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Tel. +49 (0)2104-960256
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Software Documentation

Part 3

DCP Support
Release 1.1 (April 2005)

Project
Ford using ControlLogix
 Part 3 – Modifications

Modifications of DCP Support Release 1.0

No Modification Date (DMY) Signature

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Ford ControlLogix – DCP Specification 2

 Part 3 – Contents

CONTENTS

Modifications of DCP Support

Contents

1. DCP Qualities of the Project 1–1

2. Software Design 2–1

2.1 Proposal of Software Design and Programming 2–1
2.1.1 Design 2–1
2.1.2 Programming 2–1
2.1.3 DCP Functions 2–6

3. Communications 3–1
3.1 Fieldbus Interbus S 3–1
3.2 Ethernet 3–1
3.2.1 Central Data 3–1
3.2.2 User Data 3–2
3.2.3 Ethernet Diagnosis 3–2

4. Central PLC 4–1

4.1 Interface Line DCU 4–1
4.1.1 Type Information 4–2
4.1.2 Produced Parts 4–2
4.1.3 Cycle Times 4–3
4.1.4 Step Times 4–3
4.1.5 Ethernet Diagnostics 4–4

5. Flow Charts 5–1

5.1 Modes 5–1
5.1.1 Manual (Manual) 5–1
5.1.2 Manual Lead Thru (ManualLead) 5–2
5.1.3 Automatic (Automatic) 5–4
5.1.4 Step by Step (StepByStep) 5–5
5.1.5 Single Cycle (SingleCycle) 5–6
5.1.6 End of Cycle (Eoc) 5–7
5.1.7 Auto/Semi (AutoSemi) 5–8
5.1.8 Fixture Reset (FixReset) 5–9
5.1.9 Weld Reset (WeldReset) 5 – 10
5.2 States of Sequence 5 – 11
5.2.1 Sequence Ready (Ready) 5 – 11
5.2.2 Sequence Start (Start) 5 – 12
5.2.3 Sequence Waits in Run 5 – 13
5.2.4 Sequence Stop 5 – 14
5.3 DCP Functions (see CMU specification) 5 – 15
5.3.1 Step Increment 5 – 15
5.3.2 Step Decrement 5 – 16
5.3.3 Step Counter Reset 5 – 17
5.3.4 Step Search (Resequence) 5 – 18

Ford ControlLogix – DCP Specification 3

 Part 3 – Contents

5.3.5 First Interlock Fault 5 – 19

5.3.6 Timeout Fault 5 – 20
5.3.7 Display Last Step 5 – 21
5.3.8 Lamp Test 5 – 22
5.3.9 Teach In Function (see Chapter 5.1.4) 5 – 23

Appendix
A. Form Sheets Programmable Assistance
Sequence Overview Diagram A–1
Sequence and Interlock Chart A–2
Programming Chart A–3

B. Data Exchange PLC – Line DCU

Data to Realize the Communication B–1
Screen Type Information (Central PLC) B–2
Screen Produced Parts (Central PLC) B–2
Screen Cycle Times (Central PLC) B–3
Screen Step Times B–4

Ford ControlLogix – DCP Specification 4

 Part 3 – Chapter 1

1. DCP Qualities of the Project

1. DCP Qualities of the Project 1–1

Ford ControlLogix – DCP Specification 1–0

 Part 3 – Chapter 1

1. DCP Qualities of the Project

A production line consists of up to:

– 1 EtherNet network
– 10 PLCs (Central PLC included)
– 1 Line DCU, via Ethernet connected to all PLCs
– 20 CMU
– Max. 3 CMU / PLC (if more are required the it should be clarified with Ford Group Staff)
– 48 stations
– 30 safety areas
– 30 sequences / PLC
– 99 steps / sequence (1...99)
– variable number of fault messages / sequence (default = 3200)
– 14 robots / station
– 9 robots / sequence
– 120 cycle times
– 100 different types.

CMU = Control and Monitoring Unit (Rockwell VersaView CE)

DCU = Diagnostic Control Unit: PC based human machine interface (HMI) for statistics information of the
line. See chapter 4 and specification Line DCU.

Ford ControlLogix – DCP Specification 1–1

 Part 3 – Chapter 2

2. Software Design

2. Software Design 2–1

2.1 Proposal of Software Design and Programming 2–1
2.1.1 Design 2–1
2.1.2 Programming 2–1
2.1.3 DCP Functions 2–6

Ford ControlLogix – DCP Specification 2–0

 Part 3 – Chapter 2

2. Software Design

2.1 Proposal of Software Design and Programming

2.1.1 Design

To design the software detailed knowledge of the machine and its processing outlet are necessary (see part
1 chapter 2). Qualified aids are documents of the machine, for example:

- Technical drawings of the machine

- Process technological plans
- Timing diagrams
- Electric hardwired plans
- List of electrical devices as actuators, sensors, aggregates
- Factory and security conditions of electric installation.

By means of the named documents and knowledge the machine structure and its process functions of
production can be analysed (example):

Production line: consists of physical operation units or machines to build a complete product
or part of it
Machine: Several parallel running processes of the line chosen with 1 mode switch
Station: Single process with subsequent working functions, repeating the
process cycle wise
Mechanism: Production unit of a station carrying out a special job (actuator, robot)
Function: Action of a mechanism as smallest element of the process.

Assignment of the process functions to controller system and software:

Production line = ≥ one controller
Machine = controller (part) with common mode switch and ≥ 1 sequence
Station = sequence
Mechanism = control function block (FB) for control and fault diagnosis of the mechanism
Function = one action of the function block (mechanism) on step level of the sequence.

After the analysis of the process the form sheets (see appendix A, B, and part 1 chapter 2) can be edited.
The PLC programming follows.

2.1.2 Programming

First the file of the DCP Standard DcpCcar_10_yyyyyy.ACD is to open with the programming software
RSLogix 5000 (yyyyyy = date with year/month/day). It contains all program parts which are necessary to
control a machine. To adapt the DCP standard to a machine application by the programmer each required
configuration is described in detail at the respective rung of the P_, M_ and U_ routines (see ladder of DCP
standard). In according to the directions in part 1, chapter 2 and 3 each sequence is attached to an own
program and data area.

Ford ControlLogix – DCP Specification 2–1

 Part 3 – Chapter 2

NOTE:
– Do not change the S_routines (system routines only changed by DCP developer).
– It is recommended to do not change the tags named zz... and the data types written in capital letters
(standard data), user own data areas (e.g. user defined data structure) should be generated.
– Do not change anything in the unscheduled program Sequence 00 (only used to copy into the
continuous task).
– It is not allowed to change the order of JSR calls of the standard routines.
– If an update of the DCP standard is required, please follow the items of update description. We
recommend to load / change the tags before the ladder part.

A proposal to realise a machine application with the DCP standard is described as follows:

x= sequence number (1...30)

y= ID number of CMU (1...10)

No. Subject Detail

1 Task Copy program sequence 0 Æ x times to task continuous as you need.
2 Each sequence Copy required M_Fct...-type x times as this type exists hardwired.
3 Delete not used M_Fct.
4 Tag zzSeq Configure range of array zzSeq[x] depending on number of sequences (last
sequence + 1).
5 Program Sequence x Replace zzSeq[0] by zzSeq[x] in the whole program depending on your
sequence number with „search and replace“-function in each sequence
being in task continuous.
6 Organizer: Correct the program name of Sequence x according your
application (sequence ID + station description).
7 Organizer: Correct the routine name of all M_Fct.. according your
application (note WEI specification of Ford). The M_Fct number of the
standard should be placed additionally in the routine name or at the
beginning of the routine in rung 0.
8 Configure each M_Fct function block according your application (see part 1
chapter 2 + 5, part 2).
9 I/O configuration Configure Ethernet (ENBT), CMU, PLC_PLC data transfer (see chapter 3).
10 Tag zzVv Configure range of array zzVv[y] depending on ID number of CMU which
communicates with this PLC (last CMU + 1).
11 CMU See CMU specification
12 Line DCU Check: PLC5 mapping table must match to the DCP (see chapter 5.1).
13 Interbus S See OEM specification part 4 (not part of DCP).

Program Global:
14 P_SystemParameters – ID number of this PLC (1...10).
– This PLC = Central PLC ? (L) / (U).
– Node of remote PLCs (1...10) Note: each PLC ≥ 1 connection.
– Which sequence is active? (bit 1...30).
– Which sequences are connected to which safety area.
– Line DCU is active? (bit 0,1). Note: configure in each of the PLCs.
– Which CMU communicates with this PLC (ID number 1...10)?
– Select fieldbus type (see OEM specification part 4).
– Which fieldbus scanner is active (see OEM specification part 4)?
15 Percent value of reference cycle time: 0...99%, default = 10%.
(Diagnosis of limit overrun = actual > reference + percent value).
16 Number of different types (0…100).(10 = default)
17 Global fault range: Number of DINT data (central faults) beginning with
fault bit 1 (Bit 0 not allowed, reserved for DCP).
Default = 10 (bit 1...319 in the fault table).
18 Ranges of fault bit tables of all sequences in this PLC

Ford ControlLogix – DCP Specification 2–2

 Part 3 – Chapter 2

No. Subject Detail

Default:
– Number of bits in the fault table = 1600 (word 0 – 49).
– Fault range Cm = bit 1...159 (word 0 – 4).
– Fault range Cmi = bit 160...319 (word 5 – 9).
– Fault range SIZ = bit 320...1535 (word 10 – 47).
– Fault range SSZ = bit 1536...1567 (word 48).
– Fault range GMsg = bit 1568...1599 (word 49).
19 Manual lead mode: Time to delay the automatic change of CMU page for
manual operation (if more than one function can be executed on different
pages in the current step).
Default = 5 sec.
20 P_CentralParameters – Delay automatic reset after PLC power on (default = 60 sec.).
– Delay automatic reset after area power on (default = 2 sec.).
– Conditions of control central outputs: Power on, Estop, reset request,...
21 P_EthernetParameters Each remote PLC: Timeout limit of Ethernet communication
Central PLC only:
– Path and name of ENBT module of this PLC.
– Node of accessory ENBT module.
– All nodes of the line which will be monitored on screen Ethernet
diagnostics of Line DCU.
See chapter 3.2.3 and OEM specification.
22 P_FieldbusParameters Jump to the fieldbus definition (Interbus).
See OEM specification part 4 (not part of DCP).
23 P_InterbusParameters – Take over input data and status information from Interbus scanner.
– Hand over output data and standard function data to Interbus scanner.
See OEM specification part 4 (not part of DCP).
24 P_UserScreenVersaView – Active Line (e.g lh or rh)
25 P_VersaviewParameters – CMU: If ≥ 1 device are used, configure timeout limit of Ethernet
handshake to reset pushbuttons.
– Each CMU: Copy and configuration of rung pushbutton control (take
over pushbuttons and reset pushbuttons in case of Ethernet
communication error).
– Sequences to monitor only from each CMU
26
27 U_GlobalFaults Control of global (central) faults (user dependent).
28 P_UserScreenVersaview Control of further CMU user screens (user dependent).
See CMU specification.
29 U_StartUp Control of start up conditions (user dependent).

Program of each
sequence:
30 P_SequenceParameters – Rung 1 shows all important status data of the sequence and is very
helpful for maintenance and service (do not configure).
– Number of sequence steps (1...99).
– DOSA time (0...200msec.). See Part 1 chapter 5.1.7.
– Enable modes of operation
– Maximum types used with sequence
31 – Configure multiple manual function to control action(s) with a manual
pushbutton also in another sequence.
– Conditions of controlling safety key flag.
– Conditions of controlling reset pushbutton flag.
32 – Conditions of status sequence empty.
– Conditions of status all previous sequences in this PLC are empty.
– Conditions of enable central end of cycle request.
33 – Conditions of preventing step time measuring to diagnose timeout fault
(e.g. cause of step time delay located in another sequence).
– Conditions of preventing cycle time measuring (e.g. cause of cycle time
delay located in another sequence).

Ford ControlLogix – DCP Specification 2–3

 Part 3 – Chapter 2

No. Subject Detail

34 U_SequenceFaults Change fault bit number of following states depending on Cmi range in the
fault bit table:
– Waiting for safety key switch (default = 318).
– No operation mode selected (default = 319).
Change fault bit number of following states depending on SSZ bit range in
the fault bit table:
– Line is cleared (default = 1536).
– Sequence is cleared (default = 1537).
– Single cycle complete (default = 1538).
– Waiting for start PB in step by step mode (default = 1539).
– Waiting for sequence start (default = 1540).
– Waiting for auto/semi mode (default = 1541).
– Waiting for manual mode (default = 1542).
– Waiting for sequence end of cycle reached (default = 1548).
– Waiting for central start (default = 1558).
If required: Configure further control of fault bits of this sequence which is
independent of step operation - general messages also (user dependent).
35 U_SequenceFunctions Call each applicated M_Fct function block with JSR instruction (user
dependent).
Note: Calls are actuator-organized, but not organized for sequence steps.
36 U_Sequence Step Start/stop steps:
Conditions – Configure step(s) to start clear line mode.
– Configure step(s) to stop in automatic mode (end of cycle).
– Configure step(s) to stop in single cycle mode.
– Configure step(s) to start and stop in fixture reset mode.
– Configure step(s) to start and stop in weld reset mode.
– Configure step(s) to stop in ‘QuickStop’
– Configure step(s) if ‘step.DN’ is not passed through at end of
sequence.
Jumping forward / backward in a sequence as described in the ladder
examples (user dependent). See part 1 chapter 6.3.

Progam User
37 U_GlobalOutputs Examples of lamp control (user dependent):
– hardwired lamp on start/reset boxes: central start.
– hardwired lamp on start/reset boxes and HMI: central end of cycle.
– hardwired lamp on CMU cabinet: central Estop.
– Hardwired lamp on start/reset boxes: central Estop.
38 U_Statistics Provide displayed data areas on statistic screens of Line DCU (user
dependent). See chapter 5 and specification LineDCU.
39 U_TypeInfo Example of type shift register (user dependent).
See chapter 5.1.1 – 5.1.3 (not part of DCP).
40 Pos_Oem_Block Software of Plant Operating System (Ford application). See OEM
Pos_Block specification part 4 (not part of DCP).
Diag_PosMsgErrlog
PosMsg
U_PosMonitor

CMU
41 CMU standard Each CMU communicates with one PLC. Screens 1 – 30 (Online screens)
are assigned to sequence 1 – 30.
– Delete not used online screens depending on your sequence(s) to be
displayed on the CMU.
– Adjust node and station.
– Choose language.

Ford ControlLogix – DCP Specification 2–4

 Part 3 – Chapter 2

No. Subject Detail

– Online screens: Change / assign the text of following text fields:
sequence, step, fault messages, general messages, pages, Fkeys
(Use EXCEL as possible).
– Screen sequence / page selection: Assign text of sequence(s) / pages.
– Screen line overview: Change text of stations.
– Create user screen(s) if required.
– CMU: Change the tag name zzVvTrI/D(y) in the tag database except
the Fkeys (y = ID number of CMU, ID number = 1...10).
See CMU standard application (RSView Studio).

Ford ControlLogix – DCP Specification 2–5

 Part 3 – Chapter 2

2.1.3 DCP Functions

Sequence / Station
Enable / disable

Safety Area

Selected from
Mode
Item

PLC

Line

Display
1 Manual x Kkey 11 Online screen
2 Automatic x Kkey 12 Online screen
3 x Single cycle x Last page Last page
4 x Step by step Forward x Last page Last page
Last page Last page
x Step by step Backward x One hand start box
5
6 x Manual leadthrough Forward x Last page Last page
7 x Manual leadthrough Backward x Last page Last page
Last page Online screen
Sequence start x One hand start box Last page
One hand start box
8
Last page Online screen
Sequence halt eoc x Last page
9
10 Increment step x Last page Step
11 Decrement step x Last page Step
12 Reset step x Last page Step
13 Step search x Last page Step
Last page Online screen:
Fault message
Last interlock fault x Fault type
Step
14
Last page Online screen:
Fault message
Last timeout fault x Fault type
Step
15
Last page Online screen:
Last step x Step
16
17 Clear line x x x1 Last page Last page
18 x Dry run x x1 Last page Last page
19 x Fixture reset x Last page Last page
20 x Weld reset x Last page Last page
Dedicated button Dedicated lamp
Central start x x1 Kkey 13 Online screen
Gate box Gate box
21
Dedicated button Dedicated lamp
Central halt eoc x x1 Kkey 14 Online screen
22
Dedicated button
Central Reset x x1 One hand start box
Gate box
23
24 Area start x Dedicated button Dedicated lamp
25 Area halt eoc x Dedicated button Dedicated lamp
Dedicated button Dedicated lamp
x Quickstop x Gate box Gate box
26

NOTE:
When more than one option is marked then the option required should be selected (X1: Default option).
Kkeys: Located on CMU (Versaview).
Last page: Online screen page 30 on CMU.
Eoc: End of cycle.

Ford ControlLogix – DCP Specification 2–6

 Part 3 – Chapter 3

3. Communications

3. Communications 3–1
3.1 Fieldbus Interbus S 3–1
3.2 Ethernet 3–1
3.2.1 Central Data 3–1
3.2.2 User Data 3–2
3.2.3 Ethernet Diagnosis 3–2

Ford ControlLogix – DCP Specification 3–0

 Part 3 – Chapter 3

3. Communications

3.1 Fieldbus Interbus S

The serial bus system Interbus S (IBS) by Phoenix is used to transfer I/O data to/from the PLC. Routine
P_FieldbusParameter and S_Fieldbus of the DCP and the routines P_InterbusParameters and S_Interbus
handle the transfer between the PLC and IBS scanner module (delivered by SST), make diagnosis, and
control the IBS diagnostics screen via ActiveX control on the HMI (see CMU specification).

Interbus S is not part of the DCP. Detailed description see OEM specification part 4.

3.2 Ethernet

Ethernet provides the communication between PLC – PLC, PLC – CMU and PLC – Line DCU (see DCU
specification).

3.2.1 Central Data

Central data controls line accessory data which is transferred by consumed / produced tags from / to PLC
(scheduled data transfer). The transfer can be disabled if necessary.
Reserved Tags are:
1. Input data:
- zzPlc1RemoteIn
...
- zzPlc10RemoteIn
2. Output data:
- zzPlcRemoteOut.

The user defined data structure type of these tags is called REMOTE_DATA and contains BOOL members
as follows:

Message Tag name: Request Tag name:

zzPlc..RemoteIn.. zzPlc..RemoteIn..
zzPlcRemoteOut.. zzPlcRemoteOut..
All sequences in automatic Auto x
mode
All sequences ready to start Ready x Central start StartReq
All sequences running in Start x
automatic
All sequences at end of cycle AtEoc x Central end of cycle EocReq x
All sequences are empty Empty x Central clear line ClearReq x
Central dry run DryRunReq x
Central dry run initialize DryRunInitReq x
Central reset Reset Req
Central lamp test LpTestReq
Central part reset PartActualResetReq

NOTE: Column marked with “x”: Transfer can be disabled P_CentralParameters (zzCentral.DisableTransfer).

Ford ControlLogix – DCP Specification 3–1

 Part 3 – Chapter 3

The DCP controls the shown information. The Programmer only has to define the existing data as consumed
/ produced tags depending on active remote PLCs, (data zzPlcRemoteOut as produced tag: 1 connection for
structure and 1 connection per PLC, zzPlc...RemoteIn as consumed tag depending on remote PLCs data).
PartActualResetReq is controlled by the Fkey on DCU screen produced parts to reset the current parts.
Generally the PLCs controlling the station before and after the station(s) of this PLC will be configured as
remote in routine P_SystemParameters.
User has the opportunity to supplement the structure with own data.

NOTE: The data structure must be the same in all PLCs communicating together.

To realize a transfer the user has to do following:

- I/O configuration: Define the remote PLC.
- Produced tag (zzPlcRemoteOut): Enter the number of remote PLCs which will receive this data.
- Consumed tags: Choose the remote PLC which sends the produced data (zzPlcRemoteOut) to the
received (consumed) data zzPlcxRemoteIn in ths PLC (x = ID of PLC).
- Routine P_SystemParameters: Define the ID of this and remote PLCs.

See DCP standard and OEM specification.

3.2.2 User Data

Time-critical data can be sent as scheduled data and user defined data structure (see chapter before).
Time-uncritical user data should be transferred with message instruction MSG via Ethernet. This kind of
communication especially is recommended to transfer larger data quantities, because the unscheduled data
transfer via MSG does not affect the fast transfer of the scheduled data (see Rockwell manual of Ethernet
bridge 1756-ENBT).

3.2.3 Ethernet Diagnosis

The Ethernet diagnosis monitors:

1. Transfer PLC – PLC (chapter 2.1.2 and OEM specification)

2. Transfer PLC – CMU, enclosed in Routine S_Versaview of DCP (see CMU specification)
3. Connections to all devices on the network.

If a communication fault occurs, a message is displayed on CMU. In case of transfer error PLC – CMU the
states of function keys are reset in the PLC.

Ford ControlLogix – DCP Specification 3–2

 Part 3 – Chapter 4

4. Central PLC

4. Central PLC 4–1

4.1 Interface Line DCU 4–1
4.1.1 Type Information 4–2
4.1.2 Produced Parts 4–2
4.1.3 Cycle Times 4–3
4.1.4 Step Times 4–3
4.1.5 Ethernet Diagnostics 4–4

Ford ControlLogix – DCP Specification 4–0

 Part 3 – Chapter 4

4. Central PLC

All line relevant data is collected in a Central PLC, selected by the OEM. One line has one Central PLC.. The
Central PLC itself is the connection to the other PLCs to exchange line data (this data exchange is not part
of DCP but user program).
The Central PLC is defined by the user in the routine P_SystemParameters.

Ford ControlLogix – DCP Specification 4–1

 Part 3 – Chapter 4

4.1.1 Type Information

A production line consists of up to 50 stations and 50 accessory stations of transport with up to 100 different
types.
These stations with its types and CARIN (Car Identification number) are shown on screen Type Information
(10 stations/page). An input value of each type and CARIN is sent to the Central PLC in separate data areas.
Each input action is reported with the change of the TAN (transaction number) – tag zzDcu.TypeInputTan.

The user has to provide all values of types and the CARIN in the Central PLC in following reserved tags (see
appendix C):

Station Current type [DINT] CarIn [REAL]

1 Type.InStation[1] Type.InStationCarIn[1]
2 Type.InStation[2] Type.InStationCarIn[2]
.... .... ....
50 Type.InStation[50] Type.InStationCarIn[50]
1 Type.InStationInput[1] Type.InStationCarInInput[1]
2 Type.InStationInput [2] Type.InStationCarInInput[2]
.... .... ....
50 Type.InStationInput[50] Type.InStationCarInInput[50]

Transport Current type [DINT] CarIn [REAL]

1 Type.InTransp[1] Type.InTranspCarIn[1]
2 Type.InTransp[2] Type.InTranspCarIn[2]
.... .... ....
50 Type.InTransp[50] Type.InTranspCarIn[50]
1 Type.InTransp[1] Type.InTranspCarInInput[1]
2 Type.InTransp[2] Type.InTranspCarInInput[2]
.... .... ....
50 Type.InTransp[50] Type.InTranspCarInInput[50]

A proposal of shift register to control produced parts of types is located in routine U_TypeInfo using the tags
Type... (see OEM specification, not part of DCP).

4.1.2 Produced Parts

The DCU screen produced parts shows the number of target and actual parts of up to 100 types (20 types /
page).
Total number of target and actual parts is calculated.
The DCU interface routine S_Dcu of the Central PLC supports the Reset push-button to clear all actual parts
(see chapter 3.2.1).
The user has to provide all values in the Central PLC in following reserved tag data:

Type Target [DINT] Actual [DINT]

1 Type.PartTarget[1]. Type.PartActual[1].
2 Type.PartTarget[2]. Type.PartActual[2]
.... .... ....
100 Type.PartTarget[100]. Type.PartActual[100]
Reset PB Type.PartActualResetReq

Ford ControlLogix – DCP Specification 4–2

 Part 3 – Chapter 4

4.1.3 Cycle Times

Cycle times are gauged at each station (sequence) and each robot that belongs to a station.
The DCP standard is sequence, not station organized. Therefore a standardization of cycle time is only
prepared as follows.
A station or a robot is named unit. Each unit has 3 cycle time variables: current, minimal, and given cycle
time. The given cycle time of each unit is configured in the Excel file DCUStats.xls of the line DCU. The
screen cycle times displays up to 120 units (20 units/page). The routine S_Dcu in the Central PLC calculates
the minimal cycle time of each unit and sends the current and the minimal cycle times to the Line DCU. The
minimal cycle times of all units are cleared with the Reset function key.

The user has to adjust and program following (see appendix E):

– Providing of current cycle times of all stations and robots in each PLC.
If a station = sequence, the sequence cycle time (zzSeq[xx].CycleLast) provided by DCP can be used.
– Ethernet transfer of cycle times of each PLC to the Central PLC (MSG recommended).
– Copy of all current cycle times to reserved tag data in the Central PLC.

Description Tag name [DINT]

Current cycle time of unit 1 CycleT.Current[1]
Current cycle time of unit 2 CycleT.Current[2]
.... ....
Current cycle time of unit 120 CycleT.Current[120]

Minimal cycle time of unit 1 CycleT.Min[1]

Minimal cycle time of unit 2 CycleT.Min[2]
.... ....
Minimal cycle time of unit 120 CycleT.Min[120]

4.1.4 Step Times

The DCU screen step times shows the time of current, reference and shortest sequence steps of the
selected sequence. Up to 99 steps (step 1 ... 99) per sequence are displayed at maximum (20 steps/page). If
automatic mode is selected, the teach function can be called out (see chapter 6).

Teach function:
During the current sequence cycle each step time will be gauged and saved as current step time. When the
cycle is finished the saved step times are displayed and stored as reference step times, teach is finished
(see chapter 6.3.9). During the following cycles a user defined tolerance value in % will be added to each
reference step time. Exceeds the step time value of the current step the reference one corrected by the
tolerance, a timeout fault will be caused and displayed as fault message and fault type on the DC Online
screen of CMU. If the fault is gone, the user can show the last timeout fault by pressing the Fkey 11 on page
16 of the CMU (fault message, fault type and step appeared).
Further information see Part 1 chapter 3.4.1.2.

On the Line DCU the user can change the reference time of each sequence step and the percent value.
All shortest step times of the shown sequence can be cleared with the reset pushbutton.

Ford ControlLogix – DCP Specification 4–3

 Part 3 – Chapter 4

NOTE:
– In some cases, e.g. waiting of a part from another station, it is recommendable to lock the timeout
detection. If the reference step time is set to zero by the user the diagnosis is disabled in this step. To
lock the timeout detection for special steps see chapter 2, Part 1 chapter 4.1.2 and DCP
(P_SequenceParameters).
– The percentage is related to all sequences programmed in the PLC of the selected sequence.

The screen step times is controlled completely by DCP standard, (S_Dcu, S_SequenceMain), and Line
DCU.
Modification or programming by user is not necessary.

4.1.5 Ethernet Diagnostics

Ethernet diagnosis see Line DCU.

Ford ControlLogix – DCP Specification 4–4

 Part 3 – Chapter 5

5. Flow Charts

5.1 Modes 5–1

5.1.1 Manual (Manual) 5–1
5.1.2 Manual Lead Thru (ManualLead) 5–2
5.1.3 Automatic (Automatic) 5–4
5.1.4 Step by Step (StepByStep) 5–5
5.1.5 Single Cycle (SingleCycle) 5–6
5.1.6 End of Cycle (Eoc) 5–7
5.1.7 Auto/Semi (AutoSemi) 5–8
5.1.8 Fixture Reset (FixReset) 5–9
5.1.9 Weld Reset (WeldReset) 5 – 10

5.2 States of Sequence 5 – 11

5.2.1 Sequence Ready (Ready) 5 – 11
5.2.2 Sequence Start (Start) 5 – 12
5.2.3 Sequence Waits in Run 5 – 13
5.2.4 Sequence Stop 5 – 14

5.3 DCP Functions 5 – 15

5.3.1 Step Increment 5 – 15
5.3.2 Step Decrement 5 – 16
5.3.3 Step Counter Reset 5 – 17
5.3.4 Step Search (Resequence) 5 – 18
5.3.5 First Interlock Fault 5 – 19
5.3.6 Timeout Fault 5 – 20
5.3.7 Display Last Step 5 – 21
5.3.8 Lamp Test 5 – 22
5.3.9 Teach In Function (see Chapter 5.1.4) 5 – 23

NOTE:

– Used short cuts:

xx = step number
Eoc = end of cycle.
– ( .... ) = tag names in DCP Standard. Tag names of sequence are only described as structure members,
but without leading sequence element zzSeq[xx].
– Flow chart:
branch: junction line downwards = yes
junction line right hand = no.
– All operating and display functions belong to DC Online screen of CMU if not described otherwise.
– Manual P/Bs and P/B lamps of 16 pages (DC Online screen) are described as follows:
F2 page 16, L2 page 16, etc.

Ford ControlLogix – DCP Specification 5–0

 Part 3 – Chapter 5

5.1 Modes

5.1.1 Manual (Manual)

manual mode
(Manual)

F9 page 1 mode = manual ?

manual mode

- no CM
and
(FixReset) - fixture or weld reset
(WeldReset) mode not active ?

Fkey page 2...12

pressed for desired
manual function ?

no manual interlock
(ManDiag)
fault ?

(ManRelease) - manual release for

interlock fault message
movement
displayed on DCP Online
(ManReq) - manual request for
screen
movement

end position
reached ?

control output switches control output switches

off on

- accessory Fkey lamp - accessory Fkey lamp required function[s] are

illumimates flashes displayed on DCP
- 1st fault line: - 1st fault line: Online screen to start
display of start or fault display of destination sequence in current
message fault message step

end

Ford ControlLogix – DCP Specification 5–1

 Part 3 – Chapter 5

5.1.2 Manual Lead Thru (ManualLead)

manual lead thru mode

(ManualLead)

mode = lead thru

F10 page 1
mode [MLT] ?

- manual lead thru mode

selected
(ManualLead)
- L4/L10 page 1
illuminates

lead thru mode

selected ?

F12 page 1 Backward ?

- manual lead backward

mode selected
(Backward)
- Fkey lamp L10/L12
page 1 illuminates

- mode change:
sequence stops
F4 page 1 Forward ?
- fault message:
required function to
start sequence in
- manual lead forward shown step
mode selected - L4/L10/L12 page 1
(MLeadFwd)
- L4/L10 page 1 off
illuminates

Ford ControlLogix – DCP Specification 5–2

 Part 3 – Chapter 5

mode = Manual
lead thru
(Start) and
sequence is
running ?

- 1st fault line:

next function of current step is displayed
- accessory Fkey lamp of function is flashing
on correct page to inform the operator, that
(Fault)
the associated Fkey has to be pushed to
continue the machine process
- page changes automatically if next function
locates on another page

Fkey of flashing
lamp pushed ?

Fkey lamp
illuminates ?

destination reached
control output on
[control output off]

step functions
finished ?

- step change
- next function is shown
and read to carry out

end

Ford ControlLogix – DCP Specification 5–3

 Part 3 – Chapter 5

5.1.3 Automatic (Automatic)

automatic
(Automatic)

mode =
F1 page 1
automatic ?

sequence
(Start)
running ?

start fault or faults

with higher
priority are shown
last step finished
?

step finished ?

- step is working
- step function
- step change displayed message:
(StepCounter) sequence continuous
- next step is - operation shown waiting of mode
(Step.Flag[xx]) with next cycle at step 1
active in 1st fault line change in auto
[SIZ]

end

Ford ControlLogix – DCP Specification 5–4

 Part 3 – Chapter 5

5.1.4 Step by Step (StepByStep)

step by step
(StepByStep)

F3 page 1 mode = step by step ?

sequence is
(Start)
running ?

start fault or faults with

step completed higher priority are
no SIZ shown
?

- step is working
1st fault line:
- step function displayed
waiting on pressing start
- operation shown in 1st
P/B
fault line [SIZ]

start P/B pushed

F13 page 1
?

- step change
- next step operates

end

Ford ControlLogix – DCP Specification 5–5

 Part 3 – Chapter 5

5.1.5 Single Cycle (SingleCycle)

single cycle
(SingleCycle)

mode = single
F2 page 1
cycle ?

start fault or faults

with higher priority
sequence is
(Start) are shown
running ?

last step:
one or more last step of this
various steps are cycle is finished step is finished ?
programmable by ?
the user

- step is working
- step change - step function
- next step displayed
operates - operation shown
in fault line [SIZ]

end

Ford ControlLogix – DCP Specification 5–6

 Part 3 – Chapter 5

5.1.6 End of Cycle (Eoc)

end of cycle
(Eoc)

mode =
F1 page 1
automatic ?

end of cycle
F14/F6 page 1
selected ?

- EOC active
(Eoc) - P/B lamp 'local
L14/L6 page 1 EOC' or 'central
EOC' is flashing

sequence is
(Start)
running ?

step of EOC
(EocSteps) reached:
one or more various step 'EOC
steps (EocStep) are reached' ? start fault or fault
programmable by the with higher
user priority are shown

- steps are
- sequence waits on working
restart - operations are
- 1st fault line: waiting shown in fault line
(zzCentral.AtEndOfCycle)
on start P/B pressed [SIZ]
(AtEoc)
- lamp 'local EOC' or - lamp 'local EOC'
'central EOC' or 'central EOC'
illuminates flashes

end

Ford ControlLogix – DCP Specification 5–7

 Part 3 – Chapter 5

5.1.7 Auto/Semi (AutoSemi)

auto / semi
(AutoSemi)

mode =
- manual lead
thru
or
- automatic
or
- single cycle
or
- step by step ?

(AutoSemi) auto / semi reset auto / semi

sequence is
(Start)
running ?

sequence does
wait on restart ?

- operations
are shown in
L13/L5 page 1 fault line [SIZ] - 1st fault line: waiting
- start P/B lamp on restart
illuminates - start P/B lamp flashes

faults are
start of sequence is
displayed to
possible with start P/B repair them
F13/F5 page 1

end

Ford ControlLogix – DCP Specification 5–8

 Part 3 – Chapter 5

5.1.8 Fixture Reset (FixReset)

fixture reset
(FixReset)

- mode = manual
and
- F1 page 15 is pressed
constantly
and
- safety key switch is on
and
start step is active ?

- reset 'fixture reset'

(FixReset) fixture reset active - L1 page 15 off

- interlock fault
or
- no fault ?

inkrement step sequence fault

control function:
- does control function active
(FctActive)
in this step
and
- is fixture reset branch
rung manual request
programmed parallel to
(ManReq)
manual Fkey ?

start and stop step:

one or more various steps
step finished ?
are programmable by the
user
control output is on

step 'fixture reset'

(FixAtPos)
finished

- reset 'fixture reset'

- associated L1 page 15 illuminates

end

Ford ControlLogix – DCP Specification 5–9

 Part 3 – Chapter 5

5.1.9 Weld Reset (WeldReset)

weld reset
(WeldReset)

(WeldReset) corresponds to 'fixture

F9/L9 page 15 reset' if used

end

Ford ControlLogix – DCP Specification 5 – 10

 Part 3 – Chapter 5

5.2 States of Sequence

5.2.1 Sequence Ready (Ready)

sequence ready to start

(Ready)

mode =
(Automatic) - automatic
or
(SingleCycle) - single cycle
or
(StepByStep) - step by step
or
(ManualLead) - manual lead
thru ?

not active:
(CmFault) - CM
and
(CmiFault) - CMI
and
(IntFault) - interlock fault
and
(Resequence) - step search
(resequence)

- reset sequence ready

(Ready) - sequence ready to start to start
L13/L5 page 1 - start P/B lamp flashes - start P/B lamp off

Ende

Ford ControlLogix – DCP Specification 5 – 11

 Part 3 – Chapter 5

5.2.2 Sequence Start (Start)

sequence start [is

running]
(Start)

- local start P/B F13

to start the sequence
page 1
local, DC Online
or
screen of this
- central start P/B
sequence must be
F5 page 1
displayed
is pressed ?

sequence ready
(Ready)
to start [start P/B
L13/L5 page 1
lamp flashes] ?

sequence starts with

current step - reset sequence start
(Start) - sequence is running - sequence stops
- start P/B lamp - start P/B lamp off
illuminates

end

Ford ControlLogix – DCP Specification 5 – 12

 Part 3 – Chapter 5

5.2.3 Sequence Waits in Run

sequence is waiting
in run

- sequence fault [step is working]

(SeqFault)
or
- step is completed in step by step mode
or
- single cycle is completed in single cycle
or
- end of cycle is reached during end of cycle
function
or
- dry run or clear line is finished
or
- each other start condition reporting in
1st fault line
?

to continue, sequence is waitung on:

- completation of current step [sequence fault in
1st fault line]
- carrying out the reported start condition shown
in 1st fault line

end

Ford ControlLogix – DCP Specification 5 – 13

 Part 3 – Chapter 5

5.2.4 Sequence Stop

sequence stops run

immediately

(CmFault) - CM
or
(CmiFault) - CMI
or
(IntFault) - interlock fault
or
- mode change ?

sequence stops
immediately
[reset (Ready), (Start)]

end

Ford ControlLogix – DCP Specification 5 – 14

 Part 3 – Chapter 5

5.3 DCP Functions (see CMU specification.2.4.2)

5.3.1 Step Increment

step increment
(IncStep)

- manual mode
(Manual) and
- F1 page 16

max. step

(StepCounter) step 1 -> step counter step + 1

end

Ford ControlLogix – DCP Specification 5 – 15

 Part 3 – Chapter 5

5.3.2 Step Decrement

step decrement
(DecStep)

- manual mode
(Manual) and
- F9 page 16 ?

step 1 ?

(StepCounter) last step -> step counter step - 1

end

Ford ControlLogix – DCP Specification 5 – 16

 Part 3 – Chapter 5

5.3.3 Step Counter Reset

step reset

(Manual) - manual mode

and
- F2 page 16
pushed >3 sec ?

(SeqResetTime.DN) 3 sec ?

reset step counter

(StepCounter) L2 page 16 flashes
[step 1]

end

Ford ControlLogix – DCP Specification 5 – 17

 Part 3 – Chapter 5

5.3.4 Step Search (Resequence)

step search (Resequence)

(AutoSemi) - auto / semi

and
(Start) - sequence not running
and
- F10 page 16 ?

(ReseqStep) save of current step

(ReseqReq) resequence request

- resequence request
and
- no manual mode ?

- step search active

(Resequence)
- L10 page 16 illuminates

step search active ?

step with interlock fault ?

last step ?

(StepCounter.ACC) step 1 -> step counter step + 1

- step counter has changed from last step to step 1

and
- current step >= saved step ?

reset step search reset step search

saved step -> step counter

end

Ford ControlLogix – DCP Specification 5 – 18

 Part 3 – Chapter 5

5.3.5 First Interlock Fault

First interlock fault

(FirstIntFault)

sequence is
running ?

(CmFault) - Cm
or
(CmiFault) - Cmi
or
(IntFault) - interlock fault ?

- saving of fault reported

at 1st fault line [fault bit,
(InterlockBit)
current step]
(InterlockStep)
- L3 page 16 flashes
- sequence stops

F3 page 16
show first fault
pressed ?

- fault, that caused the

last stop of running
sequence, is displayed
with fault text, fault type,
(FirstIntFault) current fault, current
and step
- L3 page 16 goes off, fault type, and current
when Fkey is being step are displayed
released

end

Ford ControlLogix – DCP Specification 5 – 19

 Part 3 – Chapter 5

5.3.6 Timeout Fault

timeout fault
(FirstTimeFault)

sequence is
running ?

(StepTime.ACC) current step time >

(CurrRefStepTime) reference step time
(StepTimePercent) + %-value
and
(AtEoc) not at EOC
and
(Clear) line not clear ?

(TimeFault) new timeout fault

- saving of sequence
fault reported at 1st fault
(TimeoutBit)
line [fault bit, current
(TimeoutStep)
step]
- L11 page 16 flashes

show first F11 page 16

timeout fault pressed ?

- last occured and

saved timeout fault is
displayed with fault text, current fault, current
(FirstTimeFault) fault type, and step fault type, and current
- L11 page 16 goes off, step are displayed
when Fkey is being
released

end

Ford ControlLogix – DCP Specification 5 – 20

 Part 3 – Chapter 5

5.3.7 Display Last Step

display last step

(StepDisplay)

(AutoSemi) - auto/semi
and
- step change ?

(AutoStep) saving of the new step

- manual mode
and
- F4 page 16 ?

(AutoStep) last step running in

current step is displayed
(StepDisplay) auto/semi is displayed

end

Ford ControlLogix – DCP Specification 5 – 21

 Part 3 – Chapter 5

5.3.8 Lamp Test

lamp test
(LampTest)

F12 page 16 testing lamps ?

all lamps of operator

tables illuminate

L12 page 16 illuminates

end

Ford ControlLogix – DCP Specification 5 – 22

 Part 3 – Chapter 5

5.3.9 Teach Function (see Chapter 5.1.4)

Teach function
(Teach)

(Automatic) automatic ?

sequence is running
(Start)
?

(StepTime.ACC) saving the step time of

(LastStep[xx]) operated step after each step
change continuously

- DCU screen 'step times'

and
- Fkey Teach is pressed
?

- Teach function active

(Teach) - DCU Fkey lamp Teach
flashes

- Teach function active

and
(StepCounter.DN)
- last step of sequence is
finished ?

last step times of all steps of

(LastStep[xx])
current sequence cycle are
(ReferenceStep[xx])
saved to reference step times

(CycleLast)
last cycle time of sequence is
(CycleReference)
saved to reference cycle time
(CycleTime.PRE)

- reset Teach function

- DCU Fkey lamp Teach off

end

Ford ControlLogix – DCP Specification 5 – 23

 Part 3 – Appendix A

Appendix A

A. Form Sheets Programmable Assistance

Sequence Overview Diagram A–1

Programming Chart A–2
Push Button Chart A–3

Ford ControlLogix – DCP Specification A–0

 Part 3 – Appendix A

Ford ControlLogix – DCP Specification A–1

 Part 3 – Appendix A

Ford ControlLogix – DCP Specification

A–2
 Part 3 – Appendix A

Ford ControlLogix – DCP Specification

A –
3
 Part 3 – Appendix B

Appendix B

C. Data Exchange PLC – Line DCU

Data to Realize the Communication C–1

Screen Type Information (Central PLC) C–2
Screen Produced Parts (Central PLC) C–2
Screen Cycle Times (Central PLC) C–3
Screen Step Times C–4

Ford ControlLogix – DCP Specification B–0

 Part 3 – Appendix B

Data to Realize the Communication

DCU DCU
Output Mapping DCU Interface Description Input Mapping DCU Interface
N260:12 zzDCUN260[12] zzDcu.Button[0] Fkeys / Lamps N261:12 zzDcuN261[12] zzDcu.Lamp[0]
N260:13/0 zzDCUN260[13].0 zzDcu.Req[0].CtlFlags.0 Toggle bit N261:13/0 zzDCUN261[13].0 zzDcu.Ack[0].CtlFlags.0
N260:13/1 zzDCUN260[13].1 zzDcu.Req[0].CtlFlags.1 Second bit N261:13/1 zzDCUN261[13].1 zzDcu.Ack[0].CtlFlags.1
N260:14 zzDCUN260[14] zzDcu.Req[0].DcuRev reserved
N260:15 zzDCUN260[15] zzDcu.Req[0].Seq Sequence ID N261:15 zzDcuN261[15] zzDcu.Ack[0].Seq
N260:16 zzDCUN260[16] zzDcu.Req[0].Page Page N261:16 zzDcuN261[16] zzDcu.Ack[0].Page
N260:17 zzDCUN260[17] zzDcu.Req[0].PlcNode PLC Node N261:17 zzDcuN261[17] zzDcu.Ack[0].PlcNode
N260:18 zzDCUN260[18] zzDcu.Req[0].Screen Screens: N261:18 zzDcuN261[18] zzDcu.Ack[0].Screen
6 = Type Info
7 = Produced Parts
8 = Cycle Times
9 = Step Times
10= Line Overview

DCU clock zzDcuS2[4].0

The N260 data are sent from DCU and are responsed by N261 data from PLC.
This data table is only served for service information of user. All of these data are reserved for communication handling and handshake to realize the data transfer
between Line DCU and PLC.

Ford ControlLogix – DCP Specification B–1

 Part 3 – Appendix B

Screen Type Information (Central PLC)

DCU DCU Data

Output Input Mapping DCU Interface User Interface Type Length Description
N281:1 zzDcuN281[0] zzDcu.TypeInputTan DINT 1 Transaction number for handshake.
If input data are accepted at DCU,
the data is sent to PLC. Afterwards
the transaction number changes its
value to give an information that the
inputs are transferred.

N281:1 zzDcuN281[1] Type.InStationInput[1] DINT 50 Input Type in station

N281:51zzDcuN281[51] Type.InStation[1] DINT 50 Type in station
N281:101 zzDcuN281[101] Type.InTranspInput[1] DINT 50 Input type in transport
N281:151 zzDcuN281[151] Type.InTransp[1] DINT 50 Type in transport
F280:1 zzDcuF280[1] Type.InStationCarInInput[1] REAL 50 Input Car In data type in station
F280:51 zzDcuF280[51] Type.InStationCarIn[1] REAL 50 Car In data type in station
F280:101 zzDcuF280[101] Type.InTranspCarInInput[1] REAL 50 Input Car In data type in transport
F280:151 zzDcuF280[151] Type.InTranspCarIn[1] REAL 50 Car In data type in transport

All of the input data (DCU output) are available for user application.
All of the actual data (DCU input) have to be provided by user.

Ford ControlLogix – DCP Specification B–2

 Part 3 – Appendix B

Screen Produced Parts (Central PLC)

DCU DCU Data

Input Output Mapping DCU Interface User Interface Type Length Description
N285:1 zzDcuN285[1] zzDcu.PartsTarget[1] Type.PartTarget[1] DINT 100 Target parts of type
N286:1 zzDcuN286[1] zzDcu.PartsActual[1] Type.PartActual[1] DINT 100 Actual produced parts of type
N282:1 zzDcuN282[1] zzDcu.PartsSumActual DINT 1 Sum of target parts
N282:2 zzDcuN282[2] zzDcu.PartsSumTarget DINT 1 Sum of produced parts

The user has to provide the actual produced parts of each type.

Screen Cycle Times (Central PLC)

DCU DCU Data

Input Output Mapping DCU Interface User Interface Type Length Description
N283:0 zzDcuN283[0] zzDcu.CtimeCurrent[1] CycleT.Current[1] DINT 120 Current cycle time of station / unit
N284:0 zzDcuN284[0] zzDcu.CtimeShort[1] CycleT.Short[1] DINT 120 Shortest cycle time of station / unit
N260:12/6 zzDcuN260[12].6 zzDcu.Button[0].6 BOOL Reset Fkey of all shortest cycle times

The user has to provide the current cycle times.

The shortest cycle times and the reset pushbutton are handled by DCP standard.
The displayed reference cycle times are only input data at DCU and its are not sent to the PLC.

If a station corresponds to a sequence the DCP offers cycle time data:

Current cycle time = zzSeq[xx].CycleLast
Shortest cycle time = zzSeq[xx].CycleShort.
In this case the user has to program the reset of shortest cycle times.

Ford ControlLogix – DCP Specification B–3

 Part 3 – Appendix B

Screen Step Times

DCU DCU Data

Input Output Mapping DCU Interface Type Length Description
N241:0 N241:0 zzDcuN241[0] zzSystem.StepTimePercent DINT 1 Percent value as offset for reference step times of all
sequences in the PLC (timeout diagnosis)
N241:21 zzDcuN241[21] zzSeq[yy].LastStep[xx] DINT 20 Actual step time of last step
N241:41 zzDcuN241[41] zzSeq[yy].ShortStep[xx] DINT 20 Shortest step time
N241:61 N241:61 zzDcuN241[61] zzSeq[yy].ReferenceStep[xx] DINT 20 Reference step time of step to produce timeout fault
N260:2/5 zzDcuN260[2].5 zzDcu.Button[0].5 BOOL Fkey Teach to start teach mode
N260:2/6 zzDcuN260[2].6 zzDcu.Button[0].6 BOOL Fkey reset to reset shortest step times
N261:2/5 zzDcuN261[2].5 zzDcu.Lamp[0].5 BOOL Lamp of Fkey Teach

xx = step no. according to the page no. on the DCU.

yy = sequence no.

Page 1: Step 1 .. 20
Page 2: Step 21 .. 40
Page 3: Step 41 .. 60
Page 4: Step 61 .. 80
Page 5: Step 81 .. 99

This data table is only served for user information. There is no configuration of user. Complete data handling is realized in the DCP standard.

Ford ControlLogix – DCP Specification B–4