION - SOFTWARE ........................................................................................9

1.15 CLX CONFIGURATION - HARDWARE....................................................................................9

1.16 CLX CONFIGURATION - SOFTWARE LOGIC ..........................................................................9

1.17 CLX CONFIGURATION - SOFTWARE DATA VIA MANUAL CONFIGURATION..........................9

1.18 CLX CONFIGURATION - FIS.................................................................................................9

1.19 CLX STARTING UP ..............................................................................................................9




Document Revision History

Date Revision

Number

Name Description (include pages affected)

2008 Feb 27 1.2 Mas40 Change name to Chrysler

2007 Feb 16 1.1 MAS40 Updated PLC-5 OEM File 80 DB dwell time. Section 1.6.9

2006 Dec15 1.0 MAS40 2006 AVI Training Manual Update Project

Supporting Documentation

The DaimlerChrysler documents listed below are instrumental in defining this chapter's systems and

its configuration.

Doc. No. Rev. Date Title Link

AMS 0220

Section 4.2.3

2.2 2005 Aug 1 Book of Implmentation Guidelines:

Programming and Memory Requirements

for PLC-5

DCX BOIG web site

AMS 0220

Section 5.4.2

1.5 2006 Feb 1 Book of Implmentation Guidelines:

Design & Installation Requirements for

DNet

DCX BOIG web site

AMS 0220

Section 14.2.1

2.1 2004 Jan 05 Book of Implmentation Guidelines:

AVI/VMS Driver Installation &

confiuration for PLC-5

DCX BOIG web site

AMS 0220

Section 14.2.2

2.1 2004 Jan 05 Book of Implementation Guidelines:

AVI/VMS Reader Comm & Config for

PLC-5

DCX BOIG web site

AMS 0220

Section 14.2.3

2.1 2004 Jan 05 Book of Implementation Guidelines:

AVI/VMS Implementation Guideline for

PLC-5

DCX BOIG web site

AMS 0220

Section 14.3.1

1.0 2005 Aug 31 Book of Implmentation Guidelines:

AVI/VMS Driver Installation &

confiuration for CLx

DCX BOIG web site

AMS 0220

Section 14.3.3

1.0 2004 Aug 15 Book of Implementation Guidelines:

AVI/VMS Implementation Guideline for

CLx

DCX BOIG web site

AMS 0220

Section 14.3.4

1.1 2005 Aug 01 Book of Implementation Guidelines:

AVI Dnet Reader Install & Conifig for

CLx

DCX BOIG web site

3.0 2004 Dec 10 APICS USD PLC Manual Configuration DCX APICS web site

1.0 APICS USC Configuration DCX APICS web site

1756-IN566B-

EN-P

2001 April AB ControlLogix DeviceNet Scanner

Install Instructions

AB web site




1 PLANT FLOOR DRIVER INSTALLATION AND CONFIGURATION

1.1 Overview

The order of an AVI floor installation is as follows:

1. Equipment installation

2. Download software

3. Configure the PLC

4. Configure the hardware

5. Configure the software

6. Start up the application

�




1.2 PLC-5 Background information - Software package of USP

For the ITM PLC-5 floor systems, a common structure was set up among the applications

of AVI, FIS and PFCS. This formed the Unified Systems Platform (USP). From within

the common structure, the platform contained several sections: PLC code/drivers (USD),

operator interfaces (USD PanelView files), configuration (USC) and emulators (USE).

1.2.1 Unified Systems Driver (USD)

The Unified Systems Driver (USD) is PLC logic designed to integrate multiple plant

processes (AVI, FIS, and PFCS) in one common package. When used in conjunction

with its associated Unified System Configurator (USC), the integrator is able to

configure these processes with one common interface. By providing the USD and the

USC to the systems integrator, the software in each PLC becomes a uniform standard

throughout the corporation.

The USD provides the following benefits:

� DCX Plant floor IT systems are linked using a predefined program and data file

structure, eliminating the possibility of memory overlap.

� Customized machine interface logic is minimized, which aids in maintaining logic

standardization across the corporation.

� PLC configuration may be saved for later use or printed out in an easily readable

format using the associated USC.

� Common tools for configuration ensure consistency from one AVI point to the

next.

1.2.2 Unified Systems Configurator (USC)

The Unified Systems Configurator (or USC) is a PLC GUI designed specifically to

configure the Unified Systems Driver in an easy-to-use/easy-to-understand manner:

� The tool stores configuration data in an MS Access database format, this means

the Unified Systems Driver can be configured even before the actual PLC program

is created.

� When configuration data is downloaded into a PLC, only the data tables are

changed, which eliminates the need for complex, manual changes in ladder logic,

which could result in mistakes or errors.

� It provides a reporting tool for visual certification of proper configuration, thus

aiding in error proofing the configuration before it is downloaded into a PLC.

1.2.3 Unified Systems Emulator (USE)

The Unified Systems Emulator is a Visual Basic application that emulates the actions

of a DCX UNIX workcell for AVI and PFCS. This allows testing of floor

configuration to be done outside of the plant.

�




1.3 PLC-5 Installation - Equipment

The floor equipment is mostly outlined in Chapter 3 Plant Floor Vehicle Identification.

The recommended equipment installation order for a new AVI point is:

1. PLC (unless installed in an OEM PLC)

2. PLC cards: DB or RB in recommended slot 4, and DCM in recommended slot 7

3. Floor readers and associated hubs

4. Communication medium from floor readers to PLC

5. Communication medium from PLC to AVI Supervisor PLC

1.4 PLC-5 Installation - Software

1.4.1 PLC-5 Software

The AVI PLC-5 software is known as the USD AVI (see section 1.2.1 Unified

Systems Driver).

For a complete installation, two additional software components are required

� USD Common

� USD FIS

Also, AVI has several optional software sub modules

� USD AVI Marriage - Used at Plant Marriage setup

� USD Style Setup - Used on Style Setups

� USD AVI GS GN Compare - Used on QAS2 TNG setups

All PLC-5 software can be downloaded from the APICS web site. It is recommended

that an APICS or ASLM team member verify the versions of the downloaded software

modules. It will typically always be the latest version.

BOIG document 14.2.1 Section 3 (PLC-5 Memory requirements) goes in detail of the

layout of the program files and data files of the PLC-5 software.

1.4.2 PLC-5 Paste Files

Follow the outline given in the BOIG document 14.2.1 Section 4 for the step by step

instructions in pasting the AVI driver.




1.4.3 PLC-5 PanelView paste file

The standard AVI paste file distributed with the USD includes logic to support one

PanelView.

Use PanelBuilder software to download the screens into the PanelView terminal.

The AVI PanelView driver is located in program file 80. It can support up to 10

PanelViews of the following types:

� 1200e Keypad or Touchscreen



The driver supports PanelViews using RIO communications. (DH+ communication is

not supported at this time.)

The USD contains the PanelView file for screen numbers 249 through 254. The OEM

will paste these screens into the Panel Builder software and include these screens in

their main menu.

The screens use two block transfer files:

� B5: used for the BTW

� B6: used for the BTR.

In addition, the PanelView file contains a discreet input word, for reporting the screen

number to the PLC, and a discreet output word, for the PLC controlled screen number.

The discreet input and output words, N275:138 and N275:139, can be found under

“PLC I/O Control” in the Panel Builder software.

If an AVI Point has one or more PanelViews associated with it, the user must:

� Load these screens into the PanelView(s).

� Configure the AVI Driver to communicate with the PanelView(s).

� Add support logic as required (if multiple PanelViews are used).

�




1.5 PLC-5 Configuration - Hardware

This section provides the information necessary to configure the following hardware to

communicate with AVI (not all used in all AVI projects):

♦ Allen-Bradley 2760-RB Flexible Interface Module

♦ Allen-Bradley 1771-DB Basic Module

♦ Allen-Bradley 1771-DCM-B Direct Communications Module

♦ Allen-Bradley 1771-SDN DeviceNet Scanner Module

1.5.1 A-B 2760-RB Flexible Interface Module

The RB module will require some parameters to be entered and some DIP switches

set. The parameters are entered via a terminal session (HyperTerminal). Such a

session is created by connecting a null modem cable to the configuration port of a PC.

After connecting, the configuration menu needs to be invoked. To invoke the

configuration menu send the RB a BREAK command. Parameter and switch settings

are shown in the BOIG Section 14.2.2, AVI/VMS Reader Communications &

Configuration for PLC-5.

Complete the following to configure an RB module (Figure 5-1). Settings of switches

SW1 and SW2 may need to be changed depending on the slot addressing of the rack

(single or 2 slot).




Figure 5-1: A-B 1771-RB Flexible Interface Module Switch Locations

Switch SW3

Switches SW3 & SW4

are located under here.

Switch SW4

Switches SW1 &

SW2 Switches SW1 &

SW2 are located on

top of the RB

Memory module

2760-SFC2 plugged

into Protocol A

Serial cables plugs

into this

Configuration Port




1.5.1.1 A-B 1771-RB Flexible Interface Module Configuration Steps

1. Set all switches in switch bank SW1 to off.

2. Set all switches in switch bank SW2 to off, except the second, which must be ON for

single slot addressing, or OFF for 2 slot addressing.

3. The switches in switch banks SW3 and SW4 configure ports 1, 2, and 3 for either RS-232

or RS-422 communications. Set the switches as shown in the BOIG 14.2.2 Appendix B.

4. Plug in protocol A Module (2760-SFC2).

5. Power up the RB module by providing power to the chassis.

6. Plug into the configuration port with a standard RS-232 null modem cable.

7. Open the Terminal.exe file.

8. Send a CTRL BREAK command to the RB module to initiate the software configuration

menu.

9. Set all ports to dumb ASCII terminals using option 3 before continuing to the detailed

configuration.

Note: Using terminal session option 3, set all ports to “2760-SFC2 DT” Dumb Terminal.

Note: See BOIG document section 14.2.2 section 8.0 2760-RB Configuration settings for

correct settings and code.

10. Send a CTRL BREAK.

11. Using option 11 for port 1, option 12 for port 2, option 13 for port 3 and set software

configurations to the settings in the BOIG 14.2.2 Appendix B.

Note: Use terminal session option 11, 12, or 13 to configure each port.

Note: Enter “90A” to reset the RB if needed.

12. Using terminal session option C, exit configuration.




1.5.1.2 DB Module Hardware and Software Configuration

Figure 5-2: Allen-Bradley 1771-DB Module Switch & Jumper Locations (B Module Shown)

Hard reset

Switch

JW1 switch

location

Jumper switches

JW2 - JW7

JW1 switch

location

Jumper switches

JW8 & JW9




1.5.1.3 A-B 1771-DB Series A Basic Module Configuration Steps

The basic code can be found in BOIG document 14.2.2 section 9.0 DB Module Basic

program (series A)

Complete the following to configure an A-B 1771 DB Series A module.

1. Set peripheral port jumper to 9600 (side of module).

2. Connect to program port using a null-modem cable, load the basic program using MS

Window terminal, and press [CTRL + C], or secure EEPROM containing the program

listed in the BOIG 14.2.2 Appendix C (series A).

3. Load in the program by using “Send Text File.” The file is called db_a_vms.txt

4. Ensure the program is loaded as shown above. If it is incorrect, correct the data strings.

5. Type “run”, then press “Enter” (program is then installed and running).

6. Disconnect null-modem cable.

1.5.1.4 A-B 1771-DB Series B Basic Module Configuration Steps

The basic code can be found in the BOIG document 14.2.2 section 10.0 DB Module Basic

program (series B).

Complete the following to configure an A-B 1771 DB Series B module.

Set jumpers on DB module (series B) as listed below.

Jumper Setting Description

JW1 Watchdog Enabled (default)

JW2 8K/32K EEPROM 8K PROM (default)

JW3 Speed Turbo

JW4 PRT1=PGM, PRT2=ASCII, DH485=RUN (default)

JW5 16 Point Back Plane (depending on rack configuration)

JW6 PRT2 1200 Baud Rate

JW7 Battery Enabled

JW8 PRT1 Protocol (RS232)

JW9 PRT2 Protocol (RS232)

Table 5-1: Set Jumpers on DB Module (Series B)

1. Connect to port 1 with a terminal and load the program listed below. Connect to Port 1 by

using the STD.TRM and press [CTRL + C].

2. Load in the program as shown in the BOIG 14.2.2 Appendix D (series B).

3. Disconnect and change configuration jumper JW4 to PRT1=ASCII, PRT2=ASCII, and

DH485=PGM to make both ports available for reader connections.

4. Change JW6 PRT2 back to 9600 Baud Rate.

5. Set JW8 and JW9 according to input connections (RS422 or RS232). RS232 is optional

depending on the length (contact ITM personal before using RS232).




1.5.2 Direct Communications Module (DCM) Switch Settings

Figure 5-3: A-B 1771-B Direct Communications Module (DCM) Switch Locations

DCM Module

switch banks

DCM Module

switch banks

If using a three

prong Phoenix

plug, use the top

three prongs




1.5.2.1 A-B 1771-DCM-B Direct Communications Module Configuration Steps

Complete the following to configure an A-B 1771 DCM-B module (Figure 5-3) that is

used to connect to the AVI supervisor PLC.

To configure the DCM module, switches in bank 0 and bank 1 must be set. There are eight

switches in each bank as shown in Figure 5-4.

Figure 5-4: DCM Switch Settings

�




1.6 PLC-5 Configuration - Software Logic

1.6.1 Ladder logic file 80

The OEM is required to make ladder logic changes on each installation of AVI. These

are changes that cannot be accommodated via data table adjustments.

All the bit changes are listed in the BOIG document 14.2.1 section 5.5 Interface

Programming - bits. The following components are addressed:

� Sensor Blocks: I/O address for in position, vehicle leaving and empty carriers

◊ In Position: The vehicle in position sensor will signal the AVI driver that a Read

condition should have occurred. If the reader did not read a bar code, it declares a No

Read condition.

◊ Vehicle Leaving: The vehicle-leaving sensor will signal the AVI driver that a carrier

is leaving the zone and the AVI driver should stop any requests and clear data.

◊ Empty Carrier: The empty carrier sensor will signal the AVI driver to declare an

"empty carrier" or turn on the reader beam if no empty carrier is present.

� AVI Mode: I/O address for a AVI conveyor interlock bypass mode

� Read: Address of signal whenever the reader reads a label

� No-Read: Address of signal when the reader did not read label but should have

� Data Auto Delivered: Address of signal that data is ready to the OEM software

and reset upon 'OEM Data Accept' or a vehicle leaving switch

� OEM Data Accept: Address of signal that that the OEM software has obtained

the vehicle ID

� Data Style Mismatch: Address of signal that the OEM software does not agree

with the style of the vehicle delivered.

� AVI Timeout: Address of signal that the OEM software has waited past the time

it expected to wait for AVI to finish its functions.

� AVI Systems Fault: Address of signal that the OEM can use list conditions that

will turn on the AVI Systems Fault light and FIS fault bit

� Reader Beam On: Address of signal to turn the reader beam on

� Read Beam Off: Address of signal to turn the reader beam off

All the PanelView communication changes are listed in the BOIG document 14.2.1

section 5.7 PanelView Configuration. The following components are addressed:

� PanelView - Communication to the operator terminal.

All the Reader communication changes are listed in the BOIG document 14.2.1

section 5.8 RB / DB Configuration. The following components are addressed:

� RB/DB - Communication to the Reader




1.6.2 Sensor Blocks

Sensor blocks are defined as the block of logic per reader area which indicates to the

driver a No-Read condition, an event counter, communication to the reader to turn on

its beam to read the barcode label and to turn off its beam as the read is complete.

Each sensor block tells the driver to count statistical information, when a no-read

occurs, when an empty carrier arrives, and when the vehicle leaves. This requires

OEM input of in position IO, leaving IO and empty carrier IO. Sensor block addresses

are in increments of 10 words starting at PLC address N281:10.

Note: The first sensor block is word for configuration 18, the second is word 28, the

third is word 38, and so on. There are a maximum of 99 sensor blocks available.

Replace the “AFI’s” in Figure 5-5 logic with the required plant specific inputs or

internal signals.

Figure 5-5: Sensor Block Logic

1.6.3 AVI Mode

This signal tells the AVI driver if it is being bypassed. This signal does not stop the

driver from running or processing any data. The driver will still request build data,

send up statuses, and send up indexes. This signal is used to flag the WCC and FIS

that the driver is in bypass. This signal causes the OEM logic to perform differently.

The OEM will not hold up the line for AVI responses or release the carrier on an AVI

vehicle release timeout if the station is in AVI bypass mode. This rung is programmed

as follows:

Note: For the first point, the address for the AVI mode coil is N282:25/00. For the

second point, the address would be 50 words higher, so the address would be

N282:75/00. In the logic shown in Figure 5-6, the “AFI’s” are to be replaced with the

required plant specific inputs or internal signals.




Figure 5-6: AVI Mode Logic

1.6.4 Data Style Mismatch

The OEM sets this signal to notify the plant floor operator through an FIS alarm that

AVI delivered style does not match the style detected in station. (AVI is not alarmed,

only FIS!). It is the OEM’s responsibility to keep the station from cycling and to have

an appropriate operating procedure in place to deal with this type of fault. This rung is

programmed as follows:

Note: For the first point, the address for the Data Style Mismatch coil is N282:25/01.

For the second point, the address would be 50 words higher, so the address would be

N282:75/01. In the logic shown in Figure 5-7, the “AFI” must be replaced with the

required plant specific input or internal signal.

Figure 5-7: Data Style Mismatch Logic

1.6.5 OEM Data Accept

The OEM sets this signal to notify the AVI driver that the OEM accepted the data. The

OEM sets this signal after the AVI driver has set the Data Auto Delivered signal and

the OEM has accepted the data and stored the data to other data table areas. The Data

Auto Delivered signal is used by the OEM to know when data is delivered from the

workcell. This signal is set when the driver receives a valid response from the AVI

WCC. This signal is reset when the OEM turns on Data Accept or the vehicle leaves.

Note: For the first point, the address for the Data Accept coil is N282:25/02. For the

second point, the address would be 50 words higher, so the address would be




N282:75/02. In the logic shown in Figure 5-8, the “AFI” must be replaced with the

required plant specific input or internal signalable areas.

Figure 5-8: OEM Data Accept Logic

1.6.6 Reader Beam On/Off

The empty signal carrier of the AVI driver is used to turn on the reader arm. The OEM

is required to associate the correct sensor block logic. When the empty carrier is

blocked (unit approaches) the reader beam should be turned on. When the empty

carrier is not blocked or at the leave signal (unitl well past the reader) the reader beam

should be turned off.

Note: For the first point, the address for the AVI Timeout contact is N282:25/3. For

the second point, the address would be 50 words higher, so the address would be

N282:75/3.

Figure 5-9: Reader Beam On/Off




1.6.7 AVI Timeout

The OEM is supplied an AVI driver timeout so the OEM knows that the vehicle has

been sitting in the stop past the time that was set for AVI to finish its function (Figure

5-10). This time is set in the Configuration. This timer is supplied so AVI does not

always have to hold a vehicle at a stop. This signal is not used at all points; it should

not be used at critical AVI points. It will be the OEM’s responsibility to verify with

AVI personnel if this signal should be used.

Note: For the first point, the address for the AVI Timeout contact is N282:25/12. For

the second point, the address would be 50 words higher, so the address would be

N282:75/12.

AVI Driver

AVI OEM

Timeout Logic

N282:25/12 XX:XX/XX

--| |-------------------------------------( )—

Figure 5-10: AVI Timeout Logic

1.6.8 PanelView Driver Configuration

When the standard AVI USD logic is pasted into the PLC, the BTR and BTW

instructions for the PanelView each have a Rack, Group, and Slot value of 0. These

values shall not be changed in the logic, as the USC will change those values when

downloading the point configuration to the PLC.

The discreet inputs and outputs are not setup, however, by the USC, and must be

manually configured in the Logic:

� The discrete input word is represented in the standard driver by N275:138. This

must be replaced by the actual input word (Figure 5-11 and Error! Reference

source not found.).

� The discreet output word is represented in the standard driver by N275:139. This

must be replaced by the actual output word (Figure 5-11 and Figure 5-12).




Figure 5-11: PanelView Support Logic




Figure 5-12: AVI USD PanelView Support Logic (continued)

1.6.9 RB/DB Module Support Logic

The standard driver is supplied with the first module programmed. If more than one

module is needed, the OEM will need to copy the following rungs for the first module,

and re-address them for the module needed. These rungs reside in File #80.




The dwell time has to be adjusted according to the activity encountered in the module.

The time in the GRT instruction shown Figure 5-13 needs to be set as follows

1 set of points, 300 (3 seconds)

2-3 set of points 500 (5 seconds)

4-5 set of points 700 (7 seconds)

Figure 5-13: Module dwell timer logic

Note: There are 2 temporary words in the rung logic used as placeholders for the RB

module RG address. They must be changed to I:RG for the appropriate location. For

example, if the RB module is in Rack 0, Group 4, the address is I:004




Figure 5-14: RB/DB Module Support Logic




Figure 5-15: RB/DB Module Support Logic (Continued)




Figure 5-16: RB/DB Module Support Logic (Continued)

�




1.7 PLC-5 Configuration - Software Data via Unified Systems Configurator

Once the driver is pasted into the PLC, it will need to be configured. This is done by

using the Unified Systems Configurator (USC). The installer has the option of

configuring the system via the manual configuration (manually changing data table

address values). Although the driver can be manually configured, it is not

recommended due to the complexity of the AVI driver. The USC can be used to

configure the USD. However, your computer must be connected to a PLC prior to

downloading the configuration to a PLC.

Note: It is not possible to configure the driver while offline at this time.

Note: USC may not be updated to support the latest USD versions. Check with APICS on

this regard.

1.7.1 USC System Requirements

To install and use the USC, your computer must meet the following requirements:

� Windows 9x, 2000, XP (will not work with Windows NT).

� Full version of RS Linx (will not work with RS Linx Lite), version 2.0 or higher.

� 10 MB free hard drive space

� 32 MB of RAM

See document APICS USC Configuration for the installation and usage of the USC

application.

�




1.8 PLC-5 Configuration - Software Data via Manual Configuration

The same configuration mentioned in Section 1.7 can be done by manually editing data

tables in the PLC.

Please refer to document: APICS AVI USD Manual PLC configuration.

1.9 PLC-5 Configuration - FIS

The USD is loaded on an Allen-Bradley PLC 5/80. Each PLC has an Ethernet side card

for communications with FIS. Configuration is required on both the PLC and the FIS

Workcell. Contact FIS implementation group/plant FIS department for getting updates

done on the FIS Workcell. Like the data entry portion, the data can be edited via the USC

tool or done via manual entry.

1.9.1 Configuration via USD Configuration Tool

The Configuration tool will create a paste file, USDFIS.pc5, for each PLC from a

paste file template. (The most recent template revisions are called UFIS0102.pc5,

UFIS0102.sy5, and UFIS0102.fix.) The paste file will resize the appropriate data

table files and populate the PLC data tables with the required information for FIS

communications when pasted into the PLC. Data for each PLC configuration is stored

in a Microsoft Access database.

1.9.2 Configuration Via Manual Data Entry

1.9.2.1 N75 FIS Processing Data file

# of Datablocks in

Processor

# of Datablocks

Per Scan Status Ethernet

N75: 20 21 30 31

12 12 0=stop

99=restart

0=DH+

1=Ethernet

Figure 5-17: N75

The data words in N75 deals with all the FIS datablocks in the PLC.

1.9.2.2 N80 FIS Datablock Configuration Data File

Ma

ch i

d

Stn

id

DB

id

Db

len

gth

Hea

rtb

eat

Sta

rt o

f st

ate

Ch

an

nel

Des

t st

n

Des

t ta

ble

Nex

t d

ata

blo

ck

Ty

pe

So

urc

e fi

le

So

urc

e w

ord

Des

t S

tart

wo

rd

Len

gth

Ty

pe

So

urc

e fi

le

So

urc

e w

ord

Des

t st

art

wo

rd

Len

gth

N80: 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Point 4910 0 42 30 450 3 48 8 8 20 7 87 3 3 27 0 0 0 0 0

Reader main 4921 0 42 30 450 3 48 8 8 20 7 88 3 3 27 0 0 0 0 0

Reader backup 4922 0 42 30 450 3 48 8 8 20 7 88 33 3 27 0 0 0 0 0

Figure 5-18: N80

Each AVI point and AVI reader have their own entry in N80 datablock definitions.




Note: Each AVI point FIS data starts at N87:3 and skips 30 words for the next AVI point.

Each AVI reader FIS data starts at N88:3 and skips 30 words for the next AVI reader.

�




1.10 PLC-5 Starting Up

The steps below describe how to start up the USD driver:

1. Enable USD

2. Enable AVI

3. Enable FIS driver in N75:30

4. Check all status messages on the PanelView and review all faulted conditions

�




1.11 PLC-5 AVI Supervisor PLC Configuration

The Supervisor PLC's main task is to be a data concentrator. It will gather messages

from all the Floor PLCs and the information into one message to the WCC.

The Supervisor PLC talks to the WCC through Ethernet. The packet size to the WCC

is 113 words. The first word is a protocol word and the next 112 words are data words.

The WCC and the Supervisor PLC must be in sync before any data can be transferred

back and forth. The Supervisor PLC and AVI Workcell use Data Strobes and Echoes

for a communication handshake that the other one received the message. If there is no

message traffic between the Supervisor PLC and WCC for 30 seconds, the Supervisor

PLC will send out a heartbeat (800 hex) in the protocol word.

1.11.1 Adding a Link to Supervisor PLCs

When adding a link to the Supervisor PLC, the plant’s link chart must be used (System

Analysts have control of this document) to figure the RGS address. There can be a

maximum of 60 links to the Supervisor PLC for Block Transfer. USD. FILES N51:0-

N65:0 are the dedicated files that are used if a discrete link is being added. Because of

the nature of the discrete links, certain files have been preprogrammed to handle each

instance. Table 5-2 shows the Discrete Rack and the associated Data Table file that

must be adhered to:

Note: The files shown below can be used for USD or Block Transfer floor drivers, but the

Discrete Floor Drivers (if any) must use these files.

Discrete Rack Data Table File Discrete Rack Data Table File

01 N51:0-499 10 N58:0-499

02 N52:0-499 11 N59:0-499

03 N53:0-499 12 N60:0-499

04 N54:0-499 13 N61:0-499

05 N55:0-499 14 N62:0-499

06 N56:0-499 15 N63:0-499

07 N57:0-499 16 N64:0-499

17 N65:0-499

Table 5-2: Discrete Rack and Associated Data Table Files




The steps to add a link to the supervisory panel for Block Transfer are shown below.

1. Select a file for the new link. The file must be the next file not in use in the link file

section N11:0 – N70:0.

2. Set file N10:____. Corresponds with the file number (which is now the word for

N:10) selected in step one. The integer value of that word will be set to 500.

Example: If N34: was selected as the new link in data table N10, N10:34 would need to be

created with an integer value of 500.

3. Make memory for the new file to 600 words if it does not already exist.

Example: If N34 is the new file you need to ensure there are 600 words of memory (create

N34:599).

4. Set word two in the new file with the length of the block transfer using an integer

value of 32.

Example: If N34 is the new file, set N34:2 to an integer value of 32.

5. Set word three in the new file with the Rack, Group, and Slot (RGS) value from the

link chart described in Figure 5-19.

Example: If N34 is the new file and the link equaled 45, the rack would equal 14 and

group would equal 0 (group will be 0, 2, 4, or 6), the slot will always equal 0. The integer

value for N34:3 would equal 448 and the binary equivalent would equal 0000 0001 1100

0000.

Reserved for VMS Usage

X XXX X XXXX XXX X XXX

11 8 3 015 12 7 4

RGS Value Layout

Slot Number (0-1)

Rack Number (0-127)

Group Number (0-15)

Reserved Figure 5-19: RGS Layout for Adding a Link to the Supervisory Panel for Block Transfer




DEVICE LOCATION – CONFIGURE FOR DCM Link

RACK/GROUP/SLOT to Supervisor PLC(RGS Value Layout)

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

MODULE SLOT NUMBER

MODULE GROUP BIT 0

MODULE GROUP BIT 1

MODULE GROUP BIT 2

MODULE GROUP BIT 3

RACK NUMBER BIT 0

RACK NUMBER BIT 1

RACK NUMBER BIT 2

RACK NUMBER BIT 3

RACK NUMBER BIT 4

RACK NUMBER BIT 5

RACK NUMBER BIT 6

RESERVED (SET TO 0)

RESERVED (SET TO 0)

RESERVED (SET TO 0)

RESERVED (SET TO 0)

Table 5-3: N11:0 through N11:70 Bit Layout

6. Set word six in the new file with the link timeout preset (in milliseconds) using an

integer value of 3000.

Example: If N34 is the new file, set N34:6 to an integer value of 3000.

7. Set word nine in the new file to 300. This is the number of free words in the buffer to

the floor.

Example: if N34 is the new file, set N34:9 to an integer value of 300.

8. Set word 10 in the new file to 200. This is the number of words for the load printer.

Example: if N34 is the new file set N34:10 to an integer value of 200.

9. Set word 11 in the new file to 200. This is the number of words for the unload printer.

Example: if N34 is the new file, set N34:11 to an integer value of 200.

10. Set word 12 in the new file to the link number to the WCC. This number is the link

number plus 100, 200, or 300, depending on the Supervisor PLC area (BIW is 100,

Paint is 200, and T/C/F is 300).




Example: If N34 is the new file and the new link is 45 for BIW, set N34:12 to an integer

value of 145.

11. Set word 13 in the new file to 0-3. 0 = USD, 1 = Block Transfer, 2 = Multiblock, 3 =

Discrete

12. Set word zero, bit zero in the new file to enable link.

Example: If N34 is the new file, set N34:0 bit 0 to 1.

13. Set word zero, bit two in the new file to initialize the link.

Example: If N34 is the new file, set N34:0 bit 2 to 1.

Troubleshooting tip: When adding or reconfiguring causes the processor to fault out,

follow these steps:

1. Reconfigure the link (Steps 1-11).

2. Zero out all words in the link file after word 13.

3. Reinitialize the link (Steps 12-13).




1.11.2 Supervisor PLC-5 DCM Channel Setting Example

North Body Shop PLC Link : 102Rack/Group : 1/2 Name : South PierceSupv. File : N12

VMS-DCM-150-000

To PLC #2 (Channel 1A)

RIO RIO RIODH+

1A 2B2A1B

North Body Shop PLC Link : 103Rack/Group : 1/4 Name : North PierceSupv. File : N13

VMS-DCM-150-001

VMS-DCM-150-002

VMS-DCM-150-003

North Body Shop PLC Link : 104Rack/Group : 1/6 Name : Pierce VisionSupv. File : N14

VMS-DCM-150-004

North Body Shop PLC Link : 105Rack/Group : 2/0 Name : Cpu-01Supv. File : N15

North Body Shop PLC Link : 101Rack/Group : 1/0 Name : CPU-11Supv. File : N11

VMS-DCM-151-000

South Body Shop PLC Link : 121Rack/Group : 6/0 Name : ARSNTH-1Supv. File : N22

VMS-DCM-151-001

South Body Shop PLC Link : 141Rack/Group : 13/0 Name : URS N-1Supv. File : N32

VMS-DCM-151-002

South Body Shop PLC Link : 122Rack/Group : 6/2 Name : ARSSTH-1Supv. File : N23

South Body Shop PLC Link : 123Rack/Group : 6/4 Name : Roof-1Supv. File : N24

South Body Shop PLC Link : 142Rack/Group : 13/2 Name : URS S-1Supv. File : N33

South Body Shop PLC Link : 143Rack/Group : 13/4 Name : URS GaugeSupv. File : N34

VMS-DCM-152-000

VMS-DCM-152-001

VMS-DCM-152-002

North Body Shop PLC Link : 106Rack/Group : 2/2 Name : Door ShuttleSupv. File : N16

VMS-DCM-150-005

VMS-DCM-150-006


VMS-DCM-150-007

North Body Shop PLC Link : 108Rack/Group : 2/6 Name : Gap & Flush

Supv. File : N18 Vision

VMS-DCM-150-008

North Body Shop PLC Link : 109Rack/Group : 3/0 Name : Bare Metal

Supv. File : N19 Auto Inspect

VMS-DCM-150-009


VMS-DCM-151-003

South Body Shop PLC Link : 124Rack/Group : 6/6 Name : Roof GaugeSupv. File : N25

South Body Shop PLC Link : 125Rack/Group : 7/0 Name : CPU-21Supv. File : N26 Toy Tab

VMS-DCM-151-004

VMS-DCM-151-005

South Body Shop PLC Link : 126Rack/Group : 7/2 Name : CPU-22Supv. File : N27

VMS-DCM-151-006

South Body Shop PLC Link : 127Rack/Group : 7/4 Name : CPU-23Supv. File : N28 ARS Pull Off

VMS-DCM-151-007

South Body Shop PLC Link : 128Rack/Group : 7/6 Name : FRMSTH-1Supv. File : N29

South Body Shop PLC Link : 129Rack/Group : 10/0 Name : FRMNTH-1Supv. File : N30

South Body Shop PLC Link : 130Rack/Group : 10/2 Name : FRM GaugeSupv. File : N31

VMS-DCM-151-009

VMS-DCM-151-008


VMS-DCM-150-010

South Body Shop PLC Link : 144Rack/Group : 13/6 Name : EngineSupv. File : N35

VMS-DCM-152-003

Figure 5-20: Supervisor PLC5 DCM Channel Setting Example

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1.12 CLx Background information - Software package

Upon migrating to the ControlLogix platform, the ITM floor PLC applications of PFCS,

AVI and FIS have less in common. The applications are still PLC drivers but a universal

configuration tool doesn't exist.

1.13 CLx Installation - Equipment

The floor equipment is mostly outlined in Chapter 3 Plant Floor Vehicle Identification.

The recommended equipment installation order for a new AVI point is:

1. PLC (unless installed in an OEM PLC)

2. PLC cards: ITM processor in slot 8, ITM Ethernet in slot 9.

3. Floor readers and associated hubs

4. Communication medium from floor readers to PLC

1.14 CLx Installation - Software

When installing a new AVI point, an AVI point specification document must be

prepared and approved. The approval process may be lengthy depending on many

plant and corporate factors. The AVI point specification document is typically

downloaded and completed by OEM engineering personnel and approved by APICs

personnel during original equipment installation. Plant IT personnel would only need

to complete this process when adding a point where the equipment has already been

accepted (bought off) by the plant.

1.14.1 Obtaining Software

To obtain the AVI ControlLogix point specification document and download the

appropriate AVI driver files, follow the steps below.




Figure 5-21: DaimlerChrysler Extranet Login Screen

1. Log into the APICs website (Figure 5-21)

Note: Obtain a password to the Extranet website from plant ITM.




Figure 5-22: APICS Homepage Screen

2. From the APICS home page, select “Systems” from the left side menu (Figure 5-22).

Figure 5-23: Downloads Screen

3. Select “Downloads” from the left side menu.

4. Select “Clx Platform” from the left side menu.

Select

Systems

Select

Downloads

Select CLx

Platform




Figure 5-24: AVI CLx Driver

5. Select the AVI CLx Driver to download the zip files.

Figure 5-25: AVI CLx Driver Zip Folder

6. From the APICS web site, extract AVI DriveMaster and AVI CommInterface and save

to your programming directory to run in RS Logix5000.

Note: The zip folder contains instructions for upgrading, revision notes, and AVI files.

Select AVI

CLx Driver




1.14.2 CLx Processor Configurations

Figure 5-26: Open RSLogix 5000

1. Open RS Logix5000 and open the AVI Drive Master file that was just saved (Figure

5-26)

2. Go to I/O configuration and select the OEM PLC.

Figure 5-27: Change modules in I/O configuration

3. Change the properties to the OEM PLC controller as needed (Figure 5-27).

4. Select “Apply.”




1.14.3 Download to Processor

To download the processor to the CLx follow the steps below:

Figure 5-28: Communication Download

1. Select “Communication” from the menu and click on “Download” (Figure 5-28).

Figure 5-29: Select IP Address

2. Select the IP address and where the program should be downloaded (Figure 5-29).

The IP address can be obtained from the Point Specification Document.

3. Click Download.

1.14.4 DeviceNet Configuration

Refer to BOIG AVI DeviceNet Reader Installation and Configuration for

ControlLogix 14.3.4.




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1.15 CLx Configuration - Hardware

This section provides the information necessary to configure the following hardware to

communicate with AVI (not all used in all AVI projects):

♦ Allen-Bradley 1756 DNB. DeviceNet Scanner

1.15.1 DeviceNet Scanner

Refer to document AB ControlLogix DeviceNet Scanner Installation Instructions for

further details.

Refer to BOIG doc 5.4.2 for DeviceNet standards within the DCX Corporation.

The 1756-DNB module is used in ControlLogix communications systems as the host

device between the CDN-108 module and the PLC.

The DeviceNet Scanner card needs to be configured for a communication baud rate

and a node (MAC) ID address. These settings are per the implementation

documentation.

Figure 5-30: ControlLogix 1756-DNB Module

Button

Readout




Figure 5-31 DeviceNet Scanner Display and Configuration

The Manual Configuration Pushbutton (Figure 5-31) allows for the scrolling and

setting of the configuration

If your module is not connected to the network:

1. Select the network baud rate by pushing and holding the pushbutton.

Note: The module’s alphanumeric display cycles through the allowable baud rates (125k

250k, 500k).

2. Release the button when the baud rate you want to select is shown on the display.

If your module is connected to the network:

3. Select the network node address by pushing in and holding the pushbutton. The

display starts at the current MAC ID and cycles through all legitimate the network

node addresses (00-63).

4. Release the button when the address you want to select is shown on the display.

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1.16 CLx Configuration - Software Logic

Refer to BOIG 14.3.1 section “6.0 OEM Interface Programming.” The OEM is

responsible for the program file “AVI OEM Custom Interface.” The program file

contains basic rungs and needs to be configured to each plant’s specific needs.

1.17 CLx Configuration - Software Data via Manual Configuration

Refer to BOIG 14.3.1 “AVI Driver Integration for Control Logix.” The subsections are

the same as in “5.0 AVI Driver Configuration” section of the BOIG document.

Refer to BOIG section “7.0 Installing the AVI Interface Programming.”

1.18 CLx Configuration - FIS

See BOIG document 14.3.1 AVI driver installation and configuration for CLx, section

5.16 for FIS configuration.

1.19 CLx Starting Up

Steps for starting up the AVI CLx driver are described below:

1. Enable AVI

2. Check all status messages on the PanelView Plus and review all faulted

messages/indicators

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Documents

Chp5 Plant Floor Installation & Configuration