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System: AVI Title: AVI Training Manual Chapter 5: Plant Floor Install and Config
Owner: APICS Page 1 of 44 Revision: 1.2
Document: Chp5 Plant Floor Installation & Configuration.doc Revised: 2008 Feb 27
Automatic Vehicle Identification System (AVI)
Training Manual
Chapter 5: Plant Floor Installation & Configuration
System: AVI Title: AVI Training Manual Chapter 5: Plant Floor Install and Config
Owner: APICS Page 2 of 44 Revision: 1.2
Document: Chp5 Plant Floor Installation & Configuration.doc Revised: 2008 Feb 27
TABLE OF CONTENTS
1 PLANT FLOOR DRIVER INSTALLATION AND CONFIGURATION........................4 1.1 OVERVIEW ..............................................................................................................................4
1.2 PLC-5 BACKGROUND INFORMATION - SOFTWARE PACKAGE OF USP .....................................5
1.3 PLC-5 INSTALLATION - EQUIPMENT .......................................................................................6
1.4 PLC-5 INSTALLATION - SOFTWARE ........................................................................................6
1.5 PLC-5 CONFIGURATION - HARDWARE....................................................................................8
1.6 PLC-5 CONFIGURATION - SOFTWARE LOGIC ..........................................................................9
1.7 PLC-5 CONFIGURATION - SOFTWARE DATA VIA UNIFIED SYSTEMS CONFIGURATOR.............9
1.8 PLC-5 CONFIGURATION - SOFTWARE DATA VIA MANUAL CONFIGURATION..........................9
1.9 PLC-5 CONFIGURATION - FIS.................................................................................................9
1.10 PLC-5 STARTING UP ...........................................................................................................9
1.11 PLC-5 AVI SUPERVISOR PLC CONFIGURATION..................................................................9
1.12 CLX BACKGROUND INFORMATION - SOFTWARE PACKAGE ..................................................9
1.13 CLX INSTALLATION - EQUIPMENT .......................................................................................9
1.14 CLX INSTALLATION - SOFTWARE ........................................................................................9
1.15 CLX CONFIGURATION - HARDWARE....................................................................................9
1.16 CLX CONFIGURATION - SOFTWARE LOGIC ..........................................................................9
1.17 CLX CONFIGURATION - SOFTWARE DATA VIA MANUAL CONFIGURATION..........................9
1.18 CLX CONFIGURATION - FIS.................................................................................................9
1.19 CLX STARTING UP ..............................................................................................................9
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Document Revision History
Date Revision
Number
Name Description (include pages affected)
2008 Feb 27 1.2 Mas40 Change name to Chrysler
2007 Feb 16 1.1 MAS40 Updated PLC-5 OEM File 80 DB dwell time. Section 1.6.9
2006 Dec15 1.0 MAS40 2006 AVI Training Manual Update Project
Supporting Documentation
The DaimlerChrysler documents listed below are instrumental in defining this chapter's systems and
its configuration.
Doc. No. Rev. Date Title Link
AMS 0220
Section 4.2.3
2.2 2005 Aug 1 Book of Implmentation Guidelines:
Programming and Memory Requirements
for PLC-5
DCX BOIG web site
AMS 0220
Section 5.4.2
1.5 2006 Feb 1 Book of Implmentation Guidelines:
Design & Installation Requirements for
DNet
DCX BOIG web site
AMS 0220
Section 14.2.1
2.1 2004 Jan 05 Book of Implmentation Guidelines:
AVI/VMS Driver Installation &
confiuration for PLC-5
DCX BOIG web site
AMS 0220
Section 14.2.2
2.1 2004 Jan 05 Book of Implementation Guidelines:
AVI/VMS Reader Comm & Config for
PLC-5
DCX BOIG web site
AMS 0220
Section 14.2.3
2.1 2004 Jan 05 Book of Implementation Guidelines:
AVI/VMS Implementation Guideline for
PLC-5
DCX BOIG web site
AMS 0220
Section 14.3.1
1.0 2005 Aug 31 Book of Implmentation Guidelines:
AVI/VMS Driver Installation &
confiuration for CLx
DCX BOIG web site
AMS 0220
Section 14.3.3
1.0 2004 Aug 15 Book of Implementation Guidelines:
AVI/VMS Implementation Guideline for
CLx
DCX BOIG web site
AMS 0220
Section 14.3.4
1.1 2005 Aug 01 Book of Implementation Guidelines:
AVI Dnet Reader Install & Conifig for
CLx
DCX BOIG web site
3.0 2004 Dec 10 APICS USD PLC Manual Configuration DCX APICS web site
1.0 APICS USC Configuration DCX APICS web site
1756-IN566B-
EN-P
2001 April AB ControlLogix DeviceNet Scanner
Install Instructions
AB web site
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1 PLANT FLOOR DRIVER INSTALLATION AND CONFIGURATION
1.1 Overview
The order of an AVI floor installation is as follows:
1. Equipment installation
2. Download software
3. Configure the PLC
4. Configure the hardware
5. Configure the software
6. Start up the application
�
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1.2 PLC-5 Background information - Software package of USP
For the ITM PLC-5 floor systems, a common structure was set up among the applications
of AVI, FIS and PFCS. This formed the Unified Systems Platform (USP). From within
the common structure, the platform contained several sections: PLC code/drivers (USD),
operator interfaces (USD PanelView files), configuration (USC) and emulators (USE).
1.2.1 Unified Systems Driver (USD)
The Unified Systems Driver (USD) is PLC logic designed to integrate multiple plant
processes (AVI, FIS, and PFCS) in one common package. When used in conjunction
with its associated Unified System Configurator (USC), the integrator is able to
configure these processes with one common interface. By providing the USD and the
USC to the systems integrator, the software in each PLC becomes a uniform standard
throughout the corporation.
The USD provides the following benefits:
� DCX Plant floor IT systems are linked using a predefined program and data file
structure, eliminating the possibility of memory overlap.
� Customized machine interface logic is minimized, which aids in maintaining logic
standardization across the corporation.
� PLC configuration may be saved for later use or printed out in an easily readable
format using the associated USC.
� Common tools for configuration ensure consistency from one AVI point to the
next.
1.2.2 Unified Systems Configurator (USC)
The Unified Systems Configurator (or USC) is a PLC GUI designed specifically to
configure the Unified Systems Driver in an easy-to-use/easy-to-understand manner:
� The tool stores configuration data in an MS Access database format, this means
the Unified Systems Driver can be configured even before the actual PLC program
is created.
� When configuration data is downloaded into a PLC, only the data tables are
changed, which eliminates the need for complex, manual changes in ladder logic,
which could result in mistakes or errors.
� It provides a reporting tool for visual certification of proper configuration, thus
aiding in error proofing the configuration before it is downloaded into a PLC.
1.2.3 Unified Systems Emulator (USE)
The Unified Systems Emulator is a Visual Basic application that emulates the actions
of a DCX UNIX workcell for AVI and PFCS. This allows testing of floor
configuration to be done outside of the plant.
�
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1.3 PLC-5 Installation - Equipment
The floor equipment is mostly outlined in Chapter 3 Plant Floor Vehicle Identification.
The recommended equipment installation order for a new AVI point is:
1. PLC (unless installed in an OEM PLC)
2. PLC cards: DB or RB in recommended slot 4, and DCM in recommended slot 7
3. Floor readers and associated hubs
4. Communication medium from floor readers to PLC
5. Communication medium from PLC to AVI Supervisor PLC
1.4 PLC-5 Installation - Software
1.4.1 PLC-5 Software
The AVI PLC-5 software is known as the USD AVI (see section 1.2.1 Unified
Systems Driver).
For a complete installation, two additional software components are required
� USD Common
� USD FIS
Also, AVI has several optional software sub modules
� USD AVI Marriage - Used at Plant Marriage setup
� USD Style Setup - Used on Style Setups
� USD AVI GS GN Compare - Used on QAS2 TNG setups
All PLC-5 software can be downloaded from the APICS web site. It is recommended
that an APICS or ASLM team member verify the versions of the downloaded software
modules. It will typically always be the latest version.
BOIG document 14.2.1 Section 3 (PLC-5 Memory requirements) goes in detail of the
layout of the program files and data files of the PLC-5 software.
1.4.2 PLC-5 Paste Files
Follow the outline given in the BOIG document 14.2.1 Section 4 for the step by step
instructions in pasting the AVI driver.
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1.4.3 PLC-5 PanelView paste file
The standard AVI paste file distributed with the USD includes logic to support one
PanelView.
Use PanelBuilder software to download the screens into the PanelView terminal.
The AVI PanelView driver is located in program file 80. It can support up to 10
PanelViews of the following types:
� 1200e Keypad or Touchscreen
� 1400e Keypad or Touchscreen
� 1000e Keypad or Touchscreen
The driver supports PanelViews using RIO communications. (DH+ communication is
not supported at this time.)
The USD contains the PanelView file for screen numbers 249 through 254. The OEM
will paste these screens into the Panel Builder software and include these screens in
their main menu.
The screens use two block transfer files:
� B5: used for the BTW
� B6: used for the BTR.
In addition, the PanelView file contains a discreet input word, for reporting the screen
number to the PLC, and a discreet output word, for the PLC controlled screen number.
The discreet input and output words, N275:138 and N275:139, can be found under
“PLC I/O Control” in the Panel Builder software.
If an AVI Point has one or more PanelViews associated with it, the user must:
� Load these screens into the PanelView(s).
� Configure the AVI Driver to communicate with the PanelView(s).
� Add support logic as required (if multiple PanelViews are used).
�
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1.5 PLC-5 Configuration - Hardware
This section provides the information necessary to configure the following hardware to
communicate with AVI (not all used in all AVI projects):
♦ Allen-Bradley 2760-RB Flexible Interface Module
♦ Allen-Bradley 1771-DB Basic Module
♦ Allen-Bradley 1771-DCM-B Direct Communications Module
♦ Allen-Bradley 1771-SDN DeviceNet Scanner Module
1.5.1 A-B 2760-RB Flexible Interface Module
The RB module will require some parameters to be entered and some DIP switches
set. The parameters are entered via a terminal session (HyperTerminal). Such a
session is created by connecting a null modem cable to the configuration port of a PC.
After connecting, the configuration menu needs to be invoked. To invoke the
configuration menu send the RB a BREAK command. Parameter and switch settings
are shown in the BOIG Section 14.2.2, AVI/VMS Reader Communications &
Configuration for PLC-5.
Complete the following to configure an RB module (Figure 5-1). Settings of switches
SW1 and SW2 may need to be changed depending on the slot addressing of the rack
(single or 2 slot).
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Figure 5-1: A-B 1771-RB Flexible Interface Module Switch Locations
Switch SW3
Switches SW3 & SW4
are located under here.
Switch SW4
Switches SW1 &
SW2 Switches SW1 &
SW2 are located on
top of the RB
Memory module
2760-SFC2 plugged
into Protocol A
Serial cables plugs
into this
Configuration Port
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1.5.1.1 A-B 1771-RB Flexible Interface Module Configuration Steps
1. Set all switches in switch bank SW1 to off.
2. Set all switches in switch bank SW2 to off, except the second, which must be ON for
single slot addressing, or OFF for 2 slot addressing.
3. The switches in switch banks SW3 and SW4 configure ports 1, 2, and 3 for either RS-232
or RS-422 communications. Set the switches as shown in the BOIG 14.2.2 Appendix B.
4. Plug in protocol A Module (2760-SFC2).
5. Power up the RB module by providing power to the chassis.
6. Plug into the configuration port with a standard RS-232 null modem cable.
7. Open the Terminal.exe file.
8. Send a CTRL BREAK command to the RB module to initiate the software configuration
menu.
9. Set all ports to dumb ASCII terminals using option 3 before continuing to the detailed
configuration.
Note: Using terminal session option 3, set all ports to “2760-SFC2 DT” Dumb Terminal.
Note: See BOIG document section 14.2.2 section 8.0 2760-RB Configuration settings for
correct settings and code.
10. Send a CTRL BREAK.
11. Using option 11 for port 1, option 12 for port 2, option 13 for port 3 and set software
configurations to the settings in the BOIG 14.2.2 Appendix B.
Note: Use terminal session option 11, 12, or 13 to configure each port.
Note: Enter “90A” to reset the RB if needed.
12. Using terminal session option C, exit configuration.
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1.5.1.2 DB Module Hardware and Software Configuration
Figure 5-2: Allen-Bradley 1771-DB Module Switch & Jumper Locations (B Module Shown)
Hard reset
Switch
JW1 switch
location
Jumper switches
JW2 - JW7
JW1 switch
location
Jumper switches
JW8 & JW9
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1.5.1.3 A-B 1771-DB Series A Basic Module Configuration Steps
The basic code can be found in BOIG document 14.2.2 section 9.0 DB Module Basic
program (series A)
Complete the following to configure an A-B 1771 DB Series A module.
1. Set peripheral port jumper to 9600 (side of module).
2. Connect to program port using a null-modem cable, load the basic program using MS
Window terminal, and press [CTRL + C], or secure EEPROM containing the program
listed in the BOIG 14.2.2 Appendix C (series A).
3. Load in the program by using “Send Text File.” The file is called db_a_vms.txt
4. Ensure the program is loaded as shown above. If it is incorrect, correct the data strings.
5. Type “run”, then press “Enter” (program is then installed and running).
6. Disconnect null-modem cable.
1.5.1.4 A-B 1771-DB Series B Basic Module Configuration Steps
The basic code can be found in the BOIG document 14.2.2 section 10.0 DB Module Basic
program (series B).
Complete the following to configure an A-B 1771 DB Series B module.
Set jumpers on DB module (series B) as listed below.
Jumper Setting Description
JW1 Watchdog Enabled (default)
JW2 8K/32K EEPROM 8K PROM (default)
JW3 Speed Turbo
JW4 PRT1=PGM, PRT2=ASCII, DH485=RUN (default)
JW5 16 Point Back Plane (depending on rack configuration)
JW6 PRT2 1200 Baud Rate
JW7 Battery Enabled
JW8 PRT1 Protocol (RS232)
JW9 PRT2 Protocol (RS232)
Table 5-1: Set Jumpers on DB Module (Series B)
1. Connect to port 1 with a terminal and load the program listed below. Connect to Port 1 by
using the STD.TRM and press [CTRL + C].
2. Load in the program as shown in the BOIG 14.2.2 Appendix D (series B).
3. Disconnect and change configuration jumper JW4 to PRT1=ASCII, PRT2=ASCII, and
DH485=PGM to make both ports available for reader connections.
4. Change JW6 PRT2 back to 9600 Baud Rate.
5. Set JW8 and JW9 according to input connections (RS422 or RS232). RS232 is optional
depending on the length (contact ITM personal before using RS232).
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1.5.2 Direct Communications Module (DCM) Switch Settings
Figure 5-3: A-B 1771-B Direct Communications Module (DCM) Switch Locations
DCM Module
switch banks
DCM Module
switch banks
If using a three
prong Phoenix
plug, use the top
three prongs
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1.5.2.1 A-B 1771-DCM-B Direct Communications Module Configuration Steps
Complete the following to configure an A-B 1771 DCM-B module (Figure 5-3) that is
used to connect to the AVI supervisor PLC.
To configure the DCM module, switches in bank 0 and bank 1 must be set. There are eight
switches in each bank as shown in Figure 5-4.
Figure 5-4: DCM Switch Settings
�
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1.6 PLC-5 Configuration - Software Logic
1.6.1 Ladder logic file 80
The OEM is required to make ladder logic changes on each installation of AVI. These
are changes that cannot be accommodated via data table adjustments.
All the bit changes are listed in the BOIG document 14.2.1 section 5.5 Interface
Programming - bits. The following components are addressed:
� Sensor Blocks: I/O address for in position, vehicle leaving and empty carriers
◊ In Position: The vehicle in position sensor will signal the AVI driver that a Read
condition should have occurred. If the reader did not read a bar code, it declares a No
Read condition.
◊ Vehicle Leaving: The vehicle-leaving sensor will signal the AVI driver that a carrier
is leaving the zone and the AVI driver should stop any requests and clear data.
◊ Empty Carrier: The empty carrier sensor will signal the AVI driver to declare an
"empty carrier" or turn on the reader beam if no empty carrier is present.
� AVI Mode: I/O address for a AVI conveyor interlock bypass mode
� Read: Address of signal whenever the reader reads a label
� No-Read: Address of signal when the reader did not read label but should have
� Data Auto Delivered: Address of signal that data is ready to the OEM software
and reset upon 'OEM Data Accept' or a vehicle leaving switch
� OEM Data Accept: Address of signal that that the OEM software has obtained
the vehicle ID
� Data Style Mismatch: Address of signal that the OEM software does not agree
with the style of the vehicle delivered.
� AVI Timeout: Address of signal that the OEM software has waited past the time
it expected to wait for AVI to finish its functions.
� AVI Systems Fault: Address of signal that the OEM can use list conditions that
will turn on the AVI Systems Fault light and FIS fault bit
� Reader Beam On: Address of signal to turn the reader beam on
� Read Beam Off: Address of signal to turn the reader beam off
All the PanelView communication changes are listed in the BOIG document 14.2.1
section 5.7 PanelView Configuration. The following components are addressed:
� PanelView - Communication to the operator terminal.
All the Reader communication changes are listed in the BOIG document 14.2.1
section 5.8 RB / DB Configuration. The following components are addressed:
� RB/DB - Communication to the Reader
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1.6.2 Sensor Blocks
Sensor blocks are defined as the block of logic per reader area which indicates to the
driver a No-Read condition, an event counter, communication to the reader to turn on
its beam to read the barcode label and to turn off its beam as the read is complete.
Each sensor block tells the driver to count statistical information, when a no-read
occurs, when an empty carrier arrives, and when the vehicle leaves. This requires
OEM input of in position IO, leaving IO and empty carrier IO. Sensor block addresses
are in increments of 10 words starting at PLC address N281:10.
Note: The first sensor block is word for configuration 18, the second is word 28, the
third is word 38, and so on. There are a maximum of 99 sensor blocks available.
Replace the “AFI’s” in Figure 5-5 logic with the required plant specific inputs or
internal signals.
Figure 5-5: Sensor Block Logic
1.6.3 AVI Mode
This signal tells the AVI driver if it is being bypassed. This signal does not stop the
driver from running or processing any data. The driver will still request build data,
send up statuses, and send up indexes. This signal is used to flag the WCC and FIS
that the driver is in bypass. This signal causes the OEM logic to perform differently.
The OEM will not hold up the line for AVI responses or release the carrier on an AVI
vehicle release timeout if the station is in AVI bypass mode. This rung is programmed
as follows:
Note: For the first point, the address for the AVI mode coil is N282:25/00. For the
second point, the address would be 50 words higher, so the address would be
N282:75/00. In the logic shown in Figure 5-6, the “AFI’s” are to be replaced with the
required plant specific inputs or internal signals.
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Figure 5-6: AVI Mode Logic
1.6.4 Data Style Mismatch
The OEM sets this signal to notify the plant floor operator through an FIS alarm that
AVI delivered style does not match the style detected in station. (AVI is not alarmed,
only FIS!). It is the OEM’s responsibility to keep the station from cycling and to have
an appropriate operating procedure in place to deal with this type of fault. This rung is
programmed as follows:
Note: For the first point, the address for the Data Style Mismatch coil is N282:25/01.
For the second point, the address would be 50 words higher, so the address would be
N282:75/01. In the logic shown in Figure 5-7, the “AFI” must be replaced with the
required plant specific input or internal signal.
Figure 5-7: Data Style Mismatch Logic
1.6.5 OEM Data Accept
The OEM sets this signal to notify the AVI driver that the OEM accepted the data. The
OEM sets this signal after the AVI driver has set the Data Auto Delivered signal and
the OEM has accepted the data and stored the data to other data table areas. The Data
Auto Delivered signal is used by the OEM to know when data is delivered from the
workcell. This signal is set when the driver receives a valid response from the AVI
WCC. This signal is reset when the OEM turns on Data Accept or the vehicle leaves.
Note: For the first point, the address for the Data Accept coil is N282:25/02. For the
second point, the address would be 50 words higher, so the address would be
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N282:75/02. In the logic shown in Figure 5-8, the “AFI” must be replaced with the
required plant specific input or internal signalable areas.
Figure 5-8: OEM Data Accept Logic
1.6.6 Reader Beam On/Off
The empty signal carrier of the AVI driver is used to turn on the reader arm. The OEM
is required to associate the correct sensor block logic. When the empty carrier is
blocked (unit approaches) the reader beam should be turned on. When the empty
carrier is not blocked or at the leave signal (unitl well past the reader) the reader beam
should be turned off.
Note: For the first point, the address for the AVI Timeout contact is N282:25/3. For
the second point, the address would be 50 words higher, so the address would be
N282:75/3.
Figure 5-9: Reader Beam On/Off
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1.6.7 AVI Timeout
The OEM is supplied an AVI driver timeout so the OEM knows that the vehicle has
been sitting in the stop past the time that was set for AVI to finish its function (Figure
5-10). This time is set in the Configuration. This timer is supplied so AVI does not
always have to hold a vehicle at a stop. This signal is not used at all points; it should
not be used at critical AVI points. It will be the OEM’s responsibility to verify with
AVI personnel if this signal should be used.
Note: For the first point, the address for the AVI Timeout contact is N282:25/12. For
the second point, the address would be 50 words higher, so the address would be
N282:75/12.
AVI Driver
AVI OEM
Timeout Logic
N282:25/12 XX:XX/XX
--| |-------------------------------------( )—
Figure 5-10: AVI Timeout Logic
1.6.8 PanelView Driver Configuration
When the standard AVI USD logic is pasted into the PLC, the BTR and BTW
instructions for the PanelView each have a Rack, Group, and Slot value of 0. These
values shall not be changed in the logic, as the USC will change those values when
downloading the point configuration to the PLC.
The discreet inputs and outputs are not setup, however, by the USC, and must be
manually configured in the Logic:
� The discrete input word is represented in the standard driver by N275:138. This
must be replaced by the actual input word (Figure 5-11 and Error! Reference
source not found.).
� The discreet output word is represented in the standard driver by N275:139. This
must be replaced by the actual output word (Figure 5-11 and Figure 5-12).
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Figure 5-11: PanelView Support Logic
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Figure 5-12: AVI USD PanelView Support Logic (continued)
1.6.9 RB/DB Module Support Logic
The standard driver is supplied with the first module programmed. If more than one
module is needed, the OEM will need to copy the following rungs for the first module,
and re-address them for the module needed. These rungs reside in File #80.
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The dwell time has to be adjusted according to the activity encountered in the module.
The time in the GRT instruction shown Figure 5-13 needs to be set as follows
1 set of points, 300 (3 seconds)
2-3 set of points 500 (5 seconds)
4-5 set of points 700 (7 seconds)
Figure 5-13: Module dwell timer logic
Note: There are 2 temporary words in the rung logic used as placeholders for the RB
module RG address. They must be changed to I:RG for the appropriate location. For
example, if the RB module is in Rack 0, Group 4, the address is I:004
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Figure 5-14: RB/DB Module Support Logic
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Figure 5-15: RB/DB Module Support Logic (Continued)
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Figure 5-16: RB/DB Module Support Logic (Continued)
�
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1.7 PLC-5 Configuration - Software Data via Unified Systems Configurator
Once the driver is pasted into the PLC, it will need to be configured. This is done by
using the Unified Systems Configurator (USC). The installer has the option of
configuring the system via the manual configuration (manually changing data table
address values). Although the driver can be manually configured, it is not
recommended due to the complexity of the AVI driver. The USC can be used to
configure the USD. However, your computer must be connected to a PLC prior to
downloading the configuration to a PLC.
Note: It is not possible to configure the driver while offline at this time.
Note: USC may not be updated to support the latest USD versions. Check with APICS on
this regard.
1.7.1 USC System Requirements
To install and use the USC, your computer must meet the following requirements:
� Windows 9x, 2000, XP (will not work with Windows NT).
� Full version of RS Linx (will not work with RS Linx Lite), version 2.0 or higher.
� 10 MB free hard drive space
� 32 MB of RAM
See document APICS USC Configuration for the installation and usage of the USC
application.
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1.8 PLC-5 Configuration - Software Data via Manual Configuration
The same configuration mentioned in Section 1.7 can be done by manually editing data
tables in the PLC.
Please refer to document: APICS AVI USD Manual PLC configuration.
1.9 PLC-5 Configuration - FIS
The USD is loaded on an Allen-Bradley PLC 5/80. Each PLC has an Ethernet side card
for communications with FIS. Configuration is required on both the PLC and the FIS
Workcell. Contact FIS implementation group/plant FIS department for getting updates
done on the FIS Workcell. Like the data entry portion, the data can be edited via the USC
tool or done via manual entry.
1.9.1 Configuration via USD Configuration Tool
The Configuration tool will create a paste file, USDFIS.pc5, for each PLC from a
paste file template. (The most recent template revisions are called UFIS0102.pc5,
UFIS0102.sy5, and UFIS0102.fix.) The paste file will resize the appropriate data
table files and populate the PLC data tables with the required information for FIS
communications when pasted into the PLC. Data for each PLC configuration is stored
in a Microsoft Access database.
1.9.2 Configuration Via Manual Data Entry
1.9.2.1 N75 FIS Processing Data file
# of Datablocks in
Processor
# of Datablocks
Per Scan Status Ethernet
N75: 20 21 30 31
12 12 0=stop
99=restart
0=DH+
1=Ethernet
Figure 5-17: N75
The data words in N75 deals with all the FIS datablocks in the PLC.
1.9.2.2 N80 FIS Datablock Configuration Data File
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N80: 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Point 4910 0 42 30 450 3 48 8 8 20 7 87 3 3 27 0 0 0 0 0
Reader main 4921 0 42 30 450 3 48 8 8 20 7 88 3 3 27 0 0 0 0 0
Reader backup 4922 0 42 30 450 3 48 8 8 20 7 88 33 3 27 0 0 0 0 0
Figure 5-18: N80
Each AVI point and AVI reader have their own entry in N80 datablock definitions.
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Note: Each AVI point FIS data starts at N87:3 and skips 30 words for the next AVI point.
Each AVI reader FIS data starts at N88:3 and skips 30 words for the next AVI reader.
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1.10 PLC-5 Starting Up
The steps below describe how to start up the USD driver:
1. Enable USD
2. Enable AVI
3. Enable FIS driver in N75:30
4. Check all status messages on the PanelView and review all faulted conditions
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1.11 PLC-5 AVI Supervisor PLC Configuration
The Supervisor PLC's main task is to be a data concentrator. It will gather messages
from all the Floor PLCs and the information into one message to the WCC.
The Supervisor PLC talks to the WCC through Ethernet. The packet size to the WCC
is 113 words. The first word is a protocol word and the next 112 words are data words.
The WCC and the Supervisor PLC must be in sync before any data can be transferred
back and forth. The Supervisor PLC and AVI Workcell use Data Strobes and Echoes
for a communication handshake that the other one received the message. If there is no
message traffic between the Supervisor PLC and WCC for 30 seconds, the Supervisor
PLC will send out a heartbeat (800 hex) in the protocol word.
1.11.1 Adding a Link to Supervisor PLCs
When adding a link to the Supervisor PLC, the plant’s link chart must be used (System
Analysts have control of this document) to figure the RGS address. There can be a
maximum of 60 links to the Supervisor PLC for Block Transfer. USD. FILES N51:0-
N65:0 are the dedicated files that are used if a discrete link is being added. Because of
the nature of the discrete links, certain files have been preprogrammed to handle each
instance. Table 5-2 shows the Discrete Rack and the associated Data Table file that
must be adhered to:
Note: The files shown below can be used for USD or Block Transfer floor drivers, but the
Discrete Floor Drivers (if any) must use these files.
Discrete Rack Data Table File Discrete Rack Data Table File
01 N51:0-499 10 N58:0-499
02 N52:0-499 11 N59:0-499
03 N53:0-499 12 N60:0-499
04 N54:0-499 13 N61:0-499
05 N55:0-499 14 N62:0-499
06 N56:0-499 15 N63:0-499
07 N57:0-499 16 N64:0-499
17 N65:0-499
Table 5-2: Discrete Rack and Associated Data Table Files
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The steps to add a link to the supervisory panel for Block Transfer are shown below.
1. Select a file for the new link. The file must be the next file not in use in the link file
section N11:0 – N70:0.
2. Set file N10:____. Corresponds with the file number (which is now the word for
N:10) selected in step one. The integer value of that word will be set to 500.
Example: If N34: was selected as the new link in data table N10, N10:34 would need to be
created with an integer value of 500.
3. Make memory for the new file to 600 words if it does not already exist.
Example: If N34 is the new file you need to ensure there are 600 words of memory (create
N34:599).
4. Set word two in the new file with the length of the block transfer using an integer
value of 32.
Example: If N34 is the new file, set N34:2 to an integer value of 32.
5. Set word three in the new file with the Rack, Group, and Slot (RGS) value from the
link chart described in Figure 5-19.
Example: If N34 is the new file and the link equaled 45, the rack would equal 14 and
group would equal 0 (group will be 0, 2, 4, or 6), the slot will always equal 0. The integer
value for N34:3 would equal 448 and the binary equivalent would equal 0000 0001 1100
0000.
Reserved for VMS Usage
X XXX X XXXX XXX X XXX
11 8 3 015 12 7 4
RGS Value Layout
Slot Number (0-1)
Rack Number (0-127)
Group Number (0-15)
Reserved Figure 5-19: RGS Layout for Adding a Link to the Supervisory Panel for Block Transfer
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DEVICE LOCATION – CONFIGURE FOR DCM Link
RACK/GROUP/SLOT to Supervisor PLC(RGS Value Layout)
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
MODULE SLOT NUMBER
MODULE GROUP BIT 0
MODULE GROUP BIT 1
MODULE GROUP BIT 2
MODULE GROUP BIT 3
RACK NUMBER BIT 0
RACK NUMBER BIT 1
RACK NUMBER BIT 2
RACK NUMBER BIT 3
RACK NUMBER BIT 4
RACK NUMBER BIT 5
RACK NUMBER BIT 6
RESERVED (SET TO 0)
RESERVED (SET TO 0)
RESERVED (SET TO 0)
RESERVED (SET TO 0)
Table 5-3: N11:0 through N11:70 Bit Layout
6. Set word six in the new file with the link timeout preset (in milliseconds) using an
integer value of 3000.
Example: If N34 is the new file, set N34:6 to an integer value of 3000.
7. Set word nine in the new file to 300. This is the number of free words in the buffer to
the floor.
Example: if N34 is the new file, set N34:9 to an integer value of 300.
8. Set word 10 in the new file to 200. This is the number of words for the load printer.
Example: if N34 is the new file set N34:10 to an integer value of 200.
9. Set word 11 in the new file to 200. This is the number of words for the unload printer.
Example: if N34 is the new file, set N34:11 to an integer value of 200.
10. Set word 12 in the new file to the link number to the WCC. This number is the link
number plus 100, 200, or 300, depending on the Supervisor PLC area (BIW is 100,
Paint is 200, and T/C/F is 300).
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Example: If N34 is the new file and the new link is 45 for BIW, set N34:12 to an integer
value of 145.
11. Set word 13 in the new file to 0-3. 0 = USD, 1 = Block Transfer, 2 = Multiblock, 3 =
Discrete
12. Set word zero, bit zero in the new file to enable link.
Example: If N34 is the new file, set N34:0 bit 0 to 1.
13. Set word zero, bit two in the new file to initialize the link.
Example: If N34 is the new file, set N34:0 bit 2 to 1.
Troubleshooting tip: When adding or reconfiguring causes the processor to fault out,
follow these steps:
1. Reconfigure the link (Steps 1-11).
2. Zero out all words in the link file after word 13.
3. Reinitialize the link (Steps 12-13).
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1.11.2 Supervisor PLC-5 DCM Channel Setting Example
North Body Shop PLC Link : 102Rack/Group : 1/2 Name : South PierceSupv. File : N12
VMS-DCM-150-000
To PLC #2 (Channel 1A)
RIO RIO RIODH+
1A 2B2A1B
North Body Shop PLC Link : 103Rack/Group : 1/4 Name : North PierceSupv. File : N13
VMS-DCM-150-001
VMS-DCM-150-002
VMS-DCM-150-003
North Body Shop PLC Link : 104Rack/Group : 1/6 Name : Pierce VisionSupv. File : N14
VMS-DCM-150-004
North Body Shop PLC Link : 105Rack/Group : 2/0 Name : Cpu-01Supv. File : N15
North Body Shop PLC Link : 101Rack/Group : 1/0 Name : CPU-11Supv. File : N11
VMS-DCM-151-000
South Body Shop PLC Link : 121Rack/Group : 6/0 Name : ARSNTH-1Supv. File : N22
VMS-DCM-151-001
South Body Shop PLC Link : 141Rack/Group : 13/0 Name : URS N-1Supv. File : N32
VMS-DCM-151-002
South Body Shop PLC Link : 122Rack/Group : 6/2 Name : ARSSTH-1Supv. File : N23
South Body Shop PLC Link : 123Rack/Group : 6/4 Name : Roof-1Supv. File : N24
South Body Shop PLC Link : 142Rack/Group : 13/2 Name : URS S-1Supv. File : N33
South Body Shop PLC Link : 143Rack/Group : 13/4 Name : URS GaugeSupv. File : N34
VMS-DCM-152-000
VMS-DCM-152-001
VMS-DCM-152-002
North Body Shop PLC Link : 106Rack/Group : 2/2 Name : Door ShuttleSupv. File : N16
VMS-DCM-150-005
VMS-DCM-150-006
North Body Shop PLC Link : 107Rack/Group : 2/4 Name : CPU-02Supv. File : N17
VMS-DCM-150-007
North Body Shop PLC Link : 108Rack/Group : 2/6 Name : Gap & Flush
Supv. File : N18 Vision
VMS-DCM-150-008
North Body Shop PLC Link : 109Rack/Group : 3/0 Name : Bare Metal
Supv. File : N19 Auto Inspect
VMS-DCM-150-009
North Body Shop PLC Link : 110Rack/Group : 3/2 Name : CPU-05Supv. File : N20
VMS-DCM-151-003
South Body Shop PLC Link : 124Rack/Group : 6/6 Name : Roof GaugeSupv. File : N25
South Body Shop PLC Link : 125Rack/Group : 7/0 Name : CPU-21Supv. File : N26 Toy Tab
VMS-DCM-151-004
VMS-DCM-151-005
South Body Shop PLC Link : 126Rack/Group : 7/2 Name : CPU-22Supv. File : N27
VMS-DCM-151-006
South Body Shop PLC Link : 127Rack/Group : 7/4 Name : CPU-23Supv. File : N28 ARS Pull Off
VMS-DCM-151-007
South Body Shop PLC Link : 128Rack/Group : 7/6 Name : FRMSTH-1Supv. File : N29
South Body Shop PLC Link : 129Rack/Group : 10/0 Name : FRMNTH-1Supv. File : N30
South Body Shop PLC Link : 130Rack/Group : 10/2 Name : FRM GaugeSupv. File : N31
VMS-DCM-151-009
VMS-DCM-151-008
North Body Shop PLC Link : 111Rack/Group : 3/4 Name : CPU-06Supv. File : N21
VMS-DCM-150-010
South Body Shop PLC Link : 144Rack/Group : 13/6 Name : EngineSupv. File : N35
VMS-DCM-152-003
Figure 5-20: Supervisor PLC5 DCM Channel Setting Example
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1.12 CLx Background information - Software package
Upon migrating to the ControlLogix platform, the ITM floor PLC applications of PFCS,
AVI and FIS have less in common. The applications are still PLC drivers but a universal
configuration tool doesn't exist.
1.13 CLx Installation - Equipment
The floor equipment is mostly outlined in Chapter 3 Plant Floor Vehicle Identification.
The recommended equipment installation order for a new AVI point is:
1. PLC (unless installed in an OEM PLC)
2. PLC cards: ITM processor in slot 8, ITM Ethernet in slot 9.
3. Floor readers and associated hubs
4. Communication medium from floor readers to PLC
1.14 CLx Installation - Software
When installing a new AVI point, an AVI point specification document must be
prepared and approved. The approval process may be lengthy depending on many
plant and corporate factors. The AVI point specification document is typically
downloaded and completed by OEM engineering personnel and approved by APICs
personnel during original equipment installation. Plant IT personnel would only need
to complete this process when adding a point where the equipment has already been
accepted (bought off) by the plant.
1.14.1 Obtaining Software
To obtain the AVI ControlLogix point specification document and download the
appropriate AVI driver files, follow the steps below.
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Figure 5-21: DaimlerChrysler Extranet Login Screen
1. Log into the APICs website (Figure 5-21)
Note: Obtain a password to the Extranet website from plant ITM.
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Figure 5-22: APICS Homepage Screen
2. From the APICS home page, select “Systems” from the left side menu (Figure 5-22).
Figure 5-23: Downloads Screen
3. Select “Downloads” from the left side menu.
4. Select “Clx Platform” from the left side menu.
Select
Systems
Select
Downloads
Select CLx
Platform
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Figure 5-24: AVI CLx Driver
5. Select the AVI CLx Driver to download the zip files.
Figure 5-25: AVI CLx Driver Zip Folder
6. From the APICS web site, extract AVI DriveMaster and AVI CommInterface and save
to your programming directory to run in RS Logix5000.
Note: The zip folder contains instructions for upgrading, revision notes, and AVI files.
Select AVI
CLx Driver
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1.14.2 CLx Processor Configurations
Figure 5-26: Open RSLogix 5000
1. Open RS Logix5000 and open the AVI Drive Master file that was just saved (Figure
5-26)
2. Go to I/O configuration and select the OEM PLC.
Figure 5-27: Change modules in I/O configuration
3. Change the properties to the OEM PLC controller as needed (Figure 5-27).
4. Select “Apply.”
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1.14.3 Download to Processor
To download the processor to the CLx follow the steps below:
Figure 5-28: Communication Download
1. Select “Communication” from the menu and click on “Download” (Figure 5-28).
Figure 5-29: Select IP Address
2. Select the IP address and where the program should be downloaded (Figure 5-29).
The IP address can be obtained from the Point Specification Document.
3. Click Download.
1.14.4 DeviceNet Configuration
Refer to BOIG AVI DeviceNet Reader Installation and Configuration for
ControlLogix 14.3.4.
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1.15 CLx Configuration - Hardware
This section provides the information necessary to configure the following hardware to
communicate with AVI (not all used in all AVI projects):
♦ Allen-Bradley 1756 DNB. DeviceNet Scanner
1.15.1 DeviceNet Scanner
Refer to document AB ControlLogix DeviceNet Scanner Installation Instructions for
further details.
Refer to BOIG doc 5.4.2 for DeviceNet standards within the DCX Corporation.
The 1756-DNB module is used in ControlLogix communications systems as the host
device between the CDN-108 module and the PLC.
The DeviceNet Scanner card needs to be configured for a communication baud rate
and a node (MAC) ID address. These settings are per the implementation
documentation.
Figure 5-30: ControlLogix 1756-DNB Module
Button
Readout
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Figure 5-31 DeviceNet Scanner Display and Configuration
The Manual Configuration Pushbutton (Figure 5-31) allows for the scrolling and
setting of the configuration
If your module is not connected to the network:
1. Select the network baud rate by pushing and holding the pushbutton.
Note: The module’s alphanumeric display cycles through the allowable baud rates (125k
250k, 500k).
2. Release the button when the baud rate you want to select is shown on the display.
If your module is connected to the network:
3. Select the network node address by pushing in and holding the pushbutton. The
display starts at the current MAC ID and cycles through all legitimate the network
node addresses (00-63).
4. Release the button when the address you want to select is shown on the display.
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1.16 CLx Configuration - Software Logic
Refer to BOIG 14.3.1 section “6.0 OEM Interface Programming.” The OEM is
responsible for the program file “AVI OEM Custom Interface.” The program file
contains basic rungs and needs to be configured to each plant’s specific needs.
1.17 CLx Configuration - Software Data via Manual Configuration
Refer to BOIG 14.3.1 “AVI Driver Integration for Control Logix.” The subsections are
the same as in “5.0 AVI Driver Configuration” section of the BOIG document.
Refer to BOIG section “7.0 Installing the AVI Interface Programming.”
1.18 CLx Configuration - FIS
See BOIG document 14.3.1 AVI driver installation and configuration for CLx, section
5.16 for FIS configuration.
1.19 CLx Starting Up
Steps for starting up the AVI CLx driver are described below:
1. Enable AVI
2. Check all status messages on the PanelView Plus and review all faulted
messages/indicators
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