IAI America E-Con User Manual

E-Con Controller

Operation Manual Fifteenth Edition

Please Read Before Use

Thank you for purchasing our product.

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

Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of the product.

The CD that comes with the product contains operation manuals for IAI products.

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

(1) Hold · Servo ON Signal

When operating the E-Con Controller, you will need to turn ON the Hold & Servo ON signal Input Signal of PIO.

In case the Hold Stop Input Signal of PIO remains OFF, E-CON will not move due to hold status. Therefore, please be careful.

(2)Although the exterior of the power supply 100V type controller and 200V type controller is the same, applying 200V to the 100 type controller will cause damage. Please be extra careful when connecting power.

(3)Position 0 may be output regardless of the actual position. At the timings specified below, the positioning completion signal turns ON no matter where the actual position is. As a result, the output status becomes “Position 0.”

1.When the power is turned on

2.When the emergency stop is reset

3.When the alarm is reset

4.When a reset is performed after hold Be extra careful when using Position 0.

(4)With the absolute type, 0E5 (Encoder Reception Error) will be displayed under certain conditions, such as when the power is first turned on after disconnecting the battery or PG cable. This display does not indicate fault. Perform an absolute reset in accordance with the specified procedure.

(5)Recommendation for backing up latest data

This controller uses nonvolatile memory to store position table data and parameters. Although data in the memory is retained even after the power is cut off, the stored data will be lost if the nonvolatile memory is damaged.

It is therefore recommended that you regularly back up the latest position table data and parameters in case of accidental data loss. Regular backup will also let you restore data quickly if the controller must be replaced for other reasons.

Use the following methods to back up data:

[1]Use the PC software to save the data to a CD or FD.

[2]Create a position table sheet or parameter sheet and keep a written record of backup.

Table of Contents

Safety Guide				1
1.	Overview			1
	1-1	Forward....................................................................................................................................................		1
	1-2 How to Read Model Number ...................................................................................................................			2
	1-3	Safety Precautions...................................................................................................................................		3
	1-4 Warranty Period and Scope of Warranty .................................................................................................			4
	1-5 Setting Environment and Noise Measures ..............................................................................................			5
	1-6 Heat Dissipation and Mounting................................................................................................................			8
2.	Specifications			9
	2-1	Basic Specifications .................................................................................................................................		9
	2.1.1		Backup Battery (Absolute Specification)	10
	2-2 Name of Parts and Functions ...............................................................................................................			12
	2-2-1 Names			12
	2-2-2		Functions	12
	2-2-3		Signal Tables for Connectors and Terminal Blocks	16
	2-3	External Dimensional Diagram .............................................................................................................		18
	2-3-1		Standard Specifications	18
	2-3-2		Absolute Specification	19
	2-4	Connection Method...............................................................................................................................		20
	2-4-1		Standard Item	20
	2-4-2		Absolute Specifications	21
	2-5	Supplied Cables....................................................................................................................................		22
	2-5-1		I/O Flat Cable	22
	2-5-2		Motor Extension Cable	23
	2-5-3		Encoder Extension Cable (Single-axis Robot Type)	23
	2-5-4		Encoder Extension Cable (ROBO Cylinder Type)	24
	2-5-5		Limit Switch Extension Cable	24
	2-6	Wiring....................................................................................................................................................		25
	2-6-1		Wiring for Power • Emergency Stop	25
	2-6-2		External Connection Diagram	26
	2-6-3		PIO Interface	27
	2-6-4		External I/O Specifications	30
3.	Data Input (Basic)			32
	3-1	Position Data Table ...............................................................................................................................		33
	3-1-1		Push Force at Standstill	36
	3-2	Mode Explanation .................................................................................................................................		37
	3-3	Timing Chart..........................................................................................................................................		41
	3-4 Items to Note on Gripper (RCS-G20) ...................................................................................................			42

4. Using the Controller <Practice>				43
	4-1	Power-Up (Standard Specification).......................................................................................................		43
	4-2 Absolute Reset Procedure (Absolute Specifications) ...........................................................................			45
	4-3	Move After Power-Up (Standard)..........................................................................................................		47
	4-4 Positioning Mode (2 point space reciprocation)....................................................................................			49
	4-5	Push Mode............................................................................................................................................		51
	4-6 Speed Change Movement During Transfer ..........................................................................................			53
	4-7 Movement Using Different Acceleration Value • Deceleration Value ....................................................			55
	4-8	Hold.......................................................................................................................................................		57
	4-9	Zone Signal Output ...............................................................................................................................		59
	4-10	Transfer to Home ................................................................................................................................		61
	4-11 Incremental Movement in Relative Coordinate ...................................................................................			63
	4-12 Caution Regarding Relative Coordinate Assign..................................................................................			65
5.	Parameters			67
	5-1	Parameter Classification .......................................................................................................................		67
	5-2	Parameter List.......................................................................................................................................		67
	5-3	Parameter Settings ...............................................................................................................................		68
	5-3-1 Parameters Relating to Actuator Stroke Range			68
	5-3-2 Parameters Relating to Actuator Operating Characteristics			69
	5-3-3 Parameters Relating to External Interface			72
	5-3-4		Servo Gain Adjustment	72
6.	Troubleshooting			73
	6-1 What to Do When A Problem Occurs....................................................................................................			73
	6-2	Alarm Level Classification.....................................................................................................................		74
	6-3 Alarm Output by PIO.............................................................................................................................			74
	6-4	Alarms, Causes and Actions.................................................................................................................		75
		(1)	Message Alarms........................................................................................................................	75
		(2)	Operation Cancellation Alarms..................................................................................................	76
		(3)	Cold Start Alarms.......................................................................................................................	78
	6-5 Messages Displayed during Operations Using Teaching Pendant or PC Software .............................			82
7. Regenerative Resistance Unit (Optional)				84
Appendix				86
		Specification List of Supported Actuators..........................................................................................		86
		Example of Basic E-Con Positioning Sequence ...............................................................................		89
		Position Table Record .....................................................................................................................		92
		Parameter Record.............................................................................................................................		94
Change History				95

Safety Guide

When designing and manufacturing a robot system, ensure safety by following the safety guides provided below and taking the necessary measures.

Regulations and Standards Governing Industrial Robots

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

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

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

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

JIS B 8433

(Manipulating industrial robots – Safety)

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

Industrial Safety and Health Law Article 59

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

Ordinance on Industrial Safety and Health

Article 36 --- Operations requiring special education

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

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

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

Pre.-1

Requirements for Industrial Robots under Ordinance on Industrial Safety and Health

Work area	Work condition	Cutoff of drive source	Measure	Article
Outside	During		Signs for starting operation	Article 104
movement	automatic	Not cut off	Installation of railings, enclosures,	Article 150-4
range	operation		etc.
		Cut off (including	Sign, etc., indicating that work is in	Article 150-3
		stopping of operation)	progress
			Preparation of work rules	Article 150-3
			Measures to enable immediate	Article 150-3
	During teaching,		stopping of operation
	etc.
		Not cut off	Sign, etc., indicating that work is in	Article 150-3
			progress
			Provision of special education	Article 36-31
			Checkup, etc., before	Article 151
Inside			commencement of work
movement
			To be performed after stopping the	Article 150-5
range		Cut off	operation
			Sign, etc., indicating that work is in	Article 150-5
			progress
	During		Preparation of work rules	Article 150-5
			Measures to enable immediate
	inspection, etc.	Not cut off (when		Article 150-5
		inspection, etc., must	stopping of operation
			Sign, etc., indicating that work is in
		be performed during		Article 150-5
		operation)	progress
			Provision of special education	Article 36-32
			(excluding cleaning and lubrication)

Pre.-2

Applicable Models of IAI’s Industrial Robots

Machines meeting the following conditions are not classified as industrial robots according to Notice of Ministry of Labor No. 51 and Notice of Ministry of Labor/Labor Standards Office Director (Ki-Hatsu No. 340):

(1)Single-axis robot with a motor wattage of 80 W or less

(2)Combined multi-axis robot whose X, Y and Z-axes are 300 mm or shorter and whose rotating part, if any, has the maximum movement range of within 300 mm3 including the end of the rotating part

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

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

1.Single-axis ROBO Cylinders

RCS2/RCS2CR-SS8 whose stroke exceeds 300 mm

2.Single-axis robots

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

3.Linear servo actuators

All models whose stroke exceeds 300 mm

4.Cartesian robots

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

5.IX SCARA robots

All models whose arm length exceeds 300 mm

(All models excluding IX-NNN1205/1505/1805/2515, NNW2515 and NNC1205/1505/1805/2515)

Pre.-3

Notes on Safety of Our Products

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

No.	Task	Note
1	Model	 This product is not planned or designed for uses requiring high degrees of safety.
	selection	Accordingly, it cannot be used to sustain or support life and must not be used in the
		following applications:

[1]Medical devices relating to maintenance, management, etc., of life or health

[2]Mechanisms or mechanical devices (vehicles, railway facilities, aircraft facilities, etc.) intended to move or transport people

[3]Important safety parts in mechanical devices (safety devices, etc.)

Do not use this product in the following environments:

[1]Place subject to flammable gases, ignitable objects, flammables, explosives, etc.

[2]Place that may be exposed to radiation

[3]Place where the surrounding air temperature or relative humidity exceeds the specified range

[4]Place subject to direct sunlight or radiated heat from large heat sources

[5]Place subject to sudden temperature shift and condensation

[6]Place subject to corrosive gases (sulfuric acid, hydrochloric acid, etc.)

[7]Place subject to excessive dust, salt or iron powder

[8]Place where the product receives direct vibration or impact

Do not use this product outside the specified ranges. Doing so may significantly shorten the life of the product or result in product failure or facility stoppage.

2Transportation  When transporting the product, exercise due caution not to bump or drop the product.

Use appropriate means for transportation.

Do not step on the package.

Do not place on the package any heavy article that may deform the package.

When using a crane with a capacity of 1 ton or more, the crane must be operated by personnel qualified to operate cranes and perform slinging operations.

When using a crane or other equipment, never use it to hoist any article exceeding the rated load of the applicable crane, etc.

Use hoisting accessories suitable for the article to be hoisted. Select appropriate hoisting accessories by making sure there is an ample allowance for safety in their cutting load, etc.

Do not climb onto the article being hoisted.

Do not keep the article hoisted.

Do not stand under the hoisted article.

3Storage/  The storage/preservation environment should conform to the installation environment.

preservation	Among others, be careful not to cause condensation.
4 Installation/	(1) Installing the robot, controller, etc.
startup	 Be sure to firmly secure and affix the product (including its work part).
	If the product tips over, drops, malfunctions, etc., damage or injury may result.
	 Do not step on the product or place any article on top. The product may tip over or the
	article may drop, resulting in injury, product damage, loss of/drop in product
	performance, shorter life, etc.
	 If the product is used in any of the following places, provide sufficient shielding
	measures:
	[1] Place subject to electrical noise
	[2] Place subject to a strong electric or magnetic field
	[3] Place where power lines or drive lines are wired nearby
	[4] Place subject to splashed water, oil or chemicals
Pre.-4

4Installation/ startup

5 Teaching

(2) Wiring the cables

Use IAI’s genuine cables to connect the actuator and controller or connect a teaching tool, etc.

Do not damage, forcibly bend, pull, loop round an object or pinch the cables or place heavy articles on top. Current leak or poor electrical continuity may occur, resulting in fire, electric shock or malfunction.

Wire the product correctly after turning off the power.

When wiring a DC power supply (+24 V), pay attention to the positive and negative polarities.

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

Securely connect the cables and connectors so that they will not be disconnected or come loose. Failing to do so may result in fire, electric shock or product malfunction.

Do not cut and reconnect the cables of the product to extend or shorten the cables. Doing so may result in fire or product malfunction.

(3) Grounding

 Be sure to provide class D (former class 3) grounding for the controller. Grounding is required to prevent electric shock and electrostatic charges, improve noise resistance and suppress unnecessary electromagnetic radiation.

(4) Safety measures

Implement safety measures (such as installing safety fences, etc.) to prevent entry into the movement range of the robot when the product is moving or can be moved. Contacting the moving robot may result in death or serious injury.

Be sure to provide an emergency stop circuit so that the product can be stopped immediately in case of emergency during operation.

Implement safety measures so that the product cannot be started only by turning on the power. If the product starts suddenly, injury or product damage may result.

Implement safety measures so that the product will not start upon cancellation of an emergency stop or recovery of power following a power outage. Failure to do so may result in injury, equipment damage, etc.

Put up a sign saying “WORK IN PROGRESS. DO NOT TURN ON POWER,” etc., during installation, adjustment, etc. If the power is accidently turned on, electric shock or injury may result.

Implement measures to prevent the work part, etc., from dropping due to a power outage or emergency stop.

Ensure safety by wearing protective gloves, protective goggles and/or safety shoes, as necessary.

Do not insert fingers and objects into openings in the product. Doing so may result in injury, electric shock, product damage, fire, etc.

When releasing the brake of a vertically installed actuator, be careful not to pinch your hand or damage the work part, etc., due to the slider dropping by its dead weight.

Whenever possible, perform teaching from outside the safety fences. If teaching must be performed inside the safety fences, prepare “work rules” and make sure the operator understands the procedures thoroughly.

When working inside the safety fences, the operator should carry a handy emergency stop switch so that the operation can be stopped any time when an abnormality occurs.

When working inside the safety fences, appoint a safety watcher in addition to the operator so that the operation can be stopped any time when an abnormality occurs. The safety watcher must also make sure the switches are not operated inadvertently by a third party.

Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.

When releasing the brake of a vertically installed actuator, be careful not to pinch your

hand or damage the work part, etc., due to the slider dropping by its dead weight. * Safety fences --- Indicate the movement range if safety fences are not provided.

Pre.-5

6 Confirmation	 After teaching or programming, carry out step-by-step confirmation operation before
operation	switching to automatic operation.
	 When carrying out confirmation operation inside the safety fences, follow the specified
	work procedure just like during teaching.
	 When confirming the program operation, use the safety speed. Failure to do so may
	result in an unexpected movement due to programming errors, etc., causing injury.
	 Do not touch the terminal blocks and various setting switches while the power is
	supplied. Touching these parts may result in electric shock or malfunction.

7Automatic  Before commencing automatic operation, make sure no one is inside the safety fences. operation  Before commencing automatic operation, make sure all related peripherals are ready to

operate in the auto mode and no abnormalities are displayed or indicated.

Be sure to start automatic operation from outside the safety fences.

If the product generated abnormal heat, smoke, odor or noise, stop the product immediately and turn off the power switch. Failure to do so may result in fire or product damage.

If a power outage occurred, turn off the power switch. Otherwise, the product may move suddenly when the power is restored, resulting in injury or product damage.

8Maintenance/  Whenever possible, work from outside the safety fences. If work must be performed

inspection	inside the safety fences, prepare “work rules” and make sure the operator understands
	the procedures thoroughly.

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

When working inside the safety fences, the operator should carry a handy emergency stop switch so that the operation can be stopped any time when an abnormality occurs.

When working inside the safety fences, appoint a safety watcher in addition to the operator so that the operation can be stopped any time when an abnormality occurs. The safety watcher must also make sure the switches are not operated inadvertently by a third party.

Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.

Use appropriate grease for the guides and ball screws by checking the operation manual for each model.

Do not perform a withstand voltage test. Conducting this test may result in product damage.

When releasing the brake of a vertically installed actuator, be careful not to pinch your

hand or damage the work part, etc., due to the slider dropping by its dead weight. * Safety fences --- Indicate the movement range if safety fences are not provided.

9	Modification	 The customer must not modify or disassemble/assemble the product or use
		maintenance parts not specified in the manual without first consulting IAI.
		 Any damage or loss resulting from the above actions will be excluded from the scope of
		warranty.
10	Disposal	 When the product becomes no longer usable or necessary, dispose of it properly as an
		industrial waste.

When disposing of the product, do not throw it into fire. The product may explode or generate toxic gases.

Pre.-6

Indication of Cautionary Information

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

	Level	Degree of danger/loss
	Danger	Failure to observe the instruction will result in an imminent
		danger leading to death or serious injury.
	Warning	Failure to observe the instruction may result in death or serious
		injury.
	Caution	Failure to observe the instruction may result in injury or property
		damage.
		The user should take heed of this information to ensure the
	Note	proper use of the product, although failure to do so will not result
		in injury.

Symbol

Danger

Warning

Caution

Note

Pre.-7

Pre.-8

1. Overview

1-1 Forward

Thank you very much for purchasing the E-Con Controller. This manual explains the features of this machine and its operating procedures.

Without knowing beforehand how to correctly use or operate the controller, not only will the user be unable to take full advantage of all the functions built into this product but the user might also, inadvertently cause damage to the robot or shorten its life. Please read this manual as well as other manuals carefully pertaining to the product to acquire an understanding of the proper method of handling and operating the controller. Keep this manual handy so that you can refer to the appropriate sections as the need arises.

Also refer to the operation manuals for the various actuators you are using, as well as the operation manual(s) for the optional PC software and/or teaching pendant if applicable.

Absolute Specifications:

With the absolute home controller, once power is applied, and absolute reset is executed, you can execute positioning without the need to home after reapplying the power. Other basic functions are the same as the standard E-Con Controller.

Absolute reset is not set at time of shipment. Please execute absolute reset by yourself.

Only the absolute actuator can be operated using the E-Con Controller absolute specification. The incremental actuator cannot be used.

Notes on installing the absolute data backup battery

Follow the steps below to install the battery in order to initialize the battery circuit and thereby prevent the battery from being consumed early:

(1)Connect the encoder cable.

(2)Turn on the power.

(3)Install the absolute data backup battery.

Be sure to perform the above operation after the encoder cable is disconnected for relocation, etc.

Actuator Duty

Operate IAI’s actuator at a duty of 50% or less to maintain an optimum balance between its service life and precision. The duty is calculated using the formula below:

Duty (%) = Operating time / (Operating time + Stationary time) x 100

1

1-2 How to Read Model Number

<Series>

<Encoder type>

I:Incremental

A:Absolute

<Actuator>

[1]Motor capacity

[2]Brake

B:With brake Blank: Without brake

[3]Creep sensor

C:With creep sensor Blank: Without creep sensor

[4]Overtravel sensor

L:With home sensor and overtravel sensor Blank: Without home sensor or overtravel sensor

<I/O signal type>

P: PNP specification [Source] Blank: NPN specification [Sink]

<CE compliance> EU: CE-compliant

Blank: Not CE-compliant

<Input supply voltage>

<Open network>

DV: DeviceNet specification CC: CC-Link specification PR: ProfiBus specification Blank: Not network-ready

2

Controller Version

A “SERIAL No.” label is attached on the right side face of the controller.

The last two characters (alphabet and number) in the portion following SERIAL No. indicate the controller version.

Example) If the label reads “SERIAL No. ET352720 I3,” the controller version is “I3.”

When the controller version is increased, the alphabet changes in an alphabetical order while the number is incremented by one.

The specifications of the controller vary slightly, depending on the version

*All precautions have been taken to ensure the precision of the contents of this manual. However, if you become aware of any inaccuracies or discrepancies, please contact IAI.

Keep this manual in a handy place so that you can reference it quickly as necessary.

1-3 Safety Precautions

Please read the following information carefully in order to gain an understanding of safety precautions.

This product was developed as components for driving automated equipment and is designed not to produce greater torque or speed than is necessary. However, strictly observe the following items to prevent any accidents from occurring.

1.As a rule, any handling or operating methods not described in this manual should be viewed as things that should not be attempted. Please contact IAI if any portion of the contents of this manual are unclear.

2.Use only the products specified for wiring between the actuator and controller.

3.Stand clear of the operating range of the machine when it is in motion or is ready to operate (when the control power is on). Surround the system with safety partitions if there is a possibility that people can enter the area where the machine is being used.

4.When assembling, adjusting, or performing maintenance on the machine, always disengage the power supply to the controller. During work, display a sign stating work in progress where it is readily visible. Also, keep the power cable close to the operator so that another person cannot inadvertently switch on the power.

5.When more than one person is working on the system, agree on signals beforehand to ensure everyone's safety before beginning work. In particular, when doing work involving axis movement, always call out for everyone's safety regardless of whether power is ON or OFF, or the axis is to be mechanically driven or manually moved.

6.When the user needs to lengthen the cables, check the wiring carefully to make sure it is correct before turning the power ON since miswiring can lead to malfunction.

3

1-4 Warranty Period and Scope of Warranty

The E-Con Controller undergoes stringent testing before it is shipped from our factory. IAI provides the following warranty:

1. Warranty Period

The warranty period expires upon elapse of one of the following periods, whichever occurs first.

18 months after the shipment from IAI

12 months after delivery to the location specified by the user.

2. Scope of Warranty

If within the period specified above, a breakdown occurs while operating the controller under normal conditions and is clearly the responsibility of the manufacturer, IAI will repair the unit at no cost. However, the following items are not covered by this warranty:

Faded paint or other changes that occur naturally over time.

Consumable components that wear out with use (battery, etc.).

Unit seems to be noisy or similar impressions that do not affect machinery performance.

Damage resulting from improper handling or use.

Damage resulting from user error or failure to perform proper maintenance.

Use of any part which is not a genuine part of IAI

Any alterations not authorized by IAI or its representatives, including parameters.

Damage caused by fire and other natural disasters or accidents.

The warranty pertains to the purchased product itself and does not cover any loss that might arise from a breakdown of the product. Any repairs will be done at our factory.

Make sure you understand the foregoing terms of warranty.

4

1-5 Setting Environment and Noise Measures

Please be careful for controller setting environment

1-5-1 Installation Environment

This controller can be used in an environment of pollution degree 2*1 or equivalent.

*1 Pollution degree 2: Normally only nonconductive pollution occurs. Temporary conductivity caused by condensation is to be expected.

(EN60947-5-1)

(1)Do NOT block the air vents of your controller when installing your IA system.

(Unavailability of sufficient ventilation not only prevents the controller from demonstrating its designed performance, but it may also lead to a controller failure.)

(2)Prevent foreign matters from entering the controller through the vent holes. Your controller is NOT dust, water, or oil proof. Avoid using your IA system in environments subject to contamination by dust, oil, mist, or cutting oil.

(3)Do not expose your IA system to direct sunlight or radiation heat from a large heat source such as heat treat furnace, etc.

(4)Avoid placing your IA system under conditions of extreme temperatures above 40 C or below 0 C. The level of humidity should not be exceed 85%. Do NOT expose to corrosive or inflammable gas.

(5)Avoid external vibration, unnecessary impact, or excessive shocks to your controller.

(6)Take steps to shield controllers and wiring cables from electromagnetic noise.

1-5-2 Power Source

There are AC 100 V and AC 200 V depending on the controller specification.

1-5-3 Noise Elimination Measures and Grounding

(1) Wiring and Power Supply

The PE terminal on the power-supply terminal block is used for safety grounding. Provide a class D grounding connection to this terminal.

The thickness of the cable should be 0.75 mm2 (#18AWG) or larger and above AC cables.

5

(2)Noise Elimination Grounding

You will need to set noise compliance and grounding whether AC 100 or 200 V.

1.Directly screw the main body to the metal box.

2. Wiring Notes

Isolate the controller cable from high power lines such as motor circuits (Do not bundle, and do not place in the same piping circuit).

Consult with IAI's technical service department or sales engineering department if you need longer motor and encoder cables than what comes with the controller.

6

(3) Noise Source and Noise Suppression

When using electrical components such as electromagnets, solenoid valve, magnet switch or relays which create electromagnetic noise, some type of noise suppression device should be used.

1. AC solenoid valve · magnetic switch · relay

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

Point

Install a surge absorber to each coil over a minimum wiring length.

Installing a surge absorber to the terminal block or other part will be less effective because of a longer distance from the coil.

2.DC solenoid valve · magnetic 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 reverse polarity will damage the diode, internal parts of the controller and/or DC power supply, so exercise due caution.

7

1-6 Heat Dissipation and Mounting

The size of the controller panel, controller position and cooling method should all be designed so that the controller boundary temperature remains under 40ºC. As the diagram below shows, mount vertically (wall mounting). Controllers are cooled by active ventilation (brewing upward). For installation, make sure to leave more than 100mm of space above and 50mm of space below the controller, following this direction. When mounting with several controllers lined up, also mount an agitator fan above the controllers in order to maintain surrounding air temperature. In addition, the spacing between the controller front side and wall (cover) should be more than 100mm..

Direction of air

Fan

As for the spacing in between the controllers, whether or not it’s a single controller or multiple controllers, please leave enough space so that controller mounting and removal may be done easily.

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2. Specifications

2-1	Basic Specifications
		Item			Specification
		Power Voltage		Motor Capacity: 20 to 200 W		Single phase AC 90 to 125 V
				20 to 750 W		Single phase AC 180 to 250 V
				Motor capacity: 30 W or less		Rating: 60 W/100 VA
				60 W			100 W / 160 VA
				100 W			150 W / 240 VA
	Power Current / Capacity			150 W			210 W / 350 VA
		(Note 1)		200 W			270 W / 450 VA
				400 W			520 W / 870 VA
				600 W			770 W / 1300 VA
				750 W			1000 W / 1600 VA
		Rush current		Single phase AC 90 to 125 V		44 A
(Maximum, instantaneous) (Note 2)				Single phase AC 180 to 250 V		200 W or less/88 A, 400 W or more/112 A
		Unit Weight		1,200 g (Standard), 1,500 g (Absolute specification)
Surrounding Air Temperature /				Temperature: 0 to 40 C, Humidity: Less than 85%RH
		Humidity
	Surrounding Environment			IP 10 (No Corrosive Gas)
		Protective Function		Motor overvoltage, motor overcurrent, driver temperature error, encoder error,
				motor overload, etc.
	Withstand voltage (Note 3)			1500 VAC, 1 minute
		LED Display		RDY (green), RUN (green), ALM (red), ENC (orange)
		DI/DO Interface		24 VDC Isolation
				Start
			Exclusive Input	Command Position Number (6 bit Binary)
				Hold
			10 port
				Reset
				Servo ON
				Complete Position Number (6 bit Binary)
I/O		PIO		Complete Positioning
Signal				Complete Homing
			Exclusive Output	Zone
			13 port	Emergency Stop
				Alarm
				Moving
				Battery Alarm
			SIO	Termi-Bus communication protocol
		Position Number		64 points
		Data Input Method		Teaching Pendant or PC Interface Software
Regenerative Resistance Unit				Motor Capacity
		(Note 4)		60 to 150 W			Integrated into the controller
				200 to 750 W			External unit
		Accessories		PIO Flat Cable, Power Connector, EMG Connector
*Note 1: Instantaneous value is 3 times more.

*Note 2: Select a medium-speed NFB.

*Note 3: The withstand voltage of the motor used in the actuator is 1000 V for 1 minute. Before performing a withstand voltage test with the controller and actuator connected, make sure that the supplied voltage will not exceed 1000 V for a period over 1 minute.

*Note 4: Whether you need an external unit or not, it depends on condition of usage. Refer to 7, “Regenerative Resistance Unit (Optional).”

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2.1.1Backup Battery (Absolute Specification)

(1) Battery Specifications

Item	Description
Model Number	AB-1
Type	Lithium battery
Manufacturer	Toshiba Battery (ER6VP)
Nominal voltage	3.6 V
Rated capacity	2000 mAh
Weight	Approx. 8.5 g
Battery retention time *1	Approx. 20,000 hours (at surrounding air temperature of 20 C)

Note 1) The current consumption during absolute data backup is approx. 100 A (approx. 4 A if the main controller power is on).

*To avoid breakdown, do not attempt to modify or extend the battery cable.

*The battery is always replaced together with the battery board. The battery cannot be replaced separately. Only use the battery specified by IAI.

(2)Battery Alarm and Battery Error

Once the battery voltage has dropped to approx. 3.1 V, a battery alarm occurs (alarm code: 07A). This alarm is output to PIO connector pin 7. The controller does not stop operating immediately upon occurrence of a battery alarm. The alarm merely alerts the user that the battery must be replaced as soon as possible. After a battery alarm occurs, the controller can still operate for approx. 220 hours (approx. 9 days) before a battery error occurs.

To temporarily reset the battery alarm, input a reset signal or press the BEGIN/END key on the teaching pendant for at least 2.5 seconds.

Note) The battery alarm function is supported on controllers of version H2 or later.

Once the battery voltage has dropped to approx. 2.5 V, a battery error occurs. This error (alarm code: 0E5) will be detected the next time the controller power is turned on. A battery error is detected only after the controller power has been turned on.

The controller can no longer operate once a battery error occurs. You must replace the battery and perform an absolute reset.

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If the battery was replaced when the controller power was off, the retention condition of position information (absolute data) will vary as follows, depending on how long the controller has been out of battery.

	Battery-out duration	Retention condition of position information (absolute data)
	Less than 5 minutes	Position information (absolute data) has been retained. Absolute reset is not
		required.
	5 to 15 minutes	A battery alarm occurs. Position information has been retained. Absolute reset is
		not required.
	More than 15 minutes	A battery error occurs. Position information has not been retained. Absolute
		reset is required.

Note) The function to retain position information (absolute data) during battery replacement is supported on controllers of version H2 or later.

If a battery error was present prior to the replacement, an absolute reset is required even when the battery has been out for less than 15 minutes.

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2-2 Name of Parts and Functions

2-2-1 Names

(6) Battery Connector	(8) RUN (green)	(9) ALM (red)
	(7) RDY (green)	(10) ENC (orange)
(1) Emergency Stop Connecter		(11) PIO Connector
(2) Actuator Sensor Input Connector		(12) Piano Switch 3 (SW3)
		(13) Piano Switch 2 (SW2)
		(14) Piano Switch 1 (SW1)
(3) Motor Connector
		(15) Brake Release Switch
(4) Regenerative		(16) Encoder Brake Connector
Resistance Unit Connector
		(17) Port Switch
(5) Power Terminal		(18) Main Communication Port Connector
		(19) DSIO Connector

2-2-2 Functions

(1) Emergency Stop Connector

EMG: This is a terminal block for emergency stop. B contact when open. It is connected at the time of shipment.

(2) Actuator Sensor Input Connector

This is a connector for Limit Switch (LS) · CREEP · Over Travel (OT) sensor.

(3) Motor Connector

This is the connector for the motor power cable of the actuator.

(4) Regenerative Resistance Unit Connector

This is the connector for the Regenerative Resistance Unit.

Necessity depends on user application conditions.

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(5) Power Terminal

L · N: This is the connection from the AC Power source.

PE: This is contact for safety (D Type contact work)

(6) Battery Connector

This is the connector for the absolute encoder backup battery (absolute specifications).

(7~10) LED Display

(7)	RDY(green):	Turns on when no alarm is present or no emergency stop is actuated.
(8)	RUN (green):	Turns on when the servo is ON and the actuator is moving.
(9)	ALM (red):	Turns on during alarm.

(10)ENC (orange): This will turn on when encoder breaks or not detected.

(11)PIO connector (PIO)

Connector for the PIO cable.

(12) Piano switch 3 (SW3)

This is the interchange switch for encoder voltage. This is used when voltage drop must be considered for special cable application. Interchange assembly of 1 and 2 will change the encoder voltage as follows:

1	2	Applicable Cable Length
ON	OFF	~ 15 m
OFF	ON	15 to 25 m
ON	ON	25 to 30 m

Caution: Piano Switch number starts from the bottom side.

(13) Piano switch 2 (SW2)

1: Clears ABS-CLR and absolute encoder data. This is used when resetting the absolute: Normally

(Bottom) OFF

2:FWP, Light Protect Switch. This is used during remote-UP: Normally OFF

(Top)

*The piano switch turns ON when tilted to right, and turns OFF when tilted to left, as viewed from the front side.

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(14) Piano switch 1 (SW1)

Piano Switch 1~4: Axis number setting switch

When connecting more than 2 axes onto the SIO Connector, serial reorganization occurs when setting the actuator axis number. You may set up to 0~15 axes (at the time of shipment, numbers 1~4 are all set as OFF. This application is for single axis unit). For every controller, please set the piano switch and set the desired axis number. As for the number, make sure that the same number is not used for more than controller. As long as all numbers are unique, they may not be consecutive or some numbers may be skipped in between.

	Axis Number		Piano Switch Number
		1	2	3	4
	0	OFF	OFF	OFF	OFF
	1	ON	OFF	OFF	OFF
	2	OFF	ON	OFF	OFF
	3	ON	ON	OFF	OFF
	4	OFF	OFF	ON	OFF
	5	ON	OFF	ON	OFF
	6	OFF	ON	ON	OFF
	7	ON	ON	ON	OFF
	8	OFF	OFF	OFF	ON
	9	ON	OFF	OFF	ON
	10	OFF	ON	OFF	ON
	11	ON	ON	OFF	ON
	12	OFF	OFF	ON	ON
	13	ON	OFF	ON	ON
	14	OFF	ON	ON	ON
	15	ON	ON	ON	ON

Caution: In case of number of axes greater than 1, the emergency stop of the teaching pendant will only effect the controller axis connected to the teaching pendant.

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(15) Brake Release Switch (BK)

Effective when only break option is selected.

RLS: Release position turns the brake OFF.

NOM: Normal position makes the brake active. (normal setting)

(16) Encoder • Brake Connector (ENC)

This is the connector for Encoder & Brake power cable.

(17) Port Switch (PORT)

ON:	PORT IN Port (Teaching Pendant · PC Software) will be activated. However, in case of
	exclusive teaching pendant and exclusive cables are not connected, emergency stop status
	will occur.
OFF:	PORT IN Port (Teaching Pendant · PC Software) will be deactivated (Since SIO line is hot,
	communication between the controllers will be possible).

(18) Main Communication Port Connector (PORT IN)

This is the connector for the teaching pendant or external device communication cable. This is also the connector for the controller link cable for connection with two or more axes.

(19) SIO Connector (SIO)

This is the connector for connection between controllers when connecting two or more controllers.

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2-2-3 Signal Tables for Connectors and Terminal Blocks

SIO Connector

Pin. No	Signal Name		Function
1	(+5 V)		(5 VDC Power Output) or (Reserve Signal Terminal)
2	S GA		Line transceiver I/O positive logic side
3	G ND		Ground for communication
4	S GB		Line Transceiver I/O negative logic side
5	G ND		Ground for communication
6	+5 V		5 VDC Power Output
Main Communication Port Connector
Pin. No	Signal Name		Function
1	SGA		Serial Communication
2	SGB		Serial Communication
3	5 V		5 V Power Output
4	EMGS		Emergency Stop Status
5	EMGA		*1
6	24 V		24 V Power Point
7	GND		Ground
8	EMGB		*1

*Note 1: This is used as an emergency stop (B contact).

When disconnecting the emergency stop, please short-circuit.

Motor Connector (GIC2.5/4-STF-7.62 Phoenix Contact)

Signal Name	Connection Line
PE	Motor FG
U	Motor U Phase
V	Motor V Phase
W	Motor W Phase

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