Motoman XRC User manual

Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: [phone]
FAX: [phone]
24-Hour Service Hotline: [phone]
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Part Number: 148148-1CD
Revision: 0

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.
©2003 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

TABLE OF CONTENTS
MOTO MAN i Fieldbus (XFB01) Instruction Manual
Section Page
1 INTRODUCTION
1.1 About this Document .................................................................................................... 1-1
1.2 Reference to Other Documentation................................................................................ 1-1
1.3 Customer Service Information....................................................................................... 1-1
2 SAFETY
2.1 Introduction .................................................................................................................. 2-1
2.2 Standard Conventions................................................................................................... 2-2
2.3 General Safeguarding Tips............................................................................................ 2-4
2.4 Mechanical Safety Devices............................................................................................ 2-4
2.5 Installation Safety.......................................................................................................... 2-5
2.6 Programming Safety ..................................................................................................... 2-5
2.7 Operation Safety............................................................................................................ 2-6
2.8 Maintenance Safety....................................................................................................... 2-7
3 OPTIONAL FUNCTION FIELDBUS INTERFACE BOARD XFB01
1 General ........................................................................................................................ 3-1
2 Installation.................................................................................................................. 3-7
3Configuration and Indicators........................................................................................3-9
4I/O Map...... ................................................................................................................ 3-13
5 InterBus-S...................................................................................................................3-17
6 Profibus-DP............................................................................................................... 3-21
7DeviceNet....................................................................................................................3-25

Fieldbus (XFB01) Instruction Manual ii MOTO MAN
NOTES

MOTO MAN 1-1 Fieldbus (XFB01) Instruction Manual
SECTION 1
INTRODUCTION
1.1 About this Document
This manual pro vides instructions for the Fieldb us Interf ace XFB01 Board
(AnyBus) and contains the following sections:
SECTION 1 – INTRODUCTION
General information about this manual, a list of reference documents, and
customer service information.
SECTION 2 – SAFETY
Provides information for the safe use and operation of Motoman products.
SECTION 3 – OPTIONAL FUNCTION FIELDBUS INTERFACE BOARD (XFB01)
Provides detailed instructions to operate the Fieldbus Interface XFB01 Board.
1.2 Reference to Other Documentation
For additional information refer to the following:
• Concurrent I/O Parameters Manual for XRC 2001 (P/N 147626-1)
• Operator’s Manual for General Purpose (P/N 142099-1)
• Operator’s Manual for Handling (P/N 142100-1)
• Operator’s Manual for Spot Welding (P/N 142101-1)
• Operator’s Manual for Arc Welding (P/N 142098-1)
• Motoman UP6, XRC 2001 Manipulator Manual (P/N 145960-1)
• Motoman UP20, XRC 2001 Manipulator Manual (P/N 145965-1)
• Motoman UP50, XRC 2001 Manipulator Manual (P/N 145964-1)
• Motoman UP130/165, XRC 2001 Manipulator Manual (P/N 145967-1)
1.3 Customer Service Information
If you are in need of technical assistance, contact the Motoman service staff at
[phone]. Please have the following information ready before you call:
• Robot Type (UP6, UP130, UP165, etc.)
• Application Type (welding, handling, etc.)
• Robot Serial Number (located on the back side of the robot arm)
• Robot Sales Order Number (located on back side of XRC controller)

INTRODUCTION
Fieldbus (XFB01) Instruction Manual 1-2 MOTO MAN
NOTES

MOTO MAN 2-1 Fieldbus (XFB01) Instruction Manual
SECTION 2
SAFETY
2.1 Introduction
.
We suggest that you obtain and re view a cop y of the ANSI/RIA National Safety
Standard for Industrial Robots and Robot Systems. This information can be
obtained from the Robotic Industries Association by requesting ANSI/RIA
R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: [phone]
FAX: [phone]
Ultimately, the best safe guard is trained personnel. The user is responsible for
providing personnel who are adequately trained to operate, program, and maintain
the robot cell. The robot must not be operated by personnel who have not been
trained!
We recommend that all personnel who intend to operate, program, repair , or use
the robot system be trained in an appro ved Motoman training course and become
familiar with the proper operation of the system.
This safety section addresses the following:
• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming Safety (Section 2.6)
• Operation Safety (Section 2.7)
• Maintenance Safety (Section 2.8)
It is the purchaser's responsibility to ensure that all local, county,
state, and national codes, regulations, rules, or laws relating to
safety and safe operating conditions for each installation are met
and followed.

SAFETY
Fieldbus (XFB01) Instruction Manual 2-2 MOTO MAN
2.2 Standard Conventions
This manual includes information essential to the safety of personnel and
equipment. As you read through this manual, be alert to the four signal words:
• DANGER
• WARNING
• CAUTION
•NOTE
Pay particular attention to the information pro vided under these headings which
are defined bel w (in descending order of severity).
DANGER!
Information appearing under the DANGER caption concerns the
protection of personnel from the immediate and imminent hazards
that, if not avoided, will result in immediate, serious personal injury
or loss of life in addition to equipment damage.
WARNING!
Information appearing under the WARNING caption concerns the
protection of personnel and equipment from potential hazards that
can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing under the CAUTION caption concerns the
protection of personnel and equipment, software, and data from
hazards that can result in minor personal injury or equipment
damage.
NOTE: Information appearing in a NOTE caption provides additional information which is helpful in
understanding the item being explained.

SAFETY
MOTO MAN 2-3 Fieldbus (XFB01) Instruction Manual
2.3 General Safeguarding Tips
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and an yone w orking near the robot must become f amiliar with the
operation of this equipment. All personnel in volved with the operation of the
equipment must understand potential dangers of operation. General safe guarding
tips are as follows:
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
should be permitted to operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made
within the standard v oltage and current ratings of the robot I/O (Inputs and
Outputs).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use
lockout/tagout procedures during equipment maintenance. Refer also to
Section 1910.147 (29CFR, P art 1910), Occupational Safety and Health
Standards for General Industry (OSHA).
2.4 Mechanical Safety Devices
The safe operation of the robot, positioner , auxiliary equipment, and system is
ultimately the user's responsibility . The conditions under which the equipment
will be operated safely should be reviewed by the user. The user must be aware of
the v arious national codes, ANSI/RIA R15.06 safety standards, and other local
codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following safety
measures are available:
• Safety fences and barriers
• Light curtains
• Door interlocks
• Safety mats
• Floor markings
• Warning lights
Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.

SAFETY
Fieldbus (XFB01) Instruction Manual 2-4 MOTO MAN
2.5 Installation Safety
Safe installation is essential for protection of people and equipment. The
following suggestions are intended to supplement, but not replace, existing federal,
local, and state laws and regulations. Additional safety measures for personnel and
equipment may be required depending on system installation, operation, and/or
location. Installation tips are as follows:
• Be sure that only qualified personnel amiliar with national codes, local
codes, and ANSI/RIA R15.06 safety standards are permitted to install the
equipment.
• Identify the w ork en velope of each robot with floor markings, signs, an
barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry
into the work envelope.
• Eliminate areas where personnel might get trapped between a mo ving robot
and other equipment (pinch points).
• Provide suf ficient room inside the orkcell to permit safe teaching and
maintenance procedures.
2.6 Programming Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and an yone w orking near the robot must become f amiliar with the
operation of this equipment. All personnel in volved with the operation of the
equipment must understand potential dangers of operation. Programming tips are
as follows:
• Any modifications of the controller PLC can cause s vere personal injury or
death, as well as damage to the robot! Do not make any modifications to th
PLC. Making any changes without the written permission of Motoman will
VOID YOUR WARRANTY!
• Some operations require standard passw ords and some require special
passwords. Special passw ords are for Motoman use only . YOUR
WARRANTY WILL BE VOID if you use these special passwords.
• Back up all programs and jobs onto a flop y disk whenever program changes
are made. To avoid loss of information, programs, or jobs, a backup must
always be made before an y service procedures are done and before an y
changes are made to options, accessories, or equipment.
• The concurrent I/O (Input and Output) function allo ws the customer to
modify the internal ladder inputs and outputs for maximum robot
performance. Great care must be tak en when making these modifications
Double-check all modifications under very mode of robot operation to
ensure that you ha ve not created hazards or dangerous situations that may
damage the robot or other parts of the system.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel f amiliar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.

SAFETY
MOTO MAN 2-5 Fieldbus (XFB01) Instruction Manual
• Inspect the robot and w ork en velope to be sure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place.
• Check the E-ST OP button on the teach pendant for proper operation before
programming.
• Carry the teach pendant with you when you enter the workcell.
• Be sure that only the person holding the teach pendant enters the workcell.
• Test any new or modified program at l w speed for at least one full cycle.
2.7 Operation Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and an yone w orking near the robot must become f amiliar with the
operation of this equipment. All personnel in volved with the operation of the
equipment must understand potential dangers of operation. Operation tips are as
follows:
• Be sure that only trained personnel f amiliar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
are permitted to operate this robot system.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Inspect the robot and w ork en velope to ensure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Ensure that all safeguards are in place.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel f amiliar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the cell.
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• This equipment has multiple sources of electrical supply . Electrical
interconnections are made between the controller , e xternal serv o box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections
• All modifications made to the controller will change the ay the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder, and I/O (Input and Output)
modifications. Check and test all changes at sl w speed.

SAFETY
Fieldbus (XFB01) Instruction Manual 2-6 MOTO MAN
2.8 Maintenance Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and an yone w orking near the robot must become f amiliar with the
operation of this equipment. All personnel in volved with the operation of the
equipment must understand potential dangers of operation. Maintenance tips are
as follows:
• Do not perform an y maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel f amiliar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
• Back up all your programs and jobs onto a flop y disk whene ver program
changes are made. A backup must al ways be made before an y servicing or
changes are made to options, accessories, or equipment to a void loss of
information, programs, or jobs.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the cell.
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• Be sure all safeguards are in place.
• Use proper replacement parts.
• This equipment has multiple sources of electrical supply . Electrical
interconnections are made between the controller , e xternal serv o box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections
• All modifications made to the controller will change the ay the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder , and I/O (Input and
Output) modifications. Check and test all changes at sl w speed.
• Improper connections can damage the robot. All connections must be made
within the standard v oltage and current ratings of the robot I/O (Inputs and
Outputs).

MOTOMAN
MOTOMAN ROBOTICS EUROPE
A subsidiary of YASKAWA Electric Corporation
MOTOMAN XRC
OPTIONAL FUNCTION
Fieldbus Interface Board
Upon receipt of the product and prior to initial operation, read these instructions thoroughly,
and retain for future reference.
MANUAL NO. MRS50250

MOTOMAN ROBOTICS EUROPE
Reference list
Operator’s manual Basic programming
Maintenance manual MOTOMAN XRC
......
Revision
990920
First release of this manual (Preliminary)
010309
Correcting of DeviceNet / DT-module setting.
010314
Correcting of DeviceNet / DT-module baudrate setting

Created: 99-09-20 Revised: 01-03-09 Doc. name: MRS50250TOC.fm
Fieldbus Interface Board Page: I
MOTOMAN ROBOTICS EUROPE
1. General .................................................................1
About this manual 1
Fieldbus interface kit comprises 1
Safety 2
Manufacturer 2
Introduction 3
Terms 3
Fieldbus systems 3
AnyBus® 4
Introduction to the Fieldbus Interface Board 4
Hardware comparability 5
2. Installation ............................................................7
3. Configurations and indications .............................9
Interface board overview 9
Configurations 10
❏ I/O size configuration SW2 10
❏ Operation and set-up configuration S1 10
❏ Master configurations 11
Indications 11
❏ Power LED 11
❏ Status indication LED 11
❏ Fieldbus status indications 11
AnyBus module interface 12
❏ AnyBus 64 I/O and 32 I/O modules 12
❏ AnyBus DataTransfer modules 12
4. I/O map ...............................................................13
Fieldbus input data map 13
Fieldbus output data map 14
Module and network status 15
5. InterBus-S ...........................................................17
General 17
❏ Specifications 17
❏ Features supported by AnyBus-module 17
I/O-modules 18
❏ Indicator 18
❏ Terminating last module 18
DT-module 19
❏ Features 19
❏ Indicator 19
❏ Terminating last module 19
6. Profibus-DP ........................................................21
General 21
❏ Specifications 21
❏ Features supported by AnyBus module 21
I/O-modules 22
❏ Indicator 22
❏ Setting up the module 22

Fieldbus Interface Board
Page: II MOTOMAN ROBOTICS EUROPE
Created: 99-09-20 Revised: 01-03-09 Doc. name: MRS50250TOC.fm
❏ Baudrate 22
❏ Terminating last module 22
DT-module 23
❏ Features 23
❏ Indicator 23
❏ Setting up the module 23
❏ Baudrate 23
❏ Terminating last module 23
7. DeviceNet ...........................................................25
General 25
❏ Specifications 25
❏ Features supported by AnyBus module 25
I/O-modules 25
❏ Indicators 25
❏ Terminate module 25
❏ Setting up the module 26
❏ Address setting 26
❏ Baudrate 26
❏ Fieldbus connector BUS 26
DT-modules 27
❏ Features 27
❏ Indicators 27
❏ Terminate module 27
❏ Setting up the module 27
❏ Address setting 28
❏ Baudrate 28
❏ Fieldbus connector BUS 28

Created: 99-04-30 Revised: 99-09-20 Doc. name: MRS50250-ch1.fm
Fieldbus Interface Board Page: 1
About this manual
MOTOMAN ROBOTICS EUROPE
Fieldbus interface Board
1. General
1.1 About this manual
This Instruction manual comprises information about:
✔ Installation
✔ Setup
This documents may not be copied without our written permission and the con-
tents thereof must not be imparted to a third party nor be used for any unauthor-
ized purpose.
The Fieldbus board is valid for both MOTOMAN XRC (Hereafter called XRC).
Text written in BOLD letters means command or button.
Text written in ITALIC means text shown on display.
1.2 Fieldbus interface kit comprises
✔ One Carrier board JANCD-MFB01
✔ One AnyBus®module
✔ One data disk for setup (not necessary for all types)
Bus type Fieldbus kit, Motoman Part No.
32 I/O 64 I/O DT
Interbus-S 347069-81 347069-82 347069-83
Profibus DP 347070-81 347070-82 347070-83
DeviceNet 347071-81 347071-82 347071-83

Fieldbus Interface Board
Page: 2
Safety
MOTOMAN ROBOTICS EUROPE
Created: 99-04-30 Revised: 99-09-20 Doc. name: MRS50250-ch1.fm
1.3 Safety
This equipment is constructed, produced and tested according to the
laws of the Member States relating to machinery (98/37/EEC), the
demands of the EMC-directives (89/336/EEC) and (93/68/EEC) and
also the LVD-directives (73/23/EEC).
Motoman Robotics Europe AB’s responsibility does not cover errors
or safety risks that may occur in equipment connected to the Moto-
man Robotics Europe AB machine, nor errors or safety risks that may
occur in the machine caused by equipment connected to the Moto-
man Robotics Europe AB’s machine.
External cables must be connected according to our cable connec-
tion guide, see separate document.
1.4 Manufacturer
Address Motoman Robotics Europe AB
Box 504
385 25 Torsås
Sweden
Telephone: [phone]
Telefax: [phone]
Type: JANCD-MFB01

Created: 99-04-30 Revised: 99-09-20 Doc. name: MRS50250-ch1.fm
Fieldbus Interface Board Page: 3
Introduction
MOTOMAN ROBOTICS EUROPE
1.5 Introduction
The purpose of this document is to provide instructions for users of the MOTO-
MAN Fieldbus Interface Board (hereafter referred to FBIB). This document is to
provide support for configuration and usage of the FBIB. For information regard-
ing fieldbus configuration and programming please refer to the AnyBus manuals
or contact the supplier of the fieldbus master/scanner system.
This document is limited to the functionality of the FBIB and the connections to
the MOTOMAN Robot Controller (hereafter referred to as XRC) and the fieldbus
system via standard AnyBus modules. It is assumed that the reader has an
understanding of the functionality of the XRC.
1.6 Terms
Throughout this document the term “user“ refers to the person or persons who are
installing and programming the XRC system with an FBIB installed. The end-user
of the robot equipment will be referred to as the customer.
As in all communication systems the terms “inputs“ and “outputs“ can be ambigu-
ous, because their meaning depends on which end of the link that is being refer-
enced. The convention in this document is that “inputs“ and “outputs“ are always
being referenced from the XRC systems end of the link.
1.7 Fieldbus systems
Instead of using traditional wiring to distribute input and output signals, the auto-
mation industry more frequently relays on computer communications. By using
communication systems cost for material, installation, documentation and mainte-
nance can be greatly reduced. The communication system can also be used for
more advanced features like connecting different control systems and to distribute
the control functions to intelligent sub-systems, sensors and actuators.
The communication systems used for these tasks are commonly called a fieldbus
system. Fieldbus systems are used in all sectors of automation: Factory automa-
tion, manufacturing automation, assembly automation, building automation, proc-
ess automation, etc.
Fieldbus protocols are based on ISO Reference Model for Open System Intercon-
nection (OSI-RM), ISO 7498. However, Fieldbus uses only layers 1, 2, 7 of OSI-
RM, layer 3 through 6 are often bypassed for real-time purpose. There is also a
new User Layer added on top of the Application Layer, where distributed control
strategy is implemented and which makes Fieldbus much more than a communi-
cation network.
Different systems are used because of different technical requirements of the
application. Those different requirements are different levels of bus systems, bus
structures, real-time behaviour, amount of data being transferred, transmission
media, distribution of power on the communication media. The difference
between the technical demands and the fact that no system on the market fulfils
all requirements has lead to a wide variety of different fieldbus systems.
A major problem is that many products need to be connected to many of the field-
bus systems on the market. The same product may have to be able to exchange
data over some or all the available fieldbus systems and by doing this fulfilling dif-
ferent of the above mentioned requirements depending on the fieldbus system.
One example are operator panels which must be able to connect on different lev-
els of industrial network systems. In most applications on sensor/actuator level, in
many applications on the process level but also on the factory network level.

Fieldbus Interface Board
Page: 4
AnyBus®
MOTOMAN ROBOTICS EUROPE
Created: 99-04-30 Revised: 99-09-20 Doc. name: MRS50250-ch1.fm
1.8 AnyBus®1
When developing a product with a fieldbus interface special considerations has to
be made to the communication system. This will most likely result in one product
version for each supported fieldbus.
The AnyBus product is a series of small fieldbus modules. There is one AnyBus
module for each fieldbus system. All electronics, software and control for the field-
bus is integrated on the module. All AnyBus modules uses the same standardised
product interface. Since all AnyBus modules supports the standardised interface
the modules can be interchanged with other AnyBus modules without having to
change the product design. This standardised interface provide a way to design a
product that supports all the major fieldbus systems in one and the same product
version. This means that the product does not have to handle the fieldbus charac-
teristics, all that is handled by the AnyBus module.
The AnyBus modules are designed to fit into applications with different complexity
levels. There are three different types of AnyBus modules depending on the
amount of data that has to be handled. There will be an AnyBus for all major field-
bus system and the customer does not have to consider any fieldbus specific
information, fieldbus dependent settings or installations for the design of an appli-
cation product.
✔ AnyBus 32 I/O. 16 digital inputs and 16 digital outputs
✔ AnyBus 64 I/O. 32 digital inputs and 32 digital outputs
✔ AnyBus DataTransfer. 0-480 input bytes and 0-480 output bytes
1.9 Introduction to the Fieldbus Interface Board
The FBIB is designed to make it possible to connect the XRC to the most com-
monly used fieldbus systems on the market. The FBIB controls the exchange of
data between the XRC and the AnyBus modules witch constitutes the fieldbus
interface.
To achieve a flexible solution the FBIB can be equipped with the following slave
modules within the AnyBus family.
✔ AnyBus 32 I/O module
✔ AnyBus 64 I/O module
✔ AnyBus DataTransfer module
The FBIB is also prepared to be equipped with AnyBus master modules.
1. AnyBus ® is a registered trade mark of HMS Fieldbus System AB, Halmstad, Sweden
Fig.1 AnyBus sytem
Application using the
AnyBus module to inter-
face the fieldbus system.
Fieldbus data and
events is transferred to/
from the application via
thestandardisedproduct
interface.
FieldbusProduct AnyBus module