System Parameters

3 Topic: IO Signals
The following parameters are found under the topic IO Signals:

- Specification of all I/O units

- Name and characteristics of input and output signals
- Groups of digital signals
- Cross connections
- List of all available unit types
- System signals
• Choose Topics: IO Signals.

3.1 Defining I/O Units

• Choose Topics: IO Signals

• Choose Types: IO Units.

All defined units will be displayed, as shown in Figure 5.

Figure 5 System parameters of the type IO Units.

• Select the appropriate I/O unit to be changed and press Enter , or add a new one
by pressing Add.
• Select the desired parameter and change its value.
• Press OK to confirm.

To delete a unit

• Select the appropriate unit.

• Press .

All the signals on this unit will remain defined. These must be deleted separately.

User’s Guide 12-9

System Parameters

Parameter Description
Unit Name The name of the unit (max. 16 characters).
Unit Type Unit type (see also 3.2 below).
Compare with the designation on the cover of the unit.
Unit type eip000 is used for simulated digital and analog
signals. This simulated unit can handle up to 100 digital inputs,
100 digital outputs, 30 analog inputs and 30 analog outputs.
For more information about the selected unit type press the
function key Info.
Unit Bus The bus on which the unit is located, normally BASE, except
for simulated units which are located on the SIM bus.
Address The address of the BASE unit on the bus according to the
physical keying, see Product Manual - Installation and
Commissioning.
Digital Outputs The number of digital output signals to be used.
Digital Inputs The number of digital input signals to be used.
Analog Inputs The number of analog input signals to be used.
Analog Outputs The number of analog output signals to be used.
PollRate Some units needs to be polled to update input and output
signals. The parameter specifies the time between two
consecutive polls.
NOTE. All units produced by ABB Robotics Products, except
the Allen-Bradley Remote I/O adapter, are event driven. With
these units the polling mechanism is used as heart-beat only. It
is recommended to use the default poll rate, 1 second, with
these units (10 ms to10 s, resolution 10 ms).
Disabled Specifies that the I/O unit will not be present on the bus at start
up.

3.2 Additional parameters for field bus units

Allen-Bradley Remote I/O adapter DSQC 350 (Unit Type = d350)

Parameter Description

Rack Address The rack address is entered in decimal form while Allen-
Bradley use octal (0-7). Valid values are from 0 to 63 (Allen-
Bradley 0-77). Note that the Allen-Bradley PLC series 2/30
starts from octal address 1.
Data Rate The data rate on the RIO Bus.
Valid values are: 57.6 KBaud.
115.2 KBaud.
230.4 KBaud.
Starting Quarter The DSQC 350 starting quarter.
Valid values are:First PLC value 0
Second 2

12-10 User’s Guide

 System Parameters

Third 4
Fourth 6
Rack Size The DSQC 350 rack size.
Valid values are:1/4 rack32 out, 32+2 in1
1/2 rack 64 out, 64+2 in1
3/4 rack 96 out, 96+2 in1
full rack 128 out, 128+2 in1
Last Rack Determines whether the DSQC 350 is the last rack on the RIO
Bus.
Valid values are: No
Yes

Interbus-S slave adapter DSQC 351 (Unit Type = d351)

Parameter Description
Data Width The data width determines the number of I/O signals. The valid
values are:
1 word = 16 out, 16+1 in2
2 words = 32 out, 32+1 in2
3 words = 48 out, 48+1 in2
4 words = 64 out, 64+1 in2

Profibus-DP slave DSQC 352 (Unit Type = d352)

Parameter Description
Master Input Size The master input size determines the number of digital
output signals. The valid values are:
0 word = 0 out 0 bytes output, no consistency
1 word = 16 out 2 bytes output, no consistency
2 words = 32 out 4 bytes output, no consistency
3 words = 48 out 6 bytes output, no consistency
4 words = 64 out 8 bytes output, no consistency
5 words = 80 out 10 bytes output, no consistency
6 words = 96 out 12 bytes output, no consistency
7 words = 112 out 14 bytes output, no consistency
8 words = 128 out 16 bytes output, no consistency
Master Output Size The master output size determines the number of digital
input signals. The valid values are:
0 word = 0+1 in 0 bytes input, no consistency
1 word = 16+1 in 2 bytes input, no consistency
2 words = 32+1 in 4 bytes input, no consistency
3 words = 48+1 in 6 bytes input, no consistency
4 words = 64+1 in 8 bytes input, no consistency
5 words = 80+1 in 10 bytes input, no consistency

1. Input numbers 33, 65, 97 or 129 respectively, correspond to NAC status LED flashing (high at RIO link
particularly up, i.e. PLC in programming mode)
Input numbers 34, 66, 98 or 130 respectively, correspond to NAC status LED steadily lit (high at RIO link up)
2. Input numbers 17, 33, 49 or 65 respectively, correspond to Interbus-S status LED BA steadily lit (Bus
Active)
User’s Guide 12-11
System Parameters

6 words = 96+1 in 12 bytes input, no consistency

7 words = 112+1 in 14 bytes input, no consistency
8 words = 128+1 in 16 bytes input, no consistency
Station Address The Profibus node address entered in decimal form. Valid
values are from 2 to 126. 126 is reserved for uninitialised
nodes.

To configure the Profibus master use the GSD-file supplied on the diskette Controller
Parameters, file SERVICE\GSD\ABB_0600.GSD. The modules to be chosen depends
on the I/O definition.

Note When working with Profibus master configuration tools, i.e. COM PROFI-
BUS, which calculates the configuration bytes for the modules itself, it is important to
be aware that the input and output modules for the DSQC352 are byte oriented instead
of word oriented.

3.3 Defining input and output signals

• Choose Topics: IO Signals.

• Choose Types: User Signals.

All named signals will be displayed (see Figure 6).

Figure 6 System parameters of the type User Signals.

Note that several signals can be connected to the same physical channel. The same sig-
nals cannot, however, be connected to different physical channels.

• Select the signal to be changed and press Enter , or add a new one by pressing
Add.
• Select the desired parameter and change its value.
• Press OK to confirm.

To delete a signal

• Select the appropriate signal.

• Press .
12-12 User’s Guide
 System Parameters

Parameter Description
Signal Name The name of the signal (max. 16 characters).
Unit Name The unit to which the signal is connected.
For more information about the selected unit press the function
key Info.
Signal Type The type of signal: DI= Digital Input, DO= Digital Output,
AI= Analog Input, AO= Analog Output.
Signal Number The physical channel to which the signal is connected.
The numbering restarts from 1 for each unit and “signal type”.
Logical Max The scaling between the programmed and physical value of
Physical Max an analog signal (see Figure 7). Must be set to 0 for digital
Logical Min signals.
Physical Min

Physical value of the

output signal (V, mA, etc.)

Physical Max

Logical Max
Logical value in the
Logical Min program

Physical Min

Figure 7 Diagram to show how analog signal values are scaled

Logical max/min. is the maximum/minimum value that an

analog input or output can be set to, from a RAPID program or
from the teach pendant. The units are user defined (e.g. meter/
minute).
Physical max/min. is the maximum/minimum physical value
that can be set on the output or input. To obtain the physical
limit for a specified unit, see the Product Manual.
If both physical and logical max/min. are set to 0, the default
values for the unit are picked up, which are the physical
maximum and minimum limits. The logical and physical is set
to the same value, which gives an amplification factor of 1.
If any of the values is set by the user, all four must be defined.
Therefore, make sure that:
physical maximum is > physical minimum
logical maximum is > logical minimum.
Example: An analog unit is controlling a current source with
an amplification of 50 A/V and a max current of 500A. The
following settings could then be applicable.
Physical Max = 10 V
Physical Min = 0 V
Logical Max = 500 A/V
Logical Min = 0 A/V

User’s Guide 12-13

System Parameters

Filter Passive The time (in millisecs) that a digital input signal must be zero,
before the robot acts on the signal change (10 ms to 32 s).
Filter Active The time (in millisecs) that a digital input signal must be 1,
before the robot acts on the signal change (10 ms to 32 s).

If two signals are connected to the same physical channel, the

filter time for these signals must be the same. The filter
parameters must be set to for analog signals and digital
outputs.
Inverted Set to YES, if the digital signal shall be inverted, i.e. if logical
”1” should be set on the output as ” ”. This must be ”NO” for
analog signals.
Store If set to YES, the digital outputs will be stored at a power
failure, and restored when the system is powered up again.
It should be noted that the value is connected to a logical signal.
If more than one logical signal is connected to the same
physical signal, an unexpected value may be obtained. In such
cases this parameter should be set to NO.
Access This parameter is used to make a signal write protected. The
parameter can be set to SYSTEM or ALL. Default is ALL,
which means write enabled for all. Set to SYSTEM, only the
system itself can write to the signal and all others can only read
the signal, i.e. write protected from MMC, RAPID, and
external computer (RAP).

Maximum number of user defined signals including group signals = 512.

Signals connected to a simulated unit (Type = eip000) can not use Delay, Pulse or any
time related instruction, only “clean” set and reset of digital input signals.

3.4 Defining signal groups

Digital signals can be grouped together and handled as if they were one signal. The
value of such a signal will thus be a positive integer that is binary coded using the indi-
vidual digital signals as a basis.

• Choose Topics: IO Signals.

• Choose Types: Groups.

All defined signal groups will be displayed (see Figure 8).

12-14 User’s Guide

 System Parameters

Figure 8 System parameters of the type Groups.

• Select the signal group to be changed, and press Enter , or add a new one by
pressing Add.
• Select the desired parameter and change its value.
• Press OK to confirm.

To delete a signal group

• Select the appropriate signal group.

• Press .

Parameter Description
Signal Name The name of the signal (max. 16 characters).
Unit Name The unit to which the signal is connected.
For more information about the unit type press the function
key Info.
Signal Type The type of signal: GI= Group of input signals, GO= Group of
output signals.
Group length The number of digital signals in the group. The length must be
set so that the group is within one unit. The maximum value for
length is 16.
Start signal The physical channel of the unit to which the first signal (the
least significant) is connected. The remaining signals are
automatically connected to the next channels on the same
unit.
Inverted Set to Yes if all signals in the group shall be inverted.
Store If set to YES, the digital outputs will be stored at a power
failure, and restored when the system is powered up again.
It should be noted that the value is connected to a logical
signal. If more than one logical signal is connected to the same
physical signal, an unexpected value may be obtained. In such
cases this parameter should be set to NO.

User’s Guide 12-15

System Parameters

3.5 Defining cross connections

A digital input or output signal can be logically connected to one or several digital input
or output signals. This means that a cross-connected signal will automatically be
changed when the “activation” signal is changed. For more information, see RAPID
Reference Manual - Motion and I/O Principles.

• If the signal has not already been defined, then define its name in the normal way. See
Defining input and output signals on page 12.
• Choose Topics: IO Signals
• Choose Types: Cross Connections.

All the defined cross connections will be displayed (see Figure 9).

Figure 9 An output signal can be logically connected to an input signal.

• Select the cross connection to be changed and press Enter , or add a new one by
pressing Add.
• Define the ”activation (From)” signal and the corresponding ”cross connected (To)”
signal.
• Press OK to confirm.

A maximum of 60 signals can be cross connected. Make sure that the same signal is not
connected on both the ”From” and ”To” sides, in the same chain.

To delete a cross connection

• Select the appropriate cross connection.

• Press .

Cross connections with logical conditions (Option)

The digital I/O signals can have the logical conditions AND or OR, to set up a condition
for a cross connection. These conditions cannot be entered from the teach pendant.
They are instead set up in the configuration file EIO.CFG in the cross-connection sec-
tion (starting with the line “EIO_CROSS:”) using a standard PC. The same rules apply
12-16 User’s Guide
 System Parameters

to the logical condition connections for the result signals as for the normal cross-con-
nected result signals. The actors in the cross-connection section have the logical con-
dition operators.

The logical condition operators are:

- AND, syntax in configuration file = “&”

- OR, syntax in configuration file = “!”

For each logical condition connection there can only be one kind of logical operator.
Each logical condition connection can be seen as a logical operator box.

The AND operator has the following function:

- If all in signals (actor signals) to the AND box are high, the result signals will
be high.

The OR operator has the following function:

- If any in signals (actor signals) to the OR box are high, the result signals will
be high.

There is one help operator:

- INV, syntax in configuration file = “*” , inverted.

The INV help operator can be connected before an in signal (actor signal) to an AND
or OR box which means that the signal is inverted before being checked in the operator
box.

Examples

Logical

di1

do2

do10
& do26

In Configuration file:

EIO_CROSS:
-Lres do26 -Lact “di1 & do2 & do10”

User’s Guide 12-17

System Parameters

Logical

di1

do2

do10
! do26

In Configuration file:

EIO_CROSS:
-Lres do26 -Lact “di1 ! do2 ! do10”

di1
= INV = Invert

do2

do10
! do26

In Configuration file:

EIO_CROSS:
-Lres do26 -Lact “*di1 ! do2 ! *do10”

The actor signals can be both digital In and Out signals. There can be 5 actor signals in
each condition but there can be several conditions. The cross-connected signals cannot
use Delay or Pulse or any parameters, only “clean” set and reset of digital in and out
signals. The example below describes a configuration file that has several logical con-
dition connections.

12-18 User’s Guide

 System Parameters

di2
do3
& do11

do15
!
di12
do3
& do14

do54
!

di13
di11
do33
do3
& do23
&
do17

do3 & do61

In Configuration file:

EIO_CROSS:
-Lres do11 -Lact “di2 & do3”
-Lres do14 -Lact “di12 & *do3”
-Lres “di11 + do23 + do17” -Lact “di13 & do3”
-Lres do15 -Lact “do11 ! do14 ! *di11”
-Lres do33 -Lact “di11 & do23”
-Lres do61 -Lact “do17 & do3”
-Lres do54 -Lact “do15 ! *do33”

Calculation of number of signals

No Logical cross connections involved.

If you use a simple cross connection, without any logical gates involved, the number
of cross connection objects used is the sum of all signals on both the Lact and Lres side.
If you use the same signal more than once, then you must count it as a new object each
time.

Ex 1:
-Lact di1 -Lres do2 result in 2 cross objects

User’s Guide 12-19

System Parameters

Ex 2:
-Lact di1 -Lres “do2+do3” result in 3 cross objects.

Ex 3:
-Lact di1 -Lres do2
-Lact di1 -Lres do3 result in 4 cross objects.

Logical cross connections involved.

If logical cross connections are used, the number of objects for each gate is calculated
as:

Number of cross objects = Inputs*(Outputs +1)

For the single OR gate above

Ex 4:
-Lres do26 -Lact “*di1!do2!*do10”
3 inputs and 1 output which gives 3*(1+1) = 6 cross connection objects.

For the big logical example above you have:

Ex 5:
You have 5 gates with 2 inputs and 1 output
1 gate with 3 inputs and 1 output
1 gate with 2 inputs and 3 outputs
this will give 5*(2)*(1+1) + (3)*(1+1) + (2)*(3+1) = 34 cross connection objects,
although you have only used 13 signals.

3.6 List all available I/O Unit Types

• Choose Topics: IO Signals

• Choose Types: Unit Types

All available unit types will be displayed, as shown in Figure 10.

Figure 10 List of all available unit types.

To get detailed information about a particular unit type:

12-20 User’s Guide
 System Parameters

• Select the appropriate unit type and press Enter

Parameter Description
Unit Type Name of the unit type
Vendor Name of the vendor that manufactures this unit type
Product Description of this unit type
Vendor ID Vendor’s identification code
Product ID Unit’s product identification
Device Type ID Unit type identification code
Major Revision Major revision for the software resident in the unit
Minor Revision Minor revision for the software resident in the unit
Digital Inputs Maximum number of digital input signals available on
this unit type
Digital Outputs Maximum number of digital output signals available on
this unit type
Analog Inputs Maximum number of analog input signals available on
this unit type
Analog Outputs Maximum number of analog output signals available on
this unit type

Adding User Defined I/O Unit Types (Option)

I/O devices that does not have a unit type equivalent listed on the teach pendent, needs
to be defined in the EIO.CFG configuration file. This cannot be done from the teach
pendant. It has to be done using a standard PC.

User defined unit types are defined in the unit type section of the configuration file.
Create this section by writing “EIO_UNIT_TYPE:” at the end of the file.

The unit types are defined in the configuration file, using the syntax below filling in
the appropriate italic- value:

EIO_UNIT_TYPE:
-Name typename \
-VendorId 75 \
-VendorName "Vendor Name" \
-DeviceType 7 \
-ProductId 334 \
-ProductName "Product Name" \
-MajorRev 2 \
-MaxDigin 16 \
-MaxDigout 16 \
-MaxAnin 0 \
-MaxAnout 0

Some devices may respond incorrectly to commands sent from the robot controller

User’s Guide 12-21

System Parameters

during connection establishment. The robot controller will then generate the error
message: 71102 “DeviceNet incompatible”.

This can be avoided by explicitly specifying that the controller should use a more
trivial method for connection establishment. This is done by adding the line; ‘-Device-
Driver DNGeneric’ to the configuration file:

EIO_UNIT_TYPE:
-Name typename \
-VendorId 75 \
-VendorName "Vendor Name" \
-DeviceType 7 \
-DeviceDriver DNGeneric\
-ProductId 335 \
-ProductName "Product Name" \
-MajorRev 2 \
-MaxDigin 16 \
-MaxDigout 16 \
-MaxAnin 0 \
-MaxAnout 0

3.7 Physical Signal Configuration

With “Mapped I/O” is it possible to inform the S4C controller about how the data
fields to/from an I/O unit are represented in terms of digital and analog signals. With
the “Mapped I/O” configuration is it also possible to describe the data type
(UNSIGNED/TWO_COMPL/FLOAT), the digital representation (i.e. 10 V = 32767;
0 V = 0) of the analog signals in the data fields.

Mapped I/O should be used to configure analog signals on I/O units, which the S4C
controller is not able to automatically configure i.e.:

- I/O Units of GenericDevice type

- I/O Units on the Profibus
- Filter unimportant status bits to/from the I/O Unit
- Write analog signals to pure digital I/O units.

If no physical signals are specified in the configuration for a unit, the S4C system
assumes that all signals to and from that unit are digital signals. To tell the S4C system
that there is a different meaning of the input and/or output signals, a definition of the
physical signals has to be provided in a configuration file. This file can be created
offline on a PC.

For a definition of the data representation to and from the unit, please refer to the
vendor’s documentation for the specific unit type.

It is not possible to configure Physical Signals from the Teach Pendant.

12-22 User’s Guide

 System Parameters

Configuration of Physical Signals from a Configuration File

To define a physical signal use the following syntax:

EIO_UNIT_MAP = EIO_PHS_MAP:
-PhSig 1 \
-Type “AI” \
-Unit “Board1” \
-Startbit 1 \
-NoOfBits 16 \
-EncType “TWO_COMPL” \
-HighAnalog 10,0 \
-HighDigital 32767 \
-LowAnalog -10,0 \
-LowDigital -32768

Physical Signal Parameter Definition

Only valid for analog

Entry Meaning Values
signals

PhSig The physical channel to which the signal is 1, 2, 3, ...

connected. The numbering restarts from 1
for each unit and “signal type”.

Type Type of the signal AI, AO, DI, DO

Unit The unit to which the signal is connected Name of a unit

StartBit Specifies the bit in the data area, where the 0 .. max bits on unit
signal starts.

NoOfBits Defines how long the signal is in the data 0 .. max no of bits on Yes
area unit

EncType Specifies how a signal value has to be esti- TWO_COMP Yes

mated from the value that is in the data area FLOAT
i.e data representation UNSIGNED

HighAnalog see Figure 12 (analog value for p2) depends on signal Yes

HighDigital see Figure 12 (digital value for p2) depends on signal Yes

LowAnalog see Figure 12 (analog value for p1) depends on signal Yes

LowDigital see Figure 12 (digital value for p1) depends on signal Yes

BitSwap Converts the value from BIG_ENDIAN to Yes

LITTLE_ENDIAN.

Figure 11 Entries in the physical signal description section.

User’s Guide 12-23

System Parameters

Physical value of the

signal (V, mA, etc)

p2

p1 Value representation

Figure 12 Analog value representation

The values HighAnalog, HighDigital, LowAnalog, and LowDigital together define

how the analog values are represented for the I/O unit. Look in the documentation
from the I/O units vendor for the values of these attributes.

Example:
Data given in vendor’s documentation (SIEMENS ET200M):
The signal is represented as two’s complement.
The signal is represented by 16 bits.
The value 5 V is represented as 27648.
The value 1 V is represented as 0.

=>
EIO_UNIT_MAP = EIO_PHS_MAP:
-PhSig 1 \
-Type “AI” \
-Unit “Board1” \
-Startbit 1 \
-NoOfBits 16 \
-EncType “TWO_COMPL” \
-HighAnalog 5,0 \
-HighDigital 27648\
-LowAnalog 1,0 \
-LowDigital 0

3.8 I/O Data Specifications

The names of I/O signals, units etc. have a maximum limit of 16 characters.
Each name must be unique in the topic IO Signals.
I/O signals connected to a simulated I/O unit cannot use Pulse, Delay or Filter.
A maximum of 20 I/O units, including internal units “Panel IO”, “Eiolog”, and simu-
lated I/O units can be defined.
A maximum of 10 simulated I/O units can be defined.

12-24 User’s Guide

 System Parameters

“Pollrate” for I/O units has the range:

- Minimum: 10 ms
- Maximum 10 seconds
- Step: 10 ms
A maximum of 512 signal names, including user signals and group signals can be
defined.
Filter Passive and Active time has the range:
- Minimum: 10 ms
- Maximum: 32 seconds
- Step: 10 ms
A maximum of 128 I/O signals can be defined with the “Store” parameter.
A maximum of 60 cross connections can be defined.

User’s Guide 12-25

System Parameters

3.9 Defining system inputs

The input signals can be assigned specific system actions. In this case, they will
automatically be handled by the robot. See also PLC Communication on page 30.
System inputs with actions including a MOTORS ON order or Start of any robot
movement are allowed in automatic mode only. When a system input order is rejected
because the system is in manual mode or due to any other unfulfilled requirement, no
error messages will be displayed on the teach pendant.

The reason for this is that the teach pendant is normally not being used by the operator
in these situations and there is therefore no sense in displaying the messages on the
teach pendant. However, the messages will still be stored in the error log, so you may
check for an answer there as to why a system input gives no action.

• If the signal has not already been defined, define its name in the normal way. See Defining
input and output signals on page 12.
• Choose Types: System Inputs.

All defined system inputs will be displayed (see Figure 13).

Figure 13 Input signals can be assigned specific system actions.

• Select the system input to be changed and press Enter , or add a new one by
pressing Add.
• Define the name of the signal and the system action that is assigned to it. To add the system
actions MotOnStart, Start, StartMain, Interrupt, LoadStart and Sync ExtAx, define their
arguments as well.
• Press OK to confirm.

The following system actions are available:

System action Description

MotorOn Sets the robot to the MOTORS ON state.

12-26 User’s Guide

 System Parameters

MotOnStart Sets the robot to the MOTORS ON state and starts the program
(continuous or cycle execution) from the current instruction,
i.e. from the program pointer.
MotorOff1 Sets the robot to the MOTORS OFF state.
If a program is executing, it will be stopped before changing
state. The robot cannot be set to the MOTORS ON state when
this signal is high.
Start Starts the program (continuous or cycle execution) from the
current instruction, i.e. from the program pointer.
StartMain Starts the program (continuous or cycle execution) from the
beginning.
Not valid during program execution.
Stop1 Stops program execution. A program cannot be started when
this signal is high.
QuickStop1 Stops program execution. Gives a quicker stop and some devi-
ation from the programmed path. A program cannot be started
when this signal is high.
StiffStop1 Stops program execution. Gives an even quicker stop and
some more deviation from the programmed path than Quick-
Stop.
A program cannot be started when this signal is high.
StopInstr1 Stops program execution after the current instruction has been
finished. A program cannot be started when this signal is high.
StopCycle1 Stops program execution when the complete program has been
executed, i.e. when the last instruction in the main routine has
been executed. A program cannot be started when this signal is
high.
SysReset Performs a system reset (restart), i.e. similar to power off/on.
Interrupt Executes a routine (procedure) without changing the start
pointer.
Not valid during program execution. When the routine has
been executed, the normal program can be restarted.
The name of the routine to be executed is also defined in this
dialog, e.g. routine1.

This signal, for example, can be used to go to a service

position. When the normal program is started again, the robot
will move to the point where it was stopped and continue from
there.
ResetError Resets the system output signal Error.
SyncExtAx Synchronises an external mechanical unit. The unit to be
synchronised is also defined in this dialog e.g. orbit1. One sig-
nal is required for each unit. (S4 only)
LoadStart Loads a program from diskette or other mass storage device.
The program is then started from the beginning.
The program file name (including mass memory unit) to be

User’s Guide 12-27

System Parameters

loaded is also defined in this dialog, e.g.

flp1: PROGRAM1.PRG.
Not valid during program execution.
ResetEstop Resets the emergency stop. The robot can then be set to the
MOTORS ON state.
AckErrDialog Acknowledge the error dialogue on the teach pendant, i.e. the
same operation as pressing OK on the teach pendant.

Several input signals can be assigned the same system actions, but several system
actions may not be assigned to the same signal.
1. Allowed in both manual and automatic mode.

To delete a system action

• Select the signal to be deleted.

• Press

The system action assigned to this signal is then deleted, but the signal itself remains
defined.

3.10 Defining system outputs

The output signals can be assigned a specific system status. In this case, they will auto-
matically be handled by the robot.

• If the signal has not already been defined, define its name in the normal way. See Defining
input and output signals on page 12.
• Choose Types: System Outputs.

All defined system outputs will be displayed (see Figure 14).

Name Status

Figure 14 Output signals can be assigned specific types of system status

12-28 User’s Guide

 System Parameters

• Select the system output to be changed and press Enter , or add a new one by press-
ing Add.
• Define the name of the signal and the system action assigned to it.
• Press OK to confirm.

The following types of system status are available:

System status Description

MotorOn The robot is in the MOTORS ON state. If the robot system is
not synchronised, the output will start flashing.
MotOnState The robot is in the MOTORS ON state.
The output is stable, i.e. no flashing.
MotorOff The robot is in the MOTORS OFF state.
If the safety chain is broken, the output will start flashing.
MotOffState The robot is in the MOTORS OFF state.
The output is stable, i.e. no flashing.
CycleOn2 A program is executing.
EmStop The robot is in the Emergency Stop state. The emergency stop
must be reset before the robot can be set to the MOTORS ON
state.
AutoOn The robot is in automatic mode.
RunchOk The run chain is not broken.
TCPSpeed An analog signal that describes the speed of the TCP.
The logical value of the signal is specified in m/s, e.g. a speed
of 2000 mm/s corresponds to the logical value 2. The scaling
factor for the physical value is specified in the system param-
eters of the corresponding signal.
Error The robot program execution has been stopped due to an error.
(If an error occurs when a program is not executing, this output
will not be set.)
PFError A power failure error has occurred.
The program would not restart after this type of error. The pro-
gram can usually be started, but it will start from the beginning.
MotSupTrigg The motion supervision function has been triggered.
MotSupOn The motion supervision function is active.
RegainDistError An attempt to start the program has been done but this failed
due to that the robot was outside the Regain Distance zone (i.e.
too far from the programmed path).
The output is reset by one of the following actions:
- A restart of the program has to succeed (the robot must be
jogged into the zone first)
- The PP has to be set to Main.

Several output signals can be assigned the same system status, but several system sta-
tus may not be assigned to the same signal.
2. Also active for Event Routine execution.

User’s Guide 12-29

System Parameters

To delete a system status

• Select the signal to be deleted.

• Press .

The system status assigned to this signal is then deleted but the signal itself remains
defined.

3.11 PLC Communication

This chapter describes how to control the robot using, for example, digital signals from
a PLC.

For a definition of the signals see chapter Defining system inputs on page 26 and Defin-
ing system outputs on page 28.

All system inputs are 0 to 1 level sensitive and the pulse length must exceed 50 ms.

Most system inputs are only permitted in the automatic mode. If any interactive unit,
such as the teach pendant, a computer link, etc., has reserved exclusive rights to one or
more functions in the system, the system input request will be denied. The signals
MotorOff and Program stop signals from the system Input are active in Manual mode
also.

Some examples of the signal sequences are described below.

To verify that the robot is in automatic mode

Signal sequence:
1
AutoOn (Out)
0

To switch the robot to MOTORS ON state

Requirement: Robot in MOTORS OFF state and Runchain is closed (=RunchOK)

Signal sequence:

1
MotorOn (IN)
Order 0

1
MotorOn (OUT)
Response 0

12-30 User’s Guide

 System Parameters

To switch the robot to MOTORS OFF state

Requirement: Robot in MOTORS ON state.

Signal sequence:
1
MotorOff (IN)
Order 0

1
MotorOff (OUT)
Response 0
If the program is running (CycleOn), the MotorOff action will stop execution of the
program.

To start the program from the beginning of the main routine

Requirement: Robot in MOTORS ON state and program control not occupied by any
other resource (e.g. external computers).

Signal sequence:
1
StartMain (IN)
Order 0

1
CycleOn (OUT)
Response 0

To start or restart program execution from the current instruction or after a power
failure

Requirement: Robot in MOTORS ON state and program control not occupied by any
other resource (e.g. external computers). A PFError indicates that a
power failure error has occurred

Signal sequence:
1
Start (IN)
Order 0

1
CycleOn (OUT)
Response 0

User’s Guide 12-31

System Parameters

To load and start a program

Load a program from diskette or another mass storage device. The program will then
start from the beginning. If a program is running, execution will stop first.

Requirement: Robot in MOTORS ON state and program control not occupied by any
other resource (e.g., external computers).

Signal sequence:
1
Load (IN)
Order 0

1
CycleOn (OUT)
Response 0

To stop, QuickStop, StiffStop program execution

Requirement: Valid in all modes.

Signal sequence:
1
Stop (IN)
Order 0

1
CycleOn (OUT)
Response 0

To stop at the end of the cycle

Stops program execution when the complete program cycle has been executed.

Requirement: Valid in all modes.

Signal sequence:

1
StopCycle (IN)
Order 0

1
CycleOn (OUT)
Response 0

12-32 User’s Guide

 System Parameters

To detect spontaneous execution stops

Requirement: Robot in AutoOn (1), MotorOn (1) and CycleOn (1).

Signal sequence:

1
CycleOn (OUT)
Response 0

There are three main reasons why stops occur:

1. Program controlled exit, stop (or error in the program).

2. Emergency stop.

3. Safety chain broken due to reasons other than an emergency stop.

Detect case 1 with:

Error (1).

Detect case 2 with:

MotorOn (0), CycleOn (0), EmStop (1) and RunchOK (0).

Detect case 3 with:

MotorOn (0), CycleOn (0), EmStop (0) and RunchOK (0).

To reset an emergency stop

Switches the robot back to MOTORS OFF state after a spontaneous emergency stop.

Requirement: Robot in automatic mode after an emergency stop. The safety chain must
be closed, by resetting the emergency stop.

Signal sequence:
1
ResetEstop (IN)
Order 0

EmStop (OUT) 1
Response
0

1
RunchOK (OUT)
Response 0

Continue by switching the power to the motors back on.

User’s Guide 12-33

System Parameters

RunchOK

Indicates that the robot is back to MOTOR OFF state after a spontaneous safety chain
stop.

Requirement: Robot in automatic mode and spontaneous stop case 3 (see above).

Signal sequence:

Wait until the RunchOK is high (the safety chain is closed).

1
RunchOK (OUT)
Response 0

Continue by switching the power to the motors back on.

12-34 User’s Guide