flopro prac appl training wk 1 topgun

General Motors Corporation GMPT Romulus Engine

FloPro Practical Applications Training

Manual One

Week One

Rev. 4A (April 30, 1999)

Infinite Systems, Inc. 1100 Centre Road

Auburn Hills, MI 48326 1.800.967.9622

General Motors Corporation Romulus Engine Plant - V8 i

Table of Contents TABLE OF FIGURES..................................................................................................................... VI

1 INTRODUCTION .......................................................................................................................... 1 1.1 OVERVIEW.............................................................................................................................................. 1 1.2 PREREQUISITES ...................................................................................................................................... 1 1.3 COURSE OBJECTIVES .............................................................................................................................. 1

2 INTRODUCTION TO PC BASED CONTROLS AND FLOWCHART PROGRAMMING ........... 3 2.1 OVERVIEW.............................................................................................................................................. 3 2.2 OBJECTIVES ........................................................................................................................................... 3 2.3 OVERVIEW OF PC BASED CONTROLS........................................................................................................ 4 2.4 OVERVIEW OF FLOWCHART PROGRAMMING ............................................................................................... 8 2.5 TYPICAL FLOWCHART GROUPS ................................................................................................................13

3 CREATING AND EDITING A FLOWCHART PROGRAM......................................................... 17 3.1 OVERVIEW.............................................................................................................................................17 3.2 OBJECTIVES ..........................................................................................................................................17 3.3 DETAILED EXECUTABLE FLOWCHARTS......................................................................................................18 3.4 MNEMONICS ..........................................................................................................................................19 3.5 CRITERIA BLOCKS ..................................................................................................................................24 3.6 INSTRUCTION BLOCKS.............................................................................................................................27 3.7 FLOWCHART PROGRAM EXAMPLE ............................................................................................................42

4 INTEGRATING MOTION ........................................................................................................... 47 4.1 OVERVIEW.............................................................................................................................................47 4.2 OBJECTIVES ..........................................................................................................................................47 4.3 FLOWCHART SERVO MOTION...................................................................................................................48 4.4 SERVO MOTION: AXIS BLOCKS................................................................................................................48 4.5 SERVO MOTION: SPINDLE BLOCKS ..........................................................................................................61

5 RUNNING AND TESTING A FLOWCHART PROGRAM.......................................................... 67 5.1 OVERVIEW.............................................................................................................................................67 5.2 OBJECTIVES ..........................................................................................................................................67 5.3 FLOWCHART I/O EXECUTION MODES........................................................................................................68 5.4 FLOWCHART PROGRAM EXECUTION MODES .............................................................................................68 5.5 FLOWCHART DEBUGGER.........................................................................................................................69

6 XYCOM PC/AT FLAT PANEL INDUSTRIAL COMPUTER ...................................................... 77 6.1 OVERVIEW.............................................................................................................................................77 6.2 OBJECTIVES ..........................................................................................................................................77 6.3 OPERATION ...........................................................................................................................................78 6.4 STATUS INDICATORS...............................................................................................................................78 6.5 SYSTEM CHASSIS...................................................................................................................................80 6.6 MAINTENANCE .......................................................................................................................................83 6.7 SAVING / RESTORING RETENTIVE MEMORY...............................................................................................84 6.8 RESCUE DISK OPERATION.......................................................................................................................84

6.8.1 RESCUE DISK Procedure:...................................................................................... 85 6.8.2 UPLOADING Process.............................................................................................. 85 6.8.3 DOWNLOADING Process ....................................................................................... 85

6.9 BLOCK DIAGRAM / PIN OUTS..................................................................................................................87

7 GENIUS NETWORK INTERFACE CARD ................................................................................. 91 7.1 OVERVIEW.............................................................................................................................................91 7.2 OBJECTIVES ..........................................................................................................................................91 7.3 OPERATION ...........................................................................................................................................92 7.4 STATUS INDICATORS...............................................................................................................................92

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7.5 DIAGNOSTICS.........................................................................................................................................92 7.6 CONFIGURATION ....................................................................................................................................93 7.7 REPLACEMENT.......................................................................................................................................95 7.8 CONFIGURATION LAB ..............................................................................................................................96

8 IPN200 ETHERNET / FLONET INTERFACE BOARD.............................................................. 99 8.1 OVERVIEW.............................................................................................................................................99 8.2 OBJECTIVES ..........................................................................................................................................99 8.3 OPERATION .........................................................................................................................................100 8.4 FLONET INTERFACE CONFIGURATION IN IDENTITY.BAT ........................................................................101 8.5 IPN200 ETHERNET/FLONET INTERFACE CONFIGURATION........................................................................102

9 ENHANCED GENIUS COMMUNICATIONS MODULE........................................................... 106 9.1 OVERVIEW...........................................................................................................................................106 9.2 OBJECTIVES ........................................................................................................................................106 9.3 OPERATION .........................................................................................................................................107 9.4 BUS CONNECTION ................................................................................................................................107 9.5 STATUS INDICATORS.............................................................................................................................108 9.6 CONFIGURATION ..................................................................................................................................109 9.7 REPLACEMENT.....................................................................................................................................115 9.8 CONFIGURATION LAB ............................................................................................................................117

10 SERIES 90-30 I/O MODULES ............................................................................................... 119 10.1 OVERVIEW.........................................................................................................................................119 10.2 OBJECTIVES ......................................................................................................................................119 10.3 OPERATION .......................................................................................................................................120 10.4 24 VDC INPUT MODULE .....................................................................................................................120 10.5 24 VDC OUTPUT MODULE..................................................................................................................120 10.6 CONFIGURATION ................................................................................................................................121 10.7 REPLACEMENT...................................................................................................................................121 10.8 CONFIGURATION LAB ..........................................................................................................................122

11 GENIUS DISCRETE I/O BLOCKS ........................................................................................ 124 11.1 OVERVIEW.........................................................................................................................................124 11.2 OBJECTIVES ......................................................................................................................................124 11.3 OPERATION .......................................................................................................................................125 11.4 16 CIRCUIT DC INPUT/OUTPUT BLOCKS...............................................................................................125 11.5 ANALOG INPUT/OUTPUT BLOCKS .........................................................................................................127 11.6 CONFIGURATION ................................................................................................................................129 11.7 I/O USED IN THE FLOWCHARTS............................................................................................................134 11.8 REPLACEMENT...................................................................................................................................136 11.9 CONFIGURATION LAB ..........................................................................................................................139

12 I/O LINK INTERFACE MODULE ........................................................................................... 141 12.1 OVERVIEW.........................................................................................................................................141 12.2 OBJECTIVES ......................................................................................................................................141 12.3 OPERATION .......................................................................................................................................142 12.4 COMMUNICATION................................................................................................................................143 12.5 DIAGNOSTICS.....................................................................................................................................145 12.6 CONFIGURATION ................................................................................................................................146 12.7 REPLACEMENT...................................................................................................................................147 12.8 CONFIGURATION LAB ..........................................................................................................................148

13 HORNER ELECTRIC REMOTE MESSAGE UNIT (RMU) .................................................... 150 13.1 OVERVIEW.........................................................................................................................................150 13.2 OBJECTIVES ......................................................................................................................................150 13.3 HORNER ELECTRIC RMU....................................................................................................................150 13.4 RMU BASIC FUNCTIONS .....................................................................................................................151 13.5 OPERATOR INTERFACE UNIT FEATURES ...............................................................................................151 13.6 REPLACEMENT...................................................................................................................................152

General Motors Corporation Romulus Engine Plant - V8 iii

13.7 RMU CONNECTORS ...........................................................................................................................153 13.8 RMU DIP SWITCHES ..........................................................................................................................155 13.9 CONFIGURATION ................................................................................................................................156 13.10 FLOWCHART INTERFACE WITH THE RMU............................................................................................157 13.11 RMU MANUAL SEQUENCE LAB..........................................................................................................159 13.12 CONFIGURATION LAB ........................................................................................................................160

14 POWERMATE D .................................................................................................................... 162 14.1 OVERVIEW.........................................................................................................................................162 14.2 OBJECTIVES ......................................................................................................................................162 14.3 OPERATION .......................................................................................................................................163 14.4 SERVO INTERFACE MODULE ................................................................................................................164 14.5 BATTERY REPLACEMENT.....................................................................................................................166 14.6 SERVO AMPLIFIER MODULE.................................................................................................................167 14.7 CONFIGURATION ................................................................................................................................168 14.8 REPLACEMENT...................................................................................................................................169 14.9 POWERMATE D PARAMETERS AND MAINTENANCE FUNCTIONS ................................................................170 14.10 CONFIGURATION LAB ........................................................................................................................175

15 SERIES 16/18 MAINTENANCE CRT DISPLAY.................................................................... 177 15.1 OVERVIEW.........................................................................................................................................177 15.2 OBJECTIVES ......................................................................................................................................177 15.3 OPERATION .......................................................................................................................................178 15.4 SCREEN OPERATION ..........................................................................................................................180 15.5 STATUS DISPLAY................................................................................................................................182 15.6 SYSTEM DIAGNOSTICS........................................................................................................................183 15.7 SETTING PARAMETERS .......................................................................................................................189 15.8 EDITING PROGRAMS ...........................................................................................................................194 15.9 SERIES 16/18 COMMUNICATIONS.........................................................................................................198

15.9.1 Series 16/18 Setup ................................................................................................ 198 15.9.2 DOWNLOADING FROM THE SERIES 16/18 TO THE PC................................... 199 15.9.3 CNC Parameters.................................................................................................... 199 15.9.4 PMC Ladder Program and PMC Parameters ........................................................ 200 15.9.5 PMC Parameters ................................................................................................... 200 15.9.6 PMC LADDER Procedure if Not Stored in EPROM .............................................. 202 15.9.7 PART PROGRAMS ............................................................................................... 203 15.9.8 TOOL OFFSET ...................................................................................................... 204 15.9.9 MACRO VARIABLES............................................................................................. 205 15.9.10 PITCH ERRORS ............................................................................................... 206 15.9.11 UPLOADING TO THE SERIES 16/18 FROM THE PC..................................... 207 15.9.12 CNC PARAMENTERS ...................................................................................... 207 15.9.13 PMC Ladder Program and PMC Parameters.................................................... 208 15.9.14 PMC LADDER LOADING.................................................................................. 208 15.9.15 PMC Parameter Loading.................................................................................. 210 15.9.16 Part Programs ................................................................................................... 211 15.9.17 Macro Variables................................................................................................. 212 15.9.18 OFFSET............................................................................................................. 213 15.9.19 Pitch Error Compensation ................................................................................. 213

16 BALOGH TAGS AND TRANSCEIVERS............................................................................... 217 16.1 OVERVIEW.........................................................................................................................................217 16.2 OBJECTIVES ......................................................................................................................................217 16.3 OPERATION- RFID SYSTEM ................................................................................................................218 16.4 TAG TYPE AND LEVELS ......................................................................................................................219 16.5 TRANSMISSION ZONES........................................................................................................................220 16.6 BALOGH PM-15 HAND HELD RF READER.............................................................................................223 16.7 RFID SYSTEM AND BUILD INFORMATION...............................................................................................226 16.8 TRANSCEIVER WIRING ........................................................................................................................229 16.9 CONFIGURATION LAB ..........................................................................................................................230

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17 BALOGH BIGE ...................................................................................................................... 232 17.1 OVERVIEW.........................................................................................................................................232 17.2 OBJECTIVES ......................................................................................................................................232 17.3 OPERATION .......................................................................................................................................233 17.4 BIGE HARDWARE CONNECTIONS ........................................................................................................234 17.5 BIGE – CONFIGURATION ....................................................................................................................235 17.6 BIGE – RF TAG/BAR CODE BLOCKS ...................................................................................................237 17.7 RFID READ / WRITE FLOWCHART....................................................................................................240 17.8 BIGE – GLOBAL DATA STATUS............................................................................................................242 17.9 BIGE – REPLACEMENT.......................................................................................................................243

18 FESTO.................................................................................................................................... 245 18.1 OVERVIEW.........................................................................................................................................245 18.2 OBJECTIVES ......................................................................................................................................245 18.3 OPERATION .......................................................................................................................................246 18.4 FESTO STATUS INDICATORS AND CONNECTIONS....................................................................................247 18.5 FESTO – CONFIGURATION ...................................................................................................................251 18.6 FESTO – REPLACEMENT......................................................................................................................262

19 GE VARIABLE FREQUENCY DRIVE ................................................................................... 266 19.1 OVERVIEW.........................................................................................................................................266 19.2 OBJECTIVES ......................................................................................................................................266 19.3 OPERATION .......................................................................................................................................267 19.4 GENIUS GATEWAY COMMUNICATION / DIP SWITCH SETUP......................................................................268 19.5 WORD DESCRIPTION/ DIAGNOSTICS .....................................................................................................269 19.6 REPLACING THE GE – VFD.................................................................................................................271 19.7 GE VFD WIRING DIAGRAM / SETUP PARAMETERS ................................................................................272 19.8 TERMINAL ID AND FUNCTION DEFINITIONS ............................................................................................274 19.9 HORNER ELECTRIC GENIUS GATEWAY–WIRING / CONFIGURATION..........................................................275 RS 232/485 INTERFACE CARD- GE AF-300B DRIVES .................................................................................276 19.11 HORNER ELECTRIC OPTION CARD - GE AF-300E$ DRIVES .................................................................281 VFD FLOWCHART EXAMPLE-TURNTABLE.....................................................................................................287 19.13 FAULT CONDITION DESCRIPTION AND OPERATION ...............................................................................290

20 ATLAS COPCO AFS CSS-91 NUTRUNNER........................................................................ 293 20.1 OVERVIEW.........................................................................................................................................293 20.2 OBJECTIVES ......................................................................................................................................293 20.3 OPERATION .......................................................................................................................................294 20.4 CSS-91 SPINDLE PROCESSOR RACK...................................................................................................294 20.5 CSS-91 SUPERVISOR ........................................................................................................................295 20.6 SPINDLE PROCESSOR MODULE............................................................................................................297 20.7 STATION I/O MODULE FOR GENIUS BUS...............................................................................................298 20.8 FUNCTIONS OF THE STATION CONTROLS .............................................................................................300 20.9 CONFIGURATION OF THE STATION I/O MODULE .....................................................................................303 20.10 FLOPRO CONFIGURATION OF THE CSS-91 NUTRUNNER ......................................................................304 20.11 FLOPRO INTERFACE WITH THE CSS-91 NUTRUNNER ..........................................................................306

21 FLOPRO CONFIGURATION SUMMARY ............................................................................. 313 21.1 ASSEMBLY SIMULATION CONFIGURATION..............................................................................................313 21.2 MACHINING SIMULATION CONFIGURATION.............................................................................................315

22 GENERAL FLOWCHARTING THEORY ............................................................................... 319 22.1 FLOWCHARTING FUNCTIONALITY BY TYPE .............................................................................................319 22.2 MENU FLOWCHARTS...........................................................................................................................319 22.3 AUTO FLOWCHARTS ...........................................................................................................................321 22.4 DIAGNOSTIC FLOWCHARTS..................................................................................................................322 22.5 OUTPUT/MOTION CONTROL FLOWCHARTS............................................................................................324 22.6 MESSAGE MANAGER FLOWCHART........................................................................................................325 22.7 UPDATE MENU F-KEYS FLOWCHARTS ..................................................................................................325 22.8 STATUS FLOWCHARTS ........................................................................................................................328

General Motors Corporation Romulus Engine Plant - V8 v

22.9 OTHER FLOWCHART TYPES.................................................................................................................329 22.10 FLOWCHART INTERACTION ................................................................................................................329 22.11 SEQUENCE FROM KEY PRESS TO OUTPUT ..........................................................................................330 22.12 TRACING STEPS IN REVERSE DIRECTION ............................................................................................333 22.13 TRACING DIAGNOSTIC MESSAGES TO ORIGINATION .............................................................................333 22.14 DIAGNOSTIC CUSTOMIZATION ............................................................................................................334 22.15 FLOPRO INTERFACE TO CNC ............................................................................................................336

vi General Motors Corporation Romulus Engine Plant - V8

Table of Figures Figure 1 Components of a Typical PC Based Controls System..................................................... 5 Figure 2 Typical Hardware Configuration for a Stand-Alone AT System....................................... 6 Figure 3 Typical Hardware Configuration for a Rack Mounted AT System ................................... 7 Figure 4 Typical Procedural Flowchart for a Retail Clerk............................................................... 8 Figure 5 Typical Test and Action Blocks in Flowchart.................................................................... 9 Figure 6 Typical Flowchart Runtime Display ................................................................................ 11 Figure 7 Typical Remote Message Unit Display .......................................................................... 11 Figure 8 Flowchart Program Example.......................................................................................... 12 Figure 9 Horizontal Thread Used to Drive an Actuator Output .................................................... 15 Figure 10 Example Flowchart With Flowchart Elements.............................................................. 19 Figure 11 Typical Mnemonics....................................................................................................... 20 Figure 12 Typical Pulse Table Screen ......................................................................................... 21 Figure 13 Typical Timer Table Screen ......................................................................................... 22 Figure 14 Typical Timer Blocks .................................................................................................... 22 Figure 15 Freeze Criteria Block.................................................................................................... 24 Figure 16 Enable Criteria Block.................................................................................................... 26 Figure 17 Insruction Block Types ................................................................................................. 28 Figure 18 Control Block ................................................................................................................ 29 Figure 19 Move Blocks ................................................................................................................. 30 Figure 20 Moving Multiple Sources to a Single Destination......................................................... 30 Figure 21 Moving a Single Source to a Multiple Destination........................................................ 31 Figure 22 Moving Multiple Sources to Multiple Destinations........................................................ 31 Figure 23 Table of Valid Move Locations ..................................................................................... 32 Figure 24 Wait Block .................................................................................................................... 33 Figure 25 Exit Flowchart Block ..................................................................................................... 34 Figure 26 Decision Block.............................................................................................................. 35 Figure 27 Compare Block............................................................................................................. 36 Figure 28 Table of Valid Comparisons ......................................................................................... 37 Figure 29 RF Tag/Bar Code Read Block...................................................................................... 38 Figure 30 RF Tag/Bar Code Write Block...................................................................................... 39 Figure 31 RF Tag/Bar Code Cancel Block ................................................................................... 39 Figure 32 RF Tag/Bar Code Test Status Block ............................................................................ 40 Figure 33 Integer Math Block ....................................................................................................... 41 Figure 34 PLC Motor Start/Stop Circuit ........................................................................................ 43 Figure 35 Axis Default Block ........................................................................................................ 49 Figure 36 Axis Control Block ........................................................................................................ 50 Figure 37 Axis Move Block ........................................................................................................... 54 Figure 38 Axis Test Block (Test Status) ....................................................................................... 59 Figure 39 Axis Test Block (At Position) ........................................................................................ 60 Figure 40 Spindle Default Block ................................................................................................... 62 Figure 41 Spindle Control Block Example.................................................................................... 63 Figure 42 Spindle Test Block........................................................................................................ 65 Figure 43 Flowchart Task Timing ................................................................................................. 70 Figure 44 Data Entry Keypad Diagnostic Testing ......................................................................... 78 Figure 45 Serial Loopback Connector.......................................................................................... 79 Figure 46 Main Menu................................................................................................................... 79 Figure 47 Front Panel................................................................................................................... 80 Figure 48 9987 Back Panel ......................................................................................................... 80 Figure 49 9987 Power Panel ....................................................................................................... 81 Figure 50 9987 I/O Panel ............................................................................................................. 81 Figure 51 9987 Slide-Out Module.................................................................................................. 82 Figure 52 PC/AT Processor Switch Settings................................................................................ 82

General Motors Corporation Romulus Engine Plant - V8 vii

Figure 53 Changing the Filter ....................................................................................................... 83 Figure 54 Changing the Fuse....................................................................................................... 83 Figure 55 System Block Diagram................................................................................................. 87 Figure 56 COM1/COM2 SERIAL PORT CONNECTOR .............................................................. 88 Figure 57 Keyboard Connector .................................................................................................... 88 Figure 58 PCIM Card LED Indicators........................................................................................... 92 Figure 59 PCIM Card DIP Switch Location .................................................................................. 93 Figure 60 PCIM Card DIP Switch Settings................................................................................... 93 Figure 61 PCIM Card FloPro Configuration ................................................................................. 94 Figure 62 IPN 200 Ethernet/FloNet Memory Segment Switch 1................................................ 102 Figure 63 IPN 200 Ethernet/FloNet IRQ Switches E1-E4 ........................................................... 102 Figure 64 Ethernet / FloPro Mode Selection ............................................................................... 103 Figure 65 Ethernet Mode ROM Address Selection ..................................................................... 103 Figure 66 Ethernet / FloPro I/O Port Selection........................................................................... 103 Figure 67 IPN200 SRAM Memory Address Selection................................................................ 104 Figure 68 IPN200 Battery Connection........................................................................................ 104 Figure 69 Genius Serial Connections......................................................................................... 108 Figure 70 GCM+ Status LEDs.................................................................................................... 108 Figure 71 GCM+ Configuration Parameters............................................................................... 109 Figure 72 Logicmaster CPU Configuration................................................................................. 110 Figure 73 Logicmaster GCM+ Configuration.............................................................................. 111 Figure 74 Logicmaster GCM+ Configuration.............................................................................. 112 Figure 75 Logicmaster GCM+ Configuration.............................................................................. 112 Figure 76 GCM+ Configuration Parameters for FloPro.............................................................. 114 Figure 77 Series 90-30 Module Replacement............................................................................ 115 Figure 78 Series 90-30 Module Replacement............................................................................ 115 Figure 79 Series 90-30 Module Replacement............................................................................ 116 Figure 80 Discrete 16 Point DI/DO Block Status LEDs............................................................. 125 Figure 81 16 Point DI/DO Block Configuration Parameters ....................................................... 126 Figure 82 Discrete 4I/2O Analog Block Status LEDs ................................................................. 127 Figure 83 Discrete Analog Block Configurarion Parameters..................................................... 128 Figure 84 Discrete Block Parameters in the Drawing Package ................................................. 129 Figure 85 Hand Held Monitor Configuration............................................................................... 130 Figure 86 Discrete I/O FloPro Configuration .............................................................................. 133 Figure 87 Inputs in the Flowcharts ............................................................................................. 134 Figure 88 Outputs in the Flowcharts........................................................................................... 135 Figure 89 Genius Block Replacement........................................................................................ 136 Figure 90 Replacement of the Electronics Assembly................................................................. 137 Figure 91 I/O Link Module Jumper Plug..................................................................................... 142 Figure 92 I/O Link Module Powermate D Serial Connection...................................................... 143 Figure 93 I/O Link Module Master/Slave Connection................................................................. 143 Figure 94 I/O Link Master/Slave Connection.............................................................................. 144 Figure 95 I/O Link Optical Adapter ............................................................................................. 144 Figure 96 I/O Link Module Status LEDs ..................................................................................... 145 Figure 97 I/O Link Module Replacement.................................................................................... 147 Figure 98 RMU Front Panel........................................................................................................ 150 Figure 99 RMU DC Connector Pinout ........................................................................................ 153 Figure 100 RMU Connector Locations – Rear View .................................................................. 153 Figure 101 RMU Genius Connector Pinout................................................................................ 154 Figure 102 RS232 Connector Between RMU Serial Port & PMD Serial Port ............................ 154 Figure 103 DIP Switch Settings for RMU Address & Baud Rate ............................................... 155 Figure 104 RMU Main Board DIP Switch Assignments ............................................................. 156 Figure 105 RMU Manual Menu Display ..................................................................................... 157 Figure 106 RMU Manual Menu Display ..................................................................................... 158 Figure 107 GMPT Romulus PMD Connection on the Genius Network...................................... 163 Figure 108 Powermate D Front Panel........................................................................................ 164

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Figure 109 Powermate D Status Indicators................................................................................ 165 Figure 110 PMD Rotary Switch/Device Number Settings .......................................................... 165 Figure 111 PMD Fuse Location.................................................................................................. 166 Figure 112 PMD LED Error Codes............................................................................................. 167 Figure 113 FloPro Configurations for the Powermate D ............................................................ 169 Figure 114 PMD Bottom Panel Connectors ............................................................................... 170 Figure 115 CRT/MDI Panel ......................................................................................................... 178 Figure 116 Explanation of the Key Board................................................................................... 179 Figure 117 CRT/MDI panel - Chapter Soft Key.......................................................................... 180 Figure 118 Description of Each MDI) Display (CRT/................................................................... 182 Figure 119 SYSTEM ALARMS.................................................................................................... 183 Figure 120 SERVO ALARMS..................................................................................................... 184 Figure 121 PROGRAM ERRORS (P/S ALARM)....................................................................... 185 Figure 122 Displaying Internal States on the CNC.................................................................... 186 Figure 123 Details of CNC Internal Status ................................................................................. 187 Figure 124 Displaying I/O Interface Signals ............................................................................... 188 Figure 125 Setting Parameters CRT/MDI Panel ......................................................................... 189 Figure 126 Setting Parameters CRT/MDI Panel......................................................................... 189 Figure 127 Setting /Display of Tool Offsets Values.................................................................... 190 Figure 128 Macro Variable .......................................................................................................... 191 Figure 129 Display in Workpiece Coordinate System................................................................. 192 Figure 130 Display in Relative Coordinate System..................................................................... 192 Figure 131 Display in Overall Coordinate System....................................................................... 193 Figure 132 Inserting a Word ....................................................................................................... 195 Figure 133 Modify a Word ........................................................................................................... 196 Figure 134 Deleting a Word......................................................................................................... 196 Figure 135 Deleting a Block ........................................................................................................ 197 Figure 136 Interaction between Balogh’s Transceiver and TAG through electromagnetic fields.

............................................................................................................................................ 218 Figure 137 Shows a Transceiver and READ/WRITE TAGS. ..................................................... 219 Figure 138 Electromagnetic field Transmission Zone ................................................................ 220 Figure 139 Side and Top view of a Static Transmission Zone................................................... 220 Figure 140 Maximum lateral and angular offset in a dynamic transmission zone ..................... 221 Figure 141 The Primary Transmission Zone contains three-dimensional fields surrounding the

Transceiver and TAG shown in the top and side views above. Recommended distances between two Transceivers(ERC – 85/QC) is 1m................................................................ 221

Figure 142 The Primary Transmission Zone recommended distances between two TAGS(OMX-93/R8) is 200mm................................................................................................................. 222

Figure 143 PM-15 Hand Held RF reader can read, writes, and initializes TAGS ...................... 223 Figure 144 PM-15 Hand Held RF reader TAG read/write screens ........................................... 224 Figure 145 PM-15 Hand Held RF Reader TAG write screens ................................................... 224 Figure 146 PM-15 Hand Held RF reader TAG Fault Messages ................................................ 225 Figure 147 PM-15 Hand Held RF Reader Key Function Summary ........................................... 225 Figure 148 Important Byte on All TAGS ..................................................................................... 226 Figure 149 Build Information On TAGS....................................................................................... 228 Figure 150 Transceiver wiring .................................................................................................... 229 Figure151 Balogh BIGE Module (Balogh Interface to General Electric) ..................................... 233 Figure152 Balogh BIGE Module and Transceiver Connectors .................................................. 234 Figure 153 Balogh BIGE Module Genius Bus DIP Switch Settings ........................................... 235 Figure 154 Balogh BIGE Module Genius I/O RF configuration................................................... 236 Figure 155 RF Tag/Bar Code Read Block.................................................................................. 237 Figure 156 RF Tag/Bar Code Write Block.................................................................................. 238 Figure 157 RF Tag/Bar Code Cancel Block ............................................................................... 238 Figure 158 RF Tag/Bar Code Test Status Block ........................................................................ 239 Figure 159 RF Tag READ program ........................................................................................... 240 Figure 160 RF Tag WRITE program .......................................................................................... 241

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Figure 161 Balogh BIGE Nema Global Data Status................................................................... 242 Figure 162 Balogh BIGE Nema 4/12 Enclosure......................................................................... 243 Figure 163 Festo Valve Terminals............................................................................................... 246 Figure 164 Festo Valve Terminals............................................................................................... 247 Figure 165 Display Indicators for I/O Modules ............................................................................ 248 Figure 166 Input Module Pin Assignment for 4/8 Inputs PNP/NPN Circuits. .............................. 249 Figure 167 Output module pin assignment for 4Outputs PNP circuits...................................... 250 Figure 168 Configuration ............................................................................................................. 251 Figure 169 Setting field bus baud rate ........................................................................................ 252 Figure 170 Configuration Parameters using HMI ........................................................................ 253 Figure 171 Read Parameters using HMI.................................................................................... 253 Figure 172 Saving the Configuration........................................................................................... 254 Figure 173 Selecting the Valve Terminal .................................................................................... 254 Figure 174 Outputs Priorities....................................................................................................... 255 Figure 176 Output Default State.................................................................................................. 255 Figure 177 Hold Last State.......................................................................................................... 256 Figure 178 Monitoring the valve terminal .................................................................................... 256 Figure 179 Recording the number of Inputs and Outputs ........................................................... 257 Figure 180 Configured a Generic I/O device.............................................................................. 258 Figure 181 Combination Valves and Digital I/O modules............................................................ 259 Figure 182 Valves Configuration DIP Switch .............................................................................. 260 Figure 183 Coded Diagnostics .................................................................................................... 261 Figure 184 Module Replacement ................................................................................................ 262 Figure 185 Fuse Replacement .................................................................................................... 263 Figure 186 Power Supply Connector........................................................................................... 264 Figure 187 GE Variable Frequency Drive ................................................................................... 267 Figure 188 Genius Gateway Communication / Dip Switch Setup ............................................... 268 Figure 189 Input Word Description............................................................................................. 269 Figure 190 Output Word Description......................................................................................... 269 Figure 191 Fault Word Description............................................................................................. 270 Figure 192 Replacing the GE – VFD.......................................................................................... 271 Figure 193 GE VFD Wiring Diagram ........................................................................................... 272 Figure 194 GE Variable Frequency Drive Operating Parameters............................................... 273 Figure 195 Terminal ID and Function.......................................................................................... 274 Figure 196 Horner Electric Genius Gateway/GE RS485 Interface Card..................................... 275 Figure 197 Horner Electric Drive Gateway FloPro Configuration................................................ 275 Figure 198 VFD Control and RS232/485 PC Boards................................................................. 276 Figure 199 Genius Gateway, VFD Control and RS232/485 PC Boards Wiring........................ 277 Figure 200 Function and Data Codes Setting Procedure ......................................................... 278 Figure 201 Function and Data Code Setting Table .................................................................... 279 Figure 202 Function and Data Code Setting Table .................................................................... 280 Figure 203 Error Codes ............................................................................................................... 280 Figure 204 GE AF-300E$ and Genius Connection ..................................................................... 281 Figure 205 Installation of the Option Card ................................................................................. 282 Figure 206 Drive Keyboard Function and Layout........................................................................ 283 Figure 207 Drive Option Parameters........................................................................................... 284 Figure 208 VFD Flowchart Example-Turntable ........................................................................... 289 Figure 209 Fault Condition Description and Operation ............................................................... 290 Figure 210 CSS-91 Spindle Processor Rack ............................................................................. 294 Figure 211 CSS-91 Supervisor Module...................................................................................... 295 Figure 212 CSS-91 Supervisor Module Status Indicators.......................................................... 296 Figure 213 CSS-91 Spindle Processor Module.......................................................................... 297 Figure 214 CSS-91 Station I/O Module for Genius Bus............................................................. 298 Figure 215 CSS-91 FloPro Digital I/O Configuration Parameters .............................................. 304 Figure 216 CSS-91 FloPro Serial Communication Parameters ................................................. 305 Figure 217 Nutrunner Flowcharts - Read Nutrunner Values...................................................... 307

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Figure 218 Nutrunner Flowcharts - Auto Cycle Index/Alignm./Nutr. .......................................... 309 Figure 219 Nutrunner Charts - Auto Cycle Spindle .................................................................... 311 Figure 220 Nutrunner Flowcharts - Auto Cycle Spindle ............................................................. 311 Figure 221 Flowcharting Theory - Main Menu............................................................................ 320 Figure 222 Flowcharting Theory - Manual Motion Menu............................................................ 320 Figure 223 Flowcharting Theory - Auto Sequence..................................................................... 321 Figure 224 Flowcharting Theory - Diagnostic Chart................................................................... 322 Figure 225 Flowcharting Theory - Output/Motion Control .......................................................... 324 Figure 226 Flowcharting Theory - Message Manager................................................................ 325 Figure 227 Flowcharting Theory - Update Menu F-Keys ........................................................... 326 Figure 228 Flowcharting Theory - Update Menu F-Keys ........................................................... 327 Figure 229 Flowcharting Theory - Status Charts........................................................................ 328 Figure 230 Flowcharting Theory - Machine Services Menu....................................................... 330 Figure 231 Flowcharting Theory - Diagnostic Chart................................................................... 331 Figure 232 Flowcharting Theory - XFER Output Control ........................................................... 332 Figure 233 Flowcharting Theory - CNC Station Status .............................................................. 336 Figure 234 Flowcharting Theory - CNC Station Motion Status .................................................. 337 Figure 235 Flowcharting Theory - CNC Station Auto Sequence................................................ 338 Figure 236 Flowcharting Theory - CNC Auto Sequence............................................................ 339

General Motors Corporation Romulus Engine Plant - V8 xi

General Motors Corporation 1 Romulus Engine Plant - V8

1 Introduction

1.1 Overview The purpose of this course is to provide students with basic troubleshooting tools needed to help keep a FloPro system up and running. The hardware discussed in this course includes hardware components found on the existing GMPT Romulus FloPro Demo Unit. This design is intended to represent the actual hardware found on the current V8 engine lines.

1.2 Prerequisites The participant should be familiar with the PC/MS-DOS and Windows 95 environment and the basic commands for file and directory manipulation. Participants should also be familiar with current terms and methods for designing controls (i.e. emergency return, full depth.)

1.3 Course Objectives The following components will be covered:

• Genius Network Interface Card • Xycom Monitor • Enhanced Genius Communications Module • Series 90-30 I/O Modules • Genius Discrete I/O Blocks • I/O Link Interface Module • Horner Electric RMU • Powermate D • Balogh Tag & Transceivers • Balogh BIGE • Festo • Series 16/18 CNC & CRT Display • GE Variable Frequency Drive

2 General Motors Corporation Romulus Engine Plant - V8

At the conclusion of this course, the student will be able to:

• Understand a valid FloPro configuration. • Troubleshoot any problems in a given FloPro configuration. • Understand the Genius network connections and the FloPro interface. • Perform maintenance procedures on the listed hardware components.

Including: Assembly, cabling, replacement, & configuration.

• Begin basic troubleshooting techniques by interrogating indicator lights and/or messages which appear on the listed hardware components.

• Understand how the listed hardware components are handled in the flowcharts.

• Understand basic flowchart types and their interaction. • Understand block line flowcharting theory. • Understand crank line flowcharting theory. • Understand head line flowcharting theory. • Understand assembly line flowcharting theory. • Utilize the FloPro debug tools to track faults to their source in a block,

crank, head, or assembly line application program.


2 Introduction to PC Based Controls and Flowchart Programming

2.1 Overview This module is an introduction to PC based controls and the use of flowcharts as a machine control development and execution language. The content defines the major components of a PC based control system and flowchart programming. In addition, the major runtime attributes of flowchart programming are introduced.

2.2 Objectives At the conclusion of this module, the participant will be able to:

• List the hardware components of a typical PC based control system. • Explain why PC based controls are used. • List the two main components of a flowchart program. • Explain why flowchart programming is used.


2.3 Overview of PC Based Controls Typical PC Based Control Hardware A PC based control system utilizes DOS based computers for flowchart application program development and control program execution. An industrially hardened AT compatible computer, instead of a PLC, is used to operate machinery. Program development can occur on any AT platform. Figure 2-1 shows the components of a typical PC based control system.

Note: The letters PC-AT refer to Personal Computer Advanced Technology, a title and hardware standard created by IBM. This standard includes:

• An INTEL 286 or higher (386, 486, etc.) processor. • A 16-bit accessory bus (video cards, disk controller, etc.)

A typical PC based control system would be composed of:

• Industrially Hardened AT or Compatible Computer — The flowchart "host" and is responsible for solving the equipment control program, generating and sending fault messages, running diagnostic tasks, and maintaining a user interface. The computer must be equipped with MS/PC-DOS 5.0 or higher and a minimum of 1Mb extended memory. Typical applications use 4Mb of extended memory.

• VGA Display — Used to display runtime information, debugger menu

items, and flowcharts. VGA stands for Video Graphics Array and represents a standard developed by IBM for displaying screen images.

• I/O System — Includes I/O modules and network adapters which

becomes the electronic link between the field equipment and the PC. This component is used in exactly the same way that a standard PLC installation would be used.

• I/O Scanner — Supplies the PC with an I/O processor responsible for

polling and buffering input and output status. The types of I/O scanners used are dependent on the I/O system manufacturer. Multiple I/O scanners or multiple types of I/O scanners connecting different I/O systems can be used in the same PC.

• Remote Message Units (RMU's) — ASCII devices controlled by the

flowchart application program which, display machine status and diagnostic messages and/or replace the local pushbutton control station. These RMU's may also be used to download parameters, jog stations, and restart a machine cycle.


Figure 1 Components of a Typical PC Based Controls System

I/OScanner

VGA Display

Industrial Hardened AT Compatible Computer

I/O System

RMU

RMU

RMU

RMU


Why PC Based Controls Are Being Used PC based control systems are used for the following reasons:

• A PC based control system is an open-architecture system allowing a user to select a control platform from any one of hundreds of PC manufacturers without regard to the brand of I/O being used.

• Flowchart application program development is not I/O or controller specific

and can be started before the control equipment has been selected. • PC Platforms can be completely exchanged without re-development or

conversion of the existing flowchart application program. The impact of hardware obsolescence on program engineering is minimized.

• PC based control systems use a common CRT for operators,

maintenance personnel and management reports. This simplifies the interface between equipment and personnel.

1 6

7

8

9

10

2

3

4

5

Main MenuREPORTSHELP

SELECTPART TYPE

VENDORSPECIFICOPTION

MACHINESTATUS

Julian Date: 0 Prod. Count: 0 Product ID: A Good Part Count: 0Hydraulics STOPPED : Air OFF : Mode

MAIN PANEL ENABLEINPUTS IS OFF

- 120 -

Pallet Present OFFPallet StopPart GrippersWedge LockEscapementCurrent Axis

Part Present OFFPallet LiftPart LiftPin PressPin Present OFFPOWER OFF

SIMULATION

Figure 2 Typical Hardware Configuration for a Stand-Alone AT System


Hardware Architecture of a Machine Control PC Typical installations of a PC in a PC controls system will resemble two styles:

• Stand-alone Industrial AT installed with an I/O scanner — Composed of what resembles a conventional AT with a standard interface card that allows it to communicate on a proprietary I/O bus and perform the tasks normally associated with the I/O processor of a PLC. Figure 2 shows a typical hardware configuration for a stand-alone AT system.

• Industrial AT mounted in a card rack — Uses an AT computer that can

be inserted into a proprietary housing or card rack. Figure 3 shows a typical hardware configuration for a rack mounted AT system.

Figure 3 Typical Hardware Configuration for a Rack Mounted AT System


2.4 Overview of Flowchart Programming What Is a Flowchart? A flowchart is a method of graphically representing a procedure whose steps may change based upon the answers to questions that are built into the steps. Figure 4 shows an example of a flowchart. Typical flowcharts include the following features:

• Decisions are always represented by yes/no questions placed inside a diamond-like shape called Test Blocks. A yes or no response directing the program to flow down either of the two possible paths answers these questions.

• Actions are represented by statements placed inside rectangles. • Lines with arrows are used to indicated the next step in the process.

Figure 4 Typical Procedural Flowchart for a Retail Clerk

CUSTOMERAT

WINDOW?

ATTEMPT TO SELLCUSTOMER LOTTERY

TICKETS

INFORM CUSTOMEROF TOTAL

OBTAIN PAYMENT

CALL POLICE ISSUE RECEIPT

ISSUE CUSTOMERADDITIONAL GOODS

GENERATE TOTAL

NO

YES

ADDITIONALSALES

?

YES

NO

SUFFICIENTFUNDS

?

YES

NO

START


What Is Flowchart Programming? Flowchart programming is a visual language in which the machine control program resembles the decision and action blocks of an ordinary flowchart. Figure 5 shows typical test (decision) and action blocks in a flowchart application program. The flowchart instruction set will be presented in a later module. The main components of a flowchart program are:

• Test blocks — Used to test conditions and direct program execution or flow. Test blocks are represented by diamond shaped blocks in a flowchart. These blocks are used as Decisions or compares.

• Action blocks — Used to perform operations like turning on and off

outputs or flags, controlling timers and counters, and writing information to runtime displays. Rectangular shaped blocks in a flowchart represents action blocks.

Figure 5 Typical Test and Action Blocks in Flowchart

POWER ON FREEZE CRITERIA:NONE

ISSTATION #2MAIN SLIDE

FAULT?


READY?

2000.00

2001.00

NO2002.00

AXIS-IFAULT

AXIS-I

YES

2002.00

YES2004.00

AXIS-IREADYNO

2003.00

2008.00

2004.00

NO2007.00

I 95 ANDF 245YES

AXIS: STATION #2 MAIN SLIDEDISABLE


AT RETURNEDPOSITION

(UNDEFINED)?

ISSTA. #2 MAIN

SLIDE AT HOMEON AND

STA. #2 MAINSLIDE HOMED

ON?

NO

2007.00

AXIS-IAT POS-0

YES

2005.00

T.OFF STA #2 MAIN SLIDE HOMED

T.OFF STA #2 MAIN SLIDE RETURNED

T.ON STA #2 MAIN SLIDE RETURNED


2003.00

F 245

F 380

2008.00 2008.00

2006.00 2007.00

F 380 F 380


Why Flowchart Programming Is Being Used Flowchart programming is used for the following reasons:

• Flowcharts are found in descriptions of virtually every industrial and commercial process. They are commonly found in the user documentation of consumer appliances like refrigerators, televisions and cars. They are a universally recognized method for displaying a procedure.

• The language typically used for designing the overall process, a flowchart,

is the same language used for developing the controls program. • Actual machine control programs can typically be written from detailed

versions of the machine operational descriptions. Meaning programmers many times will not need the assistance of state.

• Ladder logic programs are useful when performing simple tasks like

discrete control but unsuited for complex operations like servo control or database management for production reports.

• Diagnostics are incorporated into the same system as development and

runtime operations. This eliminates the need for an external diagnostic system.

• Multiple flowcharts are used to control a complex process. This allows

the complex process to be broken down into smaller, less complex operations.

Advantages of Flowchart Programming Flowchart programming software has integrated tools for easily building:

• A runtime Man-Machine Interface (MMI) • System diagnostics • A self-documenting machine control program

Runtime Man-Machine Interface (MMI) The flowchart application program allows developers to generate a runtime Man-Machine Interface (MMI). Runtime displays diagnostic displays and messages can be generated from blocks within any flowchart. Figure 6 shows a typical flowchart runtime display. Diagnostic and system messages can also be sent to several remote annunciator displays located throughout the equipment. Figure 7 shows a typical Remote Message Unit display.


Figure 6 Typical Flowchart Runtime Display

2-4 RMU Display

RMUSelect

Execute

0 1 2 3 4 5 6

7 8 9 • * # -

Station #7 Loader Jaw #1 Clamped is off 17105 (I-341)

Figure 7 Typical Remote Message Unit Display

1 6

7

8

9

10

2

3

4

5

AUTOMATIC RUNNING MODEAUTOMATIC

HAND

DISPLAYSTATIONCYCLE TIMESON/OFF

STATION 6STATUS

STATION 7CLAMPSTATUS

STATION 7LOADERSTATUS

RETURNTOMAIN MENU

LAST CYCLE NORMAL CYCLE

STATION #7 LOADER JAW #1 CLAMPEDSIMULATEA FAULTCONDITION

STA #1STA #2 MILLSTA #4 DRILLSTA #5 PROBESTA #5 MARKERSTA #5 DRILLSTA #6 INDEXSTA #6 REAMERSTA #7 UNCLAMPLOAD/UNLOADERMACHINE TOTAL

9.5015.0011.003.00

12.503.50

12.0015.0016.5018.50

SECSECSECSEC

SECSECSECSECSECSEC


System Diagnostics Flowcharts can be developed to monitor system diagnostics, which could include I/O system health and machine status. This permits the MMI to report on the failure of an I/O module and its location or a specific servo fault as easily as reporting a switch failure. Self-Documenting Machine Control Programs Mnemonics are imbedded in the flowchart application program and always present. Unlike ladder logic programs in which the annotation file is located in the programming panel and not in the PLC. The need for a separate programming panel is eliminated. Figure 8 shows an example of a flowchart program to illustrate the self-documenting feature of flowchart programming.

Figure 8 Flowchart Program Example

POWER ON FREEZE CRITERIA:NONE


FAULT?


READY?

2000.00

2001.00

NO2002.00

AXIS-IFAULT

AXIS-I

YES

2002.00

YES2004.00

AXIS-IREADYNO

2003.00

2008.00

2004.00

NO2007.00

I95 ANDF 245YES

AXIS: STATION #2 MAIN SLIDEDISABLE


AT RETURNEDPOSITION

(UNDEFINED)?

ISSTA. #2 MAIN

SLIDE AT HOMEON AND

STA. #2 MAINSLIDE HOMED

ON?

NO

2007.00

AXIS-IAT POS -0

YES

2005.00

T.OFF STA #2 MAIN SLIDE HOMED




2003.00

F 245

F 380

2008.00 2008.00

2006.00 2007.00

F 380 F 380


2.5 Typical Flowchart Groups Typical Flowchart Order Within a Machine A typical machine has a minimum number of flowcharts required for operation. Every machine will contain some or all of the flowcharts listed below. These flowcharts will provide operator interface, system diagnostics, etc. Some machines may be broken down differently than what is shown below, depending upon the application. The following list represents the approximate order that flowcharts are solved.

• Screen Saver Flowchart • Function Keys • PLC Error Handling w/Screens • I/O Fault Handling w/Screens • System Status • Transfer Sta Status • Balancer Sta Status • Proper FloPro for BT-XXXX Menu • Main Menu • Select Mode Menu • Automatic Mode Menu • Auto Mode Help Menu • Manual Mode Menu • Manual Setup Menu • Manual Menu Help • Transfer Manual Menu • Balancer Manual Menu • Production Reset Info. Menu • Fault Recovery • Fault Reset • Close Punch • Open Punch • Clamp Chuck • Unclamp Chuck • Advance Air Coupling • Retract Air Coupling • Close Grippers • Open Grippers • Jog Punch • Raise Transfer Tilt • Lower Transfer Tilt • Raise Transfer Lift • Lower Transfer Lift • Advance Transfer • Retract Transfer


Typical Flowchart Order Within a Machine (Continued) • Cycle Transfer • Cycle Balancer • Auto Mode • Test Balancer • Index • Retract Punch • Advance Punch • Punch Home Position F/C • Lube Control • Current Machine Operating Mode • Transfer Sta Diagnostics • Balancer Sta Diagnostics • System Diagnostics • Reports Main Menu • Fault Reset/Acknowledge Menu • Update Prod/Status Info F/C • Exit Controls for Assy. Group • System Fault Handling • Transfer Sta Fault Handling • Balancer Sta Fault Handling • Fault Display Mgr. w/o PwrMate • Fault Logging Mgr. w/o PwrMate • E-Stop


Typical Flowcharts Within a Station/Actuator One of the keys to making flowchart more manageable is to make them smaller. Due to the system and process complexity, this requires flowchart groups to be broken down at the station or mechanism level. Depending upon the control requirements, these groups may represent individual actuators on the equipment. These station/mechanism groups can essentially be represented by six flowcharts:

• System / Station Status • Auto Cycle • Manual Motion • Recovery • Diagnostics • Output Control The relationship of these flowcharts is illustrated in Figure 9 and can be described by the sequence given below.

Figure 9 Horizontal Thread Used to Drive an Actuator Output

1. An Auto, Manual, or Recovery Flowchart creates a request for motion 2. The Diagnostic Flowchart checks any (as long as they have been

programmed) condition that may inhibit motion, and sets a flag(s) if a fault occurs.

3. The Outputs Flowchart turns on a given output(s) if there are no faults. At the same time, a diagnostic timer is started. If there is a fault, or the diagnostic timer expires, or the request goes away, the output is then turned off.

SystemStatus

Auto/Manual

Diag-nostic Outputs

MechanismAdvanced?

AdvanceMechanism

MechanismFault

MechanismAdvanced?

AdvanceMechanism

MechanismFault

MechanismOutputs


Flowcharts Typically Solved Early in a Scan Critical information such as key presses, interference information and mode control needs to be detected during the first part of the scan. This type of information is used in flowcharts solved later in the scan. Listed below are typical flowcharts solved early in the scan.

• Screen Saver Flowchart • Function Keys • PLC Error Handling w/Screens • I/O Fault Handling w/Screens • System Status • Transfer Sta Status • Balancer Sta Status • Proper FloPro for BT-XXXX Menu • Main Menu • Select Mode Menu • Automatic Mode Menu • Auto Mode Help Menu

Flowcharts Typically Solved Late in a Scan Tasks or information based on other flowcharts needs to be solved during the last part of the scan. These include messages and display updates or flowchart exits. Listed below are typical flowcharts solved late in the scan.

• Reports Main Menu • Fault Reset/Acknowledge Menu • Update Prod/Status Info F/C • Exit Controls for Assy. Group • System Fault Handling • Transfer Sta Fault Handling • Balancer Sta Fault Handling • Fault Display Mgr. w/o PwrMate • Fault Logging Mgr. w/o PwrMate • E-Stop Note: The Emergency stop (E-Stop) flowchart will be the last flowchart solved

in the scan.

NOTES


3 Creating and Editing a Flowchart Program

3.1 Overview This module discusses creating and editing executable flowcharts and introduces the flowchart instruction set. Flowchart application programs consist of five types of elements: Mnemonics, Criteria Blocks, Instruction Blocks, Screens and Data Tables. This module defines these elements, lists the various types of each element, and identifies the valid value range for each type.


• List characteristics of a given flowchart program instructions. • Perform the steps necessary to develop and enter executable flowcharts

into a computer. • Enter flowcharts and mnemonic labels into the computer.


3.3 Detailed Executable Flowcharts Detailed executable flowcharts serve as the actual program executed by the PC to control the machine. A detailed executable flowchart has the following characteristics:

• I/O points are defined • Mnemonics are defined • Timers, counters, registers, etc. are assigned • Flowchart instruction blocks have been programmed

Before flowcharts can be programmed, flowchart-programming elements must be defined. A flowchart application program consists of four elements: Mnemonics, Criteria blocks, Instruction blocks, and Data Tables.

• Mnemonics are descriptive representations of discrete inputs and outputs, timers, counters, remote message units, etc. The descriptive can be a length of 2 lines of 30 characters long. Mnemonics are used in the flowchart program in addition to actual addresses.

• Criteria Blocks allow flowcharts to be enabled, disabled or stopped

based on certain conditions. There are two types of Criteria Blocks; Freeze and Enable. With Criteria Blocks the user could control a process with two separate flowcharts (i.e. Automatic and Manual mode).

• Instruction Blocks contain the actual commands of the flowchart

program by defining the tests and actions taken to control a process. These actions include: move, wait, exit, compare, start, stop, turn on, and turn off, among others.

• Data tables consist of the timer values, pulse output values, and the

motion variables. These values are used in the flowchart application program.

The Flowchart Programming Grid A flowchart application program will consist of one or more flowcharts. Each flowchart is assembled by placing flowchart criteria and instruction blocks in a grid that, as of this writing, is 5 columns wide (columns A through E) and up to 3277 rows (numbered 0 through 3276 in length. Figure 10 shows a portion of a flowchart with mnemonics, criteria blocks, instruction blocks and data table values.


Figure 10 Example Flowchart With Flowchart Elements

3.4 Mnemonics Mnemonics are user-defined names (labels) given to the Field Address components (I/O points, Timers, Counters, etc.), which are listed below:

• Inputs • ASCII Characters • Outputs/Pulse Outputs • Remote Message Units • Flags • Servo Axis • Timers • Servo Spindles • Counters • Servo Variables • Registers • R.F. Tag/Bar Code Reader • Numbers • Network Node

Criteria Block

IS STATION #2 MAIN SLIDE

FAULT ?


READY ?

1.00

2.00

NO3.00

AXIS-I FAULT

AXIS- I

YES

3.00

YES5.00

AXIS-I READYNO

4.00

5.00

NO8.00

I95 AND F245YES

AXIS: STATION #2 MAIN SLIDE DISABLE


AT RETURNED POSITION (0.000000)

?

IS STA. #2 MAIN

SLIDE AT HOME ON AND

STA. #2 MAIN SLIDE HOMED

ON?

NO

8.00

AXIS-I AT POS-0YES

6.00



9.00 9.00

7.00 8.00

F380 F380

FREEZE CRITERIA: NONE

Mnemonic Labels

Data Table Value

InstructionBlocks

POWER ON

Mnemonic Field Addresses


These components of a flowchart application program are assigned a mnemonic label that is used in the flowchart program. Each mnemonic is defined by the following:

• Field Address — Uniquely identifies each input, output, flag, etc. After an Instruction Block has been programmed, Field Addresses will automatically appear in the Graphics Editor to the right of that block in conjunction with a corresponding label.

• Label — A user or client-defined 30 alphanumeric character name given

to a Field Address used in flowchart programs. Each label will automatically appear within the correct block(s) once it has been assigned to a Field Address. If a Label has not been assigned to a given Field Address, then only the Field Address appears by itself in the Graphics Editor.

Figure 11 shows typical mnemonics for some of the components listed above. I 1 Station #1 Mid C 0 Station #1 O 0 Advance Clamp # R 1 Station #1 Prev 1 Solenoid Cycle Time F 3 Station #1 N 5 Pallet Number Manual Mode T 5 Station #1 A 3 Part Build Code Cycle Time

Figure 11 Typical Mnemonics


Inputs Inputs refer to discrete real world input devices wired to I/O points or modules. These input devices (proximity switches, pressure switches, float switches, etc.) are assigned Mnemonic Labels which are used to identify the function of the Input in the flowchart program. Outputs/Pulse Outputs Outputs refer to discrete real world output devices wired to I/O modules. These output devices (solenoid valves, relays, etc.) are assigned Mnemonic Labels, which are used to identify the function of the Output in the flowchart program.

Pulse outputs are used to turn on an output for a specified length of time. After that time has elapsed, the output is automatically turned off. Pulse outputs have a value range of .01 to

9,999.99 seconds. Regular outputs become Pulse outputs once users assign time values to a given output in the Pulse Table.

Figure 12 shows a typical Pulse Table screen.

0 3.00 SEC 1 .50 SEC

2 ______ 3 ______

4 ______ 5 ______

6 ______ 7 ______

8 ______ 9 ______

10 5.00 SEC 11 ______

12 ______ 13 ______

14 ______ 15 ______

Figure 12 Typical Pulse Table Screen

Note: Outputs turned on (T.ON) will remain on until turned off (T.OFF) or until flowchart execution is terminated. Flags Flags refer to internal status bits used to track events. These status bits are used in the same way as PLC internal coils.


Timers (32 Bits) Timers are used to delay the start of an event or to measure the elapsed time of an event. Timers are started, stopped, and reset using instruction blocks. Timers have a value range of .01 to 9,999.99 seconds, and these values must be set up in the Timer Table. Figure 13 shows a typical Timer Table screen.

0 ______ 1 2.01 SEC

2 ______ 3 ______

4 15.50 SEC 5 ______

6 ______ 7 ______

8 ______ 9 ______

10 2.00 SEC 11 ______

12 ______ 13 ______

14 ______ 15 ______

Figure 13 Typical Timer Table Screen

Timers Usage Timers have four blocks associated with controlling delay, they are: • Reset Block • Start Block • Done Block • Stop Block

Figure 14 Typical Timer Blocks

34.00

NO

YES

T1

T1

T1

33.00

IS

TIMER

?

RESET TIMER

START TIMER

DONE

35.00

STOP TIMER T1


The Reset Timer Block is used to initialize a given timer back to 0.00 seconds. The Start Block is used for starting a given timer from either a reset or stopped condition. The Done Block is used to check when the Timer Accumulator has reached the preset value in the Timer Table. The Stop Block is used to temporarily halt the progress of a Timer Accumulator. Timer progress will resume ascending toward the preset value once a Start Delay Block is encountered in a program. Note: The three connected Timer Blocks shown above are in a common

configuration, but do not have to be used in this way. Counters (16 Bits) Counters are used to track the number of occurrences of an event. Counters are an internal storage area with a value range of –32,768 to 32,767. They can be incremented, decremented, and cleared using instruction blocks. The counter value is stored in binary format (the most significant bit is a sign bit). Counters can be used to pass values from the flowchart application program to a user program. Registers (16 Bits BCD Format) Registers are internal storage areas that accept integer values. Registers have a value range of 0 to 9,999 and are stored in a BCD format. Registers can be used to pass values from the flowchart application program to a user program. Numbers (32 Bits) Numbers are internal storage areas that accept integer values. Numbers have a range of –2,147,483,648 to 2,147,483,647. Like Registers, Numbers can be used to pass values between flowcharts and user programs. ASCII Characters (8 Bits)


ASCII refers to another type of internal storage area in which the user can store a single ASCII character or its integer representation (a number between 0 and 255.) ASCII characters can be used to pass values between flowcharts and user programs.

3.5 Criteria Blocks There are two types of criteria blocks: Freeze Criteria Block and Enable Criteria Block. They allow individual flowcharts to be: • Enabled (solved) and disabled (not solved) using Enable Criteria • Halted (stopped) Freeze Criteria. Freeze Criteria Freeze Criteria allows the user to freeze (halt) the execution of a flowchart based on the state of one or more inputs, outputs, flags or timers. Unlike Enable Criteria, Freeze Criteria is not represented graphically. Figure 15 shows an example of Freeze Criteria being setup in the Block Editor. Once this “block” is programmed, the Graphics Editor will show only the criteria in the flowchart and not a block representation.

Note: Using Freeze Criteria is not an accepted practice at GM Powertrain.

( EMERGENCY ) NOT F 1 AND ( RETURN ) ( CRM ON ) I 0 AND ( ) ( CONTROL RESET ) O 0 AND ( ) ( RESET TIMER ) T 0 OR ( ) ( SYSTEM ERROR ) F 0

Figure 15 Freeze Criteria Block

HAULT


Freeze Criteria is programmed at the beginning of each flowchart. Freeze Criteria blocks can contain NO CRITERIA or up to seven of the following conditions. The following conditions can be combined using the AND/OR logical operators:

• Input • Not Input • Output • Not Output • Flag • Not Flag • Timer • Not Timer

The Freeze Criteria operates in the following manner:

• The flowchart execution is halted at the current block in the flowchart, when the Freeze Criteria becomes TRUE

• Flowchart execution is resumed at the block where it was stopped, when

the Freeze Criteria becomes FALSE • When a flowchart is frozen, the outputs remain in their last state prior

to freezing. Freezing a flowchart does not turn off outputs • If NO CRITERIA is programmed; the flowchart cannot be frozen

Logical Precedence When logical operators AND and OR are used to combine several statements together in a single criteria, test, or decision block, the following rules are observed regarding the order in which they are solved.

• AND statements are solved from left to right. Among a group of AND operators, the left most AND is solved first. The right most AND is solved last.

• OR statements are also solved from left to right. Among a group of OR

operators, the left-most OR is solved first. The right-most OR is solved last.

• All AND operations are performed before any OR operators are solved


Enable Criteria Enable Criteria allows the user to enable or disable the execution of a flowchart based on the state of one or more inputs, outputs, flags or timers. Figure 16 shows Enable Criteria being setup in the Block Editor.

( CRM ON ) O 1 AND ( ) ( FUNCTION KEY F1 ) I 0 AND ( ) ( CONTROL FAULT ) NOT F 1 AND ( ) ( AUTO TIMER ) NOT T 1 OR ( ) ( RESET INTRLOCK ) I 2

Figure 16 Enable Criteria Block

Enable Criteria is programmed at the beginning or top of each flowchart. Enable Criteria blocks can contain NO CRITERIA or up to seven of the following conditions. The following conditions can be combined using the AND/OR logical operators:

• Input • Not Input • Output • Not Output • Flag • Not Flag • Timer • Not Timer

POWER ON


The Enable Criteria operates in the following manner:

• During the first scan in which the enable criteria is TRUE, the flowchart is solved starting at the beginning of the flowchart. During subsequent scans when the Enable Criteria is TRUE, flowchart solving begins in the flowchart where it left off on the previous scan.

• The flowchart is disabled when the Enable Criteria is FALSE. When the

flowchart is re-enabled, solving will begin at the top of the chart. • The destination line from the enable criteria block is always connected to

the lowest numbered instruction block in the flowchart. • Enable Criteria takes precedence over Freeze Criteria. The Enable

Criteria must be TRUE in order for the program to check the Freeze Criteria.

• If NO CRITERIA is programmed; the flowchart will be solved on every

scan. • Once enabled, the flowchart will be solved completely in that scan even if

the enable criteria becomes untrue.

3.6 Instruction Blocks A flowchart consists of several different types of instruction blocks. Each instruction block performs a specific task. Instruction blocks must adhere to the following rules:

• Each Instruction Block must have a unique block number ranging from .01 to 9,999.99. The block number is located outside of the block in the upper right corner.

• Each Instruction Block must have a destination block. • A flow line from an Instruction Block can only have one destination block.

— Action blocks will have a single flow-line leaving the block for a single destination.

— Test blocks will have 2 flow-lines leaving the block, each bound for a

single destination. Due to the GM spec., only the horizontal path can return to the issuing block


The following instruction blocks are explained in this module:

• Control Block • Compare Block • Move Block • RF Tag/Bar Code Block • Wait Block • Special Function Block • Exit Flowchart Block • Integer Math Block

• Decision Block

The following instruction blocks will be explained in later modules:

• Display Block • Axis Test Block • Remote Message Block • Spindle Default Block • Axis Default Block • Spindle Control Block • Axis Control Block • Spindle Test Block • Axis Move Block

Figure 17 Insruction Block Types

Control Block Control blocks allow the programmer to cause specific actions to take place. Figure 18 shows an example of a Control Block containing six commands.

INSTRUCTIONBLOCKS

DECISIONBLOCK

COMPAREBLOCK

AXISTEST

SPINDLETEST

CONTROLBLOCK

MOVEBLOCK

WAITBLOCK

EXITBLOCK

DISPLAYBLOCK

SENDREMOTE

MESSAGEBLOCK

MESSAGEUNITTEST

BLOCK

TESTBLOCKS

ACTIONBLOCKS


Up to seven of the following conditions can be programmed in a Control Block: • T.ON — Turn on an output or flag • RESET — Reset a timer • T.OFF — Turn off an output or flag • INCR — Increment a counter • PULSE — Pulse an output • DECR —Decrement a counter • START — Start a timer • CLEAR — Clear a counter • STOP — Stop a timer 1.00

2.00

Figure 18 Control Block

Control Block Rules Control blocks must adhere to the following rules:

• No two operations can be performed on the same output or flag in the same Control Block.

• Flags and output bits are updated immediately, but outputs are not written

to the real world until the logic scan is complete. • You can clear, then increment or decrement the same counter in a single

Control Block, but you cannot increment or decrement then clear the same counter in a single Control Block.

• You can reset then start the same timer in a single Control Block, but you

cannot start then reset the same timer in a single Control Block. • The destination of a Control Block must always be another block. The

Control Block cannot loop back to itself.

O 0 O 1 O 2 F 1 T 1 C 1

T. ON PUMP MOTOR T. OFF FAULT PILOT LIGHT PULSE CYCLE START T. ON IN CYCLE START CYCLE TIMER INCR PART COUNTER


Move Block Move blocks are used to move data from one location to another location. Figure 19 shows a series of Move blocks.

Figure 19 Move Blocks

Move Block Behavior Moving Multiple Sources to a Single Destination • The Destination bit, byte, word, or double word, becomes the “MSB” and

FloPro adds and appends all other needed bits, bytes, words, or double words. Figure 20 displays a block doing this kind of move.

Figure 20 Moving Multiple Sources to a Single Destination

MOVE OP. 10 MODE MM

TO LAST DISPLAYED CONDITION REC.

73.00

74.00

R 31

R 61

STA. 2 PALLETSTOP RAISEDSTA. 2 ESCAPEMENTCLOSEDLAST DISPLAYEDCONDITION INP.

MOVE

THRU

TO

HYDRAULIC PUMPISTA. 2 OPENESCAPEMENT SOL.LAST DISPLAYEDCONDITION OUT.

MOVE

THRU

TO

74.00

75.00

I 321

I 341

R 2

75.00

76.00

0 40

0 61

R 3

STA. 2 ESCAPEMENT CLOSED

STA. 2 PALLET STOP RAISED

MOVE

THRU

LAST DISPLAYED CONDITION INP.

TO

I 321

I 341

R 2

3.00

4.00


Moving a Single Source to Multiple Destinations • The top destination bit becomes the MSB with the bottom bit becoming the LSB. Figure 21 displays a block doing this kind of move.

Figure 21 Moving a Single Source to a Multiple Destination

Moving Multiple Sources to Multiple Destinations • The source bits are moved – top to bottom to the respective destination bits –

top to bottom. Figure 22 displays a block doing this kind of move.

Figure 22 Moving Multiple Sources to Multiple Destinations

VALUE COUNTERMOVE

Y-AXIS

X-AXIS DB0

TO

I 321

I 341

O 28THRUO 19

4.00

5.00

Thumbwheel DB0

Thumbwheel DB11

Display DB0

Display DB11

MOVE

TO

I 28THRUI 39

O 36THRUO 47

5.00

6.00


Move Block Rules Move blocks must adhere to the following rules: • The movement of data into registers, counters, numbers, ASCII character

fields, output bits, flags, timers, or motion variables occurs immediately. However, outputs are not written to the real world until the logic scan has been completed.

• The destination of a Move Block must always be another block. The Move block cannot loop back to itself.

The following table shows the allowed move locations:

Out

put

Flag

Tim

er

Cou

nter

(Don

e)

Reg

iste

r

Num

ber

ASC

II

Pos

ition

Dis

tanc

e

Spe

ed

Dw

ell

InputOutputFlagTimer (Current)CounterRegisterNumberASCIIFixed IntegerFixed ASCIICurrent DateTime of DayKeyboard InputRMU InputPositionDistanceSpeedCurrent PositionCurrent Torque

TO

MOVE

FRO

M

Figure 23 Table of Valid Move Locations


Wait Block Wait blocks are used to delay the execution of the flowchart at the position of the Wait Block for a specified time. Figure 24 shows a Wait Block.

Figure 24 Wait Block

Wait Block Rules Wait blocks must adhere to the following rules:

• The wait time must be in the range of 0.00 to 9,999.99 seconds. • A wait time of 0.00 seconds is equal to 1 scan delay. • A Wait Block only affects the flowchart in which it is used. All other

enabled flowcharts are solved in that scan. • The destination of a Wait block must always be another block. The Wait

block cannot loop back to itself.

Note: It may be advisable to use a Timer instead of a Wait Block since a Wait Block effectively causes a flowchart to pause. The use of a timer permits the developer to test or monitor other conditions while waiting for the Timer to expire.

WAIT 10.00 SECONDS

6.00

7.00


Exit Flowchart Block Exit Flowchart blocks are used to exit or branch out of flowchart processing and execute user programs written in another programming language. Typical user programs will print reports and/or record machine information in a database. To locate the exit routine look in the directory for a file with the extension of *.exe. In the following example the directory will show a file called “5.exe.” Figure 3-16 shows an Exit Flowchart block.

Figure 25 Exit Flowchart Block

Exit Flowchart Rules Exit Flowchart blocks must adhere to the following rules:

• Only 1 exit can be performed at a time. If another Exit Flowchart Block is encountered, the active exit must be completed before the new exit is performed.

• The exit number can range from 1 to 511. • The execution of the flowchart that performed the exit is halted until the

user program issues a return. All other enabled flowcharts are executed normally.

• The destination of a Exit Flowchart Block must always be another block.

The Exit Flowchart Block cannot loop back to itself.

Note: Because only 1 exit per flowchart application can be performed at one time, and because all activity within a flowchart is suspended until the user program issues a return, developers will typically place all flowchart exits in the same flowchart.

EXIT FLOWCHARTS 5

7.00

8.00


Decision Block Decision blocks are used to test conditions of inputs, outputs, flags, timers and function keys. Decision blocks will direct program execution or flow based on the conditions. Figure 26 shows a Decision Block in the Block Editor.

8.00

YES ( AUTOMATIC TIMER) T 0 AND ( ) ( STOP PB ) I 1 AND ( ) ( FUNCTION KEY ) K 1 OR ( NUMBER 1 ) ( FUNCTION KEY ) K 2 ( NUMBER 2 )

9.00

Figure 26 Decision Block

Decision blocks can contain up to seven of the following conditions. These conditions can be combined using the AND/OR logical operators.

• Input is on/off • Output is on/off • Flag is on/off • Timer is done/not done • Function key is pressed • Keyboard ENTER key is pressed (when a cursor is displayed)

Decision Block Rules Decision blocks must adhere to the following rules:

• The YES and NO flow lines cannot go to the same destination block. • The destination of either the YES or NO flow lines from the Decision Block

does not have to be another block. The horizontal branch of a Decision Block can loop back to itself.

NO 10.00


Compare Block Compare blocks are used to compare the values of two numbers. Figure 27 shows a Compare Block in the Block Editor. 9.00

YES ( CYCLE TIMER ) T 0 ( ) ( GREATER THAN ) > ( MAXIMUM CYCLE ) R 0 ( TIME ) 11.00

Figure 27 Compare Block

Compare blocks test the relative values of two numbers using the following operators:

• < Less Than • = Equal To • > Greater Than

NO


The following table shows the allowed comparisons:

Cou

nter

(Don

e)

Reg

iste

r

Num

ber

AS

CII

Cha

r.

Fixe

d In

tege

r

Fixe

d A

SC

II C

hara

cter

Timer (Current)

Counter

Register

Number

ASCII Char.

Keyboard Input

RMU Input

CO

MPA

RE

TO

Figure 28 Table of Valid Comparisons

Compare Block Rules Compare blocks must adhere to the following rules:

• The YES and NO flow lines cannot go to the same destination block. • Care must be taken when using the equal to (=) operator. It is possible for

a value to change between scans, causing the program to miss the window of detection.

• The destination of either the YES or NO flow line from the Compare Block

does not have to be another block. The horizontal branch of a Compare Block can loop back to itself.


RF Tag/Bar Code Blocks The RF Tag/Bar Code blocks allow the user to read from and write to an RF Tag/Bar Code device. Information can be read from or written to the following areas:

• Counters • Registers • Numbers • ASCII Characters

There are four RF Tag/Bar Code blocks:

• Read Block • Write Block • Cancel R/W Block • Test Status Block

Read Block Read blocks allow the user to read data from a RF Tag/Bar Code device. The Read Block can read a single unit of data or a range of units into one or more mnemonic variables. Figure 29 shows a Read Block.

11.00

12.00

Figure 29 RF Tag/Bar Code Read Block

R/W 0 R 0 R 1

READ STATION #1 CODE READER

INTO PALLET NUMBER THRU PART NUMBER


Write Block Write blocks allows the user to write data from a RF Tag/Bar Code device. The Write Block can write a single unit of data or a range of units to the RF Tag/Bar Code device. Figure 30 shows a Write Block.

12.00

13.00

Figure 30 RF Tag/Bar Code Write Block

Cancel Block Cancel blocks allows the user to cancel a read or write data on a RF Tag/Bar Code device. If there is a read or write operation pending, it may be canceled with this block. Figure 31 shows a Cancel Block.

13.00

14.00

Figure 31 RF Tag/Bar Code Cancel Block

R/W 0

CANCEL STATION #1 CODE

READER

WRITE STATION #1 CODE READER INTO PALLET NUMBER THRU PART NUMBER

R/W 0 R 0 R 1


Test Status Block Test Status blocks are used to test the status of a RF Tag/Bar Code device. The Test Status Block will direct program execution or flow based on the status of the RF Tag/Bar Code device. Figure 32 shows a Test Status Block as being programmed in the Block Editor.

14.00

NO 16.00

YES

( STATION #1 CODE ) R/W 0 ( READER ) READ DONE

15.00

Figure 32 RF Tag/Bar Code Test Status Block

One of the three following conditions can be programmed in a RF Tag/Bar Code Test Status block:

• Read Done • Write Done • Error

RF Tag/Bar Code Block Rules RF Tag/Bar Code blocks must adhere to the following rules:

− The destination of a Read or Write block must always be another block. The Read or Write block cannot loop back to itself.

− The YES and NO flow lines of the Test Status Block cannot go to the same destination.

− The destination of either the YES or NO flow lines from Test Status Block does not have to be another block. The horizontal branch of the Test Status Block can loop back to itself.


Integer Math Blocks Integer Math blocks allow the user to perform basic math functions within flowcharts. The Integer Math Block allows the following operations:

• Addition • Subtraction • Multiplication • Division

Figure 33 shows an Integer Math Block. 15.00

17.00

Figure 33 Integer Math Block

Integer Math Block Rules Integer Math blocks must adhere to the following rules:

• The Integer Math Block can only use counters, numbers or fixed integers as operands.

• Both operands of an Integer Math Block cannot be fixed integers. • The destination of an Integer Math Block must always be another block.

The Integer Math Block cannot loop back to itself.

ADD SHIFT 1 PROD COUNT TO TODAY’S PROD COUNT RESULT TODAY’S PROD COUNT OVFL MATH OVERFLOW

C 1 C 4 C 4 F 1


3.7 Flowchart Program Example Conveyer Motor Start/Stop Part 1: Initial Requirements Using the exercise materials developed in the previous module, construct a flowchart for a Conveyor motor start/stop circuit using the following inputs, output, flags, operating criteria and conditions:

• Mnemonic Labels

Inputs Output _______ Start PB _______ Conveyor Motor _______ Stop PB (NC) _______ Remote Start PB

Flags ______ Safety Interlocks OK: This flag (create more if you feel it is necessary) can be driven by individual inputs representing motor overload, low fluid level, dirty filter faults, disconnect open, etc.

• Operating Criteria

There will be no Enable or Freeze Criteria.


Figure 34 shows an equivalent PLC Conveyor motor start/stop circuit. Draw the flowchart on the next page, in the space provided.

PB I-3

O-1

Figure 34 PLC Motor Start/Stop Circuit

Start Stop Safeties OK Conveyor PB I-1 PB I-2 F-4 Motor O-1

CONVEYOR MOTOR ON


Part 2: Develop a Detailed (Executable) Flowchart When you are done with this phase, let your Instructor know that you have completed it. FREEZE CRITERIA NONE

POWER ON


NOTES


4 Integrating Motion

4.1 Overview Single axis, non-coordinated servo motion is supported in the flowchart-programming environment. This module discusses the steps necessary to define and implement servo control in flowcharts and the impact of hardware selection on program design.


• List characteristics of flowchart program servo instructions. • Program and configure servo motion operations for a given application. • List the programming considerations with regard to hardware.

Note: These rules & examples are generic. They are created for multiple motion systems.


4.3 Flowchart Servo Motion The flowchart programming language supports up to 128 axes of single axis, non-coordinated servo motion and up to 64 spindle controllers. The flowchart servo motion blocks are divided into two groups: Axis Control — For accurate positioning of equipment such as slides, drills, etc. Spindle Control — For controlling rotating equipment such as drills, mills and grinding wheels.

4.4 Servo Motion: Axis Blocks Axis control blocks are used for positioning and testing a servo axis. The following axis control blocks will be discussed:

• Axis Default • Axis Control • Axis Move • Axis Test

Axis Default The Axis Default block, shown in Figure 35, establishes the default performance characteristics for the specified axis. These defaults will be in effect unless an Axis Move block overwrites them. The default characteristics that will be discussed are:

• Units • RPS • Accel/Decel • Accel Ramp • Decel Ramp • Torque Limit

Units Developers can select inches per minute (in/min), inches per revolution (in/rev), millimeters per minute (mm/min), and millimeters per revolution (mm/rev). RPS Rapid Positioning Speed represents the speed that an axis will travel when the speed is not specified in an Axis Move block. Developers can place the name of


a speed in this block instead of the actual speed value itself. On some systems, this is also the referencing (homing) speed. Accel/Decel Developers are permitted to choose from two motion profiles, linear or "S" Curve. Accel Ramp Establishes how quickly an axis will speed up to achieve a higher speed. Valid values for the Accel Ramp range from 0 to +99,999,999. Decel Ramp Establishes how quickly an axis will slow down to a given speed or stop. Valid values for the Decel Ramp range from 0 to +99,999,999. Torque Limit Specifies the amount of the available current a drive uses to maintain a given speed or position. This value is typically expressed as a percentage. Valid values for the Torque Limit range from 0 to 100.

Note: GE Fanuc Powermate equipment does not allow the user to make accel/decel choices through the flowchart program.

Figure 35 Axis Default Block

AXIS: Station 10 Slide DEFAULT VARIABLES RPS RAPID SPEED 7000.00 UNITS: IN/MIN ACC/DEC: NO CHANGE ACC RAMP: NO CHANGE DEC RAMP: NO CHANGE TORQUE LIMIT: 50.000000

1.00

2.00

AXIS 1 SPD 0


Axis Default Block Rules Axis Default blocks must adhere to the following rules:

• If NO CHANGE is programmed in a default value; the value in the motion controller is used unless specifically set by an Axis Move block.

• The destination of an Axis Default block must always be another block.

The Axis Default block cannot loop back to itself.

Note: On some systems, each flowchart that uses an Axis Motion block must place an Axis Default block before it.

Axis Control The Axis Control block, shown in Figure 36, is used to control an axis using the following functions:

• Home/Reference • Jog + (POS) • Jog - (NEG) • Stop Motion • Resume Motion • Reset • Enable • Disable • Emergency Stop

Figure 36 Axis Control Block

AXIS: Station 10 Slide STOP MOTION

2.00

AXIS 9

3.00


Home/Reference This instruction causes the axis to move until a home switch or a hard stop is encountered. Referencing sets the axis zero position from which all other distances and positions are calculated. Referencing is typically performed once when the equipment is first powered up. As long as power is maintained and a servo fault does not occur, referencing is not repeated. The Home/Reference function can be set up using the following options:

• Home in + (POS) Dir — Causes the axis to search for home in the positive

direction. • Home in - (NEG) Dir — Causes the axis to search for home in the

negative direction. • Reference — Causes the axis to move to a zero reference point defined

by a hard stop or reference switch. • Set Current Position to Zero — Sets the current axis position to zero. • Not Applicable — This is used when the MC has a HOME/REF other than

above.

Note: On G.E. Fanuc equipment, the reference speed is specified in the servo configuration parameters.

Jog + (POS) This block will jog the axis in the positive direction using the following steps:

• Step .001 — This will jog the axis in the positive direction by .001 step of

the Units specified in the Axis Default block and then stop. For example, if the Units are in/min, the axis will jog .001 inch then stop.

• Step .01 — This will jog the axis in the positive direction by .01 step of the

Units specified in the Axis Default block and then stop. For example, if the Units are in/min, the axis will jog .01 inch then stop.

• Step .1 — This will jog the axis in the positive direction by .1 step of the


• Step 1 — This will jog the axis in the positive direction by 1 step of the

Units specified in the Axis Default block and then stop. For example, if the Units are in/min, the axis will jog 1 inch then stop.

• Continuous — This will jog the axis in the positive direction until a stop

motion command is issued.


• Not Applicable — This is used when the motion controller has a jog

positive function other than above. Jog - (NEG) This block will jog the axis in the negative direction using the following steps:

• Step .001 — This will jog the axis in the negative direction by .001 step of

the Units specified in the Axis Default block and then stop. For example, if the Units are in/min, the axis will jog .001 inch then stop.

• Step .01 — This will jog the axis in the negative direction by .01 step of the


• Step .1 — This will jog the axis in the negative direction by .1 step of the


• Step 1 — This will jog the axis in the negative direction by 1 step of the

Units specified in the Axis Default block and then stop. For example, if the Units are in/min, the axis will jog 1 inch then stop.

• Continuous — This will jog the axis in the negative direction until a stop

motion command is issued. • Not Applicable — This is used when the motion controller has a jog

negative function other than above.

Stop Motion This block will cause the servo to perform a controlled stop or "hold" while maintaining position. The deceleration ramp established in the Axis Default block is used. The drive remains enabled and current continues to be supplied to the motor. This instruction is typically used to temporarily stop or suspend a "continuous" jog, but can be used to stop any motion. Resume Motion This block will resume a move from its stopping point after a Stop Motion command has been issued to the axis. This instruction is only used in conjunction with motion profiles instructions when no Reset command has been issued. This command does not work with moves like “jogs.” Reset This block will "attempt" to clear errors in the motion controller. With regard to G.E. Fanuc equipment, Reset places axis control at the top of the part program.


Enable This will turn on the amplifier and supply current to the motor. Test with Ready. Disable This will turn the amplifier off and stop supplying current to the servomotor. Emergency Stop This will cause the drive to perform a controlled stop. This action differs from the Stop motion command because the move cannot be resumed.

Note: The behavior of these instructions may differ from one drive system to another. It is important to consult with engineering when attempting to analyze or predict equipment performance.

Axis Control Block Rules Axis Control blocks must adhere to the following rules:

• The Home/Reference option of Not Applicable is invalid when using the GE PowerMate D or Modicon motion systems. It will cause a compile error message.

• The Home/Reference options of Home in + (POS) Dir, Home in - (NEG)

Dir and Set Current Position to Zero are invalid when using the GE PowerMate D motion system. It will cause a compile error message.

• The Home/Reference option of Reference is invalid when using the

Modicon motion system. It will cause a compile error message. • The destination of an Axis Control block must always be another block.

The Axis Control block cannot loop back to itself.


Axis Move The Axis Move block, shown in Figure 37, is used to move an axis to a specific position and supports three positioning methods:

• Absolute • Relative • Continuous

Figure 37 Axis Move Block

Absolute This method will move an axis to a defined absolute position. The final position is referenced from the zero or reference position. Variables used here are considered positions. The absolute positioning method allows two speed options: Rapid Positioning Speed or user specified speed.

• Rapid Positioning Speed — The axis will move at the speed set in the Axis Default block.

• User Specified Speed — The axis will move at the speed entered in the

Axis Move block.

AXIS: Station 1 Slide MOVE ABSOLUTE TO FULL DEPTH 1000.0000 SPD: FEED 120.00000 TERM: STOP ACC/DEC: NO CHANGE ACC RAMP: NO CHANGE DEC RAMP: NO CHANGE TORQUE LIMIT: NO CHANGE

3.00

4.00


The termination type must be entered for the axis. The termination type sets the axis behavior when the axis reaches its position. The termination type selection is based on the speed option selected; Rapid Positioning Speed or user specified speed. If Rapid Positioning Speed is selected, the following termination type may be selected:

• Stop — The axis will come to a complete stop when it reaches position. The axis will not start another move until it is stopped. This typically occurs at the end of a feed when the next move causes the axis to travel in the opposite direction.

• Dwell — The axis will come to a complete stop when it reaches position

and dwell for the specified time. The axis will not start another move until the dwell time has elapsed.

If a user-specified speed is entered, the following termination type may be selected:


• No Stop — The axis will not stop when it reaches position. The axis will

start the next move and the motion controller will determine the smoothest path to take.

• Hard Stop — The axis will try to move to a position beyond the hard stop.

The axis will move until a hard stop is encountered. An example of this option is when a slide is driven in to a hard stop when advancing to full depth. Pressure is exerted to maintain a fixed position against a hard stop without any deviation in position and without faulting out the drive.



Relative This method will move an axis to a position relative to the current position. The final position is based on the current position of the axis. Variables used here are considered distances. The relative positioning method allows two speed options: Rapid Positioning Speed or user specified speed.


• Rapid Positioning Speed — The axis will move at the speed set in the Axis

Default block. • User Specified Speed — The axis will move at the speed entered in the

Axis Move block.

The termination type must be entered for the axis. The termination type sets the axis behavior when the axis reaches its position. The termination type selection is based on the speed option selected; Rapid Positioning Speed or user specified speed. If Rapid Positioning Speed is selected, the following termination type may be selected:




If a user-specified speed is entered, the following termination type may be selected:


• No Stop — The axis will not stop when it reaches position. The axis will

start the next move and the motion controller will determine the smoothest path to take.

• Hard Stop — The axis will try to move to a position beyond the hard stop.

The axis will move until a hard stop is encountered. An example of this option is when a slide is driven in to a hard stop when advancing to full depth. Pressure is exerted to maintain a fixed position against a hard stop without any deviation in position and without faulting out the drive.




Continuous This method will move the axis continuously. This command is used when, for example, a servo is controlling the speed of a conveyor. There is no advanced position, so no distance is specified. The servo is typically stopped using a Stop Motion command in an Axis Control block. The continuous positioning method allows two speed options: Rapid Positioning Speed or user specified speed.

• Rapid Positioning Speed — The axis will move at the speed set in the Axis Default block.

• User Specified Speed — The axis will move at the speed entered in the

Axis Move block. The direction of travel must be entered for the axis.

• + (Positive) — The axis will move in the positive direction. • - (Negative) — The axis will move in the negative direction.

The Axis Move block can also over-ride servo performance parameters established in an Axis Default block. The move will use the value entered or if "No Change" is selected for any of these servo performance settings, the values in the Axis Default block will be used. Accel/Decel Developers are permitted to chose from two motion profiles, linear or "S" Curve. Accel Ramp Establishes how quickly an axis will speed up to achieve a higher speed. Valid values for the Accel Ramp range from 0 to +99999999. Decel Ramp Establishes how quickly an axis will slow down to a given speed or stop. Valid values for the Decel Ramp range from 0 to +99999999. Note: Compile errors will occur when attempting to set or modify the ACCEL/DECEL motion parameters using the flowchart development program on G.E. Fanuc equipment. These parameters must be adjusted directly at the motion controller. Torque Limit Specifies the amount of the available current a drive uses to maintain a given speed or position. This value is typically expressed as a percentage. Valid values for the Torque Limit range from 0 to 100.


Axis Move Block Rules Axis Move blocks must adhere to the following rules:

• If NO CHANGE is programmed in Accel/Decel, Accel Ramp, Decel Ramp or Torque Limit value and no default block is programmed, the default value set in the motion controller is used.

• The flowchart kernel does not wait for the move to complete before

leaving the Axis Move block. However, the flowchart will pause until a "receipt of command" acknowledgement is detected.

• An Axis Move block with a “No Stop” option MUST be followed by another

Axis Move block. • The destination of an Axis Move block must always be another block. The

Axis Move block cannot loop back to itself. Axis Test The Axis Test block is used to test the status of an axis or if the axis is in a specific position. Each test (TEST STATUS or AT POSITION) must be performed with a separate Axis Test block. Test Status To test the status of an axis an Axis Test block is used. Figure 38 shows an Axis Test block used to test the status of an axis. The Axis Test block can contain up to five tests. These tests can be combined using the AND/OR logical operators. The tests that can be performed are:

• Ready — An axis is ready if power is applied to the drive, the axis is prepared to move. However, faults may be present.

Note: Internally, a given drive type may require more signals before declaring itself ready. • Fault — This test indicates the presence of a drive fault. When a fault

occurs in the drive, an alarm number is also issued to the flowchart program where it can be decoded and annunciated, using flowcharts, on the runtime screen and RMU displays.

• + Limit (positive overtravel) — This test, when TRUE, indicates that an

axis has traveled beyond a software over-travel limit while traveling in a clockwise or positive direction.

• - Limit (negative overtravel) — This test, when TRUE, indicates that an

axis has traveled beyond a negative software over-travel.


• Homed — This test is performed to indicate that an axis has been homed.

In some equipment, the Move Done test is performed. • Move Done — This test is TRUE when a move has been completed

without regard to where the axis has stopped. • Emergency Stopped — This test, when true, indicates that an emergency

stop was activated. • Download OK — This is used to detect part program download failures in

the flowchart programs. If a move other than a jog or a reference is attempted on an axis where a download failure occurred, the block will be ignored. (Download fail will appear in FloPro Banner)

Figure 38 Axis Test Block (Test Status)

At Position To test the position of an axis an Axis Test block is used. Figure 39 shows an Axis Test block used to test the position of an axis. This test is performed to confirm where the axis was last sent. It also indicates if the motion was completed successfully. To perform this test, the correct position name must be specified in the instruction.

4.00

NO

YES AXIS-0ATHOME

Station 1Slide

At Home? 6.00

5.00


Figure 39 Axis Test Block (At Position)

Axis Test Block Rules Axis Test blocks must adhere to the following rules:

• The YES and NO flow lines cannot go to the same destination block. • The destination of either the YES or NO flow lines from the Axis Test block

does not have to be another block. The horizontal branch of an Axis Test block can loop back to itself.

• The Test Status options of + Limit, - Limit, At Home and Homed are invalid

when using the GE PowerMate D motion system. They will cause a compile error message.

• If an Axis Move block is programmed with a dwell, the At Position test will

not be true until the dwell is complete. The At Position test bit is reset when the next motion command is issued or if the flowchart program is terminated.

Note: The Download Status test currently applies only to Powermate “D” controllers.

6.00

NO

YES AXIS-0ATPOS -1

Station 1Slide

At Feed Position(50.000000)

? 8.00

7.00


4.5 Servo Motion: Spindle Blocks Spindle control blocks are used for cutting and grinding applications. The following spindle control blocks will be discussed:

• Spindle Default • Spindle Control • Spindle Test

Spindle Default The Spindle Default block, shown in Figure 40, establishes the default performance characteristics for the specified spindle. These defaults will be in effect unless they are over ridden by another Spindle Default block. The default characteristics that will be discussed are:

• Units • Speed • Accel/Decel • Accel Ramp • Decel Ramp • Torque Limit

Units Developers can select revolutions per minute (rev/min) or degrees per minute (deg/min). Speed Speed represents the speed that the spindle will rotate. Developers must place in this block the actual speed value itself. Accel/Decel Developers are permitted to chose from two motion profiles, linear or "S" Curve. Accel Ramp Establishes how quickly a spindle will speed up to achieve a higher speed. Valid values for the Accel Ramp range from 0 to +99,999,999. Decel Ramp Establishes how quickly a spindle will slow down to a given speed or stop. Valid values for the Decel Ramp range from 0 to +99,999,999. Note: Compile errors will occur when attempting to set or modify the ACCEL/DECEL motion parameters using the flowchart development program on


G.E. Fanuc equipment. These parameters must be adjusted directly at the motion controller. Torque Limit Specifies the amount of the available current a spindle uses to maintain a given speed. This value is typically expressed as a percentage. Valid values for the Torque Limit range from 0 to 100.

Figure 40 Spindle Default Block

Spindle Default Block Rules Spindle Default blocks must adhere to the following rules:

• If NO CHANGE is programmed in a default value; the value in the spindle controller is used unless specifically set by another Spindle Default block.

• The destination of a Spindle Default block must always be another block.

The Spindle Default block cannot loop back to itself.

SPIN: Station 4 Mill DEFAULT VARIABLES SPEED: 2000.0000 UNITS: REVS/MIN ACC/DEC: NO CHANGE ACCEL RAMP: NO CHANGE DECEL RAMP: NO CHANGE TORQUE LIMIT: NO CHANGE

7.00

8.00


Spindle Control The Spindle Control block, shown in Figure 41, is used to control a spindle using the following functions:

• Start (CW) — This will cause the spindle to rotate in the clockwise direction at the speed specified in this block or set in the Spindle Default block.

• Start (CCW) — This will cause the spindle to rotate in the counter

clockwise direction at the speed specified in this block or set in the Spindle Default block.

• Stop — This will cause the spindle to stop. • Orient — This will cause the spindle to rotate to a predetermined position

set by the spindle controller. This may be necessary to align tooling or provide clearance.

• Reset — This causes the spindle to be reset. This means that an attempt

will be made to clear errors in the controller and, as it is with motion profiles, control will resume at the top of the part program.

• Index — This will cause the spindle to index to a predetermined index

position set by the spindle controller. • Enable — Allows the controller to supply current to the spindle motor.

This will allow the spindle to rotate. • Disable — Turns off the current to the spindle motor. This will not allow

the spindle to rotate. • Emergency Stop — This will cause the spindle to stop rotation.

Figure 41 Spindle Control Block Example

SPIN: Station 1 Drill STOP

8.00

SPIN 1

9.00


Spindle Control Block Rules Spindle Control blocks must adhere to the following rules:

• The destination of a Spindle Control block must always be another block. • The Spindle Control block cannot loop back to itself.

Spindle Test The Spindle Test block is used to test the status of a spindle. The Spindle Test block, shown in Figure 42, can contain up to five tests. These tests can be combined using the AND/OR logical operators. The tests that can be performed are:

• Ready — A spindle is considered ready when power is applied to the drive, the spindle is prepared to turn, and there are no drive faults present.

• Fault — This test indicates the presence of a spindle controller fault. • At Speed — This test is performed to confirm that a spindle is rotating at

the commanded speed. • Zero Speed — This test is performed to confirm that a spindle has

stopped as commanded. • Oriented — This test confirms whether or not a spindle as reached the

orient position as commanded. • Overload — This test checks to see if the torque limit established in the

Spindle Default block has been exceeded.


Figure 42 Spindle Test Block

Spindle Test Block Rules Spindle Test blocks must adhere to the following rules:

• The YES and NO flow lines cannot go to the same destination block. • The destination of either the YES or NO flow lines from the Spindle Test

block does not have to be another block. The horizontal branch of a Spindle Test block can loop back to itself.

Station 1 Mill AT

SPEED

9.00

NO 11.00

YES 10.00

SPIN 1 AT SPEED


NOTES


5 Running and Testing a Flowchart Program

5.1 Overview Once a program has been compiled, it must be tested. This module discusses the options for program execution as well as the runtime debugging utilities available to the developer.


• List the differences between flowchart I/O execution modes. • List the differences between flowchart program execution modes. • Perform the steps necessary to simulate program execution. • Test and debug a given flowchart program. • List the diagnostic elements that can be displayed through the flowchart

debugger utility over the users runtime display. • Perform the steps necessary to force a discrete signal on or off.


5.3 Flowchart I/O Execution Modes The flowchart kernel allows 2 modes of I/O execution:

• Run Real I/O • Simulate I/O

Run Real I/O This I/O execution mode requires an I/O scanner to be installed in the PC and the I/O modules and racks must be configured correctly. When using this mode of execution, the inputs are read and the outputs are turned on and off according to the flowchart application program. Note: If a fatal error is detected in the I/O sub-system while the application program is starting, the flowchart “kernel” program may pause and display an error message. To escape from this, press the ALT and F10 keys together. Simulate I/O This I/O execution mode does not require an I/O scanner or the I/O modules and racks to be installed. When using this mode of execution, the inputs, outputs and flags can be forced on or off.

5.4 Flowchart Program Execution Modes The flowchart kernel allows three-program execution option:

• Begin Execution Using A User Program • Begin Execution Using FloPro Only • Enter Debug Directly

Begin Execution Using A User Program This program execution option allows a user program to run with the flowchart kernel to perform functions not available in the flowchart instruction set. Reports and fault logging are typical functions performed by a user program. This option requires the user program to be in the current project directory. User programs will be covered in more detail in a later module.


Begin Execution Using FloPro Only This program execution option allows a user to run the flowchart program directly. Enter Debug Directly This program execution option allows the user to setup the flowcharts and I/O to be viewed during flowchart execution:

• If running with REAL I/O, I/O will be enabled but flowcharts are not solved. • If running in SIMULATE I/O mode, I/O will not be enabled, but flowcharts

will be solved. In either case, the Debugger is substituted for the runtime screen as the initial display. The Debugger is covered in the next section.

5.5 Flowchart Debugger The Debugger is a runtime utility (meaning that the equipment can still be cycling) that provides the user with tools for monitoring and testing the I/O. The list given below is an overview of the tools a technician may find useful in troubleshooting equipment. Using the Debugger creates a task that is sliced into the scan interval of the flowchart application program. This does not lengthen scan time nor degrade equipment performance. However, you may detect a noticeable lag in display speed especially on large applications.


Figure 43 shows the task timing or time slice for the flowchart application program execution. I/O SCAN I/O SCAN TIME 20 MS FLOWCHART MEMORY TESTS

SOLVE NORMAL EXECUTION

5 MS 15 MS

FLOWCHART EXIT OR DEBUGGER MEMORY TESTS SOLVE EXIT OR DEBUGGER BEING 5 MS 10 MS 5 MS EXECUTED

FLOWCHART EXIT DEBUGGER MEMORY TESTS

SOLVE EXIT AND DEBUGGER BEING 5 MS 5 MS 5 MS 5 MS EXECUTED

Figure 43 Flowchart Task Timing The flowchart debugger allows the programmer to:

• View Flowcharts • Examine Status • Real-Time Status • Real-Time Flowchart • Breakpoint/Trace • Cross Reference • Exit debugger • Terminate execution

View Flowcharts This feature allows flowcharts to be viewed during execution. Flowcharts can be edited in this display and saved to disk. But for any changes to affect equipment performance, they must be compiled off-line. This includes changes to remote messages and display screens as well as flowcharts. When a flowchart is viewed, the block that was being solved at the moment the view command was executed will be displayed first.


Examine Status This feature allows the developer to examine the status of I/O, counters, timers, etc. The user is also able to force discrete inputs, outputs, flags and modify counter and timer done values, registers, numbers and ASCII characters values. FORCE ON INPUT This command performs 2 operations:

• The input is "disabled" meaning that control of the input is removed

from the field device and placed exclusively in Debugger menu control. • The input is "forced on" and will remain on until "forced off" or

"enabled" and then turned off by the corresponding field device. FORCE OFF INPUT This command performs 2 operations:

• The input is "disabled" meaning that control of the input is removed

from the field device and placed exclusively in Debugger menu control. • The input is "forced off" and will remain off until "forced on" or

"enabled" and then turned on by the corresponding field device. ENABLE INPUT The input is "enabled" meaning that control of the input is returned to the field device. FORCE ON OUTPUT This command performs 2 operations:

• The output is "disabled" meaning that control of the output is removed

from the flowchart program and placed exclusively in Debugger menu control.

• The output is "forced on" and will remain on until "forced off" or

"enabled" and then turned off by the corresponding flowchart action block.

FORCE OFF OUTPUT This command performs 2 operations:

• The output is "disabled" meaning that control of the output is removed

from the flowchart program and placed exclusively in Debugger menu control.


• The output is "forced off" and will remain off until "forced on" or "enabled" and then turned on by the corresponding flowchart action block.

ENABLE OUTPUT The output is "enabled" meaning that control of the output is returned to the flowchart program. FORCE ON FLAG This command performs 2 operations:

• The flag is "disabled" meaning that control of the flag is removed from

the flowchart program and placed exclusively in Debugger menu control.

• The flag is "forced on" and will remain on until "forced off" or "enabled"

and then turned off by the corresponding flowchart action block. FORCE OFF FLAG This command performs 2 operations:

• The flag is "disabled" meaning that control of the flag is removed from

the flowchart program and placed exclusively in Debugger menu control.

• The flag is "forced off" and will remain off until "forced on" or "enabled" and then turned on by the corresponding flowchart action block.

ENABLE FLAG The flag is "enabled" meaning that control of the flag is returned to the flowchart program.

Note: This feature was designed to aid the developer in testing a program in the absence of real equipment. Disabled discretes should never become permanent parts of the program. WARNING: DO NOT USE THIS FEATURE TO BYPASS DAMAGED OR MISSING EQUIPMENT. THE MACHINE SHOULD NOT BE LEFT WITH FORCES. THIS COULD RESULT IN INJURY TO PERSONNEL AND/OR EQUIPMENT DAMAGE.


Modifying Numerical Values

• Timer Done — timer done values, normally set in advance during program development, can be modified through the debugger in the examine status menu. Values can be placed in the program temporarily or permanently saved to disk.

• Counters/Registers/Numbers/ASCII — contents of these memory types

can be modified through the examine status menu and will retain values until overwritten by the flowchart application program or until program execution is terminated.

Real-time Status The contents of 12 registers, 12 discrete states can be added to the user runtime display. Even though a portion of the function key display is overwritten, function key performance is unaffected. Real-time Flowcharts The current block execution status of 12 flowcharts can be added to the user runtime display. Even though a portion of the function key display is overwritten, function key performance is unaffected. Breakpoint/Tracing Another tool in the Debugger arsenal is the flowchart TRACE Function. One or more flowcharts can be placed in a block histogram so that a list of all the blocks solved in each scan for the flowcharts in the trace list is generated. This list is a stack of the last 512 blocks solved while operating the equipment. Once active, the trace function is begun when the user returns to the runtime display. Flowchart tracing is halted when the Debugger is re-entered. This can be accomplished in one of two ways:

• Manually by the user (pressing the ALT and P keys together) • Automatically by the assignment of a breakpoint

Using a Breakpoint: To implement a breakpoint, the user identifies one block in a user-selected flowchart to be the breakpoint. Once that block is encountered in a flowchart, the Debugger is automatically executed and tracing is stopped.


Flowchart tracing can be useful when:

• Intermittent input closure is suspected of causing an equipment failure. Flowchart tracing allows the user to snapshot program execution scan by scan.

• Logical problems in the flowchart design, occurring too rapidly to detect

visually, can be recorded using this feature. Cross Reference This feature allows the developer to list all occurrences and usage of a mnemonic. The display will show the flowchart, block number and type of block where the mnemonic is used. The CROSS REFERENCE menu allows the developer to zoom directly to the flowchart block of the selected mnemonic. Pressing the SHIFT and F6 keys together will go to the next occurrence of a selected mnemonic. Exit Debugger The Exit command returns control of the runtime display to the flowchart program. THERE IS NO IMPACT ON MACHINE PERFORMANCE while the debugger is running or when it is started or stopped. Terminate Execution The Terminate command stops flowcharts from running, relinquishing machine control at the moment the program is terminated. The off-line flowchart Master Menu is then displayed.

WARNING: THE TERMINATE COMMAND HAS A DIRECT AND POTENTIALLY HAZARDOUS IMPACT UPON MACHINE OPERATION. ALWAYS VERIFY MACHINE POSITION AND PERSONNEL SAFETY BEFORE USING THE TERMINATE COMMAND.


NOTES


6 Xycom PC/AT Flat Panel Industrial Computer

6.1 Overview GMPT Romulus uses the Xycom PC/AT Flat Panel Industrial Computer for FloPro operated PC based control. This section discusses the Xycom hardware and status indicators as well as maintenance procedures should components need replacing.

6.2 Objectives After completing this chapter, the student should be able to: • Better understand the Xycom PC/AT Flat Panel Industrial Computer • Identify the status of the Xycom PC/AT based on System Status LED’s • Check System Setup • Maintenance and removing/replacing slide-out computer module


6.3 Operation Operating in an MS-DOS environment, FloPro application programs accesses the Genius I/O system to control machine process by the PC Interface Module (PCIM) installed in an ISA backplane slots. The 9987 PC/AT flat-panel industrial computer combines a PC/AT computer with a Flat-panel display to offer a powerful IBM-compatible compact package. The 9987 PC/AT has an open architecture to meet a variety of applications. The 9987 PC/AT integrates a computer card cage, disk data storage devices, display and keypads into chassis.

6.4 Status Indicators The front panel features six LEDs. Three are wired to hardware (Power, Disk, and COM) and three are programmable (Maintenance, Fault, and RADAR) and accessible through Xycom’s LED/Status register:

System Status Indicators

Figure 44 Data Entry Keypad Diagnostic Testing

Diagnostic tests are provided to verify the operation of the 9987 system hardware function under MS-DOS using Xycom System 3.5-inch bootable test disk. • Set the CPU board jumpers and switches to the factory-set position • Connect the serial loopback connector and the printer cable to the

appropriate connectors and the PC/AT keyboard to the keyboard connector. • Connect the AC power cable the proper outlet.


Figure 45 Serial Loopback Connector

Run the diagnostic tests: Step 1. Insert the diagnostic disk into drive A. Step 2. Turn the power on. Step 3. The diagnostic program will boot the computer. Step 4. From the Main Menu select an option to begin running the test. Figure 3 shows the Main Menu display options used when running the tests. The DIAG.TXT and CMOS.TXT (BIOS setup info) files on the diagnostic disk has detailed information.

MENU DIAGNOSTIC TEST SELECTION

Figure 46 Main Menu


6.5 System Chassis The Xycom 9987 Industrial Computer features, a four slot ISA backplane, 3.5-inch 1.44Mbyte floppy drive, high capacity hard drive, 10.4 inch 256 color TFT LCD type display, 32 data entry keypad, 10 sealed function keypad, 110 Watts power supply, two RS-232 COM ports, a high performance 80486 or PENTIUM processor and has NEMA 4/12 specifications for uses in harsh or industrial environments. Front Panel Lexan Shield And Display

Function Keys (F1 – F10) Access Door Latch

Figure 47 Front Panel

Back Panel

Figure 48 9987 Back Panel

There are six access panel fasteners across the top and bottom and when removed, the Slide-Out Computer Module can be removed. The floppy disk can be configured for rear panel access by removing the metal plate. The Product ID


label is located in the upper left corner of the panel and has the hard drive set up information.

Power Panel

Figure 49 9987 Power Panel

I/O Panel

Figure 50 9987 I/O Panel


Slide-Out Computer Module The slide-out computer panel allows access to the CPU boards and disk drives.

Figure 51 9987 Slide-Out Module

Removing Slide-Out Module 1. Remove the six access fasteners that attach the slide-out module to the 9987

back panel. 2. Using the handles on the right and left side back of panel, the module should

slide pulling straight back. Reconnecting Slide-Out Module 1. Match the top and bottom guides on the module with the indentation on the

inside of the front panel. 2. Push forward until the module is flush with the top and bottom of the front

panel. 3. Reinsert the six access fasteners. 4. If replacing the current module with a difference module, check for the correct

switch settings. The switch settings on the CPU board must match those listed on the label found at the bottom front panel. Incorrect switch settings will cause the fault light to blink (indicating a signal mismatch) and the display will not function. A blinking Maintenance LED indicates a communication failure between the CPU and the PKIM.

Figure 52 PC/AT Processor Switch Settings


6.6 Maintenance Replacing the Fan Filter 1. To change the fan filter, remove the grill as shown below. 2. Clean the filter with warm water and dish soap, and let the filter completely

dry. 3. Place it back in the filter holder and snap the grill back into position. 4. Do not operate the 9987 PC/AT without a filter. (Could cause damage)

Figure 53 Changing the Filter

Replacing the Fuse 1. Turn power off to the terminal before replacing the fuse. 2. The fuse holder is located on the power supply. 3. The 9987 PCAT uses a 5 amp 3AG 250 volts.

Figure 54 Changing the Fuse


6.7 Saving / Restoring Retentive Memory Retentive memory should be saved to the hard drive and then restoring it to the battery backed RAM when either the FloNet card or the battery on a FloNet card is replaced. Save retentive memory from the board to the hard drive Exit FloPro At the C:\ Prompt type the following command line (the file saved is called RM.DAT) RETMEM b d c800 4096 Restore retentive memory from the hard disk to the board At the C:\ Prompt type RETMEM d b c800 4096 The syntax for using RETMEM is; RETMEM, Source, Destination, Board Address, (system size) Where the source is (d = disk, b = board). Where the destination is (d = disk, b = board, s = screen, p = printer). Where the board address is (c800, d000, d800, e000, disk). disk address will be extracted from the PROJRET.UAI file Where the system size is optional (512, 1024, 4096, 6144)

6.8 Rescue Disk Operation If the PC using FloPro fails and is replaced with a new one or there is a new installation, the RESCUE DISK can be used to load the files needed for file transfers, FloNet and other basic functions required for the PC’s hardware to operate correctly. The files on the PC’s hard drive using the Ethernet, are backed up or uploaded to a HOST server, stored on its hard drive and also magnetic tape backed. The download option is used to recover an existing machine that has been UPLOADED to the server. Downloading to a newly installed machine should never be done.


6.8.1 RESCUE DISK Procedure: Step 1. The user is prompted to initialize the PC with files from A: to C:

YES - copies the files for file transfer, IDENTITY. BAT and other files needed for PC correct operation. NO - basic files are not copied from the A: drive. The files already exist on the hard drive.

Step 2. The user is asked, is this a new machine installation? : YES - If the machine has never had its IDENTITY.BAT edited. The YES places the user in the editor to edit the IDENTITY.BAT file. NO - If the machine is being recovered and was previously uploaded. The NO asks the user if they would like to download the files from the HOST to the PC. Answer YES to download. Answer NO to skip the download.

Step 3. Operation is complete.

6.8.2 UPLOADING Process The User can select the Ethernet mode when exiting FloPro by selecting “Y” (yes) to Ethernet mode and will begin the uploading process. After selecting the Ethernet mode: Step 1. Ethernet drivers are loaded Step 2. Directories are uploaded (FloPro \ Projects, Others, Temp, directory

listing, root directory and retentive memory files) Step 3. PC log files are uploaded Step 4. Retentive memory is saved to disk Step 5. Virus protection software and BUILD.EP (engine assembly) are

downloaded from the host Step 6. Upload process is completed and the PC reboots, returning it to FloPro

6.8.3 DOWNLOADING Process Downloading is used to recover PCs that have been UPLOADED to the server in the past. DO NOT download to new machines that have not been uploaded to server.


Step 1. User selects download option during the RESCUE DISK operation. At the C:\ prompt, type DOWNLOAD

Step 2. The PC is examined for present of certain files to complete a download and if not present, the user will use the Rescue Disk to install the basic files needed.

Step 3. If the basic files are present, the PC is put into Ethernet Mode and reboots

Step 4. Four settings in the IDENITIY.BAT file must be set correctly and verified by the user. The Items are Machldent, IpAddress, Server_IP, and Antivirus.

Step 5. If there are errors in IDENITY.BAT file, the editor will start, allowing the user to correct the errors. Completing the edits and exiting the editor, the user is prompted to verify the settings and if correct, the user is prompted to start download desired (“Y” to download, “Q” to quit the download, reboot the PC and try to start FloPro.

Step 6. IF Download was selected Step 7. Ethernet drivers are loaded Step 8. Directories are uploaded (FloPro \ Projects, Others, Temp, directory

listing, root directory and retentive memory files) Step 9. PC log files are uploaded Step 10. Retentive memory is saved to disk Step 11. Virus protection software and BUILD.EP (engine assembly) are

downloaded from the host Step 12. Upload process is completed and the PC reboots, returning it to FloPro The text file C:\HELP.TXT on the PC hard drive provides information about the IDENTITY.BAT, file transfer and running the RESCUE DISK on a FloPro PC.


6.9 Block Diagram / Pin Outs Block Diagram

Figure 55 System Block Diagram


COM1/COM2 SERIAL PORT CONNECTOR

Figure 56 COM1/COM2 SERIAL PORT CONNECTOR

Keyboard Connector Front View

Figure 57 Keyboard Connector


Notes


7 Genius Network Interface Card

7.1 Overview The Xycom interfaces with the Genius Bus by way of PCIM cards mounted in the computer. This section describes the function of the PCIM and the steps required to replace a faulting card.

7.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of the Genius Network Interface (PCIM) Card • Troubleshoot the PCIM Card based on FloPro error messages • Configure the PCIM Card in FloPro • Replace a PCIM Card when necessary


7.3 Operation The Genius PCIM Card provides a high speed link from the Xycom computer, running a FloPro application program, to GE Fanuc PLC products on a Genius Network. Its main function is to relay real world input, output, and communication information between field devices and the FloPro application program. It receives the Field Input signals and converts them into inputs for the FloPro application program. It converts the FloPro application Output signals into actual Field Outputs, controlling all machine functions. The status of all the input and output devices on the network are updated each scan cycle. The cards are plugged into open expansion slots on the Xycom motherboard. Of the 4 expansion slots, the 2 middle slots house the PCIM cards.

7.4 Status Indicators The PCIM Card has two LED’s on its outer surface which indicate its status:

LED Status Definition GENI OK ON Power is available to the PCIM card. On-board

self-test passed. OFF The watchdog timer has timed out. Improper

address assignment or RST line low ON Power on, communication enabled (Token is

being received) Comm OK OFF or

FLASHINGCommunication error

Both FLASHING together

Multiple devices with the same address.

Figure 58 PCIM Card LED Indicators

7.5 Diagnostics The Genius PCIM Card is mapped to a channel in the FloPro configuration scheme. There is a diagnostic message that may be displayed to indicate various faults: “Channel X Configuration Error” where X stands for the channel, or PCIM card, in question. The error is displayed when trying to run an application program, and some of the possible causes are:

• The PCIM configuration information is not correct • Another application running on the Host computer (Xycom) is violating

the memory space allocated for the PCIM card (Board Address) • The Genius Network is not running properly due to an incorrect

configuration of a subsequent device


7.6 Configuration A PCIM card stores configuration data in EEPROM on the motherboard. There is one dip switch on the card, which sets the I/O port address for the configuration data. The factory default is 340H. It is critical that the address set by the dip switch matches the Base I/O Port address configured in the FloPro application program.

Figure 59 PCIM Card DIP Switch Location

Dip Switches To set the address using the dip switches on the PCIM card, use the following table for a dual channel PCIM card:

Config DIP Switch Positions DIP Switch Adr (hex)

Memory Segment

I/O Port Address 1 2 3 4 5 6 7 8

340 Off Off On Off On On On On 342 D000 344 Off Off On Off On On On On 342 D400 348 Off Off On Off On On Off On 34A D800 34C Off Off On Off On On Off On 34A DC00

Figure 60 PCIM Card DIP Switch Settings

On the test stand, (1st) installed PCIM card 342H SW1/2 High digit (0-3) (2nd) installed PCIM card 34AH SW3/4/5/6 Middle digit (0-F)

SW7/8 Low digit (2,6,A,E)

8 1


FloPro Configuration FloPro must match the PCIM configuration which has been set up by the dip switches. This is done from the Project Compile menu in a FloPro application. Using the function keys, press:

Step 1. F4 ‘Project Compile’ Step 2. F1 ‘Retentive Mnemonics are Correct’ Step 3. F5 ‘Outputs Always Enabled’ Step 4. F1 ‘Criteria Correct’

You should now be at the Genius I/O Configuration page. The Romulus test stands are equipped with 2 dual channel PCIM cards. Therefore, they will be configured for 4 channels of Genius communication. In the electrical drawings, these channels are referred to as Bus 1 through Bus 4. Still using the function keys, press:

Step 5. F2 ‘Set PCIM Addresses’ Step 6. F1 RAM Address D000 Step 7. ENTER Accept the default device number of 31 Step 8. F1 Base I/O Port 340 hex Step 9. Repeat steps 5 – 8 to configure the remaining 3 channels according to

the chart in Figure 61.

HOST RAM ADDR

DEVICE NUMBER

BASE I/O PORT

D000 31 340 D400 31 344 D800 31 348 DC00 31 34C

Figure 61 PCIM Card FloPro Configuration

Step 10. F10 to return to the I/O Configuration page


Set I/O Error Action Though not specifically related to the PCIM configuration, as part of this lab the I/O Error Action will be set. When there is an I/O error, FloPro can either terminate or continue execution. GMPT Romulus does not use the termination feature, but allows execution to continue, storing the error values in the counters C12 through C17. This allows the FloPro program to decode the I/O error status and display an appropriate diagnostic message. To configure the I/O Error Action:

Step 11. Press F9 ‘Set I/O Error Action’ Step 12. Press F2 ‘Continue Execution’ Step 13. Type the number 12

FloPro will automatically create the necessary range of counters. It is now necessary to complete the compile process. From the I/O configuration screen:

Step 14. F1 'Configuration Correct' for the I/O configuration Step 15. F1 'Configuration Correct' for the Powermates Step 16. F1 'Configuration Correct' for the Balogh RF Step 17. F1 'Configuration Correct' for the Serial COM port Step 18. F1 No Printed Output

7.7 Replacement If the Genius PCIM Card needs to be replaced, the Xycom unit as well as the Genius Network should be powered down. Because the PCIM holds its configuration in EEPROM, this configuration will need to be restored in the new card. As always, the dip switches in the new card must be set to match those of the card being replaced. After setting the dip switches and installing the card in the correct slot:

Step 1. Power the new PCIM Card up while disconnected from the Genius Network.

Step 2. Load its EEPROM with the old configuration using the DPCIMCFG configuration software.

Step 3. Make sure that both LED’s are on. Step 4. Power down before reconnecting the Genius Network. Step 5. Reconnect the Genius Network


7.8 Configuration Lab

Part 1 Begin creating a FloPro configuration from scratch. Use the C:\Class\Config program which has been set up for you. There is one flowchart in the program, the Function Keys Flowchart, because a FloPro program will not compile without at least one flowchart.

Part 2 Enter the configuration parameters for the PCIM Card in the demo unit. Confirm that the values given earlier in this chapter are correct.


NOTES


8 IPN200 Ethernet / FloNet Interface Board

8.1 Overview The Xycom is equipped with a FloNet card in order to communicate across the plant network. The network connection is used to upload/download programs, communicate production data, and generate production reports. This section describes the function of the FloNet card and maintenance procedures.

8.2 Objectives After completing this chapter, the student should be able to: • Better understand the Diversified Technology Ethernet / FloPro Interface • Understand the IPN200 features • Setup configuration


8.3 Operation The IPN200 Ethernet Interface card allows the PC to interface to an Ethernet network either as a standard Ethernet card in the Ethernet mode while not running FloPro or as a specialized Ethernet card in the FloNet mode while FloPro is running. In the Ethernet mode, the IPN200 Ethernet Interface card can be configured, allowing hardware interrupts, I/O ports, and bootable ROM BIOS address locations to be setup for standard Ethernet networks. In the FloNet mode, IPN200 acts as the interface between a local host running FloPro software and an Ethernet LAN remote host. The Ethernet network interface is polled, waiting for packets, which are intended to communicate with FloPro. In this mode, all communication over the network is handled by a dedicated micro-controller on the IPN200 interface. This micro-controller handles requests from FloPro and the Network to move data between the SRAM and a machine across the network. For FloPro mode configurations, the IPN200 takes up six eight-bit I/O ports and 32K of memory. For Ethernet mode, the interface card takes an additional sixteen I/O addresses and 32K of memory space configured for a boot ROM. IPN200 Features In the FloPro mode the micro controller (80c188) used on the IPN200 allows an interface between the FloPro buffer SRAM and the network. This controller is responsible for receiving and processing monitor and FloPro requests for data transfers to and from the SRAM. The interface may be placed in and Ethernet mode either by a software command from the computer or by setting SW-8 in the OFF position. A 128K SRAM is present on board provides battery backed RAM for retentive memory during a power failure and a scratch pad memory for the IPN200 micro controller. A battery monitoring circuit on the IPN200 to check battery strength gives warning for a possible battery failure.


8.4 FloNet Interface Configuration in IDENTITY.BAT Variables defined in the “IDENTITY.BAT” file must be set for proper operation in the PC controller. If a FloNet Ethernet card is installed in the controller, the Internet address of the FloNet card must be set in the variable “IpAddress=”. GM provides this address. To set the IpAddress, on the line after “SET IpAddress=”, enter the Internet Protocol address: SET IpAddress= 198.208.54.76 If a FloNet Ethernet card is installed in the controller, the variable “HasFloNet” is set to TRUE. If the FloNet Ethernet card is NOT installed in the controller, the variable is set to FALSE. The SET line should read: SET HasFloNet= TRUE In order for the PC to communicate with a remote server it must know the remote server’s Internet Protocol (IP) address. This address is defined in the variable Server_IP. SET Server_IP= 198.208.54.12 In order for the batch files that do the file transfers that loads the correct network software, it is necessary to define the type of operation system used by the server. This is defined in the Server_OS line. If the operating system is UNIX for the server, then: SET Server_OS= UNIX The RetentMem variable is used to identify the retentive memory address used by the PC. When file transfer takes place, the program RETMEM.EXE is run from the file RETENT.BAT. This makes a copy of retentive memory, stores and uploads it to the server. SET RetentMem= C800


8.5 IPN200 Ethernet/FloNet Interface Configuration Configuration options on the board are set using jumpers, DIP switches, and utility programs. An upper memory segment address must be selected for the IPN200 firmware. DIP switches are used to select the memory segment address occupied by the SRAM and the I/O address occupied by the IPN200 control registers. The Ethernet controller is configured using the FLOCFG utility.

Figure 62 IPN 200 Ethernet/FloNet Memory Segment Switch 1

FloPro Mode IRQ Selection When the IPN200 is in FloPro mode, the board has the capability of generation an IRQ back to the system to indicate that the system should shutdown of enter the Ethernet mode. E1 through E4 jumpers are used to select the IRQ.

Figure 63 IPN 200 Ethernet/FloNet IRQ Switches E1-E4


Ethernet / FloPro Mode Selection The IPN200 can be configured to operate with FloPro or as a standard Ethernet card. DIP switch eight allows the user to select FloPro mode or Ethernet mode on power up. If the FloNet mode is set, the board may be changed to Ethernet mode through software without powering down and changing the switch setting.

Figure 64 Ethernet / FloPro Mode Selection

Ethernet Mode Configuration Switches one, two and three are used to configure the Ethernet controller when the board is placed into Ethernet mode. Placing all three switches in the off position caused the board to use the default settings of I/O base address 300h and no boot ROM. The addressed read from each EEPROM location may be changed by the used with the utility.

Figure 65 Ethernet Mode ROM Address Selection

I/O Address Selection The IPN200 has six I/O ports not directly associated with the Ethernet controller and are for monitoring and controlling other board functions. These six ports are eight-bit locations, which are six bytes mapped from a selectable base address using switches six and seven.

Figure 66 Ethernet / FloPro I/O Port Selection


SRAM Address Selection The SRAM on the IPN200 is accessible by both the FloPro software running on the PC and the micro controller on the board. The memory address for the 32K window at which the PC sees this memory is set using switches four and five and does not affect the way the micro controller accesses the memory.

Figure 67 IPN200 SRAM Memory Address Selection

Battery Connection The J1 connector on the IPN200 is the battery connector and allows the onboard battery to be left disconnected or connected to maintain the data stored in the SRAM when power is disconnected. The battery voltage is +3.6V. An external battery can be connect to J1( “+ “ to pin #2, “-“ to pin #4 ) also connection a shunt to pins #2 and #3.

Figure 68 IPN200 Battery Connection


NOTES


9 Enhanced Genius Communications Module

9.1 Overview The GCM+ module communicates the PLC data across the Genius bus. Each PLC on a Genius bus has at least one GCM+ module. The following discussion describes the function of the GCM+ module, configuration of the module, and replacement procedures.

9.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of the Enhanced Genius Communications

Module (GCM+) • Recognize the Genius Bus connection scheme • Begin to understand global data communication over the Genius Network. • Configure the GCM+ in FloPro • Replace the GCM+ Module


9.3 Operation The Enhanced Genius Communications Module (GCM+) is a global data manager. Global data is data that is transmitted automatically and continuously, allowing the formation of a shared database. The GCM+ continuously exchanges global data with other devices on the Genius Network. During each bus scan, the GCM+ can send up to 128 bytes of global data in any one of the following forms: %R (register), %I (input), %Q (output), %G (global), %AI (analog input), or %AQ (analog output). Each GCM+ broadcasts the data onto the bus, which makes that data available to any other device connected to the bus. During each bus scan, the GCM+ can also pass up to 128 bytes of global data to its PLC from up to 31 other devices connected to the bus. Because the global data is being written directly into a device’s data table, it is possible to control both Inputs and Outputs “remotely” by writing the desired states directly to the data table. Because all the global data being broadcast often exceeds what any one GCM+ module needs, the GCM+ can be configured to ignore any data it does not want using Offset and Length parameters. It is not necessary to have a PLC application running for the GCM+ to send and receive global data. When using a GCM+ in this way, it acts like a remote rack, allowing its outputs to be controlled globally, and reporting its inputs to the network. This is the configuration found in most FloPro applications. This allows the FloPro application program to receive the input information from the GCM+, and then write the output table for the GCM+ to receive and implement.

9.4 Bus Connection The maximum Genius serial bus length is 7500 feet, using shielded, twisted-pair cable. A baud rate is selected according to the bus length, and can be set up for 153.6 Kbaud standard, 153.6 Kbaud extended, 76.8 Kbaud, or 38.4 Kbaud. All devices on a bus must be set up for the same baud rate. Note: GMPT Romulus uses 153.6 Kbaud standard.


Two important points are illustrated in the following graphic:

Figure 69 Genius Serial Connections

Notice that the Shield In is not connected on the first device of the bus, and the Shield Out is not connected on the last device of the bus. Also notice that terminating resistors are required at both the beginning and the end of the bus.

9.5 Status Indicators LEDs on the front of the GCM+ module indicate its operating status, and the status of communications between the module and the Series 90-30 PLC. OK indicates that the GCM+ has passed its powerup test and is operating. COMM indicates that the GCM+ is configured and is transmitting or receiving global data. If either OK or COMM is off or blinking, look for the following causes:

OK LED

COMM LED Indicates:

ON ON Normal Operation ON Blinking Intermittent bus operation

Synchronous blinking

Synchronous blinking

Genius Bus Address conflict

ON OFF Module not configured, or no communications

OFF OFF No power or fatal powerup error

Figure 70 GCM+ Status LEDs


9.6 Configuration The GCM+ must be configured before it will send and receive global data, or communicate with its PLC. It can be connected to the bus without being configured. Also, it must be physically connected to be configured with a Hand Held Programmer or the Logicmaster software. Configuration is typically done with a laptop computer using the Logicmaster software. This requires a special serial cable connected from the COM port on the laptop to the port on the front of the PLC power supply. A Genius Hand Held Monitor cannot be used to configure a GCM+ card. Information supplied in the GCM+ configuration is as follows: Parameter Default Range Function GCM+ Slot Number

None Any Series 90-30 Slot Identification

SBA 16 0 – 31 Buss Address Drop ID 33 16 – 254 Used with Report Faults

<Optional> Baud Rate 153.6 Kb

std 153.6 Kb std, 153.6 Kb ext, 76.8 Kb, or 38.4 Kb

All Devices on the Bus Must Be Configured for the Same Baud Rate

Data Default Off Off, Hold Last State Selects Data to be Sent Upon Communication Loss

Report Faults No Yes, No Used to send Fault Reports to a Series 90-70 PLC <Optional>

S6 Reference 0 1 – 16,383 Used when Sending Global Data to a Series Six or Series Five PLC <Optional>

Status %I0001 Any Available %I in Host

32 bit Memory Space for Reporting Status

Starting Reference

None Any Available %I, %Q, %G, %AI, %AQ, %R in Host

Selects Start Point and Type of Memory (Only One Type Allowed Per Message)

Reference Length

0 0 – 64 Words, 0 to 1024 Bits

Length of Global Data to Exchange

Message Buffer Byte Offset

0 0 – 128 Bytes Used to Skip the Start of an Incoming Global Data Message <Optional>

Figure 71 GCM+ Configuration Parameters


Logicmaster configuration of the GCM+ From the C:\Prompt Step 1. Type LM90 - Loads the Logicmaster software package Step 2. Shift + F3 - Select 90-30 PCM Step 3. F2 - Logicmaster configuration package At Program Folder: Step 4. Type ‘TRAINER’ Step 5. Type ‘Y’ - Yes to create Step 6. F1 - I\O configuration Note: ALT + M will toggle ‘mode’ at bottom of screen. Select OFFLINE to configure. Step 7. Hi-lite PWR - Use arrow keys Step 8. F10 - to ‘ZOOM’ or select Step 9. Enter part # - Press F1 to bring up list (reference part list below) Step 10. Press ESC to exit screen Step 11. Select CPU - F10 to ‘ZOOM’ Step 12. Enter part # - Press F1 to bring up list (reference part list below) Step 13. Match all fields to the following diagram: (TAB key to toggles

choices)

Figure 72 Logicmaster CPU Configuration


Step 13. Press ESC twice to exit Step 14. Move cursor to Slot 1 Step 15. Press F2 - to select GCM+ card Step 16. Enter part # - Press F2 to bring up list (reference part list below) Step 17. Configure Slot 1 (GCM+ card) using the information in the following

three diagrams. Use the PAGE DOWN key to move through the SBA screens. Using the CTRL + Arrow keys allows you to move the cursor within a field.

Figure 73 Logicmaster GCM+ Configuration


You may wish to configure the remaining slots at this time. The remaining modules will be discussed in later sections of the manual. The Link module has a length of 64. All PLC module part numbers are listed below. After completing the configuration, you will need to LOAD the configuration and program to the PLC.

Step 1. Exit the configuration package by pressing the ESC key.

Step 2. Enter the Programmer package with the F1 key

Step 3. Select ‘TRAINER’ and press ENTER

Step 4. Change to ONLINE mode

Step 5. Press F9 to store to PLC

Step 6. Select ‘Y’ for Program Logic

Step 7. Select ‘Y’ for Configuration

Step 8. Select ‘N’ for Reference Tables

Step 9. Press ENTER to send to PLC

Step 10. Exit programmer package and re-enter configuration package

Step 11. Press F3 for PLC Control

Step 12. Press F1 for RUN/STOP PLC

Step 13. Set PLC in RUN mode (TAB key toggles choices)

Step 14. Exit Logicmaster

The PLC must be in ONLINE and RUN mode to run on the network. PLC modules used on the GMPT Romulus test stands: Module Part # PWS - IC693PWR322 CPU - IC693CPU313 GCM+ - IC693CMM302 I\O Link mod - IC693BEM320 16 pt. input - IC693MDL645 16 pt. output - IC693MDL740 8 pt. Output - IC693MDL730


FloPro configuration of the GCM+ When configuring a FloPro application program, there are parameters which need to be designated for the GCM+. Because the GCM+ has already been configured in the Genius Network, the FloPro configuration does not need to configure each of the devices which communicate through a particular GCM+. The FloPro application merely needs to be configured for the range of global data which the GCM+ will be exchanging. The following is a table of parameters FloPro uses to configure a Genius device, and the settings for the GCM+ on the Romulus test stand: PLC (GCM+) INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 1 16 Global 0 – 15 I0201 –

I0328 0 – 10 O0201 -

O0288 Figure 76 GCM+ Configuration Parameters for FloPro

When configuring an application, use FloPro Input designations which will correspond to the %I and %Q locations specified in the GCM+ configuration.


9.7 Replacement If the GCM+ module needs to be replaced, the rack it resides in must be powered down. The Genius bus, however, may not need to be powered down. If the incoming and outgoing wires on terminals Serial 1 have been either connected to the same terminal or jumpered together, and the terminals for Serial 2 have been either connected to the same terminal or jumpered together, then the communication bus can remain active. If this is the case, the terminal assembly must be removed first: Step 1. Open the hinged front cover of the module Step 2. Push the jacking lever upward to release the terminal block

Figure 77 Series 90-30 Module Replacement

Step 3. Grasp the narrow pull tab on the upper right of the terminal assembly, and pull until the contacts and the hook have disengaged.



Once the terminal assembly has been removed, the module can be replaced: Step 1. Press the release lever on the bottom of the module up toward the

module Step 2. While holding the lever in an up position, swing the module upward,

pivoting it about the top like a hinge


Step 3. Raise the module up to disengage the hook at the top, and remove it from the baseplate.

To install the replacement module, simply engage the hook at the top in the proper slot, and swing the module down into position until it latches into position on the baseplate. The terminal assembly can be reinstalled by carefully sliding it back into position on the module, and making sure to get it fully seated.

PRESS RELEASE LEVER



Part 1 Use the Logicmaster software to configure any GCM+. Go through the parameters and check the settings for each one.

Part 2 Enter the parameters for any GCM+ in the FloPro configuration. Confirm that the values entered match those viewed in part 1 for the Genius Network.


NOTES


10 Series 90-30 I/O Modules

10.1 Overview The Series 90-30 PLC modules communicate I/O data through the GCM+ module across the Genius network to FloPro. Each module has status indicators that can aide in finding a faulting module. This section describes the function of the 90-30 series module and their indicator lights. Also, there is discussion on the configuration of the modules in FloPro.

10.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of Series 90-30 I/O Modules • Identify the status of Series 90-30 I/O Modules based on their indicator lights • Configure Series 90-30 I/O Modules in FloPro • Replace an I/O Module


10.3 Operation There are many different types of I/O Modules which the Series 90-30 will support. Different applications require various combinations of these modules. Many features of the modules discussed here are typical of most Series 90-30 I/O modules. The modules discussed in this chapter will be the 12/24 VDC Input Module, 12/24 VDC Output Module, both commonly found in floor applications, and the Input Simulator, which is unique to the Romulus demo unit.

10.4 24 VDC Input Module There are a number of 24VDC Input Modules available depending on the needs of the application. Modules normally receive either eight or sixteen inputs, with various current, on/off time, and power consumption characteristics based on the specific module selected. There are LED’s at the top of the module to indicate the state of each input point; the top row, labeled A1 through 8 are used for points 1 through 8 on all modules, and the bottom row, labeled B1 through 8 are used for points 9 through 16 for a sixteen point module. As with all Series 90-30 modules, these modules have an insert inside the front hinged cover which describe the wiring for the module. These modules can be installed in any I/O slot of either a 5 or 10 slot baseplate Series 90-30 PLC system.

10.5 24 VDC Output Module There are also a number of 24VDC Output Modules available depending on the needs of the application. Modules normally supply either eight or sixteen inputs, with various isolation groupings. Modules also vary in current supplied, inrush current, output voltage drop, off-state leakage, and on/off response times. There are LED’s at the top of the module to indicate the state of each output point; the top row, labeled A1 through 8 are used for points 1 through 8 on all modules, and the bottom row, labeled B1 through 8 are used for points 9 through 16 for a sixteen point module. Some modules have fuse(s) to protect them, and if there is a blown fuse condition, a red LED located at the top of the module will indicate this. As with all Series 90-30 modules, these modules have an insert inside the front hinged cover which describe the wiring for the module. These modules can be installed in any I/O slot of either a 5 or 10 slot baseplate Series 90-30 PLC system.


10.6 Configuration In a FloPro application, the Series 90-30 I/O Modules are located in a rack which communicates on the Genius Network through a GCM+ module. The GCM+ module would therefore need to be configured to accept the input and output information from the modules on the baseplate with it, and then the FloPro application would be configured to communicate with the GCM+ module directly. See the GCM+ section of this manual for more information on the configuration.

10.7 Replacement See Replacement in the GCM+ section of this manual (Section 9.7).



Part 1 Use the Hand Held Programmer to examine the configuration for any Series 90-30 I/O Modules. Check the memory allocation for each I/O point.

Part 2 Examine the GCM+ to see how the individual I/O Modules are configured for communication on the Genius Network.


NOTES


11 Genius Discrete I/O Blocks

11.1 Overview Genius Discrete I/O Blocks allow for remote mounting of I/O. They communicate across the Genius network to FloPro via the Genius Bus. This section discusses the operation and configuration of the Genius Discrete I/O Blocks.

11.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of Genius Discrete I/O Blocks • Identify the status of Genius Discrete I/O Blocks based on their indicator lights • Configure Genius Discrete I/O Blocks in FloPro • Replace an I/O Block


11.3 Operation There are many different types of Genius I/O Blocks available for use. Unlike the Series 90-30 Modules in the previous chapter, the Genius I/O Blocks are stand-alone units which can be mounted virtually anywhere. These I/O Blocks actually communicate directly on the Genius Network, sending and receiving input, output, and fault information. The two modules discussed in this chapter are representative of most I/O Blocks, and are those which are found on the Romulus Demo Unit.

11.4 16 Circuit DC Input/Output Blocks There are sixteen discrete circuits available on each block, configurable to be either an input, tristate input, or output. A separate power supply is not needed, as the block uses the input/output device voltages wired to it for control power. Each circuit has electronic surge protection, which trips if 15 amps is exceeded for more than 10msec. Some of the diagnostics available for these modules are overtemperature failed, overload detection and shutdown, open wire for tristate inputs, and no-load detection. These features may be disabled on a circuit by circuit basis. Status indicators are available as follows:

LED State Meaning Unit OK On Normal Operation Blinking Fault Condition Exists I/O Enabled

On I/O Operation Enabled

XX (Circuit) On Input: Threshold Voltage Present Output: State of the Load

Off Input: Threshold Voltage Not Present Output: State of the Load

Figure 80 Discrete 16 Point DI/DO Block Status LEDs


The 16 Circuit I/O Block has a number of configurable options. In many cases, the default values may not need to be changed. The first four items must be configured for the module to communicate over the Genius Network. These parameters are listed below:

Parameter Circt/ BlockFactory Setting Range

Device Number Block Null 0 to 31 Reference Address

Block None Depends on Host CPU Type

Block I/O Type Block Input Input, Output, Combination Baud Rate Block 153.6 Kb

standard 153.6 std, 153.6 ext, 76.8, 38.4 Kb

Pulse Test - Outputs

Block Enabled Enabled, Disabled

Input Filter Time Block 20 mSec 10 – 100 mSec in 10 mSec Steps

Circuit I/O Type Circuit Input Input, Output, Tristate Input Report Faults Circuit Yes Yes, No Hold Last State Circuit No Yes, No Output Default State

Circuit Off Off, On

Detect No Load Circuit Yes Yes, No Overload Shutdown

Circuit Yes Yes, No

BSM Present Block No Yes, No BSM Controller Block No Yes, No Output Default Timer

Block 3 Bus Scans 2.5 or 10 sec

Redundancy Mode

Block None None, Hot Standby, Duplex, GMR

Duplex Default Block Off Off, On Figure 81 16 Point DI/DO Block Configuration Parameters


11.5 Analog Input/Output Blocks There are four independent input circuits and two independent output circuits available on each block. The block converts the input and output signals into engineering units values which relate to the application. A separate power supply is wired into the DC+ and DC- terminals. Each circuit has electronic surge protection, which trips if 15 amps is exceeded for more than 10msec. Some of the diagnostics available for these modules are input low and high alarm detection, open wire detection, input underrange or overrange, and output underrange or overrange. These features may be disabled on a circuit by circuit basis. Status indicators are available as follows:

LED State Meaning Unit OK On Normal Operation Blinking Fault Condition Exists I/O Enabled

On I/O Operation Enabled

Figure 82 Discrete 4I/2O Analog Block Status LEDs


The Analog I/O Block has a number of configurable options. In many cases, the default values may not need to be changed. The first three items must be configured for the module to communicate over the Genius Network. These parameters are listed below:

Parameter Circt/ Block Factory Setting Range Device Number Block Null 0 to 31 Reference Address

Block None Depends on Host CPU Type

Baud Rate Block 153.6 Kb standard

153.6 std, 153.6 ext, 76.8, 38.4 Kb

Input Filter Time Circuit 128 mSec None, or 8 – 1024 mSec Current / Voltage

Circuit 10VDC 0 – 10VDC, +/- 10VDC, 0 – 5VDC, +/- 5VDC, 4 – 20mA (1 – 5VDC)

Report Faults Circuit Yes Yes, No Hold Last Value Circuit No Yes, No Output Default Value

Circuit 0 +/- 32,767

Scaling Points Circuit (+/- 10,000 Eng. Units, +/- 4095 Counts)

(+/- 32,767 Eng. Units, +/- 4095 counts)

Low/High Alarms

Circuit +/- 10,000 +/- 32,767

Alarm Input Mode

Circuit No Yes, No

BSM Present Block No Yes, No Output Default Timer

Block 3 Bus Scans 2.5 or 10 sec

Redundancy Mode

Block None None, Standby

Figure 83 Discrete Analog Block Configurarion Parameters


11.6 Configuration Because the Genius Discrete I/O Blocks communicate directly on the Genius Network, they must be configured using a Hand Held Monitor. The parameters define the module’s operation; parameter lists will vary with specific module types, but should generally follow the listings presented earlier in this chapter. The parameters to be entered for any specific block can be found in the drawing package for that machine. The following figure is an example of the layout of the block parameters in the drawings. These examples are from OP50 on the head line.

Figure 84 Discrete Block Parameters in the Drawing Package


Hand Held Monitor Configuration

Figure 85 Hand Held Monitor Configuration

16 Circuit DC Input/Output Blocks From Main Menu:

Step 1. Press F3: CONFIGURATION

Step 2. Press F1: PROG BLOCK ID

Step 3. Press F1: ref

Step 4. Enter the I/O address range

Step 5. Enter the I/O type – Inputs, Outputs, or Inputs & Outputs

After entering the I/O type:

Step 6. Press F2: blk

Step 7. Enter the block address number (3)

Step 8. Press F4: nxt – switch to SELECT BAUD RATE

Note: The baud rate at GMPT Romulus is set at 153.6K ST.

and Remote I/O Scanner

c h n g e n t r

F R O M : n T O :C O P Y C O N F I G

F 2 : A N A L Y Z EF 1 : H H M U T I L I T I E S

F 3 : C O N F I G U R A T I O NF 4 : D E V I C E M E M O R Y

I / O (device reference)

Remote I/O Scanner

Configure a Remote

r e f b l k n x t

MapConfigure an

Genius Blocks

I/O Block

Configuration MenusDisplaying the HHM

All Devices

P R O G B L O C K I D

F 3 : C O P Y C O N F I GF 2 : C O N F I G B L O C KF 1 : P R O G B L O C K I D

F1

F 4 :

F2

F3

Field ControlDevices

F 3 : P r e v i o u s M e n u

F 2 : M o d u l e C o n f i gF 1 : G E N I U S C O N F I G

F 2 : C O N F I G U R A T I O NF 1 : M O N I T O R

F3

F2 or F3

B L O C K N O . (device#)


r e f b l k n x t



A C T I V E = 1 5 3 . 6 K S TS E L E C T B A U D R A T E

P R O G = 1 5 3 . 6 K S T t g l e n t r n x t


After entering the address and baud rate:

Step 9. Press MENUΔ : Return to previous menu

Step 10. Press F2: CONFIGURE BLOCK

Items to be configured: (See Handout)

1. Pulse Test - Enabled

2. Input Filter Time – Default (20mS)

3. I/O Circuit Type – 0-7 inputs, 8-15 outputs, no tristate inputs

4. Report Faults – (Y) Yes for all

5. Hold Last State – (N) no for all

6. Output Default State – Default (0=off for all)

7. Report No Load – Set according to type of device

8. Overload Shutdown – (Y) for all

9. BSM Present – (N) Device is connected to only one bus

10. Output Default Time – 3 bus scans

11. CPU Redundancy – No control redundancy

12. Configuration Protection - Disabled

F 2 : C O N F I G B L O C KF 1 : P R O G B L O C K I D

F 3 : C O P Y C O N F I GF 4 :

*** IMPORTANT *** In order for an I/O block to be properly configured in FloPro, all inputs must be grouped together, and all outputs must be grouped together. They cannot alternate.


Analog I/O Block – 4I/2O There is no Analog block on the Romulus test stand. This configuration information is for reference only. From Main Menu:

Step 1. Press F3: CONFIGURATION

Step 2. Press F1: PROG BLOCK ID

Step 3. Press F1: ref

Step 4. Enter the I/O address range

After entering the I/O address range:

Step 5. Press F2: blk

Step 6. Enter the block address number (4) Step 7. Press F4: nxt – switch to SELECT BAUD RATE

Note: The baud rate at GMPT Romulus is set at 153.6K ST.

After entering the address and baud rate:

Step 8. Press MENUΔ : Return to previous menu

Step 9. Press F2: CONFIGURE BLOCK Items to be configured: (See Handout)

1. Report Faults to CPU – (Y) Yes for all

2. Range Select – -10 to 10 volts DC

3. Circuit Scaling – ENG 32767, A/D 4095

4. Input Filter Time – 128mS

5. Alarm Input Mode – (N) normal input mode for all

6. Alarm Thresholds – Low (-10000), Hi (+10000)

7. Hold Last State – (N) No for all outputs

8. Output Default Value – (0) Zero for all

9. BSM Present – (N) Device is connected to only one bus

10. Output Default Time – 3 bus scans

11. CPU Redundancy – No control redundancy

12. Configuration Protection - Disabled


r e f b l k n x t



A C T I V E = 1 5 3 . 6 K S TS E L E C T B A U D R A T E

P R O G = 1 5 3 . 6 K S T t g l e n t r n x t

F 2 : C O N F I G B L O C KF 1 : P R O G B L O C K I D

F 3 : C O P Y C O N F I GF 4 :


FloPro Configuration When configuring a FloPro application program, there are also parameters which need to be designated for a Genius Discrete I/O Block. The following is a table of these parameters, and typical settings for a Genius Discrete I/O Block: Digital I/O Block INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 1 3 16 D I/O 1 – 8 I0329 –

I0336 9 – 16 O0329 -

O0336 Figure 86 Discrete I/O FloPro Configuration

It is important to note that when configuring a combination block of sixteen, all sixteen input and output memory table locations are allocated. If another device were to be configured following this one, the next available input or output would be 0345, because this device has taken up the memory table for both I0329 through I0344 and O0329 through O0344. If the block were configured as inputs only, only I0329 through I0344 would be allocated, and O0329 through O0344 could be used to configure a different block which only uses outputs.


11.7 I/O Used In the Flowcharts In FloPro, inputs are tested using decision blocks. The state of an input will determine the logic flow in a chart. Inputs are most commonly tested in the status and diagnostic charts. The following example tests the state of a gate switch’s inputs to set a status flag.

Figure 87 Inputs in the Flowcharts


Outputs are turned on and off in the flowcharts using control blocks. This is done almost exclusively in an output chart. The following example is from a block line output chart.

Figure 88 Outputs in the Flowcharts


11.8 Replacement There are actually two pieces to a Genius I/O Block. The Terminal Assembly is the base of the block. It has all the field connections for a block, and will accept only its appropriate Electronics Assembly mate. The Terminal Assembly also houses all the configuration information, so if replacement of the Electronics Assembly is required, reconfiguration is not necessary. The Electronics Assembly holds all active I/O and communication circuits. It is connected to the Terminal Assembly with connector pins and an edge connector.

Figure 89 Genius Block Replacement


Replacement of the Electronics Assembly If replacement of the Electronics Assembly is required, the block should be powered down. There is a special Block Puller tool which should be used to remove the Electronics Assembly. Follow these steps: Step 1. Unscrew the retaining screws at the top and bottom of the block

Step 2. Position the Block Puller tabs in the first vent slots; slide the Block Puller to the middle of the block, and squeeze the handle

Step 3. Pull the Electronics Assembly away from the Terminal Assembly

Figure 90 Replacement of the Electronics Assembly

Installation of the Electronics Assembly is similar to that of any circuit board type installation; position the guides carefully and push the assembly down quickly to fully seat it in the Terminal Assembly.


Replacement of the Terminal Assembly If replacement of the Terminal Assembly is required, the bus connection must be considered. If the bus connection was made with a bus connector, or a removable plug which allows the bus wire connections to remain attached to each other while removed from the Terminal Assembly, the Genius Network need not be powered down. If this was not done, however, failure to power the network down may result in corrupted communication data. To replace the Terminal Assembly: Step 1. Remove power from the block

Step 2. Remove the Electronics Assembly

Step 3. Disconnect the wiring from and remove the Terminal Assembly

Step 4. Replace and rewire the new Terminal Assembly

Step 5. Reinstall the Electronics Assembly

The bus can now be reattached, and the power connections replaced. Because the Terminal Assembly has been replaced, it must be configured using a Hand Held Monitor before the I/O block can communicate on the Genius Network.



Part 1 Use the Hand Held Monitor to examine the configuration for any Genius Discrete I/O Block. Go through the parameters and check the settings for each one.

Part 2 Enter the parameters for any Genius Discrete I/O Block in the FloPro configuration. Confirm that the values entered match those viewed in part 1 for the Genius Network.


NOTES


12 I/O Link Interface Module

12.1 Overview To communicate I/O data with the Powermate D, the Genius network used an I/O Link Interface Module on the 90-30 PLC. Like other PLC modules, the Link module has status indicators that can aid in the debug process. This section describes the function of the Link module and it’s indicators and the required configurations to allow it to communicate with the Powermate D Servo Controller.

12.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of the I/O Link Interface Module • Better understand communication over the Fanuc I/O Link • Identify the status of the I/O Link Interface Module based on its status

indicator lights • Replace the I/O Link Interface Module


12.3 Operation The I/O Link Interface Module provides a means for Genius Network components to share information with devices on a Fanuc I/O Link. The Fanuc I/O Link is a serial interface which allows I/O data exchange between a master device and up to sixteen slave devices. An I/O Link Module is a standard Series 90-30 Module. There may be an unlimited number of I/O Link Modules in any given Series 90-30 PLC. The I/O Link Module operates as a slave on the Fanuc I/O Link, and can exchange either 32 or 64 inputs and outputs with the master device. There is a jumper plug inside the front cover which selects either 32 or 64 point mode. Note: GM Romulus does not use multiple slaves. They use one PMD per Link Module.

Figure 91 I/O Link Module Jumper Plug

JUMPER PLUG


12.4 Communication

Figure 92 I/O Link Module Powermate D Serial Connection

The I/O Link Module communicates with the Master device across a full duplex serial data communications channel. They are connected via two twisted wire pairs and a signal ground, and the maximum signal rate is 1.5 Mbaud. Devices can be up to 10 meters apart using this wiring scheme; optical fiber cables can be used to extend the separation distance to 100 meters. Multiple slaves are connected in a daisy chain fashion, so that the output of the first slave drives the second, and so on. The master sends data as outputs onto the Link, and a slave device receives Link data as inputs. When the slave returns information to the master, it writes it onto the Link as outputs, to be received by the master device as inputs:

Figure 93 I/O Link Module Master/Slave Connection

The master device sends out all data for all slave devices in a continuous serial string, and slaves receive the data according to their position on the Link. Each

FROM PREVIOUS

DEVICE

TO NEXT

DEVICE


slave takes the portion of data it is configured for, reads it in as inputs, and passes the remainder on to the next slave, as illustrated below:

Figure 94 I/O Link Master/Slave Connection

In a system where optical cables must be used, an Optical Adapter must be used. This converts the communication link from an electrical cable to an optical cable. The electrical cable plugs into one side of the Optical Adapter, and the optical cable plugs into the other:

Figure 95 I/O Link Optical Adapter

Typically, there is another Optical Adapter near the next device to convert the communication link back to an electrical cable for interface into the next device.


12.5 Diagnostics Depending on the type of fault which occurs, and which device the fault occurs in, there are two ways the I/O Link can address it. The first is to allow communication to continue up to the device which is faulted. Any device which is faulted would no longer receive communication, and if there are any devices farther down the I/O Link, they would no longer receive communication either. The second possibility, used where there is critical data such as encoder information passed along the I/O Link, is to shut the I/O Link down completely, and allow each device to follow its own fault procedure. If the link is completely shut down, the procedure for restoring communication is: Step 1. Correct the fault condition Step 2. Clear the system error on each slave device by cycling power Step 3. Cycle power to each Series 90-30 I/O Link Module Step 4. Reset the I/O Link from the Master device The Series 90-30 I/O Link Module responds to a fault condition by holding their last input and output state information. When the I/O Link is restored, the module will initialize all inputs and outputs to zero, then quickly reset them to their actual states. The I/O Link Module has two status indicators at the top:

Status Meaning

OK On Indicates Normal Operation Off Module has No Power or has Failed RDY On Ready to Communicate with I/O Link Off Communication with I/O Link Not Possible

Figure 96 I/O Link Module Status LEDs


12.6 Configuration The I/O Link Module must be configured using the Logic Master Software like any other Series 90-30 Module. It is configured as a simple I/O device, specifying the %I and %Q memory spaces it will use. In a typical FloPro application, the rack which holds the I/O Link Module will also have a GCM+ Module, which will actually communicate the I/O Link Module’s I/O information across the Genius Network to the FloPro application. For this reason, the I/O Link has no direct configuration in a FloPro application. Any Powermate D units which may be communicating through this I/O Link Module will be configured separately; this is discussed in chapter 7.


12.7 Replacement When replacing any module on a Series 90-30 baseplate, the baseplate should be powered down. Once this is done, the module can be removed, and its replacement can be installed. Disconnect the I/O Link communication cables from the module. The module can now be replaced: Step 1. Press the release lever, on the bottom of the module, up toward the

module Step 2. While holding the lever in an up position, swing the module upward,

pivoting it about the top like a hinge

Figure 97 I/O Link Module Replacement

Step 3. Raise the module up to disengage the hook at the top, and remove it

from the baseplate. To install the replacement module, simply engage the hook at the top in the proper slot, and swing the module down into position until it latches into position on the baseplate. The terminal assembly can be reinstalled by carefully sliding it back into position on the module, and making sure to get it fully seated.



Part 1 Use the Hand Held Programmer to examine the configuration for any I/O Link Module. Go through the parameters and check the settings for each one.

Part 2 Examine the GCM+ configuration for the I/O Link Module parameters.


NOTES


13 Horner Electric Remote Message Unit (RMU)

13.1 Overview

13.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of the Horner Electric Remote Message Unit

(RMU) • Configure the RMU in FloPro

13.3 Horner Electric RMU The Horner Electric RMU is used as a window to retrieve data from the Genius Network. The RMU is designed to communicate over the Genius Network while providing real time text and or graphic machine status information. It allows the operator to perform functions that control machine behavior using a keypad. The text shown on the RMU is a maximum of 4 lines long with 20 characters each. The user has the comfort of offloading the processing burden from the system controller, providing flexibility for messaging and operator feedback, and doing both with as little network overhead impact as possible.

Figure 98 RMU Front Panel


13.4 RMU Basic Functions The RMU’s display and keypad are primarily controlled by the main system controller through messages to the RMU that contain ASCII text data to be displayed on the RMU display, with cursor control and positioning capability. The state of the RMU keypad is returned as real-time I/O for the system controller to read and act upon.

13.5 Operator Interface Unit Features The Horner Operator Interface Unit provides the following features: 1) Gasketed NEMA 4-12 panel with a rugged Lexan TM overlay, mounting

hardware included. 2) Four line by 20 character dot-matrix vacuum-fluorescent display. 3) Tactile feel keypad with numeric support plus special function keys.

Integrated Genius Network Interface board (uGENI) for communications on GE Fanuc's Genius Distributed I/O Network.

4) Acts as a high-performance FloPro Remote Message Unit by communicating over a high speed I/O network instead of a slower, serial based connection.

5) Standard 9-pin RS232 communications port, for connection to a GE Fanuc PowerMate Motion Controller.


13.6 Replacement Because the RMU is used in Terminal Mode, there is no information which needs to be re-loaded into it if replacement is necessary. The new unit will need to be reconfigured on the Genius Network, however, before it can communicate. As always, it is important to check that any PROM’s are of the same version number as the original unit, and be sure that the two banks of dip switches on the replacement unit are set to match those on the original unit. Mounting Requirements The RMU is designed for permanent panel mounting. To install the RMU: Step 1. Make sure all terminal connectors are removed from the RMU. Step 2. Remove the steel back cover (if installed), by removing the screws

securing it to the RMU. Step 3. Carefully lift the cover off the rear of the RMU a few inches,

disconnecting the power terminal from the power supply circuit board. The rear cover should now be completely free of the RMU.

Step 4. Remove the #6-32 hex nuts and washers from the outer mounting studs on the rear of the RMU panel.

Step 5. Insert the RMU module through the front panel cutout. The gasket material should lie between the host panel and the RMU panel.

Step 6. Install the #6-32 nuts and lock-washers on the six mounting studs of the RMU. Tighten these nuts until the gasket material forms a tight seal, do not overtighten.

Step 7. Re-install the rear cover. Be sure to re-connect the power terminal to the power supply circuit board. Re-connect all terminal connectors (power and Genius network terminals). This completes the mechanical installation of the RMU module.


13.7 RMU Connectors Power Supply Connector The RMU power supply requires a DC supply voltage between 12 and 32 volts. A maximum of 7.5 watts will be drawn by the RMU. The RMU power supply features a 2-position, removable terminal block. Connector location and pinout is shown below.

Pin Signal

1 +12-32VDC 2 DC Common

Figure 99 RMU DC Connector Pinout

Figure 100 RMU Connector Locations – Rear View

Power Connector (Main Board)

RS-485 Port

DB-15

Genius Bus Connector

RS-232 Port 1 DB-9


Genius Network Connector The RMU is also equipped with a 4-pin Genius bus connector. The mating connector provides screw terminals for each circuit. The pinout for this connector is as follows:

Pin Signal

1 Serial 1 2 Serial 2 3 Shield Out4 Shield In

Figure 101 RMU Genius Connector Pinout

RS232 Connector(s) The 9-pin “D” connector on the main circuit board provides an RS232 interface to the GE Fanuc PowerMate Motion Controller. The RMU-to-PowerMate cable pinout is as follows.

Figure 102 RS232 Connector Between RMU Serial Port & PMD Serial Port


13.8 RMU Dip Switches The uGENI board (located on the rear of the RMU module) is equipped with a bank of 8 “DIP” switches. DO NOT CONFUSE THIS DIP SWITCH WITH THE 6-POSITION DIP SWITCH ON THE MAIN CIRCUIT BOARD DESCRIBED LATER. These switches are used to configure the Genuis “bus” address or “Device Number” for the RMU module, and to set the module’s Genius baud rate.

8 7 6 5 4 3 2 1

5 4 3 2 1 Address 5 4 3 2 1 Address

CLOSD CLOSD CLOSD CLOSD CLOSD 0 OPEN CLOSD CLOSD CLOSD CLOSD 16

CLOSD CLOSD CLOSD CLOSD OPEN 1 OPEN CLOSD CLOSD CLOSD OPEN 17

CLOSD CLOSD CLOSD OPEN CLOSD 2 OPEN CLOSD CLOSD OPEN CLOSD 18

CLOSD CLOSD CLOSD OPEN OPEN 3 OPEN CLOSD CLOSD OPEN OPEN 19

CLOSD CLOSD OPEN CLOSD CLOSD 4 OPEN CLOSD OPEN CLOSD CLOSD 20

CLOSD CLOSD OPEN CLOSD OPEN 5 OPEN CLOSD OPEN CLOSD OPEN 21

CLOSD CLOSD OPEN OPEN CLOSD 6 OPEN CLOSD OPEN OPEN CLOSD 22

CLOSD CLOSD OPEN OPEN OPEN 7 OPEN CLOSD OPEN OPEN OPEN 23

CLOSD OPEN CLOSD CLOSD CLOSD 8 OPEN OPEN CLOSD CLOSD CLOSD 24

CLOSD OPEN CLOSD CLOSD OPEN 9 OPEN OPEN CLOSD CLOSD OPEN 25

CLOSD OPEN CLOSD OPEN CLOSD 10 OPEN OPEN CLOSD OPEN CLOSD 26

CLOSD OPEN CLOSD OPEN OPEN 11 OPEN OPEN CLOSD OPEN OPEN 27

CLOSD OPEN OPEN CLOSD CLOSD 12 OPEN OPEN OPEN CLOSD CLOSD 28

CLOSD OPEN OPEN CLOSD OPEN 13 OPEN OPEN OPEN CLOSD OPEN 29

CLOSD OPEN OPEN OPEN CLOSD 14 OPEN OPEN OPEN OPEN CLOSD 30

CLOSD OPEN OPEN OPEN OPEN 15 OPEN OPEN OPEN OPEN OPEN 31

7 6 Baud Rate

CLOSD CLOSD 153.6K extended

CLOSD OPEN 38.4K OPEN CLOSD 76.8K

OPEN OPEN 153.6K standard

ALWAYS OPEN

Figure 103 DIP Switch Settings for RMU Address & Baud Rate

When shipped from the factory, the RMU dip switches are configured for device number 29, and for communication baud rate of 153.6K standard.


RMU Main Circuit Board DIP Switches The MAIN circuit board is equipped with a bank of 6 “DIP” switches. These switches are accessible by removal of the metal back cover. The user should never need to change the default position(s). These switches are used to configure the following RMU options:

Switch # Definition When Closed Default

1 Always Closed Closed 2 Always Closed Closed 3 Always Open Open 4 Power to Pin 5 of RS-485 Port Closed 5 Watchdog Timer Enabled Closed 6 Run (Open for Serial Debug) Closed

Figure 104 RMU Main Board DIP Switch Assignments

13.9 Configuration An RMU must be configured to properly communicate over the Genius Bus. In FloPro applications, the RMU is configured as an I/O device with 8 inputs. The parameters which need to be designated for the Remote Message Units on the test stand are shown in the following tables:

RMU-1 INPUTS OUTPUTS

BLOCK ADDR TYPE Crct FloPro Crct FloPro 1 1 RMU-1 I3001-

I3008

RMU-2 INPUTS OUTPUTS

BLOCK ADDR TYPE Crct FloPro Crct FloPro 3 1 RMU-2 I3009-

I3016


13.10 Flowchart Interface With the RMU As discussed in module 4, FloPro uses two types of blocks to interface with the RMU: the ‘send message’ and the ‘test status’ blocks. The messages ‘sent’ to the RMU can be up to four lines of 20 characters. Once a message is sent, it will remain on the screen until replaced with a new message. When an operator utilizes the RMU for manual functions, to recover a station, or to start auto cycle, a flowchart ‘tests’ the status of the inputs from the RMU. The flowchart can monitor the use of the SEND key, the EXE key, the UP, DOWN, RIGHT, and LEFT arrow keys, and the numeric value in the RMU buffer. The following exercise explains the basic operation of a typical block line manual sequence flowchart. Understanding what is supposed to happen in the manual sequence is sometimes helpful in debugging fault conditions because the manual charts send requests for outputs and motions to be activated. If no message exists when a fault condition occurs, or a message is incorrect or misleading, knowing what the flowchart was trying to do can help steer the debug process in the right direction. The RMU Manual Flowchart Refer to the ‘Station 1 Manual Sequence’ flowchart at the end of this section. The manual flowchart is ‘enabled’ when the station is in manual. The first blocks of the chart allow for other flowcharts to complete before continuing with manual functions. Once the station is clear for manual functions, the first list of manual selections is printed to the RMU screen.

Figure 105 RMU Manual Menu Display


The operator has the option of selecting 1 – 4 from the numeric keypad. When selected, the number is stored in the RMU’s buffer for use in other blocks of the chart. Another option is for the operator to select the DOWN arrow key to display the next page of manual functions.

Figure 106 RMU Manual Menu Display

No matter which page of the menu is displayed, the operator can select any of the available options. (1 – manual functions, 2 – recover station, 5 – home station, etc…) To select a function: Step 1. Enter the number using the numeric keypad. The number will be stored

in the buffer. Step 2. Press the SEND key to ‘GoTo’ the corresponding section of the

flowchart. In the flowchart, the blocks are arranged to monitor for the ‘active’ RMU control buttons. The UP and DOWN arrow keys and the SEND key are the only buttons ‘active’ at this point in the chart. An RMU button is only ‘active’ in the flowchart if it is being monitored with a ‘test status’ block. Using the UP and DOWN arrow keys will scroll through the available menus. When the SEND key is pressed, the flowchart jumps to the section that is monitoring the value in the RMU buffer. The value in the buffer will determine the section of the flowchart that will solve next. When a function is selected, the EXE key becomes ‘active’. The EXE key is used to send the requests for outputs or motion. The EXE key must be held down to maintain a motion, such as advancing a slide. If the button is released, the motion will stop.


Also, the LEFT arrow key becomes active at this point. Pressing the LEFT arrow key will exit the current function and return to the main RMU menu. Using the ‘Station 1 Manual Sequence’ flowchart, you can follow on paper what is happening in each step of the following lab.

13.11 RMU Manual Sequence Lab The intent of this lab is to develop an understanding of how the RMU interface is developed in a flowchart. Refer to the printout of the chart as you step through this exercise. Step 1. At the Station 1 RMU, set the selector switch to manual. If all conditions are met in the Manual Sequence flowchart enable block, the chart will begin to solve. Using the printout, try to predict where the flowchart will ‘jump’ to before you proceed with each step. On the RMU keypad: Step 2. Press the DOWN Arrow - scroll through the menu options Step 3. Press 1 - Manual Functions Step 4. Press the SEND key - to ‘send’ the selection Step 5. Step through the manual sequence: Clamp; Start drill; Advance head;

return head; Stop drill; unclamp. Arrow key functions: UP arrow key - Returns to the previous operation in the sequence. DOWN arrow key - Advances to the next operation in the sequence. RIGHT arrow key - Toggles between inverse operations. LEFT arrow key - Returns to main RMU menu. After each operation, use the down arrow key to advance to the next step in the sequence.



Part 1 Examine the configuration for any RMU on the Genius Network. Go through the parameters and check the settings for each one.

Part 2 Enter the parameters for any RMU in the FloPro configuration. Confirm that the values entered match those viewed in part 1 for the Genius Network.


NOTES


14 Powermate D

14.1 Overview GMPT Romulus used the Powermate D Servo Motion Controller for all servo operations. The Powermate is a versatile servo controller with many diagnostic functions. Along with the LED display on the drive units, the Powermate sends fault codes to the CRT/MDI, the DPL/MDI and to FloPro. Alarm messages are generated on the CRT/MDI and FloPro utilizes the fault codes to generate messages on the Xycom. This section describes the function and maintenance of the Powermate D unit, and how it interfaces with FloPro.

14.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of the Powermate D • Identify Powermate D module status based on their indicator lights • Configure Powermate D axes in FloPro • Replace the components of a Powermate D system


14.3 Operation The Powermate D servo system controls the movement of a spindle motor and up to two servo axes. Through communication over the Fanuc I/O Link, separate PLC’s or CPU’s can control these movements. The following is a diagram showing a typical GMPT configuration:

Figure 107 GMPT Romulus PMD Connection on the Genius Network The Powermate D exchanges information through its Servo Interface, and then distributes this information to the devices in its control. The devices which are covered in this chapter are the Powermate D Servo Interface Module, Spindle Amplifier Module, and Servo Amplifier Module.

RS-232

RMU

Xycom

JD1A

JD5A

I/O Link

PowerMate

90-30 PLC

JD1B

JD1A

I/O Link


14.4 Servo Interface Module

Figure 108 Powermate D Front Panel


The Servo Interface Module runs on 24VDC control voltage, and connects to the Fanuc I/O Link. It also has connections for the servo axes it controls, the spindle axis it controls, and the feedback from each of these devices. The LED’s on the front indicate status as follows:

LED

Status

Indication

S0 On No Alarm Blinking Automatic Operation in Process S1 On Alarm Condition Present Off Normal Operation EN On Power Present WD On Watch Dog Alarm Condition

Present

Figure 109 Powermate D Status Indicators

The rotary switch RSW located underneath the LED’s indicates the Powermate D Device Number. The numbers are assigned in order from the first Powermate D to the last:

Device No.

RSW Setting 0 0 1 1 2 2 3 3

Figure 110 PMD Rotary Switch/Device Number Settings


14.5 Battery Replacement It is important to note that when replacing the batteries on the Servo Interface Module, the power to the module should remain on, and the machine should be in an Emergency-Stop condition. This poses a risk to the electrician, but only in the event that he comes in contact with the high voltage circuit. Replacing the battery with the power on eliminates the need to replace the control parameters stored in the Servo Interface Module which will surely be lost if the battery is replaced with power off. The battery is located on the inside of the front panel door. To replace the battery:

Step 1. Open the front panel door

Step 2. Slide the connector out of the circuit board

Step 3. Pull the battery out of the clips

Step 4. Clip the new battery in place

Step 5. Slide the connector into the circuit board

Step 6. Close the panel door

The Servo Interface Module does have a fuse for the +24 V input power. If the EN LED is not lit, and +24 V is supplied to the module, this fuse may be blown. It is located near the top of the module front, as shown on the next page:

Figure 111 PMD Fuse Location


14.6 Servo Amplifier Module The Powermate D Servo Amplifier Module has built-in error detection. If an alarm state occurs, the motor is forced to stop by a dynamic brake. There is a 7-segment LED on the front of the unit to indicate operational mode:

LED State Description - Amplifier Not

Ready Servo Amplifier is Not Ready to Drive the Motor

0 Amplifier Ready Servo Amplifier is Ready to Drive the Motor The error states which are indicated by the LED are:

LED Error Description 1 Over Voltage DC Voltage of Main Circuit Power Supply is

Abnormally High 2 Low Control Voltage DC Control Power Voltage is Abnormally Low 3 Low DC Link Voltage DC Voltage of Main Circuit Power Supply is

Abnormally Low 4 Regenerative

Discharge Control Circuit Failure

1) The Short-Term Regenerative Discharge Energy is Too High

2) The Regenerative Discharge Circuit is Abnormal

5 Over-Regenerative Discharge

1) The Average Regenerative Discharge Energy is Too High

2) The Transformer has Overheated 6 L- and M- Axis Over

Current Abnormally High Current Flows in the L- and M-Axis Motors

6 L- and M- Axis IPM L- and M-Axis Intelligent Power Module Alarm 7 Dynamic Brake

Circuit Failure The Relay Contacts of the Dynamic Brake have Welded Together

8 L-Axis Over Current Abnormally High Current Flows in the L-Axis Motor 8 L-Axis IPM L-Axis Intelligent Power Module Has Alarm 9 M-Axis Over Current Abnormally High Current Flows in the M-Axis

Motor 9 M-Axis IPM M-Axis Intelligent Power Module Has Alarm

Figure 112 PMD LED Error Codes


14.7 Configuration The Powermate D Modules have various configuration parameters which are beyond the scope of this manual. For information on these parameters, consult the appropriate Powermate D manual. When configuring the Powermate D in a FloPro application, it will appear in two ways. In chapter 4, the configuration of GCM+ modules was discussed. The GCM+ module is configured to exchange the I/O data for all modules housed in the rack with it. The I/O Link Module, discussed in chapter 7, has I/O allocated which correspond to the Powermate D. These I/O points have been configured as memory space in the GCM+ module’s configuration. The information which the FloPro application needs to complete the Powermate D configuration is how to relate to a given axis. After all of the modules are listed in the Genius I/O Configuration page, and F1 Configuration Correct is pressed, the next FloPro screen is the Powermate Configuration screen. On this screen, each Powermate D axis is configured with its axis number, I/O assignments, and the device which will download to it. Typical Powermate D configurations are shown in Figure 113. At GMPT Romulus, there are three typical Powermate configurations (represented in Figure 113). For an application such as a trnsfer bar using two servo axes, the dual axis configuration would be used. For an application such as sliding a head in for a drilling operation, the single axis configuration would be used. For an application such as a surface grind that doesn’t require a CNC, the dual axis with a spindle configuration would be used.


Dual Axis PMD --- DOWNLOAD--- ----- POWERMATE-D -----

DEVICE AXIS INPUTS OUTPUTS RMU-1 PORT 1 X=1 Y=2 I0201 -

I0265 O0201-O0265

Single Axis PMD --- DOWNLOAD--- ----- POWERMATE-D -----

DEVICE AXIS INPUTS OUTPUTS RMU-1 PORT 1 X=3 I0501-

I0565 O0501-O0565

Dual Axis PMD with Spindle --- DOWNLOAD--- ----- POWERMATE-D -----

DEVICE AXIS INPUTS OUTPUTS RMU-1 PORT 1 X=1 Y=2

SPIN=1 I0201 - I0265

O0201-O0265

Figure 113 FloPro Configurations for the Powermate D

14.8 Replacement When replacing modules in a Powermate D system, there are three things which should always be checked: 1. Any memory cartridges should be removed from the current unit and installed

into the replacement unit to preserve parameters when possible. When not possible, check that the new device has the same version number(s) as the device being replaced.

2. Any PROM’s which are on the current unit should have the same identification numbers as those on the replacement unit.

3. Any dip switches and/or rotary switches must be set on the new unit to match those on the unit being replaced for proper communication to the other devices.


14.9 Powermate D Parameters and Maintenance Functions This section includes procedures for:

• Homing drives • Flashcard memory upload/download

A Powermate D drive unit has two internal relays; the external e-stop string relay, and the enable relay. If the unit is working properly, there will be a ‘clunk’ when each of the relay’s contacts close. For debugging purposes, listen for: One ‘clunk’ - External E-Stop string is good. Two ‘clunks’ - E-Stop string & enable relay are good. No ‘clunks’ - No external E-Stop string. Many of the Powermates at GMPT Romulus don’t have a CRT/MDI attached. In this case, a crash cart with a CRT/MDI is rolled to the offending unit and plugged into the drive. The connectors for the CRT are on the bottom and at the back of the drive unit. There are two d-sub connectors; JD14 & JD15. Either one can be used to connect the CRT/MDI. Connector M4 is used to connect the DPL/MDI.

Figure 114 PMD Bottom Panel Connectors


In many cases, when a Powermate D Servo Controller is experiencing problems, the problem can be fixed by simply cycling power. To cycle power:

Step 1. Unplug the 24VDC input connector. Step 2. Plug the connector back in.

Powermate D Parameter Updates When parameters need to be updated, the Parameter Write Enable (PWE; aka peewee) needs to be set to 1. The PWE is located on the SETTING screen. Parameter changes are not recognized in the system when the PWE is set to 0. Note: Be sure to reset the PWE to 0 after parameters have been updated. To set the PWE With the DPL/MDI

Step 1. Press the MENU/VAR key. Step 2. Use the arrow up or down key until PWE is next to the cursor. Step 3. Press 1 or 0 to set or reset the PWE. Step 4. Press the Input key.

With the CRT/MDI

Step 1. Press the OFFSET/SETTING key to display the setting screen. Step 2. Place cursor on PWE using the arrow keys. Step 3. Press 1 or 0 to set or reset the PWE. Step 4. Press the Input hard or soft key.


Homing Drives When the Powermate drive experiences a major fault, the home bit(s) may be lost. The home bit must be reset before an axis can be homed. To reset the home bit(s): Parameter 1815 Step 1. Set PWE to 1 Step 2. Press the OPRT soft key Step 3. Enter parameter 1815 Step 4. Press NO.SRH soft key (Number Search) Step 5. Reset appropriate APZ bit(s) to 1 - (0 = needs to be homed; 1 =

homed) Step 6. Set PWE back to 0 Step 7. Power down Powermate (unplug 24VDC connector) Step 8. Power up Powermate (reconnect 24VDC connector) Step 9. Rehome axis using RMU manual functions Step 10. If the station doesn’t use an RMU, rehome using the Home All soft key

on the CRT/MDI Custom Screens


Outputting Data to a Memory Card With the DPL/MDI

Step 1. Enter EDIT mode or MDI mode. Step 2. Place the system in the emergency stop state. Step 3. Press the PRGRM button to display the program display screen. Step 4. Insert the memory card in the Powermate. Step 5. Enter address M Step 6. Press the WRITE key

With the CRT/MDI

Step 7. Enter EDIT mode or MDI mode. Step 8. Place the system in the emergency stop state. Step 9. Press the PRGRM button to display the program display screen. Step 10. Insert the memory card in the Powermate. Step 11. Enter address M. Step 12. Press the ⇒ soft key. Step 13. Press the PUNCH soft key Step 14. Press the EXEC soft key.

Note: The capacity of the memory card must be the same as or larger than the memory card capacity of the Powermate.


Inputting Data From a Memory Card With the DPL/MDI

Step 1. Enter the EDIT mode or MDI mode. Step 2. Place the system in the emergency stop state. Step 3. Set PWE to 1. Step 4. Press the PRGRM button to display the program display screen Step 5. Insert the memory card in the Powermate. Step 6. Enter address M. Step 7. Press the READ key.

With the CRT/MDI

Step 8. Enter the EDIT mode or MDI mode. Step 9. Place the system in the emergency stop state. Step 10. Set PWE to 1. Step 11. Press the PRGRM button to display the program display screen Step 12. Insert the memory card in the Powermate. Step 13. Enter address M. Step 15. Press the ⇒ soft key. Step 16. Press the READ soft key Step 17. Press the EXEC soft key.

Note: Be sure the PWE is set back to 0.



Part 1 Use the Hand Held Programmer to examine the configuration for any I/O Link Module. Go through the parameters and check the settings for each one. Verify that these parameters are appropriate for the Powermate D drives it is communicating to.

Part 2 Enter the parameters for any Powermate D drive in the FloPro configuration. Confirm that the values entered match those viewed in part 1 for the Genius Network.


NOTES


15 Series 16/18 Maintenance CRT Display

15.1 Overview The CRT/MDI panel is the primary interface with the GE Fanuc CNC machines. This section describes the operation and standard screens of the CRT/MDI. Troubleshooting procedures and communication setups are also discussed in this section.

15.2 Objectives After completing this chapter, the student should be able to: • Better understand the CRT/MDI panel and Menus • Identify the status of the equipment using the Status Display • Use diagnostic for troubleshooting, determining internal state of the CNC,

display I/O interface signal and interpreting Alarm Codes • Setting Parameters • Set Up Communications


15.3 Operation The CRT/MDI panel is used with a display and keypad, to display and set parameters for operating a CNC with Power Mate Series Controllers. Two or more Power Mates can share one CRT/MDI unit.

Figure 115 CRT/MDI Panel


Figure 116 Explanation of the Key Board


15.4 Screen Operation Pressing the function key on the CRT/MDI panel causes the chapter soft key that belongs to the selected function to appear. Pressing one of the chapter selection soft keys causes the screen for the selected chapter to appear. If the soft key for a target chapter is not displayed, press the continuous menu key (next menu key). Additional chapters can be selected within a chapter. When the target chapter screen is displayed, press the operation selection key to display the data to be manipulated.

Figure 117 CRT/MDI panel - Chapter Soft Key

To redisplay the chapter selection soft keys, press the return menu key. 1) Chapter (screens) included in the [POS] function key

a) [ABS] Position display screen in work piece coordinate system b) [REL] Position display screen in relative system c) [ALL] All position display screen d) [HNDL] Position display screen for handle interruption

2) Chapter (screens) included in the [PROG] function key

a) [CHECK] Program select display screen b) [PRGRM] Program display c) [CURRENT] Current block display screen d) [NEXT] Next block display screen e) [LIB] Program directory (AUTO Mode) [CHECK] – [PRGRM] – [CURRENT] – [NEXT] (MDI Mode) [ MDI] – [PRGRM] – [CURRENT] – [NEXT] (JOG Mode)

[PRGRM] – [CURRENT] – [NEXT] (EDIT Mode)


[PRGRM] – [LIB] 3) Chapter (screens) included in the [OFFSET/SETTING] function key

a) [OFFSET] Tool offset display screen b) [SETTING] Parameter setting display screen c) [MACRO] Macro variable value display screen d) [MENU] Pattern data display screen e) [OPR] Operator’s panel display screen

4) Chapter (screens) included in the [SYSTEM] function key a) [PARAM] System parameter display screen b) [DGNOS] Status in CNC display screen c) [PMC] PMC screen (ladder diagram, machine signal, parameter) d) [SYSTEM] System structural display screen e) [MEMORY] Memory content display screen f) [PITCH] Pitch error compensation display screen g) [SV. PRM] Servo setting/adjustment screen h) [SP. PRM] Spindle setting/adjustment screen i) [OPEHIS] Operator history display screen

5) Chapter (screens) included in the [MESSAG] function key

a) [ALARM] Alarm screen b) [MSG] Operator message display screen c) [HISTRY] Alarm history display screen


15.5 Status Display The screen displays the current status of the equipment, whether any alarm is being issued or the system is in the EDIT mode. The current mode, automatic operation state, alarm state and program edit state are displayed on the second to the bottom line of the screen allowing the operator to understand the condition of the system. If data setting or the input/output operation is incorrect, the CNC does not accept the operation and a warning message is displayed. Description of each display (CRT/MDI)

Figure 118 Description of Each MDI) Display (CRT/


15.6 System Diagnostics

There are many diagnostics built into the system and are run before the control is allowed for machine operation. The error messages displayed on the CRT and LED fault indicators provide a source of information for troubleshooting the control. Display Alarm Codes The error codes are defined as follows: 000 - 232 Program Errors 300 - 308 Absolute Pulse Coder (APC) Alarms 350 - 351 Serial Pulse Coder (SPC) Alarms 400 - 417 Servo Alarms 500 - 507 Overtravel Alarms 700 - 704 Overheat Alarms 750 - 762 Spindle Alarms 900 - 973 System Alarms SYSTEM ALARMS

Figure 119 SYSTEM ALARMS


SERVO ALARMS

Figure 120 SERVO ALARMS


PROGRAM ERRORS (P/S ALARM)

Figure 121 PROGRAM ERRORS (P/S ALARM)


Figure 122 Displaying Internal States on the CNC


Figure 123 Details of CNC Internal Status


Figure 124 Displaying I/O Interface Signals


15.7 Setting Parameters Setting from the CRT/MDI panel Step 1. Push the function key <OFFSET/SETTING> Step 2. Push a soft key [SETTING] to display the setting data screen

Figure 125 Setting Parameters CRT/MDI Panel

Press the cursor button and set cursor to PARAMETER WRITE. Turn the soft key into the operation selection state with [OPRT] and press the soft key [1:ON] enabling writing parameters. The NC will be in alarm #100 condition

Figure 126 Setting Parameters CRT/MDI Panel

Step 3. Display parameters on the CRT screen. Step 4. Shift the cursor to the position of the parameter number to be changed.

a) Move the cursor to the position of the parameter to be changed using the page change key/cursor move key

Or b) Change the soft key to operation selection with [OPRT] and key-input the parameter number and then the soft key [NO.SRH].

Step 5. Input a parameter value Step 6. Press soft key [INPUT]. The parameter value is set and displayed. Step 7. After all parameters have been set and confirmed, turn to the setting

screen and return the PWE setting to “0”.


Step 8. Depress the <RESET> key at release the alarm condition. When alarm #000 has occurred, cycle the power supply to release the alarm.

Setting /Display of Tool Offsets Values To set the tool-offset amount, input either the offset amount itself (absolute input) or the increase/decrease from the previous offset amount (incremental input). Step 1. Setting from the CRT/MDI panel, press the function key

<OFFSET/SETTING> several times or press the chapter-select soft key [OFFSET] after pressing the function key <OFFSET/SETTING>.

Step 2. Press the soft key [OPRT] to change the soft key display to the

operation selector key

Figure 127 Setting /Display of Tool Offsets Values

Step 3. Move the cursor to the offset number to be changed. Input the offset

number and press the soft key [NO.SRH]. The screen containing the key-input offset number is displayed and the cursor moves to the position of the offset amount corresponding to the key-input offset number

OR Move the cursor to the position of the offset amount to be changed using the page change key/cursor move key.

Step 4. To input an absolute offset value, input the offset amount to be set (input

with decimal point is also possible). Then press the soft key [INPUT]. To input an incremental offset value, input the amount to be incremented or decrement, the press the soft key [+ INPUT].


Macro Variable The common variables (#100 to#149 or #149, #500 to #531of #699) can be displayed on the CRT. When the absolute value of variable exceeds the value 99999999, “********” is displayed. Step 1. To display macro variables press the function key <OFFSET/SETTING> Step 2. Press the soft key [MACRO]

Figure 128 Macro Variable

Step 3. To set a variable, display the desired page. Step 4. Move the cursor to the desired variable number. Step 5. Input a variable value by data input key. Step 6. Press the soft key [INPUT], and the input value is displayed. Step 1. To set the coordinate value to a variable, move the cursor to the

desired variable number. Step 2. Press [X] (for the X axis) or [Y] (for the Y axis) Step 3. Press the soft key [INP.C.]. The absolute position coordinate value for X

of Y-axis is input and displayed on the variable.


Step 1. To set a blank to a variable, move the cursor to the desired variable number

Step 2. Press the soft key [INPUT]. A blank is input and displayed on the variable.

Current Position To display in workpiece coordinate system Step 1. Press the function key <POS> Step 2. Press soft key [ABS]

Figure 129 Display in Workpiece Coordinate System

To display in Relative coordinate system Step 1. Press function key <POS> Step 2. Press soft key [REL]

Figure 130 Display in Relative Coordinate System


To display in Overall coordinate system Step 1. Press the function key <POS Step 2. Press soft key [ALL]. Step 3. The current position will be as:

a) Relative Position b) Absolute Position c) Machine Position

d) Distance To GO (residual movement amount)

Figure 131 Display in Overall Coordinate System


15.8 Editing Programs In the edit mode, searching for part of the program to be edited can be done by searching by Program Number, Sequence Number, Word and Address. Function that can be preformed are, inserting, altering, and deleting a words, replacing words and addresses, coping, deleting, move, and merging programs, and deleting blocks. Registration from MDI Step 1. Select EDIT mode Step 2. Press the <PRGRM> key Step 3. Key in address 0 Step 4. Enter the number of the program to be registered Step 5. Press the <INSERT> key By pressing this key, the entered program number will be registered. Enter each word of the program followed by the <INSERT> key to register it. Part Program Editing 1. If the memory holds multiple programs, do a Program Number search.

a) Method 1

(1) Select EDIT or AUTO mode (2) Press <PROG> to display the program screen (3) Key in address 0 (4) Key in a program number to be searched for (5) Press the [O SRH] (6) The program number searched for is displayed in the upper right

corner of the CRT screen.

b) Method 2 (1) Select EDIT or AUTO mode (2) Press <PROG> to display the program screen (3) Press the [O SRH]

c) Method 3 (1) Select AUTO mode (2) Set the reset state(*1) (3) Set the program number selection signal on the machine tool side

to a number from 1 to 255 (4) Press the cycle start button


2. Deleting programs that are registered

a) Select EDIT mode b) Press <PROG> to display the program screen c) Key in address 0 d) Key in a desired program number e) Press the <DELETE> key. The program with the entered program

number is deleted. 3. Deleting all program

a) Select EDIT mode b) Press <PROG> to display the program screen c) Key in address 0 d) Key in –9999. e) Press the <DELETE> key.

4. Inserting a Word

a) Search for or scan the immediately before a desired word insertion location.

b) Key in an address where a word is to be inserted. c) Key in data. d) Press the <INSERT> key. (T15)

Figure 132 Inserting a Word


5. Altering a Word

a) Search for or scan a word to be altered. b) Key in an address to be inserted c) Key in data d) Press the <ALTER> key e) Change T15 to M14

Figure 133 Modify a Word

6. Deleting a Word a) Search for or scan a word to be deleted b) Press the <DELETE> key c) Delete X100.0

Figure 134 Deleting a Word


7. Deleting a Block The following procedure will delete a block up to its EOB code, the cursor

advances to the address of the next word.

a) Search for or scan address N for a block to be deleted b) Key in <EOB> c) Press the <delete> key. (Delete a block containing n1234)

Figure 135 Deleting a Block

It is possible to edit a program while another program is running. A program edited in the background should be registered in foreground program memory by doing the following: Step 1. Press the [OPRT] key Step 2. Press the [BG-END]


15.9 Series 16/18 Communications To transfer data from the primary device (CNC) to the PC the following tools are required: 1) IBM compatible computer 2) PROCOMM Plus Communications Software

a) Set up parameters for baud rate, stop bits and data bits 3) Null Modem Cable 4) Formatted 3.5’ Diskette

15.9.1 Series 16/18 Setup 1) Turn power ON 2) Place the control in EDIT mode through the operator panel operator panel or

place the control in Emergency Stop Note: It is not possible to place the control into the EDIT mode unless the Ladder is running. Mode changes are ignored by the CNC while in E-Stop.

3) Set PWE=1 a) Press [ OFFSET/SETTING ] b) Press <SETTING> c) Position the cursor on “PARAMETER WRITE” d) Press [ 1] then [ INPUT] 4) Set CNC communication parameters

a) Record the original values of the parameters to be able to returned to original values

b) Press [ SYSTEM ] c) Press <PARAM> d) Enter the parameter number e) Press f) Enter desired value

Series 16/18 parameter settings are as follows (Channel 1 for PC communications): Parameter Value Purpose I. 0 00000010 ISO output formatted data II. 20 1 Channel 1 III. 111 10000001 No feed holes / 2 stop bits IV. 112 0 RS232C V. 113 10 4800 baud VI. 3201 00000100 Replace programs VII. 3202 00000000 Programs 08000 – 09999 not protected


5) Set PWE = 0 a) Press [ OFFSET/SETTING ] b) Press <SETTING> c) Position the cursor on “PARAMETER WRITE” d) Press [0] then [ INPUT ]

15.9.2 DOWNLOADING FROM THE SERIES 16/18 TO THE PC

15.9.3 CNC Parameters 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and

the PC 4) Set up PC with Procomm Plus 5) At the main screen of Procomm

a) Press “Page Down” key b) Type ‘A’ for ASCII data transfer c) Insert a diskette into the A drive d) Enter the file mane to receive data (Ex. A:\B2010R15.CNC) e) Press ENTER to set the PC in the ready state ( The status line on the

PC will say “ Download in Progress ” 6) Set EDIT mode on the operator panel, not ESTOP 7) Begin data transfer

a) Press [ SYSTEM ], < PARAM>, <OPRT> b) Press the <→ > until < READ> & <PUNCH > appear in the soft-key

menu. c) Press <PUNCH> then <EXECUTE>. The word “ OUTPUT“ will flash on

the lower right hand screen of the Series 16/18. Data will be displayed on the PC as the transfer is in progress. It should be readable and appear in the format of a NC part program. The block numbers will

d) range from N0 to N9999. 8) Press the escape key ESC on the PC to close the file and end data transfer 9) Verify file on the disk

a) Press ALT + F on the PC b) Type A: and press ENTER c) Locate the file just loaded in the file list d) Verify that the file length is not 0

10) Set parameter 20 to 0 11) Remove the null modem cable 12) Return the control to system control


15.9.4 PMC Ladder Program and PMC Parameters Ladder programs are generally stored in EPROM. It is possible to run the Series 16/18 controls with the ladder in RAM. This is the exception. If the ladder program is stored in RAM, two files must be saved, because the Ladder and PMC parameters cannot be output as a single file and the procedure must be accomplished twice.

15.9.5 PMC Parameters 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and


a) Press “Page Down” key b) Type ‘A’ for ASCII data transfer c) Insert a diskette into the A drive d) Enter the file mane to receive data (Ex. A:\B2010R15.PMC) e) Press ENTER to set the PC in the ready state ( The status line on the

PC will say “ Download in Progress ” 6) Set EDIT mode on the operator panel, not ESTOP 7) Set PWE =1

a) Press [ OFFSET / SETTING ] b) Press < SETTING > c) Position the cursor on “ PARAMETER WRITE “ d) Press [ 1 ] then [ INPUT ]

8) Clear all alarms a) Press [ CAN ] + [ RESET ] to clear alarm 100 PWE

9) Set Ladder Edit menu ON (K17.1) a) Place the system in E-Stop b) Press [ SYSTEM ], <PMC> c) Press [ PMCPRM ], <KEEPRL> d) Use the cursor keys to select keep relay K17 bit 1 e) Enter [1], [ INPUT] 10) Set PMC I/O Parameters

a) Press <← >, to return to the “ PMC CONTROL SYSTEM” menu b) On the CRT press <→ > c) Press <I/O> d) Press [1] the [INPUT] to select CHANNEL = 1. The cursor will move

to DEVICE e) On the CRT press <→ > then < OTHERS> f) Select DEVICE = OTHERS g) Press [ ↓ ] to DATA KIND


h) Press < PARAMATER> i) Press <WRITE> j) Set PMC communication parameters

I. On the CRT press <→ >, <I/O>, <→ >, II. On large format displays, press <I/O> III. Select < SPEED> IV. BAUD RATE = 9600 Press [3] then [INPUT] V. PARITY =NONE Press [0] then [INPUT] VI. STOP BITS =2 Press [1] then [INPUT] VII. WRITE CODE=ASCII Press [0] then [INPUT]

The write code setting may not appear initially. This is only available after the write function has been selected.

11) Begin data transfer

a) Press <← > to display the I/O menu b) Press <EXEC>. The CNC will display “EXECUTING”. c) During the download process, the data will appear on the computer

screen. PMC parameters will appear as a part program with block numbers beginning in the N640000 range

12) When data transfer is complete, press the escape key ESC on the PC keyboard

13) Verify file on disk a) Press ALT + F on the PC b) Type A:\ and press ENTER c) Locate the file length is NOT 0

14) Set parameter 20 to 0 15) Turn off Ladder Edit menu K17.1

a) Press [SYSTEM, <PMC> b) Press <PMCPRM>, <KEEPRL> c) Use the cursor keys to select keep relay K17 bit 1 d) Enter [0], [INPUT] e) Release the E-Stop

16) Set PWE = 0 a) Press [ OFFSET/SETTING] b) Press <SETTING> c) Position the cursor on “PARAMETER WRITE” d) Press [0] the [INPUT]

17) Press RESET to clear any alarms 18) Remove the null modem cable from the control


15.9.6 PMC LADDER Procedure if Not Stored in EPROM 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and


a) Press “Page Down” key b) Type ‘A’ for ASCII data transfer c) Insert a diskette into the A drive d) Enter the file mane to receive data (Ex. A:\B2010R15.LAD) e) Press ENTER to set the PC in the ready state ( The status line on the PC

will say “ Download in Progress ” 6) Set EDIT mode on the operator panel, not E-STOP 7) Set PWE = 1

a) Press [ OFFSET/SETTUNG ] b) Press <SETTING> c) Position the cursor on “PARAMETER WRITE” d) Press [ 1] then [ INPUT]

8) Cleat all alarms a) Press [CAN]+[RESET] to cleat alarm 100 PWE

9) Set Ladder Edit menu on K17.1 a) Set the system in ESTOP b) Press [SYSTEM], < PMC > c) Press <PMC>, <KEEPRL> d) Use the cursor keys to select the keep 17 bit 1 e) Enter [1], [INPUT]

10) Set PMC Parameters a) Press <← >, to return to the “ PMC CONTROL SYSTEM” menu b) On the CRT press <→ > c) Press <I/O> d) Press [1] the [INPUT] to select CHANNEL = 1. The cursor will move

to DEVICE e) On the CRT press <→ > then < OTHERS> f) Select DEVICE = OTHERS g) Press [ ↓ ] to DATA KIND h) Press < LADDER> i) Press <WRITE> j) Set PMC communication parameters

I. On the CRT press <→ >, <I/O>, <→ >, II. On large format displays, press <I/O> III. Select < SPEED> IV. BAUD RATE = 9600 Press [3] then [INPUT] V. PARITY =NONE Press [0] then [INPUT] VI. STOP BITS =2 Press [1] then [INPUT]


VII. WRITE CODE=ASCII Press [0] then [INPUT] The write code setting may not appear initially. This is only available after the write function has been selected.

10) Begin data transfer

a) Press <← > to display the I/O menu b) Press <EXEC>. The CNC will display “EXECUTING”. c) During the download process, the data will appear on the computer

screen. When downloading the ladder the data will appear simply as hexadecimal data.

11) When data transfer is complete, press the escape key ESC on the PC Keyboard.

12) Verify file on disk a) Press ALT + F on the PC b) Type A:\ and press ENTER c) Locate the file length is NOT 0

13) Set parameter 20 to 0 14) Turn off Ladder Edit menu K17.1

a) Press [SYSTEM], <PMC> b) Press <PMCPRM>, <KEEPRL> c) Use the cursor keys to select keep relay K17 bit 1 d) Enter [0], [INPUT] e) Release the E-Stop

15) Set PWE = 0 a) Press [ OFFSET/SETTING] b) Press <SETTING> c) Position the cursor on “PARAMETER WRITE” d) Press [0] the [INPUT]

16) Press RESET to clear any alarms 17) Remove the null modem cable from the control

15.9.7 PART PROGRAMS 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and

the PC 4) Set up PC with ProComm Plus 5) At the main screen of ProComm

a) Press “Page Down” key b) Type ‘A’ for ASCII data transfer c) Insert a diskette into the A drive d) Enter the file mane to receive data (Ex. A:\B2010R15.PRG) e) Press ENTER to set the PC in the ready state ( The status line on the PC

will say “ Download in Progress ”


6) Set the Series 16/18 a) Set EDIT mode on the operator panel, not E-STOP b) Clear all alarms c) Press [PROG], <OPRT> d) Press the <→> key until <READ> & <PUNCH> appear in the soft key

menu e) Enter [0-9999] f) Press <PUNCH> then <EXEC>. The word “OUTPUT” will flash on the

lower right hand screen of the Series 16/18. Data will be displayed on the PC while the transfer is in progress. It should be readable and appear in the format of a NC part program. All part Programs will be transmitted at this time. Output individual programs may be by entering the program name.

7) Press the escape key (ESC) on the PC to close the file and end transfer 8) Verify file on disk

a) Press ALT + F on the PC b) Type A:\ and press ENTER c) Locate the file length is NOT 0

9) Set parameter 20 to 0 10) Remove the null modem cable from the control

15.9.8 TOOL OFFSET 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and


a) Press “Page Down” key b) Type ‘A’ for ASCII data transfer c) Insert a diskette into the A drive d) Enter the file mane to receive data (Ex. A:\B2010R15.OFF) e) Press ENTER to set the PC in the ready state ( The status line on the

PC will say “ Download in Progress ” 6) Set the Series 16/18

a) Set EDIT mode on the operator panel, not E-STOP b) Clear all alarms c) Press [OFFSET/SETTING], <OFFSET>, <OPRT> d) Press the <→> key until <READ> & <PUNCH> appear in the soft key

menu e) Enter [0-9999] f) Press <PUNCH> then <EXEC>. The word “OUTPUT” will flash on the

lower right hand screen of the Series 16/18. Data will be displayed on the PC while the transfer is in progress. It should be readable and


appear in the format of a NC part program. All part Programs will be transmitted at this time.




15.9.9 MACRO VARIABLES The majority of controls do not have macro variables that must be set and saved 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and


a) Press “Page Down” key b) Type ‘A’ for ASCII data transfer c) Insert a diskette into the A drive d) Enter the file mane to receive data (Ex. A:\B2010R15.MAC) e) Press ENTER to set the PC in the ready state ( The status line on the


a) Set EDIT mode on the operator panel, not E-STOP b) Clear all alarms c) Press [OFFSET/SETTING], <OFFSET>, <MACRO>, <OPRT> d) Press the <→> key until <PUNCH> appear in the soft key menu.

Read will not appear. This is a PUNCH function only. You will need to read these variables in as a part program, run them, and then remove the program when complete

e) Press <PUNCH> then <EXEC>. The word “OUTPUT” will flash on the lower right hand screen of the Series 16/18. Data will be displayed on the PC while the transfer is in progress. It should be readable and appear in the format of a NC part program. All part Programs will be transmitted at this time.





15.9.10 PITCH ERRORS 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and


a) Press “Page Down” key b) Type ‘A’ for ASCII data transfer c) Insert a diskette into the A drive d) Enter the file mane to receive data (Ex. A:\B2010R15.PIT) e) Press ENTER to set the PC in the ready state ( The status line on the


a) Set EDIT mode on the operator panel, not E-STOP b) Clear all alarms c) Press [SYSTEM], <→>, <PITCH> d) Press the <→> key until <PUNCH> appear in the soft key menu

Read will not appear. This is a PUNCH function only. You will mid to read these variables in as a part program, run them, then remove the program when complete

e) Press <PUNCH> then <EXEC>. The word “OUTPUT” will flash on the lower right hand screen of the Series 16/18. Data will be displayed on the PC while the transfer is in progress. It should be readable and appear in the format of a NC part program. All part Programs will be transmitted at this time.





15.9.11 UPLOADING TO THE SERIES 16/18 FROM THE PC The CNC parameters must be loaded and the ladder running before anything else can be loaded to memory. Therefore it is required that the CNC parameters be loaded first, and then the ladder. All other files will be loaded after the ladder is running. If memory had been reset, the system parameters (9900 and above) may be loaded manually and initialized to ensure the availability of the punch panel port (JD5A).

15.9.12 CNC PARAMENTERS 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and

the PC 4) Set up PC with ProComm Plus 5) Place the control into EDIT MODE or into the Emergency Stop condition. The

control cannot be set to any mode other than default if the ladder is not in memory. This is the case in the event of a memory reset operation. Parameters may be loaded in the Emergency Stop condition

6) Set PWE = 1 a) Press [OFFSETT/SETTING]

7) Press <SETTING > 8) Position the cursor on “PARAMETER WRITE” 9) Press [1] then [INPUT]. ALARM 100 will appear to indicate PARAMETER

WRITE ENABLE is set to enable parameters to be changed. 10) Set for data transfer at the CNC

a) Press [SYSTEM], <PARAM>, <OPRT> b) Press the <→> key until <READ> & <PUNCH> appears in the soft key

menu. c) Press <READ> then <EXEC>. The word “LSK” will flash on the lower

right hand screen of the Series 16/18. Some versions of the CNC executive firmware, enables the READ function on a temporary basis after a memory reset. If the <READ> soft key does not appear, performing a memory “RESET” will restore the function.

11) Start data transfer a) From the main screen of ProComm, press “Page Up” key b) Type ‘A’ for ASCII data transfer c) Type the file mane to send to the Series 16/18 (Ex.A:\B2010R15.CNC) d) Press ENTER to begin the transfer e) The “LSK” message will change to “INPUT” as the control begins to

receive data. f) Data will be displayed on the PC while the transfer is in progress. It

should be readable and appear in the format of a NC part program. The block numbers will range from N0 to N9999.


12) Set PWE to 0 a) Press [OFFSET/SETTING] b) Press <SETTING> c) Position the cursor on “PARAMETER WRITE” d) Press [0]a then [INPUT]

13) Set parameter 20 to 0 14) Cycle Power to establish new parameter settings 15) Remove the null modem cable from the control

15.9.13 PMC Ladder Program and PMC Parameters Ladder Programs are generally stored in EPROM. It is possible to run the Series 16/18 controls with the ladder in RAM. This is the exception. If the ladder program must be reloaded, 2 files must be transferred. Ladder and PMC parameters cannot be output as a single file.

15.9.14 PMC LADDER LOADING This procedure will not be required if the ladder is stored and executed from EPROM. 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and

the PC 4) Set up PC with ProComm Plus 5) Set PWE = 1 6) Press [OFFSETT/SETTING] 7) Press <SETTING > 8) Position the cursor on “PARAMETER WRITE” 9) Press [1] then [INPUT]. ALARM 100 will appear to indicate PARAMETER

WRITE ENABLE is set to enable parameters to be changed. 10) Set Ladder EDIT menu on K17.1

a) Press [SYSTEM], <PMC>, b) Press <PMCPRM>, <KEEPRL> c) Use the cursor keys to select keep relay K17 bit 1 d) Enter [10], [INPUT]


11) Set PMC I/O parameters a) Press <←>, to return to the PMC Control System menu. b) On the CRT, Press <→> c) Press <I/O> d) Press [1] then [INPUT] to select CHANNEL = 1. The cursor will

move to DEVICE. e) On the CRT, Press <→> f) Select <OTHER> to select DEVICE = OTHERS g) Press [↓] to FUNCTION h) Press <READ>. The DATA KIND field will go blank. The PMC

automatically determines which data type is being transmitted. i) Set communication parameters


12) Set the Series 16/18 in the E-STOP condition 13) Start the CNC

a) Press <←> to display the I/O menu b) Press <EXEC>. The PowerMate will display “EXECUTING”

14) Start data transfer a) From the main screen of ProComm, press “Page Up” key b) Type ‘A’ for ASCII data transfer c) Type the file mane to send to the Series 16/18 (Ex.A:\B2010R15.LAD) d) Press ENTER to begin the transfer e) Data will be displayed on the PC while the LOADING is in progress.

When downloading the ladder, the data will appear simply as hexadecimal data.

15) CRT will show “COMPLETE” when the transfer is successful 16) Start the ladder running

a) Press <←>, <→> b) Press <RUN>

17) Turn off the Ladder EDIT menu K17.1 a) Press <←> b) Press <PMCPRM>, <KEELRL> c) Use the cursor keys to select keep relay K17 bit 1 d) Enter [0], [INPUT]

18) Set parameter 20 to 0


19) Set PWE = 0 a) Press [ OFFSET/SETTING] b) Press <SETTING> c) Position the cursor on “PARAMETER WRITE” d) Press [0] the [INPUT] e) Remove the null modem cable and Cycle power to establish I/O link

communication

15.9.15 PMC Parameter Loading 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and

the PC 4) Set up PC with ProComm Plus 5) Set PWE = 1

a) Press [OFFSETT/SETTING] b) Press <SETTING > c) Position the cursor on “PARAMETER WRITE” d) Press [1] then [INPUT. ALARM 100 will appear to indicate

PARAMETER WRITE ENABLE is set to enable parameters to be changed.

6) Set Ladder EDIT menu on K17.1 a) Press [SYSTEM], <PMC>, b) Press <PMCPRM>, <KEEPRL> c) Use the cursor keys to select keep relay K17 bit 1 d) Enter [0], [INPUT]

7) Set PMC I/O parameters a) Press <←>, to return to the PMC Control System menu. b) On the CRT, Press <→> c) Press <I/O> d) Press [1] then [INPUT] to select CHANNEL = 1. The cursor will

move to DEVICE. e) On the CRT, Press <→> f) Select <OTHER> to select DEVICE = OTHERS g) Press [↓] to FUNCTION h) Press <READ>. The DATA KIND field will go blank. The PMC

automatically determines which data type is being transmitted. i) Set communication parameters



8) Set the Series 16/18 in the E-STOP condition 9) Start the CNC

a) Press <←> to display the I/O menu b) Press <EXEC>. The PowerMate will display “EXECUTING”

10) Start data transfer a) From the main screen of ProComm, press “Page Up” key b) Type ‘A’ for ASCII data transfer c) Type the file mane to send to the Series 16/18

(Ex.A:\B2010R15.PMC) d) Press ENTER to begin the transfer e) Data will be displayed on the PC while the LOADING is in

progress. PMC parameters will appear as a part program with block numbers beginning in the N64000 range.

11) CRT will show “COMPLETE” when the transfer is successful 12) Turn off ladder EDIT menu K17.1

a) Press , <PMC> b) Press <PMCPRM>, <KEEPRL> c) Use the cursor keys to select keep relay K17 bit 1 d) Enter [0], [INPUT]

13) Remove the null modem cable and Cycle power to establish I/O link communication

15.9.16 Part Programs 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and

the PC 4) Set up PC with ProComm Plus 5) Set EDIT MODE on the CNC 6) Enable memory edit (Memory Protect key switch on the operator panel) 7) Clear all alarms 8) Release program protection

a) Press [SYSTEM], <PARAM> b) Enter [3202], <NO. SRCH> c) Enter [00000000], [INPUT]

9) Set up CNC to receive data a) Press [PROG], <OPRT> b) Press the <→> key until <READ> & <PUNCH> appear in the

soft key menu. These soft keys will only appear when the control is in EDIT mode.

c) Press <READ> then <EXEC>. The word “LSK” will flash on the lower right hand screen of the Series 16.18


10) Begin transfer a) From the main screen of ProComm, press “Page Up” key b) Type ‘A’ for ASCII data transfer c) Type the file mane to send to the Series 16/18

(Ex.A:\B2010R15.PRG) d) Press ENTER to begin the transfer

The “LSK” message will be replaced with “INPUT” as the control begins to receive data.

11) Reset program protection (If change in step 6) a) Press [SYSTEM], <PARAM> b) Enter [3202],<NO.SRCH> c) Enter [00010001],[INPUT] d) Set parameter 20 to 0 e) Reset Memory Protect key switch f) Remove the null modem cable from the control

15.9.17 Macro Variables 1) Follow the procedure for loading part programs. 2) When prompted for “FILE NAME”, Enter the mane of the file containing Macro

variables (EX. A:\ B2010R15.MAC) 3) Note the Program number of the program loaded into memory. When the

control finishes with the program load, the current part program will be the one containing macro variable.

4) Run the part program a) Set MEMORY mode form the operator panel b) Turn feed rate override and traverse override to minimum

values to prevent damage if a wrong part program is run. c) Press cycle start to run the program

5) Verify that the macro variable have loaded a) Press [OFFSET/SETTING] b) On the CRT, Press <→> c) Select <MACRO> d) Use the [PAGE ↓] key to page through, and view the macro

variables 6) Delete the program containing macro variables from control memory

a) Press EDIT on the operator panel b) Press [PROG] c) Press[O] and enter the program number for the program

containing macro variable see step 3 d) Press [DELETE]

7) Set parameter 20 to 0 8) Disable the edit enable key switch


15.9.18 OFFSET 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and

the PC 4) Set up PC with ProComm Plus 5) Press EDIT on the operator panel 6) Set the control to receive offset data

a) Press [OFFSET\SETTING] b) Press <OPRT>, → until <READ> and appear in the soft key

menu c) Press <READ>, <EXEC>. “LSK” will mow be flashing in the

lower right corner of the CRT 7) Begin Transfer

a) From the main screen of ProComm, press “Page Up” key b) Type ‘A’ for ASCII data transfer c) Type the file mane to send to the Series 16/18

(Ex.A:\B2010R15.OFF) d) Press ENTER to begin the transfer



15.9.19 Pitch Error Compensation 1) Set CNC communications parameters 2) Set parameter 20 to 1 3) Connect the mull modem communication cable between the punch panel and

the PC 4) Set up PC with ProComm Plus 5) Set PWE = 1

a) Press [OFFSETT/SETTING] b) Press <SETTING > c) Position the cursor on “PARAMETER WRITE” d) Press [1] then [INPUT]. ALARM 100 will appear to indicate

PARAMETER WRITE ENABLE is set to enable parameters to be changed.


6) Set the control to receive Pitch error data a) Press [SYSTEM] b) On the CRT, Press <→> c) Press [PITCH] d) Press <OPRT>, <→> until <READ> appears in the soft key

menu e) Press <READ>, <EXEC>. “LSK” will mow be flashing in the

lower right corner of the CRT 7) Begin Transfer

a) From the main screen of ProComm, press “Page Up” key b) Type ‘A’ for ASCII data transfer c) Type the file mane to send to the Series 16/18

(Ex.A:\B2010R15.PIT) d) Press ENTER to begin the transfer


8) Set parameter 20 to 0 9) Set PWE = 0

a) Press [ OFFSET/SETTING] b) Press <SETTING> c) Position the cursor on “PARAMETER WRITE” d) Press [0] the [INPUT]

9) Remove the null modem cable from the control


NOTES


16 Balogh TAGS and Transceivers

16.1 Overview Balogh Tags and transceivers are used to track a part as it moves along the assembly line. Build information is written to the tag and read by the stations. Each step in the process is tracked and recorded via the use of the Balogh RFID system. This section discusses the use and maintenance of the Balogh units on the GMPT V8 assembly line.

16.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of Balogh TAGS and Transceivers • Understand the types and levels of TAGS • Understand Transmission Zones


16.3 Operation- RFID System RFID TAGS (Radio Frequency Identification) will carry product identification, special instructions and other data to perform automated operations in a process. Balogh TAGS are PASSIVE requiring no power source to operate its circuits. During data exchange, the electromagnetic fields from the transceiver creates energy in the TAG to operate its internal circuits for receiving from and transmitting RF signals to the transceiver. The RF TAG has an internal battery for SRAM memory retention (not power for communication between the TAG and the Transceiver).

Figure 136 Interaction between Balogh’s Transceiver and TAG through electromagnetic fields.

In the engine assembly process, RFID tags have engine suffix broadcast code, EUN (Engine Unit Number- unique for each engine), pallet number, date, time and station level data controlling how every station in the procces will respond to the Pallet. The Operation Program Number tells an automatic station how to perform its operation and can be used by manual stations to enable wrenches. Error Proofing Data is used to determine what selection bins should be enabled. Machine Status byte is written to the TAG indicating if it accepted, rejected or bypassed the engine.


16.4 TAG Type and Levels READ/WRITE RF TAGS • READ/WRITE READ/WRITE TAGS can be read from and has the ability for the stored data within the TAG to be altered (WRITE) without contact. READ/WRITE TAGS are classified by the amount of memory that can be stored in them. Level 3 tags contain up to 64 Bytes of data and Level 4 tags have ranges of 64 Bytes, 2K Bytes, 8K Bytes or more. There are two basic ways how RF signals are produced in a TAG. When an outside source transfers energy from the Transceiver to the TAG by means of an electromagnetic field, this type of tag is called PASSIVE. If the TAG’s RF transmission power is contained within the TAG by means of a battery, this type of tag is called ACTIVE. Some PASSIVE TAGS have a battery used to backup the TAG’s internal memory. The ACTIVE TAG can be read or written to at greater distances. ACTIVE TAGS also have a limited amount of reads and writes before they must be replaced, while PASSIVE TAGS have unlimited number of reads or writes.

Figure 137 Shows a Transceiver and READ/WRITE TAGS.

ERC-85/QC Transceiver, OMX-93/R8 tag


16.5 Transmission Zones The transceiver establishes a semi-spherical electromagnetic field defining the transmission zone.

Figure 138 Electromagnetic field Transmission Zone

There are two types of transmission zones • Static transmission zone • Dynamic transmission zone Orientation of the TAG to the transceiver is shown with direction arrows on both devices. Alignment of the device’s arrows is important for optimal reading and writing results. The recommended distance between a TAG and a transceiver is expressed as Sr = Sn * 0.4 (following variable values from specification sheets). H Typical height of transmission zone at Sr. L Typical length of transmission zone at Sr. W Typical width of transmission zone at Sr.

Figure 139 Side and Top view of a Static Transmission Zone


The Static Transmission Zone variable H, L, and W from the data sheet have values with +/- 20% tolerance and can be affected by ambient temperatures or mechanical clearances. The Dynamic Transmission Zone is a window related to the static transmission zone where it is possible to read or write to a TAG during motion. Reading or writing to a TAG on the fly, data integrity remains intact if maximum lateral and angular offsets are not exceed.

Figure 140 Maximum lateral and angular offset in a dynamic transmission zone

Potential Transmission Zones Figure 15-6 represents the main RFID zone (Primary Transmission Zone) where data exchange between the Transceiver and the TAG takes place. There is another zone present called the Potential Transmission zone. To avoid erroneous data exchange between two transceiver or two TAGS, there are recommended minimum distances required between Transceivers or TAGS.

Figure 141 The Primary Transmission Zone contains three-dimensional fields surrounding the Transceiver and TAG shown in the top and side views above. Recommended distances

between two Transceivers(ERC – 85/QC) is 1m.


Figure 142 The Primary Transmission Zone recommended distances between two TAGS(OMX-

93/R8) is 200mm.

This value provides safety, preventing any read or write error caused by two TAGS entering the same Transceiver field. TAG (OMX-93/R8) has 8K Bytes of memory, read or writes data at 0.4 ms/byte and 0.5 ms/byte respectfully.


16.6 Balogh PM-15 Hand Held RF Reader The Balogh PM-15 hand held RF reader can be used to determine the status of a pallet using the build matrix summary (A2 and A3). The RF reader has a 4 line LCD backlight display, programmable function keys, 64K internal data buffer, auto power off, a screen help menu and can display data in byte or word format and last TAG status. The “START” key powers up the unit. To STOP the unit, press “Shift” then “Start” keys. The “SHIFT” key allows access for the red labeled keys, and other functions. The “ESC” key exits a function and returns to the internal buffer.

Figure 143 PM-15 Hand Held RF reader can read, writes, and initializes TAGS

The PM-15 can be configured to work with Balogh OMX 8K byte read/write TAGS. With the power on the PM-15, press “SHIFT K” and use the “+” key on the display to select the TAG being used. After the TAG is selected, press “ESC” to exit the function. The configuration is retained by the PM-15 until it is changed. A transceiver is built into the top of the PM-15 unit. When performing a read/write function, make sure the direction arrows on the PM-15 line up with the direction arrows on the TAG. All Balogh TAGS come from the manufacturer initialized and ready to be placed in operation. If a TAG needs to be reinitialized, press “SHIFT N” and place the TAG in the proper orientation to the PM-15. A beep or the reappearing of the internal buffer will signify completion. Pressing “SHIFT T”, the status of a RF TAG can be displayed and is useful when there is trouble reading or writing to a TAGS.


TAG Read/Write: press “Shift R” (Read) or “Shift W” (Write), Step 1. Enter the TAG address to start reading/writing data, press “ENTER” Step 2. Enter the length in bytes to read/write, press “ENTER” Step 3. Enter the address internal buffer number, press “ENTER” Step 4. Place the TAG in the PM-15 transceiver zone and wait for the beep and

the internal buffer’s data to appear on the screen. To check the data which was written, follow the TAG read instruction.

Figure 144 PM-15 Hand Held RF reader TAG read/write screens

TAG Write (Same Values): press “Shift S” (Write) Step 1. Enter the TAG address to start writing data, , press “ENTER” Step 2. Enter the length in bytes to write, press “ENTER” Step 3. Enter the byte value to write to the tag (decimal of hex) , press “ENTER” Step 4. Place the TAG in the PM-15 transceiver zone and wait for the beep and

the internal buffer’s data to appear on the screen. To check the data which was written, follow the TAG read instruction.

Figure 145 PM-15 Hand Held RF Reader TAG write screens


If there is an error in communication, fault error message will be received and displayed on the screen

Figure 146 PM-15 Hand Held RF reader TAG Fault Messages

PM-15 Hand Held Key Function

Figure 147 PM-15 Hand Held RF Reader Key Function Summary

Help screen menu is available and can be accessed by pressing “SHIFT V” and using page up or page down to scroll through the menu.


16.7 RFID System and Build Information The pallet tag’s written data for the block loaded to the pallet, controls how each station on the assembly line will respond to that pallet. Currently, only 5K bytes of the tag’s memory is used for engine build information. There are areas of the tag where information such as pallet number, engine suffix broadcast code, engine unit number (EUN), date and time are load and stored. Each station had a set of data that contains one byte for station operation program, for error proofing data, and machine status. The operation program number tells an automatic machine how to perform its job and is used by manual stations to enable wrenches if needed. The error proofing byte is used to determine what selection bins should be activated. The status byte is where the stations write to the tag indicating if it accepted, bypassed or rejected the engine. BUILD.EP File The RFID tag contains the instruction for building the entire engine. The RFID gets its information from the BUILD.EP file. It is an ASCII text file on the PC hard drive at the Block Load stations and the gantries that loads the Dress Lines. This file is created from information supplied by Process and Industrial Engineering and is located in the C:\OTHER directory on the hard drive.

Figure 148 Important Byte on All TAGS


BUILD.EP Structure In figure 15-14, the suffix code XJB on the first line describes what an XJB engine is. On the next line where “PART=7”, tells the 11.exe program haw many separate part number variables have been defined. The third line starts the definition of the actual part numbers that are to be written to the TAG. After the part number are defined, the station build data begins in the following format: Column 1: Suffix code Column 2: Length of data for object described on that line Column 3: Object type (G = General, S = spare, A = automation, M = manual

station, P = part, R = repair bay) Column 4: Object name (this is an arbitrary name assigned by Krause) Column 5: Operation Program Column 6: Error proofing byte #1 Column 7: Error proofing byte #2 Column 8: Machine Status Column 9: Station Number Column 10: Starting RFID tag byte address for the objects data On the Build Line at the Block Back Up Station and on the Dress Line at the Gantry station is where the Build information (BUILD.EP ASCII text file) is written to the RFID TAGS. At the dress line gantry, the block barcode label having the complete EUN is scanned. Within the EUN the engine suffix is located. FloPro tells 11.exe that it has an engine suffix. 11.exe reads the BUILD.EP on the hard disk finding the engine suffix and loads the build information into memory. FloPro using the WRITE command writes the build information to the TAG. Because of the FloPro memory limitations, build information is loaded in two steps, half of the data per write. At the build line, there is a schedule of engines to be built. This schedule contains 100 suffix codes (engine suffix queue and is a FIFO) in FloPro’s memory. The suffix code at the top of the queue is the next engine to be loaded to the line at the Block Load Back Up Station. EDS enters the suffix codes into FloPro memory over the FloNet System.


Sample Of the BUILD.EP File

Figure 149 Build Information On TAGS


16.8 Transceiver Wiring The Transceiver is wired to the GE Balogh Interface module using a four-conductor cable. Terminals available after removing the keyed cap. The Transceiver has an LED for device power status. The maximum cable length between a transceiver and the interface is 300m (1000 ft.) The ECR-85/QC is designed quick connector and mates with Balogh’s shielded cable set.

Figure 150 Transceiver wiring


16.9 Configuration Lab Use the PM-15 RF Reader to: 1. Configure the PM-15 RF Reader to read and write to a Balogh OMX 8K TAG 2. Initialize a read/write TAG 3. Change pallet number (byte 5 and 6), data format (Dec, Bin, Hex, ASCII) 4. Display TAG status (byte 10)


NOTES


17 Balogh BIGE

17.1 Overview The Balogh system communicates across the Genius bus via the BIGE Interface module. This section describes the function of the BIGE module and hoe it interfaces with FloPro.

17.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of the Balogh BIGE Interface module • Make hardware connections to the Balogh BIGE • Better understand Datagrams and Global Status Data • Configure the Balogh BIGE Interface module • Replacement of the Balogh BIGE Interface module


17.3 Operation The BIGE (Balogh Interface to General Electric) interface module provides a two wire connection between the TAG/Transceiver devices and the high speed Genius LAN network. The BIGE module is a two-channel interface device allowing two Balogh Transceivers to the connected at each “serial bus address” on the Genius LAN Network. The BIGE unit is powered by a 24 VDC power supply, supplying 0.5 amp operating current and up to 2.0 amp peck. Interfacing to the Genius Bus and communication with a PC based system is done by using a computer–host bus controller such as the PCIM module (Personal Computer Interface Module). Through the command instruction set issued by the controller’s logic program, the BIGE can execute block reads and writes up to 128byte in length, request channel status, and using Global data provide the PC with current execution status of the BIGE. The BIGE operates with the high speed read/write Balogh series OMX tags which provide 8K bytes of battery backed SRAM and reading speeds of 0.4 msec per byte (2500Hz, 20K bits/sec) .

Figure151 Balogh BIGE Module (Balogh Interface to General Electric)


17.4 BIGE Hardware Connections The BIGE requires two 24VDC and can be jumpered together (#1). BIGE provides two separate channels for each Balogh Transceiver connections (#2). The Transceivers connections are made using a four conductor shielded cable with a shield and a drain wire. Transceiver can be wired up to 164 feet from the BIGE module. The RS-232 (#3) connection is reserved for future uses. The BIGE connected to the Genius LAN as a GENI based device. The Network cable is connected to the SHIELD/SERIAL (#4) connector on the BIGE module.

Figure152 Balogh BIGE Module and Transceiver Connectors

#2

#3

#1

#4#5


17.5 BIGE – Configuration The integrated Geni board in the BIGE module has an eight position “DIP” switch used to configure Genius “serial bus address” or “device number” and baud rate. Each device on the Genius Network must have a “Device Number” (0 to 31). The available DIP switch setting is printed on the case of the BIGE and can be observed in the next figure below.

Figure 153 Balogh BIGE Module Genius Bus DIP Switch Settings

When connecting the BIGE as a device on the Genius LAN, it is necessary to configure the Genius I/O in the FloPro configuration screen using Generic I/O with sixteen bits of input. In the Balogh RF configuration screen section, the example shows the BIGE configured to channel 1 of the (PCIM) Bus Controller as device number 5 with both channels #0 and #1 reading or writing to several memory locations.


FloPro Configuration of the BIGE BIGE (Balogh Gateway) INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 1 5 Generic 0 – 15 I0345 –

I0360 0 – 15 O0345 -

O0360

Figure 154 Balogh BIGE Module Genius I/O RF configuration


17.6 BIGE – RF Tag/Bar Code Blocks The RF Tag/Bar Code blocks allow the user to read from and write to the BIGE RF Tag/Transceiver system. Information can be read from or written to the following areas:

• Counters • Registers • Numbers • ASCII Characters

There are four RF Tag/Bar Code blocks:

• Read Block • Write Block • Cancel R/W Block • Test Status Block

Read Block Read blocks allow the user to read data from a RF Tag/Bar Code device. The Read Block can read a single unit of data or a range of units into one or more mnemonic variables.

Figure 155 RF Tag/Bar Code Read Block


Write Block Write blocks allows the user to write data from a RF Tag/Bar Code device. The Write Block can write a single unit of data or a range of units to the RF Tag/Bar Code device.

Figure 156 RF Tag/Bar Code Write Block

Cancel Block Cancel blocks allows the user to cancel a read or write data on a RF Tag/Bar Code device. If there is a read or write operation pending, it may be canceled with this block.

Figure 157 RF Tag/Bar Code Cancel Block


Test Status Block Test Status blocks are used to test the status of a RF Tag/Bar Code device. The Test Status Block will direct program execution or flow based on the status of the RF Tag/Bar Code device. Figure below shows a Test Status Block as being programmed in the Block Editor.

Figure 158 RF Tag/Bar Code Test Status Block

One of the three following conditions can be programmed in a RF Tag/Bar Code Test Status block:

• Read Done • Write Done • Error


17.7 RFID READ / WRITE Flowchart Sample of READ program

Figure 159 RF Tag READ program


Sample of WRITE program

Figure 160 RF Tag WRITE program


17.8 BIGE – Global Data Status Two bytes of data are transmitted by the BIGE as global data. Any device on the genius network may obtain the current status of the BIGE form the global data, which is transmitted cross the network by the BIGE. This information is stored in the memory location assigned to the BIGE during configuration in FloPro and on the Genius Bus Controller. Each byte of the word represents the current status of a transceiver channel on the BIGE. The low byte represents the transceiver on channel 0 and the high byte represent the transceiver on channel 1. These bytes indicate: • Command received conformed. • Type of command that is currently waiting completion or was last completed. • Current execution status of a command at the channel. • Error status of command in progress • A tag is presents in the transceiver field. The table below indicates the states and bit positions.

Figure 161 Balogh BIGE Nema Global Data Status

RXCMD Toggles each time a request is received CMD (1-0) Represents the current or last command:

00 No Command Received 01 Status Command 10 Read Command 11 Write Command

LOW BATT. Low battery Bit for TAG memory back-up. (SRAM TAGS Only). STAT (1-0) Represents the current state of the channel:

00 No Command Received 02 Command in Progress 10 Command Complete 11 Command Aborted

ERROR Set to 1 when an error occurs during a command execution. Set to 0 on next request. TAG Set to 1 when a tag is seen by the transceiver.


Present Set to 0 when a tag is not seen by the transceiver.

17.9 BIGE – Replacement Unplug the 24VDC power cable on the enclosure and remove the Phoenix connectors from the BIGE. When replacing the BIGE, make sure that the DIP switch settings match the device number and baud rate. Make all necessary power and communication connections needed to make the BIGE operational.

Figure 162 Balogh BIGE Nema 4/12 Enclosure


NOTES


18 Festo

18.1 Overview The Festo Valve Terminal is a versatile valve and I/O unit that can be mounted virtually anywhere. The hardware that makes up the Festo Valve Terminal as well as maintenance procedures are described in this section. Also the configuration and interface with FloPro are discussed.

18.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of the Festo Valve Terminal • Make hardware connections to the Festo Valve Terminal • Configure the Festo Valve Terminals on the Genius LAN • Replacement of the Festo Valve Terminal related components


18.3 Operation The Festo Valve Terminals are constructed on modular basis and permit combinations of pneumatic and electric modules. Each module is assigned different functions and features different elements for connection, display and operation. The input modules process the input signals from sensors (limit, prox. Switches) and transmit these signals to the controller via field bus. The output modules feature universal electrical outputs and control small current-consuming devices with positive logic (solenoid valves, lights, etc.).

Figure 163 Festo Valve Terminals


18.4 Festo Status Indicators and Connections Genius Bus Node and Connection (Genius Bus) There are two plugs on the mode for connecting the valve terminal to the Genius bus. One of these connections is for the incoming cable, the other for the continuing field bus cable. Two red LEDs for “Unit OK and I/O Enabled” and one LED for Power On.

Figure 164 Festo Valve Terminals


Display Indicators for I/O Modules There are one or two LEDs next to relevant connectors on the input/output modules. The colors of these LED are: • Green (Status of the digital Inputs) • Yellow ( Status of the digital Outputs) • Red ( Error of the digital Output)

Figure 165 Display Indicators for I/O Modules

The input stages of the valve terminal provide options of four or eight inputs. These input modules have two circuit logic types, NPN (negative) and PNP (positive).


Input Module

Figure 166 Input Module Pin Assignment for 4/8 Inputs PNP/NPN Circuits.


Output Module Output modules for the valve terminal are available with four outputs. The outputs have positive logic (PNP outputs).

Figure 167 Output module pin assignment for 4Outputs PNP circuits.


18.5 Festo – Configuration Configuring the valve terminal on the Genius bus must be performed in three major steps to integrate it in the control system. Step 1. Settings on the Festo Node. Step 2. Configuring the valve terminal using the Hand Held Monitor. Step 3. Configuring the valve terminal using FloPro Software. STEP 1: The following must be set in the field bus node of the valve terminal: Parameter Default Selection

Device number none 1 – 30 (Address selector switch)

Baud rate 153.6K 38.4 K; 76.8 K;

Baud 1533.6 K Standard 153.6 Kbaud extended (DIP Switch)

Figure 168 Configuration

There are four PC boards in the Festo node. The bus address of the valve terminal can be set with the two address selector switches on board 2. After setting the bus address on the valve terminal, the bus address must then be configured for the bus controller on the Genius Bus. Setting the field bus baud rate


Set the field bus baud rate on the valve terminal so that it agrees with the setting on the Genius bus controller.

Figure 169 Setting field bus baud rate


Step 2: The following configuration parameters are to be set or entered using the HHM in order to configure the valve terminal on the Genius bus. The HHM cannot be directly connected to the Festo node but access through another device on the bus (I/O block) can be used to enter configuration settings for the Festo terminal.

Figure 170 Configuration Parameters using HMI

The following parameters can only be read by the HHM:

Figure 171 Read Parameters using HMI


Saving the configuration To save the current configuration, data must be written into the EEPROM of the valve terminal by using the HHM. The HHM can be attached to any GE I/O block on the bus or bus controller. Three choices are possible in the display below:

Figure 172 Saving the Configuration

Selecting the valve terminal At power-up the HHM activates the device it is plugged into. Press <next> to find and select the appropriate valve terminal. The activated valve terminal is displayed on the HHM as follows:

Figure 173 Selecting the Valve Terminal


Identification parameter of the valve terminal displayed by the HHM • Device number is set with the address selector switch in the field bus node

of the valve terminal. The device number cannot be changed with the HHM. • Reference address is entered in the configuration menu. Make sure that the

reference address is on a byte boundary (multiple of 8 plus 1). • Baud rate is set with the DIIP switch in the field bus node of the valve

terminal. The baud rate cannot be changed with the HHM. Modifying the valve terminal configuration The following configuration parameters can be changed using the HHM: • Hold last state • Output default state • BSM present Outputs on the valve terminal are set according to priorities.

Figure 174 Outputs Priorities

Output Default State When shipped from the factory, the default state for each output is off (logic “0”). Default State can be defined for each output. After power-up or a CPU lost of communication and “Hold Last State” not enabled, each output on the valve terminal is set to its Default State.

Figure 176 Output Default State


Hold Last State When shipped from the factory, the default state for each output is off (logic “0”). This option determines how the outputs of the valve terminal react if CPU communication is lost for at least 3 bus scans. If the “Hold Last State” is enabled, each output on the valve terminal will hold its last state until either communication with the CPU is restored, the HHM changes the output by forcing it or power is removed from the valve terminal.

Figure 177 Hold Last State

Monitoring the valve terminal The valve terminal emulates a GENA board with a maximum of 128 bytes for inputs and outputs. Only 8 bytes are used by the valve terminal and can be monitored by the HHM. Inputs and outputs can be toggled during real time status monitoring of the referenced I/O data bytes.

Figure 178 Monitoring the valve terminal


Recording the number of Inputs and Outputs Press the F4 (next) function key until the following are displayed. Record the number of allocated inputs and outputs. This information is used in bus controller FloPro configuration menu.

Figure 179 Recording the number of Inputs and Outputs


Step 3: The valve terminal should be configured as a Generic I/O device in the FloPro compile configuration menu. The discrete I/O reference addresses must be configured in order to identify the valve terminal’s inputs and outputs in the Genius control system. Festo INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 3 4 Generic 1 – 64 I0633 –

I0696 1 – 64 O0633 -

O0696 Figure 180 Configured a Generic I/O device

A reference starting address must be entered for both inputs and outputs on a byte boundary (multiple of 8 plus 1; e.g.,49). The length to be entered for inputs and outputs depends on the modules installed on the valve terminal. During the power-up sequence the valve terminal recognizes all pneumatic modules and input / outputs modules, and assigns the appropriate addresses (automatic configuration). Addresses are assigned even if a valve location is not used or an input / output module not connected. Valve addresses are set by DIP switch settings on the adapter block and counting is from left to right starting at the node (Max of 26 valve solenoids). A maximum of 12 I/O modules can be used in any combination. 64 inputs are available which include 4 status bits, which always occupy the four highest addresses in the input range.


Figure 181 Combination Valves and Digital I/O modules

The valve terminal can have installed equipment consisting of combination valves and digital I/O modules, valves only and digital I/O modules only. If the valve terminal is changed from the original configuration, there may be a shifting of the I/O addresses. Possible DIP switch settings may change to accommodate the modifications. Manual DIP switch setting to configure valve terminal come into effect only after the operating voltage had been cycle OFF and ON.


Figure 182 Valves Configuration DIP Switch


Position of the status bits within the available input range, depends on the configuration.

Figure 183 Coded Diagnostics


18.6 Festo – Replacement Before the valve terminal can be expanded of modified, it must first be disassembled. • Remove all screws of the modules to be disassembled • Maintain module alignment, pull the modules carefully away from the

individual electrical plug connectors. • Replace broken or damaged seals.

Figure 184 Module Replacement

All solenoid coils have a .315 amp (fast acting) fuse located on the circuit board of the respective sub-base. When replacing defective fuses, turn power off to the valve terminal and air supply. • Open access cover on the manifold • Pull the defective fuse from its socket • Plug in new .315 amp fast-acting fuse • Close access cover


The 24V operating voltages are connected on the adapter plate between the node and the valves. The node and the I/O modules are supplied with the operating voltage via the adapter cable. • The output valves should be protected against short circuit/ overload with a

10 Amp external fuse. • The electronic components and input are fused at 3.15 Amp • Additional internal 2 Amp voltage supply protection for input and sensor • Valves are protected by a central 4 Amp fuse in the adapter

Figure 185 Fuse Replacement


Figure 186 Power Supply Connector


NOTES


19 GE Variable Frequency Drive

19.1 Overview Variable frequency drives are used on the GMPT Romulus V8 assembly line predominantly to operate turntables. The drives interface with FloPro across the Genius bus via a Genius gateway module. This section describes the function and maintenance of the variable frequency drives and their interface with FloPro.

19.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of the Variable Frequency Drive • Make hardware connections to the Variable Frequency Drive • Replacement of the Variable Frequency Drive • Configure the Genius Gateway Interface module • Configure the Horner Electric Option Card Interface


19.3 Operation The GE Variable Frequency Drive incorporates multiple control algorithms with self-tuning function resulting in high performance device. A Sinusoidal PWM control system manipulates the frequency output to the motor thereby controlling its speed. Frequency range is 0 – 400 hertz (0.2 to 60 Hz start frequency, 0.2 to 120Hz base frequency). The output torque can be controlled from 20% to 180% and up to seven selectable preset speeds are available. The GE VFD are both convection and fan cooled depending on size and horsepower (1/2Hp to 1Hp, convection). The GE-VFD requires either 230 or 480 AC 3phase power.

Figure 187 GE Variable Frequency Drive


19.4 Genius Gateway Communication / Dip Switch Setup Using a Horner Electric Drive Gateway (HE660UGD424), connection to the Genius LAN and the VFDs installed RS485 Interface (6VKB3RS) is made which allows for direct control of up to sixteen GE AF300 VFD over a Serial RS485 Network. This unit provides 33 Global input words and 18 Global output words to permit the Bus Controller to control and monitor motion commands, speed instruction, fault indicator and fault codes. The eight positions Genius Bus dip-switch is used to set the device address, baud rates and output enable.

Figure 188 Genius Gateway Communication / Dip Switch Setup


19.5 Word Description/ Diagnostics Global Input/Output Word Description Figure 189 Input Word Description

Figure 190 Output Word Description


A bit set in Global Input Word 1 (bits 1 – 16), indicates an error on the corresponding GE-VFD (1 – 16Drive).

Global Output Word 1 bits 1 – 16 when set to “0”, indicates Stop drive and set to “1” indicates Run drive on the corresponding GE-VFD.

Global Output Word 2 bits 1 – 16 when set to “0”, indicates Forward drive and set to “1” indicates Reverse drive on the corresponding GE-VFD.

Fault Word Description

Figure 191 Fault Word Description


19.6 Replacing the GE – VFD

1) Remove and lock out power before disconnecting or wiring the VFD 2) Remove the screws located at the bottom of terminal board cover 3) Press upward on the bottom of the cover and lift off. 4) If the LED light CRG1 is illuminated, hazardous voltages are present in

the Base Drive Board. DO NOT service the VFD until the LED indicator is completely off and the bus voltage has discharged to zero.

5) Connect/disconnect power supply wires to L1, L2, and L3 terminals. Connect the 3-phase motor to U, V, and W terminals (Main Circuit Terminal Board).

Figure 192 Replacing the GE – VFD


19.7 GE VFD Wiring Diagram / Setup Parameters Typical wiring for a GE Variable Frequency Drive showing motor and Genius Horner Electric Gateway/GE RS-485 connections.

Figure 193 GE VFD Wiring Diagram


Setup Parameters Typical GE Variable Frequency Drive operating parameters - Assembly Line

Figure 194 GE Variable Frequency Drive Operating Parameters


19.8 Terminal ID and Function Definitions

Figure 195 Terminal ID and Function


19.9 Horner Electric Genius Gateway–Wiring / Configuration The communication for the Drive Gateway module is fixed at 9600 baud, no parity, 8 data bits and 1 stop bit and is connected to a RS485 interface card in the VFD. Two LEDs are used to monitor the status of the Gateway. The Geni LED indicates power is applied to the interface card and the communications LED when “ON” steady, indicates communication is “OK” but when blinking, could indicate an “ERROR”. To restore the Gateway after an error, clear the error and cycle the Genius LAN power. Horner Electric Genius Gateway GE RS485 Interface Card

Figure 196 Horner Electric Genius Gateway/GE RS485 Interface Card

1) Enter the parameters for the Horner Electric Drive Network Gateway in the

FloPro configuration menu. Set configuration for Global I/O with 33 Input words and 18 output words.

Gateway (VFD) INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 3 3 Global 0 – 33 I0361 –

I0632 11 – 30 O0361 -

O0520

Figure 197 Horner Electric Drive Gateway FloPro Configuration


19.10 RS 232/485 Interface Card- GE AF-300B Drives The GE RS232/485 Interface Card provides a serial link for communication to the AF300B Variable Frequency Drive from a Horner Electric Genius Interface

Figure 198 VFD Control and RS232/485 PC Boards


Module (HE600UGD424).Connectors (CN8-2, CN9-2) on the RS232/485 Interface card connect to connectors (CN8, CN9) on the VFD control board and held in place with spacers and retaining screws. Wiring from the Horner Electric Genius Gateway connector to the GE RS 232/485 Interface terminal board must be run with a continuous cable and terminated with 120 ohms resistor at both ends.

Figure 199 Genius Gateway, VFD Control and RS232/485 PC Boards Wiring


SETTING DATA CODES To use the RS232/485 Interface Board, Data Codes must be set for Function Codes 77 to 79. Set all of the Data Codes of Functions 78 and 79 prior to setting the Data Code of Function 77. If “ERR1” (setting error) is displayed, check that the setting data has been entered correctly. The error will occur if the function data codes are set beyond the allowable limits and should be set to the correct data codes.

Figure 200 Function and Data Codes Setting Procedure


Function and Data Code Setting

Figure 201 Function and Data Code Setting Table


Figure 202 Function and Data Code Setting Table

Error Codes

Figure 203 Error Codes


19.11 Horner Electric Option Card - GE AF-300E$ Drives The GE AF-300E$ Genius option card allows the drive to reside directly on the Genius LAN, providing drive control and data access capabilities to the bus controller. The GE AF-300E$ supports three type of communications, I/O services, Global Data and Datagrams. I/O service is the manner in which data is transferred to and from Genius I/O blocks. Outputs written by the bus controller to the AF-300E$ drives include start/stop, fwd/rev, speed, fault reset, etc. and inputs (feedback) are broadcast from the drive to the bus controller as global data. Global Data is data broadcast over the network at large (no particular destination). The AF-300E$Genius interface utilizes global data to broadcast drive feedback data over Genius (speed reference, torque, current, faults, function settings, etc.). Configuring the drive’s Global output data by mapping the global output data word to drive parameters is accomplished using the keypad, or the Genius Hand Held Monitor, or using optional PC configuration utility. Datagrams are messages sent by the bus controller over the Genius LAN from one device to another and are performed in an application through a communications request (COMREQ). The COMREQs are used for occasional data access and not to be used to monitor speed reference on a continuous basis.

Figure 204 GE AF-300E$ and Genius Connection


The option card is installed in the accessory slot located beneath the drive chassis cover.

Figure 205 Installation of the Option Card

A Keypad panel is integral to the VFD unit, featuring both a LCD display and an 8 key keypad. Function keys are used to program the drive, select Operation, Program or Trip mode. The Program mode sets drive function codes and Trip mode for drive system faults. The Keypad is used to set communication parameters, map drive parameter to global data and moving control from the keypad to the Option Card.


Figure 206 Drive Keyboard Function and Layout


Setting the Drive Option Parameters from the Keyboard 1. Remove jumpers connected to FWD and CM terminals on the Drive terminal

strip 2. Wire the Option Card to the appropriate Genius network 3. Terminals 3 and 4 on P1 of the option card must be jumpered together 4. Power up drive. Follow start up instructions in User’s Manual 5. Set the drive option card parameter (P00 – P29) to desired setting (Set P03 to

1) 6. Turn over control of the drive from the keypad to the option card 7. Remove the jumper of the drive terminals 3 and 4 on the option card (P1) 8. Option Card setup using the keypad is complete Drive Option Parameters

Figure 207 Drive Option Parameters


After powering up the drive, the drive’s LCD display should display the following and indicates that the drive is in the STOP mode. The PRG key must be pressed to set the drive data.

Press the PRG key to display the start of the list of the normal drive parameters. The option parameters are at the bottom of the list and cannot be seen until the cursor keys are pressed multiple times to display them. Use the UP or DOWN cursor keys to scroll the display and highlight the options selection.

Pressing the FUNC/DATA key will show the current value of P00 and allow the user to change it. The bottom line of the display will flash between the allowable data range (0-255) and the prompt STORE > F/D key. The current value of the parameter is shown on the third line (0). Pressing the cursor keys (UP, DOWN) causes the new value to change. Pressing the UP key will cause the mew value to increment, and move the current stored value from the third line to the second line, as shown. When the option parameter is at the desired value (25), pressing the


FUNC/DATA key will cause the parameter to be stored. As the data is being stored, the option parameter list will return to the display and the next option parameter will be highlighted as shown below.

Because option parameter P00 has been edited, option parameter P01 will be highlighted. When defining P06-P29, bit mapped values should be placed first in the parameter map. The keypad will allow a larger data value (0-255) to be input than is legal for a given parameter. The option card will flag the illegal data values in the option parameter when drive control is transferred from the keypad to the option card.

If one or more of the drive parameter are illegal, an “Error 5” message will be displayed. Control parameter P02 is used to examine the value of the illegal option parameter. The illegal option control parameter will have a value of 100 + the option (P00 a value of 100, P05 a value of 105). After correcting the illegal parameter, pressing the PRG key and then pressing the RESET key will set the Control parameter (P02) to a value of 1. Control will be transferred and the “Error 5” will be reset. Hand Held Monitor - Setting the Drive Option Parameters The Hand Held Monitor can be used to setup the AF-300E$ communications card (GEN100) and used as follows: 1. Set the number of directed data words (from 1 to 30) 2. Map the directed data to drive parameters 3. Set the number of global data words broadcast by the AF-300E$ (1 to 30) 4. Map drive parameters to global data The Hand Held Monitor cannot be used to set the Genius baud rate, Genius bus address, or transfer control from the keypad to the GEN100 option card. These functions must still be performed from the AF-300E$ keypad, or optional PC configuration software.


19.12 VFD Flowchart Example-Turntable


Figure 208 VFD Flowchart Example-Turntable


19.13 Fault Condition Description and Operation

Figure 209 Fault Condition Description and Operation


NOTES


20 Atlas Copco AFS CSS-91 Nutrunner

20.1 Overview The Atlas Copco AFS CSS-91 Nutrunner is used on the GMPT Romulus V8 assembly line to perform repeatable, dependable nutrunning operations. This section describes the operation of the CSS-91 and it’s interface with FloPro.

20.2 Objectives After completing this chapter, the student should be able to: • Better understand the function of the Atlas Copco AFS CSS-91 Nutrunner • Identify the CSS-91 status indicator lights • Understand the CSS-91 Genius I/O interface with FloPro • Understand the integration of CSS-91/FloPro communication in the flowcharts


20.3 Operation The CSS-91 Nutrunner is a stand alone fastening control unit. Fastening processes are initialized in the PC control (FloPro) by way of outputs. At the end of each fastening cycle, the AFS unit communicates process feedback to the PC. Section 20.8 describes the details of the communication process.

20.4 CSS-91 Spindle Processor Rack The spindle processor rack in the following figure has a power supply, station I/O module for Genius bus, spindle processor modules, and a supervisor module. The power supply is used only for the spindle processor rack, no other types of modules can be integrated into it.

Figure 210 CSS-91 Spindle Processor Rack


20.5 CSS-91 Supervisor The CSS-91 Supervisor module (Head Processor) is a single board computer that is compatible with the Xycom AT computer. The front panel has eight status indicator lights and two RS-232 COM ports (COM 1 & COM 2). COM 2 is connected to the Xycom. COM 1 is reserved for testing and debugging with the operating system software and cannot be used for any other purpose. Both ports can also be accessed from the back of the module via a 40 pin ribbon cable with 9 pin D-Sub connectors at the other end.

Figure 211 CSS-91 Supervisor Module


Status Indicators:

Supervisor E3 RED E2 RED E1 RED

BCD Error Messages

OK GREEN

OFF NOK Cycle

M4 YELLOW M3 YELLOW M2 YELLOW M1 YELLOW

BCD Modes of Operation

Figure 212 CSS-91 Supervisor Module Status Indicators

Error Conditions Binary Coded Digit (BCD) Operating Mode Indicators (BCD) 1 = Parameter Error 1 = Normal Mode 2 = Hardware Error 2 = Automatic Mode 3 = DNC Error, Software 3 = Programming Mode 4 = Clock Error 4 = Monitor Mode 7 = Run Time Error 5 = Torque Test Mode 6 = Speed Test Mode 7 = Calibration Mode 8 = Diagnostics Mode


20.6 Spindle Processor Module Each spindle processor allows control of one or two spindles. Each processor can be equipped with a torque transducer and an incremental angle encoder. The spindle processor is also equipped with integrated pre-amplifiers for the transducer signal. The transducer cable connectors plug into the back panel.

Figure 213 CSS-91 Spindle Processor Module

Status Indicators: (front of module) 1 Spindle 2 In Cycle 2 Spindle 1 In Cycle 3 Calibration Check In Process 4 Prox Input On S.W. 392 5 Module In Torque Test Mode 6 Module In Calibration Mode 7 All Card Functions OK 8 All Card Function OK


20.7 Station I/O Module For Genius Bus The station I/O module for the Genius bus serves as an interface between the CSS-91 supervisor and the Xycom. An integrated GE Gena card communicates with the supervisor. There is a front panel status LED for each digital signal to and from the supervisor (detailed on next page). There are also three connectors on the front panel: COM 5 – 9 pin D-sub RS-232 for diagnosing and programming the I/O module software. HHM – 9 pin D-sub RS-232 for the GE Hand Held Monitor. SSB – 25 pin D-sub for a manual control switch box used for operation without bus control.

Figure 214 CSS-91 Station I/O Module for Genius Bus


Inputs A1 - Cycle Start YELLOW A2 - Mid-Cycle Stop YELLOW A3 - Section Process Start YELLOW A4 - Cycle Stop YELLOW A5 - Not Used YELLOW

B1 - Emergency Stop YELLOW B4 - Prevent Return To CL When (A4) Comes On YELLOW B5 - Not Used YELLOW

D1 - Special Purpose Signal YELLOW D4 - Forward/Reverse (OFF/ON) YELLOW Outputs C1 - Cycle Complete OK GREEN C4 - Section OK to PLC GREEN C5 - Not Used GREEN

E1 - Cycle Complete NOK RED E4 - Section NOK/Automation Release RED E5 - Not Used RED Parameter Select B2 - Input Parameter Select Echo C2 YELLOW D2 - Input Parameter Select Echo E2 YELLOW B3 - Input Parameter Select Echo C3 YELLOW D3 - Input Parameter Select Echo E3 YELLOW System Status S1 - Ready to Cycle GREEN S2 - Process Ready GREEN S3 - Gena Board and Communication OK GREEN S4 - Gena Station I/O Module Ready To Cycle GREEN

S5 - Transducer Bypass Of 1 Or More Spindles RED S6 - Out Of Operation Of 1 Or More Spindles RED S7 - Manual Control RED S8 - Not Used RED Note: For each cycle, the S1-S4 status bits must be present to start the station cycle. For the fastening process to begin, the C4 output is sent to the PC. This signals that the diagnostic test was OK. The PC must then send the A3 input back to the CSS-91 to continue the process. All fastening process related output signals will remain on between the end of a cycle (C1/E1 ON). They will turn off during a cycle.


20.8 Functions Of The Station Controls Step 1. Ready To Cycle

The CSS-91 sets this signal to ON as long as the station is in auto mode. FloPro waits for this signal to be on before it starts any activities.

Step 2. Process Ready

The CSS-91 sets this signal to ON when it’s ready for the next cycle. This means that the previous cycle, including serial data transmissions, are complete. This signal must also be on for FloPro to start any activities.

Step 3. Pallet In Station FloPro sets this signal when a pallet is in the station. Step 4. Read Pallet and Sequence Number

FloPro reads the pallet and sequence numbers for decoding the parameter set.

Step 5. Select Parameter Set FloPro checks two conditions: S1 ON – Ready to cycle is on S2 ON – Process ready is on

When these conditions are met, FloPro decodes the parameter set from the pallet and sequence number and sends the parameter set to the CSS-91.

Step 6. Get Parameter Set Echo

FloPro receives the parameter set echo and compares it to the parameter set number it sent out. After a short time, both will be equal.

Step 7. Lift Pallet FloPro checks three conditions: S1 ON – Ready to cycle is on S2 ON – Process ready is on Parameter echo OK When conditions are met, continue cycle.


Step 8. Run Diagnostic Test After receiving the A1 input, the ‘Process Ready’ (S1) and ‘Cycle OK’ or ‘Cycle NOK’ (C1/E1) outputs are reset. All status information from the previous cycle is also cleared. The nutrunners have to run free in the air for the diagnostic test. Therefore, the test must be complete before the pallet lift is done.

Step 9. Diagnostic OK Signal C4 - FloPro continues with ‘Clamp Pallet In Upper Position’.

(Step 11) Step 10. Diagnostic NOK Signal E1 – FloPro continues with ‘Spindle Status On’. (Step 14) Step 11. Clamp Pallet In Upper Position

FloPro positions and clamps the pallet in the upper position. Step 12. Start Fastening Cycle FloPro checks three conditions: S1 ON – Ready to cycle is on C4 ON – D-Test OK is On Pallet is clamped FloPro then sends a signal to the CSS-91 to start the fastening cycle. Step 13. Cycle Complete OK/NOK FloPro checks three conditions: S1 ON – Ready to cycle is on C1 ON – Cycle OK is on E1 ON – Cycle NOK is on When C1 or E1 is on, perform step 14 Step 14. Spindle Status On

The cycle complete outputs (C1/E1) indicate that the fastening is done and that the spindle status bytes in the Gena output bitmap are valid. At this point FloPro resets the following signals:

A1 – Start D-Test contact A3 – Start fastening process Parameter set select

Step 15. Update FloPro Cycle Data

FloPro reads the spindle status data from the CSS-91 Gena output bitmap and the final torque/angle values from the CSS-91 COM 1 RS-232 serial port.

Step 16. Process Ready


The CSS-91 sets the process ready output to indicate that a new cycle can be started.

Step 17. Unclamp and Lower Pallet

FloPro must unclamp and lower the pallet as soon as possible. The nut runners will be inactive for a short time after the cycle is complete.

Step 18. Release Pallet From Station

After being unclamped and lowered, the pallet can be released to move out of the station.


20.9 Configuration of the Station I/O Module The station I/O module is a genius bus connection. It is configured using the Genius Hand Held Monitor. To configure the station I/O module: Step 1. Plug the Hand Held Monitor into the HHM port on the front of the

module.

Step 2. Turn the Hand Held Monitor’s key to CFG for configuration mode.

Step 3. Turn the Hand Held Monitor on.

Step 4. The first menu is the BAUD rate setting. Use the F2 key to set the Baud

rate to 153.6K BAUD.

Step 5. Press the F4 key to accept the BAUD rate configuration.

Step 6. Press the F3 key to continue with the configuration.


20.10 FloPro Configuration of the CSS-91 Nutrunner The CSS-91 communicates process information as digital I/O and spindle information in the form of serial communication. FloPro must be configured to talk to the CSS-91 in both forms. To communicate basic process information, the CSS-91 requires 72 inputs and 72 outputs. Each spindle also requires 16 inputs. Because there is only one nutrunner spindle on the Romulus test stand, FloPro will need to be configured with 88 inputs and 72 outputs. Serial communication from COM1 on the CSS-91 supervisor module is connected to COM1 on the Xycom unit. This port must be configured in FloPro with the correct protocol to talk to the CSS-91. The following configuration procedure for the Romulus test stand is designed to help the student understand how the communication is established between FloPro and the CSS-91. These steps should never need to be performed on an existing machine. FloPro Configuration (Digital I/O)

Step 1. Enter the FloPro configuration screens (F4). Step 2. At the Genius I/O Configuration screen select Add a Block (F3). Step 3. Input the configuration information from Figure 215.

CSS-91 Nutrunner INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 3 5 Generic 1 – 88 I0697 –

I0784 1 – 72 O0697 -

O0768 Figure 215 CSS-91 FloPro Digital I/O Configuration Parameters


FloPro Configuration (Serial Data) Still in the FloPro configuration screens:

Step 1. Go to the Serial COM Port Configuration screen. Step 2. Select Configure COM Port 1 (F2). Step 3. Enter the information in Figure 216.

Parameter Setting Function Key Baud Rate 19200 F7 Data Bits 8 F2 Stop Bits 2 F2 Parity None F1 READ Termination Number of Characters F1

Figure 216 CSS-91 FloPro Serial Communication Parameters


20.11 FloPro Interface With the CSS-91 Nutrunner The following describes the typical FloPro interface with the CSS-91 Nutrunner on the GMPT Romulus V8 assembly line. Read Nutrunner Values There are multiple flowcharts involved in communicating with the CSS-91. The serial communication is handled in the Read Nutrunner Values flowchart. Data sent to COM1 on the Xycom unit is transferred to ascii variables that FloPro can utilize (Step 15 in Section 20.8). Figure 217 is a section of this chart. Each READ block represents one spindle. The data for each spindle has an ascii range assigned to it. The ascii characters are used to display the status of the spindles on the Xycom unit. The display is handled in the Spindle Status Display flowchart.


Figure 217 Nutrunner Flowcharts - Read Nutrunner Values


Auto Cycle Index/Alignm./Nutr. The Auto Cycle Index/Alignm./Nutr. chart controls the sequencing of the mechanical devices that interact with the CSS-91 nutrunner when the machine is running in auto cycle. The auto cycle chart doesn’t turn on outputs, instead it turns on flags that request outputs to be turned on. This is a common method for handling outputs that allows for better diagnostic control of field devices. After the flag has been turned on, the outputs are then turned on in the Outputs Index/Alignm./Nutr. chart. Figure 218 is a small section of an Auto Cycle Index/Alignm./Nutr. chart. After the pallet is in position (block 8.00) and the Assembly Started flag is on (block 10.00), the Raise Index Raised flag is turned on (block 11.00). This flag is used as a request to turn on the raise index output. When this flag is on, the output chart will turn on the Raise Index output. When the motion is complete, the Index Raised status flag is tuned on in the System Status chart. When this flag is on, the auto cycle continues (block 12.00). This format (request, completion, verification) is repeated for every step in the auto cycle.


Figure 218 Nutrunner Flowcharts - Auto Cycle Index/Alignm./Nutr.


Auto Cycle Spindle Process communication with the CSS-91 is handled in the Auto Cycle Spindle chart. The Auto Cycle Spindle chart transfers the program number, the pallet and sequence number, receives the OK/NOK input from the nutrunner, etc… (see Section 20.8 for process details). Unlike the Auto Cycle Index/Alignm./Nutr. chart, the Auto Cycle Spindle chart does turn on outputs. The process communication with the nutrunner is done by passing inputs and outputs back and forth between FloPro and the CSS-91 Genius I/O Module. Figure 219 is a brief section of an Auto Cycle Spindle chart that turns on the output to the nutrunner for the program number. Depending on which Helpflag Select Parameter flag is on, a program number will be sent to the nutrunner. The CSS-91 then sends an ‘Echo’ back to FloPro to verify the information. Figure 220 is another section of the same chart. This section is sending pallet number information to the nutrunner. After the information is transferred, the nutrunner sends back inputs for FloPro to verify that the information was received correctly. This process is repeated for every pallet that enters the nutrunner station. The main point to be aware of is that outputs are not usually controlled in an auto cycle chart. In this case, however, the outputs are transferring information only, not controlling field devices.


Figure 219 Nutrunner Charts - Auto Cycle Spindle

Figure 220 Nutrunner Flowcharts - Auto Cycle Spindle


NOTES


21 FloPro Configuration Summary

21.1 Assembly Simulation Configuration PCIM Configuration

HOST

RAM ADDR DEVICE

NUMBER BASE

I/O PORT

D000 31 340

D400 31 344

D800 31 348

DC00 31 34C

I/O Error Action

Continue Execution Counters C0012 – C0017

RMU-1 INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 1 1 RMU-1 I3001 –

I3008


I3016

PLC (GCM+) INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 1 16 Global 0 – 15 I0201 –

I0328 0 – 10 O0201 -

O0288 Digital I/O Block INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 1 3 16 D I/O 1 – 8 I0329 –

I0336 9 – 16 O0329 -

O0336


BIGE (Balogh Gateway) INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 1 5 Generic 0 – 15 I0345 –

I0360 0 – 15 O0345 -

O0360 Gateway (VFD) INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 3 3 Global 0 – 33 I0361 –

I0632 11 – 30 O0361 -

O0520 Festo INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 3 4 Generic 1 – 64 I0633 –

I0696 1 – 64 O0633 -

O0696 CSS-91 Nutrunner INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 3 5 Generic 1 – 88 I0697 –

I0784 1 – 72 O0697 -

O0768 FloPro COM Port Settings for the CSS-91 Nutrunner

Parameter Setting Function Key Baud Rate 19200 F7 Data Bits 8 F2 Stop Bits 2 F2 Parity None F1 READ Termination Number of Characters F1 Balogh RF Configuration R/ CHA DEVIC POR START ERROR0 1 5 0 5 C05611 1 5 0 1702 C05612 1 5 0 1712 C05613 1 5 0 1714 C056110 1 5 1 5 C056111 1 5 1 1702 C056112 1 5 1 1712 C056113 1 5 1 1714 C0561


21.2 Machining Simulation Configuration PCIM Configuration HOST RAM ADDR

DEVICE NUMBER

BASE I/O PORT

D000 31 340 D400 31 344 D800 31 348 DC00 31 34C I/O Error Action

Continue Execution Counters C0012 – C0017


I3008


I3016

PLC (GCM+) INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 1 16 Global 0 – 15 I0201 –

I0328 0 – 10 O0201 -

O0288 Digital I/O Block INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 1 3 16 D I/O 1 – 8 I0329 –

I0336 9 – 16 O0329 -

O0336


Gateway (VFD) INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 3 3 Global 0 – 33 I0361 –

I0632 11 – 30 O0361 -

O0520 Festo INPUTS OUTPUTS BLOCK ADDR TYPE Crct FloPro Crct FloPro 3 4 Generic 1 – 64 I0633 –

I0696 1 – 64 O0633 -

O0696 Dual Axis PMD --- DOWNLOAD--- ----- POWERMATE-D -----

DEVICE AXIS INPUTS OUTPUTS RMU-1 PORT 1 X=1 Y=2 I0201 -

I0265 O0201-O0265

Single Axis PMD --- DOWNLOAD--- ----- POWERMATE-D -----

DEVICE AXIS INPUTS OUTPUTS RMU-1 PORT 1 X=3 I0501-

I0565 O0501-O0565

Dual Axis PMD with Spindle --- DOWNLOAD--- ----- POWERMATE-D -----

DEVICE AXIS INPUTS OUTPUTS RMU-1 PORT 1 X=1 Y=2

SPIN=1 I0201 - I0265

O0201-O0265


NOTES


22 General Flowcharting Theory The Powertrain FloPro projects are designed using a flowcharting specification. The main benefit is that many different flowchart applications can be designed using the same component flowcharts. For example, this flowcharting theory holds true for machining transfer lines, automatic assembly machines, and assembly zones. The result is a system which allows the troubleshooting processes to remain the same across many different types of applications.

22.1 Flowcharting Functionality by Type Each flowchart in an application falls into one of the following eight categories: • Menu Flowcharts • Auto Flowcharts • Diagnostic Flowcharts • Output/Motion Control Flowcharts • Message Manager Flowcharts • Update Menu F-Keys Flowcharts • Status Flowcharts • Other Overhead/Display Flowcharts

Each category has a specific function, and all the flowcharts in a category will have a similar look, or “style”. It is important to have a general understanding of the functions of these different flowcharts to aid troubleshooting efforts. If the problem involves a diagnostic message which is being displayed incorrectly, there are certain flowcharts that could be at fault, and identifying those flowcharts eliminates all others from consideration. The remainder of this chapter is devoted to a detailed definition of each of these flowchart categories.

22.2 Menu Flowcharts In FloPro, a Menu refers to an operator’s pushbutton page at the Xycom unit. There will be at least three menu pages in each FloPro application: the Main Menu, the Auto Menu, and the Manual Menu. In many applications, there are additional manual menu pages to allow for all the manual pushbuttons required to control a machine. Some examples may be a Tooling Menu, a Gauge Menu, or a Help Menu, depending on the application. The function of a menu flowchart is to examine the operator pushbuttons at the Xycom unit, or function keys 1 through 15, and turn on appropriate command flags based on the pushbutton pressed. For example, if an operator is on the


Main Menu page and presses the F2 Manual Menu pushbutton, the FloPro program must change page to the Manual Menu. This is accomplished in the Main Menu Flowchart, as shown here:

Figure 221 Flowcharting Theory - Main Menu

The menu flowcharts most used in troubleshooting are the manual menus, typically referred to as Manual Motion Menus. When performing manual functions, command flags are both turned on and turned off in a menu flowchart. An example would be when an operator pushes a button to advance a slide. The menu flowchart for the page he is on will turn on the command flag which corresponds to advancing the slide. Then that flowchart will loop, waiting for either the slide to finish advancing, or a fault condition to arise. In either case, the same menu flowchart will turn that command flag off. This flowchart will then resume waiting for a pushbutton press. The next example is a section of a Manual Motion Menu flowchart. In the example, F3 corresponds to the button Advance Transfer. Pressing F3 turns the Advance Transfer Command F702 on.

Figure 222 Flowcharting Theory - Manual Motion Menu

It is important to note the difference between a command flag turning on and off and an actual output being energized. The menu flowchart does not directly control the actual outputs of a machine. It only turns the command flags on and off, which are like “requests” for a particular output to be turned on or off. Another flowchart (Output/Motion Control) is responsible for handling the conversion of command flags into actual field output signals.


22.3 Auto Flowcharts An auto flowchart is responsible for controlling the automatic sequence of a machine. It is usually easy to read, and follows a sequence from beginning to end. There may be many auto flowcharts for a machine which has several non-sequential components, because each of these components must be handled in a separate flowchart. For example, if an assembly machine gets its component parts from a shuttle, the shuttle may move independently from the actual assembly machine cycle. In this case, two flowcharts would be needed: one to follow the assembly function, and one to control the shuttle movement. Troubleshooting is easier because the two functions reside in separate flowcharts. Auto flowcharts are written in the following style: a command is issued, the flowchart loops until the commanded action is complete, the next command is issued, and so on down through the entire sequence. If a sequence for a station had advanced the head, it would loop until the Full Depth position is achieved, then turn on the Return Head command, loop until the head is returned, turn off that command and turn on the next command in the sequence, and so on:

Figure 223 Flowcharting Theory - Auto Sequence

Like manual flowcharts, auto flowcharts turn on command flags, but do not actually control output signals. Unlike manual flowcharts, when a fault is diagnosed the auto flowchart is disabled. In complex applications, this requires a recovery sequence to occur before resuming auto cycle. Often, the recovery command is issued at the beginning of an auto cycle flowchart, allowing the machine to return to a safe place in which to begin the auto cycle again. Another type of auto flowchart performs a particular operation one time, like a subroutine. Typically, a command flag will enable the flowchart, and once solve has reached the end of the flowchart, the command flag is turned off, disabling


the flowchart. A few examples of this type of auto flowchart are Start Sequences, Lube Sequences, Initialization Routines, Bar Code Readers, and RF Tag Readers.

22.4 Diagnostic Flowcharts The purpose of a diagnostic flowchart is to do exactly that: diagnose faults. The first section of a diagnostic flowchart checks for Level 1 faults, or E-Stop conditions. These include things like power on, CRM on, air pressure on, and I/O device faults. The second section checks for Level 2 faults, which include I/O faults, time-out faults, and process faults. The Level 2 faults stop all motion. The third section, when used, checks for Level 3 warnings, which do not affect the operation of the machine, but give information about the operation of the machine. When a diagnostic flowchart is written, the order the faults are placed in is important because the higher a fault is in the diagnostic flowchart, the higher its priority. When a fault is diagnosed, the flowchart solve is directed to turn on the fault flag and return to the beginning of the flowchart. The flowcharts solve never reaches any fault after the first one diagnosed as true. This explains the order described above, which is Level 1 faults first, Level 2 faults second, and Level 3 faults third. For Level 1 and Level 2 faults, the Power On/Fault Reset Pushbutton must be pressed to reset the diagnostic message. When a fault is diagnosed, a message must be displayed on the Xycom to inform the operator of the fault. The diagnostic flowchart’s role in this process is to load the message number which corresponds to the fault it has diagnosed into the fault counter.

Figure 224 Flowcharting Theory - Diagnostic Chart

In the above example, if message 616-9 corresponds to “Station 3R Drive E-Stop is On”, when the diagnostic flowchart detects that Station 3R E-Stop F946 is on when the Station 3R Drive is Ready F944 is on, it will load the number 9 into the fault counter C900. No screens are actually displayed from the diagnostic flowchart, but this fault value must be loaded here for use by the flowchart (CRM Message Manager) which actually displays the message. Each diagnostic fault value must have an accompanying message created in the display screen editor. The RMU message, however, is sent from this flowchart. In this case, message 9-32 is sent to RMU-1.


Note: The diagnostic flowchart must solve completely each scan, and cannot loop upon itself. At the end of every scan, it must have returned to its first block.


22.5 Output/Motion Control Flowcharts An Output/Motion Control Flowchart converts command flags into output signals. Each command flag is examined during every scan of the output flowchart and the corresponding output signal is either turned on or turned off. Diagnostic timers are started in the output flowchart also, the first scan in which the output is energized. If a fault has been diagnosed, the output flowchart will turn off an output currently energized, turn off the corresponding command flag, and reset the diagnostic timer for that command.

Figure 225 Flowcharting Theory - Output/Motion Control

When an application has motion requirements, a motion is handled in the same manner as a discrete output. Command flags are interrogated in the output flowchart for actions like Advance Head, Return Head, Move Head to Tool Change, Return to Home, etc., and the appropriate motion blocks are executed.


22.6 Message Manager Flowchart Diagnostic messages displayed on the Xycom units are displayed by the CRT Message Manager flowchart. Like the diagnostic flowchart, message groups are organized in a priority format; the most important message group is first in the flowchart. The Level 1 fault message group is first, the Level 2 fault message group is second, and the Level 3 warning message group is last. Also like the diagnostic flowchart, when a message is encountered, that message is displayed, and the flowchart returns to its first block. Again, the message displayed corresponds to the number which was loaded into the counter in the diagnostic flowchart. The earlier “Station 3R Drive E-Stop is On” fault which loaded C900 with the value 9 is shown in the following example:

Figure 226 Flowcharting Theory - Message Manager

When C900 is equal to 9, this portion of the flowchart displays diagnostic screen 616-9. Notice that a fault value of 1 is reserved for a different subset of screens; if a Powermate D fault exists, the appropriate fault message in screen set 695 will be displayed. There also may be System RMU Message Manager flowcharts which control the system level RMU display messages. In the same manner, information is displayed in a priority fashion, the highest priority at the top and in descending order of priority.

22.7 Update Menu F-Keys Flowcharts The Xycom screen consists of Menu pages, as described in section 9.1.1. The actual display screens that make up the buttons for menu pages are displayed in the Update Menu F-Keys Manager flowchart. There is only one Update Menu F-Keys Manager flowchart per application. There are usually two “states” for any particular menu button displayed. When a button function is available, meaning that the operator can perform that function


at the present time, the button is drawn in white text on a green background. When a button function is unavailable, meaning that the operator cannot perform that function at the present time, the button is drawn in white text on a blue background. The exception to this standard is for motor stop buttons, which are drawn in white text on a red background when they are available. The Update Menu F-Keys Manager flowchart solves once each time the F72 Update Screens flag turns on. (Flowcharting Specification calls for the Update Screens flag to be enabled once every quarter second.) During this solve, the flowchart goes through the screen hierarchy to determine which menu page is active. When it reaches the section for the current menu page, the flowchart goes through decisions for each of the menu buttons to determine the state that should be displayed, and displays the corresponding screen.

Figure 227 Flowcharting Theory - Update Menu F-Keys

In the previous example, the flowchart determines which state to display the F1 Reset Mode pushbutton. The two screens, 4-11 and 4-12, correspond to the two states available.


Note: The update menu buttons flowchart must solve completely each scan, and cannot loop upon itself. At the end of every scan, it must have returned to its first block.

Figure 228 Flowcharting Theory - Update Menu F-Keys


22.8 Status Flowcharts The function of the status flowchart is to handle things which must be updated every scan. Status flags which represent conditions consisting of three or more individual inputs are

Figure 229 Flowcharting Theory - Status Charts

turned on and off in the status flowchart. Any time a process must be performed regardless of machine mode, it can be controlled in the status flowchart. Modes are initialized and sometimes controlled in the status flowchart. The F72 Update Screens flag is turned on for one scan each .25 second. The status flags turned on in the status flowchart are then available for use in the remainder of the flowcharts. Note: The status flowchart must solve completely each scan, and cannot loop

upon itself. At the end of every scan, it must have returned to its first block.


22.9 Other Flowchart Types There are other flowcharts that appear in standard FloPro applications. These flowcharts are essential to the application, yet rarely are involved in troubleshooting efforts.

Function Keys – a standard GM flowchart, which converts the pushbutton presses from keypad inputs to flags 1 through 20.

Display – various status display flowcharts which display the condition of the machine I/O, the safety I/O, the machine process, etc.

Screen 30x/40x/500/1/2 Manager – displays the operator screen areas for date, time, production count, etc.

Data Collection – calculations to support C-More, ANDON, or other types of data collection for display.

Screen Saver – a standard GM flowchart that drives a screen saver function.

Warning Elimination Chart – a flowchart which eliminates the various warnings FloPro issues upon compile which are of a nuisance type.

It is important to understand the way all of the flowchart types are combined when working with a multi-station machine. Each station of the machine will have its auto, manual, diagnostic, output/motion, and status flowcharts. In this way, a station acts as a sub-section of the application. The entire application, often called the system, will also have the main auto, manual, diagnostic, output/motion, and status flowcharts, but the system also uses the peripheral flowcharts like the Update F-Keys, the Message Manager, the Displays, the Data Collection, and any other system functions necessary.

22.10 Flowchart Interaction Based on the flowcharting standard as described in the previous section, there are conventions used to control flowchart interaction. One example is the paths, which are easily traced, for turning on outputs. Diagnostic messages can be traced back to origination when troubleshooting to determine whether the problem lies in the conditions triggering the diagnostic or incorrect diagnostic text.


22.11 Sequence from Key Press to Output The path which manually turns on an output begins when an operator presses a key on a menu page of the Xycom unit. The inputs are updated, and flowchart scan begins at the first flowchart in the flowchart list. The input is converted from a keypad input to a flag in the Function Key flowchart, so if the operator wanted to Lock the Gates, and pushed function key 7, F7 will now be on. When flowchart solve reaches the menu flowchart for the currently displayed menu page (Machine Services Menu), flag F7 being on will turn on the appropriate command flags to lock all gates. For this example, Transfer Lock Gates CMD 777 will be used.

Figure 230 Flowcharting Theory - Machine Services Menu


Provided the gates are not already closed and locked (F500), the command F777 will be turned on. By returning to the beginning, the flowchart will effectively wait until the F7 key is released before performing any further commands by checking for No Function Key Pressed F50 to transition on before checking for function key presses again. Once the menu flowchart has turned the command flag on, flowchart solve continues on until it reaches the diagnostic flowchart. Upon seeing the command flag Transfer Lock Gates CMD F777 turned on, the diagnostic flowchart will then interrogate each possible fault condition in order of priority. The following is the Level II section of the XFER Diagnostics flowchart for F777:

Figure 231 Flowcharting Theory - Diagnostic Chart

In the example above, the diagnostic flowchart checks for four fault conditions. First, it checks to make sure that neither the gate #1 is opened Transfer Gate Opened SW I133 nor the gate #2 is opened Transfer Gate #2 Opened SW I141.. Then it checks two time-out faults if the diagnostic timer T103 is done: if either of the gates did not lock in the time allotted, Transfer Gate Locked LS I134 or Transfer Gate #2 Locked LS I142 is on.


If a fault condition is true, the appropriate fault message number is moved into the diagnostic counter C700, the Transfer Level II Fault Flag F760 is turned on, and the appropriate RMU message is sent. If no fault condition is detected, the fault flag remains off. Again, solve moves to the next flowchart in the flowchart list. The XFER Output Control flowchart will see that the command flag Transfer Lock Gates CMD F777 is on. The diagnostic timer T103 will be reset and started, and the corresponding outputs, Transfer Unlock Gate #1 O130 and Transfer Unlock Gate #2 O131, will be turned off – in this case, the outputs would be turned on to unlock the gates, so they are turned off to lock the gates.

Figure 232 Flowcharting Theory - XFER Output Control

This flowchart then loops, waiting for either both gates to lock Transfer Gate Locked LS I134 and Transfer Gate #2 Locked LS I142, or for the Transfer Lock Gates CMD F777 to turn off. During each subsequent scan, the output flowchart will check for its two conditions, and the diagnostic flowchart will check for any fault conditions. If either flowchart’s conditions should become true, the gate lock operation would be terminated. A command issued from an auto cycle flowchart is processed in much the same way as the above example from a manual pushbutton. The only difference is that the command flag F777 would be turned on in the auto cycle flowchart, and the auto cycle flowchart would be looping in a decision block, waiting for the commanded motion to complete. The auto cycle flowchart does not check for fault condition, because upon a fault condition it is disabled, and would not be able to respond.


22.12 Tracing Steps in Reverse Direction When an output was expected but did not occur, it can be traced back through the steps outlined in the previous section. This constitutes the majority of troubleshooting efforts. Do not overlook the diagnostic message area for clues to the nature of the error. The first step in troubleshooting is to identify the output that should have been energized. By locating this output in the output flowchart, the corresponding command flag which energizes that output can be identified. By cross-referencing the command flag, the places where it is turned on can be researched to find the one that most likely should have turned on the command flag in this situation. It is important to remember that the flowcharts involved are probably either manual flowcharts, if the machine was in manual at the time, or auto cycle flowcharts, if the machine was in auto.

22.13 Tracing Diagnostic Messages to Origination Diagnostic messages displayed on the Xycom screen can be traced back to the conditions that originated them. The first step in this process is to look at the CRT Message Manager flowchart to find the message number that is currently being displayed. By following the flowchart down the left column to the first counter which has a non-zero value, the fault value is identified as the number held in that counter. Also note the counter which is involved so that the proper fault category can be identified. Using the fault value and the counter involved, page through the diagnostic flowchart until the move block which moves the fault value into the fault counter is located. This move block can be followed back to the conditions that triggered it.


22.14 Diagnostic Customization There may be a situation where the diagnostic message displayed is triggered for the right reason, but the text in the message is incorrect, or does not accurately describe the fault condition. The way to address this is to modify the message, or display screen, which is being displayed. The previous section describes the method for tracing a diagnostic message to determine both the fault value and the fault counter. When in the CRT Message Manager, also note the subscreen set which is being displayed in the display block. Using this information, the display screen can be modified. Diagnostic messages are modified off-line. Terminate the flowchart execution, which will return to the FloPro Master Menu. From this menu, select F3 Flowchart Editor, and then select F5 Display Screens. Select F1 to Create/Edit a message and F2 for Subscreen, entering the number of the subscreen set obtained above in the CRT Message Manager display block. This brings up the screen editor, where F2 is Modify screen, and the screen number can be entered. Use the fault value retrieved earlier, which corresponds to the message number. Once inside the message editor, the text can be modified to better describe the fault condition. When all modification is complete, press F10 to exit screen and F3 to Save Using Previous Corners. F10 again will exit the message editor, and F8 will Save Modifications. Now the FloPro application can be re-compiled and re-started, and the changes made will be in effect. Note: Even changes which have been saved to disk are not actually made a part

of the running FloPro application until it is re-compiled.


22.15 FloPro Interface to CNC Conditions needed before the motion status flowchart can be enabled to reset the CNC are, CRM power on, gates closed, no level 1 or 2 faults, hydraulic in service on, and the station is not off. This logic is located in the station status flowchart.

Figure 233 Flowcharting Theory - CNC Station Status


If the CNC is not ready and there are no CNC alarms or faults present, and the station motion status flowchart is enabled, toggling the station external reset will enable the “CNC Ready CNC” input. Once the CNC is ready, all heads can be returned and spindles started.

Figure 234 Flowcharting Theory - CNC Station Motion Status


In the Station Auto Sequence flowchart, with the auto cycle running and the station on, an auto sequence can be started. With no transfer level 1 or 2 faults present and a cycle unit CMD on, and the station fixture is clamped with a part present, a diagnostic timer is started and the command flag turned on to start the CNC cycle.

Figure 235 Flowcharting Theory - CNC Station Auto Sequence


Figure 236 Flowcharting Theory - CNC Auto Sequence


When the CNC is at Full Depth (F1305), a status of Full Depth is acknowledged and the unit returns (F1310), turning off the Start Cycle CMD and resetting the diagnostic timer. In the Output flowchart, with the CNC Ready enabled and the station Cycle Unit CMD flag on, CNC attributes are set for running, and also test for a needed tool change. The Auto Sequence flowchart also turns on the Start CNC Cycle CMD (F1314) allowing the CNC cycle permit and the EXT Cycle Start CNC signals to be present advancing the CNC operation and returning the Unit after Full Depth was accomplished. The Start CNC Cycle CMD and Cycle Unit CMD flags are turned off, removing the EXT Cycle Start CNC and attribute signals form the CNC, completing its operation.


NOTES

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