SCON Controller Operation Manual Fourteenth 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. PC Software and Teaching Pendant Models New functions have been added to the entire SCON 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/E-Con controllers can no longer be used. If you are using this controller, use a compatible PC software program and/or teaching pendant selected from the following models.
Precautions Please use rotary actuators of multi-rotation specification within the range where the following formula is satisfied. Moreover, the maximum rotation angle is ±9999 [deg](NOTE1) (maximum software stroke limit). ±223 ≥ Maximum rotation angle [deg] Unit Travel Distance [deg/pulse] • Maximum rotation angle: Set the usage conditions (maximum -9999 to 9999 [deg]). Note 1 :The following models can not be rotated up to ±9999.99 [deg].
CAUTION About zone function change Applicable application version: From V001E In zone signal settings, it is now valid to specify plus side zone setting smaller than minus side zone setting. Up to V001D: Zone signals are not output in the case of plus side zone setting minus side zone setting only. From V001E: Zone signals are not output in the case of plus side zone setting = minus side zone setting only.
Table of Contents Safety Guide.................................................................................................... Pre-1 Chapter 1 Introduction .........................................................................................1 1. Overview .................................................................................................................................1 1.1 1.2 1.3 1.4 1.5 1.6 2. Specifications .........................................................................
3.10 3.11 3.12 Jogging/Teaching Using PIO ........................................................................................ 129 Operations in Solenoid Valve Mode 1 [7-point Type].................................................... 131 Operations in Solenoid Valve Mode 2 [3-point Type].................................................... 135 Chapter 3 Pulse-train Input Mode ....................................................................142 1. Overview ...........................................
Safety Guide This “Safety Guide” is intended to ensure the correct use of this product and prevent dangers and property damage. Be sure to read this section before using your product. 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 Outside movement range Work condition During automatic operation Cutoff of drive source Not cut off Cut off (including stopping of operation) During teaching, etc. Inside movement range Cut off During inspection, etc. Pre-2 Not cut off Not cut off (when inspection, etc., must be performed during operation) Measure Signs for starting operation Installation of railings, enclosures, etc. Sign, etc.
Applicable Modes of IAI’s Industrial Robot 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 Pre-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.
No. Task 4 Installation/ startup 5 Teaching Note (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.
No. Task 5 Teaching 6 Confirmation operation 7 Automatic operation 8 Maintenance/ inspection 9 Modification 10 Disposal Pre-6 Note When releasing the brake of the vertically installed actuator, be careful not to let the actuator drop due to its dead weight, causing pinched hands or damaged load, etc. * Safety fences --- Indicate the movement range if safety fences are not provided.
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.
CE Marking If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.
Chapter 1 Introduction 1. Overview 1.1 Introduction Thank you for purchasing the SCON controller. Please read this manual carefully to handle the controller with due care while ensuring the correct operation of the controller. Keep this manual with you so that you can reference the applicable sections whenever necessary.
1.2.1 Features of the Positioner Mode In the positioner mode, one of five PIO patterns is selected using a parameter. The number of positioning points and input/output functions vary depending on the PIO pattern selected. The table below lists the parameter settings and corresponding PIO patterns, as well as the features of each PIO pattern. Parameter setting 0 1 2 3 4 5 2 Features of PIO pattern Positioning mode [Standard type] 64 positioning points are supported.
1.2.2 Features of the Pulse-train Input Mode Dedicated home return signal Home return operation is supported in this mode. When this function is used, home return can be performed automatically without having to program a complex sequence or use an external sensor, etc. Brake control function The electromagnetic brake power is supplied to the controller from a power supply different from the main power. Since the controller controls the brake, there is no need to program a separate sequence.
1.
1.4 System Configuration Teaching pendant EMG switch Host control system Regenerative resistance unit It may become necessary depending on the use condition. DC24V Brake power supply Breaker Note) Noise filter MC1210 by Densei-Lambda PC Grounded Absolute battery Absolute battery Actuator Caution: The customer must provide a noise filter. A noise filter is always required at the minimum, even when your system need not conform to the EC Directives. Also add clamp filters, etc., if necessary.
1.5 Procedure from Unpacking to Test Operation and Adjustment 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. The procedure below covers the flow from unpacking to trial operation using a PC or teaching pendant. (1) Check the content in the package If you found any missing part or part specified for a different model, please contact your dealer.
(5) Set parameters Before the 24-V I/O power supply is connected, PIO power monitor can be disabled temporarily by changing the applicable parameter setting. Parameter No. 74, “PIO power monitor”: 0 (Enable) 1 (Disable) Note) After the 24-V I/O power supply has been connected, be sure to reset parameter No. 74 to “0” to enable PIO power monitor.
1.6 Warranty Period and Scope of Warranty The SCON controller you have purchased passed IAI’s shipping inspection implemented under the strictest standards. The unit is covered by the following warranty: 1. Warranty Period The warranty period shall be one of the following periods, whichever ends first: 18 months after shipment from our factory 12 months after delivery to a specified location 2. Scope of Warranty The scope of warranty shall cover our products delivered at cost.
2. Specifications 2.
2.
[1] LED indicators These LEDs indicate the condition of the controller. Name Color PWR Green SV ALM EMG Green Orange Red Description This LED illuminates when the system has become ready (after the power has been input and the CPU has started normally). This LED illuminates when the servo has turned on. This LED illuminates while an alarm is present. This LED illuminates while an emergency stop is actuated. [2] Rotary switches These switches are used to set the controller address.
[5] Regenerative unit connector This connector is used to connect an external regenerative resistance unit. The need for regenerative unit will vary depending on the use condition. [6] Motor connector This connector is used to connect the motor power cable of the actuator. Motor connector specifications Item Overview Description Connector (cable side) GIC2.5/4-STF-7.52 4-pin, 2-piece connector by Phoenix Contact Connector name M1 to 2 Motor connector Cable size 0.
[10] AUTO/MANU switch The operating mode using the teaching pendant/PC (software) connected to the SIO connector, and PIO input, will change as follows in accordance with the setting of this switch. Prohibition/permission of PIO activation is specified using the PC software/teaching pendant. PIO activation inhibited All operations are possible using the PC software/teaching pendant. (teaching mode 1 or teaching PIO inputs are not accepted.
14 Encoder sensor cable Cable model: CB-X1-PA *** Controller end Actuator end Plug connector: Hood: Plug housing: Socket contact: Retainer: (Sumitomo 3M) (Sumitomo 3M) Wiring diagram Wire Color Signal (soldered) Signal Color Wire Purple Orange Green Gray Purple Orange Gray Green Red Red Black Black Blue Drain Yellow Blue Yellow Connect the shield to the hood using a clamp.
Cable model: CB-X1-PLA *** LS side Controller end Plug connector: Hood: Actuator end (Sumitomo 3M) (Sumitomo 3M) (JST) Actuator end Plug housing: LS side Socket contact: Retainer: Plug housing: Socket contact: Retainer: (JST) X 9 (JST) (JST) (JST) X 6 (JST) Wiring diagram Wire Color Signal Signal Color White/Blue White/Blue White/Yellow White/Yellow White/Red White/Red White/Black White/Black White/Purple White/Purple White/Gray White/Gray Wire (pressurewelded) (soldered) Signal
16 Cable model: CB-X2-PA *** Actuator end Controller end Plug connector: Hood: Plug housing: Socket contact: Retainer: (Sumitomo 3M) (Sumitomo 3M) (JST) (JST) X 15 (JST) X 2 Wiring diagram Wire Color Signal (soldered) Signal Color White/Blue White/Blue White/Yellow White/Yellow White/Red White/Red White/Black White/Black White/Purple White/Purple White/Gray White/Gray Wire (pressurewelded) Orange Green Purple Drain Gray Orange Red Green Black Purple Blue Gray Red Yellow
Cable model: CB-X2-PLA *** LS side Actuator end Controller end Plug connector: Hood: Actuator end (Sumitomo 3M) (Sumitomo 3M) LS side Plug housing: Socket contact: Retainer: Plug housing: Socket contact: Retainer: (JST) (JST) X 15 (JST) X 2 (JST) (JST) X 6 (JST) Wiring diagram Wire Color Signal Signal White/Orange Color Wire White/Orange White/Green White/Green Brown/Blue Brown/Blue Brown/Yellow Brown/Yellow Brown/Red Brown/Red Brown/Black Brown/Black (soldered) Signal Color Whi
18 Cable model: CB-RCS2-PA *** Actuator end Controller end Plug connector: Hood: Plug housing: Socket contact: Retainer: (Sumitomo 3M) (Sumitomo 3M) (JST) (JST) X 17 (JST) X 2 Wiring diagram Wire Color Signal White/Green Brown/White Signal (soldered) Color Pink Pink Purple Purple White White Blue/Red Blue/Red Orange/White Orange/White Green/White Green/White Blue Brown/White Orange Black Drain Yellow Blue Green Orange Brown Black Gray Yellow Green Red Brown Connect t
Cable model: CB-RCS2-PLA *** LS side Controller end Actuator end Plug connector: Hood: Actuator end Plug housing: (Sumitomo 3M) (Sumitomo 3M) LS side (JST) (JST) X 15 Socket contact: Retainer: (JST) X 2 Plug housing: Socket contact: Retainer: (JST) Wiring diagram Wire Color Signal Signal BrownWhite Gray/White Gray/White Red/White Red/White Black/White Black/White Yellow/Black Yellow/Black Pink/Black Pnk/Black Signal (soldered) Color Brown/White Color Pink Pink Purple Purp
[15] Absolute battery connector This connector is used to connect the absolute-encoder backup battery (required when the controller is of absolute encoder specification). [16] Absolute battery holder This battery holder is used to install the absolute-encoder backup battery. [17] Grounding screw This screw is used to implement protective grounding. It is connected inside the controller to the PE terminal in the power connector.
2.3 External Dimensions External dimensions of models with a power output of less than 400 W 4.
External dimensions of models with a power output of 400 W or more 4.
3. Installation and Wiring 3.1 Installation Environment (1) When installing and wiring the controller, do not block the ventilation holes for cooling. (Insufficient ventilation may not only prevent the controller from demonstrating its design performance fully, but it may also cause a 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 connection [1] Provide dedicated class-D grounding (former class-3 grounding: Grounding resistance 100 or less) using a grounding wire with a size of 1.6 mm2 or larger. Controller Attach the grounding wire to the mounting screw of the main unit.
[2] DC solenoid valve/magnet switch relay Action --- Install a diode in parallel with the coil or use valve/relay with built-in diode. In a DC circuit, connecting a diode in reverse polarities may damage the diode, internal controller parts, or DC power supply. Exercise due caution when connecting a diode.
3.4 Wiring the Power Supply 3.4.1 Connecting the Power Cable As shown to the left, insert the stripped end of the cable into the connector and screw in the cable using a screwdriver. Recommended cable diameter Motor power (L1, L2): 2 mm (AWG14) Control power (L1C, L2C): 0.75 mm (AWG18) Recommended stripped wire length: 7 mm As shown to the left, tighten the screws to secure the connector. Caution: Always install a noise filter.
3.4.
3.5 3.5.1 Connecting the Actuator Connecting the Motor Cable (MOT1, 2) Connect the motor cable of the actuator to the motor connector on the front face of the controller. Use a screwdriver to tighten the screws at the top and bottom of the connector to secure the connector. 2. 3.5.2 Connecting the Encoder Cable (PG1, PG2) Connect the encoder cable of the actuator to the encoder connector on the front face of the controller.
3.6 Connecting the PIO Cable (I/O) Connect the supplied flat cable. Connect the opposite end of the cable (no connector) to an appropriate peripheral (host PLC, etc.). I/O flat cable (supplied) Model: CB-PAC-PIO * indicates the cable length (L). A cable length of up to 30 m is supported. Example: 080 = 8 m Flat cable: KFX-20 (S) (color) (Kaneko Cord) No connector No connector Half-pitch MIL socket: HIF6-40D-1.
3.7 External Input/Output Specifications 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. 3.7.
3.7.
3.8 Connecting the Emergency Stop Input (Wiring to the System I/O Connector) As shown to the left, insert the stripped end of the cable while pressing down the spring using a screwdriver. Applicable cable diameter: 0.2 to 1.
Emergency stop circuit when multiple controllers are linked Internal drive-source cutoff specification (Connections when the entire system requires a level of safety conforming to safety category B) Connect an emergency-stop status relay contact for each controller. Make sure to install a surge-absorbing element for the external relay. S1, S2 contact specification: 30 VDC/0.
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On Support of Safety Categories [1] System configuration When constructing a system supporting safety categories, use teaching pendant “CON-TG" and TP adapter “RCB-LB-TG." It is possible to support categories from B to 4 by changing connection of the system I/O connector. TP adapter "RCB-LB-TG" System I/O connector (The front (ENB*) is the lower side and the back (EMG*) is upper side.
[2] Wiring and setting of safety circuit [1] Power supply If a safety circuit is configured using safety relays and contactors of 24 V specifications, it is recommended to use a separate power supply from the power supply for controllers of 24 V specifications (ACON, PCON etc.). It can be configured using the common power supply between the two, but breakage may occur when falsely wired. [2] System I/O connector specification Connector used: MCDN1.5/6-G1-3.
[3] Connection of dummy plug If you operate a controller in the AUTO mode, connect a dummy plug (DP-4) to the TP connector. * Make sure to use “DP-4" as the dummy plug. If “DP-3” is used, the connector does not operate normally. [4] Enable function If you are using the enable function, set it to Enable using the controller parameter. Parameter No.
[3] Examples of safety circuits [1] In case of category 1 (or dummy plug: DP-4) Controller Enable switch Reset switch Emergency stop switch Connection cable CB-CON-LB*** Solenoid contactor Motor power supply Motor power supply 38
Detailed category 1 circuit example Connect with dedicated cable Controller connector TP adapter TP connector Emergency stop switch TP connection detection At TP detection T24V: Output Bypass relay: OPEN At TP not detected T24V: Not output Bypass relay: CLOSE Enable switch Shell System I/O connector Reset switch Enable switch Emergency stop switch Shell Solenoid contactor Motor power cutoff relay DC bus Regulator External emergency stop circuit category 1 39
[2] In case of category 2 (or dummy plug: DP-4) Controller Connection cable CB-CON-LB*** Enable switch Emergency stop switch Reset switch Motor power supply Solenoid contactor Solenoid contactor Motor power supply 40
Detailed category 2 circuit example Connect with dedicated cable Controller connector TP adapter TP connector Emergency stop switch TP connection detection At TP detection T24V: Output Bypass relay: OPEN At TP not detected T24V: Not output Bypass relay: CLOSE Enable switch Shell System I/O connector Shell System I/O connector (Safety unit connection) Enable switch Emergency stop switch Reset switch Motor power cutoff relay DC bus Regulator External emergency stop circuit category 2 Solenoid c
[3] In case of category 3 or 4 (or dummy plug: DP-4) Controller Connection cable CB-CON-LB*** Enable switch Emergency stop switch Short circuit reset switch if category 3 should be supported Reset switch Short circuit only when category 3 should be supported Motor power supply Solenoid contactor Solenoid contactor Motor power supply 42
Detailed category 3/4 circuit example Connect with dedicated cable Controller connector TP adapter TP connector Emergency stop switch TP connection detection At TP detection T24V: Output Bypass relay: OPEN At TP not detected T24V: Not output Bypass relay: CLOSE Enable switch Shell System I/O connector Shell System I/O connector (Safety unit connection) Enable switch Emergency stop switch Short circuit reset switch if category 3 should be supported Reset switch Short circuit only when category
[4] Appendix [1] TP adapter external dimensions 2-3.5 [2] Connection cable Controller/TP adapter connection cable Use this cable to connect the controller and TP adapter (RCB-LB-TG). Model: CB-CON-LB005 (standard cable length: 0.5 m) Maximum cable length: 2.
[3] Dummy plug Connect a dummy plug to the teaching pendant connecting connector. Make sure to connect a dummy plug if the AUTO mode is specified.
Connecting the Pulse-train Control Cable Use the pulse-train control cable when the controller is operated in the pulse-train input mode. It should not be connected when the controller is operated in the positioner mode. The pulse-train control cable is optional. (Normally the controller comes only with a plug and a shell.) Connecting the Brake Power Input (for Actuator with Brake) As shown to the left, insert the stripped end of the cable into the connector and screw in the cable using a screwdriver.
Connecting the Teaching Pendant/PC Software (TP) (Optional) If the teaching pendant/PC software cable is used, connect it to the teaching connector on the controller. Set the AUTO/MANU selector switch to the MANU position (right side). Caution: When the teaching pendant is disconnected, an emergency stop is actuated momentarily. The emergency stop will be cancelled immediately thereafter, but the actuator and other equipment that are operating when the teaching pendant is disconnected will stop.
3.9 Connecting the Regenerative Unit (RB) Regenerative energy produced when the actuator decelerates to a stop or moves downward in vertical installation is absorbed by means of the capacitor or resistor provided in the controller. If the produced regenerative energy cannot be fully absorbed by the controller, an overheat error (error code: 0CA) will generate. If this is the case, connect one or more regenerative resistance units externally. 3.9.
3.9.3 Connection Cables The cable used to connect the controller to a regenerative resistance unit is different from the corresponding cable used on conventional controllers (the connectors are not compatible). To connect a regenerative resistance unit to the controller, cable [1] specified below is required.
3.10 Connecting the Brake Box (RCB-110-RA13-0) One brake box can support 2 actuators. 3.10.1 Installation Standard Actuator to be used: RCS2-RA13R with brake 3.10.2 Specification Item Dimension of main unit Specification 162 x 94 x 65.5 mm Power supply voltage, current Connection cable (sold separately) 24 VDC 10% 1 A Encoder cable (model specification CB-RCS2-PLA), where indicates cable length 3.10.
3.10.4 24 V Power Supply Connector Connector on cable side Conforming cable Terminal assignment * MC1.5 / 2-STF-3.5 (Phoenix Contact) 1 2 0V 24 VIN AWG28 to 16 Power supply ground for brake excitation +24 V power supply for brake excitation It is necessary to supply +24 V to the brake power supply connector of the controller as well. 3.10.
Chapter 2 Positioner Mode 1. I/O Signal Control and Signal Functions 1.1 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: Parameter No.
Quick reference table for functions available under each PIO pattern (: Available, x: Not available) No.
1.1.1 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.
PIO pattern = 1 Teaching mode [Teaching type] Operation mode Jog/inching switching Signal abbreviation PC1 PC2 PC4 PC8 PC16 PC32 MODE JISL +jog/inching movement JOG+ -jog/inching movement JOG- Operating mode RMOD Home return Pause Start HOME *STP CSTR Current-position write PWRT Alarm reset RES Servo ON SON Completed position number PM1 PM2 PM4 PM8 PM16 PM32 Category Signal name Command position number Input Moving MOVE Mode status MODES Position zone PZONE Operating mode stat
PIO pattern = 2 256-point mode [256-point type] Category Signal name Command position number Input Brake release Operating mode Home return Pause Start Alarm reset Servo ON Completed position number Position zone Output Operating mode status Home return completion Position complete Servo-on status Emergency stop status Alarm Battery alarm 56 Signal Function overview abbreviation PC1 PC2 PC4 The target position number is input.
PIO pattern = 3 512-point mode [512-point type] Category Signal name Command position number Input Brake release Operating mode Home return Pause Start Alarm reset Servo ON Completed position number Output Operating mode status Home return completion Position complete Servo-on status Emergency stop status Alarm Battery alarm Signal Function overview abbreviation PC1 PC2 PC4 PC8 The target position number is input.
PIO pattern = 4 Solenoid valve mode 1 [7-point type] Category Input Signal name Signal abbreviation Position No. 0 move ST0 Position No. 1 move ST1 Position No. 2 move ST2 Position No. 3 move ST3 Position No. 4 move ST4 Position No. 5 move ST5 Position No. 6 move ST6 Brake release BKRL Operating mode RMOD Home return Pause Alarm reset HOME *STP RES Servo ON SON Position No. 0 complete PE0 Position No. 1 complete PE1 Position No. 2 complete PE2 Position No.
PIO pattern = 5 Solenoid valve mode 2 [3-point type] Category Signal name Rear end move command Front end move command Intermediate point move command Input ST0 ST1 ST2 Brake release BKRL Operating mode RMOD Alarm reset RES Servo ON SON Rear end position detected Front end position detected Intermediate position detected Output Signal abbreviation LS0 LS1 LS2 Zone 1 ZONE1 Position zone PZONE Operating mode status RMDS Home return completion HEND Servo-on status SV Emergency stop
1.1.2 Signal Assignment Table for Respective PIO Patterns When creating a PLC sequence or wiring signals, assign each pin correctly by referring to the assignment table below. When “1 [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. Pin No.
1.
PIO pattern 1 Teaching mode [Teaching type] Host system end Controller end PIO (signal abbreviation) Brown-1 Red-1 Orange-1 Yellow-1 Command position 1 Blue-1 Command position 4 Purple-1 Command position 8 Gray-1 Command position 16 White-1 Black-1 Operation mode Brown-2 Output side Command position 32 Jog/inching switching Red-2 +Jog Orange-2 -Jog Yellow-2 Operating mode Green-2 Home return Pause Blue-2 Purple-2 Start/position write Gray-2 Alarm reset White-2 Servo on Bl
PIO pattern 2 256-point mode [256-point type] Host system end Controller end PIO (signal abbreviation) Brown-1 Red-1 Orange-1 Yellow-1 Output side Command position 1 Blue-1 Command position 4 Purple-1 Command position 8 Gray-1 Command position 16 White-1 Command position 32 Black-1 Command position 64 Brown-2 Command position 128 Red-2 Orange-2 Break release Yellow-2 Operation mode Green-2 Home return Pause Input side Green-1 Command position 2 Blue-2 Purple-2 Start Gray-2
PIO pattern 3 512-point mode [512-point type] Host system end Controller end PIO (signal abbreviation) Brown-1 Red-1 Orange-1 Yellow-1 Output side Command position 1 Command position 2 Blue-1 Command position 4 Purple-1 Command position 8 Gray-1 Command position 16 White-1 Command position 32 Black-1 Command position 64 Brown-2 Command position 128 Red-2 Command position 256 Orange-2 Break release Yellow-2 Operation mode Green-2 Home return Pause Input side Green-1 Blue-2
PIO pattern 4 Solenoid valve mode 1 [7-point type] Host system end Controller end PIO (signal abbreviation) Brown-1 Red-1 Orange-1 Yellow-1 Output side Start position 0 Green-1 Start position 1 Blue-1 Start position 2 Purple-1 Start position 3 Gray-1 Start position 4 White-1 Start position 5 Black-1 Start position 6 Brown-2 Red-2 Orange-2 Break release Yellow-2 Operation mode Green-2 Home return Blue-2 Pause Purple-2 Alarm reset White-2 Input side Gray-2 Servo on Black-
PIO pattern 5 Solenoid valve mode 2 [3-point type] Host system end Controller end PIO (signal abbreviation) Brown-1 Red-1 Orange-1 Yellow-1 Start position 0 Green-1 Start position 1 Blue-1 Start position 2 Purple-1 Gray-1 White-1 Black-1 Output side Brown-2 Red-2 Orange-2 Break release Yellow-2 Operation mode Green-2 Blue-2 Purple-2 Gray-2 Alarm reset White-2 Servo on Black-2 Rear end detected Brown-3 Front end detected Intermediate point detected Red-3 Orange-3 Yellow-3 Green-3
1.3 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.
Home return (HOME) The controller will start home return operation upon detection of an OFF ON edge of this signal. When the home return is complete, the HEND signal will be output. The HOME signal can be input as many times as required. (Note) Even if home return is not performed after the power has been input, the actuator will automatically perform home return and then move to the target position. Therefore, this signal need not be used at all time. The actuator will move to the home position if “0.
Servo ON (SON) The servo remains ON while this signal is ON. Use this signal based on the default setting (the factory setting is “0: Enable”) if servo ON/OFF control must be performed by the PLC as part of the operation of the safety circuit covering the entire system. Whether this signal is enabled or disabled is defined by parameter No. 21, “Servo ON input.” If the SON signal is used, set this parameter to “0: [Enable].” If it is not used, set the parameter to “1: [Disable].
Jog (JOG+, JOG-) These signals function in two modes, which are toggled according to the input (ON/OFF) of the jog/inching switching signal (JISL). [1] Jog mode: The jog/inching switching signal (JISL) is OFF The actuator jogs while a jog signal is ON, and will decelerate to a stop when the signal is turned OFF. The JOG+ signal causes the actuator to jog forward, while the JOG- signal causes the actuator to jog backward.
Start position number (ST0 to ST6) Solenoid valve mode 1 [7-point type] These signals are effective when “4” is set in parameter No. 25 (= when the air-cylinder type is selected). Upon detection of an OFF ON rise edge or ON level of this signal, the actuator will move to the target position set in the corresponding position data. Before executing this command, the target position, speed and other operation data must be set in the position table using a PC/teaching pendant.
1.3.2 Details of Each Output Signal Completed position number (PM1 to PM256) These signals can be used to check the completed position number when the PEND signal turns ON. The signals are output as a binary code. Immediately after the power is input, all of the PM1 to PM256 signals are OFF. In the standard or teaching type, six bits of PM1 through PM32 are used. In the 256-point type, eight bits of PM1 through PM128 are used. In the 512-point type, nine bits of PM1 through PM256 are used.
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. If the RMOD input is disabled by parameter No.
Emergency stop status (*EMGS) This signal remains ON in a normal condition, and will turn OFF if the emergency stop switch is pressed. Program the PLC so that it will monitor this signal and implement appropriate safety measures for the entire system if the signal turns OFF. Alarm (*ALM) This signal remains ON while the controller is operating properly, and turns OFF when an alarm has generated.
Current position number signal (PE0 to PE6) Solenoid valve mode 1 [7-point type] When the PIO pattern is “4” (air-cylinder type), upon completion of positioning the position number (0 to 6) specified in the applicable move command will be output separately. If push & hold operation is specified, the corresponding PE signal will turn ON upon detection of successful push & hold operation.
Position detection output at each position (LS0, LS1, LS2) Solenoid valve mode 2 [3-point type] These signals have the same meanings as the LS signals of an air cylinder. Each signal will turn ON when the current position enters the positioning band of the target position. (Note) Even if the servo turns off or an emergency stop is actuated while the actuator is stopped at the target position, the signal will remain ON as long as the actuator is inside the positioning band.
2. 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.
(2) Position Enter the target position to move the actuator to, in [mm]. Absolute mode: Enter the target position to move the actuator to, using the distance from the home. Incremental mode: Enter the target position to move the actuator to, using the distance from the current position. A negative value can also be entered (a negative value indicates a distance in the negative direction of displayed coordinates).
(5) Push Select either the positioning mode or push & hold mode. The default setting is “0.” 0: Positioning mode (= normal operation) Other than 0: Push & hold mode [%] If the push & hold mode is selected, enter the current-limiting value to be applied to limit the AC servo motor current during push & hold operation. Caution: Take note that if the push force is too small, a false detection may occur during push & hold operation due to sliding resistance, etc.
This field defines the zone in which PZONE (zone output signal) will turn ON during operations in PIO pattern 0, 1, 2, 4 or 5. To add flexibility, a different zone can now be set for each target position. [Setting example] (8) Zone +/- Position [mm] 5.00 380.00 200.00 No. 0 1 2 Zone+ [mm] 100.00 400.00 250.00 Zone[mm] 0.00 300.00 150.00 Movement command to position No. 0 Home Movement command to position No. 1 Target position Target position + limit Movement command to position No.
S-motion During acceleration, the actuator operates along an acceleration curve that gradually rises until a certain point, and then increases sharply. Use this mode if you wish to set high acceleration/deceleration to meet the required tact time, while still allowing the actuator to accelerate gradually immediately after it starts moving and immediately before stopping. Note, however, that this setting is not reflected in jogging or inching using a PC or teaching pendant.
This field defines whether the position is specified in the absolute mode or incremental mode. The factory setting is “0.” 0: Absolute mode 1: Incremental mode (10) Incremental command Warning: On the solenoid valve mode 2 [3-point type], make sure the position is specified in the absolute mode. If it is specified in the incremental mode, the position date error (OA2) will generate. (11) Command mode This field is not used for this controller. The factory setting is “0.
Warning: If the next move command is an incremental command (constant pitch feed), never use the automatic servo-off mode. The current position may shift slightly when the servo turns off and then on again. Caution: In push & hold operation, the automatic servo-off mode is disabled if push & hold operation has completed successfully. This mode is enabled if the actuator has missed the load. As a basic rule of thumb, do not use the automatic servo-off mode in push & hold operation.
2.2 2.2.1 Explanation of Modes 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 Positioning band 2.2.
(2) Load was not contacted (missed) If the actuator does not still contact the load 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. It is recommended that a zone signal be also used as a “simple ruler” to supplement the judgment of missed load. 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 Positioning band band band Actual position reached Target position (the load was missed) 2.2.3 Speed Change during Movement Speed control involving multiple speed levels is possible in a single operation.
2.2.5 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.
Position zone output signal (PZONE) Set the signal ON zone using the “Zone-“ and “Zone+” fields of the position table Zone output (PZONE) Actuator operation + direction Home Value set in “Zone-” * Value set in “Zone+” The zone functions have been changed due to version upgrade. Refer to the precautions at the outset. 2.2.7 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.
2.2.8 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 type is provided to support these applications. The features of the teaching type are summarized below: [1] The actuator can be jogged using I/O signals input from the PLC.
2.2.9 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 one in the 64-point positioning type (PIO pattern = 0).
[2] Positioning mode [64-point 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. At least 6 msec of delay time is needed (ensured by a timer setting on the PLC side). Start input (CSTR) Completed position 1 output (PM1) (Remains OFF) Completed position 2 output (PM2) The PLC checks these 3 signals to confirm that the completed position number is “5.
2.2.10 Overview of Solenoid Valve Mode 2 [3-point Type] 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. Take note that incremental position commands are not supported in solenoid valve mode 2 [3-point type].
Item Air cylinder SCON Position check Determined by an Immediately after the power is turned on, the controller cannot upon power external detection sensor, identify the current position because the mechanical coordinates ON such as a reed switch. 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.
2.3 Power-saving Modes at Standby Positions To save energy when the actuator stands by for a long period of time, this controller provides a mode in which to reduce the power consumption while the actuator is at standstill. Use this mode after confirming that it will not present problems to any part of your system. The actuator stands by after completing the home return operation effected by the HOME input signal In this condition, you can select the power-saving mode using parameter No.
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 complete signals ON using a parameter in situations where the PLC sequence circuit is designed in such a way that problems will occur if the complete signals turn OFF. (Position complete INP) Setting of parameter No.
3. Operation 3.1 3.1.1 How to Start Incremental Specification Procedure after initial startup until actuator adjustment [1] Connect the motor relay 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. [4] Supply the 24-VDC I/O power (1A/2A pins (+24 V) and 19B/20B pins (0 V) in the PIO connector).
[11] Set a target position in the “Position” field of the position table. Set a target position in the “Position” field of each position table. Determine a desired target position by fine-adjusting the load and hand via jogging or inching. Also adjust the servo gain, if necessary. * Once a target position has been set, other fields (speed, acceleration/deceleration, positioning band, etc.) will be automatically populated by their default values.
3.1.2 [1] [1] [2] [3] Absolute Specification (Absolute Reset) On absolute reset from PC software or teaching pendant Connect the motor cable and encoder cable to the controller. Connect the host PLC to the PIO connector using the supplied flat cable. If two or more controller axes are linked, set the address of each controller using the axis setting switches. For details, refer to Appendix 4, “PC/Teaching Pendant Connection Method in Multi-axis Configurations.” [4] Connect the battery connector.
Overview of operation using the PC software Select position data in the main screen, and then click the Home button. For details, refer to the operation manual for your teaching pendant or the PC software. Using a PLC command Refer to Chapter 2, 1.1.2, “Signal Assignment Table for Respective PIO Patterns” to perform the necessary signal processing corresponding to the PIO pattern currently selected. Issue a command after confirming that the position complete signal (PEND) is ON.
Startup Timing Chart Safety circuit status Emergency stop actuated or cancelled (status of power supply to the motor drive source) Note 1 24-V PIO power input Brake power input Note 2 Control power input Motor power input Alarm reset CON-T: Press the ERROR RESET key. RCM-T/E: Press the BEGIN/END key. PC software: Click the Alarm button. Alarm output (*ALM) Alarm code output (PM8 to PM1) ALM LED Pause is cancelled.
[2] On absolute reset from PIO (supported from version V001E) It is possible to use PIO to perform absolute reset. Execute the following steps [1] to [3] in order to perform absolute reset. [1] [2] [3] Shift the controller to a status where absolute reset is possible. [1] Check that the SV signal is OFF. [2] Turn the SON signal OFF for 100 ms or longer. (Turn the SV and SON signals OFF and continue this status for 100 ms or longer.
3.1.3 Normal Operation Procedure Normally, the operation procedure follows the steps below: [1] Cancel the emergency stop or enable the motor drive power supply. [2] Supply the 24-VDC I/O power. [3] If the actuator is equipped with a brake, turn on the 24-V power supply for the brake. [4] Supply the control power and motor power to the controller. * The controller has started properly if the monitor LED [PWR] on the front panel illuminates. If [ALM] illuminates in red, an alarm has generated.
Emergency stop not actuated (motor drive power supplied) Safety circuit condition Supply of 24-VDC I/O power Supply of control power and motor power to controller Mode selector switch * Be sure to set the switch to the “AUTO” side. Operation mode status output (RMDS) * If this output signal is OFF, I/O signal communication with the PLC is enabled.
3.1.4 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. 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.
(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.
3.2 How Return Operation 3.2.1 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. 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.
3.2.2 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. 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.
3.3 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 PIO 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.
3.4 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 load and push it in the counter-motor direction).
Position table (Field(s) within thick line must be entered.) No. 0 Position [mm] * Speed [mm/s] * Acceleration [G] * Deceleration [G] * Push [%] * Positioning band [mm] * 1 280.00 200.00 0.30 0.30 50 15.00 2 : 40.00 100.00 0.30 0.30 0 0.
3.4.1 Return Action after Push & Hold by Relative Coordinate Specification 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).
3.5 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.) No. 0 Position [mm] * Speed [mm/s] * Acceleration [G] * Deceleration [G] * Push [%] * Positioning band [mm] * 1 150.00 200.00 0.30 0.30 0 10.00 2 : 200.00 100.00 0.30 0.30 0 0.
3.6 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. Controller PIO Signal name [5] [2] [1] Reference flow Category [1] Select/enter command position 1.
Position table (Field(s) within thick line must be entered.) No. 0 1 : Position [mm] * 150.00 Speed [mm/s] * 200.00 Command position Acceleration [G] * Deceleration [G] * 0.30 0.10 Push [%] * Positioning band [mm] * 0 0.10 Position 1 T1 Start Position complete Completed position Position 1 Moving Speed Positioning band Actuator movement Acceleration 0.3 G Deceleration 0.
3.7 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 Start Note Position complete Completed position Pause Moving 4 msec or less 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.
3.8 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. [2] Start input ON Start Command position 1 Input Movement to the selected position starts. [1] P Completed position OFF Command position 32 L C Completed position 1 [3] Position complete output OFF [4] Moving output ON [5] Start input OFF [6] Actuator enters the zone. Zone output ON [7] Actuator exits the zone.
Command position T1 Start Note Position complete Completed position Zone Moving Speed 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.
3.9 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] [9] L [8] [16] C [15][11][7][3] Reference flow Category [2] Start Command position 1 [1] Select/enter command position 1.
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 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 RCM-T teaching pendant, this symbol indicates that the applicable position is specified in relative coordinates.
3.9.1 Judgment Method of End Position 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 load position.
3.9.2 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.
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.) Speed [mm/ss] Positioning band [mm] No.
3.10 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 (MODE) Current operation mode (MODES) Jog/inching switching (JISL) +Jog (JOG+) -Jog (JOG-) Command position (PC1 to PC32) Position 1 Current-position write (PWRT) Write completion (WEND) T1: 40 msec or more; time after the current-position write input is turned ON until writing of the current position is completed. If an alarm generate, the writing time may become longer due to alarm registration.
3.11 Operations in 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.
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) 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.
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.
Handling of the pause (*STP) signal This is a negative-logic signal, so 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.
3.12 Operations in 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. Example of use in operation) How to move the actuator from the rear end to the front end is explained. Although the actuator does not stop at the intermediate point, you can increase the positioning band and use the intermediate point detected output signal (LS2) as a quasi zone output signal.
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.
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.
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.
Push & hold operation The following limitations apply in solenoid valve mode 2 [3-point type]: The position complete signal (PEND) is not available. In push & hold operation, the rear end position detected (LS0), front end position detected (LS1) and intermediate position detected (LS2) signals turn ON only when the actuator has reached a point within the positioning band (parameter No. 10) with respect to the target position.
Operation timings PLC processing 1: [1] The PLC turns OFF the rear end move command signal (ST0) and intermediate point move command signal (ST2), and turns ON the front end move command signal (ST1). [2] The PLC sets in the timer the period after a move command is issued until push & hold operation is completed, to enable monitoring with the timer. Operation 1: The actuator starts moving and upon reaching the front end (160 mm), it decelerates to the push speed.
Front end move command input (ST1) Rear end move command input (ST0) Timer monitor period Timer monitor complete signal Zone output Sequence processing Speed Load Stop-upon-contact position Front end command position Rear end position Rear end position – direction + direction Time Positioning band 141
Chapter 3 Pulse-train Input Mode 1. Overview In this mode, the actuator can be controlled using the positioning control function (pulse-train input) of the host controller (PLC). 1.1 Features Dedicated home return signal IAI’s original stroke-end push type home return operation is supported in this mode. When this function is used, home return can be performed automatically without having to program a complex sequence or use an external sensor, etc.
1.2 Standard Accessories (1) Pulse-train control service connector Description: Plug (10114-3000PE by Sumitomo 3M) Shell (10314-52F0-008 by Sumitomo 3M) 1.3 1.3.1 Options Pulse Converter (AK-04) Model: AK-04 Description: Pulse converter + Input/output e-CON connector Use this converter when the host controller outputs open-collector pulses. This converter is used to convert open-collector command pulses output from the host controller, to differential pulses.
On installation of AK-04 [1] Use AK-04 in environment where surrounding air temperature is 0 to 40C. [2] The temperature of AK-04 increases by approximately 30C during operation. Do not install multiple AK-04 converters closely or store them within ducts. Moreover, do not set them near other heating elements. [3] When you use several AK-04 converters, lay them out separated for 10 mm or more. A recommended installation example is shown below.
1.3.2 Pulse Converter (JM-08) Model: JM-08 Description: Pulse converter + Input/output e-CON connector This converter converts differential pulses (operation system compliant to RS-422) to open-collector pulses. It is possible to use feedback pulse output to operate other devices of open collector pulse train inputs. However, cautions must be paid to input frequency specifications of input devices.
1.3.3 Pulse-train Control Service Cable Model: CB-SC-PIOS * Enter the cable length in . Lengths up to 10 m can be specified. Example) 020 = 2 m (The maximum cable length is 2 m if the AK-04 is used to convert open-collector pulses.) Description: Plug + Shell + Shielded cable Use this cable to connect pulse-train control signals to the host equipment. The cable does not have a connector on the host equipment end.
2. Wiring 2.1 External Connection Diagram A wiring example in the pulse control mode is shown below. SCON controller PULSE 1 Not used 2 Not used 3 PP 4 /PP 5 NP 6 /NP 7 AFB 8 /AFB 9 BFB 10 /BFB 11 ZFB 12 /ZFB 13 GND 14 GND Shield External EMG switch S1 S2 EMG+ EMG- RB+ Regenerative unit (REU-1) RBPE Green Motor relay cable CB-X-MA *** Red White Black Connected to teaching pendant or PC Power supply Single-phase 100 V Single-phase 200 V MOT PE U V W 1. (SGA) 2 (SGB) 3. (+5 V) 4. (ENB) 5. (EMGA) 6.
2.2 Command Pulse-train Input Specifications [Differential line-driver input] Applicable line driver: 26C31 or equivalent Shield [Open-collector input] Pulse converter Host controller Caution: Use a host controller conforming to the figure shown above. If environmental noise is anticipated, use a host controller of differential line-driver output specification. If the host controller is of open-collector specification, use the pulse converter AK-04.
2.3 Feedback Pulse Output Part Applicable line receiver: 26C32 or equivalent Pin No. Pin No. Caution: The range in which feedback pulses can be output linearly in accordance with the actuator speed is 0 to 109 kpps. Therefore, use feedback pulses in this range in applications where positions must be read accurately while the actuator is moving, such as when performing closed-loop control or displaying positions during movement.
3. I/O Signal Control and Signal Functions Caution: To operate the actuator by allowing the controller to communicate with the PLC via I/O signals, be sure to tilt the mode selector switch on the front panel of the controller to the “AUTO” position. 3.1 Input Signals The input signals of this controller incorporate an input time constant to prevent malfunction due to chattering, noise, etc. (The external forced stop signal (CSTP) and command pulse-train input (PP•/PP, NP•/NP) are excluded.
Servo-off status 1. Once the actuator stops, no holding torque will be supplied. 2. The pulse-train input, HOME (home return signal), TL (torque-limiting selection signal) and CSTP (external forced stop signal) are all ignored. 3. The output signals SV (ready signal), HEND (home return completion signal) and TLR (torque limiting signal) are all cleared (turned OFF). 4.
3.1.3 Home Return Signal (HOME) This command signal is used to implement automatic home return. When the HOME signal is turned ON, the command will be processed at the leading edge (ON edge) of the signal and the actuator will perform home return operation automatically. Once the home return is completed, the HEND (home return completion) output signal will turn ON.
3.1.4 Torque-limiting Selection Signal (TL) This signal limits the motor torque. Function The actuator thrust (motor torque) can be limited by the torque set in parameter No. 57, “Torque-limiting value” while this signal is ON. While the TL signal is ON, the TLR (torque limiting) output signal will turn ON once the torque limit is reached. The TL signal is disabled during home return and while the actuator is forcibly stopped. Caution: Do not turn OFF the TL signal while the TLR signal is ON.
3.1.6 Deviation-counter Clear Signal (DCLR) This signal is used to clear the deviation counter. Function If a deviation generates while the TL signal is ON, this signal can be used to clear the deviation. Caution: The actuator will operate if a pulse train is input while the DCLR signal is ON. If DCLR is used, turn this signal ON only when the deviation counter is cleared. Related parameter The deviation counter clear signal (DCLR) can be disabled using parameter No. 60. 3.1.
3.1.9 Command Pulse Input Pulses up to 200 kpps in the open-collector mode, or up to 500 kpps in the differential line-driver mode, can be input. Available command pulses include the 90 phase-difference (phase-A/B x4) signal, pulse train + forward/reverse signal and forward pulse/reverse pulse, and either the positive logic or negative logic can be selected as the input pattern for each pulse signal.
3.2 3.2.1 Output Signals System Ready Signal (PWR) After the main power has been input, this signal will turn ON once the SCON enters a ready state. Function The signal will turn ON once the SCON enters a ready state after the main power has been input and the controller has been initialized successfully, regardless of the servo status or whether an alarm is present, etc. Even if an alarm is present, this signal is ON as long as the SCON is ready.
3.2.4 Home Return Completion Signal (HEND) This signal will turn ON when home return is completed and the coordinate system is established. Function This signal will turn ON when the home return initiated by the applicable signal, teaching pendant or PC software is completed. The signal will turn OFF once the servo turns off. After the servo is turned off, perform home return again. Caution: The software stroke limits set by the actuator parameters remain effective only while this signal is ON.
3.2.6 Alarm Signal (*ALM) This signal will turn OFF when the SCON’s protective circuit (function) detects an error. Function This signal will turn OFF when any of the controller’s protective circuits (functions) actuates upon detecting an alarm and the base cutoff function is executed. Once the cause of the alarm has been removed, this signal can be turned ON by turning the RES (reset) signal ON. (This does not apply to cold-start level alarms.
3.2.7 Alarm Code Output Signals (ALM1, ALM2, ALM4, ALM8) When an alarm generates, the alarm information is output using the ALM1 to 8 ports so that the nature of the alarm can also be recognized on the PLC side. For details, refer to 5.3, “Alarm Description Output Using PIO” in Appendix. 3.2.8 Zone (ZONE1, ZONE2) The ZONE1 signal turns ON when the current actuator position is inside the range specified by “Parameter No. 1: Zone 1+” and “Parameter No. 2: Zone 1-,” and OFF when outside this range.
3.2.9 Feedback-pulse Output Signals (AFB•/AFB, BFB•/BFB, ZFB•/ZFB, GND) Data of detected positions are output using differential pulses. Function Data of detected positions are output using differential pulses (phases A, B and Z). The host controller can read the current actuator position in real time using a counter function, etc.
4. How to Switch to the Pulse-train Control Mode Change the position of the piano switch located on the front panel of the controller. Front panel [1] Set SW1 to the ON position (tilt the switch to the left) when the power is still off. [2] Turn on the power. Piano switches Name 1 2 Description Operation mode selector switch OFF: Positioner mode, ON: Pulse-train mode * The setting will become effective after the power is reconnected. Used by the manufacturer for adjustment purposes.
5. Parameters 5.1 Parameter Settings Required for Operation Parameters can be set or changed using the teaching pendant or PC software. After a parameter has been changed, the new setting will become effective once a “software reset” is performed using the teaching pendant or PC software or the power is reconnected. 5.1.1 Basic Settings The parameters that must be set before the actuator can be operated are explained below.
The number of encoder pulses varies depending on the actuator type.
Calculation example To set the unit travel distance to 0.01 (1/100) (mm) for an actuator with a ball screw lead of 10 (mm), equipped with an encoder of 16,384 (pulses/rev). Electronic gear numerator (CNUM) Number of encoder pulses (pulses/rev) = × Unit travel distance (mm/pulse) Electronic gear denominato r (CDEN) Ball screw lead (mm/rev) The electronic gear numerator (CNUM) is calculated as 2,048, while the electronic gear denominator (CDEN) is calculated as 125.
(2) Command pulse mode User parameter No. 63, “Command-pulse input mode” Name Symbol Unit Input range Default setting (reference) Command-pulse input mode CPMD - 0 to 2 1 Set a desired pulse-train input pattern for command pulse input (PP•/PP, NP•/NP). * Whether to apply the positive logic or negative logic is set in accordance with (3), “Input polarity in the command pulse mode.
5.2 Effective Parameters in the Pulse-train Mode Parameters can be set or changed using the teaching pendant or PC software. After a parameter has been changed, the new setting will become effective once a “software reset” is performed using the teaching pendant or PC software or the power is reconnected. 5.2.1 Applied Settings (1) Torque limit No.
(5) Torque-limit command input No. Name Symbol Unit Input range 61 Torque-limit command input FPIO 0 to 1 You can select whether to enable or disable the torque-limiting signal (TL signal). Setting 0: Enable Setting 1: Disable Default setting 0 (6) Pulse count direction No. Name Symbol Unit Input range Default setting 62 Pulse count direction CPR 0 to 1 Set individually. You can set the direction in which the motor turns upon receiving a command pulse.
(9) Feedback pulse pattern No. Name Symbol 69 Feedback pulse pattern FBPT You can set a desired pattern in which to output feedback pulses. Negative logic Command pulse-train pattern Input terminal Forward pulse train AFB/AFB Reverse pulse train BFB/BFB Forward Unit - Input range 0 to 2 Reverse Default setting 0 Setting 2 A forward pulse train indicates motor revolutions in the forward direction, while a reverse pulse train indicates motor revolutions in the negative direction.
Appendix * Appendix 1. Actuator Specification List Stroke (mm), maximum speed (mm/sec) *1 Loading capacity *2 Rated acceleration Horizontal Vertical Horizontal Vertical (Arm/flat type) (Rod type) (Slider type) Model *1: *2: The figure in the elongated circle indicates the maximum speed for each stroke. The loading capacity is calculated by assuming actuator operation at the rated acceleration.
Appendix Stroke (mm), maximum speed (mm/sec) *1 500/sec 500/sec 500/sec (Dustproof/splashproof type) (Slider type) (Rotary type) Model *1: *2: The figure in the elongated circle indicates the maximum speed for each stroke. The loading capacity is calculated by assuming actuator operation at the rated acceleration.
Appendix Stroke (mm), maximum speed (mm/sec) *1 Loading capacity *2 Horizontal Vertical Rated acceleration Horizontal Vertical (Flat type) (Rod type) (Slider type) Model *1: *2: The figure in the elongated circle indicates the maximum speed for each stroke. The loading capacity is calculated by assuming actuator operation at the rated acceleration.
Appendix Model *1: *2: Stroke (mm), maximum speed (mm/sec) *1 The figure in the elongated circle indicates the maximum speed for each stroke. The loading capacity is calculated by assuming actuator operation at the rated acceleration.
Appendix Model *1: *2: Stroke (mm), maximum speed (mm/sec) *1 Loading capacity *2 Horizontal Vertical Rated acceleration Horizontal Vertical The figure in the elongated circle indicates the maximum speed for each stroke. The loading capacity is calculated by assuming actuator operation at the rated acceleration.
Appendix 2. Battery Backup Function The SCON controller uses the following battery: Absolute-encoder backup battery This battery is used to retain the rotation data of the absolute encoder, so that the motor rotation data will be retained, and thus can be updated, after the controller power has been cut off. Each controller to which an absolute type actuator is connected is shipped with this backup battery. The details are explained on the following pages.
Appendix 2.1 Absolute-encoder Backup Battery If the SCON controller is to drive/control an absolute type actuator, an absolute-encoder backup battery must be installed in the controller. An absolute encoder is designed to retain rotation data and detect rotations using the power supplied from the absolute-encoder backup battery, even when the controller’s control power is not supplied.
Appendix The table below lists the absolute-encoder backup specifications. List of absolute-encoder backup functions Battery model AB-5 (by IAI) Battery voltage 3.6 V Current capacity 2000 mAH Detection voltage for battery (Typical) 3.1 V, 3.0 V to 3.2 V voltage low alarm Detection voltage for battery (Typical) 2.5 V, 2.3 V to 2.
Appendix 3. Parameter Settings 3.1 Parameter Table The parameters are classified into the following seven types based on what they are for: Category: No.
Appendix No.
Appendix 3.2 Detail Explanation of Parameters If a parameter has been changed, always restart the controller using a software reset command or by reconnecting the power. 3.2.1 Parameters Relating to the Actuator Stroke Range Soft limit 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.
Appendix Zone boundary You can set the zone in which a zone output signal (ZONE1 or ZONE2) turns ON when the PIO pattern is set to 0 (positioning mode [standard type]), 4 (solenoid valve mode [7-point type]) or 5 (solenoid valve mode 2 [3-point type]) and the pulse-train input mode is selected. Each signal turns ON when the current position is inside the range defined by the set boundaries on negative side and positive side. For ZONE1, set the boundary on positive side in parameter No.
Appendix Home Return Offset, Home Preset For both the home return offset (No. 22) and home preset (No. 139), an optimal value has been set to ensure a constant distance from the mechanical end to the home. The minimum setting unit is “0.01 [mm].
Appendix 3.2.2 Parameters Relating to the Actuator Operating Characteristics PIO jog speed 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.
Appendix Default acceleration/deceleration mode This value is treated as the data in the “Acceleration/deceleration mode” field corresponding to the applicable position number when a target position has been written to the unregistered position table. The factory setting is “0 [Trapezoid]. To change the default acceleration/deceleration pattern, set an applicable value in parameter No. 52 as shown below.
Appendix Automatic servo-off delay time 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. 2: T becomes the value set by parameter No. 37.
Appendix Push speed 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 load, and so on.
Appendix Allowable time of exceeding torque allowing continuous push & hold When push & hold operation is continuously performed, a code “0C4” alarm is generated when the time set with this parameter is exceeded, thereby excessive push & hold can be prevented. This parameter is applied to actuators that allow push & hold setting exceeding 70%. * As of April 2009, the target actuators are RCS2-RA13R. Parameter No.
Appendix Overrun-sensor input polarity The overtravel detection sensor is not included in the standard specification, but it can be installed as an option. This parameter is set properly prior to the shipment according to the customer’s specification and thus normally it need not be changed, but if the customer wishes to change the mode after the shipment, change the value of parameter No. 19.
Appendix Position-command primary filter time constant Parameter No. 55 defines the delay to be applied when “1 [Primary delay filter]” is set in the “Acceleration/deceleration mode” field of the position table. The setting unit is 0.1 mm, while the setting range is 0.0 to 100.00. The factory setting is “0” [msec]. * The primary delay filter is disabled when “0” is set. The greater the value set in this parameter, the longer the delay becomes. Speed Time S-motion ratio setting Parameter No.
Appendix Caution: [1] Even if you issue a position command or high-value command with specified S-motion acceleration/deceleration in order to change moving speed while the actuator is operating, trapezoid control, rather than S-motion acceleration/deceleration control, is performed. Make sure to issue a command when the actuator is stopped. [2] S-motion acceleration/deceleration is disabled in the index mode of the rotary actuator.
Appendix 3.2.3 Parameters Relating to the External Interface PIO pattern selection 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.” Parameter No. 25 setting 0 1 2 3 4 5 190 Feature of PIO pattern Positioning mode [Standard type] A basic type supporting 64 positioning points and two zone outputs.
Appendix Movement command type This parameter defines the operating condition for move command inputs (ST0 to ST6) when the PIO pattern is “solenoid valve mode 1 [7-point type]” or “solenoid valve mode 2 [3-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.
Appendix Pause input disable selection 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].” Servo ON input disable selection 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].” Home-return input disable selection Parameter No.
Appendix Output mode of position complete signal 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.
Appendix SIO communication speed This parameter is used for controllers of serial communication type. Set the communication speed to be used when the control is performed via serial communication using the PLC’s communication module. Set an appropriate value in parameter No. 16 in accordance with the specification of the communication module. One of 9600, 19200, 38400, 115200 and 230400 bps can be selected as the communication speed. The factory setting is “38400 [bps].
Appendix 3.2.4 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.
Appendix Speed loop integral gain Parameter No. Unit 32 --- Input range 1 to 217270 Default Set individually in accordance with the actuator characteristics. 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.
Appendix Feed-forward gain Parameter No. Unit 71 --- Input range 0 to 100 Default Set individually in accordance with the actuator characteristics. This parameter sets the level of feed-forward gain to be applied to position control. Use this parameter to improve the response of the position control system. Use this parameter if you wish to improve the response of your system having low mechanical rigidity or whose mechanical configuration is subject to a high load inertia ratio.
Appendix 3.2.5 Linear/Rotary Control Axis operation type Parameter No. 78 defines the type of the actuator used. Connected actuator Setting Linear axis 0 Rotational axis 1 Remarks Actuator other than rotational axis Rotational axis (RS-30/60, RCS2-RT6/RT6R/R17/RT7R) Rotational axis mode selection Parameter No. 79 defines the mode of the rotational axis If the axis operation type (parameter No.
Appendix Rotational axis shortcut selection Parameter No. 80 defines the shortcut selection for the rotational axis. Shortcut refers to moving the actuator in the rotation direction with fewer movement with respect to the next positioning operation. Setting 0 1 Disable Enable Position No. 1 Position Position No. Position No. 4 Position data Position No. 2 With position data, 1 equals 1 mm. Position No.
200 Axis operation type Rotational axis mode selection Rotational axis shortcut selection 0 Linear movement Disable Rotational axis Supported encoder type Current position range Absolute position command range Incremental position Soft limit+ command range Soft limit- Screw lead ABS INC Disable -9999.99 to 9999.99 (Note 1) -0.15 to 9999.99 (Note 1) -9999.30 to 9999.30 (Note 1) Enable Enable Enable 0 Normal mode Disable -9999.99 to 9999.99 (Note 1) -0.15 to 9999.
Appendix 3.2.6 Others Timer period for emergency-stop relay fusing monitor The controller has a built-in emergency stop relay for cutting off the motor drive power, so fusing of this relay is detected. If the motor AC power is not cut off after elapse of the timer period set by this parameter following the cutoff of the driver power, the controller will recognize that the relay has been fused and generate an alarm. Normally this parameter need not be changed.
Appendix 4. 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.
Appendix 4.2 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) [7] e-CON connector [1] Power/emergency-stop terminal block (TB2) J4 J5 [6] Monitor LEDs [3] D-sub, 9-pin connector [5] PORT switch [4] Mini DIN, 8-pin connector [1] Power/emergency-stop terminal block (TB2) EMG1, EMG2 Provide a contact output for the emergency-stop switch on the teaching pendant.
Appendix [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.
Appendix 4.3 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.
Appendix 4.
Appendix 5. Troubleshooting 5.1 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 LEDs. SV (green) ------- The servo is ON. ALM (orange) --- An alarm is present or the motor drive power is cut off. EMG (red) ------- An emergency stop is actuated. b. Check for error in the host controller. c.
Appendix 5.2 Alarm Level Classification Alarms are classified into two levels based on the corresponding symptoms. Alarm level ALM lamp *ALM signal Operation cancellation Lit Output Cold start Lit Output Caution: 208 What happens when alarm generates The actuator decelerates to a stop and then the servo turns OFF. The actuator decelerates to a stop and then the servo turns OFF.
Appendix 5.3 Alarm Description Output Using PIO In PIO patterns 0 to 3 corresponding to the positioner mode (64 to 512-point positioning types), 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 also be identified on the PLC side.
Appendix Positioner mode, PIO = 0 to 3 ALM PM8 PM4 PM2 PM1 Pulse-train input mode ALM ALM8 ALM4 ALM2 210 Description: Code number in ( ) ALM1 Command counter overflow (0A4) Mismatching electric angle (0B4) Deviation over-flow (0D8) Software stroke limit exceeded (0D9) Feedback pulse error (0DA) Out of push & hold operation range error (0DC) Exceeded allowable time of exceeding torque allowing continuous push & hold (0C4) Moto
Appendix 5.
Appendix Code Error name 092 PWRT signal detected during movement 093 0A1 0A2 0A3 0A4 0A5 0A7 Cause/Action Cause: The current-position write signal (PWRT) was input in the 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).
Appendix Code 0B5 0BA 0BE 0BF 0C0 Error name Cause/Action Phase Z position error The position where phase Z was detected at home return was outside the specified range. Cause: Encoder failure Action: Please contact IAI. Home sensor not This error indicates that the actuator equipped with the home check sensor has detected not yet successfully completed the home return operation. Cause: [1] The load contacted any surrounding equipment or structure during home return.
Appendix Code Error name 0C2 Overrun sensor signal detected 0CF 24-V I/O power error 0D2 Motor power-supply voltage excessive Motor power-supply voltage low Deviation overflow 0D3 0D8 0D9 Software stroke limit exceeded 0DA Feedback pulse error 0DC Out of push & hold operation range error 0F5 Nonvolatile memory write verification error 214 Cause/Action This error indicates that a signal from the OT sensor installed at a mechanical end was detected.
Appendix (2) Cold-start level alarms Code 0A1 0A6 0A8 0B4 0B7 0C4 0C8 Error name Cause/Action Parameter data error Supported version: V001B~ 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. Action: Change the parameters to appropriate values.
Appendix Code Error name 0CA Overheating 0CB Current-sensor offset adjustment error 0CD Emergency stop relay fused Control power-supply voltage low 0CE 0D2 Motor power-supply voltage excessive 0D3 Motor power-supply voltage low 0D7 Belt-breaking sensor detected Overload 0E0 Cause/Action This error indicates that the temperature around the power transistor in the controller is excessively high (95C or above). Cause: [1] The surrounding air temperature is high.
Appendix Code Error name 0E4 Encoder send error 0E5 Encoder receive error 0E6 Encoder count error 0E7 Open phase A/B/Z Cause/Action When the encoder is of serial data communication type, the controller exchanges position data with the encoder via serial communication. This error indicates that the encoder could not successfully receive data sent by the controller. Cause: [1] Data turned garbage due to noise. [2] The communication IC installed on the encoder board is faulty.
Appendix Code Error name 0EE Absolute encoder error detected 2 0EF 0F0 0F4 0F5 0F6 0F8 218 Cause/Action This error indicates that the ASIC board installed in the absolute encoder cannot detect position information correctly. Cause: [1] The voltage of the absolute-encoder backup battery is low. [2] The encoder cable is disconnected. Action: [1] Check the PIO battery alarm output. If the output is OFF, replace the absolute-encoder backup battery. [2] Connect the encoder cable.
Appendix Code Error name 0FA CPU error 0FB FPGA error Cause/Action The CPU is not operating properly. Cause: [1] Faulty CPU [2] Malfunction due to noise Action: If the alarm generates again after reconnecting the power, please contact IAI. The FPGA is not operating normally. Cause: [1] Malfunction due to the effect of noise, etc. [2] The FPGA itself is faulty. [3] Faulty circuit component around the FPGA [4] Inappropriate board installation in the controller Action: Reconnect the power.
Appendix 5.5 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 11E 11F 121 122 180 181 182 183 202 20A 220 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.
Appendix Code Message name 20C CSTR-ON during operation 20E 221 301 302 304 305 306 308 30A 30B 307 Soft limit over Write prohibited in monitor mode Operation prohibited in monitor mode Overrun error (M) Framing error (M) SCIR-QUE OV (M) SCIS-QUE OV (M) R-BF OV Response timeout (M) Packet R-QUE OV Packet S-QUE OV Memory command refused 309 Write address error 30C No connected axis 223 Description This message indicates that a movement command signal was turned ON by the PLC while the actuator was
Appendix 5.6 Specific Problems I/O signals cannot be exchanged with the PLC. Cause: [1] The 24-V I/O power supply is connected in reverse. (In this case, the input circuits are not affected, but the output circuits will be damaged.) [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.
Appendix Home return ends in the middle in a vertical application. Cause: [1] The load exceeds the rating. [2] The ball screw is receiving torsional stress due to the affixing method of the actuator, tightening of bolts only on one side, etc. [3] The slide resistance of the actuator itself is large. Action: [1] If [1] is the cause, reduce the load. [2] Loosen the fixing bolts and check if the slider moves smoothly. If the slider moves smoothly, review the affixing method and bolt tightening condition.
Appendix 6. Basic Example of Positioning Sequence The following example illustrates a basic sequence that can be used to create a positioning sequence for your SCON controller. The items shown with a shaded background indicate PIO signals of the SCON controller. Note: This basic sequence cannot be used in solenoid valve mode 2 (3-point type).
Appendix (Position 2 positioning circuit) Position 2 positioning start request Position 2 positioning start pulse Position 2 positioning start request Auxiliary position 2 positioning start pulse Position achieved by completion of current positioning Auxiliary position 2 positioning start Position 2 start check Auxiliary positioning start signal for next positioning Position 2 position complete When a circuit like this is used where the last position in the sequence is clear even when the sequence has s
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 Positioning start command for positioning to other position 20 msec or more (However, the timer period must be at least 2 to 4 times the PLC scan time.
Appendix Recording of Parameters Recorded date: No.
Appendix No.
Appendix Change History Revision Date Description of Revision First edition October 2006 Second edition October 2006 Third edition March 2007 Fourth edition July 2007 Fifth edition June 2009 Sixth edition October 2009 November 2009 June 2010 August 2010 September 2010 January 2011 April 2011 December 2012 Seventh edition P48: Changed the acceleration/deceleration used as a condition for determining the number of regenerative resistors to be connected, from 0.
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Catalog No.: ME0161-14A 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 Atlanta Office: 1220 Kennestone Circle, Suite 108, Marietta, GA 30066 TEL (678) 354-9470 FAX (678) 354-9471 website: www.intelligentactuator.com Ober der Röth 4, D-65824 Schwalbach am Taunus, Germany TEL 06196-88950 FAX 06196-889524 IAI (Shanghai) Co., Ltd.
