Simple Absolute Unit
Operation Manual Tenth Edition
ACON
PCON
PSEL
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/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.
1. Controller Versions Supporting the Simple Absolute Unit
The simple absolute unit can be connected to controllers of the following firmware versions or higher:
ACON-C/CG: Ver. D
ACON-CY/SE: Ver. B
PCON: Ver. B
PSEL: Ver. 0.19
* ACON-PL/PO and PCON-PL/PO controllers do not support the simple absolute unit.
* When connecting to a controller of an older version, please contact IAI.
2. Actuators Not Supporting the Absolute Unit
RA10C and RCL
The simple absolute unit cannot be connected to the actuators mentioned above.
3. Charging the Battery
Always charge the battery when the simple absolute unit is started for the first time after the delivery,
or after the battery has been replaced.
The battery in the simple absolute unit is charged automatically while the power is supplied to the
controller, so keep the main power on for at least 72 hours. (The STATUS0 lamp will illuminate in
green when the battery has been fully charged.)
The actuator can be moved and its position table changed while the battery is charged. If the power
has been cut off for an extended period (not exceeding the specified backup time), also charge the
battery for at least 72 hours.
4. When the Power Is Cut Off
(1) Absolute data may be lost if the actuator receives vibration, shock, etc., or the slider, etc., is
moved while the power is cut off.
When you turn on the power the next time, an absolute encoder error may generate, indicated by
a green RDY/ALM lamp and red STATUS1 lamp. In this case, you must reset the alarm and
perform home return.
While the power is cut off, do not move the slider or rod at a speed greater than the specified
speed.
(2) While the battery is charged, the surrounding air temperature affects the charge efficiency. It is
recommended that the surrounding air temperature be kept to normal temperature (+10 to
+30qC) while the battery is charged.
If the surrounding air temperature exceeds 45qC, the charge efficiency will drop and the battery
will not be charged sufficiently. An excessively high surrounding air temperature during charge
may also lead to performance degradation or leakage of battery fluid.
5. Caution on Parameter Change
If any of the following parameters is changed, an absolute error will generate. You must perform an
absolute reset again after these parameters have been changed:
x ACON or PCON
(1) Parameter No. 5: Home return direction
(2) Parameter No. 22: Home return offset
(3) Parameter No. 77: Ball screw lead
(4) Parameter No. 78: Axis operation type
x PSEL
(1) Axis-specific parameter No. 1 (10) Axis-specific parameter No. 44
(2) Axis-specific parameter No. 6 (11) Axis-specific parameter No. 46
(3) Axis-specific parameter No. 10 (12) Axis-specific parameter No. 47
(4) Axis-specific parameter No. 11 (13) Axis-specific parameter No. 50
(5) Axis-specific parameter No. 12 (14) Axis-specific parameter No. 51
(6) Axis-specific parameter No. 21 (15) Axis-specific parameter No. 66
(7) Axis-specific parameter No. 38 (16) Axis-specific parameter No. 67
(8) Axis-specific parameter No. 42 (17) Axis-specific parameter No. 68
(9) Axis-specific parameter No. 43 (18) Driver parameter No. 26
CE Marking
If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual
(ME0287) that is provided separately.
Table of Contents
Safety Guide.................................................................................................................... 1
1. Overview ................................................................................................................... 1
1.1 Introduction .......................................................................................................................... 1
1.2 How to Read the Model Name............................................................................................. 2
1.3 Handling the Battery of the Absolute Unit............................................................................ 3
1.4 Safety Precautions............................................................................................................... 4
1.5 Warranty .............................................................................................................................. 5
2. Specifications ............................................................................................................ 7
2.1 Basic Specifications ............................................................................................................. 7
2.1.1 Backup Battery........................................................................................................ 8
2.2 Name and Function of Each Controller Part........................................................................ 9
2.2.1 Names..................................................................................................................... 9
2.2.2 Functions................................................................................................................
2.3 External Dimensions ...........................................................................................................
3.4.Installation and Noise Elimination..............................................................................
3.1 Installation Environment..................................................................................................... 13
3.2 Supplied Power.................................................................................................................. 13
3.3 Noise Elimination and Grounding ...................................................................................... 13
3.4 Heat Dissipation and Installation ....................................................................................... 15
10
12
Wiring ......................................................................................................................1316
4.1 Configuration...................................................................................................................... 16
4.2 Connecting the Dedicated Cable ....................................................................................... 17
4.2.1 PCON/PSEL Controller Cable .............................................................................. 17
4.2.2 ACON Controller Cable......................................................................................... 18
4.3 How to Open the Lid of the Simple Absolute Unit.............................................................. 19
4.4 Wiring the Power Supply ................................................................................................... 20
5. Operation ................................................................................................................ 21
5.1 Startup Procedure.............................................................................................................. 21
5.1.1 Piano Switch Settings ........................................................................................... 21
5.1.2 Parameter Setting (High-Order Controller)........................................................... 22
5.2 How to Perform an Absolute Reset.................................................................................... 23
5.2.1 Absolute Reset Using PIO Signals ....................................................................... 23
5.2.2 Absolute Reset from the PC Software .................................................................. 24
5.2.3 Absolute Reset from the Teaching Pendant ......................................................... 30
5.3 Replacing the Battery............................................................................................................. 31
6. Troubleshooting.......................................................................................................
6.1 What to Do When a Problem Occurs................................................................................. 33
6.2 Alarm Classification by Level............................................................................................. 35
6.3 Alarms, Causes and Actions.............................................................................................. 36
33
Change History .............................................................................................................. 40
Safety Guide
When designing and manufacturing a robot system, ensure safety by following the safety
precautions 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
Preface1
Requirements for Industrial Robots under Ordinance on Industrial
Safety and Health
Work area Work condition
Outside
movement
range
Inside
movement
range
During
automatic
operation
During
teaching, etc.
Cutoff of drive
source
Not cut off
Cut off (including
stopping of
operation)
Not cut off
Cut off
Measure Article
Signs for starting operation Article 104
Installation of railings,
enclosures, etc.
Sign, etc., indicating that work is
in progress
Preparation of work rules Article 150-3
Measures to enable immediate
stopping of operation
Sign, etc., indicating that work is
in progress
Provision of special education Article 36-31
Checkup, etc., before
commencement of work
To be performed after stopping
the operation
Sign, etc., indicating that work is
in progress
Article 150-4
Article 150-3
Article 150-3
Article 150-3
Article 151
Article 150-5
Article 150-5
During
inspection, etc.
Not cut off (when
inspection, etc., must
be performed during
operation)
Preparation of work rules Article 150-5
Measures to enable immediate
stopping of operation
Sign, etc., indicating that work is
in progress
Provision of special education
(excluding cleaning and
lubrication)
Article 150-5
Article 150-5
Article 36-32
Preface2
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 mm
(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)
3
including the tip of the rotating part
Preface3
Notes on Safety of Our Products
Common items you should note when performing each task on any IAI robot are explained below.
No. Task Note
1 Model
selection
2 Transportation z When transporting the product, exercise due caution not to bump or drop the
Storage,
3
preservation
z This product is not planned or designed for uses requiring high degrees of safety.
Accordingly, it cannot be used to sustain or support life and must not be used in the
following applications:
[1] Medical devices relating to maintenance, management, etc., of life or health
[2] Mechanisms or mechanical devices (vehicles, railway facilities, aircraft facilities,
etc.) intended to move or transport people
[3] Important safety parts in mechanical devices (safety devices, etc.)
z 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 bedewing
[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
z 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.
product.
z Use appropriate means for transportation.
z Do not step on the package.
z Do not place on the package any heavy article that may deform the package.
z 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.
z When using a crane or other equipment, never use it to hoist any article exceeding
the rated load of the applicable crane, etc.
z 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.
z Do not climb onto the article being hoisted.
z Do not keep the article hoisted.
z Do not stand under the hoisted article.
z The storage, preservation environment should conform to the installation
environment. Among others, be careful not to cause bedewing.
Preface4
No. Task Note
4 Installation/
startup
(1) Installing the robot, controller, etc.
z Be sure to firmly secure and affix the product (including its load).
If the product tips over, drops, malfunctions, etc., damage or injury may result.
z Do not step on the product or place any article on top. The product may tips over or
the article may drop, resulting in injury, product damage, loss of/drop in product
performance, shorter life, etc.
z 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
(2) Wiring the cables
z Use IAI’s genuine cables to connect the actuator and controller or connect a
teaching tool, etc.
z 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.
z Wire the product correctly after turning off the power.
z 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.
z Be sure to connect the cable connectors without fail and firmly. Failing to do so may
result in fire, electric shock or product malfunction.
z 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
z 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
z 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.
z Be sure to provide an emergency stop circuit so that the product can be stopped
immediately in case of emergency during operation.
Preface5
No. Task Note
4 Installation/
startup
z 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.
z 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.
z 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.
z Implement measures to prevent the load, etc., from dropping due to a power
outage or emergency stop.
z Ensure safety by wearing protective gloves, protective goggles and/or safety
shoes, as necessary.
z Do not insert fingers and objects into openings in the product. Doing so may result
in injury, electric shock, product damage, fire, etc.
z When releasing the brake of a vertically installed actuator, be careful not to pinch
your hand or damage the work, etc., due to the slider dropping by its dead weight.
5 Teaching z 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.
z 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.
z 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.
z Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.
z When releasing the brake of a vertically installed actuator, be careful not to pinch
your hand or damage the work, etc., due to the slider dropping by its dead weight.
* Safety fences --- Indicate the movement range if safety fences are not provided.
6 Confirmation
operation
z After teaching or programming, carry out step-by-step confirmation operation
before switching to automatic operation.
z When carrying out confirmation operation inside the safety fences, follow the
specified work procedure just like during teaching.
z 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.
z 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.
Preface6
No. Task Note
7 Automatic
operation
z Before commencing automatic operation, make sure no one is inside the safety
fences.
z Before commencing automatic operation, make sure all related peripherals are
ready to operate in the auto mode and no abnormalities are displayed or indicated.
z Be sure to start automatic operation from outside the safety fences.
z 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.
z If a power outage occurred, turn off the power switch. Otherwise, the product may
move suddenly when the power is restored, resulting in injury or product damage.
8 Maintenance/
inspection
z Whenever possible, work from outside the safety fences. If work must be
performed inside the safety fences, prepare “work rules” and make sure the
operator understands the procedures thoroughly.
z When working inside the safety fences, turn off the power switch, as a rule.
z 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.
z 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.
z Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.
z Use appropriate grease for the guides and ball screws by checking the operation
manual for each model.
z Do not perform a withstand voltage test. Conducting this test may result in product
damage.
z When releasing the brake of a vertically installed actuator, be careful not to pinch
your hand or damage the work, etc., due to the slider dropping by its dead weight.
* Safety fences --- Indicate the movement range if safety fences are not provided.
9 Modification z The customer must not modify or disassemble/assemble the product or use
maintenance parts not specified in the manual without first consulting IAI.
z Any damage or loss resulting from the above actions will be excluded from the
scope of warranty.
10 Disposal z When the product becomes no longer usable or necessary, dispose of it properly
as an industrial waste.
z When disposing of the product, do not throw it into fire. The product may explode or
generate toxic gases.
Preface7
Indication of Cautionary Information
The operation manual for each model denotes safety precautions under “Danger,” “Warning,” “Caution” and
“Note,” as specified below.
Level Degree of danger/loss Symbol
Danger
Warning
Caution
Note
Failure to observe the instruction will result in an
imminent danger leading to death or serious injury.
Failure to observe the instruction may result in death
or serious injury.
Failure to observe the instruction may result in injury
or property damage.
The user should take heed of this information to
ensure the proper use of the product, although failure
to do so will not result in injury.
Danger
Warning
Caution
Note
Preface8
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