DaimlerChrysler’s

Robotics Group Applications Standards

For ABB IRC5 Controlled Robots For Use
On
2008 RT Project

If you received this document by means other than a direct E-Mail from DaimlerChrysler AAME Robotics Group, you are
not on the distribution list and you will not receive future updates. It is the user’s responsibility to obtain latest updates to this
document.

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 TABLE OF CONTENTS
PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT OF ROBOT ................................................................. 4
ROBOTIC BY-PASS CONCEPT ............................................................................................................................................ 4
TEACH PENDANT PF KEY ASSIGNMENT........................................................................................................................ 4
A.B.B. ROBOT SIGNALS AND MACHINE AUTOMATIC................................................................................................ 5
STANDARD ROBOT PROGRAM NUMBERS..................................................................................................................... 8
D-NET MAP DESCRIPTIONS (ROBOT TO PLC) ............................................................................................................ 10
D-NET MAP DESCRIPTIONS (PLC TO ROBOT) ............................................................................................................ 14
ROBOT DEVICE NET MASTER NODE ASSIGNMENT ................................................................................................. 18
ABB ROBOT D-NET MAP DESCRIPTIONS (ROBOT TO WATERSAVER) ..........................................................................................24
A.B.B. ROBOT D-NET MAP DESCRIPTIONS (SEALER TO ROBOT ...................................................................................................27
A.B.B. ROBOT D-NET MAP DESCRIPTIONS (ROBOT TO SEALER) ..................................................................................................28
A.B.B. ROBOT D-NET MAP DESCRIPTIONS
A.B.B. ROBOT D-NET MAP DESCRIPTIONS (UTICA SERVO PIERCE UNIT A) .............................................................................35
A.B.B. ROBOT D-NET MAP DESCRIPTIONS (UTICA SERVO PIERCE UNIT B) .............................................................................36
A.B.B. ROBOT D-NET MAP DESCRIPTIONS (ATI TOOL CHANGER) ...............................................................................................36
APPLICATION ERRORS...................................................................................................................................................... 45
STANDARD ROBOT LOGIC ............................................................................................................................................... 52
ROBOT INTERFERENCE ZONES...................................................................................................................................... 63
INTERFERENCE ZONE EXAMPLE 1....................................................................................................................................................................64
INTERFERENCE ZONE EXAMPLE 2....................................................................................................................................................................65
REFERENCE FLOW CHARTS............................................................................................................................................ 66
REFERENCE PROGRAM INSTRUCTIONS ..................................................................................................................... 76
TIMING DIAGRAMS ............................................................................................................................................................ 89
SAMPLE
PROGRAMS………………………………………………………………………………………………………………….92

The logic, flow charts, and sample programs supplied are intended as a basic example and may not include all logic required to properly
control a robot in all applications. It is the build vendor'
s responsibility to provide and debug all logic and robot programming required for
proper system operation. The examples set forth in this document shall be followed. Any deviations will require approval by
DaimlerChrysler AAME robotics group.

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 RELEASE REVISION AND COMMENTS PAGE
Release # Release Date Comments
Initial release. Additional applications will be released as determined
Rel. 1.0 11-11-2005 by RT process requirements. Additional applications will affect I/O
bit maps and Application errors. Note this release has extended MH
app errors.
Logic update to rungs 4, 7 and 9.
Rel. 2.0 4-13-2006 Added MH I/O nodes 31, 32, 33, 34, 35 and 39. and Isra node 38
Revised Master Dnet map to accommodate 4 weld controls and 4
water saver and added Isra map
Updated pg 5 Robot Ready weld mode active
Pg. 8 Program 1,2 & 3 redefined
Pg. 10 DO5 – DO7 redifined
Pg. 12 DO80 redefined
Pg. 16 DI86 & DI 87 redefined
Pg. 25 Stud I/O added
Update app. Errors
Update prog. Instructions.
Added sample programs
Updated Do and DI numbers, Updated user output and user input naming
Rel. 3.0 Added WeldinPrgrsActiv for second weld control
Updated ATI bit maps
Added Norgen smart pump
Added Tool nest node
Added ISRA application errors
Added stepper approaching max to goto pounce rung and changed to alert.
Added Application error 1 DF&C
Updated logic reference.

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 PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT
OF ROBOT
It is an AAME requirement that all Body shop and Assembly robots be capable of
running a alignment program. This program will bring the robot into a position which will allow
positioning of all axes to check robot alignment. The robot alignment position and path to reach
this position must be considered when locating and processing the robot in the cell.
Consideration must also be given when dressing out robot cables, hoses, end effectors and
junction boxes on the robot arm so these items do not impede the robots ability to move to the
alignment position. Where possible, all axes should be aligned at the same time. In cases where
cell layout would be affected, or additional dress-out or safeties would be required to align all
axes simultaneously, multiple alignment positions will be allowed. In addition to alignment
program, all OEM’S must verify that the robot is set to A.B.B. factory values for alignment
position prior to programming robot. A flowchart for the alignment program is included in the
AAME robotic standards.

ROBOTIC BY-PASS CONCEPT

The Robot By-pass Mode is selected through the HMI associated with the specific robot.

When in By-pass Mode, the PLC logic should allow the following:

- In processes which allow a specific robot to be by-passed, (line capable of running

without this specific robot with manual or automatic back-up capabilities).

A. Allow the current part or job to transfer out of that station (if the robot is clear).
B. Allow the line to continue to run while the robot is in by-pass and clear of all
tooling.
C. Send required back-up information to down stream robot(s) and/or FIS/AVI for
downstream manual backup.

- In processes which do not allow for the line to run with a specific robot in by-pass.

A. Allow the current part or job to transfer out of that station (if the robot is clear).
B. Stop further machine cycles if left in by-pass mode.
C. Allow for easy changes to the PLC logic to override item “B” in the event that the
plant provides temporary manual back-up for continued production.

Note: Process Engineering, during the Design Phase of a project, will identify robots that can be
by-passed while tooling continues to operate.

TEACH PENDANT PF KEY ASSIGNMENT

The user definable keys on the robot teach pendants are to remain at A.B.B. default settings
unless a deviation is submitted by the Requestor and approved by a DaimlerChrysler Robotic Group
representative.

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 USE OF PULSED OUTPUTS
DaimlerChrysler does not allow the use of pulsed outputs.

USE OF ROBOT PROGRAM WORLD ZONES

The use of robot program world zones requires approval by a DaimlerChrysler Robot
Specialist.

A.B.B. ROBOT SIGNALS AND MACHINE AUTOMATIC

The PLC logic should monitor the following robot Device Net outputs. The “Robot
Ready” signal should be true to achieve machine automatic but is not required to maintain
machine automatic. Proper fault messages should be generated for each associated condition.

“Robot Ready” Device Net - This signal is true when the following conditions are met:

RobotInAuto (True)
RunChainOK (True)
RobotFaulted (False)
PathRestartError (False)
EStopActive (False)
MotionSupError (False)
I/OBlockedInAuto (False)
WeldMode Active (True) (Spotweld Only)

Note: Robot “Motors On” is not required (examined) to achieve “Robot Ready”

The following signals are available through Device Net and should be displayed as faults
or messages:

Device Net Map Reference

RobotInAuto
RobotReady
RobotFaulted
DryCycleActive
PathRestartError
RunChainOK
EStopActive
MotionSupError
I/OBlockedInAuto
NoStrokeActive (Spotweld Only)
WeldModeActive (Spotweld Only)
AirOK
WaterOn (Spotweld Only)
WaterBypassed (Spotweld Only)
ProcessFault
AppErrorActive

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 ROBOT PROGRAM NAMING
Robot program names shall follow the convention described below:

The name of a robot program shall be a maximum of 16 characters in length;

- Characters 1 up to 11 = System Identification (WHLHOUSEINR)
- Characters 4 and 5 from the right side end = Part Type (i.e. LH, RH, CN) LH = Left Hand, RH = Right Hand, CN =
Common
- Last 3 characters = Robot Number (R05)

Example = WHLHOUSEINRRHR05 (Wheelhouse inner left hand robot 05)

REGISTER AND COUNTER NAMING

Register and counter names shall be a maximum of 16 characters in length and the name shall reflect the purpose of the register or
counter.

ROBTARGET NAMING
1. Robtarget names shall follow the convention below:

- The robtarget name should include the robot number, station number and shall include a meaningful descriptor of the
position.

- Examples of robtarget name: R01_S01_Pounce, R01_S01_Home, R01_S01_WeldID####

ROBOT TO ROBOT HAND-OFF

The following guidelines should be followed whenever performing Robot to Robot Hand-Offs:

- Never clamp the same part with two robots at the same time. The robot with the part must release the part (open gripper)
prior to the other robot gripping the part (close gripper)

- The robot presenting the part, must be positioned at the hand-off location so that the grippers can be opened without the
part falling or moving due to gravity.

- Handshaking shall be performed through the Robot to PLC to Robot communications. All robot handshaking must be
monitored (part present/not present, clamps opened/clamps closed, vacuum on/off) to ensure a smooth and reliable part
exchange.

- The robots should be programmed in a manner consistant with a robot picking up a part from an idle fixture or dropping
off a part at an empty idle fixture.

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 BASE LIMIT CONNECTIONS AND OPERATION
- Each Base Limits Zone circuit will use 2 (two) switches per zone. These switches will be wired to the normally open
contacts and held closed by two commonly cut cams when the robot is not in the operator’s zone.

- The Safety PLC logic will examine both of these zone switches to be “ON” (Closed) indicating a clear of operator or
“OFF” (Opened) indicating not clear of operator.

- The Safety PLC logic will indicate a Base Zone Limit Switch Error if the switch signals do not match (both opened or
both closed). Since both switches will not close or open at exactly the same time, a timer delay of around 0.5 seconds will
be required to buffer the signals during the transition periods.

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 STANDARD ROBOT PROGRAM NUMBERS
PROGRAM NO. OPERATION PERFORMED BIT PATTERN
01 MAINT STYLE 1 (User Specified) 000001
02 MAINT STYLE 2 (User Specified) 000010
03 MAINT STYLE 3 (User Specified) 000011
04 PURGE PROGRAM 000100
05 TIP BURN IN 000101
06 SERVICE PROGRAM 000110
07 TIPDRESS PROGRAM 1st GUN 000111
08 TIPDRESS PROGRAM 2nd GUN 001000
09 TOOL CHANGE 001001
10 STYLE 1 BASE PROGRAM (JS) 001010
11 STYLE 1 PROGRAM NO. 1 001011
12 “ “ 2 001100
13 “ “ 3 001101
14 “ “ 4 001110
15 “ “ 5 001111
16 STYLE 1 BACK UP PRG 1 010000
17 “ “ 2 010001
18 “ “ 3 010010
19 “ “ 4 010011
20 STYLE 2 BASE PROGRAM ( ) 010100
21 STYLE 2 PROGRAM NO. 1 010101
22 “ “ 2 010110
23 “ “ 3 010111
24 “ “ 4 011000
25 “ “ 5 011001
26 STYLE 2 BACK UP PRG 1 011010
27 “ “ 2 011011
28 “ “ 3 011100
29 “ “ 4 011101
30 STYLE 3 BASE PROGRAM ( ) 011110
31 STYLE 3 PROGRAM NO. 1 011111
32 “ “ 2 100000
33 “ “ 3 100001
34 “ “ 4 100010
35 “ “ 5 100011
36 STYLE 3 BACK UP PRG. 1 100100
37 “ “ 2 100101
38 “ “ 3 100110
39 “ “ 4 100111

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 STANDARD ROBOT PROGRAM NUMBERS
CONT.
PROGRAM NO. OPERATION PERFORMED BIT PATTERN

40 STYLE 4 BASE PROGRAM (Future) 101000

41 STYLE 4 PROGRAM NO. 1 101001
42 “ “ 2 101010
43 “ “ 3 101011
44 “ “ 4 101100
45 “ “ 5 101101
46 STYLE 4 BACK UP PRG 1 101110
47 “ “ 2 101111
48 “ “ 3 110000
49 “ “ 4 110001
50 STYLE 5 BASE PROGRAM 110010
51 STYLE 5 PROGRAM NO. 1 110011
52 “ “ 2 110100
53 “ “ 3 110101
54 “ “ 4 110110
55 “ “ 5 110111
56 STYLE 5 BACK UP PRG 1 111000
57 “ “ 2 111001
58 “ “ 3 111010
59 “ “ 4 111011
60 RETURN FROM POUNCE PGM. NO. 1 111100
61 RETURN FROM POUNCE PGM. NO. 2 111101
62 111110
63 111111

87 Application 1 Calibration (Vision, Dynalog) NA

88 Application 2 Calibration (Vision, Dynalog) NA
89
90 TCP TARGET PROGRAM NA
98 AUTO LOAD CALCULATION NA
99 ROBOT SYNCH NA
100 SCANNING MAINLINE NA

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 D-NET MAP Descriptions (Robot To PLC) A.B.B .Robot
Signal Name PLC – TAG Logical Signal Description

RobotInAuto IccssNyy.b00 DO0 This robot system output signal informs the PLC that the robot is in automatic mode.

RobotReady IccssNyy.b01 DO1 This robot system output signal informs the PLC that the robot is ready for a remote PLC
StartRobot order. The conditions for RobotReady are specified on page 5 of this document.

RobotFaulted IccssNyy.b02 DO2 This robot system output signal informs the PLC that the robot is in a faulted state.

DryCycleActive IccssNyy.b DO3 This robot output signal informs the PLC that the robot is in dry cycle mode.

RobotClrFixt1 IccssNyy.b DO4 This robot output informs the PLC that the robot is clear of fixture 1. (output driven by World
Zone definition)
RobotClrFixt2 IccssNyy.b DO5 This robot output informs the PLC that the robot is clear of fixture 1. (output driven by World
Zone definition)
RobotClrFixt3 IccssNyy.b DO6 This robot output informs the PLC that the robot is clear of fixture 1. (output driven by World
Zone definition)
PathRestartError IccssNyy.b DO7 This robot system output informs the PLC that the robot has moved off the planned path
and the program cannot be remotely restarted.

RunChainOK IccssNyy.b DO8 This robot system output informs the PLC that the robot run chain is not broken.

EStopActive IccssNyy.b DO9 This robot system output informs the PLC that a robot E-stop condition is active.

MotionSupError IccssNyy.b DO10 This robot system output informs the PLC that the robot motion supervision has detected a
collision.

I/OBlockedInAuto IccssNyy.b DO11 This robot system output informs the PLC that the user has changed to AUTO. Mode and
has elected to leave one or more I/O signals blocked. (when a signal is blocked, the
connection between the logical and physical values are disconnected).

RobotAtWork IccssNyy.b DO12 This robot output signal informs the PLC that the robot is has left the Pounce position and is
entering the style routine.

RobotCycleOn IccssNyy.b13 DO13 This robot system output signal informs the PLC that the robot program is executing.

WorkComplete IccssNyy.b14 DO14 This robot output informs the PLC that the robot has successfully completed the cycle.

Clr2UnclampEarly IccssNyy.b DO15 This robot output informs the PLC that the robot is clear to unclamp early (user control).

RobotAtPounce IccssNyy.b DO16 This robot output informs the PLC that the robot is at pounce position.

RobotAtHome IccssNyy.b33 DO17 This robot system output informs the PLC that the robot is at home position.

RobotAtService IccssNyy.b18 DO18 This robot system output informs the PLC that the robot is at service position.

RobotAtUserPos1 IccssNyy.b19 DO19 This robot system output informs the PLC that the robot is at user defined position 1.

RobotAtUserPos2 IccssNyy.b20 DO20 This robot system output informs the PLC that the robot is at user defined position 2.

RobotAtUserPos3 IccssNyy.b DO21 This robot system output informs the PLC that the robot is at user defined position 3.

RobotAtUserPos4 IccssNyy.b DO22 This robot system output informs the PLC that the robot is at user defined position 4.

RobotAtUserPos5 IccssNyy.b DO23 This robot system output informs the PLC that the robot is at user defined position 5.

ActiveStyleBit1 IccssNyy.b DO24 This robot output along with the next six bits, (ActiveStyleBit2 - ActiveStyleBit64) in a binary
pattern (seven bit group output goActiveStyle), allows the robot to Acknowledge to the PLC
that it has received the ActiveStyle value that was originally sent by the PLC.
The BCD value for ActiveStyleBit1 = 1 (2^0)

ActiveStyleBit2 IccssNyy.b DO25 Reference ActiveStyleBit1. The BCD value for ActiveStyleBit2 = 2 (2^1)

ActiveStyleBit4 IccssNyy.b DO26 Reference ActiveStyleBit1. The BCD value for ActiveStyleBit4 = 4 (2^2)

ActiveStyleBit8 IccssNyy.b DO27 Reference ActiveStyleBit1. The BCD value for ActiveStyleBit8 = 8 (2^3)

ActiveStyleBit16 IccssNyy.b DO28 Reference ActiveStyleBit1. The BCD value for ActiveStyleBit16 = 16 (2^4)

ActiveStyleBit32 IccssNyy.b DO29 Reference ActiveStyleBit1. The BCD value for ActiveStyleBit32 = 32 (2^5)

ActiveStyleBit64 IccssNyy.b DO30 Reference ActiveStyleBit1. The BCD value for ActiveStyleBit64 = 64 (2^6)

ReservedPLCdo32 IccssNyy.b DO31 This robot output is not assigned.

Option1Active IccssNyy.b DO32 This robot output informs the PLC that option 1 is active.

Option2Active IccssNyy.b DO33 This robot output informs the PLC that option 2 is active.

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Signal Name PLC – TAG Logical Signal Description

Option3Active IccssNyy.b DO34 This robot output informs the PLC that option 3 is active.

Option4Active IccssNyy.b DO35 This robot output informs the PLC that option 4 is active.

RobotClrZone1 IccssNyy.b36 DO36 This robot output informs the PLC that the robot is clear of interference zone 1. Reference
the AAME zone logic standard document for further information.

RobotClrZone2 IccssNyy.b37 DO37 This robot output informs the PLC that the robot is clear of interference zone 2. Reference
the AAME zone logic standard document for further information.

RobotClrZone3 IccssNyy.b38 DO38 This robot output informs the PLC that the robot is clear of interference zone 3. Reference
the AAME zone logic standard document for further information.

RobotClrZone4 IccssNyy.b39 DO39 This robot output informs the PLC that the robot is clear of interference zone 4. Reference
the AAME zone logic standard document for further information.

RobotClrZone5 IccssNyy.b40 DO40 This robot output informs the PLC that the robot is clear of interference zone 5. Reference
the AAME zone logic standard document for further information.

RobotClrZone6 IccssNyy.b41 DO41 This robot output informs the PLC that the robot is clear of interference zone 6. Reference
the AAME zone logic standard document for further information.

RobotClrZone7 IccssNyy.b42 DO42 This robot output informs the PLC that the robot is clear of interference zone 7. Reference
the AAME zone logic standard document for further information.

RobotClrZone8 IccssNyy.b43 DO43 This robot output informs the PLC that the robot is clear of interference zone 8. Reference
the AAME zone logic standard document for further information.

UserOutput1 IccssNyy.b DO44 This robot output is designated for a user defined function.

UserOutput2 IccssNyy.b DO45 This robot output is designated for a user defined function.

UserOutput3 IccssNyy.b DO46 This robot output is designated for a user defined function.

UserOutput4 IccssNyy.b DO47 This robot output is designated for a user defined function.

UserOutput5 IccssNyy.b DO48 This robot output is designated for a user defined function.

UserOutput6 IccssNyy.b DO49 This robot output is designated for a user defined function.

UserOutput7 IccssNyy.b DO50 This robot output is designated for a user defined function.

UserOutput8 IccssNyy.b DO51 This robot output is designated for a user defined function.

ClrOfPickup1 IccssNyy.b DO52 This robot output indicates that the robot is clear of pickup position 1.

AtPickup1 IccssNyy.b DO53 This robot output indicates that the robot is at the pickup position 1.

ClrOfDropoff1 IccssNyy.b DO54 This robot output indicates that the robot is clear of drop off position 1.

AtDropoff1 IccssNyy.b DO55 This robot output indicates that the robot is at the drop off position 1.

ClrOfPickup2 IccssNyy.b DO56 This robot output indicates that the robot is clear of pickup position 2.

AtPickup2 IccssNyy.b DO57 This robot output indicates that the robot is at the pickup position 2.

ClrOfDropoff2 IccssNyy.b DO58 This robot output indicates that the robot is clear of drop off position 2.

AtDropoff2 IccssNyy.b DO59 This robot output indicates that the robot is at the drop off position 2.

ClrOfPickup3 IccssNyy.b DO60 This robot output indicates that the robot is clear of pickup position 3.

AtPickup3 IccssNyy.b DO61 This robot output indicates that the robot is at the pickup position 3.

ClrOfDropoff3 IccssNyy.b DO62 This robot output indicates that the robot is clear of drop off position 3.

AtDropoff3 IccssNyy.b DO63 This robot output indicates that the robot is at the drop off position 3.

ClrOfPickup4 IccssNyy.b DO64 This robot output indicates that the robot is clear of pickup position 4.

AtPickup4 IccssNyy.b DO65 This robot output indicates that the robot is at the pickup position 4.

ClrOfDropoff4 IccssNyy.b DO66 This robot output indicates that the robot is clear of drop off position 4.

AtDropoff4 IccssNyy.b DO67 This robot output indicates that the robot is at the drop off position 4.

AppClr1 IccssNyy.b DO68 This robot output indicates the robot is clear of machine process 1.

Appclr2 IccssNyy.b DO69 This robot output indicates the robot is clear of machine process 2

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Signal Name PLC – TAG Logical Signal Description

RobotPartPres1 IccssNyy.b DO70 This robot output indicates that Part1Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

RobotPartPres2 IccssNyy.b DO71 This robot output indicates that Part2Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

RobotPartPres3 IccssNyy.b DO72 This robot output indicates that Part3Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

RobotPartPres4 IccssNyy.b DO73 This robot output indicates that Part4Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

RobotPartPres5 IccssNyy.b DO74 This robot output indicates that Part5Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

RobotPartPres6 IccssNyy.b DO75 This robot output indicates that Part6Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

ReposTooling1 IccssNyy.b76 DO76 This robot output along with the next two bits, (ReposTooling2 - ReposTooling4) in a binary
pattern (three bit group output goReposTooling), allows the robot to remotely request the
PLC to reposition the tooling (Tooling 1 – 7). The BCD value for ReposTooling1 = 1 (2^0)

ReposTooling2 IccssNyy.b DO77 Reference ReposTooling1. The BCD value for ReposTooling2 = 2 (2^1)

ReposTooling4 IccssNyy.b DO78 Reference ReposTooling1. The BCD value for ReposTooling4 = 4 (2^2)

WaitingForPlcCmd IccssNyy.b DO79 This robot output indicates the robot has timed out waiting for a PLC command. Program
execution does NOT stop nor is it a fault condition.
ReqToEntTN IccssNyy.b DO80 This robot output informs the PLC that the robot is requesting to enter the tool change nest.
(for Tool Change).

ClrOfNest IccssNyy.b DO81 This robot output informs the PLC that the robot is clear of tool change nest (for Tool
Change).

WeldInPrgrsActiv2 IccssNyy.b DO82 This robot output indicates that a weld sequence is in progress (feedback taken directly from
the weld controller).
ReservedPLCdo84 IccssNyy.b DO83 This robot output is not assigned.

NoStrokeActive IccssNyy.b DO84 This robot output indicates that it is running in no stroke mode.

WeldModeActive IccssNyy.b21 DO85 This robot output indicates that weld current is enabled (feedback taken directly from the
weld controller).

WeldInPrgrsActiv1 IccssNyy.b22 DO86 This robot output indicates that a weld sequence is in progress (feedback taken directly from
the weld controller).

RobotAtTipDress IccssNyy.b DO87 This robot output indicates that the robot is at tip dress position.

TipDressComplt IccssNyy.b DO88 This robot output indicates that the tip dress sequence is complete.

TurnOnTipDresser IccssNyy.b 89 DO89 This robot output allows the robot to remotely request the PLC to turn on the tip dress
motor(s).

StepperReset1Ack IccssNyy.b 90 DO90 This robot output indicates that the stepper has been reset.

StepperReset2Ack IccssNyy.b DO91 This robot output indicates that all steppers have been reset.

TipBurnInComplt IccssNyy.b DO92 This robot output indicates that the tip burn in sequence is complete.

AirOK IccssNyy.b DO93 This robot output indicates that air is present at the robot.

WaterOn IccssNyy.b32 DO94 This robot output indicates that water is flowing at the robot.

WaterBypassed IccssNyy.b15 DO95 This robot output indicates that the water flow detection is bypassed.
ExtPurg1InProgrs IccssNyy.b DO96 This robot output indicates that dispenser 1 purge sequence is in progress.

ExtPurg2InProgrs IccssNyy.b DO97 This robot output indicates that dispenser 2 purge sequence is in progress.

ReqEntryZone1 IccssNyy.b DO98 This robot output is used to request PLC permission to enter interference zone 1.

ReqEntryZone2 IccssNyy.b DO99 This robot output is used to request PLC permission to enter interference zone 2.

ReqEntryZone3 IccssNyy.b DO100 This robot output is used to request PLC permission to enter interference zone 3.

ReqEntryZone4 IccssNyy.b DO101 This robot output is used to request PLC permission to enter interference zone 4.

ReqEntryZone5 IccssNyy.b DO102 This robot output is used to request PLC permission to enter interference zone 5.

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Signal Name PLC – TAG Logical Signal Description

ReqEntryZone6 IccssNyy.b DO103 This robot output is used to request PLC permission to enter interference zone 6.

ReqEntryZone7 IccssNyy.b DO104 This robot output is used to request PLC permission to enter interference zone 7.

ReqEntryZone8 IccssNyy.b DO105 This robot output is used to request PLC permission to enter interference zone 8.

RobotPartPres7 IccssNyy.b DO106 This robot output indicates that Part7Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

RobotPartPres8 IccssNyy.b DO107 This robot output indicates that Part8Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

RobotPartPres9 IccssNyy.b DO108 This robot output indicates that Part9Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

RobotPartPres10 IccssNyy.b DO109 This robot output informs the PLC that the Part10Present switch is made at the robotically
held gripper. Typical usage is PLC / robot coordination of a manual load operation to a robot
gripper.

RobotPartPres11 IccssNyy.b DO110 This robot output indicates that Part11Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

RobotPartPres12 IccssNyy.b DO111 This robot output indicates that Part12Present switch is made at the robotically held gripper.
Typical usage is PLC / robot coordination of a manual load operation to a robot gripper.

ESIO Monitor 1 IccssNyy.b DO112 This robot output echo’s the state of ESIO relay channel 1.

ESIO Monitor 2 IccssNyy.b DO113 This robot output echo’s the state of ESIO relay channel 2.

App1EquipReady IccssNyy.b DO114 This robot output indicates that application 1 process equipment is ready to run.

App2EquipReady IccssNyy.b DO115 This robot output indicates that application 2 process equipment is ready to run.

StartExtApp1Proc IccssNyy.b DO116 This robot output allows the robot to remotely request the PLC to start external application 1
process.
StartExtApp2Proc IccssNyy.b DO117 This robot output allows the robot to remotely request the PLC to start external application 2
process.
ProcessFault IccssNyy.b119 DO118 This robot output indicates that a process fault has occurred.

AppErrorActive IccssNyy.b120 DO119 This robot output indicates that a robot application error has occurred.

AppErrorBit1 IccssNyy.b DO120 This robot output along with the seven bits, (AppErrorBit2- AppErrorBit128) in a binary
pattern (eight bit group output goAppError), allows the robot to send the PLC the current
AppError table index. The BCD value for AppErrorBit1 = 1 (2^0)

AppErrorBit2 IccssNyy.b DO121 Reference AppErrorBit1. The BCD value for AppErrorBit2 =2 (2^1)

AppErrorBit4 IccssNyy.b DO122 Reference AppErrorBit1. The BCD value for AppErrorBit4 =4 (2^2)

AppErrorBit8 IccssNyy.b DO123 Reference AppErrorBit1. The BCD value for AppErrorBit8 =8 (2^3)

AppErrorBit16 IccssNyy.b DO124 Reference AppErrorBit1. The BCD value for AppErrorBit16 = 16 (2^4)

AppErrorBit32 IccssNyy.b DO125 Reference AppErrorBit1. The BCD value for AppErrorBit32 = 32 (2^5)

AppErrorBit64 IccssNyy.b DO126 Reference AppErrorBit1. The BCD value for AppErrorBit64 = 64 (2^6)

AppErrorBit128 IccssNyy.b DO127 Reference AppErrorBit1. The BCD value for AppErrorBit128 = 128 (2^7)

Reference DCX Book of Implementation Guidelines for proper Tag and UDT (Naming) - Design standards for control Logix.
AMS 0220 Section 9.3.2, 7.0 Tag – Device Net Tag Naming Guidelines, Starting on Page 28.

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D-NET MAP Descriptions (PLC To Robot) A.B.B .Robot
Signal Name PLC – TAG Logical Signal Description

StopRobot OccssNyy.b00 DI0 This robot system input allows the PLC to remotely order the robot to stop program
execution and de-energize motor power.
StartRobot OccssNyy.b01 DI1 This robot system input allows the PLC to remotely order the robot to energize motor power
and start program execution.
ClearAllFaults OccssNyy.b02 DI2 This robot system input allows the PLC to remotely order the robot to clear all robot faults.

UseDryCycle OccssNyy.b DI3 This robot input is set high when any 20 hour run bits are active in the robot program. THIS
OUTPUT MUST BE LOW OR REMOVED FOR NORMAL PRODUCTION RUNS.
ReservedPLCdi5 OccssNyy.b DI4 This robot input is not assigned.

ReservedPLCdi6 OccssNyy.b DI5 This robot input is not assigned.

ReservedPLCdi7 OccssNyy.b DI6 This robot input is not assigned.

ReservedPLCdi8 OccssNyy.b DI7 This robot input is not assigned.

ReservedPLCdi9 OccssNyy.b DI8 This robot input is not assigned.

ReservedPLCdi10 OccssNyy.b DI9 This robot input is not assigned.

ReadStyle OccssNyy.b DI10 This robot input allows the PLC to remotely request the robot to read the BCD style bits
(StyleBit1 – StyleBit64). Reference StyleBit1 - StyleBit64.
InitiateCycle OccssNyy.b DI11 This robot input allows the PLC to remotely request the robot to proceed from the Home
position to the Pounce position.
GoToWork OccssNyy.b DI12 This robot input allows the PLC to remotely request the robot to proceed from the Pounce
position and into the Active Style routine.
ReqToEnter OccssNyy.b DI13 This robot system input allows the PLC to remotely order the robot to stop program
execution after the robot has finished executing the current instruction. This allows the user
to enter the cell during midcycle without inadvertently interrupting a process sequence.
WorkCompleteAck OccssNyy.b14 DI14 This robot input allows the PLC to remotely acknowledge to the robot that the work
complete signal was received.
ReservedPLCdi16 OccssNyy.b DI15 This robot input is not assigned.

RetFromPounce OccssNyy.b DI16 This robot input allows the PLC to remotely request the robot to move from the Pounce
position back to the Home position and return to the mainline program.
ServiceCmpltReq OccssNyy.b33 DI17 This robot input allows the PLC to remotely request the robot to move from the Service
position to the Home position after system auto mode has been re-established. This input
may only be used when the robot is at the service position.
GoToServiceReq OccssNyy.b18 DI18 This robot input allows the PLC to remotely request the robot to move from the Home
position to the Service position.
ClrToExitUsrPos1 OccssNyy.b DI19 This robot input allows the PLC to signal the robot that it is clear to exit UserPos1.

ClrToExitUsrPos2 OccssNyy.b DI20 This robot input allows the PLC to signal the robot that it is clear to exit UserPos2.

ClrToExitUsrPos3 OccssNyy.b DI21 This robot input allows the PLC to signal the robot that it is clear to exit UserPos3.

ClrToExitUsrPos4 OccssNyy.b DI22 This robot input allows the PLC to signal the robot that it is clear to exit UserPos4.

ClrToExitUsrPos5 OccssNyy.b DI23 This robot input allows the PLC to signal inform the robot that it is clear to exit UserPos5.

StyleBit1 OccssNyy.b DI24 This robot input along with the next six bits, (StyleBit2 - StyleBit64) in a binary pattern
(seven bit group input giStyle), are used by the robot as program select bits. The bit weight
of these seven bits is the decimal value of the robot program to be executed.
The BCD value for StyleBit1 = 1 (2^0)
StyleBit2 OccssNyy.b DI25 Reference StyleBit1. The BCD value for StyleBit2 = 2 (2^1)

StyleBit4 OccssNyy.b DI26 Reference StyleBit1. The BCD value for StyleBit4 = 4 (2^2)

StyleBit8 OccssNyy.b DI27 Reference StyleBit1. The BCD value for StyleBit8 = 8 (2^3)

StyleBit16 OccssNyy.b DI28 Reference StyleBit1. The BCD value for StyleBit16 = 16 (2^4)

StyleBit32 OccssNyy.b DI29 Reference StyleBit1. The BCD value for StyleBit32 = 32 (2^5)

StyleBit64 OccssNyy.b DI30 Reference StyleBit1. The BCD value for StyleBit64 = 64 (2^6)

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Signal Name PLC – TAG Logical Signal Description
ReservedPLCdi32 OccssNyy.b DI31 This robot input is not assigned.
Option1 OccssNyy.b DI32 This robot input allows the PLC to remotely inform the robot that option 1 is active for the
current style.
Option2 OccssNyy.b DI33 This robot input allows the PLC to remotely inform the robot that option 2 is active for the
current style.
Option3 OccssNyy.b DI34 This robot input allows the PLC to remotely inform the robot that option 3 is active for the
current style.
Option4 OccssNyy.b DI35 This robot input allows the PLC to remotely inform the robot that option 4 is active for the
current style.
Zone1ClrToEnter OccssNyy.b36 DI36 This robot input allows the PLC to remotely inform the robot that interference zone 1 is clear
to enter. Reference the AAME zone logic standard document for further information.
Zone2ClrToEnter OccssNyy.b37 DI37 This robot input allows the PLC to remotely inform the robot that interference zone 2 is clear
to enter. Reference AAME zone logic standard document for additional info.
Zone3ClrToEnter OccssNyy.b38 DI38 This robot input allows the PLC to remotely inform the robot that interference zone 3 is clear
to enter. Reference AAME zone logic standard document for additional info.
Zone4ClrToEnter OccssNyy.b DI39 This robot input allows the PLC to remotely inform the robot that interference zone 4 is clear
to enter. Reference AAME zone logic standard document for additional info.
Zone5ClrToEnter OccssNyy.b DI40 This robot input allows the PLC to remotely inform the robot that interference zone 5 is clear
to enter. Reference AAME zone logic standard document for additional info.
Zone6ClrToEnter OccssNyy.b DI41 This robot input allows the PLC to remotely inform the robot that interference zone 6 is clear
to enter. Reference AAME zone logic standard document for additional info.
Zone7ClrToEnter OccssNyy.b DI42 This robot input allows the PLC to remotely inform the robot that interference zone 7 is clear
to enter. Reference AAME zone logic standard document for additional info.
Zone8ClrToEnter OccssNyy.b DI43 This robot input allows the PLC to remotely inform the robot that interference zone 8 is clear
to enter. Reference AAME zone logic standard document for additional info.
UserInput1 OccssNyy.b DI44 This robot input is designated for a user defined function.
UserInput2 OccssNyy.b DI45 This robot input is designated for a user defined function.
UserInput3 OccssNyy.b DI46 This robot input is designated for a user defined function.
UserInput4 OccssNyy.b DI47 This robot input is designated for a user defined function.
UserInput5 OccssNyy.b DI48 This robot input is designated for a user defined function.
UserInput6 OccssNyy.b DI49 This robot input is designated for a user defined function.
UserInput7 OccssNyy.b DI50 This robot input is designated for a user defined function.
UserInput8 OccssNyy.b DI51 This robot input is designated for a user defined function.
GoToPickup1 OccssNyy.b DI52 This robot input allows the PLC to remotely inform the robot to go to pickup position 1.
ExitPickup1 OccssNyy.b DI53 This robot input allows the PLC to remotely inform the robot to continue it’s program from
pickup position 1 and/or shift the part info. To the robot position in the shift register
GoToDropoff1 OccssNyy.b DI54 This robot input allows the PLC to remotely inform the robot to go to drop off position 1.
ExitDropoff1 OccssNyy.b DI55 This robot input allows the PLC to remotely inform the robot to continue it’s program from
drop off position 1 and/or shift the part info. to the robot position in the shift register
GoToPickup2 OccssNyy.b DI56 This robot input allows the PLC to remotely inform the robot to go to pickup position 2.

ExitPickup2 OccssNyy.b DI57 This robot input allows the PLC to remotely inform the robot to continue it’s program from
pickup position 2 and/or shift the part info. To the robot position in the shift register
GoToDropoff2 OccssNyy.b DI58 This robot input allows the PLC to remotely inform the robot to go to drop off position 2.

ExitDropoff2 OccssNyy.b DI59 This robot input allows the PLC to remotely inform the robot to continue it’s program from
drop off position 2 and/or shift the part info. To the robot position in the shift register
GoToPickup3 OccssNyy.b DI60 This robot input allows the PLC to remotely inform the robot to go to pickup position 3.

ExitPickup3 OccssNyy.b DI61 This robot input allows the PLC to remotely inform the robot to continue it’s program from
pickup position 3 and/or shift the part info. To the robot position in the shift register
GoToDropoff3 OccssNyy.b DI62 This robot input allows the PLC to remotely inform the robot to go to drop off position 3.

ExitDropoff3 OccssNyy.b DI63 This robot input allows the PLC to remotely inform the robot to continue it’s program from
drop off position 3 and/or shift the part info. To the robot position in the shift register
GoToPickup4 OccssNyy.b DI64 This robot input allows the PLC to remotely inform the robot to go to pickup position 4.

ExitPickup4 OccssNyy.b DI65 This robot input allows the PLC to remotely inform the robot to continue it’s program from
pickup position 4 and/or shift the part info. To the robot position in the shift register
GoToDropoff4 OccssNyy.b DI66 This robot input allows the PLC to remotely inform the robot to go to drop off position 4.

ExitDropoff4 OccssNyy.b DI67 This robot input allows the PLC to remotely inform the robot to continue it’s program from
drop off position 4 and/or shift the part info. To the robot position in the shift register
App1ClrToEnter OccssNyy.b DI68 This robot input is used to indicate that the Machine is clear for process 1.

App2ClrToEnter OccssNyy.b DI69 This robot input is used to indicate that the Machine is clear for process 2

Part1InFixture OccssNyy.b DI70 This robot input is used to indicate that part 1 is present in the tooling fixture.

Part2InFixture OccssNyy.b DI71 This robot input is used to indicate that part 2 is present in the tooling fixture.

Part3InFixture OccssNyy.b DI72 This robot input is used to indicate that part 3 is present in the tooling fixture.

Part4InFixture OccssNyy.b DI73 This robot input is used to indicate that part 4 is present in the tooling fixture.

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Signal Name PLC – TAG Logical Signal Description
Part5InFixture OccssNyy.b DI74 This robot input is used to indicate that part 5 is present in the tooling fixture.

Part6InFixture OccssNyy.b DI75 This robot input is used to indicate that part 6 is present in the tooling fixture.

ToolingRepod1 OccssNyy.b DI76 This robot input along with the next two bits, (ToolingRepod2 -ToolingRepod4) in a binary
pattern (three bit group input giToolingRepod), are used by the PLC to indicate to the robot
that the tooling (Tooling 1 – 7) has been repositioned. The BCD value for
ToolingRepod1 = 1 (2^0)
ToolingRepod2 OccssNyy.b DI77 Reference ToolingRepod1. The BCD value for ToolingRepod2 = 2 (2^1)

ToolingRepod4 OccssNyy.b DI78 Reference ToolingRepod1. The BCD value for ToolingRepod4 = 4 (2^2)

ClrToEntTN OccssNyy.b DI79 This robot input is used to remotly inform the PLC that the robot is clear to enter the tool
change nest.
ToolInNest1 OccssNyy.b DI80 This robot input is used to inform the robot that a tool is present in tool change nesting fixture
1.
ToolInNest2 OccssNyy.b DI81 This robot input is used to inform the robot that a tool is present in tool change nesting fixture
2.
ToolInNest3 OccssNyy.b DI82 This robot input is used to inform the robot that a tool is present in tool change nesting fixture
3.
ToolInNest4 OccssNyy.b DI83 This robot input is used to inform the robot that a tool is present in tool change nesting fixture
4.
NoStrokeReq OccssNyy.b DI84 This robot input allows the PLC to remotely request the robot to activate no stroke mode.

TipDressDumpExtd OccssNyy.b DI85 This robot input is used to inform the robot that the tip dresser dump is extended.

ReservedPLCdi87 OccssNyy.b DI86 This robot input is not assigned.

TipDressGunReq OccssNyy.b87 DI87 This robot input allows the PLC to remotely request the robot to do a tip dress sequence.

TipDrsDumpRetrct OccssNyy.b88 DI88 This robot input is used to indicate that the tip dress dump(s) are retracted.

TipDrsMotorOn OccssNyy.b89 DI89 This robot input is used to indicate the tip dress motor is running.

ExtStepperReset1 OccssNyy.b90 DI90 This robot input allows the PLC to remotely order the Weld controller to reset the steppers.

ExtStepperReset2 OccssNyy.b DI91 This robot input allows the PLC to remotely order the Weld controller to reset the steppers.

TipBurnInReq OccssNyy.b92 DI92 This robot input allows the PLC to remotely request the robot to perform a tip burn-in
sequence.
ReservedPLCdi94 OccssNyy.b DI93 This robot input is not assigned.

ExtWaterOnReq OccssNyy.b DI94 This robot input allows the PLC to remotely turn on water flow.

ExtWaterOffReq OccssNyy.b DI95 This robot input allows the PLC to remotely turn off water flow.

PurgeGun1Req OccssNyy.b DI96 This robot input allows the PLC to remotely request the robot to perform a purge sequence
for dispenser 1
PurgeGun2Req OccssNyy.b DI97 This robot input allows the PLC to remotely request the robot to perform a purge sequence
for dispenser 2
ReservedPLCdi99 OccssNyy.b DI98 This robot input is not assigned.

ReservedPLCdi100 OccssNyy.b DI99 This robot input is not assigned.

PickTool1 OccssNyy.b DI100 This robot input along with the next three bits (101 to 104) in a binary pattern (four bit group
input giPickTool), are used by the PLC to order the robot to pick up a specific tool. The
BCD value for PickTool1 = 1 (2^0)
PickTool2 OccssNyy.b DI101 Reference PickTool1 – DI101 The BCD value for PickTool2 = 2 (2^1)

PickTool4 OccssNyy.b DI102 Reference PickTool1 – DI101 The BCD value for PickTool2 = 4 (2^2)

PickTool8 OccssNyy.b DI103 Reference PickTool1 – DI101 The BCD value for PickTool2 = 8 (2^3)

MaintStyle1Req OccssNyy.b DI104 This robot input allows the PLC to remotely order the robot to execute Style1 (contents of
Style1 maintenance routine are project defined).
MaintStyle2Req OccssNyy.b DI105 This robot input allows the PLC to remotely order the robot to execute Style2 (contents of
Style2 maintenance routine are project defined).
MaintStyle3Req OccssNyy.b DI106 This robot input allows the PLC to remotely order the robot to execute Style3 (contents of
Style3 maintenance routine are project defined).
ReservedPLCdi108 OccssNyy.b DI107 This robot input is not assigned.

ReservedPLCdi109 OccssNyy.b DI108 This robot input is not assigned.

ReservedPLCdi110 OccssNyy.b DI109 This robot input is not assigned.

ReservedPLCdi111 OccssNyy.b DI110 This robot input is not assigned.

ReservedPLCdi112 OccssNyy.b DI111 This robot input is not assigned.

ExtApp1Complete OccssNyy.b DI112 This robot input is used to indicate that application 1 process is completed.

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Signal Name PLC – TAG Logical Signal Description
ExtApp2Complete OccssNyy.b DI113 This robot input is used to indicate that application 2 process is completed.

ExtApp1StartReq OccssNyy.b DI114 This robot input allows the PLC to remotely start application 1 process.

ExtApp2StartReq OccssNyy.b DI115 This robot input allows the PLC to remotely start application 2 process.

ReservedPLCdi117 OccssNyy.b DI116 This robot input is not assigned.

ReservedPLCdi118 OccssNyy.b DI117 This robot input is not assigned.

ReservedPLCdi119 OccssNyy.b DI118 This robot input is not assigned.

AppErrorAck OccssNyy.b DI119 This robot input is used to Acknowledge that the system PLC has received the Application
Error Bits.
ReservedPLCdi121 OccssNyy.b DI120 This robot input is not assigned.

PalletPosBit1 OccssNyy.b DI121 This robot input along with the next three bits, (PalletPosBit2 - PalletPosBit8) in a binary
pattern (four bit group input giPalletPos), are used by the PLC to request the robot to move to
a specific pallet position. The BCD value for PalletPosBit1 = 1 (2^0)
PalletPosBit2 OccssNyy.b DI122 Reference PalletPosBit1. The BCD value for PalletPosBit2 = 2 (2^1)

PalletPosBit4 OccssNyy.b DI123 Reference PalletPosBit1. The BCD value for PalletPosBit4 = 4 (2^2)

PalletPosBit8 OccssNyy.b DI124 Reference PalletPosBit1. The BCD value for PalletPosBit8 = 8 (2^3)

ReservedPLCdi126 OccssNyy.b DI125 This robot input is not assigned.

ReservedPLCdi127 OccssNyy.b DI126 This robot input is not assigned.

ReservedPLCdi128 OccssNyy.b DI127 This robot input is not assigned.

Reference DCX Book of Implementation Guidelines for proper Tag and UDT (Naming) - Design standards for control Logix.
AMS 0220 Section 9.3.2, 7.0 Tag – Device Net Tag Naming Guidelines, Starting on Page 28

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 DaimlerChrysler 08RT
Robot Device Net Master Node Assignment
Node Robot Inputs Robot Outputs
I/O Size Application
Number Byte Bits Byte Bits
0 Reserved by Robot
1 Reserved by Robot
2 Reserved by Robot
3 Reserved by Robot
4 Reserved by Robot
5 Reserved by Robot
6 Reserved by Robot
7 Reserved by Robot
8 Reserved by Robot
9 Reserved by Robot
10 16 IN / 16 OUT 2 16 2 16 ABB -DSQC 328
11 32 IN / 32 OUT 4 32 4 32 Weld Timer #1
12 32 IN / 32 OUT 4 32 4 32 Weld Timer #2
13 32 IN / 32 OUT 4 32 4 32 Weld Timer #3
14 32 IN / 32 OUT 4 32 4 32 Weld Timer #4
15 NOT ASSIGNED Spare
16 64 IN / 64 OUT 8 64 8 64 Stud Weld
17 32 IN / 8 OUT 4 32 1 8 Water Saver #1
18 32 IN / 8 OUT 4 32 1 8 Water Saver #2
19 32 IN / 8 OUT 4 32 1 8 Water Saver #3
20 32 IN / 8 OUT 4 32 1 8 Water Saver #4
21 NOT ASSIGNED Spare
22 NOT ASSIGNED Spare
23 NOT ASSIGNED Spare
24 NOT ASSIGNED Spare
25 32 IN / 48 OUT 4 32 6 48 Dispense System A – Nordson – Process Sentry
26 32 IN / 48 OUT 4 32 6 48 Dispense System B – Nordson – Process Sentry
27 NOT ASSIGNED Spare
28 NOT ASSIGNED Spare
29 NOT ASSIGNED Spare
30 NOT ASSIGNED Spare
31 16 IN 2 16 0 0 MH Input Block 1
32 16 IN 2 16 0 0 MH Input Block 2
33 16 IN 2 16 0 0 MH Input Block 3
34 16 IN 2 16 0 0 MH Input Block 4
35 16 IN 2 16 0 0 MH Input Block 5
36 NOT ASSIGNED Spare
37 8 IN / 8 OUT 1 8 1 8 Norgen Smart Pump
38 128 IN / 32 OUT 16 128 4 32 Isra Vision (part detect)
39 40 OUT 5 40 Numatics Valve manifold
40 NOT ASSIGNED Hemming (Proportional Regulator)
41 8 IN / 8 OUT 1 8 1 8 Ped Weld Dense Pack 1
42 8 IN / 8 OUT 1 8 1 8 Ped Weld Dense Pack 2
43 NOT ASSIGNED Spare
44 NOT ASSIGNED Spare
45 16 IN / 16 OUT 2 16 2 16 Utica Pierce Unit A Block1
46 16 IN / 16 OUT 2 16 2 16 Utica Pierce Unit A Block2
47 16 IN / 16 OUT 2 16 2 16 Utica Pierce Unit B Block1
48 16 IN / 16 OUT 2 16 2 16 Utica Pierce Unit B Block2
49 16 IN / 16 OUT 2 16 2 16 Utica Pierce Unit C Block1
50 16 IN / 16 OUT 2 16 2 16 Utica Pierce Unit C Block2
51 8 IN / 8 OUT 1 8 1 8 Spare
52 NOT ASSIGNED Spare
53 NOT ASSIGNED Spare
54 128 IN / 40 OUT 8 64 1 8 ATI – Quick Connect Redundant Tool Changer
55 8 IN / 8 OUT 1 8 1 8 Tool changer cover control
56 8 IN / 8 OUT 1 8 1 8 Tool changer cover control
57 8 IN / 8 OUT 1 8 1 8 Tool changer cover control
58 8 IN / 8 OUT 1 8 1 8 Tool changer cover control
59 NOT ASSIGNED Spare
60 NOT ASSIGNED Spare
61 NOT ASSIGNED Spare
62 NOT ASSIGNED Spare
63 NOT ASSIGNED Reserved ODVA Default

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 A.B.B. ROBOT D-NET MAP DESCRIPTIONS (ROBOT TO DISCRETE I/O)
ABB-DSQC 328
I/O unit name:
ABB-DSQC 328 I/O unit node address: 10
Signal Signal Signal Signal
Name Type Location Description
ResrvdNode10di1 Input 1 This robot input is not assigned
ResrvdNode10di2 Input 2 This robot input is not assigned
ResrvdNode10di3 Input 3 This robot input is not assigned
ResrvdNode10di4 Input 4 This robot input is not assigned
ResrvdNode10di5 Input 5 This robot input is not assigned
ResrvdNode10di6 Input 6 This robot input is not assigned
ResrvdNode10di7 Input 7 This robot input is not assigned
ResrvdNode10di8 Input 8 This robot input is not assigned
g1_temp_ok Input 9 This input from gun 1 weld transformer temperature switch is OK when
equal to “1”
g2_temp_ok Input 10 This input from gun 2 weld transformer temperature switch is OK when
equal to “1”
ResrvdNode10di11 Input 11 This robot input is not assigned
ResrvdNode10di12 Input 12 This robot input is not assigned
ResrvdNode10di13 Input 13 This robot input is not assigned
ResrvdNode10di14 Input 14 This robot input is not assigned
ResrvdNode10di15 Input 15 This robot input is not assigned
ResrvdNode10di16 Input 16 This robot input is not assigned

ABB-DSQC 328
I/O unit name:
ABB-DSQC 328 I/O unit node address: 10
Signal Signal Signal Signal
Name Type Location Description
ResrvdNode10do1 Output 1 This robot output is not assigned
ResrvdNode10do2 Output 2 This robot output is not assigned
ResrvdNode10do3 Output 3 This robot output is not assigned
ResrvdNode10do4 Output 4 This robot output is not assigned
ResrvdNode10do5 Output 5 This robot output is not assigned
ResrvdNode10do6 Output 6 This robot output is not assigned
ResrvdNode10do7 Output 7 This robot output is not assigned
ResrvdNode10do8 Output 8 This robot output is not assigned
Fault Light Output 9 This robot output is for Belvedere plant use
g1_equalize Output 10 This robot output will activate the pneumatic equalizer valve for gun1
g2_equalize Output 11 This robot output will activate the pneumatic equalizer valve for gun2
ResrvdNode10do12 Output 12 This robot output is not assigned
ResrvdNode10do13 Output 13 This robot output is not assigned
ResrvdNode10do14 Output 14 This robot output is not assigned
ResrvdNode10do15 Output 15 This robot output is not assigned
ResrvdNode10do16 Output 16 This robot output is not assigned

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 A.B.B.ROBOT D-NET MAP DESCRIPTIONS (WELDER to ROBOT)
MFDC I/O
I/O unit name:
WTC_MFDC I/O unit node address: 11
Signal Signal Signal Signal
Name Type Loc. Description
WT1WeldEnabled Input 1 This robot input from the weld timer indicates that weld current is enabled
WT1NoFault Input 2 This robot input from the weld timer indicates that no fault condition exist
WT1NoAlert Input 3 This robot input from the weld timer indicates that no alert is present
WT1WeldFltAvail Input 4 This robot input from the weld timer indicates that a weld fault/alert code is
set
WT1WeldFltBit1 Input 5 This robot input is binary bit 1 for the weld fault/alert
WT1WeldFltBit2 Input 6 This robot input is binary bit 2 for the weld fault/alert
WT1WeldFltBit4 Input 7 This robot input is binary bit 4 for the weld fault/alert
WT1WeldFltBit8 Input 8 This robot input is binary bit 8 for the weld fault/alert
WT1WeldFltBit16 Input 9 This robot input is binary bit 16 for the weld fault/alert
WT1WeldComplete Input 10 This robot input from the weld timer indicates a weld has been completed
WT1WeldInProgres Input 11 This robot input from the weld timer indicates a weld is in progress
WT1SteppersReset Input 12 This robot input from the weld timer indicates the stepper has been reset
WT1NearEndOfStep Input 13 This robot input from the weld timer indicates that end of stepper is
approaching
WT1EndOfStepper Input 14 This robot input from the weld timer indicates that end of stepper has been
reached
WT1ReadyToWeld Input 15 This robot input from the weld timer indicates that it is ready to apply welds
WT1DressTipsReq Input 16 This robot input from the weld timer indicates that tip dressing is required
WT1GunRetractA Input 17 This robot input from the weld timer will not be used for Servo weld guns
WT1GunRetractB Input 18 This robot input from the weld timer will not be used for Servo weld guns
WT1input19 Input 19 This robot input from the weld timer is currently not used
WT1input20 Input 20 This robot input from the weld timer is currently not used
WT1input21 Input 21 This robot input from the weld timer is currently not used
WT1input22 Input 22 This robot input from the weld timer is currently not used
WT1input23 Input 23 This robot input from the weld timer is currently not used
WT1input24 Input 24 This robot input from the weld timer is currently not used
WT1input25 Input 25 This robot input from the weld timer is currently not used
WT1input26 Input 26 This robot input from the weld timer is currently not used
WT1input27 Input 27 This robot input from the weld timer is currently not used
WT1input28 Input 28 This robot input from the weld timer is currently not used
WT1input29 Input 29 This robot input from the weld timer is currently not used
WT1input30 Input 30 This robot input from the weld timer is currently not used
WT1input31 Input 31 This robot input from the weld timer is currently not used
WT1input32 Input 32 This robot input from the weld timer is currently not used
WT1WeldFaultNum Group 5-9 This robot group input is a 5 bit weld fault number from weld timer1
Input

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Printed copies are not source controlled
 A.B.B.ROBOT D-NET MAP DESCRIPTIONS (ROBOT to WELDER)
MFDC I/O
I/O unit name:
WTC_MFDC I/O unit node address: 11
Signal Signal Signal Signal
Name Type Loc. Description
WT1EnableWeld Output 1 This robot output will activate weld mode on the weld timer
WT1FaultReset Output 2 This robot output will reset faults on the weld timer
WT1WeldFltAck Output 3 This robot output will acknowledge the weld fault/alert was received
WT1ProgramBit1 Output 4 This robot output is binary bit 1 for weld program selection on the weld timer
WT1ProgramBit2 Output 5 This robot output is binary bit 2 for weld program selection on the weld timer
WT1ProgramBit4 Output 6 This robot output is binary bit 4 for weld program selection on the weld timer
WT1ProgramBit8 Output 7 This robot output is binary bit 8 for weld program selection on the weld timer
WT1ProgramBit16 Output 8 This robot output is binary bit 16 for weld program selection on the weld
timer
WT1ProgramBit32 Output 9 This robot output is binary bit 32 for weld program selection on the weld
timer
WT1InitiateWeld Output 10 This robot output will initiate a weld program on the weld timer
WT1PressTest Output 11 This robot output will not be used by the robot for Servo weld guns
WT1InitRetract Output 12 This robot output will not be used by the robot for Servo weld guns
WT1ResetStepper Output 13 This robot output will reset the stepper(s) on the weld timer
WT1IsoContSvrEnb Output 14 This robot output will activate the isolation contactor saver on the weld
timer
WT1ControlStop Output 15 This robot output will order the weld timer to stop its current operation
WT1Tipsdressed Output 16 This robot output will acknowledge that the weld tips have been dressed
WT1WeldIDBit1 Output 17 This robot output is binary bit 1 for weld identification selection on the
weld timer
WT1WeldIDBit2 Output 18 This robot output is binary bit 2 for weld identification selection on the weld
timer
WT1WeldIDBit4 Output 19 This robot output is binary bit 4 for weld identification selection on the weld
timer
WT1WeldIDBit8 Output 20 This robot output is binary bit 8 for weld identification selection on the weld
timer
WT1WeldIDBit16 Output 21 This robot output is binary bit 16 for weld identification selection on the weld
timer
WT1WeldIDBit32 Output 22 This robot output is binary bit 32 for weld identification selection on the weld
timer
WT1WeldIDBit64 Output 23 This robot output is binary bit 64 for weld identification selection on the weld
timer
WT1WeldIDBit128 Output 24 This robot output is binary bit 128 for weld identification selection on the
weld timer
WT1WeldIDBit256 Output 25 This robot output is binary bit 256 for weld identification selection on the
weld timer
WT1WeldIDBit512 Output 26 This robot output is binary bit 512 for weld identification selection on the
weld timer
WT1WeldIDBit1024 Output 27 This robot output is binary bit 1024 for weld identification selection on the
weld timer
WT1WeldIDBit2048 Output 28 This robot output is binary bit 2048 for weld identification selection on the
weld timer
WT1WeldIDBit4096 Output 29 This robot output is binary bit 4096 for weld identification selection on the
weld timer
WT1WeldIDBit8192 Output 30 This robot output is binary bit 8192 for weld identification selection on the
weld timer
WT1output31 Output 31 This robot output to the weld timer is currently not used
WT1output32 Output 32 This robot output to the weld timer is currently not used
WT1ProgramNum Group 4-9 This robot group output sends a 6 bit weld program number to weld timer
Output
WT1WeldIDNum Group 17-30 This robot group output sends a 14 bit weld identification number to weld
Output timer

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Printed copies are not source controlled
 MFDC I/O
I/O unit name:
WTC_MFDC I/O unit node address: 12
Signal Signal Signal Signal
Name Type Loc. Description
WT2WeldEnabled Input 1 This robot input from the weld timer indicates that weld current is enabled
WT2NoFault Input 2 This robot input from the weld timer indicates that no fault condition exist
WT2NoAlert Input 3 This robot input from the weld timer indicates that no alert is present
WT2WeldFltAvail Input 4 This robot input from the weld timer indicates that a weld fault/alert code is
set
WT2WeldFltBit1 Input 5 This robot input is binary bit 1 for the weld fault/alert
WT2WeldFltBit2 Input 6 This robot input is binary bit 2 for the weld fault/alert
WT2WeldFltBit4 Input 7 This robot input is binary bit 4 for the weld fault/alert
WT2WeldFltBit8 Input 8 This robot input is binary bit 8 for the weld fault/alert
WT2WeldFltBit16 Input 9 This robot input is binary bit 16 for the weld fault/alert
WT2WeldComplete Input 10 This robot input from the weld timer indicates a weld has been completed
WT2WeldInProgres Input 11 This robot input from the weld timer indicates a weld is in progress
WT2SteppersReset Input 12 This robot input from the weld timer indicates the stepper has been reset
WT2NearEndOfStep Input 13 This robot input from the weld timer indicates that end of stepper is
approaching
WT2EndOfStepper Input 14 This robot input from the weld timer indicates that end of stepper has been
reached
WT2ReadyToWeld Input 15 This robot input from the weld timer indicates that it is ready to apply welds
WT2DressTipsReq Input 16 This robot input from the weld timer indicates that tip dressing is required
WT2GunRetractA Input 17 This robot input from the weld timer will not be used for Servo weld guns
WT2GunRetractB Input 18 This robot input from the weld timer will not be used for Servo weld guns
WT2input19 Input 19 This robot input from the weld timer is currently not used
WT2input20 Input 20 This robot input from the weld timer is currently not used
WT2input21 Input 21 This robot input from the weld timer is currently not used
WT2input22 Input 22 This robot input from the weld timer is currently not used
WT2input23 Input 23 This robot input from the weld timer is currently not used
WT2input24 Input 24 This robot input from the weld timer is currently not used
WT2input25 Input 25 This robot input from the weld timer is currently not used
WT2input26 Input 26 This robot input from the weld timer is currently not used
WT2input27 Input 27 This robot input from the weld timer is currently not used
WT2input28 Input 28 This robot input from the weld timer is currently not used
WT2input29 Input 29 This robot input from the weld timer is currently not used
WT2input30 Input 30 This robot input from the weld timer is currently not used
WT2input31 Input 31 This robot input from the weld timer is currently not used
WT2input32 Input 32 This robot input from the weld timer is currently not used
WT2WeldFaultNum Group 5-9 This robot group input is a 5 bit weld fault number from weld timer1
Input

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Printed copies are not source controlled
 MFDC I/O
I/O unit name:
WTC_MFDC I/O unit node address: 12
Signal Signal Signal Signal
Name Type Loc. Description
WT2EnableWeld Output 1 This robot output will activate weld mode on the weld timer
WT2FaultReset Output 2 This robot output will reset faults on the weld timer
WT2WeldFltAck Output 3 This robot output will acknowledge the weld fault/alert was received
WT2ProgramBit1 Output 4 This robot output is binary bit 1 for weld program selection on the weld timer
WT2ProgramBit2 Output 5 This robot output is binary bit 2 for weld program selection on the weld timer
WT2ProgramBit4 Output 6 This robot output is binary bit 4 for weld program selection on the weld timer
WT2ProgramBit8 Output 7 This robot output is binary bit 8 for weld program selection on the weld timer
WT2ProgramBit16 Output 8 This robot output is binary bit 16 for weld program selection on the weld
timer
WT2ProgramBit32 Output 9 This robot output is binary bit 32 for weld program selection on the weld
timer
WT2InitiateWeld Output 10 This robot output will initiate a weld program on the weld timer
WT2PressTest Output 11 This robot output will not be used by the robot for Servo weld guns
WT2InitRetract Output 12 This robot output will not be used by the robot for Servo weld guns
WT2ResetStepper Output 13 This robot output will reset the stepper(s) on the weld timer
WT2IsoContSvrEnb Output 14 This robot output will activate the isolation contactor saver on the weld
timer
WT2ControlStop Output 15 This robot output will order the weld timer to stop its current operation
WT2Tipsdressed Output 16 This robot output will acknowledge that the weld tips have been dressed
WT2WeldIDBit1 Output 17 This robot output is binary bit 1 for weld identification selection on the
weld timer
WT2WeldIDBit2 Output 18 This robot output is binary bit 2 for weld identification selection on the weld
timer
WT2WeldIDBit4 Output 19 This robot output is binary bit 4 for weld identification selection on the weld
timer
WT2WeldIDBit8 Output 20 This robot output is binary bit 8 for weld identification selection on the weld
timer
WT2WeldIDBit16 Output 21 This robot output is binary bit 16 for weld identification selection on the weld
timer
WT2WeldIDBit32 Output 22 This robot output is binary bit 32 for weld identification selection on the weld
timer
WT2WeldIDBit64 Output 23 This robot output is binary bit 64 for weld identification selection on the weld
timer
WT2WeldIDBit128 Output 24 This robot output is binary bit 128 for weld identification selection on the
weld timer
WT2WeldIDBit256 Output 25 This robot output is binary bit 256 for weld identification selection on the
weld timer
WT2WeldIDBit512 Output 26 This robot output is binary bit 512 for weld identification selection on the
weld timer
WT2WeldIDBit1024 Output 27 This robot output is binary bit 1024 for weld identification selection on the
weld timer
WT2WeldIDBit2048 Output 28 This robot output is binary bit 2048 for weld identification selection on the
weld timer
WT2WeldIDBit4096 Output 29 This robot output is binary bit 4096 for weld identification selection on the
weld timer
WT2WeldIDBit8192 Output 30 This robot output is binary bit 8192 for weld identification selection on the
weld timer
WT2output31 Output 31 This robot output to the weld timer is currently not used
WT2output32 Output 32 This robot output to the weld timer is currently not used
WT2ProgramNum Group 4-9 This robot group output sends a 6 bit weld program number to weld timer
Output
WT2WeldIDNum Group 17-30 This robot group output sends a 14 bit weld identification number to weld
Output timer

AS OF 9/27/2006 23 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 ABB ROBOT D-NET MAP DESCRIPTIONS (WATERSAVER to ROBOT)
DELTA POINT WATER SAVER I/O
I/O unit name
WaterSaver1 I/O unit node address 17
Signal Signal Signal Signal
Name Type Loc. Description
WS1Water OK to Weld Input 1 This input indicates water flow is acceptable for welding
WS1ResrvdNode17di2 Input 2 This input is reserved for water saver
WS1Water Bypassed Input 3 This input indicates the water saver is electrically bypassed
WS1ResrvdNode17di4 Input 4 This input is reserved for water saver
WS1ResrvdNode17di5 Input 5 This input is reserved for water saver
WS1ResrvdNode17di6 Input 6 This input is reserved for water saver
WS1ResrvdNode17di7 Input 7 This input is reserved for water saver
WS1Water Aux. Power Input 8 This input indicates that auxiliary power is present at the water saver
OK

ABB ROBOT D-NET MAP DESCRIPTIONS (ROBOT to WATERSAVER)

DELTA POINT WATER SAVER I/O
I/O unit name
WaterSaver1 I/O unit node address 17
Signal Signal Signal Signal
Name Type Loc. Description
WS1ResetWaterSaver output 1 This output will reset the water saver to re-establish water flow
WS1TurnWaterOff output 2 This output will turn the water valve off
WS1ResrvdNode17do3 output 3 This output is reserved by water saver
WS1ResrvdNode17do4 output 4 This output is reserved by water saver
WS1ResrvdNode17do5 output 5 This output is reserved by water saver
WS1ResrvdNode17do6 output 6 This output is reserved by water saver
WS1ResrvdNode17do7 output 7 This output is reserved by water saver
WS1ResrvdNode17do8 output 8 This output is reserved by water saver

DELTA POINT WATER SAVER I/O

I/O unit name
WaterSaver1 I/O unit node address 18
Signal Signal Signal Signal
Name Type Loc. Description
WS2Water OK to Weld Input 1 This input indicates water flow is acceptable for welding
WS2ResrvdNode17di2 Input 2 This input is reserved for water saver
WS2Water Bypassed Input 3 This input indicates the water saver is electrically bypassed
WS2ResrvdNode17di4 Input 4 This input is reserved for water saver
WS2ResrvdNode17di5 Input 5 This input is reserved for water saver
WS2ResrvdNode17di6 Input 6 This input is reserved for water saver
WS2ResrvdNode17di7 Input 7 This input is reserved for water saver
WS1Water Aux. Power Input 8 This input indicates that auxiliary power is present at the water saver
OK

DELTA POINT WATER SAVER I/O

I/O unit name
WaterSaver1 I/O unit node address 18
Signal Signal Signal Signal
Name Type Loc. Description
WS2ResetWaterSaver output 1 This output will reset the water saver to re-establish water flow
WS2TurnWaterOff output 2 This output will turn the water valve off
WS2ResrvdNode17do3 output 3 This output is reserved by water saver
WS2ResrvdNode17do4 output 4 This output is reserved by water saver
WS2ResrvdNode17do5 output 5 This output is reserved by water saver
WS2ResrvdNode17do6 output 6 This output is reserved by water saver
WS2ResrvdNode17do7 output 7 This output is reserved by water saver
WS2ResrvdNode17do8 output 8 This output is reserved by water saver

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Printed copies are not source controlled
 A.B.B. ROBOT D-NET MAP DESCRIPTIONS (STUD WELDER TO ROBOT)
EMHART STUD WELDER I/O
I/O unit name I/O unit node address 16
Signal Signal Signal Signal
Name Type Loc. Description
Std1NoFaultHead1 Input 1 This input from the Emhart control 1 indicates No Fault is present on weld head 1.
Std1WeldCmpltHd1 Input 2 This input from the Emhart control 1 indicates the stud weld was complete for head 1.
Std1HeadBackHd1 Input 3 This input from the Emhart control 1 indicates stud head 1 is retracted.
Std1SOWHead1 Input 4 This input from the Emhart control 1 indicates stud head 1 has a stud on the work piece.
Std1WeldInTolHd1 Input 5 This input from the Emhart control 1 indicates the stud weld was in tolerance for head 1.
Std1NoFaultHead2 Input 6 This input from the Emhart control 1 indicates No Fault is present on weld head 2.
Std1Weldcmplthd2 Input 7 This input from the Emhart control 1 indicates the stud weld was complete for head 2.
Std1HeadBackHd2 Input 8 This input from the Emhart control 1 indicates stud head 2 is retracted.
Std1SOWHead2 Input 9 This input from the Emhart control 1 indicates stud head 2 has a stud on the work piece.
Std1WeldInTolHd2 Input 10 This input from the Emhart control 1 indicates the stud weld was in tolerance for head 2.
Std1NoFaultHead3 Input 11 This input from the Emhart control 1 indicates No Fault is present on weld head 3.
Std1Weldcmplthd3 Input 12 This input from the Emhart control 1 indicates the stud weld was complete for head 3.
Std1HeadBackHd3 Input 13 This input from the Emhart control 1 indicates stud head 3 is retracted.
Std1SOWHead3 Input 14 This input from the Emhart control 1 indicates stud head 3 has a stud on the work piece.
Std1WeldInTolHd3 Input 15 This input from the Emhart control 1 indicates the stud weld was in tolerance for head 3.
Std1NoFaultHead4 Input 16 This input from the Emhart control 1 indicates No Fault is present on weld head 4.
Std1Weldcmplthd4 Input 17 This input from the Emhart control 1 indicates the stud weld was complete for head 4.
Std1HeadBackHd4 Input 18 This input from the Emhart control 1 indicates stud head 4 is retracted.
Std1SOWHead4 Input 19 This input from the Emhart control 1 indicates stud head 4 has a stud on the work piece.
Std1WeldInTolHd4 Input 20 This input from the Emhart control 1 indicates the stud weld was in tolerance for head 4.
Std1NoFaultHead5 Input 21 This input from the Emhart control 1 indicates No Fault is present on weld head 5.
Std1Weldcmplthd5 Input 22 This input from the Emhart control 1 indicates the stud weld was complete for head 5.
Std1HeadBackHd5 Input 23 This input from the Emhart control 1 indicates stud head 5 is retracted.
Std1SOWHead5 Input 24 This input from the Emhart control 1 indicates stud head 5 has a stud on the work piece.
Std1WeldInTolHd5 Input 25 This input from the Emhart control 1 indicates the stud weld was in tolerance for head 5.
Std1MaintRequest Input 26 This input from the Emhart control 1 indicates that service is requested.
Std1StudsLow Input 27 This input from the Emhart control 1 indicates the stud hopper is not running.
Std1ReadyForAuto Input 28 This input from the Emhart control 1 indicates that is ready to execute a cycle.
Std1ReadyToWeld Input 29 This input from the Emhart control 1 indicates that it is changed and ready to weld.
Std1FaultGrpBit1 Input 30 This input from the Emhart control 1 is a binary bit 1 for group fault condition.
Std1FaultGrpBit2 Input 31 This input from the Emhart control 1 is a binary bit 2 for group fault condition.
Std1FaultGrpBit4 Input 32 This input from the Emhart control 1 is a binary bit 4 for group fault condition.
Std1FaultBit1 Input 33 This input from the Emhart controller 1 is binary bit 1 for fault code report
Std1FaultBit2 Input 34 This input from the Emhart controller 1 is binary bit 2 for fault code report
Std1FaultBit4 Input 35 This input from the Emhart controller 1 is binary bit 4 for fault code report
Std1FaultBit8 Input 36 This input from the Emhart controller 1 is binary bit 8 for fault code report
Std1FaultBit16 Input 37 This input from the Emhart controller 1 is binary bit 16 for fault code report
Std1FaultBit32 Input 38 This input from the Emhart controller 1 is binary bit 32 for fault code report
Std1FaultBit64 Input 39 This input from the Emhart controller 1 is binary bit 64 for fault code report
Std1FaultBit128 Input 40 This input from the Emhart controller 1 is binary bit 128 for fault code report
Std1FaultBit256 Input 41 This input from the Emhart controller 1 is binary bit 256 for fault code report
Std1Input42 Input 42 This input from the Emhart controller 1 is currently not used.
Std1Input43 Input 43 This input from the Emhart controller 1 is currently not used.
Std1Input44 Input 44 This input from the Emhart controller 1 is currently not used.
Std1Input45 Input 45 This input from the Emhart controller 1 is currently not used.
Std1Input46 Input 46 This input from the Emhart controller 1 is currently not used.
Std1Input47 Input 47 This input from the Emhart controller 1 is currently not used.
Std1Input48 Input 48 This input from the Emhart controller 1 is currently not used.
Std1Head1inWpos Input 49
Std1Head2inWpos Input 50
Std1Head3inWpos Input 51
Std1Head4inWpos Input 52
Std1Head5inWpos Input 53
Std1Head1inPpos Input 54
Std1Head2inPpos Input 55
Std1Head3inPpos Input 56
Std1Head4inPpos Input 57
Std1Head5inPpos Input 58
Std1SIGrprHead1 Input 59
Std1SIGrprHead2 Input 60
Std1SIGrprHead3 Input 61
Std1SIGrprHead4 Input 62
Std1SIGrprHead5 Input 63
Std1MotionRelReq Input 64

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Printed copies are not source controlled
 A.B.B. ROBOT D-NET MAP DESCRIPTIONS (ROBOT TO STUD WELDER)
EMHART STUD WELDER I/O
I/O unit name I/O unit node address 16
Signal Signal Signal Signal
Name Type Loc. Description
Std1StartWeldHd1 Output 1 This output to the Emhart control 1 will start a weld cycle with head 1.
Std1StartWeldHd2 Output 2 This output to the Emhart control 1 will start a weld cycle with head 2.
Std1StartWeldHd3 Output 3 This output to the Emhart control 1 will start a weld cycle with head 3.
Std1StartWeldHd4 Output 4 This output to the Emhart control 1 will start a weld cycle with head 4.
Std1StartWeldHd5 Output 5 This output to the Emhart control 1 will start a weld cycle with head 5.
Std1StartFeedHd1 Output 6 This output to the Emhart control 1 initiates a stud feed cycle to head 1.
Std1StartFeedHd2 Output 7 This output to the Emhart control 1 initiates a stud feed cycle to head 2.
Std1StartFeedHd3 Output 8 This output to the Emhart control 1 initiates a stud feed cycle to head 3.
Std1StartFeedHd4 Output 9 This output to the Emhart control 1 initiates a stud feed cycle to head 4.
Std1StartFeedHd5 Output 10 This output to the Emhart control 1 initiates a stud feed cycle to head 5.
Std1WldProgBit1 Output 11 This output to the Emhart control 1 is bit value 1 of the binary weld select
Std1WldProgBit2 Output 12 This output to the Emhart control 1 is bit value 2 of the binary weld select
Std1WldProgBit4 Output 13 This output to the Emhart control 1 is bit value 4 of the binary weld select
Std1WldProgBit8 Output 14 This output to the Emhart control 1 is bit value 8 of the binary weld select
Std1WldProgBit16 Output 15 This output to the Emhart control 1 is bit value 16 of the binary weld select
Std1WldProgBit32 Output 16 This output to the Emhart control 1 is bit value 32 of the binary weld select
Std1WldProgBit64 Output 17 This output to the Emhart control 1 is bit value 64 of the binary weld select
Std1Output18 Output 18 This output to the Emhart controller 1 is currently not used.
Std1RestartWeld Output 19 This output to the Emhart control 1 will reweld a stud at the current weld position.
Someone must verify that a stud was not welded to the work piece before a reweld.
Std1ForceWeldCmp Output 20 This output to the Emhart control 1 will force a weld complete signal
Std1ModeSelect1 Output 21 This output to the Emhart control 1 is used to activate modes of operation.
Std1ModeSelect2 Output 22 This output to the Emhart control 1 is used to activate modes of operation.
Std1Output23 Output 23 This output to the Emhart controller 1 is currently not used.
Std1Output24 Output 24 This output to the Emhart controller 1 is currently not used.
Std1Output25 Output 25 This output to the Emhart controller 1 is currently not used.
Std1Output26 Output 26 This output to the Emhart controller 1 is currently not used.
Std1Output27 Output 27 This output to the Emhart controller 1 is currently not used.
Std1Output28 Output 28 This output to the Emhart controller 1 is currently not used.
Std1Output29 Output 29 This output to the Emhart controller 1 is currently not used.
Std1Output30 Output 30 This output to the Emhart controller 1 is currently not used.
Std1Output31 Output 31 This output to the Emhart controller 1 is currently not used.
Std1Output32 Output 32 This output to the Emhart controller 1 is currently not used.
Std1Output33 Output 33 This output to the Emhart controller 1 is currently not used.
Std1Output34 Output 34 This output to the Emhart controller 1 is currently not used.
Std1Output35 Output 35 This output to the Emhart controller 1 is currently not used.
Std1Output36 Output 36 This output to the Emhart controller 1 is currently not used.
Std1Output37 Output 37 This output to the Emhart controller 1 is currently not used.
Std1Output38 Output 38 This output to the Emhart controller 1 is currently not used.
Std1Output39 Output 39 This output to the Emhart controller 1 is currently not used.
Std1Output40 Output 40 This output to the Emhart controller 1 is currently not used.
Std1Output41 Output 41 This output to the Emhart controller 1 is currently not used.
Std1Output42 Output 42 This output to the Emhart controller 1 is currently not used.
Std1Output43 Output 43 This output to the Emhart controller 1 is currently not used.
Std1Output44 Output 44 This output to the Emhart controller 1 is currently not used.
Std1Output45 Output 45 This output to the Emhart controller 1 is currently not used.
Std1Output46 Output 46 This output to the Emhart controller 1 is currently not used.
Std1Output47 Output 47 This output to the Emhart controller 1 is currently not used.
Std1Output48 Output 48 This output to the Emhart controller 1 is currently not used.
Std1MovHd1ToWpos Output 49
Std1MovHd2ToWpos Output 50
Std1MovHd3ToWpos Output 51
Std1MovHd4ToWpos Output 52
Std1MovHd5ToWpos Output 53
Std1MovHd1ToPpos Output 54
Std1MovHd2ToPpos Output 55
Std1MovHd3ToPpos Output 56
Std1MovHd4ToPpos Output 57
Std1MovHd5ToPpos Output 58
Std1Output59 Output 59 This output to the Emhart controller 1 is currently not used.
Std1Output60 Output 60 This output to the Emhart controller 1 is currently not used.
Std1Output61 Output 61 This output to the Emhart controller 1 is currently not used.
Std1Output62 Output 62 This output to the Emhart controller 1 is currently not used.
Std1Output63 Output 63 This output to the Emhart controller 1 is currently not used.
Std1Output64 Output 64 This output to the Emhart controller 1 is currently not used.

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Printed copies are not source controlled
 A.B.B. ROBOT D-NET MAP DESCRIPTIONS (SEALER TO ROBOT
NORDSON SEALER I/O
I/O unit name
Nordson Process
Sentry I/O unit node address 25
Signal Signal Signal Signal
Name Type Loc. Description
Disp 1 System Ready Input 1 This input from the Nordson Controller indicates the system is ready to
dispense.
Disp 1 High Volume Fault Input 2 This input from the Nordson Controller indicates a High Volume Fault is
present
Disp 1 Low Volume Fault Input 3 This input from the Nordson Controller indicates a Low Volume Fault is
present
Disp 1 System Fault Input 4 This input from the Nordson controller indicates a System Fault is present
Disp 1 Input 5 Input 5 This input from the Nordson Controller is currently not used.
Disp 1 Input 6 Input 6 This input from the Nordson Controller is currently not used.
Disp 1 Input 7 Input 7 This input from the Nordson Controller is currently not used.
Disp 1 Input 8 Input 8 This input from the Nordson Controller is currently not used.
Disp 1 Input 9 Input 9 This input from the Nordson Controller is currently not used.
Disp 1 Input 10 Input 10 This input from the Nordson Controller is currently not used.
Disp 1 Input 11 Input 11 This input from the Nordson Controller is currently not used.
Disp 1 Input 12 Input 12 This input from the Nordson Controller is currently not used.
Disp 1 Input 13 Input 13 This input from the Nordson Controller is currently not used.
Disp 1 Spare Input 14 This input from the Nordson Controller is currently not used.
Disp 1 Spare Input 15 This input from the Nordson Controller is currently not used.
Disp 1 Dispense in Input 16 This input from the Nordson Controller indicates dispensing in process
Process
Disp 1 Temp Cond Ready Input 17 This input from the Nordson Controller indicates Temperature Conditioner
Ready
Disp 1 Input18 Input 18 This input from the Nordson Controller is currently not used.
Disp 1 Input19 Input 19 This input from the Nordson Controller is currently not used.
Disp 1 Input 20 Input 20 This input from the Nordson Controller is currently not used.
Disp 1 Input 21 Input 21 This input from the Nordson Controller is currently not used.
Disp 1 Input 22 Input 22 This input from the Nordson Controller is currently not used.
Disp 1 Input 23 Input 23 This input from the Nordson Controller is currently not used.
Disp 1 Input 24 Input 24 This input from the Nordson Controller is currently not used.
Disp 1 Input 25 Input 25 This input from the Nordson Controller is currently not used.
Disp 1 Input 26 Input 26 This input from the Nordson Controller is currently not used.
Disp 1 Input 27 Input 27 This input from the Nordson Controller is currently not used.
Disp 1 Input 28 Input 28 This input from the Nordson Controller is currently not used.
Disp 1 Input 29 Input 29 This input from the Nordson Controller is currently not used.
Disp 1 Input 30 Input 30 This input from the Nordson Controller is currently not used.
Disp 1 Input 31 Input 31 This input from the Nordson Controller is currently not used.
Disp 1 Input 32 Input 32 This input from the Nordson Controller is currently not used.

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Printed copies are not source controlled
 A.B.B. ROBOT D-NET MAP DESCRIPTIONS (ROBOT TO SEALER)
NORDSON SEALER I/O
I/O unit name
Nordson Process
Sentry I/O unit node address 25
Signal Signal Signal Signal
Name Type Loc. Description
Disp 1 Output Output 1 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 2 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 3 This output to the. Nordson controller 1 is currently not used
Disp 1 Style Bit 1 Output 4 This output is binary value 1 for dispense style selection to the Nordson controller
1.
Disp 1 Style Bit 2 Output 5 This output is binary value 2 for dispense style selection to the Nordson controller
1.
Disp 1 Style Bit 3 Output 6 This output is binary value 4 for dispense style selection to the Nordson controller
1..
Disp 1 Style Bit 4 Output 7 This output is binary value 8 for dispense style selection to the Nordson controller
1.
Disp 1 Style Bit 5 Output 8 This output is binary value 16 for dispense style selection to the Nordson
controller 1.
Disp 1 Style Bit 6 Output 9 This output is binary value 32 for dispense style selection to the Nordson
controller 1.
Disp 1 Style Bit 7 Output 10 This output is binary value 64 for dispense style selection to the Nordson
controller 1..
Disp 1 Style Bit 8 Output 11 This output is binary value 128 for dispense style selection to the Nordson
controller 1.
Disp 1 Style Bit 9 Output 12 This output is binary value 256 for dispense style selection to the Nordson
controller 1.
Disp 1 Style Bit 10 Output 13 This output is binary value 512 for dispense style selection to the Nordson
controller 1..
Disp 1 Style Bit 11 Output 14 This output is binary value 1024 for dispense style selection to the Nordson
controller 1.
Disp 1 Style Bit 12 Output 15 This output is binary value 2048 for dispense style selection to the Nordson
controller 1.
Disp 1 Output Output 16 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 17 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 18 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 19 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 20 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 21 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 22 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 23 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 24 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 25 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 26 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 27 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 28 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 29 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 30 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 31 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 32 This output to the. Nordson controller 1 is currently not used
Disp 1 Part ID Bit 0 Output 33 This output to the. Nordson controller 1 indicates the Part ID 0
Disp 1 Part ID Bit 1 Output 34 This output to the. Nordson controller 1 indicates the Part ID 1
Disp 1 Part ID Bit 2 Output 35 This output to the. Nordson controller 1 indicates the Part ID 2
Disp 1 Part ID Bit 3 Output 36 This output to the. Nordson controller 1 indicates the Part ID 3
Disp 1 Output Output 37 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 38 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 39 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 40 This output to the. Nordson controller 1 is currently not used
Disp 1 Dry Mode Output 41 This output to the. Nordson controller 1 indicates Dry Mode is Selected
Disp 1 Alarm Reset Output 42 This output to the. Nordson controller 1 indicates Alarm Reset is present
Disp 1 Gun On Output 43 This output to the. Nordson controller 1 indicates to turn on Gun 1
Disp 1 Part Strobe Output 44 This output to the. Nordson controller 1 indicates Part Strobe is active
Disp 1 Output Output 45 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 46 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 47 This output to the. Nordson controller 1 is currently not used
Disp 1 Output Output 48 This output to the. Nordson controller 1 is currently not used

AS OF 9/27/2006 28 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
Node address: 31
Module Name: MHBlock1
Type: Interlink BT FDNL-S1600-T-0203
Signal Name Type Logical Signal Description
Part3Present input 1 This input indicates that Part 3 is present.
Part4Present input 2 This input indicates that Part 4 is present.
Part5Present input 3 This input indicates that Part 5 is present.
Part6Present input 4 This input indicates that Part 6 is present.
CYL4Open input 5 This input indicates that Cylinder 4 is open.
CYL4Closed input 6 This input indicates that Cylinder 4 is Closed.
CYL5Open input 7 This input indicates that Cylinder 5 is open.
CYL5Closed input 8 This input indicates that Cylinder 5 is Closed.
CYL6Open input 9 This input indicates that Cylinder 6 is open.
CYL6Closed input 10 This input indicates that Cylinder 6 is Closed.
CYL7Open input 11 This input indicates that Cylinder 7 is open.
CYL7Closed input 12 This input indicates that Cylinder 7 is Closed.
CYL8Open input 13 This input indicates that Cylinder 8 is open.
CYL8Closed input 14 This input indicates that Cylinder 8 is Closed.
CYL9Open input 15 This input indicates that Cylinder 9 is open.
CYL9Closed input 16 This input indicates that Cylinder 9 is Closed.

Node address: 32
Module Name: MHBlock2
Type: Interlink BT FDNL-S1600-T-0203
Signal Name Type Logical Signal Description
Part7Present input 1 This input indicates that Part 7 is present.
Part8Present input 2 This input indicates that Part 8 is present.
Part9Present input 3 This input indicates that Part 9 is present.
Part10Present input 4 This input indicates that Part 10 is present.
CYL10Open input 5 This input indicates that Cylinder 10 is open.
CYL10Closed input 6 This input indicates that Cylinder 10 is Closed.
CYL11Open input 7 This input indicates that Cylinder 11 is open.
CYL11Closed input 8 This input indicates that Cylinder 11 is Closed.
CYL12Open input 9 This input indicates that Cylinder 12 is open.
CYL12Closed input 10 This input indicates that Cylinder 12 is Closed.
CYL13Open input 11 This input indicates that Cylinder 13 is open.
CYL13Closed input 12 This input indicates that Cylinder 13 is Closed.
CYL14Open input 13 This input indicates that Cylinder 14 is open.
CYL14Closed input 14 This input indicates that Cylinder 14 is Closed.
CYL15Open input 15 This input indicates that Cylinder 15 is open.
CYL15Closed input 16 This input indicates that Cylinder 15 is Closed.

AS OF 9/27/2006 29 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
Node address: 33
Module Name: MHBlock3
Type: Interlink BT FDNL-S1600-T-0203
Signal Name Type Logical Signal Description
CYL16Open input 1 This input indicates that Cylinder 16 is open.
CYL16Closed input 2 This input indicates that Cylinder 16 is Closed.
CYL17Open input 3 This input indicates that Cylinder 17 is open.
CYL17Closed input 4 This input indicates that Cylinder 17 is Closed.
CYL18Open input 5 This input indicates that Cylinder 18 is open.
CYL18Closed input 6 This input indicates that Cylinder 18 is Closed.
CYL19Open input 7 This input indicates that Cylinder 19 is open.
CYL19Closed input 8 This input indicates that Cylinder 19 is Closed.
CYL20Open input 9 This input indicates that Cylinder 20 is open.
CYL20Closed input 10 This input indicates that Cylinder 20 is Closed.
CYL21Open input 11 This input indicates that Cylinder 21 is open.
CYL21Closed input 12 This input indicates that Cylinder 21 is Closed.
CYL22Open input 13 This input indicates that Cylinder 22 is open.
CYL22Closed input 14 This input indicates that Cylinder 22 is Closed.
CYL23Open input 15 This input indicates that Cylinder 23 is open.
CYL23Closed input 16 This input indicates that Cylinder 23 is Closed.

Node address: 34
Module Name: MHBlock4
Type: Interlink BT FDNL-S1600-T-0203
Signal Name Type Logical Signal Description
CYL27Open input 1 This input indicates that Cylinder 27 is open.
CYL27Closed input 2 This input indicates that Cylinder 27 is Closed.
CYL28Open input 3 This input indicates that Cylinder 28 is open.
CYL28Closed input 4 This input indicates that Cylinder 28 is Closed.
CYL29Open input 5 This input indicates that Cylinder 29 is open.
CYL29Closed input 6 This input indicates that Cylinder 29 is Closed.
CYL30Open input 7 This input indicates that Cylinder 30 is open.
CYL30Closed input 8 This input indicates that Cylinder 30 is Closed.
CYL31Open input 9 This input indicates that Cylinder 31 is open.
CYL31Closed input 10 This input indicates that Cylinder 31 is Closed.
CYL32Open input 11 This input indicates that Cylinder 32 is open.
CYL32Closed input 12 This input indicates that Cylinder 32 is Closed.
CYL33Open input 13 This input indicates that Cylinder 33 is open.
CYL33Closed input 14 This input indicates that Cylinder 33 is Closed.
CYL34Open input 15 This input indicates that Cylinder 34 is open.
CYL34Closed input 16 This input indicates that Cylinder 34 is Closed.

AS OF 9/27/2006 30 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
Node address: 35
Module Name: MHBlock5
Type: Interlink BT FDNL-S1600-T-0203
Signal Name Type Logical Signal Description
Part1Present input 1 This input indicates that Part 1 is present.
Part2Present input 2 This input indicates that Part 2 is present.
CYL1Open input 3 This input indicates that Cylinder 1 is open.
CYL1Closed input 4 This input indicates that Cylinder 1 is Closed.
CYL2Open input 5 This input indicates that Cylinder 2 is open.
CYL2Closed input 6 This input indicates that Cylinder 2 is Closed.
CYL3Open input 7 This input indicates that Cylinder 3 is open.
CYL3Closed input 8 This input indicates that Cylinder 3 is Closed.
Part11Present input 1 This input indicates that Part 11 is present.
Part12Present input 2 This input indicates that Part 12 is present.
CYL24Open input 3 This input indicates that Cylinder 24 is open.
CYL24Closed input 4 This input indicates that Cylinder 24 is Closed.
CYL25Open input 5 This input indicates that Cylinder 25 is open.
CYL25Closed input 6 This input indicates that Cylinder 25 is Closed.
CYL26Open input 7 This input indicates that Cylinder 26 is open.
CYL26Closed input 8 This input indicates that Cylinder 26 is Closed.

NORGEN SMART PUMP

I/O unit name
NORGEN SMART I/O unit node address 37 SLSAP ONLY
PUMP
Signal Signal Signal Signal
Name Type Loc. Description
VacuumCH1PP Input 1 This input indicates that Vacuum is present on channel 1
VacuumCH2PP Input 2 This input indicates that Vacuum is present on channel 2
Input 3
Input 4
Input 5
Input 6
Input 7
Input 8
doVacCH1On output 9 This robot output will turn on vacuum on channel 1
doBlwOffCh1On output 10 This robot output will turn on blow off on channel 1
doVacCH2On output 11 This robot output will turn on vacuum on channel 2
doBlwOffCh2On output 12 This robot output will turn on blow off on channel 2
output 13
output 14
output 15
output 16

AS OF 9/27/2006 31 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 ISRA VISION I/O
I/O unit name
ISRA_IO I/O unit node address 38
Signal Signal Signal Signal
Name Type Loc. Description
diISRA_StatBit1 Input 1 This input indicates that the Status Bit 1 is high (Mirrors the Command Bits)
diISRA_StatBit2 Input 2 This input indicates that the Status Bit 2 is high (Mirrors the Command Bits)
diISRA_StatBit4 Input 3 This input indicates that the Status Bit 4 is high (Mirrors the Command Bits)
diISRA_StatBit8 Input 4 This input indicates that the Status Bit 8 is high (Mirrors the Command Bits)
diISRA_Ready Input 5 This input indicates that the ISRA Vision System is ready for type (Style).
diISRA_Meas_ip Input 6 Thiis input indicates that a measurement is in progress
diISRA_Data_ip Input 7 This input indicates that a data transfer is in progress
diISRA_ID_OK Input 8 This input indicates that the type (Style) is OK
diISRA_reservd Input 9 This input is reserved
diISRA_ErrPLC Input 10 This input indicate a general communication error with the PLC has occurred
diISRA_ErrRbt Input 11 This input indicates a communication error with the robot has occurred
diISRA_OutTol Input 12 This input indicates that the calculation is out of tolerance
diISRA_Disabl Input 13 This input indicates that a wrong type (Style) was selected
diISRA_ErrImage Input 14 This input indicates that a error occurred during image capture
diISRA_reservd1 Input 15 This input is reserved
diISRA_ErrDet Input 16 This input indicates that an error occurred during detection
diISRA_XB1 Input 17 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB2 Input 18 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB4 Input 19 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB8 Input 20 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB16 Input 21 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB32 Input 22 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB64 Input 23 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB128 Input 24 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB256 Input 25 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB512 Input 26 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB1024 Input 27 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB2048 Input 28 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB4096 Input 29 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB8192 Input 30 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB16384 Input 31 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_XB32768 Input 32 This group input (giISRA_Offs_X) indicates the X offset data
diISRA_YB1 Input 33 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB2 Input 34 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB4 Input 35 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB8 Input 36 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB16 Input 37 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB32 Input 38 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB64 Input 39 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB128 Input 40 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB256 Input 41 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB512 Input 42 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB1024 Input 43 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB2048 Input 44 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB4096 Input 45 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB8192 Input 46 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB16384 Input 47 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_YB32768 Input 48 This group input (giISRA_Offs_Y) indicates the Y offset data
diISRA_ZB1 Input 49 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB2 Input 50 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB4 Input 51 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB8 Input 52 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB16 Input 53 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB32 Input 54 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB64 Input 55 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB128 Input 56 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB256 Input 57 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB512 Input 58 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB1024 Input 59 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB2048 Input 60 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB4096 Input 61 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB8192 Input 62 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB16384 Input 63 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_ZB32768 Input 64 This group input (giISRA_Offs_Z) indicates the Z offset data
diISRA_RXB1 Input 65 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB2 Input 66 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB4 Input 67 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB8 Input 68 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB16 Input 69 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB32 Input 70 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB64 Input 71 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB128 Input 72 This group input (giISRA_Offs_RX) indicates the RX offset data

AS OF 9/27/2006 32 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 diISRA_RXB256 Input 73 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB512 Input 74 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB1024 Input 75 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB2048 Input 76 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB4096 Input 77 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB8192 Input 78 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB16384 Input 79 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RXB32768 Input 80 This group input (giISRA_Offs_RX) indicates the RX offset data
diISRA_RYB1 Input 81 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB2 Input 82 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB4 Input 83 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB8 Input 84 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB16 Input 85 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB32 Input 86 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB64 Input 87 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB128 Input 88 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB256 Input 89 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB512 Input 90 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB1024 Input 91 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB2048 Input 92 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB4096 Input 93 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB8192 Input 94 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB16384 Input 95 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RYB32768 Input 96 This group input (giISRA_Offs_RY) indicates the RY offset data
diISRA_RZB1 Input 97 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB2 Input 98 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB4 Input 99 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB8 Input 100 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB16 Input 101 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB32 Input 102 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB64 Input 103 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB128 Input 104 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB256 Input 105 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB512 Input 106 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB1024 Input 107 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB2048 Input 108 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB4096 Input 109 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB8192 Input 110 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB16384 Input 111 This group input (giISRA_Offs_RZ) indicates the RZ offset data
diISRA_RZB32768 Input 112 This group input (giISRA_Offs_RZ) indicates the RZ offset data
doISRA_CommandB1 Output 1 This group output (goISRA_Command) indicates the mode of the vision system
doISRA_CommandB2 Output 2 This group output (goISRA_Command) indicates the mode of the vision system
doISRA_CommandB4 Output 3 This group output (goISRA_Command) indicates the mode of the vision system
doISRA_CommandB8 Output 4 This group output (goISRA_Command) indicates the mode of the vision system
doISRA_Start_M Output 5 This output is used to Start Measurement
doISRA_reservd Output 6 This output is reserved
doISRA_Reset_E Output 7 This output is used to reset errors
doISRA_ID_Valid Output 8 This output indicate that the type (Style) ID/measurement is valid
doISRA_TpIDB1 Output 9 This group output (goISRA_ID) is used to identify the type ID (Style)
doISRA_TpIDB2 Output 10 This group output (goISRA_ID) is used to identify the type ID (Style)
doISRA_TpIDB4 Output 11 This group output (goISRA_ID) is used to identify the type ID (Style)
doISRA_TpIDB8 Output 12 This group output (goISRA_ID) is used to identify the type ID (Style)
doISRA_TpIDB16 Output 13 This group output (goISRA_ID) is used to identify the type ID (Style)
doISRA_TpIDB32 Output 14 This group output (goISRA_ID) is used to identify the type ID (Style)
doISRA_TpIDB64 Output 15 This group output (goISRA_ID) is used to identify the type ID (Style)
doISRA_TpIDB128 Output 16 This group output (goISRA_ID) is used to identify the type ID (Style)
doISRA_reservd Output 17 This output is reserved
doISRA_reservd Output 18 This output is reserved
doISRA_reservd Output 19 This output is reserved
doISRA_reservd Output 20 This output is reserved
doISRA_reservd Output 21 This output is reserved
doISRA_reservd Output 22 This output is reserved
doISRA_reservd Output 23 This output is reserved
doISRA_reservd Output 24 This output is reserved
doISRA_reservd Output 25 This output is reserved
doISRA_reservd Output 26 This output is reserved
doISRA_reservd Output 27 This output is reserved
doISRA_reservd Output 28 This output is reserved
doISRA_reservd Output 29 This output is reserved
doISRA_reservd Output 30 This output is reserved
doISRA_reservd Output 31 This output is reserved
doISRA_reservd Output 32 This output is reserved

AS OF 9/27/2006 33 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
Node address: 39
Module Name: MHBlock9
Type: Numatics 2012 Manifold Assembly
Signal Name Type Logical Signal Description
CloseValve1 output 1 This output closes valve 1.
OpenValve1 output 2 This output opens valve 1.
CloseValve2 output 3 This output closes valve 2.
OpenValve2 output 4 This output opens valve 2.
CloseValve3 output 5 This output closes valve 3.
OpenValve3 output 6 This output opens valve 3.
CloseValve4 output 7 This output closes valve 4.
OpenValve4 output 8 This output opens valve 4.
CloseValve5 output 9 This output closes valve 5.
OpenValve5 output 10 This output opens valve 5.
CloseValve6 output 11 This output closes valve 6.
OpenValve6 output 12 This output opens valve 6.
CloseValve7 output 13 This output closes valve 7.
OpenValve7 output 14 This output opens valve 7.
CloseValve8 output 15 This output closes valve 8.
OpenValve8 output 16 This output opens valve 8.
CloseValve9 output 17 This output closes valve 9.
OpenValve9 output 18 This output opens valve 9.
CloseValve10 output 19 This output closes valve 10.
OpenValve10 output 20 This output opens valve 10
CloseValve11 output 21 This output closes valve 11
OpenValve11 output 22 This output opens valve 11
CloseValve12 output 23 This output closes valve 12.
OpenValve12 output 24 This output opens valve 12.
CloseValve13 output 25 This output closes valve 13.
OpenValve13 output 26 This output opens valve 13.
CloseValve14 output 27 This output closes valve 14.
OpenValve14 output 28 This output opens valve 14.
CloseValve15 output 29 This output closes valve 15.
OpenValve15 output 30 This output opens valve 15.
CloseValve16 output 31 This output closes valve 16.
OpenValve16 output 32 This output opens valve 16.

AS OF 9/27/2006 34 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 A.B.B. ROBOT D-NET MAP DESCRIPTIONS (UTICA SERVO PIERCE UNIT A)
SERVO PIERCE I/O
I/O unit name
PIERCE I/O unit node address 45 - UNIT “DriveABlk1”
Signal Signal Signal Signal
Name Type Loc. Description
diDrvA_Ok Input 1
diDrvA_On Input 2
Input 3
diDrvAHomeComp Input 4
diDrvAForce_Lub Input 5
diDrvAReturned Input 6
diDrvAAtPos Input 7
Input 8
doDrvAReset output 9
output 10
doDrvAMode1Sel output 11
doDrvAMode2Sel output 12
doStyle_drvALub output 13
doDrvAAutomode output 14
output 15
output 16

SERVO PIERCE I/O

I/O unit name
PIERCE I/O unit node address 46 – UNIT “DriveABlk2”
Signal Signal Signal Signal
Name Type Loc. Description
diDrvAMode1Ackn Input 1
diDrvAMode2Ackn Input 2
Input 3
diSr400On Input 4
diSrFuseOk Input 5
Input 6
Input 7
Input 8
doDrvATorqEnble output 9
output 10
doDrvAExt_Pos1 output 11
doDrvAExt-Pos2 output 12
doDrvAPosSel output 13
output 14
output 15
output 16

AS OF 9/27/2006 35 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 A.B.B. ROBOT D-NET MAP DESCRIPTIONS (UTICA SERVO PIERCE UNIT B)
SERVO PIERCE I/O
I/O unit name
PIERCE I/O unit node address 47 - UNIT “DriveBBlk3”
Signal Signal Signal Signal
Name Type Loc. Description
diDrvB_Ok Input 1
DiDrvB_On Input 2
Input 3
diDrvBHomeComp Input 4
diDrvBForce_Lub Input 5
diDrvBReturned Input 6
diDrvBAtPos Input 7
Input 8
doDrvBReset output 9
output 10
doDrvBMode1Sel output 11
doDrvBMode2Sel output 12
doStyle_drvBLub output 13
doDrvBAutomode output 14
output 15
output 16

SERVO PIERCE I/O

I/O unit name
PIERCE I/O unit node address 48 – UNIT “DriveBBlk4”
Signal Signal Signal Signal
Name Type Loc. Description
diDrvBMode1Ackn Input 1
diDrvBMode2Ackn Input 2
Input 3
diSr400On Input 4
diSrFuseOk Input 5
Input 6
Input 7
Input 8
doDrvBTorqEnble output 9
output 10
doDrvBExt_Pos1 output 11
doDrvBExt-Pos2 output 12
doDrvBPosSel output 13
output 14
output 15
output 16

A.B.B. ROBOT D-NET MAP DESCRIPTIONS (ATI TOOL CHANGER)

ATI Tool Changer
I/O unit name
ToolChanger I/O unit node address 54
Signal Signal Signal Signal
Name Type Loc. Description
Tool Locked input 1 This robot input from the ATI tool changer indicates that the tool is
locked.
Tool Unlocked input 2 This robot input from the ATI tool changer indicates that the Tool is
unlocked.
DeviceNet Power OK input 3 This robot input from the ATI tool changer indicates that the Dnet
power is OK.
Tool Aux Power OK input 4 This robot input from the ATI tool changer indicates that the Aux
Power is OK.
Ready to Lock 1 input 5 This robot input from the ATI tool changer indicates that the changer is
ready to lock 1 is on.
AS OF 9/27/2006 36 08 RT DCX PREREL. 3.0
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 Ready to Lock 2 input 6 This robot input from the ATI tool changer indicates that the changer is
ready to lock 2 is on.
RTLV1 input 7 This robot input from the ATI tool changer indicates that the RTL1 is
verified.
RTLV2 input 8 This robot input from the ATI tool changer indicates that the RTL2 is
verified.
TSIV1 input 9 This robot input from the ATI tool changer indicates the state of TSI
switch 1.
TSIV2 input 10 This robot input from the ATI tool changer indicates the state of TSI
switch 2.
TSRV1 input 11 This robot input from the ATI tool changer indicates the state of the
TSI relay 1.
TSRV2 input 12 This robot input from the ATI tool changer indicates the state of the
TSI relay 2.
Tool Presence input 13 This robot input from the ATI tool changer tool present.
Spare input 14 This robot input from the ATI tool changer is spare.
Spare input 15 This robot input from the ATI tool changer is spare.
Spare input 16 This robot input from the ATI tool changer is spare.
RTL Mismatch input 17 This robot input from the ATI tool changer indicates there is a
mismatch between RTL1 and RTL2.
TSIV Mismatch input 18 This robot input from the ATI tool changer indicates there is a
mismatch between TSIV1 and TSIV2.
Error on Latch Output input 19 This robot input from the ATI tool changer indicates the latch output is
overloaded.
Error on Unlatch Output input 20 This robot input from the ATI tool changer indicates the unlatch output
is overloaded.
Error on Spare Output input 21 This robot input from the ATI tool changer indicates the spare output is
overloaded.
RTL/RTLV Mismatch input 22 This robot input from the ATI tool changer indicates the master PCB
has an error.
TSIV/TSRV Mismatch input 23 This robot input from the ATI tool changer indicates the tool PCB or
TSI switch has an error.
Unsafe Unlatch input 24 This robot input from the ATI tool changer indicates that the tool
changer has detected an unsafe unlatch condition and disabled the
unlatch.
Lock / Unlock Sensor Fault input 25 This robot input from the ATI tool changer indicates the tool changer
has detected lock and unlock sensors at the same time.
Latch Not Completed input 26 This robot input from the ATI tool changer indicates the latch process
did not complete.
Unlatch Not Complete input 27 This robot input from the ATI tool changer indicates the unlatch
process did not complete.
TSIV Fault input 28 This robot input from the ATI tool changer indicates TSIV Input is
stuck high.
RTL Fault input 29 . This robot input from the ATI tool changer indicates RTL Input is
stuck high
Comm Error input 30 This robot input from the ATI tool changer indicates Tool ID
Communication Timeout.
Reserved input 31 This robot input from the ATI tool changer indicates which tool ((ID)
switch 5 bit4) is coupled.
Reserved input 32 This robot input from the ATI tool changer indicates which tool ((ID)
switch 5 bit8) is coupled.
Tool ID Switch 1 Bit1 input 33 This robot input from the ATI tool changer indicates which tool ((ID)
switch 1 bit1) is coupled
Tool ID Switch 1 Bit2 input 34 This robot input from the ATI tool changer indicates which tool ((ID)
switch 1 bit2) is coupled
Tool ID Switch 1 Bit4 input 35 This robot input from the ATI tool changer indicates which tool ((ID)
switch 1 bit4) is coupled

Tool ID Switch 1 Bit8 input 36 This robot input from the ATI tool changer indicates which tool ((ID)
switch 1 bit8) is coupled
Tool ID Switch 2 Bit1 input 37 This robot input from the ATI tool changer indicates which tool ((ID)
switch 2 bit1) is coupled
Tool ID Switch 2 Bit2 input 38 This robot input from the ATI tool changer indicates which tool ((ID)
switch 2 bit2) is coupled
Tool ID Switch 2 Bit4 input 39 This robot input from the ATI tool changer indicates which tool ((ID)
switch 2 bit4) is coupled
Tool ID Switch 2 Bit8 input 40 This robot input from the ATI tool changer indicates which tool ((ID)
switch 2 bit8) is coupled
Tool ID Switch 3 Bit1 input 41 This robot input from the ATI tool changer indicates which tool ((ID)
switch 3 bit1) is coupled
Tool ID Switch 3 Bit2 input 42 This robot input from the ATI tool changer indicates which tool ((ID)
switch 3 bit2) is coupled
Tool ID Switch 3 Bit4 input 43 This robot input from the ATI tool changer indicates which tool ((ID)
switch 3 bit4) is coupled
Tool ID Switch 3 Bit8 input 44 This robot input from the ATI tool changer indicates which tool ((ID)
switch 3 bit8) is coupled
Tool ID Switch 4 Bit1 input 45 This robot input from the ATI tool changer indicates which tool ((ID)
AS OF 9/27/2006 37 08 RT DCX PREREL. 3.0
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 switch 4 bit1) is coupled
Tool ID Switch 4 Bit2 input 46 This robot input from the ATI tool changer indicates which tool ((ID)
switch 4 bit2) is coupled
Tool ID Switch 4 Bit4 input 47 This robot input from the ATI tool changer indicates which tool ((ID)
switch 4 bit4) is coupled
Tool ID Switch 4 Bit8 input 48 This robot input from the ATI tool changer indicates which tool ((ID)
switch 4 bit8) is coupled
Tool ID Switch 5 Bit1 input 49 This robot input from the ATI tool changer indicates which tool ((ID)
switch 5 bit1) is coupled
Tool ID Switch 5 Bit2 input 50 This robot input from the ATI tool changer indicates which tool ((ID)
switch 5 bit2) is coupled
Tool ID Switch 5 Bit4 input 51 This robot input from the ATI tool changer indicates which tool ((ID)
switch 5 bit4) is coupled
Tool ID Switch 5 Bit8 input 52 This robot input from the ATI tool changer indicates which tool ((ID)
switch 5 bit8) is coupled
Reserved input 53 This robot output to the ATI tool changer is not used.
Reserved input 54 This robot output to the ATI tool changer is not used.
Reserved input 55 This robot output to the ATI tool changer is not used.
Reserved input 56 This robot output to the ATI tool changer is not used.
Reserved input 57 This robot output to the ATI tool changer is not used.
Reserved input 58 This robot output to the ATI tool changer is not used.
Reserved input 59 This robot output to the ATI tool changer is not used.
Reserved input 60 This robot output to the ATI tool changer is not used.
Reserved input 61 This robot output to the ATI tool changer is not used.
Reserved input 62 This robot output to the ATI tool changer is not used.
Reserved input 63 This robot output to the ATI tool changer is not used.
Reserved input 64 This robot output to the ATI tool changer is not used.

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Printed copies are not source controlled
 ATI Tool Changer
I/O unit name
ToolChanger I/O unit node address 54
Signal Signal Signal Signal
Name Type Loc. Description
Latch or Lock Ouput 1 This robot output to the ATI tool changer will latch or lock tool
changer. Not used on DCX tool changers
Unlatch or Unlock Ouput 2 This robot output to the ATI tool changer will unlatch or unlock the tool
changer.
Spare Ouput 3 This robot output to the ATI tool changer is a spare.
Clear Errors Ouput 4 This robot output to the ATI tool changer will reset error bits.
Manual Mode Activated Ouput 5 This robot output to the ATI tool changer is for manual pendant
control.
Out of Nest Ouput 6 This robot output to the ATI tool changer indicates that the EOAT is
out of nest.

TOOL NEST AND CHANGER COVER I/O

I/O unit name
NEST T.C. COVER #1 I/O unit node address 55 SLSAP ONLY
Signal Signal Signal Signal
Name Type Loc. Description
Cover #1 Closed Input 1 This input to the robot indicates the cover over the tool changer #1 is closed
Cover #1 Open Input 2 This input to the robot indicates the cover over the tool changer #1 is open.
Tool in nest #1 switch 1 Input 3 This input to the robot indicates the tool is in the nest #1
Tool in nest #1 switch 2 Input 4 This input to the robot indicates the tool is in the nest #1.
Input 5
Input 6
Input 7
Input 8
Close Cover #1 output 9
Open Cover #1 output 10
output 11
output 12
output 13
output 14
output 15
output 16

TOOL NEST AND CHANGER COVER I/O

I/O unit name
NEST T.C. COVER #2 I/O unit node address 56 SLSAP ONLY
Signal Signal Signal Signal
Name Type Loc. Description
Cover #2 Closed Input 1 This input to the robot indicates the cover over the tool changer #2 is closed
Cover #2 Open Input 2 This input to the robot indicates the cover over the tool changer #2 is open.
Tool in nest #2 switch 1 Input 3 This input to the robot indicates the tool is in the nest #2.
Tool in nest #2 switch 2 Input 4 This input to the robot indicates the tool is in the nest #2.
Input 5
Input 6
Input 7
Input 8
Close Cover #2 output 9
Open Cover #2 output 10
output 11
output 12
output 13
output 14
output 15
output 16

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 TOOL NEST AND CHANGER COVER I/O
I/O unit name
NEST T.C. COVER #3 I/O unit node address 57 SLSAP ONLY
Signal Signal Signal Signal
Name Type Loc. Description
Cover #3 Closed Input 1 This input to the robot indicates the cover over the tool changer #3 is closed
Cover #3 Open Input 2 This input to the robot indicates the cover over the tool changer #3 is open.
Tool in nest #3 switch 1 Input 3 This input to the robot indicates the tool is in the nest #3
Tool in nest #3 switch 2 Input 4 This input to the robot indicates the tool is in the nest #3.
Input 5
Input 6
Input 7
Input 8
Close Cover #3 output 9
Open Cover #3 output 10
output 11
output 12
output 13
output 14
output 15
output 16

TOOL NEST AND CHANGER COVER I/O

I/O unit name
NEST T.C. COVER #4 I/O unit node address 58 SLSAP ONLY
Signal Signal Signal Signal
Name Type Loc. Description
Cover #4 Closed Input 1 This input to the robot indicates the cover over the tool changer #4 is closed
Cover #4 Open Input 2 This input to the robot indicates the cover over the tool changer #4 is open.
Tool in nest #4 switch 1 Input 3 This input to the robot indicates the tool is in the nest #4.
Tool in nest #4 switch 2 Input 4 This input to the robot indicates the tool is in the nest #4
Input 5
Input 6
Input 7
Input 8
Close Cover #4 output 9
Open Cover #4 output 10
output 11
output 12
output 13
output 14
output 15
output 16

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Printed copies are not source controlled
 ROBOT INPUTS XXXXXXX Xxxxx Node XX
SIGNAL NAME SIGNAL DESCRIPTION
ResrvdNodeXXd DI1 This robot input from the .
ResrvdNodeXXd DI2 This robot input from the .
ResrvdNodeXXd DI3 This robot input from the .
ResrvdNodeXXd DI4 This robot input from the .
ResrvdNodeXXd DI5 This robot input from the .
ResrvdNodeXXd DI6 This robot input from the .
ResrvdNodeXXd DI7 This robot input from the .
ResrvdNodeXXd DI8 This robot input from the .
ResrvdNodeXXd DI9 This robot input from the .
ResrvdNodeXXd DI10 This robot input from the .
ResrvdNodeXXd DI11 This robot input from the .
ResrvdNodeXXd DI12 This robot input from the .
ResrvdNodeXXd DI13 This robot input from the .
ResrvdNodeXXd DI14 This robot input from the .
ResrvdNodeXXd DI15 This robot input from the .
ResrvdNodeXXd DI16 This robot input from the .
ResrvdNodeXXd DI17 This robot input from the .
ResrvdNodeXXd DI18 This robot input from the .
ResrvdNodeXXd DI19 This robot input from the .
ResrvdNodeXXd DI20 This robot input from the .
ResrvdNodeXXd DI21 This robot input from the .
ResrvdNodeXXd DI22 This robot input from the .
ResrvdNodeXXd DI23 This robot input from the .
ResrvdNodeXXd DI24 This robot input from the .
ResrvdNodeXXd DI25 This robot input from the .
ResrvdNodeXXd DI26 This robot input from the .
ResrvdNodeXXd DI27 This robot input from the .
ResrvdNodeXXd DI28 This robot input from the .
ResrvdNodeXXd DI29 This robot input from the .
ResrvdNodeXXd DI30 This robot input from the .
ResrvdNodeXXd DI31 This robot input from the .
ResrvdNodeXXd DI32 This robot input from the .
ResrvdNodeXXd DI33 This robot input from the .
ResrvdNodeXXd DI34 This robot input from the .
ResrvdNodeXXd DI35 This robot input from the .
ResrvdNodeXXd DI36 This robot input from the .
ResrvdNodeXXd DI37 This robot input from the .
ResrvdNodeXXd DI38 This robot input from the .
ResrvdNodeXXd DI39 This robot input from the .
ResrvdNodeXXd DI40 This robot input from the .
ResrvdNodeXXd DI41 This robot input from the .
ResrvdNodeXXd DI42 This robot input from the .
ResrvdNodeXXd DI43 This robot input from the .
ResrvdNodeXXd DI44 This robot input from the .
ResrvdNodeXXd DI45 This robot input from the .
ResrvdNodeXXd DI46 This robot input from the .
ResrvdNodeXXd DI47 This robot input from the .
ResrvdNodeXXd DI48 This robot input from the .
ResrvdNodeXXd DI49 This robot input from the .
ResrvdNodeXXd DI50 This robot input from the .
ResrvdNodeXXd DI51 This robot input from the .
ResrvdNodeXXd DI52 This robot input from the .
ResrvdNodeXXd DI53 This robot input from the .
ResrvdNodeXXd DI54 This robot input from the .
ResrvdNodeXXd DI55 This robot input from the .
ResrvdNodeXXd DI56 This robot input from the .
ResrvdNodeXXd DI57 This robot input from the .
ResrvdNodeXXd DI58 This robot input from the .
ResrvdNodeXXd DI59 This robot input from the .
ResrvdNodeXXd DI60 This robot input from the .
ResrvdNodeXXd DI61 This robot input from the .
ResrvdNodeXXd DI62 This robot input from the .
ResrvdNodeXXd DI63 This robot input from the .
ResrvdNodeXXd DI64 This robot input from the .

AS OF 9/27/2006 41 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 ROBOT OUTPUTS XXXXXXX Xxxxx Node XX
SIGNAL NAME SIGNAL DESCRIPTION
ResrvdNodeXXd DO1 This robot output to the.
ResrvdNodeXXd DO2 This robot output to the.
ResrvdNodeXXd DO3 This robot output to the.
ResrvdNodeXXd DO4 This robot output to the.
ResrvdNodeXXd DO5 This robot output to the.
ResrvdNodeXXd DO6 This robot output to the.
ResrvdNodeXXd DO7 This robot output to the.
ResrvdNodeXXd DO8 This robot output to the.
ResrvdNodeXXd DO9 This robot output to the.
ResrvdNodeXXd DO10 This robot output to the.
ResrvdNodeXXd DO11 This robot output to the.
ResrvdNodeXXd DO12 This robot output to the.
ResrvdNodeXXd DO13 This robot output to the.
ResrvdNodeXXd DO14 This robot output to the.
ResrvdNodeXXd DO15 This robot output to the.
ResrvdNodeXXd DO16 This robot output to the.
ResrvdNodeXXd DO17 This robot output to the.
ResrvdNodeXXd DO18 This robot output to the.
ResrvdNodeXXd DO19 This robot output to the.
ResrvdNodeXXd DO20 This robot output to the.
ResrvdNodeXXd DO21 This robot output to the.
ResrvdNodeXXd DO22 This robot output to the.
ResrvdNodeXXd DO23 This robot output to the.
ResrvdNodeXXd DO24 This robot output to the.
ResrvdNodeXXd DO25 This robot output to the.
ResrvdNodeXXd DO26 This robot output to the.
ResrvdNodeXXd DO27 This robot output to the.
ResrvdNodeXXd DO28 This robot output to the.
ResrvdNodeXXd DO29 This robot output to the.
ResrvdNodeXXd DO30 This robot output to the.
ResrvdNodeXXd DO31 This robot output to the.
ResrvdNodeXXd DO32 This robot output to the.
ResrvdNodeXXd DO33 This robot output to the.
ResrvdNodeXXd DO34 This robot output to the.
ResrvdNodeXXd DO35 This robot output to the.
ResrvdNodeXXd DO36 This robot output to the.
ResrvdNodeXXd DO37 This robot output to the.
ResrvdNodeXXd DO38 This robot output to the.
ResrvdNodeXXd DO39 This robot output to the.
ResrvdNodeXXd DO40 This robot output to the.
ResrvdNodeXXd DO41 This robot output to the.
ResrvdNodeXXd DO42 This robot output to the.
ResrvdNodeXXd DO43 This robot output to the.
ResrvdNodeXXd DO44 This robot output to the.
ResrvdNodeXXd DO45 This robot output to the.
ResrvdNodeXXd DO46 This robot output to the.
ResrvdNodeXXd DO47 This robot output to the.
ResrvdNodeXXd DO48 This robot output to the.
ResrvdNodeXXd DO49 This robot output to the.
ResrvdNodeXXd DO50 This robot output to the.
ResrvdNodeXXd DO51 This robot output to the.
ResrvdNodeXXd DO52 This robot output to the.
ResrvdNodeXXd DO53 This robot output to the.
ResrvdNodeXXd DO54 This robot output to the.
ResrvdNodeXXd DO55 This robot output to the.
ResrvdNodeXXd DO56 This robot output to the.
ResrvdNodeXXd DO57 This robot output to the.
ResrvdNodeXXd DO58 This robot output to the.
ResrvdNodeXXd DO59 This robot output to the.
ResrvdNodeXXd DO60 This robot output to the.
ResrvdNodeXXd DO61 This robot output to the.
ResrvdNodeXXd DO62 This robot output to the.
ResrvdNodeXXd DO63 This robot output to the.
ResrvdNodeXXd DO64 This robot output to the.

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Printed copies are not source controlled
 ROBOT INPUTS XXXXXXX Xxxxx Node XX
SIGNAL NAME SIGNAL DESCRIPTION
ResrvdNodeXXd DI1 This robot input from the .
ResrvdNodeXXd DI2 This robot input from the .
ResrvdNodeXXd DI3 This robot input from the .
ResrvdNodeXXd DI4 This robot input from the .
ResrvdNodeXXd DI5 This robot input from the .
ResrvdNodeXXd DI6 This robot input from the .
ResrvdNodeXXd DI7 This robot input from the .
ResrvdNodeXXd DI8 This robot input from the .
ResrvdNodeXXd DI9 This robot input from the .
ResrvdNodeXXd DI10 This robot input from the .
ResrvdNodeXXd DI11 This robot input from the .
ResrvdNodeXXd DI12 This robot input from the .
ResrvdNodeXXd DI13 This robot input from the .
ResrvdNodeXXd DI14 This robot input from the .
ResrvdNodeXXd DI15 This robot input from the .
ResrvdNodeXXd DI16 This robot input from the .
ResrvdNodeXXd DI17 This robot input from the .
ResrvdNodeXXd DI18 This robot input from the .
ResrvdNodeXXd DI19 This robot input from the .
ResrvdNodeXXd DI20 This robot input from the .
ResrvdNodeXXd DI21 This robot input from the .
ResrvdNodeXXd DI22 This robot input from the .
ResrvdNodeXXd DI23 This robot input from the .
ResrvdNodeXXd DI24 This robot input from the .
ResrvdNodeXXd DI25 This robot input from the .
ResrvdNodeXXd DI26 This robot input from the .
ResrvdNodeXXd DI27 This robot input from the .
ResrvdNodeXXd DI28 This robot input from the .
ResrvdNodeXXd DI29 This robot input from the .
ResrvdNodeXXd DI30 This robot input from the .
ResrvdNodeXXd DI31 This robot input from the .
ResrvdNodeXXd DI32 This robot input from the .
ResrvdNodeXXd DI33 This robot input from the .
ResrvdNodeXXd DI34 This robot input from the .
ResrvdNodeXXd DI35 This robot input from the .
ResrvdNodeXXd DI36 This robot input from the .
ResrvdNodeXXd DI37 This robot input from the .
ResrvdNodeXXd DI38 This robot input from the .
ResrvdNodeXXd DI39 This robot input from the .
ResrvdNodeXXd DI40 This robot input from the .
ResrvdNodeXXd DI41 This robot input from the .
ResrvdNodeXXd DI42 This robot input from the .
ResrvdNodeXXd DI43 This robot input from the .
ResrvdNodeXXd DI44 This robot input from the .
ResrvdNodeXXd DI45 This robot input from the .
ResrvdNodeXXd DI46 This robot input from the .
ResrvdNodeXXd DI47 This robot input from the .
ResrvdNodeXXd DI48 This robot input from the .
ResrvdNodeXXd DI49 This robot input from the .
ResrvdNodeXXd DI50 This robot input from the .
ResrvdNodeXXd DI51 This robot input from the .
ResrvdNodeXXd DI52 This robot input from the .
ResrvdNodeXXd DI53 This robot input from the .
ResrvdNodeXXd DI54 This robot input from the .
ResrvdNodeXXd DI55 This robot input from the .
ResrvdNodeXXd DI56 This robot input from the .
ResrvdNodeXXd DI57 This robot input from the .
ResrvdNodeXXd DI58 This robot input from the .
ResrvdNodeXXd DI59 This robot input from the .
ResrvdNodeXXd DI60 This robot input from the .
ResrvdNodeXXd DI61 This robot input from the .
ResrvdNodeXXd DI62 This robot input from the .
ResrvdNodeXXd DI63 This robot input from the .
ResrvdNodeXXd DI64 This robot input from the .

AS OF 9/27/2006 43 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 ROBOT OUTPUTS XXXXXXX Xxxxx Node XX
SIGNAL NAME SIGNAL DESCRIPTION
ResrvdNodeXXd DO1 This robot output to the.
ResrvdNodeXXd DO2 This robot output to the.
ResrvdNodeXXd DO3 This robot output to the.
ResrvdNodeXXd DO4 This robot output to the.
ResrvdNodeXXd DO5 This robot output to the.
ResrvdNodeXXd DO6 This robot output to the.
ResrvdNodeXXd DO7 This robot output to the.
ResrvdNodeXXd DO8 This robot output to the.
ResrvdNodeXXd DO9 This robot output to the.
ResrvdNodeXXd DO10 This robot output to the.
ResrvdNodeXXd DO11 This robot output to the.
ResrvdNodeXXd DO12 This robot output to the.
ResrvdNodeXXd DO13 This robot output to the.
ResrvdNodeXXd DO14 This robot output to the.
ResrvdNodeXXd DO15 This robot output to the.
ResrvdNodeXXd DO16 This robot output to the.
ResrvdNodeXXd DO17 This robot output to the.
ResrvdNodeXXd DO18 This robot output to the.
ResrvdNodeXXd DO19 This robot output to the.
ResrvdNodeXXd DO20 This robot output to the.
ResrvdNodeXXd DO21 This robot output to the.
ResrvdNodeXXd DO22 This robot output to the.
ResrvdNodeXXd DO23 This robot output to the.
ResrvdNodeXXd DO24 This robot output to the.
ResrvdNodeXXd DO25 This robot output to the.
ResrvdNodeXXd DO26 This robot output to the.
ResrvdNodeXXd DO27 This robot output to the.
ResrvdNodeXXd DO28 This robot output to the.
ResrvdNodeXXd DO29 This robot output to the.
ResrvdNodeXXd DO30 This robot output to the.
ResrvdNodeXXd DO31 This robot output to the.
ResrvdNodeXXd DO32 This robot output to the.
ResrvdNodeXXd DO33 This robot output to the.
ResrvdNodeXXd DO34 This robot output to the.
ResrvdNodeXXd DO35 This robot output to the.
ResrvdNodeXXd DO36 This robot output to the.
ResrvdNodeXXd DO37 This robot output to the.
ResrvdNodeXXd DO38 This robot output to the.
ResrvdNodeXXd DO39 This robot output to the.
ResrvdNodeXXd DO40 This robot output to the.
ResrvdNodeXXd DO41 This robot output to the.
ResrvdNodeXXd DO42 This robot output to the.
ResrvdNodeXXd DO43 This robot output to the.
ResrvdNodeXXd DO44 This robot output to the.
ResrvdNodeXXd DO45 This robot output to the.
ResrvdNodeXXd DO46 This robot output to the.
ResrvdNodeXXd DO47 This robot output to the.
ResrvdNodeXXd DO48 This robot output to the.
ResrvdNodeXXd DO49 This robot output to the.
ResrvdNodeXXd DO50 This robot output to the.
ResrvdNodeXXd DO51 This robot output to the.
ResrvdNodeXXd DO52 This robot output to the.
ResrvdNodeXXd DO53 This robot output to the.
ResrvdNodeXXd DO54 This robot output to the.
ResrvdNodeXXd DO55 This robot output to the.
ResrvdNodeXXd DO56 This robot output to the.
ResrvdNodeXXd DO57 This robot output to the.
ResrvdNodeXXd DO58 This robot output to the.
ResrvdNodeXXd DO59 This robot output to the.
ResrvdNodeXXd DO60 This robot output to the.
ResrvdNodeXXd DO61 This robot output to the.
ResrvdNodeXXd DO62 This robot output to the.
ResrvdNodeXXd DO63 This robot output to the.
ResrvdNodeXXd DO64 This robot output to the.

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Printed copies are not source controlled
 APPLICATION ERRORS
(A.B.B. ROBOT)
THE FOLLOWING APPLICATION ERRORS ARE USED WITH MATERIAL HANDELING SYSTEMS ONLY

BIT WEIGHT DESCRIPTION

01 Disable fault and continue is active on robot XX
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

AS OF 9/27/2006 45 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 THE FOLLOWING 42 APPLICATION ERRORS ARE USED WITH SPOT WELD ONLY
BIT WEIGHT DESCRIPTION SOURCE SOURCE FAULT MESSAGE
33 Input / Output Error AC/MFDC Invalid Sequence Selected: (Fault)
AC/MFDC I/O Adapter Failure: (Fault)
AC/MFDC Weld Proceed: (Fault)
MFDC Charge / Discharge Duty Cycle: (Fault)
34 Input / Output Alarm AC/MFDC Weld Initiate not present: (Alert)
35 Incomplete Weld AC/MFDC Control Stop: (Fault)
AC/MFDC Weld Interruption: (Fault)
36 Stepper Approaching Maximum AC/MFDC Stepper Approaching Maximum: (Alert)
37 End of Stepper AC/MFDC End of Stepper: (Fault)
38 Reserved
39 High / Low Current Limit AC/MFDC High Current Limit Fault: (Fault)
AC/MFDC Low Current Limit Fault: (Fault)
40 Firing Error MFDC Control Failed to Fire : (Alert)
41-43 Reserved
44 Compensation Error MFDC Low Power Line : (Alert)
MFDC Soft Over Current : (Alert)
MFDC Current Regulation : (Alert)
45 Reserved
46 Extend Weld AC/MFDC Extend Weld: (Alert)
47 Isolation Contactor Error MFDC Inverter ISO CNTR Off : (Fault)
48 Welding Buss Voltage AC/MFDC No Zero Crossing Synchronization: (Fault)
MFDC DC Bus Over Voltage : (Fault)
MFDC Inverter Bus : (Fault)
49 Weld Data Not Programmed MFDC Weld Data Not Programmed : (Fault)
50 Analog Pressure Error AC/MFDC Pressure Not Achieved: (Fault)
AC/MFDC Pressure Current Loop Alarm: (Fault)
51 C-Factor Limit AC/MFDC High C-Factor Limit: (Alert)
AC/MFDC Low C-Factor Limit: (Alert)
52 Secondary Current MFDC Sec Current Sensor : (Fault)
53 Welding Transformer MFDC Welding Transformer : (Fault)
MFDC Output Ground : (Fault)
MFDC Transformer Duty Cycle : (Fault)
MFDC Tfmr Sec Diode Failure : (Fault)
54 Over Temperature MFDC Inverter Over Temp: (Fault)
55 Reserved
56 Internal Timer Error AC/MFDC Ram Checksum: (Fault)
AC/MFDC Rom Checksum: (Fault)
AC/MFDC Hardware/Software Incompatibility: (Fault)
MFDC Inverter Serial Comm: (Fault)
57 Inverter Fault MFDC Capacitor Discharge : (Fault)
MFDC Capacitor Charge : (Fault)
MFDC Hard Over current: (Fault)
MFDC Driver Low Voltage : (Fault)
58 Medar Not Ready AC/MFDC
59 Servo Gun Tip Consumption Alarm AC/MFDC
60 Reserved
61 Reserved
62 Reserved
63 Reserved
64 Water Not Flowing
65 Unexpected Water Flow
66 Tip Dress Request Not Reset
67 Burn In Request Not Reset
68 Reserved
69 Reserved
70 Reserved
71 Reserved
72 Reserved
73 Transformer over temperature
74 Air OK not received
75 Servo Gun Fault
Note: AC= Standard A.C. Welder, MFDC= Mid Frequency D.C. Welder, ( ) = Default Settings

AS OF 9/27/2006 46 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 THE FOLLOWING APPLICATION ERRORS ARE USED WITH ATI TOOL CHANGERS SYSTEMS ONLY

80 Insta Bus Module Failed

81 Tool changer Communication Error
82 Tool aux. power not present
83 Tool latch not open
84 Tool latch not closed
85 Tool latch solenoid not energized
86 Tool Unlatch solenoid not energized
87 Tool RTL not active
88 Tool RTLV not active
89 Tool not present
90 Unexpected tool present
91 Tool stand interlock not active
92 Nest not empty
93 Nest is empty
94 Cover not open
95 Cover not closed
96 Expected tool id not active
97 Expected robot id not active
98 Expected line id not active
99 TSIV not on

THE FOLLOWING APPLICATION ERRORS ARE USED WITH EMHART STUD WELD SYSTEMS ONLY

100 Stud Out of Tolerance

101 Stud Low in Hopper
102 Stud Welder Maintenance Required
103 Stud Welder Head Faulted
104 Stud Welder Not Ready for Auto.
105 Stud Welder Not Ready to Weld
106 Head Back signal not received
107 Weld Complete not received
108 Invalid head number programmed
109 Stud on work not received

THE FOLLOWING APPLICATION ERRORS ARE USED WITH NORDSON DISPENSE SYSTEMS ONLY

120 Remote Start is Not On

121 Dispenser Ready is Not On
122 Dispenser in Auto is Not On
123 Dispenser in Manual Is On
124 Dispenser is Not Pressurized
125 Air is Not Present at BAS pump
126 Air is Not Present at Catalyst pump
127 Dispense Volume OK is Off
128 Major Fault is On Dispenser
129 Invalid Dispenser Active
130 Dispense in Process Is Off

AS OF 9/27/2006 47 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
THE FOLLOWING APPLICATION ERRORS ARE USED WITH XX

131
132
133
134
135
136
137
138
139
140
141
142

THE FOLLOWING APPLICATION ERROR IS USED WITH ISRA VISION SYSTEMS ONLY
150 General Vision Error
151 Measurement Error
152 Type Prepare Error
153 Tolerance Error
154 Camera Reduced Features Warning
155 Laser sensor fault
156 Search Failure
157 Range Sensor 1 Fault
158 Range Sensor 2 Fault
159

THE FOLLOWING APPLICATION ERROR IS USED WITH PIERCE SYSTEMS ONLY

160 Dynalog Major fault

161 Dynalog Minor fault
162 Work Support Pressure Fault
163 Moog Mode fault
164 Moog Drive A OK fault
165 Moog Drive B OK fault
166 Moog Drive A ON fault
167 Moog Drive B ON fault
168 Moog Drive A Position fault
169 Moog Drive B Position fault
170 Moog Drive A Force fault
171 Moog Drive B Force fault
172 Perceptron Communication Fault
173 Perceptron Status Fault
174 Perceptron Bad Measurment
175

AS OF 9/27/2006 48 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 THE FOLLOWING APPLICATION ERRORS ARE USED WITH XXXXXXX ARC WELD SYSTEMS ONLY

XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX

THE FOLLOWING APPLICATION ERROR IS USED WITH PERCEPTRON CMM SYSTEMS ONLY

XX Minor Error During Quick Check

XX Moderate Error During Quick Check
XX Major Error During Quick Check
XX Spare
XX Calibration Error (Initialization or Recovery)
XX Correction (Filter) Error
XX Spare
XX Preventive Error
XX
XX
XX
XX
XX
XX
XX
XX

THE FOLLOWING APPLICATION ERROR IS USED WITH DYNALOG SYSTEMS ONLY

XX Minor Error During Quick Check

XX Moderate Error During Quick Check
XX Major Error During Quick Check
XX Spare
XX Calibration Error (Initialization or Recovery)
XX Correction (Filter) Error
XX Spare
XX Preventive Error
XX
XX
XX
XX
XX
XX
XX
XX

AS OF 9/27/2006 49 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 THE FOLLOWING APPLICATION ERRORS ARE USED WITH MATERIAL HANDELING SYSTEMS ONLY

176 Part Present 1 Fault

177 Part Present 2 Fault
178 Part Present 3 Fault
179 Part Present 4 Fault
180 Part Present 5 Fault
181 Part Present 6 Fault
182 Part Present 7 Fault
183 Part Present 8 Fault
184 Part Present 9 Fault
185 Part Present 10 Fault
186 Part Present 11 Fault
187 Part Present 12 Fault
188 MH Device 1 Retract Fault
189 MH Device 2 Retract Fault
190 MH Device 3 Retract Fault
191 MH Device 4 Retract Fault
192 MH Device 5 Retract Fault
193 MH Device 6 Retract Fault
194 MH Device 7 Retract Fault
195 MH Device 8 Retract Fault
196 MH Device 9 Retract Fault
197 MH Device 10 Retract Fault
198 MH Device 11 Retract Fault
199 MH Device 12 Retract Fault
200 MH Device 13 Retract Fault
201 MH Device 14 Retract Fault
202 MH Device 15 Retract Fault
203 MH Device 16 Retract Fault
204 MH Device 17 Retract Fault
205 MH Device 18 Retract Fault
206 MH Device 19 Retract Fault
207 MH Device 20 Retract Fault
208 MH Device 21 Retract Fault
209 MH Device 22 Retract Fault
210 MH Device 23 Retract Fault
211 MH Device 24 Retract Fault
212 MH Device 25 Retract Fault
213 MH Device 26 Retract Fault
214 MH Device 27 Retract Fault
215 MH Device 28 Retract Fault
216 MH Device 29 Retract Fault
217 MH Device 30 Retract Fault
218 MH Device 31 Retract Fault
219 MH Device 32 Retract Fault
220 MH Device 33 Retract Fault
221 MH Device 34 Retract Fault
222 MH Device 1 Extend Fault
223 MH Device 2 Extend Fault
224 MH Device 3 Extend Fault
225 MH Device 4 Extend Fault
226 MH Device 5 Extend Fault
227 MH Device 6 Extend Fault
228 MH Device 7 Extend Fault
229 MH Device 8 Extend Fault
230 MH Device 9 Extend Fault
231 MH Device 10 Extend Fault
232 MH Device 11 Extend Fault
233 MH Device 12 Extend Fault
234 MH Device 13 Extend Fault
235 MH Device 14 Extend Fault
236 MH Device 15 Extend Fault
237 MH Device 16 Extend Fault
238 MH Device 17 Extend Fault
239 MH Device 18 Extend Fault
AS OF 9/27/2006 50 08 RT DCX PREREL. 3.0
Printed copies are not source controlled
 240 MH Device 19 Extend Fault
241 MH Device 20 Extend Fault
242 MH Device 21 Extend Fault
243 MH Device 22 Extend Fault
244 MH Device 23 Extend Fault
245 MH Device 24 Extend Fault
246 MH Device 25 Extend Fault
247 MH Device 26 Extend Fault
248 MH Device 27 Extend Fault
249 MH Device 28 Extend Fault
250 MH Device 29 Extend Fault
251 MH Device 30 Extend Fault
252 MH Device 31Extend Fault
253 MH Device 32 Extend Fault
254 MH Device 33 Extend Fault
255 MH Device 34 Extend Fault

AS OF 9/27/2006 51 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 STANDARD ROBOT LOGIC
Logic Shown In Control Logix Format
ROBOT READY RUNG INDICATES ALL THE CONDITIONS REQUIRED FROM THE ROBOT FOR AUTO
| S01 R01 S01 R01 S01 R01 S01 R01 S01 R01 |
| S01 R01 SO1 R01 PATH S01 R01 MOTION I/O WELD ROBOT |
| ROBOT ROBOT RESTART E-STOP SUPERVISOR BLOCKED MODE READY |
| IN AUTO FAULTED ERROR ACTIVE ERROR IN AUTO ACTIVE SETUP |
|I10N01.B01 I10N01.B03 I10N01.B08 I10N01.B10 I10N10.B11 I10N01.B12 I10N01.B86 R01.ReadySU |
0+-+---] [------]/[------]/[------]/[------]/[-------]/[-------] [-------( )------|
| |S01 R01 S01 R01 |
| |ROBOT ROBOT S01 R01 |
| |RDY SETUP READY READY |
| |R01.ReadySU I10N01.B02 R01.Ready |
| +---] [------] [------------------------------------------------------( )------|
|
|THE ROBOT CLEAR ALL FAULTS RUNG WILL RESET ROBOT FAULTS |
| ST01 R01 ST01R01 MASTER SYSTEM ST01 R01 |
| ROBOT ROBOT FAULT FAST CLEAR ALL |
| IN AUTO FAULTED RESET FLASHER FAULTS |
| D-NET D-NET PB D-NET |
| I10N01.b00 I10N01.b02 Sys.FltReset Sys.Flasher3 O10N01.b02 |
1+------] [---+----] [---------------+-----------+---] [-------] [--------( )-----+
| |FROM SPLC | | |
| |S01 R01 S01 R01 | | S01 R01 |
| |ESTOP ESTOP | | FAULT RESET|
| |ENABLE ACTIVE | | REQUIRED |
| |FrmSfty.RES. 0 I10N01.B10 | | 01.FltResetReqd |
| +---] [--------] [-----+ +-------------------------( )----+
| |
|THE START ROBOT RUNG WILL TURN ON SERVO POWER AND START THE |
|ROBOT SCANNING FOR A STYLE. IT WILL ALSO RESTART THE ROBOT AFTER A HOLD |
|CONDITION. NO CONTROL POWER ON LOGIC IS REQUIRED |
| |
|SYSTEM FROM SPLC SYSTEM ST01 R01 ST01 R01 ST01 R01 S01 R01 S01 R01 ST01 R01 |
|AUTOMATIC S01R01 AUTOMATIC ROBOT ROBOT ROBOT STOP RUN START |
|MODE GENERAL CONSOLE FAULTED CYCLE ON READY ROBOT CHAIN OK ROBOT |
|INTERNAL STOP ENBLD PB D-NET D-NET D-NET D-NET D-NET D-NET |
|S01.Auto FrmSftyGenstpRbt.0 I0010.1 I10N01.b02 I10N01.b13 I10N01.b01 O10N01.b01 I10N01.b09 O10N01.b01|
2+--] [------] [------] [-----]/[------]/[-------] [-------]/[----] [------( )----+
| |
|THE ROBOT ENABLED RUNG IS TRUE WHEN ALL CONDITIONS ARE SATISFIED FOR REMOTE |
|OPERATION OF THE ROBOT. THIS SIGNAL MUST BE TRUE TO ALLOW GOTO POUNCE, GOTO |
|WORK, RETURN FROM POUNCE AND SERVICE REQUEST SIGNALS TO THE ROBOT |
| |
|ST01 R01 ST01 R01 ST01 R01 ST01 R01 S01 R01 |
|ROBOT ROBOT RUN ROBOT ROBOT IN BYPASS ST01 R01 |
|READY CHAIN OK FAULTED CYCLE ON MODE ENABLED |
|D-NET D-NET D-NET D-NET INTERNAL |
|I10N01.b01 I10N01.b08 I10N01.b02 I10N01.b13 R01.InBypass R01.Enabled |
3+--] [--------] [---------]/[--------] [--------]/[----------------------( )-----+

AS OF 9/27/2006 52 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 |STYLE BIT INFORMATION IS SENT TO THE ROBOT USING A BLOCK TRANSFER WHICH MOVES |
|THE 6 BIT PATTERN FROM STORAGE LOCATION N7 TO OUTPUT WORD O21. THE SECOND BLOCK |
|WORD READS THE 7 BIT ACTIVE STYLE FROM THE ROBOT |
| +-----BTD----------------+ |
4+--------------------------------------------------++ Bit Field Distributor-+-+-+
| ||Source: 7(0)| | |
| THIS BTD LOADS || 0| | |
| STYLE BITS TO ||Source Bit: 0| | |
| THE OUTPUT WORD ||Dest Local:3:0.data(1)| | |
| || 0| | |
| ||Dest Bit 0| | |
| || Length: 8| | |
| |+------------------------+ | |
| |+----BTD-----------------+ | |
| ++--Bit Field Distributor +-+ |
| |Source Local:3:1.Data(1)| |
| THIS BTD LOADS | 0| |
| THE ACTIVE STYLE |Source Bit: 0| |
| INPUTS TO A |Dest: N7(1)| |
| REGISTER | 0| |
| |Dest Bit: 0| |
| |Length: 8| |
| +------------------------+ |
|THE ROBOT RECEIVES STYLE IN A BINARY FORMAT. THE ROBOT DOES NOT REACT TO THESE |
|STYLE BITS UNTIL IT RECEIVES THE READ STYLE/GOTO POUNCE SIGNAL. THE STYLE |
|SHOULD BE UPDATED DURING MACHINE TRANSFER OR OTHER MACHINE CYCLE INITIATION |
|PROCESS AND CAN BE MAINTAINED UNTIL NEXT TRANSFER. THE SYSTEM GOTO POUNCE |
|SIGNAL MUST BE LOW BEFORE SENDING RETURN FROM POUNCE. |
| |
|SYSTEM S01 R01 |
|GOTO S01 R01 SYSTEM CYC COMP GO TO |
|POUNCE ENABLED AUTOMATIC MEMORY POUNCE |
|INTERNAL MODE INTERNAL INTERNAL |
|S01.RbtsGotopnce R01.Enabled S01.Auto R01.CycCompMem R01.GotPounce |
5+--] [---------] [------] [-----]/[---------------------------------------( )----+
| |
|S01 R01 S01 RN01 S01 RN01 S01 S01 S01 R01 S01 R01 S01 R01 |
|GO TO ENABLED ROBOT AT NO NO CYC COMP STEPPER GO TO |
|POUNCE ENABLED POUNCE PART PARTS MEMORY APCH MAX POUNCE |
|INTERNAL D-NET STYLE PRESENT INTERNAL APP ERR SEAL |
|R01.GotoPounce R01.Enabled I10N01.B17 S01.StyleNone S01.PartsPresNo R01.CycCompMem R01.GotoPounceSeal |
6+--] [-------+-- [------]/[-----]/[-----]/]----------]/[------]/[---------( )----+
|ST01 R01 | |
| GO TO | |
|POUNCE | |
| SEAL | |
|R01.GotoPncSl| |
+--] [-------+ |
| |
|S01 R01 S01 R01 S01 R01 |
|GO TO ROBOT ACTIVE S01 R01 S01 R01 |
|POUNCE CYCLE ON STYLE AT WORK READ |
|SEAL D-NET STYLE |
|R01.GotoPounceSeal I10N01.B14 R01.ActiveStyle R01.AtWork O10N01.B11 |
7+---] [-------------] [---------------------+------]/[---------]/[------( )------+
| | S01 R01 S01 R01 |
| | ACTIVE INIATE |
| | STYLE CYCLE |
| | R01.ActiveStyle O10N01.B12 |
| +------] [------------------( )------+
| |
| |

AS OF 9/27/2006 53 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 |THE ACTIVE STYLE RUNG INDICATES THAT THE STYLE SENT TO THE ROBOT MATCHES |
|THE ACTIVE STYLE BY THE ROBOT ST01 R01 |
| ACTIVE STYLE|
| INTERNAL |
|+--GRT-------------+ +--EQU-----------+ R01.ActiveStyle |
8++Greater Than (A>B)+-+Equal (A=B) +---------------------------------( )-----+
||A: R01.PgmEcho | |A: R01.PgmEcho | |
||B: 0 | |B: R01.PgmReqd | |
|+------------------+ +----------------+ |
| |
|THE RETURN FROM POUNCE RUNG IS USED TO ALLOW THE ROBOT TO MOVE FROM THE POUNCE |
|POSITION BACK TO A CYCLE START POSITION. THE SYSTEM GOTO POUNCE SIGNAL USED IN |
|THE READ STYLE RUNG MUST BE LOW PRIOR TO SENDING RETURN FROM POUNCE. |
| ST01 R01 |
|SYSTEM ST01 R01 ST01 R01 ST0 1R01 RETURN |
|RETURN ACTIVE RN01 ST01 RBT AT GOTO FROM |
|FROM STYLE ENABLED POUNCE WORK POUNCE |
|POUNCE INTERNAL INTERNAL D-NET D-NET |
|S01.RetFrmPnc R01.ActiveStyle R01.Enabled I10N01.b17 O10N01.b13 O10N01.b17 |
9+--] [-------] [-------] [-------] [-------]/[---------------------------( )-----+
| |
| |
|THE GOTO WELD RUNG WILL ALLOW THE ROBOT TO PROCEED FROM POUNCE POSITION INTO |
|THE PART. THE STATION GOTO WORK CONTACT IS A SYSTEM SIGNAL (CLAMPS CLOSED |
|ETC.).THIS OUTPUT MAY CAUSE MOTION AND MUST BE CONDITIONED WITH SYSTEM |
|AUTOMATIC. |
|ST01 R01 ST01 R01 ST01 R01 S01 R01 ST01 R01 ST01 R01 |
|GOTO ROBOT ST01 R01 ACTIVE ROBOT WORK PROGRAM NO BODY |
|WORK CYCLE ON ENABLED STYLE COMPLETE COMPLETE IN STATION |
|INTERNAL D-NET INTERNAL D-NET D-NET INTERNAL INTERNAL |
| S01.RbtsGotoWork I10N01.b13 R01.Enabled R01.ActiveStyle I10N01.b14 R01.PgmComp S01.NoBody |
10+--] [---------] [--------] [------] [-------]/[-------]/[-------]/[--- |
| ST01 R01 STO1 R01|
| CYCLE COMP GOTO |
| MEMORY WORK |
| INTERNAL D-NET |
| R01.CycCompMem O10N01.b13 |
| <-----]/[--------( )----+
| |
|THE ROBOT AT WORK RUNG IS TRUE FOR THE DURATION OF THE ROBOTS CYCLE. IT IS |
|RESET BY THE ROBOT COMPLETING ITS PROGRAM OR BYPASSING THE ROBOT. |
|ST01 R01 |
|ROBOT AT ST01 R01 |
|WORK AT WORK |
|D-NET INTERNAL |
| I10N01.b12 +--NEQ-------------- --+ R01.AtWork |
11+--] [---------+Not Equal (A≠B) +-----------------------------------------(L)----+
| |A: R01.PgmEcho| |
| |B: 0 | |
| +----------------+ |
| |
|THE ROBOT AT WORK RUNG IS TRUE FOR THE DURATION OF THE ROBOTS CYCLE. IT IS |
|RESET BY THE ROBOT COMPLETING ITS PROGRAM OR BYPASSING THE ROBOT. |
| ST01 R01 ST01 R01 |
| ROBOT AT ROBOT ST01 R01 |
| HOME COMPLETE AT WORK |
| D-NET D-NET INTERNAL |
| +--EQU-----------+ I10N01.b33 I10N01.b14 R01.AtWork |
12+--------------+Equal (A=B) +------] [-------]/[--+-------------------(U)----+
|RESET CYCLE |A: R01.PgmEcho| | |
|COMPLETE |B: 0 | | |
|ONESHOT +----------------+ | |
|R01.ResetComp | |
+--] ]------------------------------------------------+ |
AS OF 9/27/2006 54 08 RT DCX PREREL. 3.0
Printed copies are not source controlled
 |THE ROBOT CYCLE COMPLETE MEMORY RUNG IS A LATCH CIRCUIT WHICH IS SET BY A ROBOT |
|OUTPUT AT THE END OF THE ROBOT PROGRAM WHILE THE ROBOT IS ON THE ARM BACK LIMIT |
|SWITCH OR SAFELY ON THE BASE LIMIT SWITCH AND IN TIP DRESS PROGRAM AND IS RESET |
|BY THE CYCLE COMPLETE ACKNOWLEDGE ALSO AT THE END OF THE ROBOT PROGRAM. |
|ST01 RO1 ST01 R01 ST01 R01 |
|WORK ROBOT AT ST01 R01 CYCLE COMP|
|COMPLETE HOME AT WORK MEMORY |
|D-NET D-NET INTERNAL INTERNAL |
|I10N01.b14 I10N01.b33 R01.AtWork R01,CycCompMem |
13+--] [---+---] [---------------+-] [--------------------------------------(L)----+
| | STO1 RO1 IN TIP | |
| | ROBOT AT DRESS | |
| | USER POS1 CYCLE | |
| | I10N01.b19 R01.InTipDress | |
| +---] [-------] [-----+ |
|THE CYCLE COMPLETE ACK. RUNG IS USED TO HAND SHAKE WITH THE ROBOT OUTPUT CYCLE |
|COMPLETE. THE USE OF THIS SIGNAL WILL ELIMINATE THE NEED FOR A 0.5 SECOND DELAY |
|IN THE ROBOT PROGRAM. THIS RUNG WILL ALSO RESET THE STYLE REGISTER. |
| ST01 R01|
|ST01 R01 WORK |
|CYCLE COMP COMPLETE|
|MEMORY ACK |
|INTERNAL D-NET |
| R01,CycCompMem O10N01.b14 |
14+--] [-------------------------------------------+-----------------------( )-----+
| | |
| | RESET STYLE REGISTER |
| | +------MOVE-----------+ |
| +-| Move A TO B |-------+
| | A: 0 | |
| | | |
| | B: R01.PgmReqd | |
| | | |
| +---------------------+ |
| |
|THE ROBOT CYCLE COMPLETE MEMORY IS RESET BY A ONE SHOT SIGNAL CREATED IN THE |
|SYSTEM LOGIC. THIS ONE SHOT IS USED TO RESET ALL ROBOTS IN THE MACHINE. IF |
|THERE IS NO PART COMING INTO THE STATION THE ROBOT CYCLE COMPLETE CAN REMAIN |
|LATCHED. |
|ST01 |
|RESET CYC ST01 ST01 R01 |
|COMPLETE NO BODY CYCLE COMP |
|ONESHOT IN STATION MEMORY |
|INTERNAL INTERNAL INTERNAL |
| R01.ResetComp S01.NoBody R01.CycCompMem |
15+--] [-------]/[---------------------------------------------------------(U)-----+
|ROBOT PROGRAM COMPLETE SHOULD BE USED TO ALLOW THE MACHINE TO CONTINUE ITS |
|CYCLE. THIS RUNG CHECKS FOR A MAJOR FAULT, ROBOT CYCLE COMPLETE MEMORY AND ARM |
|BACK . BYPASS AND ARM BACK CAN GENERATE A PROGRAM COMPLETE IF THE ROBOT IS OUT |
|OF SERVICE AND THE PROCESS ALLOWS. TRANSFER LOGIC MUST ALSO MONITOR CLEAR TO |
|INDEX. |
|ST01 R01 ST01 R01 STO1 R01 ST01 R01 |
|CYCLE COMP PROCESS WELD MODE PROGRAM |
|MEMORY FAULT ACTIVE COMPLETE |
|INTERNAL D-NET D-NET INTERNAL |
| R01.CycCompMem I10N01.b119 I10N01.b21 R01.PgmComp) |
16+--] [-----------]/[----+--] [----+--------------------------------------( )-----+
| | | |
| | | |
| |PGM.COMP.| |
| |INTERNAL | |
| |R01.PgmComp| |
| +---] [---+ |

AS OF 9/27/2006 55 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 |ROBOT CLEAR TO INDEX INDICATES TO THE SYSTEM LOGIC THAT THE ROBOT IS CLEAR OF |
|THE FIXTURE AND THE MACHINE CAN CONTINUE ITS CYCLE. |
| |
| ST01 R01 ST01 R01 ST01 R01 |
| ROBOT AT CLEAR TO CLEAR TO |
| HOME TRANSFER INDEX |
| D-NET D-NET INTERNAL |
|I10N01.b18 I10N01.b34 R01.ClrToIndex |
17+--] [---------------+------] [-------------------------------------------( )----+
| | |
|ST01 R01 STO1 RO1| |
|ROBOT AT IN TIP | |
|USER POS1 DRESS | |
|D-NET CYCLE | |
|I10N01.b19 R01.InTipDress | |
+--] [-------] [-----+ |
| | |
|ST01 R01 ST01 R01| |
|ROBOT AT IN | |
|USER POS2 SERVICE | |
|D-NET CYCLE | |
|I10N01.b20 R01.InServ | |
+--] [--------] [----+ |
| |
|ROBOT CLEAR TO UNCLAMP IS USED TO ALLOW THE FIXTURE TO UNCLAMP EARLY WHILE THE |
|ROBOT IS MOVING HOME. |
|ST01 R01 ST01 |
|REPOS UNCLAMP |
|TOOLING 1 FIXTURE |
|D-NET O15 EARLY |
|I10N01.b76 S01.UnclpEarly |
18+--] [--------------------------------------------------------------------( )----+
| |
|THE EXTERNAL WATER VALVE RESET SIGNAL WILL TRIGGER THE ROBOT TO RESET THE WATER |
|VALVE IF IT IS FAULTED. |
|SYSTEM S01 R01 |
|WATER SYSTEM EXTERNAL |
|VALVE READY FOR WATER |
|RESET AUTOMATIC VALVE |
|PB INTERNAL RESET |
|Sys.WaterReset Sys.RdyForAuto O10N01.b94 |
19+--] [------------] [----------------------------------------------------( )-----+
| |
|THE WATER ON/BYPASSED RUNG INDICATES THE STATE OF THE WATER SAVER. THE INPUT |
|WILL BE ON IF WATER IS FLOWING AND FLASHING IF WATER SAVER BYPASSED |
|ST01 R01 ST01 R01 S01 R01 |
|WATER ON WATER WATER |
|D-NET BYPASSED ON |
|I10N01.b32 I10N01.b15 R01.WaterOn |
20+--] [----------]/[--------------------------------------------------------( )---+
| |
|ST01 R01 S01 R01 |
|WATER WATER |
|BYPASSED BYPASSED |
|I10N01.b15 R01.WaterBypassed |
21+--] [---------------------------------------------------------------------( )---+

AS OF 9/27/2006 56 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 |THE WELD COUNTER FOR TIP DRESS RUNG COUNTS ONCE FOR EVERY WELD. WHEN THE |
|COUNTER REACHES THE PRESET THE ROBOT WILL BE TOLD TO PERFORM A TIP DRESS. |
|S01 R01 S01 R01 S01 R01|
|WELD IN WELD WELD |
|PRGRS COUNTER COUNTER |
|ACTIVE FOR TIP FOR TIP |
|D-NET DRESS DRESS |
|I10N01.b87 R01.WeldCntr.DN +-MOV--------------+ +--CTU----------------+ |
22+--] [-------]/[--------------| Move |-----| Count Up |---+
| | Source 200 | | Counter R01.WeldCntr | |
| | | | Preset 200 | |
| |Dest R01.WeldCntr.PRE| | Accum 0 | |
| | 200 | +---------------------+ |
| +------------------+ |
| |
| |
|THIS RUNG RESETS THE WELD COUNTER FOR TIP DRESS WHEN THE ROBOT ENTERS THE TIP |
|DRESS CYCLE. S01 R01 |
|SO1 RO1 WELD CTR |
|IN TIP FOR TIP |
|DRESS DRESS |
|CYCLE CTR |
| R01.InTipDress R01.WeldCntr |
23+--] [------+------------------------------------------------------------[RES]---+
| | |
| STEPPER | |
| RESET 1 | |
| ACK | |
| D-NET | |
| I10N01.b91 | |
+--] [------+ |
| |
|THE TIP DRESS REQUEST RUNG ALLOWS THE PLC TO SEND THE ROBOT TO TIP DRESS FROM |
|TIP DRESS PB OR PLC WELD COUNTER. |
|S01 R01 SO1 RO1 SYSTEM S01 R01 S01 R01 |
|TIP DRESS S01 R01 IN TIP AUTOMATIC IN TIP DRESS |
|PANELVIEW ENABLED DRESS MODE SERVICE GUN REQ |
|PB INTERNAL CYCLE INTERNAL CYCLE D-NET |
|R01.HMITipDress R01.Enabled I10N01.b89 S01.Auto R01.InServ O10N01.B88 |
24+--] [------+------] [-------]/[-------] [--------]/[---------------------( )----+
| | |
|S01 R01 | NOTE: Style register N7 must be |
|WELD | set to 7 to call 1st tip |
|COUNTER | dress program #7 or 8 to |
|FOR TIP | call 2nd tip dress program |
|DRESS | #8 if more than one tip |
|R01.WeldCntr.DN| dresser is used. |
+--] [------+ |
| |
|THE TIP DRESSER DUMP RETRACTED RUNG TELLS THE ROBOT THAT THE DUMP UNIT IS CLEAR |
|OF THE PED WELDER AND THE ROBOT CAN MOVE TO THE PED WELDER. S01 R01 |
| TIP DRESS |
|SYSTEM DUMP |
|TIP DRESS RETRACTED |
|DUMP RET'D D-NET |
|S01.TipDressDumpRetd O10N01.b88 |
25+--] [-------------------------------------------------------------------( )-----+
| |

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 |THE ROBOT IN TIP DRESS CYCLE RUNG IS USED TO CREATE AN IN TIP DRESS CYCLE |
|SIGNAL FROM ACTIVE STYLE SIGNAL FROM ROBOT. SO1 RO1 |
| IN TIP |
| DRESS #1 |
| CYCLE |
|+--EQU-----------+ R01.InTipDress1|
26++Equal +-----------------------------------------------------( )------+
||Source R01.PgmEcho | |
|| 0 | |
||Source B 7 | |
|+----------------+ SO1 RO1 |
| IN TIP |
| DRESS #2 |
| CYCLE |
|+--EQU-----------+ R01.InTipDress2|
27++Equal +------------------------------------------------------( )-----+
||Source R01.PgmEcho | |
|| 0 | |
||Source B 8 | |
|+----------------+ |
| |
| |
|ROBOT TIP DRESS CONTACTOR ON IS A SIGNAL TO THE PLC TO TURN ON THE TIP DRESSER |
|MOTOR. |
|S01 R01 |
|TURN ON SO1 RO1 S01 R01 |
|TIP IN TIP TIP DRESS|
|DRESSER DRESS #1 CONTACTOR|
|D-NET CYCLE ON #1 |
|I10M01.b89 R01.InTipDress1 R01.TpDressMtr1|
28+--] [-------------------------------------------------+------] [--------( )-----+
| | |
| | SO1 RO1 S01 RO1 |
| | IN TIP TIP DRESS|
| | DRESS #2 CONTACTOR|
| | CYCLE ON #2 |
| |R01.InTipDress2 R01.TpDressMtr2|
| +----] [----------( )-----+
| |
| |
|TIP DRESSER MOTOR RUNNING INDICATES THE TIP DRESSER IS READY AND WILL ALLOW THE |
|WELD GUN TIPS TO CLOSE ON THE CUTTERS AND BE DRESSED. |
|S01 RO1 S01 R01 |
|AUX SO1 RO1 TIP DRESS|
|CONTACT IN TIP MOTOR |
|TIP DRESS #1 DRESS #1 ON |
|MTR START CYCLE D-NET |
| R01.TipDressMtrOn1 R01.InTipDress1 O10N01.b90 |
29+--] [----------] [-------+---------------------------------------------( )------+
| | |
|S01 R01 | |
|AUX SO1 RO1 | |
|CONTACT IN TIP | |
|TIP DRESS #2 DRESS #1 | |
|MTR START CYCLE | |
|R01.TipDressMtrOn2 R01.InTipDress2 | |
+--] [----------] [-------+ |
| |

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 |SERVICE REQUESTED WILL SEND THE ROBOT TO A SERVICE POSITION IF THE ROBOT IS |
|RUNNING ITS MAINLINE PROGRAM OR WHEN THE ROBOT COMPLETES ITS PROGRAM. THIS |
|OUTPUT MAY CAUSE ROBOT MOTION AND MUST BE CONDITIONED WITH SYSTEM AUTOMATIC. |
|S01 R01 |
|SERVICE S01 R01 SYSTEM SO1 RO1 S01 R01 S01 R01 |
|SELECTOR S01 R01 ROBOT AT AUTOMATIC IN TIP IN TIP GO TO |
|SWITCH ENABLED SERVICE MODE DRESS #1 DRESS #2 SERVICE |
|SS INTERNAL D-NET NTERNAL CYCLE CYCLE D-NET |
|R01.HMIGotoServ R01.Enabled I10N01.b19 S01.Auto R01.InTipDress1 R01.InTipDress2 O10N01.b18 |
30+--] [------+--] [-------]/[-------] [-------]/[-------]/[--------------( )------+
| | |
| S01 R01 | |
| SERVICE | |
| REQUESTED | |
| D-NET | |
| O10N01.b18 | |
+--] [------+ |
| |
|THE IN SERVICE CYCLE RUNG CREATES AN IN SERVICE CYCLE SIGNAL FROM THE STYLE |
|ACK. SIGNAL FROM THE ROBOT. |
|THIS BTD |
|LOADS THE ST01 R01 |
|ACTIVE STYLE IN |
|INPUTS TO SERVICE |
|REGISTER CYCLE |
|+--EQU-----------+ R01.InServCyc |
31++Equal (A=B) +-------------------------------------------------------( )----+
||Source R01.PgmEcho | |
|| 0 | |
||Source B 6 | |
|+----------------+ |
| |
|SERVICE COMPLETE WILL ALLOW THE ROBOT TO RETURN FROM SERVICE POSITION TO CYCLE |
|START POSITION AND CONTINUE THE MAINLINE PROGRAM. THIS OUTPUT MAY CAUSE ROBOT |
|MOTION AND MUST BE CONDITIONED WITH SYSTEM AUTOMATIC. |
| |
|S01 RO1 S01 R01 SYSTEM SO1 R01 |
|SERVICE ROBOT AT AUTOMATIC SERVICE |
|COMPLETE SERVICE MODE CMPLT REQ|
| PB D-NET INTERNAL D-NET |
|R01.HMIServComp I10N01.b1 9 S01.Auto O10N01.b18|
32+--] [-------+---------] [-------] [------------------------------------( )------+
| | |
| SO1 R01 | |
| SERVICE | |
| CMPLT REQ | |
| D-NET I16 | |
| O10N01.b18 | |
+--] [-------+ |
| |
| |
|ARM BACK ECHO SENDS THE STATE OF THE PLC INPUT FOR THE ARM BACK SWITCH BACK |
|TO THE ROBOT CONTROLLER. |
| S01 R01 S01 R01 |
| ROBOT ARM ARM BACK |
| BACK LS ECHO |
|(FROM Safety PLC) D-NET |
|From.Safety.Res O10N01.B06 |
33+--] [-------------------------------------------------------------------( )-----+

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 |BASE LIMIT SWITCH #1 ECHO SENDS THE STATE OF THE PLC INPUT FOR BASE LIMIT |
|SWITCH #1 BACK TO THE ROBOT CONTROLLER. (WHEN REQUIRED) S01 R01 |
|S01 R01 BASE LIMIT|
|ROBOT BASE SWITCH #1 |
|LIMIT #1 ECHO |
|(FROM SAFETY PLC) D-NET |
| From.Safety.Res O10N01.b07 |
34+--] [-------------------------------------------------------------------( )-----+
| |
| |
|BASE LIMIT SWITCH #2 ECHO SENDS THE STATE OF THE PLC INPUT FOR BASE LIMIT |
|SWITCH #2 BACK TO THE ROBOT CONTROLLER. (WHEN REQUIRED) S01 R01 |
|SO1 R01 BASE LIMIT|
|ROBOT BASE SWITCH #2 |
|LIMIT #2 ECHO |
|(FROM SAFETY PLC) D-NET |
| From.Safety.Res O10N01.b08 |
35+--] [-------------------------------------------------------------------( )-----+
| |
| |
|BASE LIMIT SWITCH #3 ECHO SENDS THE STATE OF THE PLC INPUT FOR BASE LIMIT |
|SWITCH #3 BACK TO THE ROBOT CONTROLLER. (WHEN REQUIRED) S01 R01 |
|S01 R01 BASE LIMIT|
|ROBOT BASE SWITCH #3 |
|LIMIT #3 ECHO |
|(FROM SAFETY PLC) D-NET |
| From.Safety.Res O10N01.b09 |
36+--] [--------------------------------------------------------------------( )----+
| |
| |
|REMOTE STEPPER RESET WILL CAUSE THE ROBOT TO RESET THE WELD STEPPER. |
|CAUTION!!!!!! THIS OUTPUT WILL RESET THE STEPPER COUNT. IF THE TIPS HAVE NOT |
|BEEN CHANGED WELDS MAY NOT BE ADEQUATE. NO INDICATION OF THESE BAD WELDS |
|(FAULT) WILL BE GIVEN. |
| S01 R01 |
|S01 R01 S01 R01 SYSTEM EXTERNAL |
|GLOBAL ROBOT AUTOMATIC STEPPER |
|STEPPER CYCLE ON MODE RESET |
|RESET D-NET INTERNAL D-NET |
|R01.HMIResetStep I10N01.b13 S01.Auto O10N01.B91 |
37+--] [-----------------]/[-------]/[------------------------------------( )------+
| |
| |
|REMOTE TIP BURN IN WILL SEND THE ROBOT TO A TIP BURN IN PROGRAM. |
|TIP BURN IN PROGRAM IS OPTIONAL BY PLANT PREFERENCE. |
|S01 R01 SYSTEM S01 R01 |
|GLOBAL AUTOMATIC TIP |
|TIP MODE BURN IN |
|BURN IN INTERNAL REQUEST |
|R01.HMITipBurn S01.Auto O10N01.b93 |
38+--] [-------] [--------------------------------------------------------( )------+
| |
| |
| |
| |

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 |THIS RUNG WILL LOAD THE APPLICATION ERROR BIT CODE FROM THE RIO INPUT WORD TO |
|A STORAGE WORD FOR FIS AND MACHINE DIAGNOSTIC MESSAGES |
|S01 R01 |
|APP ERROR S01 R01 |
|ACTIVE AT WORK |
|D-NET INTERNAL |
|I10N01.b120 R01.AtWork +--BTD----------------+ |
39+--] [---+---] [-----+----------------------------------+Bit Field Distributor---+
| |S01 R01 | |Source Local:3I.DATA(7)| |
| |IN TIP | | 0| |
| |DRESS | |Source Bit 9| |
| |CYCLE #1 | |Dest N7(9)| |
| | R01.InTipDress1| | 0| |
| +---] [-----+ |Dest Bit 0| |
| |S01 R01 | |Length 7| |
| |IN TIP | +---------------------+ |
| |DRESS | |
| |CYCLE #2 | |
| | R01.InTipDress2| |
| +---] [-----+ |
| |S01 R01 | |
| |IN SERVICE | |
| |CYCLE | |
| |INTERNAL | |
| | R01.InServCyc | |
| +---] [-----+ |
| |
|THE EXTERNAL STOP ROBOT SIGNAL TO THE ROBOT MUST BE HELD HIGH TO RUN THE ROBOT. |
| S01 RO1 |
| STOP |
| ROBOT |
| D-NET |
| O10N01.b00 |
40+-----------------------------------------------------------------------( )------+
| |
| THE FOLLOWING RUNG SEPARATES APPLICATION ERRORS INTO FAULTS AND ALARMS |
|S01 R01 S01 R01 S01 R01 |
|IN BYPASS APP ERROR APPLICATION|
| ACTIVE ERROR |
|D-NET D-NET TO FIS |
|O10N01.b05 I10N01.B120 +--NEQ-----------+ +--LES-----------+ B111(300)|
41+--]/[---------] [-----+Not Equal (A≠B) +++ LESS THAN (A<B)+------------+-( )----+
| |SOURCE A N7(9)|||SOURCE A N7(9)| S01 R01 | |
| |SOURCE B 0 |||SOURCE B 32| PROCESS | |
| +----------------+|+----------------+ FAULT | |
| | D-NET | |
| NOTE:VALUE FOR LES & GRT’S |+--GRT-----------+ I10N01.b119 | |
| SOURCE B: ALL APPS/STUD ONLY ++GREATERTHAN(A>B)+-----] [----+ |
| ||SOURCE A N7(9)| |
| ||SOURCE B 31|S01 R01 S01 R01 |
| |+----------------+PROCESS APPLICATION|
| | FAULT ALARM |
| | D-NET TO FIS |
| |+--GRT-----------+I10N01.b119 B111(500) |
| ++GREATERTHAN(A>B)+-----]/[------( )----+
| |SOURCE A N7(9)| |
| |SOURCE B 31| |
| +----------------+ |

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 | ROBOT INTERFERENCE ZONE LOGIC. REFER TO INTERFERENCE ZONE EXAMPLE 1 AND |
| EXAMPLE 2 FOR REFERENCE OF ROBOT LOCATIONS NOTE THIS IS A FORMAT EXAMPLE |
| ONLY ACTUAL LOGIC IS BASED ON ZONES REQUIRED |
| ROBOT 1 ROBOT 3 ROBOT 1 |
| CLEAR ZONE 6 CLR ZONE 6 CLR|
| ZONE 6 TO ENTER TO ENTER |
| D-NET D-NET D-NET |
| I10N01.b42 O10N03.b42 O10N01.b42 |
42+---------------------------------------------+--]/[--------]/[----------(L)-----+
| | |
| | ROBOT 1 ROBOT 1 |
| | CLEAR ZONE 6 CLR|
| | ZONE 6 TO ENTER |
| | D-NET D-NET |
| | I10N01.b42 O10N01.b42 |
| +---] [--------------------(U)-----+
| | |
| | ROBOT 3 ROBOT 1 ROBOT 3 |
| | CLEAR ZONE 6 CLR ZONE 6 CLR|
| | ZONE 6 TO ENTER TO ENTER |
| | D-NET D-NET D-NET |
| |I10N03.b42 O10N01.b42 O10N03.b42 |
| +--]/[--------]/[----------(L)-----+
| | |
| | ROBOT 1 ROBOT 1 |
| | CLEAR ZONE 6 CLR|
| | ZONE 6 TO ENTER |
| | D-NET D-NET |
| | I10N01.b42 O10N01.b42 |
| +---] [--------------------(U)-----+
| |
| |
| ROBOT 1 ROBOT 2 ROBOT 1 |
| CLEAR ZONE 1 CLR ZONE 1 CLR|
| ZONE 1 TO ENTER TO ENTER |
| D-NET D-NET D-NET |
| I10N01.b37 O10N02.b37 O10N01.b37 |
43+---------------------------------------------+--]/[--------]/[----------(L)-----+
| | |
| | ROBOT 1 ROBOT 1 |
| | CLEAR ZONE 1 CLR|
| | ZONE 1 TO ENTER |
| | D-NET D-NET |
| | I10N01.b37 O10N01.b37 |
| +---] [--------------------(U)-----+
| | |
| | ROBOT 2 ROBOT 1 ROBOT 2 |
| | CLEAR ZONE 1 CLR ZONE 1 CLR|
| | ZONE 1 TO ENTER TO ENTER |
| | D-NET D-NET D-NET |
| |I10N02.b37 O10N01.b37 O10N02.b37 |
| +--]/[--------]/[----------(L)-----+
| | |
| | ROBOT 2 ROBOT 2 |
| | CLEAR ZONE 1 CLR|
| | ZONE 1 TO ENTER |
| | D-NET D-NET |
| |I10N02.b37 O10N02.b37 |
| +--] [---------------------(U)-----+
| |
43+--------------------------------------------------------------------------[END]-+

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 ROBOT INTERFERENCE ZONES
Zone Identification Summary/Definitions:
Station / Work Area based zones.
Zones 1, 2& 3:
Station Zones are defined as the area where two or more robots are executing work on or exchanging (transferring) a work
piece at a physical station. Examples of stations are turntables, work fixtures, holding bucks and transfers or shuttles.
Work Area Zones are defined as the area where two or more robots are executing work on or exchanging (transferring) a
work piece without the use of a physical station. Examples of this would be robot to robot hand off by the use of Geo-fector
EOAT (End Of Arm Tooling).

Station and Work Area Zones are applied using an alternating pattern. For example a robot would pick-up a part in Zone
1then transfer it to Zone 2. The next robot would pick-up the part from Zone 2 then transfers it to Zone 1. This alternating
pattern would continue with Zone 3 only being required for a robot that needs three Station or Work Area zones.

Transition Zones/Hand-off zones

Zones 4 & 5:
Transition Zones are when two or more robots, working side by side, are needed to move (transition) from one process area
to another process area when a physical interference between the robots is present during the transition. For example
welding robots moving from a geo weld position to a re-spot weld position would require some Transition zone protection.
Hand-off Zones are used for robot to robot hand-off. Hand-off is when one robot loads the work piece from it EOAT directly
onto the other robot’s EOAT without the use of a station.
Hand-off Zones are applied using an alternating pattern. For example a robot would pick-up a part in Zone 4 then transfers it
to Zone 5. The next robot would pick-up the part from Zone 5 then transfers it to Zone 4 etc.

Process Interference Zones / Duty Zones

Zones 6 thru 9:
Process Interference Zones are defined as the zones around the work piece that the robots application is working around.
For example two or more robots might need to cross each others path in order to complete its process on the work piece. In
this case these Process Zones would be used to allow the robots to safely “chase” each other around the work piece.
Duty Zones are defined as other Duties that the process or application requires but are in excess of the previous zone
definitions. For example, gantry robots having a part transfer at a higher elevation then Zones 1-3 could use these zones like
a Work Area Zone.

Examples:
Interference Zone Example 1: This example shows Zone 1 and 2 as Station Zones. Zones 4 & 5 are Transition Zones and
Zones 6 – 9 as Process Interference Zones.

Interference Zone Example 2: This example shows Zone 1 and 2 as Work Area Zones. Zone 4 is a hand-off Zone and Zones
6 & 7 are Process Interference Zones

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 Interference Zone Example 1

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 Interference Zone Example 2

The definitions described and show above, are to be followed as described and are not subject to interpretation.
If the above definitions can not be applied to a specific application then approval from an DCX Robotics
Engineer or Launch Technician will be required to redefine how Interference Zones are to be used.

Reference Pictures Only See Standard Robot Logic Reference for Details.

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 REFERENCE FLOW CHARTS
(A.B.B. ROBOT)
NAME NUMBER APPLICATION PAGES
MAINLINE (XXXXX.100) (ALL) 61

STYLE (XXXXX.010) (SPOT WELD) 62

STYLE (XXXXX.010) (MAT./ HAND.) 63

(DISPENSE)

STYLE (XXXXX.010) (MAT./HAND.) 64

(TOOLCHANGE)

STYLE (XXXXX.010) (MAT./HAND.) 65

STYLE (XXXXX.007) (TIP DRESS ) 67

STYLE (XXXXX.008) (TOOLCHANGE) 68

STYLE (XXXXX.060) (RETURN FROM

POUNCE) FUTURE

STYLE (XXXXX.099) (PIN OUT

POSITION) FUTURE

STYLE (XXXXX.006) (SERVICE) FUTURE

STYLE (XXXXX.005) (TIP BURN IN) FUTURE

STYLE (XXXXX.009) (GUN CHANGE) FUTURE

STYLE (XXXXX.010) (STUD WELD) FUTURE

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 REFERENCE PROGRAM INSTRUCTIONS
(A.B.B. ROBOT)
ALL APPLICATIONS
Instruction Example/Argument Definition
AddMinorFISFlt 255; indicates to the PLC Add Minor FIS Fault = AddMinorFISFlt is
that the IRB has detected a Minor fault used whenever the IRB needs to alert the PLC
condition and supplies the PLC with FIS that a minor fault condition has been detected
AddMinorFISFlt
Minor fault index 255. and supplies the PLC with the appropriate FIS
Minor fault index.

ClearMajorFISFlt; indicates to the PLC that Clear Major FIS Fault = ClearMajorFISFlt is
a previously reported Major fault no longer used whenever the IRB needs to alert the PLC
exists. that a previously reported Major fault condition
ClearMajorFISFlt
no longer exists.

ClearOfApp APP_1; indicates to the PLC Clear of Application Status = ClearOfApp is

that the IRB is clear of Application 1. used to inform the PLC that the IRB is
physically clear of the Application. The
ClearOfApp
instruction allows the PLC to coordinate entry
of other IRBs into the Application.

ClearOfAppJ APP_1, p30, v1000, z30, tool2 Clear of Application Status = ClearOfAppJ is
; The TCP of the tool, tool2, is moved along used to inform the PLC that the IRB is
a non-linear path to the position p30, with physically clear of the Application. The
speed data v1000 and zone data z30. instruction allows the PLC to coordinate entry
ClearOfAppJ In the middle of the corner path at p30 the of other IRBs into the Application.
PLC will be informed that the IRB has exited
Application 1.

ClearOfAppL APP_1, p30, v1000, z30, Clear of Application Status = ClearOfAppL is

tool2; The TCP of the tool, tool2, is moved used to inform the PLC that the IRB is
along a linear path to the position p30, with physically clear of the Application. The
speed data v1000 and zone data z30. instruction allows the PLC to coordinate entry
ClearOfAppL In the middle of the corner path at p30 the of other IRBs into the Application.
PLC will be informed that the IRB has exited
Application 1.

DisableReq2Enter; Disable Request To Enter = DisableReq2Enter

disables the PLC signal ReqToEnter which
would normally result in a program stop
condition when the ReqToEnter signal is high.
DisableReq2Enter This instruction allows the PLC ReqToEnter to
be ignored during sensitive areas of the user
program such as dispense path, spotweld
instruction, etc.
EnableReq2Enter; Enable Request To Enter = EnableReq2Enter
enables the PLC signal ReqToEnter which
results in a program stop condition when the
ReqToEnter is high.
EnableReq2Enter

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 EnterApp APP_1; indicates to the PLC that Enter Application =EnterApp is used whenever
the IRB has approached Application 1, and the IRB needs to enter an Application that may
EnterApp allows the PLC to coordinate the IRB entry be in use by another IRB.
into the Application.
MoveAbsJ_KEYpos MoveAbsJ to the Key Position =
USER_POS1,v1000,tool2; The TCP of the MoveAbsJ_KEYpos is used to move the robot
tool, tool2, is moved along a non-linear path to a Key absolute position, defined in axis
MoveAbsJ_KEYpos to the absolute axis position as described by positions. A comparision of the Key position (a
USER_POS1, with speed data v1000. position which affects other robots) is made
with an associated saved position to detect if
the Key position has been modified.
MoveJ p1, vmax, z30, toolgun1; The tool Moves the robot by joint movement=MoveJ is
center point (TCP) of the tool, toolgun1, is used to move the robot quickly from one point
moved along a non-linear path to the to another when that movement does not have
MoveJ
position, p1, with speed data vmax and zone to be in a straight line.
data z30.

MoveL p1, v1000, z30, toolgun1 Moves the robot linearly = MoveL is used to
The TCP of the tool, toolgun1, is moved move the tool centre point (TCP) linearly to a
linearly to the position p1, with speed data given destination. When the TCP is to remain
MoveL
v1000 and zone data z30. stationary, this instruction can also be used to
reorient the tool.

PostMajorFISFlt 255; indicates to the PLC Post Major FIS Fault = PostMajorFISFlt is used
that the IRB has detected a Major fault whenever the IRB needs to alert the PLC that a
condition and supplies the PLC with FIS Major fault condition has occurred and supplies
PostMajorFISFlt
Major fault index 255. the PLC with the appropriate FIS Major fault
index.

RmvMinorFISFlt 255; removes FIS Minor Remove Minor FIS Fault = RmvMinorFISFlt is
fault index 255 from the Minor fault used whenever the IRB needs to remove a FIS
reporting table. Minor fault index from the FIS fault reporting
RmvMinorFISFlt
table (internal to the robot).

RepositionTool TOOL_2; Request the PLC Reposition Tool Request = RepositionTool

to reposition tool 2 and waits for PLC allows the IRB to request the PLC to reposition
acknowledgment that tool 2 has completed tooling before proceeding.
repositioning. Even if the tool repositioning is already done by
RepositionTool the PLC, this instruction can be used to allow
the IRB to verify that the tooling is repositioned
before proceeding.

StartExtProc APP_1, 10; requests the PLC Start External Process Request = StartExtProc
to start application 1 external process and is used whenever the IRB requests the PLC to
StartExtProc allows 10 seconds for the process to start a process which is not directly controlled
complete before issuing a fault. by the IRB.

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 PROGRAMMING INSTRUCTIONS continued
INTERFERENCE ZONES
Instruction Example/Argument Definition
ClearOfZone ZONE_1; indicates to the PLC Clear of Interference Zone Status =
that the IRB has exited interference zone 1. ClearOfZone is used whenever the IRB leaves
an interference zone. The instruction allows the
PLC to coordinate entry of other IRBs into the
zone.
ClearOfZone See the ClearOfZoneL and ClearOfZoneJ
instructions for a more accurate coordination of
setting the PLC signal.

ClearOfZoneJ ZONE_1, p30, v1000, z30, Clear of Interference Zone Status =

tool2 ; The TCP of the tool, tool2, is moved ClearOfZoneJ is used whenever the IRB leaves
along a non-linear path to the position p30, an interference zone. The instruction allows the
with speed data v1000 and zone data z30. PLC to coordinate entry of other IRBs into the
ClearOfZoneJ In the middle of the corner path at p30 the zone.
PLC will be informed that the IRB has exited
interference ZONE_1.

ClearOfZoneL ZONE_1, p30, v1000, z30, Clear of Interference Zone Status =

tool2; The TCP of the tool, tool2, is moved ClearOfZoneL is used whenever the IRB leaves
along a linear path to the position p30, with an interference zone. The instruction allows the
speed data v1000 and zone data z30. PLC to coordinate entry of other IRBs into the
ClearOfZoneL In the middle of the corner path at p30 the zone.
PLC will be informed that the IRB has exited
interference zone 1.

EnterZone ZONE_5; indicates to the PLC Interference Zone Entry Request = EnterZone is
that the IRB has approached interference used whenever the IRB needs to enter an
zone 5, and allows the PLC to coordinate the interference zone that may be in use by another
EnterZone
IRB entry into the zone. IRB.

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 PROGRAMMING INSTRUCTIONS continued
MATERIAL HANDLING PART 1 of 2
Instruction Example/Argument Definition
ClrOfDropoffJ DROPOFF_4, p30, v1000, Irb Dropoff Fixture location status =
z30, tool2; The TCP of the tool: tool2, is ClrOfDropoffJ is used to inform the PLC that
moved along a non-linear path to the position the IRB is physically clear of the Dropoff
p30, with speed data v1000 and zone data fixture that may be in use or held by another
ClrOfDropoffJ z30. IRB.
In the middle of the corner path at p30 the
PLC will be informed that the IRB is
physically clear of Dropoff 4 fixture.

ClrOfDropoffL DROPOFF_4, p30, v1000, Irb Dropoff Fixture location status =

z30, tool2; The TCP of the tool: tool2, is ClrOfDropoffL is used to inform the PLC that
moved along a linear path to the position the IRB is physically clear of the Dropoff
p30, with speed data v1000 and zone data fixture which may be in use or held by another
ClrOfDropoffL z30. IRB.
In the middle of the corner path at p30 the
PLC will be informed that the IRB is
physically clear of Dropoff 4 fixture.

ClrOfPickupJ PICKUP_4, p30, v1000, z30, Irb Pickup Fixture zone status = ClrOfPickupJ
tool2; The TCP of the tool: tool2, is moved is used to inform the PLC that the IRB is
along a non-linear path to the position p30, physically clear of the Pickup fixture which
with speed data v1000 and zone data z30. may be in use or held by another IRB.
ClrOfPickupJ In the middle of the corner path at p30 the
PLC will be informed that the IRB is
physically clear of pickup 4 fixture

ClrOfPickupL PICKUP_4, p30, v1000, z30, Irb Pickup Fixture Zone Status = ClrOfPickupL
tool2; The TCP of the tool: tool2, is moved is used to inform the PLC that the IRB is
along a linear path to the position p30, with physically clear of the Pickup fixture which
speed data v1000 and zone data z30. may be in use or held by another IRB.
ClrOfPickupL In the middle of the corner path at p30 the
PLC will be informed that the IRB is
physically clear of pickup 4 fixture.

ExitPickup PICKUP_4; indicates to the PLC Exit Pickup Fixture = ExitPickup is used
that the IRB is exiting Pickup 4 fixture, and whenever the IRB needs to exit a Pickup fixture
ExitPickup allows the PLC to coordinate the IRB exit that may be in use or held by another IRB.
from that fixture.
ExitDropoff DROPOFF_4; indicates to the Exit Dropoff Fixture = ExitDropoff is used
PLC that the IRB is exiting Dropoff 4 whenever the IRB needs to exit a Dropoff
ExitDropoff fixture, and allows the PLC to coordinate the fixture that may be in use or held by another
IRB exit from that fixture. IRB.
EnterPickup PICKUP_4; indicates to the Enter Pickup Fixture = EnterPickup is used to
PLC that the IRB is entering Pickup 4 inform the PLC that the IRB is entering a
EnterPickup fixture, and allows the PLC to coordinate the Pickup fixture that may be in use or held by
IRB entry into that fixture another IRB
EnterDropoff DROPOFF_4; indicates to the Dropoff Entry Request = EnterDropoff is used
PLC that the IRB has approached Dropoff 4 whenever the IRB requests entry to a Dropoff
EnterDropoff fixture, and allows the PLC to coordinate the fixture that may be in use or held by another
IRB entry into that fixture. IRB.

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 PROGRAMMING INSTRUCTIONS continued
MATERIAL HANDLING PART 2 of 2
Instruction Example/Argument Definition
GetDropoffResult; Get Dropoff Result = GetDropoffResult is a
function which returns the Dropoff fixture
value (DROPOFF_1 – DROPOFF_4). The
GetDropoffResult Dropoff fixture value is determined from the
corresponding robot input “GoToDropoffX”
signal state values.
GetPickupResult; Get Pickup Result = GetPickupResult is a
function which returns the Pickup fixture value
GetPickupResult (PICKUP_1 – PICKUP_4). The Pickup fixture
value is determined from the corresponding
robot input “GoToPickupX” signal state values.
RetractLocPins \V1; Retract the locating pins Retract Locating Pins = RetractLocPins retracts
connected to valve 1. RetractLocPins the locating pin(s) which are mounted on the
RetractLocPins \V1\V3\V5; Retract the locating pins end effector held by the IRB.
connected to valves 1, 3, and 5.
ReleasePart\V1; Retract clamps and / or turn Release part with IRB = ReleasePart releases a
off vacuum and apply blowoff to vacuum part with clamps and/or vacuum cup(s) held by
cups connected to valve 1. ReleasePart the IRB. The IRB should be in the drop-off
ReleasePart \V1\V3\V5; Retract clamps and / or turn off position when this instruction is used.
vacuum and apply blowoff to vacuum cups
connected to valve 1, 3, and 5.
PrepareToGrip\V1; Verify that valid pick-up Prepare To Grip a Part with IRB =
conditions exist for clamp(s) or part present PrepareToGrip checks conditions to be met
signal(s) connected to valve 1. before picking up a part with the IRB.
PrepareToGrip PrepareToGrip\V1\V3\V5; Verify that valid
pick-up conditions exist for clamp(s) or part
present signal(s) connected to valve 1, 3, and
5.
IrbAtPickupL PICKUP_4, p30, v1000, z1, Irb Pickup Fixture location status =
tool2; The TCP of the tool: tool2, is moved IrbAtPickup is used to inform the PLC that the
along a linear path to the position p30, with IRB is currently at a Pickup fixture that may be
speed data v1000 and zone data z1. in use or held by another IRB.
IrbAtPickupL
In the middle of the corner path at p30 the
PLC will be informed that the IRB is
physically at the pickup 4 fixture position.

IrbAtDropoffL DROPOFF_4, p30, v1000, Irb Dropoff Fixture location status =

z1, tool2; The TCP of the tool: tool2, is IrbAtDropoffL is used to inform the PLC that
moved along a linear path to the position the IRB is currently at the Dropoff fixture
IrbAtDropoffL p30, with speed data v1000 and zone data z1. which may be in use or held by another IRB.
In the middle of the corner path at p30 the
PLC will be informed that the IRB is
physically at the dropoff 4 fixture position.
GripPart \V1; Extend clamps and/or applies Grip part with IRB = GripPart engages a part
vacuum to vacuum cups connected to valve with clamps and/or vacuum gripper(s) held by
1. GripPart \V1\V3\V5; Extend clamps and / the IRB. The IRB should be in the pick-up
GripPart or applies vacuum to vacuum cups connected position when this instruction is used. Part
to valves 1, 3, and 5. present monitoring is activated as the last action
of the instruction.
ExtendLocPins \V1; Extend the locating pin Extend Locating Pins = ExtendLocPins extends
connected to valve 1. the locating pin(s) which are mounted on the
ExtendLocPins ExtendLocPins \V1\V3\V5; Extend the end effector held by the IRB.
locating pins connected to valves 1, 3, and 5.
VerifyRelease\V1; verify that the part Verify release of part = VerifyRelease verifies
controlled by valve 1 has been dropped off that no part is held by the IRB gripper
VerifyRelease successfully. VerifyRelease\V1\V3\V5;
verify that the part controlled by valves 1, 3,
and 5 has been dropped off successfully.

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 PROGRAMMING INSTRUCTIONS continued
STUD WELDING
Instruction Example/Argument Definition
LockHeadL\WPos, stud1; The robot will Lock stud weld Head = LockHead is used
order the stud weld head to be locked into whenever a stud head needs to be locked after
the weld position which is defined by the rotation has occurred.
LockHead weld program in the studdata stud1. Then
the robot executes the next program
instruction.
RotateHeadJ\WPos Rotate Head after Joint Movement =
p10,v1000,stud1,tHead1\Wobj:=wobj0; The RotateHeadJ is used whenever a stud head
TCP of the tool, tHead1, is moved with a needs to be rotated after a joint movement has
RotateHeadJ joint motion to the position p10, with speed occurred. The instruction allows the robot to
1000mm/sec. move in a joint mode to a program position and
then rotate the stud weld head.
RotateHeadL\WPos Rotate Head after Linear Movement =
p10,v1000,stud1,tHead1\Wobj:=wobj0; The RotateHeadL is used whenever a stud head
TCP of the tool, tHead1, is moved along a needs to be rotated after a linear movement has
RotateHeadL linear path to the position p10, with speed occurred. The instruction allows the robot to
1000mm/sec. move in a linear mode to a program position
and then rotate the stud weld head.
studdata is used in the StudL and StudJ Stud weld Data type = The data studdata
instructions as input parameters for the stud defines parameters the stud weld controller will
studdata weld controller. Example declaration: use for applying a stud.
CONST studdata stud1:=[1,1];

StudJ p10, v1000, stud1, tHead1\Wobj: = Stud weld after Joint move = StudJ is used
wobj0; The TCP of the tool, tHead1, is whenever a stud weld needs to be applied at a
moved with joint motion to the position p10, robot position. The instruction allows the robot
with speed 1000mm/sec terminating at a fine to move with joint motion to a fine position and
StudJ point and applying stud1. then apply a stud weld.
After the stud weld process is complete the
robot executes the next program instruction.

StudL p10, v1000, stud1, Stud weld after Linear move = StudL is used
tHead1\Wobj:=wobj0; whenever a stud weld needs to be applied at a
The TCP of the tool, tHead1, is moved along robot position. The instruction allows the robot
a linear path to the position p10, with speed to move linearly to a fine position and then
StudL 1000mm/sec terminating at a fine point and apply a stud weld.
applying stud1.
After the stud weld process is complete the
robot executes the next program instruction.

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 PROGRAMMING INSTRUCTIONS continued
TIP DRESSING
Instruction Example/Argument Definition
AdvanceDresser 1; The dump for tip dresser IRB Advance the Tip Dress Motor Dump =
1 will be advanced to the stationary weld AdvanceDresser will advance the tip dress
AdvanceDresser gun, and then will be checked to be in dump to the spot welding gun.
position.
StartWaterFlow 1; The output IRB Start Water Flow = StartWaterFlow will
StartWaterFlow1 will be energized, and the start water flow in spot welding water circuit.
StartWaterFlow input Water1Flowing will monitor for water
flow.

StopWaterFlow 1; The output IRB Stop Water Flow = StopWaterFlow will

StartWaterFlow1 will be de-energized, and stop water flow in spot welding water circuit.
StopWaterFlow the input Water1Flowing will no longer be
monitored for water flow.

StartDresserMtr 1; IRB Start Tip Dress Motor

The input signal Tipdrs1PowerOK will be
checked. Then the output StartTipdrs1Mtr StartDresserMtr will start a specific tip dress
StartDresserMtr will be energized, and the input motor for a spot welding gun.
Tipdrs1Started will be checked.

StopDresserMtr 1; The output IRB Stop Tip Dress Motor = StopDresserMtr

StartTipdrsMtr1 will be de-energized, and will stop a specific tip dress motor for a spot
StopDresserMtr the input Tipdrs1Started will be checked for welding gun.
an “Off” state.
RetractDresser 1; The dump for tip dresser 1 IRB Retract the Tip Dress Motor Dump =
will be retracted from the stationary weld RetractDresser will retract the tip dress dump
RetractDresser gun, and then will be checked to be in from the spot welding gun.
retracted position

BurnInComplete; The output for tip burn in IRB Set Tip Burn In Complete =
complete will be set to an “On” state, and the BurnInComplete will set a bit to the PLC to
BurnInComplete robot will wait for the PLC to reset the tip indicate that the tip burn in sequence was
burn in request. completed.

TipdressComplete; The output for tip dress IRB Set Tip dress Complete =
complete will be set to an “On” state, and TipdressComplete will set a bit to the PLC to
TipdressComplete then the robot will wait for the tip dress indicate that the tip dress sequence was
request input to be reset . completed.

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 PROGRAMMING INSTRUCTIONS continued
TOOL CHANGE
Instruction Example/Argument Definition
CloseNest1; The lid for tool nest 1 will be Close tool Nest = CloseNest orders a tool
CloseNest closed. stand lid to close, and will check for the lid to
be closed.
LatchTool; A request to latch the tool is Latch a Tool = LatchTool requests the tool
made. changer to advance its locking mechanism,
LatchTool and will check for the locking mechanism to
be advanced.
NestEmptyChk1; Nest Empty Check = NestEmptyChk will
NestEmptyChk Tool nest 1 will be checked for a tool not check for a tool not to be present in the tool
present. nest.
NestNotEmptyChk1; Tool nest 1 will be Nest Not Empty Check = NestNotEmptyChk
NestNotEmptyChk checked for a tool present. will check for a tool to be present in the tool
nest.
OpenNest1; The lid for tool nest 1 will be Open tool Nest = OpenNest orders a tool
opened. stand lid to open, and will check for the lid to
OpenNest be opened.

PrepMHToolXchng \V1; Closes all clamps Prepare MH Tool Exchange =

and verify all clamps are closed which are PrepMHToolXchng allows the user to close
connected to valve 1. PrepMHToolXchng all clamps and verify that all clamps are
PrepMHToolXchng \V1\V3\V5; Closes all clamps and verify closed prior to dropping off a MH tool into
all clamps are closed which are connected the tool change nest.
to valves 1, 3, and 5.
ToolNotOnWrist; The tool changer will be Check for tool not on wrist =
ToolNotOnWrist checked for tool not present. ToolNotOnWrist will check for a tool not to
be present in the tool changer.
ToolOnWrist 1,1,1; The tool that is Check for tool on wrist = ToolOnWrist will
connected to the robot will be checked for check for a tool to be present in the tool
ToolOnWrist tool id to equal 1, robot id to equal 1, and changer.
line id to equal 1.

UnLatchTool; A request to unlatch the tool UnLatch a Tool = UnLatchTool requests the
is made. tool changer to retract its locking mechanism,
UnLatchTool and will check for the locking mechanism to
be retracted.

GetDropoffResults

GetPickupResults

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 PLC / Robot Timing Diagram – System Standby to Program Start
PLC verifies that robot is in auto mode
RobotInAuto

PLC orders robot to clear any pending faults

ClearAllFaults

PLC verifies robot is ready

RobotReady

PLC orders robot to start motors and prog execution

StartRobot

PLC verifies that robot program is executing

RobotCycleOn

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 PLC / Robot Timing Diagram – Normal Cycle (Styles 10 - 127)
Robot Initializes the appropriate state bits
RobotAtHome, RobotClearbits, RobotAtWork, etc

PLC sets the appropriate Style bits (10 – 127): giStyle

PLC sets the appropriate Option bits: Option1 – Option4

PLC orders robot to read the Style and Option bits

ReadStyle

Robot reads & echo’s Style Ack bits to PLC (10 – 127): goActiveStyle
Robot reads & echo’s Option Ack bits to PLC: Option1Active – Option4Active

PLC compares echoes and orders robot to Initiate cycle

InitiateCycle

Robot moves from Home to style specific Pounce

RobotAtPounce

PLC orders robot to begin working

GoToWork

Robot proceeds to appropriate Style program

RobotAtWork

Robot informs PLC that work is complete

WorkComplete

PLC acknowledges that work complete was received

WorkCompleteAck

Robot returns Home via style specific Pounce

RobotAtHome

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 PLC / Robot Timing Diagram – Return from Pounce
Robot moves from Home to Pounce
RobotAtPounce

PLC orders robot to return Home

RetFromPounce

Robot clears ActiveStyle and Option Active bits

GoActiveStyle, Option1Active – Option4Active

Robot returns Home via style specific Pounce

RobotAtHome

WorkComplete and WorkCompleteAck is NOT sent

WorkComplete, WorkCompleteAck

PLC / Robot Timing Diagram

Maintenance request - “Go To Service”

PLC requests robot to “Go to Service”

GoToServiceReq

Robot returns Home

RobotAtHome

Robot echoes style 6 back to PLC via ActiveStyle bits

goActiveStyle

Robot executes Style6 (“Go To Service” routine)

RobotAtService

PLC requests robot to return Home from Service

ServiceCmpltReq

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 PLC / Robot Timing Diagram
Maintenance request – “Tip Dress”

PLC requests robot to Tip Dress

TipDressGunReq

Robot returns Home

RobotAtHome

Robot echoes style 7 back to PLC via ActiveStyle bits

goActiveStyle

Robot executes service Style7 (Tip Dress routine)

RobotAtTipdress

Robot completes service Style7 and returns home

TipDressComplt

Note: The above timing diagram would also apply for Style1, Style2, Style3, TipBurnIn, PurgeGun1, and PurgeGun2
maintenance requests (only the maintenance request signal(s), maintenance routine names, and active style value would
differ).

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 PLC / Robot Timing Diagram
Tip Dress (Requested from Weld Timer in mid cycle)
Robot is in cycle
RobotAtWork

Weld ctrl requests robot to perform Tip Dress

WT1DressTipsReq

Robot returns Home

RobotAtHome

Robot echoes style 7 back to PLC via ActiveStyle bits

goActiveStyle

Robot executes service Style7 (TipDress routine)

RobotAtTipdress

Robot completes tip dressing

WT1TipsDressed

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 PLC / Robot Timing Diagram – Interference zones
(*) User instruction example - EnterZone ZONE_X;
PLC is informed that robot is no longer clear of zone
RobotClrZoneX

PLC honors interference zone request

ZoneXClrToEnter

(*) Reference the EnterZone user instruction (“EnterZone.doc”) for further details.

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 PLC / Robot Timing Diagram – Tool nest entry
Robot requests PLC to enter tool nest
ReqToEntTN

PLC honors tool nest entry request

ClrToEnterTN

PLC is informed that robot is not clear of tool nest

ClrOfNest

PLC / Robot Timing Diagram – Application 1 and 2

PLC is informed that robot is no longer clear of App
AppClrX

PLC indicates that the app is not clear to enter

AppXClrToEnter

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 PLC / Robot Timing Diagram - Robot to Robot Part handoff
Dropoff sequence
PLC orders dropoff robot to continue program TO Dropoff X
(where X = 1 – 4) GoToDropoffX

Dropoff robot informs PLC it is not clear of Dropoff X

(where X = 1 – 4) ClrOfDropoffX

Dropoff robot informs PLC it is at Dropoff X

(where X = 1 – 4) AtDropoffX

Dropoff robot requests PLC permission to release part

ReposToolingX

Dropoff robot waits for PLC ack and then releases part
ToolingRepodX

PLC orders Dropoff robot to continue program FROM Dropoff X

(where X = 1 – 4) ExitDropoffX

Pickup sequence
PLC orders pickup robot to continue program TO pickup X
(where X = 1 – 4) GoToPickupX

Pickup robot informs PLC it is not clear of pickup X

(where X = 1 – 4) ClrOfPickupX

Pickup robot informs PLC it is at pickup X

(where X = 1 – 4) AtPickupX

Pickup robot requests PLC permission to release part

ReposToolingX

Pickup robot waits for PLC ack and then releases part
ToolingRepodX

PLC orders Pickup robot to continue program FROM pickup X

(where X = 1 – 4) ExitPickupX

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 MODULE DCXIPCS
PROC main()
%%%
VERSION:1
LANGUAGE:ENGLISH
%%%

MODULE DCXIPCS
! -------------------------------------------------------------------
! MAINLINE routine
! -------------------------------------------------------------------
PROC main()
RecoverFromAbort;
OverrideDefaults;
InitializeSystem;
WHILE (TRUE) DO
WaitWithMessage WAITING_FOR_REQ;
ProcessStyleInfo;
VerifyAtHome;
IF ActiveStyle<=9 THEN
! Maintenance style section: Style1 - Style9
%ActiveStylString%;
MaintStyleComplt;
ELSE
! Base style section: Style10 and higher
HomeToPounce;
WaitWithMessage WAITING_FOR_PRCD;
IF (GoToWork=1) AND (RetFromPounce=0) THEN
%ActiveStylString%;
EndWork;
EndWorkToHome;
VerifyAtHome;
EndCycle;
ELSEIF (GoToWork=0) AND (RetFromPounce=1) THEN
PounceToHome;
VerifyAtHome;
ELSE
HandlePLConflict;
ENDIF
ENDIF
ENDWHILE
ENDPROC

PROC OverrideDefaults()
!***(This Procedure is not to contain any instructions without prior**! !***written
approval from a DaimlerChrysler representative).**********!
! Override Default System Behavior
ENDPROC
ENDMODULE

NOTE:
PROC main() is common to all robots and is not to be altered.

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 MODULE PGENRPTH
%%%
VERSION:1
LANGUAGE:ENGLISH
%%%

MODULE PGENRPTH
! ***************************** GENERAL PATH ROUTINES *************************
!
PROC GoToSync()
! moves robot to sync position
CurrentTool:=CTool();
MoveAbsJ Home\NoEOffs,v500,fine,CurrentTool;
MoveAbsJ SyncPos\NoEOffs,v200,fine,CurrentTool;
WaitTime 5;
MoveAbsJ Home\NoEOffs,v500,fine,CurrentTool;
ENDPROC

PROC GoToHome()
CurrentTool:=CTool();
MoveAbsJ Home\NoEOffs,v100,fine,CurrentTool;
ENDPROC

PROC PounceToHome()
CurrentTool:=CTool();
MoveAbsJ Pounce\NoEOffs,v1000,fine,CurrentTool;
SetDO RobotAtPounce,0;
MoveAbsJ Home\NoEOffs,v1000,fine,CurrentTool;
ENDPROC

PROC HomeToPounce()
CurrentTool:=CTool();
MoveAbsJ Home\NoEOffs,v1000,fine,CurrentTool;
MoveAbsJ Pounce\NoEOffs,v1000,fine,CurrentTool;
SetDO RobotAtPounce,1;
ENDPROC

PROC HomeToService()
CurrentTool:=CTool();
MoveAbsJ Home\NoEOffs,v100,fine,CurrentTool;
MoveAbsJ Service\NoEOffs,v100,fine,CurrentTool;
ENDPROC

PROC ServiceToHome()
CurrentTool:=CTool();
MoveAbsJ Service\NoEOffs,v100,fine,CurrentTool;
MoveAbsJ Home\NoEOffs,v100,fine,CurrentTool;
ENDPROC

PROC EndWorkToHome()
CurrentTool:=CTool();
ENDPROC

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 MODULE PGENRPTH cont.
! ***************************** MAINTENANCE STYLE PATH ROUTINES *************************
!
PROC Style1()
! Reserved
ENDPROC

PROC Style2()
! Reserved
ENDPROC

PROC Style3()
! Reserved
ENDPROC

PROC Style4()
! Purge
ENDPROC

PROC Style5()
! Tip Burn In
ENDPROC

PROC Style6()
! Service sequence
HomeToService;
WaitWithMessage WAITN4SERVCMPLT;
ServiceToHome;
ENDPROC

PROC Style7()
! Gun 1 Tip Dress
ENDPROC

PROC Style8()
! Gun 2 Tip Dress
ENDPROC

PROC Style9()
! Tool Change
ENDPROC
ENDMODULE

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 MODULE PGENRDAT
%%%
VERSION:1
LANGUAGE:ENGLISH
%%%

MODULE PGENRDAT
! ******************************* USER PROGRAM DATA ***************************
!
!
PERS tooldata CurrentTool:=[TRUE,[[4.9668,-301.651,986.785],[0.5,0.5,-0.5,0.5]],[150.5,[-
25.6,-43.6,399.5],[1,0,0,0],20.686,11.342,11.51]];
PERS jointtarget Pounce:=[[37.33,-45.34,18.68,-44.1,87.66,-
137.37],[39.997,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS jointtarget Home:=[[26.55,-45.34,20.59,-44.1,87.66,-
137.37],[15,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS jointtarget Service:=[[-14.4,-45.34,28.09,-44.1,87.66,-
137.37],[39.9974,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS jointtarget
UserPos1:=[[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS jointtarget
UserPos2:=[[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS jointtarget
UserPos3:=[[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS jointtarget
UserPos4:=[[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS jointtarget
UserPos5:=[[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];
CONST jointtarget SyncPos:=[[0,0,0,0,0,0],[0,9E+09,9E+09,9E+09,9E+09,9E+09]];
ENDMODULE

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 MODULE pStyle20
%%%
VERSION:1
LANGUAGE:ENGLISH
%%%

MODULE pStyle20
LOCAL CONST robtarget
lo25:=[[1654.39,582.94,1691.88],[0.824362,0.39757,0.231432,0.329856],[-1,-
1,0,1],[14.9992,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS spotdata spot14:=[14,14,300,0,0];
PERS spotdata spot03:=[1,3,480,2.72,0];
PERS spotdata spot02:=[1,2,480,2.72,0];
LOCAL CONST robtarget
lo76:=[[1331.25,683.25,1362.56],[0.826137,0.488345,0.243926,0.139706],[0,-
1,0,0],[140.014,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo75:=[[1046.33,1144,1233.26],[0.823419,-
0.491068,0.041426,0.28128],[0,-1,-1,0],[162.615,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo73:=[[1527.4,1390.02,1395.14],[0.728886,-0.672438,-
0.006603,0.128489],[0,-2,-1,0],[164.269,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo72:=[[1527.39,1390.02,1386.42],[0.729071,-0.671331,-
0.006437,0.133153],[0,-2,-1,0],[164.269,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo_pounce:=[[1210.31,89.94,1594.29],[0.647358,-
0.65897,0.365877,0.113228],[0,-1,-2,0],[39.9975,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS spotdata spot13:=[1,13,480,0.5,0];
LOCAL CONST robtarget tipseater:=[[1202.41,-139.54,1540.74],[0.644085,-
0.625679,0.436246,0.058054],[0,-1,-2,0],[15,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget burn_tip:=[[1202.41,-139.54,1540.73],[0.644084,-
0.625679,0.436248,0.058054],[0,-1,-2,0],[15,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo71:=[[1269.44,-185.44,1666.04],[0.878936,-0.251078,0.400693,-
0.062267],[0,-1,-2,0],[14.9995,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo70:=[[960.63,-362.34,1174.64],[0.491906,0.51427,0.488758,-
0.504649],[-1,0,-1,0],[80,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget ptddep:=[[962.71,-361.61,1054.13],[0.49191,0.514274,0.488754,-
0.504645],[-1,0,-1,0],[80,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget ptdapp:=[[962.72,-361.6,1054.13],[0.491912,0.514276,0.488751,-
0.504644],[-1,0,-1,0],[80,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS forcedata TD_force:=[150,2,0,0];
LOCAL CONST robtarget ptd:=[[961.22,-400.48,1053.87],[0.491915,0.51428,0.488748,-
0.50464],[-1,0,-1,0],[59.9935,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget
lo65:=[[1661.3,1261.67,1354.07],[0.496863,0.625025,0.490172,0.349575],[0,-
1,0,1],[40.9816,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo63:=[[1202.46,-139.56,1540.81],[0.64407,-
0.625723,0.436208,0.058036],[0,-1,-2,0],[14.9998,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget
lo62:=[[1235.49,1114.82,1467.53],[0.567376,0.643886,0.410822,0.307766],[0,-
1,1,1],[103.462,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget
lo61:=[[1454.17,1301.17,1414.21],[0.513203,0.608344,0.554605,0.242805],[0,-
2,1,1],[88.5126,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo60:=[[1301.57,1234.84,1416.28],[0.714168,-
0.688001,0.053842,0.117134],[0,-1,-1,0],[188.462,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo59:=[[1301.58,1234.81,1411.26],[0.714182,-
0.687987,0.05384,0.117129],[0,-1,-1,0],[188.462,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo58:=[[1814.74,1415.13,1684.9],[0.696867,-
0.694558,0.123487,0.129299],[0,-1,-2,0],[184.995,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS spotdata spot01:=[1,1,480,1.42,0];
!Robtarget definitions for procedure rob17path
MODULE pStyle20 cont.
AS OF 9/27/2006 96 08 RT DCX PREREL. 3.0
Printed copies are not source controlled
LOCAL CONST robtarget rob17_home_start:=[[1202.46,-139.56,1540.79],[0.644066,-
0.625723,0.436215,0.058034],[0,-1,-2,0],[15,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo50:=[[1519.24,1089.66,1720.99],[0.696979,-
0.694413,0.123348,0.129602],[0,-1,-2,0],[184.999,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget l21z0_62o:=[[1924.03,1488.46,1644.1],[0.696053,-
0.693921,0.158004,0.094971],[0,-1,-2,0],[180.046,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo51:=[[1871.73,1450.27,1662.41],[0.69662,-
0.694432,0.142054,0.110936],[0,-1,-2,0],[182.334,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget l21z0_56o:=[[1881.91,1495.7,1451.23],[0.650531,-
0.628327,0.313436,0.289436],[0,-1,-2,0],[180.613,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo52:=[[1829.31,1459.95,1652.29],[0.69029,-
0.632933,0.263923,0.23074],[0,-1,-2,0],[180.402,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo54:=[[1762.16,1347.36,1688.47],[0.67413,-
0.672347,0.212916,0.219467],[0,-1,-2,0],[195.244,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo57:=[[1290.15,1234.76,1777.5],[0.698738,-
0.682967,0.155587,0.145311],[0,-1,-2,0],[188.463,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo17:=[[1277.42,1218.96,1513.22],[0.739408,-0.619104,-
0.024427,0.263419],[0,-1,-2,0],[141.013,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget
lo46:=[[1349.78,858.946,1414.66],[0.65,0.71013,0.26999,0.01786],[0,-
1,1,0],[180,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo19:=[[1759.37,1416.42,1299.67],[0.715374,-0.645589,-
0.030257,0.265595],[0,-2,-1,0],[140.105,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget l21z0_144o:=[[1787.98,1489.3,1275.02],[0.715381,-0.645582,-
0.030255,0.265591],[0,-2,-1,0],[80.1557,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget lo30:=[[1759.37,1416.42,1299.67],[0.715374,-0.645589,-
0.030258,0.265595],[0,-2,-1,0],[140.105,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget
lo53:=[[793.7,1464.82,1544.45],[0.505911,0.566566,0.503235,0.412083],[0,-
1,1,1],[103.462,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget
l21z0_122o:=[[1702.01,1438.36,1330.88],[0.468858,0.617444,0.505015,0.379336],[0,-
1,0,1],[40.9848,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget
l21z0_50o:=[[1682.79,1411.9,1293.48],[0.476589,0.605992,0.525523,0.35981],[0,-
1,0,1],[41.2871,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget
lo24:=[[1527.85,865.75,1324.08],[0.494763,0.611909,0.505571,0.353801],[-1,-
2,0,1],[40.0572,9E+09,9E+09,9E+09,9E+09,9E+09]];
LOCAL CONST robtarget rob17_home_end:=[[1202.46,-139.56,1540.79],[0.644066,-
0.625724,0.436211,0.058037],[0,-1,-2,0],[14.9998,9E+09,9E+09,9E+09,9E+09,9E+09]];
!Robot sta40_rob17 ToolData declarations:
!Robcad toolgun1 Frame Name: sta40_rob17_tl1
PERS tooldata toolgun1:=[TRUE,[[4.9668,-301.651,986.785],[0.5,0.5,-0.5,0.5]],[150.5,[-
25.6,-43.6,399.5],[1,0,0,0],20.686,11.342,11.51]];
!Robot sta40_rob17 WobjData UFrame: Default, Object Frame: r17_wobj1
PERS wobjdata r17_wobj:=[FALSE,TRUE,"",[[0,0,0],[1,0,0,0]],[[0,0,0],[1,0,0,0]]];
!Robot sta40_rob17 SpeedData declarations:
CONST speeddata v900:=[900,500,5000,1000];
CONST speeddata v1200:=[1200,500,5000,1000];
CONST speeddata v1800:=[1800,500,5000,1000];
CONST speeddata v1400:=[1400,500,5000,1000];

AS OF 9/27/2006 97 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 MODULE pStyle20 cont.
PROC r17_tipburn()
CurrentTool:=CTool();
MoveAbsJ Home\NoEOffs,v100,fine,CurrentTool;
FOR i FROM 1 TO 5 DO
SpotJ burn_tip,v500,gun1,spot01,toolgun1\WObj:=r17_wobj;
ENDFOR
CalibL tipseater,v500,gun1\TipWear,fine,toolgun1\WObj:=r17_wobj;
CurrentTool:=CTool();
MoveAbsJ Home\NoEOffs,v100,fine,CurrentTool;
BurnInComplete;
ENDPROC

PROC Style20()
r17_path;
ENDPROC

PROC r17_path()
MoveJ lo_pounce,v1200,z20,toolgun1\WObj:=r17_wobj;
SetDO RobotAtPounce,0;
EnterApp APP_1;
EnterZone ZONE_1\EnbReq2Enter;
EnterZone ZONE_3\EnbReq2Enter;
MoveJ lo50,v1000,z50,toolgun1\WObj:=r17_wobj;
MoveJ lo58,v800,z20,toolgun1\WObj:=r17_wobj;
SpotL l21z0_62o,v1000,gun1,spot01,toolgun1\WObj:=r17_wobj;
MoveL lo51,v1200,z20,toolgun1\WObj:=r17_wobj;
SpotL l21z0_56o,v1000,gun1,spot01,toolgun1\WObj:=r17_wobj;
MoveL lo52,v1200,z20,toolgun1\WObj:=r17_wobj;
MoveL lo54,v1200,z80,toolgun1\WObj:=r17_wobj;
MoveJ lo57,v900,z20,toolgun1\WObj:=r17_wobj;
ClearOfZoneJ ZONE_1,lo59,v800,z5,toolgun1\WObj:=r17_wobj;
ClearOfZoneJ ZONE_3,lo59,v800,z5,toolgun1\WObj:=r17_wobj;
MoveJ lo72,v900,z20,toolgun1\WObj:=r17_wobj;
MoveL lo19,v1400,z20,toolgun1\WObj:=r17_wobj;
SpotL l21z0_144o,v1000,gun1,spot03,toolgun1\WObj:=r17_wobj;
MoveL lo30,v1400,z20,toolgun1\WObj:=r17_wobj;
MoveL lo73,v900,z20,toolgun1\WObj:=r17_wobj;
MoveL lo60,v900,z50,toolgun1\WObj:=r17_wobj;
MoveJ lo75,v800,z50,toolgun1\WObj:=r17_wobj;
MoveJ lo76,v800,z50,toolgun1\WObj:=r17_wobj;
MoveJ lo62,v1000,z50,toolgun1\WObj:=r17_wobj;
MoveJ lo65,v1000,fine,toolgun1\WObj:=r17_wobj;
SpotL l21z0_122o,v1000,gun1,spot01,toolgun1\WObj:=r17_wobj;
SpotL l21z0_50o,v1000,gun1,spot02,toolgun1\WObj:=r17_wobj;
MoveL lo24,v1000,z40,toolgun1\WObj:=r17_wobj;
MoveJ lo25,v1000,z50,toolgun1\WObj:=r17_wobj;
CalibJ lo63,v1000,gun1\TipWear,z50,toolgun1\WObj:=r17_wobj;
MoveJ rob17_home_end,v900,fine,toolgun1\WObj:=r17_wobj;
ClearOfApp APP_1;
ENDPROC

AS OF 9/27/2006 98 08 RT DCX PREREL. 3.0

Printed copies are not source controlled
 MODULE pStyle20 cont.
PROC r17_tipdress()
MoveJ rob17_home_start,v1000,fine,toolgun1\WObj:=r17_wobj;
StartDresserMtr 1;
SetDO RobotAtTipDress,1;
MoveJ lo71,v1200,z100,toolgun1\WObj:=r17_wobj;
MoveJ lo70,v800,z20,toolgun1\WObj:=r17_wobj;
MoveL ptdapp,v200,z20,toolgun1\WObj:=r17_wobj;
SpotL ptd,v200,gun1,spot14,toolgun1;
MoveL ptddep,v200,z20,toolgun1\WObj:=r17_wobj;
MoveJ lo70,v800,z20,toolgun1\WObj:=r17_wobj;
MoveJ lo71,v1200,z100,toolgun1\WObj:=r17_wobj;
StopDresserMtr 1;
SetDO RobotAtTipDress,0;
CalibJ rob17_home_end,v1200,gun1\TipWear,z50,toolgun1\WObj:=r17_wobj;
MoveJ rob17_home_end,v1200,fine,toolgun1\WObj:=r17_wobj;
TipdressComplete 1;
ENDPROC
ENDMODULE

AS OF 9/27/2006 99 08 RT DCX PREREL. 3.0

Printed copies are not source controlled