What we do

We convert the obsolete TCP HMI screens into an easy to read Service Package for Engineers and Plant Managers to upgrade to current HMI technology.

We can reverse engineer the old TCP screens to make your HMI upgrade project simple and painless!

Many of the thousands of TCP(Total Control Products) HMI(Human Machine Interface) products, currently in service, are either worn out or have otherwise reached the end of their useful service lives.

Yet the machinery and processes they connect to have many useful years of service remaining. For the Plant Engineer, System integrator or other systems professional tasked with upgrading or replacing these HMIs, we provide, for each of the products listed, a very comprehensive ”Reverse Engineers documentation package”.

These packages provide everything the engineer (performing a conversion from TCP to another platform) needs to know about the original TCP HMI. Specific TCP HMI’s we prepare our custom packages for, are listed below.

If you are a serious Engineer with a real project that you suspect might benefit from application of one of our packages, you are encouraged to send us your source code, from which we will prepare a sales sample of our work, based on a screen of your choosing. Usually we can provide this within a couple of days after we receive the source code.

Take a look at a sample of our Service Package to see how drastically development time will be reduced.Also see how time spent learning the details of an obsolete product can be eliminated.

See the tabs below to view the TCP HMI models we support. You can also view a sample of our service package as well.

Applications for each of these products consist of a collection of logical entities called screens. Each screen consists of 1)  A ”Picture”  ( What the  Operator sees when the screen is active) , 2) A “Key file” [ list of actions ( usually control functions) that occur when each of the keys on the Smart Screen face plate is pressed and released ] and, in some cases, 3) An “Action file” [ Which is a C language like program that operates on PLC data to produce secondary screen data ]

The Reverse Engineers Documentation package includes: (for each screen)

  1.  An “A” size color screen shot of each HMI screen
  2. An “A” size  crisp Black & White screen shot of the screen’s picture, mounted in the center of a ”B”  size drawing sheet, so that reference annotation numbers can be distributed around the periphery of the screen graphic – each pointing to a specific dynamic object to be subsequently documented and described in a detailed screen description document ( 3) below.
  3. A screen description document with paragraphs referenced to the annotation numbers on the “B” sized drawing (2) above.
  4. A list of the names of each PLC variable, the Smart Screen polls to update the dynamic displays on this screen.
  5. (If required) the action file listing and explanation of what its code does.
  6. Complete listing and explanation of each key function
  7. For quality assurance, a concordance like cross reference of each “Artificial” Annotation number with its corresponding PLC address in the PLC variable list (4) above. Creation of this list assures us that every dynamic object on the screen, has been documented

The completed package is assembled into a 3 ring binder which is organized into 4 sections, as described below:

  1. SECTION 1 – A list of all screens included in the application
  2. SECTION 2 – This section is further divided into several subsections (one for each screen) each subsection contains, for each screen, the 7 items listed above.
  3. SECTION 3 - This section includes documentation of the PLC configuration details extracted from the applications archive file – Plus copies from theTCP Programmer’s manual that explain how the PLC is connected and PLC variable naming syntax rules.
  4. SECTION 4 - If the application includes advanced alarming functions, this section will include a complete list of Alarm messages, and the corresponding PLC Bit addresses that trigger the alarms

Our Reverse Engineers package for this product, costs less because it is easier  to develop but is no less useful than its Higher priced counter parts we provide for the higher end TCP Products. We start with the source DOS files. If they are unavailable we can sometimes extract them from a User provided SRAM card. If the SRAM card is unavailable we can arrange a site visit to upload the source files from an existing working Smart Touch unit. In these cases we provide the DOS computer, communication cable, keyboard and software required to accomplish the upload.

For The Smart Touch, our complete custom Reverse Engineers documentation package includes, for each Base screen:

  • A Black & White screen shot with tag names associated with each dynamic object on the screen.
  • A second ,identical screen shot with the tag names suppressed to enhance the graphic clarity and detail
  • A list of all tags used on the screen. Each entry in the list includes;
    • 1 – The tags PLC address
    • 2 – The Tags name (which also appears on the screen shot)
    • 3 – The tags location on the screen in terms of (X, Y) coordinates.

The competed package consists of 6 SECTIONS, assembled into at three ring binder with section headings and contents described below:

  • SECTION 1 – Listing of all Base Screens
  • SECTION 2 - base screen documentation. As described above, for each of the screens  listed in SECTION 1
  • SECTION 3 – Library file documentation: Listing of all library files plus , for each file in the list, a graphic print out of the library
  • SECTION 4 – Alarm Documentation: This section consists of a listing of alarm message text and the address of the PLC bits that trigger the alarm.
  • SECTION 5 – Listing of Mark files and, for each file in the list, a print – out of the files graphic
  • SECTION 6 – Communication  and system file details

This file details the communication parameters of the Smart Touch’s COM1

And the address of the so – called System data area

All 6 sections taken together include everything the Reverse Engineer needs to quickly re-create the Smart touch application in any one of several modern Windows based HMI development platforms,

If the platform of choice is one of the Digital Proface GP series of highly functional, high quality HMI panels, our services can include complete conversion of the TCP DOS files to a proface compatible windows project file. This is because the TCP Smart Touch is built on the Proface GP410 platform. See the Legacy Proface GP series service descriptions elsewhere on this web site 

Starting with the introduction of the GP410 to the North American Market (TCP Smart Touch and Cincinnati Touchview) in the late eighties, Proface began a long line of HMI panels each successor more powerful and more functional than the one that preceded it. The GP410 was superseded by the GP430, the GP430 was superseded by the GP450, and the GP450 was superseded by the GP470. And so on. Of the many examples of superb Japanese Engineering, planning and product philosophy is the fact that Proface always supported a very clear upgrade path from its early panels right up until the introduction of its latest offerings. We have exploited this unique feature of Proface Digital hardware and Software by remaining expert in the several generations of Proface software beginning with the original DOS GPPRO1, followed by two versions of GPPRO 2(Also DOS) and culminating with the latest supported Windows version of GPRO/PBIII. We even have some early DOS utilities developed by Proface unique to the GP410.

With this Software we are positioned to offer

  • File conversion from GP410 to GP450
  • File Conversion from GP450 to GP470/477R

Please contact us if there is a perception that we may be able to assist. Chances are we can.

Spencer R. Persik BSEE

Owner & Chief Engineer

Background & TCP product experience

12 years Senior Application Engineer and Supervisor, Technical Support                                     

Responsible for technical support and application engineering of TCP MMI/HMI products, including Quick Panel, SMART SCREEN, Smart Touch and Smart Panel Plus

2 years Senior Application Engineer, GE Fanuc Automation

On–site conversion engineering, resulting in very satisfied customers.  Provided application & PLC-specific training to advanced users of GP-PRO/PBIII, the MMI development package used for most conversions.  With GE Fanuc purchase of TCP, responsibility shifted from technical support to transforming customer requests for repair and technical support to new product upgrade business opportunities.  Upgrade/service business was focused on engineered conversions from obsolete operator interfaces to new product. 

  • Developed semi–automatic process for conversion of obsolete product application source code to code compatible with upgrade to new product, making it economically and technically feasible to shift customer requests for tech support or repair of obsolete product to purchase of on–site engineered upgrade to new product solution. 
  • Successfully sold and implemented over 50 engineered conversions in 30 industrial plants located all over world.  Users included GM, Bridgestone Firestone, Pactive and Toyota. 
  • Developed and promoted concept of application specific software product training as cost effective alternative to free technical support.  Customers trained included Toyota, Honda, MEIJI Corp., Train Corp., UNISIA, AMAC Brake, Toshiba Display Devices and Fuji.

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Feel free to contact us for more info. You may also use the attachment to attach source code files for us to look at.
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Contact info

GP Retro Systems, LLC

Reverse Engineering for Legacy TCP and Proface HMI's

Spencer Persik

Owner and Cheif Engineer

Phone: 262-945-9157

Email: srpersik@gmail.com

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