Introduction
The Emergency Stop (E-stop) button on the Programming Pendant is used to turn OFF servo power of the robot. The Emergency Stop Output Signals ESPOUT1 & ESPOUT2 can be used to output the contact point of the Emergency Stop (E-stop) button on the Standard Programming Pendant (177716-2) to an external machine, such as a CNC machine, machine press, or additional robot, etc.
However, when the Smart Pendant (182818-1) is used, the Emergency Stop Output Signals ESPOUT1 & ESPOUT2 do not interact with the Smart Pendant’s E-stop button. Meaning, that the contact point of E-Stop button of the Smart Pendant will not be outputted to the external machine, even though the external machine is tied to ESPOUT1 & ESPOUT2 signals. This applies to both YRC1000 or YRC1000micro on Smart Pendant.
To be more precise, internally the Smart Pendant utilizes 2 contacts for the Emergency Stop (E-Stop) button instead of 4 contacts in the Standard Programming Pendant (177716-2). This can be seen below:
Internally the Standard Programming Pendant (177716-2) has 4 contacts for the E-Stop button. 2 of the 4 contacts are connected to External Emergency Stop Output Signal ESPOUT1 & ESPOUT2, and the other 2 are connected to Programming Pendant E-Stop Signal PPESP.
Internally the Smart Pendant (182818-1) has 2 contacts for the E-Stop button. These 2 contacts are connected to Programming Pendant Emergency Stop Signal PPESP.
Overview
In this article, it will demonstrate how the Emergency Stop Output Signals ESPOUT1 & ESPOUT2 are not tied to the E-Stop button on the Smart Pendant (182818-1). In this demonstration, an HC20DT YRC1000micro Emergency Stop Output Signals ESPOUT1 & ESPOUT2 will be connected to an HC10 YRC1000. The HC20DT YRC1000micro ESPOUT1 & ESPOUT2 signals will be tied to the External Emergency Stop Input Signals EXESP1 & EXESP2 of the HC10 YRC1000.
The ESPOUT1 & ESPOUT2 signals on the YRC1000micro controller can be found on the SAFETY breakout card (185412-1 or 192528-2). In this setup, the SAFETY breakout card is part number 185412-1. The EXESP1 & EXESP2 signals can be found on CN220 breakout card on the YRC1000. Breakout card CN220 can be found inside the door panel of the YRC1000.
When the E-Stop button on the Programming Pendant (177716-2) is pressed and released on the HC20DT YRC1000micro, the HC10 YRC1000 will see the E-Stop signal from the HC20DT YRC1000micro. Then when the Smart Pendant (182818-1) is used, the E-Stop on the HC10 YRC1000 will be enabled even though the Smart Pendant’s E-Stop button is not pressed.
YRC1000micro of the HC20DT.
SAFETY (185412-1) breakout card of the HC20T YRC1000micro, where the ESPOUT1 & ESPOUT2 signals can be found.
ESPOUT1 & ESPOUT2 are tied to pin 9, 10, 19, and 20 of the SAFETY breakout card.
YRC1000 controller of the HC10.
CN220 breakout card of the HC10 YRC1000. EXESP1 & EXESP2 can be found in this breakout card.
The CN220 breakout card can be found inside the YRC1000 controller door. Pin 5, 6, 7, and 8 are associated to EXESP1 & EXESP2.
If the output contact of the Emergency Stop (E-Stop) button of the Smart Pendant is necessary, modifications will need to be made in the Safety Logic Circuit to mimic the ESPOUT1 & ESPOUT2 signals. This can be done by adding a rung to the Safety Logic Circuit, that when the Programming Pendant Emergency Stop Signal (PPESP) turns ON/OFF, a safety output signal turns ON/OFF. In the case of this demonstration, General-Purpose Safety Output Signal #2 (FSBOUT2) will be used as the External Emergency Stop signal in the Safety Logic Circuit, in combination with a Safety Relay.
Before proceeding with this setup, verify that the Functional Safety Option Function is enabled on the YRC1000 or YRC1000micro controller. Also verify that the Expansion Safety I/O Board is installed to utilize the FSBOUT2 signal. In the case of the HC20DT YRC1000micro and any HC series controller, both the Functional Safety Option Function is enabled and has the Expansion Safety I/O Board installed. The images below show where the Expansion Safety I/O Board is located when installed on YRC1000 or YRC1000micro.
Safety I/O Expansion Board connector on YRC1000micro. The user would need to attach the Safety I/O Cable (186172-2) and Safety I/O Breakout Card (149259-3).
Safety I/O Expansion Board connector on YRC1000micro for HC Series. The user would need to attach the Safety I/O Cable (186172-2) and Safety I/O Breakout Card (149259-3).
Safety I/O Expansion board and Breakout Card (CN220) on YRC1000. This is the same for the YRC1000 HC Series.
For YRC1000, General Purpose Safety Output Signals GSOUT[x] can be used instead of the FSBOUT2 signal, if the Expansion Safety I/O Board is not available. Unfortunately, GSOUT[x] or GSIN[x] are only available on YRC1000. The Expansion Safety I/O will be needed on YRC1000micro to use the FSOUT2 signal or any FSOUT signal. The GSIN and GSOUT signals can be found on the CN220 breakout card.
Setup
In this setup, FSBOUT2 will be used as the output contact when the E-Stop button is pressed/released on the Smart Pendant. Meaning, that External Emergency Stop Output Signals ESPOUT1 & ESPOUT2 will no longer be used to E-stop the external machine (HC10 YRC1000). The images below show how to wire the FSOUT signals to an external machine via safety relay and where the FSOUT signals are located on the Safety I/O Expansion Board.
The FSBOUT signals can be found on breakout card CN3 (149259-3). This example shows how to wire FSOUT signals using a Safety Relay to an External Device.
The FSOUT2 signal pin location on the CN3 (149259-3) breakout card.
Breakout card CN3 (149259-3). The HC20DT YRC1000micro FSBOUT2 signals & HC10 YRC1000 EXESP signals are connected to a Pilz PNOZ s4 (750104) safety relay.
From the image above, the FSOUT2 signals were connected EXESP1 & EXESP2 signals of the HC10 YRC1000 via a Pilz PNOZ s4 Safety Relay. Reviewing the Pilz PNOZ s4 Operating Manual-21396-EN-21 on Pilz’s site, the Safety Relay was connected following the Application Example of OSSD signals that are dual channel, without detection of shorts across the contacts, with automatic start, and with feedback loop monitoring. The Safety Relay was connected to both controllers as follows:
HC20DT YRC1000micro
FSBOUT2_1+ → X1: S12 (*1)
FSBOUT2_1- → X4: A2 (*2)
FSBOUT2_2+ → X1: S22
FSBOUT2_2- → X4: A2(*2)
HC10 YRC1000
EXESP_1+ → X3: 13
EXESP_1- → X4: 14
EXESP_2+ → X3: 23
EXESP_2- → X4: 24
Safety Relay
X1: S12 → X1: S34
X3: A1 → FSBOUT2_1+ (*1)
X4: A2 → FSBOUT2_1- (2*)
(*1) – The cables are jumper together.
(*2) – The cables are jumper together.
Then on the Safety Logic Circuit, a rung was added, that when the Programming Pendant Emergency Stop Button signal or PPESP signal is OFF, the FSOUT2 signal turns OFF. The PPESP signals or PPESP1 & PPESP2 signals are connected internally to the Emergency Stop Button on both the Standard Programming Pendant and Smart Pendant.
Safety Logic Circuit. Line 3 is the rung that turns OFF FSOUT2 when the Emergency Stop (E-Stop) button is pressed on the Smart Pendant.
Conclusion
When using the Smart Pendant (182818-1), the Emergency Stop Output Signals (ESPOUT1 & ESPOUT2) will not interact with the Emergency Stop (E-Stop) button on the Smart Pendant. If the output contact of the Emergency Stop (E-Stop) button of the Smart Pendant is necessary, following this article can accomplish that.
Modifications may be needed depending on the user’s setup. Photos, drawings, and setup from this article are representative examples and differences may exist to user’s setup. Verify and confirm user’s setup before making appropriate circuit configuration. Failing to do so may cause damage to electrical devices or to the YRC controller.
Always perform a risk assessment, before making changes to the Safety Logic Circuit, using safety signals, or installing safety devices. Actual implementation may vary, and shall be based upon, but not limited to the results of a comprehensive Risk Assessment, all applicable regulations, industry standards, and manufacturer specifications.
As mentioned earlier, the Pilz PNOZ s4 Safety Relay Operating Manual-21396-EN-21 is used in conjunction with the following manuals to perform this setup. For additional information on the setup, reference the manuals below:
* YRC1000/YRC1000micro INSTRUCTIONS FOR Smart Pendant Manual (184775-1CD)
* YRC1000 INSTRUCTIONS Manual (178642-1CD)
* YRC1000micro SUPPLEMENTARY INSTRUCTIONS FOR HC SERIES Manual (184757-1CD)
* YRC1000micro INSTRUCTIONS Manual (181274-1CD)
* YRC1000micro OPTIONS INSTRUCTION FUNCTIONAL SAFETY UNIT (FSU) Manual (183448-1CD)
Here’s a list of parts used for this setup on the YRC1000micro controller:
* 149259-3, “BOARD,PC,BREAKOUT,68 POSITION”
* 186172-2, “CABLE,I/O,MDR,68 POSITION,MDR,MALE/MALE,2M”
* 185034-1, “CABLE ASSY,SAFETY I/O,BREAKOUT,YRC1000micro,2M”
* 185412-1, “BOARD,PC,BREAKOUT,YRC1000micro,SAFETY SIGNALS,25-POS,W/JUMPERS”
Modifications have been made to the SAFETY breakout board. Now, the General Purpose Digital Input & Output breakout board and SAFETY breakout board for the YRC1000micro have been integrated into one breakout board, 192528-2, “RAIL ASSY,DIN,GPIO,SAFETY IO,HC-SERIES ROBOT,YRC1000micro”.
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