E-Con Controller Operation Manual Fifteenth 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) Hold · Servo ON Signal When operating the E-Con Controller, you will need to turn ON the Hold & Servo ON signal Input Signal of PIO. In case the Hold Stop Input Signal of PIO remains OFF, E-CON will not move due to hold status. Therefore, please be careful. (2) Although the exterior of the power supply 100V type controller and 200V type controller is the same, applying 200V to the 100 type controller will cause damage. Please be extra careful when connecting power.
Table of Contents Safety Guide 1. Overview 1-1 1-2 1-3 1-4 1-5 1-6 1 1 Forward ....................................................................................................................................................1 How to Read Model Number ...................................................................................................................2 Safety Precautions.........................................................................................................................
4. Using the Controller 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 43 Power-Up (Standard Specification)....................................................................................................... 43 Absolute Reset Procedure (Absolute Specifications) ........................................................................... 45 Move After Power-Up (Standard) ..........................................................................................................
Safety Guide When designing and manufacturing a robot system, ensure safety by following the safety guides 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 Outside movement range During automatic operation Cutoff of drive source Not cut off Cut off (including stopping of operation) During teaching, etc. Inside movement range Not cut off Cut off During inspection, etc. Not cut off (when inspection, etc., must be performed during operation) Pre.-2 Measure Signs for starting operation Installation of railings, enclosures, etc. 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 2 3 4 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.
4 Installation/ startup 5 Teaching (2) Wiring the cables Use IAI’s genuine cables to connect the actuator and controller or connect a teaching tool, etc. Do not damage, forcibly bend, pull, loop round an object or pinch the cables or place heavy articles on top. Current leak or poor electrical continuity may occur, resulting in fire, electric shock or malfunction. Wire the product correctly after turning off the power.
6 Confirmation operation 7 Automatic operation 8 Maintenance/ inspection 9 Modification 10 Disposal Pre.-6 After teaching or programming, carry out step-by-step confirmation operation before switching to automatic operation. When carrying out confirmation operation inside the safety fences, follow the specified work procedure just like during teaching. When confirming the program operation, use the safety speed.
Indication of Cautionary Information The operation manual for each model denotes safety guides under “Danger,” “Warning,” “Caution” and “Note,” as specified below. Level Degree of danger/loss 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.
Pre.
1. Overview 1-1 Forward Thank you very much for purchasing the E-Con Controller. This manual explains the features of this machine and its operating procedures. Without knowing beforehand how to correctly use or operate the controller, not only will the user be unable to take full advantage of all the functions built into this product but the user might also, inadvertently cause damage to the robot or shorten its life.
1-2 How to Read Model Number I: Incremental A: Absolute [1] Motor capacity P: PNP specification [Source] Blank: NPN specification [Sink] EU: CE-compliant Blank: Not CE-compliant DV: DeviceNet specification CC: CC-Link specification PR: ProfiBus specification Blank: Not network-ready [2] [3] [4] 2 Brake B: With brake Blank: Without brake Creep sensor C: With creep sensor Blank: Without creep
Controller Version A “SERIAL No.” label is attached on the right side face of the controller. The last two characters (alphabet and number) in the portion following SERIAL No. indicate the controller version. Example) If the label reads “SERIAL No. ET352720 I3,” the controller version is “I3.” When the controller version is increased, the alphabet changes in an alphabetical order while the number is incremented by one.
1-4 Warranty Period and Scope of Warranty The E-Con Controller undergoes stringent testing before it is shipped from our factory. IAI provides the following warranty: 1. Warranty Period The warranty period expires upon elapse of one of the following periods, whichever occurs first. 18 months after the shipment from IAI 12 months after delivery to the location specified by the user. 2.
1-5 Setting Environment and Noise Measures Please be careful for controller setting environment 1-5-1 Installation Environment This controller can be used in an environment of pollution degree 2*1 or equivalent. *1 Pollution degree 2: Normally only nonconductive pollution occurs. Temporary conductivity caused by condensation is to be expected. (EN60947-5-1) (1) Do NOT block the air vents of your controller when installing your IA system.
(2) Noise Elimination Grounding You will need to set noise compliance and grounding whether AC 100 or 200 V. 1. Directly screw the main body to the metal box. 2. Wiring Notes Isolate the controller cable from high power lines such as motor circuits (Do not bundle, and do not place in the same piping circuit). Consult with IAI's technical service department or sales engineering department if you need longer motor and encoder cables than what comes with the controller.
(3) Noise Source and Noise Suppression When using electrical components such as electromagnets, solenoid valve, magnet switch or relays which create electromagnetic noise, some type of noise suppression device should be used. 1. AC solenoid valve · magnetic switch · relay Measure: Install a surge absorber in parallel with the coil. Point Install a surge absorber to each coil over a minimum wiring length.
1-6 Heat Dissipation and Mounting The size of the controller panel, controller position and cooling method should all be designed so that the controller boundary temperature remains under 40ºC. As the diagram below shows, mount vertically (wall mounting). Controllers are cooled by active ventilation (brewing upward). For installation, make sure to leave more than 100mm of space above and 50mm of space below the controller, following this direction.
2.
2.1.1 Backup Battery (Absolute Specification) (1) Battery Specifications Item Model Number Type Manufacturer Nominal voltage Rated capacity Weight Battery retention time *1 Description AB-1 Lithium battery Toshiba Battery (ER6VP) 3.6 V 2000 mAh Approx. 8.5 g Approx. 20,000 hours (at surrounding air temperature of 20C) Note 1) The current consumption during absolute data backup is approx. 100 A (approx. 4 A if the main controller power is on).
If the battery was replaced when the controller power was off, the retention condition of position information (absolute data) will vary as follows, depending on how long the controller has been out of battery. Battery-out duration Less than 5 minutes 5 to 15 minutes More than 15 minutes Note) Retention condition of position information (absolute data) Position information (absolute data) has been retained. Absolute reset is not required. A battery alarm occurs. Position information has been retained.
2-2 Name of Parts and Functions 2-2-1 Names (6) Battery Connector (8) RUN (green) (7) RDY (green) (9) ALM (red) (10) ENC (orange) (1) Emergency Stop Connecter (2) Actuator Sensor Input Connector (11) PIO Connector (12) Piano Switch 3 (SW3) (13) Piano Switch 2 (SW2) (14) Piano Switch 1 (SW1) (3) Motor Connector (15) Brake Release Switch (4) Regenerative Resistance Unit Connector (16) Encoder Brake Connector (17) Port Switch (5) Power Terminal (18) Main Communication Port Connector (19) DSIO Connect
(5) Power Terminal L · N: This is the connection from the AC Power source. PE: This is contact for safety (D Type contact work) (6) Battery Connector This is the connector for the absolute encoder backup battery (absolute specifications). (7~10) LED Display (7) (8) (9) (10) RDY(green): RUN (green): ALM (red): ENC (orange): Turns on when no alarm is present or no emergency stop is actuated. Turns on when the servo is ON and the actuator is moving. Turns on during alarm.
(14) Piano switch 1 (SW1) Piano Switch 1~4: Axis number setting switch When connecting more than 2 axes onto the SIO Connector, serial reorganization occurs when setting the actuator axis number. You may set up to 0~15 axes (at the time of shipment, numbers 1~4 are all set as OFF. This application is for single axis unit). For every controller, please set the piano switch and set the desired axis number. As for the number, make sure that the same number is not used for more than controller.
(15) Brake Release Switch (BK) Effective when only break option is selected. RLS: Release position turns the brake OFF. NOM: Normal position makes the brake active. (normal setting) (16) Encoder • Brake Connector (ENC) This is the connector for Encoder & Brake power cable. (17) Port Switch (PORT) ON: OFF: PORT IN Port (Teaching Pendant · PC Software) will be activated. However, in case of exclusive teaching pendant and exclusive cables are not connected, emergency stop status will occur.
2-2-3 Signal Tables for Connectors and Terminal Blocks SIO Connector Pin. No Signal Name Function 1 (+5 V) (5 VDC Power Output) or (Reserve Signal Terminal) 2 S GA Line transceiver I/O positive logic side 3 G ND Ground for communication 4 S GB Line Transceiver I/O negative logic side 5 G ND Ground for communication 6 +5 V 5 VDC Power Output Main Communication Port Connector Pin.
Encoder · Brake Connector (D-Sub DE-15 Type) Pin. No Signal Name Connection Line 1 EN A+ Encoder A+ 2 EN A- Encoder A- 3 EN B+ Encoder B+ 4 EN B- Encoder B- 5 EN Z+ Encoder Z+ 6 EN Z- Encoder Z- 7 SD+ Encoder SD+ 8 SD- Encoder SD- 9 BAT+ (Battery +) 10 GND (Battery -) 11 EN5 Encoder 5 V+ 12 EN GND Encoder COM- 13 BK N Brake - 14 BK P Brake + 15 FG Shield Power Terminal Board (GMSTB2.5/3-STF-7.
2-3 External Dimensional Diagram 2-3-1 Standard Specifications 18
2-3-2 Absolute Specification 19
2-4 Connection Method 2-4-1 Standard Item PC Software option Note: 20 Always set Nos. 1 and 2 of piano switch 2 (SW2) to OFF.
2-4-2 Absolute Specifications Battery connector Battery holder 21
2-5 Supplied Cables 2-5-1 I/O Flat Cable * Accessory 200 I/O Connector (40P) Flat Cable I/O Connector (40P) No. 1 Signal Name C OMOA Color Brown - 1 No. 11 Signal Name * Emergency stop Complete position 16 * Alarm 2 C OMOA Red - 1 12 3 C OMOB Orange - 1 13 4 C OMOB Yellow - 1 14 5 NC Green - 1 15 Z one Color Brown - 2 No. 21 Signal Name C OMIA Color Brown - 3 No.
2-5-2 Motor Extension Cable Actuator end Controller end Single-axis robot type: ROBO Cylinder type: Cable color Signal abbreviation Pin no. Pin no. Signal abbreviation Cable color Green Red Red White White Black Black Green Reverse plug (Phoenix) Plug housing Socket contact (J.S.T. Mfg.) (J.S.T. Mfg.) 2-5-3 Encoder Extension Cable (Single-axis Robot Type) Actuator end Controller end Cable color Signal abbreviation Pin no. Pin no.
2-5-4 Encoder Extension Cable (ROBO Cylinder Type) Actuator end Controller end Signal abbreviation Cable color Signal abbreviation Pin no. Pin no. Cable color Pink Pink Purple Purple White White Blue/Red Blue/Red Orange/White Orange/White Green/White Green/White Blue Orange Ground Black Yellow Blue Green Orange Brown Black Gray Yellow Red Green Brown Clamp the shield to the hood.
2-6 Wiring 2-6-1 Wiring for Power • Emergency Stop * The two EMG terminals are emergency-stop switch contact terminals of the contact-b input logic. They have been shorted at the factory so that an emergency stop will not be actuated. 24 VDC is output to pin 1. Caution: When wiring power at the customer site, please make sure that the following specifications are met. Applicable conduit Specification possible conduit range Single Line -1.0 (AWG18) Stranded Line - 0.75 mm3 (AWG18) Single Line -0.
2-6-2 External Connection Diagram Screw directly to metal frame E-con Controller COMIA COMIB EMG Start Command Position 1 Command Position 2 Command Position 4 Encoder Encoder Output Command Position 8 Command Position 16 Command Position 32 Brake Upper system * Hold PIO PIO Reset Servo ON (PLC) COMOA COMOB Command Position 1 Command Position 2 PE Command Position 4 Command Position 8 U Command Position 16 Input Command Position 32 V Motor Motor Positioning Complete Homing Complete Zon
2-6-3 PIO Interface PIO Interface list for controllers with NPN I/O is indicated as below: In addition, the PIO cable end is cut off on the external device side for flat cable specifications.
(1) COMOA Power for input port (2) COMOB Power for input port Connect a DC24 V potential across COMOA & COMOB, for output functionality. Polarity does not exist between COMOA & COMOB. Pin Numbers. 1 and 2 are connected internally and Pin Numbers. 3 and 4 are also connected internally. (3) During Transfer Turns on during transfer. When you want to detect holding motor during hold, use this signal. (4) Emergency Stop Turns off at emergency stop. During normal operation, stays ON.
(10) Complete Position Turns OFF simultaneously as timing once positioning complete turns OFF. All will turn OFF during emergency stop or direct teaching. In case operation is possible afterwards, in case the current actuator position is within the positioning range from the last positioning complete position, outputs its complete position. All will remain OFF in case of being outside of the positioning band.
2-6-4 External I/O Specifications Input Area Column Specifications Number of inputs 10 points Input Voltage 24 VDC 20% Input Current 7 mA/1 Circuit ON Voltage . . . Minimum 16 V (4.5 mA) OFF Voltage . . . Minimum 6 V (1.4 mA) Photo Coupler Movement Voltage Isolation Method Internal Circuit Structure (Standard NPN Specifications) Internal Circuit Rectifying circuit Pin No. External Power 24 VDC Each input Connect 24 VDC between COMIA and COMIB.
Output Area 100 mA output circuit according to Power M O S F E T Column Specifications Number of outputs 12 points Rated Load Voltage 24 VDC/60 V (peak) (No fly wheel diodes) Maximum Load Current 100 mA/1 Circuit Isolation Method Photo Coupler Overcurrent Protection Fuse resistance 10 & 0.1 W Internal Circuit Structure (Standard NPN Specifications) Each output Load Fuse resistance 10 0.1W Load Internal Circuit ＋ Pin No.
3. Data Input (Basic) Since this controller does not have any commands, there is no need to write any programs. In order to make the actuator move to the assigned position, all you need to do is to input the position data into the position data table. Position data includes No., Position (Position), Speed (Speed), Acceleration/Deceleration (Acc/Dcc), Push (Push), Positioning Band (Positioning Band), and Acceleration Only MAX (Acc. only Max).
3-1 Position Data Table (1) No. Indicates the position number. To input the relative transfer load, type the Minus Key. When using the teaching pendant for input operation, “=” will be displayed between the number and position. For Absolute coordinate assign, setting is not necessary here. (2) Position Input the target value you want to move the actuator to. [mm] Absolute Coordinate Assign: Input the distance from the home to the target position you want to move the actuator to.
Selects either the Positioning Mode or Push Mode. The initial value is set as 0. 0: Positioning Mode (=normal operation) Other than 0: Push mode (%) (5) Push Input the current limit value to be applied to the servo motor when the work part is pushed in the Push Mode. The rated thrust of the actuator is multiplied by this value to determine the push force at standstill. Note that this value of push force at standstill is only a guide.
(7) Acceleration only MAX Selects either the assigned acceleration or the maximum acceleration. Inputs are either 1 or 0. The initial value is set as 0. 0: Assigned acceleration The value input in (4) becomes the actual acceleration/deceleration. 1: Maximum acceleration The maximum acceleration is applied only during acceleration. The deceleration corresponds to the value input in (4).
3-1-1 Push Force at Standstill To operate the actuator in the push mode, enter a current limit value (%) in the “Push” field of the position data table. With E-Con controllers, the push force at standstill must correspond to approx. 70% of the current limit value. You can increase/decrease the push force at standstill by increasing/decreasing the current limit value, but the controller will not operate normally if the current limit value is set to 30% or below.
3-2 Mode Explanation 3-2-1 Positioning Mode Push=0 (1) From the position, the positioning complete output turns ON prior to the positioning band portion and turn OFF during transfer output. Also output the complete position No. signal. 3-2-2 Push Mode (Push) = Other than 0 (1) When push-motion operation has been successful (1) After reaching the position shown, the actuator moves forward at a low rate speed.
(2) When push fails (blank shot) (1) Upon reaching the position, the actuator moves forward at a low rate speed. When the servo motor current does not reach the peak current restriction value in the positioning band, the positioning completion output will not turn ON even when the actuator moves to the positioning band range. In this case, only the complete position number outputs turn ON. Output during transfer turns OFF. To confirm stop status, check if output during transfer is OFF.
(4) When the input value of positioning band is wrong When a mistake is made in the code for the positioning band data, as the left diagram shows, only the width (positioning complete width x 2) will be off, so please be careful 3-2-3 Speed Change Movement During Transfer Multiple speed control is possible in one movement. Speed will go slower or faster at any given point. However, different position data is needed every time speed is changed.
3-2-5 Hold Input This is used for temporary stop. The actuator will hold according to the external input signal (Hold) during moving. Based on safety compliance, the signal will become a B-contact input (reversed logic). When the hold input is turned OFF, the actuator will stop at that point and will move again only when the hold input is turned back ON.
3-2-7 Homing During power-up or upon alarm release, you will need to home. After selecting the position number and starting, homing is executed first. Upon homing, homing complete output will turn ON (standard specifications). You may not execute just homing from P I/O. In addition, in case you wish to move to the home position in normal mode, we recommend you set the position number to where 0 was input into the position of position data, and then, move to that position.
3-4 Items to Note on Gripper (RCS-G20) (1) Finger Operation [1] Definition of position The stroke in the specification table indicates a sum of travels of both fingers. In other words, the travel of each finger is a half of the stroke. The specified position therefore represents the distance traveled by each finger from its home position toward the closing side. [2] Definition of speed and acceleration Speed and acceleration command values indicate a sum of both fingers.
4. Using the Controller 4-1 Power-Up (Standard Specification) (For Absolute specification, please refer to 4-2. Absolute Reset Procedure) (1) Confirm that both Nos. 1 and 2 of piano switch 2 (SW2) are set to OFF. If these switches are set to ON, tilt them back to the OFF positions. (2) Connect the motor · brake cable and encoder cable to the controller. (3) Connect the upper PLC to the P I/O Connector using the attached flat cable.
4-1-1 Movement Capable Status (1) Servo will turn ON at the same time the power is turned ON. Once Power-Up is complete, the positioning completion output turns ON.
4-2 Absolute Reset Procedure (Absolute Specifications) Caution) With the absolute type, 0E5 (Encoder Reception Error) will be displayed under certain conditions, such as when the power is first turned on after disconnecting the battery or PG cable. This display does not indicate fault. Perform an absolute reset in accordance with the specified procedure. The absolute reset procedure varies depending on the controller version. A “SERIAL No.” label is attached on the right side face of the controller.
Absolute Reset Procedure for Controller Version E* or Earlier (1) Connect the motor · brake cable and encoder cable to the controller (Note 1). (2) Connect the upper PLC to the P I/O Connector using the attached flat cable. (3) When connecting more than 2-axes, address each controller by using the piano switches. For details, refer to 2-2, “Name of Parts and Functions.” (4) Connect the battery to the controller. (5) Put actuator’s slider or rod to the home direction of mechanic end. (6) Turn on No.
4-3 Move After Power-Up (Standard) Operation application example: After Power-Up, move to point 150 mm from home at a speed of 200 mm/sec. Position data table (column with dark line indicate the input insert) No. Position Speed Acc/Dec Push Positioning Band Acc. only Max 0 0 100 0.3 0 0.1 0 1 150 200 0.3 0 0.
Caution Position 1 Transfer After Power-Up and operation preparation is ready, positioning complete output will turn ON. (If servo ON input is OFF, positioning complete output will not turn ON.) To confirm system is RDY, check if positioning complete output is on. When system is RDY and positioning is complete, positioning complete output turns ON. After power- up, the complete position outputs are all OFF, once motion is completed, position complete turns on. When completing to position No.
4-4 Positioning Mode (2 point space reciprocation) Movement example) Reciprocate 2 positions. Assign the position 1 at 250 mm from home, and Position 2 at 100 mm from home. Set speed to 200 mm/sec for Position 1 and 100 mm/sec for Position 2.
Position Data Table (Columns with the thick lines indicate the input insert) No. 0 1 2 : Position * 250 100 Speed * 200 100 Acc/Dec * 0.3 0.3 Push * 0 0 Positioning Band * 0.1 0.1 Acc. only Max * 0 0 Transfer T1: Over 6 msec Time from Command Position Select Input to Start Signal ON (However, please consider the scan time of the upper controller.) Please input Command Positron after previous positioning complete turns ON.
4-5 Push Mode Movement Example) Use via Push Mode and Positioning Mode. Assign Position 1 to 280 mm from home and Position 2 to 40 mm from home. Move to Position 1 in Push Mode (until the actuator contacts the front side). Use the Push Mode to move to Position 2 (match to opposite motor side direction). Assign the maximum push to 15 mm, and the current limit value during push to 50%. Transfer to Position 2 by positioning mode. Set transfer speed 200 mm/sec for Position 1 and 100 mm/sec for Position 2.
Position Data Table (Columns with the thick lines indicate the input insert) No. 0 1 2 : Position * 280 40 Speed * 200 100 Acc/Dec * 0.3 0.3 Push * 50 0 Positioning Band * 15 0.1 Acc. only Max * 0 0 Transfer T1: Over 6 msec Time from Command Position Select Input to Start Signal ON (However, please consider the scan time of the upper controller.) Please input Command Positron after previous positioning complete turns ON.
4-6 Speed Change Movement During Transfer Movement Example) During movement, speed decreases when approaching a given location. Assign Position 1 at 150 mm away from home, and Position 2 at 200 mm away from home. Assign Position 2 as the carry-over position, and move to Position 1 at a speed of 200 mm/sec and from Position 1 to 2 move 100 mm/sec. Method) In this case, motion is executed in consecutive order, first with Position 1, then followed by Position 2.
Position Data Table (Columns with the thick lines indicate the input insert) No. Position Speed Acc/Dec Push Positioning Band Acc. only Max 0 * * * * * * 1 150 200 0.3 0 1 0 2 200 100 0.3 0 0.1 0 : T1: Over 6 msec Time from Command Position Select Input to Start Signal ON (However, please consider the scan time of the upper controller.) Caution: 54 Positioning complete Output will turn OFF and moving output will turn on once the start signal turns ON.
4-7 Movement Using Different Acceleration Value • Deceleration Value Movement Example) Perform positioning at a speed of 200 mm/sec to a location (Position 1) 150 mm away from home. The actuator accelerates at the maximum acceleration and decelerates at 0.1 G. Method) Set “1” in the “Acc. only Max” field of the position data table to apply the maximum acceleration. Enter “0.1” in the “Acc/Dec” field of the position data table to set the deceleration to 0.1 G. E-Con Controller Reference flow * * * 8.
Position Data Table (Columns with the thick lines indicate the input insert) No. Position Speed Acc/Dec Push Positioning Band Acc. only Max 0 * * * * * * 1 150 200 0.1 0 0.1 1 : T1: Over 6 msec Time from Command position select input to start input ON. (However, please consider the scan time of the upper controller) Caution: Positioning complete Output will turn OFF and moving output will turn on once the start signal turns ON.
4-8 Hold Movement Example) Temporary stops the movement of the actuator. Method) Uses the Hold Input.
T1: Over 6 msec Time from Command Position Select Input to Start Signal ON (However, please consider the scan time of the upper controller) Caution: Positioning complete Output will turn OFF and moving output will turn on once the start signal turns ON. Please execute Start Signal OFF only after confirming that the output during motion turns ON with Start Signal ON status. You can cancel the remaining transfer by turning ON the reset input signal while the actuator is held.
4-9 Zone Signal Output Movement example) During motion, the Zone Signal output will turn ON from 40 mm from home to position 120 mm from home. (40 mm < Zone Signal Output < 120 mm). Method) Zone Signal Output boundary is set in the Parameter Zone Limit + and Zone Limit -.
T1: Over 6 msec Time from command position select input to start input ON (However, please consider the scan time of the upper controller) Caution: Positioning complete Output will turn OFF and moving output will turn on once the start signal turns ON. Please execute Start Signal OFF only after confirming that moving output turns ON with Start Signal ON status.
4-10 Transfer to Home Movement Example) Homing alone cannot be performed using PIO. You cannot home using the position data table (position 0 at 0 mm). Homing occurs when controller is told to move to a point when the actuator has not been homed yet. Method) You must create point data at distance 0 from the home and move the actuator to this position. Input the home data to position 0. To return the actuator to its home, move it to position 0.
T1: Over 6 msec Time from command position select input to start input ON (However, please consider the scan time of the controller) It is not necessary to input data with a distance of 0 mm from home to position 0. The data of distance 0 mm from home is input to position 0 mm as example here, you can also input that data to positions 1-63. Caution: Positioning complete Output will turn OFF and moving output will turn on once the start signal turns ON.
4-11 Incremental Movement in Relative Coordinate Movement example) Move to position 30 mm from home, and from there, move the actuator in increments of 10 mm. The transfer speed from home to the 30 mm location is set at 100 mm/sec, and the 10 mm incremental movements are set at 20 mm/s.
Position Data Table (Columns with the thick lines indicate the input insert) No. Position Speed Acc/Dec Push Positioning Band Acc. only Max 0 * * * * * * 1 30 100 0.3 0 0.1 0 2 = 10 20 0.3 0 0.1 0 : T1: Over 6 msec Time from command position select input to start input ON (However, please consider the scan time of the upper controller) Note 1: Positioning complete Output will turn OFF and moving output will turn on once the start signal turns ON.
4-12 Caution Regarding Relative Coordinate Assign (1) Caution During Positioning Movement When an incremental coordinate position number is selected/input and then the Start Input is turned ON while the actuator is performing positioning operation, the actuator will move to the position corresponding to the initial position plus the relative transfer load. (If the relative transfer load is negative, the actuator will move to the position corresponding to the initial position less the relative transfer load.
Example: The Start Input Position 2 is executed during movement towards Position 1 during Push Mode and the actuator moves to a position that is 10 mm away from the Input Position 1. (3) Accumulation Error Due to Consecutive Relative Transfer The position data only recognizes a minimum resolution. The minimum resolution is specified according to lead and number of encoder pulses. Therefore, an error may occur between the value input for the position and the corresponding movement of the actuator.
5. Parameters 5-1 Parameter Classification The parameters are classified into the following four types depending on their function: Types: a: Parameter relating to actuator stroke range b: Parameter relating to actuator operating characteristics c: Parameter relating to external interface d: Servo gain adjustment 5-2 Parameter List No.
5-3 Parameter Settings If you have changed any parameter, be sure to restart the controller via a software reset or reconnect the controller power. 5-3-1 Parameters Relating to Actuator Stroke Range Soft limits Set the + soft limit in parameter No. 3 and – soft limit in parameter No. 4. Both parameters have been set to the effective actuator length at the factory.
Home offset Parameter No. 22 has been set to an optimal value at the factory so that the distance from the mechanical end to home will remain constant. The minimum setting unit is 0.01 mm. This parameter can be adjusted in the following conditions: [1] Align the actuator’s home with the mechanical home on the equipment after the actuator has been assembled to the equipment. [2] Set the home position again after reversing the factory-set home direction.
Push & hold recognition time This parameter is used as a condition for determining if the actuator has contacted the work part and completed its push-mode operation. Specifically, push-mode operation is deemed complete if the current limit value set in the position table has been maintained for the time set in parameter No. 6. Set this parameter to an optimal value in accordance with the current limit value, by considering the shape and strength of the work part, etc.
Movement flag during stop This parameter defines whether to enable or disable the dynamic brake while the actuator is stopped. It has been set to “1” (Enable) at the factory. This parameter need not be changed in normal conditions of use, but there are situations where the actuator must be moved by hand with the servo turned OFF but the actuator does not move smoothly due to large slide resistance (this often occurs with actuators having a short ball screw lead).
5-3-3 Parameters Relating to External Interface ● Hold input disable selection Parameter No. 15 sets whether to enable or disable the hold input signal. Setting Enable (Use) 0 Disable (Do not use) 1 This parameter has been set to “0” (Enable) at the factory. ● Servo ON input disable selection Parameter No. 21 sets whether to enable or disable the servo ON input signal. Setting Enable (Use) 0 Disable (Do not use) 1 This parameter has been set to “0” (Enable) at the factory.
6. Troubleshooting 6-1 What to Do When A Problem Occurs If you encountered a problem, follow the steps below to conduct the specified checks to gather information needed to implement quick recovery and prevent recurrence of the problem. a. Check the status indicator lamps RDY (green) --- The controller is receiving power and the CPU is operating normally. RUN (green) --- The servo is ON and the actuator is moving. ALM (red) --- An alarm is present.
6-2 Alarm Level Classification The alarms are classified into three levels based on the corresponding symptoms. Alarm level ALM lamp *Alarm Condition at occurrence of alarm How to reset Message Unlit Not output An error is displayed on the PC software screen or teaching pendant. Operation cancellation Lit Output The actuator decelerates to a stop, and then the servo turns off. Input a reset signal from the PLC. Execute reset using the PC/teaching pendant.
6-4 Alarms, Causes and Actions (1) Message Alarms Code Error Cause/action 040 Emergency stop Cause: An emergency stop status was detected. (This is not an error.) 05A Receive overrun 05B Receive framing error 05C Receive timeout error 05D Header error An error occurred during operation using the PC software/teaching pendant or serial communication via PLC’s communication module.
(2) Operation Cancellation Alarms Code 0B0 Error Bank 30 data error Cause/action Cause: Action: 0B1 Bank 31 data error Cause: Action: 0BE Homing timeout Cause: Action: 0C0 Excessive actual speed Cause: Action: 0C9 Overvoltage Cause: Action: 76 Out-of-range or invalid data is included in the parameter area of the memory. (This alarm does not occur as a result of normal parameter input operation, but it may occur during serial communication using the PLC’s communication module.
Code Error Cause/action 0CA Overheat The surrounding air temperature of the power transistor in the controller rose excessively (to 95C or above). Cause: [1] High surrounding air temperature of the controller [2] Defective internal part of the controller Action: [1] Lower the surrounding air temperature of the controller. If the surrounding air temperature is normal, please contact IAI. 0CC Abnormal control power voltage The voltage of the 24-V input power supply dropped (by 20% or more, or to 19.
(3) Cold Start Alarms Code Error Cause/action 0BA Home sensor not yet detected The mechanical end was reached before a home sensor was detected during homing using a home sensor. (Or, the load is so heavy that the actuator cannot move.) Cause: [1] Home sensor cannot be detected because the sensor is not installed in a proper position. [2] The cable is open or the connector is not installed properly. [3] The work part is receiving external force.
Code 0C8 Error Overcurrent Cause/action Cause: Action: The output current from the power circuit became abnormally high. This alarm does not occur in normal conditions of use, but it may occur when the motor coil isolation has deteriorated. Measure inter-phase resistance between motor connection leads U, V and W as well as isolation resistance relative to the ground, to check for deterioration of isolation. Please contact IAI before performing these measurements.
Code Error Cause/action 0E5 Encoder receive error The controller and encoder exchange position data via serial communication. This error occurs when the encoder did not return correct data in response to a request from the controller, or the battery voltage became law. Cause: [1] Law battery voltage (Absolute controllers are shipped with the encoder cable removed. On these controllers, this error always occurs when the power is turned on for the first time at the user’s site.
Code Error Cause/action 0E7 Phase A/B/Z open Encoder signal cannot be detected properly. Cause: [1] Open encoder extension cable or supplied actuator cable, or poor connector contact [2] Faulty encoder Action: [1] Check the connector for possibility of open circuit, and examine the connection condition. (Perform a continuity check by referring to 2-5, “Supplied Cables.”) If the cable is normal, the encoder may be faulty. Please contact IAI.
6-5 Messages Displayed during Operations Using Teaching Pendant or PC Software The warning messages that may be displayed during operations using the teaching pendant or PC software are explained below. Code Message Description 112 Input data error An inappropriate value was input as a user parameter setting. (Example) “9601” was input as the serial communication speed by mistake. Input an appropriate value again.
Code Message Description 20C CSTR-ON during operation The start signal (CSTR) was turned ON by the PLC while the actuator was moving. As a result, duplication of movement commands occurred. 20D STP-OFF during operation The hold signal (*STP) was turned OFF by the PLC while the actuator was moving. As a result, the actuator stopped. 20E Soft limit over A soft limit was reached. 20F Missed work part in push-motion operation The actuator missed the work part in push-motion operation.
7. Regenerative Resistance Unit (Optional) A regenerative resistance unit is required only when the actuator is used as a vertical axis. It is not required in an application where the actuator is used as a horizontal axis because the built-in regenerative resistance capacity is sufficient. 7-1 Number of Units Connected If the number of regenerative resistance units is insufficient, an “Excess Power Voltage (0C9)” error generates.
7-3 Circuit Diagram 40W 470Ω RB＋ RB＋ 40W 470Ω RB－ RB－ PE－ RB RB IN E-Con RB＋ RB－ RB OUT Regenerative resistance unit Connecting one unit RB＋ RB＋ RB－ RB－ PE－ RB RB IN E-Con RB＋ RB－ RB OUT Regenerative resistance unit RB＋ RB－ RB IN RB＋ RB－ RB OUT Regenerative resistance unit Connecting two units 85
* Appendix Specification List of Supported Actuators Loading capacity (Note 2) Stroke (mm), maximum speed (mm/sec) (Note 1) RCS (Flat type) RCS (Rod type) RCS (Slider type) Model Rated acceleration HorizonHorizonVertical Vertical tal tal (Note 1) (Note 2) Rated torque Oscillation angle (deg) Maximum speed (deg/sec) Gear ratio Rated acceleration RCS (Rotary) Model number The figure in each elongated circle represents the maximum speed for the applicable stroke(s).
Loading capacity (Note 2) Model (Note 1) (Note 2) Stroke (mm), maximum speed (mm/sec) (Note 1) Rated acceleration HorizonHorizonVertical Vertical tal tal The figure in each elongated circle represents the maximum speed for the applicable stroke(s). The loading capacity is calculated by assuming actuator operation at the rated acceleration.
Model (Note 1) (Note 2) 88 Stroke (mm), maximum speed (mm/sec) (Note 1) The figure in each elongated circle represents the maximum speed for the applicable stroke(s). The loading capacity is calculated by assuming actuator operation at the rated acceleration.
Appendix Example of Basic E-Con Positioning Sequence An example of basic sequence is given below for reference when creating an E-Con positioning sequence. indicates a PIO signal of the E-Con controller.
Appendix (Position 2 positioning circuit) Position 2 positioning start request Position 2 poisoning start pulse Position 2 positioning start request Position 2 poisoning start pulse, auxiliary Current positioning completed position Position 2 poisoning start, auxiliary Start signal Moving signal Position 2 start confirmation Next positioning start auxiliary signal Position 2 positioning complete Use of a circuit like this, which enables determination of the current position in the sequence even if the
Appendix Command position 1 Position 3 set signal Position 5 set signal Command position 2 Position 3 set signal Position 6 set signal Command position 4 Command position 8 (Start signal circuit) Waiting for start 5 msec or more (Not less than the PLC’s scan time) Positioning start signal for other position Start signal 91
Appendix Position Table Record (1/2) Recorded date: No.
Appendix Position Table Record (2/2) Recorded date: No.
Appendix Parameter Record Recorded date: Type No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 94 Type a a a a a b d b b b b b b b c c c b b b c a a: b: c: d: Parameter relating to actuator stroke range Parameter relating to actuator operating characteristics Parameter relating to external interface Servo gain adjustment Name Zone limit + side Zone limit – side Soft limit + side Soft limit – side Home direction [0: Reverse/1: Forward] Push & hold recognition time Servo gain No.
Change History Revision Date Description of Revision First edition February 2004 April 2004 August 2004 Tenth edition Eleventh edition Twelfth edition Thirteenth edition Fourteenth edition • Changed the content of prohibited items relating to cable wiring. • Deleted the noise elimination measure in the form of connecting a surge absorber and surge killer in parallel. • Changed the table explaining the motor connector, power-supply terminal block and emergency-stop terminal block.
Catalog No.: ME0122-15A Head Office: 2690 W. 237th Street, Torrance, CA 90505 TEL (310) 891-6015 FAX (310) 891-0815 Chicago Office: 1261 Hamilton Parkway, Itasca, IL 60143 TEL (630) 467-9900 FAX (630) 467-9912 New Jersey Office: 7 South Main St., Suite-F, Marlboro, NJ 07746 TEL (732) 683-9101 FAX (732) 683-9103 Home page: www.intelligentactuator.
