DeviceNet Ethernet Modules for SmartChange

Tool Change Systems

MANUAL 95394 Rev 02 December 14, 2009

648 Saratoga Road Glenville, NY 12302 USA Phone: 518 384 1000 Fax: 518 384 1200 www.appliedrobotics.com

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Revision
Revision 00 01 02 Date 09-16-2009 11-23-2009 12-14-2009 Author JW JW JW Description 1st Revision; SmartChange DeviceNet Ethernet Modules 2nd Revision; minor changes Modified Ethernet Pin out to Schematic

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Contents
1 Precautions ........................................................................................................................................................... 5 2 Introduction .......................................................................................................................................................... 6 3 DeviceNet Ethernet Modules Specifications ..................................................................................................... 8 3.1 Module to SmartChange Interface ........................................................................................... 8 3.2 Coupled / Uncoupled Status Signals.......................................................................................... 9 3.3 TSM (Tool Stand Monitor) & Tool Stand Switch Jumper ........................................................ 9 3.4 Spring Pin Replacement ............................................................................................................ 10 3.5 Water Resistance........................................................................................................................ 10 3.6 Robot Side LEDs ......................................................................................................................... 11 3.7 Tool Side LEDs ............................................................................................................................ 15 3.8 MAC ID Address, Baud Rate, & Terminating Resistor Slide Switch Settings .................... 17 3.9 Line, Robot, Tool ID DIP Switches .......................................................................................... 19 3.10 Cable Connectors - Robot & Tool Side ................................................................................. 20 4 Robot Side and Tool Side Operations ............................................................................................................. 22 4.1 Robot Side Module Functional Description ............................................................................. 22 4.2 Tool Side Module & SmartCharge Functional Description .................................................. 24 4.3 First Time DeviceNet Connect Scan ....................................................................................... 24 4.4 DeviceNet Network Setup ........................................................................................................ 24 4.5 Connection Times ..................................................................................................................... 25 5 Ethernet Diagnostics .......................................................................................................................................... 26 5.1 Webpage Overview - Home Page ............................................................................................ 26 5.2 Network Page, Setup, & Ethernet Cabling.............................................................................. 28 5.3 Configuration Page..................................................................................................................... 30 5.4 XML Report.................................................................................................................................. 32 5.5 Accelerometer Page ................................................................................................................... 34 5.6 Histogram Page .......................................................................................................................... 35 6 Robot Side Object Model................................................................................................................................... 36 6.1 Identity Object............................................................................................................................ 36 6.2 DeviceNet Object........................................................................................................................ 37 6.3 Assembly Object........................................................................................................................ 38 6.4 Connection Object ...................................................................................................................... 40 6.5 Scanlist Object ............................................................................................................................ 42 7 Tool Side Object Module ................................................................................................................................... 44 7.1 Identity Object............................................................................................................................ 44 7.2 DeviceNet Object........................................................................................................................ 46 7.3 Assembly Object ......................................................................................................................... 47 7.4 Connection Object ...................................................................................................................... 48 7.5 Ack Handler ................................................................................................................................. 49 7.6 Tool Changer .............................................................................................................................. 49 8 Modbus/TCP Industrial Ethernet ...................................................................................................................... 50 8.1 Modbus/TCP Register ................................................................................................................ 50 9 Drawings ............................................................................................................................................................. 52 9.1 Robot Side Module SMR-E-DN ................................................................................................ 52 9.2 Tool Side Module SMT-E-DN ................................................................................................... 53 9.3 Schematic, SMR-E-DN .............................................................................................................. 54 9.4 Schematic, SMT-E-DN .............................................................................................................. 55

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All rights reserved. Copyright 19862009 Applied Robotics Inc. The use of this document is reserved exclusively for the use of Applied Robotics Incorporated customers and personnel. The information and drawings contained herein are the sole property of Applied Robotics Incorporated and shall not be divulged to any third party without the prior written consent of Applied Robotics Inc. The information in this document is subject to change without notice. Applied Robotics makes no warranty of any kind with regard to this users guide, including but not limited to, implied warranties or fitness for a particular purpose. Applied Robotics Inc. shall not be liable for any errors contained herein or for incidental or consequential damages in connection with the performance or use of this material.

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1 Precautions
DANGER NOTICE Indicates an imminently hazardous situation which, if not avoided, will result in serious injury or death. WARNING NOTICE Indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death. CAUTION NOTICE Indicates a potentially hazardous situation which, if not avoided, will or could result in minor or moderate injury; also used where the risk applies only to property damage.

The Smart Change DeviceNet Modules contain components that are susceptible to damage from Electro Static Discharge. Observe precautions for Electrostatic Sensitive Devices when working with these modules.

IGNORING INFORMATION ABOUT POTENTIAL HAZARDS CAN LEAD TO SERIOUS HARM TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT, AND MAY RESULT IN THE NULLIFICATION OF THE MANUFACTURERS EQUIPMENT WARRANTY.

XCHANGE TOOL CHANGER NOTE

This product is designed for robotic use only. Coupling and Uncoupling requires interface surface parallelism. This is difficult to manually maintain due to the forces generated by electrical contacts, pneumatic and hydraulic fittings. Your robot will maintain the required parallelism of the Robot and Tooling adaptor faces. Please review this manual before attempting to use this system.

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2 Introduction
The DeviceNet Ethernet Modules (0901-D33A Robot Side & 0901-D34A Tool Side) attach to Applied Robotics Inc SmartChange Tool Changers. They enable the Tool Changers to be linked to the DeviceNet network to exchange data, as well as provide I/O capabilities and diagnostics. The Robot Side Module is a DeviceNet Slave to the Robots Master network. The Robot Side Module can scan up to seven DeviceNet Slave devices (ARI Tool Side Module & other nodes) and exchanges DeviceNet data to the Robot Master.

The Ethernet Diagnostics provide a webpage to view diagnostic information such as lifetime cycle counts, maintenance counter, timing of tool change functions, a histogram of timing trends and more.

Robot Side DeviceNet Ethernet Module: 0901-D33A

Tool Side DeviceNet Ethernet Module: 0901-D34A

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The DeviceNet Ethernet Modules can also operate through Modbus/TCP. The Robot Side Module has an on-board 3 axis accelerometer. See Section 5.5 for more details. The Tool Side Module has a unique feature to retain charge for a limited time to decrease connection times during fast tool changes; it essentially eliminates the power up reset time from the equation. Tool Present signal aids in preventing dropped tools.

Robot Side Module and SmartChange Tool Changer

Robot Side & Tool Side Modules with

SmartChange

Tool Changers

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3 DeviceNet Ethernet Module Specifications

3.1 Module to Smart Change Interface
This module is for use on the Smart Change Tool Changer Systems. The DeviceNet Ethernet Robot Side Module must be mounted on position 1 of the Smart Change Tool Changer. The module attaches via the dovetail, and is screwed in from the bottom to the dovetail. Being placed on Position 1 of the Tool Changer is required to allow the Tool Changer Interface Connectors to supply the Coupled and Uncoupled status signals from the tool changer to the module.

Robot Side DeviceNet Ethernet Module: Tool Changer to Module Interface Connectors; for Coupled and Uncoupled Signal Communication.

Exploded view of the module attaching to the dovetail feature on Position 1 of Tool Changer:

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3.2 Coupled / Uncoupled Status Signals

The outputs sent to Couple / Uncouple the Tool Changer go through the M12 connector to the Tool Changer through the Valve module. The inputs to confirm that the Tool Changer has responded to the outputs are called Coupled / Uncoupled. In order to verify the Tool Changer has Coupled / Uncoupled, the status signal sensors in the Tool Changer confirm this. The coupled / uncoupled status signals are communicated to the DeviceNet Ethernet Module via the Tool Changer Interface Connectors pictured on the previous page. To know if the Tool Changer is Coupled or Uncoupled, please refer to the LEDs on the front window of the Robot Side Module. See section 3.6 for more information on the LEDs.

1 = Coupled LED

2 = Uncoupled LED

3.3 TSM (Tool Stand Monitoring) & Tool Stand Switch Jumper Plug
Item 1 is the Tool Stand Switch Jumper Plug, part number 0905-B78A. It connects to the connector (Item 2) on the tool side module when there is no tool stand switch. This jumpers the signal that typically goes through the tool stand switch for the TSM (Tool Stand Monitoring) Circuit. This jumper should be in place if there is no tool stand switch installed to sense tool stand presence. This allows the uncouple signal to work properly. The Tool Stand Plug jumpers pins 1 and 3.

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3.4 Spring Pin Replacement

Pin Removal: The spring pins in the DNET module are field replaceable. They should not need replacement unless worn or damaged. The pins are removed by placing a small screwdriver or tool under the head of the pin and gently prying it upward until free. New Pin Installation: New pins are inserted by simply pressing the new pin into the hole until it bottoms out. Once the new pin is inserted, be sure it is flush with the other pins and has spring compliance.

3.5 Water Resistance

The Applied Robotics DNET module has been tested in a spray down environment. The unit showed no malfunction when sprayed down with water. It is rated IP65.

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3.6 Robot Side Module LEDs

The Robot Side DeviceNet Ethernet Module has 12 LEDs on it, visible through a clear cover. LEDs 1-6 and 9-12 are bi-colored LEDs, meaning they can be red, green, or a combination (amber). LED 7 is amber and LED 8 is green. Most importantly the Coupled and Uncoupled LEDs in the top left indicate the Coupled / Uncoupled Status as discussed in section 3.2 of this manual. Slave Network Status indicates the status of the network between robot and robot side module. Master Network Status indicates the status of the network between robot side module and tool side module (and downstream nodes).

C 1

U 2

10

11

12

The operation of the bicolor LEDs are described in the following tables: #1 - Coupled LED COLOR None Red Red Green Green Red / Green STATE Off Solid Flashing Solid Flashing Alternating INDICATION Couple & Coupled both OFF TBD Couple & Coupled do not match Couple & Coupled both on TBD TBD

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#2 - Uncoupled LED COLOR None Red Red Green Green Red / Green STATE Off Solid Flashing Solid Flashing Alternating INDICATION Uncouple and Uncoupled both OFF TBD Uncouple and Uncoupled do not match Uncouple and Uncoupled both ON TBD TBD

#3 - Ready To Couple COLOR STATE None Red Red Amber Amber Green Green Red / Green Off Solid Flashing Solid Flashing Solid Flashing Alternating

INDICATION Ready-To-Couple (RTC) is disabled TBD All Enabled RTC inputs are NOT Ready Some enabled RTC inputs are NOT Ready TBD All enabled RTC inputs are Ready TBD TBD

#4 - Factory Maintenance LED COLOR None Red Red Amber Amber Green Green Red / Green STATE Off Solid Flashing Solid Flashing Solid Flashing Alternating INDICATION TBD Factory Maintenance Required TBD Factory Maintenance required within 500 cycles TBD No Factory Maintenance Required TBD TBD

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#5 - User Maintenance LED COLOR None Red Red Amber Amber Green Green Red / Green STATE Off Solid Flashing Solid Flashing Solid Flashing Alternating INDICATION Maintenance Indicator Disabled User Maintenance Required TBD User Maintenance required within 500 cycles TBD No User Maintenance Required TBD TBD

#6 - I/O Active LED COLOR None Red Red Green Green Red / Green STATE Off Solid Flashing Solid Flashing Alternating INDICATION TBD TBD TBD TBD TBD TBD

#7 - Ethernet LINK LED The Ethernet LINK LED is amber and works as a standard Ethernet LINK LED, on and blinking at times. If the LED is not on at all, there is no Ethernet Connection. #8 - Ethernet Activity LED The Ethernet ACTIVITY LED is green and works as a standard Ethernet Activity LED, on and blinking at times. If the LED is not on at all, there is no Ethernet Activity. #9 - Diagnostic LED COLOR None Red Red Green Green Red / Green STATE Off Solid Flashing Solid Flashing Alternating INDICATION TBD TBD TBD TBD TBD TBD

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#10 - Slave Network Status LED COLOR None Red Red Green Green Red / Green STATE Off Solid Flashing Solid Flashing Alternating INDICATION No Power Unrecoverable Fault Recoverable Fault I/O Connection Timed Out Normal runtime operation Device is idle or not allocated to a master Identify (Offline Connection Set)

#11 - Master Network Status LED COLOR None Red Red Green Green Red / Green STATE Off Solid Flashing Solid Flashing Alternating INDICATION No tool connected TBD Tool Present, I/O Timeout DeviceNet I/O established DeviceNet connection in-progress Slave List Full. More than 8 tools have been connected. Reset or cycle power on Robot Board.

#12 - Module Status LED COLOR None Red Red Green Green Red / Green STATE Off Solid Flashing Solid Flashing Alternating INDICATION No Power Unrecoverable Fault Recoverable Fault Normal operation Device Master has an empty scan list TBD

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3.7 Tool Side Module LEDs

The LEDs for the Tool Side Module are on the board, visible through the clear cover. The Tool Side Module Board has 3 bicolor LEDs: Network Status (D1), Module Status (D2), and Diagnostic (D3). It also has a 4th LED that is amber colored for Activity (D4), which indicates the SmartCharge power state of the board. See section 4.2 Tool Side Functional Description for more details on the Activity LED.

D1 D2 D3

D4

The operation of the bicolor LEDs are described in the following tables: D1 - DeviceNet Network Status LED COLOR None Red Red Amber Amber Green Green Red / Green STATE Off Solid Flashing Solid Flashing Solid Flashing Alternating INDICATION No Power Unrecoverable Fault Recoverable Fault, I/O Connection Timed Out Powerup from sleep state TBD Normal runtime operation Device is idle or not allocated to a master Identify (offline connection set)

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D2 - Module Status LED COLOR None Red Red Amber Amber Green Green Red / Green STATE Off Solid Flashing Solid Flashing Solid Flashing Alternating INDICATION No Power Unrecoverable Fault Recoverable Fault Powerup from sleep state TBD Normal operation DeviceNet Master has an empty scan list TBD

D3 - Diagnostic LED COLOR None Red Red Amber Amber Green Green Red / Green STATE Off Solid Flashing Solid Flashing Solid Flashing Alternating INDICATION No Power TBD Unrecoverable Fault Code Powerup from sleep state TBD Normal operation TBD TBD

D4 - SmartCharge LED COLOR None Amber Amber Amber STATE Off Solid Flashing 1 Hz Flashing 1/4 Hz INDICATION No Power TBD Normal Operation Sleeping

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3.8 Slide DIP Switch Settings: MAC ID, Baud Rate, & Terminating Resistor
One 10-position slide switch configures the DeviceNet MAC address and baud rate on each module. Six slide switches (1-6) configure the DeviceNet Mac ID from node address 1 to 63. Two slide switches (7 & 8) configure the baud rate to 125k, 250k, 500k, or software setting. Software configurable baud rate configures the baud rate to the last baud rate the device was powered up at and allows software configuration tools to modify the baud rate. For the Robot Side Module, the remaining two (9 & 10) are the terminating resistor switches, 9 for the Robot Side and 10 for the Tool Side. For the Tool Side Module the remaining two switches (9 & 10) are different than the Robot Side Module. Switch 9 is for enabling Diagnostics. Switch 10 enables termination on the DeviceNet Network.

Slide Switch layout:

MAC ID configuration: See next page for full MAC ID chart

Baud Rate configuration:

Labels that come on modules:

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MAC ID Address Configuration Table: On signifies Dip switch is On, and in the Up position. All others are considered Off, in the Down position.

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3.9 Rotary DIP Switch Settings: Line, Robot, and Tool ID

On the Tool Side Module, there are 5 Rotary Switches which are readable by a DeviceNet Master using a single input assembly. Switch 1 is for Line Designation. Switch 2 is for Robot Designation. Switches 3 - 5 are for Tool ID Designation.

LINE

ROBOT

TOOL 100s

TOOL 10s

TOOL 1s

SW1

SW2

SW3

SW4

SW5

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3.10 Cable ConnectorsRobot Side & Tool Side Robot Side Module Connectors:
Auxiliary Power Connector: 4 pin male Turck Minifast Pinout: 1=Aux+ (24 VDC) 2=Spare 1 3=Spare 2 4=Aux- (0 VDC)

DeviceNet Connector: 5 pin male Turck Minifast Pinout: 1=SHIELD 2=V+ (24 VDC) 3=V- (0 VDC) 4=CAN_H 5=CAN_L

Ethernet Connector: 4 socket female Binder M12 D-coded. Pinout: 1=TX+ 2=TX3=RX+ 4=RX-

Valve Connector: 3 socket female Turck Picofast M8 Pinout: 1=NC 3=Uncouple Output 4=V Aux- (0 VDC)

Tool Changer Interface Connectors (qty 2) : 3 socket female Turck Picofast M8

Pinout Uncoupled: 1=V+ (24 VDC) 3=V- (0 VDC) 4=Uncoupled Input Pinout Coupled: 1=V+ (24 VDC) 3=V- (0 VDC) 4=Coupled Input

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Tool Side Module Connectors:

Auxiliary Power Connector: 4 socket female Turck Minifast Pinout: 1=Aux+ (24 VDC) 2=Spare 1 3=Spare 2 4=Aux- (0 VDC)

DeviceNet Connector: 5 socket female Turck Minifast Pinout: 1=SHIELD 2=V+ (24 VDC) 3=V- (0 VDC) 4=CAN_H 5=CAN_L

Tool Stand Connector: 4 socket female Turck Eurofast M12 Pinout: 1=Uncouple Output 2=Vaux3=Sense Uncouple Input 4=NC

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4 Robot Side and Tool Side Operation

4.1 Robot Side Module Functional Description
The Robot Side Module uses Applied Robotics proprietary sub-network to communicate with the Tool Side Module and Tool nodes / slaves. The connected Tool Side Module and IO node information is stored in the Robot Side Module, to be accessed by the robot/plc. The Robot / PLC can communicate with the Tool Side Module and Nodes, just through the Robot Side I/O Assembly instead of directly through the Tool. This enables fast connection times. The DeviceNet Master (industrial PLC or robot) will have to recognize one DeviceNet slave device (the Robot Side DeviceNet Module) with 60 bytes of I/O. This connection on the robot side will be maintained at all times, regardless of activity on the tool side. The tool side information is in the robot side assembly when the tool is connected. The robot side module has a single I/O Assembly with 7 data bytes in each direction for each of 7 possible slaves on a single tool. It will also have 4 status bytes in each direction, totaling 60 bytes. The data is transferred regardless of the number of DeviceNet slaves / nodes connected to the robot side module via the tool side module. The number of slaves connected can be read using Class Attribute 100 of the Assembly Object. The number of Output Registers is specified using Class Attribute 102 of the Assembly Object.

Robot (PLC) 60 Bytes IO DNET Master

Robot Side Tool Changer 60 bytes IO DNET Slave to Robot ARI subnet to Tool Nodes

Tool 1 Node 1 ID 1

Tool 1 Node 2 ID 2

Tool 1 Node 3 ID 3

Tool 1 Node 4 ID 4

Tool 1 Node 5 ID 5

Tool 1 Node 6 ID 6

Tool 1 Node 7 ID 7

Inputs

Outputs

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Below shows the full 60 Byte IO of Robot Board Input to illustrate how the charts on the previous page expand. Note that Node 1 in this example is the Tool Side Module. If a Tool Side Module were not used it would look similar to Nodes 2-7 listing the generic byte data. Please see Chapter 6: Object Model for full details on Inputs and Outputs.

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4.2 Tool Side Module & SmartCharge Functional Description

The tool side must be set to MAC ID 1, and for downstream nodes, the MAC IDs sequentially should be set up to number 7. The image above shows a tool side board DIP switch set for MAC ID 1 at 500 kbaud. The I/O of each slave will be mapped into one I/O assembly on the robot side. No tool-side slave may have more than 8 data bytes in its I/O in each direction. The robot board will remember the I/O configuration of up to 7 slave devices. In order to store the tool side data, the uniqueness of each tool side is determined by a combination of the serial number of the tool side board at MAC ID 1 and the Line/Robot/Tool IDs on the tool side board. This unique ID is also displayed on the webpage along with the Tool ID. The Tool Side Module has the patented SmartCharge feature which provides a very fast DeviceNet connection between the robot side and tool side modules by allowing a warm start to occur on the tool side board. The SmartCharge LED D4 on the Tool Side board shows the power state of the board to indicate if SmartCharge is enabled (a 1/4Hz amber blink). SmartCharge is enabled on the Tool Side Module up to two minutes on its own without receiving external power from the Robot Side Module.

4.3 First Time DeviceNet Connect Scan

After power up of the robot side module, the first time it connects to a tool that it has not been connected to before, it will wait up to 5 seconds (configurable parameter on the webpage under maximum first time devicenet connect time) for all slaves / nodes on that tool to respond. It will then remember that I/O configuration until the robot side module is power-cycled or reset. All subsequent connections after the first 5 second connection will connect quickly. The robot side module has 4 discrete inputs and 4 discrete outputs. Their data is stored in the 4th byte of the assembly object. It may also be accessed in the Scanlist Object at the class level as attribute 3. It is important to note the tool side I/O values are not stored in the 60 byte I/O when a tool is not attached. That could lead to confusion about whether a robot in fact is attached to a tool or not. The robot side stores information regarding each tool (and any additional nodes) in order to connect to it more quickly. This information that is acquired and stored during the First Time DeviceNet Connect Scan is the tool side vendor, the serial number, and how many additional nodes go with it. Please allow enough time on the first time connect after robot side module power up to be able to complete this scan. If it is necessary to decrease the time for the First Time DeviceNet Connect Scan depending on application, the time can easily be changed via the webpage, on the Configuration Page. Make sure to reset robot side module power after making such changes.

4.4 DeviceNet Network Setup

As described in the Robot Side Module Functional Description, section 4.1, to setup a DeviceNet network, it is only necessary to add the robot side module, as all the tool side information is accessible through the robot side modules 60 byte I/O. The robot side module acts as a devicenet slave to the robot or PLC master, and it acts as a DeviceNet master to the tool side module to be able to acquire the tool data.

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4.5 Connection Times

Connection Times will vary depending on each node, its characteristics, and the manufacturer. Below are results attained through engineering testing at Applied Robotics, Inc to provide an idea of typical times for connection from our Robot Side Module 0809-D82A to our Tool Side Module 0809-D83A. One Tool Node: Applied Robotics Tool Side Module SmartCharge disabled - diode D4 is not blinking)

DeviceNet Connect: 150 msec DeviceNet Connect: 60 msec

SmartCharge enabled - diode D4 is blinking @ 1/4 Hz)

Note: due to the recessed Tool Present spring pin on the module, the DeviceNet Connect Time displayed on the webpage is accurate only to 50 milliseconds. The above listed times include the addition of this potential offset to eliminate any discrepancies. Under Timing on the Webpage, the times Coupled to Uncoupled and Uncoupled to Coupled are measurements of the timing of our Tool Changers cams. It is calculated by the switching of the proximity sensors inside the Tool Changer. These timings are affected by the air pressure used. The Couple to Coupled Time is the time from which the board sends the signal to the time in which the Coupled Proximity Sensor Turns on. This is the Total Tool Changer Time from signal to solenoid to valve to cams to proximity sensors.

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5 Ethernet Diagnostics
The Ethernet Diagnostics provide a series of web pages to view diagnostic information such as lifetime cycle counts, maintenance counter, timing of tool change functions, a histogram of timing trends and more. There are also LEDs on the module that correspond to some of this information. Besides diagnostics, the webpage also allows the user to set and read specific items that affect the Tool Changer such as the valve type (single or dual), calibrating the on-board accelerometer, and downloading XML files with time and date stamp of current module info. Some sections of the webpage will require a login and password to change and set information such as IP Address, Valve Type, and Maintenance Counters. User: ARI Password: Applied

5.1 Webpage Overview - Home Page

The image on the next page shows the home webpage of a Robot Side Module, uncoupled. Current I/O Status displays the following for SmartChange DeviceNet Ethernet Module:
Auxiliary Power Tool Present Signal Tool Stand (Sense Uncouple) Output 1 Couple Output 2 Uncouple Input 1 Coupled Input 2 Uncoupled

Connected Device Status shows tools and/or nodes connected with tool ID. Maintenance Status: Coupled Counter (lifetime): This is a non-resettable count of how many times the module has seen the Coupled Input from the Tool Changers proximity sensor turn on. Factory Maintenance: When the Lifetime Coupled Counter reaches 1 million cycles, the Factory Maintenance bit will turn on. The status is visible both on the webpage and also on the module as an LED (See section 3.6 for LED location and indications). Maintenance Counter: This is a resettable counter (set on the Configuration page). Maintenance Interval: A settable value set and changeable by the user. When the Maintenance Counter reaches the value in the Interval, the User Maintenance Required bit will turn on. User Maintenance: The status is visible both on the webpage and also on the module as an LED (See section 3.6 for LED location and indications). Timing is useful in defining potential problems by analyzing various timings in the system. Using the Show Histogram webpage elaborates on this data by showing general recent trends in timing.
DeviceNet Connect Coupled to Uncoupled (See Section 4.5 for Timing Descriptions) Uncoupled to Coupled Couple to Coupled Uncouple to Uncoupled Max Uncouple to Uncoupled

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5.2 Network Page, Setup, & Ethernet Cabling

Select the CommSettings Button on the Home page to direct to the Network Setup Page. Default Values are shown below. Default ARI IP Address is 192.168.2.240. Specific IP Address settings can be requested at time of order. To change parameters, simply enter new ones in fields and select Apply.

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Suggestions on Initial Network Setup of Robot Side Module:

To change IP Address from ARI default: Apply power to robot side module (DeviceNet V+ and V-: see Cable Connections section 3.10) Plug a crossover Ethernet cable directly into a non-networked computer and to the robot side module. Change IP Address of computer to 192.168.2.241 under Network Connections. Go to web browser, and enter http://192.168.2.240 On the robot side modules webpage, select CommSettings Change IP Address to desired address that will work on your network and select Apply and cycle power on robot side module. Reserve static address on server if necessary. Remember to change IP Address back on the computer under Network Connections.

Ethernet Cable: Only a 2 pair cable is necessary. The Ethernet Cable to be connected to your network will need an ODVA approved M12 D Coded 4 pin connector on the module end, and the other end will need to fit to your particular setup. Applied Robotics has tried with success both the Binder field-wireable M12 D-Coded 4 pin connector as well as the MURR M12 D-Coded 4 pin field-wireable with harax rapid termination. The other end of the Applied Robotics test Ethernet Cable is terminated with a standard RJ-45 that plugs into a switch that is on our internal network.

If permanently connecting the Ethernet Cable to the Robot Side Module, the cable will need to be able to withstand the motions of the robot. Applied Robotics used the Etherline 2 pair Cat5/5e Continuous-Flex Halogen-Free cable from Lapp. Below is an image of our wiring and connectors. Our cable is straight through since it goes to a switch. We use a standard RJ-45 on one end and a Binder field wireable 4 contact M12 D Coded on the other end. A standard M12 industrial Ethernet cable will work with our pin out.

1=TX+ (o) 2=RX+ (g) 3=TX- (O) 4=RX- (G)

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5.3 Configuration Page

The configuration page allows for many of the diagnostic settings to be changed. The Maintenance Counter can be set. The name and description of the module can be set to appear on the home webpage and in the report. The Report button gives a time and date stamped XML file of current status data. For customers not using the single solenoid valve, they can change the Hardware Configuration to double, which allows the couple and uncouple outputs and LEDs to function properly with a double solenoid. The SmartChange DeviceNet Ethernet Robot Side Module has one Ready To Couple sensor input, so that section will remain 1. The accelerometer axes can be calibrated on this page. (see Section 5.5 for more accelerometer data).

Cycle Counters and Maintenance Bits: There are two coupled cycle counters on the Robot Side Module. One is settable and one is lifetime. It is recommended to keep the module on the same tool changer if possible. If a change or move is required, it is recommended that a Report be done both before and after the change to help in calculating lifetime cycles of a tool changer. (See Section 5.4 Report for how to generate a report).

There are two maintenance bits: One turns on when the lifetime counter reaches 1 million cycles. Contact Applied Robotics to turn off the Lifetime Required Maintenance Bit once maintenance is complete at one million cycles. The other maintenance bit turns on when the settable cycle counter reaches the Module Maintenance Interval. It is to be used as a reminder of when to perform maintenance on the Tool Changers, any of the modules, or even to set any reminder related to the robot or cell if desired.

It is recommended to generate a report at least after every maintenance performed. See Section 5.4 on Reports. Please refer to Chapter 7 Maintenance of the most current revision of the SmartChange Tool Change System Manual for maintenance requirements.

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Configuration Page

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5.4 Report
To track and save data on the module and tool changer, a report can be generated in XML format from the Configuration Page. It is recommended to create a report at least after every maintenance. Such data is stored as the MAC ID, the IP Address, the Serial Number, the Date and Time the Report was created, the Cycle Counts, The Uncouple to Uncoupled Timing, and the max acceleration values. Please generate a report at first installation and email to Applied Robotics in either XML or excel format. This will give us baseline data to help us if you need support in the future. The following instructions will explain how to generate the report, save and import it into an Excel spreadsheet. On the Configuration Page, in the Maintenance Status section, select the Report button. A new webpage will open with the XML file. (see page 33 for an image of a typcal xml report). Go to File > Save As Name and Save file with an .xml format to desired location. To import into Excel: Open Excel. Go to Data > Import External Data > Import Data and select XML file. Example Excel Spreadsheet with Imported XML file:

Creating Schemas and Mapping can expand how the XML imports into Excel. The example to the right shows how they can be used.

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Example XML Report:

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5.5 Accelerometer Page

There is a 3 axis Accelerometer on the Robot Side Modules board. Its values and max values can be viewed on the webpage, and are also accessible through the DeviceNet Scanlist Object (see below). The Accelerometer can be Calibrated on the Config page (see Section 5.3). Accelerometers are helpful in a number of ways. Measuring acceleration in control systems can aide in correcting changing dynamic conditions. Accelerometer values can be used to calculate tilt and orientation, impact detection and logging, and to follow / determine recommended g forces. See the Scanlist Object in Section 6.5 and/or the ModbusTCP Register in Chapter 8 for accessing the 3 axis Accelerometer Data. Partial Image of Scanlist shown below.

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5.6 Histogram Page

The histogram page provides Timing Data on Couple to Coupled and Uncouple to Uncoupled. There are two graphs regarding Couple to Coupled. One is of the last 25 times, and the other is an over time trend, where it shows one time recorded for every 250 cycles. The Uncouple to Uncoupled timing is listed instead of graphed. The data should be similar to that of Couple to Coupled. The average time, max time, min time are listed. These times may be helpful in identifying problems with the solenoid, valve, tool changer, air pressure, proximity sensors and more. Similar values are in the XML Report, if graphs over longer periods of time are desired.

Couple to Coupled Histograms: Last 25 Measurements:

Graphs the last 25 couple to coupled times in milliseconds. Measurement Every 250 Cycles:

Records a Couple to Coupled Value every 250 cycles and graphs it to get a timing trend.

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6 Robot Side Object Model

DeviceNet Gateway object model: Identity Object (01HEX - 1 Instance) Message Router Object (02HEX - 1 Instance) (no supported attributes) DeviceNet Object (03HEX - 1 Instance) Assembly Object (04HEX - 2 Instances) Connection Object (05HEX - 2 Instances) Scanlist Object (66HEX - 8 Instances)

6.1 Identity Object (01HEX - 1 Instance)

Instance Class Instance 0 Instance 1 Attribute ID 1 1 2 3 4 5 6 7 Name Revision Vendor number Device type Product code number Product major revision Product minor revision Status Serial number Product name DNET data type UINT UINT UINT UINT USINT USINT WORD UDINT SHORT STRING 32 Data Value 1 50DEC 00HEX 51302 01 01 See below Unique 32 bit value Applied Robotics SmartChange Access Rule Get Get Get Get Get Get Get Get

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6.2 DeviceNet Object (03HEX - 1 Instance)

Instance Class Instance 0 Instance 1 Attribute ID 1 1 2 Name Revision Vendor number Baud rate DNET data type UINT USINT USINT Data Value 2 50 0=125kbps 1=250 kbps 2=500 kbps 0xFF 0 0=No Change 1=Change 0=No Change 1=Change 0-63 0-3 0 Get Get Get Get Get/Set* Access Rule Get Get/Set* Get/Set*

Structure of allocation choice byte Master MAC ID MAC ID switch changed Baud rate switch changed MAC ID switch value Baud rate switch value Quick Connect

Get Byte USINT BOOL BOOL USINT USINT BOOL

6 7 8 9 10

* When switches are used to set the MAC ID or baud rate, these attributes are not settable over the DeviceNet network. These values are stored to NVRAM.

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6.3 Assembly Object (04HEX - 2 Instances)

Instance Class Instance 0 Attribute ID 1 2 100 101 102 103 Input Instance 100 [T2O #1] 3 Name Revision Max Instance I/O Input assembly instance I/O Input produce length (30 words) I/O Output assembly instance I/O Output consume length (30 words) DeviceNet input DNET data Data Value Access Rule type UINT UINT UINT UINT UINT UINT USINT [60] 2 112 100 60 112 60 0 Get Get Get Get Get Get Get

Output Instance 112 [O2T #1]

DeviceNet output

USINT [60]

Get/Set

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Assembly Objects common services

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6.4 Connection Object (DeviceNet only) (05HEX - 2 Instances)

Instance Class Instance 0 Instance 1 Explicit connection

Attribute ID 1 1

Name Revision State

DeviceNet Data Type UINT USINT

Data Value 1 0 = nonexistent 3 = established 5 = deferred delete 0 83HEX 10xxxxxx011BIN xxxxxx = node address 10xxxxxx100BIN xxxxxx = node address 21HEX varies varies 2500 msec 1=delete 0 Null 0 Null

Access Rule Get Get

2 3 4

Instance type Transport trigger Produced connection ID

USINT USINT UINT

Get Get Get

Consumed connection ID

UINT

Get

6 7 8 9 12 13 14 15 16

Initial comm. character Produced connection size Consumed connection size Expected packet rate Watchdog timeout action Produced connection path length Produced connection path Consumed connection path length Consumed connection path

USINT UINT UINT UINT USINT UINT USINT Array UINT USINT Array

Get Get Get Get/Set Get/Set Get Get Get Get

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Instance Instance 2 Polled I/O

Attribute ID 1

Name State

DeviceNet Data Type USINT

Data Value 0 = nonexistent 1 = configuring 3 = established 4 = timed out 1 82HEX 01111xxxxxxBIN Xxxxxx = node address 10xxxxxx100BIN xxxxxx = node address 01HEX varies varies 0 0 = timeout 6 0x20 0x04 0x24 0x690x30 0x03 6 0x20 0x04 0x24 0x75 0x30 0x03

Access Rule Get

2 3 4

Instance type Transport trigger Produced connection ID

USINT USINT UINT

Get Get Get

Consumed connection ID

UINT

Get

6 7 8 9 12 13 14 15 16

Initial comm. character Produced connection size Consumed connection size Expected packet rate Watchdog timeout action Produced connection path length Produced connection path Consumed connection path length Consumed connection path

USINT UINT UINT UINT USINT UINT USINT Array UINT USint Array

Get Get Get Get Get/Set Get/Set Get Get Get

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6.5 Scanlist Object (66HEX - 7 Instances)

Instance Class Instance 0 Attribute ID 1 2 3 4 Name Revision Max instance Number of instances Pass-through timeout (100-2000) in milliseconds (round up based on CPU resolution) Status Byte Connected node status Missing Node status Board I/O input data Board I/O input data size Board I/O output data Board I/O output data size Average time to uncouple Maximum time to uncouple from node 1 Minimum time to uncouple Cycle count at maximum time to uncouple Number of times Coupled Total Number of times Coupled Total hours since reset Total running hours Accelerometer Value Accelerometer Max Value Accelerometer Raw Value Accelerometer Offset Value DeviceNet Data Type UINT UINT UINT UINT Data Value 1 7 7 500 Access Rule Get Get Get Get/Set*

10 11 12 100 101 102 103 120 121 122 123 124 125 126 127 200 201 202 203

USINT USINT USINT UINT USINT USINT USINT UINT UINT UINT UDINT UDINT UDINT UDINT UDINT UINT UINT UINT UINT

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Get/Set* Get Get Get Get Get/Set* Get Get Get Get Get Get/Set* Get Get/Set* Get Get Get/Set* Get Get/Set*

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Instance Instance 1-7

Attribute ID 1 2 3 4 5 6 7 9

Name Slave Vendor Number Slave Device Type Slave Product code number Slave Product major revision Slave Product minor revision Slave error status Slave serial number Slave product name Slave configuration consistency Value (NVRAM CRC Used with ADR) Slave Produced connection size Slave consumed connection size Slave I/O data, 1-8 bytes.

DeviceNet Data Type UINT UINT UINT USINT USINT USINT UDINT SHORT STRING32 UINT

Data Value

Access Rule Get Get Get Get Get Get Get Get

10 11 20

USINT USINT USINT[8] 0

Get Get Get/Set

** Any change to Instances 1-8 Attributes is effective immediately.

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7 Tool Side Object Model

7.1 Identity Object (01HEX - 1 Instance)
Instance Class Instance 0 Instance 1 Attribute ID 1 1 2 3 4 5 7 Name Revision Vendor Number Device Type Product Code Number Product Major Revision Product Minor Revision Status Product Name DeviceNet Data Type UINT UINT UINT UINT USINT USINT WORD SHORT STRING32 Data Value 1 50DEC 0HEX 28701 01 01 See Below Applied Robotics Toolboard Access Rule Get Get Get Get Get Get Get

Status Values: Bits 0 Called Owned Description TRUE indicates the device (or an object within the device) has an owner. Within the Master/Slave paradigm the setting of this bit means that the Predefined Master/Slave Connection Set has been allocated to a master. Outside the Master/Slave paradigm, the meaning of this bit is TBD. Reserved, shall be 0 Configured TRUE indicates the application of the device has been configured to do something different than the out-of-box default. This shall not include configuration of the communications. Reserved, shall be 0 Extended Device Status Minor Recoverable Fault Vendor-specific or as defined by Extended Device Status Table below. The EDS shall indicate if the device follows the public definition for these bits. TRUE indicates the device detected a problem with itself, which is thought to be recoverable. The problem does not cause the device to go into one of the faulted states. TRUE indicates the device detected a problem with itself, which is thought to be unrecoverable. The problem does not cause the device to go into one of the faulted states. TRUE indicates the device detected a problem with itself, which caused the device to go into the Major Recoverable Fault state. TRUE indicates the device detected a problem with itself, which caused the device to go into the Major Unrecoverable Fault state. Reserved, shall be 0

1 2

3 4-7 8

Minor Unrecoverable Fault

10 11 12-15

Major Recoverable Fault Major Unrecoverable Fault

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Extended Device Status Values:

Bits 4-7: 0 0 0 0 0 0 0 1 0 0 1 0 0 0 1 1 0 1 0 0 0 1 0 1 0 1 1 0 0 1 1 1 1 0 0 0 1 0 0 1 1 0 1 0 thru 1 1 1 1

Extended Device Status Description Self-Testing or Unknown Firmware Update in Progress At least one faulted I/O connection No I/O connection established Non-Volatile Configuration bad Major Faulteither bit 10 or bit 11 is TRUE (1) At least one I/O connection in run mode At least one I/O connection established, all in idle mode Reserved, shall be 0 Vendor / Product specific

Common Services:

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7.2 DeviceNet Object (03HEX - 1 Instance)

Instance Class Instance 0 Instance 1 Attribute ID 1 1 2 Name Revision MAC ID Baud Rate Value DNET data type UINT USINT USINT Data Value 2 Node Address: Range 0-63 0 = 125 kbps 1 = 250 kbps 2 = 500 kbps 0x00 Fault 0x00 Allocate Service 0 = No Change 1 = Change 0 = No Change 1 = Change Range 0-63 Range 0-3 0 = Disable 1 = Enable Access Rule Get Get/Set Get/Set

3 4 5 6 7 8 9 10

BOI Bus-Off Counter Structure Of: Allocation Choice Byte MAC ID switch Changed Baud Rate Switch Changed MAC ID Switch Value Baud Rate Switch Value Quick Connect

BOOL USINT STRUCT BOOL BOOL USINT USINT BOOL

Get/Set Get/Set Get Get Get Get Get Get/Set

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7.3 Assembly Object (04HEX - 1 Instance)

Instance Class Instance 0 Attribute ID 1 2 3 100 101 Input Instance 103 (0x66) 3 Name Revision Max Instance I/O Input assembly instance I/O Input produce length (30 words) I/O Output assembly instance DeviceNet input See Tool Changer Input Assembly below DNET data Data Value Access Rule type UINT UINT UINT UINT UINT USINT [60] 2 112 100 60 112 0 Get Get Get Get Get Get

Tool Changer Input Assembly:

Input Data Mapping:

* Least significant 4 bits of attribute of type USINT

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7.4 Connection Object (05HEX - 2 Instances)

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7.5 Ack Handler (2BHEX - 1 Instance)

7.6 Tool Changer (69HEX - 1 Instance)

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8 Modbus/TCP Industrial Ethernet

Using Modbus/TCP Industrial Ethernet on the Robot Side DeviceNet Ethernet Module: The Robot Side will communicate via Modbus/TCP with the Robot / PLC. The Tool Side Data and nodes will be accessible via the Robot Side Modbus/TCP Register. The Robot Side will communicate with the Tool Side via DeviceNet. Modbus/TCP cabling will go to the Robot Side M12 D-coded Ethernet connector. The Robot Side 4 pin minifast connector for Auxiliary Power needs to be connected. The Robot Side 5 pin minifast DeviceNet connector would need to be wired just for V+ and V. Use a Non-Auxiliary Power +24V and 24V to pins 2 and 3. This is just to power the boards.

8.1 Modbus/TCP Register

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* For reference from Chapter 6 Assembly Object:

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9 Drawings

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