IAI America ASEL User Manual

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ASEL Controller

Operation Manual Seventh 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 necessary.

[Important]

" 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.

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 (optional)

For retention of position data, global variables/flags, error list, strings, etc.

[2] Absolute-encoder backup battery (absolute specification)

For retention of multi-rotation data of the encoder

Since these batteries are not rechargeable, they will be eventually 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.)

Once the data is lost, the controller will not operate normally the next time the power is turned on, and recovery will take time.

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

You can specify a desired output port to issue a low voltage alarm for the system-memory backup battery.

Set “15” as the input function specification value in the I/O parameter corresponding to the output port number you want to specify.

Setting example) To specify output port No. 306 to issue a low voltage alarm for the system-memory backup battery, set “15” in I/O parameter No. 52 as the input function specification value.

You can specify a desired output port to issue a low voltage alarm for the absolute-data backup battery.

Set “16” as the input function specification value in the I/O parameter corresponding to the output port number you want to specify.

Setting example) To specify output port No. 307 to issue a low voltage alarm for the absolute-data backup battery, set “16” in I/O parameter No. 53 as the input function specification value.

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

In particular, the person in charge of overall system design should utilize this function to provide a design means for issuing an operator alarm using an output signal from an I/O port, while the person in charge of electrical design should provide an electrical means for achieving the same effect.

For the battery replacement procedure, refer to the applicable section in the operating manual.

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

CAUTION

Optional System-Memory Backup Battery

The ASEL controller can be used with the optional system-memory backup battery.

Caution: When installing the system-memory backup battery, “Other parameter No. 20” must be set to “2.”

Installing the system-memory backup battery will add the following functions to the controller:

x Save SEL global data

Data of global variables, flags and strings will be retained even after the main power is turned off.

x Save RAM position data

Position data changed by SEL programs will be retained even after the main power is turned off.

x Save an error list

An error list containing up to 100 most recent errors will be retained even after the main power is turned off.

If you need any or all of the above functions, you must install the optional system-memory backup battery.

Table of Contents

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

Chapter 1 Overview................................................................................................................................. 1

1. Introduc

2. Type ................................................................................................................................................ 1

3. ASEL Controller Functions .............................................................................................................. 2

4. System Setup .................................................................................................................................. 4

5. Warranty Period and Scope of W

Chapter 2 Specifications

1. Controller Spec

2. Name and Function of Each Part

Chapter 3 Installation and Wiring

1. External Dimens

2. Installation Environment

3. Heat Radiation and Inst

4. Noise Control Measures

5. Supply Voltage .............................................................................................................................. 27

6. Wiring ............................................................................................................................................ 28

6.1 Wiring the Control Power Supply, Emergency S

6.2 Wiring the Motor Power Cables

6.3 Connecting the Ac

6.4 Connecting the PIO Cable (I/O)

6.5 External I/O S

6.6 Connecting the Teaching Pendant/PC (Sof

6.7 Connecting the Panel Unit (Optional

6.8 Installation Method for the Absolute-Dat

6.9 Installing the System-Memory Backup B

Chapter 4 Operation

1. Startup ........................................................................................................................................... 48

1.1 Power ON Sequence

1.2 Power Cutof

2. How to Perform Absolute Res

2.1 Preparation

2.2 Procedure

tion...................................................................................................................................... 1

arranty......................................................................................... 5

.......................................................................................................................... 6

ifications.................................................................................................................. 6

.................................................................................................... 7

.......................................................................................................... 20

ions ..................................................................................................................... 20

................................................................................................................ 22

allation ..................................................................................................... 23

and Grounding....................................................................................... 24

top Switch and Enable Switch................ 28

......................................................................................... 29

tuator .................................................................................................... 30

......................................................................................... 31

pecifications................................................................................................. 36

tware) (TP) (Optional) .................................... 40

) ................................................................................ 40

a Backup Battery ................................................ 46

attery (Optional)................................................. 47

.............................................................................................................................. 48

......................................................................................................... 49

f Sequence..................................................................................................... 49

et (Absolute Specification) ............................................................. 50

........................................................................................................................ 50

.......................................................................................................................... 50

Table of Contents

3. How to Start a Program

3.1 Starting a Program by Auto-S

3.2 Starting via External Signal

4. Drive-Source Recovery Request and Operation-Pause Reset Request

5. Controller Dat

5.1 How to Save Dat

5.2 Points to Note

Chapter 5 Maintenance

1. Inspection points ........................................................................................................................... 64

2. Spare consumable p

3. Replacement Procedure for System-M

4. Replacement Procedure for Absolute-Dat

a Structure............................................................................................................... 60

................................................................................................................. 55

tart via Parameter Setting ................................................... 56

Selection................................................................................ 57

...................................... 59

a .............................................................................................................. 61

.................................................................................................................... 63

......................................................................................................................... 64

arts................................................................................................................ 64

emory Backup Battery (Optional) .................................... 65

a Backup Battery (Optional)........................................ 67

Part 2 Programs .................................................................................................... 69

Chapter 1 SEL Language Data ............................................................................................................. 69

1. Values and Symbols Used in SEL

1.1 List of Values and Symbols Used

1.2 I/O Port

1.3 Virtual I/O Port

1.4 Flags

1.5 Variables ............................................................................................................................ 74

1.6 Tags ................................................................................................................................... 77

1.7 Subroutines

1.8 Symbols ............................................................................................................................. 79

1.9 Character-String Literals

1.10 Axis Spec

2. Position Part

3. Command Part

3.1 SEL language S

3.2 Extension Condition

Chapter 2 List of SEL

1. By Func

2. Alphabetical Order

s............................................................................................................................. 70

s.................................................................................................................. 71

.................................................................................................................................. 73

........................................................................................................................ 78

ification............................................................................................................... 80

.................................................................................................................................. 82

.............................................................................................................................. 83

Language Command Codes.............................................................................. 85

tion ................................................................................................................................... 85

......................................................................................................................... 90

tructure..................................................................................................... 83

Language................................................................................ 69

...................................................................................... 69

.................................................................................................... 79

........................................................................................................... 84

Table of Contents

Chapter 3 Explanation of Commands

................................................................................................... 95

1. Commands .................................................................................................................................... 95

1.1 Variable Ass

1.2 Arithmetic Operation

1.3 Function Operation

1.4 Logical Operation

1.5 Comparison Operation

ignment .......................................................................................................... 95

.......................................................................................................... 98

.......................................................................................................... 101

............................................................................................................. 104

..................................................................................................... 107

1.6 Timer................................................................................................................................ 108

1.7 I/O, Flag Operation

1.8 Program Control

...........................................................................................................111

............................................................................................................... 122

1.9 Task Management............................................................................................................ 125

1.10 Position Operation

1.11 Actuator Control Dec

1.12 Actuator Cont

........................................................................................................... 130

laration............................................................................................ 145

rol Command ............................................................................................. 161

1.13 Structural IF...................................................................................................................... 184

1.14 Structural DO

1.15 Multi-Branching

................................................................................................................... 187

................................................................................................................ 189

1.16 System Information Acquisition........................................................................................ 193

1.17 Zone................................................................................................................................. 196

1.18 Communication................................................................................................................ 200

1.19 String Operation

1.20 Arch-Motion-Related

1.21 Palletizing-Related

1.22 Palletizing Calc

1.23 Palletizing Movement Command

1.24 Building of Pseudo-Ladder T

1.25 Extended Command

Chapter 4 Key Characteristics of Actuator Control

1. Continuous Movement Commands

............................................................................................................... 207

........................................................................................................ 216

........................................................................................................... 221

ulation Command.................................................................................... 228

..................................................................................... 231

ask ...................................................................................... 233

........................................................................................................ 235

Commands and Points to Note ........................... 238

............................................................................................. 238

2. PATH/PSPL Commands.............................................................................................................. 240

3. CIR/ARC Commands

4. CIR2/ARC2/ARCD/ARCC Commands

Chapter 5 Palletizing Function (2-axis S

1. How to Use

.................................................................................................................................. 241

2. Palletizing Setting

3. Palletizing Calc

4. Palletizing Movement

5. Program Examples

.................................................................................................................. 240

........................................................................................ 240

pecification).......................................................................... 241

........................................................................................................................ 241

ulation ................................................................................................................. 246

.................................................................................................................. 247

...................................................................................................................... 248

Table of Contents

Chapter 6 Pseudo-Ladder T

ask........................................................................................................... 250

1. Basic Frame ................................................................................................................................ 250

2. Ladder Statement Field

............................................................................................................... 251

3. Points to Note.............................................................................................................................. 251

4. Program Example

Chapter 7 Application Program Examples

1. Operation by Jog Command

2. Operation by Point Movement Command [Riveting Sys

Chapter 8 Real-Time Multi-T

........................................................................................................................ 252

.......................................................................................... 253

[Doll-Picking Game Machine]........................................................ 253

tem]...................................................... 256

asking..................................................................................................... 259

1. SEL Language............................................................................................................................. 259

2. Multi-Tasking ............................................................................................................................... 260

3. Difference from a Sequencer

...................................................................................................... 261

4. Release of Emergency Stop........................................................................................................ 262

5. Program Swit

Chapter 9 Example of Building a Sys

ching ...................................................................................................................... 263

tem............................................................................................ 264

1. Equipment ................................................................................................................................... 264

2. Operation

3. Overview of the Screw-T

..................................................................................................................................... 264

ightening System ................................................................................. 265

4. Hardware..................................................................................................................................... 266

5. Software ...................................................................................................................................... 267

Chapter 10 Example of Building a Sys

1. Position T

2. Programming Format

3. Positioning to Five Pos

4. How to Use T

able .............................................................................................................................. 269

.................................................................................................................. 270

itions ....................................................................................................... 271

AG and GOTO ....................................................................................................... 272

5. Moving Back and Forth bet

6. Path Operation

............................................................................................................................ 274

7. Output Control during Path Movement

8. Circle/Arc Operation

.................................................................................................................... 276

9. Home Return Completion Output

10. Axis Movement by Input W

11. Changing the Moving S

peed ....................................................................................................... 279

12. Changing the Speed during Operation

13. Local/Global Variables

14. How to Use Subroutines

15. Pausing the Operation

and Flags................................................................................................ 281

.............................................................................................................. 282

................................................................................................................. 283

16. Canceling the Operation 1 (CANC)

17. Canceling the Operation 2 (ST

18. Movement by Position Number S

19. Movement by External Position Dat

tem............................................................................................ 269

ween Two Points .............................................................................. 273

........................................................................................ 275

................................................................................................ 277

aiting and Completion Output........................................................... 278

........................................................................................ 280

............................................................................................. 284

OP) ............................................................................................. 285

pecification.............................................................................. 286

a Input ................................................................................. 287

Table of Contents

20. Conditional Jump

21. Waiting Multiple Input

22. How to Use Offs

23. Executing an Operation N t

24. Constant-pitch Feed

25. Jogging........................................................................................................................................ 293

26. Switching Programs

27. Aborting a Program

......................................................................................................................... 288

s ................................................................................................................ 289

et ....................................................................................................................... 290

imes ................................................................................................. 291

.................................................................................................................... 292

.................................................................................................................... 294

..................................................................................................................... 295

Part 3 Positioner Mode........................................................................................ 296

Chapter 1 Modes and Signal Assignments ......................................................................................... 296

1. Feature of Eac

2. Number of Positions Supported in Eac

3. Quick Mode Function Ref

4. Interface List of All

Chapter 2 Standard Mode

1. I/O Interfac

2. Parameters.................................................................................................................................. 300

3. Details of Each Input Signal

4. Details of Each Output Signal

5. Timing Chart

5.1 Recognition of I/O Signals

5.2 Home Return

5.3 Movements through Pos

Chapter 3 Product Switching Mode

1. I/O Interfac

2. Parameters.................................................................................................................................. 309

3. Details of Each Input Signal

4. Details of Each Output Signal

5. Timing Chart

5.1 Recognition of I/O Signals

5.2 Home Return

5.3 Movements through Pos

Chapter 4 2-axis Independent Mode

1. I/O Interfac

2. Parameters.................................................................................................................................. 319

3. Details of Each Input Signal

4. Details of Each Output Signal

5. Timing Chart

h Mode................................................................................................................. 296

h Mode ........................................................................... 297

erence Table ....................................................................................... 297

PIO Patterns ................................................................................................. 298

................................................................................................................... 299

e List .......................................................................................................................... 299

........................................................................................................ 300

..................................................................................................... 303

................................................................................................................................304

............................................................................................... 304

.................................................................................................................... 305

itions ......................................................................................... 306

..................................................................................................... 308

e List .......................................................................................................................... 308

........................................................................................................ 310

..................................................................................................... 313

................................................................................................................................314

............................................................................................... 314

.................................................................................................................... 315

itions ......................................................................................... 316

................................................................................................... 318

e List .......................................................................................................................... 318

........................................................................................................ 320

..................................................................................................... 322

................................................................................................................................324

Table of Contents

5.1 Recognition of I/O Signals

5.2 Home Return

5.3 Movements through Pos

Chapter 5 Teac

1. I/O Interfac

.................................................................................................................... 325

hing Mode ................................................................................................................... 327

e List .......................................................................................................................... 328

............................................................................................... 324

itions ......................................................................................... 326

2. Parameters.................................................................................................................................. 329

3. Details of Each Input Signal

4. Details of Each Output Signal

5. Timing Chart

................................................................................................................................334

5.1 Recognition of I/O Signals

5.2 Home Return

5.3 Movements through Pos

5.4 Timings in the T

Chapter 6 DS-S-C1 Comp

1. I/O Interfac

e List .......................................................................................................................... 338

.................................................................................................................... 335

atible Mode................................................................................................ 338

........................................................................................................ 329

..................................................................................................... 332

............................................................................................... 334

itions ......................................................................................... 336

eaching Mode ......................................................................................... 337

2. Parameters.................................................................................................................................. 339

3. Details of Each Input Signal

4. Details of Each Output Signal

5. Timing Chart

................................................................................................................................342

5.1 Recognition of I/O Signals

5.2 Home Return

.................................................................................................................... 343

5.3 Movements through Pos

........................................................................................................ 339

..................................................................................................... 341

............................................................................................... 342

itions ......................................................................................... 344

Table of Contents

Appendi

x ................................................................................................................. 347

Battery Backup Function ................................................................................................................... 347

1. System-Memory Backup Battery................................................................................................. 347

2. Absolute-Data Backup Battery for Absolute Encoder ................................................................. 349

Parameter Utilization ......................................................................................................................... 351

1. Utilization Examples of I/O Parameters ...................................................................................... 352

2. Utilization Examples of Axis-specific Parameters ....................................................................... 359

3. Parameter Utilization Examples (Reference).............................................................................. 368

4. Servo Gain Adjustment................................................................................................................ 372

List of Parameters.............................................................................................................................. 374

1. I/O Parameters ............................................................................................................................ 375

1.1 I/O Parameters................................................................................................................. 375

1.2 I/O Function Lists............................................................................................................. 381

2. Parameters Common to All Axes ................................................................................................ 383

3. Axis-Specific Parameters ............................................................................................................ 385

4. Driver Parameters ....................................................................................................................... 389

5. Encoder Parameters ................................................................................................................... 392

6. I/O Devices.................................................................................................................................. 393

7. Other Parameters........................................................................................................................ 394

8. Manual Operation Types ............................................................................................................. 399

Combination Table of ASEL Linear/Rotary Control Parameters ........................................................ 340

Error Level Control............................................................................................................................. 401

Error List ............................................................................................................................................ 403

Error List ............................................................................................................................................ 435

Troubleshooting of ASEL Controller .................................................................................................. 439

Trouble Report Sheet ........................................................................................................... 443

.............

Change History 444

..........................................................................................................

Safety Guide

“Safety Guide” has been written to use the machine safely and so prevent personal injury or property damage beforehand. Make sure to read it before the operation of this product.

Safety Precautions for Our Products

The common safety precautions for the use of any of our robots in each operation.

No.

1 Model

Description

Selection

Operation

Description

Ɣ This product has not been planned and designed for the application where

high level of safety is required, so the guarantee of the protection of human life is impossible. Accordingly, do not use it in any of 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 (For vehicle, railway facility or air navigation facility)

3) Important safety parts of machinery (Safety device, etc.)

Ɣ Do not use the product outside the specifications. Failure to do so may

considerably shorten the life of the product.

Ɣ Do not use it in any of the following environments.

1) Location where there is any inflammable gas, inflammable object or explosive

2) Place with potential exposure to radiation

3) Location with the ambient temperature or relative humidity exceeding the specification range

4) Location where radiant heat is added from direct sunlight or other large heat source

5) Location where condensation occurs due to abrupt temperature changes

6) Location where there is any corrosive gas (sulfuric acid or hydrochloric acid)

7) Location exposed to significant amount of dust, salt or iron powder

8) Location subject to direct vibration or impact

Ɣ For an actuator used in vertical orientation, select a model which is

equipped with a brake. If selecting a model with no brake, the moving part may drop when the power is turned OFF and may cause an accident such as an injury or damage on the work piece.

No.

Operation

Description

2 Transportation Ɣ When carrying a heavy object, do the work with two or more persons or

utilize equipment such as crane.

Ɣ When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

Ɣ When in transportation, consider well about the positions to hold, weight

and weight balance and pay special attention to the carried object so it would not get hit or dropped.

Ɣ Transport it using an appropriate transportation measure.

The actuators available for transportation with a crane have eyebolts attached or there are tapped holes to attach bolts. Follow the instructions in the operation manual for each model.

Ɣ Do not step or sit on the package. Ɣ Do not put any heavy thing that can deform the package, on it. Ɣ When using a crane capable of 1t or more of weight, have an operator

who has qualifications for crane operation and sling work.

Ɣ When using a crane or equivalent equipments, make sure not to hang a

load that weighs more than the equipment’s capability limit.

Ɣ Use a hook that is suitable for the load. Consider the safety factor of the

hook in such factors as shear strength.

Ɣ Do not get on the load that is hung on a crane. Ɣ Do not leave a load hung up with a crane. Ɣ Do not stand under the load that is hung up with a crane.

3 Storage and

Preservation

Ɣ The storage and preservation environment conforms to the installation

environment. However, especially give consideration to the prevention of condensation.

Ɣ Store the products with a consideration not to fall them over or drop due to

an act of God such as earthquake.

4 Installation

and Start

(1) Installation of Robot Main Body and Controller, etc. Ɣ Make sure to securely hold and fix the product (including the work part). A

fall, drop or abnormal motion of the product may cause a damage or injury. Also, be equipped for a fall-over or drop due to an act of God such as earthquake.

Ɣ Do not get on or put anything on the product. Failure to do so may cause

an accidental fall, injury or damage to the product due to a drop of anything, malfunction of the product, performance degradation, or shortening of its life.

Ɣ When using the product in any of the places specified below, provide a

sufficient shield.

1) Location where electric noise is generated

2) Location where high electrical or magnetic field is present

3) Location with the mains or power lines passing nearby

4) Location where the product may come in contact with water, oil or chemical droplets

No.

Operation

Description

4 Installation

and Start

Description

(2) Cable Wiring Ɣ Use our company’s genuine cables for connecting between the actuator

and controller, and for the teaching tool.

Ɣ Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not

coil it around. Do not insert it. Do not put any heavy thing on it. Failure to do so may cause a fire, electric shock or malfunction due to leakage or continuity error.

Ɣ Perform the wiring for the product, after turning OFF the power to the unit,

so that there is no wiring error.

Ɣ When the direct current power (+24V) is connected, take the great care of

the directions of positive and negative poles. If the connection direction is not correct, it might cause a fire, product breakdown or malfunction.

Ɣ Connect the cable connector securely so that there is no disconnection or

looseness. Failure to do so may cause a fire, electric shock or malfunction of the product.

Ɣ Never cut and/or reconnect the cables supplied with the product for the

purpose of extending or shortening the cable length. Failure to do so may

cause the product to malfunction or cause fire. (3) Grounding Ɣ The grounding operation should be performed to prevent an electric shock

or electrostatic charge, enhance the noise-resistance ability and control

the unnecessary electromagnetic radiation. Ɣ For the ground terminal on the AC power cable of the controller and the

grounding plate in the control panel, make sure to use a twisted pair cable

with wire thickness 0.5mm

(AWG20 or equivalent) or more for grounding work. For security grounding, it is necessary to select an appropriate wire thickness suitable for the load. Perform wiring that satisfies the specifications (electrical equipment technical standards).

Ɣ Perform Class D Grounding (former Class 3 Grounding with ground

resistance 100: or below).

No.

Operation

Description

4 Installation

and Start

(4) Safety Measures Ɣ When the work is carried out with 2 or more persons, make it clear who is

Description

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

Ɣ When the product is under operation or in the ready mode, take the safety

measures (such as the installation of safety and protection fence) so that nobody can enter the area within the robot’s movable range. When the robot under operation is touched, it may result in death or serious injury.

Ɣ Make sure to install the emergency stop circuit so that the unit can be

stopped immediately in an emergency during the unit operation.

Ɣ Take the safety measure not to start up the unit only with the power turning

ON. Failure to do so may start up the machine suddenly and cause an injury or damage to the product.

Ɣ Take the safety measure not to start up the machine only with the

emergency stop cancellation or recovery after the power failure. Failure to do so may result in an electric shock or injury due to unexpected power input.

Ɣ When the installation or adjustment operation is to be performed, give

clear warnings such as “Under Operation; Do not turn ON the power!” etc. Sudden power input may cause an electric shock or injury.

Ɣ Take the measure so that the work part is not dropped in power failure or

emergency stop.

Ɣ Wear protection gloves, goggle or safety shoes, as necessary, to secure

safety.

Ɣ Do not insert a finger or object in the openings in the product. Failure to do

so may cause an injury, electric shock, damage to the product or fire.

Ɣ When releasing the brake on a vertically oriented actuator, exercise

precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity.

5 Teaching Ɣ When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

Ɣ Perform the teaching operation from outside the safety protection fence, if

possible. In the case that the operation is to be performed unavoidably inside the safety protection fence, prepare the “Stipulations for the Operation” and make sure that all the workers acknowledge and understand them well.

Ɣ When the operation is to be performed inside the safety protection fence,

the worker should have an emergency stop switch at hand with him so that the unit can be stopped any time in an emergency.

Ɣ When the operation is to be performed inside the safety protection fence,

in addition to the workers, arrange a watchman so that the machine can be stopped any time in an emergency. Also, keep watch on the operation so that any third person can not operate the switches carelessly.

Ɣ Place a sign “Under Operation” at the position easy to see. Ɣ When releasing the brake on a vertically oriented actuator, exercise

precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity.

* Safety protection Fence : In the case that there is no safety protection

fence, the movable range should be indicated.

No.

Operation

Description

6 Trial Operation Ɣ When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

Ɣ After the teaching or programming operation, perform the check operation

one step by one step and then shift to the automatic operation.

Ɣ When the check operation is to be performed inside the safety protection

fence, perform the check operation using the previously specified work procedure like the teaching operation.

Ɣ Make sure to perform the programmed operation check at the safety

speed. Failure to do so may result in an accident due to unexpected motion caused by a program error, etc.

Ɣ Do not touch the terminal block or any of the various setting switches in

the power ON mode. Failure to do so may result in an electric shock or malfunction.

7 Automatic

Operation

Ɣ Check before starting the automatic operation or rebooting after operation

stop that there is nobody in the safety protection fence.

Ɣ Before starting automatic operation, make sure that all peripheral

equipment is in an automatic-operation-ready state and there is no alarm indication.

Ɣ Make sure to operate automatic operation start from outside of the safety

protection fence.

Ɣ In the case that there is any abnormal heating, smoke, offensive smell, or

abnormal noise in the product, immediately stop the machine and turn OFF the power switch. Failure to do so may result in a fire or damage to the product.

Ɣ When a power failure occurs, turn OFF the power switch. Failure to do so

may cause an injury or damage to the product, due to a sudden motion of the product in the recovery operation from the power failure.

No.

Operation

Description

8 Maintenance

and Inspection

Ɣ When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with

Description

each other to ensure the safety of the workers.

Ɣ Perform the work out of the safety protection fence, if possible. In the case

that the operation is to be performed unavoidably inside the safety protection fence, prepare the “Stipulations for the Operation” and make sure that all the workers acknowledge and understand them well.

Ɣ When the work is to be performed inside the safety protection fence,

basically turn OFF the power switch.

Ɣ When the operation is to be performed inside the safety protection fence,

the worker should have an emergency stop switch at hand with him so that the unit can be stopped any time in an emergency.

Ɣ When the operation is to be performed inside the safety protection fence,

Ɣ Place a sign “Under Operation” at the position easy to see. Ɣ For the grease for the guide or ball screw, use appropriate grease

according to the Operation Manual for each model.

Ɣ Do not perform the dielectric strength test. Failure to do so may result in a

damage to the product.

Ɣ When releasing the brake on a vertically oriented actuator, exercise

precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity.

Ɣ The slider or rod may get misaligned OFF the stop position if the servo is

turned OFF. Be careful not to get injured or damaged due to an unnecessary operation.

Ɣ Pay attention not to lose the cover or untightened screws, and make sure

to put the product back to the original condition after maintenance and inspection works. Use in incomplete condition may cause damage to the product or an injury.

* Safety protection Fence : In the case that there is no safety protection

fence, the movable range should be indicated.

9 Modification

and Dismantle

Ɣ Do not modify, disassemble, assemble or use of maintenance parts not

specified based at your own discretion.

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

properly as an industrial waste.

Ɣ When removing the actuator for disposal, pay attention to drop of

components when detaching screws.

Ɣ Do not put the product in a fire when disposing of it.

The product may burst or generate toxic gases.

11 Other Ɣ Do not come close to the product or the harnesses if you are a person

who requires a support of medical devices such as a pacemaker. Doing so may affect the performance of your medical device.

Ɣ See Overseas Specifications Compliance Manual to check whether

complies if necessary.

Ɣ For the handling of actuators and controllers, follow the dedicated

operation manual of each unit to ensure the safety.

Alert Indication

The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the warning level, as follows, and described in the Operation Manual for each model.

lobmySegamaDdnaregnaDfoeergeDleveL

Danger

Warning

Caution

Notice

This indicates an imminently hazardous situation which, if the product is not handled correctly, will result in death or serious injury.

This indicates a potentially hazardous situation which, if the product is not handled correctly, could result in death or serious injury.

This indicates a potentially hazardous situation which, if the product is not handled correctly, may result in minor injury or property damage.

This indicates lower possibility for the injury, but should be kept to use this product properly.

Danger

Warning

Caution

Notice

CE Marking

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

Part 1 Installation

Chapter 1 Overview

1. Introduction

Thank you for purchasing the ASEL Controller.

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 relevant items when needed.

When actually starting up your system or if you have encountered a problem, you should also refer to the manuals for the 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.”

* Utmost effort has been made to ensure accuracy and completeness of the information contained in this

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

Keep this manual in a convenient place so that you can quickly reference it whenever necessary.

Part 1 Installation Chapter 1 Overview

2. Type

Refer to the following table for details on type specification.

Example of type specification

Type specification table

Details of axis 1 to axis 2

Series

Controller

type

(Standard

specification)

Number

of axes

(Axis 1)

(Axis 2)

Motor

output (W)

Encoder

type

(Incremental)

(Absolute)

Brake

Blank

(Without

brake)

(With brake)

(Without home

Home

sensor

Blank

sensor)

(With home

sensor)

Standard

I/O

Standard PIO

24 inputs/8 outputs

NPN specification

Standard PIO

24 inputs/8 outputs

PNP specification

I/O flat

cable length

(Standard)

None

Powersource voltage

0: 24 VDC

3. ASEL Controller Functions

The functions provided by the ASEL controller are structured in the following manner.

Part 1 Installation

The ASEL controller has the “program mode” in which SEL programs are input to operate the actuator(s), and the “positioner mode” in which position numbers are specified from the host PLC to operate the actuator(s).

Chapter 1 Overview

The positioner mode provides five sub-modes to meet the needs of various applications. The program mode has been selected at the factory prior to the shipment of the controller (Other parameter No. 25 = 0).

ASEL

Program mode

Positioner mode

Standard mode

Product switching mode

2-axis independent mode

Teaching mode

DS-S-C1 compatible mode

Caution: Two modes cannot be selected at the same time.

Part 1 Installation

This controller can be configured with one axis and two axes. Just like other conventional SEL controllers, this controller can be combined with various actuators. When connecting an actuator, be sure to use a dedicated cable.

x Turn on the I/O power before or simultaneously with the main power (control power + motor power). x Take the control power and motor power from the same power supply and turn on both powers

simultaneously.

x Before performing a check or inserting/removing a connector, turn off the power and wait for at least 10

minutes.

x About actuator duty

IAI recommends that our actuators be used at a duty of 50% or less as a guideline in view of the relationship of service life and accuracy:

Part 1 Installation Chapter 1 Overview

Duty (%) =

Inactivity time Motion



Time onDecelerati / onAccelerati

X 100

x After turning off the control power, be sure to wait for at least 5 seconds before turning it back on. x Do not insert or remove connectors while the controller power is on. Doing so may cause malfunction.

x Note on introducing a controller of absolute specification

The following steps must be taken to initialize the absolute-data backup battery circuit to prevent the battery from being consumed quickly. Perform the initialization by following these steps: [1] Before connecting the encoder cable, disconnect the absolute-data backup battery connector. [2] Connect the encoder cable. [3] Turn on the main power. [4] Connect the absolute-data backup battery. The above steps must always be performed after the encoder cable has been disconnected for any reason, such as to move the controller.

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.

4. System Setup

Part 1 Installation

Host

system

Chapter 1 Overview

24-VDC power supply

Teaching

pendant

Enable switch

Conversion cable

Dummy plug

Emergency stop switch

Panel unit

* Note on connecting the encoder cable to a controller of absolute specification

Follow the steps below when connecting the encoder cable to a controller of absolute specification. If the specified steps are not followed, the absolute-data backup battery may be consumed quickly. [1] Before connecting the encoder cable, disconnect the absolute-data backup battery connector. [2] Connect the encoder cable, and turn on the main power. [3] Connect the absolute-data backup battery connector. Once the connector has been plugged in, the main

power can be turned off. For the installation of the absolute-data backup battery, refer to 6.8, “Installation Method for the Absolute-Data Backup Battery” in Chapter 3 of Part 1. If you have disconnected the encoder cable for any reason, such as to move the controller, also follow the same steps to connect the absolute-data backup battery connector.

5. Warranty Period and Scope of Warranty

Part 1 Installation

The ASEL 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:

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

2. Scope of Warranty

Should the product fail during the above period under a proper use condition due to a fault on the part of the manufacturer, IAI will repair the defect free of charge. However, the following cases are excluded from the scope of warranty:

x Discoloration of paint or other normal aging x Wear of consumable parts due to use x Subjective imperfection, such as noise not affecting mechanical function x Defect caused by inappropriate handling or use by the user x Defect caused by inappropriate or erroneous maintenance/inspection x Defect caused by use of a part other than IAI’s genuine part x Defect caused by unauthorized modification, etc., not approved by IAI or its agent x Defect due to an act of God, accident, fire, etc.

The warranty covers only the product as it is delivered. IAI shall not be liable for any loss arising in connection with the delivered product. The user must bring the defective product to our factory to receive a warranty repair.

Part 1 Installation Chapter 1 Overview

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:

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

Chapter 2 Specifications

1. Controller Specifications

Base specifications of this product

Total output when maximum number of axes are connected

Control power input

Motor power input

Part 1 Installation

Chapter 2 Specications

Resistance against momentary power failure

Withstand voltage

Insulation resistance

Drive-source cutoff method Internal relay

Emergency stop input Contact B input (Internal power-supply type)

Emergency stop action Deceleration stop + Regenerative brake by timer

Enable input Contact B input (Internal power-supply type)

Control method AC full digital servo

Position detection method

Battery

Programming language Super SEL language

Number of program steps 2000 steps (total)

Number of positions 1500 positions (total)

Number of programs 64 programs

Multi-tasking capability 8 programs

Storage device Flash ROM

Data input method Teaching pendant or PC software

PIO power input

Safety category Category B (Built-in relay)

Regenerative resistor

PIO inputs 24 points, NPN or PNP (Selectable as factory setting)

PIO outputs 8 points, NPN or PNP (Selectable as factory setting)

Air cooling method Natural convection method

Weight 450 g

External dimensions 43 (W) x 159 (H) x 110 (D); mounting pitch 151 mm

Accessories

Part 1 Installation

30 W x 2 axes

24 VDC r 10% 24 VDC r 10%

Maximum 0.5 msec

1500 VAC for 1 minute (Measured between all power-supply terminals and FG)

500 VDC, 10 M: or more

Incremental serial encoder Absolute serial encoder ABZ parallel encoder Absolute-data backup battery/System-memory backup battery (Optional) Lithium battery: AB-5 by IAI, 3.6 V/2000 mAh

24 VDC r 10%

Built-in, 100 : (2 W). An external resistor of 22 : (5 W) can be connected.

I/O flat cable Motor power connector Control power & system I/O connector RB connector (Not normally used)

2. Name and Function of Each Part

Part 1 Installation

2.1 Name of Each Part

2.1.1 Front View

[9] PIO connector

[10] MANU/AUTO switch

Part 1 Installation Chapter 2 Specications

[1] Axis 1 motor

connector

[2] Axis 2 motor

connector

[3] Axis 1 brake-release

switch

[4] Axis 1 encoder

connector

[5] Axis 2 brake-release

switch

[6] Axis 2 encoder

[11] USB connector

[12] Teaching connector

*1 For the 1-axis specification, [2], [5] and [6] are not installed and the front panel is masked.

connector

[7] LED indicators

[8] Panel unit connector

2.1.2 Down View

[14] Control power &

Part 1 Installation

[15] Regenerative

[16] Motor power

system I/O connector

resistor connector

connector

Part 1 Installation

[17] Axis 1 absolute-data

backup battery connector

[18 Axis 2 absolute-data

backup battery connector

2.1.3 Top View

[13] System-memory backup

Chapter 2 Specications

battery connector

Part 1 Installation

[1] Axis 1 motor connector (M1): This connector is used to connect the motor cable for axis 1.

Motor Connector Specifications

Item Specification Remarks

2.5-mm pitch connector, 3 pins Cable-end

connector Connector name M1 Maximum connection distance Connected cable Motor cable AWG22 X 3C

20 m

DF1E-3P-2.5DS (Hirose) Applicable connector

DF1E-3S-2.5C (Hirose) Contact: DF1E-2022SC (Hirose)

[2] Axis 2 motor connector (M2): This connector is used to connect the motor drive-source cable for

axis 2. The specifications are the same as those of the axis 1 motor connector.

Part 1 Installation Chapter 2 Specications

[3] Axis 1 brake-release switch

(BK1):

RLS (left) NOM (right)

This switch is used to forcibly release the electromagnetic brake of the actuator constituting axis 1.

Name Description

RLS Supply the power to the brake and forcibly release the brake.

NOM

Turn the brake ON/OFF using an internal sequence. Normally this switch is set to the “NOM” side.

Part 1 Installation

[4] Axis 1 encoder/sensor

connector (PG1):

Part 1 Installation

This connector is used to connect the encoder cable for axis 1. It connects the encoder cable of the actuator constituting axis 1.

Encoder Connector Specifications

Item Specification Remarks

2-mm pitch, double-

S18B-PHDRS-B (JST) Applicable connector row connector, 18 pins Cable-end connector PHDR-18VR (JST)

Contact: SPHD-001T-

P0.5 (JST)

Connector name PG1 Maximum connection distance

20 m

Connected cable Motor cable AWG26 X 7P Shielded

Chapter 2 Specications

Part 1 Installation

Part 1 Installation Chapter 2 Specications

Actuator end

welded)

(pressure-

Red

Drain

Color Wire

Signal

ABZ Serial

Plug housing: XMP-18V (JST) X 1

Socket contact: BXA-001T-P0.6 (JST) X 15

Retainer: XMS-09V (JST) X 2

White/Red

White/Blue

White/Black

White/Yellow

White/Purple

Orange

Gray

Green

Purple

Blue

Black

Yellow

White/Gray

(“White/blue” and other designations under

“Color” indicate band color/insulator color.)

Drain wire and braided shield wire

Blue

Yellow

White/Gray

White/Purple

Wiring diagram

Housing: (JST) X 1 (red)

Contact: (JST) X 15

Encoder cable

Cable model:

Wire Color Signal

White/Red

White/Blue

White/Yellow

Green

Orange

White/Black

welded)

(pressure-

Red

Gray

Purple

Black

Drain

Controller end

Part 1 Installation

Actuator end

welded)

(pressure-

Chapter 2 Specications

Red

Gray

Color Wire

Signal

ABZ Serial

Plug housing: XMP-18V (JST) X 1

Socket contact: BXA-001T-P0.6 (JST) X 15

Retainer: XMS-09V (JST) X 2

Black

Yellow

Blue

Pink

Drain

White

Purple

Blue/Red

Orange/White

Green/White

Green

Brown

Orange

(“White/blue” and other designations under

“Color” indicate band color/insulator color.)

Drain wire and braided shield wire

Blue

Green

Orange

Wiring diagram

Housing: (JST) X 1 (red)

Contact: (JST) X 15

Encoder cable

Cable model:

Wire Color Signal

Red

Gray

Brown

Pink

Black

Yellow

(pressure-

White

Purple

Red/Blue

Orange/White

Green/White

welded)

Drain

Controller end

Part 1 Installation

[5] Axis 2 brake-release switch

(BK2):

This switch is used to forcibly release the electromagnetic brake of the actuator constituting axis 2. The specifications are the same as those of the axis 1 brake-release switch in [3].

[6] Axis 2 encoder/sensor

connector (PG2):

This connector is used to connect to the encoder cable for axis 2. The specifications are the same as those of the axis 1 encoder/sensor connector in [4].

[7] LED indicators: These indicators indicate the controller status.

Name Color Status when the LED is lit

PWR

RDY Green The controller is ready.

ALM Orange

EMG Red An emergency stop is being actuated.

SV1 Green The servo for axis 1 is on.

SV2 Green The servo for axis 2 is on.

Green

The controller has been started successfully and is receiving power.

An alarm is present (an error of message level or higher has generated.)

[8] Panel unit connector: This connector is used to connect the optional panel unit.

Part 1 Installation Chapter 2 Specications

[9] PIO connector: This 34-pin, flat DIO connector consists of 24 inputs and eight

outputs.

Standard I/O Interface Specifications (key items)

Item Description

Connector name I/O

Applicable connector Flat connector, 34 pins

Power supply

Inputs

Outputs

Connected to External PLC, sensor, etc.

Power is supplied from connector pin Nos. 1 and 34. 24 points (including general-purpose inputs and dedicated inputs) 8 points (including general-purpose outputs and dedicated outputs)

I/O Interface List (Program mode)

Pin No. Category Port No. Function Cable color

1A - External power supply 24 V 1-Brown

1B 016

2A 017

2B 018

3A 019

3B 020

Part 1 Installation

Chapter 2 Specications

4A 021

4B 022

5A 023

5B 000

6A 001

6B 002

7A 003

7B 004

8A 005

8B 006

9A 007

9B 008

10A 009

10B 010

11A 011

11B 012

12A 013

12B 014

13A

13B 300

14A 301

14B 302

15A 303

15B 304

16A 305

16B 306

17A 17B N External power supply 0 V 4-Yellow

Input

Output

Program specification (PRG No. 1) 1-Red

Program specification (PRG No. 2) 1-Orange

Program specification (PRG No. 4) 1-Yellow

Program specification (PRG No. 8) 1-Green

Program specification (PRG No. 10) 1-Blue

Program specification (PRG No. 20) 1-Purple

Program specification (PRG No. 40) 1-Gray

Software reset (restart) 1-White

Program start 1-Black

General-purpose input 2-Brown

General-purpose input 2-Red

General-purpose input 2-Orange

General-purpose input 2-Yellow

General-purpose input 2-Green

General-purpose input 2-Blue

General-purpose input 2-Purple

General-purpose input 2-Gray

General-purpose input 2-White

General-purpose input 2-Black

General-purpose input 3-Brown

General-purpose input 3-Red

General-purpose input 3-Orange

General-purpose input 3-Yellow

General-purpose input 3-Green

015

Alarm output 3-Blue

Ready output 3- Purple

Emergency-stop output 3-Gray

Emergency-stop output 3-White

General-purpose output 3-Black

General-purpose output 4-Brown

General-purpose output 4-Red

General-purpose output 4-Orange

307

Part 1 Installation

The above functions reflect the factory settings for the program mode. These functions can be changed by changing the corresponding parameters.

Part 1 Installation

[10] MANU/AUTO switch: This switch is used to specify the controller operation mode.

MANU AUTO

(left) (right)

Teaching pendant/PC software operation

(When the teaching connector is used)

PC software operation (when the USB connector is used)

Starting of an auto start program Not possible Possible

Possible Not possible

Possible

Note)

Not possible

Note) When this switch is set to the “MANU” side and the USB

connector is used, the servo cannot be turned on unless a dummy plug or teaching pendant is connected to the TP connector. When the USB connector is used, always keep a dummy plug or PC software cable connected to the TP plug while the controller is in use. (This is to cancel the disabled condition.)

If a dummy plug is used, always operate the controller in a

condition where the emergency stop switch is within an easy reach.

[11] USB connector: This connector is used to connect the PC software and the

controller via a USB cable. Connector: USB connector B (XM7B-0442) Connected to: USB cable The maximum USB cable length is 5 m.

Part 1 Installation Chapter 2 Specications

Note y When the USB port is used, the USB driver contained in the “X-SEL PC Software IA-101-X-USB” CD-

ROM must be installed by connecting all applicable controllers one by one. For the driver installation method, refer to the X-SEL PC Software Operation Manual.

y When the USB port is used, a dummy plug must be connected to the teaching connector [12].

Dummy plug model: DP-3

Part 1 Installation

[12] Teaching connector

(TP):

Part 1 Installation

Chapter 2 Specications

The teaching interface connects IAI’s teaching pendant or a PC (PC software) to enable operation and setting of your equipment from the teaching pendant/PC. The interface is a RS232C system based on a 26-pin, half-pitch I/O connector. The signal level conforms to RS232C, and a desired baud rate (maximum 115.2 kbps) can be selected based on the program. This connector can be used only when the mode switch is set to “MANU.”

Interface Specifications of Teaching Serial Interface

Item Description Details

26-pin, half-pitch I/O connector Mating connector TX20A-26PH1-D2P1-D1E (by JAE)

Connector name Baud rate Up to 115.2 kbps Half-duplex communication speeds of

Maximum wiring distance Interface standard Connected unit Dedicated teaching

Connection cable Power supply 5 VDC or 24 VDC A multi-fuse (MF-R090) is installed to

Protocol X-SEL teaching

Emergencystop control

Enabling control

T.P. Teaching connector

10M At 38.4 kbps

RS232C

pendant

protocol Series emergencystop relay drive (24 V)

Enable switch line (24 V)

TX20A-26R-D2LT1-A1LHE (by JAE) Connector

up to 115.2 kbps are supported.

IAI’s standard IA-T-X (D) for X-SEL

Dedicated cable

protect each line against short current (the fuse will trip with currents of between 1.1 A and 2.2 A). The connector supports the X-SEL teaching pendant interface protocol. An emergency-stop relay drive line is provided in the interface connector. This line is connected in series with other emergency-stop contact. A line for connecting an enable switch is provided as an operator interlock..

Teaching pendant & dedicated communication cable connector

Item Specification Remarks

Pin No. I/O Signal name

1 SG Signal ground

2 Out EMGS Emergency-stop status

Power output (Standard IA-T-X/XD power supply (5 V))

Power output (ANSI compliant IA-T-XA power supply (24 V))

Clear to send (Not used / Used as the TPconnection detection terminal)

Terminal

assignments

3 Out VCC

4 In DTR Data terminal ready (Shorted to DSR)

5 NC Not connected

6 NC Not connected

7 NC Not connected

8 Out RSVVCC

9 In EMGIN Emergency-stop contact output, negative

10 Out RSVVCC

11 NC Not connected

12 Out EMGOUT2 Emergency-stop contact output, positive

13 Out RTS Request to send (Not used; fixed to 0 V)

14 In CTS

15 Out TXD Transmitted data

16 In RXD Received data

17 Out DSR Data set ready (Shorted to DTR)

18 NC Not connected

19 NC Not connected

20 NC Not connected

21 NC Not connected

22 NC Not connected

23 In ENBTB Enable input

24 Out ENBVCC Enable drive power (24V)

25 NC Not connected (Reserved by ENBTBX2)

26 SG Signal ground

Part 1 Installation

Part 1 Installation Chapter 2 Specications

Part 1 Installation

[13] System-memory backup

battery connector:

[14] Control power & system

I/O connector:

Part 1 Installation

Chapter 2 Specications

This connector is used to install the system-memory backup battery.

This connector is used to input the 24-VDC control power and connect the emergency stop switch and enable switch. The power supply connected to this connector is used for the controller internal power, brake power, and so on, and not used as the motor drive source. The 0-V input is connected to the ground for the controller’s internal power supply and is not insulated.

Item Specification Remarks

3.5 mm, 2-piece COMBICON, 6 pins

Applicable connector

Connector name CP EMG ENB

Input voltage 24 VDC + 10%/-10% Maximum input

current

Terminal assignments

Cable-end connector

Applicable wire size AWG20 ~ 16 (0.5 ~ 1.25 sq) Recommended stripped-

wire length

1.2 A

No. Name Function

1 EMG+ Emergency stop switch +

2 EMG- Emergency stop switch -

3 ENB+ Enable switch +

4 ENB- Enable switch -

5 0V

6 24V Control power input +24 V

MC1.5/6-G-3.5 by Phoenix Contact MC1.5/6-ST-3.5 by Phoenix Contact

7 mm

Control power input ground (Connected to the internal ground)

[15] Regenerative resistor

connector:

This connector is used to connect a regenerative resistor when the built-in regenerative resistor alone cannot provide enough capacity in highacceleration/high-load operation, etc. This connector is not normally used with the ASEL controller.

Part 1 Installation

[16] Motor power connector: This connector is used to input the 24-VDC motor power.

The power supply connected to this connector is used as the dedicated motor drive source. Since the controller has a built-in drive-source cutoff relay, the power supply to the motor will be cut off internally if an emergency stop is actuated or other abnormality occurs. Although the motor power and control power are input independently, the 0-V terminals of both are connected inside the controller. They are also connected to the ground for the controller’s internal power supply and are not insulated.

Item Specification Remarks

5.08 mm, 2-piece COMBICON, 2 pins

Applicable connector

Connector name MP

Input voltage Maximum input

current

Terminal assignments

Cable-end connector

Applicable wire size AWG20 ~ 14 (0.5 ~ 2.0 sq) Recommended stripped-

wire length

24 VDC r 10%

10.2 A 5.1 A per axis

No. Name Function

1 0V

2 24V Motor power input +24 V

MSTB2.5/2-GF-5.08 by Phoenix Contact MSTB2.5/2-STF-5.08 by Phoenix Contact

7 mm

Motor power input ground (Connected to the internal ground)

Part 1 Installation Chapter 2 Specications

[17] Axis 1 absolute-data

backup battery connector:

[18] Axis 2 absolute-data

backup battery connector:

This connector is used to connect the absolute-data backup battery for axis 1. (This connector is required only if your controller is of absoluteencoder specification.)

This connector is used to connect the absolute-data backup battery for axis 2. (This connector is required only if your controller is of absoluteencoder specification.)

Chapter 3 Installation and Wiring

1. External Dimensions

(1) 2-axis specification

Part 1 Installation

(The same external dimensions also apply to the 1-axis specification.)

5

110

Part 1 Installation

Chapter 3 Installation and Wiring

159

151

137

Part 1 Installation

(2) 2-axis specification with battery

Part 1 Installation

Chapter 3 Installation and Wiring

As for the use environment, this product can be used in an environment of pollution degree 2 equivalent.

*1 Pollution degree 2: Normally only non-conductive pollutants exist, which are expected to be

temporarily conductive due to condensation. (EN60947-5-1)

2. 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

Part 1 Installation

failure.)

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

not designed as dustproof or waterproof (oilproof), avoid using it in a dusty place or place subject to oil mist or splashed cutting fluid.

(3) Do not expose the controller to direct sunlight or radiant heat from a high heat source such as a heat-

treating furnace. (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

Part 1 Installation

Chapter 3 Installation and Wiring

Item Specification and description

Operating temperature range

0 ~ 40qC

Operating humidity range 10% ~ 95% (Non-condensing; conforming to JIS C3502 RH-2)

Storage temperature range

-25qC ~ 70qC (Excluding the battery)

Maximum operating altitude 2000 m

Protection class IP20

Vibration

Impact

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

X, Y and Z directions

147 mm/s

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

directions

(continuous), 9.8 m/s2 (intermittent)

3. Heat Radiation and Installation

Part 1 Installation

Design the control panel size, controller layout and cooling method so that the ambient temperature around the controller will be kept at or below 40°C.

Install the controller vertically on a wall, as illustrated below. The controller will be cooled by natural

convection. Be sure to install the controller in the aforementioned direction and provide a minimum clearance of 50 mm above and below the controller.

If multiple controllers are to be installed side by side, providing additional suction fans on top of the controllers will help maintain a uniform ambient temperature.

Provide a minimum clearance of 95 mm between the front side of the controller and a wall (enclosure).

Airflow direction

Fan

50 mm min.

95 mm min.

Part 1 Installation

50 mm min.

Airflow

If multiple controllers are to be connected on top of one another, prevent the controller above from taking in the exhaust air from the controller below.

Chapter 3 Installation and Wiring

Part 1 Installation

4. Noise Control Measures and Grounding

The ASEL controller has no dedicated terminal to connect the FG to ground. Accordingly, provide

grounding using the controller mounting screw.

[1] Provide dedicated Class D grounding. The grounding wire should have a size of 2.0 to

Part 1 Installation

[2] Notes on wiring method

Use twisted wires for the 24-VDC external power supply.

5.5 mm

or larger.

Controller

Other

equipment

Connect a cable of the largest possible size over the shortest possible distance.

Metal

enclosure

Controller

Other

equipment

Class D grounding Proper grounding Avoid using this method.

Chapter 3 Installation and Wiring

Wire the controller cables separately from lines creating a strong electric field such as power circuit

lines (by not bundling them together or placing in the same cable duct).

If you wish to extend the motor cable or encoder cable beyond the length of each supplied cable,

please contact IAI’s Technical Service Section or Sales Engineering Section.

Part 1 Installation

(3) Noise sources and noise elimination

There are many noise sources, but solenoid valves, magnet switches and relays are of particular

concern when building a system. Noise from these parts can be eliminated using the measures

specified below:

[1] AC solenoid valve, magnet switch, relay

Measure --- Install a surge killer in parallel with the coil.

Surge killer

m Point

Wire from each coil over the shortest distance. Installing a surge killer on the terminal block, etc., will be less effective because of a longer distance from the coil.

Part 1 Installation

[2] DC solenoid valve, magnet switch, relay

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

the load capacity.

In a DC circuit, connecting a diode in reversed polarity will damage the diode, internal parts of the controller and DC power supply. Exercise due caution.

Diode

The above noise elimination measures are particularly important when a 24-VDC relay is driven

directly by a controller output and there is also a 100-VAC solenoid valve, etc.

Chapter 3 Installation and Wiring

Reference Circuit Diagram

Part 1 Installation

Controller

Surge absorber

Chapter 3 Installation and Wiring

Solenoid valve

5. Supply Voltage

Part 1 Installation

The supply voltage to the controller is 24 VDC r 10%. The power-supply current varies depending on the number of axes, as shown below.

1-axis specification 2-axis specification

[1] Control power-supply current 1.2 A

[2] Rated motor power-input current 1.7 A 3.4 A

[3] Maximum motor power-input current 5.1 A 10.2 A

[4] Rated current ([1] + [2]) 2.9 A 4.6 A

[5] Maximum current ([1] + [3]) 6.3 A 11.4 A

Part 1 Installation

Chapter 3 Installation and Wiring

Part 1 Installation

6. Wiring

6.1 Wiring the Control Power Supply, Emergency Stop Switch and Enable Switch

As shown to the left, insert the stripped end of each cable into the control power & system I/O connector, and tighten the screws with a screwdriver.

Part 1 Installation

Enable switch

Recommended cable size: 0.75 mm Recommended stripped-wire length: 7 mm

Emergency stop switch

24 VDC

(AWG18)

Chapter 3 Installation and Wiring

6.2 Wiring the Motor Power Cables

Part 1 Installation

As shown to the left, insert the stripped end of each cable into the motor power connector, and tighten the screws with a screwdriver.

Recommended cable size: 2 mm

(AWG14)

Recommended stripped-wire length: 7 mm

As shown to the left, tighten the screws to affix the connector.

Part 1 Installation

24 VDC

Chapter 3 Installation and Wiring

6.3 Connecting the Actuator

6.3.1 Connecting the Motor Cable (M1/M2)

Part 1 Installation

6.3.2 Connecting the Encoder Cable (PG1/PG2)

Part 1 Installation

Connect the motor cable from the actuator to the applicable motor connector on the front face of the controller.

Chapter 3 Installation and Wiring

Connect the encoder cable from the actuator to the applicable encoder connector on the front face of the controller.

Caution: With the absolute specification,

disconnect the absolute-data backup battery connector before connecting the encoder cable. Connect the absolute-data backup battery connector after turning on the main power.

6.4 Connecting the PIO Cable (I/O)

Part 1 Installation

I/O flat cable (supplied): Model CB-DS-P10020

Connect the supplied flat cable. Connect the opposite end (open end without connector) of the cable to a desired peripheral (host PLC, etc.).

No connector

Part 1 Installation

Chapter 3 Installation and Wiring

Flat cable (34 cores)

No. Color Wire No. Color Wire

1A Brown 1 9B Gray 2 1B Red 1 10A White 2 2A Orange 1 10B Black 2 2B Yellow 1 11A Brown-3 3A Green 1 11B Red 3 3B Blue 1 12A Orange 3 4A Purple 1 12B Yellow 3 4B Gray 1 13A Green 3 5A White 1 13B Blue 3 5B Black 1 14A Purple 3 6A Brown-2 14B Gray 3 6B Red 2 15A White 3 7A Orange 2 15B Black 3 7B Yellow 2 16A Brown-4 8A Green 2 16B Red 4 8B Blue 2 17A Orange 4 9A Purple 2

Flat cable,

pressure-

welded

Flat cable,

pressure-

welded

17B Yellow 4

6.4.1 I/O Connection Diagram

(1) NPN specification (Program mode)

Part 1 Installation

Pin No.

Category

Input

Port No. Function Cable color

External power supply 24 V Program specification (PRG No. 1) Program specification (PRG No. 2) Program specification (PRG No. 4) Program specification (PRG No. 8) Program specification (PRG No. 10) Program specification (PRG No. 20) Program specification (PRG No. 40) Software reset (restart) Program start

General-purpose input General-purpose input General-purpose input General-purpose input General-purpose input General-purpose input General-purpose input

General-purpose input General-purpose input General-purpose input General-purpose input General-purpose input

General-purpose input

General-purpose input General-purpose input

1 - Brown

1 - Red

1 - Orange

1 - Yellow

1 - Green

1 - Blue

1 - Purple

1 - Gray

1 - White

1 - Black

2 - Brown

2 - Red

2 - Orange

2 - Yellow

2 - Green

2 - Blue

2 - Purple

2 - Gray

2 - White

2 - Black

3 - Brown

3 - Red

3 - Orange

3 - Yellow

3 - Green

Chapter 3 Installation and Wiring

Pin No.

Category

Port No.

Alarm output

Ready output General-purpose output

Output

General-purpose output General-purpose output General-purpose output General-purpose output General-purpose output External power supply 0 V

The above functions reflect the factory settings.

Function

Cable color

3 - Blue

3 - Purple

3 - Gray

3 - White

3 - Black

4 - Brown

4 - Red

4 - Orange

4 - Yellow

(2) PNP specification (Program mode)

Part 1 Installation

Pin No.

Category

Input

Port No. Function Cable color

General-purpose input General-purpose input General-purpose input General-purpose input General-purpose input General-purpose input General-purpose input

General-purpose input General-purpose input General-purpose input General-purpose input General-purpose input

General-purpose input

General-purpose input General-purpose input

1 - Brown

1 - Red

1 - Orange

1 - Yellow

1 - Green

1 - Blue

1 - Purple

1 - Gray

1 - White

1 - Black

2 - Brown

2 - Red

2 - Orange

2 - Yellow

2 - Green

2 - Blue

2 - Purple

2 - Gray

2 - White

2 - Black

3 - Brown

3 - Red

3 - Orange

3 - Yellow

3 - Green

Chapter 3 Installation and Wiring

Pin No.

Category

Port No. Function Cable color

Alarm output

Ready output General-purpose output

Output

General-purpose output General-purpose output General-purpose output General-purpose output General-purpose output External power supply 0 V

The above functions reflect the factory settings.

3 - Blue

3 - Purple

3 - Gray

3 - White

3 - Black

4 - Brown

4 - Red

4 - Orange

4 - Yellow

(3) NPN specification (Positioner mode)

Part 1 Installation

Pin No.

Category

Input

Port No.

Standard mode

Position input 10

Position input 11

Position input 12

Position input 13

Error reset

Start

Home return

Servo ON

Push motion

*Pause

*Cancellation

Interpolation

Position input 1

Position input 2

Position input 3

Position input 4

Position input 5

Position input 6

Position input 7

Position input 8

Position input 9

Product switching mode

Input 10

Input 11

Input 12

Input 13

Input 14

Input 15

Input 16

Error reset

Start

Home return

Servo ON

Push motion

*Pause

*Cancellation

Interpolation

Input 1

Input 2

Input 3

Input 4

Input 5

Input 6

Input 7

Input 8

Input 9

Positioner mode

2-axis independent

mode

24-V input

Position input 7

Position input 8

Position input 9

Position input 10

Position input 11

Position input 12

Position input 13

Error reset

Axis 1 start

Home return

Axis 1 servo ON

*Axis 1 pause

*Axis 1 cancellation

Axis 2 start

Axis 2 home return

Axis 2 servo ON

*Axis 2 pause

*Axis 2 cancellation

Position input 1

Position input 2

Position input 3

Position input 4

Position input 5

Position input 6

Teaching mode

Axis 1 jog-

Axis 2 jog+

Axis 2 jog-

Inching (0.01 mm)

Inching (0.1 mm)

Inching (0.5 mm)

Inching (1 mm)

Error reset

Start

Sarvo ON

*Pause

Position input 1

Position input 2

Position input 3

Position input 4

Position input 5

Position input 6

Position input 7

Position input 8

Position input 9

Position input 10

Position input 11

Teaching mode

specification

Axis 1 jog+

DC-S-C1 compatible

mode

Position No. 1000 input

CPU reset

Start

Pause

Cancellation

Interpolation setting

Position No. 1 input

Position No. 2 input

Position No. 4 input

Position No. 8 input

Position No. 10 input

Position No. 20 input

Position No. 40 input

Position No. 80 input

Position No. 100 input

Position No. 200 input

Position No. 400 input

Position No. 800 input

Cable

color

1 - Brown

1 - Red

1 - Orange

1 - Yellow

1 - Green

1 - Blue

1 - Purple

1 - Gray

1 - White

1 - Black

2 - Brown

2 - Red

2 - Orange

2 - Yellow

2 - Green

2 - Blue

2 - Purple

2 - Gray

2 - White

2 - Black

3 - Brown

3 - Red

3 - Orange

3 - Yellow

3 - Green

Chapter 3 Installation and Wiring

Pin No.

Category

Output

Port No.

Standard mode

*Alarm

Ready

Positioning complete

Home return complete

Servo ON output

Push motion complete

System battery error

Absolute battery error

Product switching mode

*Alarm

Ready

Positioning complete

Home return complete

Servo ON output

Push motion complete

System battery error

Absolute battery error

Positioner mode

2-axis independent

mode

*Alarm

Ready

Axis 1 positioning

complete

Axis 1 home return

complete

Axis 1 servo ON

Axis 2 positioning

complete

Axis 2 home return

complete

Axis 2 servo ON

0-V input

Teaching mode

*Alarm

Ready

Positioning complete

Home return complete

Servo ON output

System battery error

Absolute battery error

DC-S-C1 compatible

mode

*Alarm

Ready

Positioning complete

System battery error

Absolute battery error

Cable

3 - Blue

3 - Purple

3 - Gray

3 - White

3 - Black

4 - Brown

4 - Red

4 - Orange

4 - Yellow

*: Contact B (Always ON)

color

(4) PNP specification (Positioner mode)

Part 1 Installation

Pin No.

Category

Input

Port No.

Standard mode

Position input 10

Position input 11

Position input 12

Position input 13

Error reset

Start

Home return

Servo ON

Push motion

*Pause

*Cancellation

Interpolation

Position input 1

Position input 2

Position input 3

Position input 4

Position input 5

Position input 6

Position input 7

Position input 8

Position input 9

Product switching mode

Input 10

Input 11

Input 12

Input 13

Input 14

Input 15

Input 16

Error reset

Start

Home return

Servo ON

Push motion

*Pause

*Cancellation

Interpolation

Input 1

Input 2

Input 3

Input 4

Input 5

Input 6

Input 7

Input 8

Input 9

Positioner mode

2-axis independent

mode

24-V input

Position input 7

Position input 8

Position input 9

Position input 10

Position input 11

Position input 12

Position input 13

Error reset

Axis 1 start

Home return

Axis 1 servo ON

*Axis 1 pause

*Axis 1 cancellation

Axis 2 start

Axis 2 home return

Axis 2 servo ON

*Axis 2 pause

*Axis 2 cancellation

Position input 1

Position input 2

Position input 3

Position input 4

Position input 5

Position input 6

Teaching mode

Axis 1 jog-

Axis 2 jog+

Axis 2 jog-

Inching (0.01 mm)

Inching (0.1 mm)

Inching (0.5 mm)

Inching (1 mm)

Error reset

Start

Sarvo ON

*Pause

Position input 1

Position input 2

Position input 3

Position input 4

Position input 5

Position input 6

Position input 7

Position input 8

Position input 9

Position input 10

Position input 11

Teaching mode

specification

Axis 1 jog+

DC-S-C1 compatible

mode

Position No. 1000 input

CPU reset

Start

Pause

Cancellation

Interpolation setting

Position No. 1 input

Position No. 2 input

Position No. 4 input

Position No. 8 input

Position No. 10 input

Position No. 20 input

Position No. 40 input

Position No. 80 input

Position No. 100 input

Position No. 200 input

Position No. 400 input

Position No. 800 input

Cable

color

1 - Brown

1 - Red

1 - Orange

1 - Yellow

1 - Green

1 - Blue

1 - Purple

1 - Gray

1 - White

1 - Black

2 - Brown

2 - Red

2 - Orange

2 - Yellow

2 - Green

2 - Blue

2 - Purple

2 - Gray

2 - White

2 - Black

3 - Brown

3 - Red

3 - Orange

3 - Yellow

3 - Green

Chapter 3 Installation and Wiring

Pin No.

Category

Output

Port No.

Standard mode

*Alarm

Ready

Positioning complete

Home return complete

Servo ON output

Push motion complete

System battery error

Absolute battery error

Product switching mode

*Alarm

Ready

Positioning complete

Home return complete

Servo ON output

Push motion complete

System battery error

Absolute battery error

Positioner mode

2-axis independent

mode

*Alarm

Ready

Axis 1 positioning

complete

Axis 1 home return

complete

Axis 1 servo ON

Axis 2 positioning

complete

Axis 2 home return

complete

Axis 2 servo ON

0-V input

Teaching mode

*Alarm

Ready

Positioning complete

Home return complete

Servo ON output

System battery error

Absolute battery error

DC-S-C1 compatible

mode

*Alarm

Ready

Positioning complete

System battery error

Absolute battery error

Cable

3 - Blue

3 - Purple

3 - Gray

3 - White

3 - Black

4 - Brown

4 - Red

4 - Orange

4 - Yellow

*: Contact B (Always ON)

color

6.5 External I/O Specifications

6.5.1 NPN Specification

(1) Input part

Part 1 Installation

External Input Specifications (NPN Specification)

Item Specification

Input voltage

Input current 7 mA per circuit

ON/OFF voltage

Insulation method Photocoupler insulation

External devices

24 VDC r10%

ON voltage --- 16.0 VDC min. OFF voltage --- 5.0 VDC max.

[1] No-voltage contact (minimum load of approx. 5 VDC/1 mA) [2] Photoelectric/proximity sensor (NPN type) [3] Sequencer transistor output (open-collector type) [4] Sequencer contact output (minimum load of approx. 5 VDC/1 mA)

Part 1 Installation

Chapter 3 Installation and Wiring

[Input circuit]

560 :

P24*

External power supply 24 VDC 10%

Internal circuit

3.3 K:

Input terminal

* P24: I/O interface pin No. 1

Caution

If a non-contact circuit is connected externally, malfunction may result from leakage current. Use a circuit in which leakage current in a switch-off state does not exceed 1 mA.

 ASEL controller’s input signal

ON duration

At the default settings, the system recognizes the ON/OFF durations of input signals if they are approx. 4 msec or longer. The ON/OFF duration settings can also be changed using I/O parameter No. 20 (input filtering frequency).

OFF duration

(2) Output part

Part 1 Installation

External Output Specifications (NPN Specification)

Item Specification

Load voltage 24 VDC

Maximum load current 100 mA per point, 400 mA per 8 ports Note)

Leakage current 0.1 mA max. per point

Insulation method Photocoupler insulation

External devices

Note) 400 mA is the maximum total load current of output port Nos. 300 to 307.

[1] Miniature relay [2] Sequencer input unit

TD62084 (or equivalent)

[Output circuit]

P24*

Surge absorber

Load

Internal circuit

Output terminal

Part 1 Installation

Chapter 3 Installation and Wiring

External power supply 24 VDC r 10%

* P24: I/O interface pin No. 1A * N: I/O interface pin No. 17B

Caution

In the event that the load is short-circuited or current exceeding the maximum load current is input, the overcurrent protection circuit will be actuated to cut off the circuit. However, give due consideration to the circuit connection layout to prevent short-circuit or overcurrent.

6.5.2 PNP Specification

(1) Input part

Part 1 Installation

External Input Specifications (PNP Specification)

Item Specification

Input voltage

Input current 7 mA per circuit

ON/OFF voltage

Insulation method Photocoupler insulation

External devices

24 VDC r10%

ON voltage --- 8 VDC max. OFF voltage --- 19 VDC min.

[1] No-voltage contact (minimum load of approx. 5 VDC/1 mA) [2] Photoelectric/proximity sensor (PNP type) [3] Sequencer transistor output (open-collector type) [4] Sequencer contact output (minimum load of approx. 5 VDC/1 mA)

[Input circuit]

Input terminal

Part 1 Installation

Chapter 3 Installation and Wiring

External power

560 :

supply 24 VDC 10%

Internal circuit

3.3 K

* N: I/O interface pin No. 17B

Caution

If a non-contact circuit is connected externally, malfunction may result from leakage current. Use a circuit in which leakage current in a switch-off state does not exceed 1 mA.

 ASEL controller’s input signal

ON duration

OFF duration

(2) Output part

Part 1 Installation

External Output Specifications (PNP specification)

Item Specification

Load voltage 24 VDC

Maximum load current 100 mA per point, 400 mA per 8 ports Note)

Leakage current 0.1 mA max. per point

Insulation method Photocoupler insulation

External devices

Note) 400 mA is the maximum total load current of output port Nos. 300 to 307.

[1] Miniature relay [2] Sequencer input unit

TD62784 (or equivalent)

[Output circuit]

P24

Surge absorber

10 :

Part 1 Installation

Internal circuit

Output terminal

Load

External power supply 24 VDC 10%

* P24: I/O interface pin No. 1A * N: I/O interface pin No. 17B

Caution

In the event that the load is short-circuited or a current exceeding the maximum load current is input, the overcurrent protection circuit will be actuated to cut off the circuit. However, give due consideration to the circuit connection layout to prevent short-circuit or overcurrent.

Chapter 3 Installation and Wiring

6.6 Connecting the Teaching Pendant/PC (Software) (TP) (Optional)

Part 1 Installation

6.7 Connecting the Panel Unit (Optional)

Part 1 Installation

The ASEL controller’s teaching connector (TP) is a small, half-pitch connector. If you are using a teaching pendant or PC software cable, connect the cable to a connector conversion cable, and then connect the conversion cable to the teaching connector on the controller.

When the optional panel unit is connected, the controller status (program number of each active program, error codes, etc.) can be monitored.

Chapter 3 Installation and Wiring

Part 1 Installation

6.7.1 Explanation of Codes Displayed on the Panel Unit (Optional)

(1) Application

Display Priority (*1) Description

1 Control power cut off

1 System-down level error

2 Writing data to the flash ROM.

3 Emergency stop is being actuated (except during the update mode).

4 Enable switch (deadman switch/safety gate) OFF (except in the update mode)

5 Cold-start level error

5 Operation-cancellation level error

Part 1 Installation

5 Operation-cancellation level error

6 Waiting for a drive-source cutoff reset input (except during the update mode).

6 Operation is in pause (waiting for restart) (except during the update mode).

7 All servo axes are interlocked (except during the update mode).

8 Message level error

9 Core update mode

9 Core update is in progress.

9 Core update has completed.

9 Slave update mode

9 Slave update is in progress.

9 Slave update has completed.

9 Running a program (last started program); “No.” indicates program number.

Chapter 3 Installation and Wiring

9 Initialization sequence number

9 Debug mode

(*1) The priority increases as the number decreases.

Part 1 Installation

Display Priority (*1) Description

9 Ready status (auto mode) (Program mode)

9 Ready status (manual mode) (Program mode)

9 Operating in positioner mode; “No.” indicates positioner mode number.

9 Ready status (auto mode) (Positioner mode)

Part 1 Installation

9 Ready status (manual mode) (Positioner mode)

(*1) The priority increases as the number decreases.

Chapter 3 Installation and Wiring

(2) Core

Part 1 Installation

Display Priority (*1) Description

1 Control power cut off

1 Cold-start level error

1 Operation-cancellation level error

2 Message level error

2 Application update mode

2 Application update is in progress.

2 Application update has completed.

2 Hardware test mode process

2 Clearing the application flash ROM.

2 Application flash ROM has been cleared.

Part 1 Installation

Chapter 3 Installation and Wiring

2 Jump to the application

2 Core flash-ROM check process

2 Application flash-ROM check process

2 SDRAM check process

(*1) The priority increases as the number decreases.

6.7.2 Current Monitor and Variable Monitor

By setting other parameter Nos. 49 and 50 appropriately, the optional panel unit can be used to monitor either current levels or variables.

(1) Current monitor Currents of up to four axes having continuous axis numbers can be monitored. Parameter settings Other parameter No. 49 = 1 Other parameter No. 50 = Smallest axis number among the axes to be monitored

Part 1 Installation

Example) If other parameter No. 49 is set to “1” and other parameter No. 50 to “1” for a 2-axis controller,

Part 1 Installation

the far-right segment digit will show the current for axis 1.

Axis 2 Axis 1

Chapter 3 Installation and Wiring

When data is written to the flash ROM or a software reset (restart) is executed after the parameter values have been input, the panel window will show the motor current to rating ratio (%) by a segment pattern, instead of “ready status” or “program run number.” The segment display patterns and corresponding motor current to rating ratios (%) are shown below.

0 < Motor current to rating ratio (%) d 25

25 < Motor current to rating ratio (%) d 50

50 < Motor current to rating ratio (%)

75 < Motor current to rating ratio (%)

d 75

d 100

100 < Motor current to rating ratio (%) d 150

150 < Motor current to rating ratio (%) d 200

200 < Motor current to rating ratio (%)

Thick lines indicate illuminated segments.

Part 1 Installation

(2) Variable monitor The contents of global integer variables can be displayed on the panel window. Positive integers of 1 to 999 can be displayed. Parameter settings Other parameter No. 49 = 2 Other parameter No. 50 = Variable number of the global integer variable to be monitored

When data is written to the flash ROM or a software reset (restart) is executed after the parameter values have been input, the panel window will show the content of the global integer variable, instead of “ready status” or “program run number.” The far-left segment digit should read “U.” Display example)

Part 1 Installation

Chapter 3 Installation and Wiring

6.8 Installation Method for the Absolute-Data Backup Battery

The ASEL controller does not come with a holder or any other dedicated piece for installing the absolutedata backup battery. The user must affix the battery using tie-bands.

Example of installation

Part 1 Installation

As shown to the left, guide tie-bands through the controller and tie the ends to make loose loops.

Guide the batteries into the tie-band loops. Tighten the tie-bands and cut off any excess length at the end.

Chapter 3 Installation and Wiring

Connect each battery connector. Pay attention to the connector orientation. (The connector hook should face the left side when viewed from the front of the controller.)

Caution: If the main power cannot be turned

on immediately after the encoder cable has been connected, do not connect the battery connector.

6.9 Installing the System-Memory Backup Battery (Optional)

Part 1 Installation

As shown to the left, install the supplied battery holder on the left side face of the controller.

Insert the battery into the holder.

Connect the battery connector. Pay attention to the connector orientation. (The connector hook should face the right side.)

Part 1 Installation

Chapter 3 Installation and Wiring

Chapter 4 Operation

1. Startup

(1) Connect the motor cable and encoder cable to the controller. (2) Connect the PIO connector to the host PLC using the supplied flat cable. (3) Execute an emergency stop. (4) Connect the PC or teaching pendant. Set the AUTO/MANU switch to the “MANU” side. (5) Supply the 24-V PIO power through the flat cable.

Part 1 Installation

(6) Turn on the control power and motor power at the same time. (They should be taken from the same

power supply.

(7) Reset the emergency stop.

 The EMG lamp turns off.  If the ALM lamp is lit, an error is present. Check the error list to identify the problem.

If the 24-V PIO power is not supplied, an “E69” error will generate. If your controller is of absolute specification, a “914” or “CA2” error may generate during the startup, indicating that an absolute reset must be performed. Refer to “How to Perform Absolute Reset.” To check for errors, connect the teaching pendant, PC software or panel unit.

Part 1 Installation

Chapter 4 Operationg

Part 1 Installation

1.1 Power ON Sequence

x Although separate inputs are provided for the control power and motor power, they should be supplied

from the same power-supply terminal.

x Turn on the PIO power first. You can turn on the PIO power much earlier than the control power and

motor power, as long as it is turned on before the control power/motor power.

The PIO power must be turned on

Taken from the same power supply.

before the control power, in order to perform checks during initialization and self-diagnosis and apply a hardware latch upon detection of an error.

Part 1 Installation

Control power

Motor power

Controller status

PIO power

Must be turned on first, as a rule.

Must be turned on simultaneously, as a rule.

Initialization/self-diagnosis

Normal operating condition

* If the PIO power is not turned on before the control power is turned on, an error will be detected.

1.2 Power Cutoff Sequence

x If the PIO power is turned off before the control power and motor power (before the power cutoff

processing is performed), a PIO power error may be logged internally by the controller.

x The PIO power can be turned off much later than the control power and motor power, as long as it is

turned off after the control power/motor power.

Once the control power drops to approx. 19 V or below, the power cutoff

Control power

Motor power

Must be turned off simultaneously, as a rule.

processing is started.

Chapter 4 Operation

Controller status

PIO power

If the PIO power is turned off during this period, an error may be logged internally by the controller.

Power cutoff processing

Part 1 Installation

2. How to Perform Absolute Reset (Absolute Specification)

If the ASEL controller experiences any abnormal absolute-encoder battery voltage or the battery or encoder cable is disconnected, an encoder battery error will generate. In this case, you must perform an absolute reset. This chapter explains how to perform an absolute reset using the PC software. For the procedure to perform an absolute reset from the teaching pendant, refer to the operation manual for your teaching pendant.

Part 1 Installation

2.1 Preparation

(1)

PC in which IAI’s X-SEL PC software (X_SEL.exe) has been installed

(2) PC cable (supplied with the PC software)

RS232C cross cable (fitted with a female 9-pin connector on the PC end and a male 25-pin connector on the controller end) +Connector conversion cable Alternatively, use a USB cable and a dummy plug (optional).

(3) All adjustment items other than absolute reset must have been completed.

2.2 Procedure

(1) Turn off the ASEL controller power. Turn on the PC power and wait for the OS to start.

(2) Connect the 9-pin D-sub connector on the PC cable to the communication port on the PC, and

connect the 25-pin D-sub connector to the teaching connector on the controller. Alternatively, connect the PC and controller using a USB cable. If the USB port is used, a dummy plug must be connected to the teaching connector.

(3) Turn on the controller power. An encoder battery error will generate. If no other adjustment item is

outstanding, “ECA2” or “E914” should be displayed on the 7-segment LED. This indicates that the controller has detected the encoder battery error.

(4) Launch the X-SEL PC software (X_SEL.exe) on the PC. The following steps explain the operating

Chapter 4 Operationg

procedures in the X-SEL PC software.

(5) When the Connection Check dialog box appears, set the communication port you are using on your

PC. Click OK. (The baud rate need not be set. The software will automatically detect and set the baud rate.)

(6) The main window of the X-SEL PC software opens.

Click OK to close the error message.

Part 1 Installation

(7) From the M

onitor menu, select Error Detail to check the condition of the present error.

If the controller is experiencing an encoder battery error, the displayed window should look like the one shown below (an absolute encoder is used for axis 2 in this example). After checking the error detail, close the Error Detail window.

Chapter 4 Operation

Part 1 Installation

(8) From the C

(9) When the Warning dialog box appears, click OK.

Part 1 Installation

(10) The Absolute Reset dialog box appears.

Click here

ontroller menu, select Absolute Reset.

to select the axis you want to perform an absolute reset for.

Chapter 4 Operationg

(11) Click Encoder Rotation Data Reset 1. When the Warning dialog box appears, click Y

es.

Part 1 Installation

(12) Another Warning dialog box is displayed. Click Y

es again.

(13) After the controller has finished processing encoder rotation data reset 1, the red arrow will move to

the next item. Click the following processing buttons in this order (the arrow will move to the next one after each processing is completed):

1. Controller Error Reset

2. Servo ON

3. Home Return

4. Servo OFF

Encoder rotation data reset 2 is performed with the servo turned on. Accordingly, the Servo OFF step will be skipped.

5. Encoder Rotation Data Reset 2

After you have clicked Encoder Rotation Data Reset 2 and the processing is finished, the red arrow will return to the position in shown in (10). To perform an absolute encoder reset for another axis, select the target axis and perform the steps from (10) again. To end the procedure, click Close to close the Absolute Reset dialog box. (Note) If you have encountered a situation where an absolute encoder reset is required for two or

more axes, be sure to repeat steps (10) to (13) for all applicable axes before performing the software reset in step (14) below.

Part 1 Installation

Chapter 4 Operation

Part 1 Installation

(14) When the Confirmation dialog box appears, click Y

Part 1 Installation

(Note) If you continue to operate the controller without resetting the software or reconnecting the

(15) If an optional panel unit is connected and no other error is present, “rdy” (when the controller is in the

program mode) or “Pry” (in the positioner mode) should be displayed on the 7-seg LED.

(16) This completes the absolute reset.

To repeat the absolute reset, close the X-SEL PC software and perform the steps from the beginning.

es to restart the controller.

power, the following errors may generate: Error No. C70: ABS coordinate non-confirmation error Error No. C6F: Home-return incomplete error

Chapter 4 Operationg

3. How to Start a Program

Part 1 Installation

With the ASEL Controller, the stored programs can be started (run) using four methods. Of these methods, two are mainly used to debug programs or perform trial operations, while the remaining two are used in general applications on site.

The former two methods are “starting from the teaching pendant” and “starting from the PC software.”

These methods provide simple means of checking the operation. For details on “starting from the teaching pendant,” read the operation manual for the optional teaching pendant. For “starting from the PC software,” read the applicable explanation in the manual supplied with the PC software.

The latter two methods are “starting automatically via parameter setting” and “starting via external signal selection.” This chapter only explains the methods for “starting automatically via parameter setting” and “starting via external signal selection.”

Starting via

Teaching pendant

ASEL

Controller

external signal

selection

Part 1 Installation

PC software

Start

Starting

automatically via

parameter setting

Start

Chapter 4 Operation

3.1 Starting a Program by Auto-Start via Parameter Setting

Other parameter No. 7 (Auto program start setting) = 1 (Standard factory setting)

This parameter is set using the teaching pendant or PC software.

Part 1 Installation

Set an auto-start program number

Automatically starting the program

Caution

[Note on starting a program by auto-start] The automatic operation will begin immediately after the controller is reset, so the user may be surprised by unexpected movements of the equipment, particularly those caused by a sudden activation of the servo actuator. To ensure safety, always provide an interlocking function, such as allowing the program execution to proceed only after receiving a confirmation signal at the beginning of the program.

Chapter 4 Operationg

If you wish to start multiple programs at the same time, write multiple “EXPG” commands at the beginning of the main program to start the remaining programs. Provide safety measures for each program to be started.

Reset the controller

Set the number of the program you wish to start automatically in other parameter No. 1 (auto-start program number). Set the controller mode to AUTO.

Reconnect the power or execute a software reset, and the controller will be reset.

Once the controller is reset in the above step, the program of the set number will start automatically. *

* If the following setting is performed, the program of the selected program number will start automatically at the

ON edge of the signal received by the selected input port. The program will be aborted at the OFF edge. You can set a desired input port for receiving the auto program start signal (dedicated function). Set the input function setting value “5” in the I/O parameter corresponding to the desired input port number (Nos. 30 through 45, 251 through 258). (Refer to “I/O Function Lists” and “I/O Parameters.”)

3.2 Starting via External Signal Selection

Part 1 Installation

Select a desired program number externally and then input a start signal.

(1) Flow chart

Controller

Power ON

Ready output

READY signal ON

External device

Power ON

READY signal

confirmed?

Various I/O

processing

Program number

confirmed?

input

Program number

specification

External start input

Start signal confirmed?

Start signal ON

Program run

Emergency-stop

signal confirmed?

Emergency-stop input

Emergency-stop

switch ON?

Emergency-stop

signal ON

Controller

error?

Part 1 Installation

When the READY signal (Output port No. 301) turns ON, the RDY lamp (green) on the controller front panel will illuminate.

Input a desired program number as a BCD code from the external device (Input port Nos. 16 through

22).

Input a start signal (input port No. 0) from the external device.

Chapter 4 Operation

If the optional panel unit is connected, the CODE display area indicates the program number of each program that has been started.

If an emergency-stop signal was input from the external device or a controller error occurred, the controller will turn off the servo power. (The RDY lamp will turn off.)

Servo OFF

ALARM signal ON

Alarm output

ALARM signal

confirmed?

ALARM

processing

Note) The assignments of dedicated

input/output port functions (such as RDY output start signal) reflect the factory settings.

[2] Timing chart

[1] Program start

Part 1 Installation

Ready output

Program number input

External start input

Part 1 Installation

[2] Auto program start

* Set input function specification value 5 (auto-start program start signal) for input port No. *.

Ready output

Auto-start program start signal input

Auto program start

[3] Soft reset signal

* Set input function specification value 3 (soft reset signal) for input port No. *.

Ready output

Soft reset signal input

Program starting

[4] Servo ON signal

* Set input function specification value 4 (servo ON signal) for input port No. *.

Ready output

Servo ON signal input

Servo ON

Chapter 4 Operationg

Program 1

Program 2

T1: Duration after the ready output turns ON until

input of external start signal is permitted T1 = 10 msec min.

T2: Duration after the program number is input

until input of external start signal is permitted T2 = 50 msec min.

T3: Input duration of external start signal

T3 = 100 msec min.

T1: Time after the ready output turns ON until the

auto-start program start signal can be input to input port No. * T1 = 10 msec min.

* Auto program start:

Set “0” in other parameter No. 7, “Auto program start setting.”

T1: T1: Time after the ready output turns ON until

input function specification value 3 (soft reset signal) can be input to input port No. * T1 = 10 msec min.

T2: T2: Time until the soft reset signal becomes

effective T2 = 1 sec min.

T3: Time after the soft reset signal is cancelled

until the ready signal is output

T1: Time after the ready output turns ON until input

function specification value 4 (servo ON signal) can be input to input port No. * T1 = 10 msec min.

T2: Interval after the servo is turned OFF until it is

turned ON again T2 = 1.5 sec min.

Warning : Turning the servo ON near the mechanical end may disturb the magnetic pole phase detection,

and may cause the magnetic pole unconfirmed error or the magnetic pole detection error. Put the slider or rod away from the mechanical end when turning the servo ON.

[5] When the recovery type after emergency stop or enable operation is set to “Operation continued”

* Set other parameter No. 10 to “2,” and set input function specification value 7 (operation-pause reset signal) for input port No. *. Set input function specification value 17 (drive-source cutoff reset input signal) for other input port No. *.

Program starting

Emergency stop

Drive-source cutoff reset

Pause reset

T1: Time after the emergency stop input is reset until

the drive-source cutoff reset signal can be input. T1 = 2 sec min.

T2: Time during which the drive-source cutoff reset

signal is input T1 = 10 msec min.

T3: Time during which the pause reset signal is input

T1 = 10 msec min.

Part 1 Installation

4. Drive-Source Recovery Request and Operation-Pause Reset Request

(1) Drive-source recovery request

[1] Case where a drive-source request is required A drive-source recovery request is required in the following case:

x Specify a desired input port for receiving the drive-source cutoff reset input signal (dedicated

function).

Occurrence of a drive-source cutoff factor o Recovery after the cutoff factor is removed.

[2] How to request a drive-source recovery A drive-source recovery request can be issued using one of the following methods:

x Set the input function specification value “17” in the I/O parameter corresponding to the desired

input port number (Nos. 30 through 45, 251 through 258). (Refer to “I/O Function Lists” and “I/O Parameters.”)

Input the ON edge to the input port of the specified number. x Select [Drive-Source Recovery Request (P

screen.

x Select Ctl (controller operation) and RPwr (drive-source recovery request) on the mode

selection screen of the teaching pendant.

(2) Operation-pause reset request

[1] Cases where an operation-pause reset request is required An operation-pause reset request is required in any of the following cases:

x An emergency stop was actuated during automatic operation when other parameter No. 10

was set to “2” (Emergency-stop recovery type = Continued operation) (only during automatic operation) o Recovery (reset of operation pause) after the emergency stop is reset.

x The automatic operation was stopped using the deadman switch or enable switch when other

parameter No. 11 was set to “2” (Deadman/enable switch recovery type = Continued operation) (only during automatic operation) o Recovery (reset of operation pause) after the stop is reset.

x Specify a desired input port for receiving the operation-pause input signal (dedicated function).

Set the input function specification value “8” in the I/O parameter corresponding to the desired input port number (Nos. 30 through 45, 251 through 258). (Refer to “I/O Function Lists” and “I/O Parameters.”)

OFF level signal input is received by the import port of the specified number during auto

operation (operations pause) o Recovery after detection of ON signal level by the input port (operation pause is reset).

)] from the [Controller (C)] menu on the PC software

Part 1 Installation

Chapter 4 Operation

[2] How to request an operation-pause reset An operation-pause reset request can be issued using one of the following methods:

x Specify a desired input port for receiving the operation-pause input signal (dedicated function).

Set the input function specification value “7” in the I/O parameter corresponding to the desired input port number (Nos. 30 through 45, 251 through 258). (Refer to “I/O Function Lists” and “I/O Parameters.”)

Input the ON edge to the input port of the specified number. x Select [Operation-Pause Reset Request (L

screen.

x Select Ctl (controller operation) and RAct (operation-pause reset request) on the mode

selection screen of the teaching pendant.

* If the case in [1] of (1) and any of the cases in [1] of (2) are present at the same time, a drive-source

recovery request must be issued first, followed by an operation-pause reset request.

)] from the [Controller (C)] menu on the PC software

5. Controller Data Structure

The controller data consists of parameters as well as position data and application programs used to implement SEL language.

Part 1 Installation

ASEL Controller Data Structure

Main

SEL language

The user must create position data and application programs. The parameters are predefined, but their settings can be changed in accordance with the user’s system. Refer to Appendix, “List of Parameters,” for details on the parameters.

Chapter 4 Operationg

Parameters

Position

data

Application

programs

5.1 How to Save Data

Part 1 Installation

The flow to save data in the ASEL controller is illustrated below. When data is transferred from the PC software or teaching pendant to the controller, the data is only written to the main CPU memory as shown in the diagram below and will be erased once the controller is powered down or reset.

For important data, always write to the flash memory so that they will not be lost.

5.1.1 Factory Settings: When the System-Memory Backup Battery is Not Used

Other parameter No. 20 = 0 (System-memory backup battery not installed)

Data edited on the PC

or teaching pendant

Transfer

software,

Transfer

Data will be retained while the power

is on and cleared upon reset

Main CPU memory

Programs

Parameters (other than

encorder parameters)

Symbols

Positions

Encoder parameters

Write to flash memory

Transfer upon reset

Transfer

Data will be retained even after

the power is turned off

Main CPU flash memory

Slave card memory

Part 1 Installation

Chapter 4 Operation

Transfer upon reset

SEL global data (flags,

variables, strings)

Error lists

Since the programs, parameters and symbols are read from the flash memory at restart, the data in the temporary memory will remain the same as the original data before edit unless the edited data are written to the flash memory.

The controller always operates in accordance with the data in the main CPU memory (excluding the parameters).

Note: SEL global data cannot be retained if the backup battery is not installed. SEL global data will be cleared once the control power is turned off or a software reset is

executed.

The error list will be cleared once the control power is turned off.

5.1.2 When the System-Memory Backup Battery (Optional) is Used

Change the setting of other parameter No. 20 to 2 (System-memory backup battery installed).

Part 1 Installation

Data edited on the PC

or teaching pendant

Part 1 Installation

software,

Transfer

Data will be retained while the power

is on and cleared upon reset

Main CPU memory

Programs

Parameters (other than

encorder parameters)

Symbols

Encoder parameters

Transfer

Write to flash memory

Transfer upon reset

Transfer

Transfer upon reset

Data will be retained even after

the power is turned off

Main CPU flash memory

Slave card memory

Battery backup memory

Positions

Since the programs, parameters and symbols are read from the flash memory at restart, the data in the

Chapter 4 Operationg

temporary memory will remain the same as the original data before edit unless the edited data are written to the flash memory.

The controller always operates in accordance with the data in the main CPU memory (excluding the parameters).

SEL global data (flags,

variables, strings)

Error lists

5.2 Points to Note

Part 1 Installation

Point to note when transferring data and writing to the flash memory

Never turn off the main power while data is being transferred or written to the flash memory. The data will be lost and the controller operation may be disabled.

Point to note when saving parameters to a file

The encoder parameters are stored in the EEPROM of the actuator’s encoder itself (unlike other parameters, they are not stored in the EEPROM of the controller). The encoder parameters will be read from the encoder’s EEPROM to the controller when the power is turned on or upon software reset.

Therefore, if the parameters are saved to a file after turning on the controller (or restarting it via a software reset) without an actuator (encoder) connected, the encoder parameters saved to the file will become invalid.

Point to note when transferring a parameter file to the controller

When a parameter file is transferred to the controller, the encoder parameters will be transferred to the EEPROM of the encoder (excluding manufacturing/function information).

Therefore, if the parameter file transferred to the controller has been read from a controller that was started without an actuator connected, invalid encoder parameters will be written to the encoder’s EEPROM (provided that an actuator is connected to the controller to which the file was transferred).

Part 1 Installation

When saving the parameters to a file, do so with an actuator connected to the controller.

Chapter 4 Operation

Part 1 Installation

Chapter 5 Maintenance

x Routine maintenance and inspection are necessary so that the system will operate properly at all

times. Be sure to turn off the power before performing maintenance or inspection.

x The standard inspection interval is six months to one year. If the environment warrants, however, the

interval should be shortened.

1. Inspection points

Part 1 Installation

x Check to see if the supply voltage to the controller is inside the specified range. x Inspect the ventilation holes in the controller and remove dirt, dust and other foreign attachments, if

x Inspect the controller cables (controller o actuator) and check for any loose screws or cable

x Check the controller mounting screws, etc., for looseness. x Inspect each cable (axis link cable, general-purpose I/O cable, system I/O cable, power cable) for

2. Spare consumable parts

Without spare parts, a failed controller cannot be repaired even when the problem is identified quickly. We recommend that you keep the following consumable parts as spares:

Consumable parts

x Cables x System-memory backup battery (optional): AB-5 by IAI -- Must be replaced after approx. 5 years* x Absolute-data backup battery (optional): AB-5 by IAI -- Must be replaced after approx. 2 years*

(Absolute specification)

When the battery voltage drops, an applicable error code will be displayed on the panel window.

any.

disconnection.

loose connection, disconnection, play, etc.

*: The actual replacement timing will vary depending on the use condition. For details, refer to “

Battery Backup Function” in Appendix.

Chapter 5 Maintenanceg

Error Codes Indicating Low Battery Voltage

System-memory backup battery A01 or A02

Absolute-data backup battery A23

Part 1 Installation

3. Replacement Procedure for System-Memory Backup Battery (Optional)

Backing up the system memory

If the optional system-memory backup battery is installed in the ASEL controller and “Other parameter No. 20: Backup battery installation function type” is set to “2” (Installed), the following SRAM data will be retained even after the power is turned off:

x Position data x SEL global data (flags, integer/real variables, string variables) x Error list

Always follow the procedure below when replacing the system-memory backup battery:

Note: If the system-memory backup battery is disconnected while other parameter No. 20, “Backup

battery installation function type” is still set to “2” (Installed), the data stored in the SRAM will be lost. So that the position data can be restored after an accidental loss from the SRAM, save the position data to a file using the PC software before disconnecting the battery. For the method to save the position data to a file, refer to 6, “Position Data Edit Window” in the X-SEL PC Software Operation Manual.

(1) Turn on the controller power.

(2) Record (write down) the current setting of “Other parameter No. 20, Backup-battery installation

function type.” (This will be used when reverting the parameter to its original setting following the replacement of system-memory backup battery.)

Part 1 Installation

(3) If the PC software is installed in your PC, save the position data to a file using the PC software.

The data will be used as a backup in case the SRAM data saved to the flash ROM fails.

(4) Change “Other parameter No. 20, Backup-battery installation function type” to “1” and transfer

the setting to the controller, and then perform a flash ROM write. (The point data will be saved to the flash ROM.)

* Confirm that the flash ROM writing process has completed.

(5) Perform a software reset to restart the controller. (The SEL global data and error lists will be

saved to the special area in the flash ROM.)

(6) When the controller has been restarted, turn off the power.

* Be sure to keep the power on from the start of controller restart until the RDY LED lamp on teh controller

illuminates.

(7) Replace the system-memory backup battery. SRAM data will be lost if steps (1) through (6) are

not performed properly.

Chapter 5 Maintenance

Battery Replacement Procedure

Part 1 Installation

[1] Remove the battery connector and pull out the

battery.

[2] Insert a new battery into the holder and plug in the

battery connector. The connector hook should face the right side.

(8) When the replacement of system-memory backup battery is complete, confirm that the battery is

installed securely and then turn on the controller power.

(9) Revert “Other parameter No. 20, Backup-battery installation function type” to the value recorded in

step (2), transfer the setting to the controller, and then perform a flash ROM write.

* Confirm that the flash ROM writing process has completed.

(10) Perform a software reset (restart the controller).

(Note) Commencing the operation without first executing a software reset or reconnecting the

Chapter 5 Maintenanceg

(11) When the controller has been restarted, confirm that the SRAM data have been restored.

power may generate the following errors: Error No. C70: ABS coordinate non-confirmation error Error No. C6F: Home-return incomplete error

Part 1 Installation

4. Replacement Procedure for Absolute-Data Backup Battery (Optional)

The replacement procedure is different depending on which error is present (No. A23, 914, CA2), or if no error is present at all, when the battery is replaced.

x If no error is present, perform steps (1) to (4). x If an absolute-data backup battery voltage-low warning (Error No. A23) has been issued, perform

steps (1) to (11).

x If an absolute-data backup battery voltage error (Error No. 914 or CA2) has been issued, perform

steps (1) to (4) and then perform the procedure explained in Chapter 4-2 of Part 1 “How to Perform Absolute Reset.”

Note: Among the steps explained below, complete (2) to (4) within 15 minutes.

(1) Turn off the controller power. (Turn off both the control power and drive power.)

(2) Remove the battery connector and pull out

the battery.

Part 1 Installation

(3) Insert a new battery into the holder and plug

in the battery connector. The connector hook should face the right side.

Chapter 5 Maintenance

(4) Turn on the controller power. (5) Start the PC software on a PC connected to the controller. From the C

(6) When the Warning dialog box appears, click OK.

Part 1 Installation

(7) The Absolute Reset dialog box appears.

Part 1 Installation

ontroller menu, select

bsolute Reset.

Warning

(8) Set the address number corresponding to

the axis whose battery has just been replaced.

Note) Do not click Encoder Rotation Data

Reset 1.

(11) In the PC software window, click the C

controller.

Chapter 5 Maintenanceg

(Note) If you continue to operate the controller without resetting the software or reconnecting the power, the

following errors may generate: Error No. C70: ABS coordinate non-confirmation error Error No. C6F: Home-return incomplete error

This completes the procedure to reset a battery voltage low alarm/error.

(9) Click Encoder Error Reset.

(10) Close the dialog box.

Absolute Reset

ontroller menu and then select Software Reset to restart the

Confirmation

Part 2 Programs

Chapter 1 SEL Language Data

Part 2 Programs

1. Values and Symbols Used in SEL Language

1.1 List of Values and Symbols Used

The various functions required in a program are represented by values and symbols.

Function Global range Local range Remarks

Input port 000 ~ 299 (300)

Output port 300 ~ 599 (300)

Flag 600 ~ 899 (300) 900 ~ 999 (100)

Variable (integer)

Variable (real)

String 300 ~ 999 (700) 1 ~ 299 (299)

Tag number 1 ~ 256 (256)

Subroutine number 1 ~ 99 (99)

Zone number 1 ~ 4 (4)

Pallet number 1 ~ 10 (10)

Axis number 1 ~ 2 (2)

Axis pattern 0 ~ 11 Position number 1 ~ 1500 (1500) Program number 1 ~ 64 (64)

Step number 1 ~ 2000 (2000)

Task level NORMAL/HIGH (2)

SIO channel number 0 (1)

Wait timer 1

1-shot pulse timer

Ladder timer Local flag (100)

Virtual input port (SEL

system o SEL user

program)

Virtual output port (SEL user

program o SEL system)

Number of symbol definitions 500

Number of times symbol can

be used in commands

200 ~ 299 (100)

1200 ~ 1299 (100)

300 ~ 399 (100)

1300 ~ 1399 (100)

7000 ~ 7299 (300)

7300 ~ 7599 (300)

2500 (including literals)

Used in common from any

program.

Referenced separately in each program. Cleared when the program is started.

1 ~ 99 (99)

1001 ~ 1099 (99)

100 ~ 199 (100)

1100 ~ 1199 (100)

16 (Number of timers that

can be operated

simultaneously)

Varies depending on the function. Varies depending on the function.

99 is used for IN, INB, OUT, OUTB, etc. 199 is used for PPUT, PGET, PARG, etc.

Varies depending on the function.

Part 2 Programs Chapter 1 SEL Language Data

Caution

x Variables 99 and 199 are special variables this system uses in operations.

Avoid using these two variables for general purposes.

x The values in the table represent ranges that can be processed by

software. Items that require physical devices, such as I/O ports and functions relating to axis number and SIO, will be determined by possible combinations and models of commercial boards, etc., available for each device application.

z If the optional system-memory backup battery is installed, data of global variables and flags will be

retained even after the controller power is turned off.

(Other parameter No. 20 must be set to “2.” Refer to 5.1.2, “When the System Memory Backup Battery

is Used” in Chapter 5 of Part 1.)

z The variables and flags in the local range will be cleared when the program is started.

z Ranges of values that can be used in SEL language

Integers and real numbers can be used. However, pay due attention to the following limitations:

(1) Numeric data

The ASEL Controller can handle values of maximum eight digits including a sign and a decimal point.

Part 2 Programs

Integer: -9,999,999 to 99,999,999 Real number: Maximum eight digits including a sign and decimal point, regardless of the size of value Example) 999999.9, 0.123456, -0.12345 If a floating point is used in operations, the number of valid digits will be limited to seven. Also note that operations using a floating point are subject to error.

(2) Position data

The input range of position data consists of four integer digits and three decimal digits. –9999.999 to 9999.999 (The maximum value varies depending on the actuator model.) If position data are used in internal operations as numeric data (repeated multiplications and divisions), the accuracy of the last digit may decrease.

Part 2 Programs

1.2 I/O Ports

Chapter 1 SEL Language Data

Consider the above limitations fully when using values. Particularly when the CPEQ command is used in a comparison operation using real numbers, a match will rarely result. In this case, the CPLE or CPGE command that looks at the magnitude relationship of two terms must be used.

(1) Input ports

Used as input ports for limit switches, sensor switches, etc.

Input number assignment

000 to 023 (standard)

(2) Output ports

Used as various output ports.

Output number assignment

300 to 307 (standard)

1.3 Virtual I/O Ports

(1) Virtual input ports

Port No. Function

7000 Always OFF

7001 Always ON

7002 Voltage low warning for system-memory backup battery

7003 Abnormal voltage of system-memory backup battery

7004 (For future expansion = Use strictly prohibited)

7005 (For future expansion = Use strictly prohibited)

7006 Top-level system error = Message level error is present

7007 Top-level system error = Operation-cancellation level error is present

7008 Top-level system error = Cold-start level error is present

7009 (For future expansion = Use strictly prohibited)

7010 Drive-source cutoff factor is present (including when waiting for cutoff reset input)

7011

7012

7013

7014 (For future expansion = Use strictly prohibited)

7015 Voltage low warning for axis-1 absolute-data backup battery

7016

7017 Voltage low warning for axis-2 absolute-data backup battery

7018

7019 ~ 7026 (For future expansion = Use strictly prohibited)

7027 ~ 7040 (For future expansion = Use strictly prohibited)

7041 ~ 7070 (For future expansion = Use strictly prohibited)

7071 In AUTO mode

7072 During automatic operation

7073 ~ 7100 (For future expansion = Use strictly prohibited)

7101 Running program No. 01 (including during pause)

~ ~

7164 Running program No. 64 (including during pause)

7165 ~ 7299 (For future expansion = Use strictly prohibited)

Latch signal indicating that all-operation-cancellation factor is present (latch signal for recognizing 1-shot cancellation factor; latch is cancelled by 7300-ON) All-operation-pause factor is present (including when waiting for restart switch signal) (Valid only during automatic operation recognition) All-servo-axis-interlock factor is present (all-operation-pause factor + interlock input-port factor)

Abnormal voltage of axis-1 absolute-data backup battery (latched until power-on reset or software reset)

Abnormal voltage of axis-2 absolute-data backup battery (latched until power-on reset or software reset)

Part 2 Programs

Part 2 Programs Chapter 1 SEL Language Data

(2) Virtual output ports

Port No. Function

Latch cancellation output for a latch signal indicating that all-operation-cancellation factor

7300

is present (7011) (latch is cancelled only when operation-cancellation factor is no longer present) (7300 will be turned OFF following an attempt to cancel latch.)

7301 ~ 7380 (For future expansion = Use strictly prohibited)

7381 ~ 7399 (For future expansion = Use strictly prohibited)

Part 2 Programs

Chapter 1 SEL Language Data

7400 ~ 7599 (For future expansion = Use strictly prohibited)

Part 2 Programs

1.4 Flags

Contrary to its common meaning, the term “flag” as used in programming means “memory.” Flags are used to set or reset data. They correspond to “auxiliary relays” in a sequencer.

Flags are divided into global flags (Nos. 600 to 899) that can be used in all programs, and local flags (Nos. 900 to 999) that can be used only in each program.

Global flags will be retained (backed up by battery) even after the power is turned off.

Local flags will be cleared when the power is turned off.

Flag number 600 ~ 899 Can be used in all programs “Global flags”

Flag number 900 ~ 999 Used only in each program “Local flags”

Program 1 Program n

Part 2 Programs Chapter 1 SEL Language Data

BTON 600

Turn on flag 600

(Like this, global flags can be used to exchange signals.)

WTON 600

Wait for flag 600 to turn ON

BTON 900 BTON 900

(Although the number is the same, these are local flags and can exist only in their respective programs.)

1.5 Variables

(1) Meaning of variable

“Variable” is a technical term used in software programming. Simply put, it means “a box in which a value is put.” Variables can be used in many ways, such as putting in or taking out a value and performing addition or subtraction.

Part 2 Programs

A variable can be used in many ways, such as:

Putting in a value (1234),

Taking out a value (456), or

Command Operand 1 Operand 2

If this command is applied to variable box 1, which already contains 2, then 1 will be added to the current

Chapter 1 SEL Language Data

value and 3 will result.

Variable

box 1

ADD 1 1

Adding a value (+1).

1 is added.

Variable

box 1

(Already contains 2)

(2) Types of variables

Variables are classified into two types, as follows:

[1] Integer variables These variables cannot handle decimal places. [Example] 1234

Integer variable box

Variable

box 1

Part 2 Programs

Part 2 Programs Chapter 1 SEL Language Data

1 2 3 4

Integer variable number

200 ~ 299

1200 ~ 1299

1 ~ 99

1001 ~ 1099

Can be used in all programs “Global integer variables”

Used only in each program “Local integer variables”

Integer 99 is a special register this system uses in integer

Caution

operations. Any value in the range from –9,999,999 to 99,999,999 can be input in programs.

[2] Real variables Actual values. These variables can handle decimal places. [Example] 1234.567

(Decimal point)

Real variable box

Variable

box 1

1234.567

Real variable number

Caution

300 ~ 399

1300 ~ 1399

100 ~ 199

1100 ~ 1199

Can be used in all programs “Global real variables”

Used only in each program “Local real variables”

Real number 199 is a special register this system uses in realnumber operations. Any value in the range from –99,999.9 to 999,999.9 (eight digits including a sign) can be input in programs.

Part 2 Programs

[3] Variables with “*” (asterisk) (indirect specification) An “*” (asterisk) is used to specify a variable. In the following example, the content of variable box 1 will be put in variable box 2. If variable box 1

contains “1234,” then “1234” will be put in variable box 2.

Command Operand 1 Operand 2

LET 1 1234

1 2 3 4

Part 2 Programs

Chapter 1 SEL Language Data

Variable

box 1

1 2 3 4

Command Operand 1 Operand 2

LET 2 *1

Variable

box 2

1 2 3 4

Put in.

Variable

box 1

1 2 3 4

The above use of variables is called “indirect specification.”

An “*” is also used when indirectly specifying a symbol variable (refer to 1.8, “Symbols”).

Command Operand 1 Operand 2

LET ABC 1

LET BCD 2

ADD ABC *BCD

Put 1 in variable ABC.

Put 2 in variable BCD. Add the content of variable BCD, or 2, to variable ABC.

(The content of variable ABC becomes 3.)

Part 2 Programs

1.6 Tags

The term “tag” means “heading.” Tags are used in the same way you attach labels to the pages in a book you want to reference frequently. A tag is a destination specified in a jump command “GOTO.”

Tag

Part 2 Programs Chapter 1 SEL Language Data

Command Operand 1

TAG Tag number (Integer between 1 and 256)

They are used only in each program.

TAG 1

GOTO 1

1.7 Subroutines

By taking out the parts of a program that are used repeatedly and registering them as “subroutines,” the same processing can be performed with fewer steps. (A maximum of 15 nests are accommodated.)

They are used only in each program.

Command Operand 1

Subroutine execution command

Part 2 Programs

Command Operand 1

Subroutine start declaration

Command Operand 1

Subroutine end declaration

Part 2 Programs

EXSR Subroutine number (Integer between 1 and 99; variable is also supported)

BGSR Subroutine number (Integer between 1 and 99)

EDSR



Chapter 1 SEL Language Data

EXSR 1

Subroutines are called.

EXSR 1

BGSR 1

Subroutines

EDSR

IAI America ASEL User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Please Read Before Use

Operator Alarm on Low Battery Voltage

Table of Contents

Safety Guide

CE Marking

Part 1 Installation

Chapter 1 Overview

1. Introduction

2. Type

3. ASEL Controller Functions

4. System Setup

5. Warranty Period and Scope of Warranty

Chapter 2 Specifications

1. Controller Specifications

2. Name and Function of Each Part

Chapter 3 Installation and Wiring

1. External Dimensions

2. Installation Environment

3. Heat Radiation and Installation

4. Noise Control Measures and Grounding

5. Supply Voltage

6. Wiring

Chapter 4 Operation

1. Startup

2. How to Perform Absolute Reset (Absolute Specification)

3. How to Start a Program

4. Drive-Source Recovery Request and Operation-Pause Reset Request

5. Controller Data Structure

Chapter 5 Maintenance

1. Inspection points

2. Spare consumable parts

3. Replacement Procedure for System-Memory Backup Battery (Optional)

4. Replacement Procedure for Absolute-Data Backup Battery (Optional)

Chapter 1 SEL Language Data

Part 2 Programs

1. Values and Symbols Used in SEL Language