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Yasnac MRC Controller
MRC I/O Structure
Manual
Part Number 133400-1
October 24, 1995
MOTOMAN
805 Liberty Lane
West Carrollton, OH 45449
TEL: 513-847-6200
FAX: 513-847-6277
24-HOUR SERVICE HOTLINE: 513-847-3200
The information contained within this document is the proprietary property of Motoman, Inc., and
may not be copied, reproduced or transmitted to other parties without the expressed written
authorization of Motoman, Inc.
©1995 by MOTOMAN
Because we are constantly improving our products, we reserve the right to change specifications without
notice. YASNAC and MOTOMAN are registered trademarks of YASKAWA Electric Manufacturing.
TABLE OF CONTENTS
Section
Page
1.0 INTRODUCTION............................................................................................ 1
1.1
MRY01 BOARD................................................................................. 1
1.2
MIO01 and MIO02 BOARDS ............................................................2
1.3
MIO03 BOARD................................................................................. 2
1.4
MIO04 BOARD................................................................................. 2
1.5
MEW01 AND MEW02 BOARDS........................................................2
1.6
MARIO AND MIF05 BOARDS..........................................................2
1.7
MRC I/O BY MOTOMAN APPLICATION..........................................2
1.8
I/O RACK LOCATION........................................................................3
1.9
POWER SUPPLY ...............................................................................4
1.10
REFERENCE TO OTHER DOCUMENTATION ...................................4
1.11
CUSTOMER SERVICE INFORMATION.............................................4
2.0 DEDICATED I/O.............................................................................................5
2.1
EXTERNAL EMERGENCY STOP INPUT............................................6
2.2
SERVO ON INPUT ............................................................................7
2.3
EXTERNAL HOLD INPUT .................................................................8
2.4
REMOTE MODE SELECT INPUT.......................................................9
2.5
SERVO ON OUTPUT....................................................................... 10
2.6
SHOCK SENSOR INPUT................................................................. 11
3.0 MIO03 AND MIO04 BOARDS..................................................................... 13
3.1
TRANSISTOR INPUTS.................................................................... 13
3.1.1
3.1.2
3.2
Input Connections............................................................. 13
Input Conditions................................................................ 13
RELAY OUTPUTS............................................................................ 15
3.2.1
3.2.2
Output Relay Description................................................... 15
Output Connections........................................................... 16
4.0 MIO01 AND MIO02 BOARDS..................................................................... 17
4.1
TRANSISTOR INPUTS.................................................................... 17
4.2
TRANSISTOR OUTPUTS................................................................. 18
5.0 MRC I/O ALLOCATION AND CONFIGURATION.........................................20
5.1
LOGICAL RELAY ADDRESSES.........................................................20
5.2
RULES AND LIMITATIONS............................................................. 21
5.3
MRC I/O ASSIGNMENTS BY APPLICATION..................................24
APPENDIX A - MRC I/O BLOCK DIAGRAMS................................................... A-1
INDEX ............................................................................................................ Index
LIST OF FIGURES
Figure
Page
Figure 1-1 Location of MRC I/O Boards ................................................................3
Figure 2-1 External Emergency Stop Input Connection..........................................6
Figure 2-2 Servo On Input Connection..................................................................7
Figure 2-3 External Hold Input Connection...........................................................8
Figure 2-4 Remote Mode Select Input Connection on an MIO04 Board.................9
Figure 2-5 Servo On Output Connection on an MIO04 Board ............................. 10
Figure 2-6 Connection Diagram Using the Shock Sensor for E-Stop Condition ..... 11
Figure 3-1 Input Connection on MIO04 Board.................................................... 14
Figure 3-2 Input Connections on MIO03 Board in Sinking and Sourcing
Configurations.................................................................................... 14
Figure 3-3 MIO04 Output Relays ....................................................................... 15
Figure 3-4 MIO03 Output Relays ....................................................................... 15
Figure 3-5 MIO04 or MIO03 Board Output With DC Relay Coil ......................... 16
Figure 4-1 Input Connection on MIO01 Board .................................................... 17
Figure 4-2 Input Connection on MIO02 Board.................................................... 18
Figure 4-3 Output Connection on MIO01 Board.................................................. 18
Figure 4-4 Output Connection on MIO02 Board ................................................. 19
Figure 5-1 Setting Up Input and Output Addresses..............................................20
Figure 5-2 Example of Addressing With All I/O Slots Filled..................................22
Figure 5-3 Example of Addressing for an ArcWorld Product With One Additional
Board ................................................................................................23
LIST OF TABLES
Table
Page
Table 2-1 How to Place Jumpers on Pins for Shock Sensor Input........................ 12
Table 5-1 Inputs for Arc Welding Using Two MIO04 Boards...............................25
Table 5-2 Outputs for Arc Welding Using Two MIO04 Boards............................26
Table 5-3 Inputs for General or Universal Applications Using
Two MIO04 Boards .............................................................................27
Table 5-4 Outputs for General or Universal Applications Using
Two MIO04 Boards .............................................................................28
Table 5-5 Inputs for Spot Welding Using Two MIO04 Boards .............................29
Table 5-6 Outputs for Spot Welding Using Two MIO04 Boards...........................30
Table 5-7 Inputs for Material Handling Using Two MIO04 Boards ..................... 31
Table 5-8 Outputs for Material Handling Using Two MIO04 Boards...................32
1.0 INTRODUCTION
Motoman robots with MRC controllers have a variety of dedicated and standard
inputs and outputs (I/O). The I/O is used for controlling the robot and for
interfacing it to external equipment.
The MRC software can support up to 144 inputs and 144 outputs, as well as 4
analog outputs. Depending upon the application, the first 16 to 24 inputs and the
first 16 to 24 outputs are assigned as dedicated I/O for application- and robotspecific functions, such as Servo Power On, Hold, Alarm Reset, and Wire
Shortage. The remainder can be user-defined I/O, and the amount available
depends on the type and number of I/O boards installed in the MRC.
This manual provides the following information about the MRC I/O structure:
•
Section 1.0 provides an overview of MRC I/O boards and describes their
location in the MRC controller.
•
Section 2.0 describes MRC dedicated I/O and provides examples of electrical
connections.
•
Section 3.0 describes the MIO03 and MIO04 boards and provides examples of
electrical connections.
•
Section 4.0 describes the MIO01 and MIO02 boards and provides examples of
electrical connections.
•
Section 5.0 contains MRC I/O allocation and configuration information and
MRC I/O assignment tables for standard applications.
•
Appendix A contains MRC I/O block diagrams for standard arc welding, spot
welding, universal, and handling applications.
For more information about your system's I/O, refer to drawings in the Operator's
Manual for your system. Refer to the YASNAC MRC Maintenance Manual for
additional information on the MRY01, MIO01, MIO03, and MIO04 boards,
including schematic drawings.
➪
CAUTION!
The following I/O boards are static sensitive. Handling these
boards without static protection can result in permanent product
damage. Use static protection, such as static protective wrist
straps, when handling these boards.
1.1
MRY01 BOARD
The MRY01 board has input relays energized by 24 volts DC. This board is used
for robot critical interlock signals, such as external Emergency Stop, Servo On,
MRC I/O Structure Manual
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MOTOMAN
external Hold, and Overtravel. It also has four optically isolated transistor inputs
(DIN0 through DIN3) that are mapped directly into the CPU for fast input
response. These inputs are intended for use by Motoman only, for special options.
This board is standard in all MRC controllers.
1.2
MIO01 and MIO02 BOARDS
These boards support 32 optically isolated transistor inputs and 32 transistor
outputs. The MIO01 board has NPN (sinking) inputs and outputs, and the MIO02
board has PNP (sourcing) inputs and outputs. See Section 4.0 for additional
information.
1.3
MIO03 BOARD
The MIO03 board has 16 optically isolated transistor inputs, which can be wired in
sinking or sourcing configuration, and 16 normally open, dry-relay contact outputs
that are individually isolated. See Section 3.0 for additional information.
1.4
MIO04 BOARD
The MIO04 board has 24 NPN (sinking), optically isolated transistor inputs and 24
normally open, dry-relay contact outputs. Unlike the MIO03 board, the output
relays are arranged in groups of four with each group sharing one common
termination point. See Section 3.0 for additional information.
1.5
MEW01 AND MEW02 BOARDS
The MEW01 and MEW02 boards are analog output boards used in Motoman
welding and painting applications. Each board supplies two analog, ± 14 volt DC
output channels. The MEW01 board supplies 8-bit digital to analog (D/A)
conversion. The MEW02 board supplies 12-bit D/A conversion.
1.6
MARIO AND MIF05 BOARDS
The MARIO and MIF05 boards are for serial communication I/O. Each board
can be configured to support up to 112 inputs and 112 outputs in increments of
eight. The MARIO board is designed to interface to the Allen-Bradley Remote I/O
(RIO) network cable Blue Hose. The MIF05 board is designed to interface to most
other programmable logic controllers (PLC) by means of Y (Yaskawa) or T
(Toyota) protocol.
MRC I/O Structure Manual
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MOTOMAN
1.7
MRC I/O BY MOTOMAN APPLICATION
Although the type and number of I/O boards can vary according to the robotic
application, the MRC controller typically has two MIO04 boards for the general
applications, spot welding, and handling applications, and one MIO04 board for arc
welding applications.
For ArcWorld and FabWorld applications, the MRC controller typically has two
MIO04 boards and one MEW02 board.
MRC I/O Structure Manual
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MOTOMAN
1.8
I/O RACK LOCATION
The I/O rack for all the boards listed above is located on the MBB02 back board
inside the MRC cabinet (see Figure 1-1). The MRY01 board, which is a standard
board found in all MRC controllers, is always installed in Slot 00 of the I/O rack.
Five additional slots (01 through 05) are available in the I/O rack for additional I/O
boards. Except for MEW01 or MEW02 boards, all MRC I/O boards must be
installed beginning with Slot 01. Always install a new board in the first empty slot
after the MRY01 board. However, MEW01 and MEW02 boards must be
installed in Slot 05. If a second MEW01 or MEW02 board is required, that board
must be installed in Slot 04.
In addition to the MRY01 board, the standard I/O board for the MRC is the MIO04
board, installed in Slot 01. Typically, for many Motoman applications, an
additional MIO04 board or an MIO03 board might be installed in Slot 02. Always
visually verify which I/O boards are in your MRC controller before planning
changes or additions to your system.
Inside of
MRC Cabinet
I/O Rack
(MBB02 Back
Board)
MRY01 Board
Additional I/O Boards
(based on application)
00
02
03
04
05
MEW02-1
MIO03
CN2
CN2
TM1
TM1
Connector
01
MIO04
CN2
MRY01
CN2
Connector
CN1
CN1
CN1
CN1
Connector
Figure 1-1 Location of MRC I/O Boards
MRC I/O Structure Manual
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MOTOMAN
1.9
POWER SUPPLY
The MRC controller has a 24-volt DC, 1-amp internal power supply. When using
loads that exceed 1 amp, use an external 24-volt DC, regulated, linear transistor
power supply. Refer to the YASNAC MRC Maintenance Manual for instructions
on installing an external power supply.
1.10
REFERENCE TO OTHER DOCUMENTATION
For additional information, refer to the following:
1.11
•
Motoman MRC User Functions Manual (Part Number 132331-1)
•
YASNAC MRC Maintenance Manual (a section in the Motoman Robot
Manipulator Manual for your system)
•
Motoman Operator's Manual for your system
CUSTOMER SERVICE INFORMATION
If you are in need of technical assistance, contact the Motoman service staff at
(513) 847-3200 . Have the following information ready before you call:
•
Robot Type
•
System Number (located on the cover page of this manual)
•
Robot Serial Number (located on the back side of the robot arm)
•
Application Type (welding, handling, spot welding, or general use)
MRC I/O Structure Manual
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MOTOMAN
2.0 DEDICATED I/O
The Motoman robots with MRC controllers have many dedicated inputs and
outputs used for robot- and application-specific functions. Some are located on the
MRY01 board. Typically, most of them are located on the board in Slot 01. Most
applications use 16 to 24 inputs and 16 to 24 outputs for dedicated I/O. The actual
number and use of some I/O can change based on how the robot is configured and
its application. These dedicated inputs and outputs are used for controlling the
robot and for interfacing it to external equipment.
This section contains information on the following dedicated I/O:
•
External Emergency Stop Input
•
Servo On Input
•
External Hold Input
•
Remote Mode Select Input
•
Servo On Output
•
Shock Sensor Input
Refer to the following for additional information about MRC dedicated I/O:
➪
•
YASNAC MRC Maintenance Manual for additional information on the
MRY01, MIO04, and MIO03 boards, including schematic drawings
•
Section 3.0 in this manual for specific information on the MIO04 board,
including I/O circuit design
•
Motoman Operator's Manual for your system for specific MRC I/O drawings
•
Motoman MRC User Functions Manual for I/O addressing
CAUTION!
The boards discussed in this section are static sensitive.
Handling these boards without static protection can result in
permanent product damage. Use static protection, such as static
protective wrist straps, when handling these boards.
MRC I/O Structure Manual
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MOTOMAN
2.1
EXTERNAL EMERGENCY STOP INPUT
The external Emergency Stop (E-Stop) input puts the MRC in an E-Stop condition
and turns off the servo power to the robot. This input is located on the MRY01
board. Typically, an external device such as a normally closed switch is connected
across the input's connection points, as shown in Figure 2-1. Activating the switch
signals the E-Stop condition to the MRC.
One pair of connection points, terminal 23 and the 24-volt DC terminal on
connector TM1, is used for the external E-Stop input. Any number of external
devices can be connected in series to this input. When an external device is not
connected to this input, the connection points for the input must be connected with a
jumper wire.
Refer to the YASNAC MRC Maintenance Manual for additional information on
the MRY01 board and this input. Refer to the electrical drawings section of your
Motoman Operator's Manual for the specific MRC I/O drawings for your system.
➪
WARNING
To prevent injury to personnel or damage to equipment, check all
safety equipment frequently for proper operation.
➪
CAUTION!
Improper connections can damage the robot. Before making
connections, check for proper voltages and currents.
MRY01 Board
+24 VU
EXESP
External E-STOP 1
Term.14,15,16,
+24
VU
17, 24, or 25
External E-STOP 2
Terminal 23 EXESP
R
0 VU
+24 VU
MRC I/O Structure Manual
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MOTOMAN
Figure 2-1 External Emergency Stop Input Connection
MRC I/O Structure Manual
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MOTOMAN
2.2
SERVO ON INPUT
The Servo On input turns on servo power to the robot. This input is located on the
MRY01 board. Typically, an external device such as a normally open momentary
switch is connected across the input's connection points, as shown in Figure 2-2.
Activating the switch signals the MRC to turn on servo power.
One pair of connection points, terminal 21 and the 24-volt DC terminal on
connector TM1, is used for the Servo On input.
Refer to the YASNAC MRC Maintenance Manual for additional information on
the MRY01 board and this input. Refer to the electrical drawings section of your
Motoman Operator's Manual for the specific MRC I/O drawings for your system.
➪
CAUTION!
Improper connections can damage the robot. Before making
connections, check for proper voltages and currents.
MRY01 Board
Servo On
+24 VU
EXSVON
Term. 14,15,16,
+24 VU
17, 24, or 25
Terminal 21 EXSVON
R
0 VU
Figure 2-2 Servo On Input Connection
MRC I/O Structure Manual
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MOTOMAN
2.3
EXTERNAL HOLD INPUT
The external Hold input stops robot motion by placing the MRC in a Hold
condition. This input is located on the MRY01 board. Typically, an external device
such as a normally closed switch or relay is connected across the input's connection
points, as shown in Figure 2-3. Activating the external device signals the Hold
condition to the MRC.
One pair of connection points, terminal 22 and the 24-volt DC terminal on
connector TM1, is used for the external Hold input. Any number of external
devices can be connected in series to this input. When an external device is not
connected to this input, the connection points for the input must be connected with a
jumper wire.
Refer to the YASNAC MRC Maintenance Manual for additional information on
the MRY01 board and this input. Refer to the electrical drawings section of your
Motoman Operator's Manual for the specific MRC I/O drawings for your system.
➪
WARNING!
Robot Hold does NOT remove servo power. The Hold condition
only stops robot motion. Use the E-STOP button to stop the robot
before entering the robot cell. The robot and other equipment can
move unexpectedly, which can cause severe personal injury or
death, as well as damage to the robot!
MRY01 Board
+24 VU
EXHOLD
R
External HOLD
Term. 14, 15, 16,
+24 VU
17, 24, or 25
Terminal 22 EXHOLD
0 VU
Figure 2-3 External Hold Input Connection
+24 VU
MRC I/O Structure Manual
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MOTOMAN
2.4
REMOTE MODE SELECT INPUT
The Remote Mode Select input must be active before the Teach or Play mode can
be activated from a remote external device, such as an operator station or a PLC.
This input is located on the board installed in Slot 01. An external device such as a
normally open switch is connected to the input's connection points, as shown in
Figure 2-4. Activating the external device inputs a signal to the system's concurrent
I/O. The system uses this signal to determine if it will allow the Teach or Play
mode to be activated remotely. This input must remain active while either of these
modes is in use.
For an MIO04 board, the connection points for the Remote Mode Select input is
terminal 2-B3 and 0 volts DC (common) on connector CN2.
➪
CAUTION!
Improper connections can damage the robot. Before making
connections, check for proper voltages and currents.
MIO04 Board
24 VU
Remote Mode
Select
Terminal 2-B3
0 VU
Figure 2-4 Remote Mode Select Input Connection on an MIO04 Board
MRC I/O Structure Manual
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MOTOMAN
2.5
SERVO ON OUTPUT
The Servo On output is used to signal external equipment that the robot is ready.
This output is turned on when the servo power is turned on. This output is NOT
the same as the emergency stop (E-Stop).
The Servo On output is turned off when any one of the following conditions
occurs:
➪
•
The E-Stop button on the MRC front panel is pressed.
•
The E-Stop button on the MRC teach pendant is pressed.
•
The external E-Stop connection between terminal 23 on the MRY01 board and
24 volts DC is opened (see Section 2.1).
•
MRC power is turned OFF.
•
The tool mount shock sensor is impacted (optional).
•
Servo power is OFF.
CAUTION!
The SERVO ON output must NOT be used in an external E-STOP
loop.
On an MIO04 board, the connection points for the Servo On output are
terminals 2-A9 and 2-A8/2-B8 on connector CN2, as shown in Figure 2-5.
NOTE:
The relay shown below in Figure 2-5 must be rated for 24 volts DC and draw less than 50 mA
of current.
MIO04 Board
Servo On
Output
Terminal
2-A9
R
+
D1
Output
Common
Terminal 2-A/B8
0V
24 VDC
MRC I/O Structure Manual
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MOTOMAN
Figure 2-5 Servo On Output Connection on an MIO04 Board
MRC I/O Structure Manual
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MOTOMAN
2.6
SHOCK SENSOR INPUT
The Shock Sensor input is located on the MTU01 board (see Figure 2-6). When a
crash occurs, the shock sensor switch opens and places the MRC in an emergency
stop (E-Stop) condition or a Hold condition. A jumper on the MRY01 board
determines whether an E-Stop or Hold condition occurs. Typically, the jumper is
factory set to the E-Stop condition. The Shock Sensor input is a separate input
from the external E-Stop and external Hold inputs described in Sections 2.1 and
2.3.
Table 2-1 shows how to jumper the pins on the MBB02 board when a sensor is
used and when a sensor is not used. Table 2-1 also shows how to jumper the pins
on the MRY01 board to cause either an E-Stop or Hold condition. Figure 2-6
shows the connections when the shock sensor is used for an E-Stop condition.
Refer to the YASNAC MRC Maintenance Manual for additional information on
the MTU01, MBB02, and MRY01 boards and this input. Refer to your Motoman
Operator's Manual for specific information on shock sensor recovery after a robot
collision.
NOTE:
The MTU01 board is mounted on the MTU02 board inside the MRC cabinet in the back, upper
left corner above the MBB02 board .
NOTE:
A shock sensor override is located on MRY01 boards with a B designation; that is, MRY01B
boards.
MTU01
MBB02
+ 24 V
Robot Shock Sensor
MRY01
+ 24 V
CN6
2
Normally
Closed
CN5
20
9
18
10
CN3
TM4
1
2
3
SW1
1
HOLD
2
3
E-STOP
Figure 2-6 Connection Diagram Using the Shock Sensor for E-Stop Condition
MRC I/O Structure Manual
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MOTOMAN
➪
CAUTION!
Improper connections can damage the robot. Before making
connections, check for proper voltages and currents.
➪
CAUTION!
The following boards are static sensitive. Handling these boards
without static protection can result in permanent product
damage. Use static protection, such as static protective wrist
straps, when handling these boards.
Table 2-1 How to Place Jumpers on Pins for Shock Sensor Input
Shock Sensor
MBB02 Board
MRY01 Board
For E-Stop (SERVO
OFF), place jumper on
pins 2 and 3 on SW1.
Used
Place jumper on pins 2
and 3 on TM4.
For Hold, place jumper
on pins 1 and 2 on
SW1.
Not Used
MRC I/O Structure Manual
Place jumper on pins 1
and 2 on TM4.
Page 15
Place jumper on pins 1
and 2 or on pins 2 or 3
on SW1. Either setting
is acceptable.
MOTOMAN
3.0 MIO03 AND MIO04 BOARDS
Depending on the I/O requirements of the application, most standard MRC
controllers have two MIO04 boards. Each MIO04 board has 24 inputs and 24
outputs.
If an application requires isolated relay outputs or a combination of sinking and
sourcing inputs, an MIO03 board can be used. The MIO03 board has 16 inputs
and 16 outputs.
The inputs and outputs on both boards share the following characteristics:
Input type: optically isolated transistor, rated at 24 volts DC, 5 mA (maximum)
Output type: 0.5 ampere, 24 volt DC, normally open, dry-relay contact for DC
voltage only
Refer to the YASNAC MRC Maintenance Manual for additional information on
the MIO04 and MIO03 boards, including schematic drawings.
➪
CAUTION!
MIO03 and MIO04 boards are static sensitive. Handling these
boards without static protection can result in permanent board
damage. Use static protection, such as static protective wrist
straps, when handling these boards.
3.1
TRANSISTOR INPUTS
3.1.1
Input Connections
Each of the 24 inputs on the MIO04 board can be wired in a sinking configuration
only. Figure 3-1 shows how to wire an input's single connection. Each of the 16
inputs on the MIO03 board can be wired in either a sinking or sourcing
configuration. Figure 3-2 provides examples of how to wire an input's two
connections in either a sinking configuration or a sourcing configuration.
3.1.2
Input Conditions
Each transistor input is optically isolated, as shown in Figures 3-1 and 3-2. The
input condition must remain stable for a minimum of 10 milliseconds (ms). The
MRC scans the inputs, and if there is a change in logic, it scans a second time to
confirm the change. This eliminates relay contact bounce that might occur and give
MRC I/O Structure Manual
Page 16
MOTOMAN
a false status indication. When the transistor is activated by either a switch, a
contact, or a PLC, the input is confirmed approximately 20 ms later.
The maximum current drawn is 5 mA for each input. Some PLCs require greater
load current to keep their outputs energized. If relays are used to activate an input,
use relays with crosspoint or bifurcated, redundant relay contacts.
➪
CAUTION!
Improper connections can damage the robot. Before making
connections, check for proper voltages and currents.
MIO04 Board
24 VU
5 mA MAX
External Connection
0 VU
Figure 3-1 Input Connection on MIO04 Board
MRC I/O Structure Manual
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MOTOMAN
MIO03 Board (Sourcing Input)
MIO03 Board (Sinking Input)
24 VU
5 mA MAX
24 VU
5 mA MAX
External
Connections
External
Connections
0 VU
0 VU
Figure 3-2 Input Connections on MIO03 Board in Sinking and Sourcing Configurations
MRC I/O Structure Manual
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MOTOMAN
3.2
RELAY OUTPUTS
3.2.1
Output Relay Description
The output relays on both MIO04 and MIO03 boards have a rating of 0.5 ampere,
24 volts DC. The relays have normally open, dry-relay contacts, rated for DC
voltage only. If an application requires AC voltage control, use an external relay to
control the AC voltage. On the MIO04 board, the 24 output relays are divided into
six groups of four relays, with each group sharing one common termination point,
as shown in Figure 3-3. On the MIO03 board, all 16 output relays are isolated
from each other, as shown in Figure 3-4.
0 V or 24 V
Output
Internal
MIO04
Output
Relays
External
Connections
Output
Output
Output
Figure 3-3 MIO04 Output Relays
0 V or 24 V
Output
0 V or 24 V
Internal
MIO03
Output
Relays
Output
0 V or 24 V
External
Connections
Output
0 V or 24 V
Output
MRC I/O Structure Manual
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MOTOMAN
Figure 3-4 MIO03 Output Relays
3.2.2
Output Connections
Figure 3-5 provides an example of an output connection. Typically, 24-volt-DC
relays are connected to the internal hard relay contacts. Relays should be selected
with the voltage and current rating based on application and typical loads.
Even though the output relay rating is 0.5 ampere (maximum), the contact can be
damaged by high voltage transients caused by the inductive kick of relay coils. To
prevent such damage, apply a "fly back" diode across the DC relay coil, as shown
in Figure 3-5.
NOTE:
If the relay has an LED indicator, add 5-10 mA to total relay current draw and observe the coil
and LED polarity.
➪
CAUTION!
Improper connections can damage the robot. Before making
connections, check for proper voltages and currents.
MIO03 or MIO04 Board
External Relay
Output
R
+
24 VDC, 0.5 A MAX
D1
Output
Common
Figure 3-5 MIO04 or MIO03 Board Output With DC Relay Coil
MRC I/O Structure Manual
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MOTOMAN
4.0 MIO01 AND MIO02 BOARDS
Depending on the I/O requirements of the application, the MRC controller might
have an MIO01 or MIO02 board. The MIO01 board has 32 NPN (sinking)
transistor inputs and 32 NPN (sinking) transistor outputs. The MIO02 board has
32 PNP (sourcing) transistor inputs and 32 PNP (sourcing) transistor outputs. The
inputs and outputs on both boards share the following characteristics:
Input Type: optically isolated transistor, rated at 24 volts DC, 5 mA (maximum)
Output Type: transistor, rated at 24 volts DC, 50 mA (maximum)
Refer to the YASNAC MRC Maintenance Manual for additional information on
the MIO01 board, including a schematic drawing.
➪
CAUTION!
MIO01 and MIO02 boards are static sensitive. Handling these
boards without static protection can result in permanent board
damage. Use static protection, such as static protective wrist
straps, when handling these boards.
4.1
TRANSISTOR INPUTS
Each input has only one connection. Figure 4-1 shows how to wire an input
connection on an MIO01 board. Figure 4-2 shows how to wire an input
connection on an MIO02 board.
➪
CAUTION!
Improper connections can damage the robot. Before making
connections, check for proper voltages and currents.
MRC I/O Structure Manual
Page 21
MOTOMAN
MIO01 Board
24 VU
5 mA MAX
External Connection
0 VU
Figure 4-1 Input Connection on MIO01 Board
MIO02 Board
24 VU
5 mA MAX
External Connection
0 VU
Figure 4-2 Input Connection on MIO02 Board
4.2
TRANSISTOR OUTPUTS
The MIO01 board has NPN (sinking) transistor outputs, as shown in Figure 4-3,
and the MIO02 board has PNP (sourcing) transistor outputs, as shown in Figure
4-4. Both types of outputs are rated at 24 volts DC, 50 mA (maximum).
To prevent damage to the output transistors, apply a "fly back" diode across a DC
relay coil, as shown in Figures 4-3 and 4-4, to suppress the high voltage when the
relay coil is de-energized. A transistor can easily be damaged by DC relay high
voltage transients caused by inductive relay coils. The maximum current allowed
for either type of transistor is 50 mA. Do not exceed 50 mA, or the board can be
damaged seriously.
➪
CAUTION!
MRC I/O Structure Manual
Page 22
MOTOMAN
Improper connections can damage the robot. Before making
connections, check for proper voltages and currents.
MIO01 Board
External Relay
Output
R
24 VDC MAX, 50 mA
D1
0 VU
Figure 4-3 Output Connection on MIO01 Board
MIO02 Board
24 VDC MAX, 50 mA
External Relay
Output
R
D1
0 VU
Figure 4-4 Output Connection on MIO02 Board
MRC I/O Structure Manual
Page 23
MOTOMAN
5.0 MRC I/O ALLOCATION AND
CONFIGURATION
5.1
LOGICAL RELAY ADDRESSES
MRC I/O logical relay addressing is based on the octal number system, which has
a base of eight. (The number system that we commonly use has a base of ten.)
For all practical purposes, that simply means addresses are divided into groups of
eight consecutive numbers. The first address in each group ends with a zero (for
example, 2010) and the last address in the group ends with a seven (for example,
2017). Addresses for inputs are 2000-series numbers and range from 2010 to
2187. Addresses for outputs are 3000-series numbers and range from 3010 to
3187. Figure 5-1 shows a typical address configuration for an MRC I/O board.
MIO04 Board
24 Inputs
24 Outputs
Slot 01
MIO04
Addresses for
Inputs are
2000-series
numbers
Eight addresses
per group
First address in
each group ends
with a zero
2010
2011
2012
2013
2014
2015
2016
2017
2020
2021
2022
2023
2024
2025
2026
2027
2030
2031
2032
2033
2034
2035
2036
2037
Eight addresses
per group
3010
3011
3012
3013
3014
3015
3016
3017
3020
3021
3022
3023
3024
3025
3026
3027
3030
3031
3032
3033
3034
3035
3036
3037
Last address in each
group ends with a 7
Last address in each
group ends with a 7
MIO04 Board has 24 Inputs requiring
3 groups of logical relay addresses (24/8 = 3).
MRC I/O Structure Manual
Addresses for
Outputs are
3000-series
numbers
First address in
each group ends
with a zero
Page 24
MIO04 Board has 24 Outputs requiring
3 groups of logical relay addresses (24/8 = 3).
MOTOMAN
Figure 5-1 Setting Up Input and Output Addresses
MRC I/O Structure Manual
Page 25
MOTOMAN
5.2
RULES AND LIMITATIONS
5.2.1
Available Slots in I/O Rack
MRC software is capable of supporting up to 144 inputs and 144 outputs.
However, the amount of actual I/O is limited by the number of available slots in the
I/O rack (refer to Section 1.8 for additional information about the I/O rack).
Because an MRY01 board always occupies Slot 00, only five slots remain for
dedicated I/O and user-defined I/O. As shown in the example in Figure 5-2, the
I/O rack can be filled completely without using all available inputs and outputs.
5.2.2
Board Location and Addressing
Figures 5-2 and 5-3 demonstrate several important details about board location and
addresses:
5.2.3
•
Except for the MEW02 board in Figure 5-3, the logical relay addresses are
consecutive, beginning with the lowest addresses in Slot 01 and ending with the
highest addresses in Slot 05. Keep in mind that each new board must be
installed in the next available slot after the MRY01 board.
•
The MEW02 (or MEW01) board, which must be located in Slot 05, uses the
following logical relay addresses: 2170 - 2177 (input addresses) and 3170 3177 (output addresses). In a welding system, the default setting assumes that
an MEWO board is in the last slot. If a second MEWO board is needed, it
must be installed in Slot 04 and use the last two sets of addresses: 2180 - 2187
and 3180 - 3187.
•
If one or two MEW02 (or MEW01) boards are installed in the I/O rack, the
maximum number of I/O supported by the MRC software is reduced to 128
inputs and 128 outputs. A total of 16 inputs and 16 outputs and the logical
relay addresses 2170 - 2177, 2180 - 2187, 3170 - 3177, and 3180 - 3187 are
utilized even if only one MEW0 board is installed.
•
The number of addresses used by a board are based on the number of inputs
and outputs on the board, even if all the inputs and outputs are not used in the
application. For example, in Figure 5-2, the MIO01 board in Slot 02 might use
only 24 of its 32 outputs to control devices. Yet, because the board has 32
outputs, 32 addresses are reserved.
Determining the Amount of User-Defined I/O
The amount of user-defined I/O available depends on the type and number of I/O
boards installed in the I/O rack. As shown in Figures 5-2 and 5-3, the combination
of I/O boards can vary.
In addition, dedicated I/O typically uses the first 16 to 24 inputs and the first 16 to
24 outputs for application- and robot-specific functions. (The Remote Mode Select
MRC I/O Structure Manual
Page 26
MOTOMAN
Input and the Servo On Output, described in Sections 2.4 and 2.5, respectively, are
examples of dedicated I/O.)
In an arc welding application, for example, the first 16 inputs and 16 outputs are
reserved for dedicated I/O. Figure 5-3 shows an arc welding application with
MRC I/O Structure Manual
Page 27
MOTOMAN
MIO04 Board
MRY01 Board
24 Inputs
(always in Slot 00) 24 Outputs
MIO01 Board
32 Inputs
32 Outputs
MIO02 Board
32 Inputs
32 Outputs
MIO04 Board
24 Inputs
24 Outputs
MIO03 Board
16 Inputs
16 Outputs
Slot 00
Slot 01
Slot 02
Slot 03
Slot 04
Slot 05
MRY01
MIO04
MIO01
MIO02
MIO04
MIO03
* The first 24 Inputs use
these ADDRESSES:
2010 - 2017 = 8 Inputs
2020 - 2027 = 8 Inputs
2030 - 2037 = 8 Inputs
Total = 24 Inputs
* The first 24 Outputs use
these ADDRESSES:
3010 - 3017 = 8 Outputs
3020 - 3027 = 8 Outputs
3030 - 3037 = 8 Outputs
Total = 24 Outputs
The next 32 Inputs use
these ADDRESSES:
2080 - 2087 = 8 Inputs
2090 - 2097 = 8 Inputs
2100 - 2107 = 8 Inputs
2110 - 2117 = 8 Inputs
Total = 32 Inputs
The next 16 Inputs use
these ADDRESSES:
2150 - 2157 = 8 Inputs
2160 - 2167 = 8 Inputs
Total = 16 Inputs
The next 16 Outputs use
these ADDRESSES:
3150 - 3157 = 8 Outputs
3160 - 3167 = 8 Outputs
Total = 16 Outputs
The next 32 Outputs use
these ADDRESSES:
3080 - 3087 = 8 Outputs
3090 - 3097 = 8 Outputs
3100 - 3107 = 8 Outputs
3110 - 3117 = 8 Outputs
Total = 32 Outputs
The next 24 Inputs use
these ADDRESSES:
2120 - 2127 = 8 Inputs
2130 - 2137 = 8 Inputs
2140 - 2147 = 8 Inputs
Total = 24 Inputs
The next 32 Inputs use
these ADDRESSES:
2040 - 2047 = 8 Inputs
2050 - 2057 = 8 Inputs
2060 - 2067 = 8 Inputs
2070 - 2077 = 8 Inputs
Total = 32 Inputs
The next 24 Outputs use
these ADDRESSES:
3120 - 3127 = 8 Outputs
3130 - 3137 = 8 Outputs
3140 - 3147 = 8 Outputs
Total = 24 Outputs
The next 32 Outputs use
these ADDRESSES:
3040 - 3047 = 8 Outputs
3050 - 3057 = 8 Outputs
3060 - 3067 = 8 Outputs
3070 - 3077 = 8 Outputs
Total = 32 Outputs
Total Inputs: 24 + 32 + 32 + 24 + 16 = 128
Total Outputs: 24 + 32 + 32 + 24 + 16 = 128
128 Inputs and 128 Outputs and all available I/O slots are used.
* The first 16 to 24 inputs and outputs are used for dedicated I/O.
Figure 5-2 Example of Addressing With All I/O Slots Filled
MRC I/O Structure Manual
Page 28
MOTOMAN
MRY01 Board
(always in Slot 00)
MIO04 Board
24 Inputs
24 Outputs
MIO04 Board
24 Inputs
24 Outputs
MIO03 Board
16 Inputs
16 Outputs
Empty
Slot
MEW02 Board
(When used,
place in last slot)
Slot 01
Slot 02
Slot 03
Slot 04
Slot 05
MIO04
MIO04
MIO03
Slot 00
MRY01
* The first 24 Inputs use
these ADDRESSES:
2010 - 2017 = 8 Inputs
2020 - 2027 = 8 Inputs
2030 - 2037 = 8 Inputs
Total = 24 Inputs
The next 16 Inputs use
these ADDRESSES:
2070 - 2077 = 8 Inputs
2080 - 2087 = 8 Inputs
Total = 16 Inputs
* The first 24 Outputs use
these ADDRESSES:
3010 - 3017 = 8 Outputs
3020 - 3027 = 8 Outputs
3030 - 3037 = 8 Outputs
Total = 24 Outputs
The next 16 Outputs use
these ADDRESSES:
3070 - 3077 = 8 Outputs
3080 - 3087 = 8 Outputs
Total = 16 Outputs
MEW02
An MEW0 Board in this
slot always uses these
addresses:
Input ADDRESSES
are 2170 - 2177
Output ADDRESSES
are 3170 - 3177.
Input Addresses 2180 2187 and Output
Addresses 3180 - 3187
are also reserved (see
Section 5.2.2).
The next 24 Inputs use
these ADDRESSES:
2040 - 2047 = 8 Inputs
2050 - 2057 = 8 Inputs
2060 - 2067 = 8 Inputs
Total = 24 Inputs
The next 24 Outputs use
these ADDRESSES:
3040 - 3047 = 8 Outputs
3050 - 3057 = 8 Outputs
3060 - 3067 = 8 Outputs
Total = 24 Outputs
Total dedicated and user-defined inputs: 24 + 24 + 16 = 64
Total dedicated and user-defined outputs: 24 + 24 + 16 = 64
* The first 16 to 24 inputs and outputs are used for dedicated I/O.
Figure 5-3 Example of Addressing for an ArcWorld Product With One Additional Board
MRC I/O Structure Manual
Page 29
MOTOMAN
64 inputs and 64 outputs. If the dedicated I/O uses 16 inputs and 16 outputs, that
leaves 48 inputs and 48 outputs for user-defined I/O. As shown in Tables 5-1 and
5-2 in Section 5.3, user-defined inputs and outputs are available beginning with
addresses 2030 and 3030. The tables in Section 5.3 and the drawings in Appendix
A show the dedicated I/O for a number of applications. Refer to the Appendix in
your system's Operator's Manual for drawings specific to your application.
5.3
MRC I/O ASSIGNMENTS BY APPLICATION
➪
WARNING!
The following tables are for reference only. Your MRC controller
might have a modified ladder diagram with unique I/O
assignments. Assigning incorrect I/O addresses can cause
unexpected equipment operation, which can result in serious
injury or death and in equipment damage.
Input and output address assignments depend upon the number of boards installed
in the MRC controller and the application. Refer to the YASNAC MRC
Maintenance Manual and the MRC User Functions Manual for additional
information on the MIO03 and MIO04 board I/O assignments. Refer to the
electrical drawings section of your Motoman Operator's Manual for the specific
MRC I/O drawings for your system.
The following tables list the I/O assignments for specific applications. Be sure that
you use the correct tables for your application. If in doubt, check with your
authorized service representative. Also, refer to Appendix A in this manual for
block diagrams of these applications using MIO04 boards. Check and test all
changes at slow speed.
Under the MIO04 column, the first number refers to the Phoenix connector number (CN1 or
CN2). The letter and number that follow are the terminal number. For example, 2-B1 is
connector CN2, terminal B1.
MRC I/O Structure Manual
Page 30
MOTOMAN
Note:
The MIO04 board has 24 inputs and 24 outputs.
Table 5-1 Inputs for Arc Welding Using Two MIO04 Boards
Logical
Relay
*I/O
Type
Address
Slot 01
MIO04
Function
(Phoenix)
Logical
Relay
*I/O
Type
Address
Slot 02
MIO04
Function
(Phoenix)
7, 17, 18
O VDC
7, 17, 18
O VDC
19, A20
24 VDC
19, A20
24 VDC
B20
B20
Frame ground
2040
I
2-B1
Frame
ground
IN#9
External start
2041
I
2-A1
IN#10
Master job call
2042
I
2-B2
IN#11
Alarm / error
reset
Remote mode
sel
Play mode select
2043
I
2-A2
IN#12
2044
I
2-B3
IN#13
2045
I
2-A3
IN#14
2046
I
2-B4
IN#15
2-A4
Teach mode
select
-
2047
I
2-A4
IN#16
I
2-B5
Cube 1 prohibit
2050
I
2-B5
IN#17
2021
I
2-A5
Cube 2 prohibit
2051
I
2-A5
IN#18
2022
I
2-B6
Work prohibit
2052
I
2-B6
IN#19
2023
I
2-A6
Work response
2053
I
2-A6
IN#20
2024
I
1-B1
-
2054
I
1-B1
IN#21
2025
I
1-A1
-
2055
I
1-A1
IN#22
2026
I
1-B2
Weaving prohibit
2056
I
1-B2
IN#23
2027
I
1-A2
Sensing prohibit
2057
I
1-A2
IN#24
2030
I
1-B3
IN#1
2060
I
1-B3
IN#25
2031
I
1-A3
IN#2
2061
I
1-A3
IN#26
2032
I
1-B4
IN#3
2062
I
1-B4
IN#27
2033
I
1-A4
IN#4
2063
I
1-A4
IN#28
2034
I
1-B5
IN#5
2064
I
1-B5
IN#29
2035
I
1-A5
IN#6
2065
I
1-A5
IN#30
2036
I
1-B6
IN#7
2066
I
1-B6
IN#31
2037
I
1-A6
IN#8
2067
I
1-A6
IN#32
2010
I
2-B1
2011
I
2-A1
2012
I
2-B2
2013
I
2-A2
2014
I
2-B3
2015
I
2-A3
2016
I
2-B4
2017
I
2020
-
* I = Input and O = Output
MRC I/O Structure Manual
Page 31
MOTOMAN
Table 5-2 Outputs for Arc Welding Using Two MIO04 Boards
Logical *I/O
Relay Type
Address
Slot 01
MIO04
Function
Logical
Relay
(Phoenix)
2-A8, 2-B8
*I/O
Type
Address
Slot 02
MIO04
Function
(Phoenix)
3010
O
2-B9
† Common to four
below
Operating
3011
O
2-A9
Servo on
3041
O
2-A9
OT#10
3012
O
2-B10
Top of Master Job
3042
O
2-B10
OT#11
3013
O
2-A10
Alarm / error occur
3043
O
2-A10
OT#12
2-A11, 2-B11 † Common to four
below
2-B12
Battery low
3014
O
3015
O
2-A12
3016
O
3017
O
2-A8, 2-B8
† Common to four below
3040
O
2-B9
OT#9
2-A11, 2-B11 † Common to four below
3044
O
2-B12
OT#13
Remote mode
3045
O
2-A12
OT#14
2-B13
Play mode
3046
O
2-B13
OT#15
2-A13
Teach mode
3047
O
2-A13
OT#16
2-A14, 2-B14 † Common to four
below
2-B15
In Cube 1
3020
O
3021
O
2-A15
3022
O
3023
O
2-A14, 2-B14 † Common to four below
3050
O
2-B15
OT#17
In Cube 2
3051
O
2-A15
OT#18
2-B16
In Cube 8 (Home)
3052
O
2-B16
OT#19
2-A16
Sequence executing
3053
O
2-A16
OT#20
1-A8, 1-B8
3054
O
1-B9
OT#21
3024
O
1-B9
† Common to four
below
Gas shortage monitor
3025
O
1-A9
Wire shortage monitor
3055
O
1-A9
OT#22
3026
O
1-B10
Wire sticking monitor
3056
O
1-B10
OT#23
3027
O
1-A10
Arc shortage monitor
3057
O
1-A10
OT#24
1-A11, 1-B11 † Common to four
below
1-B12
OT#1
3030
O
3031
O
1-A12
3032
O
3033
O
1-A8, 1-B8
† Common to four below
1-A11, 1-B11 † Common to four below
3060
O
1-B12
OT#25
OT#2
3061
O
1-A12
OT#26
1-B13
OT#3
3062
O
1-B13
OT#27
1-A13
OT#4
3063
O
1-A13
OT#28
1-A14, 1-B14 † Common to four
below
1-B15
OT#5
3034
O
3035
O
1-A15
3036
O
1-A14, 1-B14 † Common to four below
3064
O
1-B15
OT#29
OT#6
3065
O
1-A15
OT#30
1-B16
OT#7
3066
O
1-B16
OT#31
3037
O
1-A16
* I = Input and O = Output
OT#8
3067
O
1-A16
OT#32
MRC I/O Structure Manual
Page 32
MOTOMAN
† See Section 3.2.1 and Figures 3-3 and 3-4.
MRC I/O Structure Manual
Page 33
MOTOMAN
Note:
The MIO04 board has 24 inputs and 24 outputs.
Table 5-3 Inputs for General or Universal Applications Using Two MIO04 Boards
Logical
Relay
*I/O
Type
Address
Slot 01
MIO04
Function
(Phoenix)
Logical
Relay
*I/O
Type
Address
Slot 02
MIO04
Function
(Phoenix)
7, 17, 18
O VDC
7, 17, 18
O VDC
19, A20
24 VDC
19, A20
24 VDC
B20
Frame ground
External start
2010
I
2-B1
2011
I
2-A1
2012
I
2-B2
2013
I
2-A2
2014
I
2-B3
2015
I
2-A3
2016
I
2-B4
2017
I
2020
B20
Frame ground
2040
I
2-B1
IN#9
2041
I
2-A1
IN#10
Master job call
2042
I
2-B2
IN#11
Alarm / error
reset
Remote mode
sel
Play mode select
2043
I
2-A2
IN#12
2044
I
2-B3
IN#13
2045
I
2-A3
IN#14
2046
I
2-B4
IN#15
2-A4
Teach mode
select
-
2047
I
2-A4
IN#16
I
2-B5
Cube 1 prohibit
2050
I
2-B5
IN#17
2021
I
2-A5
Cube 2 prohibit
2051
I
2-A5
IN#18
2022
I
2-B6
Work prohibit
2052
I
2-B6
IN#19
2023
I
2-A6
Work response
2053
I
2-A6
IN#20
2024
I
1-B1
Cube 3 prohibit
2054
I
1-B1
IN#21
2025
I
1-A1
Cube 4 prohibit
2055
I
1-A1
IN#22
2026
I
1-B2
-
2056
I
1-B2
IN#23
2027
I
1-A2
-
2057
I
1-A2
IN#24
2030
I
1-B3
IN#1
2060
I
1-B3
IN#25
2031
I
1-A3
IN#2
2061
I
1-A3
IN#26
2032
I
1-B4
IN#3
2062
I
1-B4
IN#27
2033
I
1-A4
IN#4
2063
I
1-A4
IN#28
2034
I
1-B5
IN#5
2064
I
1-B5
IN#29
2035
I
1-A5
IN#6
2065
I
1-A5
IN#30
2036
I
1-B6
IN#7
2066
I
1-B6
IN#31
2037
I
1-A6
IN#8
2067
I
1-A6
IN#32
-
* I = Input and O = Output
MRC I/O Structure Manual
Page 34
MOTOMAN
Table 5-4 Outputs for General or Universal Applications Using Two MIO04 Boards
Logical *I/O
Relay Type
Address
Slot 01
MIO04
Function
Logical
Relay
(Phoenix)
2-A8, 2-B8
*I/O
Type
Address
Slot 02
MIO04
Function
(Phoenix)
3010
O
2-B9
† Common to four
below
Operating
3011
O
2-A9
Servo on
3041
O
2-A9
OT#10
3012
O
2-B10
Top of Master Job
3042
O
2-B10
OT#11
3013
O
2-A10
Alarm / error occur
3043
O
2-A10
OT#12
2-A11, 2-B11 † Common to four
below
2-B12
Battery low
3014
O
3015
O
2-A12
3016
O
3017
O
2-A8, 2-B8
† Common to four below
3040
O
2-B9
OT#9
2-A11, 2-B11 † Common to four below
3044
O
2-B12
OT#13
Remote mode
3045
O
2-A12
OT#14
2-B13
Play mode
3046
O
2-B13
OT#15
2-A13
Teach mode
3047
O
2-A13
OT#16
2-A14, 2-B14 † Common to four
below
2-B15
In Cube 1
3020
O
3021
O
2-A15
3022
O
3023
O
2-A14, 2-B14 † Common to four below
3050
O
2-B15
OT#17
In Cube 2
3051
O
2-A15
OT#18
2-B16
In Cube 8 (Home)
3052
O
2-B16
OT#19
2-A16
Sequence executing
3053
O
2-A16
OT#20
1-A8, 1-B8
3024
O
1-B9
† Common to four
below
In Cube 3
3025
O
1-A9
In Cube 4
3055
O
1-A9
OT#22
3026
O
1-B10
Work instruction
3056
O
1-B10
OT#23
3027
O
1-A10
3057
O
1-A10
OT#24
-
1-A11, 1-B11 † Common to four
below
1-B12
OT#1
3030
O
3031
O
1-A12
3032
O
3033
O
1-A8, 1-B8
† Common to four below
3054
O
1-B9
OT#21
1-A11, 1-B11 † Common to four below
3060
O
1-B12
OT#25
OT#2
3061
O
1-A12
OT#26
1-B13
OT#3
3062
O
1-B13
OT#27
1-A13
OT#4
3063
O
1-A13
OT#28
1-A14, 1-B14 † Common to four
below
1-B15
OT#5
3034
O
3035
O
1-A15
3036
O
1-A14, 1-B14 † Common to four below
3064
O
1-B15
OT#29
OT#6
3065
O
1-A15
OT#30
1-B16
OT#7
3066
O
1-B16
OT#31
3037
O
1-A16
* I = Input and O = Output
OT#8
3067
O
1-A16
OT#32
MRC I/O Structure Manual
Page 35
MOTOMAN
† See Section 3.2.1 and Figures 3-3 and 3-4.
MRC I/O Structure Manual
Page 36
MOTOMAN
Note:
The MIO04 board has 24 inputs and 24 outputs.
Table 5-5 Inputs for Spot Welding Using Two MIO04 Boards
Logical
Relay
*I/O
Type
Address
Slot 01
MIO04
Function
(Phoenix)
Logical
Relay
*I/O
Type
Address
Slot 02
MIO04
Function
(Phoenix)
7, 17, 18
O VDC
7, 17, 18
O VDC
19, A20
24 VDC
19, A20
24 VDC
B20
Frame ground
B20
Frame ground
2010
I
2-B1
External start
2040
I
2-B1
IN#1
2011
I
2-A1
-
2041
I
2-A1
IN#2
2012
I
2-B2
Master job call
2042
I
2-B2
IN#3
2013
I
2-A2
Alarm / error reset
2043
I
2-A2
IN#4
2014
I
2-B3
Remote mode sel
2044
I
2-B3
IN#5
2015
I
2-A3
Play mode select
2045
I
2-A3
IN#6
2016
I
2-B4
Teach mode select
2046
I
2-B4
IN#7
2017
I
2-A4
2047
I
2-A4
IN#8
2020
I
2-B5
Cube 1 prohibit
2050
I
2-B5
IN#9
2021
I
2-A5
Cube 2 prohibit
2051
I
2-A5
IN#10
2022
I
2-B6
Work prohibit
2052
I
2-B6
IN#11
2023
I
2-A6
Work response
2053
I
2-A6
IN#12
2024
I
1-B1
Cube 3 prohibit
2054
I
1-B1
IN#13
2025
I
1-A1
Cube 4 prohibit
2055
I
1-A1
IN#14
2026
I
1-B2
2056
I
1-B2
IN#15
2027
I
1-A2
2057
I
1-A2
IN#16
2030
I
1-B3
2060
I
1-B3
IN#17
2031
I
1-A3
-
2061
I
1-A3
IN#18
2032
I
1-B4
-
2062
I
1-B4
IN#19
2033
I
1-A4
Wire sticking error
2063
I
1-A4
IN#20
2034
I
1-B5
Welding error
2064
I
1-B5
IN#21
2035
I
1-A5
Welding completed
2065
I
1-A5
IN#22
2036
I
1-B6
2066
I
1-B6
IN#23
2037
I
1-A6
Gun short open
completed
Gun full open completed
2067
I
1-A6
IN#24
-
Tip replacement
completed
-
* I = Input and O = Output
MRC I/O Structure Manual
Page 37
MOTOMAN
Table 5-6 Outputs for Spot Welding Using Two MIO04 Boards
Logical *I/O
Relay Type
Address
Slot 01
MIO04
Function
Logical
Relay
(Phoenix)
2-A8, 2-B8
*I/O
Type
Address
Slot 02
MIO04
Function
(Phoenix)
3010
O
2-B9
† Common to four
below
Operating
3011
O
2-A9
Servo on
3041
O
2-A9
OT#2
3012
O
2-B10
Top of Master Job
3042
O
2-B10
OT#3
3013
O
2-A10
Alarm / error occur
3043
O
2-A10
OT#4
2-A11, 2-B11 † Common to four
below
2-B12
Battery low
3014
O
3015
O
2-A12
3016
O
3017
O
2-A8, 2-B8
† Common to four below
3040
O
2-B9
OT#1
2-A11, 2-B11 † Common to four below
3044
O
2-B12
OT#5
Remote mode
3045
O
2-A12
OT#6
2-B13
Play mode
3046
O
2-B13
OT#7
2-A13
Teach mode
3047
O
2-A13
OT#8
2-A14, 2-B14 † Common to four
below
2-B15
In Cube 1
3020
O
3021
O
2-A15
3022
O
3023
O
2-A14, 2-B14 † Common to four below
3050
O
2-B15
OT#9
In Cube 2
3051
O
2-A15
OT#10
2-B16
In Cube 8 (Home)
3052
O
2-B16
OT#11
2-A16
Sequence executing
3053
O
2-A16
OT#12
1-A8, 1-B8
3024
O
1-B9
† Common to four
below
In Cube 3
3025
O
1-A9
In Cube 4
3055
O
1-A9
OT#14
3026
O
1-B10
Welding error monitor
3056
O
1-B10
OT#15
3027
O
1-A10
Tip replacement request
3057
O
1-A10
OT#16
1-A11, 1-B11 † Common to four
below
1-B12
Welding timer d0
3030
O
3031
O
1-A12
3032
O
3033
O
1-A8, 1-B8
† Common to four below
3054
O
1-B9
OT#13
1-A11, 1-B11 † Common to four below
3060
O
1-B12
OT#17
Welding timer d1
3061
O
1-A12
OT#18
1-B13
Welding timer d2
3062
O
1-B13
OT#19
1-A13
Welding timer d3
3063
O
1-A13
OT#20
1-A14, 1-B14 † Common to four
below
1-B15
-
3034
O
3035
O
1-A15
3036
O
1-B16
3037
O
1-A16
* I = Input and O = Output
MRC I/O Structure Manual
1-A14, 1-B14 † Common to four below
3064
O
1-B15
OT#21
Welding on
3065
O
1-A15
OT#22
Gun pressure
3066
O
1-B16
OT#23
Gun full open
3067
O
1-A16
OT#24
Page 38
MOTOMAN
† See Section 3.2.1 and Figures 3-3 and 3-4.
MRC I/O Structure Manual
Page 39
MOTOMAN
Note:
The MIO04 board has 24 inputs and 24 outputs.
Table 5-7 Inputs for Material Handling Using Two MIO04 Boards
Logical
Relay
*I/O
Type
Address
Slot 01
MIO04
Function
(Phoenix)
Logical
Relay
*I/O
Type
Address
Slot 02
MIO04
Function
(Phoenix)
7, 17, 18
O VDC
7, 17, 18
O VDC
19, A20
24 VDC
19, A20
24 VDC
B20
Frame ground
B20
Frame ground
2010
I
2-B1
External start
2040
I
2-B1
IN#1
2011
I
2-A1
-
2041
I
2-A1
IN#2
2012
I
2-B2
Master job call
2042
I
2-B2
IN#3
2013
I
2-A2
Alarm / error reset
2043
I
2-A2
IN#4
2014
I
2-B3
Remote mode sel
2044
I
2-B3
IN#5
2015
I
2-A3
Play mode select
2045
I
2-A3
IN#6
2016
I
2-B4
Teach mode select
2046
I
2-B4
IN#7
2017
I
2-A4
2047
I
2-A4
IN#8
2020
I
2-B5
Cube 1 prohibit
2050
I
2-B5
IN#9
2021
I
2-A5
Cube 2 prohibit
2051
I
2-A5
IN#10
2022
I
2-B6
Work prohibit
2052
I
2-B6
IN#11
2023
I
2-A6
-
2053
I
2-A6
IN#12
2024
I
1-B1
-
2054
I
1-B1
IN#13
2025
I
1-A1
-
2055
I
1-A1
IN#14
2026
I
1-B2
Sensor input 7
2056
I
1-B2
IN#15
2027
I
1-A2
Sensor input 8
2057
I
1-A2
IN#16
2030
I
1-B3
Sensor input 1
2060
I
1-B3
IN#17
2031
I
1-A3
Sensor input 2
2061
I
1-A3
IN#18
2032
I
1-B4
Sensor input 3
2062
I
1-B4
IN#19
2033
I
1-A4
Sensor input 4
2063
I
1-A4
IN#20
2034
I
1-B5
Sensor input 5
2064
I
1-B5
IN#21
2035
I
1-A5
Sensor input 6
2065
I
1-A5
IN#22
2036
I
1-B6
Shock sensor (NC)
2066
I
1-B6
IN#23
2037
I
1-A6
Air pressure drop
2067
I
1-A6
IN#24
-
* I = Input and O = Output
MRC I/O Structure Manual
Page 40
MOTOMAN
Table 5-8 Outputs for Material Handling Using Two MIO04 Boards
Logical *I/O
Relay Type
Address
Slot 01
MIO04
Function
Logical
Relay
(Phoenix)
2-A8, 2-B8
*I/O
Type
Address
Slot 02
MIO04
Function
(Phoenix)
3010
O
2-B9
† Common to four
below
Operating
3011
O
2-A9
Servo on
3041
O
2-A9
OT#2
3012
O
2-B10
Top of Master Job
3042
O
2-B10
OT#3
3013
O
2-A10
Alarm / error occur
3043
O
2-A10
OT#4
2-A11, 2-B11 † Common to four
below
2-B12
Battery low
3014
O
3015
O
2-A12
3016
O
3017
O
2-A8, 2-B8
† Common to four below
3040
O
2-B9
OT#1
2-A11, 2-B11 † Common to four below
3044
O
2-B12
OT#5
Remote mode
3045
O
2-A12
OT#6
2-B13
Play mode
3046
O
2-B13
OT#7
2-A13
Teach mode
3047
O
2-A13
OT#8
2-A14, 2-B14 † Common to four
below
2-B15
In Cube 1
3020
O
3021
O
2-A15
3022
O
3023
O
2-A14, 2-B14 † Common to four below
3050
O
2-B15
OT#9
In Cube 2
3051
O
2-A15
OT#10
2-B16
In Cube 8 (Home)
3052
O
2-B16
OT#11
2-A16
Sequence executing
3053
O
2-A16
OT#12
1-A8, 1-B8
3024
O
1-B9
3025
O
1-A9
3026
O
1-B10
3027
O
1-A10
† Common to four
below
-
O
3031
O
1-A12
3032
O
3033
O
† Common to four below
3054
O
1-B9
OT#13
3055
O
1-A9
OT#14
Tool Valve 4-1
3056
O
1-B10
OT#15
Tool Valve 4-2
3057
O
1-A10
OT#16
-
1-A11, 1-B11 † Common to four
below
1-B12
Tool Valve 1-1
3030
1-A8, 1-B8
1-A11, 1-B11 † Common to four below
3060
O
1-B12
OT#17
Tool Valve 1-2
3061
O
1-A12
OT#18
1-B13
Tool Valve 2-1
3062
O
1-B13
OT#19
1-A13
Tool Valve 2-2
3063
O
1-A13
OT#20
1-A14, 1-B14 † Common to four
below
1-B15
Tool Valve 3-1
3034
O
3035
O
1-A15
3036
O
1-B16
3037
O
1-A16
* I = Input and O = Output
MRC I/O Structure Manual
1-A14, 1-B14 † Common to four below
3064
O
1-B15
OT#21
3065
O
1-A15
OT#22
-
3066
O
1-B16
OT#23
-
3067
O
1-A16
OT#24
Tool Valve 3-2
Page 41
MOTOMAN
† See Section 3.2.1 and Figures 3-3 and 3-4.
MRC I/O Structure Manual
Page 42
MOTOMAN
APPENDIX A - MRC I/O BLOCK DIAGRAMS
Appendix A contains MRC I/O block diagrams showing addresses and
connections for standard arc welding, universal (or general), spot welding, and
handling applications.
Drawing Number
Title
Sheet Number
M4AS1C2
Arc Welding App, Slot 1
1
M4AS1C1
Arc Welding App, Slot 1
1
M4AS2C2
Arc Welding App, Slot 2
1
M4AS2C1
Arc Welding App, Slot 2
1
M4US1C2
Universal App, Slot 1
1
M4US1C1
Universal App, Slot 1
1
M4US2C2
Universal App, Slot 2
1
M4US2C1
Universal App, Slot 2
1
M4SWS1C2
Spot Welding App, Slot 1
1
M4SWS1C1
Spot Welding App, Slot 1
1
M4SWS2C2
Spot Welding App, Slot 2
1
M4SWS2C1
Spot Welding App, Slot 2
1
M4HS1C2
Handling App, Slot 1
1
M4HS1C1
Handling App, Slot 1
1
M4HS2C2
Handling App, Slot 2
1
M4HS2C1
Handling App, Slot 2
1
MRC I/O Structure Manual
Appendix A
MOTOMAN
INDEX
C
Connection Diagram Using the Shock Sensor for E-Stop Condition, 11
Customer Service Information, 4
D
Dedicated I/O, 5
E
Example of Addressing for an ArcWorld Product With One Additional Board, 23
Example of Addressing With All I/O Slots Filled, 22
External Emergency Stop Input, 6
External Emergency Stop Input Connection, 6
External Hold Input, 8
External Hold Input Connection, 8
H
How to Place Jumpers on Pins for Shock Sensor Input, 12
I
I/O Rack Location, 3
Input Conditions, 13
Input Connection on MIO01 Board, 17
Input Connection on MIO02 Board, 18
Input Connection on MIO04 Board, 14
Input Connections, 13
Input Connections on MIO03 Board in Sinking and Sourcing Configurations, 14
Inputs for Arc Welding Using Two MIO04 Boards, 25
Inputs for General or Universal Applications Using Two MIO04 Boards, 27
Inputs for Material Handling Using Two MIO04 Boards, 31
Inputs for Spot Welding Using Two MIO04 Boards, 29
Introduction, 1
L
MRC I/O Structure Manual
Index
MOTOMAN
Location of MRC I/O Boards, 3
Logical Relay Addresses, 20
MRC I/O Structure Manual
Index
MOTOMAN
M
MARIO and MIF05 Boards, 2
MEW01 and MEWO2 Boards, 2
MIO01 and MIO02 Boards, 1
MIO01 and MIO02 Boards, 17
MIO03 AND MIO04 Boards, 13
MIO03 Board, 2
MIO03 Output Relays, 15
MIO04 Board, 2
MIO04 or MIO03 Board Output With DC Relay Coil, 16
MIO04 Output Relays, 15
MRC I/O ALlocation And Configuration, 20
MRC I/O Assignments by Application, 24
MRC I/O Block Diagrams, A-1
MRC I/O by Motoman Application, 2
MRY01 Board, 1
O
Output Connection on MIO01 Board, 18
Output Connection on MIO02 Board, 19
Output Connections, 16
Output Relay Description, 15
Outputs for Arc Welding Using Two MIO04 Boards, 26
Outputs for General or Universal Applications Using Two MIO04 Boards, 28
Outputs for Material Handling Using Two MIO04 Boards, 32
Outputs for Spot Welding Using Two MIO04 Boards, 30
P
Power Supply, 4
R
Reference to Other Documentation, 4
Relay Outputs, 15
Remote Mode Select Input, 9
Remote Mode Select Input Connection on an MIO04 Board, 9
Rules and Limitations, 21
MRC I/O Structure Manual
Index
MOTOMAN
S
Servo On Input, 7
Servo On Input Connection, 7
Servo On Output, 10
Servo On Output Connection on an MIO04 Board, 10
Setting Up Input and Output Addresses, 20
Shock Sensor Input, 11
T
Transistor Inputs, 13, 17
Transistor Outputs, 18
MRC I/O Structure Manual
Index
MOTOMAN