IAI America PCON-CA User Manual

Download

PCON-CA/CFA Controller

Instruction Manual

Fifth Edition

POWER CON

PCON-CA/CFA

Please Read Before Use

Thank you for purchasing our product.

This Instruction Manual describes all necessary information items to operate this product safely such as the operation procedure, structure and maintenance procedure. Before the operation, read this manual carefully and fully understand it to operate this product safely. The enclosed CD/DVD in this product package includes the Instruction Manual for this product. For the operation of this product, print out the necessary sections in the Instruction Manual or display them using the personal computer.

After reading through this manual, keep this Instruction Manual at hand so that the operator of this product can read it whenever necessary.

[Important]

x This Instruction Manual is original. x The product cannot be operated in any way unless expressly specified in this Instruction

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

x Information contained in this Instruction Manual is subject to change without notice for the

purpose of product improvement.

x If you have any question or comment regarding the content of this manual, please contact

the IAI sales office near you.

x Using or copying all or part of this Instruction Manual without permission is prohibited. x The company names, names of products and trademarks of each company shown in the

sentences are registered trademarks.

POWER CON

PCON-CA/CFA

POWER CON

PCON-CA/CFA

Safety Guide ·····················································································································1 Precautions in Operation ·································································································· 8 International Standards Compliances············································································· 11 CE Marking ····················································································································· 11 UL ······················································································································· 11 Name for Each Parts and Their Functions······································································ 13 Actuator Axes··················································································································17 Starting Procedures ········································································································ 19

Chapter 1 Specifications Check······················································································21

1.1 Product Check ············································································································ 21

1.1.1 Parts····················································································································· 21

1.1.2 Teaching Tool······································································································· 21

1.1.3 Instruction manuals related to this product, which are contained in the instruction manual (CD/DVD). ······································································· 22

1.1.4 How to read the model plate················································································22

1.1.5 How to read the model························································································· 22

1.2 List of Basic Specifications ························································································· 23

1.3 Appearance·················································································································24

1.3.1 CA Type ··········For Incremental Screw-fixed Type ··············································24

1.3.2 CA Type ··········For Incremental DIN rail-fixed Type ············································ 25

1.3.3 CA Type ··········For Simple Absolute Screw-fixed Type······································· 26

1.3.4 CA Type ········· For Simple Absolute DIN rail-fixed Type····································· 27

1.3.5 CFA Type ········For Incremental Screw-fixed Type ··············································28

1.3.6 CFA Type ········For Incremental DIN rail-fixed Type ············································ 29

1.3.7 Absolute Battery Unit (Option for Simple Absolute Type)···································· 30

1.4 I/O Specifications ········································································································31

1.4.1 PIO Input and Output Interface············································································31

1.4.2 Pulse Train Input Output Interface·······································································32

1.5 Options························································································································ 32

1.5.1 Pulse converter : AK-04 ······················································································· 32

1.6 Installation and Storage Environment ·········································································33

1.7 Noise Elimination and Mounting Method ····································································34

Chapter 2 Wiring·············································································································37

2.1 Positioner Mode (PIO Control)···················································································· 37

2.1.1 Wiring Diagram (Connection of devices)····························································· 37

2.1.2 PIO Pattern Selection and PIO Signal································································· 38

2.1.3 Circuit Diagram ····································································································43

[1] Power Supply Connector (for power supply and emergency stop) ······················· 43 [2] Motor • Encoder Circuit·························································································· 44 [3] Absolute Circuit (For Simplified Absolute Type Only)············································ 44 [4] PIO Circuit ············································································································· 45

2.2 Pulse Train Control Mode ···························································································51

2.2.1 Wiring Diagram (Connection of devices)····························································· 51

2.2.2 I/O Signals in Pulse Train Control Mode······························································ 52

2.2.3 Circuit Diagram ····································································································53

[1] Power Supply Connector (for power supply and emergency stop) ······················· 53 [2] Motor • Encoder Circuit·························································································· 54 [3] PIO Circuit ············································································································· 55 [4] Circuits for Pulse Train Control·············································································· 56

POWER CON

PCON-CA/CFA

2.3 Wiring Method············································································································· 57

2.3.1 Wiring Layout of Power Supply Connector·························································· 57

2.3.2 Connection to Actuator ························································································ 58

2.3.3 Connection of PIO ······························································································· 59

2.3.4 Connection of Pulse Train Signal·········································································60

2.3.5 SIO Connector Connection··················································································61

Chapter 3 Operation ······································································································· 63

3.1 Basic Operation ·········································································································· 63

3.1.1 Basic Operation Methods ···················································································· 63

3.1.2 Parameter Settings······························································································65

3.2 Operation in Positioner Mode······················································································· 66 [1] PIO Pattern Selection and Main Functions ···························································66 [2] Overview of major Functions·················································································67 [3] Operation modes of rotary actuator in multiple rotation mode and

command limitations······························································································ 67

3.2.1 Set of Position Table (This section is not required in selection of pulse train control mode.)················ 68

3.2.2 Control of Input Signal ························································································· 73

3.2.3 Operation Ready and Auxiliary Signals = Common to Patterns 0 to 5················ 73

[1] Emergency stop status (EMGS)············································································73 [2] Operation Mode (RMOD, RMDS)·········································································· 74 [3] Servo ON (SON, SV, PEND) ················································································· 75 [4] Home Return (HOME, HEND, PEND, MOVE)······················································ 76 [5] Zone Signal and Position Zone Signal (ZONE1, ZONE2, PZONE)······················ 80 [6] Alarm, Alarm Reset (*ALM, RES)·········································································· 82 [7] Binary Output of Alarm Data Output (*ALM, PM1 to 8) ········································· 83 [8] Brake release (BKRL)···························································································· 85

3.2.4 Operation with the Position No. Input = Operations of PIO Patterns 0 to 3 ········ 86

[1] Positioning [Basic]

(PC1 to PC**, CSTR, PM1 to PM**, PEND, MOVE, LOAD, TRQS) ····················· 86 [2] Speed change during the movement····································································· 91 [3] Pitch Feeding (relative movement = incremental feed)·········································92 [4] Pressing operation································································································· 94 [5] Tension Operation ································································································· 99 [6] Multi-step pressing ······························································································101 [7] Teaching by PIO (MODE, MODES, PWRT, WEND, JISL, JOG+, JOG-) ············ 102 [8] Pause and Operation Interruption (*STP, RES, PEND, MOVE)·························· 104

3.2.5 Direct Position Specification (Solenoid Valve Mode 1) = Operation of PIO Pattern 4··················· 106

[1] Positioning [Basic] (ST1 to ST6, PE1 to PE6, PEND)········································· 106 [2] Pitch Feeding (relative movement = incremental feed)·······································108 [3] Pressing operation······························································································· 110 [4] Tension Operation ······························································································· 114 [5] Multi-step pressing ······························································································ 116 [6] Pause and Operation Interruption (ST*, *STP, RES, PE*, PEND)······················ 117

3.2.6 Direct Position Specificatio

n (Solenoid Valve Mode 2) =

Operation of PIO Pattern 5··················· 119

[1] Home return (ST0, HEND) ·················································································· 119 [2] Features of LS signals (LS0 to 2)········································································123 [3] Positioning [Basic] (ST0 to ST2, LS0 to LS2)······················································124 [4] Speed change during the movement··································································· 126 [5] Pause and Operation Interruption (ST*, *STP, RES, PE*, PEND)······················ 128

POWER CON

PCON-CA/CFA

3.3 Pulse Train Control Mode (for Pulse Train Type)······················································ 129

3.3.1 I/O Signal Controls····························································································· 130

3.3.2 Operation Ready and Auxiliary Signals ····························································· 130

[1] System Ready (PWR) ·························································································130 [2] Emergency stop status (*EMGS)········································································· 130 [3] Operation Mode (RMOD, RMDS)········································································131 [4] Compulsory Stop (CSTP) ···················································································· 132 [5] Servo ON (SON, SV)···························································································132 [6] Home Return (HOME, HEND)············································································· 133 [7] Zone (ZONE1, ZONE2)·······················································································137 [8] Alarm, Alarm Reset (*ALM, RES)········································································ 138 [9] Binary Output of Alarm Data Output (*ALM, ALM1 to 8) ····································· 138 [10] Brake Forcible Release (BKRL) ·········································································· 139

3.3.3 Pulse Train Input Operation··············································································· 140

[1] Command Pulse Input (PP•/PP, NP•/NP)····························································140 [2] Position complete (INP)······················································································· 141 [3] Torque Limit Select (TL, TLR)··············································································142 [4] Deviation Counter Clear (DCLR)·········································································142

3.3.4 Settings of Basic Parameters Required for Operation ······································ 143

[1] Electrical Gear Setting························································································· 143 [2] Format Settings of Command Pulse Train ··························································145

3.3.5 Parameter Settings Required for Advanced Operations ···································146

[1] Position command primary filter time constant····················································146 [2] Torque Limit ·········································································································146 [3] Clearing deviation during servo OFF or alarm stop ············································ 146 [4] Error monitor during torque limiting····································································· 147 [5] Deviation Counter Clear Input ·············································································147 [6] Torque limit command input·················································································147 [7] Pulse count direction ··························································································· 147 [8] Compulsory Stop Input ························································································147

Chapter 4 Field Network ······························································································· 149

Chapter 5 Power-saving Function (Automatic Servo-off and Full Servo Functions)····· 151

Chapter 6 Absolute Reset and Absolute Battery ··························································155

6.1 Absolute Reset·········································································································· 155

6.2 Absolute Battery········································································································ 159

6.2.1 Absolute encoder backup specifications ··························································· 159

6.2.2 Absolute Battery Charge···················································································· 159

6.2.3 Absolute Battery Voltage Drop Detection ·························································· 160

6.2.4 Replacement of absolute battery······································································· 161

Chapter 7 I/O Parameter ······························································································163

7.1 I/O Parameter List·····································································································164

7.2 Detail Explanation of Parameters ·············································································168

7.3 Servo Adjustment······································································································ 194

Chapter 8 Troubleshooting ··························································································· 197

8.1 Action to Be Taken upon Occurrence of Problem·····················································197

8.2 Fault Diagnosis ········································································································· 198

8.2.1 Impossible operation of controller······································································198

8.2.2 Positioning and speed of poor precision (incorrect operation) ·························· 202

8.2.3 Generation of noise and/or vibration ································································· 204

8.2.4 Impossible Communication ··············································································· 205

8.3 Alarm Level ···············································································································206

8.4 Alarm List ·················································································································· 207

POWER CON

PCON-CA/CFA

Chapter 9 Appendix ······································································································ 217

9.1 Way to Set Multiple Controllers with 1 Teaching Tool ··············································· 217

9.1.1 Connecting Example·························································································· 217

9.1.2 Detailed Connection Diagram of Communication Lines···································· 218

9.1.3 Axis No. Setting ································································································· 218

9.1.4 Handling of e-CON connector (how to connect)················································ 219

9.1.5 SIO Converter····································································································220

9.1.6 Communications Cable······················································································ 222

9.1.7 External Dimension···························································································· 222

9.2 Conformity to Safety Category··················································································223 [1] System Configuration ··························································································223 [2] Wiring and setting of safety circuit······································································· 224 [3] Examples of safety circuits··················································································226 [4] TP adapter and accessories················································································232

9.3 When Connecting Power Supply with + Grounding··················································234

9.4 Example of Basic Positioning Sequence (PIO pattern 0 to 3) ·································· 235

9.4.1 I/O Assignment ··································································································235

9.4.2 Ladder Sequence ······························································································ 236 [1] Servo ON (Emergency Stop) Circuit···································································· 236 [2] Operation and Stop Circuit ·················································································· 236 [3] Pause Circuit ·······································································································237 [4] Reset Circuit ········································································································ 238 [5] Home Return Circuit····························································································239 [6] Decode Circuit of Positioning Complete Position No. ·········································240 [7] Actuator Start Circuit····························································································240 [8] Position 1 Operation Circuit················································································· 241 [9] Position 2 Operation Circuit················································································· 242 [10] Position 3 Operation Circuit················································································· 243 [11] Commanded Position No. Output Ready Circuit·················································244 [12] Commanded Position No. Output Circuit ···························································· 245 [13] Start Signal Output Circuit··················································································· 245 [14] Other Display Circuits (Zone 1, Position Zone, and Manual Mode) ···················· 246

9.5 List of Specifications of Connectable Actuators ························································247

Chapter 10 Warranty ···································································································· 283

10.1 Warranty Period ·········································································································283

10.2 Scope of the Warranty································································································283

10.3 Honoring the Warranty ·······························································································283

10.4 Limited Liability··········································································································· 283

10.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications································································································· 284

10.6 Other Items Excluded from Warranty·········································································284

Change History ············································································································· 285

POWER CON

PCON-CA/CFA

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.

Operation

Description

1 Model

Selection

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.

POWER CON

PCON-CA/CFA

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 instruction 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

POWER CON

PCON-CA/CFA

No.

Operation

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.

4 Installation

and Start

(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).

POWER CON

PCON-CA/CFA

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 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.

POWER CON

PCON-CA/CFA

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.

POWER CON

PCON-CA/CFA

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 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

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 Instruction 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

instruction manual of each unit to ensure the safety.

POWER CON

PCON-CA/CFA

Alert Indication

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

Level Degree of Danger and Damage Symbol

Danger

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

Danger

Warning

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

Warning

Caution

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

Caution

Notice

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

Notice

POWER CON

PCON-CA/CFA

Precautions in Operation

1. Make sure to follow the usage condition, environment and specification range of the product.

Not doing so may cause a drop of performance or malfunction of the product.

2. Use the following teaching tools.

Use the PC software and the teaching pendant stated in the next clause as applicable for this controller. [Refer to 1.1.2 Teaching Tool.]

3. Backup the data to secure for breakdown.

A non-volatile memory is used as the backup memory for this controller. All the registered position data and parameters are written into this memory and backed-up at the same time. Therefore, you will not usually lose the data even if the power is shut down. However, make sure to save the latest data so a quick recovery action can be taken in case when the controller is broken and needs to be replaced with another one.

How to Save Data (1) Save the data to CD-R or hard disk with using the PC software (2) Hard-copy the information of position tables and parameters on paper

4. Set the operation patterns.

This controller processes 7 types of control logics (including 6 types of PIO patterns and pulse train control) to meet various ways of usage, and changes the role of each PIO signal following the selected control logic.

1) In PIO specification, there are 6 types of PIO patterns available to choose from.

2) For Pulse Train specification, not only the pulse train control mode, but also 6 types of PIO patterns are available.

The setup can be performed by using the operation mode change switch or parameter No.25 “PIO pattern selection” on the front panel. [Refer to Chapter 3 Operation and Chapter 7 I/O Parameter.] The PIO pattern is set to “0” (Standard Type) when the unit is delivered. Set the operation pattern setting to the logic that suits to your use after the power is turned on.

5. Clock Setting in Calendar Function

There may be a case that “Error Code 069 Real Time Clock Vibration Stop Detect” is issued at the first time to turn the power on after the product is delivered. In the case this happens, set the current time with a teaching tool. If the battery is fully charged, the clock data is retained for approximately 10 days after the power is turned off. Even though the time setting is conducted before the product is shipped out, the battery is not fully charged. Therefore, there may be a case that the clock data is lost even with fewer days than described above passed since the product is shipped out.

6. In pulse train control mode, actuator operation is unavailable through serial communication.

In the pulse train control mode, the actuator operation is unavailable through serial communication. However, it is possible to monitor the current status.

Warning : Please note it is very risky when the control sequence and PIO pattern setting do not

match to each other. It may not only cause the normal operation disabled, but also may cause an unexpected operation.

POWER CON

PCON-CA/CFA

7. Attempt not to exceed the actuator specifications in the pulse train control mode.

In the pulse train control, the acceleration/deceleration speed is also controlled by the change of the command pulse frequency from the host controller. Do not have an operation exceeding the maximum acceleration/deceleration rate of the actuator. The use of the actuator with excessive acceleration/deceleration rate may cause a malfunction.

8. Actuator would not operate without servo-on and pause signals.

(1) Servo ON Signal (SON)

Servo ON signal (SON) is selectable from “Enable” or “Disable” by using a parameter. It is settable by parameter No.21 “selection of servo-on signal disable”. [Refer to Chapter 7 I/O Parameter.] If it is set to “Enable”, the actuator would not operate unless turning this signal on. If parameter No.21 is set to “1”, SON requirement is disabled. If it is set to “Disable”, the servo becomes on and the actuator operation becomes enabled as soon as the power supply to the controller is turned on and the emergency stop signal is cancelled. This parameter is set to “0” (Enable) at delivery. Have the setting that suits the desired control logic.



(2) Pause Signal (*STP)

The input signal of the pause signal (*STP) is always on considering the safety. Therefore, in general, the actuator would not operate if this signal is not on. It is available to make this signal to “Disable”, if this signal is undesirable. It is settable by parameter No.15 “Pause input disable”. [Refer to Chapter 7 I/O Parameter.] If parameter No.15 is set to “1” (Disable), the actuator can operate even if this signal is not on. This parameter is set to “0” (Enable) at delivery.

9. Note that there are some frictions and/or torsions in through-hole of rotary actuator when it is used.

When using rotary actuator with a through hole in the center of the revolution and using the hole to put cables through, have a treatment to prevent wear from rubbing or wire break due to the cables getting twisted. Take particular note on actuators of 360-degree specification because they can be rotated infinitely in a single direction.

POWER CON

PCON-CA/CFA

10. Limitations on operation of rotary actuator in index mode

Rotary actuators of 360-degree specification can select the normal mode for finite rotations or the index mode enabling multi-rotation control by using parameter No.79 “Rotational axis mode selection”. [Refer to Chapter 7 I/O Parameter.] The following limitations are applied to the index mode:

1) Index Mode cannot be selected in Pulse Train Control Mode.

2) In the JOG or Inching Operation using a teaching tool such as PC software or using PIO

signal, the range of 1 time of command is 360q at maximum for JOG while 1q at maximum for Inching.

3) Pressing is unavailable. The pressing torque can only be set to 0.

4) Do not issue positioning command around 0qrepeatedly during movement near 0q. Failure

to follow this may cause the actuator to rotate in the direction reverse to the specified rotation direction or operate indefinitely.

5) Software stroke limit is invalid in the index mode.



11. Transference of PIO Signal between Controllers

Please note the following when conducting transference of PIO signal between controllers. To certainly transfer the signal between controllers with different scan time, it is necessary to have longer scan time than the one longer than the other controller. To ensure to end the process safely, it is recommended to have the timer setting more than twice as long as the longer scan time at least.

䎃

Ɣ Operation Image

䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃䎃

Also, if one tries to read the signal that is being re-written by the other, the signal may be read wrongly. Make sure to read the signal after the rewriting is complete. (It is recommended to have more than 2 scan periods to wait.) Make sure not to have the output side to change the output until the other side completes the reading. Also, a setting is made on the input area not to receive the signal less than a certain time to prevent a wrong reading of noise. This duration also needs to be considered.

This controller

(scan time 1msec)

PLC

(e.g. scan time is 20msec)

Output Process

Input Process

As shown in the diagram, the input and output timings of two devices that have different scan time do not match, of course, when transferring a signal. There is no guarantee that PLC would read the signal as soon as this controller signal turns on. In such a case, make the setting to read the signal after a certain time that is longer than the longer scan time to ensure the reading process to succeed on the PLC side. It is the same in the case this controller side reads the signal. In such a case, it is recommended to ensure 2 to 4 times of the scan time for the timer setting margin. It is risky to have the setting below the scan time since the timer is also processed in the scan process. In the diagram, PLC can only read the input once in 20msec even though this controller output once in 1msec. Because PLC only conducts output process once in 20msec, this controller identifies the same output status for that while.

POWER CON

PCON-CA/CFA

12. PLC Timer Setting

Do not have the PLC timer setting to be done with the minimum setting. Setting to “1” for 100msec timer turns ON at the timing from 0 to 100msec while 10msec timer from 0 to 10msec for some PLC. Therefore, the same process as when the timer is not set is held and may cause a failure such as the actuator cannot get positioned to the indicated position number in Positioner Mode. Set “2” as the minimum value for the setting of 10msec timer and when setting to 100msec, use 10msec timer and set to “10”.

International Standards Compliances

PCON-CA comply with the following international standards: Refer to Overseas Standard Compliance Manual(ME0287) for more detailed information.

RoHS Directive CE Marking UL

{

To be scheduled To be scheduled

POWER CON

PCON-CA/CFA

POWER CON

PCON-CA/CFA

Name for Each Parts and Their Functions

CA Type

CFA Type

14) Fan Unit Desorption Lever

1) Absolute Battery Connector

(For Simple Absolute Type)

2) Absolute Battery (For Simple Absolute Type)

3) Absolute Battery Status Indicator LED (For Simple Absolute Type)

5) Controller Status Indicator LED

7) Axis Number Setting Switch

8) Operation Mode Setting Switch

9) SIO Connector

10) Motor • Encoder Connector

11) Brake Release Switch

12) Power Supply Connector

4) PIO Connector /Field Network Connector

6) LED for Power/Alarm Monitoring

1) Absolute Battery Connector (Not to be used)

13) Fan Unit

3) Absolute Battery Status Indicator LED (Not to be used)

5) Controller Status Indicator LED

7) Axis Number Setting Switch

8) Operation Mode Setting Switch

9) SIO Connector

10) Motor • Encoder Connector

11) Brake Release Switch

12) Power Supply Connector

4) PIO Connector /Field Network Connector

6) LED for Power/Alarm Monitoring

2) Absolute Battery (Unavailable)

POWER CON

PCON-CA/CFA

1) Absolute Battery Connector [Refer to Chapter 6] It is the connector to plug in the enclosed battery if applicable for Simple Absolute Type (option).

2) Absolute Battery [Refer to Chapter 6] It is enclosed if applicable for Simple Absolute Type (option). It is used to retain the encoder information. Use unit by affixing it on the side of PCON body with fabric hook-and-loop fastener or store it Absolute Battery Unit (option).

3) Absolute Battery Status Indicator LED [Refer to Chapter 6] It is equipped if applicable for Simple Absolute Type (option). It displays the status such as battery charge condition and error generation. { : Illuminating × : OFF

LED Operation status

RDY(GN)/

ALM(RD)

1 (GN/RD) 0 (GN/OR/RD) Description

× × × Control Power OFF

{ (GN) { (GN)

{

(Either color)

Absolute Reset Complete

{ (GN) { (RD)

{

(Either color)

Absolute Reset Incomplete

{ (RD) { (RD)

{

(Either color)

Error occurred.

{

(Either color)

{

(Either color)

{ (GN) Battery Fully Charged

{

(Either color){

(Either color)

{ (OR) Battery Charging Operation

{

(Either color){

(Either color)

{ (RD) Battery Disconnected

4) PIO Connector/Field Network Connector PIO Type is equipped with the input and output signal connectors for control and Fieldbus Network Type with connectors for each field network connection. [Refer to 2.1.2 PIO Pattern Selection and PIO Signal or 2.2.2 I/O Signals in Pulse Train Control Mode] [For the details of the field network, refer to Chapter 4 and the instruction manual for each field network.]

5) Controller Status Indicator LED Following show the controller operation status: { : Illuminating × : OFF ڏ : Flashing

LED Status of PIO Output Signal

SV (GN)

ALM (RD)

Operation status

SV Output

(Servo ON)

*ALM Output

(Note 1)

*EMGS

Output

(Note 1)

(Emergency

stop status)

Control Power OFF

× ×

Servo OFF

Alarm

(Operation Cancellation

Level or more)

OFF OFF OFF

Motor Driving Power

Supply OFF

{

In the Emergency Stop

OFF OFF ON

{

× Servo ON ON ON OFF

During Automatic

servo-off

(Note 2)

OFF ON OFF

{ (OR)

During initialization after

power is supplied

OFF OFF OFF

Note 1 *ALM output is an active low signal that is turned on when in normal condition and

turned off when an error is generated.

Note 2 Signal during automatic servo-off : [Refer to Chapter 5]

POWER CON

PCON-CA/CFA

6) LED for Current/Alarm Monitoring In the ordinary use, it shows the command current percentage and shows the alarm code during an alarm being generated.

LED Operation Status

STS3 (GN)

STS2 (GN)

STS1 (GN)

STS0 (GN)

Status Display

x During servo-off: it displays the current command current ratio

(proportional to the rated current).

{ : Illuminating × : OFF

STATUS

3 2 1 0

Command Current Ratio

ALM8 ALM4 ALM2 ALM1 Simple alarm code

× × × × 0.00% to 6.24% × × ×

{

6.25% to 24.99%

× ×

{ {

25.00% to 49.99%

{ { {

50.00% to 74.99%

{ { { {

75.00% to 100.00% or more

x During alarm generation: it displays the simple alarm code.

[Refer to 3.2.3 [7] and 3.3.2 [9] Binary Output of Alarm Data Output]

7) Axis Number Setting Switch It is the switch to set the axis numbers when having an operation of multiple axes by the serial communication, or when having the gateway operation. Using the SIO converter allows multiple axes to be controlled on a teaching tool without connection/disconnection of the connection cable connector. The SIO converter can specify up to 16 axes with hexadecimal numbers 0 to F. The setting of the switch is read at power-on of the controller. Changing the setting after the power-on is invalid.

Caution : Note duplicate axis number setting, which causes a communication error

(alarm code 30C: no connection axis error) to occur and disables normal communication.

8) Operation Mode Setting Switch (MANU/AUTO) This switch is used for interlock so that a moving command from PIO (PLC) and a command from the teaching tool may not be issued at a time.

AUTO… Allows auto operation by PIO signals. The teaching tool can only operate the

monitor.

MANU…Allows the teaching tool to operate the controller.

9) SIO Connector (SIO) [Refer to 2.3.5 SIO Connector Connection.] The SIO connector is used to connect the controller with a teaching tool or a gateway unit through a proper communication cable.

10) Motor • Encoder Connector [Refer to 2.1.3 [2] and 2.2.3 [2] Motor • Encoder Circuit] It is the connector to connect the actuator motor and encoder cable.

Point the arrow at a desired number with a flat-head screwdriver

POWER CON

PCON-CA/CFA

11) Brake Release Switch (BK RLS/NOM) For the actuator equipped with a brake, the switch is used to release the brake forcibly. BK RLS ····· Brake forcible release NOM·········· Normal operation (brake is activated)

12) Power Supply Connector [Refer to 2.3.1 Wiring Layout of Power Supply Connector] It is the connector for the power supply (for controller control power, actuator driving and brake control power) and for the input of emergency status signal.

13) Fan Unit It is a forced cooling unit dedicated for PCON-CFA Type.

14) Fan Unit Desorption Lever When replacing the fan unit, pull the lever up and the fan unit can be taken out. After replacing with a new unit, push the lever down to affix the unit.

Warning : Always set the switch to “NOM” in normal operation.

(Make sure the opportunity to put the switch to RLS side is the minimum and is limited to when startup and adjustment. Make certain to set the switch to NOM side in normal use.) The brake would not work even with the servo OFF condition if the switch is on the RLS side. In the vertical oriented mount, the work may drop and cause an injury or the work to be damaged.

POWER CON

PCON-CA/CFA

Actuator Axes

Refer to the pictures below for the actuator axes that can be controlled by PCON. 0 defines the home position, and items in ( ) are for the home-reversed type (option).

(1) Rod Type

(2) Slider Type

(3) Table Type

(4) Arm Type

Caution : There are some actuators that are not applicable to the origin reversed type.

Check further on the catalog or the Instruction Manual of the actuator.

(0)

(+)

(0)

(+)

(0)

(+)

POWER CON

PCON-CA/CFA

(5) Gripper Type

(3-Finger Gripper)

Note Finger attachment is not included in the actuator package. Please prepare separately.

(6) Rotary Type

(300q Rotation Specification) (Multiple Rotation Specification)

For Multiple Rotation Type with the origin reversed type, the directions of  and  are the other way around.

㧜

330

㧙

㧗

Finger Attachment (Note)

POWER CON

PCON-CA/CFA

Starting Procedures

1. Positioner Mode

When using this product for the first time, make sure to avoid mistakes and incorrect wiring by referring to the procedure below. “PC” stated in this section means “PC software”.

ωYes

No ψ

ωYes

No ψ

Check Item

Is the Controller Status Display LED turned OFF?

Connect the teaching tool such as PC to confirm the content of alarm and have an appropriate treatment.

Servo ON

Turn the servo ON with the operation on the teaching tool such as PC.

Check Item

Is the Controller Status Display LED turned ON in green [SV]?

Safety Circuit Check

Does the emergency stop circuit (drive cutoff circuit) work properly and turn the servo OFF?

Check the emergency stop circuit.

Target Position Setting

Set the target position in “Position” Box in each position table. Perform a home-return operation first when Direct Teaching is to be performed. When moving the actuator manually, set the Brake Release Switch to “BK RLS” side for the brake equipped type. Put the switch back after the setting is complete.

No ψ

ωYes

Safety Speed Setting

Set the Parameter No.35 if necessary. The safet

y sp

eed is set to 100mm/s or less at the delivery.

Test Run Adjustment 1

Check the operation without mounting a work and set the safety speed invalid on the teaching tool such as PC, and then check the operation with a work mounted.

Check if there is any problem with the installation of the actuator and the condition of the actuator use exceeds the ranges of the rated values. Adjust the servo if necessary.

Power Supply and Alarm Check

Connect a teaching tool such as PC, turn the operation mode setting switch to “MANU” side and turn the power ON for unit. Select [Teaching Mode 1 Safety Speed Activated / PIO Operation Invalid] in the teaching tool.

If an alarm is generated, connect the PC or teaching pendant and check the content of the alarm to have the right treatment.

ωYes

φYes

Test Run Adjustment 2

1) Set the operation mode setting switch to “AUTO”.

2) Output the operation command from PLC to the controller and check the system operation.

Check Item

Any vibration or abnormal noise?

No ψ

ωYes

Check of Packed Items

Are there all the delivered items?

 Caution To ensure safety, it is recommended

that safety speed be enabled during initial movements.

Installation and Wiring [Refer to Chapter 1, 2.1, 2.3]

Perform the installation of and wiring for the actuator and controller.

Caution Please perform this process with the actuator away from the mechanical end or interfering subjects as much as possible. Put the actuator away if it interferes with surroundings. It may generate an alarm if the actuator hit the mechanical end or interfering subjects when the servo is turned ON. The slider may get slightly dropped by self-weight if servo ON and OFF is repeatedly performed at the same position. Be careful not to pinch the hand or damage the work.

Warning In the case the actuator is installed in vertical orientation and put the brake release switch to [BK RLS] side, be

careful not to drop it with self-weight and pinch your hand or damage the work.

PIO Pattern Settings

Set the used PIO pattern to Parameter No.25.

Point Check Item

• Is frame ground (FG) connected?

• Has the noise countermeasure been taken?

POWER CON

PCON-CA/CFA

2. Pulse Train Control Mode (for Pulse Train Type)

This product is capable for the positioning control using the pulse train of IAI actuators. It is necessary to have the positioning control function able to output the pulse train on the host controller (PLC). When using this product for the first time, make sure to avoid mistakes and incorrect wiring by referring to the procedure below. “PC” stated in this section means “PC software”.

Set the Electronic Gear [Refer to 3.3.4 [1]]

Set the electronic gear ratio based on the amount of actuator operation per pulse in Parameters No.65 and 66.

Check Item

Is the minimum unit of operation set to the value bigger than the minimum resolution of the encoder? Is the fraction of the electronic gear ratio reduced to its lowest terms?

φYes

Pulse Train Input Output Mode Setting [Refer to 3.3.4 [2]]

Set the command pulse train input status for the parameter No.63 and No.64. Put Operation Mode Setting Switch to “AUTO” side when the setting is complete.

Servo ON

Input servo ON signal from PLC.

Check Item

Is the Controller Status Display LED turned ON in green [SV]?

No ψ

Confirm the content of alarm on the teaching tool such as PC to have an appropriate treatment.

φYes

Safety Circuit Check

Check that the emergency stop circuit (or motor drive-power cutoff circuit) operates normally to turn OFF the servo.

No ψ

Check the emergency stop circuit.

ωYes

No ψ

ωYes

No ψ

Check Item

Is the Controller Status Display LED turned OFF?

Connect the teaching tool such as PC to confirm the content of alarm and have an appropriate treatment.

Test Run Adjustment 2 [Operation Mode AUTO]

Output the pulse train from PLC to the controller and check the system operation.

No ψ

Check the electronic gear ratio setting. Confirm the command pulse train input mode setting.

Confirm that there is no problem in the actuator installation, the actuator operation condition demands a voltage more than rated voltage, and appropriate pulse trains are input.

Power Supply and Alarm Check

ωYes

φYes

Check of Packed Items

Are there all the delivered items?

Installation and Wiring [Refer to Chapter 1, 2.2, 2.3]

Perform the installation of and wiring for the actuator and controller.

Point Check Item

• Is frame ground (FG) connected?

• Has the noise countermeasure been taken?

Test Run Adjustment 1 [Operation Mode MANU]

Check with a teaching tool such as the PC with no work being loaded, and check the operation range with JOG operation with the work being loaded.

Check if there is any problem in the way of actuator mount.

Check Item

Is there any risk of interfering with peripheral equipment?

Yes ψ

ωNo

Can the positioning operation be performed normally?

ωYes

Is it in condition without any vibration and abnormal noise?

Test Run Adjustment 3

Check the system operation conducted by PLC.

PIO Pattern Settings

Set the used PIO pattern to Parameter No.25.

POWER CON

PCON-CA/CFA

Chapter 1 Specifications Check

1.1 Product Check

1.1.1 Parts

This product is comprised of the following parts if it is of standard configuration. If you find any fault in the contained model or any missing parts, contact us or our distributor.

No. Part Name Model Quantity Remarks

1 Controller

Refer to “How to read the model plate”, “How to read the model”.

Accessories

2 I/O Flat Cable CB-PAC-PIO*** 1

***shows the cable length (Example) *** : 020 2 [m]

3 Power Connector

FMC1.5/8-ST-3.5 (Supplier : Phoenix Contact)

Recommended cable size AWG16 to 20 (1.25 to 0.5mm

)

Absolute Battery (Option)

AB-7 or SEP-ABU* 1 For Simple Absolute Type

5 First Step Guide 1

Instruction Manual (CD/DVD)

7 Safety Guide 1

1.1.2 Teaching Tool

A teaching tool such as PC software is necessary when performing the setup for position setting, parameter setting, etc. that can only be done on the teaching tool. Please prepare either of the following teaching tools.

No. Part Name Model

PC Software (Includes RS232C Adapter  Peripheral Communication Cable)

RCM-101-MW

PC Software (Includes USB Adapter  USB Cable  Peripheral Communication Cable)

RCM-101-USB

3 Teaching Pendant (Touch Panel Teaching) CON-PTA

4 Teaching Pendant (Touch Panel Teaching with deadman switch) CON-PDA

Teaching Pendant (Touch Panel Teaching with deadman switch  TP Adapter (RCB-LB-TG))

CON-PGA

Chapter 1 Specications Check

POWER CON

PCON-CA/CFA

1.1.3 Instruction manuals related to this product, which are contained in the instruction manual (CD/DVD).

No. Name Manual No.

1 PCON-CA Controller Instruction Manual ME0289

PC Software RCM-101-MW/ RCM-101-USB Instruction Manual

ME0155

3 Touch Panel Teaching CON-PTA/PDA/PGA Instruction Manual ME0295

4 Instruction Manual for the serial communication [for Modbus] ME0162

5 CC-Link Instruction Manual ME0254

6 DeviceNet Instruction Manual ME0256

7 PROFIBUS-DP Instruction Manual ME0258

8 CompoNet Instruction Manual ME0220

9 MECHATROLINK Instruction Manual ME0221

10 EtherCAT Instruction Manual ME0273

11 EtherNet/IP Instruction Manual ME0278

1.1.4 How to read the model plate

1.1.5 How to read the model

P C O N - C A - 2 0 P I - N P - 2 - 0 - A B - D N– **

<Type>

CA : Standard Type CFA : High Thrust Actuator Connected Type

[Motor Type] 20P : 20Ƒ pulse motor 20SP : 20Ƒ pulse motor 28P : 28Ƒ pulse motor 28SP : 28Ƒ pulse motor 35P : 35Ƒ pulse motor 42P : 42Ƒ pulse motor 56P : 56Ƒ pulse motor 86P : 86Ƒ pulse motor [Encoder Type? I : Incremental

NP : NPN PIO Specification (Sync. Type) PLN : Pulse Train NPN Specification PN : PNP Specification (Source Type) PLP : Pulse Train PNP Specification CC : CC-Link Connection Type DV : DeviceNet Connection Type PR : PROFIBUS-DP Connection Type CN : CompoNet Connection Type ML : MECHATROLINK Connection Type EC : EtherCAT Connection Type EP : EtherNet/IP Connection Type

There is no identification in some cases

(Not Specified) : Screw Attachment Type DN : DIN Rail Mounting Type

AB : Simple Absolute Type (With the Absolute Battery) ABU : Simple Absolute Type

(With the Absolute Battery Unit

(SEP-ABU)) ABUN : Simple Absolute Type (With no Absolute Battery)

<Power-supply Voltage>

0 : 24V DC

0 : Equipped with no cable 2 : 2m (Standard) 3 : 3m 5 : 5m

Model

Serial numbe

+ 266 hidden pages

IAI America PCON-CA User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Please Read Before Use

Table of Contents

Safety Guide

Precautions in Operation

International Standards Compliances

Name for Each Parts and Their Functions

Actuator Axes

Starting Procedures

Chapter 1 Specifications Check

1.1 Product Check