Configuring Digital I/O

Review the wiring diagram and build a signal list

Confirm which physical terminals carry which field signals before you touch the pendant. Note the device kind, rack, and slot for each module, since the controller identifies every physical signal by rack, slot, and physical number (in1, in2, out1, out2, and so on). Decide the logical DI[i] and DO[i] numbers you want each device to land on.

Confirm the I/O device is recognized

Press MENU, select 5 I/O, press F1 [TYPE], and select Link Device to open the I/O Link list screen. It lists each slave unit connected to the I/O link with its rack and slot, for example PrcI/O JB at rack 0 slot 1. If the module you expect is missing here, stop and fix the hardware or connection before assigning signals.

Open the Digital I/O screen

Press MENU, select 5 I/O, press F1 [TYPE], and select Digital. The list shows each port, its SIM flag (U for normal, S for simulated), its STATUS (ON or OFF), and a comment field. Press F3 IN/OUT to switch between the digital input list and the digital output list.

Open the configuration screen

From the Digital list, press F2 CONFIG to reach the assignment screen with columns RANGE, RACK, SLOT, START, and STAT. Each row maps a block of logical ports to a physical device, and the Device Name line names the module for that block. Press F2 LIST or MONITOR to return to the list screen at any time.

Enter the rack, slot, and start values

Place the cursor on RANGE and enter the block of signals to assign, for example DO[1-20]; line division happens automatically for the range you set. Enter RACK for the module kind (0 is a process I/O board or I/O link connection unit, 48 is the R-30iB Mate main board CRMA15 and CRMA16), the SLOT for that module, and START for the first physical number the block maps to. Any unassigned signal is picked up automatically on another logical number.

Confirm the assignment validates

When your entries are valid, STAT shows PEND, which means the assignment is correct and will become active after a power cycle. If STAT shows INVAL, a value is out of range for that hardware, so recheck rack, slot, and start against the signal list. UNASG means no assignment exists yet, and PMC means the row was set by the PMC and cannot be edited here.

Caution: Before you redefine physical numbers, check how each signal is already used in the cell. Remapping a live output onto the wrong device can drive the wrong actuator and cause injury or equipment damage.

Delete any leftover or conflicting rows

Press F4 DELETE to remove an unneeded assignment line so it does not overlap the block you just defined. Overlapping ranges on the same logical ports lead to unpredictable mapping. Keep one clean row per physical block.

Cycle power to activate the assignment

A PEND assignment does not take effect until you power the controller off and on, after which STAT reads ACTIV. Save any other pending work first, since the first power-up after an I/O reassignment skips power recovery even when it is enabled. Return to the Digital list and confirm the ports now read live states.

Add a comment to each I/O point

On the Digital list, press NEXT then F4 DETAIL to open the port detail screen for the selected signal. Move the cursor to the Comment line, press ENTER, choose a naming method, and type a clear function label such as GRIPPER OPEN or PART PRESENT. Press F3 NXT-PT to step to the next port and PREV to return to the list.

Set signal polarity where the field logic is inverted

On the detail screen, set Polarity to NORMAL so current turns on when the signal is on, or INVERSE so current turns on when the signal is off. Use INVERSE only when the field device or sensor is wired active-low. Verify the choice against the wiring diagram rather than guessing.

Set complementary output pairs if the tool needs them

Complementary ties two successive outputs so an odd-numbered signal going on forces the next even-numbered signal off, and the reverse. This suits a two-solenoid valve where open and close must never both be on. Set Complementary to TRUE on the detail screen only for the pairs your hardware actually requires.

Force-test each output

On the Digital Out list, move the cursor to the STATUS field of a port and press F4 ON or F5 OFF to drive it, then confirm the correct physical device responds. Forced output activates connected equipment directly, so work one output at a time and watch the actual actuator. Assignment of the signal must be complete before forcing has any effect.

Caution: Forcing an output can move a gripper, cylinder, or clamp with no program running. Keep hands and bystanders clear of every actuator, and know what each output drives before you toggle it.

Verify each input by triggering the real device

On the Digital In list, actuate each physical sensor or switch and confirm the matching DI[i] STATUS changes on the pendant. A stuck or inverted reading points to wiring, polarity, or a wrong start number rather than a program fault. Confirm the comment you added matches the device that actually moved the input.

Use simulated I/O only for bench testing without peripherals

When field devices are not yet connected, move the cursor to the SIM field and press F4 SIMULATE, then set the internal state with F4 ON or F5 OFF to test program logic. The S flag means the port is simulated, so its real input from the field is ignored and its real output to the field is held. Reserve this for controlled bench checks, never for live production.

Caution: Simulated I/O and forced states can mask real interlock signals and mislead anyone watching the cell. Confirm which signals are simulated before you let the robot run, and treat a simulated safety-related input as untrusted.

Clear every forced and simulated state before auto

Return each forced output to its correct resting state and cancel all simulation before handing the cell back to automatic. From the function menu you can select UNSIM ALL I/O to cancel simulated settings on every signal at once. Confirm the list shows U flags and expected states across all ports.

Save the finished I/O configuration

After all signals are assigned and commented, save the configuration to external storage so it can be reloaded if the setting is ever lost or changed. Keep this backup with the cell documentation alongside the wiring diagram and signal list. Print or export the final I/O map for the maintenance record.

What can go wrong: assignment stays PEND or signals read wrong

A new or edited assignment reads its old behavior until you cycle power, and STAT stays PEND until then. If ports still map wrong after a power cycle, recheck rack, slot, and start against the actual module. Confirm on the Link Device screen that the module is present at the rack and slot you assigned.

What can go wrong: an output will not respond to force or program

If a DO refuses to hold the state you set, check whether an I/O interconnect is driving it, since a DI-to-DO connection writes that output at regular intervals and overrides pendant or program changes. Open the Interconnect screen (F1 [TYPE], Interconnect) and disable the connection if it is not wanted. Also confirm the port is not still flagged simulated, which holds the field output unchanged.

What can go wrong: an input is stuck or reads backward

A DI that never changes may be simulated, wired to the wrong pin, or set to the wrong polarity. Clear any S flag, verify the physical pin against the start number in the assignment, and confirm NORMAL versus INVERSE matches the sensor. Trigger the device again and watch the STATUS field to confirm the fix.