GCCS2MasterRev6 0

GCCS-2
Global Common Control Software Design

LMS # 33544
Document Version 6.0
Module 1: Overview
DOCUMENT MANAGEMENT INFORMATION
Sponsoring Group:
Manufacturing Engineer: Noel Miller

ME Engineering Group: GM Vehicle Systems-Automation Standards
Manufacturing Engineer Phone: 810-602-9768
Template Version 1.0
Document Revisions:
Date Revision By Revision History

8-26-13 5.0 J. Hocking Updated graphics.
Synchronized to G16 with Powertrain and
6-8-15 6.0 J. Hocking
EtherNet I/O
This training is based on the Course Title. Please refer to the Standard manual found
on the GM intranet or www.gmsupplypower.com. The Standard manual is
comprehensive and will have the latest information. This training manual is used as an
instructional guide
Copyright Information
Copyright General Motors Company, 2015, Detroit, Michigan. All rights reserved under
U.S., International, and Universal Copyright Conventions. Published in the United
States of America. These materials may be used only with related printed materials.
In no event will the General Motors Company be responsible or liable for
incidental or consequential damages resulting from the use or application of the
materials in this manual.
The examples, diagrams, and charts in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular safety situation, the General Motors Company expressly disclaims all
express and implied warranties relating to the materials in this manual, including
all examples, diagrams, and charts.
Reproduction of the contents of this manual, in whole or in part, without written
permission of the General Motors Company is prohibited.
2015 General Motors Company. All Rights Reserved

i
Table of Contents
1. Overview ............................................................................................. 1-1
1.1. Course Objective ................................................................................................. 1-1
1.2. Course Scope ...................................................................................................... 1-1
1.3. Course Overview ................................................................................................. 1-1
1.4. Course Audience ................................................................................................. 1-1
1.5. Purpose ................................................................................................................ 1-1
1.6. Module 1: Objectives .......................................................................................... 1-3
1.7. Deviations ............................................................................................................ 1-4
1.8. Definitions ............................................................................................................ 1-5
1.9. Normative References ........................................................................................ 1-7
1.10. Locate the Global Ethernet e-Tools. ................................................................ 1-8
1.11. ControlLogix Environment ............................................................................. 1-13
1.11.1. Definitions ............................................................................................... 1-13
1.12. Plant Floor Systems (PFS) ............................................................................. 1-14
1.12.1. Plant Monitoring and Control (PM & C or PMC) ...................................... 1-14
1.12.2. Plant Floor Event (PFE) .......................................................................... 1-14
1.13. Project Structure ............................................................................................. 1-15
1.13.1. Controls Design Environment, CDE Software Tool ................................. 1-16
1.13.2. Program Description ............................................................................... 1-16
1.13.3. Main Routine ........................................................................................... 1-17
1.13.4. Routine Names ....................................................................................... 1-17
1.14. Ladder Logic Contents ................................................................................... 1-17
1.14.1. Rung Comments ..................................................................................... 1-17
1.14.2. Operand Description ............................................................................... 1-18
1.14.3. Pass-Thru................................................................................................ 1-18
1.15. Review .............................................................................................................. 1-20

ii
Table of Figures
Figure 1: Add-On Instruction Example ........................................................................ 1-7
Figure 7: Covisint (GM Supply Power host) Home Screen.......................................... 1-8
Figure 8: Covisint Login Screen ................................................................................... 1-9
Figure 9: Covisint Directed Communications Page ..................................................... 1-9
Figure 10: GM Supply Power Home Page ................................................................ 1-10
Figure 11: GM Supply Power Home Page Application ............................................ 1-10
Figure 12: GM SupplyPower Vehicle Systems Automation Standards Home Page ... 1-11
Figure 13: Global Standards Home Page................................................................... 1-11
Figure 14: GM Supply Power Home Page - Global Ethernet e-Tools ........................ 1-12
Figure 2: Safety Task ................................................................................................ 1-15
Figure 3: Program and Routine Description .............................................................. 1-16
Figure 4: The TBD Tag Blocking Logic...................................................................... 1-17
Figure 5: Rung Comments ........................................................................................ 1-18
Figure 6: Pass-Thru Description ................................................................................ 1-19

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1. Overview
1.1. Course Objective
The overall course objective is to be able to use the GCCS-2 standard to improve
accuracy, speed, and commonality in RS Logix 5000 programming. Engineers
who integrate, start-up, maintain, and/or design automation cells will benefit from
this course.
1.2. Course Scope
The provisions of the GCCS-1a Integration Document apply to the control system
software designs for all GM facilities. Only national or local codes and regulations
(legal requirements) shall supersede this document for any GM project. Any and
all conflicts must be documented and presented to the GM personnel responsible
for resolution, prior to implementation of these specifications.
1.3. Course Overview
GCCS-1 (Global Common Controls Standard - 1) is the standard for General
Motors logic software programming. GCCS-2 is the standard software template
that provide solutions for most automation controls situations in meeting the
requirements in GCCS-1. This training program will focus on the body shop area
while also providing examples from conveyance, stamping, paint, powertrain, and
general assembly.
1.4. Course Audience
This standard is primarily for use by design, startup, and maintenance personnel.
It shall be used by all personnel (e.g., control engineers, body shop equipment
suppliers, installation personnel, and in-plant resources involved in the operation
of GM controls systems. This standard shall be used in all phases of the
equipments life, including:
1. Design.
1. Installation.
2. Commissioning.
3. Acceptance.
4. Production.
1.5. Purpose
The purpose of this course is to provide the foundation for designing ladder logic
programs for Rockwell Automation/Allen-Bradley ControlLogix, GuardLogix, and
CompactLogix Series controllers and Siemens HMIs. The objective of standard
GCCS-1 is to provide common, lean, flexible, and cost effective control systems.
In turn, this enhances both the productivity and maintainability of the systems, as
Rev. 6.0 2015 General Motors Company. All Rights Reserved 1-1
well as the quality of the products produced. The application of this standard shall
result in common systems software that:
1. Assures the safe operation and maintainability of the manufacturing
equipment.
2. Introduces common systems to all areas of the facility.
3. Reduces development costs.
4. Leverages global engineering resources.
5. Provides flexible designs to accommodate changes to the product and/or
process.
1-2 2015 General Motors Company. All Rights Reserved Rev. 6.0
1.6. Module 1: Objectives
1. The student will be able to describe the purpose of GCCS-1 and GCCS-2
standards.
2. The student will be able to describe how ladder logic is generated for various
manufacturing applications.
3. The student will be able to demonstrate how to document program
descriptions.
4. The student will be able to demonstrate how to document rung comments.
1.7. Deviations
Any deviation from GCCS-1 standard requires the advance, written approval of
the controls engineer responsible for the project. Any approved deviation(s) shall
only apply to that specific instance; it shall not be considered a change to this
standard. Past approved deviations from this standard shall not be construed as
setting any approved precedent alternative to the provisions of this specification.
1.8. Definitions
ControlLogix, These terms all refer to the Programmable Logic
GuardLogix, Controller (PLC) that is used on all GM projects.
Logix5000
Processor,
Controller
RSLogix5000 Windows-Based programming software used to
develop, upload/download, and maintain the PLC
software.
Firmware Computer code running at a hardware level in the
PLC and other smart cards in this architecture.
Specific bugs can be fixed by using the correct
firmware identified on the Blockpoint.
Blockpoint A GM specific document that defines, by project,
what the proper software and firmware versions
are. Projects should not move ahead or lag behind
the versions listed for the specific project on the
Blockpoint.
Data Types Defines the size and memory layout that will be
allocated when a tag of a particular data type is
created. All tags have a data type.
Predefined Basic data types that are pre-defined by the
Data Type controller.
Module Are pre-defined and are used in the tags that are
Defined Data automatically created when I/O modules are added
Type to the I/O Configuration.
UDTs UDTs are made from pre-defined, module-defined,
or other user-defined data types. UDTs are visible
throughout the controller. User-Defined Data Types
are created by either the -Automation Standards
group or the actual user.
Tags A Tag is a named memory area that holds data of a
defined data type. Tags are defined by their data
type, either pre-defined or user-defined. Data in a
Logix processor is contained in tags.
Tag Scope Defines how visible the tag is and which routines
can access the tags data. Tags have scope of
either program or controller. All programs can see
Controller Tags. Conversely, Program Tags are
only visible within the program in which they are
contained.
Tag Aliasing Points a tag to another tag so that the two tags
have the same meaning and share the same data.
The data resides in the base tag. GCCS-1 base
tags are always controller tags. When alias tags
are used, the base tag is a controller tag and the
alias tag is a program scope tag. All non alias tags
are base tags, not all base tags have alias tags.
Tag Class Either Standard or Safety. All tags within the safety
task have to be of the class Safety, as well as any
controller tags accessed by the safety task.
Tasks Tasks used in GCCS-1 are continuous or periodic.
The Main Task is continuous, executes all
programs, then starts over, and calls all programs
except those in the Safety Task. The Safety Task
is periodic, interrupts the Main Task, and calls all
safety programs.
Normative References which contain hardware, software, and
References operating standards.
Ladder Logic A program written in a format resembling a ladder-
like diagram. The program is used by a
programmable controller to control equipment
motion or process.
The ladder is broken down into smaller steps called
rungs to simplify the identification and modification
of operations.
Rung Rung comments describe logic function or how to
Comments configure a rung based on a specific situation.
Operand Describes the address of computer instruction
Description data to be operated on.
Add-On User defined instruction sets that behave like a
Instruction Logix predefined instruction. Add-On Instructions
(AOI) are a collection of Logix instructions constructed
with ladder logic or other programming languages.
They reside in the Add-On Instruction folder in the
Controller Organizer and resemble an RSLogix
program. AOIs can be copied and
exported/imported to other projects.
Figure 1: Add-On Instruction Example
Item Description
1 AOI name, also used in project routines where AOI functionality is used
2 Parameters and tags used by the AOI
3 AOI Logic routine, one or more may be used
1.9. Normative References

The following normative references contain the provisions of the GCCS-1 standard.
The editions indicated were valid at the time of publication. All normative references
are subject to revision and the most recent editions of the normative standards
indicated below shall apply.
GM GCCS-1 Common Controls Software
GM NA Blockpoint Release Schedule
GM GME Blockpoint Release Schedule
GM AP Blockpoint Release Schedule
GMNA Powertrain Blockpoint Release Schedule
GM Engineering Process Standards GEP-1
1.10. Locate the Global Ethernet e-Tools.
The Global Ethernet e-Tools are located on GM SupplyPower or Socrates. GM
SupplyPower is hosted on Covisint.com. Users must be registered. Contact your
companys Administrator or GM for registration.
1. From your internet browser type covisint.com
2. Select Automotive from Login menu.
Figure 2: Covisint (GM Supply Power host) Home Screen
3. Enter your User ID and Password.

4. Click Login
Figure 3: Covisint Login Screen
5. Click GM SupplyPower under Covisint Applications > Automotive Portals
Figure 4: Covisint Directed Communications Page
6. Click the Applications tab.
Figure 5: GM Supply Power Home Page
7. Scroll to Manufacturing Engineering Vehicle Systems and click the link.
Figure 6: GM Supply Power Home Page Application
8. Click Global Standards, Specifications, and Procedures on Home Page.
Figure 7: GM SupplyPower Vehicle Systems Automation Standards Home Page
9. Click eTools & Checklists
Figure 8: Global Standards Home Page
10. Scroll down to view the Global EtherNet eTools
11. Click the name of any desired eTOOL to begin its download.
Figure 9: GM Supply Power Home Page - Global Ethernet e-Tools
1.11. ControlLogix Environment
Logix 5000 PLC programs are created with the following software or templates. Their
use is dependent upon where the program is used in the plant:
o Controls Design environment, CDE Software
o eConveyor Software
o GCCS-2 reference software and templates for the specific equipment
The development conventions are as follows:
Bodyshop - Logix 5000 PLC programs shall be developed with the CDE software
generation tool.
Conveyance outside of tooling Logix 5000 PLC programs shall be developed
with the eConveyor software generation tool.
Powertrain - Logix 5000 PLC programs shall be developed with GCCS-2
reference software and templates provided for the specific equipment.
General Assembly Logix 5000 PLC programs shall be developed with GCCS-2
Paint Logix 5000 PLC programs shall be developed with GCCS-2 reference
software and templates provided for the specific equipment.
Metal Stamping - Logix 5000 PLC programs shall be developed with GCCS-2
All work must be performed using the versions of RSLogix and ControlLogix firmware
specified in the latest GM Blockpoint Release Schedule. An applicable version of
this document shall be made available on request by the GM Automation Standards
Controls Project Engineer or designated representative. Powertrain projects must
use RSLogix and ControlLogix firmware as specified in the latest GMNAPT
Blockpoint Release Schedule.
1.11.1. Definitions
GCCS-1 uses numerous terms to describe system components and functions. A
discussion of the more commonly used items follows here:
ControlLogix, GuardLogix, CompactLogix, Logix 5000, Processor, Controller -
all refer to the Programmable Logic Controller (PLC) that is used on all GM projects.
RSLogix 5000 & Studio 5000- is the Windows-Based programming software used
to develop, upload/download, and maintain the PLC software.
Firmware is the code running at a hardware level in the PLC and other smart cards
in the architecture. Specific bugs can be fixed by using the correct firmware
identified on the Blockpoint.
Blockpoint Is a GM specific document that defines, by project, what the proper
software and firmware versions are. Projects should not move ahead or lag behind
the versions listed for the specific project on the Blockpoint.
Data types define the size and memory layout that will be allocated when a tag of
a particular data type is created. All tags have a data type.
Three categories of data types are used:
Pre-Defined
Module-Defined
User-Defined
Pre-Defined Data Types - Basic data types that are pre-defined by the controller.
Module-Defined Data Types - Are pre-defined and are used in the tags that are
automatically created when I/O modules are added to the I/O Configuration.
User-Defined Data Types (UDTs) - UDTs are made from Pre-Defined, Module-
Defined, or other User-Defined Data Types. UDTs are visible throughout the
controller. User-Defined Data Types are created by either or the actual user.
1.12. Plant Floor Systems (PFS)

There are a couple of different Plant Floor Systems that are designed to
accommodate sharing of maintenance, production and other related data.
Automation and plant level systems send data between the PLC controllers and
plant level systems such as Cimplicity and marquees.
1.12.1. Plant Monitoring and Control (PM & C or PMC)
PM & C is communication logic that is used to send Alarm messages and other
maintenance and production information to upper level plant systems such as
Cimplicity and display marquis. Several routines require configuration to coincide
with physical stations types, operator and robot use within the stations.
1.12.2. Plant Floor Event (PFE)
The Plant Floor Systems (PFS) Plant Floor Event (PFE) feature is a replacement
for the conventional Production Monitoring and Control (PM&C or PMC) PLC
logic template. Both the PLC logic and HMI program are affected.
The PLC PFE based logic uses a messaging protocol to send data to a host
device (either a PFS Appliance or a Cimplicity server) and requires much less
configuration in both the PLC and host systems. With PFE based logic, events
are opened, maintained and closed in the PLC. GCCS-2 PLC programmers will
notice little change in the logic. The PM&C ASCII Echo concept has been
extended to include many different types of events.
Three types of events are utilized:
1. Digital faults, warnings, statuses
2. Value counts, timers, temps
3. Record a user defined structure of digital and value events (ODD, CView,
RPM)
A PFE Logic User Guide is available from GM, for additional information contact:
Jeff Sousley, GM 810.602.8250
1.13. Project Structure
RSLogix 5000 & Studio 5000 permit multiple programs within a single RSLogix
project. Each program is similar to a stand-alone PLC. They have their own
program tags and also have access to global controller tags. Tags will be defined
later.
Each controller program structure is based on cell component data configured
during the software generation process. The GCCS-1 standard mandates that
the logic structure consist of at least one task, the Main Task.
The Main Task is a continuous task containing control programs for cell(s),
stations and related automation components. The Main Task executes all
programs, then starts over, and calls all programs except those in the Safety
Task.
Projects using GuardLogix also require a Safety Task. The Safety Task
monitors all of the cell safety I/O systems.
Figure 10: Safety Task
The Safety Task is periodic, interrupts the Main Task, and calls all safety
programs.
1.13.1. Controls Design Environment, CDE Software Tool
The CDE software tool generation process creates the entire controller logic
program structure. This ensures common logic structures from controller to
controller. Note that the output from the CDE software will require modification by
the start-up engineer to complete and start up the equipment.
1.13.2. Program Description
Each program and routine in the Main Task and Safety Task shall include
descriptions of their function in their properties description box. See Figure 11.
Figure 11: Program and Routine Description
1.13.3. Main Routine
Every program will have a main routine (A000_Main) that will call most of the
remaining routines of the program. Routines not called by A000_Main must be
called by other routines in the program. Uncalled routines cannot reside in a
programs logic structure.
1.13.4. Routine Names

Routine names shall adhere to the GCCS-1 naming standard.
1.14. Ladder Logic Contents

The following objects must be documented in the ladder logic:
Programs
Routines
Rung comments
The software generation process as well as template logic may contain ladder
logic rungs that have place-holder bits. These bits are identified by the TBD tag.
All TBD bits must be removed or replaced with the appropriate logic. Finished
logic that is ready for buy-off must not contain TBD, Temp Bits, or Jumpers of any
kind unless hardware devices are not present at the time of buy-off. Rung
comments often explain what is required to replace the TBD appropriately in the
logic.
Figure 12: The TBD Tag Blocking Logic
1.14.1. Rung Comments

Rung comments are used to describe logic function or how to configure a rung
based on a specific situation. Rung comments are required as shown in the
GCCS-2 reference. Alarm and prompt text resides in specially formatted rung
comments. A macro program is used to extract alarms and prompts from an L5K
text file of the controller logic for importation into the HMI.
Figure 13: Rung Comments
1.14.2. Operand Description

GCCS-1 standards dictate that every controller scope and program scope tag
have an operand description that briefly describes its function, without exception.
The GCCS-2 reference contains examples of the descriptions for each type of
tag. Most tags have pass-thru descriptions from the data-types.
1.14.3. Pass-Thru
In Figure 14, the top or Main Description can be edited to indicate the appropriate
cylinder number. The UDT will pass-thru main description text to all members of
the UDT, indicating that each member is part of the tag as shown in Figure 14.
Pass-thru descriptions have a grayed-out appearance. UDT member comments
will be added to the main tag comment to create the individual tag comment.
Figure 14: Pass-Thru Description
Note: Only the Main Description is editable by the user.
1.15. Review
1. What is the purpose of the GCCS-1 standard?
2. What is the purpose of GCCS-2 standard?
3. How is ladder logic generated for the various GM groups?
4. What types of objects must be documented in the ladder logic?
GCCS-2
LMS # 33544
Module 2: RSLogix Overview

Sponsoring Group:

Document Revisions:

6-8-15 6.0 J. Hocking
EtherNet I/O
This training is based on the Global Common Software Design Standards, GCCS-1.
Please refer to the GCCS-1 manual found on the GM intranet or
www.gmsupplypower.com. The GCCS-1 manual is comprehensive and will have the
latest information. This training manual is used as an instructional guide.
permission of the General Motors Company, is prohibited.

i
Table of Contents
2. RSLogix 5000 Overview..................................................................... 2-1
2.1. Objectives ............................................................................................................ 2-1
2.2. GCCS-1 Systems ................................................................................................. 2-2
2.3. Controller Organization ...................................................................................... 2-2
2.4. Processor and Logix File Naming...................................................................... 2-4
2.5. I/O Module Configuration ................................................................................... 2-5
2.5.1. Adding New Modules .................................................................................. 2-8
2.5.2. Configuration Review Utility ...................................................................... 2-12
2.5.3. Controller Properties General Tab Processor ........................................ 2-13
2.5.4. Controller Properties Advanced Tab Processor ..................................... 2-14
2.5.5. Controller Properties Safety Tab Processor ........................................... 2-15
2.5.6. Input and Output Card ............................................................................... 2-16
2.5.7. Ethernet Bridge Properties ........................................................................ 2-16
2.5.8. DeviceNet.................................................................................................. 2-18
2.5.9. Configuring Remote Devices..................................................................... 2-20
2.5.10. Configuring a Remote Processor for Producer/Consumer ...................... 2-21
2.5.11. Remote Processor Configuration ............................................................ 2-23
2.5.12. Configuring Devices for Ethernet IP Communication .............................. 2-25
2.5.13. Configuring a Robot for Ethernet IP Communication .............................. 2-25
2.5.14. Configuring a Block I/O Module:.............................................................. 2-27
2.5.15. Configuring a Camera for Ethernet IP Communications: ........................ 2-28
2.6. Data Types Pre-Defined, Module-Defined, and User-Defined ..................... 2-29
2.6.1. Pre-Defined Data Types (Basic)................................................................ 2-29
2.6.2. Pre-Defined Data Types (Advanced) ........................................................ 2-30
2.6.3. Module Defined Data Types ................................................................... 2-30
2.6.4. User-Defined Data Types .......................................................................... 2-31
2.7. Tags .................................................................................................................... 2-32
2.7.1. Tag Scope ................................................................................................. 2-32
2.7.2. Tag Classes .............................................................................................. 2-34
2.7.3. Tag Aliasing .............................................................................................. 2-35
2.7.4. Setting up an Alias .................................................................................... 2-35
2.7.5. Modifying Tags and User-Defined Data Types (UDTs) ............................. 2-39
2.8. Tasks Main and Safety ................................................................................... 2-40
2.8.1. Main (Continuous) Task ............................................................................ 2-40
2.8.2. Safety Task ............................................................................................... 2-44
2.8.3. Safety Task Organization .......................................................................... 2-45
2.9. Programs and Routines .................................................................................... 2-45
2.10. Studio 5000 Navigation ................................................................................... 2-47

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2.11. Exercises ......................................................................................................... 2-49
2.11.1. Exercise 1 Creating UDTs and Tags. ...................................................... 2-49
2.11.2. Exercise 2 Creating a Tag Alias. ............................................................. 2-54
2.12. Searching the Logic ........................................................................................ 2-56
2.13. Logic Cross Referencing ................................................................................ 2-60
2.14. Producer/Consumer Communications .......................................................... 2-62
2.14.1. Setting up the Producer .......................................................................... 2-63
2.14.2. Setting up the Consumer(s) .................................................................... 2-65
2.14.3. Downloading Producer/Consumer Programs .......................................... 2-66
2.15. Review .............................................................................................................. 2-67

iii
Table of Figures
Figure 1: GCCS-1 Systems ......................................................................................... 2-2
Figure 2: Controller Organization for Standard Controller ........................................... 2-3
Figure 3: Controller Organization for Guard Logix Controller ...................................... 2-4
Figure 4: Setting the Controller Naming ...................................................................... 2-5
Figure 5: Adding I/O Modules to the Local Chassis .................................................... 2-6
Figure 6: Selection of the Correct Controller Module to be Added .............................. 2-7
Figure 7: Download Add On Profile zips...................................................................... 2-8
Figure 8: Starting the Setup Wizard ............................................................................ 2-9
Figure 9: Accept the EULA .......................................................................................... 2-9
Figure 10: Choose Install .......................................................................................... 2-10
Figure 11: Install Status Window ............................................................................... 2-10
Figure 12: Click Finish, Install is Complete................................................................ 2-11
Figure 13: Configuration Review Utility ..................................................................... 2-12
Figure 14: Controller Properties General Tab Slot #, Chassis Size, Name ............ 2-13
Figure 15: Controller Properties General Tab Definitions & Settings ..................... 2-13
Figure 16: Controller Properties Advanced Tab Fault Handler, Overhead Time Slice 2-
14
Figure 17: Controller Advanced Tab Definitions & Settings.................................... 2-14
Figure 18: Controller Properties Safety Tab Select Configure Always Setting ....... 2-15
Figure 19: Input Card Output Card is Similar ......................................................... 2-16
Figure 20: ENxT Properties Name, Slot #, IP Address, Keying .............................. 2-16
Figure 21: ENxT Properties Definitions & Settings ................................................. 2-17
Figure 22: DeviceNet Card Properties Name, Node #, Slot#, Size, Keying............ 2-18
Figure 23: Configure DeviceNet Properties (General Tab) Definitions & Settings .. 2-18
Figure 24: DeviceNet Card Properties RPI............................................................. 2-19
Figure 25: Tree View of Scheduled Ethernet Connections ........................................ 2-20
Figure 26: Adding a Remote ENxT ........................................................................... 2-21
Figure 27: Configuring a Remote ENxT Name, Slot, Chassis, Keying, and IP ....... 2-22
Figure 28: Remote ENxT Properties Definitions & Settings ................................... 2-23
Figure 29: Adding a Remote Processor .................................................................... 2-24
Figure 30: Adding a Remote Processor Definitions & Settings .............................. 2-24
Figure 31: Adding a Local Fanuc Ethernet Robot Name, IP, and Parameters ....... 2-25
Figure 32: Add a Local Fanuc Ethernet Robot Name, IP and Parameters - Definitions
& Settings ................................................................................................................... 2-26
Figure 33: Set the Requested Packet Interval (RPI) to 60ms .................................... 2-26
Figure 34: Adding an Ethernet IP Block I/O 16 Input Name, IP, and Parameters ..... 2-27
Figure 35: Add an 16 Input I/O Block ........................................................................ 2-27
Figure 36: Connection Settings Block I/O.................................................................. 2-27
Figure 37: Adding an Ethernet IP Camera Name, IP, and Parameters .................. 2-28
Figure 38: Adding an Ethernet IP Camera Definitions and Settings ....................... 2-28
Figure 39: Advance Pre-Defined Data Type.............................................................. 2-30

iv
Figure 40: Module Pre-Defined Data Type ................................................................ 2-30
Figure 41: Typical User-Defined Data Type .............................................................. 2-31
Figure 42: Tag Example ............................................................................................ 2-32
Figure 43: Tag Scope Overview in the Controller ...................................................... 2-33
Figure 44: Standard Class Tags ................................................................................ 2-34
Figure 45: Safety Class Tags .................................................................................... 2-34
Figure 46: Adding a Controller Tag ........................................................................... 2-35
Figure 47: Adding a Controller Tag Definition Description...................................... 2-36
Figure 48: Program Scope Generic Tag .................................................................. 2-37
Figure 49: Cell Tag with Alias Makes the Tag Unique and Controller Scope ............ 2-38
Figure 50: Logic Using an Alias ................................................................................. 2-38
Figure 51: Do Not Modify Data Types or System Routines with a "Z" Prefix .............. 2-39
Figure 52 Task Organization GCCS-2 template ...................................................... 2-41
Figure 53: Main Task Properties ............................................................................... 2-41
Figure 54: Scheduled Order of the Programs to be Executed ................................... 2-42
Figure 55: Scheduled Order of the Programs to be Executed - Definitions & Settings .. 2-
42
Figure 56: Unscheduled Programs ............................................................................ 2-43
Figure 57: Safety Task Periodic Settings .................................................................. 2-44
Figure 58: Setting the Period for the Safety Task...................................................... 2-44
Figure 59: Setting the Main Routine for a Program ................................................... 2-46
Figure 60: Setting the Main Routine for a Program - Definitions & Settings .............. 2-46
Figure 61: RSLogix 5000 User Interface ................................................................... 2-47
Figure 62: RSLogix 5000 User Interface - Definitions & Settings .............................. 2-48
Figure 63: Create an UDT ......................................................................................... 2-49
Figure 64: New UDT with Members Added ................................................................ 2-50
Figure 65: Selecting a Data Type ............................................................................... 2-51
Figure 66: Expanded View of KA070Style Tag .......................................................... 2-52
Figure 67: KA070Tag with DINT used for the Data Type ........................................... 2-53
Figure 68: Choosing the Alias for KA070Tag(C) ........................................................ 2-54
Figure 69: Changing Data Type on the Base Tag ...................................................... 2-55
Figure 70: Effects of Changing the Data Type of the Base Tag on the Alias Data Type 2-
55
Figure 71: Searching for an Item ............................................................................... 2-56
Figure 72: Search Function - Definitions & Settings .................................................. 2-57
Figure 73: Find Next Instance of a Tag ..................................................................... 2-58
Figure 74: Search and Replace .................................................................................. 2-59
Figure 75: Cross Reference of a Tag ........................................................................ 2-60
Figure 76: Cross Reference Results ......................................................................... 2-61
Figure 77: Cross Reference Results - Definitions & Settings .................................... 2-61
Figure 78: Cross Reference Results ......................................................................... 2-61
Figure 79: Tag Properties Setting to Produced ...................................................... 2-63
Figure 80: The Connection Button ............................................................................ 2-64

v
Figure 81: Produced Tag Setting Max # of Consumers.......................................... 2-64
Figure 82: Tag Properties Setting to Consumed .................................................... 2-65
Figure 83: Consumed Tag Setting Connections ..................................................... 2-66
Figure 84: Consumer Tag Connection Definitions & Settings ................................ 2-66

vi
2. RSLogix 5000 Overview
2.1. Objectives
1. The student will be able to define the organization of Standard and Guard
Logix controllers.
2. The student will be able to define tag scope.
3. The student will be able to define how routines are organized and called.
4. The student will be able to configure Ethernet devices.
5. The student will be able to configure DeviceNet safety modules.
6. The student will be able to configure a safety task period.
2.2. GCCS-1 Systems
The following is an overview of the systems used in the GCCS-1 standard to control
machines and processes as well as provide a way interface with users. We will explore
more detail on specific systems as we go along.
Figure 1: GCCS-1 Systems
2.3. Controller Organization

The family of Rockwell Automation Logix controllers is organized as follows:
The processor is also referred to as the controller.

Modules that reside in the PLC (Logix) rack are often referred to as cards.
Examples include: Input card, DeviceNet card, Ethernet card.
Data in a Logix processor is contained in tags.
Tags have scope of either program or controller. See Module 2.7 for more details.
Tags are defined by their data type, either Pre-Defined or User-Defined. See
Module 2.6 for more details.
Programs are contained in tasks.
There is always a continuous task. See Figure 2.
There may also be a safety task if the application is using a GuardLogix
processor. See Figure 3. The safety task is periodic in nature and interrupts the
continuous task. Tasks are discussed further in Module 2.8.
Routines are contained in programs. A program can have an unlimited number of
routines, limited only by the memory of the processor.
Ladder logic is contained in routines.
Programs are limited to 100.
Standard Processor
Controller Scope Tags
Continuous Task
Program 1
Program Scope Tags
Routine 1
Routine 2
Routine 3
Routine 4
Figure 2: Controller Organization for Standard Controller
Guard Logix Processor
Controller Scope Tags
Continuous Task Periodic Safety Task
Program 1 Program 1
Program Scope Tags Program Scope Tags
Routine 1 Routine 1
Routine 2 Routine 2
Routine 3 Routine 3
Routine 4 Routine 4
Figure 3: Controller Organization for Guard Logix Controller
2.4. Processor and Logix File Naming

The controller and .ACD logix file are named according to the conventions outlined in
GCCS-1 Appendix 1 Naming. The processor name can be renamed by:
1. Right-clicking on the controller. See Figure 4.
2. Selecting Properties.
3. Selecting the General tab in the Controller Properties window.
4. Rename the processor.
Figure 4: Setting the Controller Naming
2.5. I/O Module Configuration

Each I/O module that communicates with the controller must be defined. This includes
local modules, as well as remote modules. The hierarchy in the module configuration
process (from highest to lowest) is:
1. Local ENxT The x is typically a 2 (ENxT)
A. Ethernet
1. Remote ENxT
a. Remote Processor
The first modules to be defined are the cards that are in the local chassis. Note that
the processor and safety partner located in slots 0 and 1 will be configured
automatically by RSLogix when choosing your processor. The chassis type and size
is set up under controller properties on the same page as the processor naming
shown in section 2.4 above.
Modules are added by right-clicking on the chassis under I/O Configuration. Then select
New Module.
Figure 5: Adding I/O Modules to the Local Chassis
To narrow the scope of your search, select the module type and type
vendor.
Then select the correct controller module (Figure 6).
Figure 6: Selection of the Correct Controller Module to be Added
Once the correct controller module is selected, there are multiple items that must
be filled in that are specific to the selected module. Some typical examples,
including the processor, Ethernet, I/O cards, and DeviceNet begins in section
2.5.2.
In some cases, it will be necessary to add new modules to your RS Logix
installation, the procedure follows in section 2.5.1.
2.5.1. Adding New Modules

Newly released I/O modules may not be included in your RSLogix installation.
The following is a list of preferred means to obtain a suitable module:
1. Copy an older version of the module from the GCCS-2 template, if it is
available.
2. Use a generic profile if the module cannot be copied from GCCS-2.
3. Install an AOP, if items 1 and 2 cannot be done.
Do NOT install an AOP for any of these modules:
Network Cards (ENxT, DNB, SDN)
PLCs
To add new modules to RSLogix will require registering an EDS file , installing an
Add On Profile (AOP), or both.
Installing an AOP is shown in the following steps, for help with registering EDS
files refer to Common Task Module 13.
1. Locate and download the desired AOP. You can use Rockwells website to
obtain the AOP; however, use Supply Power if possible, it is more straight
forward.
Figure 7: Download Add On Profile zips

2. Extract the entire zip before attempting to install.
3. Double click the setup icon within the extracted folder.
4. The Setup Wizard will open, Click Next.
Figure 8: Starting the Setup Wizard

5. Accept the End User License Agreement.
Figure 9: Accept the EULA
6. Select Install and click next.
Figure 10: Choose Install

7. Once the Install is complete, a status window will be displayed, click next to
continue.
Figure 11: Install Status Window
8. The Finish window will open. Click Finish.
Note: You can deselect the Display RSLogix 5000 Module Profiles Release
Notes if you want to skip them.
9. Repeat procedure for any other new modules.
Figure 12: Click Finish, Install is Complete
2.5.2. Configuration Review Utility
Use the GM Configuration Review Utility to verify your configuration or locate
configuration errors present in your project. The utility is Excel-based. The
"Configuration Review Utility" scans an .L5K file, RSLogix 5000 text import/export
file, and outputs the current configuration of the PLC project. Any configuration
issues that are found are highlighted in yellow along with a description of the
problem. An .L5K file is necessary to use the utility.
Figure 13: Configuration Review Utility
Item Description Definition

1 Application Select tooling or conveyors
Type
2 Select Program Choose the *.L5K file to check
3 Check Program Start checking the program
The configuration Review Utility is available on Manufacturing Engineering on
Supply Power and is included on your student disk. GM highly recommends using
this utility.
2.5.3. Controller Properties General Tab Processor
When possible, copy needed modules from the GCCS-2 template and paste them
into your project. This is faster and easier than using the module dialogs. The
following sections provide examples of configuring Modules in RSLogix I/O
configuration.
(1756-L6x, 1756-L6xS, 1756-L7x, 1756-L7xS)
Figure 14: Controller Properties General Tab Slot #, Chassis Size, Name
When configuring the processor, provide the following information on the General tab:
1 General Tab General controller properties
2 Name Name of the controller
3 Chassis Type Quantity of slots for ControlLogix Chassis
4 Slot Slot that the processor resides in. Default is 0.
The Safety Partner is defaulted to slot 1.
Figure 15: Controller Properties General Tab Definitions & Settings
2.5.4. Controller Properties Advanced Tab Processor
(1756-L6x, 1756-L6xS, 1756-L7x, 1756-L7xS)
Figure 16: Controller Properties Advanced Tab Fault Handler, Overhead Time Slice
To configure advanced settings for the processor:

1 Advanced Tab Advanced controller properties
2 Fault Handler Program executed when processor faults. Select
program from pull-down menu.
3 System Overhead IMPORTANT: Set to 20 + 5x (# of HMIs) in %. This is
Time Slice the amount of time that the processor spends servicing
internal functions.
Figure 17: Controller Advanced Tab Definitions & Settings
2.5.5. Controller Properties Safety Tab Processor
(1756-L6x, 1756-L6xS, 1756-L7x, 1756-L7xS)
Figure 18: Controller Properties Safety Tab Select Configure Always Setting
Select Configure Always.

1 Safety Tab Safety settings and status.
2 Configure Always IMPORTANT: Always select Configure Always for
GCCS-2 projects. This setting allows replacement of
safe I/O modules while a Safety Signature exists.
2.5.6. Input and Output Card
These are legacy items and are not readily encountered since the PLC in a box was
introduced.
Figure 19: Input Card Output Card is Similar
2.5.7. Ethernet Bridge Properties

(1756-ENxT)
Note: Copy and paste ENxT modules from GCCS-2 when the module exists.
Figure 20: ENxT Properties Name, Slot #, IP Address, Keying
To configure ENXT (Ethernet Bridge Module) properties:
1 Name The Ethernet card name is ENet## where ## is
replaced by the two-digit PLC slot number.
2 Slot The slot where the ENxT module is to reside.
The GCCH-1 standard is slot 2.
3 IP Address The IP address for the ENxT. Obtain from PFS
or GMIT.
4 Electronic Electronic keying should be set at Disable
Keying Keying. Use the Change button to access
keying.
Figure 21: ENxT Properties Definitions & Settings
Important: Set Rack Connection or Comm Format to None. The Rack Connection
setting replaces Comm Format in certain modules.
2.5.8. DeviceNet
(1756-DNB)
Figure 22: DeviceNet Card Properties Name, Node #, Slot#, Size, Keying
To configure DeviceNet Card Properties:

1 General Tab General card properties.
2 Connection Tab Card connection properties.
3 Name The DeviceNet card name is DNet## where ## is
replaced by the 2 digit PLC slot number.
4 Node In GCCS-1, the DNB node number is always set at 0.
5 Slot The PLC slot where the DeviceNet module resides.
6 Input/Output/Status Use the following default sizes:
Size
Input Size 124
Output Size 123
Status Size 32
7 Electronic Keying Select Disable Keying for all DNB modules.
Figure 23: Configure DeviceNet Properties (General Tab) Definitions & Settings
Requested Packet Interval (RPI) should be set at 5 to 20ms (20ms is preferred)
for DNB modules (Figure 24).
Figure 24: DeviceNet Card Properties RPI
2.5.9. Configuring Remote Devices
After properly configuring the cards that are located in the local chassis, the user
must configure certain remote devices in the I/O Configuration.
On the Ethernet network, the user must configure any scheduled connection such
as Remote Processors, Hard Auto Weld Controllers, Inspection Cameras, and
Robot Controllers. HMIs are not currently scheduled traffic; therefore they are not
configured at this time.
Expand the Local Ethernet ENxT card by left-clicking on the + sign to the left of
the ENxT card. Next, expand the configured connections by left-clicking on the +
to the left of Ethernet. Now a tree view of all the scheduled Ethernet connections
for this ENxT card will be visible (Figure 25).
Figure 25: Tree View of Scheduled Ethernet Connections
2.5.10. Configuring a Remote Processor for Producer/Consumer
To configure a remote processor for producer/consumer communication, first
create the remote Ethernet card. Right-click on the Ethernet Network, then
select New Module (Figure 26).
Figure 26: Adding a Remote ENxT
Open the communications item and select the 1756-ENxT, specified for your
project hardware design or the facilitys Blockpoint. After selection, pick a
Revision, then fill in the data as shown in Figure 27 and Figure 28.
Figure 27: Configuring a Remote ENxT Name, Slot, Chassis, Keying, and IP
IMPORTANT: Communication Format (Comm Format) or Rack Connection

defines how an I/O module communicates with the controller. Choosing a
communication format defines:
Which configuration tabs will be available, and
The tag structure and configuration method
Note: Once you create a module, you cannot change the communication format.
To change the communication format, you must delete the module configuration
and recreate it.
To configure a remote EnxT module:
1 Name The name for the remote ENxT is
XXXXX_Enet## where XXXXX is the
Remote Cell ID, and ## is the slot number
of the ENXT in the remote chassis.
2 Chassis Size The IP address for the ENxT. Obtain from
PFS or GMIT.
3 Slot The slot where the ENxT module is to
reside in the remote chassis. The GCCH-1
standard is slot 2.
4 Change Access Module Definition options. Use to
access items 5-7.
5 Electronic Electronic keying should be set to Disable
Keying Keying.
6 Rack IMPORTANT: Select None for Rack
Connection Connection.
7 Chassis Size The number of slots in the chassis that the
remote ENxT resides in.
8 OK Accept the Module Definition Options
9 OK Accept all changes.
Figure 28: Remote ENxT Properties Definitions & Settings
2.5.11. Remote Processor Configuration

With the ENxT communications defined, add the proper processor in the remote
rack so that Producer/Consumer communications can be established. See Figure
29 and Figure 30. The safety partner should be provided automatically as you
select a Guard Logix controller.
Figure 29: Adding a Remote Processor
To establish a remote processor configuration:

Item Description Procedure
1 Remote Click the plus sign (+) to view the remote rack
ExBT configuration
2 Backplane Right click and select New Module to add
processor and partner modules
3 Processors Add the processor be sure to assign the proper
slot..
Figure 30: Adding a Remote Processor Definitions & Settings
IMPORTANT: Use the processor that is the closest match to the physical remote
processor. The selected processor does not need to be an exact match. For
example a L62S can be used in place of a L72S.
Now the remote processor is available for Producer/Consumer communications.
2.5.12. Configuring Devices for Ethernet IP Communication
Modules should always be copied and pasted from GCCS-2 if available. Consult the
GCCS2 standard template logic to obtain parameters specific for the desired type of
device. The following parameters should be obtained from the template logic specific to
the destination area:
Input Assembly Instance and Size
Output Assembly Instance and Size
Configuration Assembly Instance and Size
2.5.13. Configuring a Robot for Ethernet IP Communication
Figure 31: Adding a Local Fanuc Ethernet Robot Name, IP, and Parameters
Note: Use GCCS-2 I/O configuration to determine sizes used depending on robot
version, for example Global 1, Global 2 etc. Size varies depending on the robot version
used.

1 Name Enter the robot name.
(Format = AAxx1Rxx)
2 Description Open properties for reference Ethernet
module in the I/O Configuration of the
GCCS2 template. The description will
indicate Global and above robot
configurations. Global 1 description is
simply robot. Adjust the Size column to
coincide with actual robot used.
3 Comm Format Select Data-Int for Communication
Format.
4 IP Address Enter the IP address for the module.
5 Parameters/Size Set input and output size to 4. This

configures an input/output size of 8 bytes,
which matches the Robot Input/Output
data types.
Figure 32: Add a Local Fanuc Ethernet Robot Name, IP and Parameters - Definitions & Settings
Always select Unicast when it is available. Finally, set the RPI to 60ms on the
Connection tab. See Figure 33.
Figure 33: Set the Requested Packet Interval (RPI) to 60ms
2.5.14. Configuring a Block I/O Module:
Figure 34: Adding an Ethernet IP Block I/O 16 Input Name, IP, and Parameters

1 Name Enter the Block I/O Name.
(Format = AAxx1BK01)
2 IP Address Enter IP address for the module
3 Parameters/Size Set input to 4 and output size to 1. Always verify
settings for size and instance in GCCS-2 I/O
Config.
Figure 35: Add an 16 Input I/O Block
Set the RPI to 60ms on the Connection tab and select Use Unicast on the
Connection tab.
Figure 36: Connection Settings Block I/O
2.5.15. Configuring a Camera for Ethernet IP Communications:
Figure 37: Adding an Ethernet IP Camera Name, IP, and Parameters

1 Name Enter the camera name.
(Format = AAxx1CAM01)
2 IP Address Enter the IP address for the module.
3 Parameters/Size Set based on device.
Figure 38: Adding an Ethernet IP Camera Definitions and Settings
Set the RPI to 60ms on the Connection tab.
2.6. Data Types Pre-Defined, Module-Defined, and User-
Defined
Data types define the organization of data within a tag
Data types are globally accessible within the controller
Data types are not limited in number, only by the memory capacity of the
controller
Data types are categorized as Pre-Defined, Module-Defined, or User-Defined
2.6.1. Pre-Defined Data Types (Basic)

The following is a list of Pre-Defined Data Types and their characteristics. Note
that Pre-Defined Data Types are defined in the controller and are not editable.
BOOL - Boolean. A single bit which is either on (1) or off (0).

SINT - Short integer. An eight bit signed number with values of -128 to +127.
Also used to represent an ASCII character
INT - Integer. A sixteen bit signed number with values of -32,768 to +32,767.
DINT - Double integer. A thirty-two bit signed number with values of
2,147,483,648 to +2,147,483,647.
REAL - A floating point number with values -3.40E38 to 3.40E38.
All other Data Types are comprised of the basic Pre-Defined data types
listed above.
2.6.2. Pre-Defined Data Types (Advanced)
Figure 39: Advance Pre-Defined Data Type
In
Figure 39 above, the Timer data type is an Advanced Pre-Defined data type and
contains multiple basic data types including BOOLs and DINTs
2.6.3. Module Defined Data Types

Module-defined data types are pre-defined and are used in the tags that are
automatically created when I/O modules are added to the I/O Configuration.
Figure 40: Module Pre-Defined Data Type
In Figure 40 above, a 1756-DNB was added to the I/O Configuration. Automatically,

corresponding controller-scoped tags have been created in the controller with the
Module Data Type for the DNB. At the same time, an array of DINTs has been created
that will contain data for the module.
2.6.4. User-Defined Data Types

Comprised of Pre-Defined (1), or other User-Defined data types(2)
Module-Defined are technically possible but are not currently used in GCCS-2
UDTs.
Collects User Data into a single organized tag
Reduces the number of tags in the controller
Ensures that logic is standard and consistent
Figure 41: Typical User-Defined Data Type
User-defined data types are created by the end user to compress multiple pieces
of data into a single tag. Each piece of data can be a pre-defined data type, a
module-defined data type, or other user-defined data types.
In Figure 41 above, the first two Data Type entries are DINTs and the rest are all
other user-defined data-types. If there are any errors in the user-defined data
types, there will be question marks (????) shown for the Data Type Size (1). This
could be due to a single item not completely filled out, or possibly an error in
another data type being used in this data type.
User Defined Tags in GCCS-1 always contain a revision level in the Description
Box so that future users will know when the data type is at the proper revision
level for updates.
Many User-Defined Data Types are created by GM for use in logic projects.
Do NOT modify system data types or system routines. Both are identified
by the z designation in the prefix.
(Examples: zZ999_Diagnostics, za_Action)
2.7. Tags
A tag is a named memory area that holds data of a defined data type. Tags
have both scope and class.
Program Tag Alias for Base Tag Data Type
Figure 42: Tag Example

In the tag example shown above, the Program Tag Cell is an Alias for
AA065B1Cell(C) controller tag. The controller tag is indicated by the (C) suffix.
The Base Tag AA065B1Cell(C) is the tag that contains the actual data, often the
same as the Alias for. Finally, the data type zc_BodySafetyCell determines the
structure of the tags data. When a tag is aliased, the Data Type used will always
come from the base tag.
2.7.1. Tag Scope
Tags have scope which defines how visible the tag is and defines which
routines can access the tags data. There are two types of scope tags;
controller scope and program scope.
Controller scope tags can be accessed from anywhere inside the controller
and can be accessed by other controllers via producer-consumer
communication. All programs can see Controller Tags.
Program scope tags are only visible within the program in which they are
contained.
In Figure 43 below, the controller scope tags are visible to the routines in both
Program 1 and Program 2. Program scope tags are different. The program
scope tags in Program 1 are visible only to Program 1. The program scope
tags in Program 2 are visible only to Program 2. Note that there may be tags
with the same exact name and data type in Programs 1 & 2 because these
are visible only to the program in which they reside. Consequently, there are
no duplicate tags within a program. There are no limits to the number of tags
that can be created; the size of the controller memory is the limiting factor.
Figure 43: Tag Scope Overview in the Controller
2.7.2. Tag Classes
Tags are one of two classes; Standard or Safety. Only Safety class tags can be used by
programs which reside in the safety task. Standard class tags are used anywhere within
the main task programs. See Figure 44.
Figure 44: Standard Class Tags
All tags within the safety task have to be of the class Safety, as well as any controller
tags accessed by the safety task. See Figure 45.
Figure 45: Safety Class Tags
2.7.3. Tag Aliasing
Tag aliasing points a tag to another tag so that the two tags have the same
meaning and share the same data. The data resides in the base tag. GCCS-1
base tags are always controller tags.
Tag aliasing is used extensively in GCCS-2 in the following areas:
Bodyshop
Conveyance outside of tooling
General Assembly
Metal Stamping
Paint has minimal use of alias tags; primarily for HMI configuration GCCS-2.
2.7.3.1. Benefits
o Logic can be written with generic tags such as cell or robot then aliased
to the specific cell or robot. This is faster and easier than searching and
replacing each instance.
o The same logic can be used over and over in driver files. Tags are then
only aliased to the specific piece of hardware which makes it unique.
o The alias of a tag is not dynamic; it can only be modified offline.
2.7.4. Setting up an Alias
Create the correct base tag if it does not exist in the controller tags. The base tag
must be created before the Alias For can be pointed. See Figure 46.
Figure 46: Adding a Controller Tag
Item Description Procedure
1 Scope Select Controller Scope, displayed with controller icon as
shown.
2 Edit Tags Tab Before editing Tags, be sure this tab is selected.
3 Enter Tags Row Type in the Name Field the tag to be added.
4 Select Row When copying tags form another program, select the box in
Button Enter front of the enter tags row then paste. This will bring in all
Tags Row information with the tag including the datatype.
5 Controller Base Enter the tag name and datatype from the pull down menu.
Tag The Program tag will point to this base tag.
Figure 47: Adding a Controller Tag Definition Description
In Figure 48 below, the Program Scope tag Cell does not refer to any particular
cell since it is a program scope tag that can only be viewed inside the current
program. In this example, AAxx1 is shown in the Scope selection box in the
upper left corner. When creating an alias for a new tag, it is not important to
select the proper data type. After an alias is set, the tag will automatically take on
the same data type as the Base Tag.
Figure 48: Program Scope Generic Tag
In Figure 49 below, the alias has been added to the tag cell which now makes
any instructions using the bits inside Cell the same as if they were using
AAcc1Cell. The (C) after the tag indicates that this tag is a controller-scoped tag.
Figure 49: Cell Tag with Alias Makes the Tag Unique and Controller Scope
In Figure 50 below, the logic was written to be generic by using the tag Cell.
After the Cell tag has been aliased, the logic is now specific to AAcc1Cell, as
shown above. The alias base tag shows up below the program scoped tag with
<> around it.
Figure 50: Logic Using an Alias
2.7.5. Modifying Tags and User-Defined Data Types (UDTs)
Do not modify system data types or system routines. Both are identified by the z
designation in the prefix. (Examples: zZ999_Diagnostics, za_Action) See Figure
51.
Figure 51: Do Not Modify Data Types or System Routines with a "Z" Prefix
2.8. Tasks Main and Safety
Each controller program structure is based on cell component data configured
during the software generation process. The GCCS-1 standard mandates that the
logic structure consist of at least one task, this is the Main Task. The Main Task
is a continuous task containing control programs for cell(s), stations and related
automation components.
The Main Task executes all programs, then starts over, and calls all programs
except those in the Safety Task. Projects using GuardLogix also require a Safety
Task. The Safety Task monitors all of the cell safety I/O systems. The Safety
Task is periodic, interrupts the Main Task, and calls all safety programs.
2.8.1. Main (Continuous) Task

The first program of Main Task is the MCP (Main Controller Program). The MCP
Program covers MCP Status, Device Net status, Controller Local Status and
Controller Safety Status, Constants. It is followed by programs for cells, stations,
robots, weld controllers, HMIs, etc.
The Cell Program deals with the cell-level aspects of the logic structure. These
include mapping I/O, mapping HMI, interlock statuses, modes, Gate Boxes,
Perimeter Guards, HMI configuration, and Remote Controller Status.
Each of the remaining programs of the task will handle station or component
specific aspects of the logic structure.
The programs of the Main Task, Figure 52, are organized as follows:
1. Main Task
MCP Program
Cell 1 Program
Cell 1 Station Programs
Cell 1 Robots
Cell 1 Other Programs
Cell 2 Program
Cell 2 Station Programs
Cell 2 Robots
Cell 2 Other Programs
Cell 1 HMIs
Cell 2 HMIs
PFE (When Equipped)
Figure 52 Task Organization GCCS-2 template
All GCCS-1 programs have a continuous task named Main Task.

The Main Task schedules the order in which the contained programs execute.
Programs in a task execute sequentially, one at a time.
The end user selects this order from the task properties window as shown below by
right-clicking on Main Task and selecting Properties (Figure 53).
Figure 53: Main Task Properties
Figure 54: Scheduled Order of the Programs to be Executed
The Program Schedule (Figure 54) can be adjusted from the Main Task
Properties Program Schedule screen as follows:

1 Program Select to adjust or view program
Schedule schedule
2 Add Adds unscheduled programs to the
scheduled programs list
3 Remove Sends scheduled programs to
unscheduled list
4 Scheduled Programs that will execute in the order
of the list
5 Move Moves the selected program Up/Down
(Up/Down) in the list selected
Figure 55: Scheduled Order of the Programs to be Executed - Definitions & Settings
Unscheduled programs will not be executed.

Cross reference will list instances that occur in unscheduled programs.
Any errors present in unscheduled programs will be included when verifying the
controller.
GCCS reference routines are found in the Unscheduled Programs area of the
application.
Figure 56: Unscheduled Programs
2.8.2. Safety Task
Guard Logix projects also have a second task that is periodic in nature and will
interrupt the Main Task at a timed interval. The rate of the periodic safety task is
calculated by the requirements to stop the tooling in a pre-established maximum
amount of time. Refer to Figure 57.
The following are GCCS-1 rules for the Safety Task:

Area Input RPI Periodic Rate Priority Watchdog
Bodyshop 15ms 30ms 1 18ms
Conveyors 30ms 60ms 1 30ms
Paint 30ms 60ms 1 30ms
General 15ms 30ms 1 18ms
A bl
Press 15ms 30ms 1 18ms
Powertrain 15ms 30ms 1 18ms
Figure 57: Safety Task Periodic Settings
Figure 58: Setting the Period for the Safety Task
Figure 58 shows the proper Periodic Rate setting for a Body shop Guard Logix
safety task. Use the settings in Figure 57 for your specific application.
2.8.3. Safety Task Organization
The Safety Task consists of Cell Safety Programs. These programs handle all of
the safety-related I/O aspects of the logic structure. A safety program will exist
for each cell in the Main Task.
The programs of the Safety Task, (Figure 52), are organized as follows:
1. Safety Task
a. Cell 1 Safety Program
b. Cell 2 Safety Program
2.9. Programs and Routines

Each program automatically executes a single routine which is assigned as the
Main routine.
In GCCS-1, the routine is always named A000_Main
The order of the routines displayed in the controller organizer is alphabetical and
is not necessarily the order in which the routines will execute. See Figure 59.
GCCS-1 utilizes prefixes to obtain the organizer order desired. (Examples:
B001_, F010_, S010_)
Jump Sub Routine (JSR) instructions in the A000_Main routine set the execution
order of the logic
The A000_Main in station programs will call the S000_Sequence routine. This
routine will call all station action routines, as well as build the scroll list for HMI
manual operations.
Figure 59: Setting the Main Routine for a Program
To set the Main routine for a program, proceed as follows:

1 Program Right click program and select Properties.
2 Main Routine The small #1 on the ladder icon indicates that
the routine is assigned as a main routine.
3 Main Select the routine desired to be the main routine.

For GCCS-1, this is A000_Main.
Figure 60: Setting the Main Routine for a Program - Definitions & Settings
2.10. Studio 5000 Navigation
RSLogix 5000 is the primary software used to develop, download, and monitor
the logic used in Control Logix controllers. After launching RSLogix 5000, the
user will be presented with a screen as shown below in Figure 61.
Figure 61: RSLogix 5000 User Interface
1 Cut, Copy, and Paste Use on Rungs, Programs,
Routines, and Data Types.
2 Processor Status Run, Program, Online, Forces,
Edits, and Safety Task Status
3 Processor Indicator Lights Duplicates the front of the
processor
4 Controller Organizer List of Tasks, Programs,
Routines, Tags, Data Types, and
I/O Configuration
5 Ladder Caret Indicates with a colored square
the rung that is selected.
6 Editing Window Edit Tags, Logic, UDTs. Displays
Cross Reference Results
7 Ladder Element Toolbar All of the instructions available
for the current processor.
Includes branch and new
rung tools.
8 Controller Organizer Toggles display of Controller
Display Button Organizer. Especially handy
when looking at lengthy ladder
rungs.
9 Verify Routine, The tool on the left verifies the
Verify Controller current routine. The tool on the
right verifies the entire controller.
10 RSLogix Status Bar Indicates controller name. The
active program and routine are
displayed next.
Note: If the file name is not the
same as the controller, the
controller name will be followed
by in and then the file name.
Figure 62: RSLogix 5000 User Interface - Definitions & Settings
In addition to the processes listed in Figure 62, another method of inserting rungs,
branches, and instructions is available. Right click on a rung, then select Add Ladder
Element and a list of available instructions will display. Select the desired instruction
and click OK. You can also access the ladder element list by typing Alt+Insert, selecting
the desired item, and clicking OK.
2.11. Exercises
2.11.1. Exercise 1 Creating UDTs and Tags.
The following exercise demonstrates the basics of creating UDTs and Tags.
1. Open the exercise project Core02Exercises in RSLogix5000
2. Create a new datatype named up_Style with the members WriteRequest,
WriteSetup, and WriteComplete all members are of type DINT.
a) In the controller organizer, click on Datatypes and select User-
Defined
b) Right click and select New Data Type Refer to Figure 63.
c) Set the UDT Name to up_Style
Figure 63: Create an UDT

3. Click in the Name column of the first row and set the first member to
WriteRequest. Refer to
4. Figure 64.
a) Click on the Data Type column of the first row, click [] and select
DINT from the data type dialog box
b) Repeat steps d-e for member names WriteSetup and
WriteComplete.
c) Click OK.
Figure 64: New UDT with Members Added
5. Create a controller tag named KA070Style of the type up_Style.
a) Open the controller tag database and select the Edit Tags tab
b) Move the cursor to the bottom of the tag list to the row with the tag
icon in the left margin
c) Click in the Name column on that row and set the name to
KA070Style
6. Click in the Data Type column, click [] and select up_Style from the data
type dialog box (when making a tag edit, you must move off the current
row to accept the edit). Refer to Figure 65.
Figure 65: Selecting a Data Type
a) Expand the new KA070Style tag by clicking on the + sign to its left.
b) Notice that KA070Style contains three members, WriteRequest,

WriteSetup, and WriteComplete.
Figure 66: Expanded View of KA070Style Tag
7. Create controller tag name KA070Tag of type DINT
a) Open the controller tag database and select the Edit tab.
b) Move the cursor to the bottom of the tag list to the row with tag icon
in the left margin.
c) Click in the Name column on that row and set the name to
KA070Tag.
d) Click in the Type column, click [] and select DINT from the data
type dialog box. (Default datatype may already be DINT)
e) Expand the new KA070Tag by clicking on +.
Notice that KA070Tag is a DINT and contains 32 bits (BOOLS). See Figure 67.
Figure 67: KA070Tag with DINT used for the Data Type
8. Save the project.

End of Exercise 1
2.11.2. Exercise 2 Creating a Tag Alias.
This exercise demonstrates how to create a tag alias.
1. Continue in the exercise project Core02Exercises in RSLogix5000

2. Create a tag named FriendlyAlias in the KA070 program tags. Point the
Alias For to the controller tag KA070Tag.
a) Open the KA070 program tag database and select the Edit Tags
tab. See Figure 68.
1. Move the cursor to the bottom of the tag list to the row with
tag icon in the left margin.
2. Click in the Name column on that row and set the name to
FriendlyAlias.
3. Click in the Alias For column, click [], locate the Controller
Scoped Tag KA070Tag and double-click on it.
4. Click on the next row in the program tag database (when
making a tag edit, you must move off the current row to
accept the edit).
3. Notice the following about the new tag FriendlyAlias:
a) The Alias For column shows KA070Tag(C). KA070Tag is the name
of the tag the alias is pointing to.
b) The Base Tag column shows KA070Tag(C). This shows the base
tag if the tag alias points to another tag alias.
c) The (C) shows that the tag KA070Tag is a controller tag.
d) You cannot change the datatype in the Type column because the
tag alias inherits the datatype of the base tag.
Figure 68: Choosing the Alias for KA070Tag(C)
4. Change the controller tag KA070Tag datatype to INT.
5. Open the controller tag database and select the Edit Tags tab. See
6. Figure 69.
a) Click in the Type column of the KA070Tag row.
b) Click [] and select INT from the data type dialog box.
c) Accept the tag edit by moving off the row.
Figure 69: Changing Data Type on the Base Tag

7. Verify the datatype of the KA070 tag FriendlyAlias
a) Open the KA070 program tag database.
Notice that the datatype of FriendlyAlias has changed to INT. This is because the tag
alias inherits the datatype of the base tag. Refer to Figure 70.
Figure 70: Effects of Changing the Data Type of the Base Tag on the Alias Data Type
End of Exercise 2
2.12. Searching the Logic
Searching is the most common method of finding the location of logic
instructions being referenced from a specific tag. The search function is located
at the top of the menu bar, or by pressing CTRL+F. The Search screen will
appear as shown in Figure 71.
Figure 71: Searching for an Item
1 Find What Enter in the address of the
tag or text that you are
searching for, such as
Cell.Mode.AnyStaAuto or
Cell.Safety.NoEStops.
2 Find Where Select from the following
options:
This routine only
All routines in the
current program
All routines in the
current task
All routines in the
project
3 Wrap, Direction, Configures direction and if
Match Whole Word Only search will wrap. Allows
search for exact phrases
only.
4 Components and Options Provides choices to define
the search.
5 Find Within Toggles view of
components and options so
that search options can
be set.
Figure 72: Search Function - Definitions & Settings
To search for a tag, type in the tag you wish to find and select Find Next. The
next occurrence in the logic will be displayed as shown in Figure 73.
Figure 73: Find Next Instance of a Tag
Search and Replace (Figure 74) is available only in offline editing. It is
recommended that a backup file be created before Search and Replace is
utilized. Caution should be exercised when using Search and Replace as
unexpected results may occur. So, ensure the search settings are correct for the
intended outcome.
Figure 74: Search and Replace
2.13. Logic Cross Referencing
Logic cross referencing is a way of locating programs or tags within a logic
project.
Cross referencing is the method most commonly used for finding specific
information about routines and tags in the RS Logix controller.
Cross referencing a specific routine, usually from the controller organizer, will
show where the routine is used in the controller. This is useful when locating
embedded subroutines (JSRs).
Cross referencing can also be used on Tags both at the controller and program
scope levels. When a Tag is cross referenced, all the data within the associated
tag is also cross referenced and the location of the data within the tag is
displayed at the Program/Routine/Rung levels.
To cross reference a tag, right-click on the tag and select Go To Cross
Reference . . . (Figure 75).
Figure 75: Cross Reference of a Tag
Figure 76: Cross Reference Results

1 Element The type of instruction using the tag.
2 Container Program that the instruction is used in.
3 Routine Routine that the instruction is used in.
4 Location Actual rung that the instruction is used in.
5 Reference Actual tag name used for each use.
6 Destructive Displays Y for destructive, N for non-
destructive. The reference is destructive if
data value of the tag can be changed by the
execution of instruction. The reference is
non-destructive if the instruction only uses
or reads the value and cannot modify it.
Figure 77: Cross Reference Results - Definitions & Settings
Double-clicking a row in the Cross Reference result window will navigate the view
to that use in the logic. Remember when searching for duplicate alarm, prompt,
or scroll list trigger numbers that duplication occurs only when more than one use
of alarm, prompt, or scroll list number occurs in the same program.
Figure 78 is the result of cross referencing kalarm[501]. Notice that only the last
thee lines have their Reference column equal to kalarm[501]. The Container
column shows that they are all in different programs. In this case, there is no
duplicate use of kalarm[501].
Figure 78: Cross Reference Results
2.14. Producer/Consumer Communications
Allows sharing of controller tags between controllers.
Identifies tags to be produced; no destination is required.
Creates consumed tags, points to produced tags.
A produced tag can be consumed by multiple consumers (This is not preferred).
No logic is required for basic Producer/Consumer operation.
When Producer/Consumer is used across Ethernet/IP, it is produced at the
Request for Packet Interval (RPI) setting.
May be across the backplane when controllers are in the same chassis.
Producer/Consumer traffic occurs independently of the controller mode.
Producer/Consumer operates when either controller is in Run, Program, or
Faulted modes. When the producing controller is in Program or Faulted mode,
produced data will remain in the last state when the Producer/Consumer
connection was lost.
Consumed data remains in the last state if the Producer/Consumer connection is
lost.
Producer/Consumer communication occurs asynchronous to program scan.
The process begins with setting up the producer, then the consumer. It
concludes with downloading both programs to the controllers.
2.14.1. Setting up the Producer
To set up a Producer/Consumer connection, right-click on the controller scope tag
and select Edit Properties. The window that comes up will look similar to the one
shown in Figure 79. Under Type:, select Produced instead of Base.
Figure 79: Tag Properties Setting to Produced
After selecting Produced, click the Connection button (Figure 80).
Figure 80: The Connection Button
When the Connection tab appears, select the number of consumers of this tag
(Figure 81). The default is always one consumer for each producer. It is not
necessary to define the consumer at this point.
Note: Always set Max Consumers to the number of consumers plus 1. Use 2 for one
consumer.
Figure 81: Produced Tag Setting Max # of Consumers
2.14.2. Setting up the Consumer(s)
To set up a consumed tag, right-click on the controller scope tag and select Edit
Tag Properties. The window that comes up will look similar to the one shown in
Figure 82. Under the selection of Type:, select Consumed instead of Base.
The data type must match between the producing controller and the consuming
controller.
Figure 82: Tag Properties Setting to Consumed
Figure 83: Consumed Tag Setting Connections

1 Producer Select correct producer from predefined list
established by the I/O connection in Module 2.3.
2 Remote This is the name of the tag in the remote controller.
Data
3 RPI Requested Packet Interval the speed at which the
consumed tag must be updated at a minimum. In
GCCS-1, the consumed tag RPI is always 60ms.
Figure 84: Consumer Tag Connection Definitions & Settings
2.14.3. Downloading Producer/Consumer Programs

After the producer and consumer tags are set up properly, both programs must
be downloaded to the controllers. If the connections are set up properly in the I/O
configuration and the data types are matched in both controllers, the controllers
will automatically establish the Producer/Consumer connection and begin to
transfer data.
If a problem occurs with the connection, a yellow triangle with an exclamation
point inside of it will appear next to the remote ENXT in the I/O configuration.
Clicking on the ENXT will give the user enhanced data on what is causing the
problem, aiding in trouble diagnosis.
2.15. Review
1. Define the organization of Guard Logix controllers.

2. How are Ethernet devices configured?
3. How are DeviceNet Safety Modules configured?
4. Define Tag Scope.
5. Define how routines are organized.
6. What routine calls many of the routines in the program?
7. What routine calls action routines and builds the scroll list for manual
motions?
8. How is the Safety Task Period set?
GCCS-2
LMS # 33544
Module 3: Naming
Sponsoring Group:

Document Revisions:
8-26-13 5.0 J. Hocking Revised graphics and exercise directions.
6-18-15 6.0 J. Hocking
EtherNet I/O.
Copyright General Motors Company, 2015, Detroit, Michigan. All rights reserved
under U.S., International, and Universal Copyright Conventions. Published in the
United States of America. These materials may be used only with related printed
materials.
incidental or consequential damages resulting from the use or application
of the materials in this manual.
The examples, diagrams, and charts in this manual are included solely for
illustrative purposes. Because of the many variables and requirements
associated with any particular safety situation, the General Motors Company
expressly disclaims all express and implied warranties relating to the
materials in this manual, including all examples, diagrams, and charts.

i
Table of Contents
3. Naming ............................................................................................... 3-1
3.1. Objectives ............................................................................................................ 3-1
3.2. Software Naming Convention ............................................................................ 3-2
3.3. Action / Result Naming Conventions ................................................................ 3-2
3.4. Device Naming .................................................................................................... 3-4
3.4.1. Panel Devices ............................................................................................. 3-4
3.4.2. Field Devices .............................................................................................. 3-4
3.4.3. Switches and Cylinders............................................................................... 3-4
3.5. IEC Naming Standard and Logix Naming ......................................................... 3-6
3.5.1. ControlLogix Program and PLC Processor Naming.................................... 3-7
3.5.2. HMI ............................................................................................................. 3-8
3.5.3. Task ............................................................................................................ 3-8
3.5.4. Program ...................................................................................................... 3-9
3.5.5. Robot ........................................................................................................ 3-10
3.5.6. Routine ..................................................................................................... 3-10
3.5.7. Module ...................................................................................................... 3-12
3.5.8. User Defined Datatype (UDT) ................................................................... 3-13
3.5.9. Safety User-Defined Data Type (UDT) ..................................................... 3-14
3.5.10. Add On Instruction .................................................................................. 3-14
3.5.11. Tags ........................................................................................................ 3-14
3.5.12. Exercise 1: Changing Routine and Tag Names and the Effects on
the Logic ............................................................................................................. 3-16
3.6. Review ............................................................................................................... 3-17

ii
Table of Figures
Figure 1: Action/Result Naming Conventions ...................................................3-3
Figure 2: Panel Devices ....................................................................................3-4
Figure 3: Field Devices .....................................................................................3-4
Figure 4: Switch and Cylinder Naming ..............................................................3-5
Figure 5: Part Present Naming Guide ...............................................................3-5
Figure 6: Controller Naming ..............................................................................3-7
Figure 7: Department IDs..................................................................................3-7
Figure 8: File Naming........................................................................................3-8
Figure 9: Program Naming ................................................................................3-9
Figure 10: Routine Naming .............................................................................3-11
Figure 11: Module Naming...............................................................................3-12
Figure 12: UDT Naming ...................................................................................3-13
Figure 13: Safety UDT Naming ........................................................................3-14
Figure 14: Tag Name Prefixes .........................................................................3-15

iii
3. Naming
3.1. Objectives
1. The student will be able to describe the Action/Result naming convention.
2. The student will be able to list the effects of changing a tag name or routine
name in RSLogix.
3.2. Software Naming Convention
All software names used should match the hardware names used. This applies to all
names provided even if they are not consistent with the standard naming rules.
3.3. Action / Result Naming Conventions
The GCCH-1 standard provides a list of action results for various devices as shown
below. These names are printed on the component labels, found in the Logix
program, and are displayed on the HMI screens.
Pushbutton / Actuator Switch / Indicator
Mech. Function
Work Load/Unload Work Load/Unload
Clamp
Contactor
Gate
Pierce CLOSE OPEN CLOSED OPENED
Weld Gun
Weld Gun Backup
Weld Gun Retract
Dump
Ejector
Index
Locator
Pivot
ADVANCE RETURN ADVANCED RETURNED
Pre-Loader
Slide
Transfer
Trunnion
Turnover
Shot Pin
Locating Pin ENGAGE DISENGAGE ENGAGED DISENGAGED
Latch
Stops
Transfer Press
RAISE LOWER RAISED LOWERED
Vertical Slide
Lifter
Lifter LOWER RAISE LOWERED RAISED
Pushbutton / Actuator Switch / Indicator
Mech. Function
Work Load/Unload Work Load/Unload
Turntable FORWARD REVERSE IN POSITION IN POSITION

Figure 1: Action/Result Naming Conventions
3.4. Device Naming
Devices (other than pushbuttons, actuators, detectors, and indicators) are also
named.
3.4.1. Panel Devices
Inside panels and cabinets, devices are named so as to be easily found on the
matching wiring diagram, as shown in Figure 2.
Device Type Device ID
Safety Relay ExxxSR
Control Relay ExxxCR or FxxxCR
Ethernet Switch ENSx
Circuit Breaker ExxxCB
Fuses ExxxFU
Motor Starter ExxxMx
Motor Starter Overload ExxxMOL, FxxxMOL
Figure 2: Panel Devices
Where:
xxx = Sheet number and line number
x = Number from 1 - 9
3.4.2. Field Devices
Devices outside of the cabinets, such as valve manifolds, input / output blocks, etc.,
are also named so as to be readily identifiable. See Figure 3.
Pneumatic Valve Manifold PMx
Hydraulic Valve Manifold HMx
IP67 Input/Output Block BKxx
Motor Mx
Figure 3: Field Devices
Where:
xx = Two digit number from 01 - 99
x = Number from 1 - 9
3.4.3. Switches and Cylinders
The MD-1, Module 2 also specifies names for switches and cylinders as shown in
Figure 4.
Cylinder Cxx
Proximity Switch PXx
Limit Switch LSx
Photo-electric Switch PEx
Part Present Pyyx
Figure 4: Switch and Cylinder Naming
Where:
x = digit number from 1 to 9
xx = digit number from 01 to 99
yy = switch type from this table
Figure 5: Part Present Naming Guide
For example:
C02PX1 Cylinder #02, Home Position Switch
C02PX2 Cylinder #02, Work Position Switch
PPX1 Part Present Proximity Switch #1
PLS2 Part Present Limit Switch #2
3.5. IEC Naming Standard and Logix Naming
The IEC-61131.3 standard specifies that components with names (like PLC programs or
HMIs), are permitted to use upper- or lower-case characters, numbers, and the
underscore ( _ ) mark in the name itself. They also have the following requirements:
Names must start with an alphabetic character or underscore
Maximum length of 40 characters nested UDTs have a maximum length of 40
characters per nest level
Cannot have consecutive or trailing underscores, or spaces
Are case insensitive ABCDE is identical to AbCdE
The following items have names:

Controllers
HMIs
Tasks
Programs
Routines
Modules some I/O modules (discrete I/O) do not require names
User-Defined Data Types (UDTs)
Tags
3.5.1. ControlLogix Program and PLC Processor Naming
The programmable logic controller and program file naming shall use the following
format:
Figure 6: Controller Naming
Note: All controller naming must be in upper case letters.
Department ID (XX in Figure 5 above) is selected from the following identifiers:

Identifier Definition
GA General Assembly
CG Conveyor Group
BA Body Assembly
PD Paint Department
MF Metal Forming
MA Metal Assembly
PT Powertrain
WF Worldwide Facilities
Figure 7: Department IDs
Example: The project file name for BA_AB030B01 will be BA_AB030B01.ACD.

Note: The ACD file extension indicates a non-user readable format that can only
be viewed inside the RSLogix 5000 software.
3.5.2. HMI
HMI application files shall be named as follows:
Field Name Controller HMI#

Description Logix controller HMI Program File name (defined later)
name as defined
previously
Sample BA_AB030B01 HMI1
Figure 8: File Naming
For example, the configuration file of the first HMI attached to the previous PLC
(BA_AB030B01) would be BA_AB030B01HMI1
Note: The ACD file extension indicates a non-user readable format that can only be
viewed inside the RSLogix 5000 software.
3.5.3. Task
Since we are using only one continuous task, we use the default name: MainTask.
In Guard Logix applications, a periodic task, the SafetyTask, exists for safety.
3.5.4. Program
Each type of controller program has its own name as shown in Figure 9.
Main Task
MCP
1st Cell
Station-1st cell
Robot 1st Cell
2nd Cell
Weld Controller
Station-2nd Cell
Robot-2nd Cell
1st HMI
Safety Task
1st Cell Safety

Program
2nd Cell Safety

Program
Figure 9: Program Naming
Remember to correct the ASCII name for programs that you rename. The ASCII
name is configured in the Parameters routine of each program.
3.5.5. Robot
Robot naming is similar to controller naming. Typically, the robot is named with the
station # with the addition of Rxx. This also depends on how the robot(s) is (are)
labeled at the time of build. Also, there may be more than one R01 in the cell based
on different stations. In the HMI program, the Robots are numbered sequentially
from R01 to R24.
3.5.6. Routine
Routines in the RSLogix5000 controller organizer are currently sorted alphabetically.
Routine names consist of a prefix and a short descriptive name of what the routine
does. This allows proper ordering of routines. See Figure 10.
Format * (Prefix ID) ###_ Description
Letter Description
A Main
B Mapping/Config
Controller/Module
C
Diagnostics
F Magnetics Diagnostics Three digits
G Gatebox/Guards followed by
an
J Job Data / Shift Register underscore.
Short name for what
M Modes
the routine does.
P HMI Screen Support For S
Description
prefixes,
S Sequence (Action)
skip by 5s Multiple words are
Turntable Common to allow titlecase.
T
Routines easy
reordering
Robot & Other Device (005, 010,
V
Common Routines 015, )
W Weld Common
X GMIT systems
Standard system
Z
routines
B 001_ MapInputs
Example
S 010_ CloseClamp
Figure 10: Routine Naming
Where:
Prefix X is controlled by GMIT
Prefix z is controlled by Standards
For example:
B001_MapInputs
S010_CloseClamp
3.5.7. Module
Modules listed in the Logix I/O Configuration area of the controller should be named.
This includes modules that are accessed across Ethernet in remote chassis.
Modules shall be named as shown in Figure 11.
Field Name RemoteControl_ Type Slot#

Optional? Yes No No
Module Abbreviation
1756-DHRIO DHRio
1756-DNB DNet 2 digit
If module is in a
remote rack, this zero
1756- padded
st ENet
Description is the 1 Logix ENET/ENxT slot
controller name in number
the remote 1756-
Mot
chassis. MO2AE/MO8SE
1756-L1/L55 See
Controller
1794-L3X naming
DNet 09
Sample
SQ060_ ENet 02
Figure 11: Module Naming
For example:
DNet09
SQ060_ENet02
3.5.8. User Defined Datatype (UDT)
UDTs will have a short descriptive name of what the UDT represents. A prefix will
be added to allow organizing their usage as shown in Figure 12.
*
Format Description
(Prefix)
Prefix Used to create
zc Controller scoped tags
HMI tags obtained by the Global

zh
Message Extractor Short name for
zp Program scoped tags what the UDT
does. Multiple
Device tags (see lesson on words are
zd
Devices) titlecase. (Title
Description
uc Controller scoped tags (User UDT) case is when
each major
ud Device tags (User UDT) word in the
uh User-Defined for HMI text starts with
a capital letter)
up Program scoped tags (User UDT)
u Either scope (User UDT)
Module I/O and other (Submember
zz
UDTs used by Standard UDTs)
Figure 12: UDT Naming
UDT examples:
zc_Station
zz_StaMode
Notes: Any prefix that begins with a letter z is not to be modified. Do not create
UDTs using any prefix that begins with the letter z.
For custom UDTs, use the prefixes uc, ud, up, or u. The prefix s_uc is
the only currently available custom safety UDT.
3.5.9. Safety User-Defined Data Type (UDT)
The UDTs in Figure 12 are specific for naming Safety UDTs.
Format * (Prefix) Description
Description Prefix Used to create Short name for what the
UDT does. Multiple words
s_zc Safety, controller scoped tags
are title case.
s_zd Safety, device tags
s_uc Safety, controller-scoped tags (User
UDT)
s_zz Safety, other UDTs.
s_zc_ For examples, see below. Body safety cell
Sample
s_zd_ MCP W/O HMI
Figure 13: Safety UDT Naming
For Example:
s_zc_BodySafetyCell
s_zd_ECS421xMCP
3.5.10. Add On Instruction

For Add On Instruction (AOI) use the following naming prefixes:
Format * (Prefix) Description
Description Prefix Used to create Short name for what the
AOI does. Multiple words
za AOI controlled by GM (no user edits)
are title case.
ua User definable AOI. (user edits
allowed)
za Za_InsertMessageTrigger Body safety cell
Sample
ua Ua_StyleOverviewIndicator MCP W/O HMI
3.5.11. Tags
Tag names representing devices shall use the device name as documented in the
drawings and as defined in GCCH-1. All other tags shall be named in a way to
describe the data.
Tag naming rules:
All general GCCS-2 naming rules apply
Program tags must not be created with the same name as a controller tag
Begin with a capital letter, unless otherwise shown in Figure 14
Some tags in the controller have prefixes added to the tag name to help
identify the use of the tag (Figure 13).
Prefix Description
k (lowercase) Tag that contains constants kDiag
z (lowercase Tag used internally by system routines zDNet
s_ (lowercase) Safety Tag
Figure 14: Tag Name Prefixes
3.5.12. Exercise 1: Changing Routine and Tag Names and the Effects
on the Logic
1. Open Core03Exercise.
2. In the KA030 rename the S040_CloseClamp to S040_CloseClampTest1
and observe the effects.
A. Expand the KA030 program.
B. Right-click the S040_CloseClamp routine.
C. Select Cross Reference.
D. Observe that a single use is referenced
E. Double-click the use to navigate to it.
F. Observe a JSR (Jump to Subroutine) that calls S040_CloseClamp.
G. Right-click on S040_CloseClamp in the controller organizer.
H. Select Properties.
I. Add text Test1 to the end of the Name box.
J. Click OK on the Properties window.
K. Observe that the JSR and the controller organizer have changed.
3. Rename the Jobdata to JobdataTest1 and observe the effects.
A. Open the Program tags in the KA030 program, select the Edit tab.
B. Locate and expand a tag named Jobdata.
C. Click in the Name cell for the Jobdata.
D. Rename the tag Jobdata to JobdataTest1.
E. Click another tag row to accept your edits.
F. Observe what happens to all members of the tag.
G. Select the JobdataTest1.NoOperation member of the tag.
H. Right-click and select Cross Reference.
I. Double-click the row with the reference of JobdataTest1.NoOperation.
J. Observe the tag use and its name.
The JobdataTest1 tag is an alias for KA030JobData(C).
4. Rename the KA030JobData to KA030JobDataTest1 and observe the
effects.
A. Open the controller tags, select the Edit tab.
B. Locate and expand the KA030JobData controller tag.
C. Rename KA030JobData to KA030JobDataTest1.
D. Observe what happens to all members of the controller tag.
E. Return to the KA030 program tags and observe JobdataTest1 tag and its
Alias For and Base Tag columns.
5. Verify and save the project.
END OF EXERCISE 1
3.6. Review
1. State the Action/Result naming convention for a locating pin.

2. What is the effect in logic when a tag is renamed?
GCCS-2
LMS # 33544
Module 4: Programs and Interlocks

Sponsoring Group:

Document Revisions:

8-26-13 5.0 J. Hocking Updated graphics.
6-18-15 6.0 J. Hocking
EtherNet I/O.
This training is based on the Course Title. Please refer to the Standard manual found
on the GM intranet or www.gmsupplypower.com. The Standard manual is
comprehensive and will have the latest information. This training manual is used as an
instructional guide
permission of the General Motors Company is prohibited.

i
Table of Contents
4. Module 4 Programs and Interlocks ................................................ 4-1
4.1. Objectives ............................................................................................................ 4-1
4.2. Programs ............................................................................................................. 4-2
4.2.1. Program Tags ............................................................................................. 4-4
4.2.2. Controller Tags for Program Examples ....................................................... 4-4
4.2.2.1. Creating a Station ............................................................................. 4-5
4.2.3. Use of Tag Aliases ...................................................................................... 4-6
4.2.3.1. The Mode Alias ................................................................................. 4-6
4.2.3.2. The Status Alias (Sts) ....................................................................... 4-7
4.3. Interlocks ............................................................................................................. 4-8
4.3.1. Interlocks between Processors ................................................................. 4-10
4.3.1.1. Creating interlocks between processors ......................................... 4-10
4.3.1.2. Producer Consumer ........................................................................ 4-14
4.3.2. Interlock Notes .......................................................................................... 4-14
4.4. Review ................................................................................................................ 4-15

ii
Table of Figures
Figure 1 Programs........................................................................................................ 4-2
Figure 2 Program Tags with Alias for Controller Tags .................................................. 4-3
Figure 3 Adding a Station ............................................................................................. 4-5
Figure 4: The Status Alias (Sts) ................................................................................... 4-6
Figure 5 The Status Alias ............................................................................................. 4-7
Figure 6 Interlock Tags................................................................................................. 4-8
Figure 7 Creating Interlocks ToPrev / ToNext Aliases .................................................. 4-8
Figure 8 Creating Interlocks FromPrev / FromNext Aliases ......................................... 4-9
Figure 9 Creating Interlocks third piece of equipment .................................................. 4-9
Figure 10 Custom Interlock UDT RSLogix v19 and above ......................................... 4-10
Figure 11 CPS Buffered Copy for Interlocks .............................................................. 4-11
Figure 12 Custom Interlock UDT RSLogix v19 and above ......................................... 4-12
Figure 13 CPS Buffered Copy Consumed Tags ......................................................... 4-13
Figure 14 Producer Consumer ................................................................................... 4-14

iii
4. Module 4 Programs and Interlocks
4.1. Objectives
After successfully completing this module, the learner will be able to:
1. Describe how programs interact in the GCCS-2 standard.
2. Describe how data types are related to program interaction.
3. Describe multiple program interaction.
4. Explain how programs are independent of controller boundaries.
4.2. Programs
A program represents a major piece of equipment that is to be controlled by the Logix
5000 / Studio 5000 or a Guard Logix processor. It is given a short name to describe
what the program is.
Each program has a corresponding controller tag with the same name as the
program. This tag contains the equipments information that needs to be available
to other programs.
Each major piece of equipment has a user defined datatype (UDT) that defines
this information.
All other information that is not required by other programs is contained in
program tags.
Controller Tag
Controller Tag UDT used
matches
Name
exists w ith EquipmentUDT
same name as type of
program. program.
Program
Station,
Name Robot, Cell,
Tags etc.
Program Tags are

used w hen data is
not required by
other programs.
Figure 1 Programs
Controller Tags
Program Tags
Figure 2 Program Tags with Alias for Controller Tags
In station type programs, the Mode and Sts are Aliases for the Controller Tags
AAxx1.Mode and AAxx1.Sts. In this case the program tags point to different members
of the same tag AAxx1.
1. Program Tag Mode is aliased to Controller Tag AAxx1.Mode
2. Program Tag Sts is aliased to Controller Tag AAxx1.Sts
4.2.1. Program Tags
Tag names match physical device names. A clamp cylinder C08 mounted on a
station has a corresponding tag with same name in the station program.
Datatypes describe physical devices. Datatype zp_Cylinder contains members
PX1 and PX2 to represent switches on the cylinder. Tag C08 is of type
zp_Cylinder the home switch is addressed as C08.PX1
Using program tags will allow reuse of programs
o Prevents naming conflicts
o Tag C08 can exist in multiple programs.
o Also shows direct physical relationships
o The cylinder is contained within the station and is contained in the station
program.
Program tags are used unless data needs to be shared between programs
o Sharing requires the use of controller tags
o Program alias tags are used to access controller tags
4.2.2. Controller Tags for Program Examples
Program types and their corresponding datatypes are shown below.
Program Type Datatype Sample Name

Cell zc_BodySafetyCell AA010Cell
Station zc_Station AA010
Robot zc_Robot AA010R01
Weld Controller zc_WS2WC6SCR AA010WC01
HMI zc_HMI HMI1
4.2.2.1. Creating a Station
The following is an example of creating station 20.
Create a program to control station 20, name it AA020.
Create a controller tag with the same name and give it the appropriate datatype.
Add logic to set data in the controller tag AA020.
Controller Tag
AA020
Program Type Datatype zc_Station
Cell zc_BodySafetyCell
AA020
Station zc_Station
Robot zc_Robot
Weld Controller zc_WS2WC6SCR
PanelView zc_HMI
Program
Figure 3 Adding a Station
4.2.3. Use of Tag Aliases
Tag aliases are used to promote easy copying of programs.
4.2.3.1. The Mode Alias
zc_Station contains 2 pieces of data: Mode and Sts (Status)
Create a program tag alias called Mode and point it to controller tag AA020.Mode
Write all logic in program AA020 using the alias tag Mode.
This output energize, (OTE) instruction, is entered using the Mode.Auto tag. The
text in brackets <> shows that the Mode.Auto tag is an alias and that the real tag
being accessed is AA020.Mode.Auto
AA020
Mode
Sts
zc_Station
AA020
Mode
Mode.Auto
<AA020.Mode.Auto>
-------( )-------
Figure 4: The Status Alias (Sts)
4.2.3.2. The Status Alias (Sts)
Status data is handled in the same manner as the Mode data
Create a program tag alias called Sts and point it to controller tag AA020.Sts
Write all logic in program AA020 using the alias tag Sts
This output energize, (OTE) instruction, is entered using the Sts.Faulted tag. The
text in brackets <> shows that the Mode.Auto tag is an alias and that the real tag
being accessed is AA020.Sts.Faulted.
AA020
Mode
Sts
zc_Station
AA020
Mode
Sts
Sts.Faulted
<AA020.Sts.Faulted>
-------( )-------
Figure 5 The Status Alias
4.3. Interlocks
Interlocks are necessary between skid stations. Interlock data is separate from the
status data. This eliminates confusion and permits the creation of as many tags as
required for interlocking purposes. A separate tag is created for each item that a
program needs to talk to. The names show the flow of the data: Interlocks from
Station 20 to Station 30 are named AA020toAA030. The datatype used depends on
the two programs being interlocked.
Figure 6 Interlock Tags
Create program aliases ToPrev and ToNext for these interlock tags. Write logic
using the alias tags, as shown in Figure 7.
AA010 AA020 AA030
AA010toAA020 AA020toAA030
FromPrev Interlock UDT FromPrev Interlock UDT FromPrev
ToPrev ToPrev ToPrev
ToNext ToNext ToNext

FromNext Interlock UDT FromNext Interlock UDT FromNext
Figure 7 Creating Interlocks ToPrev / ToNext Aliases
Create an alias named FromPrev in AA020 to access the interlocks from AA010
(controller tag AA010toAA020). Create an alias named FromNext in AA010 program
tags to access the interlocks from AA020 (tag AA020toAA010), see Figure 8.
AA010 AA020 AA030

Figure 8 Creating Interlocks FromPrev / FromNext Aliases
Finally, if Station 30 is required to talk to a third piece of equipment, simply create

another interlock tag.
AA010 AA020 AA030

AA030toAA050
Interlock UDT
Figure 9 Creating Interlocks third piece of equipment
4.3.1. Interlocks between Processors
When stations, such as skids, must interlock with stations that are in separate
processors it is necessary to ensure that communications are not lost. A Custom
UDT is used to accommodate interlocks between processors. An interlock UDT and
other device interlock UDTs may also be included such as remote actions and
robots. A connection status member will be included to ensure that the connection is
functioning.
4.3.1.1. Creating interlocks between processors
1. Create a custom UDT uc_AA010ToAA050Interlocks in MCP AA010.
A. Right click User Defined under Data Types in the Controller Organizer
B. Select New Data Type
2. Include members:
A. Comm Datatype = CONNECTION_STATUS
B. AA030ToNext Datatype = zc_SKInterlockToNext
The UDT should look like
Figure 10. Note that the Data Type Size will update after an Apply or OK button is
selected.
Figure 10 Custom Interlock UDT RSLogix v19 and above

3. Create a Controller Tag named AA010ToAA050Interlocks use the UDT
uc_AA010ToAA050Interlocks.
4. Create a Controller Tag named AA030ToNext use the UDT
zc_SKinterlockToNext.
5. Point the ToNext alias in station 30 Program Tags to the AA030ToNext
Controller Tag.
6. Use the CPS, Synchronous Copy command, to copy the data in the ToNext
tag to the AA010ToAA050Interlocks.AA030ToNext tag in the AA030
B002_MapOutputs routine. See Figure 11.
Figure 11 CPS Buffered Copy for Interlocks
A similar process is used for the FromNext alias.

7. Create a custom UDT uc_AA050ToAA010Interlocks in MCP AA010.
8. Include members:
A. Comm Datatype = CONNECTION_STATUS
B. AA050ToPrev Datatype = zc_SKInterlockToPrev
The UDT should look like
Figure 12.
Figure 12 Custom Interlock UDT RSLogix v19 and above
9. Create a Controller Tag named AA050ToAA010Interlocks use the UDT

uc_AA050ToAA010Interlocks.
10. Create a Controller Tag named AA050ToPrev use the UDT
zc_SKinterlockToPrev.
11. Point the FromNext alias in station 30 Program Tags to the AA050ToPrev
Controller Tag.
12. Use the CPS, Synchronous Copy command, to copy the data in the
AA050ToAA010Interlocks.AA050ToPrev tag to the FromNext tag in the
AA030 B001_MapInputs routine. See Figure 13.
A. Include an XIC of the AA050Controller.RunOK to stop the copy if the
remote controller is not in run and OK.
B. Include an XIO of the AA050Controller.RunOK to fill the FromNext tag
using the FLL command when the remote controller is not OK.
Figure 13 CPS Buffered Copy Consumed Tags
It will be necessary to construct two interlocks in the next processor, AA050 in this
example.
4.3.1.2. Producer Consumer
The separation of the interlock tags supports producing and consuming of the tags
across Ethernet, allowing a software design that is independent of the actual
controller boundaries.
Logix Controller 1 Logix Controller 2

AA020 AA030
Interlock UDT Interlock UDT
Figure 14 Producer Consumer
4.3.2. Interlock Notes

Other program to program interlocks exist, for example, Station to Robot, Station to
HMI, Station to SCR. The methods and UDTs used will vary depending on type of
devices that are interlocked.
4.4. Review
1. Describe how programs interact in the GCCS-2 standard?
2. How are data types related to program interaction?
3. How can multiple programs interact?
4. What makes programs are independent of controller boundaries?
GCCS-2
Global Common Control Software
Design
LMS # 33544
Module 5: HMI Screen

Functions
Sponsoring Group:

ME Engineering Group: GM Vehicle Systems-Automation
Standards
Manufacturing Engineer 810-602-9768
Phone:
Document Revisions:
Replaced graphics and content for TIA
8-26-13 5.0 J. Hocking
portal HMI differences.
6-18-15 6.0 J. Hocking
EtherNet I/O.
This training is based on the Global Common Software Design Standards,

GCCS-1. Please refer to the GCCS-1 manual found on the GM intranet or
www.gmsupplypower.com. The GCCS-1 manual is comprehensive and will have
the latest information. This training manual is used as an instructional guide.
Rev. 6.0 2015 General Motors Company. All Rights Reserved ii

Rev. 6.0 2015 General Motors Company. All Rights Reserved ii

Table of Contents
5. HMI Screen Functions ....................................................................... 5-1
5.1. Objectives ............................................................................................................ 5-1
5.2. Human Machine Interface (HMI)......................................................................... 5-2
5.2.1. Hard-Wired Interface................................................................................... 5-3
5.2.2. HMI Organizer (Siemens Specific) .............................................................. 5-4
5.2.3. Communication ........................................................................................... 5-6
5.2.4. Screen Navigation ...................................................................................... 5-7
5.2.5. Screen Color Schemes ............................................................................... 5-7
5.2.6. Button Color Schemes ................................................................................ 5-7
5.2.7. Common Screen Banner ............................................................................ 5-9
5.2.8. Individual Screens .................................................................................... 5-11
5.2.8.1. Configuration Screen ...................................................................... 5-11
5.2.8.2. Help Screen .................................................................................... 5-12
5.2.8.3. Select Screen ................................................................................. 5-13
5.2.8.4. Mode Screen .................................................................................. 5-16
5.2.8.5. Cell Maintenance Screen................................................................ 5-17
5.2.8.6. DeviceNet Screen ........................................................................... 5-18
5.2.8.7. Ethernet Screens ............................................................................ 5-19
5.2.8.8. Scroll List Screen ............................................................................ 5-21
5.2.8.9. Tool / Station Overview Screen ...................................................... 5-22
5.2.8.10. Cell Overview Screen ................................................................... 5-23
5.2.8.11. Cell Overview Pushbutton Configuration ...................................... 5-26
5.2.8.12. Robot Screen ................................................................................ 5-30
5.2.8.13. Alarm Screen Status View ............................................................ 5-32
5.2.8.14. Alarm Screen History View ........................................................... 5-34
5.2.9. Exercise 1: Cell Overview Screen ............................................................. 5-35
5.2.10. Exercise 2: Station Overview .................................................................. 5-40
5.2.10.1. Configure Network Fault Indicators............................................... 5-43
5.3. Review ............................................................................................................... 5-46

iii
Table of Figures
Figure 1: Remote Human Machine Interface .............................................................. 5-2
Figure 2: Lower Hardwired Buttons............................................................................. 5-3
Figure 3: Example Application Screens List ................................................................ 5-4
Figure 4: Input Communications Example .................................................................. 5-6
Figure 5: Output Communications Example ............................................................... 5-6
Figure 6: Button Color Scheme ................................................................................... 5-8
Figure 7: Common Banner Area ................................................................................. 5-9
Figure 8: Common Banner Area Descriptions ............................................................ 5-9
Figure 9: Common Banner Area Definitions .......................................................... 5-10
Figure 10: Configuration Screen ............................................................................... 5-11
Figure 11: Help Screen ............................................................................................. 5-12
Figure 12: Help Screen - Definitions ......................................................................... 5-12
Figure 13: Select Screen .......................................................................................... 5-13
Figure 14: Select Screen Definitions ...................................................................... 5-13
Figure 15: Select Screen Detail ................................................................................ 5-14
Figure 16: Selecting a Different Station .................................................................... 5-14
Figure 17: Selecting Another Station ........................................................................ 5-15
Figure 18: Mode Screen ........................................................................................... 5-16
Figure 19: Select Mode Screen Button - Definitions ................................................. 5-17
Figure 20: Cell Maintenance Screen ......................................................................... 5-17
Figure 21: DeviceNet Screen .................................................................................... 5-18
Figure 22: DeviceNet Screen Definitions ............................................................... 5-18
Figure 23: Ethernet Network Screen ......................................................................... 5-19
Figure 24: Ethernet Screen Device Details EN2T .................................................. 5-19
Figure 25: Ethernet Screen Device Details Robot FA010R03 ............................... 5-20
Figure 26: Scroll List ................................................................................................. 5-21
Figure 27: Tool Overview Screen.............................................................................. 5-22
Figure 28: GoTo Displayed Fault Example ............................................................... 5-23
Figure 29: Cell Overview Screen .............................................................................. 5-24
Figure 30: Cell Overview Screen Detail .................................................................... 5-25
Figure 31 Robot01_pb and its program name ........................................................... 5-26
Figure 32 Robot01_txt displays Robots Name .......................................................... 5-27
Figure 33 Robot02_pb Configuration ......................................................................... 5-27
Figure 34 Sta1_pb enter the station name station name ........................................... 5-28
Figure 35 Sta2_pb example ....................................................................................... 5-29
Figure 36: Robot Screen ........................................................................................... 5-30
Figure 37: Robot Screen - Definitions ....................................................................... 5-30
Figure 38: Robot Selected ........................................................................................ 5-31
Figure 39: Robot Function List .................................................................................. 5-31
Figure 40: Alarm Screen Status View ....................................................................... 5-33
Figure 41: Alarm Screen History View ...................................................................... 5-34
Figure 42: Cell Overview Screen Exercise 1 Configuration ................................... 5-35
Rev. 6.0 2015 General Motors Company. All Rights Reserved iv

Figure 43: Display the Toolbox Menu ....................................................................... 5-36
Figure 44: Select Graphics View ............................................................................... 5-36
Figure 45: Graphics View Window Inserted .............................................................. 5-37
Figure 46: Access the Browse Window to Select Graphic ........................................ 5-37
Figure 47: Select Graphic File from Computer .......................................................... 5-38
Figure 48: Graphic Inserted ...................................................................................... 5-38
Figure 49: Exercise 1 ................................................................................................ 5-39
Figure 50: Enter Indicator States Exercise 2 Configuration ................................... 5-40
Figure 51: Enter Indicator States .............................................................................. 5-41
Figure 52: Indicator States Completed for Cylinder C001 ......................................... 5-41
Figure 53: Alarm Values ........................................................................................... 5-41
Figure 54: Edit the General Text Field ...................................................................... 5-42
Figure 55: Edit the Miscellaneous Name .................................................................. 5-42
Figure 56: Enter Alarm Values. ................................................................................. 5-43
Figure 57: Black Background Color DeviceNet Fault Indicator Configuration ........... 5-44
Figure 58: Indicator with Configured alarm range ...................................................... 5-44
Figure 59: Exercise 2 ................................................................................................ 5-45

v
5. HMI Screen Functions
5.1. Objectives
1. The student will be able to explain the function of each standard Human
Machine Interface (HMI) screen.
2. The student will be able to state the purposes of the front panel controls on
the HMI.
3. The student will be able to navigate to each screen on the HMI.
5.2. Human Machine Interface (HMI)
The Human-Machine Interface (HMI) controls are hard-wired pushbuttons and switches
that are used in conjunction with HMI operations but are not part of the HMI itself.
These devices are mounted directly beneath the HMI in the HMI enclosure. Figure 1
illustrates the HMI and its associated hardware.
Figure 1: Remote Human Machine Interface
5.2.1. Hard-Wired Interface
Figure 2 below identifies the hard-wired buttons and lights that are mounted below
the HMI.
Figure 2: Lower Hardwired Buttons
Item Name Device State Description

1 Auto Initiate PBLT Pressed Initiates Auto for all stations in cell with Auto
(Green) (Push Button) selected
PBLT On All stations Auto
(Light)
Flash All stations ready for Auto
Fast Flash At least one station lost Auto
Off No stations Auto
2 Do PB Pressed Cause Motion or confirm critical motions
3 Undo PB Pressed Cause motion that is opposite of selected
motion
4 Reset PBLT Pressed Enables current cells power reset
(Blue) (Pushbutton)
PBLT ON Power is reset
(Light)
Flash Ready for reset
Off Not ready for reset
5 Auto Manual Key switch/ Manual All stations in manual
Selector switch
Auto All stations auto selected
6 Enable PB Pressed Enables motion while gate is open. Typically
used in tooling cells only.
7 E Stop PB (maintained) Pressed Stop current, upstream, and downstream cell
5.2.2. HMI Organizer (Siemens Specific)
Each production cell is unique in some way, and it is impractical to cover all the
variations and functionality that you might find in the entire plant. Therefore, for the
purposes of instruction, we will illustrate only the basic HMI screens.
Figure 3: Example Application Screens List
Each screen contains multiple objects such as:
Push buttons
Indicators
Message display
Lists
Global alarm banner
5.2.3. Communication
The HMI initiates all of the communication with the ControlLogix processor. HMI
communications use Ethernet I/P.
An example is shown in Figure 4 and Figure 5.
Figure 4: Input Communications Example
Figure 5: Output Communications Example
5.2.4. Screen Navigation
Typical screens are:
o Select
o Help
o Mode
o Alarm
o Scroll List
o Ethernet
o Robot
o Single Robot
o Cell overview
o Station overview
o Maintenance
Screen navigation occurs on the Select screen. The ControlLogix processor
controls all screen changes; there are no GOTO screen buttons. However,
shortcuts exist between screens when appropriate (e.g. cell overview, screen
overview).
5.2.5. Screen Color Schemes

The screen color schemes are:
Green Represents production state
Yellow Represents non-typical/Warning state

equipment can run for 5 minutes or more,
not forever.
Red Represents faulted state - equipment is

stopped or is stopping.
5.2.6. Button Color Schemes

The button color schemes are:
Figure 6: Button Color Scheme
5.2.7. Common Screen Banner
There is a common banner area on all screens. The boxed area at the top of Figure
7 highlights the common banner area.
Figure 7: Common Banner Area
Figure 8 shows the various items located in the banner area. Figure 10 defines the
various items.
Figure 8: Common Banner Area Descriptions
Item Indication/Explanation
Fault Reset ON when an alarm exists. Flashes when an alarm exists in
Auto.
Highest Priority Usually sent to upper level systems, logged to downtime
Alarm reports, and put on marquees in order to call people over.
(broadcast)
Highest Priority Only visible on the HMI. Is a means to help the HMI user.
Prompt (local)
Diagnostic Indicates the program is producing an alarm / prompt.
Locator
More Help When the alarm is present and more help is available, the
button is highlighted. When no help is available, it shows the
time and date.
Safety Cell safety status.
Production Has a GREEN background when normal and YELLOW when
Status any of the run / tryout modes are active.
Bypass Status Indicates the status of bypasses in the cell. Has a GREEN
background when no bypasses are active and BLUE if
functions are actively bypassed.
Login Status Indicates the status of the login.
Back Allows return to the previous screen.
(navigation)
Flag Selects the Language for the HMI Display.
Q&A Allows navigation to the Q & A screen. User selects from
available choices a possible solution to a machine interruption.
Figure 9: Common Banner Area Definitions
5.2.8. Individual Screens
5.2.8.1. Configuration Screen
The Configuration Screen gives the user the choice of closing or returning to the
application. Password Management can be accessed form the screen. Project
status info is available.
Figure 10: Configuration Screen
5.2.8.2. Help Screen
The help screen layout is shown in Figure 12. It shows any additional text that may
be stored in the HMI to assist in correcting the current alarm. Figure 13 explains the
different items on the help screen.
Figure 11: Help Screen
Help Category Allows the user to associate specific text with the given
message number.
Alarm-Specific When a problem occurs with DeviceNet, Safety Relay,
Help Text etc., the help category provides advice for the user (help
message that applies to multiple alarms). This is already
programmed for standard help categories.
Back Returns the user to the previous screen.
Figure 12: Help Screen - Definitions
5.2.8.3. Select Screen
The select screen is the main navigation screen. Figure 14 shows the physical
arrangement of these items on the screen. Figure 15 explains the different items.
Figure 13: Select Screen
Item Description/Explanation
Station Select Highlights the user selected station and shows all other
stations grayed out.
Screen All blue buttons are valid per the station that is selected in
Navigation the station select area.
Figure 14: Select Screen Definitions
Figures 16 thru 18 illustrate what occurs when different stations are selected.
Figure 15: Select Screen Detail
Figure 16: Selecting a Different Station
Figure 17: Selecting Another Station
The select screen has multi-station capabilities, supporting up to 30 stations, with 10

stations per screen. Notice that the station select buttons black out when not
programmed in the controller. When more than 10 stations exist, the Next Station
Page () button is used to display additional stations.
5.2.8.4. Mode Screen
The Mode Screen has Modes, Holds, and requests. The screen provides tryout
mode functions, enabling and disabling all process equipment, lamp test, etc. This
screen is shown in Figure 18.
Figure 18: Mode Screen
Item Description
Tryout Mode Toggles tryout mode on / off.
Runout Mode Toggles runout mode on / off.
End of Cycle Toggles End of Cycle Hold (EOCH). Equivalent to
EOCH button on gate box.
Fast Stop Allows actions in process finish, prohibits the start of
any new actions
Energy Stop Stops in the best position to turn off air and electricity.
Can be with parts, may be without parts, etc.
Item Description
Prepare To Stop Limits the robot(s) to only pick up parts if the dropoff
location is available. The mode should prevent a
situation where a robot is holding a part that it cant
drop. Allows all robots to get home if a different stop
mode is selected.
Lamp Test Press to test pilot lamps and horns
Remove Bypasses Removes non-robotic bypasses (scroll list, switch
bypasses
All Processes On Turns on all non-robotic process equipment.
All Processes Off Turns off all non-robotic process equipment.
Figure 19: Select Mode Screen Button - Definitions
5.2.8.5. Cell Maintenance Screen

The cell maintenance screen is the gathering point for cell specific maintenance
functions (e.g. reset steppers, cap change, etc.). The cell screen is shown in
Figure 20.
Figure 20: Cell Maintenance Screen
5.2.8.6. DeviceNet Screen
The diagnostic screen for DeviceNet is shown in Figure 21. A description and
explanation of the screen items is shown in Figure 22.
Figure 21: DeviceNet Screen
Node Status This screen has the ability to show the status of 64
nodes for one scanner.
Color Code Green Everything is fine.
Yellow Safe communication fault.
Red There is a problem with that node.
Black background with white text There is a
mismatch between the processor map I/O and the
DeviceNet scanner configuration.
Next Scanner Switches to the next scanner.
Hold Fault Message Toggles from holding a single message or scrolling all
active messages in all DeviceNet networks in the local
rack.
Fault Code DeviceNet network fault code.
Fault Message DeviceNet network fault message.
Figure 22: DeviceNet Screen Definitions
5.2.8.7. Ethernet Screens
There are two levels of Ethernet screens. There is a network overview screen with
indicators for devices on the network. The indicators are pressed to view detailed
information about the device selected.
Figure 23: Ethernet Network Screen
The next screen is the Detail Screen for the Cell EN2T.
Figure 24: Ethernet Screen Device Details EN2T
The next screen is the Detail Screen for the Robot FA010R03.
Figure 25: Ethernet Screen Device Details Robot FA010R03
5.2.8.8. Scroll List Screen
The scroll list screen (Figure 26) represents the available manual control. This
screens features are built by the program logic.
Figure 26: Scroll List
5.2.8.9. Tool / Station Overview Screen
The tool overview screen assists in locating the device that is in the alarm banner. A
flashing red light indicates the alarm location.
Figure 27: Tool Overview Screen
Fault indicators are designed to flash Red when the alarm shown in the top
banner is for that device. All alarm triggers (alarm number + message offset)
must be entered into each of the indicators. Each switch will usually have 2
faults Not on and Not off. Most cylinders will have 4 faults, 2 for each switch
(extended and retracted).
Indicators on the Tool Overview screen may be copied to create additional
indicators since the indicators are driven by unique alarm trigger values.
The GOTO DISPLAYED FAULT pushbutton (
Figure 28) navigates to the station with the active fault.
Figure 28: GoTo Displayed Fault Example
5.2.8.10. Cell Overview Screen

The cell overview screen (
Figure 29) shows the cell / equipment status. It also allows the screen operator to
navigate to the tool overview and robot screens.
Figure 29: Cell Overview Screen
If a fault is located within the station, the buttons will turn red. The station with
the highest priority blinks red. Buttons update to indicate the alarm status. This
is illustrated in Figure 30.
Figure 30: Cell Overview Screen Detail
5.2.8.11. Cell Overview Pushbutton Configuration
The robot and station pushbuttons have been setup to simplify their configuration.
Robot Pushbutton Configuration
Robot pushbuttons have tags assigned that will coincide with HMI program tag
aliasing see Figure 31.
Figure 31 Robot01_pb and its program name
The robots name will come from the logic program and is displayed in the yellow
text near the robot pushbutton, currently showing all zeros in Figure 32.
Figure 32 Robot01_txt displays Robots Name
In similar fashion, Robot02 gets its name form the logic program. Note that each robot
has 2 images on the reference screen rot45 is used when the robots image is desired
to be on an angle. The _pb robot is used for robots requiring square rotation, see
Figure 33.
Figure 33 Robot02_pb Configuration
Copy any remaining robot pushbuttons from the reference screen. Match the
program tag in the HMI logic program.
Station Pushbutton Configuration

Station pushbuttons have tags assigned that will coincide with HMI program tag
aliasing.
Figure 34 shows the Sta1_pb prior to adding the station name.
Figure 34 Sta1_pb enter the station name station name
The HMI Program tag Sta01 is an Alias For TP005. Enter TP005in Text Off field
for the Sta1_pb, see Figure 34.
The following Figure 35 is the Sta2_pb example.
Figure 35 Sta2_pb example
To configure station push buttons:

1. For Sta2_pb in the HMI, refer to the HMI program tags in the logic. Look
for, in this case Sta02; the program tag corresponds to the HMI
pushbutton.
2. In the logic, locate the Alias For that is indicated for the program tag found
in step 1, in this case TP010. Type this station name into the Text Off
field in the HMI.
3. Click anywhere in the screen window to accept the station name just
entered. The station button is now configured.
4. Complete configuration of any remaining station PBs.
5.2.8.12. Robot Screen
The robot screen indicates the status of all robots in the cell. It also provides
maintenance functions. The robot screen is shown in Figure 36.
Figure 36: Robot Screen
Robot maintenance functions are updated based on the selected robots. This is
described in Figure 37.
Cursor Up Moves the cursor Up within the robot list.
Cursor Down Moves the cursor Down within the robot list.
Select/Unselect Selects or Unselects the robot that the cursor points to.
Robot
Select/Unselect All Selects or Unselects all robots in the display.
Rbts
Robot Function List Displays the Robot Function window enabling function
selection for selected robots. See Figure 38.
Robot Status List Gray boxed area displays robot names and status
information.
Figure 37: Robot Screen - Definitions
The next view of the robot screen depicts a selected Robot, shown in reverse video.
Figure 38: Robot Selected
Next the robot function list can be opened using the Robot Func. bottom left of the
Robot Screen.
Figure 39: Robot Function List
The Function list provides additional functions based on user-selected robots.

Send Robot(s) To Repair
Return Robot(s) From Repair
Tip Dress Robot(s) Process 1/Process 2
Startup/Purge Process 1/Process 2 (Short)
Statup/Purge Process 1/Process 2 (Long)
Reset Steppers After Cap Change
Turn Process 1/Process 2 On or Off
Bypass/Remove Robot Bypass
Bypass/Remove Process 1/Process 2 Bypass
Spare Robot Functions 20-31
5.2.8.13. Alarm Screen Status View

The alarm screen status view (
Figure 40) displays the top nine active alarms ordered by priority. The highest
priority alarms are located at the top of the screen.
Figure 40: Alarm Screen Status View
Note: if an alarm on a yellow background is seen with the following text: ALARM
#/*HMI\ScnCom\O\Alarm*/ NOT PROGRAMMED IN HMI
SEARCH FOR KALARM[/*HMI\ScnCom\O\AlarmSearchNum*/] IN PROGRAM
"/*HMI\ScnCom\O\AlarmPgmName*/" this message means that an alarm
message is active in the PLC that does not have text in the HMI. Run the
message extractor see Module 14.
5.2.8.14. Alarm Screen History View
The alarm maintenance history screen view (Figure 41) displays the past 100 highest
priority alarms. Alarms can be filtered by program.
Figure 41: Alarm Screen History View
5.2.9. Exercise 1: Cell Overview Screen
In this exercise, you will configure the cell screen as shown in Figure 42.
Figure 42: Cell Overview Screen Exercise 1 Configuration
1. Open Core05Exercises using TIA Portal.

2. Open the screen 200 Cell Overview.
3. Select the View menu.
4. Select Task card to enable the toolbox menu display. Note: Task card is
usually selected by default.
Figure 43: Display the Toolbox Menu
5. Select Graphics View.
Figure 44: Select Graphics View
6. Click and drag a window to receive the graphic.
Figure 45: Graphics View Window Inserted
7. Right click on the new window.

8. Select Add graphic from pop-up menu.
Figure 46: Access the Browse Window to Select Graphic
9. Select the graphic from browse window, Core05Exercise1.
10. Click Open.
Figure 47: Select Graphic File from Computer
11. Verify the graphic desired is displayed; see Figure 48. Note: you can
resize the graphic anytime, just click and drag a grip to resize. Resize the
image to approximately the same size as shown in Figure 49.
Figure 48: Graphic Inserted
12. Copy the following graphics and indicators from the Cell Overview
Graphics screens:
9999 Cell Overview Graphics Gate, Guards
9999 Cell Overview Graphics Panels
9999 Cell Overview Graphics Robots
Follow the directions given on the Cell Overview Graphics screens, to add indicator
pushbuttons and graphics to build the Cell Overview. Note: Indicators/pushbuttons
are designed to coincide with station and robot numbers in the HMI logic, for
example:
R01 = Robot1 in Cell Overview Graphics
Sta01 = STA1 in Cell Overview Graphics
Always copy the correct numbered pushbutton/indicators for the stations and
robots into your project. Do not copy STA1 for all your stations etc.
13. Use the RSLogix project Module05Exercise1.ACD to determine the order
of the robot and station buttons in the project.
14. Verify your project looks like the Cell Overview shown in Figure 49.
Figure 49: Exercise 1
Note: See Figure 42 for robot names.

END OF EXERCISE 1
5.2.10. Exercise 2: Station Overview
In this exercise, you will configure the tool screen as shown in
Figure 50.
Figure 50: Enter Indicator States Exercise 2 Configuration
1. Continue working in Core05Exercises.HMI for this exercise.

2. Open the screen 201 Tool Overview Station 1.
3. Insert the bitmap Core05Exercise2 from your exercise folder. Resize the
image to approximately the same size as shown in
4. Figure 50.
5. Copy the graphics and indicators from screen 9999 Station Overview
Graphics.
6. Rotate the cylinders as needed.
7. Enter alarm trigger numbers for cylinder C01: 1500, 1510, 1501, & 1511.
A. Click the cylinder graphic.
B. Select the Animations tab.
C. Expand the faultInd_msi#mig1 in the tree.
D. Click on Appearance
E. Enter the range (alarm state plus offset) for the desired unit.
Figure 51: Enter Indicator States
F. Complete the remaining ranges. When finished, your screen should look
like Figure 52.
Figure 52: Indicator States Completed for Cylinder C001
C01 1500, 1510, 1501, 1511
*C02 1502, 1503, 1512, 1513.
WG200 1560, 1570.
PPX1 1101, 1111.
BK01 1010, 1011.
BK02 1012, 1013.
PM1 1014, 1015, 1016.
PM2 1024, 1025, 1026.
Figure 53: Alarm Values
*C02 was completed in step 7.
8. Copy the PM1 indicator to create a BK01 indicator.
A. Click the new indicator then select the Properties tab.
B. Expand General and edit the text in the Text field as shown in
C. Figure 54.
Figure 54: Edit the General Text Field
D. Rename the Miscellaneous to BK01_msi; located under the Properties

tab/ Miscellaneous Name field as shown in
E. Figure 55.
Figure 55: Edit the Miscellaneous Name
F. Select the Animations tab, and then select Appearance under Display.
Right click in front of any unwanted states to select then choose delete.
See Figure 56.
G. Enter the range 1010-1011, see Figure 56.
Figure 56: Enter Alarm Values.
Note: For W/G open switches, part present switches, and any other 2-state switches,
delete the first 2 ranges. Right click at the beginning of the row to be deleted; then
select Delete.
5.2.10.1. Configure Network Fault Indicators

The new HMI template application uses Network fault multi-state indicators with a
default background color black. Red background color fault indicators will require that
all states from 0-999,999 be defined (black for off and red for on). The default
background color could be changed to black to simplify state setup.
Network fault indicators for black default Background color do not need to show value
ranges for when the alarms are off. Only alarms that are on, red background color need
to be included.
Figure 57: Black Background Color DeviceNet Fault Indicator Configuration
Figure 58: Indicator with Configured alarm range
Multiple rows can be selected to delete simply hold the Ctrl key on the keyboard and left
click the selection button in front of the Value column to select then right click delete or
use the keyboard delete.
9. Add the remaining graphics/indicators to complete the exercise shown in

Figure 59. Use the table in Figure 53 to enter the trigger values.
Figure 59: Exercise 2
END OF EXERCISE 2
5.3. Review
1. What is the function of the Scroll List screen?
2. What is the function of the Tool/Station Overview screen?
3. What is the function of the Cell Overview screen?
4. What is the function of the Robot screen?
5. What is the function of the Alarm Screen Status view?
6. What is the function of the Alarm Screen History view?
7. What controls are on the front panel of the HMI and what are their
functions?
8. How do you navigate between screens in the HMI?
GCCS-2
LMS # 33544
Module 6: Actions
Sponsoring Group:

Document Revisions:
8-26-13 5.0 J. Hocking Updated graphics
7-21-15 6.0 J. Hocking
EtherNet I/O.
materials.

i
Table of Contents
6. Actions ...................................................................................... 6-1
6.1. Objectives .................................................................................................. 6-1
6.2. Actions ....................................................................................................... 6-2
6.2.1. Action ................................................................................................ 6-2
6.2.2. Action Datatype ................................................................................ 6-3
6.3. Action Routines ........................................................................................ 6-5
6.3.1. Logic Structure................................................................................ 6-11
6.3.2. Switch Internal Rung ....................................................................... 6-13
6.3.3. Action Complete Rung .................................................................... 6-14
6.3.4. Action Auto Rung ............................................................................ 6-15
6.3.5. Action Clear Rung ........................................................................... 6-16
6.3.6. Action Output Power Rung ............................................................. 6-17
6.3.7. Action Command Rung ................................................................... 6-18
6.3.8. Action Output Internal Rung............................................................ 6-19
6.3.9. Action Valve Output Rung............................................................... 6-20
6.3.10. Action Memory Rung .................................................................... 6-21
6.3.11. Action Fault Timer Rung ............................................................... 6-22
6.3.12. Action Enable Bypass Rung ......................................................... 6-23
6.3.13. Diagnostic Alarm Rung ................................................................. 6-23
6.3.14. Switch Bypass Bit Rung ................................................................ 6-24
6.3.15. Scroll List Configuration Rung ...................................................... 6-25
6.3.16. Action Prompt Rung ...................................................................... 6-27
6.3.17. Motion Prompts Rung ................................................................... 6-28
6.3.18. Action Output Power Prompt Rung ............................................... 6-29
6.3.19. Action Do/Undo PB Unlatch Rung ................................................ 6-30
6.3.20. Action Found Rung ....................................................................... 6-31
6.3.21. Switch Logic .................................................................................. 6-32
6.3.22. Switch Diagnostics Rung .............................................................. 6-34
6.4. Prompting ................................................................................................ 6-37
6.5. Error Proofing ......................................................................................... 6-40
6.5.1. Process Actions Completes ............................................................ 6-40
6.5.2. Error Proofing in Actions ................................................................. 6-40
6.5.3. Error Proofing in Part Load Actions ................................................ 6-40
6.5.4. Error Proofing in Part Unload Actions ............................................. 6-41
6.5.5. The MainCycle Routine................................................................... 6-41
6.5.6. Setting / Resetting Work an Part Memories (MainCycle) ................ 6-42
6.6. Review ..................................................................................................... 6-44
Copyright 2015 General Motors Company

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Table of Figures
Figure 1: za_Action Datatype Status Data ........................................................6-3
Figure 2 Action Tag with the za_Action Data Type ............................................6-4
Figure 3: Unscheduled Programs Action Routines ........................................6-5
Figure 4: Copy the Template Routines .............................................................6-6
Figure 5: Copy and Paste Template Routines ..................................................6-7
Figure 6: Renaming a Routine ..........................................................................6-7
Figure 7: Action Routine Organization ..............................................................6-8
Figure 8: Selecting za_Action Datatype ............................................................6-9
Figure 9: Sequentially Naming Routines .........................................................6-10
Figure 10: TBD Example ..................................................................................6-11
Figure 11: Auto & Clear Rungs Do Not Copy Conditions ................................6-12
Figure 12: @eLogic Flags ...............................................................................6-12
Figure 13: Switch Internal Rung ......................................................................6-13
Figure 14: Action Complete Rung ...................................................................6-14
Figure 15: Action Auto Rung ...........................................................................6-15
Figure 16: Action Clear Rung ..........................................................................6-16
Figure 17: Action Output Power Rung ............................................................6-17
Figure 18: Action Command Rung ..................................................................6-18
Figure 19: Action Output Internal Rung Real Output Link..........................6-19
Figure 20: Action Valve Output Rung..............................................................6-20
Figure 21: Action Memory Rung .....................................................................6-21
Figure 22: Action Fault Timer Rung ................................................................6-22
Figure 23: Action Enable Bypass Rung ..........................................................6-23
Figure 24: Diagnostic Alarm Rung ..................................................................6-23
Figure 25: Switch Bypass Bit Rung .................................................................6-24
Figure 26: Setting HMI Action Text and Action StatusType Triggers ..............6-25
Figure 27: Action Diagnostic Prompt...............................................................6-27
Figure 28: Motion Prompts Rung ....................................................................6-28
Figure 29: Action Output Power Prompt Rung ................................................6-29
Figure 30: Action Do/Undo Unlatch Rung .......................................................6-30
Figure 31: Action Found Rung ........................................................................6-31
Figure 32: Cylinder U201 PX2 Switch in Action Complete Rung ....................6-32
Figure 33: Switch Diagnostics .........................................................................6-34
Figure 34: Bypassing Bits Used in Switch Rungs ...........................................6-35
Figure 35: Switch Not Off Switch Rungs.......................................................6-36
Figure 36: Prompting ......................................................................................6-37
Figure 37: Robot Not Clear Prompt.................................................................6-38

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Figure 38: Close Clamp2 Action Clear Rung ..................................................6-39
Figure 39: Close Clamp2 Prompt ....................................................................6-39
Figure 40: Process Actions Completes Rung .................................................6-40
Figure 41: MainCycle Process Complete and Steps Complete ......................6-40
Figure 42: Error Proofing in Part Load Actions ...............................................6-41
Figure 43: Error Proofing Part Unload Actions .................................................6-41
Figure 44: Work Complete Status ....................................................................6-42
Figure 45: Part Loaded Memories...................................................................6-42
Figure 46: Reset Process Complete Rung Comment (MainCycle) ..................6-43
Figure 47: Reset Process Complete Rung (MainCycle)..................................6-43
Figure 48: Setting the Work Memories............................................................6-43

iv
6. Actions
6.1. Objectives
1. The student will be able to name the rung that shows clamp status.
2. The student will be able to describe Switch bypassing logic.
3. The student will be able to describe Prompting logic.
4. The student will be able to define the purpose of the action clear rung.
5. The student will understand error proofing elements
6.2. Actions
A sequence action or simply action refers to a single sequence step of a
machine, such as closing a clamp. For the remainder of this module, sequence
actions will simply be called actions. Actions have their own datatypes defined for
use.
6.2.1. Action
An action consists of a basic unit of data and the logic associated with that
machine sequence step. The data is represented by the action datatype
za_Action. The control logic and diagnostics for an action are located in the
action routine. Some examples of data and logic for an action include:
Switch internal
Complete conditions
Process Complete (when required)
Automatic mode conditions
Clear conditions
Output power
Command
Motion timer
Scrollist text and status ID
All control logic and diagnostics for a motion is in one routine
o ClampClose would be in one routine
o ClampOpen would be in a different routine
6.2.2. Action Datatype
As shown in Figure 1, all the status data are Boolean except the timer, text, and
status ID.
Figure 1: za_Action Datatype Status Data
Figure 2 Action Tag with the za_Action Data Type
6.3. Action Routines
The GCCS-2 template has many examples of action routines that can be used to
quickly meet the needs of most actions. Proceed to the unscheduled programs for
routine examples.
Figure 3: Unscheduled Programs Action Routines
Routines can be copied into programs as needed. Some edits will be needed to match
the details of the destination projects program. Typical unscheduled programs are
shown expanded in the next figure.
Figure 4: Copy the Template Routines
Most likely you will not require all routines in the Template unscheduled program,
depending on what routines already exists in your destination project. Right click each
routine individually, choose copy, then locate the destination program and choose paste
on the program name.
Figure 5: Copy and Paste Template Routines
After pasting the routine rename it to the appropriate name, update the S prefix number
to position the new routine in desired order.
Figure 6: Renaming a Routine
Program tags can be copied to the destination program. The examples are arranged in
small programs that contain tags and routines that can be copied to a project. Each
action has its own routine that contains all the control logic and diagnostics for that
action. The routine S000_Sequence builds the scroll list. It calls all Action routines. A
sample organization of these routines is shown in .
Each action has its own routine that contains all the control logic and diagnostics for that
action. The routine S000_Sequence builds the Scroll List. It calls all Action routines.
Figure 7: Action Routine Organization
To build an action, the programmer creates a program-scoped tag of the za_Action

data type. The data types have pass-through descriptions which allow the user to edit
the main description of a tag and the appropriate descriptions are passed thru to the
remaining members of the tag. If they fail to display properly, check for an inadvertent
entry with the description text editor. An example of data type selection is shown in
Figure 8.
Figure 8: Selecting za_Action Datatype
Routines must be created for each required action. Name them so they appear in the
desired sequence order relative to each other as shown in Figure 9.
Note: The routine names should initially skip numbers by 5s. This will make re-
sequencing actions easier because fewer routines will need to be renamed. This is
strictly a visible ordering of the routines. The action logic contained in the routine will
dictate the equipment sequence.
Figure 9: Sequentially Naming Routines
Add calls to these routines in the S000_Sequence. The order of the calls is the order
of display for the scroll list. Once the routines are created, the jumps (JSR jump
subroutine) to these routines are added in the S000_Sequence routine. The order of
the jumps is the order of the scroll list display on the HMI.
6.3.1. Logic Structure
The logic structure is set up so that the first rung(s) is (are) the Switch Internal
rung(s) followed by the Action Complete rung. As logic rungs are conditioned,
instructions added or removed to achieve the desired rung output for the application,
it will be necessary to delete TBD bits which are part of the GCCS-2 standard. TBD
bits are designed to bring the users attention to areas where user input is required.
Rung comments will give info on what is to replace TBD bits, see Figure 10.
Figure 10: TBD Example
It is important that the Action Auto and the Action Clear rungs do NOT have their
conditions duplicated. Remove any duplicate contacts from the Auto rung.
Figure 11: Auto & Clear Rungs Do Not Copy Conditions
Note: many rung comments will contain flags that are used by the logic generator
software, they begin with @eLogic and are eliminated later in the process. See Figure
12.
Figure 12: @eLogic Flags
6.3.2. Switch Internal Rung
Internal switch logic is used to enable switch bypassing. Further explanation is given in
Module 6.3.21 Switch Logic. The Switch Internal rung is introduced in
Figure 13. For switches that do not allow bypassing, the input point will directly drive
the switch internal.
Figure 13: Switch Internal Rung
6.3.3. Action Complete Rung
The Action Complete Rung is located near the top of the routine to allow you to
quickly determine the complete state of the action. The reverse actions .Out bit
is included on this Action Complete rung because a time delay occurs before the
sensor inputs change state. Including the reverse actions .Out bit helps
prevent equipment collisions by immediately turning off the actions .Comp bit
when the opposite action is initiated. An example of an Action Complete rung is
shown in Figure 14.
Figure 14: Action Complete Rung
6.3.4. Action Auto Rung
The Action Auto Rung follows the Action Complete Rung. This rung includes all
conditions required for an action to run in Auto Mode. An example is shown in
Figure 15.
Figure 15: Action Auto Rung
6.3.5. Action Clear Rung
The Action Clear Rung contains all conditions for the action to move in either
auto or manual mode. It must also contain all conditions needed to prevent
equipment damage. Action Clear Conditions follow the Auto Mode conditions and
are shown in Figure 16.
Do not duplicate conditions in both the Action Auto and Action Clear rungs.
Remove any duplicate conditions from the Auto rung
Figure 16: Action Clear Rung
6.3.6. Action Output Power Rung
The Action Output Power Rung conditions for the action. Configure with all
power conditions necessary for motion of the device.
Figure 17: Action Output Power Rung
6.3.7. Action Command Rung
The Action Command Rung sums both the Auto and Clear conditions and is
shown in Figure 18. When the action operates before / after the main cycle,
Maincycle.InCycle will need to be replaced by Mode.Auto (e.g. pins, robot init,
etc.).
Figure 18: Action Command Rung
6.3.8. Action Output Internal Rung
The Action Output Internal Rung is turned on by the Action Command. This
requires fewer logic changes and minimizes the use of the Real Output. The
Real Output is, in turn, turned on by the Action Output Internal Rung as shown
in Figure 19.
Figure 19: Action Output Internal Rung Real Output Link
The Real Output occurs only on this rung. This allows most of the logic to be
written without knowing the real output address.
6.3.9. Action Valve Output Rung
Figure 20: Action Valve Output Rung
6.3.10. Action Memory Rung
The Action Memory Rung remembers the last commanded direction. It is set and
reset by the Action Internal Output rung as shown in Figure 21.
Correctly sets
Memory bits
when manually
valving a tool.
Figure 21: Action Memory Rung
6.3.11. Action Fault Timer Rung
The Action Fault Timer Rung is used to determine when the action is faulted and
allows time for the action to complete as shown in Figure 22. The fault timer
preset value must be set to allow enough time for the action to complete without
triggering a motion fault.
Figure 22: Action Fault Timer Rung
6.3.12. Action Enable Bypass Rung
The Action Enable Bypass Rung (Error! Reference source not found.) allows
bypassing the diagnostic switches for the action. No more than one cylinder per
action is allowed to be bypassed at any given time. Switch bypassing is not
available in motions that have only one cylinder.
Figure 23: Action Enable Bypass Rung
6.3.13. Diagnostic Alarm Rung

Action routines will contain diagnostic messages for two switch faults that are
possible when the routine commands the valve. The home position switch can
become stuck on or the work position switch might not turn on. Each cylinder in
the action routine will have its own diagnostic alarm rung as well as the Switch
Bypass bit rung. Diagnostics will be further examined in Module 7.
Figure 24: Diagnostic Alarm Rung
6.3.14. Switch Bypass Bit Rung
The bits in the Switch Bypass Bit Rung are set based on currently active alarm
triggers. These active alarm triggers are displayed in the top banner on the HMI
and are maintained in the BypSw[ ] BOOL array.
Figure 25: Switch Bypass Bit Rung
6.3.15. Scroll List Configuration Rung
The last rung of the Action routine starts with setting the HMI scroll list Action Text
trigger and Action Status Type trigger as shown in
Figure 26.
Figure 26: Setting HMI Action Text and Action StatusType Triggers
The scroll list logic adds the program message offset to the Action Text value
before it is sent to the HMI. For example, if the message offset for this program
is 1000, the value sent to the HMI is 1002. A corresponding HMI scroll list
message with a trigger value of 1002 must be programmed in the HMI.
The kSL constants are used to select the appropriate text and color to describe
the action. In the example in Figure 16, the Clamp1Close.StatusType value
displays Closed, Closing, or Closed Fault. The text color is then used to
further identify the action.
Yellow = work position
Green = home position
Red = faulted
White is everything else (e.g., complete, present, etc.)
The scroll list logic also adds an offset value to the Action.StatusType to display
the action status on the HMI as follows:
Add 1 when the action is complete
Add 2 when the action is in motion
Add 3 when the action is faulted
For example, if the kSL.Yellow.Close has a value of 10, the following values and
text are generated:
11: Closed in Yellow text
12: Closing in Yellow text
13: Close Flt in Red text
6.3.16. Action Prompt Rung
The Action Prompt Rung is the diagnostic prompt for that action. This rung
displays the prompt for this action when the Action.Prompt bit is set by another
action. This is illustrated in Figure 27.
Set by Prompt
other only when
actions action is
prompting clear Diagnostic Prompt
logic programmed one time
Figure 27: Action Diagnostic Prompt
6.3.17. Motion Prompts Rung
The Motion Prompts Rung latches prompts for all motion conditions found in the Action
Clear rung. You must add branches for all items in the Clear Rung, as shown in
Figure 28.
Figure 28: Motion Prompts Rung
6.3.18. Action Output Power Prompt Rung
The Action Output Power Prompt sets latches for output power devices that are in the
Output Power rung. Ensure a latch branch is added for all components in the Output
Power Rung as shown in
Figure 29.
Figure 29: Action Output Power Prompt Rung
6.3.19. Action Do/Undo PB Unlatch Rung
The Action Do/Undo PB Unlatch Rung, as shown in Figure 30, clears the Action
Internal Push Button bit. This ensures the internal Action Push Button bit is
turned off. This rung also unlatches the OutPwrPrompt and the current motion
prompt.
Figure 30: Action Do/Undo Unlatch Rung
6.3.20. Action Found Rung
The Action Found Rung controls the cursor when Auto Cursor mode is enabled.
The conditions shown in Figure 31 will work in most cases. However, in some
instances, they may need to be modified for the Auto Cursor to work properly.
On in auto Above conditions work in most cases.

cursor May be modified for unusual cases to
mode control auto cursor.
Figure 31: Action Found Rung
6.3.21. Switch Logic
Switch logic is used for three primary functions:
To determine when an action is complete.
To determine if a fault has occurred for the switch (failed on/failed off).
To allow bypassing of certain switch faults. This allows production to
continue until the problem can be fixed.
Figure 32 shows a proximity switch providing an input to the Action Complete
rung.
Here is the switch

When Switch is NOT Real input
Bypassed Cylinder C01 PX2
Switch
Action
Motion Timer
Done
When Switch is
bypassed
Figure 32: Cylinder U201 PX2 Switch in Action Complete Rung
A switch internal is driven by the actual switch input or by a timer in the event of a
fault that is bypassed.
When the switch is not bypassed, the Real input is used. When the switch is
bypassed, the logic waits for the Action Motion Timer to finish to satisfy input to
the Action Complete rung. This is because:
Waiting for the Motion Timer allows time for the action to complete and
helps prevent equipment crashes
Using the Motion Timer also works for switches that have failed in the
ON position.
6.3.22. Switch Diagnostics Rung
The Switch Diagnostics Rung is shown in
Figure 33. When diagnosing switches, both the on and the off states must be
diagnosed.
Figure 33: Switch Diagnostics
Diagnostic priority determines if switches can be bypassed. However, the

programmer must determine whether bypassing a switch is allowed. Bypassing is
not allowed when no motion is detected.
The switch bypass bits are set based on currently active alarm triggers displayed
in the top banner and are maintained in the BypSw[ ] BOOL array.
Figure 34: Bypassing Bits Used in Switch Rungs
As shown in
Figure 34, to bypass the switch not on, the switch rung is located in the same
routine.
Bypass bits for the Open Switch PX1 Not Off are also set based on alarm triggers as
shown in Figure 35.
Figure 35: Switch Not Off Switch Rungs
6.4. Prompting
Prompting starts by looking at the Clear conditions for the action. The prompting rung
triggers prompts when the user cannot perform the action. An example is shown in
Figure 36.
Figure 36: Prompting
As shown in Figure 37, the Clamp1 prompting logic triggers the Robot Not Clear
prompt.
This rung is located in

B010_Map1Station; no
edits to be made.
Figure 37: Robot Not Clear Prompt
The following example illustrates how another action would trigger the Clamp1 prompt.
In this example,
Figure 38, the Close Clamp2 action requires Clamp1 to be closed.
Figure 38: Close Clamp2 Action Clear Rung
The Close Clamp2 prompting is shown in Figure 39.
Figure 39: Close Clamp2 Prompt
If the user is attempting to close Clamp 2 while Clamp 1 is not closed and not clear,
the prompt displayed on the HMI will indicate that Clamp1 is not closed. If Clamp1
is not clear, then prompting will indicate why. The prompting will eventually direct
the user to something that is clear and can be moved.
6.5. Error Proofing
Error Proofing is designed to insure that all product is completed successfully as
designed. All parts must be present prior to shipping the product to the next station. All
processes must be complete prior to shipping a product to the next station.
6.5.1. Process Actions Completes
Process actions do work to (change) the part. Welding, sealing, machining, piercing,
etc... The .Comp bit is used for these actions to indicate that the step has been
attempted. The .ProcComp bit is used to determine that the work was completed.
Figure 40: Process Actions Completes Rung
6.5.2. Error Proofing in Actions

Error Proofing in Actions is intended to insure that all parts needed are present in the
machine/station AND that all work has been completed on those parts.
A MainCycle routine and tag is usually present to sum that status.
Figure 41: MainCycle Process Complete and Steps Complete
6.5.3. Error Proofing in Part Load Actions

Actions controlling steps where parts are loaded to the machine must check the status
of the Work.ProcComp (work has been done) and Part.PresMemory (part loaded
memory) bits. Typically all ProcComp bits must be in the OFF state prior to loading
parts. All part load memory bits must be in the OFF state prior to loading the first part.
This provides anti-repeat / error proofing the actions to prevent a machine cycle where
parts that may not be loaded or work that may not be done.
Figure 42: Error Proofing in Part Load Actions
6.5.4. Error Proofing in Part Unload Actions

Action controlling steps where parts are unloaded from the machine/station must check
the status of the ProcComp (work has been done) and .PresMemory (part loaded
memory) bits. All .ProcComp bits must be in the ON state before unloading parts. All
part load memory bits must be in the ON state before unloading parts. This provides
anti-repeat / error proofing of the actions to prevent a machine cycle where parts may
not be loaded or work may not be done.
Figure 43: Error Proofing Part Unload Actions
6.5.5. The MainCycle Routine

The MainCycle tag and routine are used to track the status of the machines cycle
including work complete and part load memories. Work complete status is shown next.
Figure 44: Work Complete Status
Next is the part loaded memories.
Figure 45: Part Loaded Memories
6.5.6. Setting / Resetting Work an Part Memories (MainCycle)

The MainCycle routine controls the resetting of the part and work memories for each
machine/station cycle. The part and work memories should be reset by the MainCycle
routine once the unload action is complete. Rungs for the reset process complete and
set process complete follow.
6.5.6.1. Resetting Work Memories
The Reset Process Complete rung comment contains information to assist the user in
setting up the rung appropriately. Configuration information is after the @TODO flag.
Figure 46: Reset Process Complete Rung Comment (MainCycle)
The reset process complete rung is next.
Figure 47: Reset Process Complete Rung (MainCycle)
6.5.6.2. Setting Work Memories

The set process complete rung is next. Do not edit this rung.
Figure 48: Setting the Work Memories
6.6. Review
1. What rung shows the status of the clamp in the routine?
2. The Action Clear rung does what job?
3. Describe switch bypassing logic.
4. Describe prompting logic.
GCCS-2
Global Common Control Software
Design
LMS # 33544
Module 7: Diagnostics
Sponsoring Group:

Standards
Phone:
Document Revisions:
8-26-13 5.0 J. Hocking
7-1-15 6.0 J. Hocking
EtherNet I/O

materials.
incidental or consequential damages resulting from the use or application of
the materials in this manual.
express and implied warranties relating to the materials in this manual,
including all examples, diagrams, and charts.

i
Table of Contents
7. Diagnostics ................................................................................ 7-1
7.1. Objectives .................................................................................................. 7-1
7.2. Diagnostics Categories ............................................................................ 7-2
7.3. Diagnostic Numbers ................................................................................. 7-2
7.3.1. Message Offset and Message Ranges ............................................. 7-3
7.3.2. Program Diagnostic Numbers ........................................................... 7-4
7.3.3. HMI Message Numbers .................................................................... 7-5
7.3.4. Program Message Offsets ................................................................ 7-6
7.4. HMI Diagnostic Display .......................................................................... 7-11
7.4.1. First Input Parameter: Priority ........................................................ 7-13
7.4.2. Second Input Parameter: Message Number .................................. 7-17
7.4.3. Third Input Parameter: More Help ................................................. 7-18
7.5. Variable Messages .................................................................................. 7-21
7.6. Exercise 1: Programming Alarms.......................................................... 7-25
7.7. Review ..................................................................................................... 7-31

ii
Table of Figures
Figure 1: Alarms and Prompts ............................................................................... 7-2
Figure 2: Program Alarm and Prompt Numbers ..................................................... 7-4
Figure 3: HMI Message Numbers .......................................................................... 7-5
Figure 4: Program Message Offsets ...................................................................... 7-6
Figure 5: New Message Offset............................................................................... 7-7
Figure 6: Program Message Offsets ...................................................................... 7-7
Figure 7: HMI Program .......................................................................................... 7-8
Figure 8: Selection Example #1 ............................................................................. 7-9
Figure 9: Selection Example #2 ........................................................................... 7-10
Figure 10: Diagnostic Display Components ......................................................... 7-11
Figure 11: Diagnostic Display Sample Message .................................................. 7-12
Figure 12: First Input Parameter .......................................................................... 7-13
Figure 13: Typical Priorities for Alarm .................................................................. 7-15
Figure 14: Typical Priorities for Prompt ................................................................ 7-16
Figure 15: Typical Priorities for Value .................................................................. 7-16
Figure 16: Second Input Parameter ..................................................................... 7-17
Figure 17: Third Input Parameter ......................................................................... 7-18
Figure 18: Categories of kHelp ............................................................................ 7-19
Figure 19: User Help ............................................................................................ 7-20
Figure 20: Alarm Specific Help ............................................................................ 7-20
Figure 21: Embedded Variable Requirements ..................................................... 7-21
Figure 22: Embedded Variable Sample ............................................................... 7-22
Figure 23: Text List for EVs .................................................................................. 7-23
Figure 24: EV Example ........................................................................................ 7-24
Figure 25: Resulting Alarm ................................................................................... 7-24
Figure 26: Editing a Diagnostic Alarm .................................................................. 7-25
Figure 27: Editing the Switch Bypass Bit Rung .................................................... 7-27
Figure 28: Show Specific Tags in Cross Reference ............................................. 7-28
Figure 29: Sorting by Column in Cross Reference Display ................................... 7-29
Figure 30: Cross Reference after Sorting ............................................................ 7-29

iii
7. Diagnostics
7.1. Objectives
1. The student will be able to identify the two categories of diagnostic
messages.
2. The student will be able to list the number of prompt and alarm
messages possible.
3. The student will be able to identify the three values present in a
diagnostic message.
4. The student will be able to describe how messages are prioritized for the
HMI display.
5. The student will be able to use the HMI Help screen to understand fault
information.
6. The student will be able to use the HMI message to find the rung of PLC
logic that is generating a HMI alarm message.
7.2. Diagnostics Categories
The two basic categories of diagnostics messages are:
Alarms/Warnings/Status
o Call for maintenance.
o Appear in the Alarm Banner on the HMI.
o Are sent to CIMplicity, Marquees.
o Are managed by the Plant Floor Event (PFE) program.
PromptsAssist in operating the HMI.
Tell why an operation is not allowed (Cant Do) messages.
Display instructions for confirm/cancel of certain actions.
o Appear in the Local Message Display on the HMI.
o Are local to the HMI.Are managed by the HMI program.
7.3. Diagnostic Numbers
Each program (station, robot, cell, etc) generates its own Alarms and Prompts
as shown in Figure 1.
Figure 1: Alarms and Prompts
7.3.1. Message Offset and Message Ranges
The Message Offset dictates the available Message Range. The offset is
adjusted based on area and individual program need.
Examples:
Body shop, Press, GA, Conveyors = 1000 allows 999 prompts/alarms
Paint = 3000 allows 2999 prompts/alarms
Message Offsets may be adjusted as needed by individual programs within a
project.
This table is an example only and is not typical.
Program Message Offset Message Range

MCP 0 1-999
Cell 1 1000 1001-1999
AA010 2000 2001-4999
AA020 5000 5001-5999
Note: Message number 0 is not valid.
7.3.2. Program Diagnostic Numbers
The 999 Alarm numbers and 999 Prompt numbers are used as shown in Figure
2.
Figure 2: Program Alarm and Prompt Numbers
7.3.3. HMI Message Numbers
The HMI requires unique numbers (values).
Figure 3: HMI Message Numbers
7.3.4. Program Message Offsets
Message offsets allow programs to be easily duplicated. Each program is
assigned a message offset value in the 1000s range. This offset is added to
each diagnostic in the program.
Figure 4: Program Message Offsets
Figure 5: New Message Offset
Program Message Offsets

Program Offset Range
MCP Program 0
Cell Program 1,000 19,000*
Station Program 1,000 19,000*
Robot Program 50,000 73,000
Weld Controller Program 20,000 31,000
C-Flex 80,000 85,000
HMIs 90,000 92,000
Figure 6: Program Message Offsets
*Note: All projects will have an MCP program which uses 0 for its offset. All
cell programs will require an offset to be assigned.
It is possible for several programs to send messages to the HMI program at the
same time. For example, a robot may crash on an auto station welders clamp.
Two faults would be generated; one from the robot (cannot move due to following
error) and one from the welding station routine (cannot open or close the clamp).
However, the HMI can display only one alarm and one prompt at a time in the
banner at the top of the screen. See
Figure 7.
Figure 7: HMI Program
So, one alarm and one prompt must be chosen. This is done based on
priority and selected station, as shown in Figure 8 and Figure 9.
If station AA030 is selected on the HMI and AA020 has the highest priority
diagnostic:
Figure 8: Selection Example #1
Then AA020 diagnostic are sent to the HMI.
If station AA030 is selected on the HMI and all programs have equal priority.
Figure 9: Selection Example #2
Then AA030 diagnostics are sent to the HMI.
7.4. HMI Diagnostic Display
The message offset and the program name is stored inside the HMI tag for each
program. This information is displayed along with the diagnostic, including: the HMI
message number (message number + message offset), the program message
number, and the program name.
Actual
Actual HMI Message
Program
PV Message
Message Number
Message Program Name
Number 1-999 ASCII String
number Number
Figure 10: Diagnostic Display Components
A diagnostic consists of:

A priority value to determine which diagnostic to display.
A message value for the HMI.
A more help value used by the Help screen.
A diagnostic is initiated by a JSR call to routine zZ999_Diagnostics. The
zZ999_Diagnostics routine is the system diagnostic handler. Three values are
passed to the routine:
The priority of the message as identified by certain parameters.
The text of the message.
Which Help Screen to display.
It is extremely important that the proper number of parameters on a JSR are
programmed (parameter count varies depending on the subroutine). Having an
incorrect number of parameters will cause the subroutines to operate improperly, or,
in some cases, fault the controller.
Common Program
Diagnostics Routine
JSR
Jump To Subroutine
Routine Name zZ999_Diagnostics
Input Par kDiag.Alarm.Comm
Input Par kAlarm[301]
Input Par kHelp.DNFlt
Figure 11: Diagnostic Display Sample Message
7.4.1. First Input Parameter: Priority
The priority comes from the controller tag, kDiag, which provides named
constant values for priority and is used to distinguish alarms from prompts. The
names (for example, kDiag.Alarm.Comm) represent numbers that are sent to
the diagnostics routine for evaluation. The routine has to choose which alarm
has highest priority; this is how it makes the choice.
Figure 12: First Input Parameter
The following table shows typical Alarm priorities:
kDiag.Alarm.xxxx Purpose
AirAndHyd Air Pressure and Hydraulic Faults
AppFault Logix Programming Faults
Comm Communication Faults
SafetyComm Safety Communication Faults
Cycle Automatic Cycle Faults
EStops Emergency Stop PB and Power Faults
Gates Perimeter Gate Faults
LocalIO Local Chassis Input and Output Card Faults
MagnFaults Relay Faults (abnormal operation)
MagnSts Relay Status
Master Master On Faults
Mode Automatic Mode Faults
PartPres Part Present Faults
Power Power Supply and Circuit Breaker Faults
ProcessEquip Misc. Process Equipment Faults
Robots Robot Faults
Status Lowest Level Faults
SwitchFlts Switch Faults Not Bypassable
SwitchFltsBypassable Switch Faults Bypassable
SwitchFltsNoMotion Switch Fault No Motion-Not Bypassable
SwitchFltsMotionGrpLimit Switch Fault Motion Group Limit reached
VFD Variable Frequency Drive Faults
Welding Welding Faults
ProdFltAndonStop Production Fault Andon Line Stop
ProdFltOperLoad Production Fault Operator Load Device
ProdFltGeneral Production Fault General
ToolFltDimExceeded Tooling Fault Dimension Exceeded
ToolFltGeneral Tooling Fault General
QualFltGeneral Quality Fault General
TputFltBlocked Thruput Fault Blocked
TputFltStarved Thruput Fault Starved
TputFltGeneral Thruput Fault General
SysFltGeneral System Fault General
MatlFltOutOfParts Material Fault Out of Parts
MatlFltGeneral Material Fault General
MaintWarnPLCSW PLC Software Maintenance Warning (Minor Fault ...)
MaintWarnPLCHW PLC Hardware Maintenance Warning (Battery Low ...)
MaintWarnGeneral Maintenance Warning General
ProdWarn Production Warning
kDiag.Alarm.xxxx Purpose
ToolWarn Tooling Warning
QualWarn Quality Warning
TputWarn Thruput Warning
SysWarn System Warning
MatlWarn Material Warning
MaintStatusPLCForceEdit PLC Forces and/or Edits Present and/or Active
MaintStatusGeneral Maintenance Status General
ProdStatus Production Status
ToolStatus Tooling Status
QualStatus Quality Status
TputStatus Thruput Status
SysStatus System Status
MatlStatus Material Status
Figure 13: Typical Priorities for Alarm
kDiag.Prompt.xxxx Purpose
Confirm Press DO to Confirm Prompt (yellow)
PBFeedback Pushbutton Feedback (Cant Do)
Prompt
General General Prompt
Alert Alert / Warning (Process, Battery,
etc.)
Status1 Status Level 1
Bypass Device / Item Bypassed Prompt
Figure 14: Typical Priorities for Prompt
kDiag.Value.xxxx Purpose
kDiag.Value.Type.xxxx
ProductionCount ProductionCount equals 1
BankCount Bank Count equals 11
ProcessVariable Process Variable equals 21
kDiag.Value.Unit.xxxx
Integer Integer equals 1
BCD BCD equals 2
REAL REAL equals 3
Figure 15: Typical Priorities for Value
7.4.2. Second Input Parameter: Message Number
The message number is the second parameter sent to the diagnostics routine. It
is a value that will tell the HMI which message to display.
o Diagnostics are initiated by value
Alarm message numbers come from the controller tag kAlarm[ ]
Prompt message numbers come from the controller tag
kPrompt[ ]
o They provide named constant values for Alarms and Prompts.
o The array position contains a matching constant number.
kAlarm[301] contains the constant value 301 (shown in Figure
16).
kPrompt[34] contains the constant value 34
This enables searching and the cross-reference feature to show the use of all
diagnostics, and to quickly find used and unused diagnostics.
Figure 16: Second Input Parameter
7.4.3. Third Input Parameter: More Help
The More Help value comes from the controller tag, kHelp. It provides named
constant values for help categories. The example shown in Figure 17 would
show the DNet Node Not Active help message.
If no help screen or message is provided, the number zero (0) is passed to the
diagnostics routine. This is accomplished by using the parameter kHelp.None.
Figure 17: Third Input Parameter
kHelp.xxxx Purpose
None No Help Available
SpecificExists Specific Help Exists
AppFault Application (z_ Routine) Fault Help
CircuitBreaker Circuit Breaker Help
ProdConsume Producer/Consumer Help
RemProc Remote Controller not in Run Help
DNFlt DeviceNet Node Fault Help
SafetyDNFlt Safety Assembly DeviceNet Node Fault Help
ComboDNFlt Safety and Standard Devicenet Fault Help
EStop E-Stop Help
Module Logix Chassis Module Fault Help
NotOn Switch Not On (Not Made) Help
NotOnNoMotion Switch Not On (Not Made) - No Motion Detected
Help
NotOff Switch Not Off (Not Released/Stuck On) Help
Relay Control Relay Help
SRFuseOk Safety Relay Fuse Ok Help
SRNotOn Safety Relay Not On Help
SRNotOff Safety Relay Not Off (Failed/Stuck On) Help
ChOffFault Safety Channel Off Fault Help
IOPulseFault Safety I/O Pulse Test Or Input Fault
IOInputFault Safety I/O Input Fault
IOOutputFault Safety I/O Output Fault
Robot Robot Help Array
WeldController Weld Controller Help Array
User User Help Array
Figure 18: Categories of kHelp
7.4.3.1. User Help
The User General Help value comes from the controller tag, kHelp.User[x].
Nineteen predefined values are pre-programmed.
o User must enter the help message text in the HMI.
o Use these when multiple instances of the same help is required
Example Siemens ET200S Module Fault
Figure 19: User Help
7.4.3.2. Alarm Specific Help

Alarm specific help can be used for any alarm:
o Works with or without existing category help
o Uses the alarm value to add an additional 255 characters to an alarm
message
o When no category help is used, kHelp.SpecificExists is used to enable
the More Help pushbutton
Figure 20: Alarm Specific Help
7.5. Variable Messages
The PFE Alarm protocol includes Embedded Variable (EV) Alarm feature on both
HMIs and GPM&C screens. Alarm messages with EV can be substituted with
numeric and/or ASCII texts. The PLC and HMI EV Alarms code uses 3 variables
(PFEControl.VAR1, VAR2, and Var3) and the HMIs VariableTexts_TL[] text list
array to function. The following is the AlarmEmbeddedVariableExample from the
unscheduled programs in the GCCS2 template logic, consult GCCS2 for more
information.
Rung 0 is a rung comment that states the minimum revision levels required for
UDTs, Routines and Programs to permit Embedded Variables to function properly.
Figure 21: Embedded Variable Requirements
Rung 1 this is the Sample Embedded Variable Alarm Rung. Your rung will vary. Up
to 3 different embedded variables can be used and they can be used more than
once each. Do not include any MOV that is not used in your EV alarm.
1. Replace the TBD with logic conditions that will enable the alarm.
2. Replace the PFEPointer1 tag with the tag that will provide number that
populates PFEControl.Var1 (variable 1) Remove if the variable is not used.
5. Insert the OTL (latch) of PFEControl.IsEmbeddedVariable before the JSR
zZ999_Diagnostics.
6. JSR call to the zZ_Diagnostics routine. KAlarm number must be unique
within program.
Figure 22: Embedded Variable Sample
Rung 2 is an example of the text list used to populate the EVs.

1. TL58 is the maximum length of the text list entry in number of characters.
2. VariableTexts_TL[#]: is the name of the text list and the number of the text list
entry.
3. After the VariableTexts_TL[#]: is the actual text.
Figure 23: Text List for EVs
The following rungs will result in the alarm message shown after the example.
Figure 24: EV Example
Figure 25: Resulting Alarm
7.6. Exercise 1: Programming Alarms
In this exercise, you will:
Enter an alarm.
Use Cross Reference to find available alarm numbers.
Change the alarm numbers.
Change the alarm rung comments.
Change the Switch Bypass Bit rung.
Figure 26: Editing a Diagnostic Alarm
1. Open the exercise project Core07Exercises.ACD in RSLogix5000.

2. Program typical work action alarms.
A. Open TP005 program.
B. Open the CloseClamps1 routine, go to Rung 14.
C. Replace NOP instructions with a zZ999 diagnostic for alarm 63 and
64 with appropriate Help (use the alarm priority and help category
lists presented in this module to assist you). Use bypassable priority
for both alarms.
D. Check that you have only three input parameters and zero return
parameters.
E. Update switch bypass bit rung to bits 63 and 64.
Figure 27: Editing the Switch Bypass Bit Rung
Note: Having the proper number of parameters on a JSR is very important

(parameter count varies depending on the subroutine). Having an incorrect
number of parameters will cause the subroutines to operate improperly, or in
some cases, fault the controller.
3. Verify the CloseClamps1 routine.

A. Select the routine in the controller organizer, right click, and select
Verify.
4. The alarm numbers used in this case are already used elsewhere in this
program, verify using cross reference. Now, find another available alarm
number.
A. Open the controller tag database. You can just cross reference
and select the kAlarm tag.
B. Select the kAlarm tag, right click, and select Go to Cross
Reference.
C. Use the Show pull down menu to change to the TP005 under
Container (Program)
Figure 28: Show Specific Tags in Cross Reference

D. Double click the column heading of Reference to place the kAlarm
tag list in numerical order.
Figure 29: Sorting by Column in Cross Reference Display
E. Cross reference shows the alarm numbers used by each program.

Using this list find two available alarm numbers in the TP005
program (any unused number will do).
Figure 30: Cross Reference after Sorting
5. Change the alarm number of the Clamps1 Opened Not Off alarm and the
Clamps1 Closed Not On alarm.
A. Edit the alarm number (value) of the alarm in Step 2 (alarms 63,
64) to the new alarm number found in step 4E above.
B. Check that you have only three input parameters and zero return
parameters.
6. Correct the rung comment on the alarm rung to reflect the new alarm
number.
A. Double click the rung comment in the ladder editor window.
B. Change Alarm[63] and Alarm[64] to match the new alarm
number.
C. Click the green check mark when complete.
7. Update switch bypass bit rung to match the new alarm numbers chosen.
The Switch Bypass Bit rung immediately follows the Switch Diagnostic
(Alarm) rung.
8. Verify and save the exercise project.
END OF EXERCISE
7.7. Review
1. Name the two categories of diagnostic messages.
2. In the body shop, how many prompt and alarm messages are possible?
3. What are the three values present in a diagnostic message?
4. How are messages prioritized for the HMI display?
5. How is the HMI help screen used to identify fault information?
6. How can a HMI message be used to find the rung of PLC logic that is
generating a HMI alarm message?
GCCS-2
LMS # 33544
Module 8: Scroll List

Sponsoring Group:

Document Revisions:
8-26-13 5.0 J. Hocking Revised KSL content. Updated exercise.
7-30-15 6.0 J. Hocking
EtherNet I/O
materials.
2015 General Motors Company. All Rights Reserved Rev. 6.0

i
Table of Contents
8. Scroll List .................................................................................. 8-1
8.1. Objectives .................................................................................................. 8-1
8.2. Scroll List Features................................................................................... 8-2
8.2.1. Scroll List Screen .............................................................................. 8-3
8.2.2. Scroll List Expand/Collapse .............................................................. 8-4
8.2.3. Function List ..................................................................................... 8-5
8.2.4. Screen Indicators .............................................................................. 8-7
8.2.5. Status Indicators ............................................................................... 8-8
8.2.6. Action Routine Example.................................................................... 8-8
8.3. Scroll List Logic ...................................................................................... 8-11
8.3.1. Sequence Routines ........................................................................ 8-14
8.3.2. Grouping ......................................................................................... 8-16
8.4. Exercises: ................................................................................................ 8-20
8.4.1. Exercise 1: Add Items to the Scroll List........................................... 8-20
8.4.2. Exercise 2: Add Groups to the Scroll List........................................ 8-20
8.5. Review ..................................................................................................... 8-21

ii
Table of Figures
Figure 1: Scroll List ...........................................................................................8-2
Figure 2: Scroll List Screen with Selected Stations ...........................................8-3
Figure 3: Scroll List Screen (Expand and Collapse List) ...................................8-4
Figure 4: Scroll Screen (Function List) ..............................................................8-5
Figure 5: Function List ......................................................................................8-6
Figure 6: Function List Indicators ......................................................................8-7
Figure 7: Function List Indicators ......................................................................8-8
Figure 8: Scroll List Screen (Action Display) .....................................................8-8
Figure 9: Scroll List Text Value MOV ..............................................................8-9
Figure 10: Scroll List Status Indicator MOV ....................................................8-9
Figure 11: KSL Controller Tag (Partial) ............................................................8-10
Figure 12: Action Scroll List Status Types .......................................................8-10
Figure 13: KSL.Yellow Status Indicator Members ............................................8-11
Figure 14: HMI Scroll List Enable Rung (Dual HMIs) ......................................8-13
Figure 15: Sequence Routine .........................................................................8-13
Figure 16: Starting Scroll List ..........................................................................8-14
Figure 17: Adding Action to Scroll List ............................................................8-14
Figure 18: Do/Undo Parameters .....................................................................8-15
Figure 19: Ending Scroll List ...........................................................................8-15
Figure 20: Grouping Close Actions .................................................................8-16
Figure 21: Grouping Open Actions..................................................................8-17
Figure 22: Parameters for StartGroup and EndGroup ....................................8-18
Figure 23: Group Details .................................................................................8-19

iii
8. Scroll List
8.1. Objectives
1. The student will be able to describe the Function List in the Scroll List.
2. The student will be able to describe the Function Indicators in the Scroll List.
3. The student will be able to describe the logic used to generate a Scroll List.
4. The student will be able to operate the controls on the Scroll List Screen.
8.2. Scroll List Features
The Scroll List (Figure 1) represents the available manual control. For a station, this
would be the sequence of operations. For equipment without a sequence, the Scroll
List contains manual functions.
Figure 1: Scroll List
The Scroll List order is built by logic, and there are no limits to the length of list. The list
can be dynamically changed within the logic (for example, based on style or mode
selection). It also displays the status for each line with meaningful text. For example:
Close Clamps has status: Closed, Closing, and Close Flt; and Load Part has status:
Present, Not Present, and Partial.
The Scroll List also features Auto Cursor capability (Cursor follows machine sequence)
and is controlled by a rung in the Action logic routine. The Scroll List allows the grouping
of actions together (Collapse/Expand). The collapsed view shows the group line only. In
Figure 1, the Oper Loads Door is the group line. The expanded view shows all actions
within the group. In the manual mode, all actions can be:
Triggered together by pointing to the group line.
Triggered independently by pointing to a specific line within the group.
Note the group line is not an action and does not require an action routine.
8.2.1. Scroll List Screen
The Scroll List screen shows the selected stations available manual control,
including the following:
Cursor and Page Up/Page Down buttons.
Blue cursor buttons are in manual mode or active.
Gray cursor buttons are disabled because Auto Cursor is active. Touching gray
cursor buttons will make them active and disable Auto Cursor.
The Scroll List is expanded or collapsed by touching the area to the left of the list.
Figure 2: Scroll List Screen with Selected Stations
Figure 3: Scroll List Screen (Expand and Collapse List)
8.2.2. Scroll List Expand/Collapse

The Scroll List expands and collapses to show more or less detail. Group Lines are
designated with a plus (+) sign to the left when in collapsed mode (1) and with a T
when in expanded mode.
o In manual mode, when the Group Line is selected, all grouped actions are
requested together when Do / Undo is pressed.
o The action pushbutton bit (.pb) of all actions in the group turn on
simultaneously.
o Scroll List lines are clear for motion when the green indicator is ON,
indicating that the motions clear rung is true.
8.2.3. Function List
The Scroll Screen Function List provides maintenance functions not included on the
Scroll List.
Figure 4: Scroll Screen (Function List)
The Scroll List function list is updated based on the selected station and the selected
line. The functions that may be presented to the user include:
o View Normal Scroll List/Bypassable Lines/Skippable Lines.
o Turn Auto Cursor On/Off.
o Return to Load Position.
o Return to Unload Position.
o Reset/Set All Completes.
o Reset/Set Line Complete.
o Bypass Current Line / Remove Bypass.
o Skip Current Line/Remove Skip.
o Turn User Function 1-6 On/Off (example: Weld On/Off).
Figure 5: Function List
Views: Normal Scroll List / Bypassable Lines / Skippable Lines

o View Normal changes the Scroll List to Normal View
o View Bypassable changes the Scroll List to Bypassable view
o View Skippable changes the Scroll List to Skippable view
Auto Cursor On/Off
o When Auto Cursor is on, the Scroll List cursor follows the machine
sequence
o Operates in Auto or Manual Mode
Return to Load Position
Return to Unload Position
Reset / Set All Completes
o Sets or resets the station cycle complete and all process completes
The functions below apply to the Scroll List line pointed to by the Scroll List Cursor.
Reset / Set Current Line Complete
o Sets or Resets the process complete for an individual process action
Bypass Current Line / Remove Bypass
o Bypasses or removes the bypass for an individual lines process action
o The line remains bypassed until the bypass is removed
o Bypasses are cleared / removed when:
User removes line bypass using functions list.
User removes all bypasses using Remove All Bypass on cell
maintenance screen.
Controller enters Run Mode (i.e. First Scan). Any equipment that
had Bypass Present may no longer operate properly without
establishing bypasses.
Skip Current Line/Remove Skip
o Skips or removes the skip for an individual lines process action
o The skip is active only for the current cycle.
o Skipping a line will require setting the station cycle complete at the end of
the cycle.
o Station specific functions
o Example: Weld On/Off
8.2.4. Screen Indicators

Figure 6 shows the various indicators that may be present on the bottom left of
the Scroll List screen. Figure 7 describes each of these indicators.
Process Complete Indicator Load Position Indicator

No Process Completes Not at Load
Some Process Completes At Load
All Process Completes
Skip Indicator Unload Position Indicator

Not at Unload
Skippable At Unload
Bypass Indicator Station Specific Functions

Text varies depending
on function
Bypassable
Figure 6: Function List Indicators
Indicator Description
No Process Complete No process is complete in the station.
Some Processes
Some processes in the station are complete.
Complete
All Process Complete All processes in the station are complete.
The black box means you cannot skip the
Skip Indicator
current Scroll List line.
Skippable The current Scroll List line may be skipped.
The black box means you cannot bypass the
Bypass Indicator
current Scroll List line.
The current Scroll List line may be
Bypassable
bypassed.
Load position indicator Green means station is at load position.
Indicator Description
Gray means station is not at load position.
Unload position Green means station is at unload position.
indicator Gray means station is not at unload position.
Station specific Text and color will vary depending on for
functions what indicator is used.
Figure 7: Function List Indicators
8.2.5. Status Indicators

The Scroll List status indicator updates to show the current state of the action.
Figure 8: Scroll List Screen (Action Display)
8.2.6. Action Routine Example

The Scroll List Action text along with the Action status indicator are built in the Scroll List
Configuration rung in the Action routine.
1. The constant value in the first MOV source is the value that is used to set
the text in the scroll list. The number must be unique in the program among
all SL[##] entries and match the rung comment.
Figure 9: Scroll List Text Value MOV
2. The KSL.Color.Action is a controller tag that represents a constant that is
assigned its value by the routine zZ010_Constants routine located in the
MCP program. This is used to display status of the action on the right side
of the scroll list in a corresponding color. Typical actions will have an
indicator in both the work and home routines.
Figure 10: Scroll List Status Indicator MOV
The KSL controller tag is shown in .Figure 11.
Figure 11: KSL Controller Tag (Partial)
When to use KSL.Yellow or KSL.Green

Use KSL.Yellow for the work position.
o Work position of the equipment is generally the position when the
equipment is welding, sealing, filling etc.
Use KSL.Green for the home position.
o Home position of the equipment is generally the position when the
equipment is empty.
Figure 12: Action Scroll List Status Types
The KSL controller tag has many parts. Action status indicators for the Scroll List are
handled by the first two members of the tag, KSL.Yellow and KSL.Green, they both
have the members shown in Figure 12.
KSL.Yellow. Yellow Colored Status Indicators or
or KSL.Green Green Colored Status Indicators
Close Close Status Indicator
Open Open Status Indicator
Advance Advance Status Indicator
Return Return Status Indicator
Engage Engage Status Indicator
Disengage Disengage Status Indicator
Raise Raise Status Indicator
Lower Lower Status Indicator
On On Status Indicator
Off Off Status Indicator
Forward Forward Status Indicator
Back Back Status Indicator
InPosn In Posn Status Indicator
Work Work Status Indicator
Home Home Status Indicator
Increase Increase Status Indicator
Decrease Decrease Status Indicator
NoCarrier No Carrier Indicator
Figure 13: KSL.Yellow Status Indicator Members
Work and Home indicators display when the output memory for an Action routine is
turned on. If the Action routine completes before the Action timer is done action
completed indicator displays. If not, motion indicator displays a fault. (See below)
8.3. Scroll List Logic
All actions routines are called from the S000_Sequence routine. The Scroll List is built
by logic in the S000_Sequence routine. There are two versions of the seven routines
used to build the Scroll List. One version is used for Single HMI applications; the other
is for Dual HMI Applications. Note that two HMIs can be used per station. The routines
for single and dual applications share the same routine names as shown below:
zZ101_StartList
zZ102_AddLine
zZ103_DoUndo
zZ104_TextLine
zZ111_StartGroup
zZ112_EndGroup
zZ121_EndList
When the application has two HMIs, the HMI Scroll List enable rung must be added to
the top of the S000_Sequence routine. Refer to Figure 14.
Figure 14: HMI Scroll List Enable Rung (Dual HMIs)
Figure 15: Sequence Routine
8.3.1. Sequence Routines
The Scroll List is started by calling the zZ101_StartList. See Figure 11.
Figure 16: Starting Scroll List
Then, as the actions (sequence steps) are programmed, they are added to the Scroll
List by the logic shown in Figure 17.
Note: The order of the rungs in the S000_Sequence routine dictates the display
order of the Scroll List.
Figure 17: Adding Action to Scroll List
The parameters for Do and Undo functions are as follows:
Figure 18: Do/Undo Parameters
The Scroll List is ended by calling the zZ121_EndList.
Figure 19: Ending Scroll List
8.3.2. Grouping
To group actions, actions are surrounded with StartGroup and EndGroup routines
in the logic. See Figure 15.
Figure 20: Grouping Close Actions
Figure 21: Grouping Open Actions
Groups cannot be nested: a group must be ended before a new group is started.
The parameters for the StartGroup and EndGroup are as follows:
Figure 22: Parameters for StartGroup and EndGroup
8.3.2.1. Group Details

Grouping is executed in the S000_Sequece routine only. Groups do not have action
logic. The zZ111_StartGroup JSR will use three KSL input parameters. The first one is
the Scroll list Text number. The second input parameter indicates the status of the
Action (Do button press). The third input parameter indicates the status when the
opposite Action (UnDo button press).
The Group Indicators will display the sum of the status for all actions in the group. If
any action is faulted the fault will display. The zZ111_StartGroup JSR will include both
KSL constants for any StartGroup used.
Figure 23: Group Details
Note: Copy the rung comment from the Scroll List Configuration rung in any action
routine, like S###_CloseClamps for example. Do not forget to edit after you paste in the
rung comment.
8.4. Exercises:
8.4.1. Exercise 1: Add Items to the Scroll List
The objective of this exercise is to add calls to the action routine and add the action
to the scroll List.
1. Open the exercise project Core08Exercises.ACD in RSLogix5000.
2. Add scroll list calls to S000_ Sequence for the S045_CloseClamp2 and
S095_OpenClamp2 routines in the TP005 program.
A. Add a scroll list call rung for the S045_CloseClamp2 action to
S000_Sequence below the S040_CloseClamps1 action (use the
information presented in this module to assist you).
B. Add a scroll list call rung for the S095_OpenClamp2 action to
S000_Sequence below the S090_DisengageLocatingPin.
3. Verify and save the exercise project.
END OF EXERCISE
8.4.2. Exercise 2: Add Groups to the Scroll List

The objective of this exercise is to add group lines to the scroll list in the
S000_Sequence routine and add group line text to the scroll list in the HMI.
1. Continue in Core08Exercises.ACD in RSLogix5000.
2. Open the TP005 program S000_Sequence routine in RSLogix5000.
A. Group the Close Clamp actions using Text ID 9 (use the information
presented in this module to assist you).
B. Group the Open Clamp actions using Text ID 10.
3. Add the Scroll list text rung comment to the start group lines (copy a SL[ ]
rung comment from an already existing action scroll list rung and then
modify it).
4. Verify/Validate the project in RSLogix5000.
Important: Save your project, it will used in later exercises.
END OF EXERCISE
8.5. Review
1. How do you expand and collapse the Scroll List tree?
2. How do you use the Action Clear indicator in the Scroll List?
3. Name some items found on the Function List in the Scroll List?
4. What are the Function Indicators in the Scroll List?
5. What routine in the logic is used to generate a Scroll List?
6. How are the controls operated on the Scroll List Screen?
GCCS-2
LMS # 33544
Module 9: Robot Concepts

Sponsoring Group:

Document Revisions:
Added Path Control Signals for Global 3
8-26-13 5.0 J. Hocking
robots
7-9-15 6.0 J. Hocking
EtherNet I/O
materials.

i
Table of Contents
9. Robot Concepts................................................................................. 9-1
9.1. Objectives ............................................................................................................ 9-1
9.2. Robot Specification ............................................................................................ 9-2
9.3. Path Control Signals (GRS-3) ............................................................................ 9-3
9.4. Style (GRS-3) ....................................................................................................... 9-4
9.5. Options (GRS-3) .................................................................................................. 9-6
9.6. Path Segments (GRS-3) ...................................................................................... 9-7
9.7. Continue Signals (GRS-3) ............................................................................... 9-9
9.8. Path Decision Control ...................................................................................... 9-13
9.9. Robot Clear........................................................................................................ 9-14
9.10. Process Control Signals (GRS-3) .................................................................. 9-15
9.11. Status & Miscellaneous Signals .................................................................... 9-16
9.12. Exercise 1: Draw a Robot Path ...................................................................... 9-17
9.13. Review ............................................................................................................. 9-18

ii
Table of Figures
Figure 1: GRS-3 Path Control Signals Global 3 Robot ............................................ 9-3
Figure 2 GRS-3 Path Control Signals Robots Prior to Global 3 ................................ 9-3
Figure 3: Example of Style Numbers (1-31) for Vehicle Operations......................... 9-5
Figure 4: Path Segment Definitions ......................................................................... 9-7
Figure 5: Template Defined Path Segments ............................................................ 9-8
Figure 6: Weld Program RTC .................................................................................. 9-9
Figure 7: Robot Clear of Station .............................................................................9-10
Figure 8: Weld Task OK Successful Process .....................................................9-10
Figure 9: Weld Task OK Incomplete Process .....................................................9-11
Figure 10: Weld with Clamp Reposition ..................................................................9-11
Figure 11: Robot Code Example .............................................................................9-12
Figure 12: Weld, Pick, and Drop .............................................................................9-12
Figure 13: Decision Code .......................................................................................9-13
Figure 14: Robot Clear............................................................................................9-14
Figure 15: Robot Clear Solution ..............................................................................9-14
Figure 16: Process Control Signals.........................................................................9-15
Figure 17: Status and Miscellaneous Items ............................................................9-16

iii
9. Robot Concepts
9.1. Objectives
1. The student will be able to describe the interface between the robot and
the cell controller.
2. The student will be able to describe the use of style numbers between the
cell controller and the robot.
3. The student will be able to describe the use of option bits between the cell
controller and the robot.
4. The student will be able to describe the use of path segments.
5. The student will be able to describe the use of Request to Continue and
OK to Continue bits.
9.2. Robot Specification
GRS1 Robot Technical Specification
o Out of the box content
o Defines hardwire interface
o Defines MCP controller to robot controller interface:
EtherNet Safe communication for all safety signals
Ethernet for upload/download support and control
Safety power
o Defines interface to Auxiliary Panels
Process Control Equipment
Weld Controllers, Dispense Controllers, etc)
Dens-Pack (including PedWeld)
Defines Receptacle / Cable / Pinout for Power
GRS2 Robot Rules of Process Specification

GRS2 sets the maximum limits for robot processing. These limitations are
critical to the ability to purchase common equipment.
o Maximum of 24 Robots per Cell (Gated Area)
o Maximum of 2 process control panels per robot
Examples: 2 Spot Weld controllers, 1 Spot, 1 Dispense
o Maximum of 2 end effector functions
Examples: 2 Weldguns, 1 Weldgun & 1 Material Handling (MH), 1
Spot & 1 Dispense, etc.
GRS3 Robot Integration
o Path segment Tables
o Robot Dress
GRS4 Robot Interface
The GRS-4 specification defines all I/O and software requirements associated
with General Motors standard robot to cell controller interface to ensure
compatibility with MAAC Common Controls Software, GCCS-1.
9.3. Path Control Signals (GRS-3)
There are several types of application signals, such as Path Control, Process
Control, and Status. The Path Control signals contain information concerning the
commanded motion. Figure 1 summarizes the Path Control signals for Global 3 and
greater robots; the details of the signal usage are coming.
Controller to Robot Robot to Controller

Style Number 1127 Style Number Echo 1127
A, B, C, A, B, C,
Option Bits Option Bits Echo
D, E D, E
Initiate Style Manual Style Request
Decision Code 031 Decision Code Echo 031
Clear to Enter Zone 112 Clear Zone 112
OK to Continue Request to Continue
Path Segment 0255
In Cycle
Task OK
Figure 1: GRS-3 Path Control Signals Global 3 Robot
The path control signals for robots prior to Global 3 folows:

Style Number 131 Style Number Echo 131
Option Bits A, B, C Option Bits Echo A, B, C
Initiate Style Manual Style Request
Decision Code 015 Decision Code Echo 015
Clear to Enter Zone 16 Clear Zone 16
OK to Continue Request to Continue
Path Segment 063
In Cycle
Task OK
Figure 2 GRS-3 Path Control Signals Robots Prior to Global 3
9.4. Style (GRS-3)
Style Numbers (1 to 31) identify different robot paths required by the style of the part
being operated on.
Style Number (1 to 24) for Production Paths
Style Numbers (25 to 31) for Special / Maintenance Paths
The robot reads the style once when Initiate Style Program bit is ON from the
controller and the style is then echoed back to the controller.
The style numbers are detailed in Figure 3. Style numbers need to be defined for each
project.
Value Generic Usage Robot Program Name
0 Not valid N/A
1 Common STYLE01
2 Division #1 STYLE02
6 Platform #1 Common STYLE06
7 Platform #1 Division #1 STYLE07
25 Automatic Brake Check STYLE25
26 Tool Change STYLE26
27 Cap Change STYLE27
28 Tip Align STYLE28
29 Process 1 Tip Maintenance STYLE29
30 Process 2 Tip Maintenance STYLE30
31 Repair STYLE31
Figure 3: Example of Style Numbers (1-31) for Vehicle Operations
9.5. Options (GRS-3)
The option bits (A, B, and C) identify minor path variations within a given robot style
program. The robot reads options once when the Initiate Style Program bit is ON
from the controller and then the robot echoes the option bits to the controller.
9.6. Path Segments (GRS-3)
The Path Segments numbers (0 to 63) identify the location of a robot along its path
within a style program.
For example: A robot with Path Segment number equal to 1 represents the
robot Moving to Pounce.
Path Segment numbers must be unique within a style program.
Path Segment numbers are reused between style programs (for example: Path
segment 50 is always Robot in Process, but different style programs will have
different process paths).
Path segments 09 and 6063 have standard definitions as shown in Figure 4.
Segment # Usage
0 Unknown / Invalid segment
1 Pounce segment
2 Home to Repair segment
3 Repair to Home segment
Process 1 Tip Dress/Purge
4
segment
Process 2 Tip Dress/Purge
5
segment
6 Cap Change segment
7 Tool Change
8 Spare
9 Fast Fault Recovery
1059 Template segments
60
Reserved
61
62 Tool Clear segment (Optional)
63 All Clear segment
Figure 4: Path Segment Definitions
Path segments 10-59 have template definitions as shown in Figure 5. Keep in mind
that:
Most robots use these template segment numbers
Some robots may require re-defining these segments based on the application,
for example, a pizza rack or stacker robot with multiple drop locations.
Segment # Usage Description

10-13 Pick 1
14-17 Pick 2 There are five locations where a robot
18-21 Pick 3 can pick from. Each location can be
22-25 Pick 4 divided into four segments.
26-29 Pick 5
30-33 Drop 1
34-37 Drop 2 There are five locations where a robot
38-41 Drop 3 can drop to. Each location can be divided
42-45 Drop 4 into 4 segments.
46-49 Drop 5
There are two locations where a robot
can be processing (i.e., weld, dispense).
50-54 Process 1
Each location can be divided into five
55-59 Process 2
segments. (This allows Reposition of
Clamps.)
Figure 5: Template Defined Path Segments
9.7. Continue Signals (GRS-3)
A Request to Continue (RTC) signal is required when the robot needs to handshake
with the controller at a specific point in the path. Some of these points may be:
At pounce position (always requires RTC).
Clear to drop / pick.
No part check / part check.
Decision code point.
A path segment number with Request to Continue ON identifies a robot at a specific
point in its path. For example: A robot with path segment number equal to 1 AND with
the Request to Continue bit On, represents the robot At Pounce.
After the robot turns on the Request to Continue, it must wait for the Continue OK
bit from the controller. Once the Continue OK bit is ON, the robot changes the path
segment number and continues.
Figure 6 through Figure 10 illustrate this using a weld program example.
Figure 6: Weld Program RTC
Figure 7: Robot Clear of Station
Figure 8: Weld Task OK Successful Process
Figure 9: Weld Task OK Incomplete Process
Figure 10: Weld with Clamp Reposition
Note: This is only an example and may not match actual robot programs
GO[PathSegment] = 1 -- Group Output
Message(In Pounce) -- Message to Teach Pendant
Move ... Robot indicates to PLC
Move ... Moving to Pounce
DO[RequestToContinue] = ON -- Digital Output

Message(At Pounce) Robot indicates to PLC
At Pounce
Wait DI[OkToContinue] = ON -- Wait for Input from controller

Robot waits for PLC to
continue from pounce
GO[PathSegment] = 50
DO[RequestToContinue] = OFF -- Turning off here, prevents
timing problem
Message(In Weld Path) Robot indicates to PLC
Move ... In Weld Path
Weld ...

Figure 11: Robot Code Example
Figure 12: Weld, Pick, and Drop
9.8. Path Decision Control
Decision Code numbers are used when different paths are required within the
same robot style program as shown in Figure 13.
Typical use: Multiple pick / drop locations for the same style of part.
Requires the robot to be at a Request to Continue point.
Decision code is read by the robot when the Continue OK bit is ON from the
controller and is then echoed back to controller.
Figure 13: Decision Code
9.9. Robot Clear
Figure 14: Robot Clear
Instead of trying to identify all of the other segment numbers, the logic will check that
the robot is NOT in segment 30 or 31. Changes can be made to other areas of the
path and not affect this clear condition.
Seg[30] Seg[31] Clear of Drop

------]/[----------]/[----------------------------------( )---------
Figure 15: Robot Clear Solution
9.10. Process Control Signals (GRS-3)
Some common process control signals are highlighted in Figure 16.
Controller to
Robot to Controller
Robot
Tryout Mode Tryout Mode Tells Robot there
Request are no parts
Process 1 ON Process 1 Enabled
Request
Process 2 ON Process 2 Enabled
Request
MH Fault
Robot stops
Process 1 Fault
Process 2 Fault
MH Alert Robot continues
Process 1 Alert
Process 2 Alert
Figure 16: Process Control Signals
These are generic signal names; the application defines the meaning. For example,
Process 1 or 2 Enabled could be:
For Spot Welding weld on / off
For Dispensing wet / dry
The HMI shows process specific messages (e.g. robot screen, alarms, prompts)
9.11. Status & Miscellaneous Signals
These items are shown in Figure 17.

User Definable 1-4 User Definable 1-4
At Home
Robot responds to PLC Fast Fault Recovery Provides early
notification to
Robot independent of PLC
Interlock maintenance
Isolate
Spot: Cap Change Approaching Tip Replacement
Dispense: Nozzle Process 1 Tip Replacement Req.
Process 1 Tip Maintenance Req.
Spot: Tip dress Process 2 Tip Replacement Req.
Dispense: Purge
Process 2 Tip Maintenance Req.
Figure 17: Status and Miscellaneous Items
9.12. Exercise 1: Draw a Robot Path
The objectives of this exercise are to assign path segments, identify request for
continue points, and use decision codes to control the robot path.
1. Layout the robot path with segment numbers in the diagram below with the
request for continue points and decision codes for the following
operations:
Robot has a dual end-effector with a material handler (MH) and a carried gun.
Pick from either of two locations
Drop to a single location
Wait for station to clamp
Weld
Return home
9.13. Review
1. Where would you expect to find information about robot dress?
2. How are style numbers used between the MCP controller and the robot?
3. How are option bits used between the MCP controller and the robot?
4. What do path segments signal to the controller?
5. What is a Request to Continue bit and what sets it?
6. What is an OK to Continue bit and what sets it?
GCCS-2
LMS # 33544
Module 10: Working with RSLogix5000

Sponsoring Group:

Document Revisions:

8-26-13 5.0 J. Hocking Updated Graphics. Revised all exercises.
6-18-15 6.0 J. Hocking
EtherNet I/O.
U.S., International, and Universal Copyright Conventions. Published in the United States
of America. These materials may be used only with related printed materials.
In no event will the General Motors Company be responsible or liable for incidental
or consequential damages resulting from the use or application of the materials in
this manual.

i
Table of Contents
10. Working with RSLogix 5000.......................................................... 10-1
10.1. Objectives ........................................................................................................ 10-1
10.2. Device Level Ethernet Address Assignment................................................. 10-2
10.2.1. Maintenance Workstation Setup (Laptop) ............................................... 10-2
10.2.2. Set the Static IP Address on a Windows PC ........................................... 10-3
10.2.3. ................................................................................................................. 10-5
10.2.4. Assigning IP Addresses to Devices Using the BootP Server................... 10-6
10.2.5. Configuring an ENxT with USB ............................................................... 10-7
10.3. Disabling BootP After a Device Has Been Assigned an IP Address ......... 10-10
10.3.1. Disabling BootP on ENBT Modules ....................................................... 10-10
10.4. Configuring RSLinx ....................................................................................... 10-12
10.5. Importing / Exporting .L5K Files .................................................................. 10-14
10.6. Importing .L5K to .ACD ................................................................................. 10-14
10.7. Exporting to .L5k File .................................................................................... 10-16
10.8. Control Flash Firmware Upgrade Tool ........................................................ 10-16
10.9. Downloading to the Processor ..................................................................... 10-21
10.10. Safety Programming in RSLogix 5000 ....................................................... 10-28
10.11. Safety Module Configuration ...................................................................... 10-29
10.12. Safety Network Numbers ............................................................................ 10-43
10.12.1. CIP Safety Protocol ............................................................................. 10-43
10.12.2. Managing Safety Network Numbers .................................................... 10-43
10.13. Exercises ...................................................................................................... 10-45
10.13.1. Exercise 1: Configure RSLinx.............................................................. 10-45
10.13.2. Exercise 2: Update Controller Firmware Using Control Flash ............. 10-48
10.13.3. Exercise 3: Download Logic File to the Processor .............................. 10-49
10.13.4. Exercise 4: Export a *.L5K File ............................................................ 10-49
10.13.5. Exercise 5: Import a *.L5K File into RSLogix ....................................... 10-51
10.13.6. Exercise 6: Create a Safe Node in RSLogix ........................................ 10-51
10.13.7. Exercise 7: Generate a Safety Network Number ................................. 10-55
10.13.8. Exercise 8: Generate a Safety Signature ............................................ 10-56
10.13.9. Exercise 9: Configuring the IP Address for a ENBT Card (Optional Time
permitting) ......................................................................................................... 10-62
10.14. Review .......................................................................................................... 10-63

ii
Table of Figures
Figure 1: Open the Network and Sharing Center......................................................... 10-3
Figure 2: Change Adapter Settings ............................................................................. 10-3
Figure 3: Open the Local Area Connection ................................................................. 10-3
Figure 4: Open Internet Protocol Version 4 ................................................................. 10-4
Figure 5: NIC Configuration Windows computer........................................................... 10-4
Figure 6: TCP/IP Example ............................................................................................ 10-5
Figure 7: Changing the IP Address and Subnet Mask Definitions ............................. 10-5
Figure 8: Bootp Server Showing Devices Requesting Addresses ................................ 10-6
Figure 9: RS Who Button ............................................................................................. 10-7
Figure 10: Expand the USB Driver .............................................................................. 10-8
Figure 11: Right Click the ENxT Module...................................................................... 10-8
Figure 12: Open the Module Configuration .................................................................. 10-8
Figure 13: Example ENxT Port Configuration ............................................................... 10-9
Figure 14: Open Module Configuration to Disable BootP .......................................... 10-10
Figure 15: Disable BootP ............................................................................................ 10-11
Figure 16: Accessing the RSLinx Classic Launch Control Panel ................................ 10-12
Figure 17: Start RSLinx from Launch Control ............................................................ 10-12
Figure 18: Open RSLinx ............................................................................................ 10-13
Figure 19: Opening an RSLogix File - .ACD or .L5K ................................................. 10-14
Figure 20: Import .L5K to Generate an .ACD ............................................................ 10-15
Figure 21: Import .L5K to Generate an .ACD ............................................................ 10-15
Figure 22: Saving as an .L5K File.............................................................................. 10-16
Figure 23: Locating Control Flash.............................................................................. 10-17
Figure 24: Control flash Welcome Screen ................................................................. 10-18
Figure 25: Selection of Card Type to be Flashed ...................................................... 10-18
Figure 26: Selection of Catalog Number of Device to Flash Update.......................... 10-18
Figure 27: Selection of Actual Card Through RSLinx ................................................ 10-19
Figure 28: Available Firmware Revisions for Selected Card ...................................... 10-20
Figure 29: Set the Firmware Revision Level .............................................................. 10-20
Figure 30: Firmware Update In Progress ................................................................... 10-21
Figure 31: Successful Firmware Upgrade ................................................................. 10-21
Figure 32: Who Active Function Inside RSLogix 5000............................................... 10-22
Figure 33: Available Communication Paths from RSLinx .......................................... 10-23
Figure 34: Selection of Correct Processor for Download ........................................... 10-24
Figure 35: Path in Project Correctly Set .................................................................... 10-25
Figure 36: Downloading Into a New Controller .......................................................... 10-26
Figure 37: Project to be Downloaded Matches Current Project in Controller............. 10-27
Figure 38: Download Status to Controller .................................................................. 10-27
Figure 39: Standard and Safety Controller Scoped Tags ........................................... 10-28
Figure 40: Mapping Standard Tags to Safety Tags for use in Safety Task.......... 10-29
Figure 41: Select Standard Tags and Matching Safety Tags for Mapping........... 10-29

iii
Figure 42: Beginning Configuration of DeviceNet Safety Modules ............................. 10-30
Figure 43: 1791DS-IB12 Fill in the Proper Data as Shown......................................... 10-31
Figure 44: 1791DS-IB12 Fill in the Proper Data as Shown Definitions & Settings... 10-31
Figure 45: Set the RPI to the Proper Value for the Application................................... 10-32
Figure 46: Identify Which Inputs are Pulse-Tested ..................................................... 10-33
Figure 47 Test Output T2 and T3 Used as Standard Output ...................................... 10-34
Figure 48: Proper Configuration to Match................................................................... 10-35
Figure 49: Proper Configuration to Match................................................................... 10-36
Figure 50: Adding a New DeviceNet Safety Node ..................................................... 10-37
Figure 51: Select the Proper Safety I/O Node Type .................................................. 10-37
Figure 52: Fill In the Appropriate Data ....................................................................... 10-38
Figure 53: Set the RPI Values as Appropriate for the Application ............................. 10-38
Figure 54: Identify Which Points are Pulse Tested .................................................... 10-39
Figure 55: Safety Device Receptacles....................................................................... 10-40
Figure 56: Setting the Input Configuration Point Types and Modes .......................... 10-41
Figure 57: Configuring the Test Output ..................................................................... 10-42
Figure 58: Setting the Output Configuration .............................................................. 10-43
Figure 59: Generate a Safety Network Number ......................................................... 10-44
Figure 60: Click to Generate the Safety Network Number .......................................... 10-44
Figure 61: RSLinx Running Indicator in PC System Tool Tray ................................... 10-45
Figure 62: Main RSLinx Window ................................................................................ 10-45
Figure 63: Configure Drivers in RSLinx ...................................................................... 10-46
Figure 64: Configuring Ethernet Devices Driver ......................................................... 10-46
Figure 65: Add an Ethernet Devices Driver - Definitions ............................................ 10-47
Figure 66: Current Running Drivers in RSLinx ........................................................... 10-47
Figure 67: Adding Ethernet IP Addresses to RSLinx Manually (New Driver).............. 10-48
Figure 68: Safety I/O Page F1 .................................................................................... 10-52
Figure 69: Safety I/O Page F2 .................................................................................... 10-53
Figure 70: Safety Network Number Generation ......................................................... 10-55
Figure 71: Safety Network Number Generation and Copy/Paste .............................. 10-55
Figure 72: Select Program or Remote Program ......................................................... 10-56
Figure 73 Select Safety Lock/Unlock .......................................................................... 10-57
Figure 74: Select Change Password .......................................................................... 10-57
Figure 75: Enter and Confirm New Password ........................................................... 10-58
Figure 76: Generate Signature and Enter Password Before Locking ........................ 10-58
Figure 77: Processor is Locked ................................................................................. 10-59
Figure 78: Placing Processor in the Remote Run Mode ............................................ 10-59
Figure 79: Open the Mode Screen ............................................................................ 10-60
Figure 80: The Mode Screen ..................................................................................... 10-60
Figure 81: Signature Screen...................................................................................... 10-61
Figure 82: Safety Signature Locked .......................................................................... 10-61

iv
10. Working with RSLogix 5000
10.1. Objectives
1. Create a device level Ethernet address assignment.
2. Assign an Ethernet address to a Maintenance Workstation.
3. Configure drivers in RSLinx.
4. Set up an ENxT card using the USB connection.
5. The student will be able to import an .L5K file.
6. The student will be able to export an .L5K file.
7. The student will be able to update firmware with Control Flash.
8. The student will be able to download to the processor.
9. The student will be able to create a Safety I/O Module in RSLogix.
10. The student will be able to create a Safety Network Number.
11. The student will be able to create a Signature and lock the processor.
10.2. Device Level Ethernet Address Assignment
Setting up the Ethernet system requires that each device on the network has an
individual address including the following:
Each ENxT
Each HMI
Each Robot
Each Weld SCR
Each Managed Switch
Each MWS Maintenance Workstation
Each PC such as a Process Tool or Vision Computer
Optional Each Programming Port
Ethernet I/O devices
It is easiest to use the real addresses when setting up the network the first time.
The Plant Floor Systems (PFS) group requires a comprehensive list of devices
that will require IP addresses to properly assign them in the plant. For each of
the devices, the PFS group will need the type of device, the MAC ID, and
possible additional information depending on the facility.
After all of the devices above are submitted to the PFS group, a spreadsheet will
be delivered back to the responsible GM engineer with the proper IP addresses.
If the devices must be configured before the official IP addresses are delivered,
the startup engineer can pick a temporary range of addresses to begin with then
switch at a later point. For example: 198.168.XXX.XXX with a subnet mask of
255.255.255.0.
10.2.1. Maintenance Workstation Setup (Laptop)

It is important that the Network Interface Card (NIC) in the maintenance
workstation (or laptop) is properly configured with an IP address in the same
range as the devices that it will communicate with. Most Ethernet devices will
default to either BootP or DHCP which is a mode where the device sends out a
request on the network and looks for a server assigned IP address. If the tools
are being integrated at a build source, there will probably not be a DHCP or
BootP server available; the user will have to use Static IP addresses.
10.2.2. Set the Static IP Address on a Windows PC
1. Right click the wireless signal display. (if not available use the
computers control panel to access the Network and Sharing Center.)
2. Click Open Network and Sharing Center.
Figure 1: Open the Network and Sharing Center

3. Click Change adapter settings.
Figure 2: Change Adapter Settings

4. Right click on Local Area Connection.
Figure 3: Open the Local Area Connection

5. Double Click Internet Protocol Version 4 (TCP/IPv4).
Figure 4: Open Internet Protocol Version 4
6. Select Use the following IP address:
7. Enter IP Address, Subnet Mask, and Gateway.
Figure 5: NIC Configuration Windows computer

8. Click OK.
The following is an example of configuring the TCP/IP properties for a Windows
computer.
Figure 6: TCP/IP Example

1 Use the following IP Select to use a static, manually entered, IP
address: Address.
2 IP Address: Type in the given address, this example:
120.7.6.100
3 Subnet Mask: Type in the Subnet Mask, this example:
255.255.255.0; This configures 120.7.6.0 thru
120.7.6.255 to be accessible.
4 Default gateway Type in the Default gateway address, usually
the first address in the network. For example:
120.7.6.1 If working with a private network
that does not have a Gateway, then omit the
Gateway address.
5 OK Click OK when finished entering the IP and
Subnet Mask.
Figure 7: Changing the IP Address and Subnet Mask Definitions
Many computers can adjust the IP address without a re-boot of the machine.
However, if Windows prompts for a re-boot, re-boot. The computer should now
be ready to communicate on the network.
10.2.4. Assigning IP Addresses to Devices Using the BootP
Server
In most cases it is best to use the USB method, shown next, instead of BootP to
configure the initial IP address in ENxT Ethernet modules and Compact Logix
Controllers. USB is easier to use. BootP will be necessary if the device does not
have the USB connection.
To assign addresses to equipment configured with BootP, first ensure that the
Ethernet network is powered up and all devices including the maintenance
workstation (or maintenance laptop) are connected to the switch. Open the
BootP software on the computer and wait for the devices to begin requesting
addresses as shown in Figure 17. If the BootP server can not be located on the
computer, it can be found on the GM Supply Power website under GCCS
applications.
There is a possibility that software running on the computer will prevent the
computer from getting the broadcast message from the devices that are
requesting addresses. Some software firewalls have been known to block these
requests and, therefore, the firewall software should be shut down while using
the BootP server.
Figure 8: Bootp Server Showing Devices Requesting Addresses
9. The time data stamp and the Ethernet MAC Address of the requesting
device(s) will appear as each device requests.
10. Double-click the Ethernet Address (MAC) and the New Entry window
appears. (To verify the MAC ID belongs to the device you are trying
to address, look on the device for a white sticker with the Ethernet
Address on it.)
11. Enter the IP address and Subnet Mask, and Gateway address; omit
Gateway if the network does not have a Gateway.
12. Click OK.
The Status window at the bottom of the BootP server will read Unable to service
BootP request for a brief moment. However, when the device requests an IP
address again, the Status window will read: Sent IP address to device. Also
note that the Request History will now show the device as having an IP address
and a Subnet Mask.
After the IP addresses have been assigned, close the BootP Server.
10.2.5. Configuring an ENxT with USB
Starting with EN2T model Ethernet modules an USB connection is available on
the front of the module to interface between the module and your computer.
RSLinx is used to establish communication.
1. Connect a USB cable from the programming computer to the port on the
front of the ENxT module.
2. Open RSLinx.
3. Click the RS Who button.
Figure 9: RS Who Button
4. Expand the USB driver.
Figure 10: Expand the USB Driver

5. Right click the ENxT that appears directly below the USB driver.
Figure 11: Right Click the ENxT Module

6. Click Module Configuration from the menu.
Figure 12: Open the Module Configuration
7. Set up the Port Configuration as follows:
a. Select the Port Configuration tab.
b. Select Static
c. Enter IP Address
d. Enter Network Mask
e. Enter Gateway Address
f. Verify that the Auto Negotiate check box is selected
Important: Auto-negotiate setting is project specific. Some projects may use
Speed=100 and Full duplex. Please confirm appropriate settings with GM project
engineer.
Figure 13: Example ENxT Port Configuration
10.3. Disabling BootP After a Device Has Been Assigned an
IP Address
Once an IP address has been assigned to a device, the BOOTP feature needs to
be disabled. This will ensure that the device will retain its IP address even when
power on the device is cycled.
10.3.1. Disabling BootP on ENBT Modules

1. Open RSLinx and under Communications select RS Who.
2. Select the appropriate driver (configured previously) and expand.
Ethernet devices on the network will be displayed.
3. Select the appropriate ENxT module, right click and select Module
Configuration.
Figure 14: Open Module Configuration to Disable BootP
.
4. Configure the module for Static Network Configuration.
5. Select Static under Network Configuration Type.
6. Click OK and close the ENBT Configuration.
Figure 15: Disable BootP
10.4. Configuring RSLinx
RSLinx is the communications package used by Rockwell Software that allows
Windows-based Rockwell programs to interface with Rockwell Hardware. The
software packages that GCCS-1 currently uses are RSLogix and RSNetworx.
These software packages, when using RSLinx, allow many different
communication paths to the hardware such as Ethernet, USB, ControlNet, and
Serial. This manual exercise will focus on Ethernet and USB with a Serial
backup should problems arise.
RSLinx can be run as a service on your computer, starts at boot-up and is always
running. It can cause problems with some communication tasks that your
computer performs, for example printing. You can elect to use the Launch
Control Panel to start and stop RSLinx software as needed.
Using the RSLinx Classic Launch Control Panel
1. Click the start menu, expand All Programs, expand Rockwell Software,
expand RSLinx and select RSLinx Classic Launch Control Panel. You can
make a shortcut or pin it to the Start Menu or tool bar.
Figure 16: Accessing the RSLinx Classic Launch Control Panel

2. Click the Start button.
Figure 17: Start RSLinx from Launch Control
3. If RSLinx does not open, look for the RSLinx symbol on your tool bar or
notification window. Click the symbol to open RSLinx.
Figure 18: Open RSLinx
10.5. Importing / Exporting .L5K Files
RSLogix 5000 can save and open files in two different formats; .ACD and
.L5K.
.ACD is the default format and is used to view the logic in a graphical format
online. The .ACD format is a non-user readable format that can only be
viewed inside the RSLogix 5000 software.
.L5K is a text-based format that can be read using any text editor, such as
Notepad or Excel. The .L5K format contains all of the information needed to
recreate the logic and configuration in the controller. Since .L5K is a text-
based format, it is used to manipulate the logic with GM specific tools, such as
the Message Extractor.
10.6. Importing .L5K to .ACD
Figure 19: Opening an RSLogix File - .ACD or .L5K
To import the .L5K, open RSLogix 5000 and choose to open a file. Then
select the proper directory where both the .ACD and .L5K files will be
displayed. Set the Files of type: to All RSLogix 5000 Files (*.ACD, *.L5K,
*.L5X, *XML) as shown in Figure 19.
Figure 20: Import .L5K to Generate an .ACD
The window shown in Figure 20 will display after selecting an *.L5K for import
into RSLogix 5000.

1 Revision Indicates the revision that *.L5K
From (import file) was created from.
2 Revision To Select Revision that is desired for
logic output.
3 File name Enter the desired filename for the
*.ACD file.
4 Import Click Import to begin the
importation process.
Figure 21: Import .L5K to Generate an .ACD
10.7. Exporting to .L5k File
To save an opened file in RSLogix 5000 as an .L5K file, use Save as type:
from the file menu then select *.L5K as the type as shown in Figure 22.
Figure 22: Saving as an .L5K File
10.8. Control Flash Firmware Upgrade Tool

Most Control Logix 1756, Compact Logix 1769, and Flex Logix 1788 cards
are firmware upgradeable to different revision levels. Each major version of
RSLogix requires the controller to be at the matching major revision to enable
upload /download/online capability. New processors are shipped without
firmware so they are ready to be flashed to the proper version.
Communication cards used on GM projects are tested at specific revision
levels. It is not the intent of GM to update to the latest revisions as they are
released unless the new release fixes a specific issue that affects the cell in
question.
The proper version of firmware for the 1756 Cards is listed in the Blockpoint
for the project. To obtain the latest Blockpoint, contact the responsible GM
engineer for the project. The Blockpoint is also maintained on the GM
SupplyPower website: www.gmsupplypower.com
For Control Flash to work properly, the proper files for each revision need to
be installed. The firmware files are contained on the GCCS-1 release disks
under Software, on the Blockpoint software disks, and directly from the
Rockwell Automation website.
Locate the Control Flash shortcut or find it in the Program menu, under Flash
Programming Tools. Select Control Flash.
Figure 23: Locating Control Flash
Click Next to continue.
Figure 24: Control flash Welcome Screen
Figure 25: Selection of Card Type to be Flashed

1 Catalog Select the catalog number of the device you wish
Number to update.
2 Next Once your selection is made, click Next.
Figure 26: Selection of Catalog Number of Device to Flash Update
Once the Next button is clicked, an RSLinx window will open.
Figure 27: Selection of Actual Card Through RSLinx
Now select the proper card, using the correct IP address and slot number in the
backplane as shown in Figure 27. Ensure that the card that is selected matches
the card type selected in Figure 25. Click the OK button.
IMPORTANT: When using Control Flash to update a Guard Logix
Controller (LxS), you must also update the Safety Partner (LSP).
Figure 28: Available Firmware Revisions for Selected Card

1 Status Info Displays the following info for the selected
card:
Catalog Number.
Serial number of the card.
Current Firmware revision level.
2 Firmware Displays all available revision levels.
Revision Choose the proper level as dictated by your
project.
Note: Only the revisions that have been
installed in Control Flash are available.
3 Next Begins the flash update process.
Figure 29: Set the Firmware Revision Level
Certain hardware series of cards will not accept all revision levels for the
product ID. Example: 1756-DNB Series B cannot be flashed to a revision lower
than 6.002 even though 1756-DNB Series A can be flashed to all of the
lower revisions.
Figure 30: Firmware Update In Progress
After starting a firmware update, DO NOT interrupt the process until the
screen looks similar to
Figure 31. Interrupting the update could cause the module to end up in an
unusable state. Starting with Control Flash version 19 the Safety Partner will
be updated when the Safety Controller is updated.
Figure 31: Successful Firmware Upgrade
10.9. Downloading to the Processor

Now that the processor is at the proper revision level, it can be downloaded or
uploaded. However, uploading a processor when the matching Logic file is
not present on the host computer will result in a file that is missing the
documentation such as Rung Comments and Address Comments since these
are stored in the .ACD file. Communications paths to the processor are set
up in RSLinx, which is covered in Exercise 2.
The first time that a processor is downloaded, there will not be a path set up in
the .ACD file. The easiest way to download to the processor is to use the
Who Active function of RSLogix as shown in Figure 32.
Figure 32: Who Active Function Inside RSLogix 5000
Figure 33 shows the different drivers that have been set up in RSLinx. It also
shows that the path is set for the open project in RSLogix 5000.
Figure 33: Available Communication Paths from RSLinx
Select the proper drivers as shown in Figure 34.
Figure 34: Selection of Correct Processor for Download
Select the path to the processor as highlighted in Figure 34 above. The

buttons for Online, Upload, and Download are now available. From the same
screen, the firmware can be updated, and the path in the project can be set
so that it is easier to go online next time.
At this time, select Set Project Path so the screen looks like
Figure 35. If the Project Path is set and must be changed, click the Clear
Project Path button then click the Set Project Path Button.
Figure 35: Path in Project Correctly Set
Now, select Download to prepare for the final confirmation as shown in
Figure 36.
Figure 36: Downloading Into a New Controller
Figure 36 above shows the final confirmation before the project will be
downloaded to the controller. There is no program in the controller currently,
so it is OK to download this program.
In Figure 37, the controller already has a program that matches the program
that is to be downloaded. This is the typical screen that the user should see.
If the names do not match, check to ensure the processor selection is correct.
Figure 37: Project to be Downloaded Matches Current Project in Controller
After the download is complete, the user may be asked to go back into the run
mode if the controller was in the run mode before the download (Figure 38).
At this point, the program is in the controller and the user can begin making
changes and viewing the logic online.
Figure 38: Download Status to Controller
10.10. Safety Programming in RSLogix 5000
In GCCS-1, Safety Tags, Safety UDTs, and Safety I/O tags are identified
uniquely with the first letter of s. Additional letters may follow the s such as sz_,
su_, or s_. The only exception is Safety Program Scope tags which are not
named with the s. The Safety Program can only contain Safety tags. See Figure
39.
Figure 39: Standard and Safety Controller Scoped Tags
Standard tags that are to be used in the Safety Task must be first mapped
into Safety Tags. Only tags of the class Safety can be used in the Safety
Task. To map a standard tag into a safety tag, select Logic, Map Safety
Tags as shown in Figure 40.
Figure 40: Mapping Standard Tags to Safety Tags for use in Safety Task
In the left column, select the standard tag name. In the right column,
select the matching safety tag name. Refer to Figure 41.
Figure 41: Select Standard Tags and Matching Safety Tags for Mapping
10.11. Safety Module Configuration
For networks, Safe I/O must have their safety connections configured in
RSLogix 5000. GCCS-2 contains examples of the safe I/O configuration for
many of the ECS panels. It is recommended that the configuration from
GCCS-2 be used for all existing modules.
Safe I/O can be copied from the GCCS-2 reference and modified or can be
added from scratch. The copying procedure is outlined below.
Typical configurations for the GCCS-2 safe I/O can be dragged and dropped
from the GCCS-2 template to the users application. Safe I/O modules must be
configured.
1. Once the module has been copied or dragged and dropped to
desired Network. Under I/O Configuration, Expand the view of the
network then right-click on the proper safe I/O module and select
Properties. See Figure 42.
Figure 42: Beginning Configuration of DeviceNet Safety Modules

After the node is selected, verify data for 1791DS-IB12 as shown in
2. Figure 43 and Figure 44.
Figure 43: 1791DS-IB12 Fill in the Proper Data as Shown

1 Name Enter the Safety Node Name
(Format = sz_ or su_XXXXXXX)
2 Node Safety I/O node number
Number
3 Safety Sets the Input RPI
4 Input Sets the Pulse Testing Configuration for
Configuration Inputs
5 Test Output Sets the Pulse Test Outputs
6 Module Illustrates the correct Module
Definition Configuration for 1791DS-I8XOB8
Input/Output module
Figure 44: 1791DS-IB12 Fill in the Proper Data as Shown Definitions & Settings
Figure 45: Set the RPI to the Proper Value for the Application
3. Set the RPI settings to the appropriate value for the application, see
Module 2.
4. The input configuration is set to match the hardware design. An
example is shown in Figure 46.
Figure 46: Identify Which Inputs are Pulse-Tested

In Figure 46, Input points 0, 4, and 5 are wired to pulse test T0. All of the
other inputs shown are wired as safety inputs without pulse testing. Test
Outputs T2 and T3 are used as standard outputs as shown in Figure 47.
Figure 47 Test Output T2 and T3 Used as Standard Output
Figure 48 shows the correct input configuration to match.
Figure 48: Proper Configuration to Match

1. Type: All input points should be of the type Single.
2. Point Mode: Only the points identified on the prints as being pulse
tested should be selected as Safety Pulse Test; otherwise they
should be marked as Safety.
3. Test Source: Any points that have been identified as Safety Pulse
Test must also have an associated Test Source that is clearly
identified on the prints. In the example, Input Points 0, 4, and 5
have a test source of T0.
4. The Test Output tab must be configured with each of the output
points identified as a Pulse Test, Standard or Power Supply
Output. Configure all test outputs connected to input devices as
pulse test. Configure test outputs connected to output devices as
standard. Configure unused test outputs as standard. See Figure
49
Figure 49: Proper Configuration to Match
5. Continue this configuration method for each safe I/O module in the
application.
For Safe nodes that are not listed in GCCS-2, follow the instructions below
to add new Safe nodes into the application.
1. Under I/O Configuration, right click on the network below the proper
DeviceNet scanner and select New Module as shown in
2. Figure 50.
Figure 50: Adding a New DeviceNet Safety Node

3. Select the module that matches the prints. Refer to Figure 51.
Figure 51: Select the Proper Safety I/O Node Type
4. After the module is selected, fill in the appropriate data. See Figure 52.
DeviceNet is shown on the right.
Figure 52: Fill In the Appropriate Data

5. Set the RPI values to the appropriate value for the application. Refer to
Figure 53. The input configuration is set to match the hardware design.
Figure 53: Set the RPI Values as Appropriate for the Application
Input Point 0 is wired to pulse test T0. All of the other inputs shown are wired
as safety inputs without pulse testing. Refer to Figure 54. The correct
configuration for this example is next.
Figure 54: Identify Which Points are Pulse Tested

Test pulse 0 connection is shown next in Figure 55.
Figure 55: Safety Device Receptacles
1. All input points should be of the type Single. See Figure 56.
2. Only points identified on the prints as being pulse tested should be
selected as Safety Pulse Test; otherwise they should be marked as
Safety. Any points that have been identified as a Safety Pulse Test must
also have an associated Test Source that is clearly identified on the prints.
In the example, Input Point 0 has a test source of T0.
Figure 56: Setting the Input Configuration Point Types and Modes
3. The Test Output tab must be configured with each of the test output points
identified as a Pulse Test or Standard Output. Refer to Figure 57.
If a pulse test output point is used on the prints, it MUST be configured on
this tab as a Pulse Test output.
Figure 57: Configuring the Test Output
4. The outputs on the Output Configuration tab should be set as Single and
Safety Pulse Test. Refer to. Continue this method for each safe I/O
module in the application.
Note: Not all modules will have this tab in their configuration.
Figure 58: Setting the Output Configuration

Note: Change Point Mode to Safety if problems exist.
End of Procedure
10.12. Safety Network Numbers
10.12.1. CIP Safety Protocol
The CIP Safety protocol is an end-node to end-node safety protocol which
allows routing of CIP Safety messages to and from CIP Safety devices
through bridges, switches, and routers.
To maintain safety integrity when routing through non-certified bridges,
switches, or routers, each end node within a routable CIP Safety Control
System must have a unique reference. This unique reference is a
combination of a Safety Network Number (SNN) and the Node Address of
the network device.
10.12.2. Managing Safety Network Numbers
Safety Network Numbers assigned to each safety network or network
segment must be unique. You must ensure that unique Safety Network
Numbers (SNNs) are assigned to each:
DeviceNet network that contains safety nodes
Chassis that contains one or more safety devices
After the Safe I/O modules have been created, generate a Safety Network
Number for all modules (Figure 59).
Figure 59: Generate a Safety Network Number

Select Time-based and click the Generate button on each module you open.
This process must be repeated for each DeviceNet Network in the chassis,
generate a unique number for each device on all networks.
Figure 60: Click to Generate the Safety Network Number
10.13. Exercises
10.13.1. Exercise 1: Configure RSLinx
1. RSLinx may already be running on the computer when the computer

boots up. RSLinx can be identified by the chain symbol in the system
icon tray in the lower right.
Figure 61: RSLinx Running Indicator in PC System Tool Tray
2. Start RSLinx by clicking on the icon shown in Figure 61, or by clicking

on the shortcut in Windows. The screen will appear as shown in
Figure 62. New installs of RSLinx will not have any drivers configured
for communications. Once RSLinx has been set up the first time on
the computer, it will retain its configuration until the user changes it in
RSLinx.
Figure 62: Main RSLinx Window
3. Select the Configure Drivers Icon as shown in
4. Figure 63 below.
Figure 63: Configure Drivers in RSLinx

5. Select Add New and select a name for the driver. The default name
is OK in most cases, see
6. Figure 64.
Figure 64: Configuring Ethernet Devices Driver
7. The Ethernet Devices Driver setup procedure is summarized in Figure
65.

1 Available Driver Types Select Ethernet Devices.
2 Add New Adds a new driver of type selected.
3 Add New RSLinx Driver Default name is usually ok. You may
choose a different name.
4 OK Click OK, the driver is created.
Figure 65: Add an Ethernet Devices Driver - Definitions
8. IMPORTANT: Do NOT use the EtherNet / IP driver. The driver uses
broadcast messages that create network traffic storms and cause
devices to stop working.
9. Figure 66 illustrates a driver running in RSLinx.
Figure 66: Current Running Drivers in RSLinx
10. Once the Ethernet devices driver is added, the Configure driver
Station Mapping screen will open as shown in
11. Figure 67.
Figure 67: Adding Ethernet IP Addresses to RSLinx Manually (New Driver)

This screen allows the user to define all of the IP addresses that RSLinx will be
communicating with. Only Rockwell Ethernet devices (e.g. 1756-ENxT) need to
be entered into the RSLinx drive. Other devices on the Ethernet network may
use a different software package for communication.
10.13.2. Exercise 2: Update Controller Firmware Using Control
Flash
1. Begin by updating the controller. Find the Control Flash icon or in

the program menu under Flash Programming Tools. Select Control
Flash.
2. Select the catalog number for the device to be updated, which is
Guard Logix Processor 1756-L71S.
3. Click Next.
4. Select the proper card in the RSLinx window using the IP Address
and backplanes as shown below. Make sure the card selected is
the same type as that selected above.
5. Click OK.
6. Select the appropriate firmware revision level. Notice you can see
the card type, serial number, and the current revision level.
7. Click Next.
8. Do not interrupt the process at this point. Wait until the Update
status screen appears with the status window message indicating
Update Complete. The box will be green. Interrupting this process
may leave the module in an unusable state.
9. Repeat the Control Flash procedure outlined above to flash the
Safety Partner module (L7SP), if using revision 16.
END OF EXERCISE 2
10.13.3. Exercise 3: Download Logic File to the Processor
Warning: Uploading a processor when a matching logic file is not present
on the host computer will result in a file that is missing the documentation,
such as rung comments and address comments.
1. Open your completed Core08Exercises, from the Core Exercises with

RSLogix.
Note: The TP010B1.acd file is located in the G12 Trainer/PLC folder. The
files are setup to coincide with its corresponding Trainer, this can be used as
a alternate file.
2. From the Main menu bar, select Communications and then Who
Active. This is required for the first download as there is no path
currently set in the project.
3. Choose the appropriate driver. For this project, choose AB_ETH-1,
Ethernet.
4. Browse for the 1756-EN2T. Left-click to open the tree. Note: use the
DCDL to determine the IP address for the EN2T.
5. Select the processor in slot 0, [0] 1756-L71S. At this point, the
Download button, located on the right side of the window, will become
active. Select the Download button.
6. The Download confirmation window will appear. Verify the project is
going to download to the proper processor, and click Download. If
you are unsure the project is correct, click Cancel and begin again
from Step 1.
7. The Download progress window will appear, tracking the Download
status.
END OF EXERCISE 3
10.13.4. Exercise 4: Export a *.L5K File

1. Open RSLogix and open Core08Exercises.
2. From the File menu, select Save As. The Save Window will appear.
The default (the current filename) will be highlighted.
3. Below Filename, select the Save as type pull-down menu and select
RSLogix 5000 Import/Export File [*.L5K] and select Save.
4. The Exporting Progress window will appear.
5. A successful export will end with Project exported with no errors or
warnings message in the lower left corner of the main RSLogix
window.
END OF EXERCISE 4
10.13.5. Exercise 5: Import a *.L5K File into RSLogix
1. Open RSLogix.
2. Select Open. The file open selection window will appear.
3. Notice that both RSLogix and *.L5K files are displayed.
4. Select the *.L5K created in Exercise 4. Click Open. The Save
Imported Project As window will open.
5. Change the Filename so that you do not overwrite the existing file.
Use Core08Exercises_a.
6. Review the lower left corner of the window is the Revision Level
setting. The From: indicates the RSLogix version utilized for the
project. The To: gives a chance to select the output revision level.
7. Click Import. The Importing status window will appear. A successful
import will end with Project imported with no errors or warnings.
message in the lower left corner of the main RSLogix window.
END OF EXERCISE 5
10.13.6. Exercise 6: Create a Safe Node in RSLogix

1. Open ComTask10Exercise6
2. Create a new safe node in the RSLogix program. Use the prints
shown in Figure 68 and Figure 69.
3. See Module 2: RSLogix Overview in this manual to configure Module
definition settings.
4. The device is a 1791DS-IB16, 16 Input Safety I/O Module at node 5 in
DNet05. The device name is s_KA030G4.
Figure 68: Safety I/O Page F1
Figure 69: Safety I/O Page F2
5. Pulse Test T0 is used by Inputs 0, 2, 4, 6, 14.
6. Pulse Test T1 is used by Inputs 5, 7.
7. Test Outputs 2-15 are configured as standard outputs.
END OF EXERCISE 6
10.13.7. Exercise 7: Generate a Safety Network Number
1. Open ComTask10Exercise7.
2. Open the I/O configuration at the end of the Controller Organizer.
3. Generate a New Safety Network Number for each module in DNet03.
Begin with the first Safety I/O Module as shown in Figure 70
Figure 70: Safety Network Number Generation
Figure 71: Safety Network Number Generation and Copy/Paste

Each device will have its own unique Safety Network Number. Click Generate for
each module, do not use Copy.
END OF EXERCISE 7
10.13.8. Exercise 8: Generate a Safety Signature
After the Safety Task has been created and verified for functionality, it must be
locked with a password to prevent future changes. A Signature is a mixture of
time and the program checksum. The signature is used to identify that the
Safety Task has not been changed from the time that the task was validated.
1. Open Core08Exercises.
2. Go Online with the processor.
3. Select Program or Remote Program mode. See Figure 72.
Figure 72: Select Program or Remote Program
4. Click Safety Locked or Safety Unlocked. When the drop-down menu
appears, select Safety Lock/Unlock. See Figure 73.
Figure 73 Select Safety Lock/Unlock
Click Change Password (Figure 74).
Figure 74: Select Change Password
5. Select Safety Unlock as shown in
6. Figure 75
7. Enter the New Password and enter the Confirm New Password.
8. Click OK. Refer to Figure 75.
Figure 75: Enter and Confirm New Password

9. Select Generate Safety Signature. Refer to Figure 76.
10. Enter password (as needed) and click Lock.
Figure 76: Generate Signature and Enter Password Before Locking
The processor must be in program mode to Generate the Safety Signature.

Locking/Unlocking the Safety Application as well as deleting the Safety
signature can be accomplished in Run or Program Mode. The screen shown
in Figure 76 also allows the user to change the passwords used to lock and
unlock the processor. A password is usually assigned to the Safety Unlock
only. Be sure to write down the password.
12. Figure 77 shows a locked processor.
Figure 77: Processor is Locked
13. Go to Run or Remote Run mode (Figure 78).
Figure 78: Placing Processor in the Remote Run Mode
The final steps of locking the processor with a Safety Signature will be carried
out from the HMI.
14. From the Select screen, click the Signature Screen Button. See
Figure 79.
Figure 79: Open the Mode Screen
15. The status of the Safety Signature is indicated here.
Figure 80: The Mode Screen

16. Press the Use Current Signature button to open the Signature
Screen. See Figure 81. After a slight delay the signature will
appear below the Safety PLC Status.
Figure 81: Signature Screen
17. Press the Use Current PLC Signature Button.
18. After a short delay the signature status will update to [OK-Locked
Safety Signature: (the number, time and date will be displayed).
See Figure 82.
Figure 82: Safety Signature Locked
Once the processor has a signature or is locked, edits to the Safety Task are
no longer possible. This is the steady state of the tooling in a production
ready state. The Monitored Power System (MPS) is designed to function only
after there is a signature that matches the signature stored in the processor.
There is typically an additional memory location for the signature (either
PM&C or possibly plant safety) to verify that the Safety Task is intact and
verified.
END OF EXERCISE 8
10.13.9. Exercise 9: Configuring the IP Address for a ENBT Card

(Optional Time permitting)
1. Connect the USB cable between the computer and the ENxT module.
2. Open RSLinx.
3. Set the ENxT to Dynamic in the Network Configuration Type.
4. Cycle power to the ENxT switch.
5. Examine the ENxT cards display. It should match the address you
entered.
6. Open RSLinx and select Static for the card you just addressed.
7. Uncheck the Auto-negotiate port speed and duplex box.
8. Select 100 in the Current Port Speed pull-down menu.
9. Select Full Duplex in the Current Duplex pull-down menu.
10. Restart the power to the ENBT card to set the port and speed
changes.
END OF EXERCISE 9
10.14. Review
1. How do you import an .l5K file?
2. How do you export an .l5K file?
3. How do you update firmware in certain smart cards?
4. How is logic downloaded to the processor?
5. How do you create Safety I/O Modules in RSLogix?
6. How is the Safety Network Number Created?
7. How do you generate the safety signature and lock the processor with
a password?
GCCS-2
LMS # 33544
Module 11: Ethernet/IP Networks

Sponsoring Group:

Document Revisions:
8-26-13 5.0 J. Hocking Updated Supply Power graphic
7-9-15 6.0 J. Hocking
EtherNet I/O
materials.

i
Table of Contents
11. Ethernet/IP Networks .................................................................... 11-1
11.1. Objectives ........................................................................................................ 11-1
11.2. Hirschmann Octopus Switch ......................................................................... 11-2
11.3. Hirschmann Octopus Switch DLR Capable ............................................... 11-3
11.3.1. Power Over EtherNet (POE) ................................................................... 11-3
11.4. Hirschmann Octopus Switch Configuration ................................................. 11-3
11.4.1. GM Octopus Ethernet Switch Setup Utility - e-Tool ................................ 11-3
11.4.1.1. GM Switch Configuration Utility .................................................... 11-5
11.5. Module Review .............................................................................................. 11-10

ii
Table of Figures
Figure 1: Hirschmann Octopus Switch Training Panel Only ................................. 11-2
Figure 2: Open the Octopus EtherNet Switch Configuration Utility .......................... 11-5
Figure 3: Import the DCDL ...................................................................................... 11-6
Figure 4: General Settings ...................................................................................... 11-7
Figure 5: Click the Reset Switch button .................................................................. 11-7
Figure 6: Reset Switch Dialogs ............................................................................... 11-8
Figure 7: High Discovery used to Set the Switch Address ...................................... 11-8
Figure 8: Ethernet Switch Configured Properly ........................................................ 11-9

iii
11. Ethernet/IP Networks
11.1. Objectives
1. The student will identify basic features of the Hirschmann Switch.
2. The student will identify the softwares used to configure a Hirschmann Octopus
Switch.
3. The student will understand the use of the Switch Configuration e-Tool.
4. The student will understand how to configure a Hirschmann Octopus Switch.
11.2. Hirschmann Octopus Switch
The global switch is a Hirschmann Octopus (See figure 15). The Octopus switch is
an IP 67 managed switch. IP 67 is a number to specify the environmental protection
of the enclosure of the switch. The first number 6 represents an enclosure that
totally protects against dust. The second number 7 represents protection against
the effect on immersion between 15 cm and 1 m. The OCTOPUS switch comes in 8,
16, and 24 port varieties.
Standardized 4-pin-M12-D technology for the connection of terminating
equipment
Totally encapsulated design
Management via SNMP v1, v2, v3, Web GUI or TELNET
Support for auto-configuration adapter
Redundancy mechanisms such as Rapid Spanning
Access check according to IEEE 802.1X
Filter possibilities per port
Flow control with prioritization and traffic shaping
Fast commissioning according to the plug & play principle
Redundant power supply for high availability
LED display for device and network status
External signaling of alarms via signal contact
Compatible with PROFINET, EtherNet/IP, Modbus TCP etc.
The OCTOPUS switch can be mounted either on the wall or directly on the machine.
The IP 67 variants of the manageable Hirschmann switches have 8/16/24 twisted
pair ports, utilizing 4-pin-M12-D technology.
Figure 1: Hirschmann Octopus Switch Training Panel Only
11-2 2015General Motors Company. All Rights Reserved Rev. 6.0

11.3. Hirschmann Octopus Switch DLR Capable
Whats new with the DLR capable switch?
DLR capable switch is thicker
Allows single hop routing
Acts as level 3 device, legacy switch is level 2 device
Eliminates the need for additional network card in PLC rack saves money.
Supports additional network address for example:
o 120.7.6.xxx PLCs, Robots, HMIs etc..
o 192.168.1.xxx for I/O blocks, valve manifolds etc.
11.3.1. Power Over EtherNet (POE)
Uses 4 pin connector
Only limited devices require POE
Most device that require POE are cameras
11.4. Hirschmann Octopus Switch Configuration

The Hirschmann switch can be configured with the Hirschmann HiDiscovery
software and the GM Ethernet Switch Setup Utility. Using the Octopus Ethernet
Switch Setup Utility is more time effective. Hirschmann HiDiscovery software must
be installed on the workstation.
HiDiscovery software can be loaded from a CD or from the switch utility.
By default, the login and password to write to a switch is login = admin and
password = private
You can view read only by logging in with login = user and password = public
A switch out of the box behaves as an unmanaged switch.
A power supply 2 error will be displayed until configured.
The switch IP address, Subnet Mask, and Gateway can be assigned using
HiDiscovery.
11.4.1. GM Octopus Ethernet Switch Setup Utility - e-Tool

The Octopus Ethernet Switch Setup Utility can be found in the e-Tools portion of the
GM Standards homepage. The utility links to the Octopus switch configuration
procedure found in GCCS-1 on GM SupplyPower. You must use HiDiscovery in
conjunction with the GM Ethernet Switch Setup Utility.
Key points of the Switch Configuration e-Tool:
Configures Hirschmann Octopus and MS020 Switches
Can import the DCDL data or be filled out by manual input.
Stand-alone application Does not use other applications as dependencies
Requires the switch firmware to be at an acceptable blockpoint revision
Switch must have the correct IP Address from the DCDL configured.
HiDiscovery is very helpful for this

11.4.1.1. GM Switch Configuration Utility
1. Open the utility through the Start menu or a desktop icon.
Figure 2: Open the Octopus EtherNet Switch Configuration Utility
The Main Screen opens.
2. Click 1-Import From DCDL button in the lower left.

3. Select file M_TEC_Training_Zone_DCDLEtherNetIPTemplate.xlsm.
4. Select Trainer 1, 2, 3, or 4 from the Read DCDL dialog box. Choose the
trainer with the Ethernet switch that is to be read, reset and configured.
Figure 3: Import the DCDL
5. Click Import DCDL Information on the bottom of the Read DCDL window.
6. Select the number of ports of the switch. The global trainers in the class
room are all 8 port switches.
7. Select GMT-0500 EST, Eastern US in the Time Zone Tab.
8. Type Controls Engineer in the Contact Person Tab.
9. Select 8 in the IP Range of General Purpose Network. (Add one to second
octet of the IP Address.)
Note: Item 7 and 8 are usually the only manual entry required depending on
imported DCDL completeness.

Figure 4: General Settings
10. Click 2-Reset Switch button and click OK and OK
Figure 5: Click the Reset Switch button
Important: If Firmware is different after clicking Yes you must select the proper
firmware for the switch to configure properly. Version (07.1.04)
11. Click Reset on the SNMP dialog

Use pull-down to change password if password used is not accepted, use
private.
12. Click OK
13. Click OK to reminder to set IP address.
Figure 6: Reset Switch Dialogs
14. Open HiDiscovery.

A. Click Rescan
B. Highlight the desired switch.
C. Select Properties.
D. Enter IP Address, Subnet Mask, and Default Gateway and click Set As
Default button and click OK.
Figure 7: High Discovery used to Set the Switch Address

15. Go back to the utility and click 3-Configuration button and click Yes.
16. Verify that the configuration was successful. You will see the dialog box
below if the information configured correctly.
Figure 8: Ethernet Switch Configured Properly
11.5. Module Review
1. When configuring the IP addresses of the workstation to the MTEC Trainer,
where are the convenience port IP addresses located?
2. What two software are used to configure a Hirschmann Octopus Switch?
3. What three different variety of ports are offered with the Hirschmann
Octopus Switch.

`
GCCS-2
LMS # 33544
Module 12: RSNetworx and DeviceNet

Sponsoring Group:

Document Revisions:
Updated graphics. Synchronized DeviceNet
8-26-13 5.0 J. Hocking
to consistent examples.
7-9-15 6.0 J. Hocking
EtherNet I/O

i
Table of Contents
12. RSNetworx & DeviceNet ............................................................... 12-1
12.1. Objectives ........................................................................................................ 12-1
12.2. DeviceNet Limitations in GCCS-1 .................................................................. 12-2
12.3. EDS Files for DeviceNet Devices ................................................................... 12-3
12.3.1. Registering an EDS file in RSNetworx .................................................... 12-3
12.4. Creating an RSNetworx .DNT Configuration File ......................................... 12-9
12.5. Configuring a Device .................................................................................... 12-16
12.6. The DNB Scanlist .......................................................................................... 12-19
12.7. Downloading the Configuration to the DNB ............................................... 12-27
12.8. Uploading Parameters from a Device ......................................................... 12-28
12.9. Uploading the Entire Network ...................................................................... 12-29
12.10. Replacing a Node on the DeviceNet Network ........................................... 12-30
12.11. Certifying the Network ................................................................................ 12-30
12.12. Troubleshooting a DeviceNet Network ..................................................... 12-31
12.12.1. Bus Errors ........................................................................................... 12-32
12.12.2. Bus Traffic........................................................................................... 12-35
12.12.3. Bus Power .......................................................................................... 12-35
12.12.4. Shield Voltage ..................................................................................... 12-36
12.13. Common Mode Voltage .............................................................................. 12-37
12.14. CANH/L Differential Voltage (Recessive Data 1) ................................... 12-37
12.15. CANH/L Differential Voltage (Dominant Data 0) .................................... 12-37
12.16. Exercise 1: Configure the DeviceNet Scanlist .......................................... 12-38
12.17. Review.......................................................................................................... 12-39

ii
Table of Figures
Figure 1: Node Limitations on DeviceNet.................................................................. 12-2
Figure 2: Using the EDS Wizard in RSNetworx for DeviceNet .................................. 12-3
Figure 3: Register an EDS File Descriptions & Definitions..................................... 12-4
Figure 4: Select EDS File to Register ....................................................................... 12-4
Figure 5: Select EDS File to Register - Descriptions & Definitions............................ 12-4
Figure 6: EDS File Installation Test Results .............................................................. 12-5
Figure 7: EDS File Installation Test - Description & Definition .................................. 12-5
Figure 8: Change Graphic Image .............................................................................. 12-6
Figure 9: Change Graphic Image - Descriptions & Definitions .................................. 12-6
Figure 10: Select a New Graphic Image (Icon) ......................................................... 12-7
Figure 11: Select a New Graphic Image (Icon) - Descriptions & Definitions ............. 12-7
Figure 12: EDS Wizard is Complete ......................................................................... 12-8
Figure 13: EDS Wizard is Complete - Description & Definition ................................. 12-8
Figure 14: RSNetworx for DeviceNet ........................................................................ 12-9
Figure 15: Open Network Properties window .......................................................... 12-10
Figure 16: Set Online Path...................................................................................... 12-10
Figure 17: Select the Correct DeviceNet Network Path .......................................... 12-11
Figure 18: Scanning all Nodes on Network ............................................................. 12-12
Figure 19: Scanning All Nodes on Network - Descriptions & Definitions................. 12-12
Figure 20: Network Scan Complete All Nodes Found .......................................... 12-13
Figure 21: Saving a DeviceNet Network File .......................................................... 12-14
Figure 22: Naming the DeviceNet Network File ...................................................... 12-14
Figure 23: Enter the *.dnt File Name....................................................................... 12-15
Figure 24: Siemens ET200S Communication Adapter Properties .......................... 12-16
Figure 25: Siemens ET200S Communication Adapter - Descriptions & Definitions 12-16
Figure 26: Upload or Download Decision................................................................ 12-17
Figure 28: Siemens ET200S Adapter Parameters .................................................. 12-18
Figure 30: Opening the Scanlist .............................................................................. 12-19
Figure 31: Accessing Scanner Properties - Descriptions & Definitions ................... 12-20
Figure 32: DNB Properties in RSNetworx ............................................................... 12-20
Figure 33: DNB Properties in RSNetworx - Descriptions & Definitions ................... 12-20
Figure 34: Upload from DNB to RSNetworx ............................................................ 12-21
Figure 35: Move Devices from Available Devices to Scanlist ................................. 12-22
Figure 36: Move Devices from Available Devices to Scanlist - Descriptions & Definitions
................................................................................................................................. 12-22
Figure 37: All Available Devices Added to Scanlist ................................................. 12-23
Figure 38: Changing the I/O Parameters for a Configurable Device ....................... 12-24
Figure 39: Edit I/O Parameters for a Configurable Device ...................................... 12-24

iii
Figure 40: Individual Device I/O Mapping into DNB ................................................ 12-25
Figure 41: Using AutoMap to Map the I/O for Each DNB Node .............................. 12-26
Figure 42: Using AutoMap to Map the I/O for Each DNB Node - Descriptions &
Definitions ................................................................................................................ 12-26
Figure 43: Click OK or Apply at Any Time to Download to the DNB ....................... 12-27
Figure 44: Upload Individual Node Settings ............................................................ 12-28
Figure 45: Upload all Parameters from the Entire Network ..................................... 12-29
Figure 46: Upload All Parameters from the Entire Network .................................... 12-29
Figure 47: NetAlert NetMeter for DeviceNet (P/N : DN-MTR) ................................. 12-31
Figure 48: Example DeviceNet Network with Bus-Off Condition or Error Traffic..... 12-32
Figure 49: Terminators Moved in to DNB................................................................ 12-33
Figure 50: One Terminator Moved to Original Location .......................................... 12-33
Figure 51: Terminator Moved to First Tee on Troubled Half ................................... 12-34
Figure 52: Terminator Moved to Next Tee on Troubled Half ................................... 12-34

iv
12. RSNetworx & DeviceNet
12.1. Objectives
1. The student will be able to define a DeviceNet network.
2. The student know how to troubleshoot a DeviceNet network.
3. The student will be able to use RSNetworx to configure the DeviceNet
network.
4. The student will be able to develop a DNB scan list.
12.2. DeviceNet Limitations in GCCS-1
The defined baud rate for DeviceNet in GCCS-1 is 250k in all PLC applications.
Refer to the proper GM Robot Specifications for the speed of the network
between the robot and the end of arm tooling.
In GCCS-1, the DeviceNet scanner in the MCP is always assigned Node 0 or
Node 1.
DeviceNet allows for 64 total nodes on a network. However, GCCS-1 allows
fewer nodes on the network, as shown in Figure 1. These node limitations are
due to design considerations such as maximum network length, network
troubleshooting, cumulative drop length, and available bandwidth.
Area Maximum Maximum Total Nodes

Safe Nodes
Bodyshop 10 20
Conveyors 15 30
Paint 15 30
General Assembly 10 20
Press 10 20
Figure 1: Node Limitations on DeviceNet
Node number 62 is never used in GCCS-1.
Nodes should never be assigned to Node number 63; this is the default node
number for nodes that have a software selectable node number.
If a DeviceNet network is longer than the maximum distance of 820ft at 250k
Baud, a repeater must be placed into the network such that the repeater B
network begins at a distance of no more than 820ft from the scanner.
A maximum of one repeater is allowed per DeviceNet network.
o A Repeater does not count as a node.
o Does not change the maximum node limits.
If the network has more than the number of nodes shown in Figure 6 above, an
additional DeviceNet network should be used.
Overloading of the network with too many nodes will cause the safety nodes to
have connection problems and the safety system to fail to a safe state.
12.3. EDS Files for DeviceNet Devices
Each type of DeviceNet device requires an EDS file registered in RSNetworx to work
properly. EDS files are simple text files used by network configuration tools such as
RSNetworx to help identify products and easily commission them on a network. EDS
files describe a product's device type, product revision, and configurable parameters on
a DeviceNet network. Allen Bradley devices are already registered with RSNetworx by
default. EDS files for the devices typically used by GM MAAC are included with each
GCCS-1 release in the Software directory.
12.3.1. Registering an EDS file in RSNetworx
Figure 2: Using the EDS Wizard in RSNetworx for DeviceNet
1 EDS Wizard Select the EDS Wizard from the Tools menu.
2 Welcome Screen Read Wizard tasks and click Next.
3 Register an EDS Select to register a single EDS file or a directory of
file(s) EDS files.
4 Next Proceed with the option selected.
Figure 3: Register an EDS File Descriptions & Definitions
Figure 4: Select EDS File to Register

1 Register a single file. Selection will register one EDS file.
2 Register a directory of Selection will register an entire directory of
EDS files. EDS files.
3 Browse Browse for the desired directory or file.
4 Look in subfolders Select the Look in Subfolders check box
to include subfolders in the registration.
(Enable after browsing for a directory of
EDS files.
5 Next Continue the registration process.
Figure 5: Select EDS File to Register - Descriptions & Definitions
Figure 6: EDS File Installation Test Results
From the EDS File Installation Test Results screen, click Next to continue.
To change the icon, if required, click the desired file in the installation results list.
Then click Next to change to a different icon.

1 Next Continue from EDS File Installation Test Results.
Figure 7: EDS File Installation Test - Description & Definition
Figure 8: Change Graphic Image

1 Current Select device to change icon.
Icon
2 Change Click to open a selection of available images
icon (optional).
3 Next Continue from Change Graphic Image. Click Next
if the graphic image is OK for the device.
Figure 9: Change Graphic Image - Descriptions & Definitions
Figure 10: Select a New Graphic Image (Icon)
Selecting a new graphic image is optional.

1 Select Icon Select a new icon (graphic image) for the device.
2 Browse Click Browse to search for an icon on the
computer.
3 OK Accept the new icon.
Figure 11: Select a New Graphic Image (Icon) - Descriptions & Definitions
Figure 12: EDS Wizard is Complete

1 Finish Click to close the EDS Wizard.
Figure 13: EDS Wizard is Complete - Description & Definition
Note: EDS files need only be registered once per computer. RSNetworx will
automatically recognize the devices the next time it is used.
The graphic image (icon) representing the device can be changed from the EDS
Wizard as a separate task or while registering the EDS file for a single device.
12.4. Creating an RSNetworx .DNT Configuration File
1. Begin by opening RSNetworx for DeviceNet.
2. Click the Online button, when working from a new file or to use the current
Online path.
Figure 14: RSNetworx for DeviceNet

Note: It may be necessary to change the Online Path. See steps 3-5.
3. Click the Network menu.
4. Select Properties. See Figure 15.
3
Figure 15: Open Network Properties window

5. Click the Set Online Path button.
Figure 16: Set Online Path
6. Click on the DeviceNet Network that is under the desired scanner module.
7. Click OK.
6
Figure 17: Select the Correct DeviceNet Network Path
1
2
3
Figure 18: Scanning all Nodes on Network

1 OK Click OK on the advisory screen;
(Configuring online devices requires first an
upload or download).
2 1756-DNB/A The DeviceNet scanner module is first to
Node 0 appear once the online scan begins.
3 Graph Display In the Graph view, this line is populated with
Line devices that RSNetworx for DeviceNet
detects when scanning.
4 Browsing Network Indicates DeviceNet Network browsing (node
window scanning) progress.
5 Cancel Click to terminate the active scan.
Figure 19: Scanning All Nodes on Network - Descriptions & Definitions
RSNetworx will scan all of the nodes on the network as shown in Figure 20 and
display them on the screen. If a node is not displayed on the screen, it may be
set with a duplicate address or it may be set with an incorrect baud rate. Devices
with node addresses that are software configured only must be connected to the
network one-at-a-time until the addresses have been set.
Figure 20: Network Scan Complete All Nodes Found
Important: Verify against the drawing that all nodes in the network are
represented in the completed online scan.
Once the network scan has been started a *.dnt network file can be saved. As
configuration of the network continues, the file can be saved again at any time.
Use the following procedure to save a *.dnt file:
1. Click File.
2. Click Save. See Figure 21.
Figure 21: Saving a DeviceNet Network File

3. Enter the name of the file; AA110DNet06.dnt in this example.
When saving the DeviceNet network, the format is a combination of the MCP or
controller name followed by the DNet and finally the slot where the DeviceNet
scanner resides.
Note: Some upper level systems have limited characters available. The name
format BA_AB030B01DNet06 may be necessary.
BA_AB030B01DNet06
PLC DeviceNet DeviceNet

Name network scanner
identifier Slot
Figure 22: Naming the DeviceNet Network File
4. Click Save. See Figure 23.
3 4
Figure 23: Enter the *.dnt File Name
12.5. Configuring a Device
Certain devices may need to be configured inside RSNetworx. The Siemens ET200S
Point IO module is a flexible I/O module that consists of a communication module and a
variable amount of input and output cards.
Figure 24: Siemens ET200S Communication Adapter Properties

1 Siemens Icon Double click the device icon to open the
Properties window.
(200S Adapter)
2 General Tab General information for the device.
3 Parameters Tab Select to view parameters.
Figure 25: Siemens ET200S Communication Adapter - Descriptions & Definitions
1 2 3
Figure 26: Upload or Download Decision

When the software and device do not match, the user will be prompted to upload or
download the configuration or settings.

1 Upload Uploads the configuration of the device.
2 Download Downloads the settings in RSNetworks
software to the device.
3 Cancel Closes the Properties window.
1
2
3
Figure 28: Siemens ET200S Adapter Parameters

1 Data Input Size Write this number down. It will vary depending
on the I/O connected to the adapter module.
2 Data Output Size Write this number down. It will vary depending
on the I/O connected to the adapter module.
3 Operating Mode Set to Auto Config Mode.
4 I/O Status Byte Set to Enable.
Enable
Important: Always ensure the module is in Auto Config Mode and the I/O Status Byte
is Enabled. Write down the Data Input Size (Item 1) and the Data Output Size (Item 2)
as shown in
Figure 28. The data sizes are used in the mapping of the device into the scanner since
the .EDS file is generic. Note that the I/O size will vary with the quantity of I/O
connected to the adapter module.
12.6. The DNB Scanlist

The DNB contains a Scanlist that configures where the individual nodes map I/O in the
scanner. This ensures that the processor can easily retrieve and set the data. The
Scanlist is simply a look-up table that aligns the nodes with a memory location. The
scanner contains 124 input words (32-bit (DINTs)) and 123 output words (32-bit). In
GCCS-1 the standard for mapping device I/O to the scanner I/O Image is at
DINT[Node Number x 2]. Using this rule, each node is allowed 8 bytes of data (2-32
bit words) before it will overlap with the next node.
Example:
Node 20 maps into the DNB with a starting address of word 40.
Node 31 maps into the DNB with a starting address of word 62.
Figure 30: Opening the Scanlist

1 Scanner (Node 0) Double-click to open Properties.
Figure 31: Accessing Scanner Properties - Descriptions & Definitions
Figure 32: DNB Properties in RSNetworx

1 Scanlist Click the tab to view the Scanlist.
2 Input Click the tab to view the Input parameters for
devices in the Scanlist.
3 Output Click the tab to view the Output parameters for
devices in the Scanlist.
4 Address Node address for the displayed device.
DeviceNet (DNB) Scanner is always node 0 for
GCCS-1.
Figure 33: DNB Properties in RSNetworx - Descriptions & Definitions
Selecting the Scanlist, Input, or Output tabs will produce the Upload/Download decision
prompt as shown in Figure 34.
Important: When configuring a new network, like this example, the Scanlist is not
configured in RSNetworx so the proper selection is to always Upload from the DNB.
Figure 34: Upload from DNB to RSNetworx
Figure 35: Move Devices from Available Devices to Scanlist

1 Scanlist Scanlist tab is active.
2 Automap on Add Always deselect. Does not map to GCCS-1
standards.
3 >> Click to move all Available Devices into the
Scanlist.
Figure 36: Move Devices from Available Devices to Scanlist - Descriptions & Definitions
In Figure 36 above, the list of Available Devices came from RSNetworx online browsing
the network. It is important to uncheck the Automap on Add checkbox (Item #2)
on the Scanlist tab. Automap on Add allows the scanner to automatically map in the
devices for the user when they are added to the Scanlist. However, there is no
standard as to how the nodes are mapped; they are placed into the next available
memory location. Click on the >> key to add all Available Devices to the Scanlist. At
this point, the screen should look like Figure 37.
.
Figure 37: All Available Devices Added to Scanlist
Most devices will be configured automatically when they are added to the Scanlist
because the .EDS file contains the correct info for RSLinx to determine parameters and
settings. Any modules that were configured in Module 12.5 will also have to be
configured at this point before mapping the I/O. After adding the devices to the Scanlist,
highlight the specific device and select the Edit I/O Parameters button as shown in
Figure 38.
Figure 38: Changing the I/O Parameters for a Configurable Device
Figure 39: Edit I/O Parameters for a Configurable Device
As illustrated in Figure 39, the user can input the data that was written down for the
specific device in Module 12.5. The reason this information has to be input like this is
that the .EDS file for a device such as the Siemens ET200S is generic and does not
comprehend the number of input and output cards that have been added to it in the final
configuration.
After all of the configurable nodes have the correct I/O settings, map the scanner.
In Figure 40, all of the devices are now being scanned by the DNB but the mapping of
the actual I/O is not yet complete. Continue by selecting the Input tab. Each device
that contains input data is shown.
Figure 40: Individual Device I/O Mapping into DNB
The top node window shows each device: Type of connection (polled or Change of
State (COS)), Size (in bytes), and Mapping of the current location in the DNB.
Node 10 is a Change of State Node; 3 bytes of Input data are required, and it is not
currently mapped to any real I/O in the DNB.
The easiest way to map the data for each node is to adjust the Start DWord to Node
number x 2 and click the AutoMap button. Note that this AutoMap button is different
from the AutoMap on Add checkbox on the Scanlist.
Figure 41: Using AutoMap to Map the I/O for Each DNB Node

1 Node Select a node to configure.
2 Start DWord Adjust to double the node # (this example
Node 10 = Start DWord = 20).
3 Automap Maps the node to the selected StartDword.
4 Bitmap Verify that the device is mapped to the proper
data number.
Figure 42: Using AutoMap to Map the I/O for Each DNB Node - Descriptions & Definitions
In Figure 41 above, Node 10 has been properly mapped into the DNB starting at word
20 in the DNB. In RSLogix 5000, the I/O for Node 10 on a DNB in slot 6 can now be
found at Local:6:I.Data[20]. Continue this same technique for each node in the Inputs
and Outputs until all devices have been correctly mapped.
In Figure 41, it is important to understand that using the Node number x 2 method
allows only 8 bytes in the mapping for each device. If a device contains more than 8
bytes (e.g. RF tag reader/writer) of data, it will utilize the data table area reserved for the
next node. Therefore, that node cannot be used by another device.
Example:
Node 10 contains 24 Bytes of Input Data. When it is mapped starting with word 20, the
data will use up a total of 6-32 bit DNB words, ending at word 25. There cannot be a
Node 11 or 12 on this network since the data location is already being used by Node 10
(Node 11 would have used word 22 and node 12 would have started at word 24).
12.7. Downloading the Configuration to the DNB

After the Scanlist has been properly configured, it must be downloaded to the DNB. To
download to the DNB, the processor in the local chassis must be in either the Program
or Remote Program Mode. Select either Apply or OK in the DNB properties window at
any time while online to download to the DNB module.
Figure 43: Click OK or Apply at Any Time to Download to the DNB
12.8. Uploading Parameters from a Device
Most nodes will not need individual configuration in RSNetworx. Examples of nodes
that do not need to be configured individually are Safe Nodes (these are configured
inside RSLogix), Prox Blocks, and Valve Stacks.
After double-clicking on a node that has configurable settings, there will be a prompt to
upload, download, or cancel as shown in Figure 44.
Figure 44: Upload Individual Node Settings
Uploading from a node brings the current configuration from the node into the
RSNetworx software. This is preferred at this point in the configuration since the data in
RSNetworx may not be up to date. After a network is completely set up, individual
nodes can be replaced and downloaded from the saved settings in RSNetworxs.
12.9. Uploading the Entire Network
Before saving the RSNetworx file, it is important to upload all settings from all of the
devices on the Network. This ensures the offline file contains all of the necessary data
to rebuild the network in the event of a device failure. While online, select Network,
then select Upload from Network.
Figure 45: Upload all Parameters from the Entire Network
Figure 46: Upload All Parameters from the Entire Network
After the network upload has been completed, save it to the computer as a .DNT file.
12.10. Replacing a Node on the DeviceNet Network
Most DeviceNet nodes can be replaced by simply setting the new node to the same
address and baud rate and plugging it in. In the case of intelligent DeviceNet nodes,
the configuration may have to be downloaded to the device from within RSNetworx for
DeviceNet. Safe nodes receive their configuration from the processor and generally will
not have to be downloaded.
12.11. Certifying the Network

After the Scanlist has been properly configured and downloaded, each DeviceNet
network must be performance certified.
This certification must adhere to the standards listed on the DeviceNet buy-off sheet
located in GCCS-1i, Appendix B. This document is located on the GM MAAC website.
It is recommended that certification and troubleshooting of the DeviceNet network be
accomplished with a DeviceNet meter such as the NetAlert! NetMeter from Woodhead
Connectivity. A typical multi-meter cannot update fast enough to identify problems on a
DeviceNet network.
Any items identified by the NetMeter with either the or icons must be approved by
the GM Engineer responsible for the project.
12.12. Troubleshooting a DeviceNet Network
It is important to remember that DeviceNet is a communication network that contains
traffic on the CAN-H and CAN-L wires. Network traffic can be hard to diagnose without
the proper tools.
There are software based tools available that are good at providing the user with
information on the packets of data out on the network. The Net Meter shown below is
the size of a multi-meter, and can be plugged passively into a DeviceNet network to
diagnose issues and take measurements.
Figure 47: NetAlert NetMeter for DeviceNet (P/N : DN-MTR)

Woodhead Connectivity
50 NorthLand Road
Waterloo, Ontario
Canada N2V 1N3
(519) 725-5136
The NetMeter can be powered from either AA batteries or from the DeviceNet network.
Begin by plugging the meter into an available point in the network. It may also be useful
to take measurements at more than one place on the network, such as the farthest
distance from the power sources (typically the MCP and Power Taps).
Each selector switch setting on the NetMeter provides a different measurement of the
DeviceNet network. There are also multiple types of measurements for each item, such
as current running value, and minimum, and maximum values. The minimum and
maximum values represent the network values since the NetMeter was plugged in.
These can be reset by powering off the NetMeter and powering the unit on, or by
cycling from Run to and back to Run.
Pressing the button on the NetMeter cycles the display through each of the
different measurements available at that particular switch position.
A description of the network errors that the NetMeter can help detect is given in the
following sections.
12.12.1. Bus Errors

DeviceNet is a tolerant network that can remain functional even while error traffic
exists on the network. If a network was stable and has been verified to have no
errors but then at a later point begins to have errors, there is a high probability that
there is a media problem.
The 1756-DNB card in the Logix chassis does not give any indication that error
frames exist on the network. At a certain threshold, the number of errors will
overwhelm the DeviceNet network and the network will go offline (typically a code 91
on the DNB for Bus-Off) The NetMeter tracks data errors in real-time. Any error rate
greater than zero is undesirable in a robust DeviceNet network, even though the
network may continue to function. An error rate of greater than 10 errors per second
indicates a problem that should be investigated as soon as possible.
When a network error is Bus-Off, it is usually very difficult to continue
troubleshooting since communications to the networks are down. In this case. it is
usually easiest to begin isolating the problem section.
Figure 48: Example DeviceNet Network with Bus-Off Condition or Error Traffic
Begin isolating the trouble node or network section by moving the terminating
resistors to the scanner on the network. Then cycle the network by removing
and re-inserting the DNB in the chassis.
TR TR
Figure 49: Terminators Moved in to DNB

In Figure 49, both terminating resistors have been placed immediately next to the
DNB. After a cycle of the network, the scanner should no longer be in a Bus-Off
or error traffic condition. If it is, there is a problem inside this isolated network,
either with the DNB, the power supply(s), or the media.
In Figure 55, the media problem is not in this isolated network. If the scanner
resets properly and begins trying to connect to nodes, move a terminating
resistor (terminator) downstream on one half of the network back to its original
placement as shown in Figure 56.
TR
Figure 50: One Terminator Moved to Original Location

In Figure 50, the network is now divided in half. The Bus-Off or error condition
will now either be present or the network will function properly. In the example
network, the problem is on the other half of the network so there will be no errors
at this point. Continue on to the next step by moving the other terminator out to
the first tee on the network half that has been identified with the problem.
TR
Figure 51: Terminator Moved to First Tee on Troubled Half
In Figure 51 above, the terminator has been moved out to the first tee in the
problem half of the network. If the meter indicates a problem at this point, the
problem is caused by one of the devices on this tee. In the example network, the
problem is still further downstream, so the meter will still be showing no errors.
Now move the terminator downstream to the next tee.
TR
Figure 52: Terminator Moved to Next Tee on Troubled Half

In Figure 52 above, the terminator has been moved to the tee with the problem
device or cable connected to it. At this point, the network is now showing errors;
if the errors are significant enough, the network may go to a Bus-Off state. The
problem has now been identified as being connected to this tee.
Disconnect all devices on this drop and add them back in one at a time until one
of the device connections causes the problem to surface. The source of the
problem has been identified and can now be corrected.
Excessive cable lengths not to specifications and faulty nodes can cause errors
in the data from other/all nodes on the network. Do not automatically assume that
a node that is having trouble on the network is the one causing the errors on the
network.
12.12.2. Bus Traffic
The NetMeter can monitor the message traffic on the network and identify the
amount of bandwidth that is being consumed. Networks in GCCS-1 should be
designed with a maximum bandwidth usage of 80% to allow for future changes or
upgrades to the network that may consume additional bandwidth. Note that
bandwidth usage can be a deceptive number.
DeviceNet will always poll the network as fast as it can for the baud rate. On a
network with all standard nodes, the bandwidth will eventually level out and the
polling time will slow significantly. Safe Nodes are a higher priority than standard
nodes and will preempt the communication of standard nodes. This can
potentially slow down communication to the standard nodes.
12.12.3. Bus Power

The NetMeter constantly monitors the quality of the bus power on the DeviceNet
network. It is important to record the minimum and maximum voltage levels as
well as the maximum peak-to-peak voltage. Peak-to-peak transient voltages of
greater than 2V can cause communication faults and network errors;
consequently, they should be investigated.
Transients greater than 10V indicate serious problems that must be investigated
immediately. Some items to check for include cables routed too closely to strong
sources of interference, or possibly a power supply with an unstable output.
12.12.4. Shield Voltage
The NetMeter can measure live, minimum, and maximum voltages between V- and
shield. The DeviceNet specification requires that the shield and V- be connected to
a single location. In GCCS-1, this location is in the MCP.
The following are characteristics of a properly wired network:
a. There is no current flow in the shield, and it is at the same voltage as V-
throughout the system.
b. Current flow in V- causes a voltage rise in V-.
c. Since the maximum voltage drop in V- is 5V, the negative shift in shield
voltage is between -5V and 0V.
d. Systems connected in accordance to the DeviceNet specifications have a
normal shield voltage between -5V and 0V.
e. If the NetMeter indicates an overload (OL) condition, the shield is not
connected. Make sure the shield is connected at the MCP to V- only.
12.13. Common Mode Voltage
Transceivers in the devices subtract the CANH and CANL signals to determine the
value of the signal as either a 1 or a 0. Noise that is induced into the system is
induced into both wires and therefore is cancelled out. The transceivers require that
the CANH and CANL signals be within specifications so that a 0 or a 1 are not
confused with each other, otherwise errors will result.
DC Common Mode voltage caused by excessive voltage drop in the cabling can
cause a voltage offset on the network and result in errors. The Common Mode
voltage causes a shift in the DC values without a corresponding shift in the
differential voltage. This can cause the Recessive (0) voltage to be confused with
the Dominant (1) voltage.
The NetMeter can measure the maximum total Common Mode Voltage since it was
powered on in the network. The DeviceNet recommendation is not to exceed DC
Common Mode Voltage of 5.0V.
Check for devices that may be requiring more power than expected on the network.
At this time, also double check the cabling in the network for proper length.
12.14. CANH/L Differential Voltage (Recessive Data 1)
The NetMeter measures differential CANH and CANL signals and displays the
difference. Data (0 and 1) are transmitted as the difference in voltage between
CANH and CANL. This value is a measure of the quality of the signal. Typically this
value is in the low millivolt range. If the recessive, a data 1, voltage differential is
insufficiently small, it can be misinterpreted as a dominant, or a data 0, and errors
will occur.
Check for shorts or opens in the CANH and CANL wires. Ensure there are only two
terminators on the network and they are positioned at each end of the network.
12.15. CANH/L Differential Voltage (Dominant Data 0)
The measurement of the Dominant voltage levels is important for the same reasons
as shown above in Module 12.14. The typical dominant differential voltage should
be around 2.0 V. If the differential voltage is too small, it can be interpreted as a
recessive voltage and errors will occur.
The NetMeter measures only when a single node is communicating. A measured
dominant voltage of greater than 3.0V when a single node is communicating
indicates a network problem. Check for shorts and opens in the CANH and CANL
wires. Ensure there are only two terminators on the network and they are positioned
at each end of the network.
12.16. Exercise 1: Configure the DeviceNet Scanlist
1. Scan the network for nodes. Verify against the drawing that all nodes are
present.
2. Obtain I/O parameters for devices that do not automatically map (e.g.
Siemens adapter modules).
3. Configure the Scan list.
4. Upload the entire network and save the network.
5. Download to the DNB module.
END OF EXERCISE
12.17. Review
1. What is a DeviceNet network?

2. How do you troubleshoot a DeviceNet network?
3. How is a DeviceNet network configured?
4. How is a DNB scan list created?
GCCS-2
LMS # 33544
Module 13: Multi-Language

Message Extractor
Sponsoring Group:

Standards
Phone:
Document Revisions:
8-26-13 5.0 J. Hocking Updated graphics and procedures.
7-9-15 6.0 J. Hocking
EtherNet I/O


i
Table of Contents
13. Multi-Language Message Extractor ............................................. 13-1
13.1. Module Objectives: ......................................................................................... 13-1
13.2. Message Extractor Overview ......................................................................... 13-2
13.3. Message Extractor Requirements in the PLC Program ............................... 13-2
13.3.1. Message Extractor Requirements for Prompts and Alarms in Logic ....... 13-2
13.3.2. Message Extractor Requirements for Scrollist Text in Logic ................... 13-4
13.3.3. Message Extractor Requirements for Text Lists in Logic ........................ 13-5
13.3.4. Message Extractor Requirements for Multiple Items in a Single Rung
Comment ............................................................................................................ 13-6
13.3.5. Flags for Non-Alarm, Prompt, or Scroll list Rung Comments .................. 13-6
13.3.6. Flags for Extraction Options.................................................................... 13-7
13.3.7. Flags for Language Translation .............................................................. 13-8
13.4. Message Extractor Tag Extraction ................................................................ 13-8
13.4.1. Message Extractor Requirements for Tag Extraction in Logic ................ 13-8
13.4.2. Message Extractor Additional Tags Option ........................................... 13-10
13.5. Using the Message Extractor ....................................................................... 13-11
13.5.1. Additional Message Extractor Features ................................................ 13-11
13.5.2. Exercise 1: Run the Message Extractor on a PLC Program ................. 13-12
13.6. Language Translation ................................................................................... 13-17
13.6.1. Exercise 2: Language Translation ........................................................ 13-17
13.6.2. Language Discrepancies ...................................................................... 13-19
13.6.3. Proper Use of Parameters in the Translation Library ............................ 13-20
13.7. Transferring Messages from the Extractor to the Application.................. 13-20
13.8. Review ........................................................................................................... 13-21

ii
Table of Figures
Figure 1: Typical GCCS-1 Prompt Rungs and Corresponding Rung Comments ...... 13-3
Figure 2: Typical GCCS-1 Scrollist Text Setup and Corresponding Rung Comment 13-4
Figure 3: Typical GCCS-1 Text List (TL) Setup and Corresponding Rung Comment 13-5
Figure 4: Proper use of the Warning Flag in a Rung Comment ................................ 13-6
Figure 5: Example of Rung Comment Flags, SYS then TODO ................................. 13-7
Figure 6 : Example of Extracted Tags Date, Time Not Extracted ........................... 13-9
Figure 7: Sample Additional Tags Information ........................................................ 13-10
Figure 8: Message Extractor HMI & Alarm Setup Tab ............................................ 13-11
Figure 9: Opening the Global Message Extractor ................................................... 13-12
Figure 10: Open the .L5K File ................................................................................. 13-13
Figure 11: Extract Messages .................................................................................. 13-14
Figure 12: Main File Extractor ................................................................................. 13-14
Figure 13: Errors Tab in Message Extractor *.TMP file ........................................... 13-15
Figure 14: Warnings Tab in Message Extractor *.TMP file ..................................... 13-15
Figure 15: Review the HMI & Alarm Setup Tab ...................................................... 13-16
Figure 16: Open the Translation Library File ........................................................... 13-17
Figure 17 Language Translator Options .................................................................. 13-18
Figure 18: Example - Parameterized Alarm in the Library ...................................... 13-20

iii
13. Multi-Language Message Extractor
13.1. Module Objectives:
1. The student will be able to use Message Extractor to extract HMI text.
2. The student will be able to correct errors in ladder logic.
3. The student will be able to create multi-language *.L5K files.
13.2. Message Extractor Overview
Checks an RSLogix *.L5K file, for certain common programming errors relating to
the length and formatting of documentation
Extracts alarm, prompt, scroll list, and text list information for Siemens
WinCCFlexible and Comfort (TIA Portal) HMI displays. Only Siemens HMIs are
used in the global architecture at this time.
Extracts tag information for the Siemens HMI.
Handles language translations in the HMI and also writes the translated
information back into the *.L5K file.
Provides error and warning messages for prompt, scroll list, alarm and text lists.
13.3. Message Extractor Requirements in the PLC Program

13.3.1. Message Extractor Requirements for Prompts and Alarms in
Logic
There are several requirements that must be followed inside the RSLogix application
to ensure all the features of Message Extractor work properly. First, every call to the
Diagnostics Routine using kAlarm and kPrompt must have a properly formatted rung
comment to document the message appropriately.
1
Figure 1: Typical GCCS-1 Prompt Rungs and Corresponding Rung Comments
Note the format of the rung comment:

The Rung Comment begins with <@DIAG> to identify a diagnostic message (1).
The message for extraction begins with < and ends with > (2).
It must have Alarm or Prompt followed by the message number in brackets [ ]
and a colon (:).
Following the colon is the alarm or prompt message the HMI will display (3).
Multiple alarms or prompts can be included in one comment as long as all of the
messages are on the same rung as the instructions.
13.3.2. Message Extractor Requirements for Scrollist Text in Logic
Each action displayed on the Scrollist requires a matching piece of text in the rung
comment that must be properly formatted to document the message appropriately.
Figure 2: Typical GCCS-1 Scrollist Text Setup and Corresponding Rung Comment

The Rung Comment begins with <@DIAG> to identify a diagnostic message (1)
The message for extraction starts with < and ends with >.
It must have SL followed by the message number in brackets [ ] and a colon: (2).
13.3.3. Message Extractor Requirements for Text Lists in Logic
Each Text List (TL) entry that you want created from the PLC program requires a
matching piece of text in a rung comment to document the message appropriately.
Figure 3: Typical GCCS-1 Text List (TL) Setup and Corresponding Rung Comment

The Rung Comment begins with <@DIAG> to identify a diagnostic message.
The message for extraction starts with < and ends with >.
The message must have TL followed by the maximum length of the entry and a
space, then the name of the text list, and finally the entry number in brackets [ ]
and a colon :. See Figure 3 above.
Following the colon is the text list entry that the HMI will display.
13.3.4. Message Extractor Requirements for Multiple Items in a Single
Rung Comment
Messages are displayed in the rung comment immediately above the location that
will call the message in logic, in most cases. There are some situations where the
alarm number might be a variable.
In the near future, when the alarm number is a variable, there will be a rung
comment with many alarms, but a single call that doesnt match the values in the
comment above. The extractor checks each of the extracted messages to make
sure that the values in the comment match the values in the rung calling them. In
these specific situations, additional functionality has been added to the extractor to
suppress the warnings.
The warning flag corrects the condition listed above. Any rung comment surrounded
by the warning flag <@WA=Off> (1) and <@WA=On> (2) will not be processed for
any potential warnings that the Message Extractor might discover. See figure 6.2.3
for an example of proper use of the warning flag.
Figure 4: Proper use of the Warning Flag in a Rung Comment
The prompts listed above will not trigger any warning messages for duplicate prompt
messages, or for not having a properly formatted rung.
13.3.5. Flags for Non-Alarm, Prompt, or Scroll list Rung Comments
Rung comments that contain information outside of alarms, prompts, and scrollist
text can be modified via the extractor with the proper flag. SYS, INFO, USER,
PARAM, and TODO are all flags that are used to inform Message Extractor that the
rung comments are of particular importance, and therefore can be translated or
deleted, as required. The flags are for these different types of rung comments are:
SYS - System Message; Do not delete.

INFO - Information Message; May be deleted.
USER - User Message.
PARAM - Parameter Message.
TODO - To Do Message; Instructions for user.
The SYS flag (1 in Figure 5) is slightly different than the others, in that the Message
Extractor will not allow deletion of those comments.
Figure 5: Example of Rung Comment Flags, SYS then TODO
You can use multiple flags in the same comment one after another if there are
different sections of the rung comment with separate functions. Note that all of
these flags must be above the listing of alarm, prompt, or scroll list messages. This
is to facilitate the translation of those messages for multiple languages.
13.3.6. Flags for Extraction Options
The extraction option flags shown below allow flexibility in how messages are
extracted, diagnosed, and formatted for the HMI.
WA - Warning/Error for RC message (defaulted ON).
PN/PM - Add program name to message (default Alarms:ON, SL:OFF,
Prompt:OFF).
EX - Extract RC message (default ON).
13.3.7. Flags for Language Translation

The final flags used by Message Extractor are actually not used by the user at all
Message Extractor uses the LA and MSGLA flags to indicate what language each
piece of a rung comment is so that it can re-read those messages again later and
place each of the messages in the proper location.
LA - Language Flag (default English en-US).
MSGLA Message Language Flag (default English en-US).
13.4. Message Extractor Tag Extraction

Message Extractor will extract tag information from the PLC for tags that either have the
correct UDT naming format or are requested from the Additional Tags screen. Tags are
exported as .csv files that can be imported into WinCCFlexible. Tags are built up in a
folder structure, where the program name is the first folder, followed by a folder for each
nested UDT until base tag types are reached. Controller-scoped tags are put into a
folder called Controller Tags.
There are exceptions to the rules listed above. The HMI program is always called HMI
instead of HMI1, robot IO is extracted to R01-R24 instead of the robot program name,
etc This allows easy translation from HMI1 to HMI2, and for more pre-programmed
functionality in the WinCCFlexible application.
13.4.1. Message Extractor Requirements for Tag Extraction in Logic

Message Extractor will only extract certain tags to keep the tag database as small
and manageable as possible. It will extract any UDTs that start with uh_* or zh_*.
All tags that are inside of those UDTs will be extracted, including other UDTs, even if
they do not have the proper header.
If a uh_* or zh_* UDT is nested inside of other UDTs, only the tags that are at
the uh_* or zh_* level and below will be extracted, although the full folder path
will still be extracted as described above.
Figure 6 : Example of Extracted Tags Date, Time Not Extracted
13.4.2. Message Extractor Additional Tags Option
If there are tags or UDTs that are not structured properly to be automatically
extracted, there is an Additional Tags sheet in Message Extractor. Type in the tag
or UDT name that needs to be extracted, along with a T or U to indicate if it is a
tag or a UDT. Message Extractor will also extract any tags that have that name or
that UDT name in addition to the tags that are properly formatted.
Figure 7: Sample Additional Tags Information
13.5. Using the Message Extractor
This message extractor is designed for Siemens HMI messages. It will create GM
config files required for the Siemens HMI. For the application to run properly Macro
security must be set to Medium or lower.
13.5.1. Additional Message Extractor Features
The message extractor zip package includes a PDF description of added functions of
the message extractor. Once a L5K file is extracted, a HMI & Alarm Setup tab will be
provided next to the Errors tab. This tab reveals status of the projects Diagnostic
Name, Message Offset, and other items. Cells that are shaded in yellow have
warnings; red shaded cells indicate errors are present. All errors, including Scroll List,
Prompts, Alarms, and Text Lists must be resolved before HMI files can be generated.
This helps prevent erroneous HMI projects from being built.
Figure 8: Message Extractor HMI & Alarm Setup Tab
13.5.2. Exercise 1: Run the Message Extractor on a PLC Program
1. Open ComTask13Exercises and save the logic file in RSlogix as an .L5K
file.
2. Open the GlobalMessageExtractor.xls file.
Figure 9: Opening the Global Message Extractor
3. Click Open RSLogix L5K File. Refer to Figure 10.

4. Select the *.L5K formatted PLC program file that was just saved.
5. Click Open. Refer to Figure 10.
Figure 10: Open the .L5K File
6. If the program is a conveyor, pre-G08 or a paint program check the > 1000
Alarms per Program (paint, pre-G08 Conveyor selection. Refer to Figure
11.
7. To include the HMI name to the output files for the HMI select the Add HMI
Name to the Output file names, these will be imported through WinCC to the
HMI project.
8. Select from the menu list the HMI type for your application. Select TIA
Portal for any TIA Portal application.
9. Click the Extract Msgs button, this process will take 10 to 60 seconds
depending on application size and the computers speed.
Figure 11: Extract Messages
The Main File Extractor will display the total quantity of errors and warnings. While it is
helpful to resolve Warnings, the Errors must be resolved to get output files from the
Message Extractor.
Figure 12: Main File Extractor
10. Correct any errors in the RSLogix 5000 application that are listed on the
Errors tab of message extraction data file. Errors must be corrected in the
logic that save as an .L5K and re-run the message extractor until the project
is error free. You can cross reference for any kprompt or kalarm numbers if
listed. You can search for Alarm/Prompt or Msg/Text entries. Make sure to
copy the text from the Excel formula bar. This can be pasted to the Find
dialog in the logic.
Figure 13: Errors Tab in Message Extractor *.TMP file
Additional hints for locating errors in the logic using the Message Extractor:
Column F indicates the Program, Routine and Rung number of the error location. You
can navigate to the rung directly.
The Scroll List , Prompts, Alarms, and Text Lists tabs list all diagnostics that are in the
project.
These tabs are useful for diagnosing duplicate message numbers and what values are
available to use.
11. Check the Warnings tab and correct any issues in the RSLogix 5000
application.
Figure 14: Warnings Tab in Message Extractor *.TMP file

12. Resolve any errors (red items) displayed on the HMI & Alarm Setup tab.
Figure 15: Review the HMI & Alarm Setup Tab
13. If any changes were made to the RSLogix 5000 file, close everything,
resave the modified RSLogix program as an *.L5K file, and run the extractor
again.
END OF EXERCISE 1
13.6. Language Translation
Not all projects require language translation. The procedure for language translation is
shown in Exercise 2 below.
13.6.1. Exercise 2: Language Translation
1. Open the *.XLS file that is created by the Global MessageExtractor.
2. Select the Main Tab
3. Click Load Language File (Figure 14) and follow the steps below.
4. Select Global Translation Library.xls
5. Click Open from the Open Excel file window.
Figure 16: Open the Translation Library File
Figure 17 Language Translator Options
6. Select the languages for alarms, prompts, scroll list, and rung comments
under Message Languages Selected.
A. The available languages in the drop down boxes are based on the
languages listed in the translation library file. Note that one or more of
the language options might be grayed out indicating that the language
was already set from the information read in the *.L5K file.
B. Any of the messages that have already been translated will not be re-
translated. If the translation is not correct, simply delete the entry from
the translation column and it will be translated again.
7. Select the proper options for the rung comment flags. The three options are
Translate, Leave As Is, and Delete. Note that the system flagged
messages can not be deleted.
8. Select the current language and the desired language to translate the user
defined data types.
A. Unlike the rung comments which show all of the translated languages, the
user defined data types replace the current language with the newly
selected language. This is due to the limited length of tag comments.
9. When all of the options needed for translation have been set, click
Translate Languages.
Once the translations are completed, check each tab and verify that all
messages have been translated and the translation is correct.
END OF EXERCISE 2
13.6.2. Language Discrepancies
1. If there are any messages that were not translated, there are three different
ways to continue. They are listed below in order of complexity.
o Translate the message manually in the appropriate column. The
translation will be saved for this PLC program only and will be lost if it is
not written back to the *.L5K file (see below). This method is best used if
there is a unique message that is unlikely to occur again anywhere else.
o Add the translation into the Translation Library.xls file under the
appropriate User section. Updating the translation library will require re-
running MessageExtractor.xls from the beginning (unless you also did the
1st option listed above.) However, placing it here will ensure that the
translation will be used for all messages. Use this option if there is a
message that will need translation often, or if you have many similar
messages that can be translated via parameters.
o If a message translation is incorrect or does not exist, and you believe that
it is a common message that would apply to all GM applications, submit
the message along with its translation to the GM engineer responsible.
The messages will be added to the common messages in the next release
of the translation library. Since this procedure can take some time, use
one of the above methods for your project in the interim.
2. Once all messages are translated to your satisfaction, go back to the Main
tab and click on the Create Multi-Language L5K file. This will create a
*_new.L5K file that can be imported using RSLogix 5000. This ensures all
the translations will be stored for later reprocessing, if necessary. It also
ensures the translated information will have the ability to be read inside of
the RSLogix 5000 program.
13.6.3. Proper Use of Parameters in the Translation Library
Parameters can be set for all messages except Comments and UDTs. These
parameters should have a recognizable name and be enclosed in braces {}. A
parameter will replace any one word or number, determined by the next space
encountered. Parameters properly set allow the translation of one message added
to the user section to translate multiple similar messages.
GATE {GATE} I/O MODULE {MODULE} INPUT FLTD /*R*/ INPUT/PULSE TEST
INPUTS {INPUTS} TEST-SEE HELP
Figure 18: Example - Parameterized Alarm in the Library
In the alarm shown in Figure 18, {GATE} represents a Gate # from 1 to 6,

{MODULE} represents module 1 or 2, and {INPUTS} represents the inputs that the
fault is occurring on. Using the parameters saves the local plant from translating the
same alarm repeatedly when there are only slight differences that do not affect the
translated text.
13.7. Transferring Messages from the Extractor to the

Application
The final step for the Message Extractor is to click on the Export all Siemens
Files button. This will create two files that will need to be loaded to the TIA
Portal application.
One file is used to import tags into TIA Portal. It will be named HMI1_Tags.xlsx*.
The Second File is used to import the text lists in the project
HMI1_AllTextLists.xlsx*
* HMI1 file import files represent HMI1, actual number will reflect the HMI number
chosen.
Importing these files into their appropriate programs will be covered in the next
module.
13.8. Review
1. How is message extractor used to extract HMI text?

2. How is text corrected in ladder logic?
3. How are multi-language *.L5K files created?
GCCS-2
LMS # 33544
Module 14: TIA Portal and Siemens

HMI Panels
Sponsoring Group:

Document Revisions:

Synchronized graphics and content with TIA
8-26-13 5.0 J. Hocking
Portal.
7-9-15 6.0 J. Hocking
EtherNet I/O
U.S., International, and Universal Copyright Conventions. Published in the United States
of America. These materials may be used only with related printed materials.
In no event will the General Motors Company be responsible or liable for incidental
or consequential damages resulting from the use or application of the materials in
this manual.

i
Table of Contents
14. TIA Portal and Siemens HMI Panels............................................. 14-1
14.1. Objectives: ....................................................................................................... 14-1
14.2. TIA Portal Initial Installation ........................................................................... 14-2
14.3. GM HMI Application for the Workstation ....................................................... 14-2
14.3.1. Exercise 1: Creating a GM HMI Application on the PC Workstation........ 14-2
14.4. Siemens HMI Panel Initial Terminal Setup .................................................... 14-6
14.5. Creation of a *.CSV File ................................................................................. 14-23
14.5.1. Exercise 2: Creation of a .CSV file ........................................................ 14-23
14.6. Importing Tags and Text Lists into TIA Portal ............................................ 14-24
14.6.1. Exercise 3: Importing Tags and Text Lists............................................. 14-24
14.6.2. Exercise 4: Transfer the Application to the HMI .................................... 14-29
14.7. HMI User Additions ....................................................................................... 14-34
14.7.1. How to Create Tags .............................................................................. 14-34
14.8. Tag Properties ............................................................................................... 14-36
14.8.1. General.................................................................................................. 14-36
14.8.2. Settings ................................................................................................. 14-36
14.8.3. Range .................................................................................................... 14-37
14.8.4. Linear Scaling........................................................................................ 14-37
14.8.5. Values ................................................................................................... 14-38
14.8.6. Comment ............................................................................................... 14-38
14.8.7. Multiplexing ........................................................................................... 14-39
14.8.8. Good Manufacturing Practices .............................................................. 14-39
14.9. How to Create and Fill Screens .................................................................... 14-40
14.9.1. HMI Screen Creation ............................................................................. 14-40
14.9.2. Screen Objects ...................................................................................... 14-41
14.10. Object Properties......................................................................................... 14-43
14.10.1. Object Appearance .............................................................................. 14-44
14.10.2. Object Visibility .................................................................................... 14-45
14.10.3. Object Movement ................................................................................ 14-46
14.11. System Functions ........................................................................................ 14-47
14.12. TIA Portal and GM Screen Applications .................................................... 14-49
14.12.1. Finishing the Application...................................................................... 14-49
14.12.2. Style Screen Configuration .................................................................. 14-50
14.12.3. Cell Overview Screen Configuration .................................................... 14-50
14.12.4. Custom Screen Configuration ............................................................. 14-56
14.12.5. Review................................................................................................. 14-57

ii
Table of Figures
Figure 1: Extract All Files from MP370 MultiPanel.zip ................................................. 14-2
Figure 2: Selecting a File Destination and Making New File Folders ........................... 14-3
Figure 3: Extraction Wizard .......................................................................................... 14-4
Figure 4: Correct File Directory Appearance ................................................................ 14-4
Figure 5: HMI Panel Transfer Mode ............................................................................. 14-6
Figure 6: HMI Panel Loader Window ............................................................................ 14-6
Figure 7: HMI Panel Transfer Icon................................................................................ 14-7
Figure 8: HMI Panel Transfer Settings Setup ............................................................... 14-7
Figure 9: HMI Panel IP Address, Subnet Mask and Gateway Setup ............................ 14-8
Figure 10: Network Configuration Window ................................................................... 14-8
Figure 11: Reboot the Siemens HMI Panel from OP Properties Tab............................ 14-9
Figure 12: The TIA Portal Start Page ......................................................................... 14-10
Figure 13: TIA Portal Project Setup ............................................................................ 14-11
Figure 14: TIA Portal Transfer Setup .......................................................................... 14-12
Figure 15: TIA Portal Transfer Setup Example ........................................................... 14-13
Figure 16: TIA Portal Open the Update Operating System ......................................... 14-14
Figure 17: TIA Portal HMI Panel OS Update .............................................................. 14-15
Figure 18: HMI Panel Transfer Mode ......................................................................... 14-15
Figure 19: Loader Window.......................................................................................... 14-16
Figure 20: HMI Panel Control Panel Open Volume and Sounds ............................. 14-16
Figure 21: HMI Panel Volume and Sounds ................................................................ 14-17
Figure 22: HMI Panel Control Panel Open OP ........................................................ 14-17
Figure 23: HMI Panel Touchscreen Calibration .......................................................... 14-18
Figure 24: HMI Panel Control Panel Open Regional Settings ................................. 14-18
Figure 25: HMI Panel Control Panel Regional Settings Properties .......................... 14-19
Figure 26: HMI Panel Control Panel Open Input Panel ........................................... 14-19
Figure 27: HMI Panel Resizing the HMI Input Panel .................................................. 14-19
Figure 28: HMI Panel Resizing the HMI Keyboard ..................................................... 14-20
Figure 29: HMI Panel Resizing the HMI Input Panel .................................................. 14-21
Figure 30: HMI Panel Close the Control Panel Window ............................................. 14-21
Figure 31: HMI Panel Loader Window Transfer Button .............................................. 14-22
Figure 32: Export all Siemens Files in Message Extractor ......................................... 14-23
Figure 33: Importing Tags Open the Import Dialog................................................. 14-24
Figure 34: Importing Tags Open Import File ........................................................... 14-25
Figure 35: Importing Tags Start Import ................................................................... 14-25
Figure 36: Importing Text Lists Open the Import Dialog ......................................... 14-26
Figure 37: Importing Text Lists Start Import............................................................ 14-26
Figure 38: Set the Project HMI IP Address Access the IP Protocol ........................ 14-27
Figure 39: Setting the HMI Project IP Address .......................................................... 14-27
Figure 40: Set the PLC IP Address............................................................................ 14-28
Figure 41: Set the Area Pointer if Required ............................................................... 14-28

iii
Figure 42: Downloading Computer Control Panel Display Setting ............................ 14-29
Figure 43: Compile the Application Rebuild All ....................................................... 14-30
Figure 44: Open the Operating System Update (ProSave) ....................................... 14-31
Figure 45: OS Update................................................................................................ 14-31
Figure 46: Downloading the HMI Program ................................................................ 14-32
Figure 47: Load Preview............................................................................................ 14-33
Figure 48: Extended Download to Device ................................................................. 14-33
Figure 49: HMI Tag Creation ...................................................................................... 14-35
Figure 50: Tag Addressing ......................................................................................... 14-36
Figure 51: Settings ..................................................................................................... 14-36
Figure 52: Range ........................................................................................................ 14-37
Figure 53: Linear Scaling............................................................................................ 14-37
Figure 54: Values ...................................................................................................... 14-38
Figure 55: Tag Comment............................................................................................ 14-38
Figure 56: Tag Multiplexing ........................................................................................ 14-39
Figure 57: Good Manufacturing Practices .................................................................. 14-39
Figure 58: Creating a New Screen ............................................................................. 14-40
Figure 59: Simple TIA Portal Objects ......................................................................... 14-42
Figure 60: Object Miscellaneous ................................................................................ 14-43
Figure 61: Object Appearance .................................................................................... 14-44
Figure 62: Add Visibility Animation ............................................................................ 14-45
Figure 63: Object Movement ...................................................................................... 14-46
Figure 64: Events and System Functions ................................................................... 14-47
Figure 65: Style Screen Setup .................................................................................... 14-50
Figure 66: Cell Overview Screen ................................................................................ 14-51
Figure 67 Rotating a Robot PB - Indicator .................................................................. 14-52
Figure 68: 9999 - Cell Overview Graphics Gates/Guards........................................ 14-52
Figure 69: 9999 - Cell Overview Graphics Panels ................................................... 14-53
Figure 70: 9999 - Cell Overview Graphics Robots................................................... 14-53
Figure 71: 9999 Cell Power & I/O Graphics............................................................. 14-54
Figure 72: Tool Overview Screen ............................................................................... 14-55
Figure 73: 9999 - Station Overview Graphics ............................................................. 14-55

iv
14. TIA Portal and Siemens HMI Panels
Totally Integrated Automation (TIA) Portal and Siemens HMI Panels
14.1. Objectives:
1. The student will be able to configure a GM core HMI application to suit a project
using TIA Portal software.
2. The student will be able import project diagnostic messages from logic into an
HMI project.
3. The student will be able to transfer an application to the Siemens HMI.
14.2. TIA Portal Initial Installation
TIA Portal is the programming software used to develop, configure, and transfer
applications from a workstation to the Siemens Multi-Panel HMIs. For information on
installing TIA Portal, refer to the Socrates or GM Supply Power websites and look under
the GCCS-1a heading.
14.3. GM HMI Application for the Workstation

The GM implementation of the HMI requires additional files to operate correctly.
Following the steps below will create the proper directories and place the proper files in
them.
14.3.1. Exercise 1: Creating a GM HMI Application on the PC

Workstation
All HMI applications require the following steps to begin creating an application
specific to project desired.
1. Right-click on the v11 TP1200 Core App v1.291PFE.zip file. See Figure 1.
2. Select Extract All.
Figure 1: Extract All Files from MP370 MultiPanel.zip
3. Browse for a file destination. Select E:\GCCS2\Exercises\. Create a new

folder.
4. Click Make New Folder and label it HMI (Figure 2).
5. Select the HMI folder and create new folder labeled TP010HMI1.
Figure 2: Selecting a File Destination and Making New File Folders
6. Click Next on the Extraction Wizard (Figure 3).
Figure 3: Extraction Wizard

7. Click Finish on the Extraction Wizard (not shown). The file directory should
appear as shown in Figure 4.
Figure 4: Correct File Directory Appearance

When creating the project, use the application name for the .ap11 file and the folder
containing the .ap11 file. For example, AA110B1HMI1.ap11 and AA110B1HMI1 folder
name. Subfolder names are controlled by TIA Portal.
8. Rename the folder and the .ap11 file to TP010B1HMI1
9. Double-click TP010B1HMI1.ap11 to open the application.
10. Close the application; verify that file and folder name remained.
END OF EXERCISE 1
14.4. Siemens HMI Panel Initial Terminal Setup
The procedure for setting up a new Siemens Multi-panel terminal is outlined in the
following pages.
1. Power up the HMI panel.
2. Click on Cancel in the Transfer mode.
Figure 5: HMI Panel Transfer Mode

3. Click on Control Panel.
Figure 6: HMI Panel Loader Window
4. Double-click Transfer.
Figure 7: HMI Panel Transfer Icon
5. Select PN/IE (PROFINET / Industrial Ethernet).

6. Check Enable Transfer and Remote Control boxes.
7. Click Properties.
Figure 8: HMI Panel Transfer Settings Setup
8. Click Specify an IP address.
9. Input the proper IP Address, Subnet Mask, and Gateway.
10. Click OK.
Figure 9: HMI Panel IP Address, Subnet Mask and Gateway Setup
11. Click OK to close the Transfer Settings window.
Figure 10: Network Configuration Window
12. Toggle power to the WinCC unit by clicking OP on the OP Properties tab, then
the Device tab, then Reboot, or by disconnecting and reconnecting the power
source.
Figure 11: Reboot the Siemens HMI Panel from OP Properties Tab
Open TIA Portal on a laptop.
13. Click Open an Existing Project.
Figure 12: The TIA Portal Start Page
14. Browse for the .HMI file to be loaded to the HMI panel.
Figure 13: TIA Portal Project Setup
15. Right Click the Device_1 folder.
16. Click Properties.
Figure 14: TIA Portal Transfer Setup
17. Under PROFINET Interface (X1) click Ethernet addresses.
18. Input the HMI panel IP Address, Mask and Gateway (Router Address).
19. Click OK.
Figure 15: TIA Portal Transfer Setup Example
20. Right click the Device_1 HMI folder.
21. Click HMI Device Maintenance.
22. Click Update Operating System.
Figure 16: TIA Portal Open the Update Operating System
23. Click Update OS.
24. Click Yes.
Figure 17: TIA Portal HMI Panel OS Update
Update OS should take about 5-10 minutes. The HMI Panel will reboot itself when it
is finished.
Note: This needs to be performed only for a new HMI unit. Once a unit has
been updated, it will not need another update unless the WinCCFlexible
version changes.
25. Click Cancel in the Transfer mode window on the HMI panel.
Figure 18: HMI Panel Transfer Mode
26. Click Control Panel.
Figure 19: Loader Window
27. On the HMI Control Panel, double-click Volume & Sounds. Note: Volume &
Sounds is not available on portable HMI.
Figure 20: HMI Panel Control Panel Open Volume and Sounds
28. Uncheck Screen Taps
29. Click OK on the Volume & Sounds Properties window.
Figure 21: HMI Panel Volume and Sounds
30. Double-click OP.
Figure 22: HMI Panel Control Panel Open OP
31. Click Touch.

32. Click Recalibrate.
33. Click on the crosshairs as required (they move to each corner of the screen) and
double click on the screen to save settings.
34. Click OK on the OP Properties Tab.
Figure 23: HMI Panel Touchscreen Calibration
35. Double click Regional Settings on the HMI control panel.
Figure 24: HMI Panel Control Panel Open Regional Settings
36. Change Regional Settings to the appropriate region.
37. Click OK on the Regional Settings window.
Figure 25: HMI Panel Control Panel Regional Settings Properties
38. Double-click Input Panel.
Figure 26: HMI Panel Control Panel Open Input Panel
39. Select Show Resize Button. Click Open Input Panel.
Figure 27: HMI Panel Resizing the HMI Input Panel
40. Press and hold the double arrows next to the Close button.
41. Resize the HMI keyboard to the width of the screen, with an appropriate height.
Figure 28: HMI Panel Resizing the HMI Keyboard
42. Click Save on the Input Panel window.
43. Deselect Show Resize Button.
44. Click Close Input Panel.
45. Click OK on the Input Panel window.
Figure 29: HMI Panel Resizing the HMI Input Panel
46. Reset the IP Address if it was deleted or changed during the OS Update process.
If so, repeat Steps 4-12 outlined earlier.
47. Close the Control Panel window.
Figure 30: HMI Panel Close the Control Panel Window
48. Click Transfer on the Loader window.
Figure 31: HMI Panel Loader Window Transfer Button
The HMI panel is now fully configured and ready for the application to be
downloaded.
14.5. Creation of a *.CSV File
Use Message Extractor as described in Module 14 to extract the messages from the
Logix 5000 .L5k file. Do not use the language translator for this exercise. Use the
procedure in Exercise 2 to create a *.CSV file.
14.5.1. Exercise 2: Creation of a .CSV file
Select the Export all Siemens Files button (Figure 32).
1. Open Core08Exercises.acd
2. Save a *.L5K
3. Run the Message Extractor, do not use the Language Translator, see
Module 13 for directions.
Figure 32: Export all Siemens Files in Message Extractor
END OF EXERCISE 2
14.6. Importing Tags and Text Lists into TIA Portal
Message Extractor creates tags and text lists from the PLC program for use in the HMI
application. Follow the instructions in the Message Extractor; refer to Module 14, to
create the tag and text list import files from the PLC program.
14.6.1. Exercise 3: Importing Tags and Text Lists
Open the TP010B1HMI1 TIA Portal project created in Exercise 1.
14.6.1.1. Importing Tags
1. Expand the Device
2. Expand HMI tags
3. Double Click Show all tags
4. Click Import
Figure 33: Importing Tags Open the Import Dialog

5. Browse to select the tag file created by message extractor (ApplicationName-
HMIx_Tags.xlsx) Core08Exercises-HMI1_Tags.xlsx is the actual file name.
6. Click Open.
Figure 34: Importing Tags Open Import File
7. Click Import
Figure 35: Importing Tags Start Import

14.6.1.2. Importing Text Lists
2. Double click Text and Graphic Lists
3. Select Import.
Figure 36: Importing Text Lists Open the Import Dialog
4. Select the text list file created by message extractor (ApplicationName-
HMIx_AllTextLists.xlsx)
5. Select Import.
Figure 37: Importing Text Lists Start Import

14.6.1.3. Set the Project HMI Address
2. Double click Device configuration
3. Select PROFINET_Interface_1
Figure 38: Set the Project HMI IP Address Access the IP Protocol
4. The Properties should be displayed.
5. Use IP protocol should be selected.
6. Use IP router should be selected.
7. Set IP address in the project should be selected.
8. Enter the IP address, subnet mask, and IP router (gateway address) for the HMI
project.
Figure 39: Setting the HMI Project IP Address

IMPORTANT: If the Set IP address using a different method is NOT selected, the IP
address settings in the HMI will be overwritten on download. If any IP address setting is
not known, set the IP address, then select the Set IP address using a different method
option. Once all settings are known and correct, deselect the Set IP address using a
different method option.
14.6.1.4. Set the PLC IP Address
The HMI project must contain the IP address of the PLC that communicates with the
HMI.
1. Double click Connections, the PLC connection will be displayed.
2. ETHERNET Interface should be selected.
3. Set the PLC IP address.
4. If the PLC is not in slot 0, update the Communication path with 1, [Slot number of
PLC]
Figure 40: Set the PLC IP Address

14.6.1.5. Set the Area Pointer Addresses
This step can be skipped with HMI cores version 1.283 or newer. The HMI core
used in class does not require setting the Area Pointer. The Area pointer
configuration is no longer used for control. If the Area pointer properties are blank,
skip this step.
If addresses appear as shown below, update the HMIx program name to match the
HMI in the PLC application (HMI1, HMI2, HMI3). Any fields that do not have
addresses can be left alone.
Figure 41: Set the Area Pointer if Required

Note: This exercise project provided should not require the Area Pointer Address
settings.
END OF EXERCISE 3
14.6.2. Exercise 4: Transfer the Application to the HMI
14.6.2.1. The Downloading Computer Settings
Before you begin the transfer process it is critical to set the downloading computers
default display size to 100%.
The HMI font size downloaded to the HMI will change based on the downloading
computers Display setting (see picture). To insure consistent HMI font sizes, all
computers used to download HMIs must have 100% as their active setting prior to
download.
To insure a proper download, close all TIA Portal windows. Click on the Start button,
Control Panel, then open the Display property window shown below, and select
100%. After that setting is correct, open the HMI project file, do a full compile, then
download.
Figure 42: Downloading Computer Control Panel Display Setting

14.6.2.2. Open the Aplication
1. Open TP010B1HMI1 in TIA Portal
2. [Optional step replaces step 1] Extract and rename ComTask15Exercise4
(Original trainer file)
3. Set the PLC and HMI Project IP Address info as explained in Exercise 3.
14.6.2.3. Compile the Application
The application must be error free before it can be downloaded. To check for errors
and prepare for download, compile the application. Check the computers Control
Panel - Display setting prior to downloading any application.
1. Right click on the Device
2. Select Compile
3. Select Software (rebuild all) in the pull down menu.
Figure 43: Compile the Application Rebuild All

Any errors in the application will be highlighted at the bottom of the window.
Resolve all errors. Repeat this step until the application compiles without errors.
14.6.2.4. Load Firmware (Update Operating System)
Do Not Update Firmware in Class; it should be up to date.
TIA Portal loads the required firmware as part of the application download. A
minimum version is all that is required.
The Loader screen shows the firmware version of the HMI. If the firmware displayed
on the loader screen is equal to or greater than the firmware on the project
Blockpoint, skip this step. Load firmware only if the existing firmware is older than
that Blockpoint minimum, or if an error occurs in the download process.
To load firmware to the panel,
1. Open the Online menu.
2. Select HMI device maintenance
3. Select Update operating system
Figure 44: Open the Operating System Update (ProSave)
The Prosave application will launch. To test your computer and the connection
to the HMI, click on the Device status(1) button. If an error message is returned,
correct the problem. If a message that indicates that the HMI is ready for update,
click on Update OS(2) button to load the firmware.
Figure 45: OS Update
14.6.2.5. Download the HMI
Check the computers Control Panel Display setting prior to downloading the HMI.
The computer must be set to the default 100% prior to compiling / downloading.
Download the program to the HMI:
1. Right click on the Device,
2. Select Download to device
3. Select Software (all).
Figure 46: Downloading the HMI Program

The Load preview window will open. If the application requires compiling, the
compiling status will be displayed. Once the Overwrite all option is shown,
check the box and click on the Load button.
Figure 47: Load Preview
The Extended download to device window will display. Select PN/IE for the
Type of the PG/PC interface. Note: If PN/IE does not connect, select Ethernet.
Select your computers network adapter for the PG/PC interface. The software
will attempt to connect to the HMI. If a communication error is displayed, correct
the source of the error and try again. Once communication is established, click
on Load.
Figure 48: Extended Download to Device

END OF EXERCISE 4
14.7. HMI User Additions
14.7.1. How to Create Tags
Many tags are already created in the core application, and many more are created
through the Message Extractor and imported into the HMI application. Still, there
may be more data that needs to be retrieved from the PLC, or potentially needs an
internal tag for HMI use only.
14.7.1.1. HMI Tag Creation

1. Start the TIA Portal application.
2. Open your custom application file.
3. Expand the Device_1.
4. Double click to expand the HMI tags folder..
5. Double click the Show all tags or double click any folder desired.
6. In displayed tag collections double click the <Add new>
7. A copy of the previous tag will display the name will contain a _1 after the
tag name.
8. Rename the tag to the desired name.
9. Set the Data type to the appropriate data type and set the number of
elements in the array (set it to 1 if the tag is a stand alone tag.) Note that
Acquisition mode and Acquisition cycle will be grayed out and unavailable for
internal tags these values are not needed.
10. If this is an internal tag that only the HMI program is using set Connection to
<Internal tag>.
Figure 49: HMI Tag Creation
If you are creating a PLC tag, you will need to set Connection to Connection_1. Then
select the data type from the drop down list. Next, set the Address of the tag. This
should be in the following format: <PLC Program Name>:<UDT Tag Name>.<UDT Tag
Name>.<Base Data Type tag Name>. An example of this would be
HMI1:ScnCom.O.Alarm. Next, enter the array length (if it is an individual tag enter 1).
Finally, ensure the Acquisition mode is Cyclic on Use and the Acquisition cycle is set to
500 ms for all tags but strings, which should be set to 1 second.
14.8. Tag Properties
14.8.1. General
Figure 50: Tag Addressing

The General section for tags allows you to configure the address, connection and
Data type of a tag.
14.8.2. Settings
Figure 51: Settings

Acquisition mode settings are possible from Settings section.
14.8.3. Range
Figure 52: Range

The Range section allows you to set minimum and maximum limits for tags, and to
create alarms and warnings for those values. Note that the alarms and warnings are
for the Siemens alarm system, which GM is not currently utilizing. Limits can be set
to either a constant value, or to the value of another tag. Limits cannot be set on an
array of tags.
14.8.4. Linear Scaling
Figure 53: Linear Scaling

The Linear Scaling section, when enabled, allows you to set the scale factor for PLC
values. Using this you can convert a tag that represents seconds in the PLC to
represent minutes inside of the HMI application.
14.8.5. Values
Figure 54: Values

The Values section allows you to set up the Start Value for a numeric tag, which will
be displayed until overwritten by the PLC or user entry. The Update ID entry allows
you to trigger a tag update for a tag if it is configured to be updated on demand. If it is
configured, the Event Update Tag must be used with the specific Update ID to force
the tag to update. Note that there are only 100 Update IDs allowed and each tag
must have a unique Update ID, which makes this functionality of limited usefulness.
Note: The Update ID entry cannot be used at this time due to an issue in TIA Portal,
which cannot properly manage the number of directories we use.
14.8.6. Comment
Figure 55: Tag Comment

The Comment section allows you to provide a description of the tag.
14.8.7. Multiplexing
Figure 56: Tag Multiplexing

The Multiplexing section, when enabled, allows one internal tag to point to any of
several different tags based off of another tag that acts as an Index. Note that the
index values cannot be adjusted at all; it counts purely from 0 to x 1, where x is the
number of elements added to the list. The index numbers also cannot be reordered.
In order to change indexes of the tags, you must delete them and recreate them in
the correct order. Finally, no events can be triggered based off of multiplexed tags.
All of these constraints make multiplexing only of limited usefulness.
14.8.8. Good Manufacturing Practices
Figure 57: Good Manufacturing Practices

The Good Manufacturing Practices section allows settings for GMP.
14.9. How to Create and Fill Screens
14.9.1. HMI Screen Creation
Figure 58: Creating a New Screen

1. Double click on Add Screen under the Screens folder. It will create a screen
called Screen_1. You will need to rename the screen to xxx <Screen Name>,
where xxx is the screen number. This number should then be set in the Number
field. It must be a unique number. This allows the PLC to know what screen you
are on.
2. The Use template box should always be checked.
3. The Background color should be set to black.
Note that you are not able to create pop-up screens that would show on top of other
screens. If you want to do this, create the pop-up screen on the screen that would
normally call it and put it on a different layer (see layers under the Screen Objects
section below.) Then only show the items that would be on the pop-up screen based
on a specific internal tag name. This tag name should be set so that when the
specific button is pressed, that specific screen is called up.
Note that several screens are developed and available for you to add custom screen
information. These include 030 Servo_VFD, 040 Barcode, 100-105 Spare 0-5,
200 Cell Overview, and 201-230 Tool Overview Station 1-30. These screens
have been created, but left blank for you to develop for your custom application. Any
additional screens will have to have a method to launch the screens. The most
common way to implement this is to have a button that will launch a screen this will
be covered under Screen Objects that follows.
14.9.2. Screen Objects

Several screen objects will be discussed in this section, describing how the objects
are used and how to configure them.
The TIA Portal application uses the following standard drawing objects used to
create shapes:
Lines
Polylines
Polygons
Ellipses
Circles
Rectangles
TextFields display static text on the screen. Refer to Figure 59. IO Fields display tag
values either internal tags or PLC tags. IO Fields will display either string or
integer based tag values. Graphic IO Fields will display a graphic or an item from a
graphic list based on the value of a tag (see Text and Graphic Lists below for more
information.) Similarly Symbolic IO Fields will display static text or a static test list
based on the value of a tag (again see Text and Graphic Lists below for more
information.) Finally, Buttons will allow you to trigger events based on a click, press,
or release of the button.
Figure 59: Simple TIA Portal Objects
14.10. Object Properties
For all objects there are a few common properties that are the same. To set the name
of an object click on the object, then on the Properties tab in the Properties header,
click on the Misc section. Here you can change the object name and set what layer the
object should be on. By default the layer is 0. Most objects should be on this layer.
Invisible buttons have been assigned layer 1 and tags that are on the screen only to
trigger scripts (more on this later) have been assigned layer 31. If you have several
objects overlapping one another on the screen it is recommended that you assign layer
numbers to the groups of objects that are overlapping so that you can easily turn the
layers on and off via the screen Properties header Layers section. This will make it
easier to modify the objects later if need be.
Figure 60: Object Miscellaneous

The Appearance section changes slightly from object to object, but it is largely
used to set the foreground and background colors of objects as well as to set
borders and border colors.
The Layout section also changes slightly from object to object. It allows the user
to change the location of the object on the screen and the width and height of the
object by manually typing in the x and y co-ordinates and the height and width
instead of moving and stretching the object on the screen.
The Flashing section allows you to set whether you would like the object to flash
on screen continuously or not.
The Animations header has many different sections that change from object to
object, but there are several that are common for most if not all objects. The
most commonly used ones will be discussed below.
14.10.1. Object Appearance
Figure 61: Object Appearance

The Appearance section, when enabled, allows you to change the foreground color,
the background color, and if the object is flashing or not based on the value of a tag.
The tag value can be read as an integer, as a range of bits, or as a single bit.
Double click on an empty row in the table on the right to add a value and set the
properties. You can enter a range for integer values, but not for binary values.
14.10.2. Object Visibility
Figure 62: Add Visibility Animation
The Visibility section, when enabled, allows you to display or hide the object based
off of the value of a tag. Note: The Enable object section, which is only available for
objects that allow input such as I/O fields and buttons, is set up exactly like the
visibility section. The only difference is that instead of hiding or showing the object,
the object is instead enabled or disabled for value entry.
14.10.3. Object Movement
Figure 63: Object Movement
The Movement sections all do roughly the same thing, just in different orientations.
When they are enabled, they allow a tag to shift the starting x and/or y position. The
range that is set up will be scaled based on the starting and ending positions to
determine the actual location of the object. Direct Movement is slightly different in
that it will allow different values for the x and y positions on a single animation, but
they are not scaled the value of the tag will determine how far the object is shifted
with no scaling.
14.11. System Functions
The Events header is available for tags, screens, and for objects that display data
based on tag values, such as IO Fields and Symbolic IO Fields. There are over 140
System functions that can be triggered. User written scripts can be launched, as well
(scripts will be covered below.)
Figure 64: Events and System Functions

Click <Add function> and use pull down menu to select event desired. Also available for
Deactivate and Input field.
Most objects can only launch events based on object Activate, Deactivate, or Change.
Buttons have the ability to launch events based on Click, Press, and Release events as
well. Screens and tags each have their own events available to them. Screens trigger
events when the page is Loaded or Cleared. Tags trigger events based on Change
Value, High Limit, and Low Limit.
Three of the more common System functions will be described in the next sections,
including:
Calculation Functions
Edit bits Functions
Screens Functions
If you need more information, or want information on a System function not covered in
this document, hold the mouse cursor over the System function key inside of TIA Portal
for a few seconds and a description of the function will be displayed.
14.12. TIA Portal and GM Screen Applications
14.12.1. Finishing the Application
There are several standard screens that will require modification for your specific
application, including the:
Style Screen
Cell Overview Screen
Tool Overview Screens (any that are necessary for your application)
If any extra screens are needed, the Spare 0 through Spare 5 Screens are available
for modification and use.
14.12.2. Style Screen Configuration
1. Open the Style Screen, named 050 Style. Do this by using the Project
Tab, and navigating through Device_1->Screens->050 Style. Double-click
on 050 Style to open the screen.
2. Navigate to the Screen Properties.
3. Turn off Layer 1 (see Figure 65). This will hide the invisible buttons over the
Style, Option, and Build Status sections and allow you to modify the objects
beneath the buttons.
4. Click on 0: No Style and modify the text in the Properties tab in the General
category. Do the same for each Style, Option, and Build Status test field.
Figure 65: Style Screen Setup
5. Click on an empty section of the screen to bring up the screen properties

again and re-enable Layer 1.
14.12.3. Cell Overview Screen Configuration
1. Open 200 Cell Overview from the Project tab.
2. Also open all of the 9999 Cell Overview Graphics screens. Refer to Figure
66 Copy any objects that you require for the Cell Overview Screen, following
the instructions listed on the 9999 screens. This will allow you to properly
place the objects and configure them. Be sure to acquire all of the
associated items for each object. Note that each robot has two images.
This is because images in TIA Portal can be rotated in 90 degree increments
only. Select the image that can be best rotated for your application. To
rotate the image, click on the screen background, go to the Properties tab,
and turn Layer 1 off. This will hide the button that opens the robot screen.
You can then select the Robot##Body_grp object and rotate it. Turn layer 1
back on once you have rotated the object, otherwise the button will not be
copied and the object will not work properly. See Figure 67.
Figure 66: Cell Overview Screen
Layer 1 is OFF Layer 1 is ON
Rotate robot icon
only.
Figure 67 Rotating a Robot PB - Indicator
Figure 68: 9999 - Cell Overview Graphics Gates/Guards
Figure 69: 9999 - Cell Overview Graphics Panels
Figure 70: 9999 - Cell Overview Graphics Robots
Figure 71: 9999 Cell Power & I/O Graphics
Next open each of the 2xx Tool Overview Station xx Screens that you will need
for your application, and the 9999 Station Overview Graphics screens. Refer to
Figure 72 and Figure 73.
Follow the same procedure to create the Station Overview screens as you used for
the Cell Overview screen. Be sure to use the Station Overview Graphics screens
instead of the Cell Overview Graphics.
Figure 72: Tool Overview Screen
Figure 73: 9999 - Station Overview Graphics
14.12.4. Custom Screen Configuration
To build any custom screens that your application may require, use the 10x Spare
x screens first as these screens can be enabled through the PLC. If more screens
are required, you will need to trigger the screen launch yourself, either in the HMI, or
through modification of the PLC program.
14.12.5. Review
1. How do you configure a GM core HMI application using TIA Portal?

2. How do you import project diagnostic messages from logic into a GM HMI
project?
3. How is an application transferred to the Siemens HMI?
GCCS-2
LMS # 33544
Module 15: HMI Multi-Language

Functionality
Sponsoring Group:

ME Engineering Group: GM Vehicle Systems-Automation Control
Document Revisions:
8-26-13 5.0 J. Hocking Updated graphics and procedures
7-9-15 6.0 J. Hocking
EtherNet I/O
Copyright 2008, Macomb Community College

ii

i
Table of Contents
15. HMI Multi-Language Functionality ...................................... 15-1
15.1. Module Objectives: ............................................................................... 15-1
15.2. Configuring the HMI Application for Multi-Language ........................ 15-2
15.2.1. Selection of Languages to be Included in the TIA Portal Project .. 15-2
15.2.2. Selection of Languages to be Included in Runtime ....................... 15-4
15.2.3. Selection of Flags for Each Language .......................................... 15-6
15.2.4. Unicocde Echo Language ............................................................. 15-7
15.2.5. Translation of HMI Text............................................................... 15-13
15.2.6. Final Review of the Translation ................................................... 15-15
15.3. Review ................................................................................................. 15-16

ii
Table of Figures
Figure 1: Selection of Project Languages in TIA Portal............................................. 15-2
Figure 2: Selection of Languages to be Included in the Project ................................ 15-3
Figure 3: Selection of Languages and Fonts for Each .............................................. 15-4
Figure 4: Selection of Languages and Fonts in Runtime .......................................... 15-5
Figure 5: Runtime Language and Font Selection ...................................................... 15-5
Figure 6: Selection of Graphic Flags for Each Language.......................................... 15-6
Figure 7: Selection of Graphic Flags for Each Language.......................................... 15-7
Figure 8: Unicode Echo Language Tag Change ....................................................... 15-8
Figure 9: WinCC Flexible Language Codes ............................................................ 15-12
Figure 10: Export of HMI Texts ............................................................................... 15-13
Figure 11: Select Source and Target Languages ................................................... 15-14

iii
15. HMI Multi-Language Functionality
15.1. Module Objectives:
1. The student will be able to configure the HMI application for multi-language
support in TIA Portal.
2. The student will be able to select languages to be included in HMI Runtime.
15.2. Configuring the HMI Application for Multi-Language
After the HMI application has been fully developed, complete the following steps to
enable the application to support multiple languages in run-time mode.
15.2.1. Selection of Languages to be Included in the TIA Portal Project

The folder Languages and Resources (Figure 1) is part of the project shown on the
left hand side of the screen. This is displayed below the folder Documentation
Settings in the project tree.
Figure 1: Selection of Project Languages in TIA Portal
Under Language and Resources, select Project Languages and the screen will
look similar to Figure 2.
Figure 2: Selection of Languages to be Included in the Project
Most applications will only contain 2-3 languages with English being one of them.
15.2.2. Selection of Languages to be Included in Runtime
Figure 3: Selection of Languages and Fonts for Each
Under Device_1 [TP1200 Comfort] (model used may vary), double click Runtime
settings then click Languages & Fonts and the screen will look similar to Figure 4.
Figure 4: Selection of Languages and Fonts in Runtime
The table in Figure 4 populates based on the Project Languages selected earlier.
Select the Enable check box to include language in runtime.

1 Order Indicates the order for language switch, 0 is first. This
is an indicator only. To change order, begin with
item 4.
2 Enable Select (check) the box for language(s) desired for
runtime use.
3 Language Name The name of the available language.
4 Fixed Font Allows the user to define what the system font will be
for the specific language. Currently, Tahoma is used
for all languages.
5 Row Select Click button to select the row and adjust its order.
6 Up Moves selected row up in the language switching
order.
7 Down Moves selected row down in the language switching
order.
Figure 5: Runtime Language and Font Selection
15.2.3. Selection of Flags for Each Language
Figure 6: Selection of Graphic Flags for Each Language
Double click Project Graphics to begin flag selection. For each language, select the
Flag graphic and right click on the picture. Select Load from file (Figure 7). The flag
icons are stored in the Miscellaneous folder. Select the proper flag for each language
using this method. If the required flag is not available in the directory, obtain a .BMP
image of the flag and define the path to the image.
Figure 7: Selection of Graphic Flags for Each Language
15.2.4. Unicocde Echo Language

The next step is setting the Unicode Echo Language (Figure 8). First expand the
HMI Tags (1) folder, and then expand the Internal (2) folder. Click the
Tags_Internal (3) and select the InternalUnicodeEchoLang (4) tag. Under
Properties select Values (5). Enter 1033 for the Start value (6). The example
shown below sets the InternalUnicodeEchoLang tag to English.
Figure 8: Unicode Echo Language Tag Change
Language String Code
Afrikaans af 1078
Albanian sq 1052
Arabic United Arab ar-ae 14337
Emirates
Arabic - Bahrain ar-bh 15361
Arabic - Algeria ar-dz 5121
Arabic - Egypt ar-eg 3073
Arabic - Iraq ar-iq 2049
Arabic - Jordan ar-jo 11265
Arabic - Kuwait ar-kw 13313
Arabic - Lebanon ar-lb 12289
Arabic - Libya ar-ly 4097
Arabic - Morocco ar-ma 6145
Arabic - Oman ar-om 8193
Arabic - Qatar ar-qa 16385
Arabic - Saudi Arabia ar-sa 1025
Arabic - Syria ar-sy 10241
Arabic - Tunisia ar-tn 7169
Arabic - Yemen ar-ye 9217
Armenian hy 1067
Azeri Latin az-az 1068
Azeri Cyrillic az-az 2092
Basque eu 1069
Belarusian be 1059
Bulgarian bg 1026
Catalan ca 1027
Chinese - China zh-cn 2052
Chinese - Hong Kong zh-hk 3076
S.A.R.
Chinese Macau S.A.R zh-mo 5124
Chinese - Singapore zh-sg 4100
Chinese - Taiwan zh-tw 1028
Croatian hr 1050
Czech cs 1029
Danish da 1030
Dutch The Netherlands nl-nl 1043
Dutch - Belgium nl-be 2067
English - Australia en-au 3081
English - Belize en-bz 10249
English - Canada en-ca 4105
English Carribbean en-cb 9225
English - Ireland en-ie 6153
English - Jamaica en-jm 8201
English - New Zealand en-nz 5129
English Phillippines en-ph 13321
English - South Africa en-za 7177
English - Trinidad en-tt 11273
English - United en-gb 2057
Kingdom
English - United States en-us 1033
Estonian et 1061
Farsi fa 1065
Finnish fi 1035
Faroese fo 1080
French - Canada fr-ca 3084
French - France fr-fr 1036
French - Belgium fr-be 2060
French - Luxembourg fr-lu 5132
French - Switzerland fr-ch 4108
Gaelic Ireland gd-ie 2108
Gaelic - Scotland gd 1084
German - Germany de-de 1031
German - Austria de-at 3079
German - de-li 5127
Liechtenstein
German - Luxembourg de-lu 4103
German - Switzerland de-ch 2055
Greek el 1032
Hebrew he 1037
Hindi hi 1081
Hungarian hu 1038
Icelandic is 1039
Indonesian id 1057
Italian - Italy it-it 1040
Italian - Switzerland it-ch 2064
Japanese ja 1041
Korean ko 1042
Latvian lv 1062
Lithuanian lt 1063
FYRO Macedonian mk 1071
Malay - Malaysia ms-my 1086
Malay Brunei ms-bn 2110
Maltese mt 1082
Marathi mr 1102
Norwegian - Bokml no-no 1044
Norwegian Nynorsk no-no 2068
Polish pl 1045
Portuguese - Portugal pt-pt 2070
Portuguese - Brazil pt-br 1046
Raeto-Romance rm 1047
Romanian - Romania ro 1048
Romanian - Moldova ro-mo 2072
Russian ru 1049
Russian - Moldova ru-mo 2073
Sanskrit sa 1103
Serbian - Cyrillic sr-sp 3098
Serbian Latin sr-sp 2074
Setsuana tn 1074
Slovenian sl 1060
Slovak sk 1051
Sorbian sb 1070
Spanish - Spain es-es 1034
Spanish - Argentina es-ar 11274
Spanish - Bolivia es-bo 16394
Spanish - Chile es-cl 13322
Spanish - Colombia es-co 9226
Spanish - Costa Rica es-cr 5130
Spanish - Dominican es-do 7178
Republic
Spanish - Ecuador es-ec 12298
Spanish - Guatemala es-gt 4106
Spanish - Honduras es-hn 18442
Spanish - Mexico es-mx 2058
Spanish - Nicaragua es-ni 19466
Spanish - Panama es-pa 6154
Spanish - Peru es-pe 10250
Spanish - Puerto Rico es-pr 20490
Spanish - Paraguay es-py 15370
Spanish - El Salvador es-sv 17418
Spanish - Uruguay es-uy 14346
Spanish - Venezuela es-ve 8202
Sutu sx 1072
Swahili sw 1089
Swedish - Sweden sv-se 1053
Swedish - Finland sv-fi 2077
Tamil ta 1097
Tatar tt 1092
Thai th 1054
Turkish tr 1055
Tsonga ts 1073
Ukrainian uk 1058
Urdu ur 1056
Uzbek Cyrillic uz-uz 2115
Uzbek Latin uz-uz 1091
Vietnamese vi 1066
Xhosa xh 1076
Yiddish yi 1085
Zulu zu 1077
Figure 9: WinCC Flexible Language Codes
15.2.5. Translation of HMI Text
The final step that must be completed is the translation of the HMI text itself. The
HMI text includes all of the text buttons and indicators.
To do this, select Tools (1) -> Export project texts (2) -> as shown in Figure 10
below.
Figure 10: Export of HMI Texts
Select the Source Language (1) and Target Language (2) and click Export (3).
This will create an Excel file named ProjectTextExport.xlsx. Open this file and verify
the translation.
Figure 11: Select Source and Target Languages
Once you have finished the translation, re-import the screens by selecting Tools ->
Texts -> Import project texts.
Repeat these steps for each additional language that the application needs to
support.
15.2.6. Final Review of the Translation
When all the text has been translated, review each screen for every language and
make sure that the text fits in the areas that they are designated for. In some cases,
the text may have to be changed or abbreviated to allow it to fit into the area
provided.
15.3. Review
1. How is the HMI application configured for multi-language in TIA Portal?

2. How are languages selected to be included in Runtime?
GCCS-2
LMS # 33544
Module 16: Starting Up a Cell

Sponsoring Group:

Document Revisions:
Updated DeviceNet addressing section and
8-26-13 5.0 J. Hocking
graphics.
7-9-15 6.0 J. Hocking
EtherNet I/O

i
Table of Contents
16. Starting Up a Cell ................................................................. 16-1
16.1. Objectives:............................................................................................. 16-1
16.2. Cell Validation Requirements .............................................................. 16-2
16.3. Configure and Validate DeviceNet Networks...................................... 16-2
16.3.1. Create Network Files .................................................................... 16-2
16.3.2. Setup DNB .................................................................................... 16-3
16.3.3. Setup Network Devices................................................................. 16-3
16.3.4. Connecting to the DeviceNet Network .......................................... 16-3
16.3.5. Configure Network ........................................................................ 16-3
16.3.6. Debug ........................................................................................... 16-3
16.4. Validate the Safety System (Perimeter Guards, Estops, etc.) ........... 16-4
16.4.1. Perimeter Guards ......................................................................... 16-4
16.4.2. Estops (Emergency Stops) ........................................................... 16-4
16.4.3. Gate Boxes ................................................................................... 16-4
16.4.4. Light Curtains................................................................................ 16-5
16.5. Using the Scroll List in Manual Mode ................................................. 16-5
16.5.1. Verify Station Sequence Steps ..................................................... 16-5
16.5.2. Manually Initiate Motion ................................................................ 16-5
16.5.3. Verify Group / Ungroup Functionality ............................................ 16-6
16.5.4. Initiate Robot to Pounce and Back ................................................ 16-6
16.5.5. Verify Remote Actions .................................................................. 16-6
16.5.6. Verify Return to Load / Unload...................................................... 16-6
16.6. Software Checklist ................................................................................ 16-6
16.6.1. Search / Replace TBD Bits ........................................................... 16-6
16.6.2. Motion Action Clears ................................................................... 16-6
16.6.3. Mapping Routine Configurations................................................... 16-6
16.6.4. Interlocks ...................................................................................... 16-6
16.6.5. Exercise 1: Search and Replace TBD Bits in Logic. .................... 16-7
16.7. Review ................................................................................................... 16-8

ii
16. Starting Up a Cell
16.1. Objectives:
1. The student will be able to start a cell.
2. The student will be able to validate cell functionality.
3. The student will be able to validate the safety system.
16.2. Cell Validation Requirements
The following is a list of items that must be validated when starting up a tooling cell.
1. Ethernet System Configuration
2. Load firmware in all firmware upgradable devices
3. DNet Communications (Standard & Safe)
4. Safety System check EStop, Perimeter, MPS
5. Robot path segment and Interference zone check.
6. Full Cell Reset (Master On Gates Reset)
7. Manual Tool Operation from Scroll list on HMI
8. Interlocks to other cells + Transfer System
9. Validate Producer/Consumer
10. Auto Mode
A. Tryout Mode
B. With Parts
11. Interlocks to Upper Level (PMC, Tput, Ascii Echo)
12. Through-put evaluation of cell/system modify operation for required cycle
time improvements
13. Validate tooling alarms
16.3. Configure and Validate DeviceNet Networks
16.3.1. Create Network Files

Use RSNetworx to scan DeviceNet network devices and configure the DNB scan
list in the DeviceNet scanner.
The I/O of each device must be properly mapped in the DNB configuration
according to GCCS-1 standards. Device I/O is mapped to scanner I/O image at
DINT [Node number x 2].
For additional help, reference: Project Module 13.4 Creating a RSNetworks .DNT
Configuration File.
16.3.2. Setup DNB
The default node address of the DNB is set to 63 from the factory. GCCS-1 now
uses node 0 for all DeviceNet scanner modules (DNB) in Logix racks and node 1 for
all (SDN) scanner modules in CompactLogix systems.
16.3.3. Setup Network Devices

Like the DNB, the node address of new hardware devices is typically set to 63 at the
factory. Set the node address and communication baud rate on all network
hardware devices. Devices typically have a mechanism like a rotary switch or
dipswitch to set the address and the baud rate.
16.3.4. Connecting to the DeviceNet Network

Access to the DeviceNet network can be either direct or indirect.
The direct method involves connecting the programming device (i.e. laptop)
directly to the network.
o Requires the use of an adapter (e.g. 1784-PCD card for a laptop)
o Access is limited to the network the laptop is connected to.
The indirect method (i.e. Ethernet)
o Preferred connection method: The workstation or laptop can be readily
connected to the cell Ethernet network for access to the PLC and all
interconnected DeviceNet networks.
o Use another network to bridge to the DeviceNet network.
Direct and Indirect connection methods require configuration of a network driver
using RSLinx. Reference Project Module 2.4; Configuring RSLinx.
16.3.5. Configure Network

Open the network file created in Exercise Section 4.5. Set the Online Path by
accessing the Network properties. The Online Path will contain the driver created in
the previous section and the DNB number (the slot in which it resides in the
controller chassis). Go online. Once online, the network configuration stored in the
network file can be downloaded to the DNB.
16.3.6. Debug
Validate that all nodes are present in the network browse. After all nodes are
properly configured, add them to the scan list and map the nodes. Complete this
same process for each DeviceNet DNB Scanner in the MCP. After the configuration
process is complete, use a diagnostic tool, such as the NetAlert meter, to validate
that the DeviceNet network is functioning properly.
16.4. Validate the Safety System (Perimeter Guards, Estops,

etc.)
16.4.1. Perimeter Guards

The Perimeter Guard can be used for light curtains or safety mats. Regardless of the
sensing device used, two redundant clear channels are connected to a safe I/O
module within the enclosure. Confirm the module status indicators for these inputs
change state during Perimeter Guard violation. Confirm the Perimeter Guard Reset
PBLT remains off until the reset PB is pressed.
16.4.2. Estops (Emergency Stops)

Estops appear on runstands, Gateboxes, HMIs, etc. In each case, two sets of NC
contacts from the Estop switch are used to create an Estop PB OK channel A and
channel B. Confirm the change of state of the module status indicators for these
inputs during Estop activation.
Channel A & B inputs are also mapped to the safety input data structure in the
controller as tags XXX.I.NoEStopChA and XXX.I.NoEStopChB. These tags are
used in the Estop instruction in the various safety program routines for each
channel. Confirm that the output of this instruction drops when Estop is pressed and
is reactivated when reset.
16.4.3. Gate Boxes

The Safety Task must be locked with a signature for the MPS system to function
properly. After locking the safety task with a signature, use the Gatebox Functional
Specification from GCCH-1 to check the operation of each gatebox in relation to the
robots and tooling.
16.4.4. Light Curtains
Light curtain and / or safety mat safety circuits can also be found in station fixture
boxes and inter-cell light curtain boxes. Safety Device #1 channel A and B are wired
to the same safety module inputs as discussed in Module 8.4.2. Fixture boxes may
offer the option for up to three more sets of safety devices: Safety Device #2, Safety
Device #3, and Safety Device #4. Confirm the change of state of the module status
indicators for these inputs during light curtain violation.
Inputs are also mapped to the safety data structure using the same basic tag names
- XXX.I.LCYClearCh1 and XXX.I.LCYClearCh2: where XXX correlates to the
enclosure subscript (e.g. F1 Fixture Box 1, LE1 Entrance Light Curtain 1, LX2
Exit Light Curtain 2, etc.). Y correlates to the safety device number (e.g. Light
Curtain #1, Safety Mat #2, etc.). Like the Perimeter Guard safety devices, these tags
are used in RIN instructions.
16.5. Using the Scroll List in Manual Mode

In the Manual Mode, verify all manual functions using the scroll list.
16.5.1. Verify Station Sequence Steps

Verify the scroll list line items match the sequence steps of each station.
16.5.2. Manually Initiate Motion

Manually move the scroll list cursor to each line and initiate motion with the Do
pushbutton. Press the Undo pushbutton to verify opposite motion action, if
applicable. Enable the Auto Cursor function. Verify the scroll list cursor
automatically indexes to the next line item after the current motion completes.
16.5.3. Verify Group / Ungroup Functionality
Confirm that any scroll list line items that are grouped can be expanded to the
correct number of line items and condensed again. With the group expanded,
manually initiate each line item.
16.5.4. Initiate Robot to Pounce and Back
Manually initiate any scroll list motion actions that send robots to the Pounce
position. Verify the Undo pushbutton will initiate motion to return the robot from
Pounce to Home.
16.5.5. Verify Remote Actions
Verify scroll list line items for remote actions that initiate motion in remote cells, if
applicable.
16.5.6. Verify Return to Load / Unload
Confirm the return to load / unload position requests function as expected in each
station.
16.6. Software Checklist
16.6.1. Search / Replace TBD Bits

Search the logic for any remaining TBD bits created during the software generation
process and replace with the proper logic.
16.6.2. Motion Action Clears

Confirm crash conditions are addressed where station tooling interacts with other
tooling and / or robot actions. Update the prompting logic to match clear conditions.
16.6.3. Mapping Routine Configurations

Confirm all input and output devices are properly mapped in the appropriate Main
and Safety Task programs.
16.6.4. Interlocks
Confirm the configuration of station-to-station and cell-to-cell interlocks, if applicable.
For cell-to-cell communication, verify that the controller heartbeat is monitored at
each end and that alarm messages are present to announce communication
interruptions.
16.6.5. Exercise 1: Search and Replace TBD Bits in Logic.
Exercise is Optional if time permits.
1. Open ComTask16Exercises program in RSLogix 5000.
2. Open Cross Reference.
3. Verify the following settings:
4. Type = tag
5. Scope = controller has controller icon
6. Show = Show All
7. Name = TBD
8. Select Refresh to update cross reference or click Enter.
9. Double-click any cross reference line to navigate to the TBD bit use in the
logic.
10. Do what the @TODO rung comment tells you to do.
Note: TBD bits will require application-specific logic edits. Some examples are as
follows:
o Add conditions to Action Auto or Clear Rungs
o Add prompts for contacts in the clear rung to the action prompt rung
o Add routines to match your application where placeholders are given
11. Repeat this process until all TBD bits are replaced or removed.
END OF EXERCISE 1
16.7. Review
1. How is a cell started?
2. How is the safety system validated?
3. How is the functionality of the cell validated?
GCCS-2
LMS # 33544
Module 17: Common Modifications

to a Running Cell
Sponsoring Group:

ME Engineering Group: GM MAAC Vehicle Systems-Automation
Standards
Document Revisions:
8-26-13 5.0 J. Hocking Exercise Files changed
7-17-15 6.0 J. Hocking
EtherNet I/O

i
Table of Contents
17. Common Modifications to a Running Cell ................................... 17-1
17.1. Objectives ........................................................................................................ 17-1
17.2. Overview .......................................................................................................... 17-2
17.3. Changing / Updating a Tooling Sequence..................................................... 17-2
17.4. Adding / Removing Tooling Actions .............................................................. 17-3
17.4.1. Adding Tooling Actions ........................................................................... 17-4
17.4.1.1. Adding Tags .................................................................................. 17-4
17.4.1.2. Adding Routines ............................................................................ 17-5
17.4.2. Removing Tooling Actions....................................................................... 17-6
17.5. Working with Alias Tags ................................................................................. 17-7
17.5.1. Exercise 1 Working with Alias Tags ........................................................ 17-7
17.6. Removing a Station ....................................................................................... 17-24
17.6.1. Exercise 2: Deleting the a Station Program (Optional) .......................... 17-24
17.7. Adding a Station ............................................................................................ 17-28
17.7.1. Exercise 3: Adding a New Station (Optional) ........................................ 17-28
17.7.2. Exercise 4: Editing a New Station (Optional)......................................... 17-31
17.7.3. Exercise 5: Adding a New Action Routine (Optional) ............................ 17-54
17.8. Editing an Action Routine............................................................................. 17-65
17.8.1. Exercise 6: Edits After Adding a New Routine (Optional) ...................... 17-66
17.10. Adding a Gate Box ...................................................................................... 17-85
17.11. Adding / Removing Robot Actions ............................................................ 17-86
17.11.1. Adding and Modifying Tags ................................................................. 17-86
17.11.2. Adding and Modifying Routines........................................................... 17-86
17.11.3. Modifying the S000_Sequence Routine .............................................. 17-88
17.11.4. Modifying the S050_R01WeldRepo Routine ....................................... 17-89
17.11.5. Modifying the S065_OpenClamps1 Routine ....................................... 17-97
17.11.6. Configuring the S067_R01WeldClr Routine ........................................ 17-99
17.11.7. V100_R01Common ........................................................................... 17-105
17.11.8. S010_MainCycle ............................................................................... 17-107
17.11.9. Removing a Robot Action.................................................................. 17-108
17.11.9.1. Record Robot Information ....................................................... 17-108
17.11.9.2. Remove Robot Action Routine ................................................ 17-108
17.11.9.3. Search for Robot Action, Segment, Clear Tags ...................... 17-108
17.12. Adding / Removing Welding Actions ....................................................... 17-109
17.12.1. Adding Welding Action Case 1 ....................................................... 17-109
17.12.2. Adding Tags ...................................................................................... 17-109
17.12.3. Adding and Modifying Routines......................................................... 17-110
17.12.4. Adding the New Weld Action Routines .............................................. 17-110

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17.12.5. Modifying the S000_Sequence Routine ............................................ 17-111
17.12.6. Modifying the S040_1stWeld Routine ............................................... 17-111
17.12.7. Configuring the S047_AdvanceWGSlide Routine ............................. 17-113
17.12.8. Configuring the S048_2ndWeld Routine ........................................... 17-114
17.12.9. Configuring the S049_InitW2WG01 Action Routine .......................... 17-118
17.12.10. Modifying the S050_OpenWGRetract Action Routine ..................... 17-125
17.12.11. Modifying the S063_ReturnWGSlide Action Routine ...................... 17-126
17.12.12. Modifying the W001_WeldCommon Routine................................... 17-126
17.12.13. Modifying the S010_MainCycle Routine.......................................... 17-127
17.13. Adding Weld Action Case 2 ................................................................... 17-128
17.13.1. Adding the SCR3 Ethernet Module ................................................... 17-128
17.13.2. Mapping the SCR3 I/O ...................................................................... 17-129
17.13.3. Adding Tags ...................................................................................... 17-131
17.13.4. Adding and Modifying Routines......................................................... 17-132
17.13.5. Adding the New Weld Action Routine ............................................... 17-133
17.13.6. Modifying the S000_Sequence Routine ............................................ 17-134
17.13.7. Modifying the S040_1stWeld Rouitne ............................................... 17-135
17.13.8. Configuring the S051_InitWG03 Routine .......................................... 17-137
17.13.9. Modifying the W001_WeldCommon Routine..................................... 17-143
17.14. Adding Weld Action Case 3 ................................................................... 17-148
17.14.1. Adding SCR EtherNet Module........................................................... 17-148
17.14.2. Adding Tags ...................................................................................... 17-148
17.14.3. Adding the New Weld Controller Program......................................... 17-149
17.14.4. Adding Weld Controller Program Tags and Routines........................ 17-149
17.15. Removing a Weld Action .......................................................................... 17-151
17.15.1. Remove the Weld Action Routine ..................................................... 17-151
17.15.2. Search for Weld Action Tags............................................................. 17-151
17.15.3. Remove / Inhibit SCR EtherNet Module ............................................ 17-151
17.16. Adding a Robot.......................................................................................... 17-152
17.16.1. Adding the Robot Ethernet Module ................................................... 17-152
17.16.2. Adding the Robot DeviceNet Safety I/O ............................................ 17-153
17.16.3. Adding the Robot Controller Scope Tags .......................................... 17-154
17.16.4. Modifying the Safety Task ................................................................. 17-155
17.16.5. Adding the Robot Program ................................................................ 17-157
17.16.6. Adding the Robot Program Scope Tags ............................................ 17-157
17.16.7. Adding the Robot Program Routines................................................. 17-159
17.17. Removing a Robot..................................................................................... 17-168
17.17.1. Remove Robot Program from Main Task .......................................... 17-168
17.17.2. Deleting the Robot Program .............................................................. 17-169
17.17.3. Removing Robot from I/O Configuration ........................................... 17-169
17.17.4. Modify the Safety Task ...................................................................... 17-169
17.17.5. Deleting Station Components from I/O Configuration ....................... 17-169

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17.18. Adding / Removing Interlocks to Other Devices .................................... 17-170
17.18.1. Adding the Ethernet / Controller Modules.......................................... 17-170
17.18.2. Adding the Interlock Tags.................................................................. 17-173
17.18.3. Mapping the Consumed Tag Data .................................................... 17-178
17.18.4. Mapping the Produced Tag Data ...................................................... 17-183
17.19. Removing an Interlock .............................................................................. 17-185
17.19.1. Remove Ethernet / Controller Modules ............................................. 17-185
17.19.2. Remove Produced / Consumed Mapping.......................................... 17-185
17.20. Adding / Removing Styles ........................................................................ 17-186
17.20.1. Adding a Style Station Program ..................................................... 17-186
17.20.2. Adding a Style Robot Program ....................................................... 17-187
17.20.3. Removing a Style .............................................................................. 17-188
17.21. Review ........................................................................................................ 17-189

iv
Table of Figures
Figure 1: Typical Close Clamps Auto setup rungs .................................................... 17-2
Figure 2: Revised Close Clamps Auto Setup Rungs ................................................. 17-3
Figure 3: Revised Close Clamps Auto Setup Rungs ................................................. 17-3
Figure 4: New Program Tags Added ......................................................................... 17-4
Figure 5: Revised Program Routine List.................................................................... 17-5
Figure 6: Revised Clamps1, Clamps3 Auto Setup Rungs ......................................... 17-6
Figure 7: Revised Program Action Routine List ......................................................... 17-6
Figure 8: Revised S000_Sequence Routine Logic .................................................... 17-7
Figure 9: Unscheduled Programs Location ............................................................... 17-8
Figure 10: Open the Main Task Properties................................................................ 17-9
Figure 11: The Properties Program / Phase Schedule Tab ....................................... 17-9
Figure 12: Place the Scheduled Programs in Order ................................................ 17-10
Figure 13: Close the Properties Window ................................................................. 17-10
Figure 14: The KA060 Alias Tags ........................................................................... 17-11
Figure 15: Alias Tags Selected for Copy ................................................................. 17-12
Figure 16: Pasting Tags .......................................................................................... 17-13
Figure 17: Cell level Controller Tags Edit Not required ........................................ 17-14
Figure 18: Create Controller Tags for Alias Tags .................................................... 17-15
Figure 19: Changing Scope...................................................................................... 17-16
Figure 20: Changing the Sort Order ........................................................................ 17-16
Figure 21: Copy a Controller Tag ............................................................................ 17-17
Figure 22: Pasting a Tag .......................................................................................... 17-18
Figure 23: Pasted Tag Duplicate .......................................................................... 17-19
Figure 24: Rename the Tag .................................................................................... 17-19
Figure 25: Tag Name and Data Type ...................................................................... 17-20
Figure 26: Creating a Controller Tag ....................................................................... 17-21
Figure 27: KA040 Program Tags ............................................................................. 17-22
Figure 28: Controller Organizer KA040 Program.................................................. 17-23
Figure 29: AA075 Moved to Unscheduled ............................................................... 17-24
Figure 30: AA075 in Controller Organizer ............................................................... 17-25
Figure 31: AA075 with Main Assigned..................................................................... 17-26
Figure 32: Program Properties Configuration .......................................................... 17-27
Figure 33: Controller Organizer after Renaming Routines ...................................... 17-30
Figure 34: Deleting Program Tags in AA072 ........................................................... 17-31
Figure 35: Cross Reference a Program Tag ........................................................... 17-33
Figure 36: Program Tags Reflecting Edits Through Step 7 ..................................... 17-34
Figure 37: Cross Reference of LHDockingClampsClose......................................... 17-35
Figure 38: Tag Used in Sequence Routine Call ...................................................... 17-36
Figure 39: Editing the First AA072 Program Tag Alias For...................................... 17-38
Figure 40: Copy a Controller Tag ............................................................................ 17-39
Figure 41: Alias For Editing Chart ......................................................................... 17-40

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Figure 42: AA072 Program Tags After Edits ........................................................... 17-40
Figure 43: AA072 Program Tags after Creating the Alias For Controller Tag ....... 17-42
Figure 44: Expanded View of PMCD Tags in AA072 Program................................ 17-43
Figure 45: PMCD Locating the UDT to Edit............................................................. 17-44
Figure 46: Controller Organizer Opening User-Defined Data Types ....................... 17-45
Figure 47: Open the uc_PMCObjectType_AA065B1Cell UDT ................................ 17-46
Figure 48: Insert an UDT Member ........................................................................... 17-47
Figure 49: UDT with a New Member Added ............................................................ 17-48
Figure 50: Completed uc_PMCObjectType_AA065B1Cell UDT ............................. 17-49
Figure 51: AA072 PMC Tags Corrected .................................................................. 17-50
Figure 52: Delete Routine Calls That Are Not Used ................................................ 17-51
Figure 53: Delete Action Routine Calls and Group That Are Not Used. .................. 17-52
Figure 54: Selecting a New Routine ........................................................................ 17-54
Figure 55: New Routine Dialog ............................................................................... 17-55
Figure 56: New Routine........................................................................................... 17-56
Figure 57: Reference Routine for Copy ................................................................... 17-57
Figure 58: Logix Display of Selected Rungs............................................................ 17-58
Figure 59: Logix Display After Paste ....................................................................... 17-59
Figure 60: Delete the Empty Line ............................................................................ 17-60
Figure 61: Creating the Action Tag.......................................................................... 17-61
Figure 62: AA070 Program Tags after Clamp1 Edits .............................................. 17-61
Figure 63: Editing the Main Description for a Tag ................................................... 17-62
Figure 64: Edits to the Sequence Routine ............................................................... 17-63
Figure 65: Edits Finished in the Sequence Routine ................................................ 17-64
Figure 66: Close.Comp Rung .................................................................................. 17-65
Figure 67: Close.Comp Rung Description ............................................................... 17-65
Figure 68: Accessing Search and Replace ............................................................. 17-66
Figure 69: Configuring Search and Replace Options .............................................. 17-67
Figure 70: C09 and C10 Program Tags Created in AA070 ..................................... 17-68
Figure 71: Editing the Main Description for Tags C09 and C10 .............................. 17-68
Figure 72: Closed Switch Internal Rung for Cylinder C09 ....................................... 17-69
Figure 73: Switch Internal Rung for Cylinder C10 ................................................... 17-70
Figure 74: CloseClamp1.Comp Rung...................................................................... 17-71
Figure 75: Clamp1Close.Auto Rung ........................................................................ 17-71
Figure 76: Action Clear Rung .................................................................................. 17-72
Figure 77 Do Not Duplicate Conditions in Action Auto and Clear Rung ................... 17-72
Figure 78: Action Output Power Rung ..................................................................... 17-73
Figure 79: Command and Output Internal Rungs .................................................... 17-73
Figure 80: Close Valve Output Rung ....................................................................... 17-74
Figure 81: Action Close Memory, Fault and SL Not Visible Rungs ......................... 17-75
Figure 82: zDiagInternal Enable Bypass Rung ........................................................ 17-76
Figure 83: Switch Diagnostic Rung Chart................................................................ 17-77
Figure 84: Switch Diagnostic Rung and Bypass Bit Rung for Cylinder C09 ............ 17-78

vi
Figure 85: Switch Diagnostic Bypass Rung Chart ................................................... 17-78
Figure 86: Switch Diagnostic Rung and Bypass Bit Rung for Cylinder C10 ............ 17-79
Figure 87: Action Scroll List Text Rung ................................................................... 17-80
Figure 88: Close Clamps1 Prompting Logic ............................................................ 17-81
Figure 89: Close Clamp1 Output Power Prompting Logic ....................................... 17-82
Figure 90: Unlatch of PB and Prompt Bits ............................................................... 17-82
Figure 91: SL.Found Rung ...................................................................................... 17-83
Figure 92: Revised Program Routine List................................................................ 17-86
Figure 93: Program Tag List Before and After ...................................................... 17-87
Figure 94: New Robot Action JSR Added to S000_Sequence Routine ................... 17-88
Figure 95: Changes to WeldRepo.Comp Rung ....................................................... 17-89
Figure 96: Set WeldRepo.Comp, ProcComp Rung ................................................. 17-90
Figure 97: Reset WeldRepo.Comp / ProcComp, .Auto and ClrSetup Rungs .......... 17-90
Figure 98: WeldRepo.Clr Rung ............................................................................... 17-91
Figure 99: WeldRepo.OutPwr Rung ........................................................................ 17-92
Figure 100: WeldRepo.Cmd, .Out, .Mem and .Flt Rungs ........................................ 17-92
Figure 101: Changes to the Scroll List Text Rung ................................................... 17-93
Figure 102: Prompt Driver Logic ............................................................................. 17-94
Figure 103: Prompt Driver Logic (Contd) ................................................................ 17-94
Figure 104: Weld & Repo Not Complete Prompt Text ............................................. 17-95
Figure 105: HwEnable Prompt, Scroll List PB Unlatch and SL Line Found Rungs . 17-96
Figure 106: Repo Clamps1.Auto Rung.................................................................... 17-97
Figure 107: Repo Clamps1.Clear Rung .................................................................. 17-97
Figure 108: Robot Not Clear Prompt Rungs............................................................ 17-98
Figure 109: Robot WeldClr.Comp / .ProcComp Rung ............................................. 17-99
Figure 110: Typical Set/Reset Robot WeldClr.Comp / .ProcComp & Auto Rungs 17-100
Figure 111: WeldClr.ClrSetup / .Clear Rungs........................................................ 17-100
Figure 112: Typical WeldClr.OutPwr / .Cmd Rungs .............................................. 17-101
Figure 113: Typical WeldClr.Out, .Mem, .Flt Rungs .............................................. 17-102
Figure 114: Robot Action Scroll List Text Rung ..................................................... 17-102
Figure 115: Typical Prompt Driver Logic ............................................................... 17-103
Figure 116: Typical Prompt, Do /Undo and Scroll List Logic Rungs ...................... 17-104
Figure 117: V100_R01Common .ValidSeg and .MotionEnable Rungs ................. 17-105
Figure 118: V100_R01Common .MotionEnable Rung (Contd)............................. 17-106
Figure 119: R01.Clear.1 Rung .............................................................................. 17-106
Figure 120: R01.Decision.0 Rung ......................................................................... 17-107
Figure 121: MainCycle Proc / NoProcComp and Steps / NoStepsComp Rungs ... 17-107
Figure 122: Revised Program Tag List .................................................................. 17-109
Figure 123: Revised Program Routine List............................................................ 17-110
Figure 124: Modifications to the S000_Sequence Routine.................................... 17-111
Figure 125: Modifications to the S000_Sequence Routine (Contd) ...................... 17-111
Figure 126: Typical .ToolRdy Rung ....................................................................... 17-112
Figure 127: Typical Prompt Driver Rung ............................................................... 17-113

vii
Figure 128: Weld Gun Slide Advance Auto Setup Rung ....................................... 17-113
Figure 129: Weld2 Complete and Tool Ready Rungs ........................................... 17-115
Figure 130: Weld2 Previous Process Complete and Guns Clear Rungs............... 17-116
Figure 131: Typical Prompting Driver Logic .......................................................... 17-116
Figure 132: Typical Prompting Driver Logic (Contd) ............................................. 17-117
Figure 133: Typical 2nd Weld Init.Comp Rung ....................................................... 17-118
Figure 134: Typical 2nd Weld Init.Auto, .Clear, .OutPwr and .InitAntiRpt Rungs .... 17-119
Figure 135: Typical 2nd Weld Init.Cmd, .Out and .InitWeld Rungs ......................... 17-120
Figure 136: Typical 2nd Weld .SeqDone and Init.Mem Rungs ............................... 17-121
Figure 137: Typical 2nd Weld .Init.FLT, SL.NotVisible and SL Text Rungs ............ 17-122
Figure 138: Typical 2nd Weld Prompt Message and Motion Prompt Rungs .......... 17-123
Figure 139: Typical 2nd Weld Output Power Prompt Driver Rungs ........................ 17-124
Figure 140: Typical 2nd Weld Do / Undo Unlatch and SL Found Rungs ................ 17-124
Figure 141: Typical Weld Gun Retract .Auto, .Clear Rungs .................................. 17-125
Figure 142: Typical Weld Gun Retract Motion Prompt Driver Rungs .................... 17-125
Figure 143: Typical Weld Gun Slide Return .Auto Rung ....................................... 17-126
Figure 144: Typical Weld Gun Valve Output and SCR .InitiateWeld Logic............ 17-126
Figure 145: Typical Proc / NoProcComp and Steps / NoStepsComp Rungs ........ 17-127
Figure 146: SCR3 Ethernet Module Configuration ................................................ 17-128
Figure 147: Typical SCR3 Input Mapping Configuration ....................................... 17-130
Figure 148: Typical SCR3 Output Mapping Configuration..................................... 17-131
Figure 149: Revised Controller Tag List ................................................................ 17-131
Figure 150: Revised Weld Controller Program Tag List ........................................ 17-132
Figure 151: Revised Station Program Tag List ...................................................... 17-132
Figure 152: Revised Station Program Routine List ............................................... 17-133
Figure 153: Modifications to the S000_Sequence Routine.................................... 17-134
Figure 154: Modifications to Weld1.Comp Logic ................................................... 17-135
Figure 155: Modifications to Weld1.NoComp, .ProcComp, .NoProcComp Logic .. 17-135
Figure 156: Modifications to Weld1.GunsClear Logic ........................................... 17-136
Figure 157: Typical Init.Comp / .ProcComp Rungs ............................................... 17-137
Figure 158: Typical Weld Init.Auto, .Clear, .OutPwr and .InitAntiRpt Rungs ......... 17-138
Figure 159: Typical Weld Init.Cmd, .Out and .InitWeld Rungs .............................. 17-139
Figure 160: Typical Weld .SeqDone, .Mem Latch / Unlatch Rungs ....................... 17-140
Figure 161: Typical Weld Init.FLT, SL.NotVisible and SL Line Rungs ................... 17-141
Figure 162: Typical Weld Do / Undo Prompt Message and Prompt Driver Logic .. 17-142
Figure 163: Typical PB Unlatch and SL.Found Latch Logic .................................. 17-143
Figure 164: Typical Weld Gun Valve Output and SCR .InitiateWeld Logic............ 17-143
Figure 165: Typical SCR .NoControlStops and .ContactorSaver Logic ................. 17-144
Figure 166: Typical SCR .ContactorSaver (Contd) and .ResetSteppers Logic..... 17-145
Figure 167: Typical SCR .ResetFaults Rung......................................................... 17-145
Figure 168: Typical SCR .WeldModeReq and .StaTryout Rungs .......................... 17-146
Figure 169: Typical SCR End of Stepper Summation Weld Gun Open Timer Logic ... 17-
147

viii
Figure 170: Typical SCR EtherNet Module Configuration ..................................... 17-148
Figure 171: Revised Controller Tag List ................................................................ 17-148
Figure 172: Revised Station Program Tag List ...................................................... 17-149
Figure 173: Revised Controller Program List ........................................................ 17-149
Figure 174: New Weld Controller Program Tag List .............................................. 17-150
Figure 175: New Weld Controller Program Routine List ........................................ 17-150
Figure 176: Typical Robot Ethernet Module Configuration .................................... 17-152
Figure 177: Typical Robot DeviceNet Safety I/O Module Configuration ................ 17-153
Figure 178: Non-Safety Controller Tags Added .................................................... 17-154
Figure 179: Safety Controller Tags Added ............................................................ 17-154
Figure 180: Safety Task Program Tag Added ....................................................... 17-155
Figure 181: Safety Task B001_MapInputs Routine Modification ........................... 17-155
Figure 182: Safety Task B002_MapOutputs Routine Modification ........................ 17-155
Figure 183: Safety Task B010_SafetyConfig Routine Modifications ..................... 17-156
Figure 184: Safety Task Robot Routine Modifications........................................... 17-157
Figure 185: Revised Main Task List (Partial)......................................................... 17-157
Figure 186: Typical Robot Program Tag List ......................................................... 17-158
Figure 187: New Robot Program Routine List ....................................................... 17-159
Figure 188: A000_Main Routine Modifications ...................................................... 17-160
Figure 189: B001_MapInputs Routine Modifications ............................................. 17-161
Figure 190: B001_MapInputs Routine Modifications (Contd) ............................... 17-162
Figure 193: B002_MapOutputs Routine Modifications .......................................... 17-164
Figure 194: B004_Parameters Routine Modifications ........................................... 17-165
Figure 195: B010_Zones Routine Modifications .................................................... 17-165
Figure 196: X100_PMCRobot Routine Modifications ............................................ 17-166
Figure 197: X100_PMCRobot Routine Modifications ............................................ 17-167
Figure 198: Main Task Properties Dialog .............................................................. 17-168
Figure 199: Typical Controller I/O Configuration ................................................... 17-170
Figure 200: Select Communication Module Dialog ............................................... 17-171
Figure 201: New Module Configuration Dialog ...................................................... 17-172
Figure 202: Revised Controller I/O Configuration .................................................. 17-172
Figure 203: New Module Configuration Dialog ...................................................... 17-173
Figure 204: Produced Interlock Tags .................................................................... 17-174
Figure 205: Tag Properties Dialog ........................................................................ 17-175
Figure 206: Consumed Interlock Tags .................................................................. 17-176
Figure 207: Tag Properties Dialog ........................................................................ 17-177
Figure 208: Typical Consumed Tag Mapping Cell Program, B001_MapInputs
Routine ................................................................................................................... 17-178
Figure 209: Typical Standard Consumed Tag Mapping Station Program,
B001_MapInputs Routine ....................................................................................... 17-179

ix
Figure 210: Typical Standard Consumed Tag Mapping Station Program,
B001_MapInputs Routine (Contd) ......................................................................... 17-180
Figure 211: Typical Standard Consumed Tag Mapping Cell Program,
C001_InterlockStatus Routine................................................................................ 17-180
Figure 212: Typical Safety Consumed Tag Data used for Communication Diagnostics
Cell Program, C001_InterlockStatus Routine ...................................................... 17-181
Figure 213: Typical Safety Consumed Tag Data used for Communication Diagnostics
Cell Program, C001_InterlockStatus Routine (Contd) ........................................ 17-182
Figure 214: Typical Safety Consumed Tag Data used for E-stop Monitoring Cell
Safety Program, B010_SafetyConfig Routine ........................................................ 17-183
Figure 215: Typical Standard Produced Tag Data Mapping Station Program,
B002_MapOutputs Routine .................................................................................... 17-183
Figure 216: Typical Standard Produced Tag Data Mapping Station Program,
B002_MapOutputs Routine (Contd) ...................................................................... 17-184
Figure 217: Typical Safety Produced Tag Data Mapping Cell Safety Program,
B002_MapOutputs Routine .................................................................................... 17-185
Figure 218: Typical Controller I/O Configuration ................................................... 17-185
Figure 219: Typical Station Jobdata.Valid Logic ................................................... 17-186
Figure 220: Typical Station TputWsData.Type Logic ............................................ 17-187
Figure 221: Typical Robot TputRbt.Bits.Type Logic .............................................. 17-188

x
17. Common Modifications to a Running Cell
17.1. Objectives
1. Work with Alias tags
2. Delete a station program
3. Add a new station
4. Edit a new station
5. Add a new action routine
6. Edit an action routine
17.2. Overview
Once the cell equipment and PLC have been powered up and checked out, the PLC
logic will undergo almost constant changing and updating to ensure that the equipment
controlled by the system functions as designed.
Up to and sometimes including the start of production, it is critical to maintain good
backups for the ever-changing logic files. These changes typically progress from:
Simple logic modifications in the beginning to get the tooling to function as
designed.
Later product changes which may result in tooling sequence revisions.
Tooling cycle time improvements which can result in more sequence
modifications as the start of production nears.
The intent of this module is to present some common scenarios which result in changes
to the controller logic.
17.3. Changing / Updating a Tooling Sequence

The conditional logic in the Auto setup rung of each sequence step action routine
determines when the step will execute relative to the stations automatic tooling
sequence.
Modifying a stations tooling sequence effects how a station operates. Use the Clear
rung if devices must be moved in order to prevent device crashes in Manual and Auto.
The example rungs provided in Figure 1 depict two station sequence steps with the
same conditional logic. Since these steps contain the same logic, they will execute at
the same time.
Figure 1: Typical Close Clamps Auto setup rungs
Although Figure 2 shows the same two rungs as Figure 1, Figure 2 illustrates how two
sequence steps that execute simultaneously are separated so that one step is
dependent on the other.
The closing of Clamps1 will operate as before. The closing of Clamps2 now depends
on Clamps1 being closed first, thus altering the station tooling sequence.
Figure 2: Revised Close Clamps Auto Setup Rungs
17.4. Adding / Removing Tooling Actions

Adding or removing tooling actions involves creating and deleting tags and routines.
There will also be modifications to sequence step logic and diagnostic messaging. The
example in this section will build on the one presented in Figure 3.
Figure 3: Revised Close Clamps Auto Setup Rungs
17.4.1. Adding Tooling Actions
Adding a tooling action step involves adding program tags for tooling cylinders (used
for clamps in this example) and, if necessary, additional input block tags (BK) and
pneumatic valve manifold tags (PM). Adding the proper tooling action routine to the
station program will follow.
The way tags and routines are added will depend on whether these changes are
made with the controller project online or offline. If changes are made online, a
project download to the PLC will not be necessary. The downside is that tags and
routines cannot be copied and directly pasted into the program, instead, tags will
have to be created individually. Routines must be created, but the rung logic within
can be copied and directly pasted in. On the other hand, with the project offline, tags
and routines can be directly pasted in. This method offers the added benefit of tag
descriptions carried over with the pasted tag, reducing the amount of operand
description editing. The downside is the processor will require a download to go
back online with the new program changes.
For the example considered here, Clamps1 will consist of cylinders C01, C02 and
C03. Clamps2 consists of C04 and C05. The new sequence step for Clamps3 will
consist of C06 and C07. The three clamp steps will execute sequentially.
17.4.1.1. Adding Tags
Figure 4: New Program Tags Added
Figure 4 shows the tags added to the station program tag list. The BK03 and PM2
tags were added because the new cylinders (C06, C07) will be tied to a new input
block and valve manifold for demonstration purposes.
The cylinders could have utilized spare I/O if available on existing input blocks and
pneumatic manifolds. The BK03 and PM2 tags will need to be mapped to the Local
I/O in the station program B001_MapInputs and B002_MapOutputs routines (see
GCCS-1, Module 4 for more details).
Note the data type of the Clamps3 tag. Tooling action tags for cylinders are of type
za_action. See GCCS-1a, Module 2 for more information on UDT definitions and
uses.
17.4.1.2. Adding Routines
Before Adding Routine After Adding Routine
Figure 5: Revised Program Routine List
Figure 5 shows the view of a stations tooling action routine list before and after a
routine is added for an additional close clamps sequence step. Sequence step
numbering is in increments of five, permitting easier step insertion later. The GeRWD
software generation process assigns the sequence step number when generating.
As shown in Figure 5, the new step is easily inserted between two existing steps without
the need to renumber the entire list of sequence steps.
17.4.2. Removing Tooling Actions
Removing a tooling action is accomplished in a way that is very similar to adding a
tooling action, but in reverse. Consider the previous example in which a third clamp
closed sequence step was added to the two current clamp closed steps. Using this
example, the Clamps2 close step will be removed.
Figure 6: Revised Clamps1, Clamps3 Auto Setup Rungs
The Clamps3Close.Auto rung shown in Figure 6 illustrates the third clamps close
sequence will now execute based on the first clamps close being completed. Note
that the cross-hatched Clamps2Close.Comp is shown here for illustrative purposes
only. The bit is actually deleted in the logic.
Figure 7: Revised Program Action Routine List
Figure 7 shows the view of the program routine list before and after the deletion of
the Clamps2 close routine. Right-clicking on the routine name and selecting Delete
is all that is necessary to delete the routine. The next step is to open the
S000_Sequence routine and delete the rung containing the JSR for the action
routine deleted (see Figure 8).
Figure 8: Revised S000_Sequence Routine Logic
A cross reference on the program tag for the action deleted will indicate where the tag is
still being used throughout the rest of the program. Where ever the tag is still used, it
must be revised. Once all occurrences of the action tag are removed from the program,
the tag can be deleted from the program tag list.
17.5. Working with Alias Tags
The upcoming exercise will demonstrate how many programs are structured Alias tag
wise similarly.
The exercise is designed to enhance your ability to create Controller Base tags and
Program Alias tags based on the tags in other station programs within the Logix project
17.5.1. Exercise 1 Working with Alias Tags
1. Open ComTask17_1.
2. Schedule the program KA040, currently unscheduled.
Figure 9: Unscheduled Programs Location
a. Right click on the MainTask.

b. Select Properties.
Figure 10: Open the Main Task Properties
c. Click the Program / Phase Schedule tab.
Figure 11: The Properties Program / Phase Schedule Tab
d. Click Add to Schedule the KA040 program.
e. Click the Move arrows to position the program as desired.
Figure 12: Place the Scheduled Programs in Order
f. Position the KA040 program between the KA030 and KA060 programs.
g. Click OK.
Figure 13: Close the Properties Window
3. Open the KA060 program tags select the Edit Tags tab.
Note: select Edit Tags tab to view Alias For column and to perform any tag edits.
Since the KA040 program is missing its Alias tags we will copy the Alias tags from
KA060 to get started. Some controller tags will need to be created to match the KA040
station. Some tags may not be useful for the KA040 station; they can be deleted from
the KA040 program tags.
4. Examine the alias tags.
5. Copy the alias tags to the computers clipboard.
a. Double click Sort the tags by the Alias For column.
Figure 14: The KA060 Alias Tags
b. Click the square in front of the first Alias tag, Cell in this case.
c. Press the shift key and click the square in front of the last Alias tag, To
KA060R05 in this case.
d. Press ctrl +c or right click on the selection and press copy.
Figure 15: Alias Tags Selected for Copy
e. Right click on the tag creation square, select Paste.
Figure 16: Pasting Tags
Many times the programs inside a project will have similar structure for their alias tags.
Some of the Alias tags will not require edits; these are items that are shared by other
programs. These tags will be at the cell level. The next figure highlights tags that
require no editing.
Figure 17: Cell level Controller Tags Edit Not required
6. The Cell level Controller tags in the Alias For column in Figure 17 will not require
new base (Controller) tags because many programs use the tags so the
controller tags were not removed.
7. Create Controller Tags for the Alias Tags indicated in Figure 18; adjust Controller
tags to the KA040 station needs and name.
Figure 18: Create Controller Tags for Alias Tags
Controller Tags are created in the Controller Tag editor.

8. Controller tags will be copied and renamed to represent KA040 station.
9. Click the Scope pull down.
10. Scroll to the top of the list and choose the Controller Tags, signified by the
controller icon and the Controllers name.
Figure 19: Changing Scope
11. Double Click by the top of the Name column to sort by that column.
Note: Double Clicking again will reverse the sort order. The Name and the Alias For
column are the most commonly selected sorting orders.
Figure 20: Changing the Sort Order
Creating a Controller Tag has two main methods. The first method is to copy and paste
the Controller Tag and then rename it. The second method is to create a new tag with
the desired name then select the proper Data Type using the pull down menu in the
Data Type cell.
12. Select the Edit Tags tab.
13. Right Click the square in front of the tag name KA060.
14. From the drop down menu select Copy.
Figure 21: Copy a Controller Tag
15. Right Click the square in the front of the new tag row.
16. Select Paste.
Figure 22: Pasting a Tag
Duplicate tag names are not permitted in the same program. RSLogix / Studio 5000 will
add a 1 to the end of the tag name.
Figure 23: Pasted Tag Duplicate
17. Rename Tag to the desired name. KA040, in this case.
Figure 24: Rename the Tag
Now create a tag by entering its name and selecting its desired Data Type. Browse the
controller Tags and find the KA060 tags. Select a Controller tag to add for the KA040
station. Browse the KA060 Controller Tags and choose a tag to copy for station KA040.
18. Remember or write down the Tag Name and its Data Type; KA060HMI in this
case.
Figure 25: Tag Name and Data Type
19. Click the Name cell in the Tag Entry row; this is the last row in the editor.
20. Type the desired Tag name.
21. Click in the Data Type Cell.
22. Click the Select Data Type button to access the Select data Type dialog.
23. Select the desire Data Type and click OK.
Figure 26: Creating a Controller Tag
24. Proceed with creating the Controller tags for KA040 using KA060 as a guide.
Use the tag copy or the create method to create the tags.
25. Look at the KA040 program in the Controller Organizer see Figure 28. Discover
what robots interact in the stations sequence.
26. Three robots work in the station, KN020R04, KA050R01, and KA050R02.
Create program tags for each in this format ToKN020R04.
27. Open the Controller tags and create controller tags for the tags create in step 24
using this format KA040ToKN020R04. Use the data type zc_StaToRbt for each
tag.
28. Set the Alias For column in the KA040 program tags using the tags creted in
steps 24 & 25.
29. Job Data is used to track parts through stations and Material Handling (MH)
robots.
30. Create the following aliases:
Program Tag Controller Tag Data Type

Jobdata KA040Jobdata zc_Jobdata
JobdataPrev KN020R04Jobdata zc_Jobdata
JobdataNext KA050R01Jobdata zc_Jobdata
31. Create the Stop Modes which are used to manage various Stop types such as
with parts, without parts, do not allow part load as well as unload.
Program Tag Controller Tag Data Type
StopModes KA040StopModes zc_StationHold
PrevStopModes KN020R04StopModes zc_StationHold
NextStopModes KA050R01StopModes zc_StationHold
Figure 27: KA040 Program Tags
Figure 28: Controller Organizer KA040 Program
End of Exercise 1
17.6. Removing a Station
A variety of tasks must be completed in order to delete a program, for example, a
station, cell, or robot. Exercise 6 will guide you through the minimum required tasks to
delete a station program.
17.6.1. Exercise 2: Deleting the a Station Program (Optional)
2. Access the MainTask Properties, Program Schedule tab.
3. Select AA075 in the Scheduled list.
4. Click the Remove button. This moves the program to the Unscheduled
category as shown in Figure 29.
5. Click Ok, or Apply to accept the change.
Figure 29: AA075 Moved to Unscheduled
6. Locate the program in the controller organizer. It should be listed under
Unscheduled Programs. Refer to Figure 30.
7. Expand the tree for Station AA075.
Figure 30: AA075 in Controller Organizer
8. Notice the little 1 on the A000_Main routine. This indicates that
A000_Main is assigned to the program, as the main, and must be
unassigned. See Figure 31.
Figure 31: AA075 with Main Assigned
9. Right-click the program name, AA075.

10. Select Program Properties, and Configuration Tab.
11. Select from the pull down <none> for the Main under the Assigned
Routines. Refer to Figure 32.
11
Figure 32: Program Properties Configuration
12. Open the Program Tags for AA075, and enter the edit mode.
13. Delete all program tags for program AA075.
A. Select the selection button in front of the first row in the program tags.
B. Move to the last row.
C. Press and hold the Shift Key and select the selection button. All rows
should highlight.
D. Press Delete on the keyboard.
14. Now delete all routines.
A. Select the first routine, A000_Main.
B. Press the Delete key from the keyboard, click Yes.
C. Hold the Shift key, from the keyboard, while pressing the Delete key.
This will eliminate the Delete the routine warning. Repeat until all
AA075 routines are deleted.
15. Delete the program AA075 from the Unscheduled folder.
16. Verify the I/O configuration to confirm that there are no DeviceNet Safety I/O
nodes for AA 075 station equipment (i.e. Fixture Boxes, Run Stands, etc.).
Note: Controller tags that reference the deleted program should be deleted.
END OF EXERCISE 2
17.7. Adding a Station
Adding a station to a running cell will involve many modifications to the PLC project.
These modifications may include revising the controllers I/O Configuration and the
Safety Task. The controller tag list will be updated to accommodate the new station
program. Finally, the new station program will be constructed using program tags and
routines copied from other references and editing them to suit the application.
For this example, a main line station to pick up additional weld spots will be added. The
station will contain four carried weld gun robots and will have its part transfer in and out
on a skid.
17.7.1. Exercise 3: Adding a New Station (Optional)
In this exercise, a new station, AA072, is to be created between stations AA070 and
AA075. AA072 will be a four robot welding station. Additional station edits will be
applied in ComTask17Exercise4.
2. Copy station program AA070.
A. Right-click the AA070 Program.
B. Select Copy.
C. Select MainTask.
D. Right-click and choose Paste.
3. Rename AA0701 to AA072.
Note: RS Logix 5000 / Studio 5000 will always add a 1 to the end of any tag, UDT,
routine or program, that causes a collision, already exists in project.
A. Right-click AA0701 and select Properties.
B. Rename AA0701 to AA072 (located in Name: box on the General tab).
C. Click OK.
4. Move AA072 into position between AA070 and AA075.
A. Right-click MainTask.
B. Select Properties.
C. Select Program Schedule.
D. Locate the AA072 program in the Program Schedule (it will be last in the
list).
E. Select the AA072 program.
F. Move the AA072 program between AA070 and AA075 using the Up/Down
arrow buttons.
G. Click OK to accept your changes.
H. Verify that program AA072 now appears between AA070 and AA075.
It is necessary to modify some routines in the new AA072 program that was just
created. The AA072 station is a weld re-spot station. Therefore, there are no parts
being introduced into this station. Robots AA070R01 and AA070R02 (material
handlers) will not be used in the AA072 station being created.
5. Delete the following routines in the AA072 program:
A. Right-click the routine S060_AA070R01Drop and choose Delete. Use
the same procedure to delete the following routines:
B. S065_AA070R02Drop
C. S070_CloseLHDockingClamps
D. S075_CloseRHDockingClamps
E. S135_AA070R01Repo
F. S140_AA070R02Repo
G. S145_OpenLHDockingClamps
H. S150_OpenRHDockingClamps
I. S160_AA070R01PrtChkClr
J. S165_AA070R02PrtChkClr
K. V100_AA070R01Common
L. V100_AA070R02Common
Routines containing robot names must be renamed to match the new station.
6. Right-click the S035_AA070R03Init routine and select Properties. In the
Name: field, enter S035_AA072R03Init. Use the same procedure to
rename the following routines:
A. S040_AA070R04Init to S040_AA072R04Init
B. S045_AA070R05Init to S045_AA072R05Init
C. S050_AA070R06Init to S050_AA072R06Init
D. S085_AA070R03Weld to S085_AA072R03Weld
E. S090_AA070R04Weld to S090_AA072R04Weld
F. S095_AA070R03Repo to S095_AA072R03Repo
G. S100_AA070R04Repo to S100_AA072R04Repo
H. S105_AA070R05Repo to S105_AA072R05Repo
I. S110_AA070R06Repo to S110_AA072R06Repo
J. S115_AA070R03WeldClr to S115_AA072R03WeldClr
K. S120_AA070R04WeldClr to S120_AA072R04WeldClr
L. S125_AA070R05WeldClr to S125_AA072R05WeldClr
M. S130_AA070R06WeldClr to S130_AA072R06WeldClr
N. V100_AA070R03Common to V100_AA072R03Common
O. V100_AA070R04Common to V100_AA072R04Common
P. V100_AA070R05Common to V100_AA072R05Common
Q. V100_AA070R06Common to V100_AA072R06Common
7. Verify your program AA072 routines with Figure 33.
Figure 33: Controller Organizer after Renaming Routines
END OF EXERCISE 3
17.7.2. Exercise 4: Editing a New Station (Optional)
Now that the program has been created and the routines are renamed for the new
AA072 station, some edits must be made to complete the transformation of the new
station. We will begin by editing some program tags.
2. Click the + sign next to the AA072 program. This will expand the tree view
of the program.
3. Double-click the Program Tags located under the AA072 program name.
4. Select the Edit Tags tab on the bottom of the tag editor window.
5. Delete the following AA070R01 and AA070R02 za_Action tags:
A. AA070R01Drop
B. AA070R01PrtChkClr
C. AA070R01Repo
D. AA070R02Drop
E. AA070R02PrtChkClr
F. AA070R02Repo
Figure 34: Deleting Program Tags in AA072
6. In the AA072 Program Tags, rename the following robot za_Action tags:
A. Click the cell, in the Name column, containing AA070R03Init to enter the
tag edit mode. Rename the tag to AA072R03Init. Use the same
procedure to rename the following tags:
B. AA070R03Ret to AA072R03Ret
C. AA070R03Repo to AA072R03Repo
D. AA070R03Weld to AA072R03Weld
E. AA070R03WeldClr to AA072R03WeldClr
F. AA070R04Init to AA072R04Init
G. AA070R04Ret to AA072R04Ret
H. AA070R04Repo to AA072R04Repo
I. AA070R04Weld to AA072R04Weld
J. AA070R04WeldClr to AA072R04WeldClr
K. AA070R05Init to AA072R05Init
L. AA070R05Ret to AA072R05Ret
M. AA070R05Repo to AA072R05Repo
N. AA070R05WeldClr to AA072R05WeldClr
O. AA070R06Init to AA072R06Init
P. AA070R06Ret to AA072R06Ret
Q. AA070R06Repo to AA072R06Repo
R. AA070R06WeldClr to AA072R06WeldClr
In Exercise 3, several action routines were deleted to create the AA072 program.
Some of these actions or S routines contained cylinders that were moved as a result
of the action. It is necessary to delete the zp_Cylinder tags from the removed action
routines.
Figure 35: Cross Reference a Program Tag
7. Use Cross Reference for Cylinders C01 C08. Determine tags that are
unused and delete them:
A. Right-click the square button in front of the tag name that you wish to
cross reference.
B. Select Go to Cross Reference.
C. Observe the cross reference results.
If the tag is used, check the next tag.
If the tag is not used, delete it.
D. Continue Cross Referencing and deleting through all Cylinders.
Note: Four cylinders will be deleted.
Figure 36 represents the AA072 program tags edited through to Step 7.
Figure 36: Program Tags Reflecting Edits Through Step 7
Many routines that contained part present logic were deleted in Exercise 3. It is
necessary to check for unused part tags and delete them as necessary.
8. Cross reference the following tags. Delete them if they are not used:
A. HingePillarLH
B. HingePillarRH
When cross referencing za_Action tags some may appear to be used. Navigating to
the uses in the logic will reveal that the use is in the S000_Sequence routine and is
in a call rung for a routine that was deleted in earlier edits.
9. Cross reference the following tags:

A. LHDockingClampsClose
B. LHDockingClampsOpen
C. RHDockingClampsClose
D. RHDockingClampsOpen
Figure 37: Cross Reference of LHDockingClampsClose
10. Double-click all occurrences for each tag cross reference. This will navigate
to each use of the tag.
Tag Use
(Cross
reference)
Figure 38: Tag Used in Sequence Routine Call
11. Observe that the occurrences of the tag usage are in the S000_Sequence
routine and that they are used in the sequence calls for the routines that
were deleted.
12. After similar verification for the remaining tags, delete the following tags from
the AA072 program tags:
A. LHDockingClampsClose
B. LHDockingClampsOpen
C. RHDockingClampsClose
D. RHDockingClampsOpen
The unused sequence calls in the S000_Sequence will be deleted at a later time.
13. Cross reference the tags listed below. In this case, these tags are used and
should not be deleted.
A. PinClampsClose
B. PinClampsOpen
14. Double-click the column heading for the Alias For column. This will sort
the tag listing in the order of the Alias For Column.
Many of the tags that have an Alias For must have it re-pointed. RS Logix will
indicate an error with a big X in front of a tag that does not have a correct alias. We
can take advantage of this to rename our Alias For and then later create missing
controller tags.
15. Observe that some Alias For entries are controller tags that reference cell
level tags. These tags will not require an update. Do not update the
following tags Alias For:
A. A1: Alias For: AA065A1(C)
B. Cell: Alias For: AA065B1Cell(C)
C. D1: Alias For: AA065B1CellD1(C)
D. FromHMI1JobData: Alias For: AA065B1HMI1JobData(C)
16. Delete the following AA072 program tags:
A. ToAA070R01
B. ToAA070R02
17. Update the Alias For column for the tag From1stHMI
A. Click in the Alias For column and edit: AA065B1HMI1toAA070 to
AA065B1HMI1toAA072
Figure 39: Editing the First AA072 Program Tag Alias For
B. Observe that the (C) that follows the tag name in the Alias For column
will disappear after the edit is complete and that there is a big X in front of
the tag. This is because a controller tag must be created. To do this:
C. Open the Controller tag editor.
D. Select the square button in front of the row that contains the controller tag
AA065B1HMI1toAA070.
E. Copy the entire row. This ensures that the datatype will be copied.
Figure 40: Copy a Controller Tag
F. Select the new tag button to highlight the last row in the tag editor.
G. Paste the tag AA065B1HMI1toAA070, RSLogix will add a 1 at the end of
the tag. AA065B1HMI1toAA0701
H. Rename the tag:
AA065B1HMI1toAA0701 to AA065B1HMI1toAA072
I. Open the AA072 Program Tags.
J. Confirm that the tag From1stHMI has the Alias For equal to
AA065B1HMI1toAA072(C). Also notice the X is gone from the tag button.
18. Edit the Alias For column for the following tags:
Note: You may edit the Alias For the Program tags first and then create the
controller tags or complete one tag at a time as shown above. The table that follows
contains the remaining tag and Alias For edits required for the AA072 station.
Existing Tag Name New Tag Name Existing Alias For New Alias For
FromPrev FromPrev AA065ToAA070(C) AA070ToAA072
ToNext ToNext AA070ToAA075(C) AA072ToAA075
Mode Mode AA070.Mode(C) AA072.Mode
Sts Sts AA070.Sts(C) AA072.Sts
HMI HMI AA070HMI(C) AA072HMI
Jobdata Jobdata AA070JobData(C) AA072JobData
ToPrev ToPrev AA070ToAA065(C) AA072ToAA070
To1stHMI To1stHMI AA070toAA065B1HMI1(C) AA072toAA065B1HMI1
ToAA070R03 ToAA072R03 AA070toAA070R03(C) AA072toAA072R03
FromNext FromNext AA075ToAA070(C) AA075ToAA072
Figure 41: Alias For Editing Chart
19. Verify the edits to AA072 program tags as shown in Figure 42.
Figure 42: AA072 Program Tags After Edits
At this point there are several tags that do not have a controller tag to Alias For.
20. Open the Controller Tag editor.
21. Create the following controller tags:
Tag Name Alias For (controller tags) Data Type
FromPrev AA070ToAA072 zc_SKInterlockToNext
ToNext AA072ToAA075 zc_SKInterlockToNext
Mode AA072.Mode zz_StaMode*
Sts AA072.Sts zz_StaStatus*
HMI AA072HMI zc_StaHMI
Jobdata AA072JobData zc_JobData
ToPrev AA072ToAA070 zc_SKInterlockToPrev
To1stHMI AA072toAA065B1HMI1 zc_StaToHMI
FromNext AA075ToAA072 zc_SKInterlockToPrev
*Note: zz_StaMode and zz_StaStatus are members (nested UDTs) the UDT zc_Station.
A. Copy the tag AA070 in the controller tags and rename it to AA072.
B. Copy the tag AA065ToAA070 in the controller tags and rename it to
AA070ToAA072.
C. Copy the tag AA070ToAA075 in the controller tags and rename it to
AA072ToAA075.
D. Copy the tag AA070HMI in the controller tags and rename it to
AA072HMI.
E. Copy the tag AA070JobData in the controller tags and rename it to
AA072JobData.
F. Copy the tag AA070ToAA065 in the controller tags and rename it to
AA072ToAA070.
G. Copy the tag AA070ToAA065B1HMI1 in the controller tags and rename it
to AA072ToAA065B1HMI1.
H. Copy the tag AA075ToAA070 in the controller tags and rename it to
AA075ToAA072.
I. Open the AA072 Program tags. Verify there are no tags with the large X
in front of them. Figure 43 shows how AA072 Program Tags should look
after creating the Alias For controller tags.
Figure 43: AA072 Program Tags after Creating the Alias For Controller Tag
To update the Alias For for the PMCDSta and PMCDDFTSta tags it will be necessary
to update a UDT to accommodate the new AA072 station being added.
22. Open the AA072 Program tags.
23. Left-click the + in front of the PMCD tags to expand the view of the tags as
shown in Figure 44.
Figure 44: Expanded View of PMCD Tags in AA072 Program
24. Click the pull down arrow and examine the main tag. The
PMCD.AA065B1Cell tag uses the uc_PMCObjectType_AA065B1Cell UDT.
See Figure 45.
Figure 45: PMCD Locating the UDT to Edit
25. Open the User Defined folder under Data Types. See Figure 46.
Figure 46: Controller Organizer Opening User-Defined Data Types
26. As shown in Figure 47, the Data Type Size (1) will indicate ??? when there
is a problem with one the data type (UDT) used by one or more members
(2), usually the UDT for a member is missing from the project. Any UDT
used by a member must exist in the Data Types\User-Defined folder (3).
Figure 47: Open the uc_PMCObjectType_AA065B1Cell UDT
27. Right-click the square button preceding the AA070 member.
28. Select Insert Member. See Figure 48.
Figure 48: Insert an UDT Member
1. Copy the AA070 member into the newly inserted row. See Figure 49.
Figure 49: UDT with a New Member Added
2. Rename the Member Name and Description to AA072 for the new station.
3. Verify that your UDT looks like Figure 50.
4. Click Apply or OK to save the updated UDT.
Figure 50: Completed uc_PMCObjectType_AA065B1Cell UDT
5. Open the AA072 Program tags.
6. Edit the Alias For column for station AA072 for the following tags, see
Figure 51:
A. PMCDSta
B. PMCDDFTSta
Figure 51: AA072 PMC Tags Corrected
The steps taken to this point have left errors that point to routines that do not exist in the
new AA072 program. Now some corrections in the A000_Main and S000_Sequence
must be made.
7. Delete the following calls to sub routines in the A000_Main of program
AA072:
A. V100_AA070R01Common
B. V100_AA070R02Common
Delete
Figure 52: Delete Routine Calls That Are Not Used
These routines are not used in the AA072 but were in the reference program AA070.
8. Delete the following calls (the entire rung of logic) to sub routines in the
S000_Sequence of program AA072:
A. zZ111_StartGroup (1st Input Par = 31). The robot actions that are
contained in this group are not in the AA072 program.
B. S060_AA070R01Drop
C. S065_AA070R02Drop
D. zZ112_EndGroup (31)
See Figure 53.
Delete
Figure 53: Delete Action Routine Calls and Group That Are Not Used.
The docking clamps are not necessary since no part is loaded into re-spot station
AA072.
A. zZ111_StartGroup (1st Input Par = 32). The Docking Clamp actions that
are contained in this group are not in the AA072 program.
B. S070_CloseLHDockingClamps
C. S075_CloseRHDockingClamps
D. zZ112_EndGroup (32).
10. Delete the call to the S080_HingePillarPartPresentDwell sub routine (The
entire rung of logic) in the S000_Sequence of program AA072:
B. S135_AA070R01Repo
C. S140_AA070R02Repo
A. zZ111_StartGroup (1st Input Par = 37). The Docking Clamp actions that
are contained in this group are not in the AA072 program.
B. S145_OpenLHDockingClamps
C. S150_OpenRHDockingClamps
B. S160_AA070R01PrtChkClr
C. S165_AA070R02 PrtChkClr
14. Edit the Message Offset to 5000
A. Open B005_Parameters in the AA072 program.
B. Update the Move Source in the Program Message Offset rung to 5000.
15. Update the Program Name (using ASCII codes)
A. Use the ASCII converter or look up the proper codes.
B. Open B005_Parameters in the AA072 program and edit the program
name as necessary.
16. Verify and save project.
END OF EXERCISE 4
17.7.3. Exercise 5: Adding a New Action Routine (Optional)
18. Right-click on the AA070 program in the logix organizer.
19. Click New Routine.
3
2
Figure 54: Selecting a New Routine
4
5
7
Figure 55: New Routine Dialog
20. Type the new routine name; S057_CloseClamp1.

21. Type the description for the new routine; Routine to Close 1st Clamps.
22. Verify the routine will be created in the desired program, AA070
23. Click OK.
24. Verify the new routine, S057_CloseClamp1, is displayed where desired in
the controller organizer, between S055 & S060 for this project.
25. Verify the new routine ladder is empty.
26. Open the S055_ClosePinClamps routine in station AA070
10
Figure 56: New Routine
Figure 57: Reference Routine for Copy
Note: Using a routine from the current project will eliminate some work because some
conditioning will already be completed. If a suitable routine does not exist in the project,
then utilize a comparable routine from the unscheduled programs in the GCCS-2
RSLogix 5000 reference project. The GCCS-2 RSLogix 5000 reference project contains
the standard reference routines for all tooling action sequence steps.
27. Type Control + A on the keyboard to select all rungs. Rungs selected will
have a green box (dashed here for clarity) around the rung number as in
Figure 58.
28. Type Control + C on the keyboard to copy all rungs.
Figure 58: Logix Display of Selected Rungs
29. Open S057_CloseClamp1.
30. Right-click the end line and choose paste. The routine window should
appear with the last rung pasted as shown in Figure 59.
Figure 59: Logix Display After Paste
15
Figure 60: Delete the Empty Line
31. Right Click in front of the empty rung

32. Choose Delete. (Empty rungs are not allowed in RSLogix.)
33. Open the AA070 Program Tags.
34. Copy the Tags PinClampsClose and PinClampsOpen to the clipboard.
A. Select gray box to copy all information.
35. Paste the Close and Open PinClamp tags; RSLogix will change to
PinClampsClose1 and PinClampsOpen1 to avoid a name collision.
A. Select the tag box to ensure data type and other info paste properly.
Copy the tag PinClamps

18
19 Paste the tags.
Figure 61: Creating the Action Tag
36. Rename PinClampsClose1 to Clamp1Close and PinClampsOpen1 to

Clamp1Open, see Figure 62.
Figure 62: AA070 Program Tags after Clamp1 Edits
37. Edit the main description for Clamp1Close and Clamp1Open. This is a nice
new feature known as the pass through comment from the UDT structure.
See Figure 63.
Figure 63: Editing the Main Description for a Tag
24
25
Figure 64: Edits to the Sequence Routine
38. Open the S000_Sequence Routine.

39. Copy the S055_ClosePinClamps rung.
40. Paste the rung; this will become the CloseClamps1 rung.
41. Select, from pull-down, the S057_CloseClamps1 routine.
42. Select Input and Return Parameters:
A. First Input Par = Clamp1Close (Where the unit moves to when Do is
pressed.)
B. Second Input = Clamp1Open (Where the unit moves to when Undo is
pressed.)
C. Return Parameters = Copy in exact order the input parameters.
D. When the edits are finished, they should appear similar to Figure 65.
Figure 65: Edits Finished in the Sequence Routine
END OF EXERCISE 5
17.8. Editing an Action Routine
Regardless of the methods used to create the new action routine, the logic will require
the same changes. The first is to perform a Search and Replace on the action tags. A
search and replace can be performed, for example, on all text in the routine that
matches PinClamps and replace with Clamp1, or whatever is the desired tag name.
This action completes a large portion the necessary edits but the logic now requires a
rung-by-rung analysis to ensure proper configuration. Search and Replace is
available only during offline edits. Ensure that the Search and Replace Find Within
scope is set to affect the desired routines with the replace function.
Figure 66: Close.Comp Rung
Item Description
1 Rung copied from an existing routine within the program.
2 Source rung from GCCS-1 reference project.
3 Finished rung after edits to form Clamp3Close.comp.
Figure 67: Close.Comp Rung Description
The Close.Comp rungs shown in

Figure 66 represent (1) the source rung copied from an existing step in the program, (2)
the source rung from the GCCS-1 reference project and (3) the rung as it appears in the
new sequence step routine following edits for Clamps3.
17.8.1. Exercise 6: Edits After Adding a New Routine (Optional)
2. Open S057_CloseClamp1, in the AA070 station.
3. Use Search and Replace to change PinClamps to Clamp1.
A. Select Search menu from tool bar. See Figure 68.
B. Click Replace.
3A
3B
Figure 68: Accessing Search and Replace
See Figure 69.
IMPORTANT: Be sure to select Find Where search scope as needed, in this case,
use Current Routine setting.
Enter the Find What = PinClamps (what you are searching for).
Enter the Replace With = Clamp1, what you want to change to.
The Find Within button allows defining where to find the search string. All
categories selected is fine for this search.
C. Click Replace ALL.
Figure 69: Configuring Search and Replace Options
4. Open the program tags for station AA070.
5. Add C09 & C10 tags.
6. Copy an existing cylinder tag.
7. Rename the copied tag (datatype should be zp_Cylinder). See Figure 70.
Figure 70: C09 and C10 Program Tags Created in AA070
8. Edit the main description for tags C09 and C10. See Figure 71.
Figure 71: Editing the Main Description for Tags C09 and C10
9. Open AA070 CloseClamp1 routine.
10. Edit the Switch Internal rung 1.
A. Change all tags within the boxes in Figure 72 to begin with C09
B. Edit the input to BK01.I.D13
Note: To determine unused input addresses, cross reference tag BK01.I
with the scope set to the program of interest. Any used addresses should
display in the cross reference result.
C. The finished rung should look like Figure 72.
9B
Figure 72: Closed Switch Internal Rung for Cylinder C09
11. Edit the Switch Internal rung 2.
A. Change tags to C10 as shown in Step 9.
B. Edit input to BK02.I.D13 as shown in Figure 73.
12. Delete any remaining switch internal rungs (C03 and C04) after the new C10
switch internal rung.
Figure 73: Switch Internal Rung for Cylinder C10
13. Edit the Action Complete Rung.

14. Enter XIC of C09.PX2 and XIO of C09.PX1
15. Enter XIC of C10.PX2 and XIO of C10.PX1
16. Ensure XIO of Clamps1Open.Out is the last contact before the rungs coil.
Delete any unneeded operands. The finished rung should look like Figure
74.
Figure 74: CloseClamp1.Comp Rung
17. Edit the Action Auto Rung so that Clamp1 closes after PinClampsClose is
complete.
18. Ensure XIO of MainCycle.ProcComp is in the rung.
19. Add XIC of PinClampsClose.Comp.
20. Delete any unneeded operands. The finished rung should look like Figure
75.
Figure 75: Clamp1Close.Auto Rung
21. Clamp1 will now close once PinClampsClose is complete.
22. Add AA070R05 and AA070R06 to ActionClear Rung. This allows Clamps1
to close only when these robots are clear of station AA070.
A. Add XIC of ToAA070R05.Clear.1.
B. Add XIC of ToAA070R06.Clear.1.
C. The finished rung should look like Figure 76.
Figure 76: Action Clear Rung

23. Verify that the Output Power rung looks like Figure 78.
Note: Do not use the same instructions in both the Auto and the Clear rung. For
example: XIC of PinClampsClose.Comp.
Figure 77 Do Not Duplicate Conditions in Action Auto and Clear Rung
Figure 78: Action Output Power Rung
24. Verify that the Action Command and Output Internal Rungs do not require
edits. The finished rung should look like Figure 79.
Figure 79: Command and Output Internal Rungs
25. Edit the output valve assignment to PM1.O.V4S14.
26. Cross-reference to determine that this valve address is not used more than
once. The finished rung should look like Figure 80.
Figure 80: Close Valve Output Rung
27. Verify the Action Memory, Action Fault, and the Scroll List Not Visible rungs
against
28. Figure 81. Usually edits are not necessary.
Figure 81: Action Close Memory, Fault and SL Not Visible Rungs
29. Edit the zDiagnostic Internal Enable Bypass rung.
A. Add XIO C09.BypPX2NOn.
B. Add XIO C09.BypPX2NOff.
C. Add XIO C10.BypPX2NOn.
D. Add XIO C10.BypPX2NOff.
E. Delete any unwanted operands.
The finished rung should look like Figure 82.
Figure 82: zDiagInternal Enable Bypass Rung
30. Edit the Switch Diagnostic Rung using the following table:
Item Ladder Element Tag Description

1 XIC Clamp1.Close.FLT From the motion timer rung.
2 XIC BK01.CommOK I/O block has communications,
3 XIC C09.PX2 Work position switch
4 XIC C09.PX1 Home position switch
5 JSR 2nd Input Use cross reference to determine
Parameter available alarm #
Kalarm[221]
6 JSR 2nd Input Use cross reference to determine
Parameter available alarm #
Kalarm[222]
7 Rung Comment <Alarm[221]: Clamp1 Opened C09.PX1 Not Off /*R*/
BK01.I.D12 PM1.O.V4S14 >
<Alarm[222]: Clamp1 Closed C09.PX2 Not On /*R*/
BK01.I.D13 PM1.O.V4S14 >
8 XIO C09.PX2 -
Figure 83: Switch Diagnostic Rung Chart
31. Verify this rung against Figure 84.

32. Note that the Alarm[ ] number in the rung comment, Item 7, must match the
2nd parameter in the JSR kalarm[ ] number, Item 5 & 6.
7 5
3 4
1 2
6
Switch
Diagnostic
8
Rung
Switch 11 12
Diagnostic
Bypass
Rung 9
10
Figure 84: Switch Diagnostic Rung and Bypass Bit Rung for Cylinder C09
33. Edit the lower Switch Diagnostic Bypass Rung shown in Figure 84 using the
chart below.
Item Ladder Element Tag Description

9 XIC BypSw[221] Number matches kalarm # in
preceding switch diagnostic rung.
10 XIC BypSw[222] Number matches kalarm # in
preceding switch diagnostic rung.
11 OTE C09.BypPX1NOff Home position switch Not Off
12 OTE C09.BypPX2NOn Work position switch Not On
Figure 85: Switch Diagnostic Bypass Rung Chart
The Switch Bypass Bit rung corresponds to the Switch Diagnostic rung that precedes it.
The XIC BypSw[] needs to match:
The alarm numbers used in the Switch Diagnostic rung.
Alarm[] in the rung comment.
kalarm[] in the JSR call to the diagnostic program.
The OTE must match the switch that is being diagnosed by the alarm.
Complete similar edits for cylinder C10 Alarm and Switch Bypass Bit rungs. See
Figure 86.
Figure 86: Switch Diagnostic Rung and Bypass Bit Rung for Cylinder C10
The diagnostic rungs required cylinder tag revisions. Unique kAlarms were identified for
the fault messages. Using cross reference for kAlarm produces a list of all kAlarms
used in the entire project, broken down by program. Scan the list of used kAlarms with
your eyes for this station program and select unused kAlarm numbers near the ones
used for the Pin Clamps. When multiple cylinders exist in a routine, usually also on the
same valve, the edits for diagnostic rung will be repeated for each cylinder.
34. Delete the remaining Alarm and Switch Bypass Bit rungs. (Cylinders C03
and C04).
The SL number and the scroll list text value, items A & B in Figure 87, must be unique
within the current program. In this case, the number 8 cannot be used for the scroll list
text value because it is already used in the ClosePinClamps routine in station AA070
program.
35. Update the Scroll List Configuration rung as shown in Figure 87.
A. Enter the rung comment: <SL[200]: Close Clamp1>
B. Enter the constant, 200. This constant must match the SL[] number in the
rung comment.
C. Enter Move Destination, Clamp1Close.Text.
D. Enter Move Source, KSL.Yellow.Close, this is a named constant that
represents the anticipated state of the unit at the end of the sequence
step. Yellow is used for the Work position whereas Green is used for the
Home position.
E. Enter Move Destination, Clamp1Close.Status.Type, this will hold the
value used to display sequence step status on the HMI scroll list.
Figure 87: Action Scroll List Text Rung
36. Choose a Prompt[ ] and kprompt[ ] number in the same manner as choosing
a kalarm. Use Prompt[231].
37. Enter Clamp1 Not Closed in the rung comment.
38. Enter motion prompts for all devices in the action clear rung as parallel
branches as shown in see Figure 88.
Look for the

program tag
Figure 88: Close Clamps1 Prompting Logic
39. Match the conditions in the Output Power Prompting rung to the conditions
on the Output Power rung as shown in Figure 89.
Figure 89: Close Clamp1 Output Power Prompting Logic
40. The Unlatch rung verify that the tags match the routine, Clamp1Close.PB,
Clamp1Close.Prompt, and Clamp1Close.OutPwrPrompt.
Figure 90: Unlatch of PB and Prompt Bits
41. In Figure 91, the SL Found rung verifies that the tags match the routine,
Clamp1Close.Auto, Clamp1Close.Clear, and Clamp1Close.Comp. Note:
this rung can be adjusted to accommodate unusual sequences to obtain
proper Auto Cursor functioning.
Figure 91: SL.Found Rung
42. Verify and save the program.

Note: this procedure could be used to create the action routine that opens
Clamp1. Creating this routine is not part of this lab.
END OF EXERCISE 6
17.10. Adding a Gate Box
In light of there being a few different choices for gate boxes depending on the project
and the block point that is to be used it is recommended to utilize the Unscheduled
Programs within the GCCS-2 template to configure a gate box for the project. The
boxes will be identified by the ECS number and there will be two template programs for
each ECS gate box CellGateBox and SafeGateBox. Depending on the gate box ECS
accessed the SafeGateBox will contain a routine with instruction for use in the rung
comment. Some gate boxes will also have instructions in the Cell Gate Box.
17.11. Adding / Removing Robot Actions
Like the examples presented in Modules 9.1-9.9, adding or removing robot actions will
involve creating or deleting tags and routines. For this example, a reposition step will be
added to a robots weld path. Using the previous example of the two clamp motions, the
opening sequence will be revised from all clamps opening after all welding to one set of
clamps opening during the robots weld path (i.e. a reposition) and then the robot
continuing to weld.
These program changes will affect the program tag list, program routine list, the
S000_Sequence routine, the clamps open routines, the robot weld routines and the
V100_RobotCommon routine.
Figure 92 provides some insight into the changes to the program structure resulting
from the newly added robot sequence step. Note that S050 now indicates the robot will
weld to a reposition location. The Clamps1 will open, the robot will continue its weld
path, followed by Clamps2 opening.
17.11.1. Adding and Modifying Tags
Before adding a tag for the new robot action step the tag used for the current robot
action step is modified. Editing the tag name in the program tag list will automatically
update the action tag names in the current robot step.
17.11.2. Adding and Modifying Routines
As shown in Figure 92 on the previous page, the S050_BG010R01WeldClr is
renamed S050_BG010R01WeldRepo. The S067_BG010R01WeldClr routine is
added to the program routine list by right-clicking on the program name and
selecting New Routine. The new robot action is assigned a step number between
65 and 70 so, when created, it will appear between the S065_OpenClamps1 and
S070_OpenClamps2 in the routine list.
Figure 93 provides views of the robot action tags before and after the weld action tag
was modified and the new action tag added. As mentioned above, before the new robot
action tag was added the current tag, BG010R01WeldClr, was renamed to
BG010R01WeldRepo. RSLogix 5000 automatically renames all occurrences of this tag
in the program. The new tag, BG010R01WeldClr, was then added, which happened to
be the same name of the original tag.
Figure 93: Program Tag List Before and After
17.11.3. Modifying the S000_Sequence Routine
The S000_Sequence routine is modified in much the same way it was for adding a
tooling action step (see Module 9.6). The changes to the logic involve adding a JSR
rung to call the new robot action routine. This rung is placed between the JSR rungs
for the open Clamps1 and open Clamps2 See Figure 94 below.
Figure 94: New Robot Action JSR Added to S000_Sequence Routine
17.11.4. Modifying the S050_R01WeldRepo Routine
A robot performing a typical weld operation without a reposition will run through path
Seg[1] (pounce), Seg[50] (weld to clear), Seg[62] (clear of tool) and Seg[63] (all
clear) before returning to the Home position.
A robot performing a typical weld operation with a clamp reposition will run a path
with the weld portion made of two additional path segments: Seg[50] (weld), Seg[51]
(clear for clamp reposition) and Seg[52] (continue weld).
Figure 95 represents the start of logic modifications to the S050_R01WeldRepo
routine (formerly the S050_R01WeldClr routine). The figure provides a before and
after view of the WeldRepo.Comp rung logic edits (see the highlighted robot
segment bits).
Figure 95: Changes to WeldRepo.Comp Rung
The rungs shown in Figure 96 and Figure 97 remained unchanged.
Figure 96: Set WeldRepo.Comp, ProcComp Rung
Figure 97: Reset WeldRepo.Comp / ProcComp, .Auto and ClrSetup Rungs
The branch with the highlighted robot Seg[51] bit was added to the rung shown in
Figure 98 to maintain the .Clear signal while the robot transitions from Seg[50] to the
end of Seg[51] . At that point the robot motion will stop until the clamp reposition
executes.
Figure 98: WeldRepo.Clr Rung
The rungs shown in Figure 99 and Figure 100 remained unchanged.
Figure 99: WeldRepo.OutPwr Rung
Figure 100: WeldRepo.Cmd, .Out, .Mem and .Flt Rungs
Figure 101 illustrates the changes made to the rung comment. This rung comment
contains the text of the scroll list line that will be displayed on the HMI for this robot
action sequence step.
Figure 101: Changes to the Scroll List Text Rung
The rung shown in Figure 102 and Figure 103 remained unchanged.
Figure 102: Prompt Driver Logic
Figure 103: Prompt Driver Logic (Contd)
Figure 104 shows the changes made to the message text for the Not Complete
prompt (see rung comment).
Figure 104: Weld & Repo Not Complete Prompt Text
The rungs shown in Figure 105 remained unchanged.
Figure 105: HwEnable Prompt, Scroll List PB Unlatch and SL Line Found Rungs
17.11.5. Modifying the S065_OpenClamps1 Routine
The following examples illustrate the changes made to the open Clamps1 routine
relative to the robot request for the clamps reposition.
The rungs shown in Figure 106 represent the original Clamps1 open auto setup and
the revisions made to reposition the clamps when the robot has completed its initial
welding.
Figure 106: Repo Clamps1.Auto Rung
The rungs shown in Figure 107 illustrate the edits to the Clamps1 open clear setup.
Figure 107: Repo Clamps1.Clear Rung
The edits to the robot prompt driver rung shown in Figure 108 reflects the changes
made to the Clamps1.Open.Clear rung.
Figure 108: Robot Not Clear Prompt Rungs
17.11.6. Configuring the S067_R01WeldClr Routine
This is the new robot action routine added to the station program structure back in
Module 9.10. This routine is empty at this point. The correct logic for a continue from
reposition robot action routine can be found in the current version of the GCCS-2
RSLogix 5000 reference project. Simply copy the routine contents and paste them
into the routine added to this program.
Once the routine logic is pasted in, the generic action tags will be revised and the
correct rung conditioning logic inserted into each rung.
The intent of the example shown in Figure 109 is to provide an idea of what a typical
rung (top rung in the example) from the reference routine looks like. Note that the
only changes to this rung were to rename the robot action tags which can be
completed using the search and replace function on this routine.
Figure 109: Robot WeldClr.Comp / .ProcComp Rung
The rungs shown in Figure 110 and Figure 111 are configured similar to the initial
weld action. The difference is that the .ClrSetup rung is conditioned with Clamps1
open rather than closed and the .Clear rung will go true when the robot has reached
the end of path Seg [51], remaining true through Seg [52].
Figure 110: Typical Set/Reset Robot WeldClr.Comp / .ProcComp & Auto Rungs
Figure 111: WeldClr.ClrSetup / .Clear Rungs
The rung comment shown in Figure 114 will be used to create the scroll list line text
for this new robot action step. The Source of the MOV instruction in Figure 114
must be a unique number relative to this station program. For convenience, the
number selected for the Source correlates to the sequence step number. This
number, when combined with this programs message offset, will point to a specific
scroll list line text stored within the HMI.
Figure 112: Typical WeldClr.OutPwr / .Cmd Rungs
Figure 113: Typical WeldClr.Out, .Mem, .Flt Rungs
Figure 114: Robot Action Scroll List Text Rung
Note that the conditioning logic for the prompt latch bits in the rung shown in
Figure 115 mimics the conditioning logic in the clear setup rungs of Figure 111.
Figure 115: Typical Prompt Driver Logic
Note that the prompt message number selected in rung #15 shown in Figure 116
must be unique to this station program.
Figure 116: Typical Prompt, Do /Undo and Scroll List Logic Rungs
17.11.7. V100_R01Common
This is the robot to station interface routine. There are minor changes necessary to
this routine to account for the new robot action step. Refer to Figure 117.
Figure 117: V100_R01Common .ValidSeg and .MotionEnable Rungs
The highlighted portions of the rungs featured in Figure 117represent modifications
necessary to accommodate the additional robot segments resulting from the new
robot action step.
Figure 118: V100_R01Common .MotionEnable Rung (Contd)
The rung shown in Figure 119 drives the bit used in the Clamps1 open clear setup.
See Figure 118 above.
Figure 119: R01.Clear.1 Rung
The R01.Decision.0 bit is the robot decision code for general continue commands.
The highlighted branch of the rung featured in Figure 120 was added to issue the
decision code to the robot following the clamp reposition.
Figure 120: R01.Decision.0 Rung
17.11.8. S010_MainCycle
The rungs shown in Figure 121 were modified to ensure the .ProcComp and .Comp
bits from both robot sequence steps were present.
Figure 121: MainCycle Proc / NoProcComp and Steps / NoStepsComp Rungs
17.11.9. Removing a Robot Action
Looking back at the last section in which a robot reposition action was added to the
station tooling sequence, this section will cover what needs to be done to the station
program to remove the robot action.
17.11.9.1. Record Robot Information

Record the robot path segments associated with the robot action to be removed.
From the previous example, the robot action added to the station sequence used
robot path segments [51] and [52]. The program will be searched later for these
robot path segment tags.
17.11.9.2. Remove Robot Action Routine

Right-click on the robot action sequence step routine in the station program list and
select Delete. Go to the S000_Sequence routine and remove the rung containing the
JSR calling the deleted action routine. At this point, the rung should be marked with
lower case es indicating a JSR still exists for a routine that has been removed.
17.11.9.3. Search for Robot Action, Segment, Clear Tags

Open the station program tag list. Perform a cross reference on the robot action tag.
The results will show the routines where the tags are still used. Modify these
routines accordingly.
Open the controller tag list. Perform a cross reference on the robot segment tags
recorded in Module 17.11.9.2. The results will show the routines where the tags are
still used. Modify these routines accordingly. Among these routines should be the
station V100_RobotCommon routine.
Robot path segment tags are used in the .Clear.x rungs (see Figure 119). Record
any clear bits specific to the robot action being removed. Cross reference any
applicable clear tags and modify the routines where they are used accordingly.
17.12. Adding / Removing Welding Actions
For certain situations, the procedure for adding or removing welding actions will be
similar to the revisions of the other sequence actions presented previously. There are
other situations where characteristics specific to welding actions must be considered,
that is whether the new action to be added will be for a new weld gun connected to an
existing weld controller or a new weld controller. Each one of these cases will result in
different edits to the PLC project.
17.12.1. Adding Welding Action Case 1

This example will explore what program edits need to be performed in a situation in
which a weld gun that currently welds a single spot is mounted on a slide to weld an
additional spot. In this case, the weld gun is still connected to the same SCR (Silicon
Controlled Rectifier the weld controller firing board) and weld controller.
17.12.2. Adding Tags

The highlighted tags shown in Figure 122 represent the tags required for the new
weld action and group routines. Note the WGSlide tag was required for the tooling
action added.
Figure 122: Revised Program Tag List
Adding and modifying routines requires creating sequence routines for the program
routine list. All of the sequence routines added will require a rung with the respective
JSR added to the S000_Sequence routine.
17.12.4. Adding the New Weld Action Routines
Right-click on the station program name and select New Routine to create the
new sequence routines. Figure 123 provides a before (left side) and after (right
side) view of the program routine list.
Figure 124 and Figure 125 feature the rungs inserted into the S000_Sequence
routine providing the JSR instructions to call the new action routines.
Figure 124: Modifications to the S000_Sequence Routine
Figure 125: Modifications to the S000_Sequence Routine (Contd)
17.12.6. Modifying the S040_1stWeld Routine

The highlighted bit in Figure 126 was added to the Weld1.ToolRdy rung to ensure
the weld gun slide is in the return position for the first weld action.
Figure 126: Typical .ToolRdy Rung
The highlighted branch shown in Figure 127 was added to compliment the
conditional logic in the Weld1.ToolRdy rung.
Figure 127: Typical Prompt Driver Rung
17.12.7. Configuring the S047_AdvanceWGSlide Routine

This is one of two tooling action routines added (see Module 17.12.4).
The rung shown in Figure 128 illustrates that the weld gun slide will advance
following the 1st weld complete.
Figure 128: Weld Gun Slide Advance Auto Setup Rung
17.12.8. Configuring the S048_2ndWeld Routine
The S048_2ndWeld routine is one of two weld action routines added. This routine
starts out empty following its creation in Module 17.12.4. The rung contents for this
routine are copied from the current version of the GCCS-2 RSLogix 5000 reference
project.
Both of the rungs in Figure 129 required modification of the logic pasted in. In rung
#1 there were TBD bits in each branch that were removed and all weld gun
conditioning bits were corrected with the proper tag names. The rung outputs bits
required no edits. The conditioning of rung #2 was modified for this station.
Figure 129: Weld2 Complete and Tool Ready Rungs
Rung #3 conditioning logic, shown in Figure 130, as copied from reference logic
contained the .Comp bit rather than the .ProcComp bit. Rung #4 required the weld
gun conditioning bits be corrected with the proper tag names.
Figure 130: Weld2 Previous Process Complete and Guns Clear Rungs
Figure 131: Typical Prompting Driver Logic
Figure 132: Typical Prompting Driver Logic (Contd)
17.12.9. Configuring the S049_InitW2WG01 Action Routine
This is the second of two weld action routines added. The rung contents for this
routine are also copied from the current version of the GCCS-2 RSLogix 5000
reference project. Prior to any rung configuration, a Search and Replace is
performed on all weld action tags used in the routine. As shown in the following
examples, these are the instructions assigned the W2WG01RE tags.
The only modifications required to the rungs shown in Figure 133 were the updating
of the action tags.
Figure 133: Typical 2nd Weld Init.Comp Rung
In rung #3 shown in Figure 134, the W2.PrevProcComp bit replaced
W1.PrevProcComp. The Weld2.ToolRdy bit replaced the Weld1.ToolRdy bit in rung
#4. The F1.MinorPwrOn bit in rung #5 replaced a TBD place holder. No changes
were needed in rung #6.
Figure 134: Typical 2nd Weld Init.Auto, .Clear, .OutPwr and .InitAntiRpt Rungs
No changes are made to the rungs shown in Figure 135.
Figure 135: Typical 2nd Weld Init.Cmd, .Out and .InitWeld Rungs
No changes are made to the rungs shown in Figure 136.
Figure 136: Typical 2nd Weld .SeqDone and Init.Mem Rungs
Changes were made to rung #15 of Figure 137 to reflect the proper scroll list line
text and number for the new weld action.
Figure 137: Typical 2nd Weld .Init.FLT, SL.NotVisible and SL Text Rungs
Changes to the rungs shown in Figure 138 included ensuring proper prompt
message numbers in rung #16 and the Weld2.ToolRdy and Weld2.Prompt
instructions in rung #17 replaced Weld1.ToolRdy and Weld1.Prompt,
respectively.
Figure 138: Typical 2nd Weld Prompt Message and Motion Prompt Rungs
The lower two branches for the operator light curtain were added to the rung shown
in Figure 139.
Figure 139: Typical 2nd Weld Output Power Prompt Driver Rungs
No changes were necessary to the rungs shown in Figure 140.
Figure 140: Typical 2nd Weld Do / Undo Unlatch and SL Found Rungs
17.12.10. Modifying the S050_OpenWGRetract Action Routine
The highlighted instructions shown in Figure 141 illustrate the changes made to the
WGRetract.Open.Auto, .Clear rungs.
Figure 141: Typical Weld Gun Retract .Auto, .Clear Rungs
The highlighted branch shown in Figure 142 was added for the Weld2 motion prompt
driver.
Figure 142: Typical Weld Gun Retract Motion Prompt Driver Rungs
17.12.11. Modifying the S063_ReturnWGSlide Action Routine
This is the second of two tooling action routines added (see Module 17.12.4 for
details about adding a tooling action). The rung shown in Figure 143 illustrates the
weld gun slide will return following process complete and the weld gun open and
clear.
Figure 143: Typical Weld Gun Slide Return .Auto Rung
17.12.12. Modifying the W001_WeldCommon Routine
Figure 144: Typical Weld Gun Valve Output and SCR .InitiateWeld Logic
17.12.13. Modifying the S010_MainCycle Routine
The rungs shown in Figure 145 highlight the revisions made to the process complete
and steps complete logic to account for the additional weld action.
Figure 145: Typical Proc / NoProcComp and Steps / NoStepsComp Rungs
17.13. Adding Weld Action Case 2
This example will explore the program edits that need to be performed when a new weld
gun is connected to a spare SCR of an existing weld controller. The station currently
contains two weld guns connected to a SCR3 weld controller.
17.13.1. Adding the SCR3 Ethernet Module

As previously indicated, the weld controller used for this example currently uses two
of its three SCRs. Although the spare SCR is available it is not configured in the
PLCs I/O Configuration since it is not used. This section will illustrate adding the
SCR3 Ethernet communication module and the mapping of the SCR I/O.
The partial view of the PLC I/O Configuration shown in Figure 146 includes the new
Ethernet module created for SCR3. Right-clicking on the Ethernet word at the top of
the tree and selecting New Module opens the new module dialog. Another
method is to right-click on an existing module and select Copy, then right-click on
the Ethernet word at the top of the tree and select Paste. This will create a
duplicate module. Right-click on the duplicate module and select Properties to edit
the module name and IP address.
Figure 146: SCR3 Ethernet Module Configuration
17.13.2. Mapping the SCR3 I/O
To establish control of the weld controller SCR, the I/O must be mapped. When the
SCR Ethernet module was created in Module 17.14.1 the controller scope input and
output tags were created as well. These tags are mapped to the PLC control data in
the B001_MapInputs and B002_MapOutputs routines of the weld controller program.
See the GCCS-1 Standard Section 6 Hard Auto Weld Program for details on
mapping SCR I/O.
Figure 147: Typical SCR3 Input Mapping Configuration
Figure 148: Typical SCR3 Output Mapping Configuration

The following require edits:
Controller tag
Station program tag
Weld controller program tag data base.
The controller tag highlighted tag in Figure 149 provides the interface between the
station program and the weld controller program.
Figure 149: Revised Controller Tag List
In this particular case, the highlighted program tag shown in Figure 150 was created
during the software generation process. The controller tag featured in the previous
figure is aliased to this program tag to complete this portion of the station to weld
controller interface.
Figure 150: Revised Weld Controller Program Tag List
The highlighted tags shown in Figure 151 represent the tags required for the new
weld action and SCR.
Figure 151: Revised Station Program Tag List
The example under consideration in this section will result in one new sequence
routine added to the program routine list and a rung with the respective JSR added
to the S000_Sequence routine.
17.13.5. Adding the New Weld Action Routine

Right-click on the station program name and select New Routine to create the
new sequence routine. Figure 152 provides a before and after view of the program
routine list.
Figure 152: Revised Station Program Routine List
Figure 153 features the rung (#18) inserted into the S000_Sequence routine
providing the JSR instructions to call the new action routine.
Figure 153: Modifications to the S000_Sequence Routine
17.13.7. Modifying the S040_1stWeld Rouitne
The rung shown in
Figure 154, Figure 155, and Figure 156 illustrate the edits made to the Weld1
complete logic for the additional weld gun.
Figure 154: Modifications to Weld1.Comp Logic
Figure 155: Modifications to Weld1.NoComp, .ProcComp, .NoProcComp Logic
Figure 156: Modifications to Weld1.GunsClear Logic
17.13.8. Configuring the S051_InitWG03 Routine
The rung contents for this routine are copied from the current version of the GCCS-2
RSLogix 5000 reference project. Prior to any rung configuration a Search and
Replace is performed on all weld action tags used in the routine.
The rungs shown in Figure 157 required no further changes beyond renaming the
weld action tags (except for renaming the weld controller tags for the correct SCR)
Refer to the highlighted instructions at the top of rung #1.
Figure 157: Typical Init.Comp / .ProcComp Rungs
Minor edits were required to the rungs shown in Figure 158. The weld controller tag
for the highlighted instruction in rung #3 was renamed for the correct SCR. The robot
clear of tooling bit was added for this station in rung #4. The F1.MinorPwrOn bit in
rung #5 replaced a TBD place holder. No changes were needed in rung #6.
Figure 158: Typical Weld Init.Auto, .Clear, .OutPwr and .InitAntiRpt Rungs
The rungs featured in Figure 159 required no additional configuration other than the
weld controller tag for the highlighted instruction in rung #9 being renamed for the
correct SCR.
Figure 159: Typical Weld Init.Cmd, .Out and .InitWeld Rungs
The rungs featured in Figure 160 required no additional configuration other than the
weld controller tag for the highlighted instruction in rung #10 being renamed for the
correct SCR.
Figure 160: Typical Weld .SeqDone, .Mem Latch / Unlatch Rungs
The rungs shown in Figure 161 required minor edits as follows:
The weld controller tag for the highlighted instruction in rung #13 was renamed
for the correct SCR.
The rung comment for rung #15 was revised for the new weld gun.
The MOV instruction for the text number in rung#15 was revised.
Figure 161: Typical Weld Init.FLT, SL.NotVisible and SL Line Rungs
Figure 162: Typical Weld Do / Undo Prompt Message and Prompt Driver Logic
Figure 163: Typical PB Unlatch and SL.Found Latch Logic
17.13.9. Modifying the W001_WeldCommon Routine

The rungs shown in Figure 164 were added to the routine to actuate the new weld
gun valve and send the weld initiate signal to the weld controller SCR.
Figure 164: Typical Weld Gun Valve Output and SCR .InitiateWeld Logic
The highlighted branches of the rungs shown in Figure 165 and Figure 166 were
added for the spare SCR commissioned for the new weld action.
Figure 165: Typical SCR .NoControlStops and .ContactorSaver Logic
Figure 166: Typical SCR .ContactorSaver (Contd) and .ResetSteppers Logic
The rung shown in Figure 167 was added for SCR 3.
Figure 167: Typical SCR .ResetFaults Rung
The highlighted rung branches shown in Figure 168 were added for SCR 3.
Figure 168: Typical SCR .WeldModeReq and .StaTryout Rungs
The highlighted instruction of rung #18, shown in Figure 169, was added for SCR 3.
Rung #22 was added for the new weld gun.
Figure 169: Typical SCR End of Stepper Summation Weld Gun Open Timer Logic
17.14. Adding Weld Action Case 3
This example will explore the program edits that need to be performed in a situation in
which a new weld gun is connected to a new weld controller (WC02). Much of the
routine creation and modifications associated with this scenario was covered in the
previous examples. The major differences include the types of tags that need to be
created and the additional weld controller program that will be added. For convenience,
this example will build on the one used in Module 17.13.
17.14.1. Adding SCR EtherNet Module

This is the same procedure described in Module 17.13.1.
Figure 170: Typical SCR EtherNet Module Configuration

Adding a new weld gun and controller requires revising the controller and station
program tag lists.
Figure 171: Revised Controller Tag List
The tags highlighted in Figure 172 represent the new tags required for the additional
weld action.
Figure 172: Revised Station Program Tag List
17.14.3. Adding the New Weld Controller Program

A new weld controller requires that a weld controller program be added to the PLC
Main Task. Right-clicking in the Main Task word at the top of the program tree and
selecting New Program will open the new program dialog. Right-click again on
the Main Task word and select Properties to define the order the new weld
controller program will appear in the program list. See Figure 173 for the Main Task
listing with the new weld controller program.
Figure 173: Revised Controller Program List
17.14.4. Adding Weld Controller Program Tags and Routines
The program tags and routines for this program can be copied from the GCCS-2
RSLogix 5000 reference project although they will require some configuration.
To begin, the program tags will need to be aliased to the correct controller tags.
Refer to Figure 174.
Figure 174: New Weld Controller Program Tag List
The correct z33x_WS2AxSCR routine to use (Figure 175) will be determined by the
number of SCRs contained in the weld controller. The example used here is a single
SCR weld controller.
Figure 175: New Weld Controller Program Routine List
After the program routines are copied, the A000_Main routine is designated the
main routine of the program by right-clicking on the program name, selecting
Properties and selecting the Configuration tab.
Minor edits may need to be made to the A000_Main for the correct SCR driver
routine JSR. The configuration of the B001_MapInputs and B002_MapOutputs
routines was covered in Module 17.13.2. The correct program message offset and
name is defined in the B004_Parameters routine. The last two routines are standard,
no-edit routines.
Routines added to the station program pertaining to the new weld action in this
example have been previously discussed in Modules 17.12.4 or 17.13.4.
17.15. Removing a Weld Action

17.15.1. Remove the Weld Action Routine
Right-click on the weld action init sequence step routine in the station program list
and select Delete. Remove the weld group routine if the weld action is the only one
in this group. Go to the S000_Sequence routine and remove the rung containing the
JSR calling the deleted action routine (and weld group routine, if applicable). At this
point, the rung should be marked with lower case es indicating a JSR still exists for
a routine that has been removed.
17.15.2. Search for Weld Action Tags

Open the station program tag list. Perform a cross reference on the weld action and
weld gun tags. The results show the routines where the tags are still used. Modify
these routines accordingly.
17.15.3. Remove / Inhibit SCR EtherNet Module

If the weld controller SCR used by the former weld action is disconnected,
communication faults will make it necessary to remove the SCR EtherNet module
from the PLC I/O configuration or inhibit the module from its properties tab.
17.16. Adding a Robot
Adding a robot to a running cell will involve several modifications to the PLC project.
These tasks include:
Configuring the robot Ethernet and DeviceNet I/O modules
Adding robot controller tags
Modifying the Safety Task
Creating the robot program.
Creating the robot program will require copying program tags and routines from the
GCCS-2 RSLogix 5000 reference project and editing them to suit the application.
17.16.1. Adding the Robot Ethernet Module

The method used to configure the robot Ethernet module is the same as the one
used to configure the weld controller SCR Ethernet module in the previous module.
Figure 176: Typical Robot Ethernet Module Configuration
17.16.2. Adding the Robot DeviceNet Safety I/O
The method used to add the robot DeviceNet Safety I/O module is similar to the one
used to add the Ethernet module. In this case, a duplicate of the module at node 11
is made by:
Right-clicking on the module
Selecting Copy
Right clicking on the DeviceNet word
Selecting Paste
Configuring the new module for the correct node number and robot name is
performed by right-clicking on the module and selecting Properties. The new
module is highlighted in Figure 177.
Figure 177: Typical Robot DeviceNet Safety I/O Module Configuration
17.16.3. Adding the Robot Controller Scope Tags
Figure 178 and Figure 179 illustrate the tags added to the controller tag list for the
new robot. Note that the highlighted tags within the shaded regions were created
during the robot Ethernet and Safety I/O module configuration.
Figure 178: Non-Safety Controller Tags Added
Figure 179: Safety Controller Tags Added
17.16.4. Modifying the Safety Task
Updating the Safety Task for a new robot involves modifying the program tag list and
several of the routines supporting robot functionality. Refer to Figure 180, Figure
181, Figure 182, and Figure 183.
Figure 180: Safety Task Program Tag Added
Figure 181: Safety Task B001_MapInputs Routine Modification
Figure 182: Safety Task B002_MapOutputs Routine Modification
Figure 183: Safety Task B010_SafetyConfig Routine Modifications
Figure 184 highlights the modifications made to the Safety Task robot routines. The
R000_5Robots routine replaced R000_4Robots. This is the routine that calls the
individual robot routines that follow. R005_Robot5 was added for the new robot.
Note that the R000_5Robots routine is called by A000_Main. Therefore, the rung
containing the JSR calling the former R000_4Robots routine was modified.
Figure 184: Safety Task Robot Routine Modifications
17.16.5. Adding the Robot Program

Section 17.14.3 discussed the method to add a weld controller program to the Main
Task. Adding a robot program is performed in the same manner. The new robot
used for this demonstration will be added to the first station in the cell.
The highlighted robot program shown in Figure 185 was created for the new robot.
This robot will be utilized in the first station (BP005B1 in this example) to perform
spot welding.
Figure 185: Revised Main Task List (Partial)
17.16.6. Adding the Robot Program Scope Tags
These tags are copied from the reference project and edited per the application.
Figure 186 illustrates the robot program tag list as copied from the RSLogix 5000
reference project. Note that aliases for the Cell, FromSta1, HMI, R and
TputRbtCT tags have been updated per this application. Also, to update the aliases
for the PMCDDFTRobot and PMCDRobot tags the
uc_PMCObjectType_BP008Cell UDT was revised to include the new robot.
Figure 186: Typical Robot Program Tag List
17.16.7. Adding the Robot Program Routines
The routines to build the robot program are copied from the GCCS-2 reference
project. After opening the reference project, it is best to expand the robot program.
Opening each routine will determine if the routine can be copied as is or if it is a
place holder directing the engineer to another area within the reference project to
obtain the routine specific to the application.
All of the routines are first assembled in the destination project and then each one is
configured as required. Of the 19 routines used to build the robot program, only six
required some form of configuration in this case.
Figure 187 represents the completed routine list for the new robot. A check of each
routine will determine any configuration necessary to the logic copied from the robot
reference program. At this point, right-click on the program name and select
Properties. Select the Configuration tab and designate the A000_Main routine
as the programs main routine.
Figure 187: New Robot Program Routine List
The rungs shown in Figure 188 represent the only modifications made to the
A000_Main routine as copied from the reference program. All of these JSRs
contained generic routine names.
Figure 188: A000_Main Routine Modifications
The rungs shown in Figure 189 thru Figure 192 represent the rungs requiring
modifications in the B001_MapInputs routine as copied from the reference program.
Figure 189: B001_MapInputs Routine Modifications
Figure 190: B001_MapInputs Routine Modifications (Contd)
The rungs shown in Figure 193 represent the rungs requiring modifications in the
B002_MapOutputs routine as copied from the reference program.
Figure 193: B002_MapOutputs Routine Modifications
The rungs shown in Figure 194 represent the rungs requiring modifications in the
B004_Parameters routine as copied from the reference program.
Figure 194: B004_Parameters Routine Modifications
The rung shown in Figure 195 represents the rung requiring modifications in the
B010_Zones routine as copied from the reference program.
Figure 195: B010_Zones Routine Modifications
The rung shown in Figure 196 represents the rung requiring modifications in the
X100_PMCRobot routine as copied from the reference program. Also refer to
Figure 197 for more information.
Figure 196: X100_PMCRobot Routine Modifications
Figure 197: X100_PMCRobot Routine Modifications
17.17. Removing a Robot
17.17.1. Remove Robot Program from Main Task

The first step to removing a robot from the PLC project is to remove the robot
program from the controllers Main Task. This is accomplished by right-clicking
on the Main Task at the top of the program tree and selecting Properties.
Select the Program Schedule tab. Scroll down list under the heading
Scheduled: select the robot program name and click the Remove button. This
action will move the robot program name under the Unscheduled: heading (see
Figure 198). Upon clicking Apply and / or OK the actual robot program will be
moved from the Main Task to the Unscheduled area of the controller organizer.
Figure 198: Main Task Properties Dialog
17.17.2. Deleting the Robot Program
Expand the robot program tree. Right-click on each routine and select Delete.
Open the program tag list and select the Edit Tags tab. Highlight all of the tags and
select Delete. Close the program tag list. Right-click on the robot program name
and select Delete.
17.17.3. Removing Robot from I/O Configuration

Right-click on the robot Ethernet Module in the controller I/O Configuration and
select Delete. Locate the robot DeviceNet Safety I/O node in the DNB
configuration. Right-click on the I/O module and select Delete.
17.17.4. Modify the Safety Task

Refer to the module on modifications to the Safety Task for adding a robot. Remove
and replace the R000_xRobots routine to suit the revised cell configuration. Remove
the appropriate R00x_Robotx routine. Open the program tag list and re-alias any
R0x tags as necessary. Modify the A000_Main, B001_MapInputs,
B002_MapOutputs and B010_SafetyConfig routines as required. Verify the
controller.
17.17.5. Deleting Station Components from I/O Configuration

Locate any DeviceNet Safety I/O nodes for station equipment (i.e. Fixture Boxes,
Run Stands, etc.) in the DNB configuration. Right-click on each I/O module and
select Delete.
17.18. Adding / Removing Interlocks to Other Devices
A common example of an interlock between devices is when a station within one cell
must interact with a station from another cell. This scenario will require the two cells be
interlocked so that information such as communication, mode, e-stop and interference
statuses are made available to the stations on both sides. Interlocks are actually
controller scope tags produced by one controller and consumed by other controller(s).
The producer / consumer communication takes place over the cell to cell Ethernet
network.
Creating an interlock between two controllers will require adding an Ethernet module to
each controllers I/O Configuration. Custom UDTs for the produced / consumed tags
will be created based on the type of information shared between cells. Finally, the tags
will be mapped accordingly in each cell.
17.18.1. Adding the Ethernet / Controller Modules

Adding an Ethernet module to the I/O Configuration for controller to controller
communication varies somewhat from adding a weld controller SCR or robot
(Modules 17.13.1 and 17.16.1). This is actually a two step process in which the
Ethernet module is added, followed by adding the remote controller to the Ethernet
module.
Figure 199 illustrates the I/O Configuration of a typical controller (BB010) currently
interlocked to one controller (BK010).
Figure 199: Typical Controller I/O Configuration
An interlock to another controller is established by right-clicking on the Ethernet
word directly under the controllers Ethernet module (Enet02 in the figure above) and
selecting New Module. This will open the Select Module dialog consisting of three
categories:
Communications
HMI
Others.
Expand the Communications tree and select the 1756-ENBT/A type module and
select OK. Refer to Figure 200.
Figure 200: Select Communication Module Dialog
Figure 201 shows the new module setup dialog that opens once the Ethernet
module type is selected. The items highlighted are filled in according to the Ethernet
module in which the interlock is being established. When the OK button is pressed,
the module will appear in the controller I/O Configuration (see Figure 202 below).
The second part of this setup process will link the remote Ethernet module just
created to the controller in the same chassis.
Figure 201: New Module Configuration Dialog
Figure 202: Revised Controller I/O Configuration
The controller in the remote chassis is defined by right-clicking on 1756 Backplane

and selecting New Module.
This will open the Select Module dialog consisting of six categories:
Analog
Communications
Controllers
Digital
Other
Specialty.
Expand the Controllers tree and select the controller type that matches the remote
PLC (in this case a 1756-L61S) and select OK.
Figure 203 shows the new module setup dialog that opens once the controller
module type is selected. The items highlighted are filled in according to the controller
in which the interlock is being established.
Figure 203: New Module Configuration Dialog
When the OK button is pressed, the module will appear in the controller I/O
Configuration (see Figure 203, above, right) under the Ethernet module previous
created. Note that the modules appearing in slot 1 (Partner) and slot 2
(BC010_Enet02) were created when the controller in slot 0 was created.
This completes the I/O Configuration modifications in this controller. The controller in
which the interlock is being established will require the same edits to its I/O
Configuration before communication can begin.
17.18.2. Adding the Interlock Tags
Figure 204 shows the two tags (one standard, one safety) this controller (BB010)
produces to the interlocked controller (BC010). In this example, the station BB040
(located in this cell, BB010) will control the pick action for a robot residing in the
BC010 Cell. The UDT of the standard tag (BB010toBC010Interlocks in this
example) is a custom data structure based on the amount of interaction between the
cells. The UDT of the safety tag (s_BB010Interlocks) is more standardized, typically
providing the communication and other cell safety statuses.
Figure 204: Produced Interlock Tags
After the tags are created, they must be defined as produced in order for the
remote controller to retrieve the data from the tag structure. To access the properties
dialog of the tag begin by right clicking on the tag name in the tag list and select Edit
properties. Produced is selected from the pull down menu for tag Type:. Pressing
the Connection button opens a dialog in which the maximum number of
controllers consuming the tag data is defined. See Figure 205 below for more
details.
Figure 205: Tag Properties Dialog
The consumed tags are created in the same manner as the produced but the tag
properties are configured differently.
Figure 206 shows the two tags (one standard, one safety) this controller (BB010)
consumes from the interlocked controller (BC010). Again, the UDT of the standard
tag (BC010toBB010Interlocks in this example) is a custom data structure based on
the amount of interaction between the cells. This tag contains the bits to manually
initiate the robot actions from the BC010 (remote) Cell. The UDT of the safety tag
(s_BC010Interlocks) provides the same data as the produced safety tag described
in Figure 206.
Figure 206: Consumed Interlock Tags
After the tags are created, they must be defined as consumed in order to retrieve
the data from the produced tag structure in the remote controller. To access the
properties dialog of the tag, begin by right-clicking on the tag name in the tag list and
select Edit properties. Consumed is selected from the pull down menu for tag
Type:. The Connection button opens a dialog to specify where to get the data for
the consumed tag. The Producer: pull down menu contains a list of all controllers
with an Ethernet communication connection defined in this controllers I/O
Configuration. Simply select the remote controller from the list. The Remote Data: is
filled in with the name of the produced tag providing the desired data. The RPI: is
set to 60ms for standard consumed tag data (Note that the RPI: is set to 30ms
for safety tag data). See Figure 207 below for more details.
Figure 207: Tag Properties Dialog
The procedure referenced above for adding the produced / consumed interlock tags
to this controller must be performed on the remote controller before communication
can be established.
17.18.3. Mapping the Consumed Tag Data
The standard consumed tag data is mapped to controller tags in the cell and station
level programs. The safety consumed tag data is used in the C001_InterlockStatus
routine of the cell program and the B010_SafetyConfig routine of the cell safety
program. Refer to Figures 202 thru 208 below.
Figure 208: Typical Consumed Tag Mapping Cell Program, B001_MapInputs Routine
Figure 209: Typical Standard Consumed Tag Mapping Station Program, B001_MapInputs Routine
Figure 210: Typical Standard Consumed Tag Mapping Station Program, B001_MapInputs Routine (Contd)
Figure 211: Typical Standard Consumed Tag Mapping Cell Program, C001_InterlockStatus Routine
Figure 212: Typical Safety Consumed Tag Data used for Communication Diagnostics Cell Program,
C001_InterlockStatus Routine
Figure 213: Typical Safety Consumed Tag Data used for Communication Diagnostics Cell Program,
C001_InterlockStatus Routine (Contd)
Figure 214: Typical Safety Consumed Tag Data used for E-stop Monitoring Cell Safety Program, B010_SafetyConfig
Routine
17.18.4. Mapping the Produced Tag Data

Controller tags in the station level program are mapped to standard produced tag
data. A cell safety program tag is mapped to the safety produced tag data.
Figure 215: Typical Standard Produced Tag Data Mapping Station Program, B002_MapOutputs Routine
Figure 216: Typical Standard Produced Tag Data Mapping Station Program, B002_MapOutputs Routine (Contd)
Figure 217: Typical Safety Produced Tag Data Mapping Cell Safety Program, B002_MapOutputs Routine
17.19. Removing an Interlock
17.19.1. Remove Ethernet / Controller Modules

Figure 218 shows the current view of the controllers I/O configuration. Right-clicking
on the remote controller icon and selecting Delete will remove the controller and all
consumer tags linked to the controller. The Ethernet module can be deleted in the
same manner.
Figure 218: Typical Controller I/O Configuration
17.19.2. Remove Produced / Consumed Mapping

Delete the tags produced to the former remote controller. Verify the controller. The
deleted produced and consumed tags will display several errors to be displayed
following a project verify. Search all error locations and modify logic accordingly.
The F4 function key on the keyboard will navigate the display through errors one at a
time so they can be corrected.
17.20. Adding / Removing Styles
Adding or removing job styles will require modifications to station program job data and
throughput routines. Job data transfers from stations to robots are automatic but any
throughput routines residing in robot programs will require edits.
17.20.1. Adding a Style Station Program

The routines affected in the station program by the addition of a new job style are
the J001_JobData and X224_TputUser routines. For this example, the cell
currently processes style numbers 7 and 8. A new style number 9 will be added.
Figure 219: Typical Station Jobdata.Valid Logic
The rungs shown in Figure 219 are typical of the Jobdata.Valid outputs found in the
J001_JobDataRF and J001_JoDataShiftReg routines, respectively. The highlighted
branch in rung #12 was added for the new style. The High Limit of the LIM
instruction in rung #13 was increased to ensure the new style was included in the
range of valid styles.
Figure 220: Typical Station TputWsData.Type Logic
The rung shown in Figure 220 is taken from the station X224_TputUser throughput
routine. To activate this rung for the new style, an AlwayOff bit was removed from
the top branch and the EQU instruction Source B was assigned the number 9 for
the new style.
17.20.2. Adding a Style Robot Program

The routine affected in the robot program by the addition of a new job style is the
X200_TputUser routine. For this example, the cell currently processes style
numbers 7 and 8. A new style number 9 will be added.
The rung shown in Figure 221 is taken from the robot X200_TputRbtUser
throughput routine. To activate this rung for the new style an AlwayOff bit was
removed from the beginning of the rung and the EQU instruction Source B was
assigned the number 9 for the new style.
Figure 221: Typical Robot TputRbt.Bits.Type Logic
17.20.3. Removing a Style

The procedure to remove a style can follow the same procedure used to add a style.
Simply modify the station and robot job data or throughput routines for the obsolete
style number(s). Note that the engineer must be cognizant of any control logic
outside the indicated routines that may be utilizing style data being removed.
17.21. Review
1. How do you change / update a tooling sequence?
2. How do you add / remove a tooling action?
3. How do you edit an action routine?
4. How do you add a new station?
5. How do you delete a station?

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GCCS-2

Global Common Control Software Design

Manufacturing Engineer: Noel Miller

Template Version 1.0

Date Revision By Revision History

2015 General Motors Company. All Rights Reserved

2015 General Motors Company. All Rights Reserved

2015 General Motors Company. All Rights Reserved

Figure 1: Add-On Instruction Example

1.9. Normative References

Figure 2: Covisint (GM Supply Power host) Home Screen

3. Enter your User ID and Password.

5. Click GM SupplyPower under Covisint Applications > Automotive Portals

Figure 4: Covisint Directed Communications Page

6. Click the Applications tab.

7. Scroll to Manufacturing Engineering Vehicle Systems and click the link.

Figure 6: GM Supply Power Home Page Application

8. Click Global Standards, Specifications, and Procedures on Home Page.

9. Click eTools & Checklists

Figure 8: Global Standards Home Page

Figure 9: GM Supply Power Home Page - Global Ethernet e-Tools

1.12. Plant Floor Systems (PFS)

Figure 10: Safety Task

Figure 11: Program and Routine Description

1.13.4. Routine Names

1.14. Ladder Logic Contents

Figure 12: The TBD Tag Blocking Logic

1.14.1. Rung Comments

Figure 13: Rung Comments

1.14.2. Operand Description

Note: Only the Main Description is editable by the user.

Module 2: RSLogix Overview

Manufacturing Engineer: Noel Miller

Template Version 1.0

Date Revision By Revision History

2015 General Motors Company. All Rights Reserved

2015 General Motors Company. All Rights Reserved

2015 General Motors Company. All Rights Reserved

2015 General Motors Company. All Rights Reserved

2015 General Motors Company. All Rights Reserved

2015 General Motors Company. All Rights Reserved

Figure 1: GCCS-1 Systems

2.3. Controller Organization

The processor is also referred to as the controller.

Controller Scope Tags

Figure 2: Controller Organization for Standard Controller

Controller Scope Tags

Continuous Task Periodic Safety Task

Figure 3: Controller Organization for Guard Logix Controller

2.4. Processor and Logix File Naming

2.5. I/O Module Configuration

Figure 5: Adding I/O Modules to the Local Chassis

2.5.1. Adding New Modules

Figure 7: Download Add On Profile zips

Figure 8: Starting the Setup Wizard

Figure 9: Accept the EULA

Figure 10: Choose Install

Figure 11: Install Status Window

Figure 12: Click Finish, Install is Complete

Figure 13: Configuration Review Utility

Item Description Definition

To configure advanced settings for the processor:

Select Configure Always.