MRC IO Structure
MRC IO Structure
MRC IO Structure
MOTOMAN
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West Carrollton, OH 45449
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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 Input Connections............................................................. 13
3.1.2 Input Conditions................................................................ 13
3.2 RELAY OUTPUTS............................................................................ 15
3.2.1 Output Relay Description................................................... 15
3.2.2 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
LIST OF FIGURES
Figure Page
Figure 1-1 Location of MRC I/O Boards ................................................................3
Figure 2-6 Connection Diagram Using the Shock Sensor for E-Stop Condition ..... 11
Figure 3-5 MIO04 or MIO03 Board Output With DC Relay Coil ......................... 16
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 5-5 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 robot-
specific 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.
For ArcWorld and FabWorld applications, the MRC controller typically has two
MIO04 boards and one MEW02 board.
Inside of
MRC Cabinet
00 01 02 03 04 05
MRY01 MIO04 MIO03 MEW02-1
CN2
TM1
Connector
TM1
CN2
CN2
CN2
Connector
CN1
Connector
CN1
CN1
CN1
➪ 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.
➪ 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
External E-STOP 1 External E-STOP 2
Term.14,15,16,
17, 24, or 25 +24 VU
EXESP
Terminal 23 EXESP
R
0 VU
+24 VU
MRC I/O Structure Manual Page 7 MOTOMAN
Figure 2-1 External Emergency Stop Input Connection
➪ CAUTION!
Improper connections can damage the robot. Before making
connections, check for proper voltages and currents.
MRY01 Board
+24 VU Servo On
Term. 14,15,16,
17, 24, or 25 +24 VU
EXSVON
Terminal 21 EXSVON
R
0 VU
➪ 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
External HOLD
Term. 14, 15, 16,
17, 24, or 25 +24 VU
EXHOLD
Terminal 22 EXHOLD
R
0 VU
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
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
Terminal
Servo On 2-A9
R
Output +
D1
Output
Common Terminal 2-A/B8
0V
24 VDC
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.
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.
Figure 2-6 Connection Diagram Using the Shock Sensor for E-Stop Condition
➪ 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
The inputs and outputs on both boards share the following characteristics:
Output type: 0.5 ampere, 24 volt DC, normally open, dry-relay contact for DC
voltage only
➪ 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.
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
24 VU
5 mA MAX
External External
Connections Connections
0 VU
0 VU
Figure 3-2 Input Connections on MIO03 Board in Sinking and Sourcing Configurations
0 V or 24 V
Output
Internal External
MIO04 Output
Connections
Output Output
Relays
Output
0 V or 24 V
Output
0 V or 24 V
Internal External
MIO03 Output
Connections
Output 0 V or 24 V
Relays
Output
0 V or 24 V
Output
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.
External Relay
Output +
R
24 VDC, 0.5 A MAX
D1
Output
Common
➪ 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.
➪ CAUTION!
Improper connections can damage the robot. Before making
connections, check for proper voltages and currents.
External Connection
0 VU
MIO02 Board 24 VU
5 mA MAX
External Connection
0 VU
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!
MIO01 Board
External Relay
Output
R 24 VDC MAX, 50 mA
D1
0 VU
MIO02 Board
24 VDC MAX, 50 mA
External Relay
Output
R
D1
0 VU
MIO04 Board
24 Inputs
24 Outputs
Slot 01
MIO04
MIO04 Board has 24 Inputs requiring MIO04 Board has 24 Outputs requiring
3 groups of logical relay addresses (24/8 = 3). 3 groups of logical relay addresses (24/8 = 3).
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
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
* The first 24 Inputs use The next 32 Inputs use The next 16 Inputs use
these ADDRESSES: these ADDRESSES: these ADDRESSES:
2010 - 2017 = 8 Inputs 2080 - 2087 = 8 Inputs 2150 - 2157 = 8 Inputs
2020 - 2027 = 8 Inputs 2090 - 2097 = 8 Inputs 2160 - 2167 = 8 Inputs
2030 - 2037 = 8 Inputs 2100 - 2107 = 8 Inputs Total = 16 Inputs
Total = 24 Inputs 2110 - 2117 = 8 Inputs
* The first 24 Outputs use Total = 32 Inputs
The next 16 Outputs use
these ADDRESSES: these ADDRESSES:
The next 32 Outputs use
3010 - 3017 = 8 Outputs 3150 - 3157 = 8 Outputs
these ADDRESSES:
3020 - 3027 = 8 Outputs 3160 - 3167 = 8 Outputs
3080 - 3087 = 8 Outputs
3030 - 3037 = 8 Outputs Total = 16 Outputs
3090 - 3097 = 8 Outputs
Total = 24 Outputs
3100 - 3107 = 8 Outputs
3110 - 3117 = 8 Outputs
Total = 32 Outputs
* The first 24 Inputs use The next 16 Inputs use An MEW0 Board in this
these ADDRESSES: these ADDRESSES: slot always uses these
2010 - 2017 = 8 Inputs 2070 - 2077 = 8 Inputs addresses:
2020 - 2027 = 8 Inputs 2080 - 2087 = 8 Inputs
2030 - 2037 = 8 Inputs Input ADDRESSES
Total = 16 Inputs
Total = 24 Inputs are 2170 - 2177
* The first 24 Outputs use The next 16 Outputs use Output ADDRESSES
these ADDRESSES: these ADDRESSES: are 3170 - 3177.
3010 - 3017 = 8 Outputs 3070 - 3077 = 8 Outputs
3020 - 3027 = 8 Outputs Input Addresses 2180 -
3080 - 3087 = 8 Outputs
3030 - 3037 = 8 Outputs 2187 and Output
Total = 16 Outputs
Total = 24 Outputs Addresses 3180 - 3187
are also reserved (see
Section 5.2.2).
Figure 5-3 Example of Addressing for an ArcWorld Product With One Additional Board
➪ 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.
Table 5-1 Inputs for Arc Welding Using Two MIO04 Boards
Table 5-3 Inputs for General or Universal Applications Using Two MIO04 Boards
Table 5-5 Inputs for Spot Welding Using Two MIO04 Boards
Table 5-7 Inputs for Material Handling Using Two MIO04 Boards
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
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
T
Transistor Inputs, 13, 17
Transistor Outputs, 18