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Software Documentation

Part 4

DCP Control and Monitoring Unit


Release 2.0 (April 2017)

Project
JLR using ControlLogix

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JLR ControlLogix – DCP Specification
Modifications of History of Part4 (CMU)

No Modification Date (DMY) Version


1 First Release 24042017 1.1

2 Chapter 4.2.4 / 4.2.5 picture update 27092017 1.2

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JLR ControlLogix – DCP Specification
Contents
Modifications of History of Part4 (CMU)

4. Control and Monitoring Unit (CMU) ..................................................................................................... 4


4.1 Hardware CMU ............................................................................................................................ 4
PanelView Plus 7: ............................................................................................................................... 4
System Memory: ................................................................................................................................. 4
Communication: .................................................................................................................................. 4
Connection:......................................................................................................................................... 4
Operating system: ............................................................................................................................... 4
4.2 Software ...................................................................................................................................... 4
Software packages: ............................................................................................................................ 4
Standard CMU: ................................................................................................................................... 4
CMU Password ................................................................................................................................... 4
4.2.1 Organisation of Screens ................................................................................................................ 5
4.2.2 Screen Main Menu ........................................................................................................................ 6
4.2.3 Screen Sequence Selection........................................................................................................... 7
4.2.4 Screen Online ................................................................................................................................ 8
4.2.4.1 Screen Page Selection ............................................................................................................. 10
4.2.4.2 Manual Pages 1 – 30 ................................................................................................................ 11
4.2.4.3 Manual Operation ..................................................................................................................... 20
Programming Fkeys and Lamps in the controller: ............................................................................. 20
4.2.4.4 Sequence Data ......................................................................................................................... 21
4.2.5 Graphic Display ........................................................................................................................... 24
4.2.6 User Screen ........................................................................................................................... 26
4.2.7 Language Switching ............................................................................................................... 38
4.2.8 Global Objects and Navigation ............................................................................................... 39
CMU Title .......................................................................................................................................... 39
Navigation ......................................................................................................................................... 39
Global Boarder.................................................................................................................................. 40
CMU Font ......................................................................................................................................... 40
4.2.9 Display Update Times ............................................................................................................ 41

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JLR ControlLogix – DCP Specification
Part 4 – CMU

4. Control and Monitoring Unit (CMU)

This chapter describes the standard software application of the CMU for a PanelView Plus 7, used as an
operator terminal for the L551 / Darwin project. It is controlled by the DCP standard software in the PLC.

4.1 Hardware CMU


PanelView Plus 7:
– Touch with keypad
– Two USB high-speed 2.0 host ports (type A) which support removable flash drives for external storage
– One high-speed 2.0 device port (type B) which will be functional in a future release
– One SD card slot for external storage; which supports cat. no. 1784-SDx cards
– Colour display:TFT; 15 Inch; 1024 x 768 18-bit colour graphics
– Catalogue no.: 2711P-B15C22D9P

System Memory:
– System: 1 GB
– User 512 MB

Communication:
– Two 10/100Base-T, Auto MDI/MDI-X Ethernet ports RS-232 Interface (upload / download / print).

Connection:
– Connected to a Stratix 5700 managed Ethernet switch located in an A2 panel.

Operating system:
– Windows CE with Extended Features and MS Office Viewers (includes FTP, VNC client server, ActiveX
controls, PDF reader, third-party device support)

4.2 Software
Software packages:
– Developing software: FactoryTalk View Studio for Machine Edition
– Communications software: RSLinx.

Standard CMU:
Each CMU is assigned to one PLC.
In the PLC, the Routine S_VersaView controls the data transfer with the CMU.
Specification of the sequence details displayed:
– Standard application with 30 sequences
– Display of the sequence step (max. 99 steps per sequence)
– 10 fault messages can be displayed at the same time
– PanelView Plus 7 supports up to 10,000 messages per Local Message File
– Display of the general message (1 fault line). Scroll function for up to 10 messages
– Display of the fault type, fault priority, operation modes, central status, sequence status, system
message, pages of the manual functions
– Display of 30 pages / sequence with 20 manual function keys / page, 20 for manual operations and
associated function text and 20 dedicated function keys present on every page

CMU Password
On power up the user must set as password,challenge and response to PanelView1

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JLR ControlLogix – DCP Specification
Part 4 – CMU

4.2.1 Organisation of Screens


The PanelView Plus 7 starts up with the Main Screen. From here and from all the other screens functions are
directly selectable by pressing a dedicated button on the left or right row on the global border. The dedicated
buttons allow quick navigation through the screens, the association of these buttons to the screens and
functions are described in the table below:

Label Screen Function Remark


PIECE C. UserPieceCounts Displays Screen no. 101
SAFTEY UserSafteyArea Displays Screen no. 50
USER User Displays Screen no. 100 with a menu to
select other User screens
Spare

Spare

Spare

Spare

STEPS Seq1-30 Steps Depending on the OnlineSeq screen

ONLINE OnlineSeq1-30 Depending on the last selected OnlineSeq


screen
MAIN Main Displays Screen no. 45
HAND Manual Functioning on OnlineSeq screens and
Graphic screens
AUTO Automatic Functioning on OnlineSeq screens and
Graphic screens
CSTRT Central Start Functioning on OnlineSeq screens and
Graphic screens
CEOC Central End of Functioning on OnlineSeq screens and
Cycle Graphic screens
RESET
SEQ. SequenceSelect1/2 Screen no. 46/ 47 toggles the screen by
pressing SEQ.
PAGE PageSelect1/2 Screen no. 48/ 49 toggles the screen by
pressing Page.
DIAG. Graphic61- 90 Displays Screen no 61- 90
depending on the configuration
Spare
L.PAGE Displays Page 30 on the active OnlineSeq
screen

NOTE: Access to the different screens and functions is possible from every screen from the dedicated buttons.

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Part 4 – CMU

4.2.2 Screen Main Menu


The Main menu appears after power on. PanelView Plus 7 (screen no. 45)

The Main menu is used as the startup screen from here you can access the following screens by using the
dedicated buttons.
– Piece Counts
– Safety Overview
– User menu
– Online Screen
– Graphic Screen (for complex Stations)
– Active Fault Page (displays the associated manual page with highest priority fault)
– Online menu (sequence menu) via Sequence Selection menu (see chapter 4.2.2 and 4.2.3) and via Page
Selection menu (see chapter 4.2.4).

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4.2.3 Screen Sequence Selection


Sequences are selected via 2 screens Sequence Selection to call 2 x 15 sequences. PanelView Plus 7 (screen
no. 46)

NOTE: The visibility of the sequence selection is controlled by the zzSeq[*].Active flag in the PLC only active
sequences will be displayed
Sequence selection consists of 2 screens to change to DC Online screen:
– Selection of sequences 1 – 15 (screen no. 1 – 15) and displaying the status of sequences 16 - 30.
– Selection of sequences 16 – 30 (screen no. 16 – 30) and displaying the status of sequences 1- 15.

All configured sequences are displayed with sequence text and sequence status (station field).

Solid, if the sequence is running in


Automatic (start) Flashing, if the sequence
is ready to start
Solid if Manual mode has been selected

Solid if Step By Step mode has been


selected

Solid, if a timeout fault occurs

Solid, if an interlock, CMI or CMZ fault occurs

Solid, if QuickStop has been reached


Flashing if QuickStop has been selected but not reached

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Part 4 – CMU

4.2.4 Screen Online


Each sequence is assigned to a screen. On the CM (Control and Monitoring) Online screen all the important
stats of one sequence are displayed and the operator can choose and execute the relevant sequence
functions:
– Sequence description
– Current step
– Fault messages
– States of the sequence and the line
– 30 pages of manual operations with Fkeys and corresponding lamps to show the function status.

The PanelView Plus 7 (screen no. 1...30, page no. 1)


Lines explained from left to right with the number of characters (PanelView Plus 7):

1
2
3
4

13

14 20
15

16
17
22
18

19

21

1: Number of the sequence (sequence = 2 characters).


Station / sequence text ( 22 characters)
2: Step number
Step text ( 74 characters).
3: Head line of fault messages.
4 – 13: Up to 10 fault messages (message  43 characters).
Line /Lamp no. is calculated automatically.
14: General message: If more than 1 current message occurs at the same time, the display scrolls
automatically.
Up to 10 messages (message  43 characters).

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15: Central status.


Fault type of the highest priority fault displayed at upper fault line (line 4).
Operation mode
Sequence status
16: Page number 1 – 30.
Page text ( 66 characters)
Status of Fkey access
17: Function key text depends on the selected page (2 lines with 12 characters per Fkey).
Function status lamps to match the Fkeys: Lamp
shining, if the work position is reached.
Lamp flashing, if the output is active and the work position is
not reached. Lamp dark if the output is not active and the
work position is not reached.
18: Text of the actuator matches the functions (3 lines with 12 characters per Fkey pair).
19: Same as 17 but home position instead of work position.
20 Sequence Type Display
21 Sequence and Page navigation pushbuttons
22 Safety Key / Function pushbutton active

The text for each message is generated from the per sequence document.:
– Step messages (line 2).
– Fault messages (line 4 – 14).
– Text of 30 pages of manual operation (line 16 page text, line 17-19 lamp text).

NOTE: The CMU Online screen number corresponds to the sequence number.

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Part 4 – CMU

4.2.4.1 Screen Page Selection

The function soft keys located on the CM Online menu are used to select and execute the sequence related
functions, especially manual operations. 600 pushbuttons functions are available, selectable by 30 different
pages.
– SEQ. : Sequence selection and to toggle between the Sequence Selection screens.
– PAGE : Page selection and to toggle between the Page Selection screens.
If the operator presses “PAGE” on a screen the Page Selection screen is shown to choose one of the 30 pages
(15 pages selectable per Page Selection screen) of the current sequence displayed on the DC Online screen.

The PanelView Plus 7 (screen no. 48)

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4.2.4.2 Manual Pages 1 – 30


The manual pages 7 – 26 of a sequence are freely available for user functions (20 pages x 2 lines x 10 keys =
400 Fkey and lamp functions).

The following pages have been assigned.


– Page 1: Robot Selection
– Page 2: Welding
– Page 3: Reset Welding Counters
– Page 4: Tip Dress
– Page 5: Tip Dress
– Page 6: Robot Start
– Page 7: Job Done Memories
– Page 8: Tip Change
– Page 9: Robot Service
– Page 10: Robot Service
– Page 11: Robot Service or PRB 10 Mini Sequencer
– Page 12: Robot Service or PRB 9 Mini Sequencer
– Page 13: Robot Service or PRB 8 Mini Sequencer
– Page 14: Robot Service or PRB 7 Mini Sequencer
– Page 15: Robot Service / SCA Functions or PRB 6 Mini Sequencer
– Page 16: Robot Service / SCA Functions or PRB 5 Mini Sequencer
– Page 17: Tag Reader or PRB 4 Mini Sequencer
– Page 18: Barcode Reader or PRB 3 Mini Sequencer
– Page 19: Tooling Page or PRB 2 Mini Sequencer
– Page 20: Tooling Page or PRB 1 Mini Sequencer
– Page 21: Tooling Page or PRB 1 Mini Sequencer
– Page 22: Tooling Page or PRB functions
– Page 23: Roller Bed Control / Lifter / Transfer
– Page 24: Dry Cycle Functions
– Page 25: Sequence Releases 1-10
– Page 26: Sequence Releases 11-20
– Page 27: Type in Station
– Page 28: Type Selection
– Page 29: General Functions
– Page 30: General Functions

DCP standard functions are typed in bold typed

– NOTE: The page titles and pushbuttons are generated from the per sequence sheets. Unused page and
pushbutton text must be deleted. The following pages show examples of the sequence document. The
sequence documents must be modified for the functions in each facility. As much description as possible
should be added to the display. (i.e. robot / station number / model types / sequence releases etc.)
– Examples sheets can be obtained from the Standards and Controls department.

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Part 4 – CMU

Page 1: Robot Selection add up to 8 robots per sequence (R1 – R8)

Page 2: Welding add up to 8 robots per sequence (R1 – R8)

Page 3: Weld Counters add up to 8 robots per sequence (R1 – R8)

Page 4: Tip Dresser add up to 8 robots per sequence over two pages (R1 – R8)

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Page 5: Tip Dresser add up to 8 robots per sequence over two pages (R1 – R8)

Page 6: Robot Start

Page 7: Job Done Memories

Page 8: Tip Change

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Page 9: Robot Service (pages 9,10,11,12,13,14)

Page 15: Robot Service / SCA Functions

Page 16: Robot Service / SCA Functions

Page 17: Tag Reader

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Page 18 Barcode Reader

Page 19- 22 Tooling Page

Page 23 Roller Bed Control

Page 24 Dry Cycle

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Page 25 / 26 Sequence Releases

Page 27 Type In Station

Page 28 Type Selection

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Page 29 General Functions

Page 30 General Functions

10 Multi Roller bed sequence example

Function start on Page 11 to page 20

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SEW function example pages

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4.2.4.3 Manual Operation


Manual Operation with more than one CMU assigned to a PLC is allowed in the same sequence.
Example: 2 CMU’s are monitoring the same sequence in the PLC. If the Fkey of CMU 1 is pressed earlier than
the Fkey of CMU 2 the CMU 1 has priority. The Fkeys of CMU 2 are locked (message of Fkey status on CMU
2 appears). The priority of CMU 1 stays active about 7 seconds after releasing the Fkey.

The communication between PLC and CMU is checked continuously. If an Fkey is pressed and an error occurs
the status of all Fkeys are reset after a user defined time (default = 2 sec.). The user can configure the time
period in the routine P_VersaViewParameters (should be as low as possible but must be  1.5 sec.).

The CMU blocks the Fkey function if the operator presses more than one Fkey

Programming Fkeys and Lamps in the controller:


To move an actuator with a control function block in manual mode and to see the status of the movement the
manual pushbutton and the lamp has to be programmed in the function block as follows:
– Pushbutton (Fkey): zzSeq[xx].Button[yy].vv
– Lamp of pushbutton: zzSeq[xx].Lamp[yy].vv

xx = sequence number
yy = page number
vv = pushbutton: upper line: vv = 1 – 10
lower line: vv = 11 – 20.

– NOTE: All functions must have a manual pushbutton assigned. This includes transition latches and special
functions programmed by the user.

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4.2.4.4 Sequence Data

The PanelView Plus 7 supports up to 10,000 messages in each of the Local Messages. The user sequence
related data is in the associated Local Messages SeqData01 – SeqData30. The message text number is
independent of the trigger value.

Layout per SeqData:

Language 1
Trigger Contents
1 - 3199 Fault Descriptions (Matrix bit 1 - 3199)
3201 Step Counter number
3202 Step counter name
3203 PLC number
3301 - 3399 Step Description ( Step 1 - 99)
3401 - 3430 Page Descriptions ( Page 1 - 30)
4011 - 4310 Lamp Text top line ( 30 sides each with 10 lamps)
5011 - 5310 Push Button text ( 30 pages each with 10 buttons)
6011 - 6310 Lamp Text bottom line ( 30 sides each with 10 lamps)

Language 2

Trigger Contents
7000 - 10199 Fault Descriptions (Matrix bit 1 - 3199)
10201 Step Counter number
10202 Step counter name
10203 PLC number
10301 - 10399 Step Description ( Step 1 - 99)
10401 - 10430 Page Descriptions ( Page 1 - 30)
11011 - 11310 Lamp Text top line ( 30 sides each with 10 lamps)
12011 - 12310 Push Button text ( 30 pages each with 10 buttons)
13011 - 13310 Lamp Text bottom line ( 30 sides each with 10 lamps)

To generate the message data the user must select the language 1 (English) or 2 (Local Language) and press the
Generate VersaView Message File button.

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If language option 1 is selected the message trigger values will start at 1 if option 2 is selected the message trigger
values will start at 7000.
The generated messages are copied into the clipboard ready to paste into the local Message file for the
corresponding sequence.

NOTE: Do not modify the Layout of the Local Messages. Leave unused messages blank and do not change
the trigger value. Messages must be generated using the macro in the latest sequence document (available
from the JLR Standards and Controls department). It is not permitted to change the text in the Local
Message file. All changes must be generated from the sequence sheet.

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The user must paste the generated messages from the sequence chart in to the corresponding Local Messages
SeqDataXX.

Language 1 pastes into message range 1 -4231


Language 2 pastes into message range 4232 - 8463

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4.2.5 Graphic Display

Each sequence must be assigned to a graphic screen where practically possible. On the Graphic screen the
important state and position of the faulted sequence is displayed and the operator can choose and execute
the relevant sequence functions to fix the fault:
– Sequence description
– Current step
– Highest priority fault message
– States of the sequence and the line
– Fault position and corresponding page

The PanelView Plus 7 (screen no. 61...90, page no. 1)

The user must import the relevant picture into the selected graphic display screen.

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Part 4 – CMU

The graphics matrix trigger must be assigned on the sequence sheet and sent to the PLC.

NOTE: The Graphic screen number corresponds to the sequence number. The Graphic uses the same user
data as the corresponding CM online screen.

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4.2.6 User Screen

The User screens (screen no. 50 and  100) offer possibilities to design machine specific screens related to
user functions.

Preconfigured user screens are:


 User Safety Area (screen no. 50)
 User Safety Area (screen no. 51 - 59)
 User Screen (screen no. 100)
 User Piece Counts (screen no. 101)
 Sealer Inspection (screen no. 102)
 Type Flow (screen no. 103)
 Build FIFO (screen no. 104)
 User Cycle Time (screen no. 105)
 Detailed Safety (screen no. 106)
 Build Indicator (screen no. 107)
 Robot Paths (screen no. 108)
 DCP Messages (screen no. 110)
 5700 (screen no. 113)
 User Cycle Time Zone (screen no. 115)
 User Cycle Time Robot (screen no. 116)
 User Cycle Time Station (screen no. 117)
 User Cycle Time Station (screen no. 118)
 Set Shift Times (screen no. 130)
 Tip Change (screen no. 131)
 Tip Change SA1 (screen no. 134)
 Tip Change SA2 (screen no. 135)
 Tariffs (screen no. 139)
 Power Monitoring (screen no. 140)
 Power Monitoring Details (screen no. 141)
 Collision Zone1 (screen no. 151)
 Collision Zone2 (screen no. 152)

The user is responsible for the selection of the user screens, unused preconfigured screens can be removed
from the project. The screens highlighted in yellow must be used for all facilities. Screens highlighted in red
must be used for facilities with robots in addition to the yellow highlighted screens.

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User Safety Area (screen no. 50) Example

The user must import a suitable picture of the line layout that clearly show the stations, gates and emergency
stop locations. As a minimum, the safety screen should display (via a flashing graphic) the operation of all
safety devices. Additional graphical information can be displayed if it would be beneficial of the JLR
operators.

User Screen (screen no. 100)

The user must assign the go to display buttons and the local message titles for the user screens required.

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Part 4 – CMU
User Screen (screen no. 101)

The user must assign local message for the types.

Sealer Inspection (screen no.102) Example

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Type Flow (screen no. 103)

The user must configure the Type Flow page(s), to show the type in each robot / station. The layout of the
screen should depict the actual layout and flow as closely as possible.

Build FIFO (screen no. 104) Example

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User Cycle Time (screen no. 105) Example

The user must configure the User Cycle Time page to show the cycle time in each robot / station. The layout of
the screen should depict the actual layout and flow as closely as possible.

Detailed Safety (screen no.106) Example

The user must configure the detailed safety page to show All the Safety Area devices programmed. The user
must assign the go to display buttons, screen and local message titles for the safety area functions required

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Build Indicator (screen no.107) User defined (normally to turn build types on/ off)
Robot Paths (screen no.108) User defined to shown complex / special robot paths

DCP Messages (screen no.110)

5700 (screen no.113) Example

The user must configure a graphic for all the Stratix switches used on the facility.

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User Cycle Time Zone (screen no. 115) Example

The user must configure the cycle time and local messages for the robot / station. This gives the overall zone
cycle time. (the last 10 times are to be shown).

User Cycle Time Robot (screen no. 116) Example

The user must configure the cycle time and local messages for each robot (the last 10 times are to be shown).

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User Cycle Time Station (screen no. 117 /118) Example

The user must configure the cycle time and local messages for each station (the last 10 times are to be shown).

Set Shift Times (screen no. 130)

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Tip Change (screen no. 131) Example

The user must configure the Tip Change screens for all welding robots. Screens 132-138 can be used for SA Tip
Change these are user defined.

Tariffs (screen no. 139)

The user must configure the Tariff screen for each Power Monitoring Unit.

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Power Monitoring (screen no. 140)

The user must configure the Power Monitoring screen for each Power Monitoring Unit.

Power Monitoring Details (screen no. 141)

The user must configure the Power Monitoring Details screen for each Power Monitoring Unit.

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Collision Zone1 (screen no. 151)

Collision Zone2 (screen no. 152)

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Detailed Safety Screens (screen no. 1000)

The user must add and configure each detailed safety screen with the correct POP UP graphic and parameters
for all safety devices. Additional navigation buttons must be added if a second screen it required.

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4.2.7 Language Switching

Local Messages are used to allow language switching. The user must use local messages on any user screens
created.

An example of using local messages for language switching is shown below.

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4.2.8 Global Objects and Navigation


CMU Title

The user must add the CMU title name in the PLC. For each CMU add the Title to the zzVv[*].CMUTitle

Navigation

For each CMU the “CMU_Seq_Page_Scroll” Addon instruction is used in P_VersaviewParameters. The user
needs to add this instruction for all CMU’s on the line.

The user must set the Global connection for each CMU.

Under Global Connections select the Display tab.


Enter the Vv[*] number in Parameter Tag #1

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Global Boarder
For new screens the global border needs to be added and the title parameter inserted.by the user.

Open Border in Global objects

Select the border and copy. On the new screen paste the border

On the new screen select the border and right click,


Select Global Object Parameters and add the value CMUTitle. The title text will be read from the relevant vv tag
in

CMU Font
The CMU requires the Lucida Console Font to display the messages correctly. If the font is not present on the
CMU the user must load the lucon.ttf file into the c: windows/fonts directory and reboot. The font will be
automatically load from the font directory on restart.
the PLC

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4.2.9 Display Update Times

The table below shown the typical display update time settings. The user must set the required times for new
screens added into the CMU.

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