RT WAP ABB Appllication Standard Rel 3

DaimlerChryslers
Robotics Group Applications Standards

For ABB IRC5 Controlled Robots For Use
On
2008 RT and CT Projects
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 users responsibility to obtain latest updates to this
document.
AS OF 10/03/2006
Printed copies are not source controlled
08 RT DCX REL. 3.0
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
ROBOT PROGRAM NAMING............................................................................................................................................... 6
REGISTER AND COUNTER NAMING ................................................................................................................................ 6
ROBTARGET NAMING.......................................................................................................................................................... 6
ROBOT TO ROBOT HAND-OFF........................................................................................................................................... 6
BASE LIMIT CONNECTIONS AND OPERATION ............................................................................................................ 6
STANDARD ROBOT PROGRAM NUMBERS..................................................................................................................... 7
D-NET MAP DESCRIPTIONS (ROBOT TO PLC) .............................................................................................................. 9
D-NET MAP DESCRIPTIONS (PLC TO ROBOT) ............................................................................................................ 13
ROBOT DEVICE NET MASTER NODE ASSIGNMENT.................................................................................................. 17
APPLICATION ERRORS...................................................................................................................................................... 40
STANDARD ROBOT LOGIC ............................................................................................................................................... 47
ROBOT INTERFERENCE ZONES...................................................................................................................................... 60
INTERFERENCE ZONE EXAMPLE 1........................................................................................................................................................... 61
INTERFERENCE ZONE EXAMPLE 2........................................................................................................................................................... 62
REFERENCE FLOW CHARTS............................................................................................................................................ 63

REFERENCE PROGRAM INSTRUCTIONS ..................................................................................................................... 73
PLC / ROBOT TIMING DIAGRAM .................................................................................................................................... 81
(*) USER INSTRUCTION EXAMPLE - ENTERZONE ZONE_X; .................................................................................. 86
SAMPLE PROGRAMS .......................................................................................................................................................... 89
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.
AS OF 10/03/2006
08 RT DCX REL. 3.0
RELEASE REVISION AND COMMENTS PAGE

Release # Release Date
Rel. 1.0
11-11-2005
Rel. 2.0
4-13-2006
Rel. 3.0
10-03-2006
Comments
Initial release. Additional applications will be released as determined
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.
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
Pg.9 Updated Do and DI numbers, Updated user output and user
input naming
Pg.11 Added WeldinPrgrsActiv for second weld control
Pg.30 Added Norgen smart pump
Pg.36 Updated ATI bit maps
Pg.38 Added Tool nest node
Pg.40 Added Application error 1 DF&C
Pg.44 Added ISRA application errors
Pg.47 Updated logic reference.
AS OF 10/03/2006
08 RT DCX REL. 3.0
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 OEMS 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.
AS OF 10/03/2006
08 RT DCX REL. 3.0
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)
RobotFaulted
(False)
PathRestartError
(False)
EStopActive
(False)
MotionSupError
(False)
I/OBlockedInAuto
(False)
WeldMode Active
(True) (Spotweld Only)
Robot Ready
(True)
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)
WaterOn (Spotweld Only)
WaterBypassed (Spotweld Only)
ProcessFault
AppErrorActive
AS OF 10/03/2006
08 RT DCX REL. 3.0
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.
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 operators 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.
AS OF 10/03/2006
08 RT DCX REL. 3.0
STANDARD ROBOT PROGRAM NUMBERS

PROGRAM NO.
01
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
33
34
35
36
37
38
39
OPERATION PERFORMED
MAINT STYLE 1 (User Specified)
PURGE PROGRAM
TIP BURN IN
SERVICE PROGRAM
TIPDRESS PROGRAM 1st GUN
TIPDRESS PROGRAM 2nd GUN
TOOL CHANGE
STYLE 1 BASE PROGRAM (JS)
STYLE 1 PROGRAM NO. 1
5
STYLE 1 BACK UP PRG 1
4
STYLE 2 BASE PROGRAM ( )
5
4
STYLE 3 BASE PROGRAM ( )
5
STYLE 3 BACK UP PRG. 1
AS OF 10/03/2006
BIT PATTERN
000001
000010
000011
000100
000101
000110
000111
001000
001001
001010
001011
001100
001101
001110
001111
010000
010001
010010
010011
010100
010101
010110
010111
011000
011001
011010
011011
011100
011101
011110
011111
100000
100001
100010
100011
100100
100101
100110
100111
08 RT DCX REL. 3.0
STANDARD ROBOT PROGRAM NUMBERS

CONT.
PROGRAM NO.
OPERATION PERFORMED
BIT PATTERN
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
STYLE 4 BASE PROGRAM (Future)

5
4
STYLE 5 BASE PROGRAM
5
4
RETURN FROM POUNCE PGM. NO. 1
RETURN FROM POUNCE PGM. NO. 2
101000
101001
101010
101011
101100
101101
101110
101111
110000
110001
110010
110011
110100
110101
110110
110111
111000
111001
111010
111011
111100
111101
111110
111111
87
88
89
90
98
99
100
Application 1 Calibration (Vision, Dynalog)

Application 2 Calibration (Vision, Dynalog)
NA
NA
TCP TARGET PROGRAM

AUTO LOAD CALCULATION
ROBOT SYNCH
SCANNING MAINLINE
NA
NA
NA
NA
AS OF 10/03/2006
08 RT DCX REL. 3.0
D-NET MAP Descriptions (Robot To PLC) A.B.B .Robot

Signal Name
PLC TAG
Logical
Signal Description
RobotInAuto
IccssNyy.b
DO0
This robot system output signal informs the PLC that the robot is in automatic mode.
RobotReady
IccssNyy.b
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.b
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
RobotClrFixt2
IccssNyy.b
DO5
RobotClrFixt3
IccssNyy.b
DO6
PathRestartError
IccssNyy.b
DO7
This robot output informs the PLC that the robot is clear of fixture 1. (output driven by World
Zone definition)
Zone definition)
Zone definition)
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.b
DO13
This robot system output signal informs the PLC that the robot program is executing.
WorkComplete
IccssNyy.b
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.b
DO17
This robot system output informs the PLC that the robot is at home position.
RobotAtService
IccssNyy.b
DO18
This robot system output informs the PLC that the robot is at service position.
RobotAtUserPos1
IccssNyy.b
DO19
This robot system output informs the PLC that the robot is at user defined position 1.
RobotAtUserPos2
IccssNyy.b
DO20
RobotAtUserPos3
IccssNyy.b
DO21
RobotAtUserPos4
IccssNyy.b
DO22
RobotAtUserPos5
IccssNyy.b
DO23
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
ActiveStyleBit8
IccssNyy.b
DO27
ActiveStyleBit16
IccssNyy.b
DO28
ActiveStyleBit32
IccssNyy.b
DO29
ActiveStyleBit64
IccssNyy.b
DO30
ReservedPLCdo31
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
AS OF 10/03/2006
08 RT DCX REL. 3.0
Signal Name
PLC TAG
Logical
Signal Description
Option3Active
IccssNyy.b
DO34
Option4Active
IccssNyy.b
DO35
RobotClrZone1
IccssNyy.b
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.b
DO37
RobotClrZone3
IccssNyy.b
DO38
RobotClrZone4
IccssNyy.b
DO39
RobotClrZone5
IccssNyy.b
DO40
RobotClrZone6
IccssNyy.b
DO41
RobotClrZone7
IccssNyy.b
DO42
RobotClrZone8
IccssNyy.b
DO43
UserOutput1
IccssNyy.b
DO44
This robot output is designated for a user defined function.
UserOutput2
IccssNyy.b
DO45
UserOutput3
IccssNyy.b
DO46
UserOutput4
IccssNyy.b
DO47
UserOutput5
IccssNyy.b
DO48
UserOutput6
IccssNyy.b
DO49
UserOutput7
IccssNyy.b
DO50
UserOutput8
IccssNyy.b
DO51
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
AtPickup2
IccssNyy.b
DO57
ClrOfDropoff2
IccssNyy.b
DO58
AtDropoff2
IccssNyy.b
DO59
ClrOfPickup3
IccssNyy.b
DO60
AtPickup3
IccssNyy.b
DO61
ClrOfDropoff3
IccssNyy.b
DO62
AtDropoff3
IccssNyy.b
DO63
ClrOfPickup4
IccssNyy.b
DO64
AtPickup4
IccssNyy.b
DO65
ClrOfDropoff4
IccssNyy.b
DO66
AtDropoff4
IccssNyy.b
DO67
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
AS OF 10/03/2006
10
08 RT DCX REL. 3.0
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
RobotPartPres3
IccssNyy.b
DO72
RobotPartPres4
IccssNyy.b
DO73
RobotPartPres5
IccssNyy.b
DO74
RobotPartPres6
IccssNyy.b
DO75
ReposTooling1
IccssNyy.b
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
ReqToEntTN
IccssNyy.b
DO80
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.
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
RmvMnrFISFault
IccssNyy.b
DO83
This robot output indicates that a weld sequence is in progress (feedback taken directly from
the weld controller).
This robot output indicates the reported minor fault can be removed as it is no longer active.
NoStrokeActive
IccssNyy.b
DO84
This robot output indicates that it is running in no stroke mode.
WeldModeActive
IccssNyy.b
DO85
This robot output indicates that weld current is enabled (feedback taken directly from the
weld controller).
WeldInPrgrsActiv1
IccssNyy.b
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
DO89
This robot output allows the robot to remotely request the PLC to turn on the tip dress
motor(s).
StepperReset1Ack
IccssNyy.b
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.b
DO94
This robot output indicates that water is flowing at the robot.
WaterBypassed
ExtPurg1InProgrs
IccssNyy.b
IccssNyy.b
DO95
DO96
This robot output indicates that the water flow detection is bypassed.
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
ReqEntryZone3
IccssNyy.b
DO100
ReqEntryZone4
IccssNyy.b
DO101
ReqEntryZone5
IccssNyy.b
DO102
AS OF 10/03/2006
11
This robot output indicates that dispenser 1 purge sequence is in progress.
08 RT DCX REL. 3.0
Signal Name
PLC TAG
Logical
Signal Description
ReqEntryZone6
IccssNyy.b
DO103
ReqEntryZone7
IccssNyy.b
DO104
ReqEntryZone8
IccssNyy.b
DO105
RobotPartPres7
IccssNyy.b
DO106
RobotPartPres8
IccssNyy.b
DO107
RobotPartPres9
IccssNyy.b
DO108
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
RobotPartPres12
IccssNyy.b
DO111
ESIO Monitor 1
IccssNyy.b
DO112
This robot output echos the state of ESIO relay channel 1.
ESIO Monitor 2
IccssNyy.b
DO113
This robot output echos 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
StartExtApp2Proc
IccssNyy.b
DO117
ProcessFault
IccssNyy.b
DO118
This robot output allows the robot to remotely request the PLC to start external application 1
process.
This robot output allows the robot to remotely request the PLC to start external application 2
process.
This robot output indicates that a process fault has occurred.
AppErrorActive
IccssNyy.b
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
=4
(2^2)
AppErrorBit8
IccssNyy.b
DO123
=8
(2^3)
AppErrorBit16
IccssNyy.b
DO124
Reference AppErrorBit1. The BCD value for AppErrorBit16 = 16 (2^4)
AppErrorBit32
IccssNyy.b
DO125
AppErrorBit64
IccssNyy.b
DO126
AppErrorBit128
IccssNyy.b
DO127
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.
AS OF 10/03/2006
12
08 RT DCX REL. 3.0
D-NET MAP Descriptions (PLC To Robot) A.B.B .Robot

Signal Name
PLC TAG
Logical
Signal Description
This robot system input allows the PLC to remotely order the robot to stop program
execution and de-energize motor power.
This robot system input allows the PLC to remotely order the robot to energize motor power
and start program execution.
This robot system input allows the PLC to remotely order the robot to clear all robot faults.
StopRobot
OccssNyy.b
DI0
StartRobot
OccssNyy.b
DI1
ClearAllFaults
OccssNyy.b
DI2
UseDryCycle
OccssNyy.b
DI3
ReservedPLCdi4
OccssNyy.b
DI4
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.
This robot input is not assigned.
ReservedPLCdi5
OccssNyy.b
DI5
ReservedPLCdi6
OccssNyy.b
DI6
ReservedPLCdi7
OccssNyy.b
DI7
ReservedPLCdi8
OccssNyy.b
DI8
ReservedPLCdi9
OccssNyy.b
DI9
ReadStyle
OccssNyy.b
DI10
InitiateCycle
OccssNyy.b
DI11
GoToWork
OccssNyy.b
DI12
ReqToEnter
OccssNyy.b
DI13
WorkCompleteAck
OccssNyy.b
DI14
ReservedPLCdi15
OccssNyy.b
DI15
RetFromPounce
OccssNyy.b
DI16
ServiceCmpltReq
OccssNyy.b
DI17
GoToServiceReq
OccssNyy.b
DI18
ClrToExitUsrPos1
OccssNyy.b
DI19
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.
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.
This robot input allows the PLC to remotely request the robot to move from the Home
position to the Service position.
This robot input allows the PLC to signal the robot that it is clear to exit UserPos1.
ClrToExitUsrPos2
OccssNyy.b
DI20
ClrToExitUsrPos3
OccssNyy.b
DI21
ClrToExitUsrPos4
OccssNyy.b
DI22
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
StyleBit2
OccssNyy.b
DI25
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)
Reference StyleBit1.
StyleBit4
OccssNyy.b
DI26
The BCD value for StyleBit4 = 4
(2^2)
StyleBit8
OccssNyy.b
DI27
The BCD value for StyleBit8 = 8
(2^3)
StyleBit16
OccssNyy.b
DI28
StyleBit32
OccssNyy.b
DI29
StyleBit64
OccssNyy.b
DI30
AS OF 10/03/2006
This robot input allows the PLC to remotely request the robot to read the BCD style bits
(StyleBit1 StyleBit64). Reference StyleBit1 - StyleBit64.
This robot input allows the PLC to remotely request the robot to proceed from the Home
position to the Pounce position.
This robot input allows the PLC to remotely request the robot to proceed from the Pounce
position and into the Active Style routine.
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.
This robot input allows the PLC to remotely acknowledge to the robot that the work
complete signal was received.
13
08 RT DCX REL. 3.0
Signal Name
ReservedPLCdi31
Option1
PLC TAG
OccssNyy.b
OccssNyy.b
Option2
OccssNyy.b
DI33
Option3
OccssNyy.b
DI34
Option4
OccssNyy.b
DI35
Zone1ClrToEnter
OccssNyy.b
DI36
Zone2ClrToEnter
OccssNyy.b
DI37
Zone3ClrToEnter
OccssNyy.b
DI38
Zone4ClrToEnter
OccssNyy.b
DI39
Zone5ClrToEnter
OccssNyy.b
DI40
Zone6ClrToEnter
OccssNyy.b
DI41
Zone7ClrToEnter
OccssNyy.b
DI42
Zone8ClrToEnter
OccssNyy.b
DI43
UserInput1
UserInput2
UserInput3
UserInput4
UserInput5
UserInput6
UserInput7
UserInput8
GoToPickup1
ExitPickup1
OccssNyy.b
OccssNyy.b
OccssNyy.b
OccssNyy.b
OccssNyy.b
OccssNyy.b
OccssNyy.b
OccssNyy.b
OccssNyy.b
OccssNyy.b
DI44
DI45
DI46
DI47
DI48
DI49
DI50
DI51
DI52
DI53
GoToDropoff1
ExitDropoff1
OccssNyy.b
OccssNyy.b
DI54
DI55
GoToPickup2
OccssNyy.b
DI56
ExitPickup2
OccssNyy.b
DI57
GoToDropoff2
OccssNyy.b
DI58
ExitDropoff2
OccssNyy.b
DI59
GoToPickup3
OccssNyy.b
DI60
ExitPickup3
OccssNyy.b
DI61
GoToDropoff3
OccssNyy.b
DI62
ExitDropoff3
OccssNyy.b
DI63
GoToPickup4
OccssNyy.b
DI64
ExitPickup4
OccssNyy.b
DI65
GoToDropoff4
OccssNyy.b
DI66
ExitDropoff4
OccssNyy.b
DI67
App1ClrToEnter
OccssNyy.b
DI68
This robot input allows the PLC to remotely inform the robot to continue its program from
drop off position 4 and/or shift the part info. To the robot position in the shift register
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
Part3InFixture
OccssNyy.b
DI72
Part4InFixture
OccssNyy.b
DI73
AS OF 10/03/2006
Logical
DI31
DI32
Signal Description
This robot input allows the PLC to remotely inform the robot that option 1 is active for the
current style.
current style.
current style.
current style.
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.
to enter. Reference AAME zone logic standard document for additional info.
This robot input is designated for a user defined function.
This robot input allows the PLC to remotely inform the robot to go to pickup position 1.
pickup position 1 and/or shift the part info. To the robot position in the shift register
This robot input allows the PLC to remotely inform the robot to go to drop off position 1.
drop off position 1 and/or shift the part info. to the robot position in the shift register
14
08 RT DCX REL. 3.0
Signal Name
PLC TAG
Logical
Signal Description
Part5InFixture
OccssNyy.b
DI74
Part6InFixture
OccssNyy.b
DI75
ToolingRepod1
OccssNyy.b
DI76
ToolingRepod2
OccssNyy.b
DI77
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)
Reference ToolingRepod1. The BCD value for ToolingRepod2 = 2 (2^1)
ToolingRepod4
OccssNyy.b
DI78
Reference ToolingRepod1. The BCD value for ToolingRepod4 = 4
ClrToEntTN
OccssNyy.b
DI79
ToolInNest1
OccssNyy.b
DI80
ToolInNest2
OccssNyy.b
DI81
ToolInNest3
OccssNyy.b
DI82
ToolInNest4
OccssNyy.b
DI83
NoStrokeReq
OccssNyy.b
DI84
This robot input is used to remotly inform the PLC that the robot is clear to enter the tool
change nest.
This robot input is used to inform the robot that a tool is present in tool change nesting fixture
1.
2.
3.
4.
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.
ReservedPLCdi86
OccssNyy.b
DI86
TipDressGunReq
OccssNyy.b
DI87
This robot input allows the PLC to remotely request the robot to do a tip dress sequence.
TipDrsDumpRetrct
OccssNyy.b
DI88
This robot input is used to indicate that the tip dress dump(s) are retracted.
TipDrsMotorOn
OccssNyy.b
DI89
This robot input is used to indicate the tip dress motor is running.
ExtStepperReset1
OccssNyy.b
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.b
DI92
ReservedPLCdi93
OccssNyy.b
DI93
This robot input allows the PLC to remotely request the robot to perform a tip burn-in
sequence.
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
PurgeGun2Req
OccssNyy.b
DI97
ReservedPLCdi98
OccssNyy.b
DI98
This robot input allows the PLC to remotely request the robot to perform a purge sequence
for dispenser 1
This robot input allows the PLC to remotely request the robot to perform a purge sequence
for dispenser 2
ReservedPLCdi99
OccssNyy.b
DI99
PickTool1
OccssNyy.b
DI100
PickTool2
OccssNyy.b
DI101
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)
Reference PickTool1 DI101
The BCD value for PickTool2 = 2 (2^1)
PickTool4
OccssNyy.b
DI102
PickTool8
OccssNyy.b
DI103
MaintStyle1Req
OccssNyy.b
DI104
MaintStyle2Req
OccssNyy.b
DI105
MaintStyle3Req
OccssNyy.b
DI106
ReservedPLCdi107
OccssNyy.b
DI107
This robot input allows the PLC to remotely order the robot to execute Style1 (contents of
Style1 maintenance routine are project defined).
ReservedPLCdi108
OccssNyy.b
DI108
ReservedPLCdi109
OccssNyy.b
DI109
ReservedPLCdi110
OccssNyy.b
DI110
ReservedPLCdi111
OccssNyy.b
DI111
ExtApp1Complete
OccssNyy.b
DI112
This robot input is used to indicate that application 1 process is completed.
AS OF 10/03/2006
15
08 RT DCX REL. 3.0
(2^2)
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.
ReservedPLCdi116
OccssNyy.b
DI116
ReservedPLCdi117
OccssNyy.b
DI117
ReservedPLCdi118
OccssNyy.b
DI118
AppErrorAck
OccssNyy.b
DI119
ReservedPLCdi120
OccssNyy.b
DI120
This robot input is used to Acknowledge that the system PLC has received the Application
Error Bits.
PalletPosBit1
OccssNyy.b
DI121
PalletPosBit2
OccssNyy.b
DI122
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)
Reference PalletPosBit1.
The BCD value for PalletPosBit2 = 2 (2^1)
PalletPosBit4
OccssNyy.b
DI123
The BCD value for PalletPosBit4 = 4
(2^2)
PalletPosBit8
OccssNyy.b
DI124
The BCD value for PalletPosBit8 = 8
(2^3)
ReservedPLCdi125
OccssNyy.b
DI125
ReservedPLCdi126
OccssNyy.b
DI126
ReservedPLCdi127
OccssNyy.b
DI127
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
AS OF 10/03/2006
16
08 RT DCX REL. 3.0
DaimlerChrysler
08RT
Robot Device Net Master Node Assignment

Node
Number
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
I/O Size
16 IN / 16 OUT
32 IN / 32 OUT
32 IN / 32 OUT
32 IN / 32 OUT
32 IN / 32 OUT
NOT ASSIGNED
64 IN / 64 OUT
32 IN / 8 OUT
32 IN / 8 OUT
32 IN / 8 OUT
32 IN / 8 OUT
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
32 IN / 48 OUT
32 IN / 48 OUT
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
16 IN
16 IN
16 IN
16 IN
16 IN
NOT ASSIGNED
8 IN / 8 OUT
128 IN / 32 OUT
40 OUT
NOT ASSIGNED
8 IN / 8 OUT
8 IN / 8 OUT
NOT ASSIGNED
NOT ASSIGNED
16 IN / 16 OUT
16 IN / 16 OUT
16 IN / 16 OUT
16 IN / 16 OUT
16 IN / 16 OUT
16 IN / 16 OUT
8 IN / 8 OUT
NOT ASSIGNED
NOT ASSIGNED
128 IN / 40 OUT
8 IN / 8 OUT
8 IN / 8 OUT
8 IN / 8 OUT
8 IN / 8 OUT
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
NOT ASSIGNED
AS OF 10/03/2006
Robot Inputs
Byte
Bits
Robot Outputs
Byte
Bits
2
4
4
4
4
16
32
32
32
32
2
4
4
4
4
16
32
32
32
32
8
4
4
4
4
64
32
32
32
32
8
1
1
1
1
64
8
8
8
8
4
4
32
32
6
6
48
48
2
2
2
2
2
16
16
16
16
16
0
0
0
0
0
0
0
0
0
0
1
16
8
128
1
4
5
8
32
40
1
1
8
8
1
1
8
8
2
2
2
2
2
2
1
16
16
16
16
16
16
8
2
2
2
2
2
2
1
16
16
16
16
16
16
8
8
1
1
1
1
64
8
8
8
8
1
1
1
1
1
8
8
8
8
8
17
Application
Reserved by Robot
Reserved by Robot
Reserved by Robot
Reserved by Robot
Reserved by Robot
Reserved by Robot
Reserved by Robot
Reserved by Robot
Reserved by Robot
Reserved by Robot
ABB -DSQC 328
Weld Timer #1
Weld Timer #2
Weld Timer #3
Weld Timer #4
Spare
Stud Weld
Water Saver #1
Water Saver #2
Water Saver #3
Water Saver #4
Spare
Spare
Spare
Spare
Dispense System A Nordson Process Sentry
Dispense System B Nordson Process Sentry
Spare
Spare
Spare
Spare
MH Input Block 1
MH Input Block 2
MH Input Block 3
MH Input Block 4
MH Input Block 5
Spare
Norgen Smart Pump
Isra Vision (part detect)
Numatics Valve manifold
Hemming (Proportional Regulator)
Ped Weld Dense Pack 1
Ped Weld Dense Pack 2
Spare
Spare
Utica Pierce Unit A Block1
Utica Pierce Unit A Block2
Utica Pierce Unit B Block1
Utica Pierce Unit B Block2
Utica Pierce Unit C Block1
Utica Pierce Unit C Block2
Spare
Spare
Spare
ATI Quick Connect Redundant Tool Changer
Tool changer cover control
Spare
Spare
Spare
Spare
Reserved ODVA Default
08 RT DCX REL. 3.0
Node address: 10
Module Name: ABB-DSQC328
Type:
Signal Name
Type
ESISO Monitor 1
ESISO Monitor 2
ResrvdNode10di2
ResrvdNode10di3
ResrvdNode10di4
ResrvdNode10di5
ResrvdNode10di6
ResrvdNode10di7
g1_temp_ok
Input
Input
Input
Input
Input
Input
Input
Input
Input
0
1
2
3
4
5
6
7
8
g2_temp_ok
Input
ResrvdNode10di10
ResrvdNode10di11
ResrvdNode10di12
ResrvdNode10di13
ResrvdNode10di14
ResrvdNode10di15
Input
Input
Input
Input
Input
Input
10
11
12
13
14
15
Logical
Signal Description
This robot input indicates the state of channel one of the ESISO relay.
This robot input indicates the state of channel two of the ESISO relay.
This robot input is not assigned
This input from gun 1 weld transformer temperature switch is OK when
equal to 1
This input from gun 2 weld transformer temperature switch is OK when
equal to 1
Node address: 10
Module Name: ABB-DSQC328
Type:
Signal Name
Type
ResrvdNode10do0
ResrvdNode10do1
ResrvdNode10do2
ResrvdNode10do3
ResrvdNode10do4
ResrvdNode10do5
ResrvdNode10do6
ResrvdNode10do7
Fault Light
g1_equalize
g2_equalize
ResrvdNode10do11
ResrvdNode10do12
ResrvdNode10do13
ResrvdNode10do14
ResrvdNode10do15
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
AS OF 10/03/2006
Logical
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Signal Description
This robot output is not assigned
This robot output is for Belvedere plant use
This robot output will activate the pneumatic equalizer valve for gun1
This robot output will activate the pneumatic equalizer valve for gun2
18
08 RT DCX REL. 3.0
Node address: 11
Module Name: MFDC Welder
Type:
Signal Name
Type
WT1WeldEnabled
WT1NoFault
WT1NoAlert
WT1WeldFltAvail
Input
Input
Input
Input
0
1
2
3
WT1WeldFltBit1
WT1WeldFltBit2
WT1WeldFltBit4
WT1WeldFltBit8
WT1WeldFltBit16
WT1WeldComplete
WT1WeldInProgres
WT1SteppersReset
WT1NearEndOfStep
Input
Input
Input
Input
Input
Input
Input
Input
Input
4
5
6
7
8
9
10
11
12
WT1EndOfStepper
Input
13
WT1ReadyToWeld
WT1DressTipsReq
WT1GunRetractA
WT1GunRetractB
WT1input18
WT1input19
WT1input20
WT1input21
WT1input22
WT1input23
WT1input24
WT1input25
WT1input26
WT1input27
WT1input28
WT1input29
WT1input30
WT1input31
WT1WeldFaultNum
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Group
Input
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
4-8
AS OF 10/03/2006
Logical
Signal Description
This robot input from the weld timer indicates that weld current is enabled
This robot input from the weld timer indicates that no fault condition exist
This robot input from the weld timer indicates that no alert is present
This robot input from the weld timer indicates that a weld fault/alert code is
set
This robot input is binary bit 1 for the weld fault/alert
This robot input from the weld timer indicates a weld has been completed
This robot input from the weld timer indicates a weld is in progress
This robot input from the weld timer indicates the stepper has been reset
This robot input from the weld timer indicates that end of stepper is
approaching
This robot input from the weld timer indicates that end of stepper has been
reached
This robot input from the weld timer indicates that it is ready to apply welds
This robot input from the weld timer indicates that tip dressing is required
This robot input from the weld timer will not be used for Servo weld guns
This robot input from the weld timer is currently not used
This robot group input is a 5 bit weld fault number from weld timer1
19
08 RT DCX REL. 3.0
Node address: 11
Type
Signal Name
Type
WT1EnableWeld
WT1FaultReset
WT1WeldFltAck
WT1ProgramBit1
WT1ProgramBit2
WT1ProgramBit4
WT1ProgramBit8
WT1ProgramBit16
Output
Output
Output
Output
Output
Output
Output
Output
0
1
2
3
4
5
6
7
WT1ProgramBit32
Output
WT1InitiateWeld
WT1PressTest
WT1InitRetract
WT1ResetStepper
WT1IsoContSvrEnb
Output
Output
Output
Output
Output
9
10
11
12
13
WT1ControlStop
WT1Tipsdressed
WT1WeldIDBit1
Output
Output
Output
14
15
16
WT1WeldIDBit2
Output
17
WT1WeldIDBit4
Output
18
WT1WeldIDBit8
Output
19
WT1WeldIDBit16
Output
20
WT1WeldIDBit32
Output
21
WT1WeldIDBit64
Output
22
WT1WeldIDBit128
Output
23
WT1WeldIDBit256
Output
24
WT1WeldIDBit512
Output
25
WT1WeldIDBit1024
Output
26
WT1WeldIDBit2048
Output
27
WT1WeldIDBit4096
Output
28
WT1WeldIDBit8192
Output
29
WT1output30
WT1output31
WT1ProgramNum
Output
Output
Group
Output
Group
Output
30
31
3-8
WT1WeldIDNum
AS OF 10/03/2006
Logical
Signal Description
This robot output will activate weld mode on the weld timer
This robot output will reset faults on the weld timer
This robot output will acknowledge the weld fault/alert was received
This robot output is binary bit 1 for weld program selection on the weld timer
This robot output is binary bit 16 for weld program selection on the weld
timer
timer
This robot output will initiate a weld program on the weld timer
This robot output will not be used by the robot for Servo weld guns
This robot output will reset the stepper(s) on the weld timer
This robot output will activate the isolation contactor saver on the weld
timer
This robot output will order the weld timer to stop its current operation
This robot output will acknowledge that the weld tips have been dressed
This robot output is binary bit 1 for weld identification selection on the
weld timer
This robot output is binary bit 2 for weld identification selection on the weld
timer
timer
timer
timer
timer
timer
weld timer
weld timer
weld timer
weld timer
weld timer
weld timer
weld timer
This robot output to the weld timer is currently not used
This robot group output sends a 6 bit weld program number to weld timer
16-29
20
This robot group output sends a 14 bit weld identification number to weld
timer
08 RT DCX REL. 3.0
Node address: 12
Type
Signal Name
Type
WT2WeldEnabled
WT2NoFault
WT2NoAlert
WT2WeldFltAvail
Input
Input
Input
Input
0
1
2
3
WT2WeldFltBit1
WT2WeldFltBit2
WT2WeldFltBit4
WT2WeldFltBit8
WT2WeldFltBit16
WT2WeldComplete
WT2WeldInProgres
WT2SteppersReset
WT2NearEndOfStep
Input
Input
Input
Input
Input
Input
Input
Input
Input
4
5
6
7
8
9
10
11
12
WT2EndOfStepper
Input
13
WT2ReadyToWeld
WT2DressTipsReq
WT2GunRetractA
WT2GunRetractB
WT2input18
WT2input19
WT2input20
WT2input21
WT2input22
WT2input23
WT2input24
WT2input25
WT2input26
WT2input27
WT2input28
WT2input29
WT2input30
WT2input31
WT2WeldFaultNum
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Group
Input
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
5-9
AS OF 10/03/2006
Logical
Signal Description
This robot input from the weld timer indicates that weld current is enabled
This robot input from the weld timer indicates that no fault condition exist
This robot input from the weld timer indicates that no alert is present
This robot input from the weld timer indicates that a weld fault/alert code is
set
This robot input from the weld timer indicates a weld has been completed
This robot input from the weld timer indicates a weld is in progress
This robot input from the weld timer indicates the stepper has been reset
This robot input from the weld timer indicates that end of stepper is
approaching
This robot input from the weld timer indicates that end of stepper has been
reached
This robot input from the weld timer indicates that it is ready to apply welds
This robot input from the weld timer indicates that tip dressing is required
This robot group input is a 5 bit weld fault number from weld timer1
21
08 RT DCX REL. 3.0
Node address: 12
Type
Signal Name
Type
WT2EnableWeld
WT2FaultReset
WT2WeldFltAck
WT2ProgramBit1
WT2ProgramBit2
WT2ProgramBit4
WT2ProgramBit8
WT2ProgramBit16
Output
Output
Output
Output
Output
Output
Output
Output
0
1
2
3
4
5
6
7
WT2ProgramBit32
Output
WT2InitiateWeld
WT2PressTest
WT2InitRetract
WT2ResetStepper
WT2IsoContSvrEnb
Output
Output
Output
Output
Output
9
10
11
12
13
WT2ControlStop
WT2Tipsdressed
WT2WeldIDBit1
Output
Output
Output
14
15
16
WT2WeldIDBit2
Output
17
WT2WeldIDBit4
Output
18
WT2WeldIDBit8
Output
19
WT2WeldIDBit16
Output
20
WT2WeldIDBit32
Output
21
WT2WeldIDBit64
Output
22
WT2WeldIDBit128
Output
23
WT2WeldIDBit256
Output
24
WT2WeldIDBit512
Output
25
WT2WeldIDBit1024
Output
26
WT2WeldIDBit2048
Output
27
WT2WeldIDBit4096
Output
28
WT2WeldIDBit8192
Output
29
WT2output30
WT2output31
WT2ProgramNum
Output
Output
Group
Output
Group
Output
30
31
3-8
WT2WeldIDNum
AS OF 10/03/2006
Logical
Signal Description
This robot output will activate weld mode on the weld timer
This robot output will reset faults on the weld timer
This robot output will acknowledge the weld fault/alert was received
timer
timer
This robot output will initiate a weld program on the weld timer
This robot output will reset the stepper(s) on the weld timer
This robot output will activate the isolation contactor saver on the weld
timer
This robot output will order the weld timer to stop its current operation
This robot output will acknowledge that the weld tips have been dressed
weld timer
timer
timer
timer
timer
timer
timer
weld timer
weld timer
weld timer
weld timer
weld timer
weld timer
weld timer
This robot group output sends a 6 bit weld program number to weld timer
16-29
22
This robot group output sends a 14 bit weld identification number to weld
timer
08 RT DCX REL. 3.0
Node address: 17
Module Name: Delta Point Water Saver
Type:
Signal Name
WS1Water OK to Weld
WS1ResrvdNode17di1
WS1Water Bypassed
WS1ResrvdNode17di3
WS1ResrvdNode17di4
WS1ResrvdNode17di5
WS1ResrvdNode17di6
WS1Water Aux. Power
OK
Type
Input
Input
Input
Input
Input
Input
Input
Input
Logical
0
1
2
3
4
5
6
7
Signal Description
This input indicates water flow is acceptable for welding
This input is reserved for water saver
This input indicates the water saver is electrically bypassed
This input indicates that auxiliary power is present at the water saver
Node address: 17
Type:
Signal Name
Type
Logical
WS1ResetWaterSaver
WS1TurnWaterOff
WS1ResrvdNode17do2
WS1ResrvdNode17do3
WS1ResrvdNode17do4
WS1ResrvdNode17do5
WS1ResrvdNode17do6
WS1ResrvdNode17do7
output
output
output
output
output
output
output
output
0
1
2
3
4
5
6
7
Signal Description
This output will reset the water saver to re-establish water flow
This output will turn the water valve off
This output is reserved by water saver
Node address: 18
Type:
Signal Name
WS2Water OK to Weld
WS2ResrvdNode17di1
WS2Water Bypassed
WS2ResrvdNode17di3
WS2ResrvdNode17di4
WS2ResrvdNode17di5
WS2ResrvdNode17di6
WS1Water Aux. Power
OK
Type
Input
Input
Input
Input
Input
Input
Input
Input
Logical
0
1
2
3
4
5
6
7
Signal Description
This input indicates water flow is acceptable for welding
This input indicates the water saver is electrically bypassed
This input indicates that auxiliary power is present at the water saver
Node address: 18
Type:
Signal Name
Type
Logical
WS2ResetWaterSaver
WS2TurnWaterOff
WS2ResrvdNode17do2
WS2ResrvdNode17do3
WS2ResrvdNode17do4
WS2ResrvdNode17do5
WS2ResrvdNode17do6
WS2ResrvdNode17do7
output
output
output
output
output
output
output
output
0
1
2
3
4
5
6
7
AS OF 10/03/2006
Signal Description
This output will reset the water saver to re-establish water flow
This output will turn the water valve off
23
08 RT DCX REL. 3.0
Node address: 16
Module Name: Emhart Stud Weld
Type:
Signal Name
Std1NoFaultHead1
Std1WeldCmpltHd1
Std1HeadBackHd1
Std1SOWHead1
Std1WeldInTolHd1
Std1NoFaultHead2
Std1Weldcmplthd2
Std1HeadBackHd2
Std1SOWHead2
Std1WeldInTolHd2
Std1NoFaultHead3
Std1Weldcmplthd3
Std1HeadBackHd3
Std1SOWHead3
Std1WeldInTolHd3
Std1NoFaultHead4
Std1Weldcmplthd4
Std1HeadBackHd4
Std1SOWHead4
Std1WeldInTolHd4
Std1NoFaultHead5
Std1Weldcmplthd5
Std1HeadBackHd5
Std1SOWHead5
Std1WeldInTolHd5
Std1MaintRequest
Std1StudsLow
Std1ReadyForAuto
Std1ReadyToWeld
Std1FaultGrpBit1
Std1FaultGrpBit2
Std1FaultGrpBit4
Std1FaultBit1
Std1FaultBit2
Std1FaultBit4
Std1FaultBit8
Std1FaultBit16
Std1FaultBit32
Std1FaultBit64
Std1FaultBit128
Std1FaultBit256
Std1Input41
Std1Input42
Std1Input43
Std1Input44
Std1Input45
Std1Input46
Std1Input47
Std1Head1inWpos
Std1Head2inWpos
Std1Head3inWpos
Std1Head4inWpos
Std1Head5inWpos
Std1Head1inPpos
Std1Head2inPpos
Std1Head3inPpos
Std1Head4inPpos
Std1Head5inPpos
Std1SIGrprHead1
Std1SIGrprHead2
Std1SIGrprHead3
Std1SIGrprHead4
Std1SIGrprHead5
Std1MotionRelReq
Type
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
AS OF 10/03/2006
Logical
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
Signal Description
This input from the Emhart control 1 indicates No Fault is present on weld head 1.
This input from the Emhart control 1 indicates the stud weld was complete for head 1.
This input from the Emhart control 1 indicates stud head 1 is retracted.
This input from the Emhart control 1 indicates stud head 1 has a stud on the work piece.
This input from the Emhart control 1 indicates the stud weld was in tolerance for head 1.
This input from the Emhart control 1 indicates that service is requested.
This input from the Emhart control 1 indicates the stud hopper is not running.
This input from the Emhart control 1 indicates that is ready to execute a cycle.
This input from the Emhart control 1 indicates that it is changed and ready to weld.
This input from the Emhart control 1 is a binary bit 1 for group fault condition.
This input from the Emhart controller 1 is binary bit 1 for fault code report
This input from the Emhart controller 1 is currently not used.
24
08 RT DCX REL. 3.0
Node address: 16
Module Name: Emhart Stud Weld
Type:
Signal Name
Type
Logical
Std1StartWeldHd1
Std1StartWeldHd2
Std1StartWeldHd3
Std1StartWeldHd4
Std1StartWeldHd5
Std1StartFeedHd1
Std1StartFeedHd2
Std1StartFeedHd3
Std1StartFeedHd4
Std1StartFeedHd5
Std1WldProgBit1
Std1WldProgBit2
Std1WldProgBit4
Std1WldProgBit8
Std1WldProgBit16
Std1WldProgBit32
Std1WldProgBit64
Std1Output17
Std1RestartWeld
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Std1ForceWeldCmp
Std1ModeSelect1
Std1ModeSelect2
Std1Output22
Std1Output23
Std1Output24
Std1Output25
Std1Output26
Std1Output27
Std1Output28
Std1Output29
Std1Output30
Std1Output31
Std1Output32
Std1Output33
Std1Output34
Std1Output35
Std1Output36
Std1Output37
Std1Output38
Std1Output39
Std1Output40
Std1Output41
Std1Output42
Std1Output43
Std1Output44
Std1Output45
Std1Output46
Std1Output47
Std1MovHd1ToWpos
Std1MovHd2ToWpos
Std1MovHd3ToWpos
Std1MovHd4ToWpos
Std1MovHd5ToWpos
Std1MovHd1ToPpos
Std1MovHd2ToPpos
Std1MovHd3ToPpos
Std1MovHd4ToPpos
Std1MovHd5ToPpos
Std1Output58
Std1Output59
Std1Output60
Std1Output61
Std1Output62
Std1Output63
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
AS OF 10/03/2006
Signal Description
This output to the Emhart control 1 will start a weld cycle with head 1.
This output to the Emhart control 1 initiates a stud feed cycle to head 1.
This output to the Emhart control 1 is bit value 1 of the binary weld select
This output to the Emhart controller 1 is currently not used.
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.
This output to the Emhart control 1 will force a weld complete signal
This output to the Emhart control 1 is used to activate modes of operation.
This output to the Emhart control 1 is used to activate modes of operation.

25
08 RT DCX REL. 3.0
Node address: 25
Module Name: Nordson Process Sentry Dispense
Type:
Signal Name
Type
Logical
Disp 1 System Ready
Input
Disp 1 High Volume Fault
Input
Disp 1 Low Volume Fault
Input
Disp 1 System Fault

Disp 1 Input 4
Disp 1 Input 5
Disp 1 Input 6
Disp 1 Input 7
Disp 1 Input 8
Disp 1 Input 9
Disp 1 Input 10
Disp 1 Input 11
Disp 1 Input 12
Disp 1 Spare
Disp 1 Spare
Disp 1 Dispense in
Process
Disp 1 Temp Cond Ready
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
3
4
5
6
7
8
9
10
11
12
13
14
15
Input
16
Disp 1 Input17
Disp 1 Input18
Disp 1 Input 19
Disp 1 Input 20
Disp 1 Input 21
Disp 1 Input 22
Disp 1 Input 23
Disp 1 Input 24
Disp 1 Input 25
Disp 1 Input 26
Disp 1 Input 27
Disp 1 Input 28
Disp 1 Input 29
Disp 1 Input 30
Disp 1 Input 31
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
AS OF 10/03/2006
Signal Description
This input from the Nordson Controller indicates the system is ready to
dispense.
This input from the Nordson Controller indicates a High Volume Fault is
present
This input from the Nordson Controller indicates a Low Volume Fault is
present
This input from the Nordson controller indicates a System Fault is present
This input from the Nordson Controller is currently not used.
This input from the Nordson Controller indicates dispensing in process
This input from the Nordson Controller indicates Temperature Conditioner
Ready
26
08 RT DCX REL. 3.0
Node address: 25
Module Name: Nordson Process Sentry Dispense
Type:
Signal Name
Type
Logical
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Style Bit 1
Output
Output
Output
Output
0
1
2
3
Disp 1 Style Bit 2
Output
Disp 1 Style Bit 3
Output
Disp 1 Style Bit 4
Output
Disp 1 Style Bit 5
Output
Disp 1 Style Bit 6
Output
Disp 1 Style Bit 7
Output
Disp 1 Style Bit 8
Output
10
Disp 1 Style Bit 9
Output
11
Disp 1 Style Bit 10
Output
12
Disp 1 Style Bit 11
Output
13
Disp 1 Style Bit 12
Output
14
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Part ID Bit 0
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Dry Mode
Disp 1 Alarm Reset
Disp 1 Gun On
Disp 1 Part Strobe
Disp 1 Output
Disp 1 Output
Disp 1 Output
Disp 1 Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
AS OF 10/03/2006
Signal Description
This output to the. Nordson controller 1 is currently not used
This output is binary value 1 for dispense style selection to the Nordson controller
1.
1.
1..
1.
This output is binary value 16 for dispense style selection to the Nordson
controller 1.
controller 1.
controller 1..
controller 1.
controller 1.
controller 1..
controller 1.
controller 1.
This output to the. Nordson controller 1 indicates the Part ID 0
This output to the. Nordson controller 1 indicates Dry Mode is Selected
This output to the. Nordson controller 1 indicates Alarm Reset is present
This output to the. Nordson controller 1 indicates to turn on Gun 1
This output to the. Nordson controller 1 indicates Part Strobe is active
27
08 RT DCX REL. 3.0
Node address: 31
Module Name: MHBlock1
Type: Interlink BT FDNL-S1600-T-0203
Signal Name
Type Logical Signal Description
Part3Present
input
0
This input indicates that Part 3 is present.
Part4Present
input
1
Part5Present
input
2
Part6Present
input
3
CYL4Open
input
4
This input indicates that Cylinder 4 is open.
CYL4Closed
input
5
This input indicates that Cylinder 4 is Closed.
CYL5Open
input
6
CYL5Closed
input
7
CYL6Open
input
8
CYL6Closed
input
9
CYL7Open
input
10
CYL7Closed
input
11
CYL8Open
input
12
CYL8Closed
input
13
CYL9Open
input
14
CYL9Closed
input
15
Node address: 32
Signal Name
Part7Present
input
0
Part8Present
input
1
Part9Present
input
2
Part10Present
input
3
CYL10Open
input
4
CYL10Closed
input
5
CYL11Open
input
6
CYL11Closed
input
7
CYL12Open
input
8
CYL12Closed
input
9
CYL13Open
input
10
CYL13Closed
input
11
CYL14Open
input
12
CYL14Closed
input
13
CYL15Open
input
14
CYL15Closed
input
15
AS OF 10/03/2006
28
08 RT DCX REL. 3.0
Node address: 33
Signal Name
CYL16Open
input
0
CYL16Closed
input
1
CYL17Open
input
2
CYL17Closed
input
3
CYL18Open
input
4
CYL18Closed
input
5
CYL19Open
input
6
CYL19Closed
input
7
CYL20Open
input
8
CYL20Closed
input
9
CYL21Open
input
10
CYL21Closed
input
11
CYL22Open
input
12
CYL22Closed
input
13
CYL23Open
input
14
CYL23Closed
input
15
Node address: 34
Signal Name
CYL27Open
input
0
CYL27Closed
input
1
CYL28Open
input
2
CYL28Closed
input
3
CYL29Open
input
4
CYL29Closed
input
5
CYL30Open
input
6
CYL30Closed
input
7
CYL31Open
input
8
CYL31Closed
input
9
CYL32Open
input
10
CYL32Closed
input
11
CYL33Open
input
12
CYL33Closed
input
13
CYL34Open
input
14
CYL34Closed
input
15
AS OF 10/03/2006
29
08 RT DCX REL. 3.0
Node address: 35
Signal Name
Part1Present
input
0
Part2Present
input
1
CYL1Open
input
2
CYL1Closed
input
3
CYL2Open
input
4
CYL2Closed
input
5
CYL3Open
input
6
CYL3Closed
input
7
Part11Present
input
8
Part12Present
input
9
CYL24Open
input
10
CYL24Closed
input
11
CYL25Open
input
12
CYL25Closed
input
13
CYL26Open
input
14
CYL26Closed
input
15
SLSAP Only
Node address: 37
Module Name: Norgen Smart Pump
Type:
Signal Name
Type
VacuumCH1PP
Input
VacuumCH2PP
Input
Logical
Input
Input
Input
Input
Input
Input
doVacCH1On
output
doBlwOffCh1On
output
doVacCH2On
output
doBlwOffCh2On
output
output
output
output
output
AS OF 10/03/2006
Signal Description
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
This input indicates that Vacuum is present on channel 1

This input indicates that Vacuum is present on channel 2
This robot output will turn on vacuum on channel 1

This robot output will turn on blow off on channel 1
This robot output will turn on vacuum on channel 2
This robot output will turn on blow off on channel 2
30
08 RT DCX REL. 3.0
Node address: 38
Module Name: Isra Vision
Type:
Signal Name
Type
diISRA_StatBit1
diISRA_StatBit2
diISRA_StatBit4
diISRA_StatBit8
diISRA_Ready
diISRA_Meas_ip
diISRA_Data_ip
diISRA_ID_OK
diISRA_reservd
diISRA_ErrPLC
diISRA_ErrRbt
diISRA_OutTol
diISRA_Disabl
diISRA_ErrImage
diISRA_reservd1
diISRA_ErrDet
diISRA_XB1
diISRA_XB2
diISRA_XB4
diISRA_XB8
diISRA_XB16
diISRA_XB32
diISRA_XB64
diISRA_XB128
diISRA_XB256
diISRA_XB512
diISRA_XB1024
diISRA_XB2048
diISRA_XB4096
diISRA_XB8192
diISRA_XB16384
diISRA_XB32768
diISRA_YB1
diISRA_YB2
diISRA_YB4
diISRA_YB8
diISRA_YB16
diISRA_YB32
diISRA_YB64
diISRA_YB128
diISRA_YB256
diISRA_YB512
diISRA_YB1024
diISRA_YB2048
diISRA_YB4096
diISRA_YB8192
diISRA_YB16384
diISRA_YB32768
diISRA_ZB1
diISRA_ZB2
diISRA_ZB4
diISRA_ZB8
diISRA_ZB16
diISRA_ZB32
diISRA_ZB64
diISRA_ZB128
diISRA_ZB256
diISRA_ZB512
diISRA_ZB1024
diISRA_ZB2048
diISRA_ZB4096
diISRA_ZB8192
diISRA_ZB16384
diISRA_ZB32768
diISRA_RXB1
diISRA_RXB2
diISRA_RXB4
diISRA_RXB8
diISRA_RXB16
diISRA_RXB32
diISRA_RXB64
diISRA_RXB128
diISRA_RXB256
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
AS OF 10/03/2006
Logical
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
Signal Description
This input indicates that the Status Bit 1 is high (Mirrors the Command Bits)
This input indicates that the ISRA Vision System is ready for type (Style).
Thiis input indicates that a measurement is in progress
This input indicates that a data transfer is in progress
This input indicates that the type (Style) is OK
This input is reserved
This input indicate a general communication error with the PLC has occurred
This input indicates a communication error with the robot has occurred
This input indicates that the calculation is out of tolerance
This input indicates that a wrong type (Style) was selected
This input indicates that a error occurred during image capture
This input is reserved
This input indicates that an error occurred during detection
This group input (giISRA_Offs_X) indicates the X offset data
This group input (giISRA_Offs_Y) indicates the Y offset data
This group input (giISRA_Offs_Z) indicates the Z offset data
This group input (giISRA_Offs_RX) indicates the RX offset data
31
08 RT DCX REL. 3.0
diISRA_RXB512
diISRA_RXB1024
diISRA_RXB2048
diISRA_RXB4096
diISRA_RXB8192
diISRA_RXB16384
diISRA_RXB32768
diISRA_RYB1
diISRA_RYB2
diISRA_RYB4
diISRA_RYB8
diISRA_RYB16
diISRA_RYB32
diISRA_RYB64
diISRA_RYB128
diISRA_RYB256
diISRA_RYB512
diISRA_RYB1024
diISRA_RYB2048
diISRA_RYB4096
diISRA_RYB8192
diISRA_RYB16384
diISRA_RYB32768
diISRA_RZB1
diISRA_RZB2
diISRA_RZB4
diISRA_RZB8
diISRA_RZB16
diISRA_RZB32
diISRA_RZB64
diISRA_RZB128
diISRA_RZB256
diISRA_RZB512
diISRA_RZB1024
diISRA_RZB2048
diISRA_RZB4096
diISRA_RZB8192
diISRA_RZB16384
diISRA_RZB32768
doISRA_CommandB1
doISRA_CommandB2
doISRA_CommandB4
doISRA_CommandB8
doISRA_Start_M
doISRA_reservd
doISRA_Reset_E
doISRA_ID_Valid
doISRA_TpIDB1
doISRA_TpIDB2
doISRA_TpIDB4
doISRA_TpIDB8
doISRA_TpIDB16
doISRA_TpIDB32
doISRA_TpIDB64
doISRA_TpIDB128
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
doISRA_reservd
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
AS OF 10/03/2006
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

This group input (giISRA_Offs_RY) indicates the RY offset data
This group input (giISRA_Offs_RZ) indicates the RZ offset data
This group output (goISRA_Command) indicates the mode of the vision system
This output is used to Start Measurement
This output is reserved
This output is used to reset errors
This output indicate that the type (Style) ID/measurement is valid
This group output (goISRA_ID) is used to identify the type ID (Style)
32
08 RT DCX REL. 3.0
Node address: 39
Type: Numatics 2012 Manifold Assembly
Type
Logical Signal Description
Signal Name
CloseValve1
output
0
This output closes valve 1.
OpenValve1
output
1
This output opens valve 1.
CloseValve2
output
2
OpenValve2
output
3
CloseValve3
output
4
OpenValve3
output
5
CloseValve4
output
6
OpenValve4
output
7
CloseValve5
output
8
OpenValve5
output
9
CloseValve6
output
10
OpenValve6
output
11
CloseValve7
output
12
OpenValve7
output
13
CloseValve8
output
14
OpenValve8
output
15
CloseValve9
output
16
OpenValve9
output
17
CloseValve10
output
18
OpenValve10
output
19
This output opens valve 10
CloseValve11
output
20
This output closes valve 11
OpenValve11
output
21
This output opens valve 11
CloseValve12
output
22
OpenValve12
output
23
CloseValve13
output
24
OpenValve13
output
25
CloseValve14
output
26
OpenValve14
output
27
CloseValve15
output
28
OpenValve15
output
29
CloseValve16
output
30
OpenValve16
output
31
AS OF 10/03/2006
33
08 RT DCX REL. 3.0
Node address: 45
Module Name: Pierce DriveABlk1
Type:
Signal Name
diDrvA_Ok
diDrvA_On
diDrvAHomeComp
diDrvAForce_Lub
diDrvAReturned
diDrvAAtPos
doDrvAReset
doDrvAMode1Sel
doDrvAMode2Sel
doStyle_drvALub
doDrvAAutomode
Type
Logical
Input
Input
Input
Input
Input
Input
Input
Input
output
output
output
output
output
output
output
output
Signal Description
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Node address: 46
Module Name: Pierce DriveABlk2
Type:
Signal Name
diDrvAMode1Ackn
diDrvAMode2Ackn
diSr400On
diSrFuseOk
doDrvATorqEnble
doDrvAExt_Pos1
doDrvAExt-Pos2
doDrvAPosSel
Type
Input
Input
Input
Input
Input
Input
Input
Input
output
output
output
output
output
output
output
output
AS OF 10/03/2006
Logical
Signal Description
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
34
08 RT DCX REL. 3.0
Node address: 47
Module Name: Pierce DriveBBlk3
Type:
Signal Name
diDrvB_Ok
DiDrvB_On
diDrvBHomeComp
diDrvBForce_Lub
diDrvBReturned
diDrvBAtPos
doDrvBReset
doDrvBMode1Sel
doDrvBMode2Sel
doStyle_drvBLub
doDrvBAutomode
Type
Logical
Input
Input
Input
Input
Input
Input
Input
Input
output
output
output
output
output
output
output
output
Signal Description
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Node address: 48
Module Name: Pierce DriveBBlk4
Type:
Signal Name
diDrvBMode1Ackn
diDrvBMode2Ackn
diSr400On
diSrFuseOk
doDrvBTorqEnble
doDrvBExt_Pos1
doDrvBExt-Pos2
doDrvBPosSel
Type
Input
Input
Input
Input
Input
Input
Input
Input
output
output
output
output
output
output
output
output
AS OF 10/03/2006
Logical
Signal Description
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
35
08 RT DCX REL. 3.0
Node address: 54
Module Name: ATI Dual Redundant Tool Changer
Type:
Signal Name
Type
ToolLocked
input
ToolUnLocked
input
DNetPowerOK
input
AuxPowerOK
input
ReadyToLock1
input
ReadyToLock2
input
ReadyToLockV1
input
ReadyToLockV2
input
ToolStndIntlkV1
input
ToolStndIntlkV2
input
ToolStndRelayV1
input
10
ToolStndRelayV2
input
11
ToolPresent
ReservedTooldi13
ReservedTooldi14
ReservedTooldi15
RTLMismatch
input
12
This robot input from the ATI tool changer indicates that the tool is
locked.
This robot input from the ATI tool changer indicates that the Tool is
unlocked.
This robot input from the ATI tool changer indicates that the Dnet
power is OK.
This robot input from the ATI tool changer indicates that the Aux
Power is OK.
This robot input from the ATI tool changer indicates that the changer is
ready to lock 1 is on.
This robot input from the ATI tool changer indicates that the changer is
ready to lock 2 is on.
This robot input from the ATI tool changer indicates that the RTL1 is
verified.
This robot input from the ATI tool changer indicates that the RTL2 is
verified.
This robot input from the ATI tool changer indicates the state of TSI
switch 1.
This robot input from the ATI tool changer indicates the state of TSI
switch 2.
This robot input from the ATI tool changer indicates the state of the
TSI relay 1.
This robot input from the ATI tool changer indicates the state of the
TSI relay 2.
This robot input from the ATI tool changer tool present.
input
13
This robot input from the ATI tool changer is spare.
input
14
input
15
input
16
TSIVMismatch
input
17
LatchOverLoad
input
18
UnlatchOverLoad
input
19
ReservedTooldi20
input
20
RTLrtlvMismatch
input
21
TSIVtsrvMismatch
input
22
UnsafeUnlatch
input
23
LckUnlckSensFlt
input
24
LatchNotComplt
input
25
UnlatchNotComplt
input
26
TSIVFault
input
27
RTLFault
input
28
ReservedTooldi29
input
29
ReservedTooldi30
input
30
ReservedTooldi31
input
31
ToolIDswtch1bit1
input
32
ToolIDswtch1bit2
input
33
ToolIDswtch1bit4
input
34
This robot input from the ATI tool changer indicates there is a
mismatch between RTL1 and RTL2.
This robot input from the ATI tool changer indicates there is a
mismatch between TSIV1 and TSIV2.
This robot input from the ATI tool changer indicates the latch output is
overloaded.
This robot input from the ATI tool changer indicates the unlatch output
is overloaded.
This robot input from the ATI tool changer indicates the spare output is
overloaded.
This robot input from the ATI tool changer indicates the master PCB
has an error.
This robot input from the ATI tool changer indicates the tool PCB or
TSI switch has an error.
This robot input from the ATI tool changer indicates that the tool
changer has detected an unsafe unlatch condition and disabled the
unlatch.
This robot input from the ATI tool changer indicates the tool changer
has detected lock and unlock sensors at the same time.
This robot input from the ATI tool changer indicates the latch process
did not complete.
This robot input from the ATI tool changer indicates the unlatch
process did not complete.
This robot input from the ATI tool changer indicates TSIV Input is
stuck high.
. This robot input from the ATI tool changer indicates RTL Input is
stuck high
This robot input from the ATI tool changer indicates Tool ID
Communication Timeout.
This robot input from the ATI tool changer indicates which tool ((ID)
switch 5 bit4) is coupled.
switch 5 bit8) is coupled.
switch 1 bit1) is coupled
ToolIDswtch1bit8
input
35
AS OF 10/03/2006
Logical
36
Signal Description
08 RT DCX REL. 3.0
ToolIDswtch2bit1
input
36
ToolIDswtch2bit2
input
37
ToolIDswtch2bit4
input
38
ToolIDswtch2bit8
input
39
ToolIDswtch3bit1
input
40
ToolIDswtch3bit2
input
41
ToolIDswtch3bit4
input
42
ToolIDswtch3bit8
input
43
ToolIDSwth4bit1
input
44
ToolIDSwth4bit2
input
45
ToolIDSwth4bit3
input
46
ToolIDSwth4bit4
input
47
ToolIDSwtch5bit1
input
48
ToolIDSwtch5bit2
input
49
ToolIDSwtch5bit4
input
50
ToolIDSwtch5bit8
input
51
ReservedTooldi52
ReservedTooldi53
ReservedTooldi54
ReservedTooldi55
ReservedTooldi56
ReservedTooldi57
ReservedTooldi58
ReservedTooldi59
ReservedTooldi6
ReservedTooldi6
Reserved
Reserved
input
52
This robot output to the ATI tool changer is not used.
input
53
input
54
input
55
input
input
56
57

input
58
input
59
input
60
input
61
input
62
input
63
AS OF 10/03/2006
37
08 RT DCX REL. 3.0
Node address: 54
Module Name: ATI Dual Redundant Tool Changer
Type:
Signal Name
Type
Latch or Lock
Ouput
Unlatch or Unlock
Ouput
Spare
Clear Errors
Manual Mode Activated
Ouput
Ouput
Ouput
2
3
4
Out of Nest
Ouput
Logical
Signal Description
This robot output to the ATI tool changer will latch or lock tool
changer. Not used on DCX tool changers
This robot output to the ATI tool changer will unlatch or unlock the tool
changer.
This robot output to the ATI tool changer is a spare.
This robot output to the ATI tool changer will reset error bits.
This robot output to the ATI tool changer is for manual pendant
control.
This robot output to the ATI tool changer indicates that the EOAT is
out of nest.
6
7
SLSAP Only
Node address: 55
Module Name: Tool Nest and Changer Cover #1
Type:
Signal Name
Cover #1 Closed
Cover #1 Open
Tool in nest #1 switch 1
Close Cover #1
Open Cover #1
Type
Logical
Input
Input
Input
Input
Input
Input
Input
Input
output
output
0
1
2
3
4
5
6
7
8
9
output
10
output
11
output
output
output
output
12
13
14
15
Signal Description
This input to the robot indicates the cover over the tool changer #1 is closed
This input to the robot indicates the cover over the tool changer #1 is open.
This input to the robot indicates the tool is in the nest #1
This input to the robot indicates the tool is in the nest #1.
SLSAP Only
Node address: 56
Type:
Signal Name
Cover #2 Closed
Cover #2 Open
Close Cover #2
Open Cover #2
Type
Logical
Input
Input
Input
Input
Input
Input
Input
Input
output
output
0
1
2
3
4
5
6
7
8
9
output
10
output
11
output
output
output
output
12
13
14
15
AS OF 10/03/2006
Signal Description
38
08 RT DCX REL. 3.0
SLSAP Only
Node address: 57
Type:
Signal +Name
Cover #3 Closed
Cover #3 Open
Close Cover #3
Open Cover #3
Type
Logical
Input
Input
Input
Input
Input
Input
Input
Input
output
output
0
1
2
3
4
5
6
7
8
9
output
10
output
11
output
output
output
output
12
13
14
15
Signal Description
SLSAP Only
Node address: 58
Type:
Signal Name
Cover #4 Closed
Cover #4 Open
Close Cover #4
Open Cover #4
Type
Logical
Input
Input
Input
Input
Input
Input
Input
Input
output
output
0
1
2
3
4
5
6
7
8
9
output
10
output
11
output
output
output
output
12
13
14
15
AS OF 10/03/2006
Signal Description
39
08 RT DCX REL. 3.0
APPLICATION ERRORS
(A.B.B. ROBOT)
THE FOLLOWING APPLICATION ERRORS ARE USED WITH MATERIAL HANDELING SYSTEMS ONLY
BIT WEIGHT
01
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
DESCRIPTION
Disable fault and continue is active on robot XX
AS OF 10/03/2006
40
08 RT DCX REL. 3.0
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)
34
35
Input / Output Alarm

Incomplete Weld
36
37
38
39
Stepper Approaching Maximum

End of Stepper
Reserved
High / Low Current Limit
40
41-43
44
Firing Error
Reserved
Compensation Error
45
46
47
48
Reserved
Extend Weld
Isolation Contactor Error
Welding Buss Voltage
49
50
Weld Data Not Programmed

Analog Pressure Error
51
C-Factor Limit
52
53
Secondary Current
Welding Transformer
54
55
56
Over Temperature
Reserved
Internal Timer Error
57
Inverter Fault
AC/MFDC
AC/MFDC
MFDC
AC/MFDC
AC/MFDC
AC/MFDC
AC/MFDC
AC/MFDC
I/O Adapter Failure:

(Fault)
Weld Proceed:
(Fault)
Charge / Discharge Duty Cycle: (Fault)
Weld Initiate not present:
(Alert)
Control Stop:
(Fault)
Weld Interruption:
(Fault)
Stepper Approaching Maximum: (Alert)
End of Stepper:
(Fault)
AC/MFDC
AC/MFDC
MFDC
High Current Limit Fault:

Low Current Limit Fault:
Control Failed to Fire :
(Fault)
(Fault)
(Alert)
MFDC
MFDC
MFDC
Low Power Line :

Soft Over Current :
Current Regulation :
(Alert)
(Alert)
(Alert)
AC/MFDC
MFDC
AC/MFDC
MFDC
MFDC
MFDC
AC/MFDC
AC/MFDC
AC/MFDC
AC/MFDC
MFDC
MFDC
MFDC
MFDC
MFDC
MFDC
Extend Weld:
(Alert)
Inverter ISO CNTR Off :
(Fault)
No Zero Crossing Synchronization: (Fault)
DC Bus Over Voltage :
(Fault)
Inverter Bus :
(Fault)
Weld Data Not Programmed :
(Fault)
Pressure Not Achieved:
(Fault)
Pressure Current Loop Alarm: (Fault)
High C-Factor Limit:
(Alert)
Low C-Factor Limit:
(Alert)
Sec Current Sensor :
(Fault)
Welding Transformer :
(Fault)
Output Ground :
(Fault)
Transformer Duty Cycle :
(Fault)
Tfmr Sec Diode Failure :
(Fault)
Inverter Over Temp:
(Fault)
AC/MFDC
AC/MFDC
AC/MFDC
MFDC
MFDC
MFDC
MFDC
MFDC
Ram Checksum:
(Fault)
Rom Checksum:
(Fault)
Hardware/Software Incompatibility: (Fault)
Inverter Serial Comm:
(Fault)
Capacitor Discharge :
(Fault)
Capacitor Charge :
(Fault)
Hard Over current:
(Fault)
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 10/03/2006
41
08 RT DCX REL. 3.0
THE FOLLOWING APPLICATION ERRORS ARE USED WITH ATI TOOL CHANGERS SYSTEMS ONLY
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
Insta Bus Module Failed

Tool changer Communication Error
Tool aux. power not present
Tool latch not open
Tool latch not closed
Tool latch solenoid not energized
Tool Unlatch solenoid not energized
Tool RTL not active
Tool RTLV not active
Tool not present
Unexpected tool present
Tool stand interlock not active
Nest not empty
Nest is empty
Cover not open
Cover not closed
Expected tool id not active
Expected robot id not active
Expected line id not active
TSIV not on
THE FOLLOWING APPLICATION ERRORS ARE USED WITH EMHART STUD WELD SYSTEMS ONLY
100
101
102
103
104
105
106
107
108
109
Stud Out of Tolerance

Stud Low in Hopper
Stud Welder Maintenance Required
Stud Welder Head Faulted
Stud Welder Not Ready for Auto.
Stud Welder Not Ready to Weld
Head Back signal not received
Weld Complete not received
Invalid head number programmed
Stud on work not received
THE FOLLOWING APPLICATION ERRORS ARE USED WITH NORDSON DISPENSE SYSTEMS ONLY
120
121
122
123
124
125
126
127
128
129
130
Remote Start is Not On

Dispenser Ready is Not On
Dispenser in Auto is Not On
Dispenser in Manual Is On
Dispenser is Not Pressurized
Air is Not Present at BAS pump
Air is Not Present at Catalyst pump
Dispense Volume OK is Off
Major Fault is On Dispenser
Invalid Dispenser Active
Dispense in Process Is Off
AS OF 10/03/2006
42
08 RT DCX REL. 3.0
SLSAP Only
THE FOLLOWING APPLICATION ERROR IS USED WITH PERCEPTRON CMM SYSTEMS ONLY
131
132
133
134
135
136
137
138
139
140
141
142
Minor Error During Quick Check

Moderate Error During Quick Check
Major Error During Quick Check
Spare
Calibration Error (Initialization or Recovery)
Correction (Filter) Error
Spare
Preventive Error
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
Laser Sensor Warning
158
Locking Bar Not In Position Fault
159
THE FOLLOWING APPLICATION ERROR IS USED WITH PIERCE SYSTEMS ONLY

160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
Dynalog Major fault

Dynalog Minor fault
Work Support Pressure Fault
Moog Mode fault
Moog Drive A OK fault
Moog Drive B OK fault
Moog Drive A ON fault
Moog Drive B ON fault
Moog Drive A Position fault
Moog Drive B Position fault
Moog Drive A Force fault
Moog Drive B Force fault
Perceptron Communication Fault
Perceptron Status Fault
Perceptron Bad Measurment
AS OF 10/03/2006
43
08 RT DCX REL. 3.0
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 XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
THE FOLLOWING APPLICATION ERROR IS USED WITH DYNALOG SYSTEMS ONLY
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
Minor Error During Quick Check

Moderate Error During Quick Check
Major Error During Quick Check
Spare
Calibration Error (Initialization or Recovery)
Correction (Filter) Error
Spare
Preventive Error
AS OF 10/03/2006
44
08 RT DCX REL. 3.0
THE FOLLOWING APPLICATION ERRORS ARE USED WITH MATERIAL HANDELING SYSTEMS ONLY
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
Part Present 1 Fault

MH Device 1 Retract Fault
MH Device 1 Extend Fault
AS OF 10/03/2006
45
08 RT DCX REL. 3.0
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254

MH Device 31Extend Fault
255
AS OF 10/03/2006
46
08 RT DCX REL. 3.0
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 10/03/2006
47
08 RT DCX REL. 3.0
| STYLE BIT INFORMATION IS SENT TO THE ROBOT

S01 R01
S01 R01
|
| IN BINARY FORMAT
ACTIVE
PROGRAM
|
|
STYLE BIT1
RUNNING ECHO|
|
I10N01.B25
R01.PgmEcho.0 |
4+------------------------------------------------+-----] [-----------------( )---+
|
|
S01 R01
S01 R01
|
|
|
ACTIVE
PROGRAM
|
|
|
STYLE BIT2
RUNNING ECHO|
|
| I10N01.B26
R01.PgmEcho.1 |
|
+-----] [-----------------( )---+
|
|
S01 R01
S01 R01
|
|
|
ACTIVE
PROGRAM
|
|
|
STYLE BIT4
RUNNING ECHO|
|
| I10N01.B27
R01.PgmEcho.2 |
|
+-----] [-----------------( )---+
|
|
S01 R01
S01 R01
|
|
|
ACTIVE
PROGRAM
|
|
|
STYLE BIT8
RUNNING ECHO|
|
| I10N01.B28
R01.PgmEcho.3 |
|
+-----] [-----------------( )---+
|
|
S01 R01
S01 R01
|
|
|
ACTIVE
PROGRAM
|
|
| STYLE BIT16
RUNNING ECHO|
|
| I10N01.B29
R01.PgmEcho.4 |
|
+-----] [-----------------( )---+
|
|UNUSED STYLE BITS
|
|
|R01.PgmEcho.5 R01.PgmEcho.6 R01.PgmEcho.7|
|
+---(U)------(U)---------(U)----+
|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 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 10/03/2006
48
08 RT DCX REL. 3.0
|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 |
|
<-----]/[-+------( )----+
|
| S01 R01
|
|
| APPLICATION |
|
| 1 CLEAR TO |
|
| ENTER
|
|
| O10N01.B69 |
|
+-------( )---+
|
|
|THE ROBOT AT WORK RUNG IS TRUE FOR THE DURATION OF THE ROBOTS CYCLE. IT IS
|
|RESET BY THE ROBOT COMPLETING ITS PROGRAM.
|
|ST01 R01
|
|ROBOT AT
ST01 R01 |
|WORK
AT WORK |
|D-NET
INTERNAL |
| I10N01.b12
+--NEQ-------------- --+
R01.AtWork |
11+--] [---------+Not Equal (AB) +-----------------------------------------(L)----+
|
|A:
R01.PgmEcho|
|
|
|B:
0 |
|
|
+----------------+
|
|
|
AS OF 10/03/2006
49
08 RT DCX REL. 3.0
|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
|
|
+--] ]------------------------------------------------+
|
|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)-----+
AS OF 10/03/2006
50
08 RT DCX REL. 3.0
|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|
|
|
+---] [---+
|
|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.b15
S01.UnclpEarly |
18+--] [--------------------------------------------------------------------( )----+
|
|
AS OF 10/03/2006
51
08 RT DCX REL. 3.0
|THE EXTERNAL WATER VALVE RESET SIGNAL WILL TRIGGER THE ROBOT TO RESET THE WATER |
|VALVE IF IT IS FAULTED.
SYSTEM
S01 R01 |
|
ANY AUTO
SYSTEM
EXTERNAL |
|
PB PRESSED
READY FOR
WATER
|
|
AUTOMATIC
VALVE
|
|
INTERNAL
RESET
|
|
Sys.AnyAutoPB
Sys.RdyForAuto
O10N01.b94
|
19+----------------------------+---+---+---] [-----+------] [-----------+--( )-----+
|
|
|
|SYSTEM
|
|
|
|
|
|
|FAULT RESET|
|
|
|
|
|
|Sys.FltReset
|
|
|
|
|
|
+---] [-----+
|
|
|
|
|
ZONE 1
|
|
|
|
| ZONE 1
S01-S02
SYSTEM
|
|
|
|
| S01-S02
PERIMTER
RESET WATER |
|
|
|
|
MR ON
ZONE OK
SAVER VALVE |
|
|
|
|
Zn1.MR
Zn1.PreimOK
Sys.ResetWater
|
|
|
|
+----] [--------] [--------] [-------+ S01 R01 |
|
|
ZONE
EXTERNAL |
|
|
S01-S02
WATER OFF|
|
|
MR ON
REQUEST |
|
|
Zn1.MR
O10N01.B96 |
|
+--------]/[--------------------------------( )-----+
|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+--] [---------------------------------------------------------------------( )---+
|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
|
|
+--] [------+
|
AS OF 10/03/2006
52
08 RT DCX REL. 3.0
|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+--] [-------------------------------------------------------------------( )-----+
|
|
|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
+------------------------------------------------------( )-----+
|
||
0 |
|
||Source B
8 |
|
|+----------------+
|
|
|
|ROBOT TIP DRESS CONTACTOR ON IS A SIGNAL TO THE PLC TO TURN ON THE TIP DRESSER |
|MOTOR. THIS RUNG WOULD BE DUPLICATED FOR SECOND TIP DRESSER. ADDITIONAL CONTROLS|
|MAY BE REQUIRED FOR DUMP UNITS.
|
|S01 R01
|
|TURN ON FROM SFTY
S01 R01
SO1 RO1
S01 R01 |
|TIP
S01 R01
S01 R01
S01 R01 R01 TIP TIP
IN TIP
TIP DRESS|
|DRESSER GEN STOP
RUN CHAIN ROBOT
DRESSER DRESS
DRESS
CONTACTOR |
|D-NET
ENABLE
OK
CYCLE ON READY
FAULT
CYCLE
ON
|
|I10M01.b90 FrmSfty.GenStpRbt.0 I10N01.B09 I10N01.B14 I10N01.B04 R01.TipDressFlt R01.InTipDress1 R01.TpDressMtr1|
28+--] [------] [---------] [------] [------] [------]/[-+------] [----+---( )-----+
|
|
|
|
|
| SO1 RO1
| S01 RO1 |
|
| IN AUTO
| TIP DRESS|
|
|
| BLOW OFF |
|
|
| ON
|
|
|R01.InAuto
|R01.TpBlowOff |
|
+----]/[------+---( )-----+
AS OF 10/03/2006
53
08 RT DCX REL. 3.0
|
|
|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
TIP DRESS|
|CONTACT
MOTOR
|
|TIP DRESS #1
ON
|
|MTR START
D-NET
|
| R01.TipDressMtrOn1
O10N01.b90 |
29+--] [------------------------------------------------------------------( )------+
|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.b19
|
30+--] [------+--] [-------]/[-------] [-------]/[-------]/[--------------( )------+
|
|
|
| S01 R01
|
|
| SERVICE
|
|
| REQUESTED |
|
| D-NET
|
|
| O10N01.b19 |
|
+--] [------+
|
|
|
|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)
+-------------------------------------------------------( )----+
|
||
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
|
|
+--] [-------+
|
|
|
|
|
AS OF 10/03/2006
54
08 RT DCX REL. 3.0
|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+--] [-------------------------------------------------------------------( )-----+
|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+--] [-------------------------------------------------------------------( )-----+
|
|
|
S01 R01 |
|SO1 R01
BASE LIMIT|
|ROBOT BASE
SWITCH #2 |
|LIMIT #2
ECHO
|
|(FROM SAFETY PLC)
D-NET
|
| From.Safety.Res
O10N01.b08 |
35+--] [-------------------------------------------------------------------( )-----+
|
|
|
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 |
|HMI RESET
ROBOT
AUTO
S01 R01
STEPPER |
|STEPPER
CYCLE ON MODE
STEPPER
RESET
|
| PB
D-NET
INTERNAL RESET ACK
D-NET
|
|R01.HMIResetStprPB
I10N01.b14
S01.Auto
I10N01.B91
O10N01.B91 |
37+--] [--------------+--]/[-------]/[-------]/[--------------------------( )------+
|SYSTEM
|
|
|RESET ALL
|
|
|STEPPERS
|
|
|Sys.StprReset
|
|
+--] [--------------+
|
| S01 R01
|
|
| EXTERNAL
|
|
| STEPPER
|
|
| RESET
|
|
|O10N01.B91
|
|
+--] [--------------+
|
|
|
|THIS RUNG INDICATES THE STEPPERS HAVE BEEN RESET.
|
|S01 R01
S01 R01
|
|STEPPER
STEPPERS
|
|RESET ACK
ARE RESET
|
|I10N01.B91
R01.StprsAreReset |
38+---] [-----------------------------------------------------------------( )------+
AS OF 10/03/2006
55
08 RT DCX REL. 3.0
|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
S01 R01 |
|GLOBAL
S01 R01
TIP
|
|TIP
TIP BURN IN
BURN IN |
|BURN IN
COMPLETE
REQUEST |
|R01.HMITipBurn
I10N01.B93
O10N01.b93 |
39+--] [------+------]/[--------------------------------------------------( )------+
|S01 R01
|
|
|TIP BURN IN|
|
|REQUEST
|
|
|O10N01.B93
|
|
+--] [------+
|
|
|
|ROBOT APPLICATION ERROR RUNG
|
|S01 R01
|
|APP ERROR ZONE 1
S01 R01
|
|ACTIVE
S01-S02
APP ERROR
|
|D-NET
MR ON
ACTIVE
|
|I10N01.b120
Zn1.MR
R01.AppErr.Active |
40+--] [-------] [----------------------------------+----------------------( )-----+
|
|S01 R01
S01 R01
|
|
|IN TIP
APP ERROR
|
|
|DRESS
DISPLAY
|
|
|CYCLE #1
CODES TO HMI |
|
| R01.InTipDress1
R01AppErr.DisplayHMI |
|
+---] [-----+-------------( )--+
|
|IN TIP
|
|
|
|DRESS
|
|
|
|CYCLE #2
|
|
|
| R01.InTipDress2|
|
|
+---] [-----+
|
|
|S01 R01
|
|
|
|IN SERVICE |
|
|
|CYCLE
|
|
|
|INTERNAL
|
|
|
| R01.InServCyc |
|
|
+---] [-----+
|
|
|
S01
|
|
|
| AUTO MODE |
|
|
| S01.Auto
|
|
|
+---] [-----+
|
|
|
|THIS RUNG LOADS THE APPLICATION ERROR CODES
|
|
S01 R01
S01 R01
|
|
APP ERROR
APP ERROR |
|
BIT 1
ROBOT CODE |
|
I10N01.B121
R01.AppErr.RbtCode.0 |
41+------------------------------------------+-----------] [-----------------( )---+
|
|
S01 R01
S01 R01
|
|
|
APP ERROR
APP ERROR |
|
|
BIT2
ROBOT CODE |
|
|
I10N01.B122
|
+-----------] [-----------------( )---+
|
|
S01 R01
S01 R01
|
|
|
APP ERROR
PROGRAM
|
|
|
BIT 4
ROBOT CODE |
|
|
I10N01.B123
R01.AppErr.RbtCode.2|
|
+-----------] [-----------------( )---+
|
|
S01 R01
S01 R01
|
|
|
APP ERROR
PROGRAM
|
|
|
BIT 8
ROBOT CODE |
|
|
I10N01.B124
|
+-----------] [-----------------( )---+
AS OF 10/03/2006
56
08 RT DCX REL. 3.0
|
|
S01 R01
S01 R01
|
|
|
APP ERROR
APP ERROR |
|
|
BIT 16
ROBOT CODE |
|
|
I10N01.B125
|
+-----------] [-----------------( )---+
|
|
S01 R01
S01 R01
|
|
|
APP ERROR
PROGRAM
|
|
|
BIT 32
ROBOT CODE |
|
|
I10N01.B126
|
+-----------] [-----------------( )---+
|
|
S01 R01
S01 R01
|
|
|
APP ERROR
PROGRAM
|
|
|
BIT 64
ROBOT CODE |
|
|
I10N01.B127
|
+-----------] [-----------------( )---+
|
|
S01 R01
S01 R01
|
|
|
APP ERROR
PROGRAM
|
|
|
BIT 128
ROBOT CODE |
|
|
I10N01.B128
|
+--------+-----------] [-----------------( )---+
|
|S01 R01
S01 R01
S01 R01
|
|
|APP ERROR
APP ERROR
APP ERROR |
|
|ROBOT CODE
RBT CODE
RBT CODE |
|
|R01.AppErr.RbtCode.8 R01.AppErr.RbtCode.9 R01.AppErr.RbtCode.10|
|
+------(U)---------------(U)------------(U)----+
|
|S01 R01
S01 R01
S01 R01
|
|
|APP ERROR
APP ERROR
APP ERROR |
|
|ROBOT CODE
RBT CODE
RBT CODE |
|
|R01.AppErr.RbtCode.11 R01.AppErr.RbtCode.12 R01.AppErr.RbtCode.13 |
|
+------(U)---------------(U)------------(U)----+
|
|
S01 R01
S01 R01
|
|
|
APP ERROR
APP ERROR |
|
|
RBT CODE
RBT CODE |
|
|
R01.AppErr.RbtCode.14 R01.AppErr.RbtCode.15|
|
+------------------------(U)------------(U)----+
|
|
|THE APPLICATION ERROR RUNG ACKNOLODGE RUNG ACKNOLODGES THE APP ERROR TO ROBOT
|
|
S01 R01
S01 RO1 |
| S01 R01
APP ERROR
APP ERROR|
|APP ERROR
SYSTEM
NEW ERROR
NEW ERROR|
| ACTIVE
FAST FLASH
ONE SHOT
|
|R01AppErr.Active Sys.Flasher3
R01AppErr.NewOns R01AppErr.New|
42+---] [---------] [-------------------------------------+-----(ons)-----( )------+
|
|
S01 R01 |
|
|
APPLICATION|
|
|
ERROR ACK|
|
|
O10N01.B120 |
|
+----------------( )-----+
|
|
AS OF 10/03/2006
57
08 RT DCX REL. 3.0
| 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 |
43+---------------------------------------------+--]/[--------]/[----------(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 |
44+---------------------------------------------+--]/[--------]/[----------(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)-----+
AS OF 10/03/2006
58
08 RT DCX REL. 3.0
THE EXTERNAL STOP ROBOT SIGNAL TO THE ROBOT MUST BE HELD HIGH TO RUN THE ROBOT. |
|
S01 RO1 |
|
STOP
|
|
ROBOT
|
|
D-NET
|
|
O10N01.b00 |
45+-----------------------------------------------------------------------( )------+
|
|
|
|
46+--------------------------------------------------------------------------[END]-+
AS OF 10/03/2006
59
08 RT DCX REL. 3.0
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 non-alternating pattern. For example a robot would pick-up a part in Zone
1 then transfer it to Zone 2. The next robot would pick-up the part from Zone 1 then transfers it to Zone 2. This nonalternating 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 robots EOAT without the use of a station.
Hand-off Zones are applied using an non-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 4 then transfers it to Zone 5 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
AS OF 10/03/2006
60
08 RT DCX REL. 3.0
Interference Zone Example 1
AS OF 10/03/2006
61
08 RT DCX REL. 3.0
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.
AS OF 10/03/2006
62
08 RT DCX REL. 3.0
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.)
(DISPENSE)
63
STYLE
(XXXXX.010)
(MAT./HAND.)
(TOOLCHANGE)
64
STYLE
(XXXXX.010)
(MAT./HAND.)
65
STYLE
(XXXXX.007)
(TIP DRESS )
67
STYLE
(XXXXX.008)
(TOOLCHANGE)
68
STYLE
(XXXXX.060)
(RETURN FROM
POUNCE)
FUTURE
(PIN OUT
POSITION)
FUTURE
STYLE
(XXXXX.099)
STYLE
(XXXXX.006)
(SERVICE)
FUTURE
STYLE
(XXXXX.005)
(TIP BURN IN)
FUTURE
STYLE
(XXXXX.009)
(GUN CHANGE)
FUTURE
STYLE
(XXXXX.010)
(STUD WELD)
FUTURE
AS OF 11/03/2005
63
08 RT DCX REL. 0.0
AS OF 11/03/2005
64
08 RT DCX REL. 0.0
AS OF 10/03/2006
65
08 RT DCX REL. 3.0
AS OF 10/03/2006
66
08 RT DCX REL. 3.0
AS OF 10/03/2006
67
08 RT DCX REL. 3.0
AS OF 10/03/2006
68
08 RT DCX REL. 3.0
AS OF 10/03/2006
69
08 RT DCX REL. 3.0
AS OF 10/03/2006
70
08 RT DCX REL. 3.0
AS OF 10/03/2006
71
08 RT DCX REL. 3.0
AS OF 10/03/2006
72
08 RT DCX REL. 3.0
REFERENCE PROGRAM INSTRUCTIONS

(A.B.B. ROBOT)
ALL APPLICATIONS
Instruction
AddMinorFISFlt
ClearMajorFISFlt
Example/Argument
Add Minor FIS Fault = AddMinorFISFlt is

used whenever the IRB needs to alert the PLC
that a minor fault condition has been detected
and supplies the PLC with the appropriate FIS
Minor fault index.
ClearMajorFISFlt; indicates to the PLC that

a previously reported Major fault no longer
exists.
Clear Major FIS Fault = ClearMajorFISFlt is

used whenever the IRB needs to alert the PLC
that a previously reported Major fault condition
no longer exists.
ClearOfApp APP_1; indicates to the PLC

that the IRB is clear of Application 1.
Clear of Application Status = ClearOfApp is

used to inform the PLC that the IRB is
physically clear of the Application. The
instruction allows the PLC to coordinate entry
of other IRBs into the Application.
ClearOfAppJ APP_1, p30, v1000, z30, tool2

; The TCP of the tool, tool2, is moved along
a non-linear path to the position p30, with
speed data v1000 and zone data z30.
In the middle of the corner path at p30 the
PLC will be informed that the IRB has exited
Application 1.
Clear of Application Status = ClearOfAppJ is

ClearOfAppL APP_1, p30, v1000, z30,

tool2; The TCP of the tool, tool2, is moved
along a linear path to the position p30, with
Application 1.
Clear of Application Status = ClearOfAppL is

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.
This instruction allows the PLC ReqToEnter to
be ignored during sensitive areas of the user
program such as dispense path, spotweld
instruction, etc.
Enable Request To Enter = EnableReq2Enter
enables the PLC signal ReqToEnter which
results in a program stop condition when the
ReqToEnter is high.
ClearOfApp
ClearOfAppJ
ClearOfAppL
Definition
AddMinorFISFlt 255; indicates to the PLC

that the IRB has detected a Minor fault
condition and supplies the PLC with FIS
Minor fault index 255.
DisableReq2Enter
EnableReq2Enter;
EnableReq2Enter
AS OF 10/03/2006
73
08 RT DCX REL. 3.0
EnterApp
MoveAbsJ_KEYpos
MoveJ
MoveL
PostMajorFISFlt
RmvMinorFISFlt
RepositionTool
StartExtProc
EnterApp APP_1; indicates to the PLC that

the IRB has approached Application 1, and
allows the PLC to coordinate the IRB entry
into the Application.
Enter Application =EnterApp is used whenever

the IRB needs to enter an Application that may
be in use by another IRB.
MoveAbsJ_KEYpos
USER_POS1,v1000,tool2; The TCP of the
tool, tool2, is moved along a non-linear path
to the absolute axis position as described by
USER_POS1, with speed data v1000.
MoveAbsJ to the Key Position =

MoveAbsJ_KEYpos is used to move the robot
to a Key absolute position, defined in axis
positions. A comparision of the Key position (a
position which affects other robots) is made
with an associated saved position to detect if
the Key position has been modified.
Moves the robot by joint movement=MoveJ is
used to move the robot quickly from one point
to another when that movement does not have
to be in a straight line.
MoveJ p1, vmax, z30, toolgun1; The tool

center point (TCP) of the tool, toolgun1, is
moved along a non-linear path to the
position, p1, with speed data vmax and zone
data z30.
MoveL p1, v1000, z30, toolgun1
The TCP of the tool, toolgun1, is moved
linearly to the position p1, with speed data
v1000 and zone data z30.
Moves the robot linearly = MoveL is used to

move the tool centre point (TCP) linearly to a
given destination. When the TCP is to remain
stationary, this instruction can also be used to
reorient the tool.
PostMajorFISFlt 255; indicates to the PLC

that the IRB has detected a Major fault
condition and supplies the PLC with FIS
Major fault index 255.
Post Major FIS Fault = PostMajorFISFlt is used

whenever the IRB needs to alert the PLC that a
Major fault condition has occurred and supplies
the PLC with the appropriate FIS Major fault
index.
RmvMinorFISFlt 255; removes FIS Minor

fault index 255 from the Minor fault
reporting table.
Remove Minor FIS Fault = RmvMinorFISFlt is

used whenever the IRB needs to remove a FIS
Minor fault index from the FIS fault reporting
table (internal to the robot).
RepositionTool TOOL_2; Request the PLC

to reposition tool 2 and waits for PLC
acknowledgment that tool 2 has completed
repositioning.
Reposition Tool Request = RepositionTool

allows the IRB to request the PLC to reposition
tooling before proceeding.
Even if the tool repositioning is already done by
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

to start application 1 external process and
allows 10 seconds for the process to
complete before issuing a fault.
Start External Process Request = StartExtProc

is used whenever the IRB requests the PLC to
start a process which is not directly controlled
by the IRB.
AS OF 10/03/2006
74
08 RT DCX REL. 3.0
PROGRAMMING INSTRUCTIONS continued

INTERFERENCE ZONES
Instruction
Example/Argument
Clear of Interference Zone Status =

ClearOfZone is used whenever the IRB leaves
an interference zone. The instruction allows the
PLC to coordinate entry of other IRBs into the
zone.
See the ClearOfZoneL and ClearOfZoneJ
instructions for a more accurate coordination of
setting the PLC signal.
ClearOfZoneJ ZONE_1, p30, v1000, z30,

tool2 ; The TCP of the tool, tool2, is moved
along a non-linear path to the position p30,
with speed data v1000 and zone data z30.
interference ZONE_1.

ClearOfZoneJ is used whenever the IRB leaves
zone.
ClearOfZoneL ZONE_1, p30, v1000, z30,

tool2; The TCP of the tool, tool2, is moved
interference zone 1.

ClearOfZoneL is used whenever the IRB leaves
zone.
EnterZone ZONE_5; indicates to the PLC

that the IRB has approached interference
zone 5, and allows the PLC to coordinate the
IRB entry into the zone.
Interference Zone Entry Request = EnterZone is

used whenever the IRB needs to enter an
interference zone that may be in use by another
IRB.
ClearOfZone
ClearOfZoneJ
ClearOfZoneL
EnterZone
Definition
ClearOfZone ZONE_1; indicates to the PLC

that the IRB has exited interference zone 1.
AS OF 10/03/2006
75
08 RT DCX REL. 3.0

MATERIAL HANDLING PART 1 of 2
Instruction
Example/Argument
Definition
ClrOfDropoffJ
ClrOfDropoffJ DROPOFF_4, p30, v1000,

z30, tool2; The TCP of the tool: tool2, is
moved along a non-linear path to the position
p30, with speed data v1000 and zone data
z30.
PLC will be informed that the IRB is
physically clear of Dropoff 4 fixture.
Irb Dropoff Fixture location status =

ClrOfDropoffJ is used to inform the PLC that
the IRB is physically clear of the Dropoff
fixture that may be in use or held by another
IRB.
ClrOfDropoffL
ClrOfDropoffL DROPOFF_4, p30, v1000,

moved along a linear path to the position
p30, with speed data v1000 and zone data
z30.
physically clear of Dropoff 4 fixture.

ClrOfDropoffL is used to inform the PLC that
the IRB is physically clear of the Dropoff
fixture which may be in use or held by another
IRB.
ClrOfPickupJ PICKUP_4, p30, v1000, z30,

tool2; The TCP of the tool: tool2, is moved
along a non-linear path to the position p30,
with speed data v1000 and zone data z30.
physically clear of pickup 4 fixture
Irb Pickup Fixture zone status = ClrOfPickupJ

is used to inform the PLC that the IRB is
physically clear of the Pickup fixture which
may be in use or held by another IRB.
ClrOfPickupL PICKUP_4, p30, v1000, z30,

physically clear of pickup 4 fixture.
Irb Pickup Fixture Zone Status = ClrOfPickupL

is used to inform the PLC that the IRB is
physically clear of the Pickup fixture which
may be in use or held by another IRB.
ExitPickup PICKUP_4; indicates to the PLC

that the IRB is exiting Pickup 4 fixture, and
allows the PLC to coordinate the IRB exit
from that fixture.
Exit Pickup Fixture = ExitPickup is used

whenever the IRB needs to exit a Pickup fixture
that may be in use or held by another IRB.
ExitDropoff DROPOFF_4; indicates to the

PLC that the IRB is exiting Dropoff 4
fixture, and allows the PLC to coordinate the
IRB exit from that fixture.
EnterPickup PICKUP_4; indicates to the
PLC that the IRB is entering Pickup 4
IRB entry into that fixture
Exit Dropoff Fixture = ExitDropoff is used

whenever the IRB needs to exit a Dropoff
IRB.
Enter Pickup Fixture = EnterPickup is used to
inform the PLC that the IRB is entering a
Pickup fixture that may be in use or held by
another IRB
EnterDropoff DROPOFF_4; indicates to the

PLC that the IRB has approached Dropoff 4
IRB entry into that fixture.
Dropoff Entry Request = EnterDropoff is used

whenever the IRB requests entry to a Dropoff
IRB.
ClrOfPickupJ
ClrOfPickupL
ExitPickup
ExitDropoff
EnterPickup
EnterDropoff
AS OF 10/03/2006
76
08 RT DCX REL. 3.0

MATERIAL HANDLING PART 2 of 2
Instruction
Example/Argument
GetDropoffResult;
GetDropoffResult
GetPickupResult;
GetPickupResult
Definition
Get Dropoff Result = GetDropoffResult is a
function which returns the Dropoff fixture
value (DROPOFF_1 DROPOFF_4). The
Dropoff fixture value is determined from the
corresponding robot input GoToDropoffX
signal state values.
Get Pickup Result = GetPickupResult is a
function which returns the Pickup fixture value
(PICKUP_1 PICKUP_4). The Pickup fixture
value is determined from the corresponding
robot input GoToPickupX signal state values.
Retract Locating Pins = RetractLocPins retracts
the locating pin(s) which are mounted on the
end effector held by the IRB.
RetractLocPins
RetractLocPins \V1; Retract the locating pins

connected to valve 1. RetractLocPins
\V1\V3\V5; Retract the locating pins
connected to valves 1, 3, and 5.
ReleasePart
ReleasePart\V1; Retract clamps and / or turn

off vacuum and apply blowoff to vacuum
cups connected to valve 1. ReleasePart
\V1\V3\V5; Retract clamps and / or turn off
vacuum and apply blowoff to vacuum cups
connected to valve 1, 3, and 5.
Release part with IRB = ReleasePart releases a

part with clamps and/or vacuum cup(s) held by
the IRB. The IRB should be in the drop-off
position when this instruction is used.
Prepare To Grip a Part with IRB =

PrepareToGrip checks conditions to be met
before picking up a part with the IRB.
PrepareToGrip
PrepareToGrip\V1; Verify that valid pick-up

conditions exist for clamp(s) or part present
signal(s) connected to valve 1.
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
IrbAtPickupL PICKUP_4, p30, v1000, z1,

physically at the pickup 4 fixture position.
Irb Pickup Fixture location status =

IrbAtPickup is used to inform the PLC that the
IRB is currently at a Pickup fixture that may be
in use or held by another IRB.
IrbAtDropoffL DROPOFF_4, p30, v1000,

moved along a linear path to the position
p30, with speed data v1000 and zone data z1.
physically at the dropoff 4 fixture position.
GripPart \V1; Extend clamps and/or applies
vacuum to vacuum cups connected to valve
1. GripPart \V1\V3\V5; Extend clamps and /
or applies vacuum to vacuum cups connected
to valves 1, 3, and 5.

IrbAtDropoffL is used to inform the PLC that
the IRB is currently at the Dropoff fixture
which may be in use or held by another IRB.
ExtendLocPins \V1; Extend the locating pin

connected to valve 1.
ExtendLocPins \V1\V3\V5; Extend the
locating pins connected to valves 1, 3, and 5.
VerifyRelease\V1; verify that the part
controlled by valve 1 has been dropped off
successfully. VerifyRelease\V1\V3\V5;
verify that the part controlled by valves 1, 3,
and 5 has been dropped off successfully.
Extend Locating Pins = ExtendLocPins extends

the locating pin(s) which are mounted on the
end effector held by the IRB.
IrbAtDropoffL
GripPart
ExtendLocPins
VerifyRelease
AS OF 10/03/2006
77
Grip part with IRB = GripPart engages a part

with clamps and/or vacuum gripper(s) held by
the IRB. The IRB should be in the pick-up
position when this instruction is used. Part
present monitoring is activated as the last action
of the instruction.
Verify release of part = VerifyRelease verifies

that no part is held by the IRB gripper
08 RT DCX REL. 3.0

STUD WELDING
Instruction
Example/Argument
LockHead
RotateHeadJ
RotateHeadL
studdata
StudJ
StudL
LockHeadL\WPos, stud1; The robot will

order the stud weld head to be locked into
the weld position which is defined by the
weld program in the studdata stud1. Then
the robot executes the next program
instruction.
RotateHeadJ\WPos
p10,v1000,stud1,tHead1\Wobj:=wobj0; The
TCP of the tool, tHead1, is moved with a
joint motion to the position p10, with speed
1000mm/sec.
RotateHeadL\WPos
p10,v1000,stud1,tHead1\Wobj:=wobj0; The
TCP of the tool, tHead1, is moved along a
linear path to the position p10, with speed
1000mm/sec.
studdata is used in the StudL and StudJ
instructions as input parameters for the stud
weld controller. Example declaration:
CONST studdata stud1:=[1,1];
Definition
Lock stud weld Head = LockHead is used
whenever a stud head needs to be locked after
rotation has occurred.
Rotate Head after Joint Movement =

RotateHeadJ is used whenever a stud head
needs to be rotated after a joint movement has
occurred. The instruction allows the robot to
move in a joint mode to a program position and
then rotate the stud weld head.
Rotate Head after Linear Movement =
RotateHeadL is used whenever a stud head
needs to be rotated after a linear movement has
occurred. The instruction allows the robot to
move in a linear mode to a program position
and then rotate the stud weld head.
Stud weld Data type = The data studdata
defines parameters the stud weld controller will
use for applying a stud.
StudJ p10, v1000, stud1, tHead1\Wobj: =

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

whenever a stud weld needs to be applied at a
robot position. The instruction allows the robot
to move with joint motion to a fine position and
then apply a stud weld.
StudL p10, v1000, stud1,

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

whenever a stud weld needs to be applied at a
robot position. The instruction allows the robot
to move linearly to a fine position and then
apply a stud weld.
AS OF 10/03/2006
78
08 RT DCX REL. 3.0

TIP DRESSING
Instruction
Example/Argument
Definition
AdvanceDresser 1; The dump for tip dresser

1 will be advanced to the stationary weld
gun, and then will be checked to be in
position.
IRB Advance the Tip Dress Motor Dump =

AdvanceDresser will advance the tip dress
dump to the spot welding gun.
StartWaterFlow 1; The output

StartWaterFlow1 will be energized, and the
input Water1Flowing will monitor for water
flow.
IRB Start Water Flow = StartWaterFlow will

start water flow in spot welding water circuit.
StopWaterFlow 1; The output

StartWaterFlow1 will be de-energized, and
the input Water1Flowing will no longer be
monitored for water flow.
IRB Stop Water Flow = StopWaterFlow will

stop water flow in spot welding water circuit.
StartDresserMtr 1;
The input signal Tipdrs1PowerOK will be
checked. Then the output StartTipdrs1Mtr
will be energized, and the input
Tipdrs1Started will be checked.
IRB Start Tip Dress Motor
StopDresserMtr
StopDresserMtr 1; The output

StartTipdrsMtr1 will be de-energized, and
the input Tipdrs1Started will be checked for
an Off state.
IRB Stop Tip Dress Motor = StopDresserMtr

will stop a specific tip dress motor for a spot
welding gun.
RetractDresser
RetractDresser 1; The dump for tip dresser 1

will be retracted from the stationary weld
gun, and then will be checked to be in
retracted position
IRB Retract the Tip Dress Motor Dump =

RetractDresser will retract the tip dress dump
from the spot welding gun.
BurnInComplete
BurnInComplete; The output for tip burn in

complete will be set to an On state, and the
robot will wait for the PLC to reset the tip
burn in request.
IRB Set Tip Burn In Complete =

BurnInComplete will set a bit to the PLC to
indicate that the tip burn in sequence was
completed.
TipdressComplete
TipdressComplete; The output for tip dress

complete will be set to an On state, and
then the robot will wait for the tip dress
request input to be reset .
IRB Set Tip dress Complete =

TipdressComplete will set a bit to the PLC to
indicate that the tip dress sequence was
completed.
AdvanceDresser
StartWaterFlow
StopWaterFlow
StartDresserMtr
AS OF 10/03/2006
79
StartDresserMtr will start a specific tip dress

motor for a spot welding gun.
08 RT DCX REL. 3.0

TOOL CHANGE
Instruction
Example/Argument
CloseNest
LatchTool
NestEmptyChk
NestNotEmptyChk
OpenNest
PrepMHToolXchng
ToolNotOnWrist
ToolOnWrist
UnLatchTool
CloseNest1; The lid for tool nest 1 will be

closed.
LatchTool; A request to latch the tool is
made.
NestEmptyChk1;
Tool nest 1 will be checked for a tool not
present.
Definition
Close tool Nest = CloseNest orders a tool
stand lid to close, and will check for the lid to
be closed.
Latch a Tool = LatchTool requests the tool
changer to advance its locking mechanism,
and will check for the locking mechanism to
be advanced.
Nest Empty Check = NestEmptyChk will
check for a tool not to be present in the tool
nest.
NestNotEmptyChk1; Tool nest 1 will be

checked for a tool present.
Nest Not Empty Check = NestNotEmptyChk

will check for a tool to be present in the tool
nest.
OpenNest1; The lid for tool nest 1 will be

opened.
Open tool Nest = OpenNest orders a tool

stand lid to open, and will check for the lid to
be opened.
PrepMHToolXchng \V1; Closes all clamps

and verify all clamps are closed which are
connected to valve 1. PrepMHToolXchng
\V1\V3\V5; Closes all clamps and verify
all clamps are closed which are connected
to valves 1, 3, and 5.
Prepare MH Tool Exchange =

PrepMHToolXchng allows the user to close
all clamps and verify that all clamps are
closed prior to dropping off a MH tool into
the tool change nest.
ToolNotOnWrist; The tool changer will be

checked for tool not present.
Check for tool not on wrist =

ToolNotOnWrist will check for a tool not to
be present in the tool changer.
ToolOnWrist 1,1,1; The tool that is

connected to the robot will be checked for
tool id to equal 1, robot id to equal 1, and
line id to equal 1.
Check for tool on wrist = ToolOnWrist will

check for a tool to be present in the tool
changer.
UnLatchTool; A request to unlatch the tool

is made.
UnLatch a Tool = UnLatchTool requests the

tool changer to retract its locking mechanism,
and will check for the locking mechanism to
be retracted.
GetDropoffResults
GetPickupResults
AS OF 10/03/2006
80
08 RT DCX REL. 3.0
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
AS OF 10/03/2006
81
08 RT DCX REL. 3.0
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 & echos Style Ack bits to PLC (10 127): goActiveStyle
Robot reads & echos 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
AS OF 10/03/2006
82
08 RT DCX REL. 3.0
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
AS OF 10/03/2006
83
08 RT DCX REL. 3.0

Maintenance request Tip Dress
PLC requests robot to Tip Dress
TipDressGunReq
Robot returns Home
RobotAtHome
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).
AS OF 10/03/2006
84
08 RT DCX REL. 3.0

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
goActiveStyle
Robot executes service Style7 (TipDress routine)
RobotAtTipdress
Robot completes tip dressing
WT1TipsDressed
AS OF 10/03/2006
85
08 RT DCX REL. 3.0
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.
AS OF 10/03/2006
86
08 RT DCX REL. 3.0
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
AS OF 10/03/2006
87
08 RT DCX REL. 3.0
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
AS OF 10/03/2006
88
08 RT DCX REL. 3.0
Sample Programs
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.
AS OF 10/03/2006
89
08 RT DCX REL. 3.0
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;
ENDPROC
*************************
PROC GoToHome()
ENDPROC
PROC PounceToHome()
MoveAbsJ Pounce\NoEOffs,v1000,fine,CurrentTool;
SetDO RobotAtPounce,0;
ENDPROC
PROC HomeToPounce()
MoveAbsJ Pounce\NoEOffs,v1000,fine,CurrentTool;
ENDPROC
PROC HomeToService()
MoveAbsJ Service\NoEOffs,v100,fine,CurrentTool;
ENDPROC
PROC ServiceToHome()
MoveAbsJ Service\NoEOffs,v100,fine,CurrentTool;
ENDPROC
PROC EndWorkToHome()
ENDPROC
AS OF 10/03/2006
90
08 RT DCX REL. 3.0
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
AS OF 10/03/2006
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08 RT DCX REL. 3.0
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
PERS jointtarget
PERS jointtarget
PERS jointtarget
CONST jointtarget SyncPos:=[[0,0,0,0,0,0],[0,9E+09,9E+09,9E+09,9E+09,9E+09]];
ENDMODULE
AS OF 10/03/2006
92
08 RT DCX REL. 3.0
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];
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 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]];
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]];
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]];
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]];
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]];
!Robtarget definitions for procedure rob17path
AS OF 10/03/2006
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08 RT DCX REL. 3.0
MODULE pStyle20 cont.

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 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 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]];
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 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]];
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]];
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]];
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]];
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];
AS OF 10/03/2006
94
08 RT DCX REL. 3.0

PROC r17_tipburn()
CheckWaterFlow 1;
SetForce gun1,forceSeat;
Calibrate gun1\TipChg\PrePos:=20;
FOR i FROM 1 TO 5 DO
SpotL CRobT(\Tool:=CurrentTool),v100,gun1,burn_in,CurrentTool;
ENDFOR
ReCalcTCP gun1\TipChange,toolgun1;
MoveAbsJ Home\NoEOffs, vmax, fine, HomeTool;
BurnInComplete;
ENDPROC
PROC Style20()
r17_path;
ENDPROC
PROC r17_path()
MoveJ lo_pounce,v1200,z20,toolgun1\WObj:=r17_wobj;
EnterApp APP_1;
EnterZone ZONE_1\EnbReq2Enter;
EnterZone ZONE_3\EnbReq2Enter;
MoveJ lo50,v1000,z50,toolgun1\WObj:=r17_wobj;
SpotL l21z0_62o,v1000,gun1,spot01,toolgun1\WObj:=r17_wobj;
MoveL lo51,v1200,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 lo65,v1000,fine,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 10/03/2006
95
08 RT DCX REL. 3.0

PROC r17_tipdress()
MoveJ rob17_home_start,v1000,fine,toolgun1\WObj:=r17_wobj;
StartDresserMtr 1;
SetDO RobotAtTipDress,1;
MoveL ptdapp,v200,z20,toolgun1\WObj:=r17_wobj;
SpotL ptd,v200,gun1,spot14,toolgun1;
MoveL ptddep,v200,z20,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 10/03/2006
96
08 RT DCX REL. 3.0

RT WAP ABB Appllication Standard Rel 3

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DaimlerChryslers

Robotics Group Applications Standards

08 RT DCX REL. 3.0

REFERENCE FLOW CHARTS............................................................................................................................................ 63

08 RT DCX REL. 3.0

RELEASE REVISION AND COMMENTS PAGE

08 RT DCX REL. 3.0

PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT

ROBOTIC BY-PASS CONCEPT

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

TEACH PENDANT PF KEY ASSIGNMENT

08 RT DCX REL. 3.0

USE OF PULSED OUTPUTS

USE OF ROBOT PROGRAM WORLD ZONES

A.B.B. ROBOT SIGNALS AND MACHINE AUTOMATIC

08 RT DCX REL. 3.0

ROBOT PROGRAM NAMING

REGISTER AND COUNTER NAMING

Robtarget names shall follow the convention below:

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

ROBOT TO ROBOT HAND-OFF

BASE LIMIT CONNECTIONS AND OPERATION

08 RT DCX REL. 3.0

STANDARD ROBOT PROGRAM NUMBERS

08 RT DCX REL. 3.0

STANDARD ROBOT PROGRAM NUMBERS

STYLE 4 BASE PROGRAM (Future)

Application 1 Calibration (Vision, Dynalog)

TCP TARGET PROGRAM

08 RT DCX REL. 3.0

D-NET MAP Descriptions (Robot To PLC) A.B.B .Robot

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

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

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

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

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

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

This robot output is not assigned.

This robot output informs the PLC that option 1 is active.

This robot output informs the PLC that option 2 is active.

08 RT DCX REL. 3.0

This robot output informs the PLC that option 3 is active.

This robot output informs the PLC that option 4 is active.

This robot output is designated for a user defined function.

This robot output is designated for a user defined function.

This robot output is designated for a user defined function.

This robot output is designated for a user defined function.

This robot output is designated for a user defined function.

This robot output is designated for a user defined function.

This robot output is designated for a user defined function.

This robot output is designated for a user defined function.

This robot output indicates the robot is clear of machine process 1.

This robot output indicates the robot is clear of machine process 2

08 RT DCX REL. 3.0

Reference ReposTooling1. The BCD value for ReposTooling2 = 2

Reference ReposTooling1. The BCD value for ReposTooling4 = 4

This robot output indicates that it is running in no stroke mode.

This robot output indicates that air is present at the robot.

This robot output indicates that water is flowing at the robot.

This robot output indicates that dispenser 2 purge sequence is in progress.

This robot output indicates that dispenser 1 purge sequence is in progress.

08 RT DCX REL. 3.0

This robot output echos the state of ESIO relay channel 1.

This robot output echos the state of ESIO relay channel 2.