MAAC Conveyors, Controls, Robotics & Welding

GCCS-2
Integrated DeviceNet Safety Robot
Commissioning Instructions

April 8, 2011
Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

Document revisions:

Date Revision By Revision History

8Apr2011 Release N. Miller First release.

April 8, 2011 General Motors. All rights reserved. ii

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

TABLE OF CONTENTS
Section Description Page

1.  Scope ..................................................................................................................................................... 4 

2.  General Description of Required Steps ............................................................................................. 4 
2.1  IO Module Definition ...................................................................................................................... 4 
2.2  Network Commissioning ................................................................................................................ 4 
2.3  Set Module to “Out of Box” ............................................................................................................ 4 
2.4  Set Safety Network Number (SNN) ............................................................................................... 4 
2.5  Remove Network Bypass from the Robot ..................................................................................... 4 
2.6  Acknowledge Safety Change Status ............................................................................................. 4 
2.7  Store Robot Signature Value ......................................................................................................... 5 
3.  GuardLogix Safety PLCs ..................................................................................................................... 5 
3.1  Safety IO Definition........................................................................................................................ 5 
3.2  Set Module to “Out of Box” ............................................................................................................ 5 
3.3  Set Safety Network Number (SNN) ............................................................................................... 6 
3.4  Remove Network Bypass from the Robot ..................................................................................... 7 
3.5  Acknowledge Safety Change Status ........................................................................................... 10 
3.6  Store Robot Signature Value ....................................................................................................... 11 
4.  SmartGuard Safety PLC ..................................................................................................................... 11 
4.1  Safety IO Definition...................................................................................................................... 11 
4.2  Set Module to “Out of Box” .......................................................................................................... 12 
4.3  Set Safety Network Number (SNN) ............................................................................................. 12 
4.4  Remove Network Bypass from the Robot ................................................................................... 12 
4.5  Acknowledge Safety Change Status ........................................................................................... 15 
4.6  Store Robot Signature Value ....................................................................................................... 15 

April 8, 2011 General Motors. All rights reserved. iii

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

1. Scope

This document provides step by step instructions to get the Integrated DeviceNet Safety connection running
between the PLC and the robot. Other communication interfaces are not covered by this document.

2. General Description of Required Steps

The basic steps to establish safety communication with the IDNS robot are the same. The methods to
perform those steps vary by PLC. A description of the steps are below.

2.1 IO Module Definition

The I/O module must be defined in the target PLC. Always copy the module definition from the applicable
GCCS-2 reference project and follow the instructions for your application.

2.2 Network Commissioning

The network must be working correctly before connecting the I/O module to the safety PLC. Make sure the
network has power, all devices are communicating at the correct baud rate, and the programming terminal
can see all of the robot safety nodes before proceeding to the next step.

The robots must be set to the correct node numbers before proceeding to the next step.

2.3 Set Module to “Out of Box”

The safety I/O has an “ownership” property. Once a module has connected to a safety PLC, they establish
ownership between the PLC and IO module. This is done by setting safety network numbers at both ends.
If a PLC tries to connect to the I/O module using the wrong safety network number, the I/O module will not
connect to the PLC. This prevents an I/O module from being controlled by the wrong PLC.

“Out of Box” state for a safety I/O module means that it is open to a PLC establishing a connection. The
overall configuration including the safety network number can be sent to the I/O module. Once a running
connection is made, the module cannot be changed.

The IDNS safety connection in the robot is not “Out of Box” as shipped. A module reset request must be
sent prior to a safety I/O connection being established.

2.4 Set Safety Network Number (SNN)

The safety network number must be set between the module and the PLC to insure that a false connection
cannot be made.

After setting the safety network number, the I/O connection between the robot and PLC should begin
running.

2.5 Remove Network Bypass from the Robot

The robot is shipped with the safety network bypassed. This allows the robot to be moved prior to
connecting to a safety PLC. The network may also be bypassed to allow a programmer to move the robot
when other safety systems are not ready. The network bypass must be removed to allow the PLC to control
the robot.

2.6 Acknowledge Safety Change Status

The robot internally tracks the safety configuration and sets a bit value to the PLC to indicate that the
configuration has changed. This is a method to provide security to the safety configuration, any change
requires an acknowledgement from the PLC. The PLC input is called “ConfigMatch” and the PLC output is
called “ConfigChangeReset”.

April 8, 2011 General Motors. All rights reserved. 4

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding
Once the safety change status has been acknowledged, the IDNS safety connection should be working
correctly. This step must be performed each time a change is made to the robot safety configuration.
Please remember this step.

2.7 Store Robot Signature Value

The robot provides a safety signature value to the PLC. This allows monitoring of the current robot
configuration and notification of a change. The last valid signature value is stored in the PLC and in the
plant floor systems.

3. GuardLogix Safety PLCs

The steps below will connect an IDNS robot to a GuardLogix safety PLC.

3.1 Safety IO Definition

Open the safety I/O definition as shown below. Check the configuration against the most recent GCCS-2 to
insure a match.

3.2 Set Module to “Out of Box”

To set the module to an “Out of Box” state:
a. Click on the “Safety” tab. If the “Reset Ownership” button has black text, click on it.
Accept the change when any prompt windows open. Picture below:

April 8, 2011 General Motors. All rights reserved. 5

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

3.3 Set Safety Network Number (SNN)

To set the Safety Network Number:
b. Click on the “General” tab.
c. Click on the “…” button next to the “Safety Network Number” display.

d. Click on the “Set” button.

April 8, 2011 General Motors. All rights reserved. 6

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

e. The module should begin communicating. The “Status:” should indicate “Running”.

3.4 Remove Network Bypass from the Robot

To change states of CIP mode do the following:

a. Enable the TP. Press MENUS->NEXT->SYSTEM->TYPE->DCS

b. Cursor to CIP Safety and then select <ENTER>

April 8, 2011 General Motors. All rights reserved. 7

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

c. Acknowledge that setting will be changed by pressing <F4>.

d. Select the <PREV> key to return to the DCS main menu.
e. Select <F2> to [APPLY] changes DCS settings. Code number (master) = 1111.
Passwords may have been changed already when you run the wizard, Contact
program Lead Robotics Engineer for current password. General Motors are
responsible for ALL Passwords.

April 8, 2011 General Motors. All rights reserved. 8

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

f. Select <F4> [OK] to apply DCS settings.

g. CIP Safety mode will now show; PEND, cycle power to apply changes.

April 8, 2011 General Motors. All rights reserved. 9

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

3.5 Acknowledge Safety Change Status

Open the s_B010_SafetyConfigOutputs routine. Right click on the Rbt.Cfg.ChangeAcknowledge
bit in the rung shown below. Choose “Toggle Bit”. Repeat. That will send an acknowledge to the
<@SYS>
robot. The R0x.I.ConfigMatch input should now be on.
################################################################
# Individual Robot DCS Output Config
################################################################
<@INFO>
################################################################
# Robot safety configuration changes:
# If the robot safety configuration changes, for DCS changes or other, an
# acknow ledge output from the PLC must be sent for the robot to turn on its
# configuration OK output. If the safety netw ork is bypassed in the robot to allow
# isolated teaching, the configuration OK output w ill turn off, but does not have to
# be acknow ledged. Follow the instructions below to acknow ledge a robot safety
# configuration change.
#
# To acknow ledge a change to the robot safety configuration:
# 1. Save the locked safety program w ith signature
# 2. Clear the signature and unlock the safety task
# 3. Right click on the OTU Rxx.Cfg.ChangeAcknow ledge below
# select "Toggle Bit" or press CNTRL-T. Then, repeat the
# process to turn off the bit. The driver w ill then send the robot a timed signal
# to acknow ledge the change.
# 4. Dow nload the previously saved program back to the controller, this w ill
# preserve the original safety signature.
################################################################
<@TODO>
################################################################
# Do not modify the .ChangeAcknow ledge branch. It is there for error proofing the
# output to the robot.
#
# Add the safety conditions for the user configurable zones / speeds of the robot in series w ith the
# OKForDCSX outputs. See example below .
#
# If a DCS is used as an operator DLD, program the correct station(s) XIC StationYY.OpReset in
# series w ith the OKForDCSX output.
#
# If a DCS is not used, disable the configuration bit using XIC Alw aysOff. See DCS4 in the example.
#
# If a DCS is used limit the robot's envelop (distance to a fence, etc), do not use
# one of the DCS connections betw een the PLC and the robot, configure the
# DCS in the robot only.
################################################################
Robot 1 Safety Alias Robot 1 Safety Alias Robot 1 Safety Alias
Safety I/O Robot Safety Change To
Alw ays Off Bit Communication Configuration OK Robot
For Permanent OK No Changes Safety OK
Block Only R01.CommOK R01.I.ConfigMatch R01.Cfg.ChangeAcknow ledge
Alw aysOff <s_AAxx1Rx1.CommOK> <s_AAxx1Rx1.I.ConfigMatch> <s_AAxx1Rx1.Cfg.ChangeAcknow ledge>
4 U
Station 1 Safety Robot 1 Safety Alias
Alias User Config
All Operator Safety Zone /
Safety Devices Speed Setting
Are Reset OK for Robot
Station01.OpReset R01.Cfg.OKForDCS1
<s_AAxx1.OpReset> <s_AAxx1Rx1.Cfg.OKForDCS1>

Station 2 Safety Robot 1 Safety Alias

Alias User Config
All Operator Safety Zone /
Safety Devices Speed Setting
Are Reset OK for Robot
Station02.OpReset R01.Cfg.OKForDCS2
<s_AAxx2.OpReset> <s_AAxx1Rx1.Cfg.OKForDCS2>

Robot 1 Safety Alias

User Config
Safety Zone /
Alw ays Off Bit Speed Setting
For Permanent OK for Robot
Block Only R01.Cfg.OKForDCS3
Alw aysOff <s_AAxx1Rx1.Cfg.OKForDCS3>

Robot 1 Safety Alias

User Config
Safety Zone /
Alw ays Off Bit Speed Setting
For Permanent OK for Robot
Block Only R01.Cfg.OKForDCS4
Alw aysOff <s_AAxx1Rx1.Cfg.OKForDCS4>

April 8, 2011 General Motors. All rights reserved. 10

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding
3.6 Store Robot Signature Value
Open the zZ001_IDNSSafetyInterface routine for the robot. Find the rung below, toggle the
RbtSafety.CopySign bit at the left of the rung. The PLC will automatically copy the right data to
its internal registers and send the valid signature to the upper level systems.
<@TODO>
#=======================================================
# Copy Safety Signature to Compare Value
#
# The safety signature is stored in a compare value after the safety buyoff
# is complete. That allows the system to automatically detect if the safety
# signature has changed due to a safety program change.
#
# Toggle the RbtSafety.CopySign XIC bit below to copy the current
# signature into the monitoring compare word. Right click on the
# RbtSafety.CopySign address below and choose "Toggle Bit".
#
# Do this ONLY when the safety program has been bought off by the
# proper safety representatives. If the safety program has been changed,
# finish any buyoff procedures before copying the signature.
#=======================================================
Robot Safety
Interface Robot Safety Robot Safety
Copy Robot Robot Alias Interface Interface
Safety Signature Robot Communication Known Good Last Signature
One Shot OK Signature For Sent To
RbtSafety.CopySign R.Sts.CommOK Compare Cimplicity
<AAxx2Rx1RbtSafety.CopySign> <AAxx2Rx1.Sts.CommOK> MOV CLR
1 Move Clear
Source I.Signature Dest RbtSafety.LastSent
16#0000_0000 <AAxx2Rx1RbtSafety.LastSent>
Dest RbtSafety.CompareSignature 16#0000_0000
<AAxx2Rx1RbtSafety.CompareSignature>
16#0000_0000

Robot Safety
Interface
Copy Robot
Safety Signature
One Shot
RbtSafety.CopySign
<AAxx2Rx1RbtSafety.CopySign>
U

4. SmartGuard Safety PLC

The steps below will connect an IDNS robot to a SmartGuard Safety PLC.

4.1 Safety IO Definition

Open the safety I/O definition as shown below. Check the configuration against the most recent GCCS-2 to
insure a match. Click on the symbol with the + sign to open the detailed configuration. Check the main
connection, input connection and output connection settings.

April 8, 2011 General Motors. All rights reserved. 11

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding
4.2 Set Module to “Out of Box”
The SmartGuard does not have a convenient method to set the module to the “Out of Box” state. The
method to set the module to out of box is managed within the control PLC.

Open the robot program V001_SafetyInterface_3A routine. Find the rungs shown below. Click on the
message instruction config button (…). Check the message path for both message instructions. The path
for both should be [DnetModule],2,[Dnet node number].

Right click on the RbtSafety.ResetOwnership contact on the rung. Select “Toggle Bit”. The PLC will send
the out of box messages to the robot.
<@SYS>
#=======================================================
# Safety Ownership Reset
# For Resetting non-Rockw ell safety nodes after changing the safety network number
# 1. Edit the GetOw nership and ResetOwnership message Instruction. Change the
# communication path to the correct node number. The path should be Dnet01, 2, [Dnet node number].
# 2. Toggle the RbtSafety.ResetOwnershiip bit to trigger a read and a reset.
#=======================================================
<@INFO>
#=======================================================
# The message parameters should be:
# Message Type "CIP Generic"
# Service Type "Get Attribute Single"
# Service Code "e"
# Class "39"
# Instance "1"
# Attribute "1b"
# Destination "AAxx1Rx1OwnershipReadData[0]" controller scope tag (change name to match application)
# Path - see above
# Connected - unchecked
#
#=======================================================
Robot Safety Robot Safety
Interface Reset IDNS Robot Interface Reset
Robot Get Ow nership Robot
Safety Node Status Message Safety Node
RbtSafety.ResetOwnership To Safe Node RbtSafety.ResetOw nership
<AAxx1RX2RbtSafety.ResetOw nership> MSG <AAxx1RX2RbtSafety.ResetOw nership>
5 Message EN U
Message Control AAxx1Rx1GetOw nership ... DN
Robot Safety ER
Interface Reset
Robot
Safety I/O
Module
Ow nership Robot Safety
From HMI Interface One Shot
RbtSafety.ResetOw nershipReq RbtSafety.OneShot.0
<AAxx1RX2RbtSafety.ResetOw nershipReq> <AAxx1RX2RbtSafety.OneShot.0>
ONS

<@INFO>
#=======================================================
# The message parameters should be:
# Message Type "CIP Generic"
# Service Type "Custom"
# Source Data "AAxx1Rx1Ow nershipWriteData[0]" controller scope tag (change name to match application)
# Source Length "27"
# Service Code "54"
# Class "39"
# Instance "1"
# Attribute "0"
# Path - see above
# Connected - unchecked
#
#=======================================================
IDNS Robot
Get Ow nership
Status Message
To Safe Node
AAxx1Rx1GetOw nership.DN MOV FLL COP
6 Move Fill File Copy File
Source 1 Source 0 Source AAxx1Rx1OwnershipReadData[0]
Dest AAxx1Rx1OwnershipWriteData[1] Dest AAxx1Rx1OwnershipWriteData[17]
Dest AAxx1Rx1Ow nershipWriteData[0] Length 27 Length 10
1

IDNS Robot IDNS Robot

Reset Ownership Get Ow nership
Status Message Status Message
To Safe Node To Safe Node
MSG AAxx1Rx1GetOw nership.DN
Message EN U
Message Control AAxx1Rx1ResetOwnership ... DN
ER

4.3 Set Safety Network Number (SNN)

Once the module is set to “Out of Box”, the SmartGuard will take control of the connection. This step is
performed automatically.

4.4 Remove Network Bypass from the Robot

To change states of CIP mode do the following:

a. Enable the TP. Press MENUS->NEXT->SYSTEM->TYPE->DCS

April 8, 2011 General Motors. All rights reserved. 12

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

b. Cursor to CIP Safety and then select <ENTER>

April 8, 2011 General Motors. All rights reserved. 13

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

c. Acknowledge that setting will be changed by pressing <F4>.

d. Select the <PREV> key to return to the DCS main menu.
e. Select <F2> to [APPLY] changes DCS settings. Code number (master) = 1111.
Passwords may have been changed already when you run the wizard, Contact
program Lead Robotics Engineer for current password. General Motors are
responsible for ALL Passwords.

f. Select <F4> [OK] to apply DCS settings.

g. CIP Safety mode will now show; PEND, cycle power to apply changes.

April 8, 2011 General Motors. All rights reserved. 14

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding

4.5 Acknowledge Safety Change Status

Open the PLC cell program B002_MapOutputs routine. Find the rung below. Right click on the
C1.Safety.RbtChangeAck contact and select “Toggle Bit”. Repeat. The change acknowledge will not be
sent to the robot.
<@SYS>
#=======================================================
Rung Purpose:
This rung will send the acknowledge signal to the robot if the robot's safety configuration has been changed.
#=======================================================
<@INFO>
################################################################
# Robot safety configuration changes:
# If the robot safety configuration changes, for DCS changes or other, an
# acknowledge output from the PLC must be sent for the robot to turn on its
# configuration OK output. If the safety network is bypassed in the robot to allow
# isolated teaching, the configuration OK output will turn off, but does not have to
# be acknowledged. Follow the instructions below to acknowledge a robot safety
# configuration change.
#
# To acknowledge a change to the robot safety configuration:
# Right click on the XIC C1.Safety.RbtChangeAck below
# select "Toggle Bit" or press CNTRL-T. Then, repeat the
# process to turn off the bit. The driver will then send the robot a timed signal
# to acknowledge the change.
################################################################
Safety PLC Robot
Config Safety PLC Robot Safety PLC Robot
Change Config Config
Acknowledge Change OK Change OK
C1.Safety.RbtChangeAck Timer Timer
<AAcc1C1.Safety.RbtChangeAck> MOV TOF
2 Move Timer Off Delay EN
Source 2000 Timer C1.Safety.ConfigChangeOK
Robot Safety <AAcc1C1.Safety.ConfigChangeOK> DN
Interface Dest C1.Safety.ConfigChangeOK.PRE Preset 0
Acknowledge <AAcc1C1.Safety.ConfigChangeOK.PRE> Accum 0
Robot Safety 0
Change
AAxx1RX2RbtSafety.AckChange

Safety PLC Robot Safety PLC Robot Safety PLC Robot

Config Config Safety
Change Change OK Config Change
Acknowledge Timer Acknowledge
C1.Safety.RbtChangeAck C1.Safety.ConfigChangeOK.DN C1.Safety.O1.RbtCfgAck
<AAcc1C1.Safety.RbtChangeAck> <AAcc1C1.Safety.ConfigChangeOK.DN> <AAcc1C1.Safety.O1.RbtCfgAck>
/

4.6 Store Robot Signature Value

Open the V001_SafetyInterface_3A routine for the robot. Find the rung below, toggle the
RbtSafety.CopySign bit at the left of the rung. The PLC will automatically copy the right data to its internal
registers and send the valid signature to the upper level systems.

April 8, 2011 General Motors. All rights reserved. 15

Integrated DeviceNet Safety Robot Commissioning Instructions
General Motors Controls, Robotics & Welding
<@TODO>
#=======================================================
# Copy Safety Signature to Compare Value
#
# The safety signature is stored in a compare value after the safety buyoff
# is complete. That allows the system to automatically detect if the safety
# signature has changed due to a safety program change.
#
# Toggle the RbtSafety.CopySign XIC bit below to copy the current
# signature into the monitoring compare word. Right click on the
# RbtSafety.CopySign address below and choose "Toggle Bit".
#
# Do this ONLY when the safety program has been bought off by the
# proper safety representatives. If the safety program has been changed,
# finish any buyoff procedures before copying the signature.
#=======================================================
Robot Safety Robot Safety Robot Safety
Interface Copy Robot Robot Alias Robot Safety Interface Last Interface Copy Robot
Safety Signature Robot Communication Interface Known Good Signature Safety Signature
One Shot OK Signature Sent To One Shot
RbtSafety.CopySign R.Sts.CommOK For Compare PM&C RbtSafety.CopySign
<AAxx1RX2RbtSafety.CopySign> <AAxx1Rx2.Sts.CommOK> MOV CLR <AAxx1RX2RbtSafety.CopySign>
1 Move Clear U
Source I.Signature Dest RbtSafety.LastSent
HMI #1 16#0000_0000 <AAxx1RX2RbtSafety.LastSent>
HMI Dest RbtSafety.CompareSignature 16#0000_0000
Copy Current <AAxx1RX2RbtSafety.CompareSignature>
Device Signatures 16#0000_0000
Request
HMI1.Req.CopyDeviceSignatures
<AAcc1HMI1.Req.CopyDeviceSignatures>

End of Document

April 8, 2011 General Motors. All rights reserved. 16