IAI PCON-C, PCON-CG, PCON-CF Operation Manual

PCON-C/CG/CF Controller Positioner Type

Operation Manual Sixth Edition

CAUTION

 Changes to Zone Function

Applicable application versions: V0016 and later Among the zone signal settings, those that result in “Zone setting+ < Zone setting-” are now effective. V0015 and earlier: “Zone setting+  Zone setting-”  A zone signal is not output. V0016 and later: “Zone setting+ = Zone setting-”  This is the only condition in which a zone signal is not output. Accordingly, you can now output a zone signal even when a rotary actuator is operated over the 0 position in the index mode. An example is given below.

[Rotary actuator in index mode]

Set value Set value

Zone setting+: 70 Zone setting+: 315 Zone setting-: 315 Zone setting-: 70

[Linear axis]

Current position

Zone signal output

Zone signal ON range

Set value Zone setting+: 70 mm Zone setting-: 30 mm

Set value Zone setting+: 30 mm Zone setting-: 70 mm

CAUTION

1. 24-V Power Supplies Required for UL Certification

PCON controllers (PCON-C/CG, CY, SE, PL/PO) are UL-certified, where one condition for the certification is to use Class 2 24-V power supplies. Accordingly, you must use Class 2 power supplies for both the input power supply and I/O power supply for your equipment incorporating the PCON, if the equipment as a whole must be UL-certified.

2. Use Environment

PCON controllers can be used in an environment of pollution degree 2 or equivalent.

3. PC Software and Teaching Pendant Models

New functions have been added to the entire PCON 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 RCP2 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.

Model Remarks

PC software RCM-101-***

Teaching pendant CON-T, RCM-T

Simple teaching pendant RCM-E

Data setting unit RCM-P

Touch panel display RCM-PM-01 Not compatible with RCP2 controllers

4. Recommendation for Backing up Latest Data

This product uses nonvolatile memory to store the position table and parameters. Normally the memory will retain the stored data even after the power is disconnected. However, the data may be lost if the nonvolatile memory becomes faulty. (We strongly recommend that the latest position table and parameter data be backed up so that the data can be restored quickly in the event of power failure, or when the controller must be replaced for a given reason.) The data can be backed up using the following methods: [1] Save to a CD or FD from the PC software. [2] Hand write the position table and parameter table on paper.

All are compatible with existing RCP2

controllers

CAUTION

5. Initial Parameter Settings at Startup

After applying power, at least the three parameters specified below must be set in accordance with the specific application. Inappropriate settings of these parameters will prevent the controller from operating properly, so exercise due caution. For details on how to set the parameters, refer to “Parameter Settings” in the operation manual for the PC or teaching pendant.

[1] Selecting the PIO pattern

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 factory setting is “0 [Standard type].”

Parameter No.

25 setting

0 Standard type

A basic type supporting 64 positioning points and two zone outputs. * How to set zone boundaries within which to output a zone signal: Zone boundaries are set using parameter Nos. 1 and 2 for one zone output, and in the position table for another zone output.

Feature of PIO pattern

1 Teaching type

In this type, 64 positioning points and one zone output (boundaries are set in the position table) are supported. In addition to the normal positioning mode, the user can also select the teaching mode in which the actuator can be jogged via commands from a PLC and the current actuator position can be written to a specified position. (Note 1) Jog commands from a PLC are also accepted in the positioning mode. (Note 2) Positions can be rewritten by approximately 100,000 times.

2 256-point positioning type

The number of positioning points is increased to 256, so only one zone output is available (boundaries are set in the position table).

3 512-point positioning type

The number of positioning points is increased to 512, so no zone output is available.

4 7-point type

The number of positioning points is limited to seven to offer separate direct command inputs and position complete outputs for respective positions. PLC ladder sequence circuits can be designed easily.

5 3-point type

Use of the controller as an air cylinder is assumed in this type. Position complete output signals function differently in this type, compared to the 7point type. Specifically, the signal functions not only to “indicate position complete,” but also to “detect a position” in the same manner as auto-switches of an air cylinder.

CAUTION

[2] Enabling/disabling the servo ON input signal (SON)

The servo ON input signal has been added to allow for servo ON/OFF control on the PLC side. Depending on the needs, therefore, the user must enable/disable this signal.

To select a desired setting, set “0” or “1” in parameter No. 21 (Servo ON input disable selection).

Enable (use) 0

Disable (do not use) 1

The factory setting is “0 [Enable].”

[3] Enabling/disabling the pause signal (*STP)

The pause signal uses the contact b logic to provide a failsafe function. Therefore, this signal must remain ON in normal conditions of use. Since there are applications where this signal is not used, a parameter is provided to disable the pause signal so it doesn’t have to be turned ON.

To select a desired setting, set “0” or “1” in parameter No. 15 (Pause input disable selection).

Enable (use) 0

Disable (do not use) 1

The factory setting is “0 [Enable].”

6. Using a Rotary Actuator in Multi-rotation Specification

Rotary actuators of multi-rotation specification models let you select multi-rotation operation or limitedrotation operation using a parameter.

6.1 Notes Pay attention to the setting of the PIO pattern parameter for the controllers specified below. Each controller does not support relative coordination specification in the PIO pattern specified.

[1] PCON-C/CG: PIO pattern = 5 (User parameter No. 25) [2] PCON-CY: PIO pattern = 0 (User parameter No. 25)

 The index mode cannot be selected for rotational axes of simple absolute unit specification.

Accordingly, these axes cannot be specified for multi-rotation specification.

6.2 Applicable Models

Actuators

RCP2-RTBL-I-28P-20-360-* PCON-C-28PI-* RCP2-RTBL-I-28P-30-360-* PCON-CG-28PI-* RCP2-RTCL-I-28P-20-360-* PCON-CY-28PI-* RCP2-RTCL-I-28P-30-360-*

Controllers

PCON-SE-28PI-*

CE Marking

1 European Union EC Directive

The European Union EC Directive was issued for the products to be distributed in EU (European Union)

region to protect the health and secure the safety of the users and consumers of the products. It aims at the

respect and satisfaction of the new approach directive issued by the European Commission and security of

the free distribution of the products within the EU region. Accordingly, the corporations related to the export to

or having any production base in EU countries, have to conform to the conditions for the CE Marking as the

essential condition.

(1) Low Voltage Directive

ACON and PCON have been designed to comply with the low voltage directive as a single unit.

(2) EMC Directive

For the EMC Directive, the subjects are all components including the control units and electric and

electronic components used in the controller and equipment manufactured by our company. We have

determined the connection and installation model (conditions) for the controllers, actuators and

peripheral components and demonstrated the compliance with the standards related to the EMC

Directive using the above model.

2 Applicable Standards

EN 50178 (Electronic Equipment used in Electrical Facility)

EN55011 (Radio Interference for Industrial, Scientific or Medical Radio-Frequency Equipment)

EN61000-6-2 (Industrial Environment Immunity)

EN61000-4-2 (Electro-Static Discharge Immunity)

EN61000-4-3 (Radiated, Radio-Frequency, Electromagnetic Field Immunity)

EN61000-4-5 (Electrical First Transient/Burst Immunity Test)

EN61000-4-5 (Surge Immunity Test)

EN61000-4-6 (Immunity Test to Conducted Disturbances, Induced by Radio-Frequency Fields)

EN61000-4-8 (Power-Frequency Magnetic Field Immunity Test)

3 Peripheral Unit Configuration

Control Board

AC Power Bus

Circuit Breaker

*R • A • V-781BW7-4 (Maker : OKAYA ELECTRIC INDUSTIES)

Earth Leakage Breaker

Surge Protector*

DC24V Power Supply

Power Te rminal

FG Fixing using the Main Body Set Bolt

(1) Environments

Use the ACON or PCON under the environment with the contamination level 2 or 1 specified in IEC60664-1.

For example, it is installed on the control board with the structure (IP54) where water, oil, carbon or dust

is not entered.

(2) Power Unit

A) Use it under the environment with the Overvoltage Category II specified in IEC60664-1. For this

purpose, make sure to install the breaker for the wiring between the distribution panel and DC24V

power unit.

B) Use the DC24V power unit conforming to CE marking.

(3) Grounding

Make sure to connect the FG earth terminal for ACON or PCON and protective earth (earth plate) for the

control board to avoid electric shock.

(4) Earth Leakage Breaker

Install the earth leakage breaker (BCD) between the distribution panel and DC24V power unit.

(5) Surge Protector

Install the surge protector on the primary side of the DC24V power unit.

Maker : OKAYA ELECTRIC INDUSTRIES CO. , LTD.

Model Name: R x A x V-781BW7-4

Resin

Case

Wire to be taken out

Surge Protector External View

(6) Cable

For all the cables, such as the motor cable, encoder cable and various network cables to be connected to

ACON or PCON, use them with the length less than 30m.

Safety Precautions (Please read before using the product.)

Before installing, operating, maintaining or inspecting this product, please peruse this operating manual as well as the operating manuals and other related documentations for all equipment and peripheral devices connected to this product in order to ensure the correct use of this product and connected equipment/devices. Those performing installation, operation, maintenance and inspection of the product must have sufficient knowledge of the relevant equipment and their safety. The precautions provided below are designed to help you use the product safely and avoid bodily injury and/or property damage.

In this operating manual, safety precautions are classified as “Danger,” “Warning,” “Caution” and “Note,” according to the degree of risk.

Danger

Failure to observe the instruction will result in an imminent danger leading to death or serious injury.

Warning

Caution

It should be noted that the instructions under the Caution and Note headings may also lead to serious consequences, if unheeded, depending on the situation. All instructions contained herein provide vital information for ensuring safety. Please read the contents carefully and handle the product with due caution. Please keep this operating manual in a convenient place for quick reference whenever needed, and also make sure that the manual will get to the end-user.

Note

Failure to observe the instruction may result in death or serious injury.

Failure to observe the instruction may result in injury or property damage.

The user should take heed of this information to ensure the proper use of the product, although failure to do so will not result in injury.

Danger

[General]

 Do not use this product for the following applications:

1. Medical equipment used to maintain, control or otherwise affect human life or physical health

2. Mechanisms and machinery designed for the purpose of moving or transporting people

3. Important safety parts of machinery This product has not been planned or designed for applications requiring high levels of safety. Use of this product in such applications may jeopardize the safety of human life. The warranty covers only the product as it is delivered.

[Installation]

 Do not use this product in a place exposed to ignitable, inflammable or explosive substances. The

product may ignite, burn or explode.

 Avoid using the product in a place where the main unit or controller may come in contact with water or

oil droplets.

 Never cut and/or reconnect the cables supplied with the product for the purpose of extending or

shortening the cable length. Doing so may result in fire.

[Operation]

 Do not allow the product to come in contact with water. If the product contacts water or is washed with

water, it may operate abnormally and cause injury, electric shock, fire, etc.

[Maintenance, Inspection, Repair]

 Never modify the product. Unauthorized modification may cause the product to malfunction, resulting in

injury, electric shock, fire, etc.

 Do not disassemble and reassemble the product. Doing so may result in injury, electric shock, fire, etc.

Warning

[General]

 Do not use the product outside the specifications. Using the product outside the specifications may

cause it to fail, stop functioning or sustain damage. It may also significantly reduce the service life of the product. In particular, observe the maximum loading capacity and speed.

[Installation]

 If the machine will stop in the case of system problem such as emergency stop or power failure, design

a safety circuit or other device that will prevent equipment damage or injury.

 Be sure to provide Class D grounding for the controller and actuator (formerly Class 3 grounding:

Grounding resistance at 100  or less). Leakage current may cause electric shock or malfunction.

 Before supplying power to and operating the product, always check the operation area of the

equipment to ensure safety. Supplying power to the product carelessly may cause electric shock or injury due to contact with the moving parts.

 Wire the product correctly by referring to the operation manual. Securely connect the cables and

connectors so that they will not be disconnected or come loose. Failure to do so may cause the product to malfunction or cause fire.

[Operation]

 Do not touch the terminal block or various switches while the power is supplied to the product. Failure

to observe this instruction may result in electric shock or malfunction.

 Before operating the moving parts of the product by hand (for the purpose of manual positioning, etc.),

confirm that the servo is turned off (using the teaching pendant). Failure to observe this instruction may result in injury.

 Do not scratch the cables. Scratching, forcibly bending, pulling, winding, crushing with heavy object or

pinching a cable may cause it to leak current or lose continuity, resulting in fire, electric shock, malfunction, etc.

 If the product is generating heat, smoke or a strange smell, turn off the power immediately. Continuing

to use the product may result in product damage or fire.

 If any of the internal protective devices (alarms) of the product has actuated, turn off the power

immediately. Continuing to use the product may result in product damage or injury due to malfunction. Once the power supply is cut off, investigate and remove the cause and then turn on the power again.

 If the LEDs on the product do not illuminate after turning on the power, turn off the power immediately.

The protective device (fuse, etc.) on the live side may remain active. Request repair to the IAI sales office from which you purchased the product.

[Maintenance, Inspection, Repair]

 Before conducting maintenance/inspection, parts replacement or other operations on the product,

completely shut down the power supply. At this time, take the following measures:

1. Display a sign that reads, “WORK IN PROGRESS. DO NOT TURN ON POWER” at a conspicuous place, in order to prevent a person other than the operator from accidentally turning on the power.

2. When two or more operators are to perform maintenance/inspection together, always call out every time the power is turned on/off or an axis is moved in order to ensure safety.

[Disposal]

 Do not throw the product into fire. The product may burst or generate toxic gases.

Caution

[Installation]

 Do not use the product under direct sunlight (UV ray), in a place exposed to dust, salt or iron powder,

in a humid place, or in an atmosphere of organic solvent, phosphate-ester machine oil, etc. The product may lose its function over a short period of time, or exhibit a sudden drop in performance or its service life may be significantly reduced. The product may also malfunction.

 Do not use the product in an atmosphere of corrosive gases (sulfuric acid or hydrochloric acid), etc.

Rust may form and reduce the structural strength.

 When using the product in any of the places specified below, provide a sufficient shield. Failure to do

so may result in malfunction:

1. Place where large current or high magnetic field is present

2. Place where welding or other operations are performed that cause arc discharge

3. Place subject to electrostatic noise

4. Place with potential exposure to radiation

 Do not install the product in a place subject to large vibration or impact. Doing so may result in the

malfunctioning of the product.

 Provide an emergency-stop device in a readily accessible position so the device can be actuated

immediately upon occurrence of a dangerous situation during operation. Lack of such device in an appropriate position may result in injury.

 Provide sufficient maintenance space when installing the product. Routine inspection and maintenance

cannot be performed without sufficient space, which will eventually cause the equipment to stop or the product to sustain damage.

 Always use IAI’s genuine cables for connection between the controller and the actuator. Also use IAI’s

genuine products for the key component units such as the actuator, controller and teaching pendant.

 Before installing or adjusting the product or performing other operations on the product, display a sign

that reads, “WORK IN PROGRESS. DO NOT TURN ON POWER.” If the power is turned on inadvertently, injury may result due to electric shock or sudden activation of an actuator.

[Operation]

 Turn on the power to individual equipment one by one, starting from the equipment at the highest level

in the system hierarchy. Failure to do so may cause the product to start suddenly, resulting in injury or product damage.

 Do not insert a finger or object in the openings in the product. It may cause fire, electric shock or injury.

[Maintenance, Inspection, Repair]

 Do not touch the terminals when performing an insulation resistance test. Electric shock may result.

(Do not perform any withstand voltage test, since the product uses DC voltage.)

Note

[Installation]

 Do not place objects around the controller that will block airflows. Insufficient ventilation may damage

the controller.

 Do not configure a control circuit that will cause the load to drop in case of power failure. Configure a

control circuit that will prevent the table or load from dropping when the power to the machine is cut off or an emergency stop is actuated.

[Installation, Operation, Maintenance]

 When handling the product, wear protective gloves, protective goggles, safety shoes or other

necessary gear to ensure safety.

[Disposal]

 When the product becomes no longer usable or necessary, dispose of it properly as an industrial waste.

Others

 IAI shall not be liable whatsoever for any loss or damage arising from a failure to observe the

items specified in “Safety Precautions.”

1. Overview ................................................................................................................... 1

1.1 Introduction.................................................................................................................................. 1

1.2 How to Read the Model Specification.......................................................................................... 2

1.3 System Configuration .................................................................................................................. 3

1.3.1 Internal Drive-Power Cutoff

1.3.2 External Drive-Power Cuto

1.4 Procedure from Unpacking to Test Operation and Adjustment ................................................... 5

1.5 Warranty Period and Scope of Warranty..................................................................................... 7

2. Specifications ............................................................................................................ 8

2.1 Basic Specifications..................................................................................................................... 8

2.2 Name and Function of Each Part of the Controller ..................................................................... 9

2.3 External Dimensions...................................................................................................................11

Relay Type (PCON-C/CF) .......................................... 3

ff Relay Type (PCON-CG) ............................................ 4

3. Installation and Noise Elimination............................................................................ 12

3.1 Installation Environment ............................................................................................................ 12

3.2 Power Supply ............................................................................................................................ 12

3.3 Noise Elimination and Grounding.............................................................................................. 12

3.4 Heat Radiation and Installation.................................................................................................. 14

4. Wiring ...................................................................................................................... 15

4.1 Internal Drive-Power Cutoff Relay Type (PCON-C/CF)............................................................. 15

4.1.1 External Connection Diagram ............................................................................... 15

4.1.2 Wiring the Power Supply/E

4.2 External Drive-Power Cutoff Relay Type (PCON-CG) .............................................................. 23

4.2.1 External Connection Diagram ............................................................................... 23

4.2.2

4.3 Connecting the I/O Cables ........................................................................................................ 27

 PIO pattern 0 [Standard Type] ............................................................................................. 27

 PIO pattern 1 [Teaching Type] ............................................................................................. 28

 PIO pattern 2 [256-piont mode]............................................................................................ 29

 PIO pattern 3 [512-piont mode]............................................................................................ 30

 PIO pattern 4 [Solenoid valve mode 1] ................................................................................ 31

 PIO pattern 5 [Solenoid valve mode 2] ................................................................................ 32

4.4 Connecting the Actuator ............................................................................................................ 34

Wiring the Power Supply/E

4.4.1 Connecting the PCON-C/C

4.4.2 Connecting the PCON-CF and Actuator............................................................... 36

4.5 Connecting the Communication Cable...................................................................................... 37

mergency-Stop Switch ............................................... 16

mergency-Stop Switch ............................................... 24

G and Actuator........................................................... 34

5. I/O Signal Control and Signal Functions.................................................................. 38

5.1 Interface Circuit ......................................................................................................................... 38

5.1.1 External Input Specifications................................................................................. 38

5.1.2 External Output Specifications.............................................................................. 39

5.2 PIO Patterns and Signal Assignments ...................................................................................... 40

5.2.1 Explanation of Signal Names................................................................................ 41

 PIO pattern = 0: Positioning mode [Standard type].............................................................. 41

 PIO pattern = 1: Teaching mode [Teaching type] ................................................................ 42

 PIO pattern = 2: 256-point mode [256-point type]................................................................ 43

 PIO pattern = 3: 512-point mode [512-point type]................................................................ 44

 PIO pattern = 4: Solenoid valve mode 1 [7- point type] ....................................................... 45

 PIO pattern = 5: Solenoid valve mode 2 [3-point type] ........................................................ 46

5.2.2 Signal Assignment Table for Respective PIO Patterns ......................................... 47

5.3 Details of I/O Signal Functions .................................................................................................. 48

5.3.1. Details of Each Input Signal.................................................................................. 48

 Operating mode (RMOD) ..................................................................................................... 48

 Start (CSTR) ................................................................................................................ 48

 Command position number (PC1 to PC256)........................................................................ 48

 Pause (*STP)........................................................................................................................ 49

 Home return (HOME) ........................................................................................................... 49

 Servo ON (SON)................................................................................................................... 49

 Alarm reset (RES) ................................................................................................................ 49

 Brake release (BKRL) .......................................................................................................... 50

 Operation mode (MODE) ..................................................................................................... 50

 Current-position write (PWRT) ............................................................................................. 50

 Manual operation switching (JISL) ....................................................................................... 50

 Jog (JOG+, JOG-) ................................................................................................................ 51

 Direct position command (ST0 to ST6) [7-point type] .......................................................... 51

 Movement to each position (ST0 to ST2) [3-point type]....................................................... 52

5.3.2 Details of Each Output Signal

 Operating mode status (RMDS)........................................................................................... 53

 Completed position number (PM1 to PM256) ...................................................................... 53

 Moving (MOVE).................................................................................................................... 53

 Position complete (PEND).................................................................................................... 53

 Home return completion (HEND) ......................................................................................... 54

 Zone (ZONE1, ZONE2)........................................................................................................ 54

 Current operation mode (MODES)....................................................................................... 54

 Write completion (WEND) .................................................................................................... 54

 Movement complete at each position (PE0 to PE6) [7-point type]....................................... 55

 Position detection output at each position (LS0 to LS2) [3-point type] ................................ 55

 Ready (SV)........................................................................................................................... 55

 Alarm (*ALM)........................................................................................................................ 55

 Emergency stop (*EMGS).................................................................................................... 56

 Load output judgment status (LOAD)................................................................................... 56

 Torque level status (TRQS) ................................................................................................. 56

 Output Signal Changes in Each Mode ................................................................................. 56

............................................................................... 53

6. Data Entry <Basics>................................................................................................ 57

6.1 Description of Position Table ..................................................................................................... 57

6.1.1 Relationship of Push Force at St

 Slider type..................................................................................................................... 61

(1) SA5C/SA6C/SS7C type................................................................................... 61

(2) SA7C type........................................................................................................ 61

andstill and Current-Limiting Value .................... 61

(3) SS8C type........................................................................................................ 62

 Rod type ....................................................................................................................... 63

(1) RA2C type........................................................................................................ 63

(2) RA3C type........................................................................................................ 63

(3) RA4C type........................................................................................................ 64

(4) RA6C type........................................................................................................ 64

(5) RA10C/W-RA10C type .................................................................................... 65

6.2 Explanation of Modes ................................................................................................................ 66

6.2.1 Positioning Mode .................................................................................................. 66

6.2.2 Push & Hold Mode................................................................................................ 66

6.2.3

6.2.4 S

6.2.5

Torque Check Function in Push & Hold Operation ............................................... 68

peed Change during Movement ......................................................................... 70

Operation at Different Acce

leration and Deceleration Settings ............................. 70

6.2.6 Pause ................................................................................................................... 71

6.2.7 Zone

Signal Output............................................................................................... 71

6.2.8 Home Return ........................................................................................................ 72

6.2.9 Ov

erview of Teaching T

6.2.10 Overview of 7-point Ty

6.2.11 Overview of 3-point Ty

6.3 Notes on the ROBO Gripper...................................................................................................... 78

6.4 Power-saving Modes at Standby Positions ............................................................................... 80

6.5 Using a Rotary Actuator in Multi-rotation Specification.............................................................. 83

ype................................................................................... 73

pe ...................................................................................... 74

pe ...................................................................................... 76

6.5.1 How to Use ........................................................................................................... 83

7. Operation <Practical Steps>.................................................................................... 84

7.1 How to Start............................................................................................................................... 84

7.1.1 Timings after Power On ........................................................................................ 84

 Procedure after initial startup until actuator adjustment .................................................... 84

 Procedure of Normal Operation......................................................................................... 86

7.1.2 Position Table and Parameter Settings Required for Operation ........................... 88

 Startup adjustment............................................................................................................. 88

Safety speed during manual feed...................................................................................... 88

Speed override for movement commands from the PLC .................................................. 88

 Full-scale operation ........................................................................................................... 89

Saving energy when the actuator stands by for a long time after the power has been

turned on............................................................................................................................ 89

Saving energy when the actuator stands by after completing the home return operation

effected by the HOME input signal .................................................................................... 89

Saving energy when the actuator stands by for a long time at the target position............ 89

Output mode of complete signal ........................................................................................ 89

7.2 Home Return Operation ............................................................................................................ 90

7.2.1 Method Using the HOME Input Signal (PIO Pattern = 0 to 4)............................... 90

7.2.2 Method Used When No HOME Input Signal Is

7.3 Positioning Mode (Back and Forth Movement between Two Points)........................................ 93

7.4 Push & Hold Mode..................................................................................................................... 95

7.4.1 Return Action after Push & Hold by Relativ

7.5 Speed Change during Movement.............................................................................................. 98

7.6 Operation at Different Acceleration and Deceleration Settings ............................................... 100

7.7 Pause....................................................................................................................................... 102

Available (PIO Pattern = 5).......... 92

e Coordinate Specification................. 97

7.8 Zone Signal Output.................................................................................................................. 104

7.9 Incremental Moves .................................................................................................................. 107

7.9.1 Judgment Method of End Position...................................................................... 109

7.9.2

7.10 Jogging/Teaching Using PIO ....................................................................................................113

7.11 Operation in 7-point Type .........................................................................................................115

7.12 Operation in 3-point Type .........................................................................................................119

Notes on Increment

al Mode.................................................................................110

8. Parameters............................................................................................................ 123

8.1 Parameter Table ...................................................................................................................... 123

8.2 Detail Explanation of Parameters............................................................................................ 125

8.2.1 Parameters Relating to the Actuator Stroke Range ............................................ 125

 Soft limit ...................................................................................................................... 125

 Software limit margin .................................................................................................. 125

 Zone boundary .......................................................................................................... 126

 Home return direction ............................................................................................... 127

 Home return offset...................................................................................................... 127

8.2.2 Parameters Relating to the Actuator Operating Characteristics

 PIO jog speed ............................................................................................................. 127

 PIO inching distance................................................................................................... 127

 Default speed.............................................................................................................. 127

 Default acceleration/deceleration ............................................................................... 128

 Default positioning band ........................................................................................... 128

 Current-limiting value at standstill during positioning ................................................. 128

 Current-limiting value during home return .................................................................. 128

 Home sensor input polarity......................................................................................... 128

 Speed override ........................................................................................................... 128

 Default direction of excited-phase signal detectio...................................................... 129

 Excited-phase signal detection time ........................................................................... 129

 Safety speed ............................................................................................................. 129

 Automatic servo-off delay time ................................................................................. 130

 Default standstill mode .............................................................................................. 130

 Push speed ............................................................................................................... 131

 Push completion judgment time ................................................................................. 131

 Enable function........................................................................................................... 132

 Polarity of home check sensor input ......................................................................... 132

 Load output judgment time ......................................................................................... 132

 Torque check range .................................................................................................. 133

 Ball screw lead length ............................................................................................... 133

 Axis operation type ................................................................................................... 133

 Rotational axis mode selection................................................................................... 133

 Shortcut selection for rotational axis........................................................................... 133

 Absolute unit ............................................................................................................... 134

 Current-limiting value at standstill after missing work in push & hold operation ........ 134

8.2.3 Parameters Relating to the External Interface

 PIO pattern selection ................................................................................................ 135

 Movement command type .......................................................................................... 136

 Pause input disable selection ................................................................................... 137

 Servo ON input disable selection .............................................................................. 137

 Home-return input disable selection........................................................................... 137

 Operating-mode input disable selection ..................................................................... 137

 Output mode of position complete signal ................................................................... 138

 SIO communication speed.......................................................................................... 138

.................................................... 135

.......................... 127

 Minimum delay time for slave transmitter activation ................................................. 138

 Silent interval multiplier............................................................................................... 139

8.2.4 Servo Gain Adju

 Servo gain number .................................................................................................... 140

 Speed loop proportional gain...................................................................................... 140

 Speed loop integral gain............................................................................................. 141

 Torque filter time constant .......................................................................................... 141

stment ....................................................................................... 140

9. PC/Teaching Pendant Connection Method in Multi-axis Configurations................ 142

9.1 Connection Example ............................................................................................................... 142

9.2 SIO Converter (Optional)......................................................................................................... 143

9.3 Address Switch........................................................................................................................ 145

9.4 Connection Cables .................................................................................................................. 145

9.5 Detail Connection Diagram...................................................................................................... 146

10. Troubleshooting..................................................................................................... 147

10.1 Action to Be Taken upon Occurrence of Problem ................................................................... 147

10.2 Alarm Level Classification ....................................................................................................... 148

10.3 Alarm Description Output Using PIO....................................................................................... 149

10.4 Alarm Description and Cause/Action....................................................................................... 150

(1) Message level alarms......................................................................................................... 150

(2) Cold-start level alarms........................................................................................................ 155

10.5 Messages Displayed during Operation Using the Teaching Pendant ..................................... 157

10.6 Specific Problems.................................................................................................................... 160

 I/O signals cannot be exchanged with the PLC. ................................................................ 160

 The ALM lamp illuminates when the power is input........................................................... 160

 The SV lamp does not illuminate when the servo ON signal is input after the power was

input.................................................................................................................................... 160

 Home return ends in the middle in a vertical application. .................................................. 161

 Noise occurs during downward movements in a vertical application................................. 161

 Vibration occurs when the actuator is stopped. ................................................................. 161

 The actuator overshoots when decelerated to a stop........................................................ 161

 The home and target positions sometimes shift................................................................. 161

 The speed is slow during push & hold operation. .............................................................. 161

 The actuator moves only a half of, or twice as much as, the specified movement............ 161

 A servo error occurred while the actuator was moving (ROBO Gripper)........................... 162

 Abnormal operation results when the servo is turned ON after the power ON.................. 163

 The SV lamp blinks. ........................................................................................................... 163

* Appendix ................................................................................................................... 164

List of Supported Actuator Specifications .......................................................................................... 164

Fault check and replacement of the cooling fan ................................................................................ 177

Example of Basic PCON Positioning Sequence................................................................................ 179

Recording of Parameters................................................................................................................... 182

1. Overview

1.1 Introduction

This product is a dedicated RCP2 / RCP3 actuator controller that provides the same functions of the RCP2 controller as well as a set of new functions designed to achieve greater convenience and safety. The product also provides a power-saving function in response to growing energy-saving needs. The key features and functions are listed below.

 More positioning points

The standard type supports up to 64 points, while the extended types can handle up to 512 points. Availability of more positioning points is ideal for production lines where many types of products are produced in small volumes.

 Setting of zone output boundaries for each position in the position table

Before, zone output boundaries were set by parameters and therefore fixed. To add flexibility, new fields have been added to the position table so that different boundaries can be set for each position. This feature is useful in preventing contact with surrounding equipment and reducing the tact time, among others.

 Separate acceleration/deceleration settings

Acceleration and deceleration are now set in separate fields of the position table. Depending on the material or shape of the load, it is desirable to reduce shock and vibration when the actuator stops. Since acceleration and deceleration can be set differently, only the deceleration value can be reduced to make the deceleration curve more gradual.

 Limitation of feed speed in test operation and adjustment

The feed speed to be used in test operation and adjustment can be limited for added safety.

 Power-saving measures

In general, pulse motors consume more holding current in standstill state than AC servo motors. This product provides a power-saving means to support situations where the actuator must stand by for a long period.

When actually starting up your system or if you have encountered any problem, also refer to the operation manuals for the actuator, teaching pendant, PC software and other components used with the system, in addition to this manual.

This manual does not cover all possible operations other than normal operations, or unexpected events such as complex signal changes resulting from use of critical timings. Accordingly, you should consider items not specifically explained in this manual as “prohibited.”

* We have made every effort to ensure precision of the information provided in this manual. Should you

find an error, however, or if you have any comment, please contact IAI. Keep this manual in a convenient place so it can be referenced readily when necessary.

1.2 How to Read the Model Specification

<Type>

C: Positioner type with internal drive-

power cutoff relay

CG: Positioner type with external drive-

power cutoff relay

CF: High-output positioner type with internal

drive-power cutoff relay

<Actuator type> [Motor flange size]

20P: 20, square 28P: 28, square 28SP: 28, square (RA3 type only) 42P: 42, square 56P: 56, square 86P: 86 square [Encoder type] I: Incremental

Specified for connecting the

simple absolute unit <Power-supply voltage> 0: 24 VDC

<I/O flat cable length> 0: No cable 2: 2 m 3: 3 m 5: 5 m

<Input/output signal pattern> NP: NPN (Sink type) PN: PNP (Source type) DV: DeviceNet connection specification CC: CC-Link connection specification PR: PROFIBUS connection specification CN: CompoNet connection specification ML: MECHATROLINK connection

1.3 System Configuration

1.3.1 Internal Drive-Power Cutoff Relay Type (PCON-C/CF)

RS232C type <RCM-101-MW> USB type <RCM 101-USB>

PC software

(optional)

Standard teaching

<CON-T, RCM-T>

pendant

PERSONAL

COMPUTER

Input power supply 24 VDC

Supplied flat

cable

RCP2 actuator

External EMG switch

24 V 0 V

Host system <PLC>

24-VDC I/O

power supply

Caution: Connect one end of the EMG switch to the 24-V output of the input power supply and the

other end to the S1 terminal. Also short the S2 and EMG terminals using a jumper wire.

1.3.2 External Drive-Power Cutoff Relay Type (PCON-CG)

RS232C type <RCM-101-MW> USB type <RCM 101-USB>

PC software

(optional)

Standard teaching

PERSONAL

COMPUTER

pendant

<RCM-T>

Input power supply 24 VDC

Supplied flat

cable

RCP2 actuator

Motor drivepower cutoff circuit Safety relay Contactor

Host system <PLC>

24-VDC I/O

power supply

S1 S2 MPI MPO 24V 0V EMG-

1.4 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.

Check the content in the package

If you found any missing part or part specified for a different model, please contact your dealer.  Controller

PCON-C PCON-CG PCON-CF

 Operation manual

<Options>  Teaching pendant  PC software

RCM-T (standard) RC232C type <RCM-101-MW> RCM-E (simple) RC232 type <RCM-101-USB> RCM-P (data setting unit) (Software comes with connection cables.)

Installation

[1] Affix the actuator first, and then install the robot hand.  Refer to the operation manual for the

[2] Install the controller.  Chapter 3, “Installation”

Wiring/connection

 Wire the 24-V power supply.  Connect the grounding wire to ground.  Wire the emergency stop circuit and motor drive power supply.  Connect the motor cable and encoder cable.  Connect the I/O flat cable.

Turn on the power and check for alarms

Supply the 24-V power after confirming that the emergency stop circuit is not actuated. If the monitor LED [SV/ALM] on the front face of the controller illuminates for two seconds and then turns off, the controller is functioning properly. If [SV/ALM] illuminates in red, it means an alarm has generated. Connect a PC or teaching pendant to check the nature of the alarm, and remove the cause by referring to Chapter 10, “Troubleshooting.”

Set the PIO pattern/safety speed

Set the mode selector switch on the front face of the controller to the “MANU” side. On the PC screen or teaching pendant, set the MANU operating mode to [Teaching mode: Enable safety speed/Inhibit PIOs]. In this condition, set appropriate values in parameter No. 25 (PIO pattern selection) and parameter No. 35 (Safety speed). * The factory-set PIO pattern and safety speed are “standard type” and “100 mm/s or less,” respectively.

 Chapter 8, “Parameter Settings”

 Actuator  I/O flat cable

CB-PAC PIO* * *

 Motor cable

CB-RCP2-MA* * *

applicable actuator.

 Encoder cable

CB-RCP2-PA* * *

Turn on the servo

Confirm that the slider or rod is not contacting a mechanical end. If the slider/rod is contacting a mechanical end, move it away from the mechanical end. If the actuator is equipped with a brake, turn on the brake forced-release switch to forcibly release the brake before moving the actuator. The load may suddenly drop when the brake is released, so exercise due caution not to pinch your hand or damage the robot hand by the falling load.

Turn on the servo from the PC or teaching pendant. If the actuator enters a servo lock mode and the monitor LED [SV/ALM] on the front face of the controller illuminates in green, the controller is functioning properly.

Check the operation of the safety circuit

Confirm that the emergency stop circuit (or motor drive-power cutoff circuit) operates properly.  Chapter 4, “Wiring”

Set a target position

Perform home return first, and then set a target position in the “Position” field for each position in the position table. Determine a desired position by finely adjusting the load or robot hand. * Once a target position is set, all other fields (speed, acceleration/deceleration, positioning band, etc.)

will be automatically populated with their default values.  Chapter 6, “Position Table Settings”

* To ensure safety, it is recommended that the safety speed be enabled during initial movements.

To move the actuator at the actual speed set in the “Speed” field of the position table, change the MANU operating mode to [Teaching mode 2: Disable safety speed/Inhibit PIOs].

Trial operation and adjustment

Set the mode selector switch on the front panel of the controller to the “AUTO” side. Input a movement command from the PLC to perform positioning. If necessary, perform fine adjustments including the items specified below:  Vibration or noise may generate depending on the weight, material or shape of the load. If vibration or

noise is observed, lower the speed, acceleration and/or deceleration.

 To prevent contact with surrounding equipment or reduce the tact time, adjust the boundaries for each

zone output signal and also adjust the positioning band.

 Adjust the current-limiting value, judgment time and push speed to be used in push & hold operation.

Caution: Before changing any parameter, set the mode selector switch to the “MANU” side. Or,

keep the mode selector switch on the “AUTO” side and turn on the MODE input signal.

1.5 Warranty Period and Scope of Warranty

The 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

If an obvious manufacturing defect is found in the IAI product you have purchased during the above warranty period under an appropriate condition of use, IAI will repair the defect free of charge. Note, however, that the following items are excluded from the scope of warranty:

 Aging such as natural discoloration of coating  Wear of a consumable part due to use  Noise or other sensory deviation that doesn’t affect the mechanical function  Defect caused by inappropriate handling or use by the user  Defect caused by inappropriate or erroneous maintenance/inspection  Defect caused by use of a part other than IAI’s genuine part  Defect caused by an alteration or other change not approved by IAI or its agent  Defect caused by an act of God, accident, fire, etc.

Take note that the warranty specified herein covers only the delivered product. Any losses arising from a failure of the delivered product are excluded from the scope of warranty. Also note that the product must be brought to the factory for repair.

Please read carefully the above conditions of warranty.

2. Specifications

2.1 Basic Specifications

Specification item

(Internal Drive-Power Cutoff

PCON-C

Relay Type)

PCON-CG

(External Drive-Power

Cutoff Relay Type) Number of controlled axes 1 axis/unit Supply voltage

Power-source capacity

Actuator Rated Max. *2 Rated Max. *2 Rated Max. *3 20, 28P motor 0.4 A 0.4 A 35, 42, 56P motor 1.2 A

24 VDC 10%

2.0 A

1.2 A

2.0 A

86P motor 4.2 A 6.0 A Heat output 9.6 W 9.6 W 26.4 W Control method Weak field-magnet vector control Encoder resolution Incremental specification 800 Puls/rev

Positioning command Number of positioning points: 64 points (standard) to 512 points (maximum)

* The number of positioning points varies depending on the selected PIO

pattern.

Backup memory

Position data and parameters are saved in nonvolatile memory. Serial EEPROM can be rewritten approx. 100,000 times.

PIO interface 24-VDC I/O

LED indicators SV (green) --- Servo on, ALM (red) --- Alarm present

Serial communication RS485, 1 channel (conforming to the Modbus protocol) Electromagnetic-brake forced release function Cable length

NOM/BK RLS switch (front panel)

Actuator cable: 20 m or less

I/O flat cable: 5 m or less Insulation strength Environment

Surrounding air temperature Surrounding humidity Surrounding environment Storage temperature

500 VDC, 10 M

0 to 40C

85%RH or less (non-condensing)

Not subject to corrosive gases.

-10 to 65C

Storage humidity 90%RH or less (non-condensing)

Vibration resistance

10 to 57 Hz in XYZ directions / Pulsating amplitude: 0.035 mm (continuous),

0.075 mm (intermittent)

57 to 150 Hz in XYZ directions: 4.9 m/s

(continuous), 9.8 m/s2

Protection class IP20 Cooling method Natural air cooling Forced air cooling Weight 300 g or less 30 g or less 300 g or less External dimensions 35 W x 175.5 H x 68.1 D mm

*1 Rush current of around 5 to 12 times the rated current flows for approx. 1 to 2 msec

after the power is turned on. Take note that the value of rush current varies according to the impedance of the power-supply line.

*2 Excitation detection operation is performed after the power is turned on. The

maximum current flows during this operation (normally for 100 msec). Note, however, that approx. 6.0 A of current flows (for approx. 1 to 2 msec) if the motor drive source is cut off and then turned on again.

*3 Excitation detection operation is performed after the power is turned on. The

maximum current flows during this operation (normally for 100 msec).

Note, however, that approx. 10.0 A of current flows (for approx. 1 to 2 msec) if the motor drive source is cut off and then turned on again.

For the +24-V DC power supply, select a unit of the “peak load accommodation” specification or having a sufficient allowance with respect to the peak load. In particular, exercise caution when your system has a remote sensing function.

Caution: Position data, parameters, etc., are written to the EEPROM. Take note

that the EEPROM can be rewritten for up to approx. 100,000 times.

PCON-CF

(Internal Drive-Power

Cutoff Relay Type)

2.2 Name and Function of Each Part of the Controller

PIO connector

Connects the PLC and PIOs.

Mode selector switch

SIO connector

Connects the teaching pendant/PC.

The model name of the actuator to be connected is indicated here.

Motor connector

Connects the motor cable.

Power-supply terminal block

 Indication of PIO pattern number

If you have multiple systems and a different PIO pattern is used for each system, it is recommended that you specify an applicable PIO pattern number on each controller to prevent confusion.

 Explanation of input/output signal pattern

NPN --- Sink type PNP --- Source type

 Explanation of motor drive-power cutoff circuit

INT --- PCON-C/CF [Internal drive-power cutoff relay type] EXT --- PCON-CG [External drive-power cutoff relay type]

 Indication of model name of actuator to be connected

The type name, ball screw lead length and stroke of the applicable actuator are indicated. When connecting the cables, check this information to confirm that they are connected to the correct actuator.

Example of indication:

RA4C L: 5 mm ST: 200

 The actuator type is RA4C.  The ball screw lead length is 5 mm.  The stroke is 200 mm.

Status indicator LEDs

SV (green) --- The servo is on

A blinking green light indicates that the automatic servo-off mode is active.

LM (red) --- An alarm is present.

The motor drive-power cutoff circuit is indicated here.

The PIO pattern number is specified here.

The input/output signal pattern is indicated here.

Address switch

Encoder connector

Connects the encoder cable.

Brake release switch

 Explanation of each switch [1] Address switch

If multiple axes are used, the PC/teaching pendant must be plugged into/out of different connectors to communicate with different axes. To save the hassle, you can use link cables to connect all axes via SIO converters. Under this method, however, the PC/teaching pendant must be able to identify each axis by the number assigned to the axis. This switch is used to set this number. For details, refer to Chapter 9, “How to Connect a PC/Teaching Pendant to Multiple Axes.”

[2] Mode selector switch

This interlock switch is used to prevent unexpected movement or data rewrite as a result of duplicate operation in which a movement command is input from the PLC and operation using the PC/teaching pendant is performed at the same time. AUTO: Always set to the “AUTO” side during auto operation using PIO signals from the PLC. MANU: Always set to the “MANU” side during operation using the PC/teaching pendant.

[3] Brake release switch

When the actuator is equipped with a brake, this switch is used to forcibly release the brake. RLS: Forcibly release the brake NOR: Normal setting (The brake is released by the controller.)

 Warning: The load may suddenly drop when the brake is forcibly released, so exercise due caution

not to pinch your hand or damage the robot hand by the falling load.

 Explanation of power-supply terminal block [1] PCON-C/CF [Internal drive-power cutoff relay type]

Provide a contact output for the emergency-stop button on the teaching pendant.

S1, S2

* Whether or not a teaching pendant is connected is determined by an internal

circuit. If no teaching pendant is connected, the S1 and S2 terminals are closed.

Provide a contact for cutting off the motor drive power. MPI and MPO represent the

MPI, MPO

input side and output side of the motor power supply, respectively. (Short these terminals using a jumper wire if not used. The controller is shipped with MPI and MPO shorted.)

24V Positive side of the 24-VDC input power supply

0V Negative side of the 24-VDC input power supply

EMG- Emergency-stop input

[2] PCON-CG [External driver-power cutoff relay type]

Provide a contact output for the emergency-stop button on the teaching pendant.

S1, S2

* Whether or not a teaching pendant is connected is determined by an internal

circuit. If no teaching pendant is connected, the S1 and S2 terminals are closed.

Motor drive-power cutoff contacts conforming to safety category 1

MPI, MPO

MPI and MPO represent the input side and output side of the motor power supply, respectively. (Connect an external safety circuit.)

24V Positive side of the 24-VDC input power supply

0V Negative side of the 24-VDC input power supply

EMG- Emergency stop signal detection

2.3 External Dimensions

An external view and dimensions of the product are shown below.

5

(Mounting dimension)

3. Installation and Noise Elimination

Pay due attention to the installation environment of the controller.

3.1 Installation Environment

(1) When installing and wiring the controller, do not block the cooling ventilation holes. (Insufficient

ventilation will not only prevent the controller from demonstrating its full performance, but it may also cause breakdown.)

(2) Prevent foreign matter from entering the controller through the ventilation holes. Since the enclosure

of the controller is not dustproof or waterproof (oilproof), avoid using the controller in a place subject to significant dust, oil mist or splashes of cutting fluid.

(3) Do not expose the controller to direct sunlight or radiating heat from a large heat source such as a

heat treatment furnace.

(4) Use the controller in an environment free from corrosive or inflammable gases, under a temperature

of 0 to 40C and humidity of 85% or less (non-condensing). (5) Use the controller in an environment where it will not receive any external vibration or shock. (6) Prevent electrical noise from entering the controller or its cables.

3.2 Power Supply

The power supply specification is 24 VDC  10%. (Supply current: 2 A max.: C/CG, 6 A: CF)

3.3 Noise Elimination and Grounding

This section explains how to eliminate noise in the use of the controller.

(1) Wiring and power supply

[1] Provide a dedicated class D grounding using a wire with a size of 2.0 to 5.5 mm2 or larger.

Controller

Use a cable of a maximum possible size and keep the wiring length at a minimum.

Metal frame

Class D grounding Good Avoid this grounding method.

Other

equipment

Controller

Other

equipment

[2] Precautions regarding wiring method

Use a twisted cable for connection to the 24-VDC external power supply. Separate the controller cables from high-power lines such as a cable connecting to a power circuit. (Do not bundle together the controller cables with high-power lines or place them in the same cable duct.) When extending the supplied motor cable or encoder cable, consult IAI’s Technical Support.

(2) Noise sources and elimination

Among the numerous noise sources, solenoid valves, magnet switches and relays are of particular concern when building a system. Noise from these sources can be eliminated by implementing the measures specified below.

[1] AC solenoid valves, magnet switches and relays

Measure: Install a surge absorber in parallel with the coil.

[2] DC solenoid valves, magnet switches and relays

Measure: Install a diode in parallel with the coil. Determine the diode capacity in accordance with the

load capacity.

 Point

Install a surge absorber to each coil over a minimum wiring length. Installing a surge absorber to the terminal block or other part will be less effective because of a longer distance from the coil.

In a DC circuit, connecting a diode in reverse polarity will damage the diode, internal parts of the controller and/or DC power supply, so exercise due caution.

3.4 Heat Radiation and Installation

Design the control panel size, controller layout and cooling method in such a way that the temperature around the controller will not exceed 40C.

Install the controller vertically on a wall, as shown below. Since cooling is provided by way of natural convection, always observe this installation direction and provide a minimum clearance of 50 mm above and below the controller to ensure sufficient natural airflows.

When installing multiple controllers side by side, providing a ventilation fan or fans above the controllers will help maintain a uniform temperature around the controllers.

Keep the front panel of the controller away from the wall (enclosure) by at least 95 mm.

Regardless of whether your system consists of a single controller or multiple controllers, provide sufficient clearances around each controller so that it can be installed/removed easily.

Fan

50 mm or more

95 mm

or more

Airflow

4. Wiring

4.1 Internal Drive-Power Cutoff Relay Type (PCON-C/CF)

4.1.1 External Connection Diagram

An example of standard wiring is shown below. (Note) The encoder cable shown in the example is the standard cable.

As for the robot cable, refer to 4.4.1 as the color of the cable is different.

Connected to teaching pendant or PC

External EMG switch

Terminal block

Input power supply 24 VDC

I/O flat cable

0 V (NPN specification) 24 V (PNP specification)

24 V (NPN specification) 0 V (PNP specification)

24-VDC power for input/output signals

For details on I/O signal connection, refer to 4.3, “Connecting the I/O Cables.”

Load

Input

Output

Controller

detection circuit

Connection

Motor relay cable

Orange

Gray

White

Yellow

Pink

Yellow (Green)

Encoder relay cable

Yellow

Blue

Orange

Pink

Purple

Green

Brown

Gray

Red

Brake release switch

Tighten together with the mounting screw.

Actuator

Motor

Encoder

Holding brake

4.1.2 Wiring the Power Supply/Emergency-Stop Switch

(1) Wiring the power supply

Input power supply 24 VDC

(2 A max. per controller)

24V

0V FG

To connect multiple controllers, provide a relay terminal block. Use a power cable satisfying the following specifications:

Item Specification

Applicable wire length

Single wire: 1.0 / Stranded: 0.8 mm

Stripped wire length 10 mm Temperature rating of

insulated sheath

60C or above

* Use a flathead screwdriver with a blade tip of approx. 2.6 mm to push in the wire.

S1 S2 MPI MPO 24V 0V EMG-

, AWG size 18, (copper wire)

(2) Wiring the emergency-stop switch

In many cases multiple controllers are used in a single system. To provide an emergency-stop function for the entire system, the controller circuit is designed in such a way that a single EMG switch is able to actuate an emergency stop in all connected controllers.

[Internal emergency-stop circuit]

Input power supply (2 A max.)

24V

EMG signal

MPI

MPO

24V

EMG-

(Note) The current consumption of the internal relay is 10 mA or less.

(Reference) Cutoff voltage Cutoff current EMG switch on teaching pendant 30 VDC 3 A

[Example of recommended circuit]

24V

External EMG reset switch

External EMG circuit

(Note) To cut off the motor drive power supply in conformance with safety category 2, connect 24V to the

EMG terminal and a contactor or other contact device to the MPI/MPO terminals. (Refer to 4.2.3; rush current: 8 A.)

MP1

MPO

24V

EMG-

Teaching pendant

Controller power supply

PCON-C controller

EMG switch on

teaching pendant

(3A)

Connection detection circuit

Relay

PCON-C controller

Connection detection circuit

Relay

Motor power supply

S2S1

Coil current:

0.1 A or less

Representative connection examples are explained below.  Connecting the teaching pendant directly to the controller

[1] Connecting multiple controllers (8 units or less) using a single power supply  Short the MPI and MPO terminals using a jumper wire. (The controller is shipped with these terminals

shorted.)

 Connect one end of the EMG signal to the 24-V output of the input power supply and the other end to

the S1 terminal. Then, provide connections by sequentially connecting the S2 terminal of controller 1 to the S1 terminal of controller 2, the S2 terminal of controller 2 to the S1 terminal of controller 3, and so on, and connect the S2 terminal on the last controller to the EMG terminals on all controllers. Use a relay terminal block for connection to the EMG terminals. (Note) Do not connect two or more wires to one terminal.

24V

EMG signal

MPI

MPO 24V

EMG-

MPI

MPO 24V

EMG-

MPI

MPO 24V

EMG-

[Controller 1]

Teaching pendant

Connection

detection circuit

Relay

[Controller 2]

Connection

detection circuit

Relay

[Controller 3]

Connection

detection circuit

Relay

[Controller 4]

MPI

MPO 24V

EMG-

Connection

detection circuit

Relay

[2] Using a power supply other than the input power supply (Note) Use an auxiliary relay with a coil current of 0.1 A or less and connect a diode for coil surge

absorption.

control

EMG signal

MPI

MPO 24V

EMG-

MPI

MPO 24V

EMG-

[Controller 1]

Teaching pendant

Connection

detection circuit

Relay

[Controller 2]

Teaching pendant

Connection

detection circuit

Relay

[Controller 3]

S2S1

MPI

MPO 24V

Connection

detection circuit

EMG-

Relay

[3] Enabling the EMG switch on the teaching pendant for the connected axis or axes only

24V

EMG signal

Teaching pendant

MPI

MPO

24V

EMG-

Teaching pendant

MPI

MPO 24V

EMG-

Teaching pendant

[Controller 1]

Connection

detection circuit

Relay

[Controller 2]

Connection

detection circuit

Relay

[Controller 3]

MPI

MPO 24V

EMG-

detection circuit

Connection

Relay

 Connecting the teaching pendant to a SIO converter

Configure the contact circuit for the EMG switch on the teaching pendant using EMG1/EMG2 on the

power/emergency-stop terminal block on the SIO converter.

(S1/S2 on the controller’s terminal block are not used.)

24V 0V

SIO converter

EMG signal

EMG2 EMG1

Teaching pendant

OFF

Port switch

MPI

MPO

24V

EMG-

MPI

MPO 24V

EMG-

[Controller 1]

Relay

[Controller 2]

Relay

[Controller 3]

MPI

MPO 24V

EMG-

Relay

4.2 External Drive-Power Cutoff Relay Type (PCON-CG)

4.2.1 External Connection Diagram

An example of standard wiring is shown below. (Note) The encoder cable shown in the example is the standard cable.

As for the robot cable, refer to 4.4.1 as the color of the cable is different.

Connected to teaching pendant or PC

Input power supply 24 VDC

Motor drivepower cutoff circuit

Terminal block

I/O flat cable

0 V (NPN specification) 24 V (PNP specification)

24 V (NPN specification) 0 V (PNP specification)

24-VDC power for input/output signals

For details on I/O signal connection, refer to

4.3, “Connecting the I/O Cables.”

Input

Output

Controller

Connection

Motor relay cable

Orange

Gray

White

Yellow

Pink

Yellow (Green)

Encoder relay cable

Yellow

Blue

Orange

Pink

Purple

Green

Brown

Gray

Red

Brake release switch

Actuator

Motor

Encoder

Holding brake

4.2.2 Wiring the Power Supply/Emergency-Stop Switch

(1) Wiring the power supply

Input power supply 24 VDC

(2 A max. per controller)

24V

0V FG

To connect multiple controllers, provide a relay terminal block. Use a power cable satisfying the following specifications:

Item Specification

Applicable wire length

Single wire: 1.0 / Stranded: 0.8 mm

Stripped wire length 10 mm Temperature rating of

insulated sheath

60C or above

* Use a flathead screwdriver with a blade tip of approx. 2.6 mm to push in the wire.

S1 S2 MPI MPO 24V 0V EMG-

, AWG size 18, (copper wire)

(2) Wiring the motor power cutoff relay

Explained below is a safety circuit conforming to safety category 2. The user is responsible for implementing additional safety measures in the actual circuit configuration, such as providing double contactor contacts to prevent fusing.

The circuit illustrated below is for reference purposes only.  The input side of the motor drive power supply is connected to the MPI terminal, while the output side

is connected to the MPO terminal. Connect a contactor or other contact device to these terminals. (Note) The rush current must be 8 A or less. The rated current is 2 A.  The contact for the EMG switch on the teaching pendant is provided by the S1/S2 terminals. (Note) When connecting the teaching pendant to a SIO converter, the contact for the EMG switch on the

teaching pendant is provided by the EMG1/EMG2 terminals on the SIO converter.

[Example of basic circuit]

24V

External EMG

reset switch

External EMG

circuit

Coil current: 0.1 A or less

(Rush-in current: 8 A, rated current: 2 A)

MPI

MPO

(MAX. 2A)

24V

EMG-

Teaching pendant

EMG switch

(3A)

Connection

detection circuit

Motor power

supply Controller power supply

PCON-CG controller

[Connection example of a multiple-axis configuration]

Input power supply

24V

Connect to 24-V terminal Connect to 0-V terminal

[Controller 1] [Controller 2] [Controller 3]

MPI

MPO

24V

EMG-

MPI

MPO

24V

EMG-

Contactor

EMG signal

Phoenix contact (PSR-SCP-24UC-/ESA2/4X1/1X2/B)

Safety relay unit

MPI

MPO

24V

EMG-

External reset switch

4.3 Connecting the I/O Cables

 PIO pattern 0 [Standard Type]

Host system <PLC> end

+24 [V]

Command position 1

Command position 2

Command position 4

Command position 8

Command position 16

Command position 32

Output side

Brake release

Operating mode

Home return

Pause

Start

Alarm reset

Servo ON

Completed position 1

Completed position 2

Completed position 4

Completed position 8

Completed position 16

Completed position 32

Moving

Zone output

Input side

Position zone output

Operating mode status

Home return completion

Position complete

Ready

Emergency stop

Alarm

0 [V]

Upper stage

Lower stage

Brown 1

Red 1

Orange 1

Yellow 1

Green 1

Blue 1

Purple 1

Gray 1

White 1

Black 1

Brown 2

Red 2

Orange 2

Yellow 2

Green 2

Blue 2

Purple 2

Gray 2

White 2

Black 2

Brown 3

Red 3

Orange 3

Yellow 3

Green 3

Blue 3

Purple 3

Gray 3

White 3

Black 3

Brown 4

Red 4

Orange 4

Yellow 4

Green 4

Blue 4

Purple 4

Gray 4

White 4

Black 4

Controller end

(signal abbreviation)

PIO

LOAD/TRQS

(Note) *STP, *ALM and *EMGS are based on the negative logic.

 PIO pattern 1 [Teaching Type]

Host system <PLC> end

+24 [V]

Command position 1

Command position 2

Command position 4

Command position 8

Command position 16

Command position 32

Operation mode

Manual operation

switching

Output side

Operating mode

Completed position 1

Completed position 2

Completed position 4

Completed position 8

Completed position 16

Completed position 32

Current operation mode

Input side

Position zone output

Operating mode status

Home return completion

Position complete/write

Emergency stop

Jog+

Jog-

Home return

Pause

Start/currentposition write

Alarm reset

Servo ON

Moving

completion

Ready

Alarm

0 [V]

Upper stage

Lower stage

Brown 1

Red 1

Orange 1

Yellow 1

Green 1

Blue 1

Purple 1

Gray 1

White 1

Black 1

Brown 2

Red 2

Orange 2

Yellow 2

Green 2

Blue 2

Purple 2

Gray 2

White 2

Black 2

Brown 3

Red 3

Orange 3

Yellow 3

Green 3

Blue 3

Purple 3

Gray 3

White 3

Black 3

Brown 4

Red 4

Orange 4

Yellow 4

Green 4

Blue 4

Purple 4

Gray 4

White 4

Black 4

Controller end

PIO

(signal abbreviation)

(Note) *STP, *ALM and *EMGS are based on the negative logic.

 PIO pattern 2 [256-piont mode]

Host system <PLC> end

Upper stage

+24 [V]

Command position 1

Command position 2

Command position 4

Command position 8

Command position 16

Command position 32

Command position 64

Command position 128

Pause

Start

Ready

Alarm

0 [V]

Lower stage

Output side

Brake release

Operating mode

Home return

Alarm reset

Servo ON

Completed position 1

Completed position 2

Completed position 4

Completed position 8

Completed position 16

Completed position 32

Completed position 64

Completed position 128

Input side

Position zone output

Operating mode status

Home return completion

Position complete

Emergency stop

Brown 1

Red 1

Orange 1

Yellow 1

Green 1

Blue 1

Purple 1

Gray 1

White 1

Black 1

Brown 2

Red 2

Orange 2

Yellow 2

Green 2

Blue 2

Purple 2

Gray 2

White 2

Black 2

Brown 3

Red 3

Orange 3

Yellow 3

Green 3

Blue 3

Purple 3

Gray 3

White 3

Black 3

Brown 4

Red 4

Orange 4

Yellow 4

Green 4

Blue 4

Purple 4

Gray 4

White 4

Black 4

Controller end PIO (signal abbreviation)

LOAD/TRQS

(Note) *STP, *ALM and *EMGS are based on the negative logic.

 PIO pattern 3 [512-piont mode]

Host system <PLC> end

Upper stage

Command position 1

Command position 2

Command position 4

Command position 8

Command position 16

Command position 32

Command position 64

Command position 128

Command position 256

Output side

Brake release

Operating mode

Home return

Pause

Start

Alarm reset

Servo ON

Completed position 1

Completed position 2

Completed position 4

Completed position 8

Completed position 16

Completed position 32

Completed position 64

Completed position 128

Input side

Completed position 256

Operating mode status

Home return completion

Position complete

Emergency stop

Ready

Alarm

Lower stage

Brown 1

Red 1

Orange 1

Yellow 1

Green 1

Blue 1

Purple 1

Gray 1

White 1

Black 1

Brown 2

Red 2

Orange 2

Yellow 2

Green 2

Blue 2

Purple 2

Gray 2

White 2

Black 2

Brown 3

Red 3

Orange 3

Yellow 3

Green 3

Blue 3

Purple 3

Gray 3

White 3

Black 3

Brown 4

Red 4

Orange 4

Yellow 4

Green 4

Blue 4

Purple 4

Gray 4

White 4

Black 4

Controller end

(signal abbreviation)

PIO

LOAD/TRQS

(Note) *STP, *ALM and *EMGS are based on the negative logic.

 PIO pattern 4 [Solenoid valve mode 1]

Host system <PLC> end

Upper stage

Direct position command 0

Direct position command 1

Direct position command 2

Direct position command 3

Direct position command 4

Direct position command 5

Direct position command 6

Output side

Input side

Brake release

Operating mode

Home return

Pause

Alarm reset

Servo ON

Movement complete 0

Movement complete 1

Movement complete 2

Movement complete 3

Movement complete 4

Movement complete 5

Movement complete 6

Zone output

Position zone output

Operating mode status

Home return completion

Position complete

Ready

Emergency stop

Alarm

Lower stage

Brown 1

Red 1

Orange 1

Yellow 1

Green 1

Blue 1

Purple 1

Gray 1

White 1

Black 1

Brown 2

Red 2

Orange 2

Yellow 2

Green 2

Blue 2

Purple 2

Gray 2

White 2

Black 2

Brown 3

Red 3

Orange 3

Yellow 3

Green 3

Blue 3

Purple 3

Gray 3

White 3

Black 3

Brown 4

Red 4

Orange 4

Yellow 4

Green 4

Blue 4

Purple 4

Gray 4

White 4

Black 4

Controller end

(signal abbreviation)

PIO

LOAD/TRQS

(Note) *STP, *ALM and *EMGS are based on the negative logic.

 PIO pattern 5 [Solenoid valve mode 2]

Host system <PLC> end

Upper stage

Rear end move

Front end move

Intermediate point move

detected

Ready

Alarm

Lower stage

Output side

Brake release

Operating mode

Alarm reset

Servo ON

Rear end detected

Front end detected

Intermediate point

Zone output

Input side

Position zone output

Operating mode status

Home return completion

Emergency stop

Brown 1

Red 1

Orange 1

Yellow 1

Green 1

Blue 1

Purple 1

Gray 1

White 1

Black 1

Brown 2

Red 2

Orange 2

Yellow 2

Green 2

Blue 2

Purple 2

Gray 2

White 2

Black 2

Brown 3

Red 3

Orange 3

Yellow 3

Green 3

Blue 3

Purple 3

Gray 3

White 3

Black 3

Brown 4

Red 4

Orange 4

Yellow 4

Green 4

Blue 4

Purple 4

Gray 4

White 4

Black 4

Controller end

PIO

(signal abbreviation)

(Note) *STP, *ALM and *EMGS are based on the negative logic.

Bulls-Eye Terminal Block Kit provides mating connector & break-out board with wiring diagram

Caution: When performing a continuity check of the flat cable, pay due attention not to expand the female

pins in the connector. It may cause contact failure and disable normal operation of the controller.

Black 4

Brown 3

Black 2

Brown 1

Lower stage

Upper stage

20A

20B

Bulls-Eye Terminal Block Kit - P,A,S-Con (-CF) Controller I/O Wiring For TB with/without LED's

Lower

P I/O Pattern Setting Definitions From Parameter Setting # 25

Upper

Wire Color 0=Standard 1=Teaching Mode 2=256 Point Mode 3=512 Point Mode 4=7-Point Mode 5=3-Point Mode

1 Brown-1 24 Volt 24 Volt 24 Volt 24 Volt 24 Volt 24 Volt 24v 24v

2 Red-1 24 Volt 24 Volt 24 Volt 24 Volt 24 Volt 24 Volt 7mA/pt. 7mA/pt.

3 Orange-1 DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT

4 Yellow-1 DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT

5 Green-1 PC1 PC1 PC1 PC1 Start to Pt.0 Start to Pt.0 24V 0V/Com

6 Blue-1 PC2 PC2 PC2 PC2 Start to Pt.1 Start to Pt.1 24V 0V/Com

7 Purple-1 PC4 PC4 PC4 PC4 Start to Pt.2 Start to Pt.2 24V 0V/Com

8 Grey-1 PC8 PC8 PN8 PN8 Start to Pt.3 24V 0V/Com

9 White-1 PC16 PC16 PC16 PC16 Start to Pt.4 24V 0V/Com

10 Black-1 PC32 PC32 PC32 PC32 Start to Pt.5 24V 0V/Com

11 Brown-2 Mode PC64 PC64 Start to Pt.6 24V 0V/Com

12 Red-2 Jog On/Off PC128 PC128 24V 0V/Com

13 Orange-2 Jog + PC256 24V 0V/Com

14 Yellow-2 Brake Release Jog - Brake Release Brake Release Brake Release Brake Release 24V 0V/Com

15 Green-2 Auto / Manual (RMOD) Auto / Manual (RMOD) Auto / Manual (RMOD) Auto / Manual (RMOD) Auto / Manual (RMOD) Auto / Manual (RMOD) 24V 0V/Com

16 Blue-2 Home Home Home Home Home 24V 0V/Com

17 Purple-2 **Stop / Pause **Stop / Pause **Stop / Pause **Stop / Pause **Stop / Pause 24V 0V/Com

18 Grey-2 Cycle Start Cycle Start / Pos.Write Cycle Start Cycle Start 24V 0V/Com

19 White-2 Reset Reset Reset Reset Reset Reset 24V 0V/Com

20 Black-2 **Servo On **Servo On **Servo On **Servo On **Servo On **Servo On 24V 0V/Com

21 Brown-3 PM1 PM1 PM1 PM1 Pos. End-Pt.0 LS0 0V/Com 24v O

22 Red-3 PM2 PM2 PM2 PM2 Pos. End-Pt.1 LS1 0V/Com 24v

23 Orange-3 PM4 PM4 PM4 PM4 Pos. End-Pt.2 LS2 0V/Com 24v U

24 Yellow-3 PN8 PN8 PN8 PN8 Pos. End-Pt.3 0V/Com 24v

25 Green-3 PM16 PM16 PM16 PM16 Pos. End-Pt.4 0V/Com 24v T

26 Blue-3 PM32 PM32 PM32 PM32 Pos. End-Pt.5 0V/Com 24v

27 Purple-3 Move Move PM64 PM64 Pos. End-Pt.6 0V/Com 24v P

28 Grey-3 Zone 1 Mode Confirm PM128 PM128 Zone 1 Zone 1 0V/Com 24v

29 White-3 Pos. Zone Pos. Zone Pos. Zone PM256 Pos. Zone Pos. Zone 0V/Com 24v U

30 Black-3 Auto / Manual Status Auto / Manual Status Auto / Manual Status Auto / Manual Status Auto / Manual Status Auto / Manual Status 0V/Com 24v

31 Brown-4 Home Status Home Status Home Status Home Status Home Status Home Status 0V/Com 24v T

32 Red-4 Pos. End Pos. End / Write Done Pos. End Pos. End Pos. End 0V/Com 24v

33 Orange-4 Servo On Servo On Servo On Servo On Servo On Servo On 0V/Com 24v S

34 Yellow-4 *Emergency *Emergency *Emergency *Emergency *Emergency *Emergency 0V/Com 24v

35 Green-4 *Alarm *Alarm *Alarm *Alarm *Alarm *Alarm 0V/Com 24v

36 Blue-4 ***Load/TRQ DO NOT CONNECT ***Load/TRQ ***Load/TRQ ***Load/TRQ DO NOT CONNECT

37 Purple-4 DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT

38 Grey-4 DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT DO NOT CONNECT

39 White-4 0 Volt 0 Volt 0 Volt 0 Volt 0 Volt 0 Volt 0 Volt 0 Volt

40 Black-4 0 Volt 0 Volt 0 Volt 0 Volt 0 Volt 0 Volt 0 Volt 0 Volt

- Connection For LED's PnP Only 0 Volt N/A

Notes

Terminal Block Dimensions: 115 x 80 x 60, Din Rail Mount

PNP Wiring

NPN Wiring

Be sure to set the desired PIO Pattern in the parametes before wiring and programming

* These

outputs are normally on.

** This input must be turned on for normal operation unless deactivated from parameter setting

*** This is only available on the PCON-CF Controller

For PnP Type I/O,

24 volts turns on

inputs, outputs give

out 24 volts

For NpN Type I/O,

0 volts turns on

inputs, outputs give

out 0 volts

4.4 Connecting the Actuator

4.4.1 Connecting the PCON-C/CG and Actuator

Use dedicated relay cables to wire the controller and actuator. (1) RCP2 motor cable

Model: CB-RCP2-MA

Pin layout

Housing: 1-1318119-3 (AMP) Contact: 1318107-1

(2) RCP2 encoder cable/encoder robot cable

Model for standard cable: CB-RCP2-PB Model for robot cable: CB-RCP2-PB-RB (optional)

Pin layout

( indicates the cable length L. Example. 080 = 8 m)

Cable model marking

Pin No.

(Front view)

Controller end

Signal name

Cable color

Orange

Yellow

Yellow (Green)

Gray

White

Pink

( indicates the cable length L. Example. 080 = 8 m)

(Front view) Cable model marking

Controller end

Signal

Pin No.

name

Housing: PHDR-16VS (J.S.T. Mfg.) Contact: SPHD-001T-P0.5

Cable color

Standard cable

Blue (Red 1)

White

Red

Gray

Brown

Green

Purple

Pink

Yellow

Orange

Blue

Ground

Robot cable

Orange (Black 2)

Orange (Red 2)

Orange (Black 1)

Orange (Red 1)

Light gray (Black 1)

Light gray (Red 1)

White (Black 1)

White (Red 1)

Yelloow (Black 1)

Pink (Red 1)

Pink (Black 1)

Ground

Description

Home check

sensor

Brake power

Encoder phase

A signal

Encoder phase

B signal

Encoder control signal

Encoder powe

Shield

Pin layout

(Front view)

Actuator end

Pin No.

Housing: SLP-06V (J.S.T. Mfg.) Socket contact: BSF-21T-P1.4

Pin layout

(Front view)

Actuator end

Signal

Pin No.

name

Housing: XMP-18V (J.S.T. Mfg.) Contact: BXA-001T-P0.6 Retainer: XMS-09V

)

(3) RCP3 motor/encoder integrated cable

Model: CB-PCS-MPA

( indicates the cable length L. Example. 080 = 8 m)

(Front view)

Controller end

Housing: D-2100D 1-1318119-3 (Hirose) Contact: D-2 1318105-1

Pin No.

Signal

name

Pin No.

Signal

name

Cable name

Black

White

Red

Green

Yellow

Brown

Description

Home check

sensor

Cable name

Brake power

Encoder phase A

signal

Encoder phase B

signal

Encoder control signal

Encoder power

Orange (blue dots)

Orange (continuous red dots Orange (continuous blue dots Gray (continuous red dots Gray (continuous blue dots

Housing: PHDR-16VS (J.S.T. Mfg.) Contact: SPHD-001T-P0.5

Shield

Pink (red dots)

Pink (blue dots)

White (red dots)

White (blue dots)

Pink (red dots)

Gray (red dots)

Gray (blue dots)

Shield

Cable model marking

Housing: D-1100D1-1827863-1 (AMP) Contact: D-1 1827570-2

Actuator end

Pin No.

4.4.2 Connecting the PCON-CF and Actuator

Use dedicated relay cables to wire the controller and actuator. (1) RCP2 motor cable

Model: CB-RCP2-MA

( indicates the cable length L. Example. 080 = 8 m)

Pin layout

Housing: 1-1318119-3 (AMP) Contact: 1318107-1

Pin No.

(Front view)

Controller end

Signal name

Cable color

Orange

Gray

White

Yellow

Pink

Yellow

(Green)

(2) RCP2 encoder cable/encoder robot cable (dedicated cable for PCON-CF)

Model for standard cable: CB-RFA-PA Model for robot cable: CB-RF-PA -RB (optional)

( indicates the cable length L. Example. 080 = 8 m)

Pin layout

(Front view)

Controller end

Signal

Pin No.

name

Cable color

Standard cable

Housing: PHDR-16VS (J.S.T. Mfg.) Contact: SPHD-001T-P0.5

Red

Gray

Brown

Green

Purple

Pink

Yellow

Blue

Orange

Ground

Cable model marking

Description

Brake power

Encoder phase

A signal

Encoder phase

B signal

Encoder control signal

Encoder powe

Robot cable

Purple

White

Blue

White

Yellow

White

Green

White

Red

Ground

Housing: SLP-06V (J.S.T. Mfg.) Socket contact: BSF-21T-P1.4

Shield

Housing: XMP-18V (J.S.T. Mfg.) Contact: BXA-001T-P0.6 Retainer: XMS-09V

Pin No.

(Front view)

Actuator end

Pin No.

(Front view)

Actuator end

Pin layout

Signal name

Pin layout

4.5 Connecting the Communication Cable

Connect the communication cable to the SIO connector.

RS485 conversion adapter end

Brown

Yellow

Red

Orange

Blue

Green

Signal name

SGA

GND

SGB

GND

Pin No.

Cable color

Shorting wire UL1004AWG28 (black)

CB-RCA-SIO***

Pin No.

Signal name

SGA

SGB

EMGS

EMGA

24V

GND

EMGB

Controller end

Cable color

Centered

Orange

Brown/Green

Black

Red/Blue

Black

ShieldedShielded, not connected

Pin assignments of the

cable-end connector





5. I/O Signal Control and Signal Functions

5.1 Interface Circuit

The standard interface specification of the controller is NPN, but the PNP specification is also available as an option. To prevent confusion during wiring, the NPN and PNP specifications use the same power line configuration. Accordingly, there is no need to reverse the power signal assignments for a PNP controller.

5.1.1 External Input Specifications

Item Specification

Number of input points 16 points

Input voltage

Input current 5 mA/point

Operating voltage

Leak current 1 mA or less/point

Insulation method Photocoupler

Internal circuit configuration

[NPN specification]

External power supply

+24V

Each input

[PNP specification]

External power supply

+24V

Each input

24 VDC  10%

ON voltage: Min. 18 V (3.5 mA)

OFF voltage: Max. 6 V (1 mA)

Controller

P24V

R=680

R=5.6 k

Controller

R=68

R=5.6 k

Internal circuit

R =22 k

C=0.1 F

Internal circuit

R=22 k

C=0.1

5.1.2 External Output Specifications

Item Specification

Number of output points 16 points

Rated load voltage 24 VDC

Maximum current 50 mA/point

Residual voltage 2V or less

Insulation method Photocoupler

Internal circuit configuration

[NPN specification]

[PNP specification]

Internal circuit

Controller

Each output

P24V

Load

External power

supply

+24V

External power

supply

+24V

5.2 PIO Patterns and Signal Assignments

Parameter No.

25 setting

Positioning mode (Standard type) A basic type supporting 64 positioning points and two zone outputs. * How to set zone boundaries within which to output a zone signal: Zone boundaries are set using parameter Nos. 1 and 2 for one zone output, and in the position table for another zone output.

Teaching mode (Teaching type) In this type, 64 positioning points and one zone output (boundaries are set in the position table) are supported. In addition to the normal positioning mode, the user can also select the teaching mode in which the actuator can be jogged via I/Os and the current actuator position can be written to a specified position. (Note) Positions can be rewritten by approximately 100,000 times.

256-point mode (256-point positioning type) The number of positioning points is increased to 256, so only one zone output is available (boundaries are set in the position table).

512-point mod (512-point positioning) The number of positioning points is increased to 512, so no zone output is available.

Solenoid valve mode 1 (7-point type) The number of positioning points is limited to seven to offer separate direct command inputs and movement complete outputs. PLC ladder sequence circuits can be designed easily.

Solenoid valve mode 2 (3-point type) Use of the controller as an air cylinder is assumed in this type. Movement complete output signals function differently in this type, compared to the 7point type. Specifically, the signal functions not only to “indicate movement complete,” but also to “detect a position” in the same manner as auto-switches of an air cylinder. Push & hold operation cannot be performed.

Quick reference table for functions available under each PIO pattern (: Available, X: Not available)

Number of

No. 25

positioning

points

0 64 points 1 64 points x 2 256 points 3 512 points 4 7 points 5 3 points

Brake

release

 

      

Input signals Output signals

Home

return

  

x x x

(Note) For “Zone” and “Position zone,” different methods are used to set boundaries defining the range

within which the zone signal will turn ON. “Zone” is set by parameter Nos. 1 and 2, and thus its setting will become effective after home return is completed. “Position zone” is set in the “Zone+” and “Zone-“ fields for each position number in the position table, and thus its setting will become effective after a movement command is input.

Feature of PIO pattern

Current-

Jog

x x

x x x x x x x x x x

position

write

Zone

  

   

Position

zone

  

Ready

x x

5.2.1 Explanation of Signal Names

The following explains the signal names, and gives a function overview of each signal. In the explanation of operation timings provided in a later section, each signal is referenced by its selfexplanatory name for clarity. If necessary, however, such as when marker tubes are inserted as a termination of the flat cable, use the signal abbreviations.

 PIO pattern = 0: Positioning mode [Standard type]

Category Signal name

Command position number

Input

Brake release BKRL

Operating mode RMDO Home return HOME *Pause *STP Start CSTR Alarm reset RES

Servo ON SON

Completed position number

Moving MOVE

Zone ZONE1

Position zone PZONE

Output

Operating mode status RMDS

Home return completion

Position complete PEND

Ready SV

*Emergency stop *EMGS

*Alarm *ALM

Load output judgment status

Torque level status TRQS

Signal

abbreviation PC1 PC2 PC4 PC8 PC16 PC32

PM1 PM2 PM4 PM8 PM16 PM32

HEND

LOAD

Function overview

The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.

This signal is used on an actuator equipped with a brake to forcibly release the brake. This signal switches the operating mode between AUTO and MANU.

Home return operation is started at a rise edge of this signal. ON: Actuator can be moved, OFF: Actuator decelerates to a stop The actuator will start moving at a rise edge of this signal. An alarm is reset at a rise edge of this signal. The servo remains ON while this signal is ON.

The servo remains OFF while this signal is OFF.

The relevant position number is output when positioning has completed. The signal will turn OFF when the next start signal is received. It is used by the PLC to check if the commanded position has definitively been reached, and also to provide a position interlock, etc.

This signal will remain ON while the actuator is moving, and OFF while the actuator is standing still. It is used to determine whether the actuator is moving or paused. This signal becomes effective after home return. It will turn ON when the current actuator position enters the range set by the parameters and remain ON until the actuator exits the range. This signal becomes effective after a position movement command is input. It will turn ON when the current actuator position enters the range specified in the position table and remain ON until the actuator exits the range. This signal will remain OFF during the AUTO mode, and ON during the MANU mode.

This signal is OFF immediately after the power is input, and turns ON when home return has completed.

This signal turns ON when the target position was reached and the actuator has entered the specified in-position range. It is used to determine whether positioning has completed. This signal is always output once the servo is turned ON and the controller is ready to operate. When this signal is OFF, it means that an emergency stop is being actuated. This signal remains ON in normal conditions of use and turns OFF when an alarm generates. This signal will turn ON when the command torque exceeds the threshold while the actuator is inside the check range. Note) Dedicated output signal for the PCON-CF This signal will turn ON when the motor current reaches the threshold. Note) Dedicated output signal for the PCON-CF

 PIO pattern = 1: Teaching mode [Teaching type]

Category Signal name

Command position number

Operation mode MODE Mode selection (ON: Teaching mode, OFF: Normal mode) Jog/inching switching JISL OFF: Jog, ON: Inching

+jog/inching movement JOG+

-jog/inching movement JOG-

Input

Operating mode RMDO This signal switches the operating mode between AUTO

Signal

abbreviation PC1 PC2 PC4 PC8 PC16 PC32

The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.

The actuator will start jogging or inching in the positive direction at an ON edge of this signal. The actuator will start jogging or inching in the negative direction at an ON edge of this signal.

and MANU.

Home return HOME Home return operation is started at a rise edge of this signal.

ON: Actuator can be moved, OFF: Actuator decelerates to a stop

When this signal has remained ON for 20 msec or longer, the current position will be stored under the position number selected by PC1 to PC32.

The servo remains ON while this signal is ON. The servo remains OFF while this signal is OFF.

This signal will remain ON while the actuator is moving, and OFF while the actuator is standing still. It is used to determine whether the actuator is moving or paused.

This signal becomes effective after a position movement command is input. It will turn ON when the current actuator position enters the range specified in the position table and remain ON until the actuator exits the range. This signal will remain OFF during the AUTO mode, and ON during the MANU mode. This signal is OFF immediately after the power is input, and turns ON when home return has completed. This signal turns ON when the target position was reached and the actuator has entered the specified in-position range. It is used to determine whether positioning has completed. This signal is output upon completion of writing to the nonvolatile memory in response to a current-position write command (PWRT). This signal is always output once the servo is turned ON and the controller is ready to operate.

This signal remains ON in normal conditions of use and turns OFF when an alarm generates.

Output

*Pause *STP

Start CSTR The actuator will start moving at a rise edge of this signal.

Current-position write PWRT

Alarm reset RES An alarm is reset at a rise edge of this signal.

Servo ON SON

PM1 PM2

Completed position number

Moving MOVE

Mode status MODES ON: Teaching mode, OFF: Normal mode

Position zone PZONE

Operating mode status RMDS

Home return completion

Position complete PEND

Write completion WEND

Ready SV

*Emergency stop *EMGS OFF: Emergency stop has been actuated

*Alarm *ALM

PM4 PM8 PM16 PM32

HEND

Function overview

 PIO pattern = 2: 256-point mode [256-point type]

Category Signal name

Command position number

Input

Output

Brake release BKRL

Operating mode RMDO

Home return HOME Home return operation is started at a rise edge of this signal.

*Pause *STP

Start CSTR The actuator will start moving at a rise edge of this signal. Alarm reset RES An alarm is reset at a rise edge of this signal.

Servo ON SON

Completed position number

Position zone PZONE

Operating mode status RMDS

Home return completion

Position complete PEND

Ready SV

*Emergency stop *EMGS OFF: Emergency stop has been actuated

*Alarm *ALM

Load output judgment status

Torque level status TRQS

Signal

abbreviation PC1 PC2 PC4 PC8 PC16 PC32 PC64 PC128

PM1 PM2 PM4 PM8 PM16 PM32 PM64 PM128

HEND

LOAD

The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.

This signal is used on an actuator equipped with a brake to forcibly release the brake. This signal switches the operating mode between AUTO and MANU.

ON: Actuator can be moved, OFF: Actuator decelerates to a stop

The servo remains ON while this signal is ON. The servo remains OFF while this signal is OFF.

This signal becomes effective after a position movement command is input. It will turn ON when the current actuator position enters the range specified in the position table and remain ON until the actuator exits the range. This signal will remain OFF during the AUTO mode, and ON during the MANU mode. This signal is OFF immediately after the power is input, and turns ON when home return has completed. This signal turns ON when the target position was reached and the actuator has entered the specified in-position range. It is used to determine whether positioning has completed. This signal is always output once the servo is turned ON and the controller is ready to operate.

This signal remains ON in normal conditions of use and turns OFF when an alarm generates. This signal will turn ON when the command torque exceeds the threshold while the actuator is inside the check range. Note) Dedicated output signal for the PCON-CF This signal will turn ON when the motor current reaches the threshold. Note) Dedicated output signal for the PCON-CF

Function overview

 PIO pattern = 3: 512-point mode [512-point type]

Category Signal name

Command position number

Input

Output

Brake release BKRL

Operating mode RMDO

Home return HOME Home return operation is started at a rise edge of this signal.

*Pause *STP

Start CSTR The actuator will start moving at a rise edge of this signal. Alarm reset RES An alarm is reset at a rise edge of this signal.

Servo ON SON

Completed position number

Operating mode status RMDS

Home return completion

Position complete PEND

Ready SV

*Emergency stop *EMGS OFF: Emergency stop has been actuated

*Alarm *ALM

Load output judgment status

Torque level status TRQS

Signal

abbreviation PC1 PC2 PC4 PC8 PC16 PC32 PC64 PC128 PC256

PM1 PM2 PM4 PM8 PM16 PM32 PM64 PM128 PC256

HEND

LOAD

The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.

This signal is used on an actuator equipped with a brake to forcibly release the brake. This signal switches the operating mode between AUTO and MANU.

ON: Actuator can be moved, OFF: Actuator decelerates to a stop

The servo remains ON while this signal is ON. The servo remains OFF while this signal is OFF.

This signal will remain OFF during the AUTO mode, and ON during the MANU mode. This signal is OFF immediately after the power is input, and turns ON when home return has completed. This signal turns ON when the target position was reached and the actuator has entered the specified in-position range. It is used to determine whether positioning has completed. This signal is always output once the servo is turned ON and the controller is ready to operate.

Function overview

 PIO pattern = 4: Solenoid valve mode 1 [7- point type]

Category Signal name

Direct position command 0 Direct position command 1 Direct position command 2 Direct position command 3 Direct position command 4

Input

Direct position command 5 Direct position command 6

Brake release BKRL

Operating mode RMDO Home return HOME *Pause *STP Alarm reset RES

Servo ON SON

Movement complete 0 PE0

Movement complete 1 PE1

Movement complete 2 PE2

Movement complete 3 PE3

Movement complete 4 PE4

Movement complete 5 PE5

Movement complete 6 PE6

Zone ZONE1

Position zone PZONE

Output

Operating mode status RMDS

Home return completion HEND

Position complete PEND

Ready SV

*Emergency stop *EMGS

*Alarm *ALM

Load output judgment status

Torque level status TRQS

Signal

abbreviation

ST0

ST1

ST2

ST3

ST4

ST5

ST6

LOAD

The actuator will start moving to position No. 0 at a rise edge of this signal.

The actuator will start moving to position No. 1 at a rise edge of this signal.

The actuator will start moving to position No. 2 at a rise edge of this signal.

The actuator will start moving to position No. 3 at a rise edge of this signal.

The actuator will start moving to position No. 4 at a rise edge of this signal.

The actuator will start moving to position No. 5 at a rise edge of this signal.

The actuator will start moving to position No. 6 at a rise edge of this signal.

This signal is used on an actuator equipped with a brake to forcibly release the brake. This signal switches the operating mode between AUTO and MANU.

Home return operation is started at a rise edge of this signal. ON: Actuator can be moved, OFF: Actuator decelerates to a stop An alarm is reset at a rise edge of this signal. The servo remains ON while this signal is ON.

The servo remains OFF while this signal is OFF. This signal will turn ON when the actuator completes moving to position No. 0. This signal will turn ON when the actuator completes moving to position No. 1. This signal will turn ON when the actuator completes moving to position No. 2. This signal will turn ON when the actuator completes moving to position No. 3. This signal will turn ON when the actuator completes moving to position No. 4. This signal will turn ON when the actuator completes moving to position No. 5. This signal will turn ON when the actuator completes moving to position No. 6. This signal becomes effective after home return. It will turn ON when the current actuator position enters the range set by the parameters and remain ON until the actuator exits the range. This signal becomes effective after a position movement command is input. It will turn ON when the current actuator position enters the range specified in the position table and remain ON until the actuator exits the range. This signal will remain OFF during the AUTO mode, and ON during the MANU mode. This signal is OFF immediately after the power is input, and turns ON when home return has completed. This signal is used to determine if the controller is ready following the power on. The controller is ready to perform operation if an emergency stop is not actuated, motor drive power is not cut off (= the servo is on) and the pause signal is input. This signal is always output once the servo is turned ON and the controller is ready to operate. OFF: Emergency stop has been actuated This signal remains ON in normal conditions of use and turns OFF when an alarm generates. This signal will turn ON when the command torque exceeds the threshold while the actuator is inside the check range. Note) Dedicated output signal for the PCON-CF This signal will turn ON when the motor current reaches the threshold. Note) Dedicated output signal for the PCON-CF

Function overview

 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

Output

Brake release BKRL

Operating mode RMDO

Alarm reset RES An alarm is reset at a rise edge of this signal.

Servo ON SON

Rear end detected LS0 This signal will remain ON while the rear end is recognized.

Front end detected LS1 This signal will remain ON while the front end is recognized.

Intermediate point detected

Zone ZONE1

Position zone PZONE

Operating mode status RMDS

Home return completion

Ready SV

*Emergency stop *EMGS OFF: Emergency stop has been actuated

*Alarm *ALM

Load output judgment status

Torque level status TRQS

Signal

abbreviation

ST0

ST1

ST2

LS2 This signal will remain ON while the intermediate point is

HEND

LOAD

The actuator will move toward the rear end while this signal remains at ON level. The actuator will move toward the front end while this signal remains at ON level. The actuator will move toward the intermediate point while this signal remains at ON level. This signal is used on an actuator equipped with a brake to forcibly release the brake. This signal switches the operating mode between AUTO and MANU.

The servo remains ON while this signal is ON. The servo remains OFF while this signal is OFF.

(This signal is not output during push & hold operation.)

recognized. (This signal is not output during push & hold operation.) This signal becomes effective after home return. It will turn ON when the current actuator position enters the range set by the parameters and remain ON until the actuator exits the range. This signal becomes effective after a position movement command is input. It will turn ON when the current actuator position enters the range specified in the position table and remain ON until the actuator exits the range. This signal will remain OFF during the AUTO mode, and ON during the MANU mode. This signal is OFF immediately after the power is input, and turns ON when home return has completed. This signal is always output once the servo is turned ON and the controller is ready to operate.

Function overview

5.2.2 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.

Category Wire color

No.

1A +24V 2A Red - 1 3A Orange - 1 (Not used) 4A Yellow - 1 (Not used) 5A Green - 1 PC1 PC1 PC1 PC1 ST0 ST0 6A Blue - 1 PC2 PC2 PC2 PC2 ST1 ST1 (JOG+) 7A Purple - 1 PC4 PC4 PC4 PC4 ST2 ST2 (-) 8A Gray - 1 PC8 PC8 PC8 PC8 ST3 -

9A White - 1 PC16 PC16 PC16 PC16 ST4 10A Black - 1 PC32 PC32 PC32 PC32 ST5 11A Brown - 2 - MODE PC64 PC64 ST6 12A Red - 2 - JISE PC128 PC128 - 13A Orange - 2 - JOG+ - PC256 - 14A Yellow - 2 BKRL JOG- BKRL BKRL BKRL BKRL 15A Green - 2 RMOD 16A Blue - 2 HOME 17A Purple - 2 *STP 18A Gray - 2 CSTR 19A White - 2 RES 20A

2B Red - 3 PM2 PM2 PM2 PM2 PE1 LS1 (TRQS)

3B Orange - 3 PM4 PM4 PM4 PM4 PE2 LS2 (-)

4B Yellow - 3 PM8 PM8 PM8 PM8 PE3 -

5B Green - 3 PM16 PM16 PM16 PM16 PE4 -

6B Blue - 3 PM32 PM32 PM32 PM32 PE5 -

7B Purple - 3 MOVE MOVE PM64 PM64 PE6 -

8B Gray - 3 ZONE1 MODES PM128 PM128 ZONE1 ZONE1

9B White - 3 PZONE PZONE PZONE PM256 PZONE PZONE 10B Black - 3 RMDS 11B Brown - 4 HEND 12B Red - 4 PEND PEND/WND PEND PEND PEND 13B Orange - 4 SV 14B Yellow - 4 *EMGS 15B Green - 4 *ALM 16B 17B Purple -4 (Not used) 18B Gray - 4 (Not used) 19B White - 4 20B

Input

Output

Upper stage

Brown - 1

Black - 2 SON

Lower stage

Brown - 3

Blue - 4

Black - 4

0 1 2 3 4 5

CSTR/PWRT

PM1 PM1 PM1 PM1 PE0 LS0

LOAD/TRQS

Caution: [1] The signals indicated by * in the table (*ALM, *STP and *EMGS) are based on the

negative logic, meaning that they remain ON in normal conditions of use.

[2] Do not connect pins denoted by “Not used” (orange-1, yellow-1, blue-4, purple-4, gray-

4), but insulate them instead.

[3] The NPN and PNP specifications use the same power line configuration, so there is no

need to reverse the power signal assignments for a PNP controller.

( ) indicates signals before home return.

Parameter No. 25 setting Pin

P24

CSTR CSTR - -

LOAD/TRQS LOAD/TRQS LOAD/TRQS

5.3 Details of I/O Signal Functions

An input time constant is provided for the input signals of this controller, in order to prevent malfunction due to chattering, noise, etc. Except for certain signals, switching of each input signal will be effected when the signal has been received continuously for at least 6 msec. For example, when an input is switched from OFF to ON, the controller will only recognize that the input signal is ON after 6 msec. The same applies to switching of input signals from ON to OFF (Fig. 1).

Recognition by controller

Input signal

Not recognized

6 [msec] 6 [msec]

Fig. 1 Recognition of Input Signal

5.3.1. Details of Each Input Signal

 Operating mode (RMOD)

This controller has a mode selector switch on the front panel of the controller to prevent malfunction and data loss due to duplicate operations. Normally this switch should be set to the “AUTO” position when the actuator is operated in the auto mode using I/O signals exchanged with a PLC, or to the “MANU” position when the actuator is operated manually using a PC or teaching pendant. If the controller is mounted in a control panel, however, this switch is not readily accessible. Accordingly, a function has been added to allow the setting of this switch to be changed from a PLC for added convenience. Specifically, the internal operating mode of the controller will become “AUTO” when this signal is turned OFF, or “MANU” when this signal is turned ON, if the mode selector switch is set to the “AUTO” position. If the mode selector switch is set to the “MANU” position, the internal operating mode of the controller will remain “MANU” regardless of the status of this signal. Use this signal in applications where the operation mode must be switched frequently between auto and manual and the selector switch is provided on the equipment side.

 Start (CSTR)

Upon detecting an OFF  ON rise edge of this signal, the controller will read, as a binary code, the target position number consisting of six bits from PC1 to PC32 (or eight bits from PC1 to PC128 when the PIO pattern is “256-point type,” or nine bits from PC1 to PC256 when the PIO pattern is “512-point type”), and execute positioning to the target position of 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. If a start command is issued when home return operation has not been performed yet after the power was input (the HEND output signal is OFF), the controller will automatically perform home return operation before positioning to the target position.

 Command position number (PC1 to PC256)

When a movement command is effected upon OFF  ON of the start signal, the nine-bit binary code consisting of signals PC1 to PC256 will be read as the command position number. In the standard or teaching type, six bits of PC1 through PC32 are used. In the 256-point type, eight bits of PC1 to PC128 are used. In the 512-point type, nine bits of PC1 through PC256 are used. The weight of each bit is as follows: 2 position number between 0 and 511 (maximum) can be specified.

for PC1, 21 for PC2, 22 for PC4, …, and 29 for PC256. A desired

 Pause (*STP)

When this signal turns OFF while the actuator is moving, the actuator will decelerate to a stop. The remaining movement is retained and will be resumed when the signal is turned ON again. To abort the movement command, turn ON the alarm reset signal while this signal is OFF to cancel the remaining movement. The *STP signal can be used for the following purposes: [1] Provide a low-level safety measure to stop the axis while the servo is ON, such as a sensor that

detects a person approaching the system [2] Prevent contact with other equipment [3] Perform positioning based on sensor or LS detection (Note) If the *STP signal is input while the actuator is performing home return, the movement command

will be retained if the actuator is yet to contact a mechanical end. If the signal is input after the actuator has reversed upon contacting a mechanical end, home return will be performed again from the beginning.

 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.

 Servo ON (SON)

The servo remains ON while this signal is ON. When the power is turned on, make sure this signal will turn ON after the safety of the entire equipment is ensured, i.e., after a confirmation that the actuator will not contact surrounding equipment. If the SON signal need not be used in view of the nature of the equipment, you can disable the signal using parameter No. 21. When this signal is disabled, the servo will turn on automatically after the power is turned on. The factory setting is to enable the SON signal.

 Alarm reset (RES)

This signal provides two functions. [1] Reset the alarm output signal (*ALM) that turned OFF due to an alarm

If an alarm has generated, turn ON this signal after confirming the nature of the alarm. The controller will reset the alarm upon detection of a rise edge of the RES signal. (Note) Certain alarms cannot be reset by the RES signal. For details, refer to 10, “Troubleshooting.”

[2] Cancel the remaining movement when the pause signal is OFF

This function is used when the remaining movement must be cancelled to allow for incremental moves (movements at a constant increment) from the position where the actuator stopped following a sensor detection.

 Brake release (BKRL)

When the actuator is equipped with a brake, you may want to forcibly release the brake in certain situations such as when starting up the system for the first time. Normally the brake release switch on the front panel of the controller is set to the “RLS” side to release the brake. For added convenience, the brake can now be released from the PLC. If this signal is ON while the servo is off, the brake is released. Use this signal to provide a release switch near the actuator when the actuator is located away from the controller.

 Operation mode (MODE)

This signal is effective when the teaching type is selected. When this signal is turned ON while the actuator is standing still, the normal operation mode will change to the teaching mode. The controller will turn ON the MODES output signal upon receiving this signal. Program the PLC so that it will accept a current-position write command after confirming that the MODES output signal is ON. When this signal is turned OFF, the controller will return to the normal operation mode.

 Current-position write (PWRT)

This signal is enabled when the aforementioned MODES output signal is ON. When this signal has remained ON for 20 msec or longer, the controller will read the position number specified by a binary code consisting of PC1 through PC32 as currently detected, and write the current position data in the “Position” field of the corresponding position number. If data of other items (speed, acceleration/deceleration, positioning band, etc.) are yet to be defined, the default settings of the corresponding parameters will be written. When the writing completes successfully, the WEND output signal will turn ON. Configure the system in such a way that the PLC will turn OFF the PWRT signal when WEND turns ON. The controller will turn OFF WEND once the PWRT signal turns OFF. (Note) An alarm will generate if a write command is issued when home return has not been performed

yet or while the actuator is moving.

 Manual operation switching (JISL)

This signal is enabled when the teaching type is selected. The JISL signal is used to switch operations in the manual mode. Specifically, the actuator will jog when this signal is OFF, or inch when this signal is ON. If this signal is turned ON while the actuator is jogging, the actuator will decelerate to a stop. If this signal is turned OFF while the actuator is inching, the actuator will continue with its inching movement.

 Jog (JOG+, JOG-)

This signal is enabled when the teaching type is selected. When the actuator is jogging (i.e., the JISL signal is OFF), it will jog toward the +/- software stroke limit upon detection of an OFF  ON rise edge of this signal. If an ON  OFF fall edge of this signal is detected while the actuator is moving, the actuator will decelerate to a stop. The jogging speed is defined by parameter No. 26, “PIO jog speed.” * If any of the following input signal changes occurs while the actuator is jogging, the actuator will

decelerate to a stop:

[1] Both the JOG+ and JOG- signals have turned ON. [2] The JISL signal has turned ON (i.e., the operation mode has changed to inching). [3] The CSTR signal has turned ON (i.e., a positioning command has been input).

Upon detection of an OFF  ON rise edge of this signal while the actuator is inching (i.e., the JISL signal is ON), the actuator will travel the distance defined in parameter No. 48, “PIO inching distance.” The actuator will continue with its inching movement if this signal is switched while the actuator is inching.

Caution: If jogging or inching is performed before a home return is completed, the actuator may

collide with a mechanical end because the software stroke limits are not yet effective. Exercise due caution.

 Direct position command (ST0 to ST6) [7-point type]

These signals are effective when “4” is set in parameter No. 25. Upon detection of an OFF  ON rise edge of this signal or detection of the ON level of the 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. If ON edges of two or more signals are detected at the same time, priority will be given to the position command of the smallest number among all detected command signals. (Example: If ON edges of ST0 and ST1 signals are detected at the same time, the actuator will start moving to position 0.) Although commands are executed upon detection of an ON signal edge, priority is given to the command that was specified the earliest. In other words, a signal input will not be accepted while the actuator is moving. Even if a different position signal is turned ON while the actuator is moving, the actuator will not commence moving to the new position after reaching the target position.

Correspondence table of input signals and command positions

Input signal Command position

ST0 Position No. 0

ST1 Position No. 1

ST2 Position No. 2

ST3 Position No. 3

ST4 Position No. 4

ST5 Position No. 5

ST6 Position No. 6

If a movement command is issued when the first home return is not yet completed after the power was input, home return will be performed automatically to establish the coordinates first, after which the actuator will move to the target position.

 Movement to each position (ST0 to ST2) [3-point type]

Since the number of positioning points is limited to three, the actuator can be controlled just like an air cylinder. While this signal is ON, the actuator will move toward the target position. If the signal turns OFF while the actuator is moving, the actuator will decelerate to a stop. Before executing this command, enter a target position in the “Position” field for position No. 0, 1 or 2 in the position table.

Input signal Target position Remarks

ST0 Rear end The target position is defined in the “Position” field for position No. 0.

ST1 Front end The target position is defined in the “Position” field for position No. 1.

ST2 Intermediate point The target position is defined in the “Position” field for position No. 2.

5.3.2 Details of Each Output Signal

 Operating mode status (RMDS)

The internal operating mode of the controller is output based on the AUTO/MANU selector switch on the controller and the RMOD signal received by the input port. If the selector switch is set to “AUTO” and the RMOD signal is OFF (AUTO), the controller is in the AUTO (OFF) mode. If the selector switch is set to “MANU” and/or the RMOD signal is ON (MANU), the controller is in the MANU (ON) mode.

 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. All of these signals are OFF also when the actuator is moving. As described above, this signal is output only when positioning is completed. (Note) All of these signals will turn OFF when the servo is turned OFF or an emergency stop is actuated.

They will return to the ON status when the servo is turned ON again, provided that the current position is inside the in-position range with respect to the target position. If the current position is outside the range, the signals will remain OFF. When the power is input, the PEND signal will turn ON. These signals are all OFF, this condition is the same as one achieved after positioning to position “0” is completed.

Check the position of position 0 after the movement command has completed. If an alarm is present, the corresponding alarm code (abbreviated form) consisting of four bits from PM1 to PM8 will be output. The meanings of these signals vary between the normal condition and the alarm condition, so be careful not to use them wrongly in the sequence.

 Moving (MOVE)

This signal is output while the servo is ON and the actuator is moving (also during home return, push & hold operation or jogging). Use the MOVE signal together with the PEND signal to allow the PLC to determine the actuator status. The MOVE signal will turn OFF after positioning or home return is completed or a judgment is made during push & hold operation that the load is being contacted.

 Position complete (PEND)

This signal indicates that the target position was reached and positioning has completed. Use the PEND signal together with the MOVE signal to allow the PLC to determine the positioning status. When the controller becomes ready after the power was input and the servo has turned ON, this signal will turn ON if the position deviation is within the in-position range. Then, when a movement command is issued by turning ON the start signal, the PEND signal will turn OFF. It will turn ON again when the deviation from the target position falls within the in-position range. Once turned ON, the PEND signal will not turn OFF even when the position deviation subsequently exceeds the in-position range. (Note) If the start signal remains ON, the PEND signal will not turn OFF even when the deviation from the

target position falls within the in-position range: it will turn ON when the start signal turns OFF.

Even when the motor is stopped, the PEND signal will remain OFF if the pause signal is input or

the servo is OFF.

 Home return completion (HEND)

This signal is OFF immediately after the power is input, and turns ON in either of the following two conditions: [1] Home return operation has completed with respect to the first movement command issued with the

start signal. [2] Home return operation has completed following an input of the home return signal. Once turned ON, the HEND signal will not turn OFF unless the input power supply is cut off, a soft reset is executed, or the home return signal is input again. The HEND signal can be used for the following purposes: [1] Check prior to establishing the home if movement toward the home direction is permitted, in cases

where an obstacle is located in the direction of the home [2] Use as a condition for writing the current position in the teaching mode [3] Use as a condition for enabling the zone output signal

 Zone (ZONE1, ZONE2)

[1] ZONE1 This signal will remain ON while the current actuator position is inside the zone specified by Parameter No. 1, “Zone boundary+” and Parameter No. 2, “Zone boundary-,” or OFF while the actuator is outside this range. This signal is always effective once home return has been completed and is not affected by the servo status or presence of an alarm. (Note) This signal becomes effective only after the coordinate system has been established following a

completion of home return. It will not be output immediately after the power is turned on.

[2] PZONE This signal will turn ON when the current actuator position enters the area between the zone boundaries set in the position table. After the current position movement command is completed, the signal will remain effective until the next position movement command is received.

 Current operation mode (MODES)

This signal is enabled when the teaching type is selected. The MODES signal will turn ON when the teaching mode is enabled upon selection of the teaching mode via the operation mode input signal (MODE signal ON). Thereafter, the MODES signal will remain ON until the MODE signal turns OFF. Configure the system in such a way that the PLC will start teaching operation after confirming that the MODES signal has turned ON.

 Write completion (WEND)

This signal is enabled only when the teaching type is selected. The WEND signal is OFF immediately after the controller has switched to the teaching mode. It will turn ON when the writing of position data in response to the current-position write signal is completed. When the current-position write signal turns OFF, this signal will also turn OFF. Configure the system in such a way that the PLC will acknowledge completion of writing when the WEND signal turns OFF.

 Movement complete at each position (PE0 to PE6) [7-point type]

When PIO pattern is “4,” a position number (0 through 6) corresponding to each movement command will be output upon completion of positioning. Simple alarm-code output function is not provided for these signals. If an alarm generates, only the *ALM signal will turn OFF. Check the details of the alarm code using each tool.

Correspondence table of output signals and positions completed

Output signal Position completed

PE0 Position No. 0

PE1 Position No. 1

PE2 Position No. 2

PE3 Position No. 3

PE4 Position No. 4

PE5 Position No. 5

PE6 Position No. 6

Note) These signals turn OFF when the servo is turned OFF or an emergency stop is actuated. They will

return to the ON status when the servo is turned ON again, provided that the current position is inside the in-position range with respect to the target position. If the current position is outside the range, the signals will remain OFF.

 Position detection output at each position (LS0 to LS2) [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.

Output signal Position detected Remarks

ST0 Rear end

ST1 Front end

ST2 Intermediate point

The detection position is defined in the “Position” and “Positioning band” fields for position No. 0.

The detection position is defined in the “Position” and “Positioning band” fields for position No. 1.

The detection position is defined in the “Position” and “Positioning band” fields for position No. 2.

 Ready (SV)

This is a monitor signal indicating that the servo is ON and the motor is ready. Use this signal as a condition for starting a movement command on the PLC side.

 Alarm (*ALM)

This signal remains ON while the controller is operating properly, and turns OFF when an alarm has generated. Provide an appropriate safety measure for the entire system by allowing the PLC to monitor the OFF status of this signal. For details of alarms, refer to 10, “Troubleshooting.”

 Emergency stop (*EMGS)

This signal remains ON while the controller is normal, and will turn OFF if the emergency stop circuit is cut off. Program the PLC so that it will monitor this signal and implement appropriate safety measures for the entire system if the signal turns OFF.

 Load output judgment status (LOAD) * This is a dedicated signal available only with the PCON-CF.

If used in a press-fitting application, the controller must be able to know if the specified load threshold was reached during push & hold operation. A desired load threshold and check band range are set in the position table, and this signal will turn ON when the command torque exceeds the threshold while the actuator is inside the check band range. With the LOAD signal, judgment is made based on whether the total duration of periods in which the command torque has exceeded the threshold corresponds at least to a specified time. The specific processing procedure is the same as the one used when determining a completion of push action. The time used for judgment of load output can be changed freely using user parameter No. 50, “Load output judgment time.”

 Torque level status (TRQS) * This is a dedicated signal available only with the PCON-CF.

If a load threshold is set, this signal will turn ON when the motor current reaches the load threshold while the actuator is moving. Since the level of current is monitored, the ON/OFF status of this signal will change when the current changes. In the weak field-magnet vector control used for stepping motors, the balance of current and torque will be lost once a specific speed is exceeded. To use the command current to determine if the threshold has been reached, therefore, the push speed must be limited. Note, however, that the range of permissible push speeds varies depending on the motor and lead, which means that the push speed set in user parameter No. 34 must also be adjusted according to the applicable motor and lead.

 Output Signal Changes in Each Mode

Mode classification MOVE PEND SV HEND

Actuator is stopped with the servo ON after the power was input Home return is in progress following an input of the home return signal Home return has completed following an input of the home return signal

OFF ON ON OFF OFF

ON OFF ON OFF OFF

OFF ON ON ON OFF

PM1 ~

PM256

Actuator is moving in the positioning/push & hold mode ON OFF ON ON OFF Actuator is paused in the positioning/push & hold mode OFF OFF ON ON OFF Positioning has completed in the positioning mode OFF ON ON ON ON Actuator has stopped after contacting the load in the push & hold mode Actuator has stopped after missing the load (no load) in the push & hold mode Actuator is stopped with the servo ON in the teaching mode Actuator is jogging in the teaching mode ON ON ON Actuator is being moved by hand with the servo OFF in the teaching mode

OFF ON ON ON ON

OFF OFF ON ON ON

OFF ON ON

OFF

OFF ON

Servo is OFF after home return OFF OFF OFF ON OFF Emergency stop has been actuated after home return OFF OFF OFF ON

(Note) Determine whether the actuator has stopped after contacting the load or missing the load from the

signal statuses of MOVE, PEND and PM1 to PM256.

6. Data Entry <Basics>

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. The default values vary depending on the characteristics of the actuator.

6.1 Description of Position Table

The position table is explained using an example on the PC software screen. (The items displayed on the teaching pendant are different.)

No.

Position

[mm]

0 5.00 300.00 0.30 0.30 0 0 0.10

1 380.00 300.00 0.30 0.10 0 0 0.10

2 200.00 300.00 0.30 0.10 0 0 0.10

Zone+

[mm]

100.00 0.00 0 0 0 4

400.00 300.00 0 0 0 0

250.00 150.00 0 0 0 0

(1) No.

(2) Position

(3) Speed

Speed [mm/s]

Zone-

[mm]

Acceleration

[G]

Acceleration/

deceleration

mode

Deceleration

[G]

Incremental

Push

[%]

Command

mode

Threshold

[%]

Standstill

mode

Positioning

band [mm]

Comment

Standby

position

 Indicate the position data number.

 Enter the target position to move the actuator to, in [mm].

Absolute mode: Enter a distance from the actuator home. Incremental mode: Enter a relative travel from the current position based

on constant-pitch feed.

Position

[mm]

Absolute mode The target position is 30 mm from

the home.

Incremental mode +10 mm from the current position

Incremental mode -10 mm from the current position

30.00 0

10.00

-10.00

* On the teaching pendant, this sign indicates that

the position is set in the incremental mode.

 Enter the speed at which the actuator will be moved, in [mm/sec].

The default value varies depending on the actuator type.

(4) Acceleration/deceleration

 Enter the acceleration/deceleration at which to move the actuator, in

[G]. Basically, the acceleration and deceleration should be inside the rated acceleration/deceleration range specified in the catalog. The input range is greater than the rated range in the catalog to accommodate situations where you want to “reduce the tact time when the load mass is significantly smaller than the rated load capacity.” If vibration of the load causes problem during acceleration/deceleration, decrease the set value.

Speed

cceleration Deceleration

Starting position

Increasing the set value makes the acceleration/deceleration quicker while decreasing the value makes it more gradual.

Target

position

Time

Caution: Refer to the attached list of supported actuator specifications and set appropriate speed

and acceleration/deceleration so that the actuator will not receive excessive impact or vibration under the applicable installation condition and for the load of the specific shape. Increasing the speed and acceleration/deceleration may significantly impact the actuator depending on the load mass, and the actuator characteristics also vary from one model to another. Contact IAI for the maximum limits that can be entered in your specific application.

(5) Push

 Select “positioning operation” or “push & hold operation.”

The factory setting is “0.”

0: Normal positioning operation Other than 0: Push & hold operation, where the entry indicates a

current-limiting value.

(6) Threshold

 This field sets the threshold for motor current. The factory setting is “0.” * This field is available only with the PCON-CF controller.

(7) Positioning band

 The meaning of this field varies

between “positioning operation” and “push & hold operation.”

“Positioning operation” This field defines how much before the target position the completion signal will turn ON.

The position complete signal turns ON here.

Increasing the positioning band allows the next operation in the sequence to be started early, and consequently the tact time can be

Positioning band

reduced. Set an optimal value by checking the overall balance of the system.

Target position

“Push & hold operation”

This field defines the maximum push distance after reaching the target position in push & hold operation. Consider possible mechanical variation of the load and set an appropriate positioning band that will prevent the positioning from completing before the load is contacted.

The position complete signal turns ON here, as completion of push action is recognized after the load has been contacted.

Target position

(8) Zone +/-

 This field defines the zone within which the position zone output signal

(PZONE) will turn ON. To add flexibility, a different zone can now be set for each target position.

[Setting example]

No.

Position

[mm] 0 5.00 100.00 0.00 1 380.00 400.00 300.00 2 200.00 250.00 150.00

Movement command to position No. 0

Position zone output signal

OFF

Movement command to position No. 1

Position zone output signal

OFF

Movement command to position No. 2

Position zone output signal

OFF

Load

Positioning band (maximum push distance)

Zone+

[mm]

Zone-

[mm]

Home

Target

position

0 mm 5 mm 100 mm

300 mm 380 mm 400 mm

Target

position

150 mm 200 mm 250 mm

Target

position

+ limit

(9) Acceleration/deceleration

mode

(10) Incremental

 This field is not used for this controller.

The factory setting is “0.”

 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

(11) Command mode

 This field is not used for this controller.

The factory setting is “0.”

(12) Standstill mode

 This field defines the power-saving mode to be applied while the

actuator is standing by after completing its movement to the target position set in the “Position” field for the applicable position number.

0: Disable all power-saving modes * The factory setting is “0”

(Disable).

1: Automatic servo-off mode, with the delay time defined by parameter

No. 36

2: Automatic servo-off mode, with the delay time defined by parameter

No. 37

3: Automatic servo-off mode, with the delay time defined by parameter

No. 38

4: Full servo control mode

Full servo control mode

Holding current can be reduced by servo-controlling the pulse motor. Although the exact level of current reduction varies depending on the actuator model, load condition, etc., the holding current will decrease by approx. 1/2 to 1/4. Since the servo remains on, position deviation will not occur. The actual holding current can be checked in the current monitor screen of the PC software.

Automatic servo-off mode

After positioning is completed, the servo will turn off automatically upon elapse of a specified time. (Since no holding current generates, power consumption will decrease.) When the next movement command is received from the PLC, the servo will turn on and the actuator will start moving.

Movement command

Servo status

ctuator

movement

Servo on

Target position

utomatic servo-off mode

(Green LED blinks.)

T: Delay time (seconds) after positioning

is completed until the servo turns off T is set by a parameter.

6.1.1 Relationship of Push Force at Standstill and Current-Limiting Value

When performing operation in the push & hold mode, enter the current-limiting value (%) in the push column of the position-data table. Determine the current-limiting value (%) from the push force to be applied to the load at standstill. The graphs below illustrate the relationship of push force at standstill and current-limiting value for each actuator type: Note: For information on the RCP3, check the operation manual for the RCP3.

 Slider type

(1) SA5C/SA6C/SS7C type (2) SA7C type

Push force (N)

Low-speed type

(Lead: 3 mm)

Push force (N)

Current-limiting value (%)

Medium-speed type

(Lead: 6 mm)

Push force (N)

Current-limiting value (%)

High-speed type

(Lead: 12 mm)

Push force (N)

Current-limiting value (%)

Low-speed type

(Lead: 4 mm)

Current-limiting value (%)

Medium-speed type

(Lead: 8 mm)

Current-limiting value (%)

High-speed type

(Lead: 16 mm)

Current-limiting value (%)

Caution: The precision of push force at standstill is not guaranteed. The above graphs are provided

for reference purposes only. If the push force is too small, malfunction may occur during push & hold operation due to slide resistance, etc., so exercise caution. The maximum current-limiting value is shown in the above graphs. The minimum value is 20%.

(3) SS8C type

Push force (N)

Current-limiting value (%)

Push force (N)

Current-limiting value (%)

Push force (N)

Current-limiting value (%)

Low-speed type

(Lead: 5 mm)

Medium-speed type

(Lead: 10 mm)

High-speed type

(Lead: 20 mm)

Caution: The precision of push force at standstill is not guaranteed. The above graphs are provided

 Rod type

(1) RA2C type (2) RA3C type

Push force (N)

Current-limiting value %

Push force (N)

Current-limiting value %

Medium-speed type

Push force (N)

Current-limiting value %

Low-speed type

(Lead: 2.5 mm)

(Lead: 5 mm)

Caution: The precision of push force at standstill is not guaranteed. The above graphs are provided

(3) RA4C type (4) RA6C type

Low-speed type

(Lead: 2.5 mm)

Push force (N)

Current-limiting value (%)

Medium-speed type

(Lead: 5 mm)

Push force (N)

Current-limiting value (%)

High-speed type

(Lead: 10 mm)

Push force (N)

Current-limiting value (%)

Low-speed type

(Lead: 4 mm)

Medium-speed type

(Lead: 8 mm)

High-speed type

(Lead: 16 mm)

Caution: The precision of push force at standstill is not guaranteed. The above graphs are provided

(5) RA10C/W-RA10C type

Low-speed type

(Lead: 2.5 mm)

Push force (N)

Current-limiting value (%)

Medium-speed type

(Lead: 5 mm)

Push force (N)

Current-limiting value (%)

High-speed type

(Lead: 10 mm)

Push force (N)

Current-limiting value (%)

Caution: The precision of push force at standstill is not guaranteed. The above graphs are provided

6.2 Explanation of Modes

6.2.1 Positioning Mode Push = 0

The actuator moves to the target position set in the “Position” field of the position table.

Speed

The position complete signal turns ON here.

Target position

Moving distance

Time

Positioning band

6.2.2 Push & Hold Mode Push = Other than 0

(1) Load was contacted successfully

Upon reaching the target position set in the “Position” field of the position table, the actuator moves at the push speed for the distance set in the “Positioning band” field. If the actuator contacts the load while moving and the controller recognizes that “push action has completed,” the position complete signal will turn ON.

Speed

Moving distance

 The push speed is set by parameter No. 34.

The factory setting varies with each actuator in accordance with the actuator’s characteristics. Set an appropriate speed by considering the material and shape of the load, among others. Since the maximum speed is 20 mm/s, operate the actuator at a speed not exceeding this value.

 Set a positioning band slightly longer than the last position, in order to absorb possible mechanical

variation of the load.

 “Completion of push action” is determined based on a combination of the current-limiting value set in

the “Push” field of the position table and the push completion judgment time set by parameter No. 6. Set an appropriate condition by considering the material and shape of the load, among others. For details, refer to Chapter 8, “Parameter Settings.”

The position complete signal turns ON here, as completion of push action is recognized after the load has been contacted.

Positioning band

Target position

(maximum push distance)

Warning

 If the actuator contacts the load before reaching the target position, a servo error alarm

will generate. Pay due attention to the relationship of the target position and the load position.

 The actuator continues to push the load at the push force at standstill determined by

the current-limiting value. Since the actuator is not inactive, exercise due caution when handling the machine in this condition.

(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.

Moving distance

Target position

Positioning band (maximum push distance)

(3) Load moves during push & hold operation

[1] Load moves in the pushed direction

If the load moves in the pushed direction after completion of push action, the actuator will chase the load within the positioning band. If the current drops to below the current-limiting value set in the “Push” field of the position table while the actuator is moving, the position complete signal will turn OFF. The position complete signal will turn ON when the current-limiting value increases to the specified level again.

Speed

Completion of push action is recognized here.

If the load moves in the pushed direction, the actuator will chase it within the positioning band.

Moving distance

Target position

Positioning band (maximum push distance)

[2] Load moves in the opposite direction

(Actuator is pushed back by the strong reactive force of the load) If the actuator is pushed back after completion of push action because the reactive force of the load is greater than the thrust force of the actuator, the actuator will be pushed back until its push force balances out with the reactive force of the load. The position complete signal will remain ON.

Speed

Completion of push action is recognized here.

Moving distance

(Note) If the actuator is pushed back to the target position, an alarm will generate.

Target position

Positioning band (maximum push distance)

(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

band

ctual position reached (the load was missed)

Positioning

band

Target position

Positioning

band

6.2.3 Torque Check Function in Push & Hold Operation

(1) Torque check function when a check band is set (Available only with the PCON-CF)

The load output turns ON here when the command torque has exceeded the threshold inside the torque check range.

Speed

Check band

Moving

distance

Target position

After reaching the target position set in the “Position” field of the position table, the actuator moves at the push speed by the distance set in the “Positioning band” field. If the command torque reaches the threshold before the specified distance is traveled and while the actuator is inside the threshold check band, the load output will turn ON.

 The push speed is set by parameter No. 34, “Push speed.” The factory setting varies with each actuator in accordance with the characteristics of the actuator.

Set an appropriate speed by considering the material and shape of the load, among others. Take note, however, that the maximum speed is limited to 10 mm/s.

 Set parameter No. 51, “Torque check range” to “0 [Enable].”  Set a threshold check band in the "zone + or zone -" filed of the position table.  Set a desired threshold in the “Threshold” field of the position table (input range: a desired value

within the specified push force range).  Set a desired positioning band in the “Positioning band” field of the position table. Set a positioning band slightly longer than the last position, in order to absorb possible mechanical

variation of the load. For details, refer to Chapter 8, “Parameter Settings.”

The position complete signal turns ON here, as completion of push action is recognized after the load has been contacted.

Positioning band (maximum push distance)

 This function is available only with the PCON-CF controller. (It cannot be used with the PCON-C or PCON-CG controller.)  If the actuator contacts the load before reaching the target position, a servo error alarm

Warning

will generate. Pay due attention to the relationship of the target position and the load position.

 The actuator continues to push the load at the push force at standstill determined by

the current-limiting value. Since the actuator is not inactive, exercise due caution when handling the equipment in this condition.

(2) Torque check function when a check band is not used (Available only with the PCON-CF)

The position complete signal turns ON here, as completion of push action is recognized after the load has been contacted.

Speed

Moving distance

The load output turns ON inside this range.

Target position

Positioning band (maximum push distance)

After reaching the target position set in the “Position” field of the position table, the actuator moves at the push speed by the distance set in the “Positioning band” field. If the command torque reaches the threshold before the end of the positioning band is reached, the load output will turn ON. The load output will turn OFF once the command torque drops to below the threshold.

 The push speed is set by parameter No. 34, “Push speed.” The factory setting varies with each actuator in accordance with the characteristics of the actuator.

Set an appropriate speed by considering the material and shape of the load, among others.

Take note, however, that the maximum speed is limited to 10 mm/s.

 Set parameter No. 51, “Torque check range” to “1 [Disable].”  Set a desired threshold in the “Threshold” field of the position table (input range: a desired value

variation of the load. For details, refer to Chapter 8, “Parameter Settings.”

Warning

will generate. Pay due attention to the relationship of the target position and the load position.

 The actuator continues to push the load at the push force at standstill determined by

the current-limiting value. Since the actuator is not inactive, exercise due caution when handling the equipment in this condition.

6.2.4 Speed Change during Movement

Speed control involving multiple speed levels is possible in a single operation. The actuator speed can be decreased or increased at a certain point during movement. However, the position at which to implement each speed change must be set.

Position 1 Position 2 Position 1 Position 2 Position 1 Position 2 Position 3

6.2.5 Operation at Different Acceleration and Deceleration Settings

If the load is a CCD camera or other precision equipment, the deceleration curb at stop must be made as gradual as possible. To accommodate these sensitive applications, the position table has separate fields for “acceleration” and “deceleration.” For example, you can set the deceleration differently from the acceleration, such as setting 0.3 G (rated acceleration) in “Acceleration” and 0.1 G in “Deceleration.”

Speed

Starting position

cceleration:

0.3 G

Deceleration:

0.1 G

Time

Target

position

Caution: Basically, the acceleration and deceleration should be inside the rated

acceleration/deceleration range specified in the catalog. The input range is greater than the rated range in the catalog, but this is only to accommodate situations where you want to “reduce the tact time when the load mass is significantly smaller than the rated load capacity.” If you want to use acceleration/deceleration settings greater than the rating, consult IAI beforehand because it may affect the life of the actuator.

6.2.6 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.

Actuator operation

*STP

ON ON

OFF

Target position

(Note) The deceleration corresponds to the value set in the “Deceleration” field for the current position

number in the position table.

6.2.7 Zone Signal Output

The zone output is suitable for the following applications, because a signal can be output when the actuator enters a specified zone during movement: [1] Issue a trigger signal to surrounding equipment to reduce the tact time [2] Prevent contact with surrounding equipment [3] Use as a “simple ruler” in push & hold operation

A different method is used for the zone output signal, and for the position zone output signal, to set the zone within which the signal will turn ON.  Zone output signal (ZONE1)

Set the signal ON zone using parameters. Parameter No. 1 = Zone boundary+, Parameter No. 2 = Zone boundary-

Zone output (ZONE1)

ctuator operation

 Position zone output signal (PZONE)

Set the signal ON zone using the “Zone boundary-“ and “Zone boundary+” fields of the position table.

Zone output (PZONE)

ctuator operation

Home

Value set in parameter No. 2

Value set in “Zone boundary-”

+ direction

Value set in parameter No. 1

+ direction

Value set in “Zone boundary+”

6.2.8 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.  When a dedicated input is used [PIO pattern  5]

Home return is performed using the home return (HOME) input. The actuator will return home regardless of whether or not home return has been completed once before. When home return is completed, the home return complete (HEND) output signal will turn ON.

 When a dedicated input is not used [PIO pattern = 5]

When a rear end move command is input while home return is not yet completed, the actuator will perform home return first and then move to the rear end.

 For details, refer to 7.2, “How to Execute Home Return.”

6.2.9 Overview of 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.

Continuous jog feed or inching feed can be selected by the manual switching signal to facilitate fine

position adjustment.

* This function is effective regardless of the ON/OFF state of the operation mode input (MODE)

signal.

[2] The current position can be written to the “Position” field of the position table using I/O signals input

from the PLC.

* This function is effective only when the operation mode input (MODE) signal is ON.

(Note) The number of I/O points is limited, so some I/O ports are used in both the teaching type and the

normal positioning type. Remember this when creating a sequence circuit for the PLC.

Operation mode input (MODE) * Signal for switching to the teaching mode

Current operation mode output (MODES) * Monitor output indicating the internal

mode of the controller

Meaning of I/O connector pin 18A

Meaning of I/O connector pin 12B

ON (teaching mode) OFF (positioning mode)

Current-position write input (PWRT)

Write completion output (WEND)

Start input (CSTR)

Position complete output (PEND)

Warning: Jog commands are effective even before home return is completed, but the soft stroke

checks are not performed prior to home return. Accordingly, the actuator may move all the way to the mechanical end if the jog command (JOG+/JOG-) signal remains ON. Exercise caution not to let the actuator hit the mechanical end.

6.2.10 Overview of 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).

Example) The differences are explained by using an example of moving the actuator to the target

position for position No. 5.

[1] 7-point type

Direct position command 5 input (ST5)

Movement complete 5 output (PE5)

Position complete output (PEND)

No more than 6 msec

ctuator movement

* In the 64-point type, a position command input (binary) signal and a start input signal must be turned

ON at staggered timings to initiate movement (refer to the next page). In this type, however, there is only one input signal that needs to be turned ON.

 Explanation of I/O signals

Direct position command 0 (ST0) Movement command to the target position for position No. 0 Direct position command 1 (ST1) Movement command to the target position for position No. 1 Direct position command 2 (ST2) Movement command to the target position for position No. 2 Direct position command 3 (ST3) Movement command to the target position for position No. 3 Direct position command 4 (ST4) Movement command to the target position for position No. 4 Direct position command 5 (ST5) Movement command to the target position for position No. 5 Direct position command 6 (ST6)

Movement complete 0 (PE0)

Movement complete 1 (PE1)

Movement complete 2 (PE2)

Movement complete 3 (PE3)

Movement complete 4 (PE4)

Movement complete 5 (PE5)

Movement complete 6 (PE6)

Signal name Category Function explanation

Starting position of movement

Input

Output

Combination of dedicated movement command input and complete output

Target position

Movement command to the target position for position No. 6 Indicates that the actuator reached the target position for position No. 0. Indicates that the actuator reached the target position for position No. 1. Indicates that the actuator reached the target position for position No. 2. Indicates that the actuator reached the target position for position No. 3. Indicates that the actuator reached the target position for position No. 4. Indicates that the actuator reached the target position for position No. 5. Indicates that the actuator reached the target position for position No. 6.

[2] 64-point type

Command position 1 input (PC1)

Command position 2 input (PC2)

Command position 4 input (PC4)

* All other command position inputs (PC8, PC16 and PC32) turn OFF.

t 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)

Completed position 2 output (PM2)

Completed position 4 output (PM4)

Position complete output (PEND)

Not to exceed 6 msec

ctuator movement

Starting position

of movement

Target position

(Remains OFF)

“5” is indicated by a binary code.

The PLC checks these 3 signals to confirm that the completed position number is “5.”

6.2.11 Overview of 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. * Do not use this mode for push & hold operation.

Item Air cylinder PCON

Drive method Air pressure supplied

via electromagnetic valve control

Target position setting

Target position detection

Mechanical stopper (including shock absorber)

An external detection sensor, such as a reed switch, is installed.

Speed setting Adjusted by a speed

controller.

Acceleration/ deceleration setting

Determined in accordance with the load, supplied air volume, as well as the performance of the speed controller and electromagnetic valve.

Ball-screw or timing-belt drive using a pulse motor

Desired coordinates are entered in the [Position] field of the position table. Coordinates can be entered from the PC/teaching pendant using the keyboard/keys, or the actuator can be moved to the desired position to read the achieved coordinates directly. Example) 400-mm stroke

Position No. Position

0 5 (mm) Rear end 1 400 (mm) Front end 2 200 (mm) Intermediate point

Determined based on the internal coordinates provided by the position information from the position detector (encoder). Accordingly, external detection sensor is not required.

A desired feed speed is entered in the [Speed] field of the position table (unit: mm/sec). Note that the rated speed is automatically set as the initial value.

Desired acceleration/deceleration are entered in the [Acceleration] and [Deceleration] fields of the position table (minimum setting unit: 0.01 G). Reference: 1 G = Gravitational acceleration Note that the rated acceleration/deceleration is automatically set as the initial value. Since the acceleration/deceleration can be set in fine steps, a gradual acceleration/deceleration curve can be programmed.

Acceleration

Deceleration

0.3G

0.1G

Starting position of movement

Ending position

Setting a larger value makes the curve steeper, while setting a smaller value makes the curb more gradual.

Item Air cylinder RCP2 Position check upon power ON

Determined by an external detection sensor, such as a reed switch.

Immediately after the power is turned on, the controller cannot identify the current position because the mechanical coordinates have been lost. Accordingly, a rear end command must always be executed after the power is turned on, to establish the coordinates. The actuator will perform home-return operation first, and then move to the rear end.

[1]

[2]

[3]

Home position

Power is turned on here.

Rear and position

[1] The actuator moves at the home return speed toward the

mechanical end on the motor side.

[2] The actuator contacts the mechanical end and turns back,

and then stops temporarily at the home position.

[3] The actuator moves to the rear end at the speed set in the

[Speed] field of the position table.

(Note) Pay attention not to allow any obstacle in the travel path

of the actuator during home return.

The relationship of each movement command input/position detected and corresponding position number is shown below. The input/output signals are given easy-to-identify names by following the naming convention of air-cylinder switches. However, the target position is determined by the value set in the [Position] field for each position number. Therefore, changing the magnitude relationships of settings under position Nos. 0, 1 and 2 will change the meanings of input/output signals. For this reason, it is recommended that you always use the signals under their names defined in this manual, unless doing so presents problem, so that the signals have the same meanings at all time.

Input signal Output signal Target position Rear end move (ST0) Front end move (ST1) Intermediate point move (ST2)

Rear end detected (LS0) Front end detected (LS1) Intermediate point detected (LS2)

Value set in the [Position] field for position No. 0 Example) 5 mm Value set in the [Position] field for position No. 1 Example) 390 mm

Value set in the [Position] field for position No. 2 Example) 200 mm

 Positioning relationship on the ROBO Cylinder An example of a slider type with a stroke of 400 mm is explained.

[Motor side] [Counter-motor side]

Home position (0 mm)

Rear end detected (5 mm)

Front end detected (390 mm)

Intermediate point detected (200mm)

 Position table (Enter in the fields indicated in bold)

No.

0 5.00 500.00 0.30 0.30 0 0.10 1 390.00 500.00 0.30 0.30 0 0.10 2 200.00 500.00 0.30 0.30 0 0.10

Position

[mm]

Speed

[mm/s]

Acceleration

[G]

Deceleration

[G]

Push

[%]

Positioning band

[mm]

6.3 Notes on the ROBO Gripper

(1) Finger operation

[1] Definition of position

The specified stroke of the 2-finger type indicates the sum of travel distances of both fingers. In other words, the travel distance of one finger is one half the specified stroke. A position you specify defines the distance traveled by one finger from the home position in the closing direction. Accordingly, the maximum command value is 5 mm for the GRS type and 7 mm for the GRM type.

[2] Definition of speed and acceleration

The command value applies to each finger. The relative speed and acceleration of the 2-finger type are twice the command values.

[3] Operation mode in gripper applications

When the actuator is used to grip the load, be sure to select the “push & hold mode.” (Note) In the “positioning mode,” a servo error may occur while the load is gripped.

[Diagrams of gripping force and current-limiting value]

Gripping force (N)

Gripping force P (N)

Gripping force (N)

Current-limiting value (ratio in %) Current-limiting value (ratio in %)

Gripping force P (N)

Current-limiting value (ratio in %) Current-limiting value (ratio in %)

Gripping force P (N)

Current-limiting value (ratio in %) Current-limiting value (ratio in %)

(2) Removing the gripped load This gripper is designed to maintain the load-gripping force via a self-lock mechanism even when the servo is turned OFF or the controller power is cut off. If the gripped load must be removed while the power is cut off, do so by turning the open/close screw or removing the finger attachment on one side.

[2-finger type] Turn the open/close screw or remove the finger attachment on one side.

Open/close screw

Turn the screw counterclockwise using a flathead screwdriver.

Finger attachment

(OPEN)

Opening

direction

ffixing bolt

[3-finger type] Remove one finger attachment.

Finger attachment

ffixing bolt

6.4 Power-saving Modes at Standby Positions

One general feature of pulse motors is that their holding current in standstill state is greater than AC servo motors. Therefore, this product provides energy-saving modes to reduce power consumption in situations where the actuator remains standstill for a long period at a standby position. Use these modes after confirming that they will not present problems to any part of your system. Each mode produces a different level of power-saving effect. Follow the instructions provided below and select an optimal mode appropriate for the specific standstill condition of your actuator.

 PIO pattern = 5: Solenoid valve mode 2 [3-point type]

The actuator stands by with the servo on after the power has been turned on

In this condition, you can select full servo control using parameter No. 53 (Default standstill mode). Automatic servo-off control cannot be selected. If you have set 1, 2 or 3 by mistake, the setting will be ignored. (This setting is not affected by the value in the “Standstill mode” field of the position table.)

The actuator stands by after completing the positioning to the target position set in the “Position” field for the applicable position number

In this condition, you can select one of two modes based on the value in the “Standstill mode” field of the position table. (This setting is not affected by the value of parameter No. 53.) [1] Full servo control [2] Automatic servo-off control

 PIO pattern = Other than 5: Solenoid valve mode 2 [3-point type]

The actuator stands by after completing the home return operation effected by the HOME input signal

In this condition, you can select one of two modes based on the value of parameter No. 53 (Default standstill mode). (This setting is not affected by the value in the “Standstill mode” field of the position table.) [1] Full servo control [2] Automatic servo-off control

The actuator stands by after completing the positioning to the target position set in the “Position” field for the applicable position number

2. Meanings of values set in the “Standstill mode” field of the position table and in parameter No. 53

Setting

All power-saving modes are disabled. (The actuator is completely stopped.) 0

Automatic servo-off mode. The delay time is defined by parameter No. 36. 1

Automatic servo-off mode. The delay time is defined by parameter No. 37. 2

Automatic servo-off mode. The delay time is defined by parameter No. 38. 3

Full servo control mode 4

 Full servo control mode The pulse motor is servo-controlled to reduce the holding current. Although the exact degree of current reduction varies depending on the actuator model, load condition, etc., the holding current decreases to approx. 1/2 to 1/4. Since the servo remains on, position deviation will not occur. The actual holding current can be checked in the current monitor screen of the PC software. Take note that micro-vibration or noise may occur in certain conditions where external force is applied, or depending on the position where the actuator has stopped. If micro-vibration or noise presents problem, do not use this mode.

 Automatic servo-off mode After positioning is completed, the servo will turn off automatically upon elapse of a specified time. (Since no holding current flows, power consumption will decrease.) When the next movement command is received from the PLC, the servo will turn on and the actuator will start moving. * Since the servo turns off once, some position deviation may occur. Do not use this function at standby

positions where position deviation will cause problem.

You should also note that the position complete (PEND), completed position number (PM1 to PM256) and movement complete (PE0 to PE6) signals will turn OFF because the servo turns off. However, you can keep the signals ON via a parameter in situations where the PLC sequence circuit is designed in such a way that problems will occur if complete signals turn OFF.

Setting of parameter No. 39

(Output mode of position

complete signal)

[1] PIO pattern = 0 to 3 Position complete (PEND) signal status, completed position number (PM1 to PM256) signal status [2] PIO pattern = 4 Position complete (PEND) signal status, movement complete (PE0 to PE6) signal status

0 [PEND] The signal will turn OFF unconditionally when the servo turns off.

Even when the next movement command is issued and the servo turns on again, the actuator has already started moving to the next target position, so the signal still remains OFF.

1 [INP] Even when the servo is off, the signal turns ON if the current position is

within the range set by the “Positioning band” field of the position table, with respect to the target position, and turns OFF if the current position is outside this range.

(Note) The factory setting is “0.”

IAI PCON-C, PCON-CG, PCON-CF Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CAUTION

Table of Contents

1. Overview

1.1 Introduction

1.2 How to Read the Model Specification

1.3 System Configuration

1.3.1 Internal Drive-Power Cutoff Relay Type (PCON-C/CF)

1.3.2 External Drive-Power Cutoff Relay Type (PCON-CG)

1.4 Procedure from Unpacking to Test Operation and Adjustment

1.5 Warranty Period and Scope of Warranty

2. Specifications

2.1 Basic Specifications

2.2 Name and Function of Each Part of the Controller

2.3 External Dimensions

3. Installation and Noise Elimination

3.1 Installation Environment

3.2 Power Supply

3.3 Noise Elimination and Grounding

3.4 Heat Radiation and Installation

4. Wiring

4.1 Internal Drive-Power Cutoff Relay Type (PCON-C/CF)

4.1.1 External Connection Diagram

4.1.2 Wiring the Power Supply/Emergency-Stop Switch

4.2 External Drive-Power Cutoff Relay Type (PCON-CG)

4.2.1 External Connection Diagram

4.2.2 Wiring the Power Supply/Emergency-Stop Switch

4.3 Connecting the I/O Cables

4.4 Connecting the Actuator

4.4.1 Connecting the PCON-C/CG and Actuator

4.4.2 Connecting the PCON-CF and Actuator

4.5 Connecting the Communication Cable

5. I/O Signal Control and Signal Functions

5.1 Interface Circuit

5.1.1 External Input Specifications

5.1.2 External Output Specifications

5.2 PIO Patterns and Signal Assignments

5.2.1 Explanation of Signal Names

5.2.2 Signal Assignment Table for Respective PIO Patterns

5.3 Details of I/O Signal Functions

5.3.1. Details of Each Input Signal

5.3.2 Details of Each Output Signal

6. Data Entry <Basics>

6.1 Description of Position Table

6.1.1 Relationship of Push Force at Standstill and Current-Limiting Value

6.2 Explanation of Modes

6.2.1 Positioning Mode Push = 0

6.2.2 Push & Hold Mode Push = Other than 0

6.2.3 Torque Check Function in Push & Hold Operation

6.2.4 Speed Change during Movement

6.2.5 Operation at Different Acceleration and Deceleration Settings

6.2.6 Pause

6.2.7 Zone Signal Output

6.2.8 Home Return

6.2.9 Overview of Teaching Type

6.2.10 Overview of 7-point Type

6.2.11 Overview of 3-point Type

6.3 Notes on the ROBO Gripper

6.4 Power-saving Modes at Standby Positions