Gerry

I'm guessing that the film feeding axis is configured as linear and you're using the MRP to avoid ever reaching the maximum length of the axis with repeated moves. If I'm correct, I recommend configuring the axis as rotary, set the unwind to some arbitrary value, delete the MRP, and make the moves with the MAM relative instead of absolute. You say the clamp and seal mechanism moves the film - is that by design? Or is that a mechanical problem? Generally not good practice to try to solve mechanical problems with software.  

If the devices connected to the outputs are electrically isolated from each other, then no problem. What I am pointing out is that if one side of two (or more) outputs are effectively tied together through grounded inputs (like the drive as shown above), then the outputs are no longer isolated. I'll leave it to others to analyse the interaction.

If you tie two isolated circuits to two non-isolated circuits (i.e. grounded), isolation is lost.

If you create a UDT with one member of type BOOL[64], then tags of that data type can be manipulated with COP or FLL. To do any masking with MVM, first copy the tag to an array of SINT's, INT's, or DINT's as you prefer.

There could be problems if you want to connect a second output to a second drive (or other device with single-ended input).

I suggest using the FSC command. expression: array1[x] LEQ array2[FSC_controltag.pos]   use the result to reference the particular value from array2  

First, it is not necessary to have an array as the source for the FLL - just enter 0 as an immediate variable. Second, as Joe E. hints at, the FLL won't work the way you're hoping. The instruction to use is FAL.  

Every motion instruction requires a control tag. So yes, you need a new tag. Simple questions get simple answers. But I sense that you have more questions.

But... beware that the COP instruction executes the copying one byte at a time and can be interrupted by higher priority tasks at any point. If the data being copied originates from I/O or DNet or ENet, etc. or from a periodic task, it is likely that it will change during the copy. If that matters to your application (usually would) use CPS instead of COP.  

BTR/W are implemented using MSG in Logix 5000.

Don't waste your time with an AOI for this simple task. Use bits in a DINT for the alarms and check the DINT for NEQ 0 to set the global output.

If you set up the UDT properly, a simple COPy from the raw input to an instance of the UDT is all that you need. Subroutine / AOI unnecessary.

Inputs IN1 and IN2 and output OUT1 are analogues. IN3 is a binary. When Select is '1' (set) then Select set input is transferred to Output. When Select is '0' (cleared) then Select cleared input is transferred to Output.  

Sounds like contacts are welding. Possibly from drawing inrush current for too long due to the valve solenoid sticking. Or possibly longer term overload due to solenoid not properly pulling in 100%. I can imagine a program cause, but would need to know processor type and I/O setup.  

If you're keen on using ControlLogix and your geometry isn't negotiable, then I think your only option is to use position cams. This would involve dividing each planned move's trajectory into arbitrarily short segments and then converting the cartesian co-ordinates of each segment to polar co-ordinates. Put the angles and lengths into two separate cam tables and slave them to a virtual master axis. Then, a simple move of the virtual master will drive your two axes in the desired way. Smoothness will be determined by segment length.