Digital Thread for Machine Analysis

Building a comprehensive digital representation of PSI machines — from PLC code to physical wiring — enabling AI-assisted troubleshooting, safety auditing, and fleet-wide knowledge management.

---

Overview

A digital thread connects every data source about a machine into a unified, queryable knowledge base. For PSI machines, this means linking PLC logic, robot programs, electrical schematics, BOM data, HMI definitions, risk assessments, and operational history into a single model that an AI agent (or engineer) can use to diagnose problems, audit safety, and understand machine behavior.

First Applied: Project 2399 — Robotic Shot Peen System for GE Auburn (February 2026)

Why This Matters

Problem	How Digital Thread Solves It
”The door won’t close” — where do I start?	Trace PLC logic path, identify output, map to wire number, locate physical component
Is this machine safe?	Cross-reference PLC interlocks against risk assessment control measures
What does the operator see?	Map HMI message numbers to text, link to PLC conditions
What’s different about this machine vs. another?	Compare L5X exports, BOM differences, recipe parameters
New engineer onboarding	Structured documentation of every subsystem

---

Data Architecture

The Seven Layers

Every PSI machine’s digital thread has seven layers, from most accessible to hardest to acquire:

Layer 7: Network/Infrastructure    ← How it connects
Layer 6: Operational History        ← What's gone wrong before
Layer 5: Process Knowledge          ← How it's supposed to behave
Layer 4: HMI/PRIMS                  ← What the operator sees
Layer 3: Mechanical/BOM             ← What physically exists
Layer 2: Electrical                 ← What's wired to what
Layer 1: Control Logic              ← What the code does

Layer	Coverage Goal	Key Unlock
1. Control Logic	PLC + Robot source fully parsed	Fault tracing, logic analysis
2. Electrical	Wire-to-tag mapping, safety circuits	Physical troubleshooting
3. Mechanical/BOM	Full parts hierarchy with specs	Component identification
4. HMI/PRIMS	Screen definitions, PC_Read/Write map	Operator complaint resolution
5. Process Knowledge	Recipes, procedures, specs	”Is this normal?” questions
6. Operational History	Fault logs, redbooks, service notes	Pattern recognition
7. Network/Infrastructure	Topology, IP addresses, remote access	Connectivity troubleshooting

---

Layer 1: Control Logic

What To Collect

Asset	Format	Source Location	Tool
PLC program	L5X (XML export from Logix Designer)	K:\PROJECT\{proj}\sw\PLC\	Studio 5000 → Export L5X
PLC program (binary)	ACD	Same location	Logix Designer native
Robot Karel source	.kl (text)	K:\PROJECT\{proj}\sw\Robot\Karel\	Direct read
Robot TP source	.ls (text listing)	K:\PROJECT\{proj}\sw\Robot\Backups\{date}Backup\	FANUC backup utility
Robot TP compiled	.tp (binary)	Same, or sw\Robot\Setup\LoadFiles\TP\	FANUC controller
Robot system files	.SV, .VR, .IO, .CM	sw\Robot\Backups\RoboGuide Backup\	RoboGuide or controller backup
FANUC I/O mapping	.xlsx	sw\Robot\Setup\{proj}FanucToPLC.xlsx	Controls Engineering
PLC I/O definitions	.xlsx	sw\{proj}IO.xlsx	Controls Engineering

L5X Format — Why It’s Critical

The L5X (Logix Designer XML) export is the single most valuable file for analysis. Unlike the binary ACD, L5X is:

• Fully parseable XML — every rung, tag, UDT, module, and configuration value
• Self-contained — includes I/O module config, IP addresses, data types, all programs
• Diffable — can compare two L5X files to find changes between machines or versions

How to export:

Method	Tool	Best For
GUI	Studio 5000 → File → Export → L5X	One-off exports
CLI (SDK)	l5xgit acd2l5x --acd input.ACD --l5x output.L5X	Batch conversion (recommended)
CLI (GUI shim)	acd_to_l5x.ps1 -ProjectNumbers 2399,2386	Batch conversion (legacy)
Python (no Studio)	acd_analyzer.py (direct ACD extraction)	When Studio 5000 unavailable

The l5xgit tool is from RockwellAutomation/ra-logix-designer-vcs-custom-tools and uses the official Logix Designer SDK. See L5X Tools for full documentation of the conversion toolchain.

Analysis Methodology

For a CompactLogix/ControlLogix L5X file, extract:

1. Controller configuration — processor model, firmware, security code, task setup
2. I/O module inventory — slot-by-slot with catalog numbers, RPI, connection types
3. Ethernet I/O devices — IP addresses, data sizes (this identifies robots, VFDs, remote I/O)
4. UDT definitions — the data model (PSI standard: CC1, FANUC_Robot, WD, DH, MC, FLT, SP, PP_Single, Prims, etc.)
5. Program/routine structure — execution order, rung counts, JSR calls
6. Complete I/O mapping — which physical input/output drives which tag
7. Fault catalog — every condition that sets a hold, inhibit, or abort fault
8. Safety interlocks — E-stop chain, blast permissive chain, door interlocks
9. Communication setup — MSG instructions, EtherNet/IP implicit connections

PSI Standard PLC Architecture

PSI machines share a common PLC architecture pattern. Understanding one machine transfers to the fleet:

Pattern	Description
MainProgram_Blast	Primary program with all operational routines
Fault_handler	Separate program, MajorFaultProgram assignment
MainRoutine	I/O mapping + JSR dispatch to all subroutines
PC_Read / PC_Write	PRIMS communication via shared integer arrays (typically [100] each)
CC1 UDT	Cycle Control — mode bits, cycle steps, recipe handshake
FANUC_Robot UDT	Robot interface — status, commands, heartbeat, collision guard, DCS
FLT UDT	Fault management — hold/inhibit/abort aggregation
3-tier fault system	Abort (immediate stop) → Hold (coordinated interrupt) → Inhibit (prevent new cycle)
CC.Neveron	Permanently FALSE bit used to disable code paths (dead code marker)
PRIMS watchdog	Comm failure detection via stale watchdog counter

FANUC Robot Integration Pattern

PSI FANUC robot cells use three communication layers simultaneously:

Layer	Mechanism	RPI/Rate	Purpose
EtherNet/IP Implicit	I/O assembly, generic module	10ms typical	Real-time discrete I/O + integer data
CIP Explicit Messaging	MSG instructions	Periodic	Position register read/write, string registers
PRIMS/CITS	Higher-level via PLC relay	Application	Recipe management, program selection, data recording

Critical: FANUC UOP (User Operator Panel) Signals

The EtherNet/IP I/O mapping includes FANUC UOP safety input signals. These hardware-level signals should be driven by PLC safety conditions, not permanently forced ON:

UOP Signal	Function	Should Be Driven By
UI 1 - IMSTP	Immediate Stop	E-Stop / CycleAbortFlt
UI 2 - HOLD	Hold	Cycle Hold conditions
UI 3 - SFSPD	Safety Speed (250mm/s limit)	Door open / T1 mode equivalent
UI 6 - START	Cycle Start	Cycle start sequence
UI 8 - ENBL	External Enable	CC.NotEstop (minimum)

The {proj}FanucToPLC.xlsx spreadsheet in sw\Robot\Setup\ maps every bit between the PLC generic Ethernet module and the FANUC robot I/O. This is essential for identifying which PLC output bits correspond to which UOP signals.

---

Layer 2: Electrical — “What’s Wired to What”

What To Collect

Asset	Format	Source Location	Notes
Electrical schematics	DWG/PDF	X:\ drive, by drawing part number	Part number linked via BOM
Panel layout drawings	DWG/PDF	X:\ drive, by part number	Same BOM linkage
Wire number list	.xls	K:\PROJECT\{proj}\tags\{proj}Wir.xls	Maps wire numbers to terminals
Component tag list (control)	.xls	K:\PROJECT\{proj}\tags\{proj}cpt.xls	Control panel component IDs
Component tag list (machine)	.xls	K:\PROJECT\{proj}\tags\{proj}mch.xls	Machine-side component IDs
Terminal block assignments	.xls	K:\PROJECT\{proj}\tags\{proj}TBS_TM{n}.xls	Wire-to-terminal mapping
Tag engravings	.xls	K:\PROJECT\{proj}\tags\{proj}_TAG.xls	Physical label text

Tag File Conventions

PSI uses a consistent naming convention for component tags in the tags/ folder:

• {proj}cpt.xls — Control panel components (fuse blocks FB, contactors CR, switches SW, etc.)
• {proj}mch.xls — Machine components (solenoids SOL, proximity switches PRS, pressure switches PS, motors MTR, etc.)
• {proj}Wir.xls — Wire numbers (1,000+ entries mapping every wire in the machine)
• {proj}TBS_TM{n}.xls — Terminal block TM{n} wire assignments
• {proj}_TAG.xls — Engraving text for physical tags/labels

Electrical → PLC Bridge

The critical connection is: PLC tag → I/O slot.bit → wire number → terminal → physical device

Example chain:

PLC Tag: WD.CloseSol
  → Output: Local:5:O.Data.9 (Slot 5, Bit 9)
  → Wire: (from {proj}Wir.xls)
  → Terminal: (from {proj}TBS_TM5.xls)
  → Device: (from {proj}mch.xls, e.g., 2160SOL)
  → Drawing: (from BOM/X:\ drive, by part number)

Drawing Access

Electrical schematics and layouts are stored on the X:\ drive in two locations:

• X:\DWGFiles\{partNumber}.DWG — Individual drawing files by part number
• X:\Controls\{proj}\{proj}.wdp — AutoCAD Electrical project file (drawing index)

The .wdp file is a text-readable project index that lists every drawing in the electrical package with part number and description. This is the fastest way to inventory the complete electrical drawing set for a machine.

How to find drawings for a project:

1. Open X:\Controls\{proj}\{proj}.wdp — text file listing all drawings
2. Or query PSI Explorer: GET /api/bom/dev/job/{proj} → find Controls Assembly → Electrical Drawing Index
3. Individual DWG files are at X:\DWGFiles\{partNumber}.DWG
4. AutoCAD Electrical symbol libraries: X:\Controls\Support\Libs\PTI_JIC\ (JIC standard) and PTI_pneu_iso\ (pneumatic ISO)

Note: DWG files are AutoCAD binary and not directly parseable by AI agents. For analysis, export to PDF using AutoCAD batch plot or accoreconsole.exe.

Standard Electrical Drawing Set

PSI Controls Assembly drawings follow a consistent numbering pattern. For a project with Controls Assembly part number {base} (e.g., 359803 for Project 2399), the drawing set is:

Layouts (typically {base+97} to {base+114}):

Offset	Description	Content
+97	Electrical Drawing Index	Master index of all drawings
+98	Electrical Layout - Floor	Floor plan with device locations
+99	Electrical Layout - Cabinet	Blast cabinet electrical layout
+100	Electrical Layout - Blast	Blast system electrical layout
+101	Electrical Layout - Robot	Robot cell electrical layout
+102	Electrical Layout - Spindle	Spindle system layout
+103	Electrical Layout - Reclaim	Reclaim system layout
+104	Control Enclosure Layout & BOM	Panel enclosure with component list
+105	Control Panel Layout & BOM	Control panel with component list
+106	Terminal Strip Layout	Terminal block assignments
+107	PLC Layout And BOM	PLC rack with module list
+108	Control Station Layout And BOM	Operator station layout
+109	Computer And Accessories Layout	PRIMS computer and networking
+110	Work Door Control Station Layout	Door control station

Schematics (typically {base+113} to {base+136}):

Offset	Description	Safety Relevance
+113	460 VAC Power Distribution	Main power
+114	120 VAC Power Distribution	Control power
+115	Air Conditioner & Receptacle	Support
+116	24 VDC Power Supply	Sensor power
+117	Emergency Stop String	E-stop circuit architecture — validates single/dual channel
+118	24VDC Control Schematic	Control relay logic
+119	Light Curtain Schematic	LC wiring and safety relay
+120	Media Flow Sensor	Flow detection wiring
+121	Spindle Speed Feedback	Speed sensor wiring
+123	Dust House & Sweco	Motor circuits
+124	Pressure Pot Solenoid Manifold	Solenoid valve wiring
+125	FANUC Robot Interface (pg 1)	Robot I/O, UOP signal wiring
+126	FANUC Robot Interface (pg 2)	Robot I/O continued
+128	PLC Schematic	PLC power and comm
+129-136	Rack 1 Slot 1-8 I/O Module Schematics	Every PLC I/O point → wire number → device

Pneumatic Schematics (typically {base+167} to {base+176}):

Offset	Description
+167	Pneumatic Drawing Index
+168	Pneumatic Layout - Floor
+169-176	Pneumatic Schematics (valve manifolds, regulators, piping)

Priority Drawings for Safety Analysis

When auditing a machine, these schematics are most critical:

1. E-Stop String — Reveals safety relay model, number of channels, monitoring circuit, reset logic
2. FANUC Robot Interface — Shows UOP signal wiring, EtherNet/IP connection, pendant interface
3. PLC I/O Module Schematics (Slot 1-8) — Maps every PLC tag to a wire number and physical device
4. Light Curtain Schematic — Shows LC controller model, muting configuration, safety relay integration

---

Layer 3: Mechanical / BOM — “What Physically Exists”

What To Collect

Asset	Format	Source	Tool
Full BOM hierarchy	JSON	UniData API	GET /api/bom/dev/job/{proj}
Part details	JSON	UniData API	GET /api/parts/dev/{partNumber}
Mechanical drawings	DWG/PDF	X:\ drive, by part number	SolidWorks PDM
SolidWorks models	SLDPRT/SLDASM	X:\ drive	SolidWorks
Vendor manuals	PDF	K:\PROJECT\{proj}\man\pdfman\pdfdocs\vm\	Direct access
Software manuals	PDF	K:\PROJECT\{proj}\man\pdfman\pdfdocs\sw\	Direct access

BOM API Usage

The PSI Explorer API provides the complete parts hierarchy:

GET /api/bom/dev/job/2399

Response fields per BOM item:

Field	Description
partNumber	Part identifier
description	Part description
level	Depth in hierarchy (0=root)
wbsNumber	Work Breakdown Structure position
gtCode	PU=Purchased, FA=Fabricated, MO=Manufactured, AS=Assembly
drawingNumber	Links to X:\ drive drawings
quantity	Required qty
mfgLeadTime / purchaseLeadTime	Lead times (days)
onHand / onOrder / available	Inventory status
hasChildren	Has sub-components

Spare Parts

Spare part classification is a metadata property on part numbers. The API’s part details endpoint includes inventory and lead time data. Additional vendor manuals and spare parts lists are in K:\PROJECT\{proj}\man\.

---

Layer 4: HMI/PRIMS — “What the Operator Sees”

What To Collect

Asset	Format	Source	Notes
PC_Read/Write mapping	.xlsx	K:\PROJECT\{proj}\sw\{proj}IO.xlsx	Critical — defines every HMI data point
Operator messages	Same file, “OperatorMessages” sheet	Same	Message number → display text
PRIMS source code	VB.NET	C:\git\trunk	240K LOC, 30 projects
PRIMS comm driver (AB PAC)	VB.NET	trunk\Comm\Pti.Prims.Comm.AbPac\	Allen-Bradley EtherNet/IP driver

PC_Read / PC_Write Data Dictionary

The {proj}IO.xlsx file is the Rosetta Stone between HMI and PLC. It has two sheets:

IO Sheet — Maps every bit and word:

• PC_Write[n].bit — PLC → PRIMS (status, fault flags, measurements)
• PC_Read[n].bit — PRIMS → PLC (commands, setpoints, recipe data)
• PLCIO[n] — Raw I/O slot values exposed to PRIMS

OperatorMessages Sheet — Maps message number → display text:

#	Message
0	No Message To Display
1	Ready For Cycle
2	Not In Auto
4	Machine In Cycle
6	Machine in Cycle Hold
10	Fault Active
11	System in Emergency Stop
14	Control Power Off
18	Preventive Maintenance Required

The PLC’s Messages routine selects which message number to write to PC_Write[19] based on priority logic.

PRIMS Architecture

PRIMS (Progressive Realtime Industrial Monitoring System) is an 18-year-old VB.NET WinForms/WPF application:

Component	Location	Description
Comm layer	trunk\Comm\	11 vendor-specific drivers (AB PAC, FANUC, Siemens, ABB, etc.)
Logic layer	trunk\Logic\	Config, Operation, Data, Security (9 projects)
UI layer	trunk\Prims\	70+ forms, 17 user controls (7 projects)
Database	trunk\Data\	728 stored procedures, SQL Server

The AB PAC comm driver (Pti.Prims.Comm.AbPac) uses INGEAR.NET v5 to read/write PC_Read[] and PC_Write[] arrays via EtherNet/IP.

Note: A comprehensive PRIMS code assessment exists at C:\git\trunk\assessment\ covering security (20 findings), code quality, architecture, database, safety/reliability, and modernization roadmap.

---

Layer 5: Process Knowledge — “How It’s Supposed to Behave”

What To Collect

Asset	Format	Source
Process records	.xls	K:\PROJECT\{proj}\data\process\
LDS (lifecycle data)	.xlsm	K:\PROJECT\{proj}\lds\{proj}lds.xlsm
Customer specifications	Various	K:\PROJECT\{proj}\rfq\ and K:\PROJECT\{proj}\corr\
Operating procedures	Various	K:\PROJECT\{proj}\man\
Recipe examples	PRIMS database	Requires PRIMS DB access
Robot teach points	.VR (POSREG.VR)	sw\Robot\Backups\RoboGuide Backup\POSREG.VR

Key Process Parameters (Shot Peen Systems)

For shot peen machines, normal operation involves these measurable parameters:

Parameter	PLC Tag Pattern	PRIMS Field	Units
Blast pressure	AirPress_ACT / AirPress_SP	PC_Write[21] / PC_Read[11]	PSI (scaled)
Spindle speed	C_Axis_Feedrate_Act / _SP	PC_Write[24] / PC_Write[33]	RPM (scaled)
Robot TCP speed	RobotTCPSpeed	PC_Write[18]	mm/s
Surface number	Surface_Number	PC_Write[20]	1-16
Robot position	X/Y/Z_PositionACT	PC_Write[44-46]	mm

Each parameter has 4-level alarm limits: LSD (Low Shutdown) < LAL (Low Alarm) < HAL (High Alarm) < HSD (High Shutdown).

---

Layer 6: Operational History — “What’s Gone Wrong Before”

What To Collect

Asset	Format	Source	Tool
Redbook entries	Database	Redbook Web	Search by project number
CSM records	PDF/photos	K:\PROJECT\{proj}\csm\	Direct access
CSS trip logs	Custom format (.war, .pl)	K:\PROJECT\{proj}\css\	WordPerfect-based
Field service photos	JPG	K:\PROJECT\{proj}\photos\	Direct access
Software change history	ACD backups	K:\PROJECT\{proj}\sw\PLC\	Compare L5X exports
Reference projects	ACD files	K:\PROJECT\{proj}\sw\PLC\Ref\	Related machine programs

K:\ Drive Project Folder Structure

Every project follows this standard folder layout on the K:\ drive:

K:\PROJECT\{proj}\
├── chg/          Change orders
├── corr/         Correspondence (customer, internal)
├── csm/          Commissioning records (CS{proj}-{n}/)
├── css/          Customer Support Services (punch lists, warranties, trip logs)
├── data/         Process data
│   ├── laser/    Laser measurement data
│   ├── machine/  Machine performance data
│   └── process/  Process records (Almen, saturation, pressure)
├── expense/      Expense reports
├── lds/          Lifecycle Data Sheets
├── macros/       Custom macros
├── man/          Manuals
│   └── pdfman/pdfdocs/
│       ├── sw/   Software manuals
│       └── vm/   Vendor manuals
├── meetings/     Meeting notes
├── misc/         Miscellaneous (photos, handoff notes, tooling envelopes, release forms)
├── photos/       Machine photos
├── rac/          Risk Assessment Committee
├── rfq/          Request for Quote / customer specs
├── safety/       Risk assessments (HRN + ISO 13849-1 PLr)
├── schedule/     Project schedule
├── shp/          Shipping
├── sw/           Software
│   ├── PLC/      PLC programs (ACD, L5X) + Ref/ folder with related projects
│   └── Robot/    Robot programs
│       ├── Backups/     Controller backups (dated + RoboGuide)
│       ├── Karel/       Karel source (.kl) + compiled (.pc)
│       ├── Setup/       I/O mapping xlsx, startup docs, load files
│       └── System Software/  FANUC system software
├── tags/         Electrical tag data (wire lists, component lists, terminal blocks)
└── tp/           Test procedures

File Format Notes

Many files on the K:\ drive use custom extensions that are actually WordPerfect format:

• .sw — Software handoff notes (WordPerfect)
• .lbl — Label definitions (WordPerfect)
• .cvr — Manual covers (WordPerfect)
• .vm / .vm1 — Vendor manual indices (WordPerfect)
• .war — Warranty records (WordPerfect)
• .pl — Punch lists (WordPerfect)
• .o / .o1 — Order documents (WordPerfect)
• .doc — Older MS Word binary format (not always readable by modern tools)

For AI agent access, .xlsx, .xls, .pdf, and .txt files are directly readable. WordPerfect and .doc files require conversion.

---

Layer 7: Network / Infrastructure

What To Collect

Asset	Source	Notes
PLC IP address	L5X file (Ethernet module config)	Usually 192.168.x.x
Robot IP address	L5X file (generic Ethernet module)	Usually same subnet as PLC
PRIMS server	Site-specific	Runs CITS/PRIMS application
Network switches	Site documentation	OT network typically isolated
Remote access	Site-specific	VPN, cellular modem, or none

---

Safety Analysis Framework

Risk Assessment Cross-Reference

PSI provides a formal risk assessment for each machine at K:\PROJECT\{proj}\safety\. These use the Hazard Rating Number (HRN) method and include ISO 13849-1 Performance Level required (PLr) ratings.

The risk assessment contains:

• Header — Customer, location, machine description, date, assessor
• Risk Assess - General — General machine hazards (power-up, E-stop, jogging, teaching, production, maintenance)
• Risk Assess - SP (Shot Peen specific) — Blasting hazards, media exposure, dust explosion
• Control Measures — Numbered list of 70+ safety measures (barriers, interlocks, training, procedures)
• Energy Sources — 6 types: pneumatic, electrical, kinetic, potential, explosive, thermal

PLC Safety Audit Checklist

When analyzing a PSI machine’s PLC code, verify these against the risk assessment control measures:

Check	What to Verify	Risk Assessment Reference
E-stop chain	How many channels? Safety relay feedback?	PLr rating (typically d for robot cells)
Door interlock	Sensor redundancy, shot pin, bypass conditions	Control measures re: door closed for auto
Light curtain	Independent guard or conditional? Muting?	Control measures re: LC clear for motion
Blast permissive	How many conditions in the chain?	Control measures re: doors closed for blast
Robot UOP signals	IMSTP, SFSPD, ENBL — conditional or bypassed?	Control measure #8 (velocity limited)
Test mode	Physical key switch or software-only?	Who can activate, what does it bypass?
Fault auto-reset	Which faults auto-clear? Logging?	Recurring fault investigation
Major fault handler	Halt or continue? Output safe state?	Controller behavior on watchdog/I/O failure
Controller security	Security code, source protection	Network access implications

---

Troubleshooting Knowledge Base Structure

Recommended File Organization

For each machine analyzed, create a structured knowledge base:

{project}/
├── Analysis_Report_{proj}.md      Full analysis report
├── Analysis_Report_{proj}.docx    Word document version
├── Analysis_Summary_{proj}.pptx   PowerPoint summary
├── io_map.md                      Physical I/O with wire references
├── fault_guide.md                 Fault-by-fault troubleshooting
├── pc_readwrite_map.md            PRIMS data dictionary
├── operator_messages.md           Message number → text mapping
└── safety_findings.md             Cross-referenced with risk assessment

Fault Troubleshooting Template

For each of the 54+ fault conditions, document:

## Fault: {Name} ({Tag})
- **Severity**: Abort / Hold / Inhibit
- **Trigger**: {PLC logic condition}
- **Routine**: {Source routine and rung number}
- **Operator Message**: {Message number and text}
- **Physical Cause**:
  - {Sensor failure → wire number, terminal, component tag}
  - {Actuator failure → solenoid/motor part number}
  - {Wiring issue → wire number from Wir.xls}
- **Troubleshooting Steps**:
  1. Check {physical condition}
  2. Verify {PLC input/output state}
  3. Measure {electrical test point}
- **Common Root Causes**: {From redbook history}

---

Data Source Summary

By PSI System

System	What It Provides	Access Method
K:\ Drive (K:\PROJECT\{proj}\)	Project files, manuals, software, tags, safety, data	Direct file access
X:\ Drive	Engineering drawings (electrical, mechanical) by part number	Direct file access via BOM part number
UniData API	BOM hierarchy, part details, inventory, lead times	REST API: api.progressivesurface.com
PSI Explorer	Visual BOM navigation	Web UI: explorer.progressivesurface.com
Redbook Web	Quality issues, root causes, field escapes	Web UI: redbook.progressivesurface.com
Project Explorer	Project metadata, dates, customer info	Web UI: projects.progressivesurface.com
PRIMS Source (C:\git\trunk)	HMI/SCADA source code, comm drivers, database schema	Git repository
SolidWorks PDM	Mechanical drawings, 3D models	PDM client or X:\ drive

By File Type and Readability

Format	Readable by AI?	Tool Required
.L5X	Yes (XML)	Direct parse
.xlsx / .xls	Yes	Node.js xlsx package
.xlsm	Yes (data only, no macros)	Node.js xlsx package
.pdf	Yes	PDF reader
.kl (Karel)	Yes (text)	Direct read
.ls (TP listing)	Yes (text)	Direct read
.md / .txt	Yes	Direct read
.ACD	No (binary)	Requires Studio 5000 → export to L5X
.tp (compiled TP)	No (binary)	Requires FANUC controller or RoboGuide
.doc (Word binary)	No	Requires Word or LibreOffice conversion
.DWG (AutoCAD)	No (binary)	Requires AutoCAD viewer; use PDF versions
WordPerfect (.sw, .lbl, .cvr, etc.)	No	Requires WordPerfect or conversion tool
.SV, .VR, .IO (FANUC)	Partially (some text)	FANUC backup utilities
.SLDPRT/.SLDASM	No (binary)	Requires SolidWorks

---

Implementation Roadmap

Phase 1: Static Model (Achievable Now — ~60-70% troubleshooting capability)

Step	Source	Action	Unlocks
1	L5X export	Parse full PLC program	Logic tracing, fault catalog
2	Robot Karel/TP source	Read all source files	Robot behavior, handshakes
3	{proj}FanucToPLC.xlsx	Map robot ↔ PLC I/O	UOP signal identification
4	{proj}IO.xlsx	Extract PC_Read/Write map + messages	HMI data dictionary
5	safety/risk assessment	Extract hazard scenarios + control measures	Safety cross-reference
6	tags/*.xls	Extract wire numbers, components, terminal blocks	Physical device mapping
7	BOM API	Pull full parts hierarchy	Component identification
8	Electrical PDFs	Cross-reference I/O to wire numbers	Complete troubleshooting chain

Phase 2: Knowledge Base (Structured for Retrieval)

• Build per-fault troubleshooting guides linking PLC logic → wire → component → drawing
• Create symptom-to-cause decision trees
• Index against redbook history for known failure modes
• Document “normal” parameter ranges from process records and recipes

Phase 2.5: Fleet-Wide ACD → L5X Conversion

Bulk convert all Allen-Bradley ACD files to L5X using l5xgit acd2l5x (Rockwell’s official SDK). This unlocks instant PLC analysis for the entire fleet without requiring Studio 5000 at query time.

1. Build l5xgit on a controls workstation with Studio 5000 + Logix Designer SDK
2. Scan K:\PROJECT\*\sw\PLC\ for all ACD files (~9,293 files across ~467 projects)
3. Run l5xgit acd2l5x on each primary ACD file
4. Store L5X alongside the ACD on K: drive
5. Run l5x_parser.js to pre-generate analysis JSON for the MCP server

See L5X Tools — Fleet Conversion Plan for details.

Phase 3: Fleet Analysis

• Use l5xplode explode to decompose L5X files into git-friendly directory structures
• Diff PLC programs to identify machine-specific customizations vs. standard code
• Apply safety findings fleet-wide (e.g., UOP bypass pattern may exist on all FANUC cells)
• Build a cross-project component commonality database

Phase 4: Live Digital Twin (Aspirational)

• OPC-UA or MQTT gateway on PLC network for real-time tag values
• Data historian for trend capture (pressure, speed, fault events)
• Real-time query capability: “What is the current blast pressure?” vs. “What should it be?”
• Predictive maintenance from fault pattern analysis

---

Lessons Learned (Project 2399)

What Worked Well

1. L5X export was the single best decision — enabled complete code-level analysis of all 503 rungs
2. Parallel agent analysis — launching L5X structure, ladder logic, and robot analysis simultaneously saved significant time
3. {proj}IO.xlsx was the Rosetta Stone — unlocked the entire PRIMS ↔ PLC data dictionary in one file
4. {proj}FanucToPLC.xlsx confirmed the most critical safety finding (UOP bypass) that was ambiguous from PLC code alone
5. Risk assessment provided the ISO 13849-1 PLr ratings that validated our safety findings

What Was Difficult

1. Python unavailable on the analysis workstation (Windows Store stubs only) — used Node.js with xlsx npm package instead
2. WordPerfect files (.sw, .lbl, .doc) not readable by modern tools — significant documentation locked in legacy formats
3. Agent permission issues — subagents couldn’t access certain directories; direct main-session access worked
4. Binary formats (.ACD, .tp, .DWG) require vendor-specific tools; always prefer text/XML/PDF exports
5. PRIMS source is 240K LOC VB.NET with no tests or CI — understanding specific machine configuration requires database access, not just source code

Key Findings That Transfer to Fleet

Finding	Fleet Impact
FANUC UOP signals permanently bypassed	Check ALL FANUC cells for same pattern
Controller Security Code = 0	Likely all machines — fleet-wide review
Major fault handler doesn’t halt	Standard template — affects all machines using this pattern
Test mode via software only (no key switch)	Check HMI configuration across fleet
Auto fault reset without logging	Standard pattern — consider fleet-wide logging
Single-channel E-stop in PLC	Verify external safety relay architecture on each machine

---

Related Pages

• PSI Explorer — Part hierarchy and drawing lookup
• UniData API — REST API for BOM and part data
• Redbook Web — Quality issue tracking
• Engineering Process — Controls Engineering (Dept 111)
• Terminology — PSI-specific terms
• PSI.All Architecture — UniData subroutine catalog
• Machine Intelligence MCP Server — AI agent access to all machine data (37 tools)
• Ask the Fleet — Web chat interface powered by MCP tools (any PSI employee, zero setup)
• Agentic Implementation — AI-assisted development methodology
• Claude Code — Claude Code integration and skills

---

First compiled: February 2026, from Project 2399 (GE Auburn Robotic Shot Peen System) analysis. Methodology applicable to all PSI CompactLogix/ControlLogix + FANUC robot cells.