ACON-C/CG Controller Positioner Type Operation Manual Twelfth Edition
Please Read Before Use Thank you for purchasing our product. This Operation Manual explains the handling methods, structure and maintenance of this product, among others, providing the information you need to know to use the product safely. Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of the product. The CD that comes with the product contains operation manuals for IAI products.
CAUTION 1. Use Environment ACON controllers can be used in an environment of pollution degree 2 or equivalent. 2. PC Software and Teaching Pendant Model Numbers New functions have been added to the entire ACON controller series. To support these new features, the communication protocol has been changed to the general Modbus (Modbus-compliant) mode. As a result, the existing PC software programs and teaching pendants compatible with RCS controllers can no longer be used.
CAUTION 4. Initial Parameter Settings at Startup After applying power, at least the three parameters specified below must be set in accordance with the specific application. Inappropriate settings of these parameters will prevent the controller from operating properly, so exercise due caution. For details on how to set the parameters, refer to “Parameter Settings” in the operation manual for the PC or teaching pendant.
CAUTION [2] Enabling/disabling the servo ON input signal (SON) The servo ON input signal has been added to allow for servo ON/OFF control on the PLC side. Depending on the needs, therefore, the user must enable/disable this signal. To select a desired setting, set “0” or “1” in parameter No. 21 (Servo ON input disable selection). Enable (use) 0 Disable (do not use) The factory setting is “0 [Enable].
CAUTION x Changes to Zone Function Applicable application versions: V0015 and later Among the zone signal settings, those that result in “Zone setting+ < Zone setting-” are now effective. V0014 and earlier: “Zone setting+ d Zone setting-” o A zone signal is not output. V0015 and later: “Zone setting+ = Zone setting-” o This is the only condition in which a zone signal is not output.
CE Marking If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.
Table of Contents Safety Guide.................................................................................................................... 1 1. Overview ................................................................................................................... 9 1.1 1.2 1.3 1.4 1.5 Introduction .................................................................................................................................. 9 How to Read the Model Number ....................................
4.4 Connecting the Actuator ............................................................................................................ 43 4.5 4.4.1 Wiring the ACON-C/CG and Actuator ................................................................... 43 Connecting the Communication Cable...................................................................................... 45 5. I/O Signal Control and Signal Functions.................................................................. 46 5.1 5.
6. Data Entry ................................................................................................ 65 6.1 6.2 Description of Position Table ..................................................................................................... 65 Explanation of Modes ................................................................................................................ 70 6.3 6.2.1 Positioning Mode Push = 0........................................................................
8. Parameters............................................................................................................ 122 8.1 8.2 Parameter Table ...................................................................................................................... 122 Detail Explanation of Parameters ............................................................................................ 124 8.2.1 Parameters Relating to the Actuator Stroke Range ............................................
9. PC/Teaching Pendant Connection Method in Multi-axis Configurations................ 141 9.1 9.2 9.3 9.4 Connection Example ............................................................................................................... 141 Name and Function of Each Part of the SIO Converter .......................................................... 142 Address Switch........................................................................................................................
Safety Guide When designing and manufacturing a robot system, ensure safety by following the safety precautions provided below and taking the necessary measures. Regulations and Standards Governing Industrial Robots Safety measures on mechanical devices are generally classified into four categories under the International Industrial Standard ISO/DIS 12100, “Safety of machinery,” as follows: Safety measures Inherent safety design Protective guards --- Safety fence, etc.
Requirements for Industrial Robots under Ordinance on Industrial Safety and Health Work area Work condition Cutoff of drive source Outside movement range During automatic operation Not cut off Signs for starting operation Cut off (including stopping of operation) During teaching, etc. Not cut off Cut off During inspection, etc. Not cut off (when inspection, etc., must be performed during operation) Article Article 104 Installation of railings, enclosures, etc. Article 150-4 Sign, etc.
Applicable Models of IAI’s Industrial Robots Machines meeting the following conditions are not classified as industrial robots according to Notice of Ministry of Labor No. 51 and Notice of Ministry of Labor/Labor Standards Office Director (Ki-Hatsu No.
Notes on Safety of Our Products Common items you should note when performing each task on any IAI robot are explained below. No. Task 1 Model selection z z z 2 Transportation z z z z z z z 3 4 Storage, preservation z z z z Note This product is not planned or designed for uses requiring high degrees of safety. Accordingly, it cannot be used to sustain or support life and must not be used in the following applications: [1] Medical devices relating to maintenance, management, etc.
No. Task 4 Installation/ startup Note (1) Installing the robot, controller, etc. z Be sure to firmly secure and affix the product (including its work part). If the product tips over, drops, malfunctions, etc., damage or injury may result. z Do not step on the product or place any article on top. The product may tips over or the article may drop, resulting in injury, product damage, loss of/drop in product performance, shorter life, etc.
No. Task 4 Installation/ startup 6 5 Teaching 6 Confirmation operation Note z Implement safety measures so that the product cannot be started only by turning on the power. If the product starts suddenly, injury or product damage may result. z Implement safety measures so that the product will not start upon cancellation of an emergency stop or recovery of power following a power outage. Failure to do so may result in injury, equipment damage, etc. z Put up a sign saying “WORK IN PROGRESS.
No. Task 7 Automatic operation 8 Maintenance/ inspection 9 Modification 10 Disposal Note z Before commencing automatic operation, make sure no one is inside the safety fences. z Before commencing automatic operation, make sure all related peripherals are ready to operate in the auto mode and no abnormalities are displayed or indicated. z Be sure to start automatic operation from outside the safety fences.
Indication of Cautionary Information The operation manual for each model denotes safety precautions under “Danger,” “Warning,” “Caution” and “Note,” as specified below. Level Symbol Danger Failure to observe the instruction will result in an imminent danger leading to death or serious injury. Danger Warning Failure to observe the instruction may result in death or serious injury. Warning Caution Failure to observe the instruction may result in injury or property damage.
1. Overview 1. Overview 1.1 Introduction This product is a dedicated RCA, RCA2 and RCL actuator controller that provides the same functions of the RCS controller as well as a set of new functions designed to achieve greater convenience and safety. The product also provides a power-saving function in response to growing energy-saving needs. The key features and functions are listed below.
1. Overview 1.
1.3 System Configuration 1.3.1 Internal Drive-Power Cutoff Relay Type (ACON-C) 1. Overview Standard teaching pendant Host system Supplied flat cable 24-VDC I/O power supply PC PC software (optional) RS232C type USB type RCA actuator External EMG switch Input power supply 24 VDC Caution: Connect one end of the EMG switch to the 24-V output of the input power supply and the other end to the S1 terminal.
External Drive-Power Cutoff Relay Type (ACON-CG) 1. Overview 1.3.
1.4 Procedure from Unpacking to Test Operation and Adjustment 1. 1. Overview If you are using this product for the first time, carry out each step by referring to the procedure below to ensure that all necessary items are checked and all wires are connected correctly. Check the content in the package If you found any missing part or part specified for a different model number, please contact your dealer.
6. Turn on the servo 1. Overview Confirm that the slider or rod is not contacting a mechanical end. If the slider/rod is contacting a mechanical end, move it away from the mechanical end. If the actuator is equipped with a brake, turn on the brake forced-release switch to forcibly release the brake before moving the actuator. The work part may suddenly drop when the brake is released, so exercise due caution not to pinch your hand or damage the robot hand by the falling work part.
1.5 Warranty 1.5.2 Scope of Warranty Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty will be replaced or repaired free of charge: (1) The breakdown or problem in question pertains to our product as delivered by us or our authorized dealer. (2) The breakdown or problem in question occurred during the warranty period.
1. Overview 1.5.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications (1) If our product is combined with another product or any system, device, etc., used by the customer, the customer must first check the applicable standards, regulations and/or rules. The customer is also responsible for confirming that such combination with our product conforms to the applicable standards, etc.
2. Specifications 2.1 Basic Specifications Specification item Actuator Motor type Motor power capacity (Note 1) RCA / RCA2 RCL 10 W 20 W [Model number code: 20] 30 W 20 W [Model number code: 20] Exclusively for RA3, RA4 and TA5 types 2W 5W 10 W 1.3 4.4 1.3 2.5 1.3 4.0 1.3 2.2 1.7 5.1 1.7 3.4 0.8 1.0 1.3 4.6 6.4 6.4 Heat release 8.
2.2 Name and Function of Each Part of the Controller Status indicator LEDs 6SHFL¿FDWLRQV PIO connector Connects the PLC and PIOs. SV (green) --- The servo is on A blinking green light indicates that the automatic servo-off mode is active. ALM (red) --- An alarm is present. The motor drive-power cutoff circuit is indicated here. The model of the connected actuator is indicated here. Mode selector switch The PIO pattern number is specified here. The input/output signal pattern is indicated here.
[2] Mode selector switch This interlock switch is used to prevent unexpected movement or data rewrite as a result of duplicate operation in which a movement command is input from the PLC and operation using the PC/teaching pendant is performed at the same time. AUTO: Always set to the “AUTO” side during auto operation using PIO signals from the PLC. MANU: Always set to the “MANU” side during operation using the PC/teaching pendant.
2.3 External Dimensions 6SHFL¿FDWLRQV An external view and dimensions of the product are shown below. (Note) Refer to the operation manual for each network (CC-Link, DeviceNet and ProfiBus) as well for the detailed explanation of the network connection specifications. M5 5 (Mounting dimension) 170.5 178.5 68.
3. Installation and Noise Elimination Pay due attention to the installation environment of the controller. 3.1 Installation Environment 3. Installation and Noise Elimination (1) When installing and wiring the controller, do not block the cooling ventilation holes. (Insufficient ventilation will not only prevent the controller from demonstrating its full performance, but it may also cause breakdown.) (2) Prevent foreign matter from entering the controller through the ventilation holes.
3.3 Noise Elimination Measures and Grounding The following explains the noise elimination measures that should be taken when using this controller. (1) Wiring and power supply connection 3. Installation and Noise Elimination [1] Grounding must be made by ground resistance of 100 7 or less using a dedicated grounding. Moreover, the thickness of cable shall be 1.6 mm 2 or thicker. Controller Connect the ground line to the mounting screw of the main unit.
[2] DC solenoid valves, magnet switches and relays Measure: Mount diodes in parallel with the coil or use types with built-in diodes. In a DC circuit, connecting a diode in reverse polarity will damage the diode, internal parts of the controller and/or DC power supply, so exercise due caution. 3. Installation and Noise Elimination 3.
4. Wiring 4.1 Positioner Type (with Internal Drive-power Cutoff Relay) (ACON-C) 4.1.1 External Connection Diagram 4. Wiring An example of standard wiring is shown below. (Note) The encoder cable shown in the example is the standard cable for the controller with the maximum current of 2 A. As for the robot cable or the cable for the dedicated controller for the high-thrust type, refer to 4.4.2, “Encoder Extension Cable.
4.1.2 (1) Wiring the Power Supply/Emergency-Stop Switch Wiring the power supply Input power supply 24 VDC S1 S2 MPI MPO 24V 0V EMG- 24V OV FG 4. Wiring To connect multiple controllers, provide a relay terminal block. Use a power cable satisfying the following specifications: Item Specification Applicable wire length Single wire: 1.0 / Stranded: 0.
(2) Wiring the emergency-stop switch In many cases multiple controllers are used in a single system. To provide an emergency-stop function for the entire system, the controller circuit is designed in such a way that a single EMG switch is able to actuate an emergency stop in all connected controllers. [Example of recommended circuit] 4. Wiring ACON-C controller External EMG reset switch EMG switch on teaching pendant External EMG circuit Coil current: 0.
Representative connection examples are explained below. z Connecting the teaching pendant directly to the controller 4. Wiring [1] Connecting multiple controllers (8 units or less) using a single power supply x Short the MPI and MPO terminals using a jumper wire. (The controller is shipped with these terminals shorted.) x Connect one end of the EMG signal to the 24-V output of the input power supply and the other end to the S1 terminal.
EMG signal [Controller 1] Teaching pendant 4.
[2] Using a power supply other than the input power supply (Note) Use an auxiliary relay with a coil current of 0.1 A or less and connect a diode for coil surge absorption. [Controller 1] EMG signal Teaching pendant 4.
[3] Connecting the teaching pendant to a SIO converter Configure the contact circuit for the EMG switch on the teaching pendant using EMG1/EMG2 on the power/emergency-stop terminal block on the SIO converter. (S1/S2 on the controller’s terminal block are not used.) SIO converter Teaching pendant 4.
4.
4.2 Safety Category Type (External Drive-power Cutoff Relay) (ACON-CG) 4.2.1 External Connection Diagram An example of standard wiring is shown below. (Note) The encoder cable shown in the example is the standard cable. As for the robot cable or the cable for the dedicated controller for the high-thrust type, refer to 4.4.2, “Encoder Extension Cable.” Controller 4.
4.2.2 (1) Wiring the Power Supply/Emergency-Stop Switch Wiring the power supply Input power supply 24 VDC 24V 0V FG S1 S2 MPI MPO 24V 0V EMG- 4. Wiring To connect multiple controllers, provide a relay terminal block. Use a power cable satisfying the following specifications: Item Specification Applicable wire length Single wire: 1.0 / Stranded: 0.
(2) Wiring the motor power cutoff relay 4. Wiring Explained below is a safety circuit conforming to safety category 2. The user is responsible for implementing additional safety measures in the actual circuit configuration, such as providing double contactor contacts to prevent fusing. The circuit illustrated below is for reference purposes only. x The input side of the motor drive power supply is connected to the MPI terminal, while the output side is connected to the MPO terminal.
[Connection example of a multiple-axis configuration] Input power supply Connect to 24-V terminal Connect to 0-V terminal [Controller 1] [Controller 2] [Controller 3] 4.
4.3 Connecting the I/O Cables z PIO pattern 0 [Positioning mode (Standard Type)] Host system end +24 [V] +24 [V] Upper stage Brown 1 Controller end PIO (signal abbreviation) Red 1 Orange 1 Yellow 1 4.
z PIO pattern 1 [Teaching mode (Teaching Type)] Host system end +24 [V] Upper stage Brown 1 Controller end PIO (signal abbreviation) Red 1 +24 [V] Orange 1 Yellow 1 Green 1 Command position 1 Blue 1 Command position 2 Gray 1 Command position 8 White 1 Command position 16 Black 1 Command position 32 Brown 2 Output side Operation mode Manual operation switching Red 2 Orange 2 Jog+ Yellow 2 Jog- Green 2 Operating mode Blue 2 Home return Purple 2 Pause Start/currentposition writ
z PIO pattern 2 [256-point mode (256-point type)] Host system end +24 [V] Upper stage Brown 1 Controller end PIO (signal abbreviation) Red 1 +24 [V] Orange 1 Yellow 1 Green 1 Command position 1 Blue 1 4.
z PIO pattern 3 [512-point mode (512-point type)] Host system end Upper stage Brown 1 Controller end PIO (signal abbreviation) Red 1 Orange 1 Yellow 1 Command position 1 Command position 4 Command position 8 Command position 16 Command position 32 Output side Command position 64 Command position 128 Command position 256 Brake release Operating mode Home return Pause Blue 1 4.
z PIO pattern 4 [Solenoid valve mode 1 (7-point Type)] Host system end Upper stage Brown 1 Controller end PIO (signal abbreviation) Red 1 Orange 1 Yellow 1 4.
z PIO pattern 5 [Solenoid valve mode 2 (3-point Type)] Host system end Upper stage Brown 1 Controller end PIO (signal abbreviation) Red 1 Orange 1 Yellow 1 Rear end move Front end move Blue 1 Purple 1 4.
Caution: When performing a continuity check of the flat cable, pay due attention not to expand the female pins in the connector. It may cause contact failure and disable normal operation of the controller. Black 4 Lower stage 20A 20B 1A 1B 4.
4.4 Connecting the Actuator 4.4.1 Wiring the ACON-C/CG and Actuator Use dedicated extension cables to wire the controller and actuator. (1) RCA motor cable Model number: CB-ACS-MA CB ( indicates the cable length L. Example: 080 = 8 m) (9) Pin layout Controller end 4. Wiring Pin layout Actuator end Cable model marking Pin No. Signal name Cable color Pin No. Wire size Red White Black Plug housing: SLP-03V (J.S.T. Mfg.) Socket contact: BSF-21T-P1.4 (J.S.T. Mfg.) Housing: DF1E-3S-2.
4. Wiring (I 12) (3) RCA2 integrated motor/encoder cable Model number: CB-ACS-MPA ( indicates the cable length L. Example: 080 = 8 m) Cable model marking Actuator end Controller end Housing: DF1E-3S-2.5C Contact: DF1E-2022SCF Pin No. Signal name Pin No. Cable color Red Yellow Black Pin No.
4.5 Connecting the Communication Cable Connect the communication cable to the SIO connector. Pin assignments of the cable-end connector RS485 conversion adapter end Controller end CB-RCA-SIO*** Pin No.
5. I/O Signal Control and Signal Functions 5.1 Interface Circuit The standard interface specification of the controller is NPN, but the PNP specification is also available as an option. To prevent confusion during wiring, the NPN and PNP specifications use the same power line configuration. Accordingly, there is no need to reverse the power signal assignments for a PNP controller. 5.1.1 External Input Specifications 5.
5.1.2 External Output Specifications Item Specification Number of output points Rated load voltage Maximum current Residual voltage Isolation method 16 points 24 VDC 50 mA/point 2 V or less Photocoupler 5.
5.2 PIO Patterns and Signal Assignments This controller provides six PIO pattern types to meet the needs of various applications. To select a desired type, set a corresponding value from 0 to 5 in parameter No. 25 (PIO pattern selection). The features of each PIO pattern are explained below: 5. I/O Signal Control and Signal Functions Parameter No. 25 setting 0 1 2 3 4 5 Feature of PIO pattern Positioning mode (Standard type) A basic type supporting 64 positioning points and two zone outputs.
5.2.1 Explanation of Signal Names The following explains the signal names, and gives a function overview of each signal. In the explanation of operation timings provided in a later section, each signal is referenced by its selfexplanatory name for clarity. If necessary, however, such as when marker tubes are inserted as a termination of the flat cable, use the signal abbreviations.
z PIO pattern = 1 [Teaching mode (Teaching type)] Category Signal name Command position number Operation mode Jog/inching switching Signal abbreviation PC1 PC2 PC4 PC8 PC16 PC32 MODE JISL 5. I/O Signal Control and Signal Functions +jog/inching movement JOG+ -jog/inching movement JOGInput The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.
z PIO pattern = 2 [256-point mode (256-point type)] Category Signal name Command position number Brake release BKRL Operating mode RMOD Home return HOME *Pause *STP Start Alarm reset CSTR RES Servo ON SON Completed position number PM1 PM2 PM4 PM8 PM16 PM32 PM64 PM128 Position zone PZONE Output Operating mode status RMDS Home return completion HEND Position complete PEND Ready SV *Emergency stop *EMGS *Alarm *ALM Function overview The target position number is input.
z PIO pattern = 3 [512-point mode (512-point type)] Category Signal name Command position number 5.
z PIO pattern = 4 [Solenoid valve mode 1 (7-point type)] Category Direct position command 0 Direct position command 1 Direct position command 2 Direct position command 3 Direct position command 4 Direct position command 5 Direct position command 6 Signal abbreviation ST0 ST1 ST2 ST3 ST4 ST5 ST6 Brake release BKRL Operating mode RMOD Home return HOME *Pause *STP Alarm reset RES Servo ON SON Movement complete 0 PE0 Movement complete 1 PE1 Movement complete 2 PE2 Movement complete 3 PE3
z PIO pattern = 5 [Solenoid valve mode 2 (3-point type)] Category Signal name Rear end move command (note) Front end move command (note) Intermediate point move command 5.
5.2.2 Signal Assignment Table for Respective PIO Patterns Caution: [1] [2] [3] 5. I/O Signal Control and Signal Functions When creating a PLC sequence or wiring signals, assign each pin correctly by referring to the assignment table below. When “1 [Teaching type(Teaching type)]” is selected, the meaning of each pin number will vary depending on the mode. Accordingly, also pay due attention to the mode switch timings. (Note) Data in parentheses () for ST1, ST2, LS1 and LS2 of parameter No.
5.3 Details of I/O Signal Functions An input time constant is provided for the input signals of this controller, in order to prevent malfunction due to chattering, noise, etc. Except for certain signals, switching of each input signal will be effected when the signal has been received continuously for at least 6 msec. For example, when an input is switched from OFF to ON, the controller will only recognize that the input signal is ON after 6 msec.
Command position number (PC1 to PC256) When a movement command is effected upon OFF o ON of the start signal, the nine-bit binary code consisting of signals PC1 to PC256 will be read as the command position number. 6 bits from PC1 to PC32 in case of the positioning mode (standard type) and teaching mode (teaching type), 8 bits from PC1 to PC128 in case of the 256-point mode (256-point type), and 9 bits from PC1 to PC256 in case of the 512-point mode (512-point type).
5. I/O Signal Control and Signal Functions Alarm reset (RES) This signal provides two functions. [1] Reset the alarm output signal (*ALM) that turned OFF due to an alarm If an alarm has generated, turn ON this signal after confirming the nature of the alarm. The controller will reset the alarm upon detection of a rise edge of the RES signal. (Note) Certain alarms cannot be reset by the RES signal. For details, refer to 10, “Troubleshooting.
Jog (JOG+, JOG-) This signal is valid when the teaching mode (teaching type) is selected. During jogging (JISL is turned OFF), the actuator moves up to ± each software limit if the rise edge from OFF to ON of this signal is detected. The actuator decelerates to a stop if the falling edge from ON to OFF of this signal is detected. The jog speed is defined by parameter No. 26 “PIO jog speed.” * If the following input signal changes occur during jogging, the controller decelerates to a stop.
5. I/O Signal Control and Signal Functions Movement to each position (ST0 to ST2) [Solenoid valve mode 2 (3-point type)] Since the number of positioning points is limited to three, the actuator can be controlled just like an air cylinder. While this signal is ON, the actuator will move toward the target position. If the signal turns OFF while the actuator is moving, the actuator will decelerate to a stop. Before executing this command, enter a target position in the “Position” field for position No.
5.3.2 Details of Each Output Signal Operating mode status (RMDS) The internal operating mode of the controller is output based on the AUTO/MANU selector switch on the controller and the RMOD signal received by the input port. If the selector switch is set to “AUTO” and the RMOD signal is OFF (AUTO), the controller is in the AUTO (OFF) mode. If the selector switch is set to “MANU” and/or the RMOD signal is ON (MANU), the controller is in the MANU (ON) mode.
5. I/O Signal Control and Signal Functions Home return completion (HEND) This signal is OFF immediately after the power is input, and turns ON in either of the following two conditions: [1] Home return operation has completed with respect to the first movement command issued with the start signal. [2] Home return operation has completed following an input of the home return signal.
Movement complete at each position (PE0 to PE6) [Solenoid valve mode 1 (7-point type)] When PIO pattern is “4,” a position number (0 through 6) corresponding to each movement command will be output upon completion of positioning. Simple alarm-code output function is not provided for these signals. If an alarm generates, only the *ALM signal will turn OFF. Check the details of the alarm code using each tool.
Emergency stop (*EMGS) This signal remains ON while the controller is normal, and will turn OFF if the emergency stop circuit is cut off. Program the PLC so that it will monitor this signal and implement appropriate safety measures for the entire system if the signal turns OFF. Output Signal Changes in Each Mode 5.
6. Data Entry To move the actuator to a specified position, a target position must be entered in the “Position” field. A target position can be specified in the absolute mode where a distance from the home is entered, or in the incremental mode where a relative travel from the current position is entered. Once a target position is entered, all other fields will be automatically populated with their default values set by the applicable parameters.
(4) Acceleration/deceleration x Enter the acceleration/deceleration at which to move the actuator, in [G]. Basically, the acceleration and deceleration should be inside the rated acceleration/deceleration range specified in the catalog. The input range is greater than the rated range in the catalog to accommodate situations where you want to “reduce the tact time when the transferring mass is significantly smaller than the rated load capacity.
“Push & hold operation” This field defines the maximum push distance after reaching the target position in push & hold operation. Consider possible mechanical variation of the work part and set an appropriate positioning band that will prevent the positioning from completing before the work part is contacted. The position complete signal turns ON here, as completion of push action is recognized after the load has been contacted. Load Positioning band (maximum push distance) Target position 6.
(9) Acceleration/deceleration • mode This field defines the acceleration/deceleration pattern characteristics. The factory setting is “0.” 0: Trapezoid pattern 1: S-motion 2: Primary delay filter Trapezoid pattern Speed Acceleration Deceleration Time 6. Data Entry * Acceleration and deceleration are set in the “Acceleration” and “Deceleration” fields of the position table, respectively.
Primary delay filter The actuator operates along acceleration/deceleration curves that are more gradual than those of linear acceleration/deceleration (trapezoid pattern). Use this mode in situations where you wish to prevent the work part from receiving micro-vibration during acceleration or deceleration. Speed Time * The level of primary delay is set by parameter No. 55 (Primary-filter time constant for position command). The minimum input unit is 0.1 msec, and the setting range is 0.0 to 100.0.
6.2 Explanation of Modes 6.2.1 Positioning Mode Push = 0 The actuator moves to the target position set in the “Position” field of the position table. Speed The position complete signal turns ON here. Target position Moving distance Time 6. Data Entry Positioning band 6.2.
(2) Work part was not contacted (missed) If the actuator does not still contact the work part after having moved the distance specified in the “Positioning band” field, the position complete signal will not turn ON. Therefore, include timeout check processing in the sequence circuit on the PLC side. x It is recommended that a zone signal be also used as a “simple ruler” to supplement the judgment of missed work part. Speed The position complete signal will not turn ON if the load has not been contacted.
(4) Positioning band was entered with a wrong sign Take note that if a value with a wrong sign is set in the “Positioning band” field of the position table, the operation will deviate by a distance corresponding to “positioning band x 2,” as shown below. Speed Moving distance Positioning Positioning band band Target position Actual position reached (the load was missed) 6. Data Entry Positioning band 6.2.
6.2.5 Pause The actuator can be paused during movement using an external input signal (*STP). The pause signal uses the contact b logic (always ON) to ensure safety. Turning the *STP signal OFF causes the actuator to decelerate to a stop. When *STP is turned ON subsequently, the actuator will resume the remaining movement. ON ON OFF *STP Actuator operation Target position 6.2.
6.2.7 Home Return After the power is turned on, home return must be performed to establish the home position. The method of home return varies depending on the PIO pattern. z When a dedicated input is used [PIO pattern z 5] Home return is performed using the home return (HOME) input. The actuator will return home regardless of whether or not home return has been completed once before. When home return is completed, the home return complete (HEND) output signal will turn ON.
6.2.8 Overview of Teaching Mode (Teaching Type) Depending on your system, it may be desirable to be able to use a touch panel, etc., to perform jogging operation or write the current position to the “Position” field of the position table, without using a PC or teaching pendant. The teaching mode (teaching type) is provided to support these applications. The features of the teaching mode (teaching type) are summarized below: [1] The actuator can be jogged using I/O signals input from the PLC.
6.2.9 Overview of Solenoid Valve Mode 1 (7-point Type) The number of positioning points is kept small, or specifically to seven or less. This type assumes simple applications where the PLC ladder sequence only requires a simple circuit configuration. I/O signals provide separate command inputs and movement complete outputs for respective position numbers. Accordingly, the signal pattern is different from the positioning mode (standard type) (PIO pattern = 0).
[2] In case of positioning mode (standard type) Command position 1 input (PC1) Command position 2 input (PC2) “5” is indicated by a binary code. Command position 4 input (PC4) * All other command position inputs (PC8, PC16 and PC32) turn OFF. 6. Data Entry At least 6 msec of delay time is needed (ensured by a timer setting on the PLC side).
6.2.10 Overview of Solenoid Valve Mode 2 (3-point Type) 6. Data Entry This type provides a control method adjusted to that of an air cylinder by assuming that the controller is used as an air cylinder. The key differences between this controller and an air cylinder are summarized in the table below. Program appropriate controls by referring to this table. * Do not use push-motion operations.
Item Position check upon power ON Air cylinder Determined by an external detection sensor, such as a reed switch. ACON Immediately after the power is turned on, the controller cannot identify the current position because the mechanical coordinates have been lost. Accordingly, a rear end command must always be executed after the power is turned on, to establish the coordinates. The actuator will perform home-return operation first, and then move to the rear end. [1] [2] Power is turned on here.
6.3 Power-saving Modes at Standby Positions This product provides energy-saving modes to reduce power consumption in situations where the actuator remains standstill for a long period at a standby position. Use these modes after confirming that they will not present problems to any part of your system. 6.
Also note that when the PIO pattern is “0,” “1,” “2,” “3” or “4,” the servo will turn off and therefore the position complete signal (PEND), completed position number signals (PM1 to PM256) and movement complete signals at respective positions (PE0 to PE6) will turn OFF. However, you can keep the signals ON via a parameter in situations where the PLC sequence circuit is designed in such a way that problems will occur if complete signals turn OFF. Setting of parameter No.
7. Operation 7.1 How to Start 7. Operation 7.1.1 Timings after Power On Procedure after initial startup until actuator adjustment [1] Connect the motor extension cable to the MOT connector and encoder relay connector to the PG connector. [2] Connect the supplied flat cable to the PIO connector (for connection between the host PLC and I/O unit). [3] Reset the emergency stop or enable the supply of motor drive power.
[10] Perform home return. z Overview of operation on the teaching pendant x In case of CON-T, press the “ADJ” key, enter 1 in “Adjustment No.” and press the return key. x On the RCM-T, select the “Edit/Teach” screen, bring the cursor to “*Home” in the sub display area, and then press the Return key. x On the RCM-E, select the “Teach/Play” screen, scroll until “*Home Return” is displayed, and then press the Return key.
7. Operation Procedure of Normal Operation The operating procedure in normal condition is specified below: [1] Reset the emergency stop or enable the supply of motor drive power. [2] Supply the 24-VDC I/O power. [3] Supply the 24-VDC controller power. * If the monitor LED [SV/ALM] on the front panel illuminates for 2 seconds initially and then turns off, the controller is normal. If [SV/ALM] illuminates in red, an alarm is present.
Emergency stop not actuated (motor drive power supplied) Safety circuit condition Supply of 24-VDC I/O power Supply of 24-VDC controller power * Be sure to set the switch to the “AUTO” side. Mode selector switch * If this output signal is OFF, I/O signal communication with the PLC is enabled. Operation mode status output (RMDS) 7. Operation Pause input (*STP) Green Servo ON input (SON) Monitor LED [SV/ALM] Ready output (SV) 1.
Warning: Excited phase detection is performed when the servo is turned on for the first time after the power has been turned on, or before an absolute reset is executed following the connection of a simple absolute unit. For this reason, the actuator moves 0.5 to 2 mm under the normal circumstances, although it depends on the lead length of ball screws. (Depending on the position when the power supply is turned on, the controller may move up to the length of the ball screw lead although it is very rare.
7.1.2 Position Table and Parameter Settings Required for Operation Startup adjustment Immediately after the system has been started, the moving speed can be reduced by the methods specified below to ensure safety of operators and prevent damage to jigs, etc. Change the applicable parameters, if necessary. o For details on the setting-change operations, refer to the operation manual for your PC software/teaching pendant.
Full-scale operation This product provides energy-saving modes to reduce power consumption in situations where the actuator remains standstill for a long period at a standby position. You can also select the status of position complete signal to be applied if the servo turns off or “position deviation” occurs while the actuator is standing still after completing positioning. Use these functions after confirming that they will not present problems to any part of your system.
7.2 Home Return Operation 7.2.1 Method Using the HOME Input Signal (PIO Pattern = 0 to 4) Since the home return signal (HOME) is provided in PIO patterns 0 to 4, perform home return using this signal. x When the home return signal (HOME) turns ON, the actuator starts moving toward the mechanical end on the home side. Once the mechanical end is contacted, the actuator reverses its direction and moves, and then stops at the home position.
(Note) If the home is not yet established immediately after the power has been turned on, directly inputting the command position signal and start signal without inputting the home return signal (HOME) first will cause the actuator to perform home return operation and then move to the target position. However, it is recommended that the PLC sequence circuit use the home return signal (HOME) to prevent errors. [1] PIO pattern = 0 to 3 Command position 1 to 256 input (PC1 ~ PC256) Start input (CSTR) 7.
7.2.2 Method Used When No HOME Input Signal Is Available (PIO Pattern = 5) Since no home return signal (HOME) is available in PIO pattern 5, input the rear end move command (ST0) first to perform home return. x When the rear end movement command (ST0) turns ON, the actuator starts moving toward the mechanical end on the home side. Once the mechanical end is contacted, the actuator reverses its direction and moves to the home position, stops temporarily at the home position, and then moves to the rear end.
7.3 Positioning Mode (Back and Forth Movement between Two Points) Example of use in operation) The actuator moves back and forth between two positions. The position 250 mm from the home is set as position 1, and the position 100 mm from the home is set as position 2. The travel speed to position 1 is set as 200 mm/sec, and to position 2 is set as 100 mm/sec. Controller Reference flow Signal name [13] [10] [5] [2] Category [1] Select/enter command position 1.
Position table (Field(s) within thick line must be entered.) 0 Position [mm] * Speed [mm/s] * Acceleration [G] * Deceleration [G] * Push [%] * Positioning band [mm] * 1 250.00 200.00 0.30 0.30 0 0.10 2 : 100.00 100.00 0.30 0.30 0 0.10 No.
7.4 Push & Hold Mode Example of use in operation) The actuator is caused to move back and forth in the push & hold mode and positioning mode. The position 280 mm from the home is set as position 1, and the position 40 mm from the home is set as position 2. Movement to position 1 is performed in the push & hold mode (the actuator is caused to contact the work part and push it in the counter-motor direction).
Position table (Field(s) within thick line must be entered.) 0 Position [mm] * 1 280.00 200.00 0.30 0.30 50 15.00 2 : 40.00 100.00 0.30 0.30 0 0.10 No.
7.4.1 Return Action after Push & Hold by Relative Coordinate Specification z Positioning mode The reference position is the target position for the position number used in the applicable push & hold operation. In the aforementioned example, the actuator moves to the 240-mm position if position No. 2 is set to -40 mm in the incremental mode (280 – 40 = 240 mm). Speed Position where the push & hold operation completed Return action Target position 280 mm 7.
7.5 Speed Change during Movement Example of use in operation) The actuator speed is reduced at a certain point during movement. The position 150 mm from the home is set as position 1, and the position 200 mm from the home is set as position 2. The actuator is initially located between the home and position 1. The actuator is moved to position 2 being the target position, at a travel speed of 200 mm/sec to position 1 and that of 100 mm/sec from position 1 to position 2.
Position table (Field(s) within thick line must be entered.) 0 Position [mm] * 1 150.00 200.00 0.30 0.30 0 10.00 2 : 200.00 100.00 0.30 0.30 0 0.10 No. Speed [mm/s] * Acceleration [G] * Deceleration [G] * Command position Position 1 7.
7.6 Operation at Different Acceleration and Deceleration Settings Example of use in operation) Positioning is performed to the position 150 mm from the home (position 1) at a speed of 200 mm/sec. The acceleration is 0.3 G and the deceleration is 0.1 G. Method) Set 0.3 [G] in the “Acceleration” field and 0.1 [G] in the “Deceleration” field of the position table.
Position table (Field(s) within thick line must be entered.) No. 0 1 : Position [mm] * 150.00 Speed [mm/s] * Acceleration [G] * Deceleration [G] * 200.00 0.30 0.10 Command position Push [%] * Positioning band [mm] * 0 0.10 Position 1 T1 Start 7. Operation Position complete Position 1 Completed position Moving Speed Positioning band Actuator movement Acceleration 0.3 G Deceleration 0.
7.7 Pause Example of use in operation) Pause the actuator during movement. [Effective in PIO pattern = 0 to 4] Method) Use the pause input. Controller PIO Signal name Reference flow Category [1] Select/enter a desired command position. [5][2] Start [2] Start input ON Command position 1 Movement to the selected position starts. Command position 2 [1] Command position 4 Input 7.
Command position Start Note Position complete Completed position Pause Moving 4 msec or less 7. Operation Speed Actuator movement Deceleration to a stop Start of remaining movement T1: 6 msec or more; time after selecting/entering a command position until the start input turns ON (The scan time of the host controller must be considered.) Caution: When the start signal turns ON, the position complete output will turn OFF and the moving output will turn ON.
7.8 Zone Signal Output Two types of zone output signals are available: zone output (ZONE1) and position zone output (PZONE). The boundaries defining the signal ON range are set differently for each zone output. [1] Zone output (ZONE1) --- Set by parameter No. 1/No. 2. [2] Position zone output (PZONE) --- Set in the “Zone boundary-“ and “Zone boundary+” fields of the position table. Whether these signals are available or not varies depending on the PIO pattern, as shown below.
Controller PIO Signal name [5] [2] Reference flow Category [1] Select/enter a desired command position. Start [2] Start input ON Command position 1 Input Movement to the selected position starts. [1] Completed position OFF Command position 32 Completed position 1 [3] Position complete output OFF [4] Moving output ON [5] Start input OFF 7.
Command position T1 Start Note Position complete Completed position Zone Moving Speed 7. Operation Actuator movement 0 mm T1: 40 mm 120 mm 150 mm 6 msec or more; time after selecting/entering a command position until the start input turns ON (The scan time of the host controller must be considered.) Caution: When the start signal turns ON, the position complete output will turn OFF and the moving output will turn ON.
7.9 Incremental Moves Example of use in operation) Move the actuator from the home to the 30-mm position by issuing an absolute position command (position No. 1), and thereafter move the actuator continuously at a 10-mm pitch until the final position of 200 mm is reached. (Pitch feed command: Position No. 2) Controller PIO Signal name [13][10][5][2] P [1] L [9] 7.
Position table (Field(s) within thick line must be entered.) No. Position [mm] Speed [mm/ss] Positioning band [mm] Zone + [mm] Zone [mm] Incremental 0 ½ ½ ½ ½ ½ ½ 1 30.00 100.00 0.10 0 0 0 10.00 20.00 0.10 190.50 29.50 1 = 2 Incremental feed } * On the teaching pendant screen, this sign indicates that the position is specified in the incremental mode. Command position Position 1 Position 2 T1 T1 Start 7.
7.9.1 Judgment Method of End Position 7. Operation Although completion judgment is based on the applicable count managed by the PLC, the zone output signal can be used additionally to double-check the completion of movement. Program the PLC so that the ON/OFF status of the zone output signal is checked when positioning is completed, and if the signal is OFF, the applicable position will be determined as the last work part position.
7.9.2 Notes on Incremental Mode (1) Positioning mode If any incremental position number is selected and input and then a start signal is input while positioning is in progress, the actuator will move to the position corresponding to the target position of the initial command plus the incremental distance. (If the incremental distance is a negative value, the actuator will move to the position corresponding to the target position minus the incremental distance.
(2) Push & hold mode The following explains how the actuator will move if an incremental position number is selected and input and then a start signal is input while the actuator is moving in the push & hold mode.
z Push & hold operation using the incremental position number Example) If a position 2 command is input followed by a start signal while the actuator is moving to position 1, a new target position will be set by adding the incremental distance to the current position where the start input was received. Since the target position is indeterminable, never use this method. Position table (Field(s) within thick line must be entered.) Positioning band [mm] Speed [mm/ss] No.
7.10 Jogging/Teaching Using PIO If the teaching type is selected, you can jog the actuator via operation from the PLC. You can also write the current actuator position to the “Position” field of the position table under a specified position number via operation from the PLC. If the actuator position is written to a blank “Position” field where no position has yet been defined, the positioning band and other fields will be automatically populated by their default values set in the applicable parameters.
Jogging/teaching timing Operation mode Current operation mode Manual operation switching +Jog -Jog Command position Position 1 Write completion T1: 20 msec or more; time after the current-position write input is turned ON until writing of the current position is started When the operation mode (MODE) input is turned ON, the current operation mode (MODES) output will turn ON and the teaching mode permitting PIO teaching will become effective.
7.11 Operation of Solenoid Valve Mode 1 (7-point Type) Separate movement command inputs are provided for the target positions for position Nos. 0 to 6, so simply turn ON the input signal corresponding to the position you wish to move the actuator to, and the actuator will start moving. Example of use in operation) Move the actuator to position No. 0 (5 mm), position No. 1 (200 mm) and position No. 2 (390 mm) in sequence. Controller PIO Signal name [1] [4] P 7.
Direct position command 0 input (ST0) Direct position command 1 input (ST1) Direct position command 2 input (ST2) Movement complete 0 output (PE0) Movement complete 1 output (PE1) 7. Operation Movement complete 2 output (PE2) Actuator movement Position No. 0 (5 mm) Position No. 2 (390 mm) Position No. 1 (200 mm) Caution: Movement commands are executed based on the rise edge, so input each signal continuously for 6 msec or more.
z The movement command input operates in two modes. You can select the operation condition of the movement command input (ST0 to ST6) in parameter No. 27. The factory setting is “0: [Level mode].” Description of the movement command input Level mode: The actuator starts moving when the input signal turns ON. When the signal turns OFF during the movement, the actuator will decelerate to a stop and complete its operation.
z Handling of the pause (*STP) signal This signal is a contact B signal, meaning that it must remain ON while the actuator is moving. If the pause signal turns OFF while the actuator is moving, the actuator will decelerate to a stop. The actuator will start moving when the signal turns ON again. Use this signal as an interlock that actuates when an operator entry prohibition sensor or contact prevention sensor is activated. If the pause signal is not to be used, set parameter No.
7.12 Operation of Solenoid Valve Mode 2 (3-point Type) After the power has been turned on, input the rear end move command first to complete home return, and then perform continuous operation. o Refer to 7.2.2, “Method Used When No HOME Input Signal Is Available.” Example of use in operation) How to move the actuator from the rear end to the front end is explained.
z Meaning of position detected output signals (LS0, LS1, LS2) These signals are handled in the same manner as limit switches (LSs), and turn ON when the following conditions are met: [1] The home return complete output signal (HEND) is ON. [2] The current position is within the positioning band from each target position in the positive or negative direction.
z Speed change during movement If the load is made of soft material or is a bottle or otherwise topples easily due to its shape, one of the following two methods can be used to prevent the load from receiving vibration or impact when it stops: [1] Reduce the deceleration to make the deceleration curve gradual. [2] Initially move the actuator at the rated speed, and reduce the feed speed immediately before the target position. Method [2], where the feed speed is reduced, is explained below.
z Pause during movement Since move commands are based on level mode, the actuator continues to move while a move command is ON. Once the move command turns OFF, the actuator will decelerate to a stop and complete the operation. Therefore, turn OFF the move command if the actuator must be stopped temporarily as a low-degree safety measure. (Example) Temporarily stop the actuator while it is moving to the front end.
8. Parameters 8.1 Parameter Table Category: No. 1 2 3 4 5 8.
No.
8.2 Detail Explanation of Parameters If a parameter has been changed, always restart the controller using a software reset command or by reconnecting the power. 8.2.1 Parameters Relating to the Actuator Stroke Range z Soft limit (No. 3/4 LIMM/LIML) Set the soft limit in the positive direction in parameter No. 3, and that in the negative direction in parameter No. 4. The factory setting for the soft limits conforms to the effective actuator length.
z Zone boundary (1: No. 1/2 ZONM/ZONL 2: No. 23/24 ZNM2/ZNL2) These parameters set the range where the zone output signal (ZONE1) is turned ON when the PIO pattern 0 [Positioning mode (standard type)], 4 [Solenoid valve mode 1 (7-point type)], or 5 [Solenoid valve mode 2 (3point type)] is selected. The zone output signal turns ON when the current position is between the negative-side boundary and positiveside boundary. Set the positive-side boundary in parameter No. 1, and negative-side boundary in No. 2.
8.2.2 Parameters Relating to the Actuator Operating Characteristics z PIO jog speed (No. 26 IOJV) When the selected PIO pattern is “1” [teaching mode (teaching type)], this parameter defines the jog speed to be applied when jog input commands are received from the PLC. The factory setting is “100 [mm/sec].” Set an appropriate value in parameter No. 26 in accordance with the purpose of use. The maximum speed is limited to “250 [mm/sec].” (Note) Parameter No.
z Current-limiting value during home return (No. 13 ODPW) The factory setting conforms to the standard specification of the actuator. The home-return torque becomes higher as the value gets larger. This does not usually need a change, however, it may be necessary to make the value larger in Parameter No. 13 when the home-return operation completes before reaching the proper position due to increase of slider resistance depending on the way to mount or the condition of load in vertical oriented mounting.
z Automatic servo-off delay time (No. 36 ASO1/No. 37 ASO2/No. 38 ASO3) This parameter defines the delay time after the positioning is completed until the servo turns off automatically, when the “Standstill mode” field of the position table is set to “1,” “2” or “3” (automatic servo-off control enabled) or parameter No. 53 (Default standstill mode) is set to “1,” “2” or “3”(automatic servo-off control enabled). Meaning of settings: 1: T becomes the value set by parameter No. 36.
z Push speed (No. 34 PSHV) This parameter defines the push speed to be applied after the actuator reaches the target position in push & hold operation. Before the shipment, this parameter has been set to the default value selected in accordance with the characteristics of the actuator. Set an appropriate speed in parameter No. 34 by considering the material and shape of the work part, and so on.
z Enable function (No. 42 FPIO) Whether to enable or disable the deadman switch function on an ANSI-type teaching pendant is defined by parameter No. 42. * An ANSI-type teaching pendant will be developed in the future. Setting Enable (Use) 0 Disable (Do not use) 1 The factory setting is “1 [Disable].” 8. Parameters z Polarity of home check sensor input (No. 43 AIOF) The home check sensor is not included in the standard specification, but it can be installed as an option.
z Home-sensor input polarity (No. 18 AIOF) Parameter No. 18 defines the input polarity of the home sensor. With the current models of RCA actuators, the factory setting is “0 [Sensor not used]” because these models do not adopt the home sensor method. This parameter is provided to help develop new actuator models that support the home sensor method. The customer is advised not to change the default setting.
z Ball screw lead length (No. 77 LEAD) This parameter defines the ball screw lead length. A default value appropriate for the characteristics of the actuator is set at the factory. * Do not change the setting. z Axis operation type (No. 78 ATYP) This parameter defines the type of the actuator used. Definition of settings : 0 (Linear axis) : 1 (Rotational axis) z Rotational axis mode selection (No. 79 ATYP) If the axis operation type (No.
If the actuator is moved in the order to positions 1 Æ 2 Æ 3 Æ 4, the actuator will operate differently depending on whether or not shortcut is selected, as explained below. When shortcut is not selected Point No. 1 Point No. 1 Point No. 2 Point No. 2 Point No. 3 Point No. 4 Point No. 4 Point No. 3 When shortcut is selected Point No. 1 Point No. 1 Point No. 3 Point No. 4 8. Parameters Point No. 2 Point No. 2 Point No. 4 Point No. 3 z Absolute unit (No. 83 ETYP) Parameter No.
8.2.3 Parameters Relating to the External Interface z PIO pattern selection (No. 25 IOPN) Select the PIO operation pattern in parameter No. 25. This setting forms the basis of operation, so be sure to set this parameter at the beginning. The factory setting is “0 [Positioning mode (Standard type)].” Parameter No. 25 setting 0 8. Parameters 1 2 3 4 5 134 Feature of PIO pattern Positioning mode (Standard type) A basic type supporting 64 positioning points and two zone outputs.
z Movement command type (No. 27 FPIO) Parameter No. 27 defines the operation conditions via the movement command inputs (ST0 to ST6) when the PIO pattern is “solenoid value mode 1 (7-point type)." The factory setting is “0 [Level mode].” Description of the movement command input Level mode: The actuator starts moving when the input signal turns ON. When the signal turns OFF during the movement, the actuator will decelerate to a stop and complete its operation.
z Pause input disable selection (No. 15 FPIO) Parameter No. 15 defines whether the pause input signal is disabled or enabled. Setting Enable (use) 0 Disable (do not use) 1 The factory setting is “0 [Enable].” 8. Parameters z Servo ON input disable selection (No. 21 FPIO) Parameter No. 21 defines whether the servo ON input signal is disabled or enabled. Setting Enable (use) 0 Disable (do not use) 1 The factory setting is “0 [Enable].” z Home-return input disable selection (No. 40 FPIO) Parameter No.
z Output mode of position complete signal (No. 39 FPIO) This parameter is effective when any PIO pattern other than “5” [Solenoid valve mode 2 (3-point type)] is selected. It defines the status of completed position number signals [PM1 to PM256], movement complete signals at respective positions [PE0 to PE6] and position complete signal [PEND] to be applied if the servo turns off or “position deviation” occurs while the actuator is standing still after completing positioning.
8. Parameters z Silent interval multiplier (No. 45 SIVM) This parameter is not used for this controller. It is applied to controllers of RS485 serial communication type. If specified, this parameter defines the multiplier to be applied to the silent interval time for delimiter judgment in the RTU mode. The default setting is the communication time corresponding to 3.5 characters in accordance with the Modbus specification.
8.2.4 Servo Gain Adjustment Before the shipment, the servo has been adjusted in accordance with the standard specification of the actuator. Accordingly, the servo settings need not be changed in normal conditions. Nonetheless, the parameters relating to servo adjustment are made accessible by the customer so that speedy actions can be taken in situations where vibration or noise occurs due to the affixing method of the actuator, load condition, or the like.
z Speed loop integral gain (No. 32 VLPT) Parameter No. Unit Input range 32 --- Default Set individually in accordance with the actuator characteristics. 1 ~ 217270 This parameter determines the level of response with respect to a speed control loop. Decreasing the setting results in lower response to the speed command and decreases the reactive force upon load change. If the setting is too low, compliance with the position command drops and the positioning time increases as a result.
9. PC/Teaching Pendant Connection Method in Multi-axis Configurations This section explains the method to permanently connect a PC/teaching pendant in configurations consisting of multiple axes, so that the PC/teaching pendant connector need not be removed/inserted each time. The connector is connected to a SIO converter, and the SIO converter sends/receives data to/from each controller via RS485 serial communication.
9.2 Name and Function of Each Part of the SIO Converter This is a converter unit conforming to RS485/232C. [2] Link-connection terminal block (TB1) [1] Power/emergency-stop terminal block (TB2) [6] Monitor LEDs [5] PORT switch [3] D-sub, 9-pin connector [4] Mini DIN, 8-pin connector [1] Power/emergency-stop terminal block (TB2) 3& 7HDFKLQJ 3HQGDQW &RQQHFWLRQ 0HWKRG LQ 0XOWL D[LV &RQ¿JXUDWLRQV EMG1, EMG2 24 V 0V FG Provide a contact output for the emergency-stop switch on the teaching pendant.
[2] Link-connection terminal block (TB1) A connection port for linking the controller. “A” on the left side connects to pin 1 (SGA) in the controller’s communication connector. “B” on the right side connects to pin 2 (SGB) in the controller’s communication connector. (Note) Be sure to use twisted pair wires for the above two connections (SGA/SGB). [3] D-sub, 9-pin connector A connection port with the PC. [4] Mini DIN, 8-pin connector A connection port with the teaching pendant.
9.3 Address Switch Set an address (0 to 15) as a hexadecimal (0 to F) using the ADRS switch on the front panel of each controller to define the slave number for the controller. Assign “0” to the controller nearest the host, and then assign 1, 2, 3, …, E and F to the remaining controllers in the direction of moving away from the host. After all addresses have been set, reconnect the power. Caution: After the setting, be sure to confirm that the addresses are not duplicated.
9.5 Detail Connection Diagram SIO converter (*1) Two-paired shielded cable Recommended brand: Taiyo Electric Wire & Cable Four-way junction (AMP: 5-1473574-4) HK-SB/20276XL 2PX22AWG [A] [B] (*2) Yellow Controller link cable CB-RCB-CTL002 Yellow Orange Orange Blue Blue Controller 2 E-Con connector (AMP: 3-1473562-4) Housing color: Orange (*1) The user must provide the two-paired shielded cable.
When connecting a PC to ACON without using an SIO converter (grounding to plus terminal) Make sure to use an SIO isolator (RCB-ISL-SIO) for connection. Note that the PC support software that can be used is RCM-101-USB and RCM-101-MW cannot be used. PC (USB port) Conversion unit (RCB-CV-USB) SIO isolator RS485 communication Isolation 3& 7HDFKLQJ 3HQGDQW &RQQHFWLRQ 0HWKRG LQ 0XOWL D[LV &RQ¿JXUDWLRQV Controller Isolator communication cable CB-RCB-SIO (sold separately) is required.
10. Troubleshooting 10.1 Action to Be Taken upon Occurrence of Problem Upon occurrence of a problem, take an appropriate action according to the procedure below in order to ensure speedy recovery and prevent recurrence of the problem. a. Check the status indicator lamps. SV (green) --The servo is ON. ALM (red) --An alarm is present, or an emergency stop has been actuated or the motor drive power is cut off. b. Check for error in the host controller. c. Check the voltage of the main 24-VDC power supply. d.
10.2 Alarm Level Classification Alarms are classified into two levels based on the corresponding symptoms. Alarm level ALM lamp *ALM signal What happens when alarm generates Input an alarm reset signal (RES) from the PLC. Reset by the PC/teaching pendant. Reconnect the power. Operation cancellation Lit Output The actuator decelerates to a stop and then the servo turns OFF. Cold start Lit Output The actuator decelerates to a stop and then the servo turns OFF.
10.3 Alarm Description Output Using PIO In PIO patterns 0 to 3 (64 to 512-point positioning type), alarm information can be output using the ports for completed position output signals (four bits of PM1 to PM8) so that when an alarm occurs, the nature of the alarm can be identified on the PLC side. Program the PLC so that whether a given output is a completed position number or alarm can be identified based on the status of the alarm output signal (*ALM).
10.4 Alarm Description and Cause/Action 10. Troubleshooting (1) Message level alarms Code Error name Cause/Action 092 PWRT signal detected Cause: The current-position write signal (PWRT) was input in the during movement teaching mode while the actuator was jogging. Action: Input the PWRT signal after confirming that the jog button is not pressed and the actuator is stopped (MOVE output signal is OFF).
Code Error name 0BA Home sensor not detected 0BE Home return timeout 0C0 Excessive actual speed 0CC Control power-supply overvoltage 0CE Control power-supply voltage low 0D2 Excessive motor power-supply voltage 0D8 Deviation overflow Cause: This error occurs when overvoltage of motor power has been detected (38V or more) Action: Check the motor power input voltage (MPI terminal). In case there is no fault found in voltage, malfunction of controller can be considered. Please contact us.
Code Error name 0D9 Software stroke limit overtravel error 0DC Out of push & hold operation range error 10. Troubleshooting 0ED Absolute encoder error (1) 0EE Absolute encoder error (2) 0EF Absolute encoder error (3) 152 Cause/Action Cause: [1] The actuator installed vertically overshot and exceeded a software stroke limit due to a large load or high deceleration setting when the target position was set to a point near the software stroke limit.
(2) Cold-start level alarms Code Error name 0A1 Parameter data error 0A8 Unsupported motor/encoder type 0B4 Electric angle mismatch 0B7 Magnetic pole nonconfirmation 10. Troubleshooting 0C8 Overcurrent Cause/Action Cause: The input range of parameter range data is not appropriate. (Example) This error occurs when the magnitude relationship of a pair of range parameters is inappropriate, such as when the value of soft limit- is mistakenly set to 300 mm when the value of soft limit+ is 200.3 mm.
Code Error name 0CA Overheating 0CB Current-sensor offset adjustment error 10. Troubleshooting 0E0 Overload Cause/Action Cause: [1] This error indicates that the temperature around the power transistor in the controller is excessively high (95qC or above). [2] The regenerative resistance energy is insufficient due to high decceleration setting during the downward movement in the vertival setting. [3] A faulty part inside the controller. Action: [1] Lower the surrounding air temperature.
Code Error name 0F4 Unmatched PCB 10. Troubleshooting Cause/Action This controller uses a different motor drive circuit depending on the motor capacity, and thus adopts a different printed circuit board (PCB) appropriate for each motor capacity. For this reason, whether the motor type set by the applicable manufacturer’s parameter matches the board is checked in the initialization process after startup. This error indicates that the two do not match.
10.5 Messages Displayed during Operation Using the Teaching Pendant This section explains the warning messages that may be displayed during operation using the teaching pendant. Code Message name 112 Invalid data 113 114 115 117 10. Troubleshooting 11E 11F 121 122 133 156 Description An inappropriate value was entered in a parameter. (Example) 9601 was entered as the serial communication speed by mistake. Enter an appropriate value again.
Code 180 181 182 183 202 203 Message name Address change OK Controller initialization OK Home change all clear I/O function changed Emergency stop Motor voltage low Description These messages are displayed to confirm operation. (They don’t indicate an operation error or other abnormality.) 10. Troubleshooting This message indicates that an emergency stop has been actuated. This message indicates that the motor drive power is cut off on the CG type.
10. Troubleshooting Code Message name 30C No connected axis 158 Description This message indicates that no controller address is recognized. Cause: [1] The controller is not operating properly. [2] Only the supplied communication cable (SGA/SGB) is disconnected. [3] If a SIO converter is used, 24V is supplied to the converter but the link cable is not connected. [4] The ADRS switch settings are duplicated by mistake when multiple controllers are linked.
10.6 Specific Problems z I/O signals cannot be exchanged with the PLC. Cause: [1] The 24-V I/O power supply is connected in reverse. [2] If the problem is with an output circuit, a circuit component may have been damaged due to a large load that caused the current flowing into the circuit to exceed the maximum current. [3] Contact failure in the connector or relay terminal block on the PLC end.
z Home return ends in the middle in a vertical application. Cause: [1] The ball screw is receiving torsional stress due to the affixing method of the actuator, tightening of bolts only on one side, etc. [2] The slide resistance of the actuator itself is large. Action: Check / Change the parameters set in User Parameter No. 13 (Current Limit at Home Return).
* Appendix List of Specifications of Connectable Actuators The specifications included in this specification list are limited to those needed to set operating conditions and parameters. For other detailed specifications, refer to the catalog or operation manual for your actuator. Caution x The push force is based on the rated push speed (factory setting) indicated in the list, and provides only a guideline. x Make sure the actual push force is equal to or greater than the minimum push force.
Actuator series Type RA3R RGD3R Motor No. of Feed output encoder screw pulses [W] Ball screw Ball screw 20 20 800 800 20 RA4C Ball screw RCA (rod type) 20 * Appendix Ball RGS4C screw 20 Ball screw 162 Maximum speed Maximum acceleration/ deceleration [mm/s] [mm/s] [G] 10 12.5 500 0.3 5 Horizontal/ vertical 6.25 250 0.3 2.5 Horizontal/ vertical 3.12 125 0.2 10 Horizontal/ vertical 12.5 500 0.3 5 Horizontal/ vertical 6.25 250 0.3 2.5 Horizontal/ vertical 3.
Actuator series Type Motor No. of Feed output encoder screw pulses [W] 20 RA4D Ball screw 20 Ball RGS4D screw RCA (rod type) 20 20 Ball screw [mm/s] [G] 12 15 600 0.3 6 Horizontal/ vertical 7.5 300 0.3 3 Horizontal/ vertical 3.75 150 0.2 12 Horizontal/ vertical 15 600 0.3 6 Horizontal/ vertical 7.5 300 0.3 3 Horizontal/ vertical 3.75 150 0.2 12 Horizontal/ vertical 15 600 0.3 6 Horizontal/ vertical 7.5 300 0.3 3 Horizontal/ vertical 3.75 150 0.
Actuator series Type Motor No. of Feed output encoder screw pulses [W] 20 Ball RGD4R screw RCA (rod type) SRGS4R * Appendix SRGD4R 164 20 Ball screw 20 Ball screw 20 Minimum speed Maximum speed Maximum acceleration/ deceleration [mm/s] [mm/s] [G] 12 Horizontal/ vertical 15 600 0.3 6 Horizontal/ vertical 7.5 300 0.3 3 Horizontal/ vertical 3.75 150 0.2 12 Horizontal/ vertical 15 600 0.3 6 Horizontal/ vertical 7.5 300 0.3 3 Horizontal/ vertical 3.
Actuator series Type SA4C SA4D SA4R Motor No. of Feed output encoder screw pulses [W] Ball screw Ball screw Ball screw 20 20 20 800 800 800 RCA (slider type) Lead [mm] [mm/s] [mm/s] 10 12.5 665 5 Horizontal/ vertical 6.25 330 2.5 Horizontal/ vertical 3.12 165 10 Horizontal/ vertical 5 Horizontal/ vertical 2.5 Horizontal/ vertical 10 SA5R Ball screw Ball screw 20 20 800 [G] Energy-saving spec.: 0.3 High acc/dec spec.: 1.0 Energy-saving spec.: 0.
Actuator series Type Motor No.
Actuator series RCA (slider type) Type SS6D A4R RCA (arm type) A5R A6R Ball screw 30 800 Lead [mm] 20 Ball screw 20 Ball screw 30 GS3N Lead screw 10 1048 GD3N Lead screw 10 1048 SD3N Lead screw 10 1048 ± ± 3 Horizontal/ vertical 3.
Actuator series Type Motor No.
Actuator series Type Motor No. of Feed output encoder screw pulses [W] Lead [mm] 6 SA3C Ball screw 10 800 4 2 6 SA3R Ball screw 10 800 4 2 RCA2 (slider type) 10 SA4C Ball screw 20 800 5 2.5 10 SA4R Ball screw 20 800 Mounting direction 5 2.
Actuator series Type Motor No. of Feed output encoder screw pulses [W] Lead Mounting direction [mm] Minimum speed [mm/s] Horizontal 20 25 Vertical SA5C Ball screw 20 800 +RUL]RQWDO 12 15 * Appendix Vertical +RUL]RQWDO RCA2 (slider type) 6 7.5 Vertical +RUL]RQWDO 3 3.75 Vertical +RUL]RQWDO 12 15 Vertical SA5R Ball screw 20 +RUL]RQWDO 800 6 7.5 Vertical +RUL]RQWDO 3 3.
Actuator series Type Motor No. of Feed output encoder screw pulses [W] Lead Mounting direction [mm] Minimum speed [mm/s] Horizontal 20 25 Vertical SA6C Ball screw 30 800 +RUL]RQWDO 12 15 Vertical +RUL]RQWDO 6 7.5 Vertical +RUL]RQWDO 3 3.75 Vertical +RUL]RQWDO 12 15 Vertical SA6R Ball screw 30 +RUL]RQWDO 800 6 7.5 Vertical +RUL]RQWDO 3 3.
Actuator series Type Motor No.
Actuator series Type Motor No. of Feed output encoder screw pulses [W] Lead [mm] 6 TA4R Ball screw 10 800 4 2 10 TA5C Ball screw 20 800 5 2.5 10 TA5R Ball screw 20 800 5 2.
Appendix Positioning Sequence Given below is an example of basic sequence for creating a positioning sequence indicates PIO signals of the controller. (Completed-position decoding circuit) Position complete PEND Completed position codes PM1 PM2 PM1 PM2 PM4 PM8 Timer1 PM4 PM8 Timer1 PM1 PM2 PM4 PM8 Timer1 PM1 PM2 PM4 PM8 Timer1 PM8 Timer1 PM1 PM2 PM4 Waiting for the completed position to be read Timer1 (Must be longer than the PLC’s scan time.
Appendix (Positioning circuit for position 2) Positioning start request to position 2 N M M Positioning start request to position 2 N Positioning start pulse to position 2 Auxiliary positioning start pulse to position 2 N Current positioning completed position (A) M P PEND Q O Auxiliary positioning start for position 2 P Start check for position 2 Q Completion of positioning to position 2 R Position 1 set S Position 2 set O O P P B Auxiliary start signal for next positioning If a
Appendix R PC1 Command position 1 Position 3 set signal Position 5 set signal S PC2 Command position 2 PC4 Command position 4 PC8 Command position 8 Position 3 set signal * Appendix Position 6 set signal (Start signal circuit) J Timer 2 O Start command for positioning to other position Waiting for start 5 msec or more (Must be longer than the PLC’s scan time.
Appendix Recording of Parameters Recorded date: Category: a: b: c: d: Category a a a a 5 a 6 7 8 9 10 b d b b b 13 b 15 c 16 c 17 c 21 c 22 23 24 25 26 a a a c b 27 c 28 b 29 b 30 b 31 32 33 34 35 36 37 38 d d d b b b b b 39 c 40 c Name Zone boundary 1+ Zone boundary 1– Soft limit+ Soft limit– Home return direction [0: Reverse / 1: Forward] Push & hold stop judgment period Servo gain number Default speed Default acceleration/deceleration Default positioning band (in-positio
* Appendix Appendix No.
Appendix Change History Revision Date Description of Revision First edition 2007.03 Second edition 2007.04 Third edition • Note of “1. 24-V Power Supplies Required for UL Certification” added • Note of “2. Use Environment” added 2009.01 Fourth edition 2009.08 Fifth edition 2009.12 Fifth B edition • Added "About CE Marking". 2010.02 Sixth edition • Operation Manual Catalog No. changed 2010.05 Seventh edition • “Please Read Before Use” added after top page • “Precautions for Safety” in P.
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Manual No.: ME0176-12A (December 2012) Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan TEL +81-54-364-5105 FAX +81-54-364-2589 website: www.iai-robot.co.
