SmartControllerEX User Guide

SmartController EX
User’s Guide
I602-E-03
Copyright Notice
The information contained herein is the property of Omron Adept Technologies, Inc., and shall not be
reproduced in whole or in part without prior written approval of Omron Adept Technologies, Inc. The
information herein is subject to change without notice and should not be construed as a commitment by
Omron Adept Technologies, Inc. The documentation is periodically reviewed and revised.
Omron Adept Technologies, Inc., assumes no responsibility for any errors or omissions in the
documentation. Critical evaluation of the documentation by the user is welcomed. Your comments assist
us in preparation of future documentation. Please submit your comments to: techpubs@adept.com.
Copyright 2013, 2014, 2016, 2019 by Omron Adept Technologies, Inc. All rights reserved.
Any trademarks from other companies used in this publication
are the property of those respective companies.
Created in the United States of America
Table of Contents
Chapter 1: Introduction 7
1.1 Product Description 7
Optional T20 Pendant 7
1.2 How Can I Get Help? 9
Related Manuals 9
Chapter 2: Safety 11
2.1 Dangers, Warnings, and Cautions 11
Alert Levels 11
Alert Icons 11
Special Information 12
2.2 What to Do in an Emergency / Abnormal Situation 12
Stopping the Robot 12
Fire Response 12
2.3 Safety Precautions 12
2.4 Additional Safety Information 12
Manufacturer’s Declarations 12
Robot Safety Guide 13
Emergency Stop Circuit and Buttons 13
Manual Control Pendant 13
2.5 Disposal 13
Chapter 3: Installation 15
3.1 Controller Installation 15
Before Unpacking 15
Upon Unpacking 15
Repacking for Relocation 16
Space Around the Chassis 16
Mounting the SmartController EX Motion Controller 16
Mounting Kits 16
Memory Card 20
3.2 Connecting Power 22
24 VDC Power Specifications 22
24 VDC Power Cabling 23
DC Power Connectors 24
Chassis Grounding 24
Installing 24 VDC Connectors 25
3.3 System Cable Installation 26
11069-000 Rev. H SmartController EX User's Guide 3

Table of Contents
IEEE 1394 Cable Specifications 26
Chapter 4: Operation 27
4.1 Connectors and Indicators 27
4.2 Front Panel 31
4.3 Installing the ACE Software 32
4.4 Configuring the SmartController 33
Configuring Serial Ports 33
RS-232 Connectors 34
RS-422 / 485 Connector 34
4.5 Connecting User-Supplied Safety and Power-Control Equipment 35
Emergency Stop Circuits 41
Remote Manual Mode 43
User Manual / Auto Indication 43
User High Power On Indication 43
Remote High Power ON / OFF Control 43
High Power ON / OFF Lamp 44
Remote Front Panel or User-Supplied Control Panel Usage 44
Remote Pendant Usage 45
4.6 Connecting User-Supplied Digital I/O Equipment 45
DeviceNet Connector 45
XDIO Connector 45
4.7 Belt Encoder Interface 51
Chapter 5: Technical Specifications 55

5.1 SmartController EX Motion Controller Dimensions 55
5.2 Front Panel Dimensions 56
5.3 T20 Pendant Dimensions 57
Chapter 6: DeviceNet 59
6.1 DeviceNet Specifications 59
6.2 Limitations of the DeviceNet Scanner 60
6.3 DeviceNet Port on the Controller 60
Connecting DeviceNet Hardware to the Controller 60
Configuring DeviceNet 61
6.4 DeviceNet Physical Layer and Media 61
DeviceNet Connectors 65
Termination of the DeviceNet Network 66
Power Supply and the DeviceNet Bus 67
4 SmartController EX User's Guide 11069-000 Rev. H

Revision History
Revision
Date Revised Content
code
01 June, Original release

2016
02 October, Added OAT part number for non-Omron sales channels, updated
2016 Omron logo in graphics
03 March, l Added WEEE disposal information.

2019 l Updated all www.adept.com references to www.ia.omron.com.
l Updated copyright for 2019.
l Added information about optional Mounting Kits.
l Removed references to obsolete sDIO unit.
l Removed daisy-chaining power supply details.
l Updated ACE Software installation procedure.
l Updated illustrations with call-outs for translation compatibility
and other minor improvements.
l Updated Chapter 2: Safety with new format and information.
l Replaced discontinued S8JX-G power supply with replacement
S8FS-G series.

Chapter 1: Introduction
1.1 Product Description

The SmartController EX motion controller is a member of the Omron Adept Technologies, Inc.
family of high-performance distributed motion controllers. The SmartController is designed for
use with Quattro, Hornet, eCobra, and Viper robots.
Figure 1-1. SmartController EX Motion Controller
Optional T20 Pendant

The optional T20 pendant provides a user interface and teach pendant in an ergonomic and
rugged package. The pendant is designed for right- or left-handed use. All gripping and hold-
ing positions enable comfortable and fatigue-free operation.
The safety features include:
l Emergency-stop switch (dual-channel circuit)
l 3-position enable switch (dual-channel circuits)
See the T20 Pendant User’s Guide, shipped with each pendant, for complete information on
the product.

1.1 Product Description
Figure 1-2. T20 Pendant

Chapter 1: Introduction
1.2 How Can I Get Help?

For details on getting assistance with your software or hardware, you can access the following
corporate website:
http://www.ia.omron.com
Related Manuals
This manual covers the installation and maintenance of a SmartController EX motion con-
troller. There are additional manuals that cover programming the system, reconfiguring
installed components, and adding other optional components. The following manuals provide
information on advanced configurations and system specifications.
Table 1-1. Related Manuals
Manual Title Description
Robot Safety Guide Contains safety information for Omron Adept Technologies,
Inc. robots.
T20 User’s Guide Contains information on the installation and operation of the
T20 pendant.
ACE User's Guide Describes installation and use of the ACE software.
eV+ OS User Guide Describes the eV+ operating system, including disk file oper-
ations, monitor commands, and monitor command pro-
grams.
eV+ Language User's Guide Describes the eV+ language and programming of our control
system.

Chapter 2: Safety
2.1 Dangers, Warnings, and Cautions
Alert Levels
There are three levels of alert notation used in our manuals. In descending order of import-
ance, they are:
DANGER: Identifies an imminently hazardous situation which, if not
! avoided, is likely to result in serious injury, and might result in fatality or

severe property damage.
WARNING: Identifies a potentially hazardous situation which, if not avoided,
! will result in minor or moderate injury, and might result in serious injury, fatal-
ity, or significant property damage.
CAUTION: Identifies a potentially hazardous situation which, if not avoided,
! might result in minor injury, moderate injury, or property damage.
Alert Icons
The icon that starts each alert can be used to indicate the type of hazard. These will be used
with the appropriate signal word - Warning or Caution - to indicate the severity of the hazard.
The text following the signal word will specify what the risk is, and how to avoid it.
Table 2-1. Alert Icon Meaning
Icon Meaning
This is a generic alert icon. Any specifics on the

risk will be in the text following the signal word.
This identifies a hazardous electrical situation.

2.2 What to Do in an Emergency / Abnormal Situation
Special Information
There are several types of notation used to call out special information.
IMPORTANT: Information to ensure safe use of the product.
NOTE: Information for more effective use of the product.
Additional Information: Offers helpful tips, recommendations, and best prac-

tices.
Version Information: Information on differences in specifications for different

versions of hardware or software.
2.2 What to Do in an Emergency / Abnormal Situation
Stopping the Robot

Press any E-Stop button (a red push-button on a yellow background) and then follow the
internal procedures of your company or organization for an emergency situation.
Fire Response
If a fire occurs, use CO2 to extinguish the fire.
2.3 Safety Precautions
WARNING: ELECTROCUTION RISK
During maintenance, disconnect AC power from the robot, and install a lock-
out tag-out to prevent anyone from reconnecting power.
WARNING: PERSONAL INJURY OR PROPERTY DAMAGE RISK
! An industrial robot can cause serious injury or death, or damage to itself and
other equipment, if the safety precautions in this manual are not observed.
2.4 Additional Safety Information

We provide other sources for more safety information:
Manufacturer’s Declarations
This lists the standards with which the robots and controllers comply. The Manufacturer’s
Declarations are in the Manufacturer's Declaration Guide.

Chapter 2: Safety
Robot Safety Guide

The Robot Safety Guide provides detailed information on safety for our robots. It also gives
resources for more information on relevant standards. It ships with each robot.
Emergency Stop Circuit and Buttons

The E-Stop provided complies with ISO 10218-1 (Clause 5.5.2), with stop category 1 (per IEC
60204). The E-stop button complies with ISO 13850. The E-Stop meets the requirements of PL-d
per ISO 13849.
If you design your own front panel, it must meet the requirements of ISO 13849, and be at least
PL-d. The E-Stop button must comply with IEC 60204-1 and ISO 13850, Clause 5.5.2.
If you choose to use your own E-Stop buttons, they must meet the requirements of IEC 60204-1
and ISO 13850, Clause 5.5.2.
Manual Control Pendant

The protective stop category for the pendant enable switch is category 1, which complies with
the requirements of ISO 10218-1.
The pendant is designed in accordance with the requirements of IEC 60204-1 and ISO 13849.
The E-Stop button is ISO 13850 compliant.
NOTE: Omron Adept Technologies, Inc. does not offer a cableless (wireless)
pendant.
The manual control pendant can only move one robot at a time, even if multiple robots are
connected to a SmartController EX, and the pendant is connected to the SmartController EX.
2.5 Disposal
Dispose of in accordance with applicable regulations.
Customers can contribute to resource conservation and protecting the environment by the
proper disposal of WEEE (Waste Electronics and Electrical Equipment). All electrical and elec-
tronic products should be disposed of separately from the municipal waste system via des-
ignated collection facilities. For information about disposal of your old equipment, contact your
local Omron support.

Chapter 3: Installation
3.1 Controller Installation

This equipment must be shipped and stored in a temperature-controlled environment. See the
following table. It should be shipped and stored in the original packaging, which is designed
to prevent damage from normal shock and vibration. You should protect the package from
excess shock and vibration.
Table 3-1. Environmental Specifications
Ambient temperature 5° to 40° C (41° to 104° F)
Storage and shipment temperature –25° to 55° C (-13° to 131° F)
Humidity range 5 to 90%, non-condensing
Altitude up to 1000 m (3280 ft)
Free space around controller 10 mm at back, 13 mm on sides (0.4 in., 0.5 in.)
(for proper cooling)
Chassis protection class IP20 (NEMA Type 1)
WARNING: Use an appropriate IP-rated enclosure.
!
Before Unpacking
Carefully inspect all shipping containers for evidence of damage during transit. If any damage
is indicated, request that the carrier’s agent be present at the time the container is unpacked.
Upon Unpacking
Compare the actual items received (not just the packing slip) with your equipment purchase
order, and verify that all items are present and that the shipment is correct. Inspect each item
for external damage as it is removed from its container. Contact Omron Adept Technologies,
Inc. immediately if any damage is evident.
Retain all containers and packaging materials. These items may be needed in the future to
settle a damage claim.
Perform the following steps to unpack the SmartController EX motion controller and optional
pendant. Refer to the following sections for information on mounting the equipment.

1. Remove the SmartController EX motion controller from its box. Place it near the robot or
mount it in a rack. For details, see Mounting the SmartController EX Motion Controller
on page 16.
2. Remove the optional T20 pendant from its box and place it on a flat surface near the
SmartController EX motion controller.
Repacking for Relocation

If the controller needs to be relocated, reverse the steps in the installation procedure. Reuse all
original packing containers and materials and follow all safety notes used for installation.
Improper packaging for shipment will void your warranty.
Space Around the Chassis

When the SmartController EX motion controller is installed, you must allow 10 mm at the
back of the unit and 13 mm on the sides of the unit for proper air cooling.
Mounting the SmartController EX Motion Controller

The following mounting options are available for the controller:
l Rack
l Panel
l Table
l Stack
The controller and compatible units can be mounted with one unit placed on top of
another.
NOTE: To maintain compliance with many standards, the mounting of the con-
troller and all terminations at the controller must be performed in accordance
with local and national regulations.
Mounting Kits
The following mounting kits are available (order separately).
Table 3-2. Mounting Kit Details
Item Part Number Contents
Table / Rack-Mounting Kit 00205-000 l brackets (table-mount): 4 x 40356-00001

l brackets (rack-mount): 2 x 40356-00004
l fasteners: 8 x 51052-65006
Panel-Mounting Kit 90356-40000 l brackets: 4 x 40356-00000

l fasteners: 8 x 51052-65006

Rack-Mounting the SmartController EX Motion Controller
To rack-mount the controller in a standard 19-inch equipment rack, install the optional mount-
ing brackets on the side of the controller, as shown in the following figure. These brackets must
be ordered separately. They do not come with the controller.
190.0
2X 40356-00004 3X M3 x 6MM
2X 25.0
88.1 44.4
21.8
3.8 19.1
3.6 462.0 14.2
TYP. 482.8
Figure 3-1. Rack-Mounting the SmartController EX Motion Controller (Units in mm)
Panel-Mounting the SmartController EX Motion Controller
To panel-mount the controller, install two brackets on each side at the rear of the unit, as
shown in the following figure. Use the screws from the accessories kit.

200.5
14.0
4X 40356-00000
27.4 273.9
R3.6 TYP.
8.1 8X M3 x 6MM
16.1
44.9 44.9
16.0
6.6 346.6
359.8
Figure 3-2. Panel-Mounting the SmartController EX Motion Controller (Units in mm)
Table-Mounting the SmartController EX Motion Controller
To table-mount the controller, install two brackets on each side near the bottom of the unit, as
shown in the following figure. These brackets must be ordered separately. They do not come
with the controller.

4X 40356-00001 R3.6
12.1
29.5
24.1
120.9
24.9
378.6
391.8
4X M3 x 6MM
16.2
16.0 21.6
120.9
Figure 3-3. Table-Mounting the SmartController EX Motion Controller (Units in mm)
Stack-Mounting Components
To stack-mount the SmartController EX motion controller and a compatible unit, such as a

SmartVision MX vision controller, install two brackets on each side of the units, as shown in
the following figure. These brackets are supplied with compatible units.

14393-000
328.9
15.0 52.0
150.0 225.0
162.0
186.5
Figure 3-4. Stack-Mounting SmartController EX Motion Controller (Units in mm)
Memory Card
The SmartController EX motion controller is equipped with a Secure Digital™ (SD) memory
card. The SD card is removable, and can be moved to another SmartController EX motion con-
troller for testing.
The SD card shipped with all systems is factory-configured and installed. The SD card stores
the eV+ operating system, application programs, data files, and licenses.
Only the factory-supplied SD card will work with the SmartController EX motion controller.
NOTE: This SD card is not compatible with the legacy SmartController CX or

CS motion controllers.

CAUTION: Use suitable measures for eliminating electrostatic discharge dur-
! ing removal and installation of the SD card. This includes, but is not limited to,
the use of a grounded wrist strap
CAUTION: Do not remove the SD card when power is connected to the con-
! troller.
Removing an SD Card
To remove an SD card from a SmartController EX motion controller:

1. Make sure that the controller is disconnected from its power source.
2. Locate the SD compartment (see the following figure).
Figure 3-5. (1) SD Memory Card Compartment
NOTE: If you are replacing an existing SD, the original must be sent to the fact-
ory for replacement.
3. Press the SD card in, and release. The card will pop out.
Remove the card. Contact your sales representative for instructions on returning it.
Installing an SD Card
To install an SD card into a SmartController EX motion controller:

1. Make sure that the controller is powered off.
2. Locate the SD card compartment (see the preceding figure).
3. Carefully remove the SD card from the READ ME FIRST box or shipping container.

3.2 Connecting Power
Position the card so its contacts are facing towards the controller and to the left. The
label will be facing to the right.
4. Insert the SD card into the controller.
Once installed, we recommend that you do not repeatedly remove and insert the SD card.

The SmartController EX motion controller requires filtered 24 VDC power.
NOTE: Users must provide their own power supply. Make sure the power cables
and power supply conform to the specifications that follow.
24 VDC Power Specifications
Table 3-3. Specifications for 24 VDC User-Supplied Power Supply
User-Supplied Power Supply 24 VDC (-10%, +5%), 120 W (5 A)
Circuit Protection Not more than 8 A (below the amper-

age rating of the cable used)
Power Cabling 1.5 - 1.85 mm2 (16-14 AWG), full-

cover, braided shield cable, maximum
length 10 meters
Shield Termination Braided shield connected to the marked

frame ground screw on the right side of
the controller (near the XDC con-
nector). On the other end of the cable,
the shield should be connected to the
power supply chassis.
6 3
5 4
Figure 3-6. User-Supplied 24 VDC Cable

Table 3-4. User-Supplied 24 VDC Cable

Item Description
1 11 mm (0.43 in) Outside diameter
2 65% Coverage tinned copper braid shield
3 Shield drain wire
4 DC power pair PVC (16-14 AWG tinned and stranded copper con-

ductors)
5 Aluminum / Mylar shield over each pair
6 External jacket
CAUTION: Make sure you select a 24 VDC power supply that meets the spe-
! cifications in the preceding table. Using an underrated supply can cause sys-
tem problems and prevent your equipment from operating correctly. See the
following table for recommended power supplies.
Table 3-5. Recommended 24 VDC Power Supplies
Vendor Name Model Ratings Mount
OMRON S8FS-G15024C 24 VDC, 6.5 A, 150 W Side/Bottom
OMRON S8FS-G15024CD 24 VDC, 6.5 A, 150 W DIN-Rail Mount
NOTE: The power requirements for the user-supplied power supply will vary
depending on the configuration of the SmartController EX motion controller and
connected devices. A minimum configuration of the controller, front panel, and
pendant will require 2 A at 24 VDC. However, a 24 V, 5 A power supply is
recommended to allow for additional current draw from connected devices, such
as external IEEE 1394 devices and digital I/O loads.
24 VDC Power Cabling

In order to maintain compliance with many standards, DC power must be delivered over a
shielded cable, with the shield connected to the frame ground at both ends of the cable, as
shown in the following figure. Conductors should be 1.5 mm2 to 1.85 mm2 (16 to 14 AWG) in
size. The maximum length for the 24 VDC cable is 10 meters.

SmartController EX 2
4
-+ 3
6
+
1
- 24 VDC, 5A
Figure 3-7. User-Supplied Shielded Power Cable
Table 3-6. User-Supplied Shielded Power Cable Description
Item Description
1 User supplied connector
2 Shield from cable, star washer M3 x 6 screw
3 Optional fuse
4 Frame ground
5 Shield from cable to frame ground on power supply
6 User-provided power supply
DC Power Connectors
The SmartController EX motion controller is equipped with two DC power connectors. DC
power can be applied to either the XDC1 or XDC2 connector.
CAUTION: Use only one 24 VDC power supply per circuit. Failure to do this
! could result in damage to the equipment.
CAUTION: The SmartVision MX vision controller has a higher current
! demand and should be wired independently. Do not daisy-chain its power

from a SmartController EX motion controller.
NOTE: The power switch on the SmartController EX motion controller will shut
down just the controller. The two connectors, XDC1 and XDC2, are always con-
nected to each other, so any device that receives power from XDC1 or XDC2 will
maintain power after the controller is shut down.
Chassis Grounding
The SmartController EX motion controller is equipped with a grounding point, as shown in
the following figure. We recommend connecting a ground wire from the grounding point on

the controller to earth ground and that all other interconnected components share the same
electrical ground potential. The ground wire must meet all local regulations. Additional
grounding information for our other products is provided in the documentation for those
products.
NOTE: The maximum length for the ground wire for the controller is 3 meters.
NOTE: The resistance of the ground conductor should be ≤ 10 Ω.
Figure 3-8. (1) Chassis Grounding Point
The mounting of the controller and all terminations must be performed in accordance with
local and national regulations.
Installing 24 VDC Connectors

Use the supplied connector to connect the user-supplied 24 VDC power supply to the
1. Locate the 24 VDC connector shipped with the controller. See the following figure.
2. Use 14 or 16 gauge wire to connect the 24 VDC power supply to the controller.
3. Strip 7 mm of insulation from the end of the wire that connects to the positive output of
the 24 VDC supply.
4. Insert the stripped end into the opening on the right side of the connector.
5. Tighten the screw clamp on the connector with a small slot screwdriver (2.5 mm).
6. Visually inspect the connection to ensure that the clamp has closed on the wire, not on
the insulation.
7. Gently pull on the wire to confirm that it is securely attached to the connector.
8. Repeat this process to connect the wire from the negative side of the power supply to
the left side of the connector.
9. Connect the braided shield to the ground screw on the front of the controller.
A ring lug can be used, as shown in the following figure. The ground screw is an M3.

3.3 System Cable Installation
Figure 3-9. 24 V Connector
NOTE: Although no damage will occur, the SmartController EX motion con-

troller will not turn on if the DC polarities on the XDC connectors are reversed.
3.3 System Cable Installation

The SmartController EX motion controller is used in many of our systems, including Hornet
robots, eCobra robots, Viper robots, Quattro robots, and the sMI6 Module for the SmartMotion
product.
See your specific product manual for complete details on system cabling for your SmartCon-
troller system.
IEEE 1394 Cable Specifications

We supply the IEEE 1394 cables to connect the SmartController EX motion controller to other
devices in the system. If you need a cable of a different length than those supplied, then you
must purchase a cable from one of the approved vendors listed below:
l CEI: www.componentsexpress.com
l Molex, Inc.: www.molex.com
These purchased cables must meet all specifications of the IEEE 1394 standard. Note that the
system uses 6-pin to 6-pin cables. The maximum length for a 1394 cable is 10 meters. The
1394 Trade Association provides detailed specifications for 1394 cables and other related
information. See www.1394ta.org.
WARNING: You must use cables from vendors that meet all specifications of
! the IEEE 1394 standard. Using a non-approved or inferior quality IEEE 1394
cable can cause unpredictable system performance.

Chapter 4: Operation
4.1 Connectors and Indicators
8 10 11
2 4 9 18
3 12 5 13 6 14 7 15 16 17
Figure 4-1. SmartController EX Connectors and Indicators
All of the connectors on the SmartController EX motion controller use standard-density spa-
cing, D-subminiature connectors. For customization purposes, the user needs to provide con-
nectors of the appropriate gender and pin count, or purchase optional factory-supplied cables.
1. SD Card Slot
See Installing an SD Card on page 21.
2. Top Three Status LEDs
The top three two-color LEDs indicate diagnostic test, power control, and com-
munication status.
Table 4-1. Controller LEDs

LED Green Indicates Red Indicates
OK/SF System OK System Fault
HPE/ES High Power Enabled E-Stop Open
FW/HD SmartServo Con- Read / Write from SD

nection card
During system bootup, the red OK / SF and HPE / ES LEDs are lit and the red
FW / HD LED blinks. After system bootup, the OK / SF LED should show green.
If the HPE / ES LED shows red, the E-Stop circuit is open. During SD card reads
and writes, the FW / HD LED pulses red. When a robot is connected on one of
the SmartServo ports, the FW / HD LED shows green.

3. Bottom Three Status LEDs

NOTE: The bottom status LEDs have different meanings when the
SmartController is used with ePLC Connect software. See the ePLC Con-
nect User's Guide, chapter 3, for information on those LEDs with ePLC
Connect.
The bottom three LEDs on the front of the SmartController EX motion controller give the
following information about the status of the main controller.
O = Off G = Green R = Red
Table 4-2. LED Status Indicators
LED Display Error Description

1 2 3 Number
O-O-O 0 No error.
R-O-O 1 System clock is dead or too fast. Clock interrupts are not being
received.
O-R-O 2 Hardware configuration error.
O-O-R 4 Memory test failure. Free storage error.
O-R-R 6 Software serial I/O configuration error.
R-R-R 7 Initial display set by hardware before software has started.
G-O-O 9 Transient display set when PCI is configured.
O-O-G C Uninitialized trap.
G-O-G D Bus error detected.
If the SmartController EX motion controller displays an error, cycle the power off,
then on again. If the problem persists, contact Customer Service.
4. SW1 DIP switches

The definition for DIP switches on the SmartController EX motion controller is as fol-
lows:
Switch 1:
l OFF: use IP address from configuration on SD card
l ON: use default factory IP address (printed on the bottom of the controller)
Switch 2:
l OFF: normal connection through Ethernet
l ON: communication through RS-232 on the TERM port
Switch 3 and 4: reserved for future use; always leave in the OFF position.
In normal operation, all switches should be OFF.

5. SmartServo 1.1, 1.2, and 1.3

These ports connect any SmartServo-compatible product to the controller via the IEEE-
1394 cable. These ports are interchangeable - any one can be used.
WARNING: Remove power from the controller before plugging in or
! unplugging any IEEE-1394 cables from these connectors. Failure to

remove power could result in unpredictable behavior by the system.
6. Ethernet (Eth 10/100/1000) connectors

The shielded RJ-45 receptacles support 10/100/1000 BaseT Ethernet communications.
The two ports are interchangeable.
NOTE: The default IP address for the controller is located on a label on

the bottom side of the controller chassis.
7. Fieldbus Module
This module is reserved for future use.
8. USB port
This port is reserved for future use.
9. RS-232-1 and RS-232-2 connectors
These are RS-232 serial ports for general use. See Configuring Serial Ports on page 33 for
more information.
10. RS-232 and RS-422 / 485 connectors
These ports support RS-232 and RS-422 / 485 devices, respectively. See Configuring
Serial Ports on page 33 for pin descriptions and locations.
11. DeviceNet connector
DeviceNet is a field bus for industrial devices. This standard supports a variety of
products, including sensors, digital I/O, analog I/O, RS-232, and PLCs. Other DeviceNet
product types, such as keypads and displays, can be controlled using the eV+ FCMD
program instruction (see the eV+ Language Reference Guide for details). See DeviceNet
on page 59.
12. XDIO connector
This connector includes 20 signal pairs: 8 digital outputs (100 mA max) and 12 digital
inputs, all of which are fast inputs. The digital outputs are short-circuit protected. This
connector also supplies 24 VDC power for customer equipment. See Connecting User-
Supplied Digital I/O Equipment on page 45 for more information.
13. XUSR connector
Provides switch functions for emergency stop (E-Stop) and Manual / Automatic inter-
faces to external push-buttons and other equipment. For example, an external E-Stop
can be connected to the XUSR connector. A line E-Stop from other equipment can be con-
nected. A muted safety gate that causes an E-Stop only in Automatic mode is included.

Also included are contacts to report the status of E-Stop push-buttons and the Manual /
Automatic switch.
NOTE: The SmartController EX motion controller ships with a terminator

plug attached to the XUSR connector. The terminator plug must be
installed in the absence of any user-supplied safety equipment used to
close the E-Stop circuit. Save the terminator plug, in case it is needed in
the future for troubleshooting.
For more information about the XUSR connector, see Connecting User-Sup-
plied Safety and Power-Control Equipment on page 35.
14. XSYS connector

Connects to the XSLV connector on a robot or servo controller.
15. XFP connector
Connects to the optional Front Panel. See Connecting User-Supplied Safety and Power-
Control Equipment on page 35 for information.
16. XMCP connector
The optional T20 pendant plugs into this connector, via the T20 adapter cable, which
has the mating connector for the XMCP connector. The controller ships with a ter-
minator plug in the XMCP connector. The plug must be installed in the absence of a
pendant or the E-Stop circuit will remain open, and you will not be able to start the sys-
tem.
17. 24 VDC connectors / switch
Connect power from a user-supplied 24 VDC power supply to the XDC1 or XDC2 con-
nector (see Connecting Power on page 22). If using an sMI6 module, connect a separate
cable from the unused XDC connector on the controller to the XDC1 connector on the
sMI6 module.
An ON / OFF switch turns the controller on or off. Any daisy-chained devices will
retain power, as the two connectors (XDC1 and XDC2) are connected to each other.
A ground screw is located immediately below the 24 VDC power jacks.
18. Belt Encoder connector
This is a 26-pin D-Sub connector for up to four belt encoders in a conveyor-tracking
installation. See Belt Encoder Interface on page 51 for more information.

4.2 Front Panel

The following figure shows a Front Panel.
1 2 a b 4 5
Figure 4-2. Front Panel
Before running programs, either the optional Front Panel or user-supplied switches for High
Power ON/ OFF, MAN / AUTO, and E-Stop must be connected to the XFP connector on the
NOTE: Safety regulations dictate the sequence of events required for the user to
enable high power. For instance, a user may be required to press the High Power
On button on the Front Panel after pressing the COMP / PWR button on the
pendant or issuing the eV+ Enable Power command. Users cannot jumper this
button input and still enable power (see your robot manual for further details).
1. XFP connector
Connects to the XFP connector on the controller.
2. System 5 V Power-On LED
Indicates whether or not power is connected to the Front Panel.
3. Manual / Automatic Mode Switch
Switches between Manual and Automatic mode. In Automatic mode, executing pro-
grams control the mechanism, and the mechanism can run at full speed.
In Manual mode, the system limits mechanism speed and torque, to reduce the risk to
an operator working in the cell. It is the user's responsibility to determine if this is
allowed under local regulations. Manual mode initiates software restrictions on robot
speed, commanding no more than 250 mm/sec as required by RIA and ISO standards.
Please refer to your robot manual for further details.

4.3 Installing the ACE Software
a. Manual Mode
b. Auto Mode
4. High Power ON / OFF Switch & Lamp

Controls high power, which is the flow of current to the robot motors. Enabling high
power is a two-step process. An Enable Power request must be sent from the user ter-
minal, an executing program, or a pendant. Once this request has been made, the button
light blinks, and the operator must press the button for high power to be applied. The
default timeout for the button is 10 seconds.
WARNING: Disabling the High Power button violates IEC 60204-1. It is
! strongly recommended that you not alter the use of the High Power but-
ton.
5. Emergency Stop Switch

The E-Stop is a dual-channel, passive E-Stop that supports Category 3 PL-d per EN ISO
13849 safety requirements. It maintains motor power for a fixed time after the E-Stop is
activated. This feature allows the motors to decelerate under servo control to a stop.
This can aid in eliminating coasting or overshooting on low friction mechanisms. It can
also aid in the reduction of wear on highly-geared, high-inertia mechanisms, while
maintaining safety compliance per all standards.
4.3 Installing the ACE Software
WARNING: Make sure that all cables are installed correctly and fully inserted
! and screwed down before applying power to the system. Failure to do this
could cause unexpected robot motion. Also, a connector could be pulled out or
dislodged unexpectedly.
To begin the installation:

1. Insert the ACE software media into your PC.
l If AutoPlay is enabled, the Welcome to ACE menu is automatically displayed.
l If AutoPlay is disabled, you will need to manually start the installation media.
Use Windows Explorer to browse to the installation media, right-click on the
drive, and select AutoPlay from the menu.
2. Click Read Important Information. The ReadMe file is displayed.
3. Verify that your system meets the minimum requirements described in the System
Requirements section.
4. After reviewing the information, click the close icon ( ) in the upper-right corner of
the ReadMe file window to close it.

NOTE: The online document that describes the installation process opens
in the background when you select one of the software installation steps
below.
5. Click Install ACE. The ACE installer opens.
6. The installer scans your system for prerequisite files. If any files are needed, you will be
prompted to acknowledge the installation of those files.
7. Follow the on-screen instructions to complete the installation. You will be prompted to
accept the License Agreement and confirm the destination folder for the software install-
ation. Then the installation will proceed.
8. After the installation has completed, you may be prompted to restart your computer.
The ACE software installer adds an "ACE" shortcut to your desktop.
You can also launch ACE from the program group added to the Omron > ACE folder on your
Windows Programs menu.
4.4 Configuring the SmartController
Configuring Serial Ports

The SmartController EX motion controller has four serial I/O ports:
l RS-232 / Term
l RS-422 / 485
l RS-232-1
l RS-232-2
See Connectors and Indicators on page 27 for the connector locations.
To configure a serial port, use the eV+ FSET program instruction, for example:
FSET (lun.num) "/BYTE_LENGTH 8 /STOP_BITS 1 /FLOW XON_XOFF /PARITY

NONE /SPEED 57600"
Refer to the eV+ Language User's Guide for more information on FSET. This applies to all of
the SmartController EX motion controller's serial ports.

4.4 Configuring the SmartController
RS-232 Connectors
All three types of RS-232 connectors are 9-pin DB9 male (standard PC) connectors. The user-
supplied cable to connect to the RS-232 connectors should be a DB9, F/F, null-modem data-
transfer cable. The pin assignments are the same for all three connectors and are shown in the
following table.
Table 4-3. RS-232 Connector Pin Assignments
Pin RS-232-1 & -2 RS-232 / Term
Signal Type Signal Type
1 Reserved - N/C -
2 RXD Input RXD Input
3 TXD Output TXD Output
4 Reserved - N/C -
5 GND Ground GND Ground
6 Reserved - N/C -
7 RTS Output RTS Output
8 CTS Input CTS Input
9 Reserved - N/C -
These ports support the RTS and CTS signals used for hardware handshaking (also known as
modem control). By default, these signals are not enabled. To configure hardware handshaking
and other communication parameters, use the eV+ FSET program instruction. The eV+ des-
ignations for these ports, when referenced in the eV+ ATTACH or FSET instructions, are
shown in the following table.
NOTE: To configure the port speed and other communications parameters, use
the eV+ FSET program instruction.
Table 4-4. Serial Connectors and eV+ Designations
Connector eV+ Designation
RS-232 / Term SERIAL:0
RS-232-1 SERIAL:1
RS-232-2 SERIAL:2
RS-422 / 485 SERIAL:3
RS-422 / 485 Connector

The RS-422 / 485 connector is a 9-pin DB9 male connector. The pin assignments are shown in
the following table. RS-422 is a point-to-point protocol for connecting to a single destination.

This port can also be configured as a multidrop port (RS-485).
Table 4-5. RS-422 / 485 Connector Pin Assignments
Pin Signal Type
1 N/C
2 RXD+ Input
3 TXD+ Output
4 TXD- Output
5 GND Ground
6 RXD– Input
7 N/C
8 EXPIO_5V Output
9 GND Ground
To change the configuration of the RS-422 / 485 port, see Configuring Serial Ports on page 33.
See the previous table for the eV+ designation when referenced in the eV+ ATTACH or FSET
instructions.
4.5 Connecting User-Supplied Safety and Power-Control Equipment

The user-supplied safety and power-control equipment connects to the system through the
XUSR and XFP connectors on the controller. The XUSR connector (25-pin) and XFP (15-pin)
connector are both female D-sub connectors located on the front panel of the controller. Refer to
the following table for the XUSR pin-out descriptions. Refer to the table Contacts Provided by
the XFP Connector on page 37 for the XFP pin-out descriptions. See the figure CAT-3 E-Stop Cir-
cuit on XUSR and XFP Connectors on page 39 for the XUSR wiring diagram.
Table 4-6. Contacts Provided by the XUSR Connector
Pin Description Comments

Pairs
Voltage-Free Contacts Provided by Customer
1, 14 User E-Stop CH 1 (mushroom push- N/C contacts, Shorted if NOT Used

button, safety gates, etc.)
2, 15 User E-Stop CH 2 (same as pins N/C contacts, Shorted if NOT Used

1, 14)
3, 16 Line E-Stop (used for other robot or N/C contacts, Shorted if NOT Used
assembly line E-Stop inter-
connection. Does not affect E-Stop
indication (pins 7, 20))
4, 17 Line E-Stop (same as pins 3, 16) N/C contacts, Shorted if NOT Used

Pin Description Comments

Pairs
5, 18 Muted Safety Gate CH 1 (causes E- N/C contacts, Shorted if NOT Used

Stop in Automatic mode only)
6, 19 Muted Safety Gate CH 2 (same as N/C contacts, Shorted if NOT Used

pins 5, 18)
Voltage-Free Contacts provided by the System
7, 20 E-Stop indication CH 1 Contacts are closed when Front Panel,

pendant, and customer E-Stops are not
tripped
8, 21 E-Stop indication CH 2 (same as Contacts are closed when Front Panel,

pins 7, 20) pendant, and customer E-Stops are not
tripped
9, 22 Manual / Automatic indication CH 1 Contacts are closed in Automatic mode
10, 23 Manual / Automatic indication CH 2 Contacts are closed in Automatic mode
11, 12, No connection

13, 24,
25

Table 4-7. Contacts Provided by the XFP Connector
Pin Description Requirements for User-

Pairs Supplied Front Panel
Voltage-Free Contacts Provided by Customer
1, 9 Front Panel E-Stop CH 1 User must supply N/C con-

tacts
2, 10 Front Panel E-Stop CH 2 User must supply N/C con-

tacts
3, 11 Remote Manual / Automatic switch CH 1. Optional - jumper closed for

Manual = Open Automatic = Closed Auto Mode-only operation
4, 12 Remote Manual / Automatic switch CH 2. Optional - jumper closed for

Manual = Open Automatic = Closed Auto Mode-only operation
6, 14 Remote High Power ON / OFF momentary push- User must supply moment-
button ary push-button to enable
High Power to system
Non-voltage-Free Contacts
5, 13 System-Supplied 5 VDC and GND for High Power User must supply lamp, or
ON / OFF Switch Lamp use 1 W, 47 ohm resistor -
system will not operate if not
present
7, 15 a Controller system 5 V power on LED, 5 V, 20 mA Optional - indicator only
8 No connection
PIN 8 PIN 1
PIN 15 PIN 9
See the figure Front Panel Schematic on page 41 for a schematic diagram of the Front Panel.
a Users
must exercise caution to avoid inadvertently connecting 24 V signals to these pins,
because this will damage the electronics.
NOTE: The system was evaluated by Underwriters Laboratory with a factory

Front Panel. If you provide a substitute Front Panel, this could void UL com-
pliance.

Table 4-8. Remote Pendant Connections on the XMCP Connector
Pin XMCP Description

(15-Pin D-Sub)
1, 9 Pendant E-Stop Push-button CH 1
2, 10 Pendant E-Stop Push-button CH 2
3, 11 Pendant Enable CH 1 (Hold-to-run)
4, 12 Pendant Enable CH 2 (Hold-to-run)
13 Serial GND / Logic GND
7 Pendant TXD: “eV+ to Pendant TXD”
8 Pendant RXD: “eV+ to Pendant RXD”
14 No connection
15 No connection
Shield Shield GND
6 24 V
5 No connection
Table 4-9. XSYS Connector Pin Assignments
Pin Signal Description
1 ESTOPGND GND Return
2 MANUAL1 Manual Mode ESTOP Ckt. CH 1
3 MANUAL2 Manual Mode ESTOP Ckt. CH 2
4 HIPWRDIS High Power Disable
5 HIPWRREQ High Power Request
6 AUTO1 Auto Mode ESTOP Ckt. CH 1
7 AUTO2 Auto Mode ESTOP Ckt. CH 2
8 N/C No Connection
9 ESTOPSRC 24 V Output to Slave ESTOP
NOTE: The XSYS connector is used to link the E-Stop system to our robots. It is
not intended for customer connections.

The following figure shows an E-Stop diagram for the SmartController EX motion controller.
See Emergency Stop Circuits on page 41 for a description of the functionality of this circuit.
SmartController EX
5V 24 V
1
XFP-7
2 ESTOPSRC
XFP-1 XFP-2
Grn 5 XFP-9 XFP-10
XFP-15
6 XUSER-2
4 XUSER-1
3
XUSER-14 22
XUSER-15
XUSER-7
7 ES1 XUSER-8
ES1 ES2 ES2 23
8 ES1 ES2 XUSER-21
ESTOPSRC XUSER-20
9 XUSER-4
XUSER-3
24 V
10 11
24
XFP-3 XFP-4 XUSER-16
XFP-11 XFP-12 XUSER-17
MM1
MM1 MM2 MM2
XUSER-9
XUSER-10
12 MM2 25
MM1 XUSER-23
XUSER-22
XUSER-6
13 XUSER-5
24 V
XFP-5 XFP-6 26
XUSER-18
14 15 XUSER-19
XFP-13 XFP-14
ESTOPSRC
27
16 XSYS-1
XSYS-9
17 XSYS-7
18 XSYS-6
19 XSYS-3
20 XSYS-2
21 XSYS-5
Figure 4-3. CAT-3 E-Stop Circuit on XUSR and XFP Connectors

Table 4-10. CAT-3 E-Stop Circuit on XUSR and XFP Connector Descriptions
Item Description
1 Front panel system power LED
2 E-Stop enable (current limit 1.4 A max.)
3 Channel 1 (E-Stop)
4 Channel 2 (E-Stop)
5 Front panel E-Stop
6 Pendant E-Stop
7 Logic cyclic check state machines
8 Channel 1 (logic cyclic check state machines)
9 Channel 2 (logic cyclic check state machines)
10 Front panel - Manual / Auto keyswitch
11 Manual / Auto enable
12 Pendant enable switch
13 Lamp control circuit with burnout detection
14 Front panel
15 High power ON / OFF
16 eV+ High power request
17 Auto 2
18 Auto 1
19 Manual 2
20 Manual 1
21 High power request
22 User E-Stop and gate interlock (jumper closed when not in use, must open
both channels independently if used)
23 User E-Stop indication
24 Line E-Stop (external user E-Stop system)
25 User manual / auto indication (manual = open)
26 Muted safety gate - active in auto mode only (jumper closed when not used)
27 Connections at robot or module system (no user connections)

ESTOPSRC
16
1
9 ESTOPFP1
24 VS 2
10 ESTOPFP2
MANUALSRC1 3
5 VD 11 MANUALRLY1
MANUALSRC2 4
12 MANUALRLY2
HPLT5V 5 XFP
13 HIPWRLT
6
14 HIPWRREQ
SYSPWRLT 7
15
NC 8
17
1 2 3 4
5 VD
HPLT5 V
24 VS ESTOPSRC
MANUALSRC2
SYSPWRLT
MANUALSRC1
2-PIN_MINI
D SWL1 D
SW1 SW2
HIPWRLT
MANUALRLY2 HIPWRREQ
ESTOPFP2
MANUALRLY1
ESTOPFP1
Figure 4-4. Front Panel Schematic
Table 4-11. Front Panel Schematic Descriptions
Item Description
1 System power LED
2 Manual / Auto
3 High power ON / OFF
4 Emergency stop
Emergency Stop Circuits

The SmartController EX motion controller provides connections for Emergency Stop (E-Stop)
circuits on the XUSR and XFP connectors. This gives the controller system the ability to duplic-
ate E-Stop functionality from a remote location using voltage-free contacts. See the figure CAT-
3 E-Stop Circuit on XUSR and XFP Connectors on page 39.
The XUSR connector provides external two-channel E-Stop input on pin pairs 1, 14 and 2, 15.
The XFP connector provides two-channel E-Stop input on pin pairs 1, 9 and 2, 10.
NOTE: These pins must be shorted if not used. Both channels must open inde-
pendently if used. Although an Emergency Stop will occur, the controller will
flag an error state if one channel is jumpered closed and the other channel is
opened. It will also flag an error state if the channels are shorted together.

User E-Stop Indication Contacts - Remote Sensing of E-Stop
These contacts provide a method to indicate the status of the ESTOP chain, inclusive of the
Front Panel Emergency Stop push-button, the pendant Emergency Stop push-button, and the
User Emergency Stop Contacts.
NOTE: These contacts do not indicate the status of any connections below the
User E-Stop contacts. Thus, they will NOT indicate the status of the Line E-Stop,
MCP ENABLE, or the Muted Safety gate. If you have a specific need in this area,
contact your sales representative for information on alternate indicating modes.
Two pairs of pins on the XUSR connector (pins 7, 20 and 8, 21) provide voltage-free contacts,
one for each channel, to indicate whether the E-Stop chain, as described above, on that channel
is closed. Both switches are closed on each of the redundant circuits in normal operation (no
E-Stop). The user may use these contacts to generate an E-Stop for other equipment in the work-
cell. The load on the contacts must not exceed 40 VDC or 30 VAC at a maximum of 1 A.
These voltage-free contacts are provided by a redundant, cyclically-checked, positive-drive,
safety relay circuit for Category 3 PL-d per EN ISO 13849 operation (see the figure CAT-3 E-
Stop Circuit on XUSR and XFP Connectors on page 39 and the table Contacts Provided by the
XFP Connector on page 37 for the customer E-Stop circuitry).
Line E-Stop Input
The XUSR connector on the controller contains a two-channel Line E-Stop input for workcell or
other equipment emergency-stop inputs. Generally, the customer E-Stop Indication contact out-
puts are used to generate an emergency stop in such external equipment. Thus, if one were to
wire the same equipment’s outputs into the customer E-Stop input (that is, in series with the
local robot’s E-Stop push-buttons), a lock-up situation could occur.
The Line E-Stop input comes into the circuit at a point where it cannot affect the customer E-
Stop indication relays and will not cause such a lock-up situation. For any situation where two
systems should be cross-coupled, for example, the customer E-Stop indication of one controller
is to be connected to the input of another controller, the Line E-Stop input is the point to bring
in the other controller’s output contacts. See the figure CAT-3 E-Stop Circuit on XUSR and XFP
Connectors on page 39 for more information.
Do not use the Line E-Stop for such devices as local E-Stop push-buttons, since their status
should be reported to the outside on the local user E-Stop indication output contact while the
Line E-Stop inputs will not.
Muted Safety Gate E-Stop Circuitry
Two pairs of pins on the XUSR connector (pins 5, 18 and 6, 19) provide connections for a
safety gate designed to yield an E-Stop allowing access to the workspace of the robot in
Manual mode only, not in Automatic mode. It is up to the customer to determine if teaching
the robot in Manual Mode, by a skilled programmer (See Qualification of Personnel in the
Robot Safety Guide), wearing safety equipment and carrying a pendant, is allowable under
local regulations. The E-Stop is said to be “muted” in Manual mode (for the customer E-Stop
circuitry, see the figures and tables at the beginning of the section Connecting User-Supplied
Safety and Power-Control Equipment on page 35).
The muted capability is useful for a situation where a shutdown must occur if the cell gate is
opened in Automatic mode, but you need to open the gate in Manual mode. If the mute gate is
opened in Automatic mode, the robot defaults to Manual mode operation when power is re-

enabled. In muted mode, the gate can be left open for personnel to work in the robot cell.
However, safety is maintained because of the speed restriction.
CAUTION: If you want the cell gate to always cause a robot shutdown, wire
! the gate switch contacts in series with the user E-Stop inputs. Do not wire the
gate switch into the muted safety gate inputs.
Remote Manual Mode

The Front Panel provides for a Manual Mode circuit. See Remote High Power ON / OFF Con-
trol on page 43 and your robot manual for further details about the customer Remote Manual
Mode circuitry.
The Front Panel, or the user-supplied panel, must be incorporated into the robot workcell to
provide a “Single Point of Control” (the pendant) when the controller is placed in Manual
mode. Certain workcell devices, such as PLCs or conveyors, may need to be turned off when
the operating mode switch is set to Manual mode. This is to ensure that the robot controller
does not receive commands from devices other than from the pendant, the single point of con-
trol.
If the user needs to control the Manual / Automatic mode selection from other control equip-
ment, then a custom splitter cable or complete replacement of the standard Front Panel may be
required. See Front Panel Schematic on page 41. In this situation, a pair of contacts should be
wired in series with the Front Panel Manual / Automatic mode contacts. Thus, both the Front
Panel and the customer contacts need to be closed to allow Automatic mode.
WARNING: Do not wire user-supplied Manual / Automatic contacts in par-
! allel with the factory Front Panel switch contact. This would violate the “Single
Point of Control” principle and might allow Automatic (high-speed) mode to
be selected while an operator is in the cell.
User Manual / Auto Indication

Two pairs of pins on the XUSR connector (pins 9, 22 and 10, 23) provide a voltage-free
contact to indicate whether the Front Panel and / or remote Manual / Automatic switches are
closed. The user may use these contacts to control other mechanisms (for example, conveyor,
linear modules, etc.) when Manual mode is selected. The load on the contacts should not
exceed 40 VDC or 30 VAC at a maximum of 1 A.
User High Power On Indication

In the SmartController EX motion controller, eV+ controls a normally-open relay contact on the
XDIO connector (pins 45, 46, see the table XDIO Digital I/O Connector Pin Assignments on
page 50), that will close when high power has been enabled. The user can use this feature to
power an indicator lamp or other device, that signals High Power is On. The limit on these
contacts is 1 A at 30 VDC or 30 VAC.
Remote High Power ON / OFF Control

The easiest and most effective way to provide the high power ON / OFF control in a remote loc-
ation is to mount the Front Panel in the desired location with an extension cable.

However, if the user needs to control high power ON / OFF from other control equipment or
from a location other than the Front Panel, then a custom splitter cable will be required. See the
Front Panel schematic (Front Panel Schematic on page 41) for details of the Front Panel’s wir-
ing. In this situation, a second momentary contact for high power ON / OFF would be placed
in parallel with the Front Panel push-button contact. This second contact should be suppressed
when in Manual mode (see the note on “Single Point of Control” below).
This method allows relocating the push-button switch to a more convenient location. Imple-
mentation of this method must conform to EN standard recommendations.
NOTE: European standards require that the remote High Power push-button be
located outside of the workspace of the robot.
Pins 6, 14 and 5, 13 of the XFP connector provide this remote capability. Pins 5, 13 provide
power for the lamp, +5 VDC and ground, respectively. Pins 6, 14 are inputs for voltage-free nor-
mally-open contacts from a user-supplied momentary push-button switch.
WARNING: To fulfill the “Single Point of Control” requirement, do not place
! the Manual / Automatic and High Power On controls in multiple locations.

After putting the robot into Manual mode, the operator should remove the key
for safety purposes. The system should not be wired so that a PLC or another
operator can put the system back into Automatic mode.
High Power ON / OFF Lamp

The Front Panel High Power ON / OFF Lamp (P/N: 27400-29006) will cause an error, from
eV+, if the lamp burns out. This error prevents High Power from being turned on. This safety
feature prevents a user from not realizing that High Power is enabled because the High Power
indicator is burned out.
Remote Front Panel or User-Supplied Control Panel Usage

Users can mount the Front Panel remotely by using an extension cable or by wiring a user-sup-
plied Front Panel (control panel) to the controller using the 15-pin XFP connector. The Front
Panel contains no active components, only switches and lights. Customers should be able to
adapt the Front Panel’s functionality into their own Front Panel design. To automatically con-
trol the Front Panel’s signals, use relay contacts instead of switches. See the figure Front Panel
Schematic on page 41 for a schematic drawing of the Front Panel, and see the table Contacts
Provided by the XFP Connector on page 37 for a summary of connections and pin numbers.
NOTE: The system was evaluated by Underwriters Laboratory with a factory

Front Panel. If you provide a substitute Front Panel, the system may no longer be
UL compliant.
Customers can build an extension cable to place the Front Panel in a remote location. The
extension cable must conform to the following specifications:
l Wire Size: must be larger than 26 AWG.
l Connectors: must be 15-pin, standard D-sub male and female.
l Maximum cable length is 10 meters.

NOTE: The XMCP and XFP connectors on the controller can be interchanged
without electrical damage. However, neither the Front Panel nor the pendant will
work properly unless they are plugged into the correct connector.
Remote Pendant Usage

Customers can build an extension cable to place the pendant in a remote location. The exten-
sion cable must conform to the following specifications:
l Wire Size: must be larger than 26 AWG.
l Connectors: must be 15-pin, standard D-sub male and female.
l Maximum cable length is 10 meters.
CAUTION: Do not modify the cable that is attached to the pendant.
! This could cause unpredictable behavior from the robot system.
4.6 Connecting User-Supplied Digital I/O Equipment

The controller contains two options for connecting Inputs and Outputs (I/O). I/O can be hard-
wired to the XDIO and / or DeviceNet connectors.
DeviceNet Connector
The DeviceNet connector on the controller is used to interface to a CAN using the DeviceNet
protocol. See DeviceNet on page 59 for details.
XDIO Connector
The XDIO connector on the SmartController EX motion controller is a 50-pin, standard density
D-Sub female connector (see SmartController EX Connectors and Indicators on page 27 for loc-
ation). There are 12 inputs and 8 outputs, each optically isolated from the circuitry of the con-
troller. The signals are numbered 1001 through 1012 for the inputs and 1 through 8 for the
outputs. All the signals have independent source and ground connections. These inputs con-
tain the four high-speed inputs that are used by the system for interrupts and latching. The out-
puts, although independent, have a current rating of 100 mA. See the eV+ Language User's
Guide for information on digital I/O programming.
The connector also provides 24 V pins for powering customer equipment. There are four 24 V
pins and four ground pins, which are limited to a total of 1 A of current. The source of the 24
V is the XDC connector on the front of the controller.
Input Signals
The XDIO connector handles input signals 1001 to 1012. Each channel has an input and a cor-
responding return line. See the following table for input specifications. The connector pin-outs
are shown in the table XDIO Digital I/O Connector Pin Assignments on page 50.

Table 4-12. Digital I/O Input Circuit Specifications (XDIO connector)
Operational voltage range 0 to 30 VDC
OFF state voltage range 0 to 3 VDC
ON state voltage range 10 to 30 VDC
Typical threshold voltage Vin = 8 VDC
Operational current range 0 to 7.5 mA
OFF state current range 0 to 0.5 mA
ON state current range 2.5 to 7.5 mA
Typical threshold current 2.0 mA
Impedance (Vin/Iin) 3.9 K Ω minimum
Current at Vin = +24 VDC Iin ≤ 6 mA
Turn-on response time (hardware) 5 µsec maximum

Software scan rate / response time 1 ms scan cycle/
1 ms max response time
Turn-off response time (hardware) 5 µsec maximum

Software scan rate / response time 1 ms scan cycle/
1 ms max response time
NOTE: The input current specifications are provided for reference; voltage
sources are typically used to drive the inputs.
NOTE: When the program task priorities are properly set, there is a 1 ms max-
imum latency for the fast inputs when used with the eV+ INT.EVENT instruc-
tion.
The following figure shows inputs 1001 to 1004 with a negative common, inputs 1005 to 1008
with a positive common, and inputs 1009 to 1012 with independent power supply con-
nections (no common).
NOTE: These are examples. Either method can be used on any channel.

SmartController EX
+1
1001 –2
+3
1002 –4
+
+5
1003 –6
+7
1004 –8
+9
1005 – 10
+ 11
1006 – 12
+
+ 13
1007 – 14
+ 15
1008 – 16
+ 17 +
1009 – 18
+ 19
1010 +
– 20
+ 21 +
1011 – 22
+ 23
1012 +
– 24
Figure 4-5. Digital Input Wiring Examples for XDIO Connector
NOTE: Power from pins 41-44 and 47-50 can be substituted for the input signal
power supply. See the figure Digital Output Wiring Examples for XDIO Con-
nector on page 49 and the table Digital I/O Input Circuit Specifications (XDIO
connector) on page 46 for additional information.

REACT Input Signals 1001 to 1012
Inputs 1001 to 1012 (only) may be used by the eV+ REACT and REACTI instructions. See the
eV+ Language Reference Guide for information on these instructions. If you are going to use
these instructions, you should plan your digital I/O channel usage accordingly.
In addition to functioning as normal input signals, all input signals can have the following
special uses:
l Fast DIO eV+ Interrupt Events (INT.EVENT)
l Robot and Encoder Position Latch
Fast DIO interrupt events (using INT.EVENT) require the optional eV+ Extensions License.
When the program task priorities are properly set, there is a 1 ms maximum latency for the
fast inputs when used with the eV+ INT.EVENT instruction.
See the eV+ Language Reference Guide for a description of the INT.EVENT instruction.
Output Signals
The XDIO connector handles output signals 0001 to 0008. Refer to the following table for out-
put specifications. The locations of the signals on the connector are shown in the table XDIO
Digital I/O Connector Pin Assignments on page 50. The XDIO connector provides separate pos-
itive and negative connections for each channel (no internal common connections). This
allows the choice of wiring for current-sourcing or current-sinking modes.
Table 4-13. DIO Output Specifications (XDIO connector)
Operating voltage range 0 to 24 VDC
Operational current range, per channel I out ≤ 100 mA, short-circuit pro-
tected,
1 A total at 24 V
V drop across output in ON condition V drop ≤ 2.7 V at 100 mA

V drop ≤ 2.0 V at 10 mA
Output off leakage current I out≤ 600 µA
Turn-on response time (hardware) 3 µsec maximum

Software scan rate / response time 1 ms scan cycle
1 ms max. response time
Turn-off response time (hardware) 200 µsec maximum

Software scan rate / response time 1 ms scan cycle
1 ms max. response time

The following figure shows two examples of different connections to the digital outputs on the
XDIO connector. The examples are negative common and positive common using the internal
24 V and ground connections.
Outputs 0001 to 0004 are shown with a positive common. Outputs 0005 to 0008 are shown
with a negative common.
NOTE: These are examples. Either method can be used, in any combination, on
any channel. Also, an external customer-provided power supply could have
been provided instead of the power provided on the XDIO connector.
SmartController EX
+ 25
0001 – 26
+ 27
0002 – 28
+ 29
0003 – 30
+ 31
0004 – 32
+ 33
0005 – 34
+ 35
0006 – 36
+ 37
0007 – 38
+ 39
0008 – 40
+24 V (1 A) 41
42
43
44
X
45
X
46
47
GND
48
49
50
Figure 4-6. Digital Output Wiring Examples for XDIO Connector

Table 4-14. XDIO Digital I/O Connector Pin Assignments
Pin Signal Pin Signal Pin Signal Pin Signal
1 Input 1001 2 1001 return 25 Output 0001+ 26 Output 0001–
17 Input 1009 18 1009 return 41 24 V Outputa 42 24 V Outputa
19 Input 1010 20 1010 return 43 24 V Outputa 44 24 V Outputa
21 Input 1011 22 1011 return 45 eV+ High 46 eV+ High

Power On Power On
Indicator + Indicator –
23 Input 1012 24 1012 return 47 24 V return 48 24 V return
49 24 V return 50 24 V return
Pin 17 Pin 1
Pin 33 Pin 18
Pin 50 Pin 34
a Limited to combined total of 1 A of current.
Digital I/O Connectors (Third-Party Sources)
The XDIO connector on the controller is a 50-pin, standard-density D sub-miniature female

socket. The user-supplied cable must terminate in a suitable 50-pin male D-sub plug. The plug
is not supplied.
Compatible connectors are manufactured by TE Connectivity and by Norcomp. Contact your
nearest TE Connectivity or Norcomp sales office to find your local distributor.
TE Connectivity Part Numbers for 50-Pin Male D-Sub
HDP-20 series D-Sub Connectors. Crimp snap-in contacts. Order item 1 (includes cover) or
item 2 (no cover). Contact pins not included, order separately (item 3, quantity 50).
1. 1658661-1 Kit (Connector body, shield, enclosure, jackscrews)
2. 1658641-2 Connector body only

3. 66682-2 Contact Pin, Male, wire size 28-24 AWG (0.08-0.2 mm2 )
(Pins also available for other wire sizes, contact TE Connectivity)
Norcomp Part Numbers for 50-Pin Male D-Sub
Norcomp 172 series solder cup D-Sub connectors.

l 172-E50-103R001
Screw-Terminal Field-Wiring Adapter Blocks
Several manufacturers make screw-terminal field-wiring blocks, usually DIN-rail mountable.

These can be connected to the XDIO via a suitable shielded 50-pin cable (user-supplied).
Phoenix Contact Inc.
2315159 - VARIOFACE interface modules
Automation Systems Interconnect
11008 - IMDS series transition modules
4.7 Belt Encoder Interface
For use with conveyor tracking, the SmartController EX motion controller supports four inde-
pendent external belt encoders through a 26-pin, female, D-sub connector. The pin assignments
for the Belt Encoder connector are shown in the following table. See the figure Belt Encoder Typ-
ical Input Circuit on page 53 for a typical input circuit drawing.
NOTE: An adapter cable (09550-000) is available to split the 26-pin SmartCon-

troller EX motion controller connector into two 15-pin connections, compatible
with the legacy SmartController CX. The 15-pin adapter is P/N: 09443-000. Each
15-pin adapter provides two M12 connections.
All encoder inputs for the SmartController EX motion controller use a scheme similar to an RS-
422 differential receiver based on industry standard 75175 integrated circuits. The difference is
that a custom resistor network and two differential receivers are used on each of the A and B
inputs. See the figure Belt Encoder Typical Input Circuit on page 53 for a schematic.
We strongly recommend using differential encoder outputs for maximum noise immunity. See
the ACE User's Guide for more information on setting up and programming a conveyor-track-
ing application.
NOTE: Conveyor tracking requires the eV+ Extensions License, which can be
obtained from your sales representative.

Table 4-15. Belt Encoder Connector Pin Assignments
Signal Pin Signal Pin
Encoder 5 V Out 1 ENC2_B- 14
Encoder Ground 10 ENC3_B+ 15
ENC1_A+ 2 ENC3_B- 16
ENC1_A- 3 ENC4_B+ 17
ENC2_A+ 4 ENC4_B- 18
ENC2_A- 5 ENC1_Z+ 19
ENC3_A+ 6 ENC1_Z- 20
ENC4_A+ 8 ENC2_Z- 22
ENC1_B+ 11 ENC3_Z- 24
ENC1_B- 12 ENC4_Z+ 25
ENC2_B+ 13 ENC4_Z- 26
Pin 9 Pin 1
Pin 18 Pin 10
Pin 26 Pin 19

SmartController EX
5V
26LS33 2.2K 1
220 A+ 3
2.2K A –
B+
B– +
–
I+
I–
5 V at 800 mA +
(1 A max.)
–
5V
2
26LS33 2.2K 3
220 A + +
–
2.2K A –
B+
B–
I+
I–
Figure 4-7. Belt Encoder Typical Input Circuit
Table 4-16. Belt Encoder Typical Input Descriptions
Item Description
1 Encoder 1
2 Encoder 2
3 Shield

Figure 4-8. Belt Encoder Connector

Chapter 5: Technical Specifications
This chapter shows the dimensions of the SmartController EX motion controller, Front Panel,
and T20 pendant.
5.1 SmartController EX Motion Controller Dimensions

NOTE: The dimensions for the legacy CS and CX SmartController motion con-
trollers were the same as these.
4.4 328.9
86.0
186.5 12.1
189.1
Figure 5-1. SmartController EX Motion Controller Dimensions (Units in mm)

5.2 Front Panel Dimensions
5.2 Front Panel Dimensions
152.4
38.7
55.9 88.9
16.5
30
13.1 129.5
4x M4 x 18 mm
76.2
6.4
6.4 139.7
Figure 5-2. Front Panel Dimensions (Units in mm)

Chapter 5: Technical Specifications
5.3 T20 Pendant Dimensions
Figure 5-3. T20 Pendant Dimensions (Units in mm)

Chapter 6: DeviceNet
DeviceNet is a low-cost communications link that connects industrial devices to a network

and eliminates expensive hard-wiring. The direct connectivity provides improved com-
munication between devices as well as important device-level diagnostics not easily available
using hard-wired I/O interfaces.
6.1 DeviceNet Specifications

Omron Adept Technologies, Inc. is a member of the Open DeviceNet Vendor Association
(ODVA), which is independently run and operated and not directly associated with any one
company. The ODVA controls DeviceNet technical specifications with help from Special
Interest Groups (SIGs). Each SIG develops device profiles for one line of product features to
ensure interoperability. These profiles become part of the technical specifications.
The DeviceNet Specification is divided into two volumes and defines the following elements:
Volume 1
l DeviceNet Communication Protocol and Application (Layer 7 - Application Layer1)
l Controller Area Network (CAN) and its use in DeviceNet (Layer 2 - Data Link Layer)
l DeviceNet Physical Layer and Media (Layer 1 - Physical Layer)
Volume 2
l Device profiles to obtain interoperability and interchangeability among like products
DeviceNet incorporates CAN, which defines the syntax or form of the data transmitted. The
DeviceNet application layer defines the semantics or meaning of the data transmitted. For
more information on the basics of a DeviceNet cable system, contact ODVA at:
ODVA Technology and Training Center

4220 Varsity Drive, Suite A
Ann Arbor, MI 48108-5006 USA
Phone Number: 1-734-975-8840
Fax Number: 1-734-922-0027
www.odva.org
1These layers are based on the Open Systems Interconnect (OSI) model.

6.2 Limitations of the DeviceNet Scanner
6.2 Limitations of the DeviceNet Scanner

The DeviceNet Scanner that is incorporated into the SmartController EX motion controller hard-
ware and the eV+ operating system currently supports only a subset of full DeviceNet func-
tionality. The following is a summary of this DeviceNet implementation:
l Implemented the Master-Slave operation. This is a complete subset of Peer-to-Peer oper-
ation.
l Implemented the Unconnected Message Manager (UCMM) in its DeviceNet Scanner to
establish connections.
UCMM is used to establish I/O Connections.
l The DeviceNet Scanner can be a Client or a Server on the network.
l The DeviceNet Scanner currently does not support Cyclic or Change-of-State connections.
l Only I/O Messaging is supported. I/O messages contain only data.
l Currently, only the Message Group 2 of the Predefined Master / Slave Connection Set is sup-
ported.
l Message Group 2 I/O connections support only the I/O Poll Command / Response Message
of the possible message types.
6.3 DeviceNet Port on the Controller

The DeviceNet port on the SmartController EX motion controller has the following con-
figuration:
Micro-style 12 mm thread DIN connector (female). See the following table for pin assignments.
Table 6-1. DeviceNet Signal-to-Pin Locations
Pin Signal
Number Name
1 Drain
2 V+
3 V-
4 CAN_H
5 CAN_L
See the figure Micro-Style DeviceNet Connector Pinouts (Viewed from Contact End) on page 69
for a drawing of the connectors.
Connecting DeviceNet Hardware to the Controller

To connect DeviceNet components to the controller, connect a drop line to the female Micro-
style 12 mm-thread DIN connector on the front of the controller. Then you must configure the
DeviceNet Scanner correctly using the ACE Configuration Tools.

NOTE: By default, the controller does not supply 24 V power to the DeviceNet
bus. A separate power supply can be used to power the components on the
DeviceNet bus, or the default can be overridden with jumpers. See Power Supply
and the DeviceNet Bus on page 67.
NOTE: The controller incorporates a 120 Ohm line termination impedance. It is

important that devices connected to the network also have a terminating resistor
connected between CAN-H (white) and CAN-L (blue). See Termination of the
DeviceNet Network on page 66.
Configuring DeviceNet
The SmartController EX motion controller has a default configuration such that, if you plug in
a DeviceNet module configured with a baud rate of 125 kbps, the first 64 inputs and 64 out-
puts will automatically be mapped as the following signals:
MAC_ID 1
l Input: 1289 to 1352 and
l Output: 257 to 320
MAC_ID 2
l Input: 1353 to 1416 and
l Output: 321 to 384
This makes the DeviceNet plug and play.

For other configurations, use the ACE software for software setup. This assigns the controller
signals to the physical ports of the DeviceNet nodes. Refer to the ACE User's Guide for details
on configuring DeviceNet.
NOTE: The local setting baud rate must match the DeviceNet node’s setting.
From the ACE software:

1. Double-click on the controller in the tree structure pane.
This will open the object editor for the controller.
2. Click the Configure button, check Configure DeviceNet, and click Next.
3. Follow the on-screen wizard instructions.
6.4 DeviceNet Physical Layer and Media

The DeviceNet physical layer and media specifications are published in the ODVA manual,
chapter 9, volume 1. It describes possible topologies and components of the physical layer.
The figure Trunk Lines and Drop Lines Made of Thick and Thin Cable on page 62 shows sev-
eral possible topologies. The DeviceNet specifications also specify system grounding, mixing of
thick and thin cable media, termination, and power distribution.
The basic topology is the trunkline-dropline topology. This topology uses separate twisted-pair
buses for the distribution of signals and power. The specifications allow trunk lines and drop

lines made of thick or thin cable. The baud rate, maximum distance from end-to-end of the net-
work, and cable size are dependent on each other. See the table Features of a DeviceNet Net-
work on page 63 for further details.
3 1 1 5 6
Multiple Node Node Node Drop Line Trunk Line
Branching
Drop Line 4 2
1 Multi-port Terminating
Tap 1 Resistor
Node
Node
Node Node 7
1
1 1 Multiple Node
Node Daisy Chain
2 Drop Line
8 4 1
Terminating
Tap
Resistor Multi-port Node
Node Tap
1
Node
1 Node
1 1 Drop Line
1 5 1
Node
Node Node
Zero-Length Drop Line Short Drop Lines (6 m / 20 ft)

9 10
Figure 6-1. Trunk Lines and Drop Lines Made of Thick and Thin Cable
Table 6-2. Topology Description
Item Description
1 Node
2 Terminating Resistor
3 Multiple Node Branching Drop Line
4 Multi-Port Tap
5 Drop Line
6 Trunk Line
7 Multiple Node Daisy Chain Drop Line
8 Tap
9 Zero-Length Drop Line
10 Short Drop Lines (6 m)
DeviceNet allows devices to be powered directly from the bus, and devices can use the same
cable to communicate with other devices on the bus. DeviceNet nodes are hot-pluggable —
you can remove or add components on the bus without powering down the network.

NOTE: This hot-pluggable feature requires the configuration of the controller to

match the configuration of the physical network. The default configuration auto-
matically recognizes and maps the first 64 bits of Mac ID 1 and 2. If the con-
figuration needs to be changed, use ACE Configuration Tools.
The power distribution on the network / bus does not need to be in one place. The distribution
of power supplies needs to be well-planned because there are certain constraints on the power
supply. In general, power supplies can be placed at any point in the network. The maximum
current rating of a trunk line is 8 amps. DeviceNet allows opto-isolated, externally powered
devices (e.g., AC drive starters and solenoid valves) to operate on the same bus cable. For
detailed information, see the DeviceNet Technical Specifications.
Table 6-3. Features of a DeviceNet Network
Network Size A maximum of 64 nodes [0 - 63]
Network Length Selectable, end-to-end network distance varies with speed
Data Packets 0-8 bytes
Bus Topology Linear (trunk line / drop line); power and signal on the same network
cable
Bus Addressing Multi-Master and Master / Slave special case; polled
The baud rate of the system depends on the length of the network (end-to-end) and the type of
cable. The following table shows how cable selection and trunk line length affect the max-
imum data rate on the network. The figure DeviceNet Thick Cable on page 64 shows a thick
cable, and the figure DeviceNet Thin Cable on page 65 shows a thin cable.
Table 6-4. DeviceNet Data Rates Relative to Cable Type and Length
Data Rates 125 Kbps 250 Kbps 500 Kbps
Thick Trunk Length 500 m 250 m 100 m

(1,640 ft) (820 ft) (328 ft)
Thin Trunk Length 100 m 100 m 100 m

(328 ft) (328 ft) (328 ft)
Maximum Drop Length 6m 6m 6m

(20 ft) (20 ft) (20 ft)
Cumulative Drop Length 156 m 78 m 39 m

(512 ft) (256 ft) (128 ft)

2
3
8 4
7
5
6
Figure 6-2. DeviceNet Thick Cable
Table 6-5. DeviceNet Thick Cable Descriptions
Item Description
1 11 mm outside diameter
2 65% coverage tinned copper braid shield
3 Polypropylene fillers
4 Blue and white data-pair polyethylene (18 AWG 19 x 30 tinned cop-

per conductors)
5 Red and black DC power pair PVC (15 AWG 19 x 28 tinned and stran-
ded copper conductors
6 18 AWS 19 x 30 tinned copper-stranded drain wire
7 Aluminum / mylar shield over each pair
8 External jacket

9
4
8
7 5
Figure 6-3. DeviceNet Thin Cable
Table 6-6. DeviceNet Thin Cable Descriptions
Item Description
1 7.2 mm outside diameter
2 65% coverage tinned copper braided shield
3 Polypropylene fillers
4 Blue and white data-pair polyethylene (18 AWG 19 x 30 tinned cop-

per conductors)
5 Red and black DC power pair PVC (15 AWG 19 x 28 tinned and stran-
ded copper conductors
6 18 AWG 19 x 30 tinned copper-stranded drain wire
7 Aluminum / mylar shield over each pair
8 Overall non-hydroscopic wrap
9 External jacket
DeviceNet Connectors
DeviceNet allows different connectors, which may be grouped into open and sealed con-
nectors. The open connectors are available with screw or with crimp connectors. The sealed
connectors are available in mini-style and micro-style sizes. See the following figure and table
for more details.

1 2 3 4
Figure 6-4. DeviceNet Connector Styles
Table 6-7. DeviceNet Connector Style Descriptions
Item Connector Style Description
1 Unsealed screw con- Uses screws to attach wires to a removable con-

nector nector
2 Unsealed hard-wired Uses wires attached directly to screw terminals
3 Sealed mini-style Attaches to taps and thick or thin cable
4 Sealed micro-style Attaches to thin cable only – has a reduced current

rating
Termination of the DeviceNet Network

The DeviceNet network uses the Controller Area Network (CAN) bus as the physical layer.
This requires that the trunk line of your DeviceNet network be terminated with a resistor at
each end. This terminates the signal lines.
The terminating resistor:
l Prevents reflection of communication signals on the network.
l Connects the two signal conductors.
l Must be sealed if the end node uses a sealed tee.
l Must be open if the end node uses an open-style tap.
The SmartController EX has a terminating resistor built-in, which can be used for one end of
the DeviceNet network.
It is possible to disable this resistor by moving the JP2 jumper, which is internal to the
SmartController EX. If you disable this resistor, a terminating resistor must then be used
whenever a short drop line exceeds 6 m (20 ft). See the following figure.

Figure 6-5. Internal CAN Power OFF, Terminating Resistor ON
NOTE: When using the open-style terminating resistor, connect a 121 ohm, ¼
W resistor to CAN_H and CAN_L (between blue and white data-pair wires).
PIN 4 PIN 5
Figure 6-6. Example of a Terminating Resistor Installation on a DeviceNet Bus
Power Supply and the DeviceNet Bus

The DeviceNet network allows distribution of power supplies on the network cable system. Fol-
low these general rules to achieve safe and reliable operation:
l Use power supplies rated at 24 V.
l Minimize installation problems by using a single power supply with sufficient current

to operate all the attached nodes. This must comply with national and international
safety standards.
l Make sure that each power supply incorporates current-limit protection.
l Make sure each power supply is temperature-compensated.
l Provide over-current protection for each segment of your DeviceNet cable installation.
The SmartController EX CAN driver (CAN_H / CAN_L) is protected for shorts to the power ter-
minals. The driver is protected for voltages in the range from -27 to +40 V.
By default, the 24 V supply for the DeviceNet bus on the SmartController is disabled.
If you do want the controller to supply 24 V, two jumpers need to be moved on JP1, on the
SmartController board. To do this, move the jumpers from the EXT position to the INT pos-
ition. See Figure 6-5.
l The jumpers provide an internal source of 24 V and GND from the EX controller for the
CAN+CAN+ / CAN-- lines.
l Power is polyfuse-protected and can source 24 V (equal to controller VIN) at up to 1.0 A.
l Power is diode-protected so it cannot back-drive the controller power.
Power Capabilities of a DeviceNet Cable System
A DeviceNet cable system has several power rating constraints. The cable type and the length
of the cable affect the maximum current on a cable. Thick and thin cable have:
l 24 VDC power rating
l Optional power-supply tabs
If the power supplies are equipped with Schottky diodes, the optional power supply tabs must
be protected from bus back-feeding of current among the power supplies on the bus. We also
recommend the use of fuse protection for every trunk line in the cable system.
The maximum current rating of a thick cable trunk line is 8 A. Verify that this complies with
your national and international standards. It might be necessary to limit the maximum current
to a lower value if standards in the U.S. or Canada apply. The maximum current value is a
theoretical value. The cable size supports a higher current than 8 A. Depending on the topo-
logy of nodes relative to the power supply, higher currents might be possible. See the
DeviceNet technical specifications for further information.
The maximum current rating of a thin cable trunk line is 3 A. If you use the thin cable on a
long line, the resistance of the cable decreases the maximum current value. See the following
table and the DeviceNet technical specifications for further information.
Table 6-8. Maximum Current on a Drop Line Relative to its Length
Length of Drop Line Maximum Current
1.5 m (5 ft) 3A
2.0 m (6.6 ft) 2A
3.3 m (10 ft) 1 1.5 A

Length of Drop Line Maximum Current
4.5 m (15 ft) 1A
6 m (20 ft) 0.75 A
For the calculation of the maximum current at a specific length, use the following formula:
Where:
l= Length of the drop line in meters (m)

i= Maximum current in amps
This calculation applies to the sum of the currents of all the nodes on the selected drop line.
The length (l) is not the cumulative length of the drop line; it is the maximum distance from
any node on the drop line to the trunk line.
It is important to note that voltage differences between the V– and V+ conductors need to be
between 11 V and 25 V. The common-mode voltage between any two places on the V– wire
must not exceed 5 V.
4 3
1 2
A
3 4
2 1
B
Figure 6-7. Micro-Style DeviceNet Connector Pinouts (Viewed from Contact End)

Table 6-9. Micro-Style DeviceNet Connector Pinout Legend
Item Description
A Male Connector (pins)
B Female Connector (sockets)
1 Drain (bare)
2 V+ (red)
3 V- (black)
4 CAN_H (white)
5 CAN_L (blue)

OMRON Corporation Industrial Automation Company Authorized Distributor:
Kyoto, JAPAN
Contact: www.ia.omron.com
Regional Headquarters
OMRON EUROPE B.V. OMRON ELECTRONICS LLC
Wegalaan 67-69, 2132 JD Hoofddorp 2895 Greenspoint Parkway, Suite 200 Hoffman Estates,
The Netherlands IL 60169 U.S.A.
Tel: (31)2356-81-300/Fax: (31)2356-81-388 Tel: (1) 847-843-7900/Fax: (1) 847-843-7787
OMRON ASIA PACIFIC PTE. LTD. OMRON ADEPT TECHNOLOGIES, INC.

No. 438A Alexandra Road # 05-05/08 (Lobby 2), 4550 Norris Canyon Road, Suite 150, San Ramon, CA 94583 U.S.A.
Alexandra Technopark, Tel: (1) 925-245-3400/Fax: (1) 925-960-0590 © OMRON Corporation 2019 All Rights Reserved.
Singapore 119967 In the interest of product improvement,
Tel: (65) 6835-3011/Fax: (65) 6835-2711 OMRON (CHINA) CO., LTD. specifications are subject to change without notice.
Room 2211, Bank of China Tower, 200 Yin Cheng Zhong Road,
PuDong New Area, Shanghai, 200120, China Printed in USA
Tel: (86) 21-5037-2222/Fax: (86) 21-5037-2200 Cat. No. I602-E-03 0319 (0116)
11069-000 H

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SmartController EX

11069-000 Rev. H SmartController EX User's Guide 3

IEEE 1394 Cable Specifications 26

Chapter 5: Technical Specifications 55

4 SmartController EX User's Guide 11069-000 Rev. H

01 June, Original release

03 March, l Added WEEE disposal information.

11069-000 Rev. H SmartController EX User's Guide 5

1.1 Product Description

Figure 1-1. SmartController EX Motion Controller

Optional T20 Pendant

l 3-position enable switch (dual-channel circuits)

11069-000 Rev. H SmartController EX User's Guide 7

Figure 1-2. T20 Pendant

8 SmartController EX User's Guide 11069-000 Rev. H

1.2 How Can I Get Help?

Table 1-1. Related Manuals

Manual Title Description

11069-000 Rev. H SmartController EX User's Guide 9

2.1 Dangers, Warnings, and Cautions

DANGER: Identifies an imminently hazardous situation which, if not

! avoided, is likely to result in serious injury, and might result in fatality or

WARNING: Identifies a potentially hazardous situation which, if not avoided,

CAUTION: Identifies a potentially hazardous situation which, if not avoided,

! might result in minor injury, moderate injury, or property damage.

Table 2-1. Alert Icon Meaning

This is a generic alert icon. Any specifics on the

This identifies a hazardous electrical situation.

11069-000 Rev. H SmartController EX User's Guide 11

IMPORTANT: Information to ensure safe use of the product.

NOTE: Information for more effective use of the product.

Additional Information: Offers helpful tips, recommendations, and best prac-

Version Information: Information on differences in specifications for different

2.2 What to Do in an Emergency / Abnormal Situation

Stopping the Robot

2.3 Safety Precautions

2.4 Additional Safety Information

12 SmartController EX User's Guide 11069-000 Rev. H

Robot Safety Guide

Emergency Stop Circuit and Buttons

Manual Control Pendant

Dispose of in accordance with applicable regulations.

11069-000 Rev. H SmartController EX User's Guide 13

3.1 Controller Installation

Table 3-1. Environmental Specifications

Ambient temperature 5° to 40° C (41° to 104° F)

Storage and shipment temperature –25° to 55° C (-13° to 131° F)

Humidity range 5 to 90%, non-condensing

Altitude up to 1000 m (3280 ft)

Chassis protection class IP20 (NEMA Type 1)

WARNING: Use an appropriate IP-rated enclosure.

11069-000 Rev. H SmartController EX User's Guide 15

Repacking for Relocation

Space Around the Chassis

Mounting the SmartController EX Motion Controller

Table 3-2. Mounting Kit Details

Item Part Number Contents

Table / Rack-Mounting Kit 00205-000 l brackets (table-mount): 4 x 40356-00001

Panel-Mounting Kit 90356-40000 l brackets: 4 x 40356-00000

16 SmartController EX User's Guide 11069-000 Rev. H