Simple Absolute Unit Operation Manual Tenth Edition ACON PCON PSEL
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/DVD that comes with the product contains operation manuals for IAI products.
1. Controller Versions Supporting the Simple Absolute Unit The simple absolute unit can be connected to controllers of the following firmware versions or higher: ACON-C/CG: Ver. D ACON-CY/SE: Ver. B PCON: Ver. B PSEL: Ver. 0.19 * ACON-PL/PO and PCON-PL/PO controllers do not support the simple absolute unit. * When connecting to a controller of an older version, please contact IAI. 2.
5. Caution on Parameter Change If any of the following parameters is changed, an absolute error will generate. You must perform an absolute reset again after these parameters have been changed: x ACON or PCON (1) Parameter No. 5: Home return direction (2) Parameter No. 22: Home return offset (3) Parameter No. 77: Ball screw lead (4) Parameter No. 78: Axis operation type x PSEL (1) Axis-specific parameter No. 1 (2) Axis-specific parameter No. 6 (3) Axis-specific parameter No.
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 ................................................................................................................... 1 1.1 1.2 1.3 1.4 1.5 Introduction .......................................................................................................................... 1 How to Read the Model Name................................................
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. 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 2 3 Note z 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 load). 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 5 Teaching 6 Confirmation operation Preface6 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 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.
1. Overview 1.1 Introduction Thank you for purchasing IAI’s Simple Absolute Unit. This simple absolute unit is designed exclusively for use with PCON/ACON/PSEL controllers. By connecting this unit to your PCON/ACON/PSEL controller, home return will no longer be necessary every time the controller power is turned off, as long as an absolute reset has been performed. This manual explains the features and usage of this product.
1.2 How to Read the Model Name ACON: ACON controller PCON: PCON/PSEL controller Model name for a set of simple absolute unit, battery and cables Model name for each item Simple absolute unit: Battery only: ACON connection cable: PCON/PSEL connection cable: ABU (battery included) AB-7 CB-AC-PJ *** CB-PC-PJ *** *** indicates the cable length. Example) 002: 20 cm Cable differentiation ACON connection cable: Both connectors are red.
1.3 Handling the Battery of the Absolute Unit Handle the battery by following the safety precautions specified below. 1. 2. 3. 4. 5. 6. * Never disassemble the battery. The electrolyte contained in the battery is a strong alkaline fluid that can damage the skin and clothes. Never short the battery (by connecting its positive and negative terminals directly). The equipment may be damaged or generated heat may cause burns. Never throw the battery into fire, as the battery may explode.
1.4 Safety Precautions Read the following precautions carefully and give fullest attention to safety measures. This system product has been developed as a drive part for automated machinery, etc., and is designed not to produce torque or speed beyond the levels needed to drive automated equipment. However, the following instructions must be strictly followed in order to prevent accidents. 1. Do not handle this product in any way not explained in this manual.
1.5 Warranty 1. Warranty Period One of the following periods, whichever is shorter: • 18 months after the shipment from IAI’ s factory • 12 months after the delivery to the specified location 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.
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 Model ACON/PCON-ABU Power-supply voltage 24 VDC r10% MAX 300 mA Surrounding air temperature Surrounding humidity Surrounding environment Power-supply current Environment 0~40qC 95% RH or below (non-condensing) Not containing corrosive gases or dust Ambient storage temperature Shock resistance Protection class Weight External dimensions 0~40qC (20qC is recommended, if the unit is stored together with the battery.
2.1.1 Backup Battery The absolute specification uses a secondary battery (nickel-hydrogen battery) to retain absolute counter data in the FPGA when the power is cut off, and also to supply the power intermittently to the encoder drive circuit. (1) Battery Specification Item Type Manufacturer Model Nominal voltage Rated capacity Average life Weight Charge time Approx. backup time after cutoff of power Description Cylindrical sealed nickel-hydrogen battery SANYO Electric Co., Ltd. AB-7 3.6 V (1.
2.2 Name and Function of Each Controller Part Names [1] Status indicator LEDs RDY/ALM (green/red), STATUS1 (green/red), STATUS0 (green/orange/red) [2] Setting switches [4] Ni-MH battery Guideline for battery replacement 2.2.
2.2.2 [1] Functions Status indicator LEDs RDY/ALM Steady green Operation Steady red - The system is normal. - The system is experiencing an error. RDY/ALM Operation Blinking green Blinking red Update mode STATUS1 Operation Steady green Steady red Absolute reset has been completed (with steady green RDY). - Absolute reset is not yet completed (with steady green RDY). - FPGA communication error (with steady red RDY) STATUS0 Steady green Steady red - - The battery is fully charged.
[Update mode selector switches] Switch Function 3 ON Update mode OFF Normal mode [Model selector switches] Switch Function 4 Set this to ON ON (Default setting) OFF [3] Backup battery connector This connector is used to connect the absolute-data backup battery. [4] Ni-MH battery The absolute-data backup battery is stored here. [5] Power-supply terminal block The main power (24-VDC) input terminals of this unit are provided.
2.
3. Installation and Noise Elimination Pay due attention to the environment in which the controller is installed. 3.1 Installation Environment The controller can be used in a pollution degree 2*1 or equivalent environment. *1 Pollution degree 2: Normally, only non-conductive pollution occurs. However, a temporarily electricity conductive pollution caused by condensation may be expected (EN60947-5-1). (1) When installing and wiring the controller, do not block the cooling vent holes.
[2] Wiring precautions Use a twisted cable for connecting the 24-VDC power supply. Wire the controller cables separately from high-current lines of power circuits, etc. (Do not bundle them together or place them in the same cable duct.) (2) Noise sources and how to prevent noise There are many noise sources, but the ones you should pay greatest attention to are solenoid valves, magnet switches and relays. Noise from these parts can be prevented by the methods specified below.
3.4 Heat Dissipation and Installation At least 50 Design the control panel size, controller layout and cooling method so that the surrounding air temperature around the controller will be kept to 40qC or below. Mount the controller vertically on a wall, as shown below. Since the controller is cooled by natural convection, be sure to heed this orientation and provide sufficient clearances on top and bottom to make sure sufficient air will flow around the controller.
4. Wiring 4.1 Configuration Simple absolute unit Dedicated harness Motor cable Encoder cable RCA actuator Caution: When connecting the dedicated harness to the simple absolute unit, connect it to the correct connector. There are two connectors on the simple absolute unit, one for RCA and the other for RCP2.
4.2 Connecting the Dedicated Cable Connect the dedicated harness to the PG connector on the controller and the CONTROLLER connector on the simple absolute unit. * Make sure the connectors at the ends of the cable are oriented correctly. 4.2.
4.2.2 * ACON Controller Cable Make sure the connectors at the ends of the cable are oriented correctly.
4.3 How to Open the Lid of the Simple Absolute Unit Lift the lid.
4.4 Wiring the Power Supply x Wiring the Power Supply Simple absolute unit Input power supply 24 VDC (300 mA max. per unit) Use a power cable satisfying the following specifications. Item Specification Applicable wire Single wire: 1.0 / Stranded: 0.
5. Operation 5.1 Startup Procedure 5.1.1 Piano Switch Settings These switches are used to set the rotation speed setting and to turn on/off the update mode. (The switches are designated as 1, 2, 3 and 4 from the top.) The switch settings, other than the update mode selector switch, are read and reflected when the controller power is turned off. The update mode selector switch becomes enabled after the controller power is turned off, and the battery is removed and switched. (Refer to 2.2.
Caution About Battery Charge and Discharge Please have the battery charged for more than 72 hours before using for the first time or after replacing with a new one. The battery gets charged while the controller is supplied with 24V power. It is possible to retain the encoder data for the duration shown below for each hour of battery charge. Leaving the controller power off for more than the data holding time will lead to a loss of the data. Have the battery charged as early as possible.
5.2 How to Perform an Absolute Reset 5.2.1 Absolute Reset Using PIO Signals x ACON or PCON * Refer to the operation manual for your controller for details on input signals. (1) Supply the main power (24 VDC) to the controller and simple absolute unit. (2) An absolute encoder error (2) alarm is output. (3) Input a PIO alarm reset signal. (4) Turn ON the PIO pause input. Note) When a pause signal input is provided in the selected PIO pattern. (5) Input a PIO servo ON signal.
5.2.2 Absolute Reset from the PC Software x ACON or PCON (1) Supply the main power (24 VDC) to the controller and simple absolute unit. (2) Bring the PC software online to communicate with the controller (connect the controller and PC using a dedicated communication cable). (3) Select the MANU operation mode. Select teaching mode 1 or teaching mode 2. (4) A “0EE: Absolute encoder error (2)” generates. (5) Select Yes (Y).
(7) Click Servo. The servo lamp should illuminate in blue when Servo is clicked. (8) Click Home. The home lamp should illuminate in blue when home return is completed. An absolute reset has been executed. x PSEL Perform an absolute reset based on the following procedure using “X-SEL PC Software (V7.04.00.00 ~).” (1) Supply the main power (24 VDC) to the controller and the simple absolute unit.
(4) The X-SEL PC Software window is displayed. If an error is detected, the corresponding error message will be displayed. Click the [OK] button to close the error message. If the “ABS unit encoder error (2)” is detected, the following error message will be displayed. (5) By selecting [Monitor (M)] and then [Error Details (E)] from the menu, the current error status can be checked.
(6) From the menu, select Controller (C) and then Absolute Reset (A). (7) When the [Warning] window is displayed, click the [OK] button. (8) The [Absolute Reset] window will be displayed. Click here and select the axis for which an absolute reset is to be performed.
(9) Click the following process buttons in order. When one process is completed, the red arrow moves to the next. [1] Controller error reset [2] Servo OFF [3] Simple absolute unit status initialization [4] Excitation detection completion status clear [5] Servo ON [6] Home return [7] Absolute reset [8] Completion check of an absolute reset Upon pressing the [Simple absolute unit status initialization] button, a warning dialog box is displayed, indicating that an absolute reset is to be started.
(10) When the [Confirmation] dialog box is displayed for a software reset, click the [Yes (Y)] button and restart the controller. (Note) After an absolute reset is performed, be sure to perform a software reset. (11) If no error is generated after the controller is restarted, and the panel unit is connected, the 7-segment LED will display “rdy.” (12) This completes the absolute reset operation.
5.2.3 Absolute Reset from the Teaching Pendant (Example: CON-T) x ACON or PCON (1) Connect the teaching pendant to the controller and supply the main power (24 VDC). (2) When the teaching pendant is started, select TEACH1 or TEACH2. Select either the key. or Teaching pendant operation mode selection screen (3) Select the error list on the mode selection screen. Upon confirming that an absolute encoder error is generated, reset the error. Press the key. Mode selection screen Confirm that error No.
5.3 Replacing the Battery The battery life is three years, and the expiration guideline is printed on the side of the battery. Even if no battery error is generated, it is recommended that you replace the battery if it is passed the expiration date. [Items to be prepared] Replacement battery: AB-7, Manufacturer: IAI [Procedure] [1] Stop the axis operation and turn the power off. [2] Remove the wire that is connected to the front of the controller. [3] Open the lid and remove the battery connector.
[5] Attach the replacement battery and connect the battery connector. Connect it while lightly pressing it in. [6] [7] Close the lid and return the wire that was removed in step [1]. Turn the power on and perform an absolute reset described in Section 5.2. Instead of throwing it away, please place a used battery into a recycle box at a collaborating store with a recycle symbol or a specific collection window. Cooperation from individuals will lead to recycling of natural resources.
6. Troubleshooting 6.1 What to Do When a Problem Occurs If a problem occurred, follow the steps below to facilitate speedy recovery and prevent the same problem from occurring again: a1. Check the status indicator lamps on the ACON/PCON controller. SV (steady green) --- The servo is on. ALM (steady red) --- An alarm is present, or an emergency stop has been actuated or the motor drive source has been cut off. a2. Check the status indicator lamps on the PSEL controller main unit.
(Reference) How the indicator lamps on the simple absolute unit change in each condition RDY/ALM RDY/ALM Operation Blinking green Blinking red { { Update mode (Note) Operation Steady green { Steady red - The system is normal. - { The system is experiencing an error. STATUS1 Operation Steady green Steady red { - Absolute reset has been completed (with steady green RDY). - { Absolute reset is not yet completed (with steady green RDY).
6.2 Alarm Classification by Level Alarms are classified into two levels according to the associated symptoms. Alarm level ALM lamp *ALM signal Operation cancellation Lit Output Cold start Lit Output What happens when the alarm occurs How to reset Input an alarm reset signal The actuator (RES) from the PLC. decelerates to a stop. Perform a reset from the The servo turns off. PC/teaching pendant. The actuator Reconnect the power. decelerates to a stop. The servo turns off.
6.3 Alarms, Causes and Actions (1) Alarms relating to the simple absolute unit (ACON, PCON) Code Error 0B6 Phase-Z detection timeout 0E5 0E8 0E9 0EA Cause/action Cause: Phase Z could not be detected within the phase-Z output period of the simple absolute unit.
Code Error Cause/action [3] Check the model number of the encoder cable. (Simple absolute unit Actuator) Note) RCP2 series only 0ED Absolute Cause: encoder error [1] When the power was reconnected with the simple absolute unit (1) communicating with the controller following an absolute reset, the current position changed due to an external factor, etc.
(2) Alarms relating to the simple absolute unit (PSEL) (On the panel window, three digits after E become the error numbers.) Error Error Contents/action, etc. No. 41B Absolute Cause: encoder error [1] The power was turned on again when an absolute reset was (1) completed, or [2] When an absolute reset is performed, an axis movement was detected during a communication with the simple absolute unit due to an external factor.
Error Error No. 619 ABS unit encoder receiving error Contents/action, etc. When the simple absolute unit encoder command is issued, the response could not be properly received. Cause: [1] The controller is powered up before the simple absolute unit when the 24-V power supply is turned on. [2] The simple absolute unit cannot communicate properly due to noise, etc. The controller cannot communicate properly with the simple absolute unit because the communication line in the encoder cable is disconnected.
Change History Revision Date Description of Revision First edition Second edition 2009.1 Third edition P19: Changed the method to turn on the power to turning on the absolute unit before or simultaneously with the controller (Added the simultaneous method). P25: Added the absolute reset method using the teaching pendant. P26 and 27: Added the method to replace the battery. Made corrections where necessary. 2009.8 Forth edition P10, 16, 22, and 24 through 28: Added the method of PSEL absolute reset.
Manual No.: ME0179-10A (November 2011) 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.jp/ Technical Support available in USA, Europe and China Head Office: 2690 W.
