IAI X-SEL QX, X-SEL PX Operation Manual

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X-SEL Controlle

PX/QX Type

Operation ManualSeventh Edition

Tenth Edition

Please Read Before Use

Thank you for purchasing our product.

This Operation Manual explains the handling methods, structure and maintenance of this product, among others, providing the information you need to know to use the product safely.

Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of the product. The CD or DVD that comes with the product contains operation manuals for IAI products. When using the product, refer to the necessary portions of the applicable operation manual by printing them out or displaying them on a PC.

After reading the Operation Manual, keep it in a convenient place so that whoever is handling this product can reference it quickly when ne

cessary.

• This Operation Manual is original.

• The product cannot be operated in any way unless expressly specified in this Operation Manual. IAI

shall assume no responsibility for the outcome of any operation not specified herein.

• Information contained in this Operation Manual is subject to change without notice for the purpose of product improvement.

• If you have any question or comment regarding the content of this manual, please contact the IAI sales office near you.

• Using or copying all or part of this Operation Manual without permission is prohibited.

• The company names, names of products and trademarks of each company shown in the sentences

are registered trademarks.

[Important]

CAUTION

Operator Alarm on Low Battery Voltage

This controller is equipped with the following backup batteries for retention of data in the event of power failure:

[1] System-memory backup battery For retention of position data, global variables/flags, error list, strings, etc. [2] Absolute encoder backup battery

For retention of encoder rotation data.

Since these batteries are not rechargeable, they will eventually be consumed. Unless the batteries are replaced in a timely manner, the voltage will drop to a level where the data can no longer be retained. If a power failure occurs in this condition, the data will be lost (The life of each battery varies depending on the operating time). turned on.

(Reference) System-memory backup battery --- An alarm occurs when the voltage drops to approximately 2.6 V.

Absolute-encoder backup battery --- An alarm occurs when the voltage drops to approximately 3.2 V.

Once the data is lost, the controller will not operate normally the next time the power is

Data backup becomes impossible at a battery voltage of approximately 2.3 V (rated voltage: 3.0 V).

Data backup becomes impossible at a battery voltage of approximately 2.7 V (rated voltage: 3.6 V).

To prevent this problem, the controller can output a low battery voltage alarm from its I/O port.

Output port No. 313 is assigned as an alarm output for low system-memory backup battery voltage. Output port No. 314 is assigned as an alarm output for low absolute-encoder backup battery voltage.

It is recommended that this function be utilized to prevent unnecessary problems resulting rom low battery voltage (consumption of battery life).

The person in charge of system design should utilize this function to provide a method for issuing an operator alarm using an output signal from an I/O port, while the person in charge of electrical design should provide a circuit implementation that has the same effect. Refer to the applicable section in the operating manual for the batter replacement.

It is recommended that you always backup the latest data to a PC in case of voltage drop in teh systemmemory backup battery or unexpected controller failure.

Compatible Teaching Pendant/PC Software

QX controllers only support the following teaching pendant/PC software:

Teaching pendant: IA-T-XA (ANSI type) PC software: IA-101-XA-MW (with category 4 cable)

CAUTION

Notes on Supply of Brake Power (+24 V)

Besides connecting the brake power cable from the SCARA robot, the brake power must also be supplied to the controller. Follow the illustration below to supply the brake power (+24 V) also to the controller.

200 to 230 VAC

power supply

Auxiliary power

circuit

Top: 0 V Bottom: 24 V

Example of X-SEL-PX controller (4-axis SCARA robot of 250 to 600 mm in arm length, without expansion I/Os)

Brake power

+24-V power

supply

Power-supply capacity 45 W: Arm length 500 to 800 23 W: Arm length 250 to 350 14 W: Arm length 120 to 150

SCARA robot

(Note) When the arm length is

120 to 180, the brake power need not be supplied to the robot.

CAUTION

Drive-source Cutoff Relay Error (Detection of Fused Relay: E6D)

Because of their circuit configuration, XSEL-PX controllers of single-phase, standard specification are the only class of controllers that may generate a “drive-source cutoff relay error (E6D),” notifying fusion of an internal relay, when the time after the power is turned off until it is turned back on (= until the power is reconnected) is too short. Although the specific time varies depending on the input voltage and number of external regenerative resistance boxes being connected, as a guide wait for at least 40 seconds before reconnecting the power.

CAUTION

Note on Controllers with Increased CPU Unit Memory Size

* Controllers with gateway function come with an increased memory size in their CPU unit.

If you are using a controller with increased CPU unit memory size, use PC software and teaching pendants of the versions specified below.

Teaching tool Version

X-SEL PC software V7.2.0.0 or later

Teaching pendant SEL-T/TD V1.01 or later

[How to Check if Controller Has Increased Memory Size] Check the ROM version information in the PC software (Version 6.0.0.0 or later) (by selecting

Controller (C) 

teaching pendant (IA-T-X, IA-T-XD: Version 1.121 or later / SEL-T, SEL-TD: Version 1.00 or later) (by selecting Moni   If the memory size has been increased: On the PC software screen, you will see “Main

About ROM (V)), or check the main CPU firmware version information on the

Ver  Main).

(FROM32M),” as shown below. On the teaching pendant screen, you will see “Main (FROM32M),” as shown below.

Checking in PC Software

Checking on Teaching Pendant

Table of Contents

Safety Guide.................................................................................................................................. 1

Introduction.................................................................................................................................... 1

Part 1 Installation ....................................................................................................................... 4

Chapter 1 Safety Precautions............................................................................................................... 4

Chapter 2 Warranty Period and Scope of Warranty ............................................................................. 5

1. Warranty Period........................................................................................................................... 5

2. Scope of Warranty....................................................................................................................... 5

3. Scope of Service ......................................................................................................................... 5

Chapter 3 Installation Environment and Selection of Auxiliary Power Devices.................................... 6

1. Installation Environment .............................................................................................................. 6

2. Heat Radiation and Installation.................................................................................................... 7

3. Selection of Auxiliary Power Devices .......................................................................................... 8

4. Noise Control Measures and Grounding................................................................................... 13

Chapter 4 Name and Function of Each Part....................................................................................... 16

1. Front View of Controller............................................................................................................. 16

2. Explanation of Codes Displayed on the Panel Window ............................................................ 30

2.1 Application....................................................................................................................... 30

2.2 Core................................................................................................................................. 31

2.3 Current Monitor and Variable Monitor ............................................................................. 32

Chapter 5 Specifications ..................................................................................................................... 34

1. Controller Specifications............................................................................................................ 34

2. External I/O Specifications......................................................................................................... 38

2.1. NPN Specification............................................................................................................ 38

2.2. PNP Specification............................................................................................................ 40

3. Power Source Capacity and Heat Output ................................................................................. 42

4. External Dimensions.................................................................................................................. 48

Chapter 6 Safety Circuit...................................................................................................................... 57

1. Items to Notes ........................................................................................................................... 57

2. Safety Circuit for PX Type (Standard Specification) Controller ................................................. 58

3. Safety Circuit for QX Type (Global Specification) Controller ..................................................... 60

4. Timing Chart of Safety Circuit for QX-type SEL Controller........................................................ 65

Chapter 7 System Setup..................................................................................................................... 74

1. Connection Method of Controller and Actuator ......................................................................... 74

2. I/O Connection Diagram............................................................................................................ 78

3. Multipoint DIO Board ................................................................................................................. 81

3.1 Overview ......................................................................................................................... 81

3.2 Specifications .................................................................................................................. 81

3.3 External Interface Specifications..................................................................................... 82

Multipoint I/O Board Connection Cables......................................................................... 83

3.4

3.5 Multipoint I/O Board Connection Cables......................................................................... 84

3.6 I/O Circuits....................................................................................................................... 85

Table of Contents

Chapter 8 How to Perform An Absolute Encoder Reset of A Direct Movement Axis (Absolute

Specification)...................................................................................................................... 87

1. Preparation ................................................................................................................................ 87

2. Procedure .................................................................................................................................. 87

Chapter 9 Maintenance ...................................................................................................................... 93

1. Inspection Points ....................................................................................................................... 93

2. Spare Consumable Parts........................................................................................................... 94

3. Replacement Procedure for System Memory Backup Battery.................................................. 95

4. Replacement Procedure for Absolute-Encoder Backup Battery for Linear Movement Axis ..... 98

Part 2 Operation..................................................................................................................... 101

Chapter 1 Operation ......................................................................................................................... 101

1. Starting a Program by Auto Start via Parameter Setting ......................................................... 102

2. Starting via External Signal Selection...................................................................................... 103

3. Drive Source Recovery Request and Operation Pause Reset Request................................. 105

Chapter 2 Specoal Function..............................................................................................................106

1. Driver Overload Warning Function................................................................................................ 106

Part 3 Controller Data Structure............................................................................................. 109

Chapter 1 How to Save Data............................................................................................................ 110

1. Factory Settings: When the System Memory Backup Battery is Used ................................... 110

1.1 Controller without Increased Memory Size ................................................................... 110

1.2 Controller with Increased Memory Size (with Gateway Function) ................................ 111

2. When the System Memory Backup Battery is Not Used......................................................... 112

2.1 Controller without Increased Memory Size ................................................................... 112

2.2 Controller with Increased Memory Size (with Gateway Function) .................................113

3. Points to Note ...........................................................................................................................114

Chapter 2 X-SEL Language Data......................................................................................................116

1. Values and Symbols Used in SEL Language...........................................................................116

1.1 List of Values and Symbols Used...................................................................................116

1.2 I/O Ports .........................................................................................................................117

1.3 Virtual I/O Ports ..............................................................................................................118

1.4 Flags...............................................................................................................................120

1.5 Variables.........................................................................................................................121

1.6 Tags ............................................................................................................................... 124

1.7 Subroutines ................................................................................................................... 125

1.8 Symbols......................................................................................................................... 126

1.9 Character String Literals................................................................................................ 126

1.10 Axis Specification .......................................................................................................... 127

2. Position Part ............................................................................................................................ 129

3. Command Part ........................................................................................................................ 130

3.1 SEL language Structure ................................................................................................ 130

3.2 Extension Condition ...................................................................................................... 131

Table of Contents

Part 4 Commands .................................................................................................................. 132

Chapter 1 List of SEL Language Command Codes ......................................................................... 132

Chapter 2 Explanation of Commands............................................................................................... 144

1. Commands .............................................................................................................................. 144

1.1 Variable Assignment...................................................................................................... 144

1.2 Arithmetic Operation...................................................................................................... 147

1.3 Function Operation........................................................................................................ 149

1.4 Logical Operation .......................................................................................................... 154

1.5 Comparison Operation .................................................................................................. 157

1.6 Timer ............................................................................................................................. 158

1.7 I/O, Flag Operation........................................................................................................ 161

1.8 Program Control ............................................................................................................ 172

1.9 Task Management ......................................................................................................... 175

1.10 Position Operation......................................................................................................... 180

1.11 Actuator Control Declaration ......................................................................................... 195

1.12 Actuator Control Command........................................................................................... 232

1.13 Structural IF ................................................................................................................... 264

1.14 Structural DO................................................................................................................. 267

1.15 Multi-Branching ............................................................................................................. 269

1.16 System Information Acquisition ..................................................................................... 273

1.17 Zone .............................................................................................................................. 277

1.18 Communication ............................................................................................................. 281

1.19 String Operation ............................................................................................................ 287

1.20 Palletizing-Related ........................................................................................................296

1.21 Palletizing Calculation Command ................................................................................. 311

1.22 Palletizing Movement Command ...................................................................................314

1.23 Building of Pseudo-Ladder Task ................................................................................... 320

1.24 Extended Commands .................................................................................................... 322

Chapter 3 Key Characteristics of Horizontal Articulated Robot (SCARA) Operation ....................... 327

1. CP Operation and PTP Operation ........................................................................................... 327

2. Arm System ............................................................................................................................. 330

3. SCARA Coordinate System..................................................................................................... 338

4. Simple Interference Check Zone (Dedicated SCARA Function) ............................................. 348

5. Soft Limits of SCARA Axes ...................................................................................................... 351

6. PTP Optimal Acceleration/Deceleration Function for SCARA Robot ...................................... 355

7. Horizontal move optimization function based on Z position for SCARA Robot....................... 357

Chapter 4 Key Characteristics of Actuator Control Commands and Points to Note......................... 359

1. Continuous Movement Commands [PATH, PSPL, CIR2, ARC2, CIRS, ARCS, ARCD, ARCC,

CIR, ARC]................................................................................................................................ 359

2. PATH/PSPL Commands .......................................................................................................... 361

3. CIR/ARC Commands .............................................................................................................. 361

4. CIR2/ARC2/ARCD/ARCC Commands.................................................................................... 361

Chapter 5 Palletizing Function.......................................................................................................... 362

Table of Contents

1. How to Use .............................................................................................................................. 362

2. Palletizing Setting.................................................................................................................... 362

3. Palletizing Calculation ............................................................................................................. 368

4. Palletizing Movement .............................................................................................................. 369

5. Program Examples.................................................................................................................. 371

Chapter 6 Pseudo-Ladder Task ........................................................................................................ 375

1. Basic Frame............................................................................................................................. 375

2. Ladder Statement Field ........................................................................................................... 376

3. Points to Note .......................................................................................................................... 376

4. Program Example.................................................................................................................... 377

Chapter 7 Multi-Tasking .................................................................................................................... 378

1. Difference from a Sequencer................................................................................................... 378

2. Release of Emergency Stop.................................................................................................... 379

3. Program Switching .................................................................................................................. 380

Appendix ................................................................................................................................... 381

List of Additional Linear Movement Axis Specifications........................................................... 381

How to Write Programs ........................................................................................................... 387

1. Position Table.............................................................................................................. 387

2. Program Format.......................................................................................................... 388

3. Positioning to 5 Positions (for Linear Axes) ................................................................ 389

4. How to Use TAG and GOTO....................................................................................... 390

5. Back-and-Forth Operation between 2 Points (for Linear Axes).................................. 391

6. Path Operation............................................................................................................ 392

7. Output Control during Path Movement....................................................................... 393

8. Circular, Arc Operation................................................................................................ 394

9. Output of Home Return Complete Signal (for Linear Axes) ....................................... 395

10. Axis Movement by Input Waiting and Output of Complete Signal.............................. 396

11. Change of Moving Speed (for Linear Axes)................................................................ 397

12. Speed Change during Operation ................................................................................ 398

13. Local/Global Variables and Flags ............................................................................... 399

14. How to Use Subroutines ............................................................................................. 400

15. Pausing of Operation .................................................................................................. 401

16. Aborting of Operation 1 (CANC) ................................................................................. 402

17. Aborting of Operation 2 (STOP) ................................................................................. 403

18. Movement by Position Number Specification ............................................................. 404

19. Movement by External Position Data Input (for Linear Axes)..................................... 405

20. Output of Coordinate Values....................................................................................... 406

21. Conditional Jump ........................................................................................................ 407

22. Waiting for Multiple Inputs........................................................................................... 408

23. How to Use Offsets (for Linear Axes) ......................................................................... 409

24. Execution of Operation n Times ................................................................................. 410

25. Constant Pitch Feed Operation (for Linear Axes)....................................................... 411

26. Jogging (for Linear Axes)............................................................................................ 412

27. Program Switching...................................................................................................... 413

28. Aborting of Program.....................................................................................................414

General-purpose RS232 (2-channel RS232 Unit)................................................................... 415

Table of Contents

Battery Backup Function ......................................................................................................... 422

1. System-Memory Backup Battery................................................................................ 422

2. Absolute-Encoder Backup Battery.............................................................................. 424

Expansion I/O Board (Optional)............................................................................................... 427

Number of Regenerative Units to be Connected..................................................................... 427

List of Parameters ................................................................................................................... 429

1. I/O Parameters ........................................................................................................... 430

2. Parameters Common to All Axes................................................................................ 447

3. Axis-Specific Parameters............................................................................................ 451

4. Driver Card Parameters.............................................................................................. 462

5. Encoder Parameters................................................................................................... 465

6. I/O Device Parameters ............................................................................................... 466

7. Other Parameters ....................................................................................................... 467

8. Manual Operation Types............................................................................................. 473

9. Use Examples of Key Parameters.............................................................................. 474

Combination Table of X-SEL PX/QX Axis 5/6 Linear/Rotary Control Parameter (Other than SCARA

Axes).................................................................................................................................480

Error Level Control .......................................................................................................................... 481

Error List ......................................................................................................................................... 524

Troubleshooting of X-SEL Controller............................................................................................... 528

Servo Gain Adjustment for Linear Movement Axis.......................................................................... 531

Trouble Report Sheet...................................................................................................................... 533

Change History.......................................................................................................................... 534

Safety Guide

This “Safety Guide” is intended to ensure the correct use of this product and prevent dangers and property damage. Be sure to read this section before using your product.

Regulations and Standards Governing Industrial Robots

Safety measures on mechanical devices are generally classified into four categories under the International Industrial Standard ISO/DIS 12100, “Safety of machinery,” as follows:

Safety measures Inherent safety design

Protective guards --- Safety fence, etc. Additional safety measures --- Emergency stop device, etc. Information on use --- Danger sign, warnings, operation manual

Based on this classification, various standards are established in a hierarchical manner under the International Standards ISO/IEC. The safety standards that apply to industrial robots are as follows:

Type C standards (individual safety standards) ISO10218 (Manipulating industrial robots – Safety)

JIS B 8433 (Manipulating industrial robots – Safety)

Also, Japanese laws regulate the safety of industrial robots, as follows:

Industrial Safety and Health Law Article 59

Workers engaged in dangerous or harmful operations must receive special education.

Ordinance on Industrial Safety and Health Article 36 --- Operations requiring special education

No. 31 (Teaching, etc.) --- Teaching and other similar work involving industrial robots

(exceptions apply)

No. 32 (Inspection, etc.) --- Inspection, repair, adjustment and similar work involving industrial

robots (exceptions apply)

Article 150 --- Measures to be taken by the user of an industrial robot

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Requirements for Industrial Robots under Ordinance on Industrial Safety

and Health

Work area

movement

range

Inside

movement

range

Work

condition

During

automatic

operation

During

teaching, etc.

During

inspection,

etc.

Cutoff of drive source Measure Article

Signs for starting operation Article 104 Outside

Not cut off

Cut off (including

stopping of operation)

Not cut off

Cut off

Not cut off (when

inspection, etc., must

be performed during

operation)

Installation of railings, enclosures, etc. Sign, etc., indicating that work is in progress Preparation of work rules Article 150-3 Measures to enable immediate stopping of operation Sign, etc., indicating that work is in progress Provision of special education Article 36-31 Checkup, etc., before commencement of work To be performed after stopping the operation Sign, etc., indicating that work is in progress Preparation of work rules Article 150-5 Measures to enable immediate stopping of operation Sign, etc., indicating that work is in progress Provision of special education (excluding cleaning and lubrication)

Article 150-4

Article 150-3

Article 151

Article 150-5

Article 36-32

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Applicable Modes of IAI’s Industrial Robot

Machines meeting the following conditions are not classified as industrial robots according to Notice of Ministry of Labor No. 51 and Notice of Ministry of Labor/Labor Standards Office Director (Ki-Hatsu No.

340): (1) Single-axis robo with a motor wattage of 80 W or less (2) Combined multi-axis robot whose X, Y and Z-axes are 300 mm or shorter and whose rotating

part, if any, has the maximum movement range of within 300 mm part

(3) Multi-joint robot whose movable radius and Z-axis are within 300 mm

Among the products featured in our catalogs, the following models are classified as industrial robots:

1. Single-axis ROBO Cylinders RCS2/RCS2CR-SS8 whose stroke exceeds 300 mm

2. Single-axis robots The following models whose stroke exceeds 300 mm and whose motor capacity also exceeds 80 W: ISA/ISPA, ISDA/ISPDA, ISWA/ISPWA, IF, FS, NS

3. Linear servo actuators All models whose stroke exceeds 300 mm

4. Cartesian robos Any robot that uses at least one axis corresponding to one of the models specified in 1 to 3

5. IX SCARA robots

All models whose arm length exceeds 300 mm (All models excluding IX-NNN1205/1505/1805/2515, NNW2515 and NNC1205/1505/1805/2515)

including the tip of the rotating

Pre-3

Notes on Safety of Our Products

Common items you should note when performing each task on any IAI robot are explained below.

No. Task Note

1 Model

selection

2 Transportation

3 Storage/

preservation

4 Installation/

startup

 This product is not planned or designed for uses requiring high degrees of safety.

Accordingly, it cannot be used to sustain or support life and must not be used in

the following applications: [1]Medical devices relating to maintenance, management, etc., of life or health [2]Mechanisms or mechanical devices (vehicles, railway facilities, aircraft facilities,

etc.) intended to move or transport people [3]Important safety parts in mechanical devices (safety devices, etc.)  Do not use this product in the following environments: [1]Place subject to flammable gases, ignitable objects, flammables, explosives, etc. [2]Place that may be exposed to radiation [3]Place where the surrounding air temperature or relative humidity exceeds the

specified range [4]Place subject to direct sunlight or radiated heat from large heat sources [5]Place subject to sudden temperature shift and condensation [6]Place subject to corrosive gases (sulfuric acid, hydrochloric acid, etc.) [7]Place subject to excessive dust, salt or iron powder [8]Place where the product receives direct vibration or impact  Do not use this product outside the specified ranges. Doing so may significantly

shorten the life of the product or result in product failure or facility stoppage.  When transporting the product, exercise due caution not to bump or drop the

product.

 Use appropriate means for transportation.  Do not step on the package.  Do not place on the package any heavy article that may deform the package.  When using a crane of 1 ton or more in capacity, make sure the crane operators

are qualified to operate cranes and perform slinging work.  When using a crane, etc., never hoist articles exceeding the rated load of the

crane, etc.  Use hoisting equipment suitable for the article to be hoisted. Calculate the load

needed to cut off the hoisting equipment and other loads incidental to equipment

operation by considering a safety factor. Also check the hoisting equipment for

damage.

 Do not climb onto the article while it is being hoisted.  Do not keep the article hoisted for an extended period of time.  Do not stand under the hoisted article.

 The storage/preservation environment should conform to the installation

environment. Among others, be careful not to cause condensation. (1) Installing the robot, controller, etc.

 Be sure to firmly secure and affix the product (including its work part).

If the product tips over, drops, malfunctions, etc., damage or injury may result.  Do not step on the product or place any article on top. The product may tip over

or the article may drop, resulting in injury, product damage, loss of/drop in

product performance, shorter life, etc.  If the product is used in any of the following places, provide sufficient shielding

measures: [1]Place subject to electrical noise [2]Place subject to a strong electric or magnetic field [3]Place where power lines or drive lines are wired nearby [4]Place subject to splashed water, oil or chemicals

Pre-4

No. Task Note

4 Installation/

startup

(2) Wiring the cables  Use IAI’s genuine cables to connect the actuator and controller or connect a

teaching tool, etc.  Do not damage, forcibly bend, pull, loop round an object or pinch the cables or

place heavy articles on top. Current leak or poor electrical continuity may occur,

resulting in fire, electric shock or malfunction.

 Wire the product correctly after turning off the power.  When wiring a DC power supply (+24 V), pay attention to the positive and

negative polarities.

Connecting the wires in wrong polarities may result in fire, product failure or

malfunction.  Securely connect the cables and connectors so that they will not be disconnected

or come loose. Failing to do so may result in fire, electric shock or product

malfunction.  Do not cut and reconnect the cables of the product to extend or shorten the

cables. Doing so may result in fire or product malfunction. (3) Grounding

 Be sure to provide class D (former class 3) grounding for the controller.

Grounding is required to prevent electric shock and electrostatic charges,

improve noise resistance and suppress unnecessary electromagnetic radiation. (4) Safety measures

 Implement safety measures (such as installing safety fences, etc.) to prevent

entry into the movement range of the robot when the product is moving or can be

moved. Contacting the moving robot may result in death or serious injury.  Be sure to provide an emergency stop circuit so that the product can be stopped

immediately in case of emergency during operation.  Implement safety measures so that the product cannot be started only by turning

on the power. If the product starts suddenly, injury or product damage may result.  Implement safety measures so that the product will not start upon cancellation of

an emergency stop or recovery of power following a power outage. Failure to do

so may result in injury, equipment damage, etc.  Put up a sign saying “WORK IN PROGRESS. DO NOT TURN ON POWER,” etc.,

during installation, adjustment, etc. If the power is accidently turned on, electric

shock or injury may result.  Implement measures to prevent the work part, etc., from dropping due to a power

outage or emergency stop.  Ensure safety by wearing protective gloves, protective goggles and/or safety

shoes, as necessary.  Do not insert fingers and objects into openings in the product. Doing so may

result in injury, electric shock, product damage, fire, etc.  When releasing the brake of the vertically installed actuator, be careful not to let

the actuator drop due to its dead weight, causing pinched hands or damaged

work part, etc.

5 Teaching

 Whenever possible, perform teaching from outside the safety fences. If teaching

must be performed inside the safety fences, prepare “work rules” and make sure

the operator understands the procedures thoroughly.  When working inside the safety fences, the operator should carry a handy

emergency stop switch so that the operation can be stopped any time when an

abnormality occurs.  When working inside the safety fences, appoint a safety watcher in addition to the

operator so that the operation can be stopped any time when an abnormality

occurs. The safety watcher must also make sure the switches are not operated

inadvertently by a third party.  Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.

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No. Task Note

5 Teaching  When releasing the brake of the vertically installed actuator, be careful not to let

the actuator drop due to its dead weight, causing pinched hands or damaged

load, etc. * Safety fences --- Indicate the movement range if safety fences are not provided.

6 Confirmation

operation

 After teaching or programming, carry out step-by-step confirmation operation

before switching to automatic operation.  When carrying out confirmation operation inside the safety fences, follow the

specified work procedure just like during teaching.  When confirming the program operation, use the safety speed. Failure to do so

may result in an unexpected movement due to programming errors, etc., causing

injury.  Do not touch the terminal blocks and various setting switches while the power is

supplied. Touching these parts may result in electric shock or malfunction.

7 Automatic

operation

 Before commencing automatic operation, make sure no one is inside the safety

fences.  Before commencing automatic operation, make sure all related peripherals are

ready to operate in the auto mode and no abnormalities are displayed or

indicated.

 Be sure to start automatic operation from outside the safety fences.  If the product generated abnormal heat, smoke, odor or noise, stop the product

immediately and turn off the power switch. Failure to do so may result in fire or

product damage.  If a power outage occurred, turn off the power switch. Otherwise, the product may

move suddenly when the power is restored, resulting in injury or product damage.

8 Maintenance/

inspection

 Whenever possible, work from outside the safety fences. If work must be

performed inside the safety fences, prepare “work rules” and make sure the

operator understands the procedures thoroughly.

 When working inside the safety fences, turn off the power switch, as a rule.  When working inside the safety fences, the operator should carry a handy

emergency stop switch so that the operation can be stopped any time when an

abnormality occurs.  When working inside the safety fences, appoint a safety watcher in addition to the

operator so that the operation can be stopped any time when an abnormality

occurs. The safety watcher must also make sure the switches are not operated

inadvertently by a third party.

 Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.  Use appropriate grease for the guides and ball screws by checking the operation

manual for each model.  Do not perform a withstand voltage test. Conducting this test may result in

product damage.  When releasing the brake of the vertically installed actuator, be careful not to let

the actuator drop due to its dead weight, causing pinched hands or damaged

work part, etc. * Safety fences --- Indicate the movement range if safety fences are not provided.

9 Modification  The customer must not modify or disassemble/assemble the product or use

maintenance parts not specified in the manual without first consulting IAI.  Any damage or loss resulting from the above actions will be excluded from the

scope of warranty.

10 Disposal  When the product becomes no longer usable or necessary, dispose of it properly

as an industrial waste.  When disposing of the product, do not throw it into fire. The product may explode

or generate toxic gases.

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Indication of Cautionary Information

The operation manual for each model denotes safety precautions under “Danger,” “Warning,” “Caution” and “Note,” as specified below.

Level Degree of danger/loss Symbol

Danger

Warning

Caution

Note

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

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

Warning

Caution

Note

Pre-7

CE Marking

If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.

Pre-8

Prohibited Handling of Cables

Caution

When designing an application system using actuators and controllers, incorrect wiring or connection of each cable may cause unexpected problems such as a disconnected cable or poor contact, or even a runaway system. This section explains prohibited handling of cables. Read the information carefully to connect the cables properly.

Ten Rules for Handling Cables (Must be Observed!)

1. Do not let the cable flex at a single point.

Steel band (piano wire)

Bundle loosely.

2. Do not let the cable bend, kink or twist. 3. Do not pull the cable with a strong force.

4. Do not let the cable receive a turning force at a single point.

5. When fixing the cable, provide a moderate slack and do not tension it too tight.

Use a curly

cable.

6. Do not pinch, drop a heavy object onto or cut the cable.

Do not use a spiral tube where the cable flexes frequently.

Pre-9

7. Do not let the cable got tangled or kinked in a cable track or flexible tube. When bundling the cable, keep a certain degree of flexibility (so that the cable will not become too taut when bent).

8. Do not cause the cables to occupy more than 60% of the space in the cable track.

Cable track

Cable

10. Always use a robot cable

if the cable is likely to flex significantly.

9. Do not lay signal lines together with circuit lines that create a strong electric field.

Power line

Signal lines (flat cable)

Duct

[Standard structure of cable] The standard structure of cable will vary depending on the manufacturer and type of cable.

Cover

Shield

Protective layer

Signal line (copper + tin)

Absorbing material (When the cable is bent, this material is crushed by the surrounding signal lines to maintain the shape of the signal lines.)

Need for Robot Cables

A cable connected to a moving part of an actuator system will inevitably receive repeated bending loads at the base of the cable. As a result, the cores in the cable may break over time. To minimize the risk of cable breakage, we strongly recommend that a robot cable

offering significantly higher flexibility

be used in this type of application.

Pre-10

Introduction

)

Standard

Introduction

Thank you for purchasing the X-SEL controller.

Inappropriate use will prevent this product from operating at its full potential, and may even cause unexpected failure or result in a shortened service life. Please read this manual carefully, and handle the product with due care and operate it correctly. Keep this manual in a safe place and reference relavent items when needed.

The controller types covered by this manual are listed below.

Type Specification XSEL-PX Standard XSEL-QX Global

Refer to the following table for details on type specification.

Type

[High speed model]

[1] [2] [3] [4] [5] [6] [7] [8] [9] [10]

[1]

Series

[2]

Controller type

(Large-capacity 4-axis

type)

(Large-capacity 5-axis

type)

(Large-capacity 6-axis

type)

(Large-capacity global 4-

axis type)

(Large-capacity global 5-

axis type)

(Large-capacity global 6-

axis type)

[3]

IX actuator type

(Standard type)

(High-speed type)

(Dustproof/splash-proof

type)

(Wall-mount type)

(Wall-mount inverse type)

(Ceiling-mount type)

(Inverse type)

(Cleanroom type)

[4] Axis 5 motor

wattage

Blank

(No single

axis)

[5]

Axis 6

motor

wattage

Blank

(No single

axis)

[6]

Network

(dedicated

slot

Blank

(No network

support)

(DeviceNet

type)

(CC Link type)

(ProfiBus

type)

(Ethernet

type)

[7]

Standard I/O

Slot 1 Slot 2 Slot 3 Slot 4

(Not used)

I/O board

(Not used) (Not used) (Not used)

I/O board

[8] Expansion I/O

I/O board

[9]

I/O flat

cable

length

specification

(None)

* The number of axes that are connectable as axis 5 and/or axis 6, and the total motor wattages, are

shown below.

Type Number of connectable axes Total motor wattage for axes 5/6

*N*2515H/*N*3515H 2 1500

*N*50**H/*N*60**H 2 600 *N*70**H/*N*80**H 0 -

NSN5016H/NSN6016H 0 -

* RCS2-RA7** / LSA series models cannot be connected for axes 5 and 6.

[10] Powersource voltage

3-phase,

)

ype)

Type

[Conventional models]

[1] [2] [3] [4] [5] [6] [7] [8] [9] [10]

[1]

Series

[2]

Controller type

(Large-capacity 4-axis

type)

(Large-capacity 5-axis

type)

(Large-capacity 6-axis

type)

(Large-capacity global 4-

axis type)

(Large-capacity global 5-

axis type)

(Large-capacity global 6-

axis type)

[3]

IX actuator type

(Standard type)

(High-speed type)

(Dustproof/splash-proof

(Wall-mount type)

(Wall-mount inverse type)

(Ceiling-mount type)

(Inverse type)

(Cleanroom type)

[4] Axis 5 motor

wattage

Blank

(No single

axis)

[5] Axis 6 motor

wattage

Blank

(No single

axis)

[6]

Network

(dedicated

slot

Blank

(No network

support)

(DeviceNet

type)

(CC Link type)

(ProfiBus

type)

(Ethernet

type)

[7]

Standard I/O

Slot 1 Slot 2 Slot 3 Slot 4

(Not used) (Not used) (Not used) ( Not used)

I/O board

[8] Expansion I/O

* RCS2-RA7** / LSA series models cannot be connected for axes 5 and 6.

The Axis 5 [4] and Axis 6 [5] portions of the model number are explained below.

750 A L

I/O board

[9]

I/O flat

cable

length

Standard

specification:

(None)

[10] Powersource voltage

Single-

phase

3-phase

20: 20 W 30D: 30 W for RCS2 30R: 30 W for RS 60: 60 W 100: 100 W 150: 150 W

B: With brake C: Creep sensor HA: High-acceleration/deceleration

specification L: Home sensor/LS type M: Master axis specification S: Slave axis specification

200: 200 W 300: 300 W 400: 400 W 600: 600 W 750: 750 W

I: Incremental A: Absolute G: Quasi-absolute

Introduction

This controller receives power in order to drive the actuator motor(s) (three-phase/single-phase, 200 to 220 V) and to operate the controller itself (200 to 220 V). (*The single-phase power specification is applicable only to single-phase controllers.) The actuator motor drive power supply is controlled independently of the control power supply, and the internal operations of the controller are different depending on whether it is of the global specification or standard specification. With the standard controller, the main CPU in the system performs all self-diagnosis checks and supplies power to the drive part only when the system can operate properly. With the global controller, the user must provide a separate circuit that cuts off the three phase 200 VAC motor power supplied to the controller. If this drive power cutoff circuit is not provided, safe operation of the controller cannot be guaranteed.

With the global controller, always configure a safety circuit (drive-source cutoff circuit).

 Turn on the controller power before or simultaneously with the motor power.  Turn off the controller power after or simultaneously with the motor power.  Before performing a check or inserting/removing a connector, turn off the power and wait for at least 10

minutes. Even after the power is turned off, the internal circuits will continue to carry high voltages for a short period.

 Duty of cartesian-axis actuators

IAI recommends that our cartesian-axis actuators be used at a duty of 50% or less as a guideline in view of the relationship of service life and accuracy. The duty is calculated by the formula specified below:

Duty (%) =

Inactivity time Motion



Time onDecelerati / onAccelerati

X 100

 After turning off the control power, be sure to wait for at least 5 seconds (or 40 seconds in the case of a

P type controller of single-phase specification) before turning it back on. Any shorter interval may generate “E6D: Drive-source cutoff error.”

 Do not insert or remove connectors while the controller power is on. Doing so may cause a malfunction.  Precautions for when introducing the linear movement axis absolute specification:

Follow the steps below to initialize the absolute data backup battery circuit and thereby prevent early

consumption of the battery:

[1] Set the absolute data backup battery enable/disable switch to

the bottom position. (The controller is shipped with this switch set to the bottom position.)

[2] Connect the encoder cable. [3] Turn on the power. [4] Set the absolute data backup battery enable/disable switch to

the top (ENB) position. If the encoder cable of a linear movement axis was removed to relocate the actuator, etc., you must always perform the above steps.

Read the operation manual for each actuator. If you have purchased our optional PC software and/or teaching pendant, read the respective operation manuals, as well.

* Utmost effort has been made to ensure that the information contained in this manual is true and

correct. However, should you find any error or if you have any comment regarding the content, please contact IAI.

Part 1 Installation

Caution

Chapter 1 Safety Precautions

The X-SEL PX/QX Controller can support a combination of a SCARA robot and linear movement axes to perform integrated control of all axes including peripheral equipment. In other words, the controller has the ability to control systems of all sizes ranging from a small system to a large factory automation system. In general, however, the occurrence rate of accidents due to incorrect operation or carelessness will rise as the system becomes larger and more complex. Please give due consideration to safety measures.

This system product was developed as a drive unit for an automated machine, and as such the maximum torque and speed are limited to levels acceptable for an automatically driven machine. However, strict observance of the following items is required to prevent accidents. Also read the appendix entitled, “Safety Rules and Others.”

1. Do not handle this product in a manner not specified in this manual. If you have any question regarding the content of this manual, please contact IAI.

2. Always use the specified, genuine IAI cables for wiring between the controller and the actuator.

3. Do not enter the operation area of the machine while the machine is operating or ready to operate (the controller power is on). If the machine is used in a place accessible to other people, provide an appropriate safety measure such as enclosing the machine with a cage.

4. When assembling/adjusting or maintaining/inspecting the machine, always turn off the controller power at the source beforehand. The operator should display in a conspicuous place a sign saying that operation is in progress and that the power should not be turned on. The operator should keep the entire power cable beside him or her to prevent another person from inadvertently plugging in the cable.

5. When two or more operators are to work together, they should communicate to ensure safety of all personnel during the work. In particular, a person turning on/off the power or moving an axis—either via a motor or manually—must always say what he or she is going to do and confirm the responses from the others first before actually performing the operation.

Part 1 Installation

Chapter 2 Warranty Period and Scope of Warranty

The X-SEL Controller you have purchased passed our strict outgoing inspection. This unit is covered by the following warranty:

1. Warranty Period

The warranty period shall be either of the following periods, whichever ends first:

 18 months after shipment from our factory  12 months after delivery to a specified location

2. Scope of Warranty

The warranty is valid only for the IAI product you have purchased, provided that the failure occurred during the aforementioned warranty period despite proper use of the product. If the failure is clearly caused by defective material or poor workmanship, IAI will repair the product free of charge. Take note, however, that the following items are excluded from the scope of warranty:

 Discoloration of paint or other normal aging  Wear of consumable parts due to use  Subjective imperfection, such as noise not affecting 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 unauthorized modification, etc., not approved by IAI or its agent  Defect due to an act of God, accident, fire, etc.

Only the product itself, without accessories, cables, etc., is covered by the warranty. The warranty does not cover any losses arising from a failure of the delivered product. The user must bring the defective product to our factory to receive a warranty repair.

3. Scope of Service

The price of the delivered product does not include costs incurred in association with program generation, dispatch of technician, etc. Therefore, a separate fee will be chargeable in the following cases even during the warranty period:

 Guidance on installation/adjustment and witnessing of test operation  Maintenance/inspection  Technical guidance and training on operation, wiring method, etc.  Technical guidance and training regarding programs, such as program generation  Other services and operations where IAI finds a need to charge a separate fee

Part 1 Installation

Chapter 3 Installation Environment and Selection of Auxiliary Power

Devices

1. Installation Environment

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

(insufficient ventilation will not only prevent the product from functioning fully, but it may also result in damage).

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

is not designed as dustproof or waterproof, avoid using it in a dusty place or a place subject to water

mist, oil, or cutting fluid. (3) Do not expose the controller to direct sunlight or radiant heat from a high heat source. (4) Use the controller in a non-condensing environment free from corrosive or inflammable gases. (5) Use the controller in an environment where it will not receive external vibration or impact. (6) Prevent electrical noise from entering the controller or its cables.

Environmental Condition of Controller

Item Specification and description

Surrounding Air Temperature

Range

Surrounding Humidity Range 10% ~ 95% (non-condensing; conforming to JIS C3502 RH-2)

Storage Temperature Range Maximum Operating Altitude 2000 m

Protection Class IP20

Vibration

Impact

0 ~ 40C

-25C ~ 70C (excluding the battery)

10  f < 57: 0.035 mm (continuous), 0.075 mm (intermittent) 57  f  150: 4.9 m/s

(continuous), 9.8 m/s2 (intermittent)

X, Y and Z directions 147 mm/s

, 11 ms, half-sine pulse, 3 times each in X, Y and Z

directions

Electrical Specifications of Controller

Item Specification

Power-source Voltage

Power-source Frequency

Momentary Power Failure

Resistance

Three-phase, 200 ~ 230 VAC  10%

50/60 Hz  5% (conforming to JIS C3502 RH-2)

0.5 cycle (phase independent)

Single-phase, 200 ~ 230 VAC  10%

Electric Shock Protection Class I: Basic insulation, grounding by ground terminal

Overvoltage Class

Class II: Withstand voltage of 2500 V at voltage inputs below 300

VAC (rated input)

Pollution Degree Pollution degree 2

120 A max. for motor power, 50 A max. for control power (at 40C, 200-VAC input)

Rush Current

The level of rush current will vary depending on the power-source environment. The above values are provided for reference purpose only.

Leak current 2 mA max. (controller only without any axes connected)

+ 530 hidden pages

IAI X-SEL QX, X-SEL PX Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual