Motoman NX100 Controller

DeviceNet PCI Card

Instructions Manual

Part Number: 151799-1CD

Revision: 0

Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
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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.

©2007 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.
 DeviceNet PCI Card
151799-1

Table of Contents

Chapter 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Reference to Other Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Customer Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Standard Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 General Safeguarding Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Mechanical Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Installation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Programming, Operation, and Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 3
Hardware Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Card Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1.1 Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1.2 Card Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Card Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.1 EDS FILE FOR SLAVE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 5
Network Configurations and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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Instructions Manual
Table of Contents

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Chapter 1

Introduction

This manual provides instructions for the Motoman DeviceNet PCI Interface cards (P/N 150216-1,
and 150217-1). The application of this board allows the transmission of NX100’s general-purpose I/O
data with other devices connected to DeviceNet.

DeviceNet™ is an open low-level network that provides connections between simple industrial
devices (such as sensors and actuators) and higher-level devices (such as robot controllers and
computers). The DeviceNet network uses the proven Common Industrial Protocol (CIP) to provide
the control, configure, and data collection capabilities for industrial devices. The DeviceNet network is
a flexible network that works with devices from multiple vendors.

1.1 System Configuration

The PCI DeviceNet interface cards interface with the NX100 controller, and do not require an I/O
expansion rack. The 150216-1 card has two channels, which allows the card to be configured
simultaneously as a Master and/or Slave interface. The 150217-1 single-channel card can be configured
either as a Master or Slave interface. Both cards are capable of addressing 64 words of input and output data,
(robot available I/O is dependent on controller application). Each channel can be configured at 125 k, 250 k,
or 500 k baud. Messaging type supported: Polled.

Final page 1
Instructions Manual
Chapter 1 Introduction

The following diagrams show sample DeviceNet PCI card trunk line configurations and are intended
for study purposes only. For more information on DeviceNet configurations, please contact the Open
DeviceNet Vendor Association, Inc. (ODVA) at www.odva.org.

DeviceNet PCI card trunk line configured as a Slave interface:

DeviceNet Master Communications

External PLC (sequencer) Power Supply NX100

DeviceNet PCI
Interface Card

Terminator 121
±1%‫ޓ‬1/4W‫ޓ‬Metal Film

DeviceNet Cable
DeviceNet Slave
I/O Unit

Terminator 121
±1%‫ޓ‬1/4W‫ޓ‬Metal Film

Note: DeviceNet cables and terminators are not provided. When the DeviceNet PCI card is connected
at the end of a network, connect a terminator externally. Incorrect connections of the terminators may
result in improper communications. Power line and external power supply not shown.

DeviceNet PCI card trunk line configured as a Master interface:

Communications
NX100 Power Supply

DeviceNet PCI
Interface Card
DeviceNet Slave
I/O Unit

DeviceNet Cable DeviceNet Slave

I/O Unit

Terminator 121 Terminator 121

±1%‫ޓ‬1/4W‫ޓ‬Metal Film ±1%‫ޓ‬1/4W‫ޓ‬Metal Film

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1.2 About This Document

This manual provides system information for the DeviceNet PCI interface cards and contains the
following sections:
SECTION 1 - INTRODUCTION
Provides general information about the structure of this manual, a list of reference documents, and
customer service information.
SECTION 2 - SAFETY
This section provides information regarding the safe use and operation of Motoman products.
SECTION 3 - DEVICENET PCI CARD INSTRUCTIONS
Provides detailed instructions for DeviceNet PCI Card, including installation, specifications, and
operation.

1.3 Reference to Other Documentation

For additional information refer to the following:

• NX100 Controller Manual (P/N 149201-1)
• Concurrent I/O Manual (P/N 149230-1)
• Operator’s Manual for your application
• Vendor manuals for system components not manufactured by Motoman

1.4 Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200. Please
have the following information ready before you call:
• Product (DeviceNet PCI Card serial number)
• Robot Type (EA1900N, HP5, etc.)
• Application Type (arcwelding, spot welding, handling, general)
• Robot Serial Number (located on back side of robot arm)
• Robot Sales Order Number (located on back of controller)

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Instructions Manual
Chapter 1 Introduction

NOTES

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Chapter 2

Safety

2.1 Introduction

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.

We suggest that you obtain and review a copy 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 R15.06-1999. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
INTERNET: www.roboticsonline.com

Ultimately, the best safeguard 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 approved Motoman training course and become familiar with the proper operation of the
system.

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Instructions Manual
Chapter 2 Safety

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, Operation, and Maintenance Safety (Section 2.6)

2.2 Standard Conventions

This manual includes the following alerts – in descending order of severity – that are essential to the
safety of personnel and equipment. As you read this manual, pay close attention to these alerts to
insure safety when installing, operating, programming, and maintaining this equipment.

DANGER!
Information appearing in a DANGER 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 in a WARNING 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 in a CAUTION 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 provides additional information which is helpful in understanding the item being
explained.

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2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and
anyone working near the robot must become familiar with the operation of this equipment. All
personnel involved with the operation of the equipment must understand potential dangers of
operation. General safeguarding 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 voltage 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 R15.06-1999, section 4.2.5, Sources of Energy, use
lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147
(29CFR, Part 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 various national codes, ANSI/RIA R15.06-1999 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 equipment is provided as standard:
• Safety fences and barriers
• Light curtains and/or safety mats
• Door interlocks
• Emergency stop palm buttons located on operator station, robot controller, and
programming pendant

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning
safety equipment immediately.

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Instructions Manual
Chapter 2 Safety

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 familiar with national codes, local codes, and
ANSI/RIA R15.06-1999 safety standards are permitted to install the equipment.
• Identify the work envelope of each robot with floor markings, signs, and 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 moving robot and other
equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and maintenance
procedures.

2.6 Programming, Operation, and Maintenance Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and
anyone working near the robot must become familiar with the operation of this equipment. Improper
operation can result in personal injury and/or damage to the equipment. Only trained personnel
familiar with the operation, manuals, electrical design, and equipment interconnections of this robot
should be permitted to program, operate, and maintain the system. All personnel involved with the
operation of the equipment must understand potential dangers of operation.
• Inspect the robot and work envelope 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 all safety equipment for proper operation.
Repair or replace any non-functioning safety equipment immediately.
• Do not enter the robot cell while it is in automatic operation. Be sure that only the person
holding the programming pendant enters the workcell.
• Check the E-STOP button on the programming pendant for proper operation before
programming. The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• Back up all programs and jobs onto suitable media before program changes are made. To
avoid loss of information, programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to options, accessories, or
equipment.

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• Any modifications to PART 1, System Section, of the robot controller concurrent I/O
program can cause severe personal injury or death, as well as damage to the robot! Do not
make any modifications to PART 1, System Section. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require special passwords. Special
passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use
these special passwords.
• The robot controller allows modifications of PART 2, User Section, of the concurrent I/O
program and modifications to controller parameters for maximum robot performance. Great
care must be taken when making these modifications. All modifications made to the
controller will change the way the robot operates and can cause severe personal injury or
death, as well as damage the robot and other parts of the system. Double-check all
modifications under every mode of robot operation to ensure that you have not created
hazards or dangerous situations.
• Check and test any new or modified program at low speed for at least one full cycle.
• This equipment has multiple sources of electrical supply. Electrical interconnections are
made between the controller and other equipment. Disconnect and lockout/tagout all
electrical circuits before making any modifications or connections.
• Do not perform any maintenance procedures before reading and understanding the proper
procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).

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Chapter 2 Safety

NOTES

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Chapter 3

Hardware Specifications

When the card is configured in the controller, the first byte of data from each channel is a status byte.
The information defined in each byte is outlined in the chart below:

Signal Description

2xxx0 2xxx3 (bit 0 to 3) Reserved

2xxx4 (bit 4) Not used, always set to zero

2xxx5 (bit 5) In Slave mode

Not used, always set to zero

In Master mode
0: Communication to all slave nodes normal
1: Communication error to slave node(s)

2xxx6 (bit 6) DeviceNet Communication Status

0: Normal, 1: Error

2xxx7 (bit 7) DeviceNet board status

0: Normal, 1: Error

Note: Not all PLC systems are capable of passing 64 words of data. Consult the PLC owner’s manual to
determine system maximum I/O capability.

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Chapter 3 Hardware Specifications

3.1 Card Components

Legend
1- and 2-channel
2-channel only

CHANNEL A COMM LED

CHANNEL B HLTH LED

CHANNEL A HLTH LED CHANNEL B COMM LED

CHANNEL A CAN CHANNEL B CAN

CONNECTOR CONNECTOR

The 5-pin connector is a standard removable connector that conforms to the standard DeviceNet
pinout. Pin numbers, names and color codes are identified in the figure below.

1 2 3 4 5

Pin Name: DeviceNet™

Color Code:

V+ Red

CANH White

SHIELD Bare

CANL Blue

V- Black

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There are two LEDs per channel: Health (HLTH) and Communications (COMM).

CHANNEL A CHANNEL A
COMM LED COMM LED

CHANNEL A CHANNEL B
HLTH LED HLTH LED

CHANNEL A CHANNEL B

The HLTH LED indicates the channel’s health status. The HLTH LED’s behavior is described in the
following table.

Color Status

Off Card Initialization failed or the card is not powered.

Green The firmware is loaded and running.

Red The card has not loaded, an error occurred during the load or there
is a firmware run-time error.

Amber Startup self-test complete; no firmware loaded. The firmware must

be reloaded.

The COMM LED indicates the network’s health status. The COMM LED’s behavior is described in
the following table.

Color Status

Green Established Connection

Flashing Green Ready for Connection

Flashing Red Connection Time-Out

Red Connection Not Possible

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Chapter 3 Hardware Specifications

NOTES

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Chapter 4

Installation

The following procedures outline how to configure the two channel DeviceNet card (P/N 150216-1)
with Channel 1 in a Slave configuration, and Channel 2 in a Master configuration. Configuration of the
single channel card (P/N 150217-1) can be accomplished in a similar method.
The settings below should only be used if the end-user has not specified the card configuration.

4.1 Materials
• Two Channel DeviceNet Card (P/N 150216-1)
• Single Channel DeviceNet Card (P/N 150217-1)

- Includes DeviceNet Card and SST User Manual on CD

4.1.1 Board Settings

No board settings are required.

4.1.2 Card Installation

DANGER!
Remove all power from the controller before installing the DeviceNet PCI Card! Failure to remove
power may result in injury or death!

WARNING!
Follow all Electrical Static Discharge procedures, including use of anti-static straps, to avoid
damage to the board. Never touch the mounting surfaces of the board parts directly with fingers.

1. Remove PCI card from static shielding bag.

2. Insert card in the NX100's CPU rack slot: CPU OPTION 1.
3. Secure card with M3 x 10 screw.

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Instructions Manual
Chapter 4 Installation

4.2 Card Configuration

The NX100 controller must be properly configured to use the DeviceNet PCI Card. The following
modifications require the user to be in Maintenance Mode with Management Mode selected. Make
certain DeviceNet PCI card is correctly mounted inside NX100 controller and NX100 main power
supply is OFF before proceeding.
1. Turn ON main power to NX100 while simultaneously pressing the Main Menu button on the
programming pendant. The Main Menu appears.
2. From the Main Menu select System > Security.

3. Select Management Mode.

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4. Enter password 999999.

5. Select System > Setup.

6. Select Option Board.

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Chapter 4 Installation

7. Board should be identified in slot CP02#1. Select card.

8. CH1 and CH2 should be displayed. Select CH1.

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9. Configure Slave Channel as follows:

a. Change SST-DN3_PCI-2(CH1) from UNUSED TO USED.

b. At SLAVE OR MASTER select SLAVE.
c. Set IO SIZE to 2 (number of bytes to be transferred).
d. Set MAC ID to 13 (device’s network ID#).
e. Set BAUD RATE to 500 ((125, 250, 500) must match master setting).
f. SCAN LIST not used in slave device.
g. Press Enter to return to previous menu.
10. Configure Master Channel as follows:

a. Change SST-DN3_PCI-2(CH2) from UNUSED TO USED

b. At SLAVE OR MASTER select Master
c. Set IO SIZE to 10 (number of bytes to be transferred).
d. Set MAC ID to 0 (Since this channel is Master of the network)
e. Set BAUD RATE to 500 (125, 250, or 500)
f. Select SCAN LIST. The SCAN LIST screen appears.

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Chapter 4 Installation

g. Scroll to desired MAC ID address.

h. Arrow over to IN/OUT column and press Select.
i. Enter device size for IN/OUT.
j. Select TYPE.

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k. When all devices have been added to the list, Press Enter. The Modify prompt appears.

l. Select YES and press Enter.

m. Select YES again and press Enter.

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Chapter 4 Installation

11. I/O MODULE MENU

a. I/O Module menu appears below.
b. I/O should equal (2)Status Bytes + Slave I/0 + Master I/O
c. Press Enter ->YES -> Enter

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4.2.1 EDS FILE FOR SLAVE MODE

When the card is setup for the master mode as described above, EDS files are not required for each
slave device. However the user must know how much I/O is consumed by each device. If the board is
setup for slave mode and a PLC is the master, a high level network setup software will probably be
used (RSNetworx™), which will require an EDS file for each slave device.

Note: Generic EDS files have been supplied with the DeviceNet PCI card.

Without the card connected to a network, complete validation of the card is not possible. However,
card health can be determined by verifying that LED1 and LED2 are green.

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Chapter 4 Installation

NOTES

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Chapter 5

Network Configurations and

Connections

For information on network configurations and connections for DeviceNet communications, please
refer to the ODVA Planning and Installation Manual DeviceNet™ Cable System (PUB00027R1)
located at www.odva.org.

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Instructions Manual
Chapter 5 Network Configurations and Connections

Notes

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Index

B I
Board Settings 15 Installation 15
C Installation Safety 8
Components 12 Introduction 1
Configuration 16 M
Customer Service 3 Mechanical Safety Devices 7
D N
Documentation 3 Network Configurations 25
E P
EDS FILE 23 Programming, Operation, and Maintenance Safety 8
G S
General Safeguarding Tips 7 Safety 5
H Specifications 11
Hardware 11 Standard Conventions 6
System Configuration 1

Final