RSLogix 5000 Report(s) PDF

A000_Main - Ladder Diagram Page 1
Cosma:MainTask:CELL 11/11/2010 1:27:29 PM

Total number of rungs in routine: 9 J:\A_Standards\Integrators\MASSIV\Software\CosmaLogixTemplate_0_1_example.ACD
JSR
0 Jump To Subroutine
Routine Name C001_MainRackStatus
JSR
Routine Name X002_InfoMessage
JSR
Routine Name X010_Overview
JSR
Routine Name B001_MapInputs
JSR
Routine Name G000_SafetyGates
JSR
Routine Name M001_Modes
JSR
Routine Name B002_MapOutputs
JSR
Routine Name P001_Production
JSR
Routine Name X001_StatusFault
(End)
RSLogix 5000
B001_MapInputs - Ladder Diagram Page 2
Cell Map Inputs
Any Cell-Wide inputs that have to be copied into local tags from input module
RungComment
0
Global Cell/PV PVCell

interface Fault Fault Reset
Reset button (on PV Pushbutton
Screen) (Hardware)
HMICell.FltRst_Pb HMICell.FltrstHpb
1
(End)
RSLogix 5000
B002_MapOutputs - Ladder Diagram Page 3
Cell Map Outputs
Any Cell-Wide outputs that have to be copied from local tags to actual output module
RungComment
0
System 1st Output

Card O4.1
System.O1.1 <Local:4:O.Data.1>
1
(End)
RSLogix 5000
C001_MainRackStatus - Ladder Diagram Page 4
CONTROLLER STATUS
JSR
Routine Name Z001_ControllerStatus
CONTROLLER BATTERY LOW
Cell
Controller Logix Controller
Battery Low Battery Low
Status Fault
Controller.BatteryLow Cell.RackFaults.31
1
MODULE FAULTS
A module fault is required for every Input and Output module "owned" by the controller
(do not include ControlNet, DeviceNet, or EtherNet)
TYPICAL INPUT MODULE FAULT
Monitor the module I.Fault word & clear input image

(Comm loss leaves inputs in last state - faulted inputs must be cleared)
A MVM is used because it will work with normal and diagnostic modules.
RungComment
2
INPUT/OUTPUT MODULE FAULTS
Cell
Logix I/O
Slot 3
Controller Input Card
I/O Status No Faults Fault
Controller.IOStatusOK NEQ Cell.RackFaults.0
3 / Not Equal
Source A Local:3:I.Fault
MVM
2#0000_0000_0000_0000_0000_0000_0000_0000
Masked Move
Source B 0
Source 0
Mask Local:3:I.Fault
2#0000_0000_0000_0000_0000_0000_0000_0000
Dest I2
<Local:3:I.Data>
2#0000_0000_0000_0000_0000_0000_0000_0000
I/O
Slot 2
Input Card
Faulted
Controller.SlotFault.2
Cell
Logix I/O
Slot 4
Controller Input Card
I/O Status No Faults Fault
Controller.IOStatusOK NEQ Cell.RackFaults.1
4 / Not Equal
Source A Local:4:I.Fault
I/O
2#1111_1111_1111_1111_1111_1111_1111_1111
Slot 7
Source B 0
Output Card
Faulted
Controller.SlotFault.7
=======================================================================================
DEVICENET MODULE DIAGNOSTICS
One JSR is required for every DNB module
To use this file:

1) Create a Controller Tag "DNet{ss}" of type ac_DNet.
2) Turn on t
RungComment
5
===== DeviceNet Module Slot 7 =====
DeviceNet Module
Local Slot 7
Enable
DNet07.Module.Enable
6 L
Local:7:O.CommandRegister.Run
DeviceNet Comm
Status
Sets Controller
Scope DNetXX Tags
JSR
Jump To Subroutine
Routine Name Z002_DNetStatus
Input Par 7
Input Par Local:7:S
Input Par Local:7:I.StatusRegister
Input Par DNet07
Return Par DNet07
RSLogix 5000
DeviceNet Power On Timer
Place DeviceNet Power Circuit Breaker in this rung. If more than

one breaker is used to feed the DeviceNet place them in series.
DeviceNet Module
Local Slot 7 Status
DeviceNet Module DeviceNet Module
Local Slot 7 Local Slot 7
Power On Timer Power On Timer
MOV TON
7 Move Timer On Delay EN
Source 10000 Timer DNet07.Module.PwrOnTmr
Preset 0 DN
Dest DNet07.Module.PwrOnTmr.PRE Accum 0
0
Alarm: DNet Scanner Slot 07 Not At Node 0

Alarm: DNet Scanner Slot 07 Faulted
Alarm: DNet Scanner Slot 07 Idle
Node 0
Enable
DNet07.Node[0].Enable
8
DeviceNet Module
Local Slot 7 DNet Scanner
MAC ID Slot 7
(Node Address) Not at Node 0
NEQ Cell.RackFaults.2
Not Equal
Source A DNet07.Module.Node
0
Source B 0
DeviceNet Module DeviceNet Module DNet Scanner

Local Slot 08 Local Slot 7 Slot 7
Power On Timer Any Module Fault Faulted
DNet07.Module.PwrOnTmr.DN DNet07.Module.Faulted Cell.RackFaults.3
DeviceNet Module
Local Slot 7 DNet Scanner
Not In Run Slot 7
Not Faulted Idle
DNet07.Module.Idle Cell.RackFaults.4
===== DeviceNet Module Slot 8 =====
DeviceNet Module
Local Slot 8 Status
Dnet Enable
Dnet08.Module.Enable
9 L
Local:8:O.CommandRegister.Run
DeviceNet Comm
Status
Sets Controller
Scope DNetXX Tags
JSR
Jump To Subroutine
Routine Name Z002_DNetStatus
Input Par 8
Input Par Local:8:S
Input Par Local:8:I.StatusRegister
Input Par Dnet08
Return Par Dnet08
DeviceNet Power On Timer
Place DeviceNet Power Circuit Breaker in this rung. If more than

one breaker is used to feed the DeviceNet place them in series.
DeviceNet Module
Local Slot 7 Status
DeviceNet Module DeviceNet Module
Local Slot 7 Local Slot 8 Status
Power On Timer Dnet Power On timer
MOV TON
Source 10000 Timer Dnet08.Module.PwrOnTmr
Preset 0 DN
Dest DNet07.Module.PwrOnTmr.PRE Accum 0
0
RSLogix 5000
Alarm: DNet Scanner Slot 07 Not At Node 0

Alarm: DNet Scanner Slot 07 Faulted
Alarm: DNet Scanner Slot 07 Idle
DeviceNet Module
Local Slot 8 Status
Dnet Enable
Dnet08.Node[0].Enable
11
DeviceNet Module
Local Slot 8 Status DNet Scanner Slot 8
Dnet Node Not at Node 0
NEQ Cell.RackFaults.5
Not Equal
Source A Dnet08.Module.Node
0
Source B 0
DeviceNet Module DeviceNet Module DNet Scanner

Local Slot 8 Status Local Slot 8 Status Slot 7
Dnet Power On timer Dnet Faulted Faulted
Dnet08.Module.PwrOnTmr.DN Dnet08.Module.Faulted Cell.RackFaults.6
DeviceNet Module
Local Slot 8 Status DNet Scanner Slot 8
Dnet Idle Idle
Dnet08.Module.Idle Cell.RackFaults.7
(End)
RSLogix 5000
G000_SafetyGates - Ladder Diagram Page 7
*** Add Calls to every Safety Gate Routine ***
JSR
Routine Name G00n_SGnn
Cell At least one

Safety Gate 1 gate is open in the
Open cell
SG1.GateOpen Cell.AnyGateOpen
1
Safety Gate 2
Open
SG2.GateOpen
Safety Gate 3
Open
SG3.GateOpen
Safety Gate 4
Open
SG4.GateOpen
Safety Gate 1 Cell At least one

Request to Enter Request to Enter
Memory active.
SG1.EnterReqMem Cell.AnyGateReqEntr
2
Safety Gate 2
Request to Enter
Memory
SG2.EnterReqMem
Safety Gate 3
Request to Enter
Memory
SG3.EnterReqMem
Safety Gate 4
Request to Enter
Memory
SG4.EnterReqMem
Force Clear to Enter if waiting for more than 45 sec

Cell At least one Cell Safety Gates Cell Safety Gates
Request to Enter Request to enter Request to enter
active. Timer Timer
Cell.AnyGateReqEntr MOV TON
Source 45000 Timer Cell.SGReqTmr
Preset 0 DN
Dest Cell.SGReqTmr.PRE Accum 0
0
Clear To Enter Gate

Robots
Stopped.
Cell At least one Cell OK to Clear
Request to Enter Auto drop To Enter
active. Mode Auto Cell
Cell.AnyGateReqEntr Cell.Mode.Auto Cell.Mode.Stopped Cell.SGEnterClr
4
Cell
Auto
Mode
Cell.Mode.Auto
/
Cell Safety Gates
Request to enter
Timer
Cell.SGReqTmr.DN
(End)
RSLogix 5000
G00n_SGnn - Ladder Diagram Page 8
Safety Gate Signals
RungComment
0
Standard Structure Standard Structure

For Solenoid For Solenoid
Operated Operated
Safety Gate Box Safety Gate Box
Rev. 0 Request to Rev. 0 Enter Request
Enter PB Pushbutton
SGnn.Sfty.ReqEnterPB SGnn.EnterReqHpb
1
Standard Structure
For Solenoid Standard Structure
Operated For Solenoid
Safety Gate Box Operated
Rev. 0 Power On / Safety Gate Box
Flt Reset / Auto Rev. 0 Automatic
Mode PB Mode Pushbutton
SGnn.Sfty.PwrOn_AutoPB SGnn.AStartHpb
2

Operated Operated
Rev. 0 Safety Gate Rev. 0 Safety Gate
Locked Open
SGnn.Sfty.Locked SGnn.GateOpen
3 /
Safety Gate1 Enter Request

Standard Structure
Rev. 0 Cancel Safety Gate Box
Request To Enter Rev. 0 Request to
Timer Enter Memory
SGnn.T_EntrReqOff.DN SGnn.EnterReqMem
4 U
Cell All E-Stops Ok
Cell.sfty.AllEStopOk
/
Cell At least one PVCell
gate is open in the Auto Start
cell PB(Hardware)
Cell.AnyGateOpen HMICell.AStartHpb

Standard Structure For Solenoid For Solenoid
For Solenoid Operated Operated
Operated Safety Gate Box Safety Gate Box
Safety Gate Box Rev. 0 Cancel Rev. 0 Cancel
Rev. 0 Automatic Request To Enter Request To Enter
Mode Pushbutton Timer Timer
SGnn.AStartHpb MOV TON
Move Timer On Delay EN
Source 5000 Timer SGnn.T_EntrReqOff
Preset 0 DN
Dest SGnn.T_EntrReqOff.PRE Accum 0
0

Operated Operated
Rev. 0 Enter Request Rev. 0 Request to
Pushbutton Enter Memory
SGnn.EnterReqHpb SGnn.EnterReqMem
5 L
Unlock Gate
Operated Operated
Safety Gate Box Clear Safety Gate Box
Rev. 0 Request to To Enter Rev. 0 Unlock Safety
Enter Memory Cell Gate Solenoid
SGnn.EnterReqMem Cell.SGEnterClr SGnn.UnlockGate
6
Cell All E-Stops Ok
Cell.sfty.AllEStopOk
/
Indicator Lamps
Operated Operated
Rev. 0 Request to System Normal Rev. 0 Enter Clear
Enter Memory Flasher Lamp
SGnn.EnterReqMem System.Flsh.Norm SGnn.EnterClrLmp
7
Standard Structure
For Solenoid
Operated
Safety Gate Box
Rev. 0 Unlock Safety
Gate Solenoid
SGnn.UnlockGate
RSLogix 5000
G00n_SGnn - Ladder Diagram Page 9
Standard Structure
For Solenoid
Operated
Cell Safety Gate Box
Automatic Cell Machine Power Rev. 0 Automatic
Mode Setup On System Slow Flasher Mode Lamp
Cell.Mode.AutoSet Cell.Sfty.PwrOn System.Flsh.Slow SGnn.AutoLmp
8 /
Cell All Safety Cell Machine Power
Cell All E-Stops Ok Gates Ok On System Slow Flasher
Cell.sfty.AllEStopOk Cell.sfty.AllSGOk Cell.sfty.PwrOn System.Flsh.Slow
AFI /
Cell
Automatic Cell System Normal
Mode Setup All Robots In Auto Flasher
Cell.Mode.AutoSet Cell.RbtAuto System.Flsh.Norm
Cell
Auto
Mode
Cell.Mode.Auto
PVnn
Test
Pb(S)
HMInn.Test_Pb
Standard Structure
Rev. 0 Safety Gate Safety Gate Box
Cell All E-Stops Ok E-Stop OK Rev. 0 E-Stop Lamp
Cell.sfty.AllEStopOk SGnn.Sfty.EStopOK SGnn.EStopLmp
9 /
System Normal
Flasher
System.Flsh.Norm
PVnn
Test
Pb(S)
HMInn.Test_Pb
Safety Gate Outputs

Standard Structure
For Solenoid Auxiliary Data type
Operated to drive non safety
Safety Gate Box devices on safety
Rev. 0 Enter Clear outputs Request To
Lamp Enter Lamp Output
SGnn.EnterClrLmp SGnn_Box_Outputs.ReqEnterLmp
10
Standard Structure Auxiliary Data type

For Solenoid to drive non safety
Operated devices on safety
Safety Gate Box outputs Power On /
Rev. 0 Automatic Auto Mode Lamp
Mode Lamp Output
SGnn.AutoLmp SGnn_Box_Outputs.PwrOn_AutoLmp
11
Standard Structure
For Solenoid Auxiliary Data type
Operated to drive non safety
Safety Gate Box devices on safety
Rev. 0 Unlock Safety outputs Lock
Gate Solenoid Solenoid Output
SGnn.UnlockGate SGnn_Box_Outputs.LockSolenoid
12 /
Standard Structure Auxiliary Data type

For Solenoid to drive non safety
Operated devices on safety
Safety Gate Box outputs E-Stop Lamp
Rev. 0 E-Stop Lamp Output
SGnn.EStopLmp SGnn_Box_Outputs.EStopLmp
13
(End)
RSLogix 5000
M001_Modes - Ladder Diagram Page 10
No Mode Selected
Cell Cell No
Auto Manual Mode
Mode Mode Selected
Cell.Mode.Auto Cell.Mode.Man Cell.Mode.NoMode
0 / /
Automatic Mode
Cell No Cell
Safeties Mode Cell Cell Automatic
Reset Selected All Robots In Auto Air On Cell Enable Mode Setup
Cell.Rst Cell.Mode.NoMode Cell.RbtAuto Cell.Utility.AirOn Cell.Mode.Wld.En Cell.Mode.AutoSet
1
Cell Cell in
Auto Dry
Mode Mode
Cell.Mode.Auto Cell.Mode.DryMode
Cell Auto Auto

To Man To Man
PVCell Switch Switch
Manual Push Button Delay Delay
HMICell.Man_Pb MOV TON
Source 3000 Timer Cell.Mode.TmAutoToMan
Preset 0 DN
Dest Cell.Mode.TmAutoToMan.PRE Accum 0
0
Robots
Stopped.
OK to Auto
drop Mode
Auto Shutoff
Cell.Mode.Stopped Cell.Mode.AutoOff
3
Cell
Idle
for
40 min
Cell.Mode.TmIdle.DN
Auto
To Man
Switch
Delay
Cell.Mode.TmAutoToMan.DN
PVCell Cell Auto Cell

Automatic Push Automatic Mode Cell Cell Auto
Button Mode Setup Shutoff Auto Timer Mode
HMICell.Auto_Pb Cell.Mode.AutoSet Cell.Mode.AutoOff Cell.Mode.AutoTmr.DN Cell.Mode.Auto
4 /
PVCell Cell Cell
Auto Start Auto Timer
PB(Hardware) MOV
HMICell.AStartHpb Move
Source 3000
Cell
Dest Cell.Mode.AutoTmr.PRE
Auto
0
Mode
Cell.Mode.Auto
Cell
Auto Timer
TON
Timer On Delay EN
Timer Cell.Mode.AutoTmr
Preset 0 DN
Accum 0
RepeatInputs OP OPnn:{OPName}
Turn Auto Mode Off if cell idle for 40 minutes
During the transition to Cycle Complete, both Cycle Start and Cycle Complete are ON.
We use that transition to reset the idle timer.
Cell STnn
Auto Cycle Cell Idle cell
Mode Start shutdown timer
Cell.Mode.Auto STnn.Cyc.Start MOV
5 / Move
Source 2400000
STnn
Cycle
Dest Cell.Mode.TmIdle.PRE
Complete
0
STnn.Cyc.Cpl
/
Cell Idle cell
shutdown timer
TON
Timer On Delay EN
Timer Cell.Mode.TmIdle
Preset 0 DN
Accum 0
Weld Mode Logic

PVCell
Weld Push Button Cell One Shot Cell Toggle Request
HMICell.Wld_Pb Cell.Mode.Wld.Ons Cell.Mode.Wld.Tggl
6 ONS
Cell Toggle Request Cell Enable Cell Disable

Cell.Mode.Wld.Tggl Cell.Mode.Wld.En Cell.Mode.Wld.Dis
7
RSLogix 5000
Cell PVCell Cell in
Safeties Dry Cycle Push Dry
Cell Toggle Request Reset Cell Disable Button Mode Cell Enable
Cell.Mode.Wld.Tggl Cell.Rst Cell.Mode.Wld.Dis HMICell.Dry_Pb Cell.Mode.DryMode Cell.Mode.Wld.En
8 / / /
PVCell
Auto Start
PB(Hardware)
HMICell.AStartHpb
PVCell
Automatic Push
Button
HMICell.Auto_Pb
Cell Enable
Cell.Mode.Wld.En
Cell
Auto
Mode
Cell.Mode.Auto
Manual Modes
Cell PVCell No
Safeties Automatic Push Mode Cell
Reset Button Selected Manual Setup
Cell.Rst HMICell.Auto_Pb Cell.Mode.NoMode Cell.Mode.ManSet
9 /
Cell
Manual
Mode
Cell.Mode.Man
Cell
PVCell Cell Manual
Manual Push Button Manual Setup Mode
HMICell.Man_Pb Cell.Mode.ManSet Cell.Mode.Man
10
Cell
Manual
Mode
Cell.Mode.Man
Cell Stop Requests

Cell At least one Cell
Request to Enter Stop
active. Request
Cell.AnyGateReqEntr Cell.Mode.StopReq
11
Cell
All Robots In Auto
Cell.RbtAuto
/
Cell
Water On
Cell.Utility.WtrOn
/
Cell
Stop at Home
Request
Cell.Mode.StopHome
12 AFI
************ Dry Cycle Mode *************

PVCell Cell
Dry Cycle Push Dry Cycle
Button Ons Toggle
HMICell.Dry_Pb Cell.Mode.Dry.Ons Cell.Mode.Dry.Tggl
13 ONS
Cell Cell Cell

Dry Cycle Dry Cycle Dry Cycle
Toggle Enable Disable
Cell.Mode.Dry.Tggl Cell.Mode.Dry.En Cell.Mode.Dry.Dis
14
Cell
No Cell No Cell Cell
Mode Dry Cycle Cell Cell Part Dry Cycle Dry Cycle
Selected Toggle All Ops Home All Robots Home Present Disable Enable
Cell.Mode.NoMode Cell.Mode.Dry.Tggl Cell.OpsHome Cell.RbtHome Cell.NPP Cell.Mode.Dry.Dis Cell.Mode.Dry.En
15 /
Cell
Dry Cycle
Enable
Cell.Mode.Dry.En
Cell Cell in
Dry Cycle Dry
Enable Mode
Cell.Mode.Dry.En Cell.Mode.DryMode
16 L
RSLogix 5000
Cell
Cell No STnn Cell in
Dry Cycle Cell Cell Part Cycle Dry
Enable All Robots Home All Ops Home Present Start Mode
Cell.Mode.Dry.En Cell.RbtHome Cell.OpsHome Cell.NPP STnn.Cyc.Start Cell.Mode.DryMode
17 / / U
Cell Delay when
forcing cell out of
Dry Mode
Cell.Mode.TmDryOff.DN
PVCell Cell Delay when Cell Delay when

Dry Cycle Push forcing cell out of forcing cell out of
Button Dry Mode Dry Mode
HMICell.Dry_Pb MOV TON
Source 3000 Timer Cell.Mode.TmDryOff
Preset 0 DN
Dest Cell.Mode.TmDryOff.PRE Accum 0
0
Cell in Cell
Dry Dry Cycle Dry Mode
Mode Enable Stopping
Cell.Mode.DryMode Cell.Mode.Dry.En Cell.Mode.DryStop
18 /
Line Run-Out Mode

Cell Line
No Runout
Cell Part Cell Mode
All Robots Home Present All Ops Home Enabled
Cell.RbtHome Cell.NPP Cell.OpsHome Cell.Mode.LineRunout
19 U
Line
Runout PVCell
Mode Line Runout
Enabled Pushbutton
Cell.Mode.LineRunout HMICell.Runout_Pb
Cell Line Line

Cell Cell in No PVCell Runout Runout
Auto Dry Part Line Runout Mode Mode
Mode Mode Present Pushbutton Timer Enabled
Cell.Mode.Auto Cell.Mode.DryMode Cell.NPP HMICell.Runout_Pb Cell.Mode.TmRunOut.DN Cell.Mode.LineRunout
20 / / L
Cell Line
All Robots Home Runout
Cell.RbtHome Mode
/ Timer
MOV
Cell
Move
All Ops Home
Source 3000
Cell.OpsHome
/ Dest Cell.Mode.TmRunOut.PRE
0
Line
Runout
Mode
Timer
TON
Timer On Delay EN
Timer Cell.Mode.TmRunOut
Preset 0 DN
Accum 0
******** Cell Status Indicators ********

AUTO, HOME, MAN, MANSTP, WELD, DRY
Cell
Automatic Cell System Normal PVCell
Mode Setup All Robots In Auto Flasher Automatic Indicator
Cell.Mode.AutoSet Cell.RbtAuto System.Flsh.Norm HMICell.Auto_Ind
21
Cell
Auto
Mode
Cell.Mode.Auto
Cell
Manual PVCell
Mode Manual Indicator
Cell.Mode.Man HMICell.Man_Ind
22
PVCell
Cell Enable Weld Indicator
Cell.Mode.Wld.En HMICell.Wld_Ind
23
Cell in
Dry System Normal PVCell
Mode Flasher Dry Cycle Indicator
Cell.Mode.DryMode System.Flsh.Norm HMICell.Dry_Ind
24
Cell
Dry Cycle
Enable
Cell.Mode.Dry.En
(End)
RSLogix 5000
P001_Production - Ladder Diagram Page 13
Shift Change Logic
Minutes
Elapsed
Since
Midnight
CPT
0 Compute
Dest Prod.CurrTimeM
0
Expression Controller.Time.Hour*60+Controller.Time.Min
Current
Shift
CLR
Clear
Dest Prod.CurrShift
0
Is It Shift 1?
Start of
Shift 1,
in minutes
since
midnight
CPT
1 Compute
Dest Prod.ShiftStartM[1]
0
Expression Prod.ShiftStTime[1].Hour*60+Prod.ShiftStTime[1].Min
End of
Shift 1,
in minutes
since
midnight
CPT
Compute
Dest Prod.ShiftEndM[1]
0
Expression Prod.ShiftEndTime[1].Hour*60+Prod.ShiftEndTime[1].Min
Start of
Shift 1, Minutes
in minutes Elapsed
since Since Current
midnight Midnight Shift
NEQ LIM MOV
2 Not Equal Limit Test (CIRC) Move
Source A Prod.ShiftStartM[1] Low Limit Prod.ShiftStartM[1] Source 1
0 0
Source B Prod.ShiftEndM[1] Test Prod.CurrTimeM Dest Prod.CurrShift
0 0 0
High Limit Prod.ShiftEndM[1]
0
Shift 1
Active
Prod.Shift1Active
Is it Shift 2?
Start of
Shift 2,
in Minutes
since
Midnight
CPT
3 Compute
0
End of
Shift 2,
in Minutes
since
Midnight
CPT
Compute
0
Start of
Shift 2, Minutes
in Minutes Elapsed
since Since Current
Midnight Midnight Shift
NEQ LIM MOV
0 0
0 0 0
0
Shift 2
Active
Prod.Shift2Active
RSLogix 5000
Is it Shift 3?
Start of
Shift 3,
in Minutes
since
Midnight
CPT
5 Compute
0
End of
Shift 3,
in Minutes
since
Midnight
CPT
Compute
0
Start of
Shift 3, Minutes
in Minutes Elapsed
since Since Current
Midnight Midnight Shift
NEQ LIM MOV
0 0
0 0 0
0
Shift 3
Active
Prod.Shift3Active
Calculate the elapsed hours since the start of the shift

Minutes
Elapsed
Since
Start of
Shift
CPT
7 Compute
Dest Prod.CurrMin
0
Expression Prod.CurrTimeM-Prod.ShiftStartM[Prod.CurrShift]
Minutes Minutes
Elapsed Elapsed
Since Since
Start of Start of
Shift Shift
LEQ ADD
Less Than or Eql (A<=B) Add
Source A Prod.CurrMin Source A Prod.CurrMin
0 0
Source B 0 Source B 1440
Dest Prod.CurrMin
0
Hours +1 Hours +1
Elapsed Elapsed
Since Start Since Start
of Shift of Shift
DIV ADD
Divide Add
Source A Prod.CurrMin Source A Prod.CurrHour
0 0
Dest Prod.CurrHour Dest Prod.CurrHour

0 0
Style Number Logic

Current
Style
MOV
8 Move
Source 1
Dest Prod.CurrStyle
0
Reset Part Counters 15 minutes before the beginning of each shift

Start of
Shift 1, Produced
in minutes Minutes Minutes Parts
since To Start To Start Counter
midnight of Shift 1 of Shift 1 (Shift, Hour, Style)
NEQ SUB EQU FLL
9 Not Equal Subtract Equal Fill File
Source A Prod.ShiftStartM[1] Source A Prod.ShiftStartM[1] Source A Prod.MinsToShift[1] Source 0
0 0 0 Dest ProdParts[1,0,0]
Source B Prod.ShiftEndM[1] Source B Prod.CurrTimeM Source B 15 Length 65
0 0
Dest Prod.MinsToShift[1]
Total
0
Day
Production
FLL
Fill File
Source 0
Dest ProdParts[0,0,0]
Length 65
RSLogix 5000
Start of
Shift 2, Produced
in Minutes Minutes Minutes Parts
Midnight of Shift 2 of Shift 2 (Shift, Hour, Style)
NEQ SUB EQU FLL
0 0
0
Start of
Shift 3, Produced
in Minutes Minutes Minutes Parts
Midnight of Shift 3 of Shift 3 (Shift, Hour, Style)
NEQ SUB EQU FLL
0 0
0
Cell Cycle time Measurement

Production Status Production Status
Cycle Time Cycle Time Cycle Time
Timer Timer Timer
Prod.CycTimeTmr.DN MOV RTO
12 / Move Retentive Timer On EN
Source 999999 Timer Prod.CycTimeTmr
Preset 0 DN
Dest Prod.CycTimeTmr.PRE Accum 0
0
RSLogix 5000
Last 10 cycle times and average, and Production Count (total and classified by shift, hour and style)
Production Status
Robot Cycle times for last
xxRnn Clear of Area Ons 10 cycles
xxRnn.Ctl.AreaClr.0 Prod.Ons COP
13 / ONS Copy File
Source Prod.CycleTimes[1]
Dest Prod.CycleTimes[0]
Length 9
Cycle
Time
for Last
Cycle
MOV
Move
Source Prod.CycTimeTmr.ACC
0
Dest Prod.CycleTimes[9]
0
Cycle Time
Average
for last
10 cycles
AVE
Average File EN
Array Prod.CycleTimes[0]
Dim. To Vary 0 DN
Dest Prod.CycleTimesAVG
0 ER
Control Prod.CycTimeCtrl
Length 0
Position 0
Cycle Time
Timer
Prod.CycTimeTmr
RES
Total
Day
Production
ADD
Add
Source A ProdParts[0 ,0 , 0]
0
Source B 1
Dest ProdParts[0,0,0]
0
ADD
Add
Source A ProdParts[0, 0 , Prod.CurrStyle]
0
Source B 1
Dest ProdParts[0,0,Prod.CurrStyle]
0
Current
Shift
NEQ ADD
Not Equal Add
Source A Prod.CurrShift Source A ProdParts[Prod.CurrShift , Prod.CurrHour , Prod.CurrStyle]
0 0
Dest ProdParts[Prod.CurrShift,Prod.CurrHour,Prod.CurrStyle]
0
ADD
Add
Source A ProdParts[Prod.CurrShift , Prod.CurrHour , 0]
0
Source B 1
Dest ProdParts[Prod.CurrShift,Prod.CurrHour,0]
0
ADD
Add
Source A ProdParts[Prod.CurrShift , 0 , Prod.CurrStyle]
0
Source B 1
Dest ProdParts[Prod.CurrShift,0,Prod.CurrStyle]
0
ADD
Add
Source A ProdParts[Prod.CurrShift ,0 , 0]
0
Source B 1
Dest ProdParts[Prod.CurrShift,0,0]
0
Part Counter
STnn
Cycle Part Count
Complete Counter
STnn.Cyc.Cpl CTU
14 Count Up CU
Counter Prod.PartCount
Preset 0 DN
Accum 0
PVCell
Part Counter #1
Display
MOV
15 Move
Source Prod.PartCount.ACC
0
Dest HMICell.PrtCnt_Ina
0
RSLogix 5000
Part Counter Reset
Production Status
PVCell Part Count
Counter Reset Push Reset Part Count
Button Timer Counter
HMICell.Ctres_Pb Prod.CntRstTmr.DN Prod.PartCount
16 RES
Production Status
Part Count Part Count
Reset Reset
Timer Timer
MOV TON
Source 3000 Timer Prod.CntRstTmr
Preset 0 DN
Dest Prod.CntRstTmr.PRE Accum 0
0
*
Cell Downtime Measurement
*
Production Status
Cell Down/
Downtime Downtime Overcycle
Detection Detection Detection
Timer 1 Timer 2 Timer
MOV MOV MOV
17 Move Move Move
Source Prod.TargetCycTime Source Prod.TargetCycTime Source 90000
0 0
Dest Prod.DTDetTmr1.PRE Dest Prod.DTDetTmr2.PRE Dest Prod.CellDTDetTmr.PRE
30000 30000 120000
If starting a new hour, accumulate shift downtime and reset downtime timers
Hours +1
Elapsed
Since Start
of Shift Production Status
NEQ MOV
18 Not Equal Move
Source A Prod.CurrHour Source Prod.CurrHour
0 0
Source B Prod.LastHour Dest Prod.LastHour
0 0
CPT
Compute
Dest ProdDownTime[Prod.CurrShift,0]
0
Expression ProdDownTime[Prod.CurrShift,0]+Prod.CellDTTmr.ACC/60000
CPT
Compute
Dest ProdOverCycle[Prod.CurrShift,0]
0
Expression ProdOverCycle[Prod.CurrShift,0]+Prod.OvCycleTmr.ACC/60000
Downtime OverCycle
Measurement Measurement
Timer Timer
Prod.CellDTTmr Prod.OvCycleTmr
RES RES
Downtime Detection
Count Idle Time for 1st Station
Production Status Production Status
STnn DownTime DownTime
Shift 1 Cycle Detection Detection
Active Complete Timer 2 Timer 2
Prod.Shift1Active STnn.Cyc.Cpl EQU MOV
19 Equal Move
Source A Prod.DTDetTmr2.ACC Source Prod.DTDetTmr1.ACC
Shift 2
0 0
Active
Source B 0 Dest Prod.DTDetTmr2.ACC
Prod.Shift2Active 0
Shift 3 STnn DownTime

Active Cycle Detection
Prod.Shift3Active Complete Timer 1
STnn.Cyc.Cpl TON
/ Timer On Delay EN
Timer Prod.DTDetTmr1
Preset 30000 DN
Accum 0
STnn DownTime
Cycle Detection
Complete Timer 2
STnn.Cyc.Cpl TON
Timer On Delay EN
Timer Prod.DTDetTmr2
Preset 30000 DN
Accum 0
RSLogix 5000
Downtime Discrimination:
If less than xxx seconds: Overcycle
If more, Downtime
Cell Down/
DownTime Overcycle
Detection Detection
Timer 1 Timer
Prod.DTDetTmr1.DN TON
20 Timer On Delay EN
Timer Prod.CellDTDetTmr
DownTime
Preset 120000 DN
Detection
Accum 0
Timer 1
Prod.DTDetTmr2.DN
Cell Down/
Overcycle Cell OverCycle
Detection Auto Measurement
Timer Mode Timer
Prod.CellDTDetTmr.DN Cell.Mode.Auto RTO
/ Retentive Timer On EN
Timer Prod.OvCycleTmr
Preset 86401000 DN
Accum 0
Cell Downtime
Auto Measurement
Mode Timer
Cell.Mode.Auto RTO
Timer Prod.CellDTTmr
Cell Down/
Preset 86401000 DN
Overcycle
Accum 0
Detection
Timer
Prod.CellDTDetTmr.DN
Cell
Stopped
(Cicle time
over
nominal)
Prod.CellDown
Shift 1
Active
Prod.Shift1Active DIV
21 Divide
Source A Prod.CellDTTmr.ACC
Shift 2
0
Active
Source B 60000
Prod.Shift2Active
Dest ProdDownTime[Prod.CurrShift,Prod.CurrHour]
Shift 3 0
Active
Prod.Shift3Active DIV
Divide
Source A Prod.OvCycleTmr.ACC
0
Source B 60000
Dest ProdOverCycle[Prod.CurrShift,Prod.CurrHour]
0
ADD
Add
Source A Prod.CellDT[Prod.CurrShift]
0
Source B Prod.Overcycle[Prod.CurrShift]
0
Dest Prod.TotalDT[Prod.CurrShift]
0
(End)
RSLogix 5000
P002_PartsInLineCounter - Ladder Diagram Page 19
Parts In Line Counter
Will count how many parts are there in the whole line or in a section of it
RungComment
0
Clear counter
CLR
1 Clear
Dest PartsInLine[0]
0
**** Repeat this rung for every OP ****

In any of these three conditons,
we count only one part for the station:
- PP on station
- PP on pickup robot and pickup robot in pickup area
- PP on dropoff robot and robot in dropoff area
STnn
1st Parts
All Present
STnn._1stPP.Pres ADD
2 Add
Source A PartsInLine[0]
Robot
0
xxRnn Pick up Robot
Source B 1
Complete xxRnn Clear of Area
xxRnn.Sta.PickCpl.1 xxRnn.Ctl.AreaClr.2 Dest PartsInLine[0]
/ 0
Robot
xxRnn Pick up Robot
Complete xxRnn Clear of Area
xxRnn.Sta.PickCpl.1 xxRnn.Ctl.AreaClr.1
/
**** Repeat this rung for every Robot ****

We count a part on the robot only if the robot is clear of all tools
Robot
xxRnn Pick up Robot Robot
Complete xxRnn Clear of Area xxRnn Clear of Area
xxRnn.Sta.PickCpl.1 xxRnn.Ctl.AreaClr.1 xxRnn.Ctl.AreaClr.2 ADD
3 Add
Source A PartsInLine[0]
0
Source B 1
Dest PartsInLine[0]
0
(End)
RSLogix 5000
P003_PartFaultTrack - Ladder Diagram Page 20
Parts Fault Tracker
Will move Part Tracker UDT from OP to Robot to OP...
RungComment
0
Use this rung to clear all of the members of ClrRejectInfo

This tag will be copied to other RejectInfo structures for clearing them
Blank
PartInfo Blank
Tag Used PartInfo
To Clear Tag Used
Other PartInfos Part To Clear
must be rejected at Other PartInfos
next Reject Station Style Number
ClrPartInfo.Reject CLR
1 U Clear
Dest ClrPartInfo.Style
0

When Robot goes to Pickup, copy RejectInfo from OP to Robot (If Part in OP)
STnn Robot
1st Parts Robot xxRnn Part
All Present xxRnn Clear of Area Information
STnn._1stPP.Pres xxRnn.Ctl.AreaClr.1 COP
2 / Copy File
Source STnn.PartInfo
Dest xxRnn.Sta.PartInfo
Length 1

When Pickup Robot is away from station, if there is no PP on OP, clear RejectInfo
STnn
1st Parts Robot STnn Part
All Present xxRnn Clear of Area Information
STnn._1stPP.Pres xxRnn.Ctl.AreaClr.1 COP
3 / Copy File
Source ClrPartInfo
Dest STnn.PartInfo
Length 1

When Robot goes to Dropoff, copy RejectInfo from Robot to OP (If Part in Robot)
Robot
xxRnn Pick up Robot STnn Part
Complete xxRnn Clear of Area Information
xxRnn.Sta.PickCpl.1 xxRnn.Ctl.AreaClr.2 COP
4 / Copy File
Source xxRnn.Sta.PartInfo
Dest STnn.PartInfo
Length 1

When Robot is Clear of all tools and there is no PP on it, clear RejectInfo
Robot Robot
xxRnn Pick up Robot Robot xxRnn Part
Complete xxRnn Clear of Area xxRnn Clear of Area Information
xxRnn.Sta.PickCpl.1 xxRnn.Ctl.AreaClr.1 xxRnn.Ctl.AreaClr.2 COP
5 / Copy File
Source ClrPartInfo
Dest xxRnn.Sta.PartInfo
Length 1
(End)
RSLogix 5000
X001_StatusFault - Ladder Diagram Page 21
Cell Status
RungComment
0
Safeties
Cell
Cell Machine Power Safeties
On Reset
Cell.sfty.PwrOn Cell.Rst
1
OPs at Home Position
STnn
Home Cell
Position All Ops Home
STnn.Home Cell.OpsHome
2
No Parts Present in Cell (Actually in OPs)
STnn Cell
1st Group No
No Parts Part
Present Present
STnn._1stPP.NotPresSw Cell.NPP
3
RepeatInputs RB RBnn:{RBName}
All Robots in Auto
Robot
xxRnn Robot In Cell
Automatic All Robots In Auto
xxRnn.Mode.Auto Cell.RbtAuto
4
All Robots at Home
Robot
xxRnn Robot At Home Cell
Position All Robots Home
xxRnn.Sta.Home Cell.RbtHome
5
All Robots Stopped. OK to drop Auto
Robots
Stopped.
Robot OK to
xxRnn Robot Stopped drop
at Pathseg or Home Auto
xxRnn.Sta.Stopped Cell.Mode.Stopped
6
Utilities
STnn Robot Cell Air On Debounce Cell Air On Debounce

Air On xxRnn Air On Timer Timer
STnn.Utility.AirOn xxRnn.Sta.AirOn MOV TOF
7 Move Timer Off Delay EN
Source 1000 Timer Cell.Utility.AirOnTmr
Preset 0 DN
Dest Cell.Utility.AirOnTmr.PRE Accum 0
0
Cell Air On Debounce Cell

Timer Air On
Cell.Utility.AirOnTmr.DN Cell.Utility.AirOn
8
All Robots Water OK
Robot
xxRnn Water Loss Cell
Fault Water On
xxRnn.Weld.WtrOKFlt Cell.Utility.WtrOn
9 /
Welding Controllers
Robot
xxRnn Robot Stepper Cell Any Stepper
Pre-Warning Warning
xxRnn.Weld.G1.Pre_Wrn Cell.StppWar
10
Robot
xxRnn Robot Stepper
Pre-Warning
xxRnn.Weld.G2.Pre_Wrn
Robot
xxRnn End Of Stepper Cell End Of Stepper
xxRnn.Weld.G1.EOS Cell.EndStpp
11
Robot
xxRnn End Of Stepper
xxRnn.Weld.G2.EOS
RSLogix 5000
Flasher
System Flasher Timer System Flasher Timer System Flasher Timer
System.Flsh.Tmr.DN MOV TON
12 / Move Timer On Delay EN
Source 8388608 Timer System.Flsh.Tmr
Preset 0 DN
Dest System.Flsh.Tmr.PRE Accum 0
0
System Flasher Timer System Slow Flasher

System.Flsh.Tmr.ACC.10 System.Flsh.Slow
System Normal
System Flasher Timer Flasher
System.Flsh.Tmr.ACC.9 System.Flsh.Norm
System Flasher Timer System Fast Flasher

System.Flsh.Tmr.ACC.7 System.Flsh.Fast
Pushbuttons
PVnn
Auto
Start PVCell
Pushbutton Auto Start
(Hardwire) PB(Hardware)
HMInn.AstartHpb HMICell.AStartHpb
13
Safety Gate 1
Auto/
Cycle
Start
Pushbutton
(Hardwire)
SG1.AStartHpb
Safety Gate 2
Auto/
Cycle
Start
Pushbutton
(Hardwire)
SG2.AStartHpb
Safety Gate 3
Auto/
Cycle
Start
Pushbutton
(Hardwire)
SG3.AStartHpb
Safety Gate 4
Auto/
Cycle
Start
Pushbutton
(Hardwire)
SG4.AStartHpb
Indicator Lamps
PVCell
System Normal Stack Light
Cell All E-Stops Ok Flasher Fault
Cell.sfty.AllEStopOk System.Flsh.Norm HMICell.Stk.Red
14 /
PVnn
Test
Pb(S)
HMInn.Test_Pb
Global Cell/PV
Cell Any Stepper System Normal interface Amber
Warning Flasher Light
Cell.StppWar System.Flsh.Norm HMICell.Stk.Amber
15
Cell End Of Stepper System Fast Flasher
Cell.EndStpp System.Flsh.Fast
Cell Any Stepper

Cell End Of Stepper Warning Cell Enable
Cell.EndStpp Cell.StppWar Cell.Mode.Wld.En
/ /
PVCell
Cell All E-Stops Ok E-Stop Lamp
Cell.sfty.AllEStopOk HMICell.EstopLmp
16 /
PVCell System 1st Output

E-Stop Lamp Card
HMICell.EstopLmp System.O1.3
17
PVnn
Test
Pb(S)
HMInn.Test_Pb
MAIN CONTROL PANEL FUSE FAULTS
RungComment
18
RSLogix 5000
Pilz DNet Faults
Node 1 Status Node 1
Enable
PilzNode.Enable
<DNet07.node[1].Enable>
19
DeviceNet Module
Local Slot 7 DeviceNet Module Node 1 Status Node 1 Node 1 Status Node 1
Running & Local Slot 08 Faulted Faulted Memory
Not Faulted Power On Timer PilzNode.Faulted PilzNode.FaultedMem
DNet07.Module.RunOK DNet07.Module.PwrOnTmr.DN <DNet07.node[1].Faulted> <DNet07.node[1].FaultedMem>
PVCell Pilz Safety PLC

Node 1 Status Node 1 Fault Reset DNet Node XX
Faulted Memory Pushbutton Faulted
PilzNode.FaultedMem (Hardware) Cell.CommFaults.0
<DNet07.node[1].FaultedMem> HMICell.FltrstHpb
/
Node 1 Status Node 1 Pilz Safety PLC

Active In Scanlist DNet Node XX
PilzNode.Active Not Active
<DNet07.node[1].Active> Cell.CommFaults.1
/
Cell Communications Cell Any L1 Fault

Faults present
NEQ Cell.L1FaultPresent
20 Not Equal
Source A Cell.CommFaults
0
Source B 0
Cell Safety Faults

NEQ
Not Equal
Source A Cell.SafetyFaults
0
Source B 0
Cell Rack Module

Fault
NEQ
Not Equal
Source A Cell.RackFaults
0
Source B 0
Cell Count of how Cell Any L2 Fault

many stations have Present on any
L2 Faults Station
NEQ Cell.L2FaultPresent
21 Not Equal
Source A Cell.L2FaultCount
Cell Count of how
0
many stations have
Source B 0
L2 Faults
MOV
Move
Source 0
Dest Cell.L2FaultCount
0
(End)
RSLogix 5000
X002_InfoMessage - Ladder Diagram Page 24
Info
Message
Number
CLR
0 Clear
Dest HMICell.Messages_Ina
0
System Power Not On

System
Cell Machine Power Power
On Not ON
Cell.sfty.PwrOn Cell_Messages[0].6
1 /
Select Weld Mode or Dry Cycle before Auto Mode

Select Weld Mode
Cell PVCell Cell in Or Dry Cycle
Cell Machine Power Automatic Automatic Push Dry Before Auto
On Mode Setup Button Mode Cell Enable Mode
Cell.sfty.PwrOn Cell.Mode.AutoSet HMICell.Auto_Pb Cell.Mode.DryMode Cell.Mode.Wld.En Cell_Messages[0].7
2 / / /
Safety Gates Not Reset (all closed but at least one unlocked)
Safety Gate 1 Safety Safety Gate 1 Safety Gate 2 Safety Gate 3 Safety Gate 4 Safety Gates Not
Gate Locked Open Open Open Open Reset
SG1.Sfty.Locked SG1.GateOpen SG2.GateOpen SG3.GateOpen SG4.GateOpen Cell_Messages[0].8
3 / / / / /
Safety Gate 2 Safety
Gate Locked
SG2.Sfty.Locked
/
Gate Locked
SG3.Sfty.Locked
/
Gate Locked
SG4.Sfty.Locked
/
E-Stops on Safety Gates

Safety Gate 1 Safety Safety Gate 1
Gate E-Stop OK E-Stop Pressed
SG1.Sfty.EStopOK Cell_Messages[1].0
4 /

5 /

6 /

7 /
Safety Gates Open

Safety Gate 1
Open Safety Gate 1 Open
SG1.GateOpen Cell_Messages[1].8
8
Safety Gate 2
9
Safety Gate 3
10
Safety Gate 4
11
Request to Enter Safety Gates

Safety Gate 1
Safety Gate 1 Request to Enter Request To Enter
Open Memory Safety Gate 1
SG1.GateOpen SG1.EnterReqMem Cell_Messages[1].16
12 /
Safety Gate 2
13 /
Safety Gate 3
14 /
Safety Gate 4
15 /
Safety Gates in Teach Mode

Safety Gate 1 Safety Teach Mode Selected
Gate in Run Mode at Safety Gate 1
SG1.Sfty.RunMode Cell_Messages[1].24
16 /
RSLogix 5000
17 /

18 /

19 /
Main Panel E-STOP

Main Panel
Cell Main Panel E-Stop
E-Stop Ok Pressed
Cell.sfty.MPEStopOk Cell_Messages[2].0
20 /
**** Repeat this rung for every OP **** .1:.{Counter=1}

OP E-Stops
RepeatComment OP
STnn:{OPName}
.1:.{Counter=1}
STnn
STnn Handstand E-Stop
E-Stop Ok Pressed
STnn.Sfty.EStopOk Cell_Messages[2].1
21 /
**** Repeat this rung for every Panelview **** .0:.{Counter=0}

PV E-Stops
RepeatComment PV
PVnn:{PVName}
Station HMI Box .0:.{Counter=0}
signals PVnn
Rev. 0 Panelview E-Stop
Estop Ok(S) Pressed
HMInn.Sfty.EstopOk Cell_Messages[3].0
22 /
**** Repeat this rung for every Panelview **** .8:.{Counter=8}

PVs in Teach Mode
RepeatComment PV
PVnn:{PVName}
.8:.{Counter=8}
PVnn
To Be Teach Mode
Determined Selected
TBD Cell_Messages[3].8
23
**** Repeat this rung for every Robot **** .0:.{Counter=0}

Robot E-Stops
RepeatComment RB
xxRBnn:{RBName}
.0:.{Counter=0}
Robot
RBnn
Robot E-Stop
xxRnn E-Stop Ok Pressed
xxRnn.Sfty.Estop_OK Cell_Messages[4].0
24 /

OPs Disconnect Switches Off
RepeatComment OP
STnn:{OPName}
STnn .0:.{Counter=0}
Disconnect STnn
Cell Machine Power Switch Disconnect
On On Switch Off
Cell.sfty.PwrOn STnn.Utility.Sw Cell_Messages[5].0
25 /

Air Off
RepeatComment OP
STnn:{OPName}
.0:.{Counter=0}
Cell Machine Power STnn STnn
On Air On No Air
Cell.sfty.PwrOn STnn.Utility.AirOn Cell_Messages[6].0
26 /

Air Off
RepeatComment RB
xxRBnn:{RBName}
.0:.{Counter=0}
Robot
Cell Machine Power Robot RBnn
On xxRnn Air On No Air
Cell.sfty.PwrOn xxRnn.Sta.AirOn Cell_Messages[7].0
27 /
RSLogix 5000
OPs Lightscreen Not Reset
RepeatComment OP
PVnn STnn:{OPName}
Cell Screen STnn
Cell Machine Power Manual Number STnn Light Screen LightScreen
On Mode (MASK) Reset Not Reset
Cell.sfty.PwrOn Cell.Mode.Man EQU STnn.Sfty.LsRst Cell_Messages[8].0
28 Equal /
Source A HMInn.Scrn_Ina
0
Source B 2
Cell STnn
Auto Cycle Start
Mode Memory
Cell.Mode.Auto STnn.Cyc.StartMem
Dry Cycle Messages
PV
PVCell Cell in Dry Cycle PB
Cell Machine Power Dry Cycle Push Dry Cell Fault Safety Pressed
On Button Mode Cell Enable Reset Memory
Cell.sfty.PwrOn HMICell.Dry_Pb Cell.Mode.DryMode Cell.Mode.Wld.En Cell.sfty.FltSafRst MsgMem.0
29 / / /
PV
Dry Cycle PB
Pressed
Memory
MsgMem.0
**** Repeat this rung for every OP **** ].0:].{Counter=0}

Tool Not At Home
RepeatComment OP
STnn:{OPName}
PV Panelview Cannot Enter Dry
Dry Cycle PB Home Cycle Mode:
Pressed Position STnn
Memory Panelview Ind Not at Home
MsgMem.0 STnn.HMI.Home_Ind Cell_Messages[10].0
30 /
**** Repeat this rung for every OP **** ].0:].{Counter=0}

Parts Present
RepeatComment OP
STnn:{OPName}
PV 1st Group Cannot Enter Dry
Dry Cycle PB Any Cycle Mode:
Pressed Parts Part Present
Memory Present in STnn
MsgMem.0 STnn._1stPP.AnyPp Cell_Messages[11].0
31
**** Repeat this rung for every Robot **** ].0:].{Counter=0}

Robots Not At Home
RepeatComment RB
xxRBnn:{RBName}
.0:.{Counter=0}
PV Cannot Enter Dry
Dry Cycle PB Robot Cycle Mode:
Pressed xxRnn Robot At Home Robot RBnn
Memory Position Not At Home
MsgMem.0 xxRnn.Sta.Home Cell_Messages[12].0
32 /

Robots Not In Auto
RepeatComment RB
xxRBnn:{RBName}
Cell Robot .0:.{Counter=0}
Safeties xxRnn Robot In Robot RBnn
Reset Automatic Not In Auto
Cell.Rst xxRnn.Mode.Auto Cell_Messages[13].0
33 /

Teach Mode Not Allowed (Neighbouring Robot Already in Teach Mode)
RepeatComment RB
xxRBnn:{RBName}
.0:.{Counter=0}
Robot
Robot RBnn
xxRnn Teach Mode Not Teach Mode Not
Allowed Allowed (Nearby
Cell Machine in Run Robot (Neighbouring Robot Robot Already in
Cell All E-Stops Ok Mode xxRnn In Teach Mode in Teach) Teach)
Cell.sfty.AllEStopOk Cell.sfty.RunMode xxRnn.Sfty.Teach_Mode xxRnn.Sfty.TeachMode_NA Cell_Messages[14].0
34 /

Robot Program Not Running. Check Teach Pendant
RepeatComment RB
xxRBnn:{RBName}
.0:.{Counter=0}
Robot
Cell Robot Robot RBnn
Auto xxRnn Program xxRnn Robot At Home Robot Program Not Running.
Mode Running Position xxRnn Clear of Area Check Teach Pendant.
Cell.Mode.Auto xxRnn.Sta.PrgRun xxRnn.Sta.Home NEQ Cell_Messages[15].0
35 / / Not Equal
Source A xxRnn.Ctl.AreaClr
0
Source B 510
RSLogix 5000
OP Safeties
RepeatComment OP
STnn:{OPName}
.0:.{Counter=0}
STnn
Safeties Not In
STnn Safety Pin 1 Ok Place.
STnn.Sfty.SafetyPin1 Cell_Messages[16].0
36 /
STnn Safety Pin 2 Ok
STnn.Sfty.SafetyPin2
/
STnn Motor Crank
Handle 1
STnn.Sfty.MotorHdl1
/
STnn Motor Crank
Handle 2
STnn.Sfty.MotorHdl2
/
STnn Maintenance
Switch
STnn.Sfty.MaintSw
/

Robots Bypassed
RepeatComment RB
xxRBnn:{RBName}
.0:.{Counter=0}
Robot
Robot RBnn
xxRnn Robot Bypassed Bypassed
xxRnn.Mode.Bypass Cell_Messages[17].0
37
MESSAGE SCROLL LOGIC

Rung 1 of 4
Message Scroller
Scroll Timer Message Scroller Message Scroller Message Scroller
Interval Compare Control Compare Control Result Control
Scroller.ScrollTimer.EN Scroller.CmpCtrl.DN Scroller.CmpCtrl.ER FBC
38 / / File Bit Comparison EN
Source Cell_Messages[0]
Message Scroller
Reference Scroller.Ref[0] DN
Compare Control
Result Scroller.Result[0]
Scroller.CmpCtrl.FD Cmp. Control Scroller.CmpCtrl FD
/ Length 1247
Position 0 IN
Result Control Scroller.RsltCtrl
Length 40 ER
Position 0

Rung 2 of 4
Message Scroller
Compare Control
Scroller.CmpCtrl.IN
39

Rung 3 of 4
Message Scroller Message Scroller
Message Scroller Scroll Timer Scroll Timer
Compare Control Interval Interval
Scroller.CmpCtrl.FD Scroller.ScrollTimer.DN TON
40 / Timer On Delay EN
Timer Scroller.ScrollTimer
Preset 1500 DN
Accum 0

Rung 4 of 4
Info
Message Scroller Message
Compare Control Number
Scroller.CmpCtrl.FD MOV
41 Move
Source Scroller.CmpCtrl.POS
0
Dest HMICell.Messages_Ina
0
(End)
RSLogix 5000
X010_Overview - Ladder Diagram Page 28
E-Stops on OPs Handstands
Cell Status for HMI

Overview Screen
Cell Main Panel Rev 1.0 Safeties
E-Stop Ok missing
Cell.sfty.MPEStopOk CellOverview.OPs[0].SafetiesNotOK
0 /
**** Repeat this rung for every OP **** [1]:[{Counter=1}]

RepeatComment OP
[1]:[{Counter=1}]
STnn:{OPName}
STnn Handstand STnn Safeties
E-Stop Ok Missing
STnn.Sfty.EStopOk CellOverview.OPs[1].SafetiesNotOK
1 /
E-Stops on Safety Gates
Cell Status for HMI

Overview Screen
Safety Gate 1 Safety Rev 1.0 EStop
Gate E-Stop OK pressed
SG1.Sfty.EStopOK CellOverview.Gates[1].EStop
2 /
Cell Status for HMI

Overview Screen
3 /
Cell Status for HMI

Overview Screen
4 /
Cell Status for HMI

Overview Screen
5 /
**** Repeat this rung for every Robot **** [1]:[{Counter=1}]
E-Stops on Robots
RepeatComment RB
[1]:[{Counter=1}]
xxRBnn:{RBName}
Robot xxRBnn E-Stop
xxRnn E-Stop Ok Pressed
xxRnn.Sfty.Estop_OK CellOverview.Robots[1].EStop
6 /
Safety Gates Open
Cell Status for HMI

Safety Gate 1 Overview Screen
Open Rev 1.0 Gate Open
SG1.GateOpen CellOverview.Gates[1].Open
7
Cell Status for HMI

8
Cell Status for HMI

9
Cell Status for HMI

10
Request to Enter Safety Gates
Cell Status for HMI

Safety Gate 1 Request to Enter Rev 1.0 Request to
Open Memory Enter
SG1.GateOpen SG1.EnterReqMem CellOverview.Gates[1].EnterReq
11 /
Cell Status for HMI

Open Memory Enter
12 /
Cell Status for HMI

Open Memory Enter
13 /
Cell Status for HMI

Open Memory Enter
14 /
RSLogix 5000
OP130 Safeties (Pin, Crank Handles, etc)
Cell Status for HMI

Overview Screen
STnn Contactor Rev 1.0 Safeties
Feedback Ok missing
STnn.Sfty.ContactorOk CellOverview.OPs[13].SafetiesNotOK
15 /
/
/
STnn Motor Crank
Handle 1
STnn.Sfty.MotorHdl1
/
OP Utilities (Air, Disconnect Switches, Water, Network Faults, etc)
STnn RepeatComment OP
Disconnect [1]:[{Counter=1}]
STnn Switch STnn Utility Fault STnn:{OPName}
Cell All E-Stops Ok Air On On Word STnn Utilities OK
Cell.sfty.AllEStopOk STnn.Utility.AirOn STnn.Utility.Sw EQU CellOverview.OPs[1].UtilitiesOK
16 Equal
Source A STnn.UtilityFaults_Ina
0
Source B 0
Robot Utilities (Air, Water, Network, etc)
RepeatComment RB
Robot Robot [1]:[{Counter=1}]
xxRnn Water Loss xxRnn Water Start Robot Robot xxRBnn:{RBName}
Fault Fault xxRnn Air On xxRnn Alarm Messages xxRBnn Utilities OK
xxRnn.Weld.WtrOKFlt xxRnn.Weld.WtrStrtFlt xxRnn.Sta.AirOn EQU CellOverview.Robots[1].UtilitiesOK
17 / / Equal
Source A xxRnn.Pv.Alarm_Ina
0
Source B 0
Robots in Mnaual
RepeatComment RB
Robot [1]:[{Counter=1}]
xxRnn Robot in xxRBnn:{RBName}
Manual xxRBnn Not In Auto
xxRnn.Mode.Man CellOverview.Robots[1].Manual
18
Robots at Home Position
RepeatComment RB
Robot [1]:[{Counter=1}]
xxRnn Robot At Home xxRBnn:{RBName}
Position xxRBnn at Home
xxRnn.Sta.Home CellOverview.Robots[1].Home
19
OPs at Home Position
STnn RepeatComment OP
Panelview [1]:[{Counter=1}]
Home STnn:{OPName}
Position STnn at Home
Panelview Ind Position
STnn.HMI.Home_Ind CellOverview.OPs[1].Home
20
Parts Present in Robots
RepeatComment RB
[1]:[{Counter=1}]
Robot xxRBnn:{RBName}
xxRnn Pick up xxRBnn Part Present
Complete in End Effector
xxRnn.Sta.PickCpl.1 CellOverview.Robots[1].PP1
21
Parts Present in OPs
STnn
1st Group RepeatComment OP
All Parts [1]:[{Counter=1}]
Present STnn:{OPName}
Memory STnn Parts Present
STnn._1stPP.PresMem CellOverview.OPs[1].PP1
22
OP Cycle Start
RepeatComment OP
STnn [1]:[{Counter=1}]
Cycle STnn:{OPName}
Start STnn Cycle Running
STnn.Cyc.Start CellOverview.OPs[1].CycleStart
23
RSLogix 5000
Robot Cycle Start
RepeatComment RB
[1]:[{Counter=1}]
Robot xxRBnn:{RBName}
xxRnn Program xxRBnn Program
Running Running
xxRnn.Sta.PrgRun CellOverview.Robots[1].CycleStart
24
(End)
RSLogix 5000
Z001_ControllerStatus - Ladder Diagram Page 31
CONTROLLER MINOR FAULT
Currently the only useful item is the battery status

Local Controller
Status Routine
Internals Buffer for
GSV MinorFaultBits
attribute
GSV
0 Get System Value
Class Name FAULTLOG
Instance Name
Attribute Name MinorFaultBits
Dest LocalControl.MinorFlt
0
Local Controller
Status Routine
Internals Buffer for Controller
GSV MinorFaultBits Battery Low
attribute Status
LocalControl.MinorFlt.10 Controller.BatteryLow
I/O Module Status
Local Controller
Status Routine
GSV LEDStatus
attribute
GSV
1 Get System Value
Class Name MODULE
Instance Name
Attribute Name LedStatus
Dest LocalControl.IOStatus
0
Local Controller
Status Routine
GSV LEDStatus Controller
attribute I/O Status No Faults
EQU Controller.IOStatusOK
Equal
Source A LocalControl.IOStatus
0
Source B 3
Controller Time
Used for Automatic Shift Change
Local Controller
Status Routine
GSV DateTime
attribute
GSV
2 Get System Value
Class Name WALLCLOCKTIME
Instance Name
Attribute Name DateTime
Dest LocalControl.Date[0]
0
Controller Controller Controller

Date - Day Date - Month Date - Year
MOV MOV MOV
Move Move Move
Source LocalControl.Date[2] Source LocalControl.Date[1] Source LocalControl.Date[0]
0 0 0
Dest Controller.Date.Day Dest Controller.Date.Month Dest Controller.Date.Year
0 0 0
Controller Controller Controller

Time - Hour Time - Minutes Time - Seconds
MOV MOV MOV
Move Move Move
Source LocalControl.Date[3] Source LocalControl.Date[4] Source LocalControl.Date[5]
0 0 0
Dest Controller.Time.Hour Dest Controller.Time.Min Dest Controller.Time.Sec
0 0 0
(End)
RSLogix 5000
Z002_DNetStatus - Ladder Diagram Page 32
DEVICENET COMMUNICATION STATUS FILE

(Minimum Firmware v3.002)
Input Parameters:
{nn}{ss} ModuleID. The unique module identifier.
Local:{x}:S DeviceNet Module Real Status inputs
Local:{x}:I.StatusRegister DeviceNet Module Real StatusRegister inputs
DNet{nn}{ss} Controller Tag of type ac_DNet.
Return Parameters:
DNet{nn}{ss} Controller Tag of type ac_DNet
Notes:
{x} is replaced with the slot number of the DeviceNet Module
{nn} is a 2 digit zero padded remote ControlNet node# (e.g. 01, 03, 12, ...).
(if the module is Local this is not used}
{ss} is a 2 digit zero padded slot number (e.g. 01, 03, 12, ...).
Internals used by
the DNetStatus
Internals used by routine Version Type Internals used by Internals used by
the DNetStatus - Unique # to ID the DNetStatus the DNetStatus
routine Unique Model, Manufacturer, routine Major routine Minor
module ID Firmware, etc. Version # Version #
SBR MOV MOV MOV
0 Subroutine Move Move Move
Input Par DNet.ModuleID Source 3002 Source 5 Source 0
Input Par DNet.S
Input Par DNet.I Dest DNet.V.Type Dest DNet.V.Major Dest DNet.V.Minor
Input Par DNet.DN 0 0 0
MODULE RESET/NETWORK POWER ON DELAY
Allow nodes time to start when the module is started, or network power is restored.
Internals used by Internals used by Internals used by

the DNetStatus the DNetStatus the DNetStatus Internals used by
routine DeviceNet routine DeviceNet routine DeviceNet the DNetStatus
Module Status Inputs Module Status Inputs Module Status Inputs routine Module in
(StatusRegister) (StatusRegister) (StatusRegister) reset/restart mode
DNet.I.DeviceFailure DNet.I.CommFailure DNet.I.DupNodeFail DNet.InReset
1

the DNetStatus the DNetStatus the DNetStatus
routine Module in routine Dnet Reset routine Dnet Reset
reset/restart mode Timer Timer
DNet.InReset MOV TON
Source 1000 Timer DNet.DN.SV.ResetTmr
Preset 0 DN
Dest DNet.DN.SV.ResetTmr.PRE Accum 0
0
Internals used by
the DNetStatus Internals used by Internals used by
routine DeviceNet the DNetStatus the DNetStatus
Module Status Inputs routine Dnet power routine Dnet power
(StatusRegister) On Timer On Timer
DNet.I.DnetPowerDetect MOV TON
Source 8000 Timer DNet.DN.SV.PwrOnTmr
Preset 0 DN
Dest DNet.DN.SV.PwrOnTmr.PRE Accum 0
0
MODULE STATUS
PowerUp/Reset status.
Allow the module time to reset, and when network power is reapplied allow the nodes
to power up.
Internals used by Internals used by
the DNetStatus the DNetStatus Internals used by
routine Dnet Reset routine Module reset the DNetStatus
Timer complete routine Dnet Restart
DNet.DN.SV.ResetTmr.DN DNet.Reset DNet.DN.Module.Restart
4 /
Internals used by
the DNetStatus
routine Module reset
complete
DNet.Reset
Internals used by
Internals used by the DNetStatus
the DNetStatus routine Module
routine Dnet power network power on
On Timer (delayed)
DNet.DN.SV.PwrOnTmr.DN DNet.PwrOn
Internals used by
Internals used by the DNetStatus Internals used by
the DNetStatus routine Module the DNetStatus
routine Module reset network power on routine Module reset
complete (delayed) & power on
DNet.Reset DNet.PwrOn DNet.ResetPwrOn
Module Status Words
Internals used by
Internals used by Internals used by the DNetStatus
the DNetStatus the DNetStatus routine Dnet Fault
routine Dnet Id routine Dnet Node Code
MOV MOV MOV
5 Move Move Move
Source DNet.ModuleID Source DNet.S.ScannerAddress Source DNet.S.ScannerStatus
0 16#00 16#00
Dest DNet.DN.Module.ID Dest DNet.DN.Module.Node Dest DNet.DN.Module.FaultCode
0 0 0
RSLogix 5000
Fault Status
Module does not generate a general fault bit, so OR possible fault conditions.
Internals used by
the DNetStatus
routine DeviceNet Internals used by
Module Status Inputs the DNetStatus
(StatusRegister) routine Dnet Faulted
DNet.I.Fault DNet.DN.Module.Faulted
6
Internals used by
the DNetStatus
routine DeviceNet
Module Status Inputs
(StatusRegister)
DNet.I.DisableNetwork
Internals used by
the DNetStatus
routine DeviceNet
(StatusRegister)
DNet.I.CommFailure
Internals used by
the DNetStatus
routine DeviceNet
(StatusRegister)
DNet.I.DupNodeFail
Internals used by
the DNetStatus
routine DeviceNet
(StatusRegister)
DNet.I.DnetPowerDetect
Internals used by
the DNetStatus
routine Dnet Fault
Code
NEQ
Not Equal
Source A DNet.DN.Module.FaultCode
0
Source B 0
Module in Run/Idle
The StatusReg.Run bit stays on during most fault conditions, so make our own.
Internals used by
the DNetStatus Internals used by routine DeviceNet Internals used by
routine Module reset the DNetStatus Module Status Inputs the DNetStatus
complete routine Dnet Faulted (StatusRegister) routine Dnet RunOk
DNet.Reset DNet.DN.Module.Faulted DNet.I.Run DNet.DN.Module.RunOK
7 /
Internals used by
the DNetStatus
routine DeviceNet Internals used by
Module Status Inputs the DNetStatus
(StatusRegister) routine Dnet Idle
DNet.I.Run DNet.DN.Module.Idle
/
Any node faulted.
Internals used by
Internals used by the DNetStatus Internals used by
the DNetStatus routine DeviceNet the DNetStatus
routine Module reset Module Status Inputs routine Dnet ANode
& power on (StatusRegister) Is Faulted
DNet.ResetPwrOn DNet.I.DeviceFailure DNet.DN.Module.ANodeFaulted
8
Internals used by
the DNetStatus
routine DeviceNet
(StatusRegister)
DNet.I.Autoverify
Internals used by
the DNetStatus
routine Any node
fault (Failure,
AutoVerify, or Idle)
DNet.AnyFault
MODULE SCAN TIME
Calculate scan time is msec by dividing a fixed amount of time by the number of scans.

the DNetStatus the DNetStatus
routine Dnet Scan routine Dnet Scan
Timer Timer
MOV TON
Source 2000 Timer DNet.DN.SV.ScanTmr
Preset 0 DN
Dest DNet.DN.SV.ScanTmr.PRE Accum 0
0
RSLogix 5000
the DNetStatus the DNetStatus Internals used by the DNetStatus
routine Dnet Scan routine DeviceNet the DNetStatus routine Dnet Scan
Timer Module Status routine Dnet Scan 1 Time
DNet.DN.SV.ScanTmr.DN GRT GRT CPT
10 Greater Than (A>B) Greater Than (A>B) Compute
Source A DNet.S.ScanCounter Source A DNet.DN.SV.Scan1 Dest DNet.DN.Module.ScanTime
2#0000_0000_0000_0000_0000_0000_0000_0000 0 0
Source B DNet.DN.SV.Scan1 Source B 0 Expression DNet.DN.SV.ScanTmr.PRE/(DNet.S.ScanCounter-DNet.DN.SV.Scan1)
0
Internals used by
the DNetStatus Internals used by
routine Dnet Scan the DNetStatus
Timer routine Dnet Scan 1
DNet.DN.SV.ScanTmr.DN MOV
11 Move
Source DNet.S.ScanCounter
S:FS 2#0000_0000_0000_0000_0000_0000_0000_0000
Dest DNet.DN.SV.Scan1
0
Internals used by
the DNetStatus
routine Dnet Scan
Timer
DNet.DN.SV.ScanTmr
RES
NODE FAULT ARRAY
OR all possible types of node faults to generate a general node Faulted bit.
Node status registers is copied a DINT[2] array for speed/size.
The result is then mapped to the NodeStatus structure so that the user does not have
to translate the standard module defined SINT[8] array.
Internals used by
the DNetStatus routine Copy of
routine Copy of S.AutoverifyFailureR
S.ActiveNodeRegister egister
COP COP
12 Copy File Copy File
Source DNet.S.ActiveNodeRegister[0] Source DNet.S.AutoverifyFailureRegister[0]
Dest DNet.ActiveReg[0] Dest DNet.AutoVerifyReg[0]
Length 2 Length 2
Internals used by
routine Copy of the DNetStatus
S.DeviceFailureRegis routine Copy of
ter S.DeviceIdleRegister
COP COP
Copy File Copy File
Source DNet.S.DeviceFailureRegister[0] Source DNet.S.DeviceIdleRegister[0]
Dest DNet.DevFailReg[0] Dest DNet.IdleReg[0]
Length 2 Length 2
zCD338_DNet.AnyFault was added to fix a problem with idle nodes not generating fault codes
# because the module status DeviceFailure is not set during an idle condition.

routine Any node routine Any node
fault (Failure, fault (Failure,
AutoVerify, or Idle) AutoVerify, or Idle)
OR OR
13 Bitwise Inclusive OR Bitwise Inclusive OR
Source A DNet.DevFailReg[0] Source A DNet.IdleReg[0]
2#0000_0000_0000_0000_0000_0000_0000_0000 2#0000_0000_0000_0000_0000_0000_0000_0000
Source B DNet.AutoVerifyReg[0] Source B DNet.NodeFaulted[0]
2#0000_0000_0000_0000_0000_0000_0000_0000 2#0000_0000_0000_0000_0000_0000_0000_0000
Dest DNet.NodeFaulted[0] Dest DNet.NodeFaulted[0]
2#0000_0000_0000_0000_0000_0000_0000_0000 2#0000_0000_0000_0000_0000_0000_0000_0000

OR OR
Bitwise Inclusive OR Bitwise Inclusive OR
Source A DNet.DevFailReg[1] Source A DNet.IdleReg[1]
2#0000_0000_0000_0000_0000_0000_0000_0000 2#0000_0000_0000_0000_0000_0000_0000_0000
Source B DNet.AutoVerifyReg[1] Source B DNet.NodeFaulted[1]
2#0000_0000_0000_0000_0000_0000_0000_0000 2#0000_0000_0000_0000_0000_0000_0000_0000
Dest DNet.NodeFaulted[1] Dest DNet.NodeFaulted[1]
2#0000_0000_0000_0000_0000_0000_0000_0000 2#0000_0000_0000_0000_0000_0000_0000_0000

NEQ DNet.AnyFault
Not Equal
Source A DNet.NodeFaulted[0]
2#0000_0000_0000_0000_0000_0000_0000_0000
Source B 0
Internals used by
the DNetStatus
routine Any node
fault (Failure,
AutoVerify, or Idle)
NEQ
Not Equal
Source A DNet.NodeFaulted[1]
2#0000_0000_0000_0000_0000_0000_0000_0000
Source B 0
RSLogix 5000
Map the DNet.Node[x] structure
Note: Direct mapping is used for speed.
Internals used by
the DNetStatus
routine Any node Internals used by
fault (Failure, the DNetStatus
AutoVerify, or Idle) routine Dnet Faulted
DNet.NodeFaulted[0].0 DNet.DN.Node[0].Faulted
14
Internals used by
S.ActiveNodeRegister routine Dnet Active
DNet.ActiveReg[0].0 DNet.DN.Node[0].Active

routine Dnet Faulted routine Dnet Ok
DNet.DN.Node[0].Faulted DNet.DN.Node[0].OK
/
Internals used by
the DNetStatus
15
Internals used by

/
Internals used by
the DNetStatus
16
Internals used by

/
Internals used by
the DNetStatus
17
Internals used by

/
Internals used by
the DNetStatus
18
Internals used by

/
Internals used by
the DNetStatus
19
Internals used by

/
RSLogix 5000
Internals used by
the DNetStatus
20
Internals used by

/
Internals used by
the DNetStatus
21
Internals used by

/
Internals used by
the DNetStatus
22
Internals used by

/
Internals used by
the DNetStatus
23
Internals used by

/
Internals used by
the DNetStatus
24
Internals used by

/
Internals used by
the DNetStatus
25
Internals used by

/
RSLogix 5000
Internals used by
the DNetStatus
26
Internals used by

/
Internals used by
the DNetStatus
27
Internals used by

/
Internals used by
the DNetStatus
28
Internals used by

/
Internals used by
the DNetStatus
29
Internals used by

/
Internals used by
the DNetStatus
30
Internals used by

/
Internals used by
the DNetStatus
31
Internals used by

/
RSLogix 5000
Internals used by
the DNetStatus
32
Internals used by

/
Internals used by
the DNetStatus
33
Internals used by

/
Internals used by
the DNetStatus
34
Internals used by

/
Internals used by
the DNetStatus
35
Internals used by

/
Internals used by
the DNetStatus
36
Internals used by

/
Internals used by
the DNetStatus
37
Internals used by

/
RSLogix 5000
Internals used by
the DNetStatus
38
Internals used by

/
Internals used by
the DNetStatus
39
Internals used by

/
Internals used by
the DNetStatus
40
Internals used by

/
Internals used by
the DNetStatus
41
Internals used by

/
Internals used by
the DNetStatus
42
Internals used by

/
Internals used by
the DNetStatus
43
Internals used by

/
RSLogix 5000
Internals used by
the DNetStatus
44
Internals used by

/
Internals used by
the DNetStatus
45
Internals used by

/
Internals used by
the DNetStatus
46
Internals used by

/
Internals used by
the DNetStatus
47
Internals used by

/
Internals used by
the DNetStatus
48
Internals used by

/
Internals used by
the DNetStatus
49
Internals used by

/
RSLogix 5000
Internals used by
the DNetStatus
50
Internals used by

/
Internals used by
the DNetStatus
51
Internals used by

/
Internals used by
the DNetStatus
52
Internals used by

/
Internals used by
the DNetStatus
53
Internals used by

/
Internals used by
the DNetStatus
54
Internals used by

/
Internals used by
the DNetStatus
55
Internals used by

/
RSLogix 5000
Internals used by
the DNetStatus
56
Internals used by

/
Internals used by
the DNetStatus
57
Internals used by

/
Internals used by
the DNetStatus
58
Internals used by

/
Internals used by
the DNetStatus
59
Internals used by

/
Internals used by
the DNetStatus
60
Internals used by

/
Internals used by
the DNetStatus
61
Internals used by

/
RSLogix 5000
Internals used by
the DNetStatus
62
Internals used by

/
Internals used by
the DNetStatus
63
Internals used by

/
Internals used by
the DNetStatus
64
Internals used by

/
Internals used by
the DNetStatus
65
Internals used by

/
Internals used by
the DNetStatus
66
Internals used by

/
Internals used by
the DNetStatus
67
Internals used by

/
RSLogix 5000
Internals used by
the DNetStatus
68
Internals used by

/
Internals used by
the DNetStatus
69
Internals used by

/
Internals used by
the DNetStatus
70
Internals used by

/
Internals used by
the DNetStatus
71
Internals used by

/
Internals used by
the DNetStatus
72
Internals used by

/
Internals used by
the DNetStatus
73
Internals used by

/
RSLogix 5000
Internals used by
the DNetStatus
74
Internals used by

/
Internals used by
the DNetStatus
75
Internals used by

/
Internals used by
the DNetStatus
76
Internals used by

/
Internals used by
the DNetStatus
77
Internals used by

/
Map Module Status into the Node[] status table
Internals used by
the DNetStatus
routine Dnet Node
LIM DNet.DN.Node[DNet.DN.Module.Node].Active
78 Limit Test (CIRC)
Low Limit 0
Internals used by
the DNetStatus
Test DNet.DN.Module.Node
routine Dnet RunOk
0
DNet.DN.Module.RunOK DNet.DN.Node[DNet.DN.Module.Node].OK
High Limit 63
Internals used by
the DNetStatus
routine Dnet Faulted
DNet.DN.Module.Faulted DNet.DN.Node[DNet.DN.Module.Node].Faulted
RSLogix 5000
NODE FAULT CODES/ENABLE
Update one fault code/scan

Clear the Node[x].Enable bit

routine Dnet Clear routine Dnet Clear
Ptr Ptr
LIM CLR
79 Limit Test (CIRC) Clear
Low Limit 64 Dest DNet.DN.SV.ClrPtr
0
Test DNet.DN.SV.ClrPtr
0
High Limit 0
COP
Copy File
Source DNet.S.DeviceStatus[DNet.DN.SV.ClrPtr]
Dest DNet.DN.Node[DNet.DN.SV.ClrPtr].FaultCode
Length 1
DNet.DN.Node[DNet.DN.SV.ClrPtr].Enable
U
the DNetStatus the DNetStatus the DNetStatus
routine Dnet Clear routine Dnet Clear routine Dnet Clear
Ptr Ptr Ptr
ADD LIM CLR
Add Limit Test (CIRC) Clear
Source A 1 Low Limit 64 Dest DNet.DN.SV.ClrPtr
0
Source B DNet.DN.SV.ClrPtr Test DNet.DN.SV.ClrPtr
0 0
Dest DNet.DN.SV.ClrPtr High Limit 0
0
Internals used by
the DNetStatus
routine Map global
DNet module data
in/out
RET
80 Return from Subrout...
Return Par DNet.DN
(End)
RSLogix 5000
Cosma:MainTask:STxx 11/11/2010 1:27:54 PM
Aug 05, 2005:
New calling sequence:
MapInputs is the first routine
MapOutputs is the last one
PartsPresent is now called before Sequence
RungComment
0
JSR
JSR
Routine Name M001_DryModeRestart
JSR
Routine Name S000_MainCycle
JSR
Routine Name S005_PartPresent
JSR
Routine Name S001_Sequence
Cell Any L1 Fault

present
Cell.L1FaultPresent JSR
6 / Jump To Subroutine
Cell Any L1 Fault

present
Cell.L1FaultPresent MOV MOV
Move Move
Source 0 Source 0
Dest STnnAlmSafety Dest STnnAlmComm

0 0
JSR
(End)
RSLogix 5000
***************************************************************************
Copy Signals
From DNet Scanner
To I/O Module- Specific UDT
***********************************************************************
DeviceNet Module AB FlexArmour
Local Slot 7 Status 1798-ADN
DeviceNet Module Node 0 Status Node 0 8 x 8IN Module
Local Slot 7 OK - Rev. 0 AB Flex
Running & Active and Armour
Not Faulted Not Faulted 56 IN Module
STnn_Scanner.Module.RunOK STnnFB1Node.OK Rev. 0
<DNet07.Module.RunOK> <DNet07.Node[0].OK> COP
0 Copy File
Source Local:7:I.Data[0]
Dest STnn_FB1.I
Length 1
Field Module 1
Comm OK
STnn_FB1.CommOK
AB FlexArmour
1798-ADN
8 x 8IN Module
Rev. 0 AB Flex
Armour
Field Module 1 56 IN Module
Comm OK Rev. 0
STnn_FB1.CommOK FLL
/ Fill File
Source 0
Dest STnn_FB1.I
Length 1
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
STnn_Scanner.Module.RunOK STnnFB2Node.OK Rev. 0
1 Copy File
Dest STnn_FB2.I
Length 1
Field Module 1
Comm OK
STnn_FB2.CommOK
AB FlexArmour
1798-ADN
8 x 8IN Module
Rev. 0 AB Flex
Armour
Comm OK Rev. 0
STnn_FB2.CommOK FLL
/ Fill File
Source 0
Dest STnn_FB2.I
Length 1
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
DeviceNet Module
Local Slot 7 Status
DeviceNet Module Node 0 Status Node 0
Local Slot 7 OK -
Running & Active and OPnn
Not Faulted Not Faulted Compact
STnn_Scanner.Module.RunOK STnn_DIONode.OK Block IO
2 Copy File
Dest ST10_DIO.I
Length 1
OPnn
Compact
Block IO
ST10_DIO.CommOK
OPnn OPnn
Compact Compact
Block IO Block IO
ST10_DIO.CommOK FLL
/ Fill File
Source 0
Dest ST10_DIO.I
Length 1
RSLogix 5000
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
DeviceNet Module
Local Slot 7 Status
DeviceNet Module Node 0 Status Node 0 8 Valve SMC
Local Slot 7 OK - Pneumatic Terminal
Running & Active and Rev. 0 32 Input SMC
Not Faulted Not Faulted Pneumatic Terminal
STnn_Scanner.Module.RunOK STnnPT1Node.OK Rev. 0
3 Copy File
Dest STnn_PT1.I
Length 1
Pneumatic
Terminal 1
DeviceNet
Communication
OK
STnn_PT1.CommOK
Pneumatic 8 Valve SMC

Terminal 1 Pneumatic Terminal
DeviceNet Rev. 0 32 Input SMC
Communication Pneumatic Terminal
OK Rev. 0
STnn_PT1.CommOK FLL
/ Fill File
Source 0
Dest STnn_PT1.I
Length 1
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
DeviceNet Module
Local Slot 7 Status
STnn_Scanner.Module.RunOK STnnPT2Node.OK Rev. 0
4 Copy File
Dest STnn_PT2.I
Length 1
Pneumatic
Terminal 2
DeviceNet
Communication
OK
STnn_PT2.CommOK

OK Rev. 0
STnn_PT2.CommOK FLL
/ Fill File
Source 0
Dest STnn_PT2.I
Length 1
Safety - Related Signals

RungComment
5
Safety Gate 1
To Be Fault Reset
Determined Pushbutton
TBD SG1.FaultResHpb
6
To Be STnn Light Screen

Determined Reset
TBD STnn.Sfty.LsRst
7
To Be STnn Start Button

Determined Handstand(H)
TBD STnn.Sfty.StartHPb
8
STnn Pneumatic STnn

Manifold Valve Power STnn Valve Output Power
On(S) Air On and Air On
STnn.Sfty.PMPwr STnn.Utility.AirOn STnn.Utility.OutPwrOn
9
Other Input Signals

RungComment
10
Utilities Signals:
Air
Water
RungComment
11
RSLogix 5000
STnn STnn STnn
Field Inputs Air On Air On
Field Module 1 Module 1 Debounce Debounce
Comm OK Input 0 Timer Timer
STnn_FB1.CommOK STnn_FB1.I.M1.0 MOV TOF
Source 250 Timer STnn.Utility.AirOnTmr
Preset 0 DN
Dest STnn.Utility.AirOnTmr.PRE Accum 0
0
STnn STnn
Air On
Debounce STnn
Timer Air On
STnn.Utility.AirOnTmr.DN STnn.Utility.AirOn
STnn
Air On
Indicator
STnn.HMI.AirOn_Ind
STnn STnn STnn

Field Inputs Water On Water On
STnn_FB1.CommOK STnn_FB1.I.M1.1 MOV TOF
Source 250 Timer STnn.Utility.WtrOnTmr
Preset 0 DN
Dest STnn.Utility.WtrOnTmr.PRE Accum 0
0
STnn STnn
Water On
Debounce STnn
Timer Water On
STnn.Utility.WtrOnTmr.DN STnn.Utility.WtrOn
STnn
Water On
Indicator
STnn.HMI.WtrOn_Ind
(End)
RSLogix 5000
Stack Light Buffer
STnn
Stack Light OPnn
Operator Clear to Compact
Enter Block IO Module 1
STnn.Stk.Green ST10_DIO.o.M1.0
0
STnn
Stack Light
All / Some OPnn
Parts Compact
Present Block IO Module 1
STnn.Stk.Clear ST10_DIO.o.M1.1
1
OPnn
STnn Part Request Compact
Beacon Block IO Module 1
STnn.PartReq ST10_DIO.O.M1.2
2
PVnn
Test
Pb(S)
HMInn.Test_Pb
***************************************************************************
Map Outputs:
Copy From
I/O Module-Specific UDT
to DNet Scanner
***********************************************************************
COP
3 Copy File
Source STnn_PT1.O
Dest Local:7:O.Data[0]
Length 1
***************************************************************************
Map Outputs:
Copy From
to DNet Scanner
***********************************************************************
COP
4 Copy File
Source STnn_PT2.O
Length 1
***************************************************************************
Map Outputs:
Copy From
to DNet Scanner
***********************************************************************
COP
5 Copy File
Source ST10_DIO.O
Length 1
(End)
RSLogix 5000
M001_DryModeRestart - Ladder Diagram Page 52
Dry Cycle Related Logic
RungComment
0
STnn
Cycle Start STnn
Anti Cell in Robot Dry Cycle
STnn Start Button Tie-Down Dry xxRnn Robot Bypassed Restart
Handstand(H) Timer Mode STnnDropoffRb.Mode.Bypass Enable
STnn.Sfty.StartHPb STnn.Cyc.AntiTDTmr.DN Cell.Mode.DryMode <xxRnn.Mode.Bypass> STnn.Cyc.DryRestartEn
1 /
STnn
Dry Cycle
Restart
Enable
STnn.Cyc.DryRestartEn
STnn STnn STnn

Cell Dry Cycle STnn STnn STnn Dry Cycle
Dry Cycle Restart Cycle Cycle 1st Parts Restart
Enable Enable Start Complete All Present Timer
Cell.Mode.Dry.En STnn.Cyc.DryRestartEn STnn.Cyc.Start STnn.Cyc.Cpl STnn._1stPP.Pres MOV
2 / / / Move
Source 3000
Dest STnn.Cyc.DryRestartTmr.PRE
0
STnn
Dry Cycle
Restart
Timer
TON
Timer On Delay EN
Timer STnn.Cyc.DryRestartTmr
Preset 0 DN
Accum 0
(End)
RSLogix 5000
S000_MainCycle - Ladder Diagram Page 53
Manual Home PB
Cell STnn STnn
Manual Home Enable Home
Mode Pushbutton Enable
Cell.Mode.Man STnn.HMI.Home_Pb STnn.HomeEn
0
RepeatInputs Motion Motion1:{MotionName} Hme:{MotionHme}

Home -based on actual position
Home_ind: Based on Actual Position for Karmax (No Memories)
OPnn
Motion1 STnn
AtHome Home
Complete Position
STnn_Motion1.Hme.Cpl STnn.Home
1
STnn
Panelview
Home
Position
Panelview Ind
STnn.HMI.Home_Ind
Cycle Start (Operator Station)

STnn STnn STnn
Cycle Start Cycle Start
STnn Start Button Anti Tie-Down Anti Tie-Down
Handstand(H) Timer Timer
STnn.Sfty.StartHPb MOV TON
Source 500 Timer STnn.Cyc.AntiTDTmr
Preset 0 DN
Dest STnn.Cyc.AntiTDTmr.PRE Accum 0
0
STnn
Line Cycle Start
Cell STnn STnn Runout Cell in Anti STnn STnn
Auto Valve Output Power 1st Parts Mode STnn Start Button Dry Tie-Down Cycle Cycle
Mode and Air On All Present Enabled Handstand(H) Mode Timer Complete Start
Cell.Mode.Auto STnn.Utility.OutPwrOn STnn._1stPP.Pres Cell.Mode.LineRunout STnn.Sfty.StartHPb Cell.Mode.DryMode STnn.Cyc.AntiTDTmr.DN STnn.Cyc.Cpl STnn.Cyc.Start
3 / / / /
STnn STnn
Cycle Start Dry Restart
Memory Timer
STnn.Cyc.StartMem STnn.Cyc.DryRestartTmr.DN
STnn
Cycle
Start
STnn.Cyc.Start
Cycle Start (non-Operator Station)

Cell STnn STnn STnn STnn
Auto Valve Output Power 1st Parts Cycle Cycle
Mode and Air On All Present Complete Start
Cell.Mode.Auto STnn.Utility.OutPwrOn STnn._1stPP.Pres STnn.Cyc.Cpl STnn.Cyc.Start
4 /
STnn
Cycle Start
Memory
STnn.Cyc.StartMem
STnn
Cycle
Start
STnn.Cyc.Start
STnn STnn
Cycle Cycle Start
Start Indicator
STnn.Cyc.Start STnn.HMI.CycStart_Ind
5
Cycle Start Memory: Used to be able to restart Cycle in case of losing PP signal after cycle started
STnn STnn
Cycle Cycle Start
Start Memory
STnn.Cyc.Start STnn.Cyc.StartMem
6 L
STnn Cell STnn

Cycle Dry Cycle Cycle Start
Complete Enable Memory
STnn.Cyc.Cpl Cell.Mode.Dry.En STnn.Cyc.StartMem
7 / U
STnn STnn
Home Home
Enable Position
STnn.HomeEn STnn.Home
Process Complete:
Indicates that all process are complete and station must return to Home position.
STnn STnn Process
Cycle complete (formerly
Complete Full Depth)
STnn.Cyc.Cpl STnn.ProcCpl
8 U
STnn STnn
Home Home
Enable Position
RSLogix 5000
RepeatInputs Motion Motion1:{MotionName} Wrk:{MotionWrk}
OPnn
Motion1 Robot Robot Robot STnn Process
AtWork xxRnn Weld Complete xxRnn Weld Complete xxRnn Weld Complete complete (formerly
Complete STnnWeldRbA.Weld.Cpl.0 STnnWeldRbB.Weld.Cpl.0 STnnWeldRbC.Weld.Cpl.0 Full Depth)
STnn_Motion1.Wrk.Cpl <xxRnn.Weld.Cpl.0> <xxRnn.Weld.Cpl.0> <xxRnn.Weld.Cpl.0> STnn.ProcCpl
9 L
Robot Robot Robot
xxRnn Robot Bypassed xxRnn Robot Bypassed xxRnn Robot Bypassed
STnnWeldRbA.Mode.Bypass STnnWeldRbB.Mode.Bypass STnnWeldRbC.Mode.Bypass
<xxRnn.Mode.Bypass> <xxRnn.Mode.Bypass> <xxRnn.Mode.Bypass>
e STnn
e STnn Process Full
e complete (formerly Depth
e Full Depth) Indicator
e STnn.ProcCpl STnn.HMI.Fdepth_Ind
10 e
e
Cycle Complete:
Indicates that there is no additional motion or in-station process needed for current part
STnn
STnn Process STnn STnn STnn Cell in 1st Group STnn
complete (formerly Cycle Cycle Start Cycle Dry No Parts Cycle
Full Depth) Start Memory Complete Mode Present Complete
STnn.ProcCpl STnn.Cyc.Start STnn.Cyc.StartMem STnn.Cyc.Cpl Cell.Mode.DryMode STnn._1stPP.NotPresSw STnn.Cyc.Cpl
11 / / / / U
STnn
1st Group
Cell in All Parts
Dry Present
Mode Memory
Cell.Mode.DryMode STnn._1stPP.PresMem
/
STnn Process STnn STnn

complete (formerly Home Cycle
Full Depth) Position Complete
STnn.ProcCpl STnn.Home STnn.Cyc.Cpl
12 L
STnn
STnn Cycle
Cycle Complete
Complete Indicator
STnn.Cyc.Cpl STnn.HMI.CycCpl_Ind
13
Stack Light
STnn
STnn STnn STnn Stack Light
Robots Cycle Home Operator Clear to
Clear Start Position Enter
STnn.RobClr STnn.Cyc.Start STnn.Home STnn.Stk.Green
14 /
PVnn
Test
Pb(S)
HMInn.Test_Pb
STnn
Stack Light
STnn All / Some
1st Parts Parts
All Present Present
STnn._1stPP.Pres STnn.Stk.Clear
15
STnn
1st Group
Any
Parts System Normal
Present Flasher
STnn._1stPP.AnyPp System.Flsh.Norm
PVnn
Test
Pb(S)
HMInn.Test_Pb
Tool In Position For Robots

STnn
STnn Tool Clear
STnn STnn 1st Group No Robot Robot Robot Robot to Enter For
Cycle Home Parts xxRnn Clear of Area xxRnn Clear of Area xxRnn Clear of Area xxRnn Clear of Area Robot
Start Position Present STnnWeldRbA.Ctl.AreaClr.1 STnnWeldRbB.Ctl.AreaClr.1 STnnWeldRbC.Ctl.AreaClr.1 STnnPickUpRb.Ctl.AreaClr.1 Dropoff
STnn.Cyc.Start STnn.Home STnn._1stPP.NotPres <xxRnn.Ctl.AreaClr.1> <xxRnn.Ctl.AreaClr.1> <xxRnn.Ctl.AreaClr.1> <xxRnn.Ctl.AreaClr.1> STnn.TLArea.0
16

STnn STnn
1st Group OPnn Tool Clear
STnn STnn Process All Parts Robot Robot Motion1 to Enter For
Cycle complete (formerly Present xxRnn Clear of Area xxRnn Clear of Area AtWork Robot
Start Full Depth) Memory STnnPickUpRb.Ctl.AreaClr.1 STnnDropoffRb.Ctl.AreaClr.2 Complete Weld
STnn.Cyc.Start STnn.ProcCpl STnn._1stPP.PresMem <xxRnn.Ctl.AreaClr.1> <xxRnn.Ctl.AreaClr.2> STnn_Motion1.Wrk.Cpl STnn.TLArea.1
17 /
STnn STnn
1st Group Tool Clear
STnn STnn Process STnn All Parts Robot Robot Robot Robot to Enter For
Cycle complete (formerly Home Present xxRnn Clear of Area xxRnn Clear of Area xxRnn Clear of Area xxRnn Clear of Area Robot
Start Full Depth) Position Memory STnnWeldRbA.Ctl.AreaClr.1 STnnWeldRbB.Ctl.AreaClr.1 STnnWeldRbC.Ctl.AreaClr.1 STnnDropoffRb.Ctl.AreaClr.2 Pickup
STnn.Cyc.Start STnn.ProcCpl STnn.Home STnn._1stPP.PresMem <xxRnn.Ctl.AreaClr.1> <xxRnn.Ctl.AreaClr.1> <xxRnn.Ctl.AreaClr.1> <xxRnn.Ctl.AreaClr.2> STnn.TLArea.2
18
RSLogix 5000
Conditions To Release Pathsegs
Pickup From Station:

With Cycle Start for OPs where pickup does not occur at Home
With Cycle Complete for OPs where pickup does occur at Home
STnn
Tool Clear
STnn STnn Process STnn STnn STnn to Enter For
Cycle complete (formerly Home 1st Parts 2nd Parts Robot STnn Ready for
Start Full Depth) Position All Present All Present Pickup pickup
STnn.Cyc.Start STnn.ProcCpl STnn.Home STnn._1stPP.Pres STnn._2ndPP.Pres STnn.TLArea.2 STnn.Pos.Pickup
19
STnn
Cycle
Complete
STnn.Cyc.Cpl
STnn
To Be 1st Parts STnn In reposition
Determined All Present for pickup
TBD STnn._1stPP.Pres STnn.Pos.PickupRepo
20
STnn
STnn 1st Group No
Home Parts STnn No PP after
Position Present Pickup
STnn.Home STnn._1stPP.NotPres STnn.Pos.NoPP
21
Dropoff on Station
With Cycle Start for OP Stations
With not Cycle Start for non-OP stations
STnn
STnn Tool Clear
STnn STnn STnn Process STnn 1st Group No to Enter For
Cycle Cycle complete (formerly Home Parts Robot STnn Ready for 1st
Start Start Full Depth) Position Present Dropoff Dropoff
STnn.Cyc.Start STnn.Cyc.Start STnn.ProcCpl STnn.Home STnn._1stPP.NotPres STnn.TLArea.0 STnn.Pos.Dropoff1
22 / /
STnn
To Be 1st Parts STnn In Reposition
Determined All Present for 1st Dropoff
TBD STnn._1stPP.Pres STnn.Pos.DropoffRepo1
23
STnn STnn
Home 1st Parts STnn All PP after
Position All Present 1st Dropoff
STnn.Home STnn._1stPP.Pres STnn.Pos.AllPP1
24

Tool Ready For Welding Robots
STnn STnn
STnn STnn Process All Parts Motion1 to Enter For
Cycle complete (formerly Present AtWork Robot STnn Ready for 1st
Start Full Depth) Memory Complete Weld welds
STnn.Cyc.Start STnn.ProcCpl STnn._1stPP.PresMem STnn_Motion1.Wrk.Cpl STnn.TLArea.1 STnn.Pos.Weld1
25 /
Robots Clear Of Tool

Robot Robot Robot Robot Robot STnn
xxRnn Clear of Area xxRnn Clear of Area xxRnn Clear of Area xxRnn Clear of Area xxRnn Clear of Area Robots
STnnDropoffRb.Ctl.AreaClr.2 STnnWeldRbA.Ctl.AreaClr.1 STnnWeldRbB.Ctl.AreaClr.1 STnnWeldRbC.Ctl.AreaClr.1 STnnPickUpRb.Ctl.AreaClr.1 Clear
<xxRnn.Ctl.AreaClr.2> <xxRnn.Ctl.AreaClr.1> <xxRnn.Ctl.AreaClr.1> <xxRnn.Ctl.AreaClr.1> <xxRnn.Ctl.AreaClr.1> STnn.RobClr
26
STnn
Robots Clear
Indicator
STnn.HMI.RobClr_Ind
Robot STnn Dropoff Robot A

xxRnn Clear of Area Clear Of Tool
STnnDropoffRb.Ctl.AreaClr.2 Indicator
<xxRnn.Ctl.AreaClr.2> STnn.HMI.DropoffRbAClr_Ind
27
Robot STnn Weld Robot A
STnnWeldRbA.Ctl.AreaClr.1 Indicator
<xxRnn.Ctl.AreaClr.1> STnn.HMI.WeldRobAClr_Ind
Robot STnn Weld Robot B

STnnWeldRbB.Ctl.AreaClr.1 Indicator
<xxRnn.Ctl.AreaClr.1> STnn.HMI.WeldRobBClr_Ind
Robot STnn Weld Robot C

STnnWeldRbC.Ctl.AreaClr.1 Indicator
<xxRnn.Ctl.AreaClr.1> STnn.HMI.WeldRobCClr_Ind
Robot STnn Pickup Robot A

STnnPickUpRb.Ctl.AreaClr.1 Indicator
<xxRnn.Ctl.AreaClr.1> STnn.HMI.PickupRbAClr_Ind
RSLogix 5000
Cycle Time Measurement
It is measured as the time where the station is in use.
It includes robot dropoff time and robot pickup time, but not the time while the station is waiting for the pickup robot.
Robot
xxRnn Clear of Area STnn Cycle Time
STnnDropoffRb.Ctl.AreaClr.2 Ticking
<xxRnn.Ctl.AreaClr.2> STnn.Cyc.InCycle
28 /
Robot
xxRnn Path Segment
Robot Ack
xxRnn Path Segment STnnDropoffRb.Ctl.PathOk
EQU <xxRnn.Ctl.PathOk>
Equal
Source A STnnDropoffRb.Ctl.PathSeg
STnn Cycle Time
<xxRnn.Ctl.PathSeg>
Ticking
0
Source B 30 STnn.Cyc.InCycle
STnn
Cycle STnn Ready for
Start pickup
STnn.Cyc.Start STnn.Pos.Pickup
/
Robot
xxRnn Clear of Area
STnnPickUpRb.Ctl.AreaClr.1
<xxRnn.Ctl.AreaClr.1>
/
Robot STnn Ready for
xxRnn Path Segment pickup
EQU STnn.Pos.Pickup
Equal
Source A STnnPickUpRb.Ctl.PathSeg
<xxRnn.Ctl.PathSeg>
0
Source B 10
STnn Cycle Time

Ticking STnn Cycle Timer STnn Cycle Timer
STnn.Cyc.InCycle MOV RTO
29 Move Retentive Timer On EN
Source 9999999 Timer STnn.Cyc.Timer
Preset 9999999 DN
Dest STnn.Cyc.Timer.PRE Accum 0
9999999
STnn
STnn 1st Group No Robot
STnn Cycle Time STnn Cycle Time One Cycle Parts xxRnn Clear of Area
Ticking Shot Start Present STnnPickUpRb.Ctl.AreaClr.1 STnn Cycle Time
STnn.Cyc.InCycle STnn.Cyc.Ons1 STnn.Cyc.Start STnn._1stPP.NotPres <xxRnn.Ctl.AreaClr.1> MOV
30 / ONS / Move
Source STnn.Cyc.Timer.ACC
0
Dest STnn.Cyc.Time
0
STnn Cycle Timer

STnn.Cyc.Timer
RES
(End)
RSLogix 5000
S001_Sequence - Ladder Diagram Page 57
This Routine Contains the calls for every motion in this OP
RungComment
0
**** Repeat rung for every Work Motion in this station ****
JSR
Routine Name S010_Motion1Wrk
**** Repeat rung for every Home Motion in this station ****
JSR
Routine Name S510_Motion1Hme
(End)
RSLogix 5000
S005_PartPresent - Ladder Diagram Page 58
RepeatInputs 1stPP InputBuffer:{PPXIO}
1st Part Presents
1st set of parts loaded in the station

*************
Replace STnn
With 1st Parts
Used Input Switch
************* Present
InputBuffer STnn._1stPP.PresSw
0

*************
Replace STnn
With 1st Group
Used Input No Parts
************* Present
InputBuffer STnn._1stPP.NotPresSw
1 /
STnn
STnn 1st Group
1st Group Any
No Parts Parts
Present Present
STnn._1stPP.NotPresSw STnn._1stPP.AnyPp
2 /
Dry First Pass: Loads a virtual part right away during the first Dry Mode cycle
Cell in STnn
STnn Start Button Dry Dry Cycle
Handstand(H) Mode Ons First Pass
STnn.Sfty.StartHPb Cell.Mode.DryMode STnn.OneShot.0 STnn.Cyc.DryFirstPass
3 ONS
PresMem: Virtual Part for Dry Mode

STnn
STnn 1st Group
Cell in 1st Group All Parts
Dry No Parts Present
Mode Present Memory
Cell.Mode.DryMode STnn._1stPP.NotPresSw STnn._1stPP.PresMem
4 / U
Cell in
Dry Robot
Mode xxRnn Path Segment
Cell.Mode.DryMode EQU
Equal
<xxRnn.Ctl.PathSeg>
0
Source B 12
Robot
STnn Ready for xxRnn Robot Bypassed
pickup STnnPickUpRb.Mode.Bypass
STnn.Pos.Pickup <xxRnn.Mode.Bypass>
Robot
xxRnn Robot At Home
Dry Mode STnn Ready for Position
Stopping pickup STnnPickUpRb.Sta.Home
Cell.Mode.DryStop STnn.Pos.Pickup <xxRnn.Sta.Home>
STnn
1st Group
Cell in STnn All Parts
Dry 1st Parts Present
Mode All Present Memory
Cell.Mode.DryMode STnn._1stPP.Pres STnn._1stPP.PresMem
5 / L
STnn
Cell in 1st Group STnn
Dry No Parts Dry Restart
Mode Present Timer
Cell.Mode.DryMode STnn._1stPP.NotPresSw STnn.Cyc.DryRestartTmr.DN
STnn
Dry Cycle
First Pass
STnn.Cyc.DryFirstPass
Robot
xxRnn Dropoff
Complete
STnnDropoffRb.Sta.DropCpl.0
<xxRnn.Sta.DropCpl.0>
PP.Pres Part Present is the Memory if in Dry Mode; the Switches if in Normal Auto Mode
STnn
Cell in 1st Parts STnn
Dry Switch 1st Parts
Mode Present All Present
Cell.Mode.DryMode STnn._1stPP.PresSw STnn._1stPP.Pres
6 /
STnn
1st Group
Cell in All Parts
Dry Present
Mode Memory
RSLogix 5000
STnn
STnn 1st Group STnn
Cell in 1st Group All Parts 1st Group No
Dry No Parts Present Parts
Mode Present Memory Present
Cell.Mode.DryMode STnn._1stPP.NotPresSw STnn._1stPP.PresMem STnn._1stPP.NotPres
7 / /
Cell in
Dry
Mode
Cell.Mode.DryMode
PP Indicator for PanelView

STnn
1st Group
Part Present
Indicator
MOV
8 Move
Source STnn_FB1.I.M1
0
Dest STnn._1stPP.Ind
0
RepeatInRung 1stPP InputBuffer:{PPXIO} M1.0:M1.{PPXValue-1}

PPIndicator Box (Karmax)
************* OPnn
Replace Compact
With Block IO
Used Input For PP Indicator
************* Module 1
InputBuffer ST10_DIO2.O.M1.0
9
PVnn
Test
Pb(S)
HMInn.Test_Pb
RepeatInputs 2ndPP InputBuffer:{PPXIO}
2nd Part Present

2nd Set of Parts Loaded in the Station
(Usually Parts Loaded by the Robot)
*************
Replace STnn
With 2nd Parts
Used Input Switch
************* Present
InputBuffer STnn._2ndPP.PresSw
10

*************
Replace STnn
With 2nd Group
Used Input No Parts
************* Present
InputBuffer STnn._2ndPP.NotPresSw
11 /
STnn
STnn 2nd Group
2nd Group Any
No Parts Parts
Present Present
STnn._2ndPP.NotPresSw STnn._2ndPP.AnyPp
12 /

STnn
STnn 2nd Group
Cell in 2nd Group All Parts
Mode Present Memory
Cell.Mode.DryMode STnn._2ndPP.NotPresSw STnn._2ndPP.PresMem
13 / U
Cell in
Dry Robot
Equal
<xxRnn.Ctl.PathSeg>
0
Source B 12
Robot
pickup STnnPickUpRb.Mode.Bypass
Robot
xxRnn Robot At Home
Stopping pickup STnnPickUpRb.Sta.Home
RSLogix 5000
STnn
2nd Group
Dry 2nd Parts Present
Cell.Mode.DryMode STnn._2ndPP.Pres STnn._2ndPP.PresMem
14 / L
STnn Robot
Cell in 2nd Group xxRnn Dropoff
Dry No Parts Complete
Mode Present STnnDropoffRb.Sta.DropCpl.0
Cell.Mode.DryMode STnn._2ndPP.NotPresSw <xxRnn.Sta.DropCpl.0>
STnn Robot
1st Parts xxRnn Robot Bypassed
All Present STnnDropoffRb.Mode.Bypass
STnn._1stPP.Pres <xxRnn.Mode.Bypass>
STnn
Cell in 2nd Parts STnn
Dry Switch 2nd Parts
Cell.Mode.DryMode STnn._2ndPP.PresSw STnn._2ndPP.Pres
15 /
STnn
2nd Group
Cell in All Parts
Dry Present
Mode Memory
Cell.Mode.DryMode STnn._2ndPP.PresMem
STnn
STnn 2nd Group STnn
Cell in 2nd Group All Parts 2nd Group No
Cell.Mode.DryMode STnn._2ndPP.NotPresSw STnn._2ndPP.PresMem STnn._2ndPP.NotPres
16 / /
Cell in
Dry
Mode
Cell.Mode.DryMode

STnn
2nd Group
Part Present
Indicator
MOV
17 Move
Source STnn_FB1.I.M1
0
Dest STnn._2ndPP.Ind
0
RepeatInRung 2ndPP InputBuffer:{PPXIO} M1.0:M1.{PPXValue-1}

************* OPnn
Replace Compact
With Block IO
************* Module 1
InputBuffer ST10_DIO2.O.M1.0
18
PVnn
Test
Pb(S)
HMInn.Test_Pb
Part Present Missing Alarms
(Robot Drop On Station)
Cell Cell in STnn STnn Part Dropoff

Auto Dry Robot 1st Parts Error: Part Present
Mode Mode xxRnn Path Segment STnn Fault Timer All Present Signal Missing
Cell.Mode.Auto Cell.Mode.DryMode EQU STnn._1stPP.Flt_Tmr[0].DN STnn._1stPP.Pres STnn._1stPP.Flt.0
19 / Equal /
Source A STnnDropoffRb.Ctl.PathSeg
STnn Part Dropoff
<xxRnn.Ctl.PathSeg>
STnn Error: Part Present
0
2nd Parts Signal Missing
Source B 31
All Present (2ndPP Set)
STnn._2ndPP.Pres STnn._2ndPP.Flt.0
/
Robot
xxRnn Path Segment STnn Fault Timer STnn Fault Timer
EQU MOV TON
Equal Move Timer On Delay EN
Source A STnnDropoffRb.Ctl.PathSeg Source 2500 Timer STnn._1stPP.Flt_Tmr[0]
<xxRnn.Ctl.PathSeg> Preset 0 DN
0 Dest STnn._1stPP.Flt_Tmr[0].PRE Accum 0
Source B 32 0
RSLogix 5000
Part Present Failed On Alarms
(Robot Pickup From Station)

STnn
1st Group
Cell Cell in Any STnn Part Pickup
Auto Dry Robot Parts Error: Part Present
Mode Mode xxRnn Path Segment STnn Fault Timer Present Signal Still On
Cell.Mode.Auto Cell.Mode.DryMode EQU STnn._1stPP.Flt_Tmr[1].DN STnn._1stPP.AnyPp STnn._1stPP.Flt.1
20 / Equal
STnn
<xxRnn.Ctl.PathSeg>
2nd Group STnn Part Pickup
0
Any Error: Part Present
Source B 12
Parts Signal Still On
Present (2ndPP Set)
STnn._2ndPP.AnyPp STnn._2ndPP.Flt.1
STnn Fault Timer STnn Fault Timer

MOV TON
Source 2500 Timer STnn._1stPP.Flt_Tmr[1]
Preset 0 DN
Dest STnn._1stPP.Flt_Tmr[1].PRE Accum 0
0
COP
21 Copy File
Source STnn._1stPP.Flt
Dest STnnAlmMotion[1]
Length 1
COP
Copy File
Source STnn._2ndPP.Flt
Length 1
(End)
RSLogix 5000
S010_Motion1Wrk - Ladder Diagram Page 62
Precondition
OPnn OPnn
Motion1 STnn Process Motion1
Work complete (formerly Work
Safety Full Depth) STnn Abort cycle Precondition
STnn_Motion1.wrk.Saf STnn.ProcCpl STnn.Cyc.Abort STnn_Motion1.Wrk.Pre
0 / /
Safety
OPnn
Cell STnn STnn Motion1
Safeties STnn Light Screen Valve Output Power Robots Work
Reset Reset and Air On Clear Safety
Cell.Rst STnn.Sfty.LsRst STnn.Utility.OutPwrOn STnn.RobClr STnn_Motion1.Wrk.Saf
1
Command
OPnn OPnn OPnn OPnn
Cell STnn Motion1 Motion1 Motion1 Motion1
Auto Cycle Work AtWork Work Work
Mode Start Precondition Complete Safety Command
Cell.Mode.Auto STnn.Cyc.Start STnn_Motion1.wrk.Pre STnn_Motion1.wrk.Cpl STnn_Motion1.wrk.Saf STnn_Motion1.wrk.Cmd
2 /
OPnn OPnn
Cell Motion1 Motion1 STnn
Manual Work Home Home
Mode Pushbutton Pushbutton Enable
Cell.Mode.Man STnn_Motion1.wrk.Pb STnn_Motion1.Hme.Pb STnn.HomeEn
/ /
Output
OPnn OPnn OPnn OPnn
Cell Motion1 Motion1 Motion1 Motion1
Safeties Work Home Home Work
Reset Command Command Output Output
Cell.Rst STnn_Motion1.wrk.Cmd STnn_Motion1.Hme.Cmd STnn_Motion1.Hme.Out STnn_Motion1.wrk.Out
3 / /
**** Replace OutputBuffer the appropriate Output to move to Work ****

Buffering OUTPUTS
*************
OPnn Replace
Motion1 With
Work Used Output
Output *************
STnn_Motion1.wrk.Out OutputBuffer
4
**** Include every cylinder in this motion ****

Motion complete
OPnn
OPnn OPnn Motion1
Motion1 Cyy Motion1 Cyy AtWork
AtHome AtWork Complete
STnn_Motion1_Cyy.PX1 STnn_Motion1_Cyy.PX2 STnn_Motion1.wrk.Cpl
5 /
Panelview Indicator
OPnn OPnn
Motion1 Motion1
Work System Normal AtWork
Precondition Flasher Indicator
STnn_Motion1.wrk.Pre System.Flsh.Norm STnn_Motion1.wrk.Ind
6
OPnn
Motion1
Work
Command
STnn_Motion1.wrk.Cmd
OPnn
Motion1
AtWork
Complete
STnn_Motion1.wrk.Cpl
**** Include the Work sensor for every cylinder in this motion ****
Buffering INPUTS
*************
Replace
With OPnn
Used Input Motion1 Cyy
************* AtWork
InputBuffer STnn_Motion1_Cyy.PX2
7
Faults
OPnn OPnn
Motion1 Motion1
Work Work
Output Eng Mem
STnn_Motion1.wrk.Out STnn_Motion1.wrk.Eng
8 L
OPnn OPnn
Motion1 Motion1
AtWork Cell Machine Power Home
Complete On Eng Mem
STnn_Motion1.wrk.Cpl Cell.sfty.PwrOn STnn_Motion1.Hme.Eng
/ U
RSLogix 5000
OPnn OPnn OPnn OPnn
Motion1 Motion1 Motion1 Motion1
Field Module 1 Work Work AtWork Work
Comm OK Eng Mem Flt Timer Complete Fault
STnn_FB1.CommOK STnn_Motion1.wrk.Eng STnn_Motion1.wrk.Tmr.DN STnn_Motion1.wrk.Cpl STnn_Motion1.wrk.Flt
9 /
OPnn OPnn
Motion1 Motion1
Work Work
Flt Timer Flt Timer
MOV TON
Source 3000 Timer STnn_Motion1.wrk.Tmr
Preset 0 DN
Dest STnn_Motion1.wrk.Tmr.PRE Accum 0
0
**** Repeat this rung for every Cylinder in the station ****
OPnn
Motion1 Cyy
OPnn AtWork /
Motion1 OPnn OPnn AtHome
Work Motion1 Cyy Motion1 Cyy Both PX
Fault AtHome AtWork On
STnn_Motion1.wrk.Flt STnn_Motion1_Cyy.PX1 STnn_Motion1_Cyy.PX2 STnn_Motion1_Cyy.Flt.0
10
OPnn
Motion1 Cyy
OPnn OPnn Did Not Leave
Motion1 Cyy Motion1 Cyy AtHome
AtWork AtHome Position
STnn_Motion1_Cyy.PX2 STnn_Motion1_Cyy.PX1 STnn_Motion1_Cyy.Flt.1
/
OPnn
Motion1 Cyy
OPnn Did Not Reach
Motion1 Cyy AtWork
AtHome Position
STnn_Motion1_Cyy.PX1 STnn_Motion1_Cyy.Flt.2
/

Cell Any L2 Fault
Present on any
Station
Cell.L2FaultPresent COP
11 Copy File
Source STnn_Motion1_Cyy.Flt
Length 1
Cell Any L2 Fault

Present on any
Station
Cell.L2FaultPresent CLR
/ Clear
0
(End)
RSLogix 5000
S010_MotionMan1 - Ladder Diagram Page 64
Precondition
Manual Operation on
Manual Operation on Station Control
Station Control Structure
Structure To Be Rev. 1.0
Rev. 1.0 Complete Determined Precondition
STnn_MotionMan1.Cpl TBD STnn_MotionMan1.Pre
0 /
Operation Complete
STnn Manual Operation on
STnn 1st Group No Station Control
Cycle Parts Structure
Complete Present Rev. 1.0 Complete
STnn.Cyc.Cpl STnn._1stPP.NotPres STnn_MotionMan1.Cpl
1 U
STnn STnn
Home Home
Position Enable
STnn.Home STnn.HomeEn
Manual Operation on
Station Control Manual Operation on
Structure Station Control
Rev. 1.0 To Be Structure
Precondition Determined Rev. 1.0 Complete
STnn_MotionMan1.Pre TBD STnn_MotionMan1.Cpl
2 L
Manual Operation on Manual Operation on

Manual Operation on Station Control Station Control
Station Control Structure Structure
Structure Rev. 1.0 Complete Rev. 1.0 Complete
Rev. 1.0 Complete Delay Timer Delay Timer
STnn_MotionMan1.Cpl MOV TON
Source 2000 Timer STnn_MotionMan1.TCompl
Preset 0 DN
Dest STnn_MotionMan1.TCompl.PRE Accum 0
0
Panelview Indicator
Manual Operation on
Rev. 1.0 System Normal Structure
Precondition Flasher Rev. 1.0 Indicator
STnn_MotionMan1.Pre System.Flsh.Norm STnn_MotionMan1.Ind
4
Manual Operation on
Station Control
Structure
Rev. 1.0 Complete
STnn_MotionMan1.Cpl
Faults
Manual Operation on
To Be Rev. 1.0 Structure
Determined Precondition Rev. 1.0 Fault
TBD STnn_MotionMan1.Pre STnn_MotionMan1.Flt.0
5 L
COP
6 Copy File
Source STnn_MotionMan1.Flt
Length 1
(End)
RSLogix 5000
S510_Motion1Hme - Ladder Diagram Page 65
Precondition
OPnn OPnn
Home complete (formerly Home
Safety Full Depth) Precondition
STnn_Motion1.Hme.Saf STnn.ProcCpl STnn_Motion1.Hme.Pre
0
Safety
OPnn
Safeties STnn Light Screen Valve Output Power Robots Home
Cell.Rst STnn.Sfty.LsRst STnn.Utility.OutPwrOn STnn.RobClr STnn_Motion1.Hme.Saf
1
Command
OPnn OPnn OPnn OPnn
Auto Cycle Home AtHome Home Home
Cell.Mode.Auto STnn.Cyc.Start STnn_Motion1.Hme.Pre STnn_Motion1.Hme.Cpl STnn_Motion1.Hme.Saf STnn_Motion1.Hme.Cmd
2 /
OPnn OPnn
Cell Motion1 Motion1
Manual Home Work
Mode Pushbutton Pushbutton
Cell.Mode.Man STnn_Motion1.Hme.Pb STnn_Motion1.Wrk.Pb
/
STnn
Home
Enable
STnn.HomeEn
Output
OPnn OPnn OPnn OPnn
Safeties Home Work Work Home
Cell.Rst STnn_Motion1.Hme.Cmd STnn_Motion1.Wrk.Cmd STnn_Motion1.Wrk.Out STnn_Motion1.Hme.Out
3 / /
**** Replace OutputBuffer the appropriate Output to move Home ****

Buffering OUTPUTS
*************
OPnn Replace
Motion1 With
Home Used Output
Output *************
STnn_Motion1.Hme.Out OutputBuffer
4

Motion complete
OPnn
OPnn OPnn Motion1
STnn_Motion1_Cyy.PX1 STnn_Motion1_Cyy.PX2 STnn_Motion1.Hme.Cpl
5 /
Panelview Indicator
OPnn OPnn
Motion1 Motion1
Home System Normal AtHome
STnn_Motion1.Hme.Pre System.Flsh.Norm STnn_Motion1.Hme.Ind
6
OPnn
Motion1
Home
Command
STnn_Motion1.Hme.Cmd
OPnn
Motion1
AtHome
Complete
STnn_Motion1.Hme.Cpl
**** Include the Home sensor for every cylinder in this motion ****
Buffering INPUTS
*************
Replace
With OPnn
************* AtHome
InputBuffer STnn_Motion1_Cyy.PX1
7
Faults
OPnn OPnn
Motion1 Motion1
Home Home
Output Eng Mem
STnn_Motion1.Hme.Out STnn_Motion1.Hme.Eng
8 L
OPnn OPnn
Motion1 Motion1
AtHome Cell Machine Power Work
Complete On Eng Mem
STnn_Motion1.Hme.Cpl Cell.sfty.PwrOn STnn_Motion1.Wrk.Eng
/ U
RSLogix 5000
OPnn OPnn OPnn OPnn
Field Module 1 Home Home AtHome Home
STnn_FB1.CommOK STnn_Motion1.Hme.Eng STnn_Motion1.Hme.Tmr.DN STnn_Motion1.Hme.Cpl STnn_Motion1.Hme.Flt
9 /
OPnn OPnn
Motion1 Motion1
Home Home
Flt Timer Flt Timer
MOV TON
Source 3000 Timer STnn_Motion1.Hme.Tmr
Preset 0 DN
Dest STnn_Motion1.Hme.Tmr.PRE Accum 0
0
OPnn
Motion1 Cyy
OPnn AtWork /
Home Motion1 Cyy Motion1 Cyy Both PX
Fault AtWork AtHome On
STnn_Motion1.Hme.Flt STnn_Motion1_Cyy.PX2 STnn_Motion1_Cyy.PX1 STnn_Motion1_Cyy.Flt.3
10
OPnn
Motion1 Cyy
AtHome AtWork Position
STnn_Motion1_Cyy.PX1 STnn_Motion1_Cyy.PX2 STnn_Motion1_Cyy.Flt.4
/
OPnn
Motion1 Cyy
OPnn Did Not Reach
Motion1 Cyy AtHome
AtWork Position
STnn_Motion1_Cyy.PX2 STnn_Motion1_Cyy.Flt.5
/
(End)
RSLogix 5000
Junction Box Fuse Faults
RungComment
0
DeviceNet Faults
RungComment
1

Enable
STnn_DIONode.Enable
<DNet07.Node[0].Enable>
2
DeviceNet Module
Not Faulted Power On Timer STnn_DIONode.Faulted STnn_DIONode.FaultedMem
DNet07.Module.RunOK DNet07.Module.PwrOnTmr.DN <DNet07.Node[0].Faulted> <DNet07.Node[0].FaultedMem>
PVCell OPnn
Node 0 Status Node 0 Fault Reset Compact Block I/O
Faulted Memory Pushbutton DNet Node Faulted
STnn_DIONode.FaultedMem (Hardware) STnnAlmComm.8
<DNet07.Node[0].FaultedMem> HMICell.FltrstHpb
/
Node 0 Status Node 0 OPnn

Active In Scanlist Compact Block I/O
STnn_DIONode.Active DNet Node Not Active
<DNet07.Node[0].Active> STnnAlmComm.9
/

Enable
STnn_DIO2Node.Enable
3
DeviceNet Module
Not Faulted Power On Timer STnn_DIO2Node.Faulted STnn_DIO2Node.FaultedMem
PVCell OPnn
Node 0 Status Node 0 Fault Reset Compact Block I/O #2
STnn_DIO2Node.FaultedMem (Hardware) STnnAlmComm.10
/

Active In Scanlist Compact Block I/O #2
STnn_DIO2Node.Active DNet Node Not Active
/

Enable
STnnFB1Node.Enable
4
DeviceNet Module
Not Faulted Power On Timer STnnFB1Node.Faulted STnnFB1Node.FaultedMem
PVCell OPnn
Node 0 Status Node 0 Fault Reset FB1
STnnFB1Node.FaultedMem (Hardware) STnnAlmComm.12
/

Active In Scanlist FB1
STnnFB1Node.Active DNet Node Not Active
/

Enable
STnnFB2Node.Enable
5
DeviceNet Module
Not Faulted Power On Timer STnnFB2Node.Faulted STnnFB2Node.FaultedMem
PVCell OPnn
STnnFB2Node.FaultedMem (Hardware) STnnAlmComm.14
/

STnnFB2Node.Active DNet Node Not Active
/
RSLogix 5000
Enable
STnnPT1Node.Enable
6
DeviceNet Module
Not Faulted Power On Timer STnnPT1Node.Faulted STnnPT1Node.FaultedMem
PVCell OPnn
Node 0 Status Node 0 Fault Reset PT1
STnnPT1Node.FaultedMem (Hardware) STnnAlmComm.18
/

Active In Scanlist PT1
STnnPT1Node.Active DNet Node Not Active
/
STnn Safety IO STnn Safety IO

Module Faulted Module Faulted
STnn.Sfty.Mod1Flt STnnAlmSafety.0
7 L

Module Faulted Module 2 Faulted
STnn.Sfty.Mod2Flt STnnAlmSafety.1
8 L
STnn Rollup Door

STnn Roll Up Door Dual Channel Safety
Dual Channel Fault Fault
STnn.Sfty.RUDFlt STnnAlmSafety.2
9 L
STnn EStop Dual STnn E-Stop Dual

Channel Fault Channel Safety Fault
STnn.Sfty.EStopFlt STnnAlmSafety.3
10 L
STnn Light Screen

STnn Light Screen Dual Channel Safety
Dual Channel Fault Fault
STnn.Sfty.LsFlt STnnAlmSafety.4
11 L
STnn Output Relay STnn Output Relay

Power Monitoring Monitoring Safety
Fault Fault
STnn.Sfty.OutPowerFlt STnnAlmSafety.5
12 L
Safety Gate nn Gate

SG1 Safeties Locked Lock Dual Channel
Dual Cahnnel Fault Safety Fault
SG1_Safeties.LockedFlt STnnAlmSafety.6
13 L
COP
14 Copy File
Source STnn.UtilityFaults_Ina
Length 1
Cell Count of how

many stations have
L2 Faults
NEQ ADD
15 Not Equal Add
Source A STnnAlmSafety Source A Cell.L2FaultCount
0 0
0
NEQ
Not Equal
Source A STnnAlmComm
0
Source B 0
(End)
RSLogix 5000
B001_Map_Inputs - Ladder Diagram Page 69
Cosma:MainTask:_xxRyy 11/11/2010 1:28:09 PM
Robot Safety Mapping
Robot
xxRnn Robot Pilz
COP
0 Copy File
Source xxRnn_Safeties
Dest xxRnn.Sfty
Length 1
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
DeviceNet Module
Local Slot 7 Status
Local Slot 7 OK -
Running & Active and
Not Faulted Not Faulted Signal From
xxRnn_Scanner.Module.RunOK _10R1_Node.OK RBnn
1 Copy File
Dest xxRnnDo
Length 1

OK -
Active and
Not Faulted Signal From
_10R1_Node.OK RBnn
<DNet07.Node[0].OK> FLL
/ Fill File
Source 0
DeviceNet Module
Dest xxRnnDo
Local Slot 7 Status
Length 1
DeviceNet Module
Local Slot 7
Running &
Not Faulted
xxRnn_Scanner.Module.RunOK
<DNet07.Module.RunOK>
/
Robot
xxRnn Diagnostics
BTD
2 Bit Field Distribute
0
Source Bit 24
Dest xxRnn.Sta.Diag
0
Dest Bit 0
Length 8
In Zone
Signal From Robot

RBnn Clear of Zone 1 xxRnn Request To
(DO 41) Enter Zone
xxRnnDo.Zone1_41 xxRnn.Ctl.ReqZone.1
3 /
Signal From Robot

(DO 42) Enter Zone
4 /
Signal From Robot

(DO 43) Enter Zone
5 /
Signal From Robot

(DO 44) Enter Zone
6 /
Signal From Robot

(DO 45) Enter Zone
7 /
Signal From Robot

(DO 46) Enter Zone
8 /
Signal From Robot

(DO 47) Enter Zone
9 /
Signal From Robot

(DO 48) Enter Zone
10 /
Program Ack
Signal From
RBnn Style Ack1 (DO Robot
11) xxRnn Program Ack
xxRnnDo.PrgAck1_11 xxRnn.Ctl.PrgAck.0
11
RSLogix 5000
Signal From
RBnn Style Ack 2 (DO Robot
12
Signal From
13
Signal From
14
Signal From
15
Signal From
16
Signal From
17
Signal From
RBnn Style ack 8 (DO Robot
18
Pathseg
Signal From
RBnn Pathseg Bit 1 Robot
(DO 49) xxRnn Path Segment
xxRnnDo.Path1_49 xxRnn.Ctl.PathSeg.0
19
Signal From
20
Signal From
21
Signal From
22
Signal From
23
Signal From
24
Signal From
25
Signal From
26
Signal From Robot

RBnn Pathseg Request xxRnn Path Segment
(DO 32) Request
xxRnnDo.PathReq_32 xxRnn.Ctl.PathSegReq
27
Area Clear
Signal From
RBnn Clear Of Area Robot
1 (DO 33) xxRnn Clear of Area
xxRnnDo.Area1_33 xxRnn.Ctl.AreaClr.1
28
Signal From
29
Signal From
30
RSLogix 5000
Signal From
31
Signal From
32
Signal From
33
Signal From
34
Signal From
35
Process Signals
Signal From
RBnn Weld Controller Robot
1 Near End Of xxRnn Robot Stepper
Stepper (DO 73) Pre-Warning
xxRnnDo.PreWrn1_73 xxRnn.Weld.G1.Pre_Wrn
36
Signal From
RBnn Weld Controller
1 At End Of Stepper Robot
(DO 74) xxRnn End Of Stepper
xxRnnDo.EOS1_74 xxRnn.Weld.G1.EOS
37
Signal From Robot

RBnn Tip Dress xxRnn Tip Dress
Required on Tip 1 Request
xxRnnDo.TipDrsReq1_79 xxRnn.Weld.G1.DrsReq
38
Signal From
RBnn Weld Controller Robot
2 Near End Of xxRnn Robot Stepper
Stepper (DO 80) Pre-Warning
xxRnnDo.PreWrn2_80 xxRnn.Weld.G2.Pre_Wrn
39
Signal From
RBnn Weld Controller
2 At End Of Stepper Robot
(DO 81) xxRnn End Of Stepper
xxRnnDo.EOS2_81 xxRnn.Weld.G2.EOS
40
Signal From
RBnn Tip Dress Robot
Required on Tip 2 xxRnn Tip Dress
(DO86) Request
xxRnnDo.TipDrsReq2_86 xxRnn.Weld.G2.DrsReq
41
Signal From
RBnn Air Pressure is Robot
OK (DO 27) xxRnn Air On
xxRnnDo.AirOK_27 xxRnn.Sta.AirOn
42
Signal From Robot

RBnn Water Flow Is xxRnn Water Ok Flow
OK (DO 25) Switch
xxRnnDo.WtrOK_25 xxRnn.Weld.WtrOk
43
Robot
Signal From xxRnn No Water
RBnn Water is Not Required (No Gun on
Required (DO 26) Robot)
xxRnnDo.NoWtrReq_26 xxRnn.Weld.NoWtrReq
44
(End)
RSLogix 5000
B002_Map_Outputs - Ladder Diagram Page 72
Robot
Input Mapping
Robot Signal to
xxRnn Path Segment RBnn Path OK To
Ack Continue(DI 32)
xxRnn.Ctl.PathOk xxRnnDi.PathOK_32
0
Signal to
Robot RBnn Weld State (DI
xxRnn Enable 21)
xxRnn.Mode.Weld.En xxRnnDi.WldState_21
1
Cell in Signal to
Dry RBnn Dry Cycle (DI
Mode 22)
Cell.Mode.DryMode xxRnnDi.Dry_22
2
Signal to
Robot RBnn Water On
xxRnn Water On Solenoid Valve (DI
Solenoid 25)
xxRnn.Weld.WtrOn xxRnnDi.WaterOn_25
3
Robot Zones
Robot Signal to
xxRnn Request To Robot RBnn Robot Clr to
Enter Zone xxRnn Can Lock Zone Enter Zone 1 (DI 41)
xxRnn.Ctl.ReqZone.1 xxRnn.Ctl.CanLckZn.1 xxRnnDi.Zone1_41
4
Robot
xxRnn Clear to Enter
Zone
xxRnn.Ctl.ClrEntZn.1
Robot Signal to
5
Robot
Zone
Robot Signal to
6
Robot
Zone
Robot Signal to
7
Robot
Zone
Robot Signal to
8
Robot
Zone
Robot Signal to
9
Robot
Zone
Robot Signal to
10
Robot
Zone
Robot Signal to
11
Robot
Zone
RSLogix 5000
B002_Map_Outputs - Ladder Diagram Page 73
Program Call
Signal to
Robot RBnn Robot Style
xxRnn Program Call Select 1 (DI 09)
xxRnn.Ctl.PrgCall.0 xxRnnDi.PgmSel0_09
12
Signal to
13
Signal to
14
Signal to
15
Signal to
16
Signal to
xxRnn Program Call Select6 (DI 14)
17
Signal to
18
Signal to
19
Area Enter
Robot Signal to
xxRnn Clear To Enter RBnn Robot Clr to
Area Enter Area 1 (DI 33)
xxRnn.Ctl.ClrEntAr.1 xxRnnDi.Area1_33
20
Robot Signal to
21
Robot Signal to
22
Robot Signal to
23
Robot Signal to
24
Signal to
Robot RBnn Robot Clr to
xxRnn Clear To Enter Enter Area 6 (DI
Area 38)
25
Signal to
Area 39)
26
Signal to
Area 40)
27
Map Signals:
Copy from UDT to DNet Scanner
COP
28 Copy File
Source xxRnnDi
Length 4
(End)
RSLogix 5000
B003_MapHMI - Ladder Diagram Page 74
Signal From Robot
RBnn System Ready xxRnn Robot Ready
(DO 02) Indicator
xxRnnDo.SysRdy_02 xxRnn.Pv.Ready_Ind
0
Signal From Robot

RBnn Program Running xxRnn Program
(DO 03) Running
xxRnnDo.PrgRun_03 xxRnn.Pv.PrgRun_Ind
1
Signal From Robot

RBnn Program Paused xxRnn Robot Paused
(DO 04 Indicator
xxRnnDo.PrgPause_04 xxRnn.Pv.Pause_Ind
2
Signal From Robot

RBnn Motion Held (DO xxRnn Robot Held
05) Indicator
xxRnnDo.Held_05 xxRnn.Pv.Held_Ind
3
Robot
Signal From xxRnn Fault
RBnn Fault (DO 06) Indicator
xxRnnDo.Flt_06 xxRnn.Pv.Fault_Ind
4
Robot
Signal From Robot xxRnn At Home
RBnn At Home (DO 07) xxRnn Path Segment Indicator
xxRnnDo.Hme_07 EQU xxRnn.Pv.AtHome_Ind
5 Equal
Source A xxRnn.Ctl.PathSeg
0
Source B 0
Robot Robot Robot

xxRnn Path Segment xxRnn Path Segment Robot xxRnn At Pounce
Request Ack xxRnn Path Segment Indicator
xxRnn.Ctl.PathSegReq xxRnn.Ctl.PathOk EQU xxRnn.Pv.AtPounce_Ind
6 / Equal
0
Source B 50
Robot
xxRnn Path Segment
EQU
Equal
0
Source B 10
Robot System Normal

xxRnn Decision Code Flasher
EQU System.Flsh.Norm
Equal
Source A xxRnn.Ctl.Decision
0
Source B 15
Robot
Robot xxRnn Air On
xxRnn Air On Indicator
xxRnn.Sta.AirOn xxRnn.Pv.AirOn_Ind
7
Signal From Robot

RBnn Water Flow Is xxRnn Water On
OK (DO 25) Indicator
xxRnnDo.WtrOK_25 xxRnn.Pv.WtrOn_Ind
8
Signal From
RBnn Water is Not
Required (DO 26)
xxRnnDo.NoWtrReq_26
Area Indicators
Robot
Robot xxRnn Tooling Area 1
xxRnn Clear of Area Status
xxRnn.Ctl.AreaClr.1 xxRnn.Pv.Area1_Ind
9 /
Robot
10 /
Robot
11 /
Robot
12 /
Robot
13 /
RSLogix 5000
Robot
14 /
Robot
15 /
Robot
16 /
Robot
xxRnn Current Area
Entering Number
MOV
17 Move
Source 0
Dest xxRnn.Pv.Area_Ina
0
Robot Robot
xxRnn Current Area xxRnn Current Area
Entering Number Entering Number
LIM SUB
18 Limit Test (CIRC) Subtract
Low Limit 5 Source A xxRnn.Pv.Local_Ina
0
Test xxRnn.Pv.Area_Ina Source B 4
0
High Limit 12 Dest xxRnn.Pv.Area_Ina
0
Zone Indicators
Robot
Robot Robot xxRnn Robot
xxRnn Request To xxRnn Clear to Enter Collision Zone
Enter Zone Zone Status Indicator
xxRnn.Ctl.ReqZone.1 xxRnn.Ctl.ClrEntZn.1 xxRnn.Pv.Zone1_Ind
19
System Normal
Flasher
System.Flsh.Norm
Robot
20
System Normal
Flasher
System.Flsh.Norm
Robot
21
System Normal
Flasher
System.Flsh.Norm
Robot
22
System Normal
Flasher
System.Flsh.Norm
Robot
23
System Normal
Flasher
System.Flsh.Norm
Robot
24
System Normal
Flasher
System.Flsh.Norm
RSLogix 5000
Robot
25
System Normal
Flasher
System.Flsh.Norm
Robot
26
System Normal
Flasher
System.Flsh.Norm
Pathseg & Option Indication
Robot
xxRnn Program
Running Number
MOV
27 Move
Source xxRnn.Ctl.PrgAck
0
Dest xxRnn.Pv.ProgRun_Ina
0
Robot
xxRnn Program Call
Number
MOV
28 Move
Source xxRnn.Ctl.PrgCall
0
Dest xxRnn.Pv.ProgCall_Ina
0
Robot
xxRnn Descision
Display
MOV
29 Move
Source xxRnn.Ctl.Decision
0
Dest xxRnn.Pv.Descision_Ina
0
Robot
xxRnn Pathsegment
Number
MOV
30 Move
Source xxRnn.Ctl.PathSeg
0
Dest xxRnn.Pv.PathSeg_Ina
0
Robot Robot
xxRnn Path Segment xxRnn Pathsegment
Request Request Number
xxRnn.Ctl.PathSegReq xxRnn.Pv.PathReq_Ind
31
Robot Robot
xxRnn Path Segment Robot xxRnn Descision
Request xxRnn Path Segment Request
xxRnn.Ctl.PathSegReq LIM xxRnn.Pv.DescisionReq_Ind
32 Limit Test (CIRC)
Low Limit 65
Test xxRnn.Ctl.PathSeg
0
High Limit 70
Service / Tip Dress / Tip Change Indications
Robot
Robot xxRnn Robot In
xxRnn Path Segment Service Position
EQU xxRnn.Pv.Service_Ind
33 Equal
0
Source B 3
Robot System Normal

xxRnn Path Segment Flasher
EQU System.Flsh.Norm
Equal
0
Source B 2
Robot
xxRnn Service Latch
xxRnn.Sta.SvceLtch
RSLogix 5000
Robot
xxRnn Tip Dress
Counter
MOV
34 Move
Source xxRnn.Weld.G1.Cntr.ACC
0
Dest xxRnn.Pv.TipDrsCnt_Ina
0
Robot
xxRnn Max Tip Dress
Display
MOV
35 Move
Source 99
Dest xxRnn.Pv.TipDrsMax_Ina
0
Base Limit Switches Indication
Robot Robot
xxRnn Base Limit 1 xxRnn 1st Base Limit
ON Indicator
xxRnn.Sfty.BLim1 xxRnn.Pv.BaseLm1_Ind
36
Robot Robot
xxRnn Base Limit 2 xxRnn 2nd Base Limit
ON Indicator
37
Robot Robot
xxRnn Base Limit 3 xxRnn 3rd Base Limit
ON Indicator
38
Robot
Robot xxRnn Arm Clear
xxRnn Arm Clear ON Indicator
xxRnn.Sfty.ArmClr xxRnn.Pv.ArmClr_Ind
39
Local Information Indicator
Robot
xxRnn Local Message
Display
MOV
40 Move
Source xxRnn.Sta.Diag
0
Dest xxRnn.Pv.Local_Ina
0
Weld Complete Indicators
Robot
xxRnn 1st Tool/Gun
Robot Weld Complete
xxRnn Weld Complete Indicator
xxRnn.Weld.Cpl.0 xxRnn.Pv.WldCmp1_Ind
41
Robot
xxRnn 2nd Tool/Gun
Robot Weld Complete
42 AFI
Robot
xxRnn 3rd Tool/Gun
Robot Weld Complete
43 AFI
Robot
xxRnn 4th Tool/Gun
Robot Weld Complete
44 AFI
(End)
RSLogix 5000
B020_Process1_Spotweld - Ladder Diagram Page 78
Local Robot Weld Toggle Control Logic
Signal From
RBnn Weld Mode Robot Robot
Toggle (DO 23) xxRnn One Shot xxRnn Toggle Request
xxRnnDo.WldTggl_23 xxRnn.Mode.Weld.Ons xxRnn.Mode.Weld.Tggl
0 ONS
Robot Robot Robot

xxRnn Toggle Request xxRnn Enable xxRnn Disable
xxRnn.Mode.Weld.Tggl xxRnn.Mode.Weld.En xxRnn.Mode.Weld.Dis
1
Robot
Robot Robot xxRnn Robot In Robot
xxRnn Toggle Request xxRnn Disable Automatic xxRnn Enable
xxRnn.Mode.Weld.Tggl xxRnn.Mode.Weld.Dis xxRnn.Mode.Auto xxRnn.Mode.Weld.En
2 / /
Robot
xxRnn Enable
xxRnn.Mode.Weld.En
Robot
xxRnn Robot In
Cell Enable Automatic
Cell.Mode.Wld.En xxRnn.Mode.Auto
*
Water On Logic
*
Robot Robot Robot
xxRnn Water On xxRnn Water Ok Flow xxRnn Water OK
Solenoid Switch Memory
xxRnn.Weld.WtrOn xxRnn.Weld.WtrOk xxRnn.Weld.WtrOkMem
3
Robot
xxRnn Water OK
Memory
xxRnn.Weld.WtrOkMem
Robot Robot Robot Robot

xxRnn Water On xxRnn Water OK xxRnn Water Start xxRnn Water Start
Solenoid Memory Delay Timer Delay Timer
xxRnn.Weld.WtrOn xxRnn.Weld.WtrOkMem MOV TON
Source 5000 Timer xxRnn.Weld.WtrStartTmr
Preset 0 DN
Dest xxRnn.Weld.WtrStartTmr.PRE Accum 0
0
PVCell
Robot Fault Reset Robot
xxRnn Water Start Pushbutton xxRnn Water Start
Delay Timer (Hardware) Fault
xxRnn.Weld.WtrStartTmr.DN HMICell.FltrstHpb xxRnn.Weld.WtrStrtFlt
5 /
Robot
xxRnn Water Start
Fault
xxRnn.Weld.WtrStrtFlt
Robot Robot Robot Robot Robot

xxRnn Water On xxRnn Water OK xxRnn Water Ok Flow xxRnn Water Ok Delay xxRnn Water Ok Delay
Solenoid Memory Switch Timer Timer
xxRnn.Weld.WtrOn xxRnn.Weld.WtrOkMem xxRnn.Weld.WtrOk MOV TON
Source 1000 Timer xxRnn.Weld.WtrOkTmr
Preset 0 DN
Dest xxRnn.Weld.WtrOkTmr.PRE Accum 0
0
PVCell
Robot Fault Reset Robot
xxRnn Water Ok Delay Pushbutton xxRnn Water Loss
Timer (Hardware) Fault
xxRnn.Weld.WtrOkTmr.DN HMICell.FltrstHpb xxRnn.Weld.WtrOKFlt
7 /
Robot
xxRnn Water Loss
Fault
xxRnn.Weld.WtrOKFlt
Robot
Cell Robot Robot xxRnn No Water Robot
Auto xxRnn Water Loss xxRnn Water Start Required (No Gun on xxRnn Water On
Cell All E-Stops Ok Mode Cell Enable Fault Fault Robot) Solenoid
Cell.sfty.AllEStopOk Cell.Mode.Auto Cell.Mode.Wld.En xxRnn.Weld.WtrOKFlt xxRnn.Weld.WtrStrtFlt xxRnn.Weld.NoWtrReq xxRnn.Weld.WtrOn
8 / / /
Signal From Signal From
RBnn Teach Pendant RBnn System Ready
Enabled (DO 08 (DO 02)
xxRnnDo.TPen_08 xxRnnDo.SysRdy_02
Robot / Tooling
Memory Bits
STnn STnn
Cycle
Complete Robot
xxRnnWeldOP.Cyc.Cpl xxRnn Weld Complete
<STnn.Cyc.Cpl> xxRnn.Weld.Cpl.0
9 U
STnn STnn STnn STnn Robot
Home Home xxRnn Glue Complete
Enable Position Memories
xxRnnWeldOP.HomeEn xxRnnWeldOP.Home xxRnn.Glue1.Cpl.0
<STnn.HomeEn> <STnn.Home> U
RSLogix 5000
Robot Robot
xxRnn Path Segment xxRnn Weld Complete
EQU xxRnn.Weld.Cpl.0
10 Equal L
Signal From Robot
0
RBnn Glue 1 Ok (DO xxRnn Glue Complete
Source B 51
95) Memories
xxRnnDo.Gl1Ok_95 xxRnn.Glue1.Cpl.0
L
2nd Process Complete

STnn STnn
Cycle
Complete Robot
xxRnnWeldOP.Cyc.Cpl xxRnn Weld Complete
<STnn.Cyc.Cpl> xxRnn.Weld.Cpl.1
11 U
STnn STnn STnn STnn Robot
Home Home xxRnn Glue Complete
Enable Position Memories
xxRnnWeldOP.HomeEn xxRnnWeldOP.Home xxRnn.Glue1.Cpl.1
<STnn.HomeEn> <STnn.Home> U
Robot Robot
EQU xxRnn.Weld.Cpl.1
12 Equal L
Signal From Robot
0
RBnn Glue 2 Ok (DO xxRnn Glue Complete
Source B 52
100) Memories
xxRnnDo.Gl2Ok_100 xxRnn.Glue2.Cpl.0
L
Pushbutton Delay
Robot Robot Robot

xxRnn Service xxRnn Pushbutton xxRnn Pushbutton
Pushbutton Delay Timer Delay Timer
xxRnn.Sta.SvcePb MOV TON
Source 3000 Timer xxRnn.Weld.PbDelay
Robot
Preset 0 DN
xxRnn Tip Change
Dest xxRnn.Weld.PbDelay.PRE Accum 0
Pushbutton
0
xxRnn.Weld.G1.ChgPb
Robot
xxRnn Tip Change
Pushbutton
xxRnn.Weld.G2.ChgPb
Robot
xxRnn Tip Dress
Pushbutton
xxRnn.Weld.G1.DrsPb
Robot
xxRnn Tip Dress
Pushbutton
xxRnn.Weld.G2.DrsPb
Tip Change Logic
Robot Robot Robot

xxRnn Tip Change xxRnn Tip Change Robot xxRnn Tip Change
Pushbutton Latch xxRnn Path Segment Latch
xxRnn.Weld.G1.ChgPb xxRnn.Weld.G1.ChgLatch EQU xxRnn.Weld.G1.ChgLatch
14 Equal U
0
Source B 3
Robot
Robot Robot Robot xxRnn Tip Change
xxRnn End Of Stepper xxRnn Service Latch xxRnn Tip Change ONS Latch
xxRnn.Weld.G1.EOS xxRnn.Sta.SvceLtch xxRnn.Weld.G1.ChgOns xxRnn.Weld.G1.ChgLatch
15 / ONS L
Robot
xxRnn Robot Stepper
Pre-Warning
Robot Robot
xxRnn Pushbutton xxRnn Tip Change
Delay Timer Pushbutton
xxRnn.Weld.PbDelay.DN xxRnn.Weld.G1.ChgPb
Robot Robot
xxRnn Tip Change xxRnn Tip Change
Latch Indicator
xxRnn.Weld.G1.ChgLatch xxRnn.Weld.G1.ChgInd
16
Signal to
RBnn Initiate Robot
Robot Robot TipChange on G1
xxRnn Robot At Home xxRnn Tip Change (With Prg 15) (DI
Position Latch 63)
xxRnn.Sta.Home xxRnn.Weld.G1.ChgLatch xxRnnDi.TipChgG1_63
17 / U
Signal to
RBnn Initiate Robot
Robot TipChange on G1
xxRnn Tip Change (With Prg 15) (DI
Latch 63)
xxRnn.Weld.G1.ChgLatch xxRnnDi.TipChgG1_63
18 L
RSLogix 5000
Tip Dress Logic
Robot Robot
xxRnn Tip Dress Robot xxRnn Tip Dress
Latch xxRnn Path Segment Latch
xxRnn.Weld.G1.DrsLatch EQU xxRnn.Weld.G1.DrsLatch
19 Equal U
0
Source B 5
Robot Robot
xxRnn Tip Dress Robot Robot xxRnn Tip Dress
Request xxRnn Service Latch xxRnn Tip Dress ONS Latch
xxRnn.Weld.G1.DrsReq xxRnn.Sta.SvceLtch xxRnn.Weld.G1.DrsOns xxRnn.Weld.G1.DrsLatch
20 / ONS L
Robot Robot
xxRnn Pushbutton xxRnn Tip Dress
xxRnn.Weld.PbDelay.DN xxRnn.Weld.G1.DrsPb
Robot Robot
xxRnn Tip Dress xxRnn Tip Dress
Latch Indicator
xxRnn.Weld.G1.DrsLatch xxRnn.Weld.G1.DrsInd
21
Signal to
Robot Robot RBnn Initiate Robot
xxRnn Robot At Home xxRnn Tip Dress TipDress on G1 (With
Position Latch Prg 15) (DI 64)
xxRnn.Sta.Home xxRnn.Weld.G1.DrsLatch xxRnnDi.TipDrsG1_64
22 / U
Signal to
Robot RBnn Initiate Robot
xxRnn Tip Dress TipDress on G1 (With
Latch Prg 15) (DI 64)
xxRnn.Weld.G1.DrsLatch xxRnnDi.TipDrsG1_64
23 L
Weld Fault Recovery WC1
Signal From Signal to Signal to

RBnn Weld Controller RBnn Fault Reset RBnn Fault Reset and
1 No Major Fault (DO Robot Robot Weld Controller 1 Reweld Weld Ctrl
75) xxRnn Path Segment xxRnn Weld Retry PB (DI 57) 1(DI 58)
xxRnnDo.NoMjrFlt1_75 EQU xxRnn.Weld.G1.Retry_Pb xxRnnDi.FltRstWC1_57 xxRnnDi.FltRstRwld1_58
24 / Equal /
Signal to
0
RBnn Fault Reset and
Source B 50
Reweld Weld Ctrl
1(DI 58)
xxRnnDi.FltRstRwld1_58
Signal From Signal to

RBnn Weld Controller RBnn Fault Reset
1 No Major Fault (DO Weld Controller 1 System Normal Robot
75) (DI 57) Flasher xxRnn Weld Retry Ind
xxRnnDo.NoMjrFlt1_75 xxRnnDi.FltRstWC1_57 System.Flsh.Norm xxRnn.Weld.G1.Retry_Ind
25 / /
Signal to
Reweld Weld Ctrl
1(DI 58)

RBnn Weld Controller RBnn Fault Reset and RBnn Fault Reset
1 No Major Fault (DO Robot Robot Reweld Weld Ctrl Weld Controller 1
75) xxRnn Path Segment xxRnn Weld Skip PB 1(DI 58) (DI 57)
xxRnnDo.NoMjrFlt1_75 EQU xxRnn.Weld.G1.Skip_Pb xxRnnDi.FltRstRwld1_58 xxRnnDi.FltRstWC1_57
26 / Equal /
Signal to Robot
0
RBnn Fault Reset xxRnn Part must be
Source B 50
Weld Controller 1 rejected at next
(DI 57) Reject Station
xxRnnDi.FltRstWC1_57 xxRnn.Sta.PartInfo.Reject
L

RBnn Weld Controller RBnn Fault Reset and
1 No Major Fault (DO Reweld Weld Ctrl System Normal Robot
75) 1(DI 58) Flasher xxRnn Weld Skip Ind
xxRnnDo.NoMjrFlt1_75 xxRnnDi.FltRstRwld1_58 System.Flsh.Norm xxRnn.Weld.G1.Skip_Ind
27 / /
Signal to
RBnn Fault Reset
Weld Controller 1
(DI 57)
xxRnnDi.FltRstWC1_57
Gun 2 Tip Change Logic
Robot Robot Robot

xxRnn Tip Change xxRnn Tip Change Robot xxRnn Tip Change
Pushbutton Latch xxRnn Path Segment Latch
xxRnn.Weld.G2.ChgPb xxRnn.Weld.G2.ChgLatch EQU xxRnn.Weld.G2.ChgLatch
28 Equal U
0
Source B 3
RSLogix 5000
Robot
Robot Robot Robot xxRnn Tip Change
xxRnn End Of Stepper xxRnn Service Latch xxRnn Tip Change ONS Latch
xxRnn.Weld.G2.EOS xxRnn.Sta.SvceLtch xxRnn.Weld.G2.ChgOns xxRnn.Weld.G2.ChgLatch
29 / ONS L
Robot
xxRnn Robot Stepper
Pre-Warning
Robot Robot
xxRnn Pushbutton xxRnn Tip Change
xxRnn.Weld.PbDelay.DN xxRnn.Weld.G2.ChgPb
Robot Robot
xxRnn Tip Change xxRnn Tip Change
Latch Indicator
xxRnn.Weld.G2.ChgLatch xxRnn.Weld.G2.ChgInd
30
Signal to
RBnn Initiate Robot
Robot Robot TipChange on G2
xxRnn Robot At Home xxRnn Tip Change (With Prg 15) (DI
Position Latch 65)
xxRnn.Sta.Home xxRnn.Weld.G2.ChgLatch xxRnnDi.TipChgG2_65
31 / U
Signal to
RBnn Initiate Robot
Robot TipChange on G2
xxRnn Tip Change (With Prg 15) (DI
Latch 65)
xxRnn.Weld.G2.ChgLatch xxRnnDi.TipChgG2_65
32 L
Gun 2 Tip Dress Logic
Robot Robot
xxRnn Tip Dress Robot xxRnn Tip Dress
Latch xxRnn Path Segment Latch
xxRnn.Weld.G2.DrsLatch EQU xxRnn.Weld.G2.DrsLatch
33 Equal U
0
Source B 5
Robot Robot
xxRnn Tip Dress Robot Robot xxRnn Tip Dress
Request xxRnn Service Latch xxRnn Tip Dress ONS Latch
xxRnn.Weld.G2.DrsReq xxRnn.Sta.SvceLtch xxRnn.Weld.G2.DrsOns xxRnn.Weld.G2.DrsLatch
34 / ONS L
Robot Robot
xxRnn Pushbutton xxRnn Tip Dress
xxRnn.Weld.PbDelay.DN xxRnn.Weld.G2.DrsPb
Robot Robot
xxRnn Tip Dress xxRnn Tip Dress
Latch Indicator
xxRnn.Weld.G2.DrsLatch xxRnn.Weld.G2.DrsInd
35
Signal to
Robot Robot RBnn Initiate Robot
xxRnn Robot At Home xxRnn Tip Dress TipDress on G2 (With
Position Latch Prg 15) (DI 66)
xxRnn.Sta.Home xxRnn.Weld.G2.DrsLatch xxRnnDi.TipDrsG2_66
36 / U
Signal to
Robot RBnn Initiate Robot
xxRnn Tip Dress TipDress on G2 (With
Latch Prg 15) (DI 66)
xxRnn.Weld.G2.DrsLatch xxRnnDi.TipDrsG2_66
37 L
Weld Fault Recovery WC2

RBnn Weld Controller RBnn Fault Reset RBnn Fault Reset and
2 No Major Fault (DO Robot Robot Weld Controller 2 Reweld Weld Ctrl 2
82) xxRnn Path Segment xxRnn Weld Retry PB (DI 60) (DI 61)
xxRnnDo.NoMjrFlt2_82 EQU xxRnn.Weld.G2.Retry_Pb xxRnnDi.FltRstWC2_60 xxRnnDi.FltRstRwld2_61
38 / Equal /
Signal to
0
Source B 52
Reweld Weld Ctrl 2
(DI 61)

RBnn Weld Controller RBnn Fault Reset
2 No Major Fault (DO Weld Controller 2 System Normal Robot
82) (DI 60) Flasher xxRnn Weld Retry Ind
xxRnnDo.NoMjrFlt2_82 xxRnnDi.FltRstWC2_60 System.Flsh.Norm xxRnn.Weld.G2.Retry_Ind
39 / /
Signal to
Reweld Weld Ctrl 2
(DI 61)
RSLogix 5000
RBnn Weld Controller RBnn Fault Reset and RBnn Fault Reset
2 No Major Fault (DO Robot Robot Reweld Weld Ctrl 2 Weld Controller 2
82) xxRnn Path Segment xxRnn Weld Skip PB (DI 61) (DI 60)
xxRnnDo.NoMjrFlt2_82 EQU xxRnn.Weld.G2.Skip_Pb xxRnnDi.FltRstRwld2_61 xxRnnDi.FltRstWC2_60
40 / Equal /
Signal to Robot
0
RBnn Fault Reset xxRnn Part must be
Source B 52
Weld Controller 2 rejected at next
(DI 60) Reject Station
xxRnnDi.FltRstWC2_60 xxRnn.Sta.PartInfo.Reject
L

RBnn Weld Controller RBnn Fault Reset and
2 No Major Fault (DO Reweld Weld Ctrl 2 System Normal Robot
82) (DI 61) Flasher xxRnn Weld Skip Ind
xxRnnDo.NoMjrFlt2_82 xxRnnDi.FltRstRwld2_61 System.Flsh.Norm xxRnn.Weld.G2.Skip_Ind
41 / /
Signal to
RBnn Fault Reset
Weld Controller 2
(DI 60)
xxRnnDi.FltRstWC2_60
(End)
RSLogix 5000
B020_Process2_Glue - Ladder Diagram Page 83
RBnn Fault Rest RBnn Reset Glue
Panel PB (DO 22) System 1 (DI91)
xxRnnDo.Fltpb_22 xxRnnDi.Gl1Rst_91
0
Signal to
RBnn Reset Glue
System 2 (DI 97)
xxRnnDi.Gl2Rst_97
Glue Purge Logic
Robot
Robot xxRnn Glue Purge
xxRnn Path Segment Latch
EQU xxRnn.Glue1.PurgeLtch
1 Equal U
0
Source B 4
Robot Robot Robot

xxRnn Glue Purge xxRnn Glue Purge One xxRnn Glue Purge
Push Button Shot Latch
xxRnn.Glue1.Purge_Pb xxRnn.Glue1.PurgeOns xxRnn.Glue1.PurgeLtch
2 ONS L
Robot
xxRnn Glue Purge
Timer
xxRnn.Glue1.PurgeTmr.DN
Robot Cell Robot Robot

xxRnn Glue Purge Auto Signal From xxRnn Glue Purge xxRnn Glue Purge
Latch Mode RBnn At Home (DO 07) Timer Timer
xxRnn.Glue1.PurgeLtch Cell.Mode.Auto xxRnnDo.Hme_07 MOV TON
Source 600000 Timer xxRnn.Glue1.PurgeTmr
Preset 0 DN
Dest xxRnn.Glue1.PurgeTmr.PRE Accum 0
0
Robot Signal to
xxRnn Glue Purge RBnn Purge Glue
Latch System #1 (DI 95)
xxRnn.Glue1.PurgeLtch xxRnnDi.Gl1Purge_95
4
Glue1 Redo / Bypass Logic
Signal From Robot Robot

RBnn Glue 1 Ok (DO xxRnn Glue Bypass xxRnn Glue Redo
95) Latch Latch
xxRnnDo.Gl1Ok_95 xxRnn.Glue1.Byps xxRnn.Glue1.Redo
5 / U
Signal From
RBnn At Home (DO 07)
xxRnnDo.Hme_07
Signal From Robot Robot Robot

Robot RBnn Glue 1 Ok (DO xxRnn Panelview Glue xxRnn Glue Redo xxRnn Glue Redo
xxRnn Path Segment 95) Redo Pushbutton One-Shot Latch
EQU xxRnnDo.Gl1Ok_95 xxRnn.Glue1.Redo_Pb xxRnn.Glue1.RedoOns xxRnn.Glue1.Redo
6 Equal / ONS L
0
Source B 51
Robot Signal to
xxRnn Glue Redo RBnn Repeat 1st Glue
Latch Application(DI 92)
xxRnn.Glue1.Redo xxRnnDi.Gl1Redo_92
7

Robot RBnn Glue 1 Ok (DO System Normal xxRnn Glue Bypass xxRnn Panelview Glue
xxRnn Path Segment 95) Flasher Latch Redo Indicator
EQU xxRnnDo.Gl1Ok_95 System.Flsh.Norm xxRnn.Glue1.Byps xxRnn.Glue1.Redo_Ind
8 Equal / /
0
Source B 51
Robot
xxRnn Glue Redo
Latch
xxRnn.Glue1.Redo

RBnn Glue 1 Ok (DO xxRnn Glue Redo xxRnn Glue Bypass
95) Latch Latch
xxRnnDo.Gl1Ok_95 xxRnn.Glue1.Redo xxRnn.Glue1.Byps
9 / U
Signal From
xxRnnDo.Hme_07

Robot RBnn Glue 1 Ok (DO xxRnn Panelview Glue xxRnn Glue Bypass xxRnn Glue Bypass
xxRnn Path Segment 95) Bypass Pushbutton One-Shot Latch
EQU xxRnnDo.Gl1Ok_95 xxRnn.Glue1.Byps_Pb xxRnn.Glue1.BypsOns xxRnn.Glue1.Byps
10 Equal / ONS L
0
Source B 51
RSLogix 5000
B020_Process2_Glue - Ladder Diagram Page 84
Robot RBnn Glue 1 Ok (DO System Normal xxRnn Glue Redo xxRnn Panelview Glue
xxRnn Path Segment 95) Flasher Latch Bypass Indicator
EQU xxRnnDo.Gl1Ok_95 System.Flsh.Norm xxRnn.Glue1.Redo xxRnn.Glue1.Byps_Ind
11 Equal / /
0
Source B 51
Robot
xxRnn Glue Bypass
Latch
xxRnn.Glue1.Byps
Glue2 Redo / Bypass Logic

RBnn Glue 2 Ok (DO xxRnn Glue Bypass xxRnn Glue Redo
100) Latch Latch
xxRnnDo.Gl2Ok_100 xxRnn.Glue2.Byps xxRnn.Glue2.Redo
12 / U
Signal From
xxRnnDo.Hme_07

Robot RBnn Glue 2 Ok (DO xxRnn Panelview Glue xxRnn Glue Redo xxRnn Glue Redo
xxRnn Path Segment 100) Redo Pushbutton One-Shot Latch
EQU xxRnnDo.Gl2Ok_100 xxRnn.Glue2.Redo_Pb xxRnn.Glue2.RedoOns xxRnn.Glue2.Redo
13 Equal / ONS L
0
Source B 0
Robot Signal to
xxRnn Glue Redo RBnn Repeat 2nd Glue
Latch Application (DI 98)
xxRnn.Glue2.Redo xxRnnDi.Gl2Redo_98
14

Robot RBnn Glue 2 Ok (DO System Normal xxRnn Glue Bypass xxRnn Panelview Glue
xxRnn Path Segment 100) Flasher Latch Redo Indicator
EQU xxRnnDo.Gl2Ok_100 System.Flsh.Norm xxRnn.Glue2.Byps xxRnn.Glue2.Redo_Ind
15 Equal / /
0
Source B 2
Robot
xxRnn Glue Redo
Latch
xxRnn.Glue2.Redo

RBnn Glue 2 Ok (DO xxRnn Glue Redo xxRnn Glue Bypass
100) Latch Latch
xxRnnDo.Gl2Ok_100 xxRnn.Glue2.Redo xxRnn.Glue2.Byps
16 / U
Signal From
xxRnnDo.Hme_07

Robot RBnn Glue 2 Ok (DO xxRnn Panelview Glue xxRnn Glue Bypass xxRnn Glue Bypass
xxRnn Path Segment 100) Bypass Pushbutton One-Shot Latch
EQU xxRnnDo.Gl2Ok_100 xxRnn.Glue2.Byps_Pb xxRnn.Glue2.BypsOns xxRnn.Glue2.Byps
17 Equal / ONS L
0
Source B 0

Robot RBnn Glue 2 Ok (DO System Normal xxRnn Glue Redo xxRnn Panelview Glue
xxRnn Path Segment 100) Flasher Latch Bypass Indicator
EQU xxRnnDo.Gl2Ok_100 System.Flsh.Norm xxRnn.Glue2.Redo xxRnn.Glue2.Byps_Ind
18 Equal / /
0
Source B 2
Robot
xxRnn Glue Bypass
Latch
xxRnn.Glue2.Byps
(End)
RSLogix 5000
B020_Process3_Handling - Ladder Diagram Page 85
Drpoff Memory (Used for Dry Cycle)
STnn STnn
1st Group
All Parts
Present Robot
Memory xxRnn Dropoff
xxRnnDropoffST._1stPP.PresMem Complete
<STnn._1stPP.PresMem> xxRnn.Sta.DropCpl.0
0 U
STnn STnn STnn STnn
Home Home
Enable Position
xxRnnDropoffST.HomeEn xxRnnDropoffST.Home
<STnn.HomeEn> <STnn.Home>
Robot
Robot xxRnn Dropoff
xxRnn Path Segment Complete
EQU xxRnn.Sta.DropCpl.0
1 Equal L
0
Source B 32
Pickup Memory (Used for Part Counting and Tracking)

Cell in Robot Robot Robot
Dry xxRnn Dropoff xxRnn Pick up xxRnn Pick up
Mode Complete Complete Complete
Cell.Mode.DryMode xxRnn.Sta.DropCpl.0 xxRnn.Sta.PickCpl.0 xxRnn.Sta.PickCpl.0
2 U
Signal From
Cell in RBnn Part Present on
Dry End Effector Side 1
Mode (DO106)
Cell.Mode.DryMode xxRnnDo.PP1_106
/ /
Cell in Robot
Dry Robot xxRnn Pick up
Mode xxRnn Path Segment Complete
Cell.Mode.DryMode EQU xxRnn.Sta.PickCpl.0
3 Equal L
0
Source B 12
Signal From
Mode (DO106)
/
2nd Dropoff
STnn STnn
1st Group
All Parts
Present Robot
Memory xxRnn Dropoff
xxRnnDropoffST._1stPP.PresMem Complete
<STnn._1stPP.PresMem> xxRnn.Sta.DropCpl.1
4 U
STnn STnn STnn STnn
Home Home
Enable Position
xxRnnDropoffST.HomeEn xxRnnDropoffST.Home
<STnn.HomeEn> <STnn.Home>
Robot
Robot xxRnn Dropoff
xxRnn Path Segment Complete
EQU xxRnn.Sta.DropCpl.1
5 Equal L
0
Source B 36
2nd Pickup
Cell in Robot Robot Robot
Dry xxRnn Dropoff xxRnn Pick up xxRnn Pick up
Mode Complete Complete Complete
Cell.Mode.DryMode xxRnn.Sta.DropCpl.1 xxRnn.Sta.PickCpl.1 xxRnn.Sta.PickCpl.1
6 U
Signal From
Mode (DO107)
/ /
Cell in Robot
Dry Robot xxRnn Pick up
Mode xxRnn Path Segment Complete
Cell.Mode.DryMode EQU xxRnn.Sta.PickCpl.1
7 Equal L
0
Source B 16
Signal From
Mode (DO107)
/
(End)
RSLogix 5000
C010_Zones_Areas_Pathseg - Ladder Diagram Page 86
This Routine contains
all of the logic that
depends on the particular
application
RungComment
0
Robot Clear To Enter Area Logic
STnn STnn
Tool Clear
to Enter For
Robot Robot
Pickup xxRnn Clear To Enter
xxRnnPickupST.TLArea.2 Area
<STnn.TLArea.2> xxRnn.Ctl.ClrEntAr.1
1
STnn STnn
Tool Clear
to Enter For
Robot
Weld
xxRnnWeldOP.TLArea.1
<STnn.TLArea.1>
STnn STnn
Tool Clear
to Enter For
Robot Robot
Dropoff xxRnn Clear To Enter
xxRnnDropoffST.TLArea.0 Area
<STnn.TLArea.0> xxRnn.Ctl.ClrEntAr.2
2 AFI
Robot
xxRnn Clear To Enter
Area
xxRnn.Ctl.ClrEntAr.3
3 AFI
Robot
Area
4 AFI
Robot
Area
5 AFI
Robot
Area
6 AFI
Robot
Area
7 AFI
Robot
Area
8 AFI
Robot Base-Limit Switches / Areas / Pathseg Cross-Check
RungComment
9
Robot Zone Logic
If NO OTHER robot is Clear to Enter this Zone, it means that THIS robot can Lock (reserve) the Zone
Robot
xxRnn Clear to Enter Robot
Zone xxRnn Can Lock Zone
xxRnn.Ctl.ClrEntZn.1 xxRnn.Ctl.canlckZn.1
10 /
Robot
xxRnn Can Lock Zone
xxRnn.Ctl.CanLckZn.2
11 AFI
Robot
xxRnn Can Lock Zone
12 AFI
Robot
xxRnn Can Lock Zone
13 AFI
Robot
xxRnn Can Lock Zone
14 AFI
Robot
xxRnn Can Lock Zone
15 AFI
Robot
xxRnn Can Lock Zone
16 AFI
RSLogix 5000
Robot
xxRnn Can Lock Zone
17 AFI
Robot PathSeg Logic

Service-related Pathsegs
Robot
xxRnn Path Segment
EQU xxRnnReleasePathSeg[2]
18 Equal
0
Source B 2
Robot Robot
Robot xxRnn Tip Change xxRnn Tip Change Robot
xxRnn Path Segment Latch Latch xxRnn Service Latch
EQU xxRnn.Weld.G1.ChgLatch xxRnn.Weld.G2.ChgLatch xxRnn.Sta.SvceLtch xxRnnReleasePathSeg[3]
Equal / / /
0
Source B 3
Tipdress Pathsegs
STnn STnn
Station
Ready
for Robot
Robot TipDress
xxRnn Path Segment xxRnnTDOP.TLInPos.7
EQU <STnn.TLInPos.7> xxRnnReleasePathSeg[4]
19 Equal
0
Source B 4
Robot Robot
Robot xxRnn Tip Dress xxRnn Tip Dress
xxRnn Path Segment Latch Latch
EQU xxRnn.Weld.G1.DrsLatch xxRnn.Weld.G2.DrsLatch xxRnnReleasePathSeg[5]
Equal / /
0
Source B 5
Pickup Pathsegs
Enable branch with Decision Code 15 if the robot uses Pounce position
STnn STnn
Station
Ready for
Robot Pickup Robot
xxRnn Path Segment xxRnnPickupST.TLInPos.0 xxRnn Robot Bypassed
EQU <STnn.TLInPos.0> xxRnn.Mode.Bypass xxRnnReleasePathSeg[10]
20 Equal /
Robot
0
xxRnn Decision Code
Source B 10
EQU
AFI Equal
0
Source B 15
STnn STnn
Tooling
In Reposition
Robot for PickUp
xxRnn Path Segment xxRnnPickupST.TLInPos.1
Equal
0
Source B 11
STnn STnn
No PP
After Robot
Robot Pickup
xxRnn Path Segment xxRnnPickupST.TLInPos.2
Equal
0
Source B 12
RSLogix 5000
Dropoff Pathsegs
STnn STnn
Station
Ready for
Robot Dropoff
xxRnn Path Segment xxRnnDropoffST.TLInPos.3
21 Equal
0
Source B 30
STnn STnn
Tooling
In Reposition
Robot for Dropoff
Equal
0
Source B 31
STnn STnn
All PP
After Robot
Robot Dropoff
Equal
0
Source B 32
Weld / Glue Pathsegs

Enable branch with Decision Code 15 if the robot uses Pounce position
STnn STnn
Station
Ready
for Robot
Robot Weld Robot Robot
xxRnn Path Segment xxRnnWeldOP.TLInPos.6 xxRnn Weld Complete xxRnn Robot Bypassed
EQU <STnn.TLInPos.6> xxRnn.Weld.Cpl.0 xxRnn.Mode.Bypass xxRnnReleasePathSeg[50]
22 Equal / /
Robot
0
xxRnn Decision Code
Source B 50
EQU
AFI Equal
0
Source B 15
Robot Robot
EQU xxRnn.Weld.Cpl.0 xxRnnReleasePathSeg[51]
Equal
Robot
0
xxRnn Glue Complete
Source B 51
Memories
xxRnn.Glue1.Cpl.0
Robot
xxRnn Glue Redo
Latch
xxRnn.Glue1.Redo
Robot
xxRnn Glue Reject
Latch
xxRnn.Glue1.Reject
Robot
xxRnn Glue Bypass
Latch
xxRnn.Glue1.Byps
Robot Robot
EQU xxRnn.Weld.Cpl.1 xxRnnReleasePathSeg[54]
Equal
0
Source B 54
Part Reject Pathseg

Robot
Robot xxRnn Panelview Glue
xxRnn Path Segment Reject Pushbutton
EQU xxRnn.Glue1.Reject_Pb xxRnnReleasePathSeg[55]
23 Equal
0
Source B 55
RSLogix 5000
Decision Code Pathsegs
Robot Robot
xxRnn Path Segment xxRnn Decision Code
LIM NEQ xxRnnReleasePathSeg[65]
24 Limit Test (CIRC) Not Equal
Low Limit 65 Source A xxRnn.Ctl.Decision
0 xxRnnReleasePathSeg[66]
Test xxRnn.Ctl.PathSeg Source B 0
0
High Limit 70 xxRnnReleasePathSeg[67]
xxRnnReleasePathSeg[68]
Robot Cell Robot

xxRnn Path Segment Stop xxRnn Path Segment
Request Request Ack
xxRnn.Ctl.PathSegReq Cell.Mode.StopReq xxRnnReleasePathSeg[xxRnn.Ctl.PathSeg] xxRnn.Ctl.PathOk
25 /
Robot Descision calls will be specific to each individual application.

Pathsegs 65 to 70 are used by the robot to request a Decision Code
Exception: Decision Code 15 is Return from Pounce to Home, and it is issued when robot is waiting for pathseg 10 or 50.
Decision X:
Robot Robot Robot Robot

xxRnn Path Segment xxRnn Path Segment xxRnn Path Segment xxRnn Decision Code
LES NEQ NEQ MOV
26 Less Than (A<B) Not Equal Not Equal Move
Source A xxRnn.Ctl.PathSeg Source A xxRnn.Ctl.PathSeg Source A xxRnn.Ctl.PathSeg Source 0
0 0 0
Source B 65 Source B 10 Source B 50 Dest xxRnn.Ctl.Decision
0
Robot
xxRnn Path Segment
GRT
Greater Than (A>B)
0
Source B 70
Decision Code 15 is reserved for Return From Pounce to Home

Cell Robot Robot
Auto xxRnn Path Segment Robot xxRnn Return From Robot
Mode Request xxRnn Path Segment Pounce Pushbutton xxRnn Decision Code
Cell.Mode.Auto xxRnn.Ctl.PathSegReq EQU xxRnn.Ctl.RetPouncePb MOV
27 Equal Move
Source A xxRnn.Ctl.PathSeg Source 15
Robot
0
xxRnn Service Latch
Source B 10 Dest xxRnn.Ctl.Decision
xxRnn.Sta.SvceLtch 0
Robot Cell
xxRnn Path Segment Stop at Home
EQU Request
Equal Cell.Mode.StopHome
0 Dry Mode
Source B 50 Stopping
Cell.Mode.DryStop
Robot
xxRnn Path Segment
EQU
Equal
0
Source B 65
Decision Code 1:
Cell Robot
Auto xxRnn Path Segment Robot Robot Robot
Mode Request xxRnn Path Segment xxRnn Service Latch xxRnn Decision Code
Cell.Mode.Auto xxRnn.Ctl.PathSegReq EQU xxRnn.Sta.SvceLtch MOV
28 Equal / AFI Move
0
0
Decision Code 2:
Cell Robot
29 Equal / AFI Move
0
0
Decision Code 3:
Cell Robot
30 Equal / AFI Move
0
0
RSLogix 5000
Decision Code 4:
Cell Robot
31 Equal / AFI Move
0
0
(End)
RSLogix 5000
Main - Ladder Diagram Page 91
Calling sequence:
RungComment
0
JSR
Routine Name B001_Map_Inputs
JSR
Routine Name B003_MapHMI
JSR
JSR
Routine Name Z001_Fanuc_Driver
Areas, Zones,
Pathsegs and
Decision Codes
JSR
Routine Name C010_Zones_Areas_Pathseg
to handle processes
i.e. Wld
JSR
Routine Name B020_Process1_Spotweld
i.e. glue
JSR
Routine Name B020_Process2_Glue
JSR
Routine Name B020_Process3_Handling
JSR
Routine Name X001_Faults
JSR
Routine Name B002_Map_Outputs
(End)
RSLogix 5000
Robot Program Call Logic
Robot
xxRnn Program Call
MOV
0 Move
Source 0
Dest xxRnn.Ctl.PrgCall
0
Cell Robot Cell Cell Robot

Auto xxRnn Robot Ready Robot Stop Stop at Home Dry Mode Robot xxRnn Program Call
Mode for Program Call xxRnn Robot Bypassed Request Request Stopping xxRnn Path Segment Precondition
Cell.Mode.Auto xxRnn.Sta.Ready xxRnn.Mode.Bypass Cell.Mode.StopReq Cell.Mode.StopHome Cell.Mode.DryStop EQU xxRnn.Ctl.ProgPre
1 / / / / Equal
0
Source B 0
Program 1: Move to Pounce and Get Ready for Pickup / Weld

Robot
xxRnn Program Call Robot Robot
Precondition xxRnn Service Latch xxRnn Program Call
xxRnn.Ctl.ProgPre xxRnn.Sta.SvceLtch MOV
2 / Move
Source 1
0
Program 15: Start Service Routine

Robot
xxRnn Program Call Robot Robot
Precondition xxRnn Service Latch xxRnn Program Call
xxRnn.Ctl.ProgPre xxRnn.Sta.SvceLtch MOV
3 Move
Source 15
0
Signal to
Robot RBnn Program Echo
xxRnn Path Segment (DI 26)
GRT xxRnnDi.PgmEcho_26
4 Greater Than (A>B) U
0
Source B 0
Cell
Cell No
Manual Cell Cell Part
Mode All Ops Home All Robots Home Present
Cell.Mode.Man Cell.OpsHome Cell.RbtHome Cell.NPP
Signal to
Robot RBnn Program Echo
xxRnn Program Ack (DI 26)
EQU xxRnnDi.PgmEcho_26
5 Equal L
Source A xxRnn.Ctl.PrgAck
0
Source B 1
Robot Robot
xxRnn Program Ack xxRnn Service Latch
EQU xxRnn.Sta.SvceLtch
Equal
Source A xxRnn.Ctl.PrgAck
0
Source B 15
Signal to
Robot RBnn Production
xxRnn Program Call Start (DI 18
NEQ xxRnnDi.ProdStrt_18
6 Not Equal
Source A xxRnn.Ctl.PrgCall
0
Source B 0
Robot Bypass Logic

Cell in
Dry Robot
Mode xxRnn Robot Bypassed
Cell.Mode.DryMode xxRnn.Mode.Bypass
7 / U
RSLogix 5000
Robot Service Logic
Robot
Robot xxRnn Service Robot Robot
xxRnn Path Segment Pushbutton xxRnn Service Latch xxRnn Service Latch
EQU xxRnn.Sta.SvcePb xxRnn.Sta.SvceLtch xxRnn.Sta.SvceLtch
8 Equal U
0
Source B 3
Robot
Robot xxRnn Glue Purge
xxRnn Path Segment Latch
EQU xxRnn.Glue1.PurgeLtch
Equal
0
Source B 4
Robot
xxRnn Path Segment
EQU
Equal
0
Source B 5
Robot
Cell xxRnn Service Robot Robot
Auto Pushbutton Delay xxRnn Service xxRnn Service One Robot
Mode Timer Pushbutton Shot xxRnn Service Latch
Cell.Mode.Auto xxRnn.Sta.SvcePbTmr.DN xxRnn.Sta.SvcePb xxRnn.Sta.SvceOns xxRnn.Sta.SvceLtch
9 ONS L
Robot
xxRnn Tip Change
Latch
xxRnn.Weld.G1.ChgLatch
Robot
xxRnn Tip Change
Latch
xxRnn.Weld.G2.ChgLatch
Robot
xxRnn Tip Dress
Latch
xxRnn.Weld.G1.DrsLatch
Robot
xxRnn Tip Dress
Latch
xxRnn.Weld.G2.DrsLatch
Robot
xxRnn Glue Purge
Latch
xxRnn.Glue1.PurgeLtch
Robot Robot
Robot xxRnn Service xxRnn Service
xxRnn Service Pushbutton Delay Pushbutton Delay
Pushbutton Timer Timer
xxRnn.Sta.SvcePb MOV TON
Source 3000 Timer xxRnn.Sta.SvcePbTmr
Preset 0 DN
Dest xxRnn.Sta.SvcePbTmr.PRE Accum 0
0
Robot
Robot System Normal xxRnn Robot In
xxRnn Path Segment Flasher Service Position
EQU System.Flsh.Norm xxRnn.Pv.Service_Ind
10 Equal
0
Source B 2
Robot
xxRnn Service Latch
xxRnn.Sta.SvceLtch
Robot Robot
xxRnn Path Segment xxRnn Service Latch
EQU xxRnn.Sta.SvceLtch
Equal
0
Source B 3
Robot Cycle Timer

For Material Handler Robots,
the time while the robot
is waiting for the pickup station or
for the dropoff station to be ready,
should not be counted as part of the
robot cycle time
Signal From Signal From Robot Robot Robot
Robot RBnn System Ready RBnn Program Running xxRnn Path Segment xxRnn Robot Cycle xxRnn Robot Cycle
xxRnn Path Segment (DO 02) (DO 03) Ack Time Time
GRT xxRnnDo.SysRdy_02 xxRnnDo.PrgRun_03 xxRnn.Ctl.PathOk xxRnn.Cyc.Ons1 xxRnn.Cyc.InCycle
11 Greater Than (A>B) ONS L
0
Source B 0
RSLogix 5000
Robot Robot
xxRnn Robot Cycle Robot Robot Robot xxRnn Robot Cycle
Time xxRnn Path Segment xxRnn Path Segment xxRnn Path Segment Time
xxRnn.Cyc.InCycle NEQ NEQ NEQ MOV
12 Not Equal Not Equal Not Equal Move
Source A xxRnn.Ctl.PathSeg Source A xxRnn.Ctl.PathSeg Source A xxRnn.Ctl.PathSeg Source 999900
0 0 0
Source B 10 Source B 30 Source B 50 Dest xxRnn.Cyc.TmrCycle.PRE
0
Robot Robot
xxRnn Path Segment xxRnn Robot Cycle
Request Time
xxRnn.Ctl.PathSegReq RTO
Timer xxRnn.Cyc.TmrCycle
Robot
Preset 0 DN
xxRnn Path Segment
Accum 0
Ack
xxRnn.Ctl.PathOk
Robot Robot
Signal From Robot xxRnn Robot Cycle xxRnn Robot Cycle
RBnn At Home (DO 07) xxRnn Path Segment Time Time
xxRnnDo.Hme_07 EQU xxRnn.Cyc.Ons2 xxRnn.Cyc.InCycle
13 Equal ONS U
Robot
0
xxRnn Robot Cycle
Source B 0
Time
MOV
Move
Source xxRnn.Cyc.TmrCycle.ACC
0
Dest xxRnn.Cyc.Time
0
Robot
xxRnn Robot Cycle
Time
xxRnn.Cyc.TmrCycle
RES
(End)
RSLogix 5000
X001_Faults - Ladder Diagram Page 95
Robot 1
Panelview Faults
These are standard faults, but they do not all pertain to all robots.
Please remove ones that you don't need and keep the ones you do.
Keep all the numbers the same though, because you wil use the same alarm file for all.
RungComment
0
Robot
xxRnn Alarm Messages
xxRnn.Pv.Alarm_Ina.0
1 AFI
Robot Robot RBnn

xxRnn Robot in Signal From Faulted. Check Teach
Manual RBnn Fault (DO 06) Pendant for details.
xxRnn.Mode.Man xxRnnDo.Flt_06 xxRnn.Pv.Alarm_Ina.1
2 /
Robot Robot xxRBnn Process

xxRnn Local Message Error. Check Robot
Display Screen for details.
GEQ xxRnn.Pv.Alarm_Ina.2
3 Grtr Than or Eql (A>=B)
Source A xxRnn.Pv.Local_Ina
0
Source B 128
Weld Faults
Signal From Robot RBnn
Cell RBnn Weld Controller 1st Weld
Auto 1 No Major Fault (DO Controller
Mode 75) Major Fault
Cell.Mode.Auto xxRnnDo.NoMjrFlt1_75 xxRnn.Pv.Alarm_Ina.3
4 /

Cell RBnn Weld Controller 2nd Weld
Auto 2 No Major Fault (DO Controller
Mode 82) Major Fault
Cell.Mode.Auto xxRnnDo.NoMjrFlt2_82 xxRnn.Pv.Alarm_Ina.4
5 /

Cell RBnn Weld Controller 1st Weld
Auto 1 No Minor Fault (DO Controller
Mode 76) Minor Fault
Cell.Mode.Auto xxRnnDo.NoMnrFlt1_76 xxRnn.Pv.Alarm_Ina.5
6 /

Cell RBnn Weld Controller 2nd Weld
Auto 2 No Minor Fault (DO Controller
Mode 83) Minor Fault
Cell.Mode.Auto xxRnnDo.NoMnrFlt2_83 xxRnn.Pv.Alarm_Ina.6
7 /
Robot RBnn
Robot 1st Gun
xxRnn Tip Dress Tipdress
Request Request
xxRnn.Weld.G1.DrsReq xxRnn.Pv.Alarm_Ina.7
8
Robot RBnn
Robot 2nd Gun
xxRnn Tip Dress Tipdress
Request Request
xxRnn.Weld.G2.DrsReq xxRnn.Pv.Alarm_Ina.8
9
Robot RBnn
Robot 1st Gun
xxRnn Robot Stepper Near End
Pre-Warning Of Stepper
xxRnn.Weld.G1.Pre_Wrn xxRnn.Pv.Alarm_Ina.9
10
Robot RBnn
Robot 2nd Gun
xxRnn Robot Stepper Near End
Pre-Warning Of Stepper
xxRnn.Weld.G2.Pre_Wrn xxRnn.Pv.Alarm_Ina.10
11
Robot RBnn
End
Of Stepper.
Robot Cannot Weld
xxRnn End Of Stepper Until TipChange
xxRnn.Weld.G1.EOS xxRnn.Pv.Alarm_Ina.11
12
Robot
xxRnn End Of Stepper
xxRnn.Weld.G2.EOS
Glue Faults
RBnn Glue 1 Ready Glue System 1
Cell Enable (DO 91) Not Ready
Cell.Mode.Wld.En xxRnnDo.Gl1Rdy_91 xxRnn.Pv.Alarm_Ina.12
13 /

14 /

15 /
RSLogix 5000
X001_Faults - Ladder Diagram Page 96
RBnn Glue 1 Error 1 Glue System 1
Cell Enable (DO 92) Fault 1
Cell.Mode.Wld.En xxRnnDo.Gl1Er1_92 xxRnn.Pv.Alarm_Ina.15
16 /

17 /

18 /

19 /

20 /

21 /

22 /

23 /

24 /
Devicenet Comm Failure

Enable
_10R1_Node.Enable
25
DeviceNet Module
Not Faulted Power On Timer _10R1_Node.Faulted _10R1_Node.FaultedMem
PVCell Robot RBnn

Node 0 Status Node 0 Fault Reset DeviceNet Node
Faulted Memory Pushbutton Faulted
_10R1_Node.FaultedMem (Hardware) xxRnn.Pv.Alarm_Ina.24
/
Node 0 Status Node 0 Robot RBnn

Active In Scanlist DeviceNet Node
_10R1_Node.Active Not Active
<DNet07.Node[0].Active> xxRnn.Pv.Alarm_Ina.25
/
Robot Safety Module Faults

Robot Robot xxRBnn 1st
xxRnn Safety IO Safety IO Module
Module 1 Faulted Faulted
xxRnn.Sfty.Mod1Flt xxRnn.Pv.Alarm_Ina.26
26 L
Robot Robot xxRBnn 2nd

xxRnn Safety IO Safety IO Module
Module 2 Faulted Faulted
xxRnn.Sfty.Mod2Flt xxRnn.Pv.Alarm_Ina.27
27 L
Water Flow Messages

Robot Could Not Establish
xxRnn Water Start Water Flow Through
Fault Robot xxRBnn
xxRnn.Weld.WtrStrtFlt xxRnn.Pv.Alarm_Ina.28
28
Robot Robot xxRBnn Lost

xxRnn Water Loss Water Flow During
Fault Operation
xxRnn.Weld.WtrOKFlt xxRnn.Pv.Alarm_Ina.29
29
Cell Count of how

Robot many stations have
xxRnn Alarm Messages L2 Faults
NEQ ADD
30 Not Equal Add
Source A xxRnn.Pv.Alarm_Ina Source A Cell.L2FaultCount
0 0
0
(End)
RSLogix 5000
Z001_Fanuc_Driver - Ladder Diagram Page 97
Robot Status
Signal From
RBnn Robot Cabinet Signal From Robot
Teach Key in Auto RBnn Teach Pendant xxRnn Robot In
Pos (DO 30) Enabled (DO 08 Automatic
xxRnnDo.Auto_30 xxRnnDo.TPen_08 xxRnn.Mode.Auto
0 /
Signal From Robot

RBnn Program Running xxRnn Program
(DO 03) Running
xxRnnDo.PrgRun_03 xxRnn.Sta.PrgRun
1
Robot
Signal From xxRnn Robot At Home
RBnn At Home (DO 07) Position
xxRnnDo.Hme_07 xxRnn.Sta.Home
2
Signal From
RBnn Robot Cabinet Robot
Teach Key in Auto xxRnn Robot in
Pos (DO 30) Manual
xxRnnDo.Auto_30 xxRnn.Mode.Man
3 /
Signal From
RBnn Teach Pendant
Enabled (DO 08
xxRnnDo.TPen_08
Signal From Signal From Signal From Signal From Robot

RBnn Command Enable RBnn System Ready Signal From RBnn Program Running RBnn Program Paused xxRnn Robot Ready
(DO 01) (DO 02) RBnn At Home (DO 07) (DO 03) (DO 04 for Program Call
xxRnnDo.CmdEn_01 xxRnnDo.SysRdy_02 xxRnnDo.Hme_07 xxRnnDo.PrgRun_03 xxRnnDo.PrgPause_04 xxRnn.Sta.Ready
4 / /
Cell Robot Robot

Stop xxRnn Path Segment xxRnn Robot Stopped
Request Request at Pathseg or Home
Cell.Mode.StopReq xxRnn.Ctl.PathSegReq xxRnn.Sta.Stopped
5
Signal From
RBnn Program Running
(DO 03)
xxRnnDo.PrgRun_03
/
Cell Signal From

Stop at Home RBnn Program Running
Request (DO 03)
Cell.Mode.StopHome xxRnnDo.PrgRun_03
/
Robot Sytem Logic
*
Cell Cell Signal to
Safeties Auto RBnn Robot Immediate
Reset Mode Stop (DI 01)
Cell.Rst Cell.Mode.Auto xxRnnDi.ImStp_01
6
RBnn Teach Pendant RBnn Robot Motors
Enabled (DO 08 Enable (DI 08)
xxRnnDo.TPen_08 xxRnnDi.MtrEn_08
Signal to
RBnn Robot Safety
Cell All Safety Gate Speed
Gates Ok Control(DI 03)
Cell.sfty.AllSGOk xxRnnDi.SfSpd_03
7
PVCell Signal From PVCell Robot PVCell

Cycle Stop RBnn Motion Held (DO Cycle Start Push xxRnn Cycle Start Auto Start Robot
Push Button 05) Button Pushbutton PB(Hardware) xxRnn Hold Robot
HMICell.CycStp_Pb xxRnnDo.Held_05 HMICell.CycStrt_Pb xxRnn.Ctl.CycStrtPb HMICell.AStartHpb xxRnn.Ctl.Hold
8 / / / /
Robot
xxRnn Cycle Stop
Pushbutton
xxRnn.Ctl.CycStpPb
Robot
xxRnn Hold Robot
xxRnn.Ctl.Hold
Cell Robot Signal to

Auto Robot xxRnn Water OK RBnn Robot Hold (DI
Mode xxRnn Hold Robot Memory 02)
Cell.Mode.Auto xxRnn.Ctl.Hold xxRnn.Weld.WtrOkMem xxRnnDi.Hold_02
9 /
Robot
xxRnn No Water
Required (No Gun on
Robot)
xxRnn.Weld.NoWtrReq
Signal From
RBnn Teach Pendant
Enabled (DO 08
xxRnnDo.TPen_08
RSLogix 5000
Z001_Fanuc_Driver - Ladder Diagram Page 98
PVCell
Fault Reset Signal to
Pushbutton Signal From RBnn Robot Reset
(Hardware) RBnn Fault (DO 06) Faults (DI 05)
HMICell.FltrstHpb xxRnnDo.Flt_06 xxRnnDi.RstFlt_05
10
PVCell
Auto Start
PB(Hardware)
HMICell.AStartHpb
Cell Cell Signal From Signal From Signal From PVCell Signal to
Safeties Auto RBnn Command Enable RBnn System Ready RBnn Program Paused Cycle Start Push Signal From RBnn Robot Cycle
Reset Mode (DO 01) (DO 02) (DO 04 Button RBnn Fault (DO 06) Start (DI 06)
Cell.Rst Cell.Mode.Auto xxRnnDo.CmdEn_01 xxRnnDo.SysRdy_02 xxRnnDo.PrgPause_04 HMICell.CycStrt_Pb xxRnnDo.Flt_06 xxRnnDi.CycStrt_06
11 /
PVCell
Auto Start
PB(Hardware)
HMICell.AStartHpb
Robot
xxRnn Cycle Start
Pushbutton
xxRnn.Ctl.CycStrtPb
Robot
xxRnn Program Call
GRT
Greater Than (A>B)
Source A xxRnn.Ctl.PrgCall
0
Source B 0
PVCell Signal to
Cycle Stop RBnn Robot Cycle
Push Button Stop (DI 04)
HMICell.CycStp_Pb xxRnnDi.CycStp_04
12
Robot
xxRnn Cycle Stop
Pushbutton
xxRnn.Ctl.CycStpPb
Cell Cell Signal From

Auto Manual RBnn Program Running
Mode Mode (DO 03)
Cell.Mode.Auto Cell.Mode.Man xxRnnDo.PrgRun_03
/ /
(End)
RSLogix 5000
Cosma:MainTask:HMInn 11/11/2010 1:28:28 PM
Calling sequence:
RungComment
0
JSR
JSR
Routine Name P001_DeviceNet
JSR
JSR
JSR
(End)
RSLogix 5000
Safety -Related
Inputs
Station HMI Box
signals
Rev. 0
COP
0 Copy File
Source HMInn_Safeties
Dest HMInn.Sfty
Length 1
(End)
RSLogix 5000
Map Outputs Functionality

Hase been moved to
Safety Program,
Routine L001_HMI_Lamps
RungComment
0
(End)
RSLogix 5000
P001_DeviceNet - Ladder Diagram Page 102
DEVICENET MODULE SELECTION
Selects which DeviceNets Module's status to display on the Panelview.

DO NOT MODIFY THIS RUNG!!!!!!!!
Internals used to
select the DNB to Internals used to
display on the select the DNB to
PanelView Used for display on the
rewinding the select PanelView Module
DeviceNet Screen bit. select array
HMI1DNet.Screen.DeviceNet DNetSelect.Start MOV
0 Move
Source 1
Dest DNetSelect.DNB[0]
0
Internals used to
select the DNB to
display on the
PanelView Used for
rewinding the select
bit.
DNetSelect.Start
L
Internals used to
select the DNB to
display on the
Next Scanner PanelView Constant
Pushbutton for BSL instruction
HMI1DNet.I.NextScannerPB DNetSelect.Zero
U
Internals used to Internals used to
select the DNB to select the DNB to
display on the display on the
PanelView Control PanelView Control
for BSL for BSL
MOV BSL
Move Bit Shift Left EN
Source 32 Array DNetSelect.DNB[0]
Control DNetSelect.Control DN
Dest DNetSelect.Control.LEN Source Bit DNetSelect.Zero
0 Length 0
DEVICENET PANELVIEW SCREEN
One JSR is required for every DNB to display on the PV.

Only DNBs mapped to this controller can be displayed.
Up to a max of 32 DNB's are supported.
By default this routine handles 3 DNB modules. If more than 3 exist

then this routine will have to be modified.
Note: Alias the program scoped DNB1,2 and 3 tags to their respective
Controller level DNet Tags.
To use this JSR:

1) Check that the PV is on the DeviceNet screen.
2) Add XIC DNBSelect.DNB[0].x in front of each JSR, where x is 0-31.
Do not skip numbers.
3) JSR to the routine "Z001_DNetPV" with the following parameters:
Input Parameters:
DNB{x} Alias to Controller Tag of type ac_DNet
DeviceNet Module
Local Slot 7 Status Internals used to
DeviceNet Module select the DNB to
Local Slot 7 display on the Sets Panelview
Enable PanelView Module DeviceNet Status
DeviceNet Screen DNB1.Module.Enable select array Screen Data
HMI1DNet.Screen.DeviceNet <DNet07.Module.Enable> DNetSelect.DNB[0].0 JSR
Routine Name Z001_DNetPV
Input Par DNB1
<DNet07>
Internals used to
select the DNB to
display on the
PanelView DNB module
count
ADD
Add
Source A 1
Source B DNetSelect.Count
0
Dest DNetSelect.Count
0
Internals used to
DeviceNet Module select the DNB to
Local Slot 8 Status display on the Sets Panelview
Dnet Enable PanelView Module DeviceNet Status
DNB2.Module.Enable select array Screen Data
<Dnet08.Module.Enable> DNetSelect.DNB[0].1 JSR
Jump To Subroutine
Routine Name Z001_DNetPV
Input Par DNB2
<Dnet08>
Internals used to
select the DNB to
display on the
count
ADD
Add
Source A 1
Source B DNetSelect.Count
0
0
RSLogix 5000
P001_DeviceNet - Ladder Diagram Page 103
Enables the Next Scanner PB if more than one scanner is enabled

Internals used to
select the DNB to
display on the
PanelView DNB module Next Scanner
count Indicator
GRT HMI1DNet.O.NextScannerInd
2 Greater Than (A>B)
Source A DNetSelect.Count
0
Source B 1
Internals used to
select the DNB to
display on the
count
CLR
Clear
0
(End)
RSLogix 5000
Auxiliary Data type
PVCell to drive non safety
Stack Light devices on safety
Fault outputs Fault Lamp
HMICell.Stk.Red HMInn_Box_Outputs.RedStkLmp
0
PVnn
Test
Pb(S)
HMInn.Test_Pb
Auxiliary Data type

to drive non safety
Global Cell/PV devices on safety
interface Amber outputs Manual Mode
Light Lamp
HMICell.Stk.Amber HMInn_Box_Outputs.AmberStkLmp
1
PVnn
Test
Pb(S)
HMInn.Test_Pb
Auxiliary Data type

to drive non safety
PVCell devices on safety
Stack Light outputs Auto Mode
Auto Lamp
HMICell.Stk.Green HMInn_Box_Outputs.GrnStkLmp
2
PVnn
Test
Pb(S)
HMInn.Test_Pb
Auxiliary Data type

Station HMI Box to drive non safety
signals devices on safety
Rev. 0 Panelview outputs E-Stop Lamp
Estop Ok(S) Output
HMInn.Sfty.EstopOk HMInn_Box_Outputs.EStopLmp
3 /
PVnn
Test
Pb(S)
HMInn.Test_Pb
Auxiliary Data type

to drive non safety
devices on safety
Cell All Safety System Normal outputs Control
Cell All E-Stops Ok Gates Ok Flasher Power On Lamp
Cell.Sfty.AllEStopOk Cell.Sfty.AllSGOk System.Flsh.Norm HMInn_Box_Outputs.PwrOnLmp
4
Cell Machine Power
On
Cell.Sfty.PwrOn
PVnn
Test
Pb(S)
HMInn.Test_Pb
(End)
RSLogix 5000
Panelview - related faults
Fuses, etc
RungComment
0

Enable
HMI1DIONode.Enable
1
DeviceNet Module
Not Faulted Power On Timer HMI1DIONode.Faulted HMI1DIONode.FaultedMem
PVCell PVnn
Node 0 Status Node 0 Fault Reset DIO DeviceNet
Faulted Memory Pushbutton Node XX Faulted
HMI1DIONode.FaultedMem (Hardware) HMInn.UtilityFaults_Ina.8
/
Node 0 Status Node 0 PVnn

Active In Scanlist DIO DeviceNet
HMI1DIONode.Active Node XX Not Active
<DNet07.node[0].Active> HMInn.UtilityFaults_Ina.9
/
Station HMI Box

signals
Rev. 0 Safety IO PVnn Safety IO
Module Fault Module Faulted
HMInn.Sfty.ModFlt HMInn.UtilityFaults_Ina.18
2 L
(End)
RSLogix 5000
Z001_DNetPV - Ladder Diagram Page 106
PANELVIEW DEVICENET STATUS
Input Parameters:
Controller Tag of type ac_DNet
Return Parameters: None
DNetPV Routine
Internals. Version
DNetPV Routine Type - Unique # to
Internals. Map ID Model, DNetPV Routine DNetPV Routine
global DNet module Manufacturer, Internals. Major Internals. Minor
data in/out Firmware, etc. Version # Version #
SBR MOV MOV MOV
0 Subroutine Move Move Move
Input Par DNetPV.DN Source 1 Source 5 Source 0
Dest DNetPV.V.Type Dest DNetPV.V.Major Dest DNetPV.V.Minor

0 0 0
Reset the node fault ptr and scroll timer
DNetPV Routine
Internals. Pointer
Next Scanner for displaying node
Pushbutton faults
HMI1DNet.I.NextScannerPB CLR
1 Clear
Dest DNetPV.NodePtr
Entering Current
0
Screen 1-Shot
HMI1DNet.Screen.Entering
DNetPV Routine
Internals. Node
fault display scroll
timer
DNetPV.ScrollTmr
RES
DNetPV Routine
Internals. Enable
DNetPV.Hold.En
U
DNetPV Routine
Screen Hold Fault DNetPV Routine Internals. Toggle
Pushbutton Internals. One Shot Request
HMI1DNet.I.ScreenHoldFltPB DNetPV.Hold.Ons DNetPV.Hold.Tggl
2 ONS
DNetPV Routine
Internals. Toggle DNetPV Routine DNetPV Routine
Request Internals. Enable Internals. Enable
DNetPV.Hold.Tggl DNetPV.Hold.En DNetPV.Hold.En
/
DNetPV Routine
DNetPV Routine Internals. Toggle
Internals. Enable Request
DNetPV.Hold.En DNetPV.Hold.Tggl
/
DNetPV Routine Screen Hold Fault

Internals. Enable Enable Indicator
DNetPV.Hold.En HMI1DNet.O.HoldFltEnableInd
3
DNetPV Routine
DNetPV Routine Internals. Dnet Screen Hold Fault
Internals. Enable ANode Is Faulted Disable Indicator
DNetPV.Hold.En DNetPV.DN.Module.ANodeFaulted HMI1DNet.O.HoldFltDisableInd
/ /
Calc the Chassis and Slot from the ModuleID for output to the PV.
Send FaultCode based upon the Node input.
DNetPV Routine
Internals. Dnet Id Module Chassis ID
GRT DIV
4 Greater Than (A>B) Divide
Source A DNetPV.DN.Module.ID Source A DNetPV.DN.Module.ID
0 0
Dest HMI1DNet.O.Chassis
0
Module Slot
Position
CPT
Compute
Dest HMI1DNet.O.Slot
0
Expression DNetPV.DN.Module.ID-(HMI1DNet.O.Chassis*100)
NODE FAULT SCROLL
Scroll the display thru all faulted nodes on this module.
Verify that the pointer is in range,

Initialize the scroll timer.
DNetPV Routine DNetPV Routine

Internals. Pointer Internals. Pointer
for displaying node for displaying node
faults faults
LIM CLR
Low Limit 64 Dest DNetPV.NodePtr
0
Test DNetPV.NodePtr
0
High Limit 0
RSLogix 5000
Check 1 node/scan.
If node is faulted, display on PV for the duration of the scroll timer.
Continue searching for next faulted node while current node is displayed.
This provides instant display of the next node w/o searching all nodes
every scan.
DNetPV Routine
DNetPV Routine Internals. Node DNetPV Routine
Internals. Dnet fault display scroll DNetPV Routine Internals. Current Node Address
Faulted timer Internals. Enable displayed node Indicator (MAC ID)
DNetPV.DN.Module.Faulted DNetPV.ScrollTmr.EN DNetPV.Hold.En DNetPV.DN.Node[DNetPV.NodePtr].Faulted MOV MOV
6 / / / Move Move
Source DNetPV.NodePtr Source DNetPV.CNode
0 0
Dest DNetPV.CNode Dest HMI1DNet.O.Node
0 0
Node Fault Code

Indicator
MOV
Move
Source DNetPV.DN.Node[DNetPV.CNode].FaultCode
0
Dest HMI1DNet.O.NodeFltCode
0
DNetPV Routine
Internals. Pointer
for displaying node
faults
ADD
Add
Source A DNetPV.NodePtr
0
Source B 1
Dest DNetPV.NodePtr
0

faults faults
LIM CLR
Limit Test (CIRC) Clear
0
Test DNetPV.NodePtr
0
High Limit 0
DNetPV Routine
Internals. Pointer
for displaying node
faults
DNetPV.DN.Node[DNetPV.NodePtr].Faulted ADD
/ Add
Source A DNetPV.NodePtr
0
Source B 1
Dest DNetPV.NodePtr
0
Initialize the scroll timer. Display the node for the scroll time.
Clear the display if no faults (timer not running)
DNetPV Routine
DNetPV Routine Internals. Node
Internals. Dnet DNetPV Routine fault display scroll
Faulted Internals. Enable timer
DNetPV.DN.Module.Faulted DNetPV.DN.Node[DNetPV.CNode].Faulted DNetPV.Hold.En MOV
7 / / Move
Source 3000
Dest DNetPV.ScrollTmr.PRE
0
DNetPV Routine
Internals. Node
fault display scroll
timer
TON
Timer On Delay EN
Timer DNetPV.ScrollTmr
Preset 0 DN
Accum 0

Internals. Node Internals. Node
fault display scroll fault display scroll
timer timer
DNetPV.ScrollTmr.DN DNetPV.ScrollTmr
RES
DNetPV Routine
Internals. Node
fault display scroll DNetPV Routine Node Address Node Fault Code
timer Internals. Enable Indicator (MAC ID) Indicator
DNetPV.ScrollTmr.EN DNetPV.Hold.En CLR CLR
/ / Clear Clear
Dest HMI1DNet.O.Node Dest HMI1DNet.O.NodeFltCode
0 0
Limit check the pointer when finished to minimize the prescan problems.

faults faults
LIM CLR
0
Test DNetPV.NodePtr
0
High Limit 0
RSLogix 5000
Override if module fault
DNetPV Routine
Internals. Dnet DNetPV Routine Node Address Node Fault Code
Faulted Internals. Enable Indicator (MAC ID) Indicator
DNetPV.DN.Module.Faulted DNetPV.Hold.En MOV MOV
9 / Move Move
Source DNetPV.DN.Module.Node Source DNetPV.DN.Module.FaultCode
0 0
Dest HMI1DNet.O.Node Dest HMI1DNet.O.NodeFltCode
0 0
DEVICENET NODE STATUS DISPLAY
Drive the Node Status Indicators.

Internals. Dnet Internals. Dnet Node Status
Enable Active Indicators
DNetPV.DN.Node[0].Enable DNetPV.DN.Node[0].Active HMI1DNet.O.NodeInd[0].2
10 / /
DNetPV Routine
Internals. Dnet DNetPV Routine Node Status
Enable Internals. Dnet Ok Indicators
DNetPV.DN.Node[0].Enable DNetPV.DN.Node[0].OK HMI1DNet.O.NodeInd[0].1

Active Faulted Indicators
DNetPV.DN.Node[0].Active DNetPV.DN.Node[0].Faulted HMI1DNet.O.NodeInd[0].0

11 / /
DNetPV Routine


12 / /
DNetPV Routine


13 / /
DNetPV Routine


14 / /
DNetPV Routine


15 / /
DNetPV Routine

RSLogix 5000
16 / /
DNetPV Routine


17 / /
DNetPV Routine


18 / /
DNetPV Routine


19 / /
DNetPV Routine


20 / /
DNetPV Routine


21 / /
DNetPV Routine


22 / /
DNetPV Routine

RSLogix 5000
23 / /
DNetPV Routine


24 / /
DNetPV Routine


25 / /
DNetPV Routine


26 / /
DNetPV Routine


27 / /
DNetPV Routine


28 / /
DNetPV Routine


29 / /
DNetPV Routine

RSLogix 5000
30 / /
DNetPV Routine


31 / /
DNetPV Routine


32 / /
DNetPV Routine


33 / /
DNetPV Routine


34 / /
DNetPV Routine


35 / /
DNetPV Routine


36 / /
DNetPV Routine

RSLogix 5000
37 / /
DNetPV Routine


38 / /
DNetPV Routine


39 / /
DNetPV Routine


40 / /
DNetPV Routine


41 / /
DNetPV Routine


42 / /
DNetPV Routine


43 / /
DNetPV Routine

RSLogix 5000
44 / /
DNetPV Routine


45 / /
DNetPV Routine


46 / /
DNetPV Routine


47 / /
DNetPV Routine


48 / /
DNetPV Routine


49 / /
DNetPV Routine


50 / /
DNetPV Routine

RSLogix 5000
51 / /
DNetPV Routine


52 / /
DNetPV Routine


53 / /
DNetPV Routine


54 / /
DNetPV Routine


55 / /
DNetPV Routine


56 / /
DNetPV Routine


57 / /
DNetPV Routine

RSLogix 5000
58 / /
DNetPV Routine


59 / /
DNetPV Routine


60 / /
DNetPV Routine


61 / /
DNetPV Routine


62 / /
DNetPV Routine


63 / /
DNetPV Routine


64 / /
DNetPV Routine

RSLogix 5000
65 / /
DNetPV Routine


66 / /
DNetPV Routine


67 / /
DNetPV Routine


68 / /
DNetPV Routine


69 / /
DNetPV Routine


70 / /
DNetPV Routine


71 / /
DNetPV Routine

RSLogix 5000
72 / /
DNetPV Routine


73 / /
DNetPV Routine

Internals used to
select the DNB to
display on the
PanelView Used for
rewinding the select
bit.
DNetSelect.Start
74 U
(End)
RSLogix 5000
A00_Main - Safety Ladder Diagram Page 118
Cosma:SafetyTask:SafetyProgram 11/11/2010 1:28:40 PM
Alwys Off Alwys Off Alwys Off
Always_Off Always_Off Always_Off
0 /
Alwys Off Always On
Always_Off Always_On
/
JSR
JSR
Routine Name S01_EStops
JSR
Routine Name S02_SafetyGates
JSR
Routine Name S03_RunTeach
JSR
Routine Name S04_RingSwitches
JSR
Routine Name S11_Cell_Power
JSR
Routine Name S12_Station_Power
JSR
Routine Name S13_Robot_Power
JSR
Routine Name L001_HMI_Lamps
JSR
Routine Name L002_SG_Lamps
JSR
Routine Name B002_Map_Outputs
(End)
RSLogix 5000
B001_MapInputs - Safety Ladder Diagram Page 119
OPnn First Safety IO
Module
COP
0 Copy File
Source STnn_SAFETY_IO:I
Dest STAnn_SIO.I
Length 1
OPnn First Safety IO STnn Safeties Safety

Module All Inputs Ok IO Module Faulted
STAnn_SIO.I.InputStatus STnn_Safeties.Mod1Flt
/
OPnn First Safety IO
Module All Outputs
Ok
STAnn_SIO.I.OutputStatus
/
OPnn Safety IO
Running
STAnn_SIO.I.RunMode
/
OPnn Safety IO
Connection Faulted
STAnn_SIO.I.ConnectionFaulted
OPnn Safety Gate

Safety IO Module
COP
Copy File
Source SGnn_Safety_IO:I
Dest SGnn_IO.I
Length 1
OPnn Safety Gate

Safety IO Module All STnn Safeties Safety
Inputs Ok IO Module Faulted
SGnn_IO.I.InputStatus STnn_Safeties.Mod2Flt
/
OPnn Safety Gate
Safety IO Module All
Outputs Ok
SGnn_IO.I.OutputStatus
/
OPnn Safety Gate
Safety IO Running
SGnn_IO.I.RunMode
/
OPnn Safety Gate
Safety IO Connection
Faulted
SGnn_IO.I.ConnectionFaulted

RBnn Safety IO
Module 1
COP
1 Copy File
Source xxRBnn_Safety_IO1:I
Dest xxRBnn_SIO1.I
Length 1
RBnn Safety IO xxRnn Safeties

Module 1 All Inputs Safety IO Module 1
Ok Faulted
xxRBnn_SIO1.I.InputStatus xxRnn_Safeties.Mod1Flt
/
RBnn Safety IO
Module 1 All Outputs
Ok
xxRBnn_SIO1.I.OutputStatus
/
RBnn First Safety IO
Running
xxRBnn_SIO1.I.RunMode
/
RBnn First Safety IO
Connection Faulted
xxRBnn_SIO1.I.ConnectionFaulted
RBnn Safety IO
Module 2
COP
Copy File
Source xxRBnn_Safety_IO2:I
Dest xxRBnn_SIO2.I
Length 1
RBnn Safety IO xxRnn Safeties

Module 2 All Inputs Safety IO Module 2
Ok Faulted
xxRBnn_SIO2.I.InputStatus xxRnn_Safeties.Mod2Flt
/
RBnn Safety IO
Module 2 All Outputs
Ok
xxRBnn_SIO2.I.OutputStatus
/
RBnn Second Safety
IO Running
xxRBnn_SIO2.I.RunMode
/
RBnn Second Safety
IO Connection
Faulted
xxRBnn_SIO2.I.ConnectionFaulted
RSLogix 5000
B001_MapInputs - Safety Ladder Diagram Page 120
**** Repeat this rung for every Panelview ****
PVnn Safety IO
Module
COP
2 Copy File
Source HMInn_Safety_IO:I
Dest PVnn_SIO.I
Length 1
PVnn Safety IO Safety IO Module

Module All Inputs Ok Fault
PVnn_SIO.I.InputStatus HMInn_Safeties.ModFlt
/
PVnn Safety IO
Module All Outputs
Ok
PVnn_SIO.I.OutputStatus
/
PVnn Safety IO
Running
PVnn_SIO.I.RunMode
/
PVnn Safety IO
Connection Faulted
PVnn_SIO.I.ConnectionFaulted
(End)
RSLogix 5000
B002_Map_Outputs - Safety Ladder Diagram Page 121
COP
0 Copy File
Source STAnn_SIO.O
Dest STnn_SAFETY_IO:O
Length 1
COP
Copy File
Source SGnn_IO.O
Dest SGnn_Safety_IO:O
Length 1

COP
1 Copy File
Source xxRBnn_SIO1.O
Dest xxRBnn_Safety_IO1:O
Length 1
COP
Copy File
Source xxRBnn_SIO2.O
Dest xxRBnn_Safety_IO2:O
Length 1

COP
2 Copy File
Source PVnn_SIO.O
Dest HMInn_Safety_IO:O
Length 1
(End)
RSLogix 5000
L001_HMI_Lamps - Safety Ladder Diagram Page 122
HMI Box Indicator Lamps
Auxiliary Data type

to drive non safety
devices on safety
outputs E-Stop Lamp PVnn Safety IO
Output Module
HMInn_Box_Outputs_Sfty.EStopLmp PVnn_SIO.O.M1_0
0
Auxiliary Data type

to drive non safety
devices on safety
outputs Control PVnn Safety IO
Power On Lamp Module
HMInn_Box_Outputs_Sfty.PwrOnLmp PVnn_SIO.O.M1_1
1
Auxiliary Data type

to drive non safety
devices on safety PVnn Safety IO
outputs Fault Lamp Module
HMInn_Box_Outputs_Sfty.RedStkLmp PVnn_SIO.O.M1_2
2
Auxiliary Data type

to drive non safety
devices on safety
outputs Manual Mode PVnn Safety IO
Lamp Module
HMInn_Box_Outputs_Sfty.AmberStkLmp PVnn_SIO.O.M1_3
3
Auxiliary Data type

to drive non safety
devices on safety
outputs Auto Mode PVnn Safety IO
Lamp Module
HMInn_Box_Outputs_Sfty.GrnStkLmp PVnn_SIO.O.M1_4
4
(End)
RSLogix 5000
L002_SG_Lamps - Safety Ladder Diagram Page 123
SG Box Indicator Lamps
Auxiliary Data type

to drive non safety
devices on safety
outputs Lock OPnn Safety Gate
Solenoid Output Safety IO Module
SGnn_Box_Outputs_Sfty.LockSolenoid SGnn_IO.O.M1_0
0
Auxiliary Data type

to drive non safety
devices on safety
outputs Request To OPnn Safety Gate
Enter Lamp Output Safety IO Module
SGnn_Box_Outputs_Sfty.ReqEnterLmp SGnn_IO.O.M1_1
1
Auxiliary Data type

to drive non safety
devices on safety
outputs Power On /
Auto Mode Lamp OPnn Safety Gate
Output Safety IO Module
SGnn_Box_Outputs_Sfty.PwrOn_AutoLmp SGnn_IO.O.M1_2
2
Auxiliary Data type

to drive non safety
devices on safety
outputs E-Stop Lamp OPnn Safety Gate
Output Safety IO Module
SGnn_Box_Outputs_Sfty.EStopLmp SGnn_IO.O.M1_3
3
(End)
RSLogix 5000
S01_EStops - Safety Ladder Diagram Page 124
EStops in Operator Stations
OPnn ESTOP tag
ESTOP
0 Emergency Stop
ESTOP STAnn_ESTOP O1
Reset Type AUTOMATIC CI
Channel A STAnn_SIO.I.M1_0 CRHO
0 II
Channel B STAnn_SIO.I.M1_1 FP
0
Circuit Reset Always_Off
0
Fault Reset Cell_PwrOn_PB
0
OPnn EStop Reset STnn E-Stop OK

STAnn_ESTOP.O1 STnn_Safeties.EStopOk
STnn Safeties EStop

OPnn ESTOP tag Dual Channel Fault
STAnn_ESTOP.FP STnn_Safeties.EStopFlt
RepeatConditions OP OPnn:{OPName}
All EStops OK in
STnn E-Stop OK Operator Stations
STnn_Safeties.EStopOk OPEstopsOK
1

EStops in Robots
RBnn ESTOP tag
ESTOP
2 Emergency Stop
ESTOP xxRBnn_ESTOP O1
Channel A xxRBnn_SIO1.I.M1_2 CRHO
0 II
Channel B xxRBnn_SIO1.I.M1_3 FP
0
0
0
RBnn EStop Reset xxRBnn E-Stop OK

xxRBnn_ESTOP.O1 xxRnn_Safeties.Estop_OK
xxRnn Safeties EStop

RBnn ESTOP tag Dual Channel Fault
xxRBnn_ESTOP.FP xxRnn_Safeties.EStopFlt
RepeatConditions RB RBnn:{RBName}
All EStops OK in
RBnn EStop Reset Robots
xxRBnn_ESTOP.O1 RBEStopsOK
3

EStops on Panlelviews
PVnn ESTOP tag
ESTOP
4 Emergency Stop
ESTOP PVnn_ESTOP O1
Channel A PVnn_SIO.i.m1_0 CRHO
0 II
Channel B PVnn_SIO.i.m1_1 FP
0
0
0
PVnn EStop Reset PVnn EStop OK

PVnn_ESTOP.O1 HMInn_Safeties.estopok
Estop Dual Cahnnel

PVnn ESTOP tag Fault
PVnn_ESTOP.FP HMInn_Safeties.EStopFlt
RepeatConditions PV PVnn:{PVName}
All EStops OK in
PVnn EStop Reset Panelviews
PVnn_ESTOP.O1 PVEstopsOK
5
**** Repeat this rung for every Safety Gate **** OPnn:{OPName}
EStops on Safety Gates
SGnn ESTOP tag
ESTOP
6 Emergency Stop
ESTOP SGnn_ESTOP O1
Channel A SGnn_IO.I.M1_6 CRHO
0 II
Channel B SGnn_IO.I.M1_7 FP
0
0
0
Safety Gate SG4

SGnn EStop Reset EStop OK
SGnn_ESTOP.O1 SGnn_Safeties.EStopOK
SGnn Safeties Estop

SGnn ESTOP tag Dual Cahnnel Fault
SGnn_ESTOP.FP SGnn_Safeties.EStopFlt
RSLogix 5000
S01_EStops - Safety Ladder Diagram Page 125
RepeatConditions SG SGnn:{SGName}
All EStops OK in
SGnn EStop Reset Safety Gates
SGnn_ESTOP.O1 SGEStopsOK
7
All EStops OK in All EStops OK in All EStops OK in All EStops OK in All E-Stops OK in
Operator Stations Robots Panelviews Safety Gates Cell
OPEstopsOK RBEStopsOK PVEstopsOK SGEStopsOK Cell_Safeties.AllEStopOk
8
(End)
RSLogix 5000
S02_SafetyGates - Safety Ladder Diagram Page 126
**** Repeat rung for every Safety Gate in the cell ****
Safety Gates RIN tag
RIN
0 Redundant Input
RIN SGnn_RIN O1
Channel A SGnn_IO.I.M1_4 CRHO
0 II
Channel B SGnn_IO.I.M1_5 FP
0
0
0
SGnn Safeties Safety

Safety Gates Reset Gate Locked
SGnn_RIN.O1 SGnn_Safeties.Locked
SGnn Safeties Locked

Safety Gates RIN tag Dual Cahnnel Fault
SGnn_RIN.FP SGnn_Safeties.LockedFlt
RepeatInputs SG OPnn:{OPName}
All Safety Gates OK
Safety Gates Reset in Cell
SGnn_RIN.O1 Cell_Safeties.AllSGOk
1
(End)
RSLogix 5000
S03_RunTeach - Safety Ladder Diagram Page 127
RBnn RIN tag for
Teach Mode
RIN
0 Redundant Input
RIN xxRBnn_RIN_TEACH O1
0 II
0
0
0
RBnn Key in Teach xxRBnn key is in

Position TEACH mode
xxRBnn_RIN_TEACH.O1 xxRnn_Safeties.Teach_Mode
xxRnn Safeties Teach

RBnn RIN tag for Key Dual Channel
Teach Mode Fault
xxRBnn_RIN_TEACH.FP xxRnn_Safeties.TeachFlt
(End)
RSLogix 5000
S04_RingSwitches - Safety Ladder Diagram Page 128
RBnn RIN tag for
Base Limit Switch 1
RIN
0 Redundant Input
RIN xxRBnn_RIN_BLIM1 O1
0 II
0
0
0
RBnn Key in Run RBnn

Position CLEAR OF STATION
xxRBnn_RIN_BLIM1.O1 xxRnn_Safeties.BLim1
xxRnn Safeties Base

RBnn RIN tag for Limit Switch 1 Dual
Base Limit Switch 1 Channel Fault
xxRBnn_RIN_BLIM1.FP xxRnn_Safeties.Blim1Flt
(End)
RSLogix 5000
S11_Cell_Power - Safety Ladder Diagram Page 129
RIN
0 Redundant Input
RIN Cell_SG_RIN O1
Reset Type MANUAL CI
Channel A Cell_Safeties.AllSGOk CRHO
0 II
Channel B Cell_Safeties.AllSGOk FP
0
Circuit Reset Cell_PwrOn_PB
0
0
RIN
1 Redundant Input
RIN Cell_ES_RIN O1
Channel A Cell_Safeties.AllEStopOk CRHO
0 II
Channel B Cell_Safeties.AllEStopOk FP
0
Circuit Reset Cell_PwrOn_PB
0
0
RepeatInRung PV PVnn:{PVName}
PVnn Power On PB Cell Power On PB
PVnn_SIO.I.M1_2 Cell_PwrOn_PB
2
Cell Power is On
Cell_ES_RIN.o1 Cell_SG_RIN.O1 Cell_Safeties.PwrOn
3
(End)
RSLogix 5000
S12_Station_Power - Safety Ladder Diagram Page 130
OPnn LC tag
LC
0 Light Curtain
LC STAnn_LC O1
Channel A STAnn_SIO.I.M1_6 CRHO
0 LCB
Channel B STAnn_SIO.I.M1_7 LCM
0 II
Input Filter Time 0 FP
Mute Light Curtain Always_Off
0
Circuit Reset STAnn_SIO.I.M1_2
0
0
STnn Cycle Start

Handstand Push
OPnn Palm Button button
STAnn_SIO.I.M1_2 STnn_Safeties.StartHPb
OPnn Light Curtain STnn Light Screen is

is Reset Reset
STAnn_LC.O1 STnn_Safeties.LsRst
STnn Safeties Light

Screen Dual Channel
OPnn LC tag Fault
STAnn_LC.FP STnn_Safeties.LsFlt
STnn Light Screen is STnn Output Power is

Cell Power is On Reset On
Cell_Safeties.PwrOn STnn_Safeties.LsRst STnn_Safeties.PwrOn
OPnn ROUT tag for

EStop Relay
ROUT
Redundant Output
ROUT STAnn_ROUT_ESTOP O1
Feedback Type NEGATIVE O2
Enable STnn_Safeties.PwrOn O1FF
0 O2FF
Feedback 1 STAnn_SIO.I.M1_3 FP
0
Feedback 2 STAnn_SIO.I.M1_3
0
0
OPnn ROUT tag for OPnn Valve Banks

EStop Relay Output Power OPnn Output Power
STAnn_ROUT_ESTOP.O1 STAnn_SIO.O.M1_0 STAnn_SIO.O.M1_4
STnn Safeties Output

OPnn ROUT tag for Relay Power
EStop Relay Monitoring Fault
STAnn_ROUT_ESTOP.FP STnn_Safeties.OutPowerFlt
(End)
RSLogix 5000
S13_Robot_Power - Safety Ladder Diagram Page 131
Robot Teach Mode Permission
xxRBnn Teach Mode
Not Allowed
xxRBnn key is in (Neighboring robot
TEACH mode already in Teach)
xxRnn_Safeties.Teach_Mode xxRnn_Safeties.TeachMode_NA
0
xxRBnn key is in
TEACH mode
xxRnn_Safeties.Teach_Mode
xxRBnn key is in
TEACH mode
xxRBnn key is in
TEACH mode
xxRBnn key is in
TEACH mode

Robot E-Stop Relays
All E-Stops OK in RBnn EStop Relay
Cell Enable
Cell_Safeties.AllEStopOk RBnn_ES_Enable
1
RBnn EStop Relay
Enable RBnn EStop
RBnn_ES_Enable xxRBnn_SIO1.O.M1_0

Robot Safety Gate Relays
All Safety Gates OK RBnn Safety Gate
in Cell Relay Enable
Cell_Safeties.AllSGOk RBnn_SG_Enable
2
RBnn Safety Gate
Relay Enable RBnn Fence
RBnn_SG_Enable xxRBnn_SIO1.O.M1_1

Robot E-Stop Relays
xxRBnn key is in All Safety Gates OK STnn Light Screen is RBnn Servos ON Relay
TEACH mode in Cell Reset Enable
xxRnn_Safeties.Teach_Mode Cell_Safeties.AllSGOk STnn_Safeties.LsRst RBnn_SVO_Enable
3 /
RBnn
CLEAR OF STATION
xxRnn_Safeties.BLim1
xxRBnn Teach Mode

Not Allowed
xxRBnn key is in (Neighboring robot
TEACH mode already in Teach)
xxRnn_Safeties.Teach_Mode xxRnn_Safeties.TeachMode_NA
/
RBnn Servos ON Relay

Enable RBnn Servos On
RBnn_SVO_Enable xxRBnn_SIO1.O.M1_2

Robot Welder Control Stop
RBnn EStop Relay RBnn Servos ON Relay RBnn Welder Control
Enable Enable Stop
RBnn_ES_Enable RBnn_SVO_Enable xxRBnn_SIO1.O.M1_3
4

Robot EOAT Power
RBnn EStop Relay RBnn Servos ON Relay RBnn Manipulator
Enable Enable Power
RBnn_ES_Enable RBnn_SVO_Enable xxRBnn_SIO2.O.M1_0
5
(End)
RSLogix 5000
Cosma:Unscheduled Programs:STConveyor 11/11/2010 1:28:57 PM
***************************************************************************
this will allow Local image of dnet into the tag for
PIO with... inputs
i.e node 3 data word......... for PIO- DIO-..... inputs -data word ....
***********************************************************************
Node 2 OK - OPnn
Active and Compact
Not Faulted Block IO Inputs
DNet07.Node[2].OK COP
0 Copy File
Dest OPnnDIO.I
Length 1
OPnn
Compact
Block IO DeviceNet
Communication OK
OPnnDIO.CommOK
Node 2 OK - OPnn
Active and Compact
DNet07.Node[2].OK FLL
/ Fill File
Source 0
Dest OPnnDIO.I
Length 1
STnn
OPnn Disconnect
Compact Switch
Block IO Module 3 On
OPnnDIO.I.M3.0 STnn.Utility.Sw
1
OPnn
Compact Conveyor Motor
Block IO Module 3 Switch 1
OPnnDIO.I.M3.1 OPnn_Conv_M1.LS1
2
OPnn Conveyor Motor

Compact Overload Protection
Block IO Module 3 OK
OPnnDIO.I.M3.2 OPnn_Conv_M1.Ovld
3
Safety
OPnn Gate 1
Compact Enter Request
Block IO Module 4 Pushbutton
OPnnDIO.I.M4.0 SG1.EnterReqHpb
4
Safety Gate 1
Auto/
Cycle
OPnn Start
Compact Pushbutton
Block IO Module 4 (Hardwire)
OPnnDIO.I.M4.1 SG1.AStartHpb
5
OPnn
Compact Safety Gate 1
Block IO Module 4 Open
OPnnDIO.I.M4.3 SG1.GateOpen
6
Safety Gate 2
Fault Reset
Pushbutton
Local:7:I.Data[9].19 SG2.FaultResHpb
7
(End)
RSLogix 5000
***************************************************************************
this will allow Local image of the tag into dnet for
PIO with... outputs
i.e node 3 data word......... for PIO- DIO-..... outputs -data word ....
***********************************************************************
COP
0 Copy File
Source OPnnDIO.O
Length 2
Safety
Gate 1 OPnn
Clear To Enter Compact
Lamp Block IO Module 1
SG1.EnterClrLmp OPnnDIO.O.M1.0
1
Safety Gate 1
Auto/
Cycle OPnn
Start Compact
SG1.AutoLmp OPnnDIO.O.M1.1
2
Safety
Gate 1 OPnn
Power On Compact
SG1.FaultLmp OPnnDIO.O.M1.2
3
Safety
Gate 1 OPnn
E-Stop Compact
SG1.EStopLmp OPnnDIO.O.M1.3
4
Safety
Gate 1 OPnn
Unlock Compact
Solenoid Block IO Module 2
SG1.UnlockGate OPnnDIO.O.M2.0
5
(End)
RSLogix 5000
RungComment
0
STnn
Cycle Start STnn
Anti Cell Dry Cycle
STnn Start Button Tie-Down Dry Cycle Restart
Handstand(H) Timer Enable Enable
STnn.Sfty.StartHPb STnn.Cyc.AntiTDTmr.DN Cell.Mode.Dry.En STnn.Cyc.DryRestartEn
1 /
STnn
Dry Cycle
Restart
Enable
STnn STnn STnn

Cell Dry Cycle STnn STnn Dry Cycle
Dry Cycle Restart Cycle Cycle Restart
Enable Enable Start Complete Timer
Cell.Mode.Dry.En STnn.Cyc.DryRestartEn STnn.Cyc.Start STnn.Cyc.Cpl MOV
2 / / Move
Source 3000
0
STnn
Dry Cycle
Restart
Timer
TON
Timer On Delay EN
Preset 0 DN
Accum 0
(End)
RSLogix 5000
Calling sequence:
RungComment
0
JSR
JSR
JSR
JSR
JSR
(End)
RSLogix 5000
JSR
Routine Name S010_LoadStnOpen
(End)
RSLogix 5000
S010_LoadStnOpen - Ladder Diagram Page 137
Precondition
Power & Free
Power & Free STnn Process Conveyor Station Power & Free Power & Free
Conveyor Station complete (formerly Carrier Present Conveyor Station Conveyor Station
Safety Full Depth) Switch Part Present Precondition
OPnn_Load.Stop.Opn.Saf STnn.ProcCpl OPnn_Load.CarrPresSw OPnn_Load.PP OPnn_Load.Stop.Opn.Pre
0 /
Safety
Power & Free
Cell STnn STnn Conveyor Station Power & Free Power & Free
Safeties STnn Light Screen Valve Output Power Robots Carrier in Transit Conveyor Station Conveyor Station
Reset Reset and Air On Clear in Zone After Stop Zone ClearSw Safety
Cell.Rst STnn.Sfty.LsRst STnn.Utility.OutPwrOn STnn.RobClr OPnn_Load.ZoneMem OPnn_Load.ZoneClrSw OPnn_Load.Stop.Opn.Saf
1 / /
Command
Cell STnn Power & Free Power & Free Power & Free Power & Free Power & Free
Auto Cycle Conveyor Station Conveyor Station Conveyor Station Conveyor Station Conveyor Station
Mode Start Precondition Complete Safety Carrier Clear Switch Command
Cell.Mode.Auto STnn.Cyc.Start OPnn_Load.Stop.Opn.Pre OPnn_Load.Stop.Opn.Cpl OPnn_Load.Stop.Opn.Saf OPnn_Load.CarrClrSw OPnn_Load.Stop.Opn.Cmd
2 / /
Cell Power & Free Power & Free STnn
Manual Conveyor Station Conveyor Station Home
Cell.Mode.Man OPnn_Load.Stop.Opn.Pb OPnn_Load.Stop.Cls.Pb STnn.HomeEn
/ /
Power & Free
Conveyor Station
Command
OPnn_Load.Stop.Opn.Cmd
Output
Cell Power & Free Power & Free Power & Free Power & Free
Safeties Conveyor Station Conveyor Station Conveyor Station Conveyor Station
Cell.Rst OPnn_Load.Stop.Opn.Cmd OPnn_Load.Stop.Cls.Cmd OPnn_Load.Stop.Cls.Out OPnn_Load.Stop.Opn.Out
3 / /

Buffering OUTPUTS
*************
Replace
Power & Free With
Conveyor Station Used Output
Output *************
OPnn_Load.Stop.Opn.Out OutputBuffer
4
RepeatConditions Cyl Cyy:{CylName}

Motion complete
Power & Free Power & Free Power & Free
Conveyor Station Conveyor Station Conveyor Station
Switch 1 Switch 2 Complete
OPnn_Load.StopCyl.PX1 OPnn_Load.StopCyl.PX2 OPnn_Load.Stop.Opn.Cpl
5 /
Panelview Indicator
Power & Free Power & Free
Conveyor Station System Normal Conveyor Station
OPnn_Load.Stop.Opn.Pre System.Flsh.Norm OPnn_Load.Stop.Opn.Ind
6
Power & Free
Conveyor Station
Command
OPnn_Load.Stop.Opn.Cmd
Power & Free

Conveyor Station
Complete
OPnn_Load.Stop.Opn.Cpl
RepeatInRung Cyl Cyy:{CylName} InputBuffer:{CylPXW}

Buffering INPUTS
*************
Replace
With Power & Free
Used Input Conveyor Station
************* Switch 2
InputBuffer OPnn_Load.StopCyl.PX2
7
Faults
Conveyor Station Conveyor Station
Output Engaged
OPnn_Load.Stop.Opn.Out OPnn_Load.Stop.Opn.Eng
8 L
Conveyor Station Cell Machine Power Conveyor Station
Complete On Engaged
OPnn_Load.Stop.Opn.Cpl Cell.sfty.PwrOn OPnn_Load.Stop.Cls.Eng
/ U
Power & Free Power & Free Power & Free Power & Free
Field Module 1 Conveyor Station Conveyor Station Conveyor Station Conveyor Station
Comm OK Engaged Fault Timer Complete Fault
OPnn_FB1.CommOK OPnn_Load.Stop.Opn.Eng OPnn_Load.Stop.Opn.Tmr.DN OPnn_Load.Stop.Opn.Cpl OPnn_Load.Stop.Opn.Flt
9 /
Fault Timer Fault Timer
MOV TON
Source 3000 Timer OPnn_Load.Stop.Opn.Tmr
Preset 0 DN
Dest OPnn_Load.Stop.Opn.Tmr.PRE Accum 0
0
RSLogix 5000
S010_LoadStnOpen - Ladder Diagram Page 138
Power & Free Power & Free Power & Free Power & Free
Conveyor Station Conveyor Station Conveyor Station Conveyor Station
Fault Switch 1 Switch 2 Fault
OPnn_Load.Stop.Opn.Flt OPnn_Load.StopCyl.PX1 OPnn_Load.StopCyl.PX2 OPnn_Load.StopCyl.Flt.0
10
Power & Free Power & Free Power & Free
Conveyor Station Conveyor Station Conveyor Station
Switch 2 Switch 1 Fault
OPnn_Load.StopCyl.PX2 OPnn_Load.StopCyl.PX1 OPnn_Load.StopCyl.Flt.1
/
Switch 1 Fault
OPnn_Load.StopCyl.PX1 OPnn_Load.StopCyl.Flt.2
/
RepeatInRung Cyl Cyy:{CylName} [1]:[CylValue]

COP
11 Copy File
Source OPnn_Load.StopCyl.Flt
Dest OPnnAlarms[1]
Length 1
(End)
RSLogix 5000
Conveyor Motor
System 1st Input Overload Protection STnn 2nd Safety IO
Card OK Module Faulted
System.I1.4 OPnn_Conv_M1.Ovld STnn.UtilityFaults_Ina.19
0
Status Faults
OPnn
Compact STnn Utility Fault
Block IO Inputs Word
OPnnDIO.I.Status.0 STnn.UtilityFaults_Ina.7
1
Node 2
Enable
2
DeviceNet Module
Local Slot 7 DeviceNet Module
Running & Local Slot 08 Node 2 Node 2
Not Faulted Power On Timer Faulted Faulted Memory
DNet07.Module.RunOK DNet07.Module.PwrOnTmr.DN DNet07.Node[2].Faulted DNet07.Node[2].FaultedMem
PVCell STnn
Fault Reset FB1
Node 2 Pushbutton DNet Node Faulted
Faulted Memory (Hardware) STnn.UtilityFaults_Ina.12
DNet07.Node[2].FaultedMem HMICell.FltrstHpb
/
STnn
Node 2 FB1
Active In Scanlist DNet Node Not Active
DNet07.Node[2].Active STnn.UtilityFaults_Ina.13
/
(End)
RSLogix 5000
Cosma:Unscheduled Programs:STDial 11/11/2010 1:29:07 PM
Aug 05, 2005:
RungComment
0
JSR
JSR
JSR
JSR
JSR
(End)
RSLogix 5000
***************************************************************************
PIO with... inputs
***********************************************************************
Node 10 OK - OPnn
Active and Compact
0 Copy File
Dest OPnn_DIO.I
Length 1
OPnn
Compact
Block IO DeviceNet
Communication OK
OPnn_DIO.CommOK
Node 10 OK - OPnn
Active and Compact
/ Fill File
Source 0
Dest OPnn_DIO.I
Length 1
STnn
OPnn Disconnect
Compact Switch
OPnn_DIO.I.M3.0 STnn.Utility.Sw
1
Safety
OPnn Gate 1
OPnn_DIO.I.M4.0 SG1.EnterReqHpb
2
Safety Gate 1
Auto/
Cycle
OPnn Start
Compact Pushbutton
OPnn_DIO.I.M4.1 SG1.AStartHpb
3
OPnn
OPnn_DIO.I.M4.3 SG1.GateOpen
4
Safety Gate 2
Fault Reset
Pushbutton
5
(End)
RSLogix 5000
***************************************************************************
PIO with... outputs
***********************************************************************
COP
0 Copy File
Source OPnn_DIO.O
Length 2
Safety
Gate 1 OPnn
SG1.EnterClrLmp OPnn_DIO.O.M1.0
1
Safety Gate 1
Auto/
Cycle OPnn
Start Compact
SG1.AutoLmp OPnn_DIO.O.M1.1
2
Safety
Gate 1 OPnn
Power On Compact
SG1.FaultLmp OPnn_DIO.O.M1.2
3
Safety
Gate 1 OPnn
E-Stop Compact
SG1.EStopLmp OPnn_DIO.O.M1.3
4
Safety
Gate 1 OPnn
Unlock Compact
SG1.UnlockGate OPnn_DIO.O.M2.0
5
(End)
RSLogix 5000
RungComment
0
STnn
Cycle Start STnn
Anti Cell Dry Cycle
1 /
STnn
Dry Cycle
Restart
Enable
STnn STnn STnn

2 / / Move
Source 3000
0
STnn
Dry Cycle
Restart
Timer
TON
Timer On Delay EN
Preset 0 DN
Accum 0
(End)
RSLogix 5000
Manual Home PB
Cell STnn STnn
0

OPnn
Motion1 STnn
AtHome Home
Complete Position
OPnn_Motion1.Hme.Cpl STnn.Home
1
STnn
Panelview
Home
Position
Panelview Ind
STnn.HMI.Home_Ind

STnn STnn STnn
Preset 0 DN
0
STnn
Line Cycle Start
3 / / / /
STnn STnn
Memory Timer
STnn
Cycle
Start
STnn.Cyc.Start

4 /
STnn
Cycle Start
Memory
STnn.Cyc.StartMem
STnn
Cycle
Start
STnn.Cyc.Start
STnn STnn
Cycle Cycle Start
Start Indicator
5
STnn STnn
Cycle Cycle Start
Start Memory
6 L
STnn Cell STnn

7 / U
STnn STnn
Home Home
Enable Position
Process Complete:
STnn STnn Process
8 U
STnn STnn
Home Home
Enable Position
RSLogix 5000
OPnn
Complete OPnnWeldRbA.Weld.Cpl.0 OPnnWeldRbB.Weld.Cpl.0 OPnnWeldRbC.Weld.Cpl.0 Full Depth)
OPnn_Motion1.Wrk.Cpl <xxRnn.Weld.Cpl.0> <xxRnn.Weld.Cpl.0> <xxRnn.Weld.Cpl.0> STnn.ProcCpl
9 L
Robot Robot Robot
OPnnWeldRbA.Mode.Bypass OPnnWeldRbB.Mode.Bypass OPnnWeldRbC.Mode.Bypass
STnn Process
complete (formerly STnn Process
Full Depth) Complete Indicator
STnn.ProcCpl STnn.HMI.ProcCpl_Ind
10
Cycle Complete:
STnn
11 / / / / U
STnn
1st Group
Cell in All Parts
Dry Present
Mode Memory
/

12 L
STnn
STnn Cycle
Cycle Complete
Complete Indicator
13
Stack Light
STnn
14 /
PVnn
Test
Pb(S)
HMInn.Test_Pb
STnn
Stack Light
STnn All / Some
1st Parts Parts
All Present Present
15
STnn
1st Group
Any
Parts System Normal
Present Flasher
PVnn
Test
Pb(S)
HMInn.Test_Pb

STnn
STnn Tool Clear
STnn STnn 1st Group No to Enter For
Cycle Home Parts Robot
Start Position Present Dropoff
STnn.Cyc.Start STnn.Home STnn._1stPP.NotPres STnn.TLArea.0
16

STnn STnn
Cycle complete (formerly Present AtWork Robot
Start Full Depth) Memory Complete Weld
STnn.Cyc.Start STnn.ProcCpl STnn._1stPP.PresMem OPnn_Motion1.Wrk.Cpl STnn.TLArea.1
17 /
STnn STnn
STnn STnn Process STnn All Parts to Enter For
Cycle complete (formerly Home Present Robot
Start Full Depth) Position Memory Pickup
STnn.Cyc.Start STnn.ProcCpl STnn.Home STnn._1stPP.PresMem STnn.TLArea.2
18
RSLogix 5000

STnn STnn Process STnn STnn STnn
Cycle complete (formerly Home 1st Parts 2nd Parts STnn Ready for
Start Full Depth) Position All Present All Present pickup
STnn.Cyc.Start STnn.ProcCpl STnn.Home STnn._1stPP.Pres STnn._2ndPP.Pres STnn.Pos.Pickup
19
STnn
Cycle
Complete
STnn.Cyc.Cpl
STnn
20
STnn
STnn 1st Group No
21
Dropoff on Station
With Cycle Start for TM Stations
STnn
STnn STnn STnn Process STnn 1st Group No
Cycle Cycle complete (formerly Home Parts STnn Ready for 1st
Start Start Full Depth) Position Present Dropoff
STnn.Cyc.Start STnn.Cyc.Start STnn.ProcCpl STnn.Home STnn._1stPP.NotPres STnn.Pos.Dropoff1
22 / /
STnn
To Be 1st Parts STnn In Reposition
Determined All Present for 1st Dropoff
TBD STnn._1stPP.Pres STnn.Pos.DropoffRepo1
23
STnn STnn
24

STnn
1st Group OPnn
STnn STnn Process All Parts Motion1
Cycle complete (formerly Present AtWork STnn Ready for 1st
Start Full Depth) Memory Complete welds
STnn.Cyc.Start STnn.ProcCpl STnn._1stPP.PresMem OPnn_Motion1.Wrk.Cpl STnn.Pos.Weld1
25 /

OPnnDropoffRb.Ctl.AreaClr.2 OPnnWeldRbA.Ctl.AreaClr.1 OPnnWeldRbB.Ctl.AreaClr.1 OPnnWeldRbC.Ctl.AreaClr.1 OPnnPickUpRb.Ctl.AreaClr.1 Clear
26
Dial in Unknown Position

STnn STnn STnn
Dial Table Dial Table Dial Table STnn Dial Table in
In Position A In Position B In Position C Unknown Position
STnn.TLInPos.11 STnn.TLInPos.12 STnn.TLInPos.13 STnn.TLInPos.14
27 / / /

Robot
OPnnDropoffRb.Ctl.AreaClr.2 Ticking
28 /
Robot
xxRnn Path Segment
Robot Ack
xxRnn Path Segment OPnnDropoffRb.Ctl.PathOk
Equal
Source A OPnnDropoffRb.Ctl.PathSeg
STnn Cycle Time
<xxRnn.Ctl.PathSeg>
Ticking
0
STnn
Start pickup
/
Robot
xxRnn Clear of Area
OPnnPickUpRb.Ctl.AreaClr.1
/
EQU STnn.Pos.Pickup
Equal
Source A OPnnPickUpRb.Ctl.PathSeg
<xxRnn.Ctl.PathSeg>
0
Source B 10
RSLogix 5000
STnn Cycle Time
Preset 9999999 DN
9999999
STnn
Ticking Shot Start Present OPnnPickUpRb.Ctl.AreaClr.1 STnn Cycle Time
30 / ONS / Move
0
Dest STnn.Cyc.Time
0
STnn Cycle Timer

STnn.Cyc.Timer
RES
(End)
RSLogix 5000
JSR
Routine Name S510_MotionDial1Rev
JSR
Routine Name S010_MotionDial1Fwd
(End)
RSLogix 5000
Precondition
OPnn OPnn
OPnn_Motion1.wrk.Saf STnn.ProcCpl OPnn_Motion1.Wrk.Pre
0 /
Safety
OPnn
Cell.Rst STnn.Sfty.LsRst STnn.Utility.OutPwrOn STnn.RobClr OPnn_Motion1.Wrk.Saf
1
Command
OPnn OPnn OPnn OPnn
Cell.Mode.Auto STnn.Cyc.Start OPnn_Motion1.wrk.Pre OPnn_Motion1.wrk.Cpl OPnn_Motion1.wrk.Saf OPnn_Motion1.wrk.Cmd
2 /
OPnn OPnn
Cell.Mode.Man OPnn_Motion1.wrk.Pb OPnn_Motion1.Hme.Pb STnn.HomeEn
/ /
Output
OPnn OPnn OPnn OPnn
Cell.Rst OPnn_Motion1.wrk.Cmd OPnn_Motion1.Hme.Cmd OPnn_Motion1.Hme.Out OPnn_Motion1.wrk.Out
3 / /

Buffering OUTPUTS
*************
OPnn Replace
Motion1 With
Work Used Output
Output *************
OPnn_Motion1.wrk.Out OutputBuffer
4

Motion complete
OPnn
OPnn OPnn Motion1
OPnn_Motion1_Cyy.PX1 OPnn_Motion1_Cyy.PX2 OPnn_Motion1.wrk.Cpl
5 /
Panelview Indicator
OPnn OPnn
Motion1 Motion1
OPnn_Motion1.wrk.Pre System.Flsh.Norm OPnn_Motion1.wrk.Ind
6
OPnn
Motion1
Work
Command
OPnn_Motion1.wrk.Cmd
OPnn
Motion1
AtWork
Complete
OPnn_Motion1.wrk.Cpl
Buffering INPUTS
*************
Replace
With OPnn
************* AtWork
InputBuffer OPnn_Motion1_Cyy.PX2
7
Faults
OPnn OPnn
Motion1 Motion1
Work Work
Output Eng Mem
OPnn_Motion1.wrk.Out OPnn_Motion1.wrk.Eng
8 L
OPnn OPnn
Motion1 Motion1
Complete On Eng Mem
OPnn_Motion1.wrk.Cpl Cell.sfty.PwrOn OPnn_Motion1.Hme.Eng
/ U
RSLogix 5000
OPnn OPnn OPnn OPnn
OPnn_FB1.CommOK OPnn_Motion1.wrk.Eng OPnn_Motion1.wrk.Tmr.DN OPnn_Motion1.wrk.Cpl OPnn_Motion1.wrk.Flt
9 /
OPnn OPnn
Motion1 Motion1
Work Work
Flt Timer Flt Timer
MOV TON
Source 3000 Timer OPnn_Motion1.wrk.Tmr
Preset 0 DN
Dest OPnn_Motion1.wrk.Tmr.PRE Accum 0
0
OPnn
Motion1 Cyy
OPnn AtWork /
OPnn_Motion1.wrk.Flt OPnn_Motion1_Cyy.PX1 OPnn_Motion1_Cyy.PX2 OPnn_Motion1_Cyy.Flt.0
10
OPnn
Motion1 Cyy
OPnn_Motion1_Cyy.PX2 OPnn_Motion1_Cyy.PX1 OPnn_Motion1_Cyy.Flt.1
/
OPnn
Motion1 Cyy
OPnn Did Not Reach
Motion1 Cyy AtWork
AtHome Position
OPnn_Motion1_Cyy.PX1 OPnn_Motion1_Cyy.Flt.2
/

COP
11 Copy File
Source OPnn_Motion1_Cyy.Flt
Dest OPnnAlarms[1]
Length 1
(End)
RSLogix 5000
S010_MotionDial1Fwd - Ladder Diagram Page 151
Precondition
STnn STnn Tool Ready STnn STnn Tool Ready STnn STnn Tool Ready
Cell for Dial Table to for Dial Table to for Dial Table to
OPnn MotionDial1 Fwd Stop Turn Turn Turn OPnn MotionDial1 Fwd
Safety Request OPnnSideA.TLInPos.15 OPnnSideB.TLInPos.15 OPnnSideC.TLInPos.15 Precondition
OPnn_MotionDial1.Fwd.Saf Cell.Mode.StopReq <STnn.TLInPos.15> <STnn.TLInPos.15> <STnn.TLInPos.15> OPnn_MotionDial1.Fwd.Pre
0 /
Safeties
STnn STnn STnn Tool in STnn STnn Tool in STnn STnn Tool in
Cell Disconnect Dial Table Motor STnn Safe Posiiton for Safe Posiiton for Safe Posiiton for
Safeties Switch Overload Protection Robots OPnn MotionDial1 Fwd Dial Table to Turn Dial Table to Turn Dial Table to Turn STnn Operator Gate
Reset On OK Clear Fault Latch OPnnSideA.TLInPos.16 OPnnSideB.TLInPos.16 OPnnSideC.TLInPos.16 Closed STnn Safety Pin 1 Ok
Cell.Rst STnn.Utility.Sw OPnn_MotionDial1_Cyy.Ovld STnn.RobClr OPnn_MotionDial1.Fwd.FltLtch <STnn.TLInPos.16> <STnn.TLInPos.16> <STnn.TLInPos.16> STnn.Sfty.OGCls STnn.Sfty.SafetyPin1
1 /
Dial Table Motor OPnn MotionDial1 Fwd

STnn Safety Pin 2 Ok Fault Safety
STnn.Sfty.SafetyPin2 EQU OPnn_MotionDial1.Fwd.Saf
Equal
Source A OPnn_MotionDial1_Cyy.Flt
0
Source B 0
Start Coast Fwd

OPnn MotionDial1 Fwd OPnn MotionDial1 OPnn MotionDial1 Fwd
Stop Limit Switch Coast Start One Shot Start Coast
OPnn_MotionDial1.Fwd.LimitSw OPnn_MotionDial1.Fwd.CoastOns OPnn_MotionDial1.Fwd.CoastStrt
2 ONS
OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd

Command Start Coast Stop Motion
OPnn_MotionDial1.Fwd.Cmd OPnn_MotionDial1.Fwd.CoastStrt OPnn_MotionDial1.Fwd.StopMotion
3
Command
Cell
Auto OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd
Mode Precondition Stop Motion Safety Command
Cell.Mode.Auto OPnn_MotionDial1.Fwd.Pre OPnn_MotionDial1.Fwd.StopMotion OPnn_MotionDial1.Fwd.Saf OPnn_MotionDial1.Fwd.Cmd
4 /
OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd
Command Complete
OPnn_MotionDial1.Fwd.Cmd OPnn_MotionDial1.Fwd.Cpl
/
OPnn MotionDial1 Fwd
Engaged
OPnn_MotionDial1.Fwd.Eng
Cell
Manual OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd OPnn MotionDial1 Rev
Mode Panleview PB Jog Jog
Cell.Mode.Man OPnn_MotionDial1.Fwd.Pb OPnn_MotionDial1.Fwd.CmdJog OPnn_MotionDial1.Rev.CmdJog
/ /
Command
OPnn_MotionDial1.Fwd.Cmd
Motion Engaged Memory: Used to resume motion in Auto Mode if stopped because of a safety
OPnn MotionDial1 Fwd STnn Dial Table in OPnn MotionDial1 Fwd
Engaged Unknown Position Engaged
OPnn_MotionDial1.Fwd.Eng STnn.TLInPos.14 OPnn_MotionDial1.Fwd.Eng
5 / U
Complete
OPnn_MotionDial1.Fwd.Cpl

Stop Motion
OPnn_MotionDial1.Fwd.StopMotion
Dial Table Motor

Fault
NEQ
Not Equal
0
Source B 0
OPnn MotionDial1 Fwd STnn Dial Table in OPnn MotionDial1 Fwd

Output Unknown Position Engaged
OPnn_MotionDial1.Fwd.Out STnn.TLInPos.14 OPnn_MotionDial1.Fwd.Eng
6 L
Jog
Cell
Manual OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd OPnn MotionDial1 Rev OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd
Mode Panelview Jog PB Command Panelview Jog PB Start Coast Safety Jog
Cell.Mode.Man OPnn_MotionDial1.Fwd.PbJog OPnn_MotionDial1.Fwd.Cmd OPnn_MotionDial1.Rev.PbJog OPnn_MotionDial1.Fwd.CoastStrt OPnn_MotionDial1.Fwd.Saf OPnn_MotionDial1.Fwd.CmdJog
7 / / /
RSLogix 5000
Output
This rung blocks Forward Motion for 500ms after it stopped turning (either Fwd or Rev)
Note that the timer in this rung is a TOF instruction.
OPnn MotionDial1
OPnn MotionDial1 Fwd OPnn MotionDial1 Rev OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd
Command Coast Timer Coast Timer Output
OPnn_MotionDial1.Fwd.Cmd OPnn_MotionDial1.Rev.Coast.DN OPnn_MotionDial1.Fwd.Coast.TT OPnn_MotionDial1.Fwd.Out
8 / /
OPnn MotionDial1 Fwd OPnn MotionDial1
Jog OPnn MotionDial1 Fwd
OPnn_MotionDial1.Fwd.CmdJog Coast Timer
MOV
Move
Source 500
Dest OPnn_MotionDial1.Fwd.Coast.PRE
0

Coast Timer
TOF
Timer Off Delay EN
Timer OPnn_MotionDial1.Fwd.Coast
Preset 0 DN
Accum 0
Buffer Output
OPnn
OPnn MotionDial1 Fwd Compact
Output Block IO Module 3
OPnn_MotionDial1.Fwd.Out OPnn_DIO.O.M3.1
9

Motion complete
Dial Table In Dwell Complete
OPnn_MotionDial1_Cyy.LS1 OPnn_MotionDial1.Fwd.Cpl
10
Panelview Indicator
OPnn MotionDial1 Fwd System Normal OPnn MotionDial1 Fwd
Precondition Flasher Panelview Indicator
OPnn_MotionDial1.Fwd.Pre System.Flsh.Norm OPnn_MotionDial1.Fwd.Ind
11
Command
OPnn_MotionDial1.Fwd.Cmd

Jog
OPnn_MotionDial1.Fwd.CmdJog
OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd

Precondition Command Dwell
OPnn_MotionDial1.Fwd.Pre OPnn_MotionDial1.Fwd.Cmd OPnn_MotionDial1.Fwd.Dwell
/ /
RepeatInRung Cyl Cyy:{CylName}

Buffering INPUTS
*************
Replace
With
Used Input OPnn MotionDial1 Fwd
************* Stop Limit Switch
InputBuffer OPnn_MotionDial1.Fwd.LimitSw
12
*************
Replace
With
Used Input
************* Dial Table In Dwell
InputBuffer OPnn_MotionDial1_Cyy.LS1
*************
Replace
With Dial Table Motor
Used Input Overload Protection
************* OK
InputBuffer OPnn_MotionDial1_Cyy.Ovld
*************
Replace
With
Used Input OPnn MotionDial1 Fwd
InputBuffer OPnn_MotionDial1.Fwd.LimitSw
Faults
PVCell
Fault Reset
Pushbutton OPnn MotionDial1 Fwd
(Hardware) Fault Latch
HMICell.FltrstHpb OPnn_MotionDial1.Fwd.FltLtch
13 U
Dial Table Motor
Fault
MOV
Move
Source 0
Dest OPnn_MotionDial1_Cyy.Flt
0

Start Coast Coast Memory
OPnn_MotionDial1.Fwd.CoastStrt OPnn_MotionDial1.Fwd.CoastMem
14 L

Output Coast Memory
OPnn_MotionDial1.Fwd.Out OPnn_MotionDial1.Fwd.CoastMem
15 U
RSLogix 5000
OPnn MotionDial1
Cell Machine Power OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd
On Output Fault Timer Fault Latch
Cell.sfty.PwrOn OPnn_MotionDial1.Fwd.Out OPnn_MotionDial1.Fwd.Tmr.DN OPnn_MotionDial1.Fwd.FltLtch
16 L
OPnn MotionDial1
OPnn MotionDial1 Fwd OPnn MotionDial1 Fwd
MOV TON
Source 8000 Timer OPnn_MotionDial1.Fwd.Tmr
Preset 0 DN
Dest OPnn_MotionDial1.Fwd.Tmr.PRE Accum 0
0
STnn STnn OPnn MotionDial1
Dial Table Dial Table More Than One
In Position A In Position B Position Active
STnn.TLInPos.11 STnn.TLInPos.12 OPnn_MotionDial1_Cyy.Flt.0
17
STnn STnn
Dial Table Dial Table
In Position A In Position C
STnn.TLInPos.11 STnn.TLInPos.13
STnn STnn
Dial Table Dial Table
In Position B In Position C
STnn.TLInPos.12 STnn.TLInPos.13
OPnn MotionDial1 Did

Not Reach Final
OPnn MotionDial1 Fwd Position While
Fault Latch Dial Table In Dwell Moving Fwd
OPnn_MotionDial1.Fwd.FltLtch OPnn_MotionDial1_Cyy.LS1 OPnn_MotionDial1_Cyy.Flt.1
/
OPnn MotionDial1
Motor
OPnn Thermal
Compact Dial Table Motor Overload
Block IO DeviceNet Overload Protection Protection
Communication OK OK Tripped
OPnn_DIO.CommOK OPnn_MotionDial1_Cyy.Ovld OPnn_MotionDial1_Cyy.Flt.2
/
OPnn MotionDial1
Reached Dwell
Position Before
OPnn MotionDial1 OPnn MotionDial1 Coast When Moving
Coast Memory Dial Table In Dwell Coast Start One Shot Fwd
OPnn_MotionDial1.Fwd.CoastMem OPnn_MotionDial1_Cyy.LS1 OPnn_MotionDial1.Fwd.CoastOns OPnn_MotionDial1_Cyy.Flt.3
/ ONS L
OPnn MotionDial1 OPnn MotionDial1 Fwd OPnn MotionDial1 Rev OPnn MotionDial1
Dial Table In Dwell Dwell On One Shot Output Output Lost Dwell Position
OPnn_MotionDial1_Cyy.LS1 OPnn_MotionDial1.Fwd.OnDwellOns OPnn_MotionDial1.Fwd.Out OPnn_MotionDial1.Rev.Out OPnn_MotionDial1_Cyy.Flt.4
/ ONS / / L
OPnn MotionDial1
Dwell Switch Active
STnn Dial Table in with Table in
Dial Table In Dwell Unknown Position Unknown Position
OPnn_MotionDial1_Cyy.LS1 STnn.TLInPos.14 OPnn_MotionDial1_Cyy.Flt.5
L

COP
18 Copy File
Source OPnn_MotionDial1_Cyy.Flt
Dest OPnnAlarms[1]
Length 1
(End)
RSLogix 5000
Precondition
OPnn OPnn
OPnn_Motion1.Hme.Saf STnn.ProcCpl OPnn_Motion1.Hme.Pre
0
Safety
OPnn
Cell.Rst STnn.Sfty.LsRst STnn.Utility.OutPwrOn STnn.RobClr OPnn_Motion1.Hme.Saf
1
Command
OPnn OPnn OPnn OPnn
Cell.Mode.Auto STnn.Cyc.Start OPnn_Motion1.Hme.Pre OPnn_Motion1.Hme.Cpl OPnn_Motion1.Hme.Saf OPnn_Motion1.Hme.Cmd
2 /
OPnn OPnn
Manual Home Work
Cell.Mode.Man OPnn_Motion1.Hme.Pb OPnn_Motion1.Wrk.Pb
/
STnn
Home
Enable
STnn.HomeEn
Output
OPnn OPnn OPnn OPnn
Cell.Rst OPnn_Motion1.Hme.Cmd OPnn_Motion1.Wrk.Cmd OPnn_Motion1.Wrk.Out OPnn_Motion1.Hme.Out
3 / /

Buffering OUTPUTS
*************
OPnn Replace
Motion1 With
Home Used Output
Output *************
OPnn_Motion1.Hme.Out OutputBuffer
4

Motion complete
OPnn
OPnn OPnn Motion1
OPnn_Motion1_Cyy.PX1 OPnn_Motion1_Cyy.PX2 OPnn_Motion1.Hme.Cpl
5 /
Panelview Indicator
OPnn OPnn
Motion1 Motion1
OPnn_Motion1.Hme.Pre System.Flsh.Norm OPnn_Motion1.Hme.Ind
6
OPnn
Motion1
Home
Command
OPnn_Motion1.Hme.Cmd
OPnn
Motion1
AtHome
Complete
OPnn_Motion1.Hme.Cpl
Buffering INPUTS
*************
Replace
With OPnn
************* AtHome
7
Faults
OPnn OPnn
Motion1 Motion1
Home Home
Output Eng Mem
OPnn_Motion1.Hme.Out OPnn_Motion1.Hme.Eng
8 L
OPnn OPnn
Motion1 Motion1
Complete On Eng Mem
OPnn_Motion1.Hme.Cpl Cell.sfty.PwrOn OPnn_Motion1.Wrk.Eng
/ U
RSLogix 5000
OPnn OPnn OPnn OPnn
OPnn_FB1.CommOK OPnn_Motion1.Hme.Eng OPnn_Motion1.Hme.Tmr.DN OPnn_Motion1.Hme.Cpl OPnn_Motion1.Hme.Flt
9 /
OPnn OPnn
Motion1 Motion1
Home Home
Flt Timer Flt Timer
MOV TON
Source 3000 Timer OPnn_Motion1.Hme.Tmr
Preset 0 DN
Dest OPnn_Motion1.Hme.Tmr.PRE Accum 0
0
OPnn
Motion1 Cyy
OPnn AtWork /
OPnn_Motion1.Hme.Flt OPnn_Motion1_Cyy.PX2 OPnn_Motion1_Cyy.PX1 OPnn_Motion1_Cyy.Flt.3
10
OPnn
Motion1 Cyy
/
OPnn
Motion1 Cyy
OPnn Did Not Reach
Motion1 Cyy AtHome
AtWork Position
/
(End)
RSLogix 5000
S510_MotionDial1Rev - Ladder Diagram Page 156
Precondition is always off: This table does not reverse automatically
OPnn MotionDial1 Rev
Precondition
OPnn_MotionDial1.Rev.Pre
0 AFI
Safeties
STnn STnn STnn Tool in STnn STnn Tool in STnn STnn Tool in
Cell Disconnect Dial Table Motor STnn Safe Posiiton for Safe Posiiton for Safe Posiiton for
Safeties Switch Overload Protection Robots OPnn MotionDial1 Rev Dial Table to Turn Dial Table to Turn Dial Table to Turn STnn Operator Gate
Reset On OK Clear Fault Latch OPnnSideA.TLInPos.16 OPnnSideB.TLInPos.16 OPnnSideC.TLInPos.16 Closed STnn Safety Pin 1 Ok
Cell.Rst STnn.Utility.Sw OPnn_MotionDial1_Cyy.Ovld STnn.RobClr OPnn_MotionDial1.Rev.FltLtch <STnn.TLInPos.16> <STnn.TLInPos.16> <STnn.TLInPos.16> STnn.Sfty.OGCls STnn.Sfty.SafetyPin1
1 /
Dial Table Motor OPnn MotionDial1 Rev

STnn Safety Pin 2 Ok Fault Safety
STnn.Sfty.SafetyPin2 EQU OPnn_MotionDial1.Rev.Saf
Equal
0
Source B 0
Coast Logic
OPnn MotionDial1 Rev OPnn MotionDial1 OPnn MotionDial1 Rev
Stop Limit Switch Coast Start One Shot Start Coast
OPnn_MotionDial1.Rev.LimitSw OPnn_MotionDial1.Rev.CoastOns OPnn_MotionDial1.Rev.CoastStrt
2 ONS
OPnn MotionDial1 Rev OPnn MotionDial1 Rev OPnn MotionDial1 Rev

Command Start Coast Stop Motion
OPnn_MotionDial1.Rev.Cmd OPnn_MotionDial1.Rev.CoastStrt OPnn_MotionDial1.Rev.StopMotion
3
Command
Cell
Manual OPnn MotionDial1 Rev OPnn MotionDial1 Rev OPnn MotionDial1 Fwd OPnn MotionDial1 Rev OPnn MotionDial1 Rev OPnn MotionDial1 Rev
Mode Panelview PB Jog Jog Stop Motion Safety Command
Cell.Mode.Man OPnn_MotionDial1.Rev.Pb OPnn_MotionDial1.Rev.CmdJog OPnn_MotionDial1.Fwd.CmdJog OPnn_MotionDial1.Rev.StopMotion OPnn_MotionDial1.Rev.Saf OPnn_MotionDial1.Rev.Cmd
4 / / /
Command
OPnn_MotionDial1.Rev.Cmd
Jog
Cell
Manual OPnn MotionDial1 Rev OPnn MotionDial1 Rev OPnn MotionDial1 Fwd OPnn MotionDial1 Rev OPnn MotionDial1 Rev OPnn MotionDial1 Rev
Mode Panelview Jog PB Command Panelview Jog PB Start Coast Safety Jog
Cell.Mode.Man OPnn_MotionDial1.Rev.PbJog OPnn_MotionDial1.Rev.Cmd OPnn_MotionDial1.Fwd.PbJog OPnn_MotionDial1.Rev.CoastStrt OPnn_MotionDial1.Rev.Saf OPnn_MotionDial1.Rev.CmdJog
5 / / /
Output
This rung blocks Reverse Motion for 500ms after it stopped turning (either Fwd or Rev)
Note that the timer in this rung is a TOF instruction.
OPnn MotionDial1 OPnn MotionDial1
OPnn MotionDial1 Rev OPnn MotionDial1 Fwd OPnn MotionDial1 Rev OPnn MotionDial1 Rev
Command Coast Timer Coast Timer Output
OPnn_MotionDial1.Rev.Cmd OPnn_MotionDial1.Fwd.Coast.DN OPnn_MotionDial1.Rev.Coast.TT OPnn_MotionDial1.Rev.Out
6 / /
OPnn MotionDial1 Rev OPnn MotionDial1 Rev
Jog Coast Timer
OPnn_MotionDial1.Rev.CmdJog MOV
Move
Source 500
Dest OPnn_MotionDial1.Rev.Coast.PRE
0

Coast Timer
TOF
Timer Off Delay EN
Timer OPnn_MotionDial1.Rev.Coast
Preset 0 DN
Accum 0
Buffer Outputs
OPnn
OPnn MotionDial1 Rev Compact
Output Block IO Module 3
OPnn_MotionDial1.Rev.Out OPnn_DIO.O.M3.0
7

Motion complete
Dial Table In Dwell Complete
OPnn_MotionDial1_Cyy.LS1 OPnn_MotionDial1.Rev.Cpl
8
Panelview Indicator
OPnn MotionDial1 Rev System Normal OPnn MotionDial1 Rev
Precondition Flasher Panleview Indicator
OPnn_MotionDial1.Rev.Pre System.Flsh.Norm OPnn_MotionDial1.Rev.Ind
9
Command
OPnn_MotionDial1.Rev.Cmd
Buffering INPUTS
*************
Replace
With
Used Input OPnn MotionDial1 Rev
InputBuffer OPnn_MotionDial1.Rev.LimitSw
10
RSLogix 5000
S510_MotionDial1Rev - Ladder Diagram Page 157
Faults
PVCell
Fault Reset
Pushbutton OPnn MotionDial1 Rev
(Hardware) Fault Latch
HMICell.FltrstHpb OPnn_MotionDial1.Rev.FltLtch
11 U
OPnn MotionDial1 Rev OPnn MotionDial1

Start Coast Coast Memory
OPnn_MotionDial1.Rev.CoastStrt OPnn_MotionDial1.Rev.CoastMem
12 L
OPnn MotionDial1 Rev OPnn MotionDial1

Output Coast Memory
OPnn_MotionDial1.Rev.Out OPnn_MotionDial1.Rev.CoastMem
13 U
Cell Machine Power OPnn MotionDial1 Rev OPnn MotionDial1 Rev OPnn MotionDial1 Rev OPnn MotionDial1 Rev
On Output Fault Timer Complete Fault Latch
Cell.sfty.PwrOn OPnn_MotionDial1.Rev.Out OPnn_MotionDial1.Rev.Tmr.DN OPnn_MotionDial1.Rev.Cpl OPnn_MotionDial1.Rev.FltLtch
14 / L
OPnn MotionDial1 Rev OPnn MotionDial1 Rev
MOV TON
Source 8000 Timer OPnn_MotionDial1.Rev.Tmr
Preset 0 DN
Dest OPnn_MotionDial1.Rev.Tmr.PRE Accum 0
0
OPnn MotionDial1 Did
Not Reach Final
OPnn MotionDial1 Rev Position While
Fault Latch Dial Table In Dwell Moving Rev
OPnn_MotionDial1.Rev.FltLtch OPnn_MotionDial1_Cyy.LS1 OPnn_MotionDial1_Cyy.Flt.6
15 /
OPnn MotionDial1
Reached Dwell
Position Before
OPnn MotionDial1 OPnn MotionDial1 Coast When Moving
Coast Memory Dial Table In Dwell Coast Start One Shot Rev
OPnn_MotionDial1.Rev.CoastMem OPnn_MotionDial1_Cyy.LS1 OPnn_MotionDial1.Rev.CoastOns OPnn_MotionDial1_Cyy.Flt.7
/ ONS L
(End)
RSLogix 5000
Status Faults
OPnn
OPnn_DIO.I.Status.0 STnn.UtilityFaults_Ina.7
0
Node 2
Enable
1
DeviceNet Module
PVCell STnn
Fault Reset FB1
/
STnn
Node 2 FB1
/
(End)
RSLogix 5000
Cosma:Unscheduled Programs:STStopGo 11/11/2010 1:29:19 PM
***************************************************************************
PIO with... inputs
***********************************************************************
Node 2 OK - OPnn
Active and Compact
0 Copy File
Dest OPnnDIO.I
Length 1
OPnn
Compact
Block IO DeviceNet
Communication OK
OPnnDIO.CommOK
Node 2 OK - OPnn
Active and Compact
/ Fill File
Source 0
Dest OPnnDIO.I
Length 1
STnn
OPnn Disconnect
Compact Switch
OPnnDIO.I.M3.0 STnn.Utility.Sw
1
OPnn
Compact Conveyor Motor
Block IO Module 3 Switch 1
OPnnDIO.I.M3.1 OPnn_Conv_M1.LS1
2
OPnn Conveyor Motor

Compact Overload Protection
Block IO Module 3 OK
OPnnDIO.I.M3.2 OPnn_Conv_M1.Ovld
3
Safety
OPnn Gate 1
OPnnDIO.I.M4.0 SG1.EnterReqHpb
4
Safety Gate 1
Auto/
Cycle
OPnn Start
Compact Pushbutton
OPnnDIO.I.M4.1 SG1.AStartHpb
5
OPnn
OPnnDIO.I.M4.3 SG1.GateOpen
6
Safety Gate 2
Fault Reset
Pushbutton
7
(End)
RSLogix 5000
***************************************************************************
PIO with... outputs
***********************************************************************
COP
0 Copy File
Source OPnnDIO.O
Length 2
Safety
Gate 1 OPnn
SG1.EnterClrLmp OPnnDIO.O.M1.0
1
Safety Gate 1
Auto/
Cycle OPnn
Start Compact
SG1.AutoLmp OPnnDIO.O.M1.1
2
Safety
Gate 1 OPnn
Power On Compact
SG1.FaultLmp OPnnDIO.O.M1.2
3
Safety
Gate 1 OPnn
E-Stop Compact
SG1.EStopLmp OPnnDIO.O.M1.3
4
Safety
Gate 1 OPnn
Unlock Compact
SG1.UnlockGate OPnnDIO.O.M2.0
5
(End)
RSLogix 5000
RungComment
0
STnn
Cycle Start STnn
Anti Cell Dry Cycle
1 /
STnn
Dry Cycle
Restart
Enable
STnn STnn STnn

2 / / Move
Source 3000
0
STnn
Dry Cycle
Restart
Timer
TON
Timer On Delay EN
Preset 0 DN
Accum 0
(End)
RSLogix 5000
Calling sequence:
RungComment
0
JSR
JSR
JSR
JSR
JSR
(End)
RSLogix 5000
JSR
Routine Name S010_MotionStopGo1Go
(End)
RSLogix 5000
Precondition
OPnn OPnn
0 /
Safety
OPnn
1
Command
OPnn OPnn OPnn OPnn
2 /
OPnn OPnn
/ /
Output
OPnn OPnn OPnn OPnn
3 / /

Buffering OUTPUTS
*************
OPnn Replace
Motion1 With
Work Used Output
Output *************
4

Motion complete
OPnn
OPnn OPnn Motion1
5 /
Panelview Indicator
OPnn OPnn
Motion1 Motion1
6
OPnn
Motion1
Work
Command
OPnn
Motion1
AtWork
Complete
Buffering INPUTS
*************
Replace
With OPnn
************* AtWork
7
Faults
OPnn OPnn
Motion1 Motion1
Work Work
Output Eng Mem
8 L
OPnn OPnn
Motion1 Motion1
Complete On Eng Mem
/ U
RSLogix 5000
OPnn OPnn OPnn OPnn
9 /
OPnn OPnn
Motion1 Motion1
Work Work
Flt Timer Flt Timer
MOV TON
Preset 0 DN
0
OPnn
Motion1 Cyy
OPnn AtWork /
10
OPnn
Motion1 Cyy
/
OPnn
Motion1 Cyy
OPnn Did Not Reach
Motion1 Cyy AtWork
AtHome Position
/

COP
11 Copy File
Dest OPnnAlarms[1]
Length 1
(End)
RSLogix 5000
S010_MotionStopGo1Go - Ladder Diagram Page 166
Precondition
Table is Ready to OPnn MotionStopGo1
Receive Carrier from OPnn MotionStopGo1 Is Sending Rack to
Previous Table Rack Present Next Section
OPnn_NextToMotionStopGo1.ReadyToReceive OPnn_MotionStopGo1.PPSw OPnn_MotionStopGo1.Sending
0
OPnn MotionStopGo1
Is Sending Rack to
Next Section
OPnn_MotionStopGo1.Sending
OPnn MotionStopGo1
Table is Sending Is Receiving Rack
Carrier to Next OPnn MotionStopGo1 From Previous
Table Rack Present Station
OPnn_PreviousToMotionStopGo1.Sending OPnn_MotionStopGo1.PPSw OPnn_MotionStopGo1.Receiving
1 /
OPnn MotionStopGo1
Is Receiving Rack
From Previous
Station
OPnn_MotionStopGo1.Receiving
OPnn MotionStopGo1
OPnn MotionStopGo1 Is Sending Rack to OPnn MotionStopGo1
Safe To Move Next Section Move Precondition
OPnn_MotionStopGo1.Go.Saf OPnn_MotionStopGo1.Sending OPnn_MotionStopGo1.Go.Pre
2
OPnn MotionStopGo1
Is Receiving Rack
From Previous
Station
OPnn_MotionStopGo1.Receiving
OPnn MotionStopGo1 OPnn MotionStopGo1

OPnn MotionStopGo1 Is Sending Rack to OPnn MotionStopGo1 Is Ready To Receive
Rack Present Next Section Safe To Move Rack
OPnn_MotionStopGo1.PPSw OPnn_MotionStopGo1.Sending OPnn_MotionStopGo1.Go.Saf OPnn_MotionStopGo1.ReadyToReceive
3 / /
Safety
STnn OPnn MotionStopGo1
Cell STnn Disconnect Motor Overload STnn
Safeties STnn Light Screen Valve Output Power Switch Protection Not Robots Carrier Present OPnn MotionStopGo1
Reset Reset and Air On On Tripped Clear Switch Safe To Move
Cell.Rst STnn.Sfty.LsRst STnn.Utility.OutPwrOn STnn.Utility.Sw OPnn_MotionStopGo1.MotorOvlOK STnn.RobClr OPnn_NextToMotionStopGo1.CarrPresSw OPnn_MotionStopGo1.Go.Saf
4 / /
Carrier Present
Switch
OPnn_MotionStopGo1.CarrPresSw
/
Command
Cell STnn
Auto Cycle OPnn MotionStopGo1 OPnn MotionStopGo1 OPnn MotionStopGo1
Mode Start Move Precondition Safe To Move Move Command
Cell.Mode.Auto STnn.Cyc.Start OPnn_MotionStopGo1.Go.Pre OPnn_MotionStopGo1.Go.Saf OPnn_MotionStopGo1.Go.Cmd
5
Cell STnn
Manual Home
Cell.Mode.Man OPnn_MotionStopGo1.Go.Pb STnn.HomeEn
/
Output
Cell
Safeties OPnn MotionStopGo1 OPnn MotionStopGo1
Reset Move Command Move Output
Cell.Rst OPnn_MotionStopGo1.Go.Cmd OPnn_MotionStopGo1.Go.Out
6

Buffering OUTPUTS
*************
Replace
With
OPnn MotionStopGo1 Used Output
Move Output *************
OPnn_MotionStopGo1.Go.Out OutputBuffer
7
Panelview Indicator
OPnn MotionStopGo1 System Normal
Move Precondition Flasher Indicator
OPnn_MotionStopGo1.Go.Pre System.Flsh.Norm OPnn_MotionStopGo1.Go.Ind
8
OPnn MotionStopGo1
Move Command
OPnn_MotionStopGo1.Go.Cmd
Buffering INPUTS
*************
Replace
With
Used Input OPnn MotionStopGo1
************* Rack Present
InputBuffer OPnn_MotionStopGo1.PPSw
9
*************
Replace OPnn MotionStopGo1
With Motor Overload
Used Input Protection Not
************* Tripped
InputBuffer OPnn_MotionStopGo1.MotorOvlOK
10
RSLogix 5000
S010_MotionStopGo1Go - Ladder Diagram Page 167
Faults
OPnn MotionStopGo1
Is Receiving Rack
OPnn MotionStopGo1 From Previous OPnn MotionStopGo1
Move Output Station Motor Engaged
OPnn_MotionStopGo1.Go.Out OPnn_MotionStopGo1.Receiving OPnn_MotionStopGo1.Go.Eng
11
OPnn MotionStopGo1
Is Sending Rack to
Next Section
OPnn_MotionStopGo1.Sending
Field Module 1 OPnn MotionStopGo1 OPnn MotionStopGo1 OPnn MotionStopGo1

Comm OK Motor Engaged Fault Timer Faulted
OPnn_FB1.CommOK OPnn_MotionStopGo1.Go.Eng OPnn_MotionStopGo1.Go.Tmr.DN OPnn_MotionStopGo1.Go.Flt
12
MOV TON
Source 8000 Timer OPnn_MotionStopGo1.Go.Tmr
Preset 8000 DN
Dest OPnn_MotionStopGo1.Go.Tmr.PRE Accum 0
8000
OPnn MotionStopGo1
Is Receiving Rack OPnn MotionStopGo1
OPnn MotionStopGo1 From Previous Did Not Receive
Faulted Station Carrier
OPnn_MotionStopGo1.Go.Flt OPnn_MotionStopGo1.Receiving OPnn_MotionStopGo1.Flt.0
13
OPnn MotionStopGo1 OPnn MotionStopGo1
Is Sending Rack to Did Not Finish To
Next Section Send Carrier
OPnn_MotionStopGo1.Sending OPnn_MotionStopGo1.Flt.1
OPnn MotionStopGo1
Motor Overload OPnn MotionStopGo1
Protection Not Motor Overload
Tripped Protection Tripped
OPnn_MotionStopGo1.MotorOvlOK OPnn_MotionStopGo1.Flt.2
14 /
COP
15 Copy File
Source OPnn_MotionStopGo1.Flt
Dest OPnnAlarms[1]
Length 1
(End)
RSLogix 5000
Precondition
OPnn OPnn
0
Safety
OPnn
1
Command
OPnn OPnn OPnn OPnn
2 /
OPnn OPnn
Manual Home Work
/
STnn
Home
Enable
STnn.HomeEn
Output
OPnn OPnn OPnn OPnn
3 / /

Buffering OUTPUTS
*************
OPnn Replace
Motion1 With
Home Used Output
Output *************
4

Motion complete
OPnn
OPnn OPnn Motion1
5 /
Panelview Indicator
OPnn OPnn
Motion1 Motion1
6
OPnn
Motion1
Home
Command
OPnn
Motion1
AtHome
Complete
Buffering INPUTS
*************
Replace
With OPnn
************* AtHome
7
Faults
OPnn OPnn
Motion1 Motion1
Home Home
Output Eng Mem
8 L
OPnn OPnn
Motion1 Motion1
Complete On Eng Mem
/ U
RSLogix 5000
OPnn OPnn OPnn OPnn
9 /
OPnn OPnn
Motion1 Motion1
Home Home
Flt Timer Flt Timer
MOV TON
Preset 0 DN
0
OPnn
Motion1 Cyy
OPnn AtWork /
10
OPnn
Motion1 Cyy
/
OPnn
Motion1 Cyy
OPnn Did Not Reach
Motion1 Cyy AtHome
AtWork Position
/
(End)
RSLogix 5000
Conveyor Motor
System 1st Input Overload Protection STnn 2nd Safety IO
Card OK Module Faulted
System.I1.4 OPnn_Conv_M1.Ovld STnn.UtilityFaults_Ina.19
0
Status Faults
OPnn
OPnnDIO.I.Status.0 STnn.UtilityFaults_Ina.7
1
Node 2
Enable
2
DeviceNet Module
PVCell STnn
Fault Reset FB1
/
STnn
Node 2 FB1
/
(End)
RSLogix 5000
Cosma:Unscheduled Programs:STTD 11/11/2010 1:29:30 PM
Aug 05, 2005:
RungComment
0
JSR
JSR
JSR
JSR
JSR
(End)
RSLogix 5000
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
DeviceNet Module
Local Slot 7 Status
Local Slot 7 OK -
OPnn_Scanner.Module.RunOK OPnnDIONode.OK Block IO
<DNet07.Module.RunOK> <DNet07.node[0].OK> COP
0 Copy File
Dest OPnn_DIO.I
Length 1
OPnn
Compact
Block IO
OPnn_DIO.CommOK
OPnn OPnn
Compact Compact
Block IO Block IO
OPnn_DIO.CommOK FLL
/ Fill File
Source 0
Dest OPnn_DIO.I
Length 1
(End)
RSLogix 5000
***************************************************************************
Map Outputs:
Copy From
to DNet Scanner
***********************************************************************
COP
0 Copy File
Source OPnn_DIO.O
Length 1
(End)
RSLogix 5000
Manual Home PB
Cell STnn STnn
0

All Station Memories Reset
OPnn
STnn STnn Process started STnn Process STnn Motion1
Cycle Start (first weld complete (formerly Cycle AtWork STnn All memories
Memory triggered) Full Depth) Complete Memory are reset
STnn.Cyc.StartMem STnn.Cyc.ProcStarted STnn.ProcCpl STnn.Cyc.Cpl OPnn_Motion1.Wrk.Mem STnn.MemReset
1 / / / / /

Home_ind: Based on Actual Position and Memories
OPnn
Motion1 STnn
AtHome Home
Complete Position
2
STnn
Panelview
Home
STnn All memories Position
are reset Panelview Ind
STnn.MemReset STnn.HMI.Home_Ind
Cycle Start
Cell STnn STnn STnn
Auto Valve Output Power Robot Cycle Cycle
Mode and Air On xxRnn Path Segment Complete Start
Cell.Mode.Auto STnn.Utility.OutPwrOn EQU STnn.Cyc.Cpl STnn.Cyc.Start
3 Equal /
Source A ClientRobotA.Ctl.PathSeg
<xxRnn.Ctl.PathSeg>
0
Source B 4
Robot
xxRnn Path Segment
EQU
Equal
Source A ClientRobotB.Ctl.PathSeg
<xxRnn.Ctl.PathSeg>
0
Source B 4
STnn
Cycle Start
Memory
STnn.Cyc.StartMem
STnn
Cycle
Start
STnn.Cyc.Start
STnn STnn
Cycle Cycle Start
Start Indicator
4
STnn STnn
Cycle Cycle Start
Start Memory
5 L
STnn Cell STnn

6 / U
STnn STnn
Home Home
Enable Position
Process Complete
STnn STnn Process
7 U
STnn STnn
Home Home
Enable Position
RSLogix 5000
OPnn
Motion1 STnn Process
Robot AtWork complete (formerly
xxRnn Path Segment Complete Full Depth)
EQU OPnn_Motion1.Wrk.Cpl STnn.ProcCpl
8 Equal L
Source A ClientRobotA.Ctl.PathSeg
<xxRnn.Ctl.PathSeg>
0
Source B 5
Robot
xxRnn Path Segment
EQU
Equal
Source A ClientRobotB.Ctl.PathSeg
<xxRnn.Ctl.PathSeg>
0
Source B 5
e STnn
e STnn Process Full
9 e
e
Cycle Complete
complete (formerly Cycle Cycle
Full Depth) Complete Complete
STnn.ProcCpl STnn.Cyc.Cpl STnn.Cyc.Cpl
10 / U

11 L
STnn
STnn Cycle
Cycle Complete
Complete Indicator
12

STnn
Tool Clear
STnn STnn STnn Process STnn Robot Robot to Enter For
Cycle Cycle Start complete (formerly Home xxRnn Clear of Area xxRnn Clear of Area Robot
Start Memory Full Depth) Position ClientRobotA.Ctl.AreaClr.2 ClientRobotB.Ctl.AreaClr.2 Weld
STnn.Cyc.Start STnn.Cyc.StartMem STnn.ProcCpl STnn.Home <xxRnn.Ctl.AreaClr.2> <xxRnn.Ctl.AreaClr.2> STnn.TLArea.1
13 / / /

STnn
OPnn Tool Clear
STnn STnn Process Motion1 Robot Robot to Enter For
Cycle complete (formerly AtWork xxRnn Clear of Area xxRnn Clear of Area Robot
Start Full Depth) Complete ClientRobotA.Ctl.AreaClr.2 ClientRobotB.Ctl.AreaClr.2 TipDress
STnn.Cyc.Start STnn.ProcCpl OPnn_Motion1.Wrk.Cpl <xxRnn.Ctl.AreaClr.2> <xxRnn.Ctl.AreaClr.2> STnn.TLArea.3
14 /

STnn
Tool Clear
STnn STnn STnn Process STnn to Enter For
Cycle Cycle Start complete (formerly Home Robot STnn Ready for 1st
Start Memory Full Depth) Position Weld welds
STnn.Cyc.Start STnn.Cyc.StartMem STnn.ProcCpl STnn.Home STnn.TLArea.1 STnn.Pos.Weld1
15 / / /

STnn STnn
Tool Clear OPnn Station
STnn STnn Process to Enter For Motion1 Ready
Cycle complete (formerly Robot AtWork for Robot
Start Full Depth) TipDress Complete TipDress
STnn.Cyc.Start STnn.ProcCpl STnn.TLArea.3 OPnn_Motion1.Wrk.Cpl STnn.TLInPos.7
16 /

Robot Robot STnn
xxRnn Clear of Area xxRnn Clear of Area Robots
ClientRobotA.Ctl.AreaClr.2 ClientRobotB.Ctl.AreaClr.2 Clear
<xxRnn.Ctl.AreaClr.2> <xxRnn.Ctl.AreaClr.2> STnn.RobClr
17
Robot STnn Weld Robot A

ClientRobotA.Ctl.AreaClr.2 Indicator
<xxRnn.Ctl.AreaClr.2> STnn.HMI.WeldRobAClr_Ind
18
Robot STnn Weld Robot B
ClientRobotB.Ctl.AreaClr.2 Indicator
<xxRnn.Ctl.AreaClr.2> STnn.HMI.WeldRobBClr_Ind
(End)
RSLogix 5000
RungComment
0
JSR
JSR
JSR
Routine Name S010_MotionCutter1On
(End)
RSLogix 5000
Precondition
OPnn OPnn
0 /
Safety
OPnn
1
Command
OPnn OPnn OPnn OPnn
2 /
OPnn OPnn
/ /
Output
OPnn OPnn OPnn OPnn
3 / /

Buffering OUTPUTS
*************
OPnn Replace
Motion1 With
Work Used Output
Output *************
4

Motion complete
OPnn
OPnn OPnn Motion1
5 /
Panelview Indicator
OPnn OPnn
Motion1 Motion1
6
OPnn
Motion1
Work
Command
OPnn
Motion1
AtWork
Complete
Buffering INPUTS
*************
Replace
With OPnn
************* AtWork
7
Faults
OPnn OPnn
Motion1 Motion1
Work Work
Output Eng Mem
8 L
OPnn OPnn
Motion1 Motion1
Complete On Eng Mem
/ U
RSLogix 5000
OPnn OPnn OPnn OPnn
OPnn Motion1 Motion1 Motion1 Motion1
Compact Work Work AtWork Work
Block IO Eng Mem Flt Timer Complete Fault
OPnn_DIO.CommOK OPnn_Motion1.wrk.Eng OPnn_Motion1.wrk.Tmr.DN OPnn_Motion1.wrk.Cpl OPnn_Motion1.wrk.Flt
9 /
OPnn OPnn
Motion1 Motion1
Work Work
Flt Timer Flt Timer
MOV TON
Preset 0 DN
0
OPnn
Motion1 Cyy
OPnn AtWork /
10
OPnn
Motion1 Cyy
/
OPnn
Motion1 Cyy
OPnn Did Not Reach
Motion1 Cyy AtWork
AtHome Position
/
RepeatInRung Cyl Cyy:{CylName} [1]:[{CylValue}]

COP
11 Copy File
Dest OPnnAlarms[1]
Length 1
(End)
RSLogix 5000
S010_MotionCutter1On - Ladder Diagram Page 179
Precondition
OPnn OPnn
MotionCutter1 STnn Process MotionCutter
On complete (formerly On
OPnn_MotionCutter1.On.Saf STnn.ProcCpl OPnn_MotionCutter1.On.Pre
0 /
Safety
OPnn STnn OPnn
Cell STnn MotionCutter1 Disconnect MotionCutter1
Safeties Valve Output Power Overload Protection Switch On
Reset and Air On On On Safety
Cell.Rst STnn.Utility.OutPwrOn OPnn_MotionCutter1_C01.OvldOK STnn.Utility.Sw OPnn_MotionCutter1.On.Saf
1
Command
OPnn OPnn OPnn
Cell STnn MotionCutter MotionCutter1 MotionCutter1
Auto Cycle On On On
Mode Start Precondition Safety Command
Cell.Mode.Auto STnn.Cyc.Start OPnn_MotionCutter1.On.Pre OPnn_MotionCutter1.On.Saf OPnn_MotionCutter1.On.Cmd
2
OPnn OPnn
Cell MotionCutter1 MotionCutter1 STnn
Manual On Off Home
Cell.Mode.Man OPnn_MotionCutter1.On.Pb OPnn_MotionCutter1.Off.Pb STnn.HomeEn
/ /
OPnn
MotionCutter1
On
Command
OPnn_MotionCutter1.On.Cmd
Output
OPnn OPnn
Cell MotionCutter1 MotionCutter1
Safeties On On
Reset Command Output
Cell.Rst OPnn_MotionCutter1.On.Cmd OPnn_MotionCutter1.On.Out
3
Buffering OUTPUTS
OPnn OPnn
MotionCutter1 Cutter
On Motor
Output Contactor
OPnn_MotionCutter1.On.Out OPnn_DIO.O.M1.0
4
OPnn
Blower
OPnn_DIO.O.M1.3
Motion complete
OPnn OPnn
MotionCutter1 Cutter MotionCutter1
On Contactor On
Output On Complete
OPnn_MotionCutter1.On.Out OPnn_DIO.I.M1.2 OPnn_MotionCutter1.On.Cpl
5
Panelview Indicator
OPnn OPnn
MotionCutter MotionCutter1
On System Normal On
OPnn_MotionCutter1.On.Pre System.Flsh.Norm OPnn_MotionCutter1.On.Ind
6
OPnn
MotionCutter1
On
Command
OPnn_MotionCutter1.On.Cmd
OPnn
MotionCutter1
On
Complete
OPnn_MotionCutter1.On.Cpl
Buffering INPUTS
OPnn STnn
Disconnect Disconnect
Switch Switch
On On
OPnn_DIO.I.M1.0 STnn.Utility.Sw
7
OPnn
Motor OPnn
Overload MotionCutter1
Protection Overload Protection
OK On
OPnn_DIO.I.M1.1 OPnn_MotionCutter1_C01.OvldOK
Faults
OPnn OPnn
MotionCutter1 MotionCutter1
On On
Output Eng Mem
OPnn_MotionCutter1.On.Out OPnn_MotionCutter1.On.Eng
8
RSLogix 5000
S010_MotionCutter1On - Ladder Diagram Page 180
Typical On/Off
Control
OPnn Rev. 0 OPnn OPnn OPnn
OPnn MotionCutter1 MotionCutter1 MotionCutter1 MotionCutter1
Compact On On On On
OPnn_DIO.CommOK OPnn_MotionCutter1.On.Eng OPnn_MotionCutter1.On.Tmr.DN OPnn_MotionCutter1.On.Cpl OPnn_MotionCutter1.On.Flt
9 /
Typical On/Off
Control
Rev. 0 OPnn OPnn
MotionCutter1 MotionCutter1
On On
Flt Timer Flt Timer
MOV TON
Source 3000 Timer OPnn_MotionCutter1.On.Tmr
Preset 0 DN
Dest OPnn_MotionCutter1.On.Tmr.PRE Accum 0
0
OPnn
OPnn MotionCutter1
MotionCutter1 Contactor
On Did Not
Fault Pull In
OPnn_MotionCutter1.On.Flt OPnn_MotionCutter1_C01.Flt.0
10
OPnn
MotionCutter1
OPnn Thermal
OPnn MotionCutter1 Overload
Compact Overload Protection Protection
Block IO On Tripped
OPnn_DIO.CommOK OPnn_MotionCutter1_C01.OvldOK OPnn_MotionCutter1_C01.Flt.1
11 /
COP
12 Copy File
Source OPnn_MotionCutter1_C01.Flt
Dest OPnnAlarms[1]
Length 1
(End)
RSLogix 5000
Precondition
OPnn OPnn
0
Safety
OPnn
1
Command
OPnn OPnn OPnn OPnn
2 /
OPnn OPnn
Manual Home Work
/
STnn
Home
Enable
STnn.HomeEn
Output
OPnn OPnn OPnn OPnn
3 / /

Buffering OUTPUTS
*************
OPnn Replace
Motion1 With
Home Used Output
Output *************
4

Motion complete
OPnn
OPnn OPnn Motion1
5 /
Panelview Indicator
OPnn OPnn
Motion1 Motion1
6
OPnn
Motion1
Home
Command
OPnn
Motion1
AtHome
Complete
Buffering INPUTS
*************
Replace
With OPnn
************* AtHome
7
Faults
OPnn OPnn
Motion1 Motion1
Home Home
Output Eng Mem
8 L
OPnn OPnn
Motion1 Motion1
Complete On Eng Mem
/ U
RSLogix 5000
OPnn OPnn OPnn OPnn
OPnn Motion1 Motion1 Motion1 Motion1
Compact Home Home AtHome Home
OPnn_DIO.CommOK OPnn_Motion1.Hme.Eng OPnn_Motion1.Hme.Tmr.DN OPnn_Motion1.Hme.Cpl OPnn_Motion1.Hme.Flt
9 /
OPnn OPnn
Motion1 Motion1
Home Home
Flt Timer Flt Timer
MOV TON
Preset 0 DN
0
OPnn
Motion1 Cyy
OPnn AtWork /
10
OPnn
Motion1 Cyy
/
OPnn
Motion1 Cyy
OPnn Did Not Reach
Motion1 Cyy AtHome
AtWork Position
/
(End)
RSLogix 5000
RungComment
0
DeviceNet Faults
RungComment
1

Enable
OPnnDIONode.Enable
2
DeviceNet Module
Not Faulted Power On Timer OPnnDIONode.Faulted OPnnDIONode.FaultedMem
PVCell STnn
OPnnDIONode.FaultedMem (Hardware) STnn.UtilityFaults_Ina.8
/
Node 0 Status Node 0 STnn

OPnnDIONode.Active DNet Node Not Active
<DNet07.node[0].Active> STnn.UtilityFaults_Ina.9
/
COP
3 Copy File
Dest OPnnAlarms[0]
Length 1
(End)
RSLogix 5000
Cosma:Unscheduled Programs:STWeld 11/11/2010 1:29:43 PM
Aug 05, 2005:
RungComment
0
JSR
JSR
Routine Name M001_DryModeRestart
JSR
JSR
Routine Name S005_PartPresent
JSR
JSR
JSR
(End)
RSLogix 5000
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
OPnn_Scanner.Module.RunOK OPnnFB1Node.OK Rev. 0
0 Copy File
Dest OPnn_FB1.I
Length 1
Field Module 1
Comm OK
OPnn_FB1.CommOK
AB FlexArmour
1798-ADN
8 x 8IN Module
Rev. 0 AB Flex
Armour
Comm OK Rev. 0
OPnn_FB1.CommOK FLL
/ Fill File
Source 0
Dest OPnn_FB1.I
Length 1
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
OPnn_Scanner.Module.RunOK OPnnFB2Node.OK Rev. 0
1 Copy File
Dest OPnn_FB2.I
Length 1
Field Module 1
Comm OK
OPnn_FB2.CommOK
AB FlexArmour
1798-ADN
8 x 8IN Module
Rev. 0 AB Flex
Armour
Comm OK Rev. 0
OPnn_FB2.CommOK FLL
/ Fill File
Source 0
Dest OPnn_FB2.I
Length 1
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
DeviceNet Module
Local Slot 7 Status
Local Slot 7 OK -
OPnn_Scanner.Module.RunOK OPnn_DIONode.OK Block IO Inputs
2 Copy File
Dest OPnn_DIO.I
Length 1
OPnn
Compact
Block IO DeviceNet
Communication OK
OPnn_DIO.CommOK
OPnn
Compact OPnn
Block IO DeviceNet Compact
Communication OK Block IO Inputs
OPnn_DIO.CommOK FLL
/ Fill File
Source 0
Dest OPnn_DIO.I
Length 1
RSLogix 5000
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
DeviceNet Module
Local Slot 7 Status
OPnn_Scanner.Module.RunOK OPnnPT1Node.OK Rev. 0
3 Copy File
Dest OPnn_PT1.I
Length 1
Pneumatic
Terminal 1
DeviceNet
Communication
OK
OPnn_PT1.CommOK

OK Rev. 0
OPnn_PT1.CommOK FLL
/ Fill File
Source 0
Dest OPnn_PT1.I
Length 1
***************************************************************************
Copy Signals
From DNet Scanner
***********************************************************************
DeviceNet Module
Local Slot 7 Status
OPnn_Scanner.Module.RunOK OPnnPT2Node.OK Rev. 0
4 Copy File
Dest OPnn_PT2.I
Length 1
Pneumatic
Terminal 2
DeviceNet
Communication
OK
OPnn_PT2.CommOK

OK Rev. 0
OPnn_PT2.CommOK FLL
/ Fill File
Source 0
Dest OPnn_PT2.I
Length 1
Pilz - Related Signals

RungComment
5
To Be STnn Light Screen

Determined Reset
TBD STnn.Sfty.LsRst
6
To Be STnn Start Button

Determined Handstand(H)
TBD STnn.Sfty.StartHPb
7
Safety Gate 1
To Be Fault Reset
Determined Pushbutton
TBD SG1.FaultResHpb
8
STnn Pneumatic STnn

Manifold Valve Power STnn Valve Output Power
On(S) Air On and Air On
STnn.Sfty.PMPwr STnn.Utility.AirOn STnn.Utility.OutPwrOn
9
Other Input Signals

RungComment
10
Safety Gate Signals

RungComment
11
Safety
OPnn Gate 1
OPnn_DIO.I.M1.0 SG1.EnterReqHpb
12
RSLogix 5000
Safety Gate 1
Auto/
Cycle
OPnn Start
Compact Pushbutton
OPnn_DIO.I.M1.1 SG1.AStartHpb
13
OPnn
OPnn_DIO.I.M1.3 SG1.GateOpen
14
Utilities Signals:
Air
Water
RungComment
15
STnn STnn STnn

Field Inputs Air On Air On
OPnn_FB1.CommOK OPnn_FB1.I.M1.0 MOV TOF
Source 250 Timer STnn.Utility.AirOnTmr
Preset 0 DN
Dest STnn.Utility.AirOnTmr.PRE Accum 0
0
STnn STnn
Air On
Debounce STnn
Timer Air On
STnn.Utility.AirOnTmr.DN STnn.Utility.AirOn
STnn
Air On
Indicator
STnn.HMI.AirOn_Ind
STnn STnn STnn

Field Inputs Water On Water On
OPnn_FB1.CommOK OPnn_FB1.I.M1.1 MOV TOF
Source 250 Timer STnn.Utility.WtrOnTmr
Preset 0 DN
Dest STnn.Utility.WtrOnTmr.PRE Accum 0
0
STnn STnn
Water On
Debounce STnn
Timer Water On
STnn.Utility.WtrOnTmr.DN STnn.Utility.WtrOn
STnn
Water On
Indicator
STnn.HMI.WtrOn_Ind
(End)
RSLogix 5000
Stack Light Buffer
STnn
Stack Light OPnn
Operator Clear to Compact
Enter Block IO Module 1
STnn.Stk.Green OPnn_DIO.o.M1.0
0
STnn
Stack Light
All / Some OPnn
Parts Compact
Present Block IO Module 1
STnn.Stk.Clear OPnn_DIO.o.M1.1
1
OPnn
STnn Part Request Compact
Beacon Block IO Module 1
STnn.PartReq OPnn_DIO.O.M1.2
2
PVnn
Test
Pb(S)
HMInn.Test_Pb
Safety Gate Outputs

Safety
Gate 1 OPnn
SG1.EnterClrLmp OPnn_DIO.O.M1.3
3
Safety Gate 1
Auto/
Cycle OPnn
Start Compact
SG1.AutoLmp OPnn_DIO.O.M1.4
4
Safety
Gate 1 OPnn
Power On Compact
SG1.FaultLmp OPnn_DIO.O.M1.5
5
Safety
Gate 1 OPnn
Unlock Compact
SG1.UnlockGate OPnn_DIO.O.M1.6
6
***************************************************************************
Map Outputs:
Copy From
to DNet Scanner
***********************************************************************
COP
7 Copy File
Source OPnn_PT1.O
Length 1
***************************************************************************
Map Outputs:
Copy From
to DNet Scanner
***********************************************************************
COP
8 Copy File
Source OPnn_PT2.O
Length 1
***************************************************************************
Map Outputs:
Copy From
to DNet Scanner
***********************************************************************
COP
9 Copy File
Source OPnn_DIO.O
Length 1
(End)
RSLogix 5000
M001_DryModeRestart - Ladder Diagram Page 189
RungComment
0
STnn
Cycle Start STnn
Anti Cell in Robot Dry Cycle
STnn Start Button Tie-Down Dry xxRnn Robot Bypassed Restart
Handstand(H) Timer Mode OPnnDropoffRb.Mode.Bypass Enable
STnn.Sfty.StartHPb STnn.Cyc.AntiTDTmr.DN Cell.Mode.DryMode <xxRnn.Mode.Bypass> STnn.Cyc.DryRestartEn
1 /
STnn
Dry Cycle
Restart
Enable
STnn STnn STnn

2 / / Move
Source 3000
0
STnn
Dry Cycle
Restart
Timer
TON
Timer On Delay EN
Preset 0 DN
Accum 0
(End)
RSLogix 5000
Manual Home PB
Cell STnn STnn
0

OPnn
Motion1 STnn
AtHome Home
Complete Position
1
STnn
Panelview
Home
Position
Panelview Ind
STnn.HMI.Home_Ind

STnn STnn STnn
Preset 0 DN
0
STnn
Line Cycle Start
3 / / / /
STnn STnn
Memory Timer
STnn
Cycle
Start
STnn.Cyc.Start

4 /
STnn
Cycle Start
Memory
STnn.Cyc.StartMem
STnn
Cycle
Start
STnn.Cyc.Start
STnn STnn
Cycle Cycle Start
Start Indicator
5
STnn STnn
Cycle Cycle Start
Start Memory
6 L
STnn Cell STnn

7 / U
STnn STnn
Home Home
Enable Position
Process Complete:
STnn STnn Process
8 U
STnn STnn
Home Home
Enable Position
RSLogix 5000
OPnn
Complete OPnnWeldRbA.Weld.Cpl.0 OPnnWeldRbB.Weld.Cpl.0 OPnnWeldRbC.Weld.Cpl.0 Full Depth)
OPnn_Motion1.Wrk.Cpl <xxRnn.Weld.Cpl.0> <xxRnn.Weld.Cpl.0> <xxRnn.Weld.Cpl.0> STnn.ProcCpl
9 L
Robot Robot Robot
OPnnWeldRbA.Mode.Bypass OPnnWeldRbB.Mode.Bypass OPnnWeldRbC.Mode.Bypass
e STnn
e STnn Process Full
10 e
e
Cycle Complete:
STnn
11 / / / / U
STnn
1st Group
Cell in All Parts
Dry Present
Mode Memory
/

12 L
STnn
STnn Cycle
Cycle Complete
Complete Indicator
13
Stack Light
STnn
14 /
PVnn
Test
Pb(S)
HMInn.Test_Pb
STnn
Stack Light
STnn All / Some
1st Parts Parts
All Present Present
15
STnn
1st Group
Any
Parts System Normal
Present Flasher
PVnn
Test
Pb(S)
HMInn.Test_Pb

STnn
STnn Tool Clear
STnn STnn 1st Group No to Enter For
Cycle Home Parts Robot
Start Position Present Dropoff
STnn.Cyc.Start STnn.Home STnn._1stPP.NotPres STnn.TLArea.0
16

STnn STnn
Cycle complete (formerly Present AtWork Robot
Start Full Depth) Memory Complete Weld
STnn.Cyc.Start STnn.ProcCpl STnn._1stPP.PresMem OPnn_Motion1.Wrk.Cpl STnn.TLArea.1
17 /
STnn STnn
STnn STnn Process STnn All Parts to Enter For
Cycle complete (formerly Home Present Robot
Start Full Depth) Position Memory Pickup
STnn.Cyc.Start STnn.ProcCpl STnn.Home STnn._1stPP.PresMem STnn.TLArea.2
18
RSLogix 5000

STnn STnn Process STnn STnn STnn
Cycle complete (formerly Home 1st Parts 2nd Parts STnn Ready for
Start Full Depth) Position All Present All Present pickup
STnn.Cyc.Start STnn.ProcCpl STnn.Home STnn._1stPP.Pres STnn._2ndPP.Pres STnn.Pos.Pickup
19
STnn
Cycle
Complete
STnn.Cyc.Cpl
STnn
20
STnn
STnn 1st Group No
21
Dropoff on Station
With Cycle Start for OP Stations
STnn
STnn STnn STnn Process STnn 1st Group No
Cycle Cycle complete (formerly Home Parts STnn Ready for 1st
Start Start Full Depth) Position Present Dropoff
STnn.Cyc.Start STnn.Cyc.Start STnn.ProcCpl STnn.Home STnn._1stPP.NotPres STnn.Pos.Dropoff1
22 / /
STnn
STnn Tooling
To Be 1st Parts In Reposition
Determined All Present for Dropoff
TBD STnn._1stPP.Pres STnn.TLInPos.4
23
STnn STnn
24

STnn
1st Group OPnn
STnn STnn Process All Parts Motion1
Cycle complete (formerly Present AtWork STnn Ready for 1st
Start Full Depth) Memory Complete welds
STnn.Cyc.Start STnn.ProcCpl STnn._1stPP.PresMem OPnn_Motion1.Wrk.Cpl STnn.Pos.Weld1
25 /

OPnnDropoffRb.Ctl.AreaClr.2 OPnnWeldRbA.Ctl.AreaClr.1 OPnnWeldRbB.Ctl.AreaClr.1 OPnnWeldRbC.Ctl.AreaClr.1 OPnnPickUpRb.Ctl.AreaClr.1 Clear
26

Robot
OPnnDropoffRb.Ctl.AreaClr.2 Ticking
27 /
Robot
xxRnn Path Segment
Robot Ack
xxRnn Path Segment OPnnDropoffRb.Ctl.PathOk
Equal
STnn Cycle Time
<xxRnn.Ctl.PathSeg>
Ticking
0
STnn
Start pickup
/
Robot
xxRnn Clear of Area
OPnnPickUpRb.Ctl.AreaClr.1
/
EQU STnn.Pos.Pickup
Equal
<xxRnn.Ctl.PathSeg>
0
Source B 10
STnn Cycle Time

Preset 9999999 DN
9999999
RSLogix 5000
STnn
Ticking Shot Start Present OPnnPickUpRb.Ctl.AreaClr.1 STnn Cycle Time
29 / ONS / Move
0
Dest STnn.Cyc.Time
0
STnn Cycle Timer

STnn.Cyc.Timer
RES
(End)
RSLogix 5000
RungComment
0
JSR
JSR
(End)
RSLogix 5000
1st Part Presents
1st set of parts loaded in the station

*************
Replace STnn
With 1st Parts
Used Input Switch
************* Present
InputBuffer STnn._1stPP.PresSw
0

*************
Replace STnn
With 1st Group
Used Input No Parts
************* Present
InputBuffer STnn._1stPP.NotPresSw
1 /
STnn
STnn 1st Group
1st Group Any
No Parts Parts
Present Present
STnn._1stPP.NotPresSw STnn._1stPP.AnyPp
2 /
Dry First Pass: Loads a virtual part right away during the first Dry Mode cycle
Cell in STnn
STnn Start Button Dry Dry Cycle
Handstand(H) Mode Ons First Pass
STnn.Sfty.StartHPb Cell.Mode.DryMode STnn.OneShot.0 STnn.Cyc.DryFirstPass
3 ONS

STnn
STnn 1st Group
Cell in 1st Group All Parts
Mode Present Memory
Cell.Mode.DryMode STnn._1stPP.NotPresSw STnn._1stPP.PresMem
4 / U
Cell in
Dry Robot
Equal
<xxRnn.Ctl.PathSeg>
0
Source B 12
Robot
pickup OPnnPickUpRb.Mode.Bypass
Robot
xxRnn Robot At Home
Stopping pickup OPnnPickUpRb.Sta.Home
STnn
1st Group
Dry 1st Parts Present
Cell.Mode.DryMode STnn._1stPP.Pres STnn._1stPP.PresMem
5 / L
STnn
Cell in 1st Group STnn
Dry No Parts Dry Restart
Mode Present Timer
Cell.Mode.DryMode STnn._1stPP.NotPresSw STnn.Cyc.DryRestartTmr.DN
STnn
Dry Cycle
First Pass
STnn.Cyc.DryFirstPass
Robot
xxRnn Dropoff
Complete
OPnnDropoffRb.Sta.DropCpl.0
<xxRnn.Sta.DropCpl.0>
STnn
Cell in 1st Parts STnn
Dry Switch 1st Parts
Cell.Mode.DryMode STnn._1stPP.PresSw STnn._1stPP.Pres
6 /
STnn
1st Group
Cell in All Parts
Dry Present
Mode Memory
RSLogix 5000
STnn
STnn 1st Group STnn
Cell in 1st Group All Parts 1st Group No
Cell.Mode.DryMode STnn._1stPP.NotPresSw STnn._1stPP.PresMem STnn._1stPP.NotPres
7 / /
Cell in
Dry
Mode
Cell.Mode.DryMode

STnn
1st Group
Part Present
Indicator
MOV
8 Move
Source OPnn_FB1.I.M1
0
Dest STnn._1stPP.Ind
0
RepeatInRung 1stPP InputBuffer:{PPXIO} M1.0:M1.{PPXValue-1}

************* OPnn
Replace Compact
With Block IO
************* Module 1
InputBuffer OPnn_DIO2.O.M1.0
9
PVnn
Test
Pb(S)
HMInn.Test_Pb
2nd Part Present

2nd Set of Parts Loaded in the Station
(Usually Parts Loaded by the Robot)
*************
Replace STnn
With 2nd Parts
Used Input Switch
************* Present
InputBuffer STnn._2ndPP.PresSw
10

*************
Replace STnn
With 2nd Group
Used Input No Parts
************* Present
InputBuffer STnn._2ndPP.NotPresSw
11 /
STnn
STnn 2nd Group
2nd Group Any
No Parts Parts
Present Present
STnn._2ndPP.NotPresSw STnn._2ndPP.AnyPp
12 /

STnn
STnn 2nd Group
Cell in 2nd Group All Parts
Mode Present Memory
Cell.Mode.DryMode STnn._2ndPP.NotPresSw STnn._2ndPP.PresMem
13 / U
Cell in
Dry Robot
Equal
<xxRnn.Ctl.PathSeg>
0
Source B 12
Robot
pickup OPnnPickUpRb.Mode.Bypass
Robot
xxRnn Robot At Home
Stopping pickup OPnnPickUpRb.Sta.Home
RSLogix 5000
STnn
2nd Group
Dry 2nd Parts Present
Cell.Mode.DryMode STnn._2ndPP.Pres STnn._2ndPP.PresMem
14 / L
STnn Robot
Cell in 2nd Group xxRnn Dropoff
Dry No Parts Complete
Mode Present OPnnDropoffRb.Sta.DropCpl.0
Cell.Mode.DryMode STnn._2ndPP.NotPresSw <xxRnn.Sta.DropCpl.0>
STnn Robot
1st Parts xxRnn Robot Bypassed
All Present OPnnDropoffRb.Mode.Bypass
STnn._1stPP.Pres <xxRnn.Mode.Bypass>
STnn
Cell in 2nd Parts STnn
Dry Switch 2nd Parts
Cell.Mode.DryMode STnn._2ndPP.PresSw STnn._2ndPP.Pres
15 /
STnn
2nd Group
Cell in All Parts
Dry Present
Mode Memory
Cell.Mode.DryMode STnn._2ndPP.PresMem
STnn
STnn 2nd Group STnn
Cell in 2nd Group All Parts 2nd Group No
Cell.Mode.DryMode STnn._2ndPP.NotPresSw STnn._2ndPP.PresMem STnn._2ndPP.NotPres
16 / /
Cell in
Dry
Mode
Cell.Mode.DryMode

STnn
2nd Group
Part Present
Indicator
MOV
17 Move
Source OPnn_FB1.I.M1
0
Dest STnn._2ndPP.Ind
0
RepeatInRung 2ndPP InputBuffer:{PPXIO} M1.0:M1.{PPXValue-1}

************* OPnn
Replace Compact
With Block IO
************* Module 1
InputBuffer OPnn_DIO2.O.M1.0
18
PVnn
Test
Pb(S)
HMInn.Test_Pb
Part Present Missing Alarms
(Robot Drop On Station)
Cell Cell in STnn STnn Part Dropoff

Auto Dry Robot 1st Parts Error: Part Present
Mode Mode xxRnn Path Segment STnn Fault Timer All Present Signal Missing
Cell.Mode.Auto Cell.Mode.DryMode EQU STnn._1stPP.Flt_Tmr[0].DN STnn._1stPP.Pres STnn._1stPP.Flt.0
19 / Equal /
STnn Part Dropoff
<xxRnn.Ctl.PathSeg>
STnn Error: Part Present
0
2nd Parts Signal Missing
Source B 31
All Present (2ndPP Set)
STnn._2ndPP.Pres STnn._2ndPP.Flt.0
/
Robot
xxRnn Path Segment STnn Fault Timer STnn Fault Timer
EQU MOV TON
Equal Move Timer On Delay EN
Source A OPnnDropoffRb.Ctl.PathSeg Source 2500 Timer STnn._1stPP.Flt_Tmr[0]
<xxRnn.Ctl.PathSeg> Preset 0 DN
0 Dest STnn._1stPP.Flt_Tmr[0].PRE Accum 0
Source B 32 0
RSLogix 5000
Part Present Failed On Alarms
(Robot Pickup From Station)

STnn
1st Group
Cell Cell in Any STnn Part Pickup
Auto Dry Robot Parts Error: Part Present
Mode Mode xxRnn Path Segment STnn Fault Timer Present Signal Still On
Cell.Mode.Auto Cell.Mode.DryMode EQU STnn._1stPP.Flt_Tmr[1].DN STnn._1stPP.AnyPp STnn._1stPP.Flt.1
20 / Equal
STnn
<xxRnn.Ctl.PathSeg>
2nd Group STnn Part Pickup
0
Any Error: Part Present
Source B 12
Parts Signal Still On
Present (2ndPP Set)
STnn._2ndPP.AnyPp STnn._2ndPP.Flt.1
STnn Fault Timer STnn Fault Timer

MOV TON
Source 2500 Timer STnn._1stPP.Flt_Tmr[1]
Preset 0 DN
Dest STnn._1stPP.Flt_Tmr[1].PRE Accum 0
0
COP
21 Copy File
Source STnn._1stPP.Flt
Dest OPnnAlarms[1]
Length 1
COP
Copy File
Source STnn._2ndPP.Flt
Dest OPnnAlarms[2]
Length 1
(End)
RSLogix 5000
Precondition
OPnn OPnn
0 /
Safety
OPnn
1
Command
OPnn OPnn OPnn OPnn
2 /
OPnn OPnn
/ /
Output
OPnn OPnn OPnn OPnn
3 / /

Buffering OUTPUTS
*************
OPnn Replace
Motion1 With
Work Used Output
Output *************
4

Motion complete
OPnn
OPnn OPnn Motion1
5 /
Panelview Indicator
OPnn OPnn
Motion1 Motion1
6
OPnn
Motion1
Work
Command
OPnn
Motion1
AtWork
Complete
Buffering INPUTS
*************
Replace
With OPnn
************* AtWork
7
Faults
OPnn OPnn
Motion1 Motion1
Work Work
Output Eng Mem
8 L
OPnn OPnn
Motion1 Motion1
Complete On Eng Mem
/ U
RSLogix 5000
OPnn OPnn OPnn OPnn
9 /
OPnn OPnn
Motion1 Motion1
Work Work
Flt Timer Flt Timer
MOV TON
Preset 0 DN
0
OPnn
Motion1 Cyy
OPnn AtWork /
10
OPnn
Motion1 Cyy
/
OPnn
Motion1 Cyy
OPnn Did Not Reach
Motion1 Cyy AtWork
AtHome Position
/

COP
11 Copy File
Dest OPnnAlarms[1]
Length 1
(End)
RSLogix 5000
S010_MotionNutFeed1 - Ladder Diagram Page 201
Precondition
STnn Process
OPnn MotionNutFeed1 complete (formerly OPnn MotionNutFeed1
Feed Safety Full Depth) Feed Precondition
OPnn_MotionNutFeed1.Feed.Saf STnn.ProcCpl OPnn_MotionNutFeed1.Feed.Pre
0 /
Safety
Cell STnn STnn
Safeties STnn Light Screen Valve Output Power Robots OPnn MotionNutFeed1
Reset Reset and Air On Clear Feed Safety
Cell.Rst STnn.Sfty.LsRst STnn.Utility.OutPwrOn STnn.RobClr OPnn_MotionNutFeed1.Feed.Saf
1
Command
Cell STnn
Auto Cycle OPnn MotionNutFeed1 OPnn MotionNutFeed1 OPnn MotionNutFeed1 OPnn MotionNutFeed1 OPnn MotionNutFeed1
Mode Start Feed Precondition Feed Memory Feed Complete Feed Safety Feed Command
Cell.Mode.Auto STnn.Cyc.Start OPnn_MotionNutFeed1.Feed.Pre OPnn_MotionNutFeed1.Feed.Mem OPnn_MotionNutFeed1.Feed.Cpl OPnn_MotionNutFeed1.Feed.Saf OPnn_MotionNutFeed1.Feed.Cmd
2 / /
Cell
Manual OPnn MotionNutFeed1
Mode Feed Pushbutton
Cell.Mode.Man OPnn_MotionNutFeed1.Feed.Pb
OPnn MotionNutFeed1
Feed Command
OPnn_MotionNutFeed1.Feed.Cmd
Output
Cell
Safeties OPnn MotionNutFeed1 OPnn MotionNutFeed1
Reset Feed Command Feed Output
Cell.Rst OPnn_MotionNutFeed1.Feed.Cmd OPnn_MotionNutFeed1.Feed.Out
3
Buffering OUTPUTS
*************
Replace
With
OPnn MotionNutFeed1 Used Output
Feed Output *************
OPnn_MotionNutFeed1.Feed.Out OutputBuffer
4
Motion complete
If More than One nut from the same feeder, replace _Sel_1_ accordingly
Degensha Automatic
Degensha Automatic Dual Unit Nut Feeder
Dual Unit Nut Feeder Interface
Interface Rev 1 Feed Complete OPnn MotionNutFeed1
OPnn MotionNutFeed1 Rev 1 Feed Select 1 - Ready To Start Feed Complete Delay OPnn MotionNutFeed1
Feed Output Delay Timer Weld Timer Feed Complete
OPnn_MotionNutFeed1.Feed.Out OPnn_NutFeeder1.Feed_Sel_1_Delay.DN OPnn_NutFeeder1.Feed_Cpl OPnn_MotionNutFeed1.Feed.TCompl.DN OPnn_MotionNutFeed1.Feed.Cpl
5
OPnn MotionNutFeed1
Feed Complete Delay
Timer
MOV
Move
Source 500
Dest OPnn_MotionNutFeed1.Feed.TCompl.PRE
0
OPnn MotionNutFeed1
Feed Complete Delay
Timer
TON
Timer On Delay EN
Timer OPnn_MotionNutFeed1.Feed.TCompl
Preset 0 DN
Accum 0
Feed Complete Memory

OPnn MotionNutFeed1 OPnn MotionNutFeed1 OPnn MotionNutFeed1
Feed Output Feed Complete Feed Memory
OPnn_MotionNutFeed1.Feed.Out OPnn_MotionNutFeed1.Feed.Cpl OPnn_MotionNutFeed1.Feed.Mem
6 L
Feed Complete Memory Reset

STnn
Cycle OPnn MotionNutFeed1
Complete Feed Memory
STnn.Cyc.Cpl OPnn_MotionNutFeed1.Feed.Mem
7 U
STnn STnn
Home Home
Enable Position
Panelview Indicator
OPnn MotionNutFeed1 System Normal OPnn MotionNutFeed1
Feed Precondition Flasher Feed Indicator
OPnn_MotionNutFeed1.Feed.Pre System.Flsh.Norm OPnn_MotionNutFeed1.Feed.Ind
8
OPnn MotionNutFeed1
Feed Command
OPnn_MotionNutFeed1.Feed.Cmd
OPnn MotionNutFeed1
Feed Memory
OPnn_MotionNutFeed1.Feed.Mem
RSLogix 5000
S010_MotionNutFeed1 - Ladder Diagram Page 202
Feed Faults
Degensha Automatic
Dual Unit Nut Feeder
Interface
Field Module 1 OPnn MotionNutFeed1 Rev 1 Feed Select 1 OPnn MotionNutFeed1 OPnn MotionNutFeed1 OPnn MotionNutFeed1
Comm OK Feed Output Delay Timer Feed Fault Timer Feed Complete Feed Fault
OPnn_FB2.CommOK OPnn_MotionNutFeed1.Feed.Out OPnn_NutFeeder1.Feed_Sel_1_Delay.DN OPnn_MotionNutFeed1.Feed.Tmr.DN OPnn_MotionNutFeed1.Feed.Cpl OPnn_MotionNutFeed1.Feed.Flt
9 /
OPnn MotionNutFeed1
Feed Fault Timer
MOV
Move
Source 3000
Dest OPnn_MotionNutFeed1.Feed.Tmr.PRE
0
OPnn MotionNutFeed1
Feed Fault Timer
TON
Timer On Delay EN
Timer OPnn_MotionNutFeed1.Feed.Tmr
Preset 0 DN
Accum 0
(End)
RSLogix 5000
S010_MotionWeldGun1 - Ladder Diagram Page 203
Gun Close Precondition
STnn Process
MotionWeldGun1 Close complete (formerly MotionWeldGun1 Close
Safeties Full Depth) Precondition
OPnn_MotionWeldGun1.Cls.Saf STnn.ProcCpl OPnn_MotionWeldGun1.Cls.Pre
0 /
Gun Close Safety

Cell STnn STnn OPnn_WC01
Safeties STnn Light Screen Valve Output Power Robots No MotionWeldGun1 Close
Reset Reset and Air On Clear Faults Safeties
Cell.Rst STnn.Sfty.LsRst STnn.Utility.OutPwrOn STnn.RobClr OPnn_WCU1.NoFaults OPnn_MotionWeldGun1.Cls.Saf
1
Gun Close Command

Cell STnn
Auto Cycle MotionWeldGun1 Close Weld Control MotionWeldGun1 Close MotionWeldGun1 Close
Mode Start Precondition Rev. 0 Complete Safeties Command
Cell.Mode.Auto STnn.Cyc.Start OPnn_MotionWeldGun1.Cls.Pre OPnn_MotionWeldGun1.Weld.Cpl OPnn_MotionWeldGun1.Cls.Saf OPnn_MotionWeldGun1.Cls.Cmd
2 /
WC01
MotionWeldGun1 Close Is
Command Firing
OPnn_MotionWeldGun1.Cls.Cmd OPnn_WCU1.Firing
Cell STnn
Manual MotionWeldGun1 Close MotionWeldGun1 Open Home Enable
Mode Pushbutton Pushbutton Pushbutton
Cell.Mode.Man OPnn_MotionWeldGun1.Cls.Pb OPnn_MotionWeldGun1.Opn.Pb STnn.HMI.Home_Pb
/ /
MotionWeldGun1 Close WC01
Command Is
OPnn_MotionWeldGun1.Cls.Cmd Firing
OPnn_WCU1.Firing
Gun Close Output

Cell
Safeties MotionWeldGun1 Close MotionWeldGun1 Close
Reset Command Output
Cell.Rst OPnn_MotionWeldGun1.Cls.Cmd OPnn_MotionWeldGun1.Cls.Out
3
Buffering OUTPUTS
*************
Replace
With
MotionWeldGun1 Close Used Output
Output *************
OPnn_MotionWeldGun1.Cls.Out OutputBuffer
4

Motion complete
OPnn OPnn OPnn

MotionWeldGun1 Close MotionWeldGun1 Cyy MotionWeldGun1 Cyy MotionWeldGun1 Cyy
Output Nut Present AtWork AtHome
OPnn_MotionWeldGun1.Cls.Out OPnn_MotionWeldGun1_Cyy.PX3 OPnn_MotionWeldGun1_Cyy.PX2 OPnn_MotionWeldGun1_Cyy.PX1
5 /
Weld Control
Rev. 0
MotionWeldGun1 Close MotionWeldGun1 Close
Complete Delay Timer Complete
OPnn_MotionWeldGun1.Cls.TCompl.DN OPnn_MotionWeldGun1.Cls.Cpl
Weld Control
Rev. 0
Complete Delay Timer Complete Delay Timer
MOV TON
Source 1000 Timer OPnn_MotionWeldGun1.Cls.TCompl
Preset 1000 DN
Dest OPnn_MotionWeldGun1.Cls.TCompl.PRE Accum 0
1000

OPnn
MotionWeldGun1 Close MotionWeldGun1 Cyy MotionWeldGun1 Open
Output AtHome Complete
OPnn_MotionWeldGun1.Cls.Out OPnn_MotionWeldGun1_Cyy.PX1 OPnn_MotionWeldGun1.Opn.Cpl
6 /
Weld Command
Current
Cell Schedule
Auto STnn MotionWeldGun1 Close To Fire
Mode Water On Complete (From WC)
Cell.Mode.Auto STnn.Utility.WtrOn OPnn_MotionWeldGun1.Cls.Cpl MOV
7 Move
Source 1
Cell
Manual Weld Control
Dest OPnn_WCU1.Schedule
Mode Rev. 0 Pushbutton
0
Cell.Mode.Man OPnn_MotionWeldGun1.Weld.Pb
Weld Control
WC01 Rev. 0 Output
Is OPnn_MotionWeldGun1.Weld.Out
Firing
OPnn_WCU1.Firing
Weld complete
WC01 WC01
MotionWeldGun1 Close Initiate OPnn_WC01d Weld Control
Output Weld Complete Rev. 0 Complete
OPnn_MotionWeldGun1.Cls.Out OPnn_WCU1.InitiateWeld OPnn_WCU1.WeldComplete OPnn_MotionWeldGun1.Weld.Cpl
8 L
RSLogix 5000
Weld Complete Reset
STnn
Cycle Weld Control
Complete Rev. 0 Complete
STnn.Cyc.Cpl OPnn_MotionWeldGun1.Weld.Cpl
9 U
STnn STnn
Home Home
Enable Position
Panelview Indicator
MotionWeldGun1 Close System Normal MotionWeldGun1
Precondition Flasher Closed Indicator
OPnn_MotionWeldGun1.Cls.Pre System.Flsh.Norm OPnn_MotionWeldGun1.Cls.Ind
10
MotionWeldGun1 Close
Command
OPnn_MotionWeldGun1.Cls.Cmd
Complete
OPnn_MotionWeldGun1.Cls.Cpl
Panelview Indicator
MotionWeldGun1 Close System Normal MotionWeldGun1 Open
Command Flasher Indicator
OPnn_MotionWeldGun1.Cls.Cmd System.Flsh.Norm OPnn_MotionWeldGun1.Opn.Ind
11 /
MotionWeldGun1 Open
Complete
OPnn_MotionWeldGun1.Opn.Cpl
Weld Complete Panelview Indicator

MotionWeldGun1 Close Weld Control System Normal Weld Control
Complete Rev. 0 Complete Flasher Rev. 0 Indicator
OPnn_MotionWeldGun1.Cls.Cpl OPnn_MotionWeldGun1.Weld.Cpl System.Flsh.Norm OPnn_MotionWeldGun1.Weld.Ind
12 /
Weld Control
Rev. 0 Complete
OPnn_MotionWeldGun1.Weld.Cpl
Buffering INPUTS
*************
Replace
With OPnn
Used Input MotionWeldGun1 Cyy
************* AtWork
InputBuffer OPnn_MotionWeldGun1_Cyy.PX2
13
Buffering INPUTS
*************
Replace
With OPnn
Used Input MotionWeldGun1 Cyy
************* AtHome
InputBuffer OPnn_MotionWeldGun1_Cyy.PX1
14
Close Faults
Weld Control
Rev. 0
Field Module 1 MotionWeldGun1 Close MotionWeldGun1 Close MotionWeldGun1 Close MotionWeldGun1 Close
Comm OK Output Fault Timer Complete Fault
OPnn_FB2.CommOK OPnn_MotionWeldGun1.Cls.Out OPnn_MotionWeldGun1.Cls.Tmr.DN OPnn_MotionWeldGun1.Cls.Cpl OPnn_MotionWeldGun1.Cls.Flt
15 /
Weld Control
Rev. 0
MOV TON
Source 3000 Timer OPnn_MotionWeldGun1.Cls.Tmr
Preset 0 DN
Dest OPnn_MotionWeldGun1.Cls.Tmr.PRE Accum 0
0
OPnn
MotionWeldGun1 Cyy
AtWork /
OPnn OPnn AtHome
MotionWeldGun1 Close MotionWeldGun1 Cyy MotionWeldGun1 Cyy Both PX
OPnn_MotionWeldGun1.Cls.Flt OPnn_MotionWeldGun1_Cyy.PX1 OPnn_MotionWeldGun1_Cyy.PX2 OPnn_MotionWeldGun1_Cyy.Flt.0
16
OPnn
MotionWeldGun1 Cyy
MotionWeldGun1 Cyy MotionWeldGun1 Cyy AtHome
OPnn_MotionWeldGun1_Cyy.PX2 OPnn_MotionWeldGun1_Cyy.PX1 OPnn_MotionWeldGun1_Cyy.Flt.1
/
OPnn
MotionWeldGun1 Cyy
OPnn Did Not Reach
MotionWeldGun1 Cyy AtWork
AtHome Position
OPnn_MotionWeldGun1_Cyy.PX1 OPnn_MotionWeldGun1_Cyy.Flt.2
/
RSLogix 5000
If gun is closed but PX3 is not made, the nut is missing, so the Feed/Weld cycle has to be retried
Weld Control
OPnn OPnn OPnn Rev. 0 OPnn
MotionWeldGun1 Close MotionWeldGun1 Cyy MotionWeldGun1 Cyy MotionWeldGun1 Cyy MotionWeldGun1 Close MotionWeldGun1 Cyy
Fault AtHome AtWork Nut Present Retry Counter No Nut Detected
OPnn_MotionWeldGun1.Cls.Flt OPnn_MotionWeldGun1_Cyy.PX1 OPnn_MotionWeldGun1_Cyy.PX2 OPnn_MotionWeldGun1_Cyy.PX3 OPnn_MotionWeldGun1.Cls.RetryCntr.DN OPnn_MotionWeldGun1_Cyy.Flt.6
17 / / /
Weld Control
Rev. 0
Retry Counter
MOV
Move
Source 3
Dest OPnn_MotionWeldGun1.Cls.RetryCntr.PRE
3
Retry Counter
CTU
Count Up CU
Counter OPnn_MotionWeldGun1.Cls.RetryCntr
Preset 3 DN
Accum 0
OPnn
Weld Control MotionWeldGun1 Cyy
Rev. 0 No Nut Detected
MotionWeldGun1 Close after Max Number of
Retry Counter Retries
OPnn_MotionWeldGun1.Cls.RetryCntr.DN OPnn_MotionWeldGun1_Cyy.Flt.7
Open Faults
Weld Control
Rev. 0
Field Module 1 MotionWeldGun1 Close MotionWeldGun1 Open MotionWeldGun1 Open MotionWeldGun1 Open
Comm OK Output Fault Timer Complete Fault
OPnn_FB2.CommOK OPnn_MotionWeldGun1.Cls.Out OPnn_MotionWeldGun1.Opn.Tmr.DN OPnn_MotionWeldGun1.Opn.Cpl OPnn_MotionWeldGun1.Opn.Flt
18 / /
Weld Control
Rev. 0
MotionWeldGun1 Open MotionWeldGun1 Open
MOV TON
Source 3000 Timer OPnn_MotionWeldGun1.Opn.Tmr
Preset 0 DN
Dest OPnn_MotionWeldGun1.Opn.Tmr.PRE Accum 0
0
OPnn
MotionWeldGun1 Cyy
AtWork /
OPnn OPnn AtHome
MotionWeldGun1 Open MotionWeldGun1 Cyy MotionWeldGun1 Cyy Both PX
OPnn_MotionWeldGun1.Opn.Flt OPnn_MotionWeldGun1_Cyy.PX1 OPnn_MotionWeldGun1_Cyy.PX2 OPnn_MotionWeldGun1_Cyy.Flt.3
19
OPnn
MotionWeldGun1 Cyy
MotionWeldGun1 Cyy MotionWeldGun1 Cyy AtWork
OPnn_MotionWeldGun1_Cyy.PX1 OPnn_MotionWeldGun1_Cyy.PX2 OPnn_MotionWeldGun1_Cyy.Flt.4
/
OPnn
MotionWeldGun1 Cyy
OPnn Did Not Reach
MotionWeldGun1 Cyy AtHome
AtWork Position
OPnn_MotionWeldGun1_Cyy.PX2 OPnn_MotionWeldGun1_Cyy.Flt.5
/
MotionWeldGun1 Close OPnn_WC01

Fault No Fault OPnn WC01 Weld Fault
OPnn_MotionWeldGun1.Cls.Flt OPnn_WC01.I.NoFault OPnn_WC01.Flt.0
20 /
OPnn_WC01 Medar Weld
No Fault Controller
OPnn_WC01.I.NoFault OPnn_WC01.Flt.1

COP
21 Copy File
Source OPnn_MotionWeldGun1_Cyy.Flt
Dest OPnnAlarms[1]
Length 1
(End)
RSLogix 5000
Precondition
OPnn OPnn
0
Safety
OPnn
1
Command
OPnn OPnn OPnn OPnn
2 /
OPnn OPnn
Manual Home Work
/
STnn
Home
Enable
STnn.HomeEn
Output
OPnn OPnn OPnn OPnn
3 / /

Buffering OUTPUTS
*************
OPnn Replace
Motion1 With
Home Used Output
Output *************
4

Motion complete
OPnn
OPnn OPnn Motion1
5 /
Panelview Indicator
OPnn OPnn
Motion1 Motion1
6
OPnn
Motion1
Home
Command
OPnn
Motion1
AtHome
Complete
Buffering INPUTS
*************
Replace
With OPnn
************* AtHome
7
Faults
OPnn OPnn
Motion1 Motion1
Home Home
Output Eng Mem
8 L
OPnn OPnn
Motion1 Motion1
Complete On Eng Mem
/ U
RSLogix 5000
OPnn OPnn OPnn OPnn
9 /
OPnn OPnn
Motion1 Motion1
Home Home
Flt Timer Flt Timer
MOV TON
Preset 0 DN
0
OPnn
Motion1 Cyy
OPnn AtWork /
10
OPnn
Motion1 Cyy
/
OPnn
Motion1 Cyy
OPnn Did Not Reach
Motion1 Cyy AtHome
AtWork Position
/
(End)
RSLogix 5000
V001_DegenshaNutFeeder - Ladder Diagram Page 208
Feed Select: Replace the TBD bits with the .Cmd bits from the corresponding Motion block
Degensha Automatic
OPnn MotionNutFeed1 Interface
Feed Command Rev 1 Feed Request 1
OPnn_MotionNutFeed1.Feed.Cmd OPnn_NutFeeder1.Feed_Req_1
0
Degensha Automatic
OPnn MotionNutFeed1 Interface
Feed Command Rev 1 Feed Request 2
OPnn_MotionNutFeed1.Feed.Cmd OPnn_NutFeeder1.Feed_Req_2
1
Feed Select Arbitration

Degensha Automatic Degensha Automatic Degensha Automatic
Dual Unit Nut Feeder Dual Unit Nut Feeder Dual Unit Nut Feeder
Interface Interface Interface
Rev 1 Feed Request 1 Rev 1 Feed Select 2 Rev 1 Feed Select 1
OPnn_NutFeeder1.Feed_Req_1 OPnn_NutFeeder1.Feed_Sel_2 OPnn_NutFeeder1.Feed_Sel_1
2 /
Degensha Automatic
Interface
Rev 1 Feed Select 1
Delay Timer
MOV
Move
Source 250
Dest OPnn_NutFeeder1.Feed_Sel_1_Delay.PRE
0
Degensha Automatic
Interface
Rev 1 Feed Select 1
Delay Timer
TON
Timer On Delay EN
Timer OPnn_NutFeeder1.Feed_Sel_1_Delay
Preset 0 DN
Accum 0
Degensha Automatic Degensha Automatic Degensha Automatic

Dual Unit Nut Feeder Dual Unit Nut Feeder Dual Unit Nut Feeder
Interface Interface Interface
Rev 1 Feed Request 2 Rev 1 Feed Select 1 Rev 1 Feed Select 2
OPnn_NutFeeder1.Feed_Req_2 OPnn_NutFeeder1.Feed_Sel_1 OPnn_NutFeeder1.Feed_Sel_2
3 /
Degensha Automatic
Interface
Rev 1 Feed Select 2
Delay Timer
MOV
Move
Source 250
Dest OPnn_NutFeeder1.Feed_Sel_2_Delay.PRE
0
Degensha Automatic
Interface
Rev 1 Feed Select 2
Delay Timer
TON
Timer On Delay EN
Timer OPnn_NutFeeder1.Feed_Sel_2_Delay
Preset 0 DN
Accum 0
Buffering INPUTS
Degensha Automatic
************* Dual Unit Nut Feeder
Replace Interface
With Rev 1 Feed Complete
Used Input - Ready To Start
************* Weld
InputBuffer OPnn_NutFeeder1.Feed_Cpl
4
Buffering OUTPUTS
*************
Degensha Automatic Replace
Dual Unit Nut Feeder With
Interface Used Output
Rev 1 Feed Select 1 *************
OPnn_NutFeeder1.Feed_Sel_1 OutputBuffer
5
*************
Degensha Automatic Replace
Dual Unit Nut Feeder With
Interface Used Output
Rev 1 Feed Select 2 *************
OPnn_NutFeeder1.Feed_Sel_2 OutputBuffer
Degensha Automatic *************

Dual Unit Nut Feeder Replace
Interface With
Rev 1 Feed Select 1 Used Output
Delay Timer *************
OPnn_NutFeeder1.Feed_Sel_1_Delay.DN OutputBuffer
Degensha Automatic
Interface
Rev 1 Feed Select 2
Delay Timer
OPnn_NutFeeder1.Feed_Sel_2_Delay.DN
RSLogix 5000
V001_DegenshaNutFeeder - Ladder Diagram Page 209
Faults
Degensha Automatic
OPnn MotionNutFeed1 Interface OPnn Nut Feeder
Feed Fault Rev 1 Feed Select 1 Failed to feed Nut 1
OPnn_MotionNutFeed1.Feed.Flt OPnn_NutFeeder1.Feed_Sel_1 OPnn_NutFeeder1.Flt.0
6
Degensha Automatic
OPnn MotionNutFeed1 Interface OPnn Nut Feeder
Feed Fault Rev 1 Feed Select 2 Failed to feed Nut 2
OPnn_MotionNutFeed1.Feed.Flt OPnn_NutFeeder1.Feed_Sel_2 OPnn_NutFeeder1.Flt.1
7
COP
8 Copy File
Source OPnn_NutFeeder1.Flt
Dest OPnnAlarms[1]
Length 1
(End)
RSLogix 5000
W001_MedarMidFreq - Ladder Diagram Page 210
***************************************************************************
Map signals from DNet Scanner into Medar-Specific UDT
***********************************************************************
Medar Weld
Node 0 Status Node 0 Controller Medar
OK - Medium Frequency
Active and Weld Control -
Not Faulted Inputs
OPnn_WC01_Node.OK Rev. 0
<DNet07.node[0].OK> COP
0 Copy File
Dest OPnn_WC01.I
Length 1
WC01
Comm
OK
OPnn_WC01.CommOK
Medar Weld
Node 0 Status Node 0 Controller Medar
OK - Medium Frequency
Active and Weld Control -
Not Faulted Inputs
OPnn_WC01_Node.OK Rev. 0
<DNet07.node[0].OK> FLL
/ Fill File
Source 0
Dest OPnn_WC01.I
Length 1
***************************************************************************
Map signals from Medar-Specific UDT to DNet Scanner
***********************************************************************
COP
1 Copy File
Source OPnn_WC01.O
Length 1
Medar Medium Frequency

Weld Control Logic
WC01 OPnn_WC01
Comm OPnn_WC01 No
OK No Fault Faults
OPnn_WC01.CommOK OPnn_WC01.I.NoFault OPnn_WCU1.NoFaults
2
WC01 WC01 WC01

Comm Weld Weld
OK Mode ON Mode
OPnn_WC01.CommOK OPnn_WC01.I.WeldMode OPnn_WCU1.WeldMode
3
WC01
WC01 WC01 WC01 WC01 WC01 Ready
Comm OPnn_WC01 Weld Weld Contactor Weld To
OK No Fault Complete In Progress Open Mode ON Weld
OPnn_WC01.CommOK OPnn_WC01.I.NoFault OPnn_WC01.I.ProcCmplt OPnn_WC01.I.InProgrss OPnn_WC01.I.ContactorOpen OPnn_WC01.I.WeldMode OPnn_WCU1.ReadyToWeld
4 / /
WC01
Contactor Saver
Enable
OPnn_WC01.O.EnContact
WC01
Initiate
Weld
OPnn_WC01.O.InitWeld
WC01 WC01 WC01 WC01

Initiate Weld Comm OPnn_WC01d
Weld Complete OK Complete
OPnn_WCU1.InitiateWeld OPnn_WC01.I.ProcCmplt OPnn_WC01.CommOK OPnn_WCU1.WeldComplete
5
WC01
OPnn_WC01d
Complete
OPnn_WCU1.WeldComplete
WC01 WC01 WC01 WC01

Initiate Comm OPnn_WC01 Weld Is
Weld OK No Fault In Progress Firing
OPnn_WCU1.InitiateWeld OPnn_WC01.CommOK OPnn_WC01.I.NoFault OPnn_WC01.I.InProgrss OPnn_WCU1.Firing
6
WC01
Is
Firing
OPnn_WCU1.Firing
WC01 WC01
Weld Not
Complete Firing
OPnn_WC01.I.ProcCmplt OPnn_WCU1.SeqDone
7
OPnn_WC01
No Fault
OPnn_WC01.I.NoFault
/
WC01
Comm
OK
OPnn_WC01.CommOK
/
RSLogix 5000
WC01
WC01 WC01 Contactor
Comm Contactor Is
OK Open Open
OPnn_WC01.CommOK OPnn_WC01.I.ContactorOpen OPnn_WCU1.ContactorOpen
8
Select Schedule #0 when resetting steppers

WC01 Current
WC01 Stepper Schedule
Reset Initiate Is To Fire
Steppers Weld Reset (From WC)
OPnn_WCU1.ResetSteppers OPnn_WC01.O.InitWeld OPnn_WC01.I.StepReset CLR
9 / / Clear
Dest OPnn_WCU1.Schedule
0
Check for valid schedule number

Current Current
Schedule Schedule The Schedule
To Fire To Fire Selected
(From WC) (From WC) Is Valid
GEQ LEQ OPnn_WC01.ValidSchedule
10 Grtr Than or Eql (A>=B) Less Than or Eql (A<=B)
Source A OPnn_WCU1.Schedule Source A OPnn_WCU1.Schedule
0 0
Copy weld schedule number to weld schedule select inputs and make sure it doesn't change during welding
Structure for an
Medium Frequency
Weld Control
Current
WC01 The Schedule Schedule WC01
Initiate Selected To Fire Comm Medar Weld
Weld Is Valid (From WC) OK Controller Data1
OPnn_WC01.O.InitWeld OPnn_WC01.ValidSchedule OPnn_WCU1.Schedule.0 OPnn_WC01.CommOK OPnn_WC01.O.Data1
11 /
WC01
Initiate Medar Weld
Weld Controller Data1
OPnn_WC01.O.InitWeld OPnn_WC01.O.Data1
Structure for an
Medium Frequency
Weld Control
Current
12 /
WC01
Initiate Medar Weld
Structure for an
Medium Frequency
Weld Control
Current
13 /
WC01
Initiate Medar Weld
Structure for an
Medium Frequency
Weld Control
Current
14 /
WC01
Initiate Medar Weld
Structure for an
Medium Frequency
Weld Control
Current
15 /
WC01
Initiate Medar Weld
WC01 The Schedule WC01 WC01

Initiate Selected Comm Initiate
Weld Is Valid OK Weld
OPnn_WCU1.InitiateWeld OPnn_WC01.ValidSchedule OPnn_WC01.CommOK OPnn_WC01.O.InitWeld
16
RSLogix 5000
WC01 WC01 WC01 WC01
Weld Mode Initiate Comm Weld
Request Weld OK Mode
OPnn_WCU1.WeldModeReq OPnn_WCU1.InitiateWeld OPnn_WC01.CommOK OPnn_WC01.O.WeldMode
17 /
WC01 WC01 WCU
Weld Initiate Mode Request
Mode Weld Delay
OPnn_WC01.O.WeldMode OPnn_WCU1.InitiateWeld MOV
Move
Source 500
Dest OPnn_ModeChng.PRE
0
WCU
Mode Request
Delay
TON
Timer On Delay EN
Timer OPnn_ModeChng
Preset 0 DN
Accum 0
alarm:SXXX WCU 1 Has a Weld Fault

WC01
Comm OPnn_WC01 STnn Utility Fault
OK No Fault Word
OPnn_WC01.CommOK OPnn_WC01.I.NoFault STnn.UtilityFaults_Ina.20
18 /
alarm:SXXX WCU 1 Weld Requested Not in Weld
WC01 WCU WC01

Comm Mode Request Weld STnn Utility Fault
OK Delay Mode ON Word
OPnn_WC01.CommOK OPnn_ModeChng.DN OPnn_WC01.I.WeldMode STnn.UtilityFaults_Ina.21
19 /
alarm:SXXX WCU 1 Schedule is Not Valid
Current
WC01 Schedule
Initiate To Fire STnn Utility Fault
Weld (From WC) Word
OPnn_WCU1.InitiateWeld LES STnn.UtilityFaults_Ina.22
20 Less Than (A<B)
Source A OPnn_WCU1.Schedule
0
Source B 0
Current
Schedule
To Fire
(From WC)
GRT
Greater Than (A>B)
Source A OPnn_WCU1.Schedule
0
Source B 31
alarm:SXXX Contactor Did Not Close

WC01 WC01 WC01 WC01 Contactor
Contactor Comm Weld Initiate Not Closed
Open OK Mode Weld Fault Timer
OPnn_WC01.I.ContactorOpen OPnn_WC01.CommOK OPnn_WC01.O.WeldMode OPnn_WCU1.InitiateWeld MOV
21 Move
Source 500
Dest OPnn_ConClsdFltTmr.PRE
0
Contactor
Not Closed
Fault Timer
TON
Timer On Delay EN
Timer OPnn_ConClsdFltTmr
Preset 0 DN
Accum 0
Contactor
Not Closed STnn Utility Fault
Fault Timer Word
OPnn_ConClsdFltTmr.DN STnn.UtilityFaults_Ina.23
WC01 WC01
Comm Contactor Contactor Saver
OK Saver Enable
OPnn_WC01.CommOK OPnn_WCU1.ContactorSaver OPnn_WC01.O.EnContact
22
WC01
WC01 WC01 Stepper Medar Weld
Comm Reset Initiate Is Controller Caps
OK Steppers Weld Reset Changed
OPnn_WC01.CommOK OPnn_WCU1.ResetSteppers OPnn_WC01.O.InitWeld OPnn_WC01.I.StepReset OPnn_WC01.O.CChanged
23 / /
Medar Weld
Controller Caps
Changed
OPnn_WC01.O.CChanged
RSLogix 5000
WC01 WC01 WC01 WCU
Comm Reset Initiate OPnn_WC01 Fault Reset
OK Faults Weld No Fault Hold Timer
OPnn_WC01.CommOK OPnn_WCU1.ResetFaults OPnn_WC01.O.InitWeld OPnn_WC01.I.NoFault MOV
24 / / Move
Source 500
WCU
Fault Reset
Dest OPnn_FaultResetTimer.PRE
Hold Timer
0
OPnn_FaultResetTimer.EN
WCU
Fault Reset
Hold Timer
TON
Timer On Delay EN
Timer OPnn_FaultResetTimer
Preset 0 DN
Accum 0
WC01
Fault
Reset
OPnn_WC01.O.FaultReset
(End)
RSLogix 5000
W002_WeldCommon - Ladder Diagram Page 214
This rung initiates the weld.

Each weld step shall initiate a weld, in parallel to any other weld step.
WC01 WC01
Weld Control OPnn_WC01d Initiate
Rev. 0 Output Complete Weld
OPnn_MotionWeldGun1.Weld.Out OPnn_WCU1.WeldComplete OPnn_WCU1.InitiateWeld
0 /
Weld Control
Rev. 0 Output
OPnn_MotionWeldGun1.Weld.Out
WC01
Initiate
Weld
OPnn_WCU1.InitiateWeld
For Automatic Stations with No Operator Interface

REPLACE Cyc.Start & Utility.OutputPower
WITH Mode.Auto
Cell STnn
Safeties Cycle STnn Light Screen Contactor
Reset Start Reset Saver
Cell.Rst STnn.Cyc.Start STnn.Sfty.LsRst OPnn_WCU1.ContactorSaver
1
Steppers and Faults

Reset
Reset
Steppers
OPnn_WCU1.ResetSteppers
2 AFI
OPnn_WC01 WC01
No STnn Start Button Reset
Faults Handstand(H) Faults
OPnn_WCU1.NoFaults STnn.Sfty.StartHPb OPnn_WCU1.ResetFaults
3 /
PVCell
Fault Reset
Pushbutton
(Hardware)
HMICell.FltrstHpb
Cell
Dry Cycle WC01
Mode Weld Mode
Cell Enable On Request
Cell.Mode.Wld.En Cell.Mode.DryOn OPnn_WCU1.WeldModeReq
4 /
(End)
RSLogix 5000
RungComment
0
DeviceNet Faults
RungComment
1

Enable
OPnn_DIONode.Enable
2
DeviceNet Module
Not Faulted Power On Timer OPnn_DIONode.Faulted OPnn_DIONode.FaultedMem
PVCell STnn
OPnn_DIONode.FaultedMem (Hardware) STnn.UtilityFaults_Ina.8
/

OPnn_DIONode.Active DNet Node Not Active
<DNet07.Node[0].Active> STnn.UtilityFaults_Ina.9
/

Enable
OPnn_DIO2Node.Enable
3
DeviceNet Module
Not Faulted Power On Timer OPnn_DIO2Node.Faulted OPnn_DIO2Node.FaultedMem
PVCell STnn
Node 0 Status Node 0 Fault Reset Compact Block I/O #2
OPnn_DIO2Node.FaultedMem (Hardware) STnn.UtilityFaults_Ina.10
/

Active In Scanlist Compact Block I/O #2
OPnn_DIO2Node.Active DNet Node Not Active
/

Enable
OPnnFB1Node.Enable
4
DeviceNet Module
Not Faulted Power On Timer OPnnFB1Node.Faulted OPnnFB1Node.FaultedMem
PVCell STnn
OPnnFB1Node.FaultedMem (Hardware) STnn.UtilityFaults_Ina.12
/

OPnnFB1Node.Active DNet Node Not Active
/

Enable
OPnnFB2Node.Enable
5
DeviceNet Module
Not Faulted Power On Timer OPnnFB2Node.Faulted OPnnFB2Node.FaultedMem
PVCell STnn
OPnnFB2Node.FaultedMem (Hardware) STnn.UtilityFaults_Ina.14
/

OPnnFB2Node.Active DNet Node Not Active
/
RSLogix 5000
Enable
OPnnPT1Node.Enable
6
DeviceNet Module
Not Faulted Power On Timer OPnnPT1Node.Faulted OPnnPT1Node.FaultedMem
PVCell STnn
Node 0 Status Node 0 Fault Reset PT1
OPnnPT1Node.FaultedMem (Hardware) STnn.UtilityFaults_Ina.16
/

Active In Scanlist PT1
OPnnPT1Node.Active DNet Node Not Active
/

STnn.Sfty.Mod1Flt STnn.UtilityFaults_Ina.18
7 L
STnn Safety IO STnn 2nd Safety IO

STnn.Sfty.Mod2Flt STnn.UtilityFaults_Ina.19
8 L
COP
9 Copy File
Dest OPnnAlarms[0]
Length 1
(End)
RSLogix 5000

RSLogix 5000 Report(s) PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

RSLogix 5000 Report(s) PDF

Uploaded by

Copyright:

Available Formats

A000_Main - Ladder Diagram Page 1

Cosma:MainTask:CELL 11/11/2010 1:27:29 PM

Global Cell/PV PVCell

System 1st Output

CONTROLLER BATTERY LOW

TYPICAL INPUT MODULE FAULT

Monitor the module I.Fault word & clear input image

INPUT/OUTPUT MODULE FAULTS

One JSR is required for every DNB module

To use this file:

===== DeviceNet Module Slot 7 =====

DeviceNet Power On Timer

Place DeviceNet Power Circuit Breaker in this rung. If more than

Alarm: DNet Scanner Slot 07 Not At Node 0

DeviceNet Module DeviceNet Module DNet Scanner

===== DeviceNet Module Slot 8 =====

DeviceNet Power On Timer

Place DeviceNet Power Circuit Breaker in this rung. If more than

Alarm: DNet Scanner Slot 07 Not At Node 0

DeviceNet Module DeviceNet Module DNet Scanner

Cell At least one

Safety Gate 1 Cell At least one

Force Clear to Enter if waiting for more than 45 sec

Clear To Enter Gate

Standard Structure Standard Structure

Standard Structure Standard Structure

Safety Gate1 Enter Request

Standard Structure Standard Structure

Standard Structure Standard Structure

Safety Gate Outputs

Standard Structure Auxiliary Data type

Standard Structure Auxiliary Data type

Cell Auto Auto

PVCell Cell Auto Cell

Weld Mode Logic

Cell Toggle Request Cell Enable Cell Disable

Cell Stop Requests

************ Dry Cycle Mode *************

Cell Cell Cell

PVCell Cell Delay when Cell Delay when

Line Run-Out Mode

Cell Line Line

******** Cell Status Indicators ********

Shift Change Logic

Calculate the elapsed hours since the start of the shift

Dest Prod.CurrHour Dest Prod.CurrHour

Style Number Logic

Reset Part Counters 15 minutes before the beginning of each shift

Cell Cycle time Measurement

Shift 3 STnn DownTime

**** Repeat this rung for every OP ****

**** Repeat this rung for every Robot ****

Use this rung to clear all of the members of ClrRejectInfo

**** Repeat this rung for every OP ****

**** Repeat this rung for every OP ****

**** Repeat this rung for every OP ****

**** Repeat this rung for every Robot ****

STnn Robot Cell Air On Debounce Cell Air On Debounce

Cell Air On Debounce Cell

System Flasher Timer System Slow Flasher

System Flasher Timer System Fast Flasher

Cell Any Stepper

Dry Cycle Mode *

Cell Status Indicators

Repeat this rung for every OP

Repeat this rung for every Robot

Repeat this rung for every OP

Repeat this rung for every OP

Repeat this rung for every OP

Repeat this rung for every Robot

Repeat this rung for every OP .1:.{Counter=1}

Repeat this rung for every Panelview .0:.{Counter=0}

Repeat this rung for every Panelview .8:.{Counter=8}

Repeat this rung for every Robot .0:.{Counter=0}

Repeat this rung for every OP .0:.{Counter=0}

Repeat this rung for every OP .0:.{Counter=0}

Repeat this rung for every Robot .0:.{Counter=0}

Repeat this rung for every OP ].0:].{Counter=0}

Repeat this rung for every OP ].0:].{Counter=0}

Repeat this rung for every Robot ].0:].{Counter=0}

Repeat this rung for every Robot .0:.{Counter=0}

Repeat this rung for every Robot .0:.{Counter=0}

Repeat this rung for every Robot .0:.{Counter=0}

Repeat this rung for every Robot .0:.{Counter=0}

Repeat this rung for every OP [1]:[{Counter=1}]

Repeat this rung for every Robot [1]:[{Counter=1}]

Repeat this rung for every OP [1]:[{Counter=1}]

Repeat this rung for every Robot [1]:[{Counter=1}]

Repeat this rung for every Robot [1]:[{Counter=1}]

Repeat this rung for every Robot [1]:[{Counter=1}]

Repeat this rung for every OP [1]:[{Counter=1}]

Repeat this rung for every Robot [1]:[{Counter=1}]