TED Controller Hardware & Connections:

  • Updated

 

External Connections & Controls:

  1. Main Power Switch (SW3B010): The main power disconnect switch for the unit and the 120V outlets. This resettable breaker/switch is limited to 10A max and is illuminated when powered on. If the 10A limit is tripped, simply turning off the unit and restarting it will reset the breaker.
  2. Momentary CPU Reset (PB3E090): This momentary pushbutton allows CPU power to be reset without having to disrupt all the 120VAC and 24VDC circuits. It will reset the YRC CPU will leaving all external devices operational.
  3. USB Port (5V020): This USB 2.0 port allows an external USB drive to be inserted for data transfer. This is internally connected to the USB port (CN102) on the ACP01 board. This is a mass-storage port only and can not be used with other USB devices (ie card reader, camera, or mouse)
  4. VGA Debug Port (5V090): This VGA port allows connection of an LCD monitor for debug purposes of Moto+ applications. It allows "printf" statements to be added to Moto+ source code which will then be sent to the LCD screen as commanded.
  5. 110/120VAC Outlets (RECP3B010 & RECP3B011): These two outlets allow for laptops or the LCD monitor used for debug purposes mentioned above to be connected and powered. They are powered from the main 10A disconnect so heavy loads are not recommended.
  6. Ethernet Ports (PP3J100 & PP3J140): Two RJ45 ethernet ports allow access to all the internal ports (LAN#1, 2, 3) and are connected to an internal ethernet switch which can be configured for port mirroring which could allow monitoring of traffic to & from various devices connected to the switch.

  7. Programming Pendant Port (PP3J120): Connection point for either the YRC1000 standard pendant or the alternative "Smart Pendant". Power needs to be removed when either pendant is added or removed.

    Internal Connections & Controls:

8. 12VDC & 24VDC Fuse Module (FB3E020): These fuses provide the internal 12VDC and 24VDC power for various components within the enclosure. They utilize MDL-style glass fuses of the following size:

  • FU1 (2A): Powers the 12VDC needs of the CPU system of the controller
  • FU2 (1A): Powers the main cabinet's 24VDC (DB3E410) power needs. Users should not connect to DB3E410 and instead make connections off FU3 & DB3F010
  • FU3 (3A): User 24VDC power connection provided to DB3F010 in the right-hand side compartment
  • FU4 (2A): Powers the cooling fan and the reset logic for the momentary pushbutton on the front of the enclosure

9. Managed Ethernet Switch (SW3J030): This managed switch ties to all the various LAN ports of the robot controller, the two RJ45 ports on the front of the enclosure and provides opportunity to additional devices. Web access and port mirroring details can be found in the following article:___________________________

10. 12VDC-1 & GND Blocks (12VDC-1 & GND): This is the power distribution for 12VDC and the earth ground connections within the unit. Connections to the 12VDC should not be made but additional earth ground connections can be made if needed.

11. 24VDC & 0VDC Power Distribution (24VDC-1 & 0VDC-1): This is the main power distribution area for all the componets within the main compartment of the enclosure (DB3E410). Users again should not connect their own external devices to these distribution points.

12. Direct Connect IO Cards (CN306-309): User accessible inputs and outputs are made available on these DirectConnect IO cards. They are detailed in the schematics detailed in following article:____________

13. LAN Ports (CN105-CN107 "LAN1-LAN3"): Robot communication ports all cabled to the managed switch for wider system use. Ports are detailed below with their default IP-addresses and uses:

  • LAN1 (CN105) = 10.: Programming Pendant port
  • LAN2 (CN106) = 192.168.1.31: Main communication port used for most auxiliary device communication. This is only port which can communicate via EtherNet/IP
  • LAN3 (CN107) = DISABLED: This auxiliary Ethernet port is disabled by default but can be enabled in Maintenance Mode and configured to whatever IP address is desired

14. Rotary Dial (S1): This dial setting needs to be at "6" in order to allow the TED unit to run without a connected robot arm. Any other setting will result in unresetable alarms that will prevent operation of the unit.

15. SD Card (CN104): System files are stored on this removable SD card along with Moto+ applications. The card can be removed and backed-up if needed.

16. Fan Thermocouple (TPS3E200): The temperature of the enclosure is monitored by this thermocouple and sent to the fan controller which regulates the speed of the fan. See item#19 below for more details

17. USB Port (CN102): This is the same USB port that is cabled to the front of the TED unit. The cable can disconnected and an internal USB can be inserted and used intally if desired. Just be aware that only USB drives can be added as other devices are not supported by the operating system.

18. RS232 COM Port (CN103): The YRC1000 does support RS232 communication which originates from this port and can be programmatically controlled by either INFORM jobs or Moto+ applications. Parameters control the baud-rate and stop bit configuration.

19. Fan Controller (TPC3E140): The actively cooled TED unit's fan is controlled by this fan controller. It's programmed to run at 20% fan speed until reaching an internal temperature of 100F after which it increases in speed up to 100% speed as the temperature increases.

20. Expansion Safety Relay Board (RBD5G010): Many of today's modern safety devices have test-pulses on their transistor outputs in order to maintain safety certification. These test pulses can often be detected by the YRC1000 and cause safety signal mismatches resulting in robot errors. The Expansion Safety Relay Board can be wired to isolate the test-pulses from being seen by either the safety device when being output from the TED unit or from a device safety device being wire to the TED unit as input (see page 5G of the TED diagram for example connections). 

21. Expansion Safety Breakout Card (X181-CN220): This FSU related IO breakout card have 8 dual-channel inputs and 8 dual-channel outputs on detailed on page 5G & 5H of the TED diagram. These transistor inputs and outputs have self-checking health functions integrated into their software controls which allows them to achieve PLd/SIL3 rating but may require use of the relay board mentioned above to ensure false trips of the safety circuit does not occur.

22. Power Distribution (DB3F010): This is the intended customer interface point for 24VDC and 0VDC for adding additional componentry and sensors to the TED unit. It's powered by a 3A fuse FU3 and able to power most moderate wattage devices.

23. Time Delay Reset Relay (CR3E090): To achieve "software reset" functionality of being able to do a "CPU Reset" from the programming pendant this time delay reset relay forces power to remain off for 3-seconds when performing a "CPU Reset" from the pendant or pressing the momentary reset button on the front of the enclosure.

24. X18-CN220 Safety Board Breakout: This is the standard safety IO breakout board for signals like "On Enable", "Overtravel", "Rapid Inputs", "GSIN/GSOUT" safety IO, E-stop inputs, and Safety Gate inputs. This  break out board can also be interfaced with the Safety Relay Board if needed in order to isolate the inputs & outputs to prevent false trips as detailed above it item#21 above.