IAI America PCON-CY User Manual

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PCON-CY Controller Solenoid Valve Type

Operation Manual Ninth Edition

Fourteenth Edition

Please Read Before Use

Thank you for purchasing our product.

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

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

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

[Important]

• This Operation Manual is original.

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

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

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

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

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

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

trademarks.

CAUTION

1. Use Environment

PCON controllers can be used in an environment corresponding to pollution degree 2 or equivalent.

2. PC Software and Teaching Pendant Models

New functions have been added to the entire PCON controller series. To support these new features, the communication protocol has been changed to the general Modbus (Modbus-compliant) mode. As a result, the existing PC software programs and teaching pendants compatible with RCP2 controllers can no longer be used. If you are using this controller, use a compatible PC software program and/or teaching pendant selected from the following models.

skrameRledoM

PC software (with RS232C communication cable) PC software (with USB communication cable)

Teaching pendant RCM-T

Simple teaching pendant RCM-E

Data setting unit RCM-P

RCM-101-MW

RCM-101-USB

All are compatible with existing RCP2 controllers.

3. Recommendation for Backing Up Latest Data

This product uses nonvolatile memory to store the position table and parameters. Normally the memory will retain the stored data even after the power is disconnected. However, the data may be lost if the nonvolatile memory

becomes faulty. We strongly recommend that the latest position table and parameter data be backed up so that the data can be

restored quickly when the controller must be replaced for a given reason. The data can be backed up using the following methods:

[1] Save to a CD or FD from the PC software. [2] Create a position table sheet or parameter sheet and keep a written record of backup.

CAUTION

4. Using Rotary Actuators in Multi-rotation Specification

Rotary actuators of multi-rotation specification models can be set to operate in the multi-rotation mode or limited-rotation mode using a parameter.

4.1 Note

Pay attention to the PIO pattern parameter setting for the following controllers. Each controller does not support relative coordinate specification in the PIO pattern specified below:

[1] PCON-C/CG: PIO pattern = 5 (User parameter No. 25) [2] PCON-CY: PIO pattern = 0 (User parameter No. 25)

4.2 Applicable Models

Actuators

RCP2-RTCL-I-28P-30-360-*

Controllers

*-IP82-C-NOCP*-063-02-P82-I-LBTR-2PCR

*-IP82-GC-NOCP*-063-03-P82-I-LBTR-2PCR

*-IP82-YC-NOCP*-063-02-P82-I-LCTR-2PCR

PCON-SE-28PI-*

CE Marking

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

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

1. Overview ..........................................................................................................................................9

1.1 Introduction ....................................................................................................................................................9

1.2 Differences from Air Cylinders in Control Functions.....................................................................................10

1.3 How to Read Model Name ........................................................................................................................... 12

1.4 System Configuration...................................................................................................................................13

1.5 Steps from Unpacking to Adjustment by Trial Operation..............................................................................14

1.6 Warranty.......................................................................................................................................................16

1.6.1 Warranty Period................................................................................................................................ 16

1.6.2 Scope of Warranty............................................................................................................................ 16

Honoring the Warranty......................................................................................................................

1.6.3

1.6.4 Limited Liability..................................................................................................................................16

1.6.5 Conditions of Conformance with Applicable Standards/Regulations, Etc.,

and Applications................................................................................................................................17

1.6.6 Other Items Excluded from Warranty................................................................................................ 17

2. Specifications.................................................................................................................................18

2.1 Basic Specifications .....................................................................................................................................18

2.2 Name and Function of Each Part of the Controller.......................................................................................19

2.3 External Dimensions ....................................................................................................................................20

3. Installation and Wiring....................................................................................................................21

3.1 Installation Environment............................................................................................................................... 21

3.2 Supplied Voltage..........................................................................................................................................21

3.3 Noise Elimination Measures and Grounding ................................................................................................ 22

3.4 Heat Radiation and Installation ....................................................................................................................23

3.5 External Connection Diagram ......................................................................................................................24

3.6 Wiring the Power Supply..............................................................................................................................25

3.7 Wiring the Brake Forced-release Switch......................................................................................................25

3.8 Wiring the Emergency Stop Circuit ..............................................................................................................26

3.8.1 Cutting Off the Drive Signal (Standard) ............................................................................................26

3.8.2 Cutting Off the Motor Drive Power .................................................................................................... 28

3.9 Connecting the Actuator...............................................................................................................................29

3.9.1 Motor Relay Cable ............................................................................................................................ 29

3.9.2 Encoder Relay Cable........................................................................................................................30

3.10 Connecting the I/O Flat Cable......................................................................................................................31

3.11 Connecting the Communication Cable.........................................................................................................32

4. Position Table Settings ..................................................................................................................33

4.1 Details of the Position Table ........................................................................................................................33

4.2 Notes on the ROBO Gripper ........................................................................................................................38

5. Operation Using I/O Signals ..........................................................................................................40

5.1 Interface Circuit............................................................................................................................................40

5.1.1 External Input Specifications.............................................................................................................40

5.1.2 External Output Specifications..........................................................................................................41

5.1.3 Recognition of Input Signals .............................................................................................................42

5.2 Proximity Switch Type..................................................................................................................................43

5.2.1 Explanation of I/O Signals.................................................................................................................43

5.2.2 Timings after Power On ....................................................................................................................45

Steps from Initial Startup to Actuator Adjustment........................................................................45

Normal Operating Procedure ......................................................................................................46

5.2.5 Positioning Operation .......................................................................................................................51

z Meaning of Position Detection Output Signals (LS0, LS1, LS2)..................................................52

z Notes on Setting the Positioning Band........................................................................................52

z Speed Change during Movement................................................................................................53

z Pausing during Movement...........................................................................................................54

z Forced Return in Case of Emergency .........................................................................................54

5.3 Standard Type .............................................................................................................................................55

5.3.1 Explanation of I/O Signals.................................................................................................................55

5.3.2 Timings after Power On .................................................................................................................... 57

z Steps from Initial Startup to Actuator Adjustment........................................................................57

z Normal Operating Procedure ......................................................................................................58

5.3.3 Position Table and Parameter Settings Required for Operation .......................................................60

 Test Operation ............................................................................................................................60

Safety speed during manual feed .....................................................................................................60

Speed override for move commands from the PLC .......................................................................... 60

 Full-scale Operation ....................................................................................................................61

Power-saving when the standby time after power on is long ............................................................61

Power-saving when the standby time at the target position is long...................................................61

Complete signal output mode ...........................................................................................................61

5.3.4 Homing .............................................................................................................................................62

5.3.5 Positioning Operation .......................................................................................................................63

z Meaning of Positioning Complete Output Signals (PE0, PE1, PE2)............................................64

z Notes on Setting the Positioning Band........................................................................................64

z Speed Change during Movement................................................................................................65

z Pausing during Movement...........................................................................................................66

z Forced Return in Case of Emergency .........................................................................................66

z Constant Pitch Feed....................................................................................................................67

5.3.6 Zone Output Signal...........................................................................................................................69

5.3.7 Push-motion Operation .....................................................................................................................70

5.3.8 Examples of Tact Time Reduction Combining Zone Outputs and 3 Stop Points ..............................76

5.4 Power-saving Modes at Standby Positions .................................................................................................. 78

5.5 Using Rotary Actuators in Multi-rotation Specification..................................................................................81

5.5.1 How to Use .......................................................................................................................................81

6. Parameter Settings ........................................................................................................................82

6.1 Parameter List..............................................................................................................................................82

6.2 Detail Explanation of Parameters.................................................................................................................83

6.2.1 Parameters Relating to Actuator Stroke Range ................................................................................83

z Soft Limits (No.3/4 LIMM/LIML)...................................................................................................83

z Home Direction (No.5 ORG) .......................................................................................................83

z Home Offset (No.22 OFST).........................................................................................................84

z Zone Limits (1: No. 1/2 ZONM/ZONL 2: No. 23/24 ZNM2/ZNL2)................................................ 84

6.2.2 Parameters Relating to Actuator Operating Characteristics..............................................................85

z Default Speed (No.8 VCMD) .......................................................................................................85

z Default Acceleration/Deceleration (No.9 ACMD).........................................................................85

z Default Positioning Band (In-position) (No.10 INP) .....................................................................85

z Current-limiting Value during Homing (No.13 ODPW) ................................................................85

z Current-limiting Value at Standstill after Positioning (No.12 SPOW)...........................................85

z Speed Override (No.46 OVRD)...................................................................................................85

z Default Direction of Excited Phase Signal Detection (No.28 PHSP) ...........................................86

z Excited Phase Signal Detection Time (No.29 PHSP)..................................................................86

z Automatic Servo-off Delay Time (No.36 ASO1/ No.37 ASO2/ No.38 ASO3) ..............................87

z Default Standstill Mode (No.53 CTLF) ........................................................................................87

z Push Speed (No.34 PSHV) .........................................................................................................88

z Push-motion Completion Judgment Time (No.6 PSWT) .............................................................88

z Enable Function (No.42 FPIO) ....................................................................................................89

z Home Check Sensor Input Polarity (No.43 AIOF) .......................................................................89

z Home Sensor Input Polarity (No. 18, LS) ....................................................................................90

z Ball Screw Lead (No. 77, LEAD) .................................................................................................90

z Axis Operation Type (No. 78, ATYP) ..........................................................................................90

z Rotational Axis Mode Selection (No. 79, ATYP) .........................................................................90

Push Speed (No.34 PSHV) .........................................................................................................88

Push-motion Completion Judgment Time (No.6 PSWT) .............................................................88

Enable Function (No.42 FPIO) ....................................................................................................89

Home Check Sensor Input Polarity (No.43 AIOF) .......................................................................89

Home Sensor Input Polarity (No. 18, LS) ....................................................................................90

Ball Screw Lead (No. 77, LEAD) ................................................................................................. 90

Axis Operation Type (No. 78, ATYP) ..........................................................................................90

Rotational Axis Mode Selection (No. 79, ATYP) .........................................................................90

Shortcut Selection for Rotational Axis (No. 80, ATYP)................................................................91

Absolute Unit (No. 83, ETYP)......................................................................................................91

6.2.3 Parameters Relating to External Interface ........................................................................................92

PIO Pattern Selection (No.25 IOPN) ...........................................................................................92

Positioning Complete Signal Output Mode (No.39FPIO) ............................................................92

Servo-on Input Disable Selection (No.21 FPIO)..........................................................................93

SIO Communication Speed (No.16 BRSL)..................................................................................93

Minimum Delay Time for Slave Transmitter Activation (No.17 RTIM) .........................................93

Silent Interval Multiplication Factor (No.45 SIVM) .......................................................................93

6.2.4 Servo Gain Adjustment .....................................................................................................................94

Servo Gain Number (No.7 PLG0) ...............................................................................................94

Speed Loop Proportional Gain (No.31 VLPG).............................................................................94

Speed Loop Integral Gain (No.32 VLPT) ....................................................................................95

Torque Filter Time Constant (No.33 TRQF)................................................................................95

7. Troubleshooting .............................................................................................................................96

7.1 What to Do When A Problem Occurs...........................................................................................................96

7.2 Alarm Level Classification ............................................................................................................................97

7.3 Alarms, Causes and Actions ........................................................................................................................ 98

(1) Operation Cancellation Alarms....................................................................................................98

(2) Cold Start Alarms ...................................................................................................................... 101

7.4 Messages Displayed during Teaching Pendant Operation ........................................................................104

7.5 Common Problems and Recommended Actions .......................................................................................106

I/O Signals Cannot Be Sent or Received to/from the PLC. .......................................................106

The ALM Lamp Illuminates after the Power Is Turned On.........................................................106

After Turning On the Power, the SV Lamp Does Not Illuminate upon Servo-on Signal Input....106

With an Actuator Installed in Vertical Orientation, Positioning Completes Prematurely. ...........107

With an Actuator Installed in Vertical Orientation, Noise Generates during Downward Movement.

107

Vibration Occurs when the Actuator Is at Standstill...................................................................107

The Actuator Overshoots while Decelerating to a Stop.............................................................107

Stopped Position Sometime Deviates from the Home Position or Target Position....................107

The Actuator Moves Slow during Push-motion Operation.........................................................107

The Actuator Moves Only a Half, or as Much as Twice, the Specified Travel. ..........................107

A Servo Error Occurred while the ROBO Gripper Was Moving.................................................108

The Actuator Malfunctions when the Servo Is Turned On after Turning On the Power............. 109

The SV Lamp Blinks..................................................................................................................109

* Appendix...........................................................................................................................................110

List of Specifications of Connectable Actuators ....................................................................................................110

Correlation diagram of speed and load capacity for the slider type (motor-straight type) ...................................122

Correlation diagram of speed and load capacity for the slider type (motor-reversing type) ................................123

Correlation diagram of speed and load capacity for the standard rod type ...........................................................124

Correlation diagram of speed and load capacity for the single-guide type ............................................................125

Correlation diagram of speed and load capacity for the double-guide type...........................................................126

Correlation diagram of speed and load capacity for the dustproof/splash-proof type ............................................127

Correlation diagram of speed and load capacity for the RCP3 slider type ............................................................128

Correlation diagram of speed and load capacity for the RCP3 table type .............................................................129

Push Force and Current-limiting Value..................................................................................................................130

Position Table Record ........................................................................................................................................... 137

Parameter Change History

Record .................................................................................................................................................138

139......................................................................................................................................................

Safety Guide

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

Safety Precautions for Our Products

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

No.

1 Model

Operation

Description

Selection

Description

 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.)

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

considerably shorten the life of the product.

 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

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

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

No.

Operation

Description

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

utilize equipment such as crane.

 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.

 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.

 Transport it using an appropriate transportation measure.

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

in the operation manual for each model.  Do not step or sit on the package.  Do not put any heavy thing that can deform the package, on it.  When using a crane capable of 1t or more of weight, have an operator

who has qualifications for crane operation and sling work.  When using a crane or equivalent equipments, make sure not to hang a

load that weighs more than the equipment’s capability limit.  Use a hook that is suitable for the load. Consider the safety factor of the

hook in such factors as shear strength.  Do not get on the load that is hung on a crane.  Do not leave a load hung up with a crane.  Do not stand under the load that is hung up with a crane.

3 Storage and

Preservation

 The storage and preservation environment conforms to the installation

environment. However, especially give consideration to the prevention of

condensation.  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.  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.  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.  When using the product in any of the places specified below, provide a

sufficient shield.

1) Location where electric noise is generated

2) Location where high electrical or magnetic field is present

3) Location with the mains or power lines passing nearby

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

No.

Operation

Description

4 Installation

and Start

Description

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

and controller, and for the teaching tool.

 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.

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

so that there is no wiring error.

 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.

 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.

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

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

cause the product to malfunction or cause fire. (3) Grounding  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.  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).

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

resistance 100 or below).

No.

4 Installation

Operation

Description

and Start

Description

(4) Safety Measures  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.

 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.

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

stopped immediately in an emergency during the unit operation.

 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.

 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.

 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.

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

emergency stop.

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

safety.

 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.

 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  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.

 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.

 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.

 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.

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

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

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

fence, the movable range should be indicated.

No.

Operation

Description

6 Trial Operation  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.

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

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

 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.

 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.

 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

 Check before starting the automatic operation or rebooting after operation

stop that there is nobody in the safety protection fence.

 Before starting automatic operation, make sure that all peripheral

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

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

protection fence.

 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.

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

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

No.

8 Maintenance

Operation

Description

and Inspection

Description

 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.

 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.

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

basically turn OFF the power switch.

 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.

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

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

according to the Operation Manual for each model.

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

damage to the product.

 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.

 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.

 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

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

specified based at your own discretion.

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

properly as an industrial waste.

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

components when detaching screws.

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

The product may burst or generate toxic gases.

11 Other  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.

 See Overseas Specifications Compliance Manual to check whether

complies if necessary.

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

operation manual of each unit to ensure the safety.

Alert Indication

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

Level Degree of Danger and Damage Symbol

Danger

Warning

Caution

Notice

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

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

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

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

Danger

Warning

Caution

Notice

1. Overview

1.1 Introduction

As a dedicated controller for our RCP2 and RCP3 actuators, this controller becomes smaller and more affordable and incorporates a new set of features to offer greater convenience and safety, while maintaining the functions of the RCP2 controller. This controller also provides power-saving functions to address the growing need for saving energy. The key features and functions of this controller are summarized below.

z Limited I/O positioning points (3 points)

The I/O signals are designed to function in the same manner as those of air cylinders. Two operation types are supported. The movement complete signals have different meanings in each type.

• Proximity switch type --- Each movement complete signal works as an auto switch. Even when positioning operation is not performed, a movement complete signal is output once the specified position is passed.

• Standard type --- A movement complete signal is output only when positioning operation has completed following a move command.

* The controller is configured to support the proximity switch type before shipment.

z Separate zone output limits for each of 3 positions (rear end, intermediate point, front end)

Before, the zone output limits were set by parameters and thus fixed to a certain width for all positions. To increase flexibility, setting fields have been added to the position table to allow different limits to be set for each position. This function is useful in preventing contact with peripheral equipment or reducing the tact time.

z Independent acceleration and deceleration settings

The position table now has separate fields for acceleration and deceleration. The purpose of this change is to prevent works made of certain materials or having certain shapes from receiving impact or vibration when the actuator decelerates to a stop. By reducing the deceleration setting, a more gradual deceleration curve can be achieved.

z Limitation of feed speed during adjustment by test operation

The feed speed during adjustment by test operation can be limited to ensure safety.

z Power-saving measures

In general, pulse motors consume more holding current in standstill state than AC servo motors. Accordingly, this controller provides power-saving means by assuming situations where the motor is used in applications requiring a long standby time.

1. Overview

When actually starting your system or if you have encountered any problem, also refer to the manuals for the actuator, teaching pendant, PC software and/or any other component you are using, in addition to this manual.

This manual does not cover all possible deviations from normal operations or unexpected phenomena such as complex signal changes resulting from critical timings. Therefore, the reader should assume that items not described in this manual are “not permitted,” as a rule.

* This manual has been prepared with the utmost attention to ensure accuracy and completeness. However, there may still

be inaccuracies and omissions. Should you find any inaccurate description or if you have any comment, please contact IAI. Keep this manual in a convenient place so that you can easily reference it whenever necessary.

1.2 Differences from Air Cylinders in Control Functions

For those of you who have been using air cylinders and have never used motorized cylinders before, this section gives a brief explanation of how this controller is different from air cylinders. Read the following information and implement controls appropriate for your system.

1. Overview

Drive method Air pressure by solenoid valve control. Ball screw or timing belt drive using a pulse motor.

Target position setting Mechanical stopper (including shock

Target position detection

Speed setting Adjustment by a speed controller. Entry of a feed speed in the “Speed” field of the position

Acceleration/ deceleration setting

Item Air cylinder PCON

Entry of a coordinate value in the “Position” field of the

absorber).

Installation of a reed switch or other external detection sensor.

In accordance with the load, air supply volume, and speed controller/solenoid valve performance.

position table. A value can be entered by keying in a number from a PC/teaching pendant, or by moving the actuator to a desired position and then reading the achieved position directly. Example) Example of entry of “400 mm” stroke

Position No. Position

0 5 (mm), rear end 1 400 (mm), front end 2 200 (mm), intermediate point

Judgment based on internal coordinates determined by the position information received from the position detector (encoder). No external detection sensor is required.

table (unit: mm/sec). Note that the rated speed is set automatically as the default feed speed.

Entry in the “Acceleration” and “Deceleration” fields of the position table (minimum setting unit: 0.01 G). Reference: 1 G = Gravitational acceleration Note that the rated acceleration and deceleration are set automatically as the default acceleration and deceleration. Desired values can be set in fine steps to achieve gradual acceleration/deceleration curves.

Acceleration

Start position of movement

The greater the set value, the steeper the curve becomes. On the other hand, the smaller the set value, the more gradual the curve becomes.

Deceleration

End position

Item Air cylinder PCON

Position check upon power on

Judgment using a reed switch or other external detection sensor.

When the power is turned on, mechanical coordinates are not stored in the controller and thus the current position is not yet determined. For this reason, a rear end move command must be executed after the power has been turned on, in order to establish coordinates. The actuator performs homing first, and then moves to the rear end.

[1]

[2]

[3]

-on position

Powe

Rear end

Home position

[1] The actuator moves toward the mechanical end on

the motor side at the homing speed.

[2] The actuator contacts the mechanical end, reverses

its direction, and stops temporarily at the home position.

[3] The actuator moves to the rear end at the speed set

in the “Speed” field of the position table.

(Note) Make sure there is no obstacle along the homing

path.

1. Overview

1.3 How to Read Model Name

1. Overview

<Type> CY: Dedicated controller for 3-point

<Actuator characteristics> [Motor flange size] 20P: 20, square 28P: 28, square 28SP: 28, square (RA3 type only) 42P: 42, square 56P: 56, square [Encoder type] I: Incremental

positioning by I/Os

High-acceleration loading specification

Specifiation for connecting the simple absolute unit

<Power-supply voltage> 0: 24 VDC

<I/O flat cable length> 0: No cable 2: 2 m 3: 3 m 5: 5 m

<I/O signal type> NPxxNPN [Sink] PNxxPNP [Source]

1.4 System Configuration

This controller performs positioning to 3 points (rear end, intermediate point, front end) via a PLC and I/O signals.

Standard teaching

pendant

Host system <PLC>

PCON-CY controller

Flat cable <supplied with the controller>

* If a PLC will not be used,

Cable length: 2 m

disable the servo-on input by the applicable parameter.

24-VDC I/O

power supply

1. Overview

RS232C type USB type

PC software

(optional)

Input power supply 24 VDC

Brake forced-release switch

External EMG switch

RCP2 actuator

Power-supply terminal block

Caution: If the actuator is not equipped with a brake, the BK terminal need not be connected.

1.5 Steps from Unpacking to Adjustment by Trial Operation

If you are using this controller for the first time, refer to the steps explained below and perform the specified tasks carefully by making sure you check all necessary items and connect all required cables.

1. Overview

Should you find any of the following items missing or of a wrong model type, please contact your IAI sales agent.

z Controller z Actuator z I/O flat cable z Motor cycle z Encoder cable PCON-CY CB-PACY-PIO *** CB-RCP2-MA *** CB-RCP2-PA ***

z Operation manual

<Options> z Teaching pendant z PC software RCM-T (standard) RS232C type <RCM-101-MW> RCM-E (simple) USB type <RCM-101-USB> RCM-P (data setting) (Each software program comes with a cable.)

[1] Affix the actuator and install the robot hand → Refer to the operation manual for your actuator. [2] Install the controller → Chapter 3, “Installation and Wiring”

• Wire the 24-V power supply.

• Wire the brake forced-release switch (if the actuator is equipped with a brake).

• Connect the grounding wire to ground.

• Wire the emergency stop circuit and motor drive power supply.

• Connect the motor cable and encoder cable.

• Connect the I/O flat cable.

Checking the items in the package

Installation

Wiring/connection

Confirm first that the emergency stop circuit is not actuated, and then supply the 24-V power. If the monitor LED [SV/ALM] on the front face of the controller illuminates in orange for 2 seconds and then turns off, the controller is normal. If the [SV/ALM] illuminates in red, it means that an alarm is present. In this case, connect a PC or teaching pendant and check the nature of the alarm, and remove the cause by referring to Chapter 7, “Troubleshooting.”

Set the MANU operation mode to [Teaching mode 1: Enable safety speed / Inhibit PIO] on the PC or teaching pendant. In this condition, set appropriate values in parameter No. 25 (PIO pattern selection) and parameter No. 35 (Safety speed). * The factory settings of PIC pattern and safety speed are “Standard type” and “100 mm/s or less,” respectively.

Turning on the power and checking for alarms

Setting a PIO pattern/safety speed

→ Chapter 6, “Parameter Settings”

Operating when the servo is ON

Confirm that the slider or rod is not contacting a mechanical end. If the slider or rod is contacting a mechanical end, move it away from the mechanical end. If the actuator is equipped with a brake, move the actuator after turning ON the forced brake release switch to forcibly release the brake. At this time, be careful not to get your hand pinched or the robot hand damaged by the actuator dropping suddenly due to its dead weight.

Turn ON the servo using the PC or teaching pendant. If the actuator enters a servo lock state and the monitor LED [SV/ALM] on the front face of the controller illuminates in green, the controller is normal.

1. Overview

Confirm that the emergency cutoff circuit (or motor drive-power cutoff circuit) operates normally.

Use the teaching pendant or PC to set a target position in the “Position” field of the position table (rear end, front end, intermediate point). * If any movement operation is started without setting a target position first, the message “No movement data” will be

displayed. Determine an appropriate target position by fine-tuning the work or robot hand.

* Once a target position is set, other items (speed, acceleration/deceleration, positioning band, etc.) will be set to their defaults

automatically. → Chapter 4, “Position Table Settings”

Input a move command from the PLC to perform positioning. If necessary, perform the following fine adjustments:

• Depending on the weight, material and/or shape of the work, vibration or noise may occur. If you notice undesirable vibration or noise, lower the speed, acceleration and/or deceleration.

• You may also want to adjust the zone output signal limits and positioning band to prevent contact with peripheral equipment or reduce the tact time.

• If push-motion operation will be performed, select optimal current-limiting value, push-motion completion judgment time and push speed.

Confirming the safety circuit operation

→ Chapter 3, “Installation and Wiring”

Setting a target position

Adjustment by test operation

→ Chapter 4, “Position Table Settings” → Chapter 5, “Operation Using I/O Signals”

1.6 Warranty

1.6.1 Warranty Period

One of the following periods, whichever is shorter:

Elapse of 18 months after the shipment from IAI Elapse of 12 months after the delivery to the specified location

1. Overview

1.6.2 Scope of Warranty

Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty will be replaced or repaired free of charge: (1) The breakdown or problem in question pertains to our product as delivered by us or our authorized dealer. (2) The breakdown or problem in question occurred during the warranty period. (3) The breakdown or problem in question occurred while the product was in use for an appropriate purpose under the

(4) The breakdown or problem in question was caused by a specification defect or problem, or by the poor quality of

Note that breakdowns due to any of the following reasons are excluded from the scope of warranty:

conditions and environment of use specified in the operation manual and catalog.

our product.

[1] Anything other than our product [2] Modification or repair performed by a party other than us (unless we have approved such modification or repair) [3] Anything that could not be easily predicted with the level of science and technology available at the time of shipment

from our company [4] A natural disaster, man-made disaster, incident or accident for which we are not liable [5] Natural fading of paint or other symptoms of aging [6] Wear, depletion or other expected result of use [7] Operation noise, vibration or other subjective sensation not affecting function or maintenance

Note that the warranty only covers our product as delivered and that any secondary loss arising from a breakdown of our product is excluded from the scope of warranty.

1.6.3 Honoring the Warranty

As a rule, the product must be brought to us for repair under warranty.

1.6.4 Limited Liability

[1] We shall assume no liability for any special damage, consequential loss or passive loss such as a loss of expected

profit arising from or in connection with our product.

[2] We shall not be liable for any program or control method created by the customer to operate our product or for the result

of such program or control method.

1.6.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications

(1) If our product is combined with another product or any system, device, etc., used by the customer, the customer must

first check the applicable standards, regulations and/or rules. The customer is also responsible for confirming that such combination with our product conforms to the applicable standards, etc. In such a case we will not be liable for the conformance of our product with the applicable standards, etc.

(2) Our product is for general industrial use. It is not intended or designed for the applications specified below, which

require a high level of safety. Accordingly, as a rule our product cannot be used in these applications. Contact us if you must use our product for any of these applications:

[1] Medical equipment pertaining to maintenance or management of human life or health [2] A mechanism or mechanical equipment intended to move or transport people (such as a vehicle, railway facility

or aviation facility) [3] Important safety parts of mechanical equipment (such as safety devices) [4] Equipment used to handle cultural assets, art or other irreplaceable items

(3) Contact us at the earliest opportunity if our product is to be used in any condition or environment that differs from

what is specified in the catalog or operation manual.

1.6.6 Other Items Excluded from Warranty

The price of the product delivered to you does not include expenses associated with programming, the dispatch of engineers, etc. Accordingly, a separate fee will be charged in the following cases even during the warranty period:

[1] Guidance for installation/adjustment and witnessing of test operation [2] Maintenance and inspection [3] Technical guidance and education on operating/wiring methods, etc. [4] Technical guidance and education on programming and other items related to programs

1. Overview

2. Specifications

2.1 Basic Specifications

Number of controlled axes 1 axis per unit Power-supply voltage 24 VDC +10%/-10% Power-supply capacity 2 A max. Control method Field-weakening vector control (patent pending)

2. Speciﬁcations

Encoder resolution 800 P/rev

Positioning command

Backup memory

PIO interface 24-VDC insulation

LED indicator

Serial communication RS485, 1 channel (conforming to the Modbus protocol) Encoder interface Incremental specification conforming to EIA RS-422A/423A Forced release of electromagnetic brake 24 V is applied to the BK terminal on the power-supply terminal block.

Cable length

Dielectric strength Environment Surrounding air temperature

Protection class Natural air cooling (IP20) Weight 128 g or below External dimensions 35 (W) x 120 (H) x 68 (D) mm

Specification item Description

YC-NOCPledoM

Separate commands for positioning to rear end, front end and intermediate point

Position number data and parameters are stored in the nonvolatile memory. Serial EEPROM life: Approx. 100,000 times of rewriting

4 input points

• Front end move command

• Rear end move command

• Intermediate point move command

• Servo-on

6 output points

• Front end movement complete

• Rear end movement complete

• Intermediate point movement complete

• Ready (or zone output under the standard type)

• Homing complete

• *Alarm

SV (green) --- Whether or not the servo is on / ALM (red) --- Whether or not an alarm is present.

Actuator cable: 20 m or shorter I/O flat cable: 5 m or shorter 500 VDC 10 mΩ

0to40°C Surrounding humidity 85% RH or below (non-condensing) Surrounding environment Refer to 3.1 Installation Environment

Storage temperature Storage humidity 90% RH or below (non-condensing)

Vibration resistance

-10 to 65°C

10 to 57 Hz in all X/Y/Z directions / Single amplitude: 0.035 mm

(continuous), 0.075 mm (intermittent)

2.2 Name and Function of Each Part of the Controller

Status indicator LED

PIO connector

Connects the PLC and PIO.

SIO connector

Connects the teaching pendant/PC.

The model of the connected actuator is indicated here.

Motor connector

Connects the motor cable.

SV (Green) --- Indicates whether or not the

servo is on.

If this LED is blinking, the

controller is in the automatic servo-off mode.

ALM (Red) --- Indicates whether or not an

alarm is present.

The PIO pattern number is indicated here. If the PIO pattern is different for each system, indicate the applicable PIO pattern here to prevent confusion.

The I/O signal type is indicated here. NPN --- Sink type PNP --- Source type

Encoder connector

Connects the encoder cable.

2. Speciﬁcations

Power-supply terminal block

MPI, MPO

24 V Positive side of the 24-VDC input power supply.

0 V Negative side of the 24-VDC input power supply.

EMG -

 Model indication of the connected actuator type The type, ball screw lead and stroke of the actuator are indicated. When connecting the cables, confirm that the actuator is

of the correct specifications.

Example of indication:

Connection terminal for the brake forced-release switch to be used when the actuator is equipped with a brake. Connect the opposite side of the switch to 24 V. Contacts for cutting off the motor drive power to achieve a safety level of safety category 1. MPI and MPO connect to the input side and output side of the motor power supply, respectively. (If these contacts are not used, connect them using a jumper cable. The controller is shipped with MPI and MPO connected by a jumper cable.)

Connection terminal for the emergency stop circuit (for cutting of motor drive signals). A common ground is used, so connect the opposite side of the emergency stop switch (or contacts) to the positive side of the 24-VDC input power supply.

The actuator type is RA4C.

The ball screw lead is 5 mm.

The stroke is 200 mm.

2.3 External Dimensions

An external view and dimensions of this product are shown below.

2. Speciﬁcations

∅5

3. Installation and Wiring

Pay due attention to the environment where the controller is installed.

3.1 Installation Environment

This product is capable for use in the environment of pollution degree 2*1 or equivalent. *1 Pollution Degree 2 : Environment that may cause non-conductive pollution or transient conductive pollution by frost

(IEC60664-1)

[1] Installation Environment

Do not use this product in the following environment.

• Location where the surrounding air temperature exceeds the range of 0 to 40°C

• Location where condensation occurs due to abrupt temperature changes

• Location where relative humidity exceeds 85%RH

• Location exposed to corrosive gases or combustible gases

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

• Location subject to direct vibration or impact

• Location exposed to direct sunlight

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

• Environment that blocks the air vent [Refer to 3.3 Noise Elimination Measures and Grounding]

When using the product in any of the locations specified below, provide a sufficient shield.

• Location subject to electrostatic noise

• Location where high electrical or magnetic field is present

• Location with the mains or power lines passing nearby

[2] Storage and Preservation Environment

• Storage and preservation environment follows the installation environment. Especially, when the product is to be left for a long time, pay special attention to condensed water. Unless specially specified, moisture absorbency protection is not included in the package when the machine is delivered. In the case that the machine is to be stored in an environment where dew condensation is anticipated, take the condensation preventive measures from outside of the entire package, or directly after opening the package.

3. Installation and Wiring

3.2 Supplied Voltage

The controller takes a supplied voltage of 24 VDC ± 10%. (Maximum power-supply current: 2 A)

3.3 Noise Elimination Measures and Grounding

The following explains the noise elimination measures that should be taken when using this controller.

(1) Wiring and power connection

[1] Provide dedicated class-D grounding using a grounding wire with a size of 2.0 to 5.5 mm2or larger.

3. Installation and Wiring

Other

Controller

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

Metal

enclosure

[2] Cautions on wiring method

Use a twisted cable to connect the 24-VDC external power supply. Separate the controller wiring from high-power lines of motive power circuits, etc. (Do not tie them together or place in the same cable duct.) If you want to extend the motor or encoder cable beyond the length of the supplied cable, contact IAI.

equip-

ment

Controller

Other

equip-

ment

.nrettapsihtdiovAdooGgnidnuorgD-ssalC

(2) Noise sources and elimination

Noise generates from many sources, but the most common sources of noise you should consider when designing a system are solenoid valves, magnet switches and relays. Noise generation from these components can be prevented by the method explained below.

AC solenoid valves, magnet switches, relays

Method --- Install a surge absorber in parallel with the coil

Point Connect to each coil over the shortest possible wiring distance. When a surge absorber is installed on the terminal block, etc., its noise elimination effect will decrease if the distance from the coil is long.

3.4 Heat Radiation and Installation

Design the control panel size, controller layout and cooling method so that the temperatures around the controller will always be kept to 40°C or below. Mount the controller vertically on the wall, as shown below. Since cooling is provided by means of natural convection, follow this orientation and provide a minimum clearance of 50 mm above and below the controller to allow sufficient airflows to circulate. If you are installing multiple controllers side by side, provide a fan on top of the controllers to agitate the airflows as an effective way to keep the surrounding air temperatures constant. Provide a minimum clearance of 80 mm between the front face of the controller and the wall (cover).

3. Installation and Wiring

Fan

Regardless of whether you are installing one or more controllers, provide sufficient clearances around each controller to permit easy access for installation and removal of the controller.

At least 50 mm

At least 80 mm

Airflow

3. Installation and Wiring

3.5 External Connection Diagram

An example of standard wiring is shown below.

(Note) The PIO signal names are those based on the proximity switch type. The color of the encoder relay cable is different for the robot cable specification. Refer to 3.9.2, “Encoder Relay

Input power supply 24 VDC

Cable.”

For teaching pendant/PC connection

Brake release switch

External EMG

switch

PCON-CY controller

Terminal block

24-VDC power

supply for I/O signals

Brown 1

Red 1

Orange 1

Yellow 1

Green 1

Blue 1 Purple 1

Gray 1

White 1

Black 1

Brown 2

Red 2

Flat cable

Motor relay cable

Orange

Gray

White

Yellow

Pink

Yellow (Green)

0 V (NPN specification) 24 V (PNP specification)

Load

Load Load

Load

0 V (NPN specification) 24 V (PNP specification)

Actuator

Motor

Tighten together with a mounting screw.

Encoder relay cable

Yellow

Orange (black 2)

Orange (red 2)

Yellow (black 1)

Yellow (red 1)

White (black 1)

White (red 1)

Light blue (black 1)

Light blue (red 1)

Encoder

Holding brake

3.6 Wiring the Power Supply

Connect the positive side and negative side of the 24-VDC power supply to the 24-V terminal and N terminal on the power-supply terminal block, respectively.

Push with a flat-head screwdriver to open the cable inlet.

Input power supply 24 VDC (Max. 2 A per unit)

Use a wire satisfying the following specifications.

Item Specification

Applicable wire Twisted wire: AWG 22 (0.3 mm2) (copper wire)

(Note) Provide proper termination to prevent shorting due to contact with wire offcut. If the wiring path is long, provide a relay terminal block and connect the original wire to

another wire of a different size.

Input power

supply

Temperature rating of insulation sheath Length of bare wire

60°C or above

Power-supply terminal block

Relay terminal block Power-supply terminal block

Cable inlet

3. Installation and Wiring

3.7 Wiring the Brake Forced-release Switch

If the actuator is equipped with a brake, provide a forced-release switch to permit a reset means during startup adjustment or in case of emergency. The customer must provide the switch (24 VDC, with a minimum contact capacity of 0.2 A). Connect one side of the switch to the positive side of the 24-VDC power supply, and connect the other side to the BK terminal on the power-supply terminal block. The brake will be released when the switch is closed.

Input power supply 24 VDC (Max. 2 A per unit)

Danger: If the actuator is oriented vertically, exercise due caution when releasing the brake to prevent the slider/rod

from dropping unexpectedly to pinch your hand or damage the robot hand or work.

Brake forced-release switch

Power-supply terminal block

3.8 Wiring the Emergency Stop Circuit

3.8.1 Cutting Off the Drive Signal (Standard)

Connect one side of the external EMG switch to the positive side of the 24-VDC power supply, and connect the other side to the BK terminal.

(Note) The EMG switch on the teaching pendant works only on the controller connected to the switch.

3. Installation and Wiring

Teaching pendant

EMG switch

24-VDC input power

supply

(Max. 2 A per unit)

External EMG switch

SIO connector

Power-supply terminal block

PCON-CY controller

Connection detection signal (H)

EMG signal detection (H)

Time

constant

SIO

connector

connection

detection

circuit

Drive stop signal (L)

Motor

drive

circuit

Power-supply

terminal block (2nd)

Power-supply

terminal block (3rd)

If a separate emergency stop circuit is provided to stop the entire system, or when multiple controllers are linked together and each controller has a different power supply, connect external EMG relay contacts.

24-VDC control power supply

24-VDC input power supply (Max. 2 A per unit)

External EMG reset switch

External EMG circuit

DC 0V

3. Installation and Wiring

Relay

Power-supply

terminal block (1st)

Power-supply

terminal block (2nd)

24-VDC input power supply (Max. 2 A per unit)

Power-supply

terminal block (3rd)

3.8.2 Cutting Off the Motor Drive Power

If the motor drive power must be cut off in order to meet the required safety category of the entire system, connect external EMG relay contacts between the MPI terminal and MPO terminal. Also connect the 24-V controller power supply to the EMG terminal.

(Note) The EMG switch on the teaching pendant cuts off the motor driver signal. It does not cut off the motor drive power.

3. Installation and Wiring

24-VDC control power supply

24-VDC input power supply (Max. 2 A per unit)

External EMG reset switch

External EMG circuit

DC 0V

Relay

Power-supply

terminal block (1st)

For driving the motor These lines are shorted internally.

Power-supply

terminal block (2nd)

24-VDC input power supply (Max. 2 A per unit)

For driving the motor These lines are shorted internally.

Power-supply

terminal block (3rd)

For driving the motor These lines are shorted internally.

3.9 Connecting the Actuator

3.9.1 Motor Relay Cable

• Connect the motor relay cable to the MOT connector. Signal table of controller-end connector (CN2)

Pin No. Signal Wire color Description

A2 VMM Gray Motor power line A3

B B1 A Yellow Motor drive line (phase +A) B2 VMM Pink Motor power line B3 B Yellow (Green) Motor drive line (phase +B)

Controller end Actuator end

CN2 pin layout CN1 pin layout

Orange Motor drive line (phase -A)

White Motor drive line (phase -B)

3. Installation and Wiring

Cable color

Orange

Gray

White

Yellow

Pink

Yellow (Green)

Housing: 1-1318119-3 (AMP) Housing: SLP-06V (J.S.T. Mfg.) Receptacle contact: 1318107-1 Socket contact: BSF-21T-P1.4

Signal

abbreviation

Pin No. Cable color

Pin No.

Signal

abbreviation

Yellow

Gray

Orange

Yellow (Green)

Pink

White

3. Installation and Wiring

3.9.2 Encoder Relay Cable

• Connect the encoder relay cable to the PG connector. Signal table of controller-end connector (CN2)

Pin No. Signal abbreviation Description

1 F.G Shielded wire 2 - (Not used) 3 - (Not used) 4 - (Not used) 5 GND 6 5V 7 VPS Encoder control signal output 8 - (Reserved)

ENB

10 ENB 11

ENA 12 ENA 13 BK - Brake power – 14 BK + Brake power + 15 16 -

Controller end Actuator end CN2 pin layout CN1 pin layout

Encoder power output

Encoder differential signal phase-B input

Encoder differential signal phase-A input

(Not used)

Cable color

Robot cable Standard cable

Purple

White (with purple)

Blue

White (with blue)

Yellow

White (with yellow)

Green

Red

White (with red)

Drain

Housing: PHDR-16VS (J.S.T. Mfg.) Contact: SPHD-001T-P0.5

Red

Gray

Brown

Green

Purple

Pink

Yellow

Orange

Blue

Drain

Signal

abbreviation

(Reserved)

Standard cable Robot cable

Pin No.

Enter the cable length (L) in *** (up to 20 m). Example) 080 = 8 m

Pin No.

abbreviation

Housing: XMP-18V (J.S.T. Mfg.)

Contact: BXA-001T-P0.6

Retainer: XMS-09V

Signal

Cable color

Standard cable Robot cable

Brown

Green

Purple

Pink

Blue

Orange

Yellow

Red

Gray

Drain

Blue

White (with blue)

Yellow

White (with yellow)

White (with red)

Red

Green

Purple

White (with purple)

Drain

3.10 Connecting the I/O Flat Cable

Cable type:

Red 2

Brown 1

3. Installation and Wiring

Housing: Contact:

No.

1 24 V Brown-1

2 0 V Red-1

3 Rear end move command input Rear end move command Orange-1

4 Front end move command input Front end move command Yellow-1

Intermediate point move command

input

6 Servo-on command input Servo-on command input Blue-1

7 Rear end detection output Rear end positioning complete output Purple-1

8 Front end detection output

9 Intermediate point detection output

10 Ready output Zone output Black-1

11 Homing complete output Homing complete output Brown-2

12 Alarm output Alarm output Red-2

Warning: When checking the continuity of the flat cable, exercise due caution not to bend the female pins on the

Proximity switch type Standard type

connector outward. It may cause contact failure, resulting in malfunction.

Signal name

Intermediate point move command Green-1

Front end positioning complete output Intermediate point positioning complete output

Color Wiring

Flat cable

(pressure-

welded)

Gray-1

White-1

3.11 Connecting the Communication Cable

Connect the communication cable to the SIO connector.

RS485 conversion adapter end Controller end

Pin layout of cable-end connector

3. Installation and Wiring

Cable color

Brown

Yellow

Red

Orange

Blue

Green

Shorting wire UL1004AWG28 (Black)

Not connected to the shield.

Signal

abbreviation

Pin No.

Signal

abbreviation

Cable color

Yellow

Orange

Brown/Green

Black

Red/Blue

Black

Shield

4. Position Table Settings

To move the actuator to a specified position, basically you must enter the target position in the “Position” field of the position table. A target position can be specified as an absolute coordinate indicating a distance from the home (absolute mode), or as a relative coordinate indicating a relative travel from the current position (incremental mode). Once a target position is entered, all other fields will be automatically populated by the defaults set by the corresponding parameters. The defaults vary depending on the actuator characteristics.

4.1 Details of the Position Table

The position table is explained by using the PC software screen as an example. (The display on the teaching pendant is different.)

4. Position Table Settings

Position Speed Acceleration Deceleration Push Threshold

[mm] [mm/s] [G] [G] [%] [%] [mm]

Zone + Zone – Incremental Comment

[mm] [mm]

(1) No.

(2) Position

Positioning band

Acceleration/

deceleration

mode

• Each number indicates a position data number. The respective numbers are defined as follows: No. 0 --- Entry field for conditions to move to the rear end. No. 1 --- Entry field for conditions to move to the front end. No. 2 --- Entry field for conditions to move to the intermediate point.

• Enter a target position of the front end, rear end or intermediate point, in mm. Absolute mode: Enter a distance from the actuator home. Incremental mode: The actuator is assumed to operate at a constant pitch. Enter a relative travel

from the current position. For example, you can move the actuator to the front end from the intermediate point via incremental moves at a 30-mm pitch. (Use of the standard type is recommended because zone output signals are available in this type.)

Command

mode

Standstill

mode

Rear end

Front end

Intermediate point

Position

Absolute mode: The rear end is positioned 5 mm away from the home.

Incremental mode: The front end is positioned 30 mm away from the current position.

Absolute mode: The intermediate point is positioned 200 mm away from the home.

* On the teaching pendant, an equal sign indicates that the applicable position is set in the incremental mode.

(3) Speed

• Enter a speed at which to move the actuator, in mm/sec. The default speed varies depending on the actuator type.

(4) Acceleration/ deceleration

4. Position Table Settings

• Enter an acceleration/deceleration at which to move the actuator, in G. Basically, specify values inside the rated acceleration/deceleration range shown in the catalog. The input range is greater than the rated range specified in the catalog. This is to accommodate

situations where “the tact time must be reduced when the work is substantially lighter than the rated load capacity.”

If the work generates detrimental vibration during acceleration/deceleration, decrease the

acceleration/deceleration settings.

Speed

Acceleration

0.3 G

Start position

Increasing the set value makes deceleration/deceleration quicker, while decreasing it makes deceleration/deceleration more gradual.

Caution: When setting speed and acceleration/deceleration, refer to the supplied specification list of supported

actuators and also consider the installation condition and load shape to determine appropriate values that will not cause the actuator to receive excessive impact or vibration.

To set values higher than the recommended values, the payload should be considered and the actuator

characteristics vary depending on the model. Therefore, for the maximum settings allowed for each actuator model, please contact IAI’s Sales Engineering Section.

Deceleration

0.2 G

Time

Target position

(5) Push

(6) Threshold

• Select “positioning operation” or “push-motion operation.” The factory setting is “0.” 0: Normal positioning operation Other than 0: The set value indicates a current-limiting value, meaning that push-motion operation

is performed.

• This field is not used with this controller. The factory setting is “0.”

(7) Positioning band

• What this field means is different in “positioning operation” and “push-motion operation.” “Positioning operation”: In the proximity switch type, this field defines the width within which the movement complete signal

turns ON.

In the standard type, this field defines how far before the target position the movement complete

signal turns ON.

The factory setting is “0.1” mm.

Proximity switch type

Movement complete signal

Positioning band

Standard type

Target position Increasing the positioning band quickens the starting of next sequence operation, and

consequently the tact time becomes shorter. Set an optimal value by considering the balance of the entire system.

Positioning band

“Push-motion operation”:

This field defines the maximum push distance to be applied during push-motion operation from the target position. Consider the mechanical variation of the work and set an appropriate positioning band so that positioning will not complete before the work is contacted.

4. Position Table Settings

The movement complete signal turns ON here.

Target position

The work is contacted and push-motion operation is deemed complete, so the movement complete signal turns ON here.

Work

Positioning band (maximum push distance)

Target position

(8) Zone +/–

4. Position Table Settings

• This field defines the range within which the zone output signal turns ON during operation of the standard type.

To increase flexibility, a different range can be set for each target position.

[Setting example]

Position Zone + Zone – Comment

[mm] [mm] [mm]

Rear end

Front end

Intermediate point

Move command to the rear end

Home

Rear end

Zone output signal

Move command to the front end

Front end

+ side limit

Zone output signal

Move command to the

intermediate point

point

Intermediate

Zone output signal

(9) Acceleration/

deceleration

• This field is not used with this controller.

The factory setting is “0.”

mode

(10) Incremental

• This field defines whether to use the absolute mode or incremental mode.

The factory setting is “0.” 0: Absolute mode 1: Incremental mode

Warning: When using the proximity switch type, be sure to specify the absolute mode. If the incremental mode is

specified, a position data error will occur.

(11) Command mode

• This field is not used with this controller.

The factory setting is “0.”

(12) Standstill mode

• This field defines the power-saving mode to be applied while the actuator is standing by after completing the positioning to the target position set in the “Position” field under the applicable position number. 0: All power-saving modes are disabled. * The factory setting is “0” (disabled). 1: Automatic servo-off mode. The delay time is defined by Parameter No. 36. 2: Automatic servo-off mode. The delay time is defined by Parameter No. 37. 3: Automatic servo-off mode. The delay time is defined by Parameter No. 38. 4: Full servo control mode

Full servo control mode

Automatic servo-off mode

The servo automatically turns off after elapse of a specified time following the completion of positioning. (Since no holding current is required, power consumption decreases.) When the PLC issues the next move command, the servo will turn on again and the actuator will start moving.

Move command

Automatic servo-off mode

Servo status

Servo on

Actuator movement

(The green LED blinks.)

4. Position Table Settings

Target position

Delay time after completion of positioning until the servo turns off (sec) This delay time is set by a parameter.

4.2 Notes on the ROBO Gripper

(1) Finger Operation

4. Position Table Settings

[1] Definition of position

With the two-finger type, the stroke specification indicates the total sum of travels by both fingers. In other words, the travel by one finger is one-half this stroke. A position is specified as a travel by one finger from the home position toward the closing direction. Therefore, the maximum command value is 5 mm for the GRS type, and 7 mm for the GRM type.

[2] Definition of speed and acceleration

The command value applies to one finger. With the two-finger type, the relative speed and acceleration are double the command values, respectively.

[3] Gripper operation mode

In applications where the work is to be gripped, be sure to use the “push-motion mode.” (Note) If the “positioning mode” is used, a servo error may occur while the work is gripped.

[Diagram of gripping force and current-limiting value]

Gripping force (N)

Gripping force P (N)

Gripping force (N)

Current-limiting value (%) Current-limiting value (%)

Gripping force P (N)

Current-limiting value (%) Current-limiting value (%)

Gripping force P (N)

Current-limiting value (%) Current-limiting value (%)

(2) Removing the gripped work The ROBO Gripper is structured in such a way that even when the controller power is cut off, the work gripping force will still be maintained by a self-lock mechanism. If you must remove the gripped work while the power is cut off, turn the open/close screw or remove one of the finger attachments to release the work.

[Two-finger type] Turn the open/close screw or remove one of the finger attachments.

Finger attachment

Open/close screw

Turn counterclockwise using a flat-head screwdriver.

4. Position Table Settings

OPEN

[Three-finger type] Remove one of the finger attachments.

Finger attachment

Opening

direction

Affixing bolt

5. Operation Using I/O Signals

This chapter explains the wiring/connection and operation timings you should know to perform positioning operation using a PLC and I/O signals. For PIO pattern, two types are available. The movement complete signals have different meanings in each type, so select an appropriate type according to your specific application. * The factory setting is to use the LS mode.

5.1 Interface Circuit

The standard interface circuit conforms to the NPN specification, but the PNP specification type is also available as an option. To simplify wiring, a common power line is used for both the NPN specification and PNP specification. Accordingly you need not reverse the power connections when using the PNP specification.

5.1.1 External Input Specifications

Item Specification

Number of input points 4 points

Input voltage

Input current 5 mA per circuit

Operating voltage

5. Operation Using I/O Signals

Leak current Max. 1 mA per point

Insulation method Photocoupler

24 VDC ± 10%

ON voltage: Min. 18 V (3.5 mA) OFF voltage: Max. 6 V (1 mA)

Internal circuit configuration

[NPN specification]

+24-V external

power supply

[PNP specification]

+24-V external

power supply

Controller

Internal circuit

Each input

Controller

Internal circuit

Each input

5.1.2 External Output Specifications

Item Specification

Number of input points 6 points

Rated load voltage 24 VDC

Maximum current 50 mA per point

Residual voltage Max. 2 V

Insulation method Photocoupler

Internal circuit configuration

[NPN specification]

[PNP specification]

Internal circuit

5. Operation Using I/O Signals

Controller

Load

Each output

Load

+24-V external

power supply

Controller

Each output

+24-V external

power supply

Load

5.1.3 Recognition of Input Signals

The input signals of this controller have an input time constant to prevent malfunction due to chattering, noise, etc. Each input signal is switched when the new signal state has continued for at least 6 msec. In other words, when the input is switched from OFF to ON, the controller will recognize that the input signal is ON after 6 msec. The same applies when the input is switched from ON to OFF.

Input signal

Recognition by the controller

5. Operation Using I/O Signals

Not recognized

5.2 Proximity Switch Type

This type assumes applications where the servo is turned on/off frequently by the PLC or the automatic servo-off function is used. Use this type if your application meets the following conditions:

[1] The servo is turned off as a secondary safety measure when the emergency stop circuit is configured to directly cut off

the input power. (Note) When the servo-on signal is turned OFF, the actuator will decelerate to a stop at the emergency stop torque

for a specified time, after which the servo will turn off. [2] The servo is turned off to reduce power consumption in case the standby time is long. [3] The actuator is equipped with a brake, and when reactive force is applied upon stopping due to clamping of the work,

etc., the servo is turned off to apply brake force to supplement the built-in brake.

* Do not use push-motion operation.

Caution: The controller is shipped with the proximity switch type pre-selected, so you need not change any parameter

if the proximity switch type is to be used.

5.2.1 Explanation of I/O Signals

Pin No. Wire color Signal name Signal abbreviation Function overview

1 Brown 1 +24 V P24V 2 Red 1 0 V N

3 Orange 1

4 Yellow 1

5 Green 1

6 Blue 1 Servo-on command input SON

7 Purple 1

8 Gray 1

9 White 1

10 Black 1 Ready output SV This signal is output when the servo is on.

11 Brown 2 Homing complete output HEND

12 Red 2 Alarm output *ALM

Rear end move command input Front end move command input Intermediate point move command input

Rear end detection output Front end detection output Intermediate point detection output

ST0 Move command to the rear end

ST1 Move command to the front end

ST2 Move command to the intermediate point

LS0

LS1

LS2

I/O power supply

The servo remains on while this signal is ON. The servo remains off while this signal is OFF. This signal remains ON while the rear end is recognized. This signal remains ON while the front end is recognized. This signal remains ON while the intermediate point is recognized.

This signal is OFF immediately after the power is turned on, and turns ON once homing is completed. This signal remains ON while the actuator is normal, and turns OFF if an alarm has occurred.

5. Operation Using I/O Signals

 Move Command Input for Each Position (ST0, ST1, ST2)

Since the number of positioning points is limited to three, you can use these inputs just like when controlling an air cylinder. While each signal remains ON, the actuator moves to the target position. If the signal turns OFF before the movement is completed, the actuator will decelerate to a stop. Before executing each move command, enter a target position as an absolute coordinate in the “Position” field under one of Nos. 0 to 2 in the position table.

Input signal Target position Remarks

ST0 Rear end The target position is defined in the “Position” field under Position No. 0. ST1 Front end The target position is defined in the “Position” field under Position No. 1. ST2 Intermediate point The target position is defined in the “Position” field under Position No. 2.

 Servo-on Command Input (SON)

The servo remains on while this signal is ON. To ensure safety, it is recommended that the PLC be configured to monitor the condition of the entire system and turn ON this signal once all conditions required for movement are satisfied.

 Detection Output for Each Position (LS0, LS1, LS2)

Just like the LS signals of an air cylinder, each signal turns ON when the current actuator position is inside the positioning band set for the applicable target position. (Note) Even if the servo turns off or an emergency stop is actuated while the actuator is standing still at the target

position, the signal will remain ON as long as the actuator position is inside the positioning band.

Output signal Position detected Remarks

LS0 Rear end

LS1 Front end

LS2 Intermediate point

 Ready Output (SV)

This signal is a monitor signal indicating that the servo is on and the motor can be driven. While this signal is ON, the SV LED (green) on the front face of the enclosure is lit. The SV LED (green) blinks during the auto servo-off mode. Use this signal as a condition for starting a move command on the PLC side.

 Homing Complete Output (HEND)

5. Operation Using I/O Signals

Once turned ON, this signal will remain ON until the input power is cut off. Use this signal as an interlock signal before homing.

The detection position is defined in the “Position” and “Positioning band” fields under Position No. 0. The detection position is defined in the “Position” and “Positioning band” fields under Position No. 1. The detection position is defined in the “Position” and “Positioning band” fields under Position No. 2.

(Reference) Acceptance of each move command before homing is explained below:

[1] A rear end move command is accepted. [2] An intermediate point move command is not accepted. [3] A front end move command is accepted, but once the actuator moves forward at the homing speed and

contacts the mechanical end, the actuator will stop and a front end detection output (LS1) will turn ON. In this case, the LS1 signal should be recognized as a tentative signal. Movement to the front end is permitted to accommodate a situation where there is an obstacle between the actuator and the rear end.

 Alarm Output (*ALM)

This signal remains ON while the actuator is normal, and turns OFF if an alarm has occurred. Cause the PLC to monitor the OFF state of this signal and provide an appropriate safety measure for the entire system. Check the nature of each alarm by connecting a PC/teaching pendant, and remove the cause. For details of alarms, refer to Chapter 7, “Troubleshooting.”

5.2.2 Timings after Power On

(Note1)

z Steps from Initial Startup to Actuator Adjustment

[1] Confirm that the slider or rod is not contacting a mechanical end or that the work is not contacting any peripheral

equipment. [2] Cancel the emergency stop or connect the motor drive power. [3] Supply the 24-VDC I/O power (PIO connector pins 1 and 2). [4] Supply the 24-VDC controller power (24-V and 0-V terminals on the power-supply terminal block). [5] Set the minimum required parameters.

(Example) • To temporarily disable the servo-on input because the PLC is not yet ready to accept the input, change

the value of Parameter No. 21 (Servo-on input disable selection) to “1.”

• To change the feed speed during teaching, change the value of Parameter No. 35 (Safety speed). [6] Input a servo-on signal from the PLC (if the servo-on input is enabled). [7] Connect a PC or teaching pendant to adjust the actuator.

• Set optimal values in the “Position,” “Speed,” “Acceleration,” “Deceleration” and other fields under Nos.

0 to 2 in the position table.

5. Operation Using I/O Signals

Safety circuit status

Emergency stop cancelled

Supply of 24-VDC I/O power

Supply of 24-VDC controller power

Initial parameter

settings

* Servo-on input (SON)

Green

n orange light comes

SV lamp (front panel)

Ready output (SV)

on for 2 seconds, and then turns off.

Use a teaching pendant or PC to set optimal values in the respective fields under Nos. 0 to 2 in the position table.

* If you have changed the value of Parameter No. 21 (Servo-on input disable selection) to “1,” the servo-on input signal

is not required.

Caution: In the “Emergency stop actuated → Turn on the power → Servo-on input → Cancel the emergency stop”

sequence, the servo will turn on up to T

(Note 1)

after the emergency stop is cancelled.

Servo-on input

(Note 1) : Excited-pole detection time = 0.2 to 12 sec

Normally the detection of excited pole completes in approx. 0.2 sec, although the exact time varies from one actuator to another due to individual differences and also depending on the load condition. If the detection of excited pole has failed, the excited-pole detection operation will be continued for up to 12 sec.

Emergency stop cancelled

Servo on

(Note 1) sec

z Normal Operating Procedure

(Note1)

The operating procedure in a normal condition is explained below. [1] Confirm that the slider or rod is not contacting a mechanical end or that the work is not contacting any peripheral

equipment. [2] Cancel the emergency stop or connect the motor drive power. [3] Supply the 24-VDC I/O power. [4] Supply the 24-VDC controller power. [5] Input a servo-on signal from the PLC (if the servo-on input is enabled). [6] First, input a rear end move command signal from the PLC (to cause the actuator to stand by at the rear end). [7] Start automatic operation.

Safety circuit status

Supply of 24-VDC I/O power

Supply of 24-VDC controller power

Servo-on input (SON)

5. Operation Using I/O Signals

SV lamp (front panel)

Emergency stop cancelled

Green

Ready output (SV)

Input a move command after the SV has turned ON. (If a move command is input when the SV is OFF, the command will be

Rear end move

command input (ST0)

Homing complete

output (HEND)

Rear end detection

output (LS0)

Max. 6 msec

Power-on position

(Note 1) : Excited-pole detection time = 0.2 to 12 sec

Mechanical end

Home position

Start of continuous

Rear end

operation

Warning: Since the drive motor is a pulse motor, the excited phase is detected when the servo is turned on for the

first time after turning on the power. Therefore, one condition for the servo to turn on is that the actuator can move once the servo is turned on. If the slider or rod is contacting a mechanical end or the work is contacting any peripheral equipment, the excited phase may not be detected correctly and an erroneous movement or excitation detection error may occur. In this case, move the actuator manually to an appropriate position before turning the servo on. If the actuator is equipped with a brake, the brake must be forcibly released by turning on the brake release switch. At this time, be careful not to pinch your hand or damage the robot hand or work by the slider/rod, as the slider/rod may drop unexpectedly by its dead weight. If the actuator cannot be moved by hand, you can change Parameter No. 28 (Direction of excited phase signal detection). Before changing this parameter, contact IAI.

5. Operation Using I/O Signals

5.2.3 Position Table and Parameter Settings Required for Operation

 Test Operation

Immediately after the system has been started, the movement speed can be reduced as follows to ensure safety of the operator and prevent damage to the jigs, etc. Change the applicable parameters as necessary. → For details on the change operation, refer to the operation manual for the PC/teaching pendant you are using.

Safety speed during manual feed

The feed speed that applies when the actuator is moved with a PC/teaching pendant is defined by Parameter No. 35. The factory setting of this parameter is 100 mm/s. Change the setting if necessary. Note that the maximum speed is limited to 250 mm/s.

Speed override for move commands from the PLC

You can reduce the feed speed that applies when the actuator is moved by outputting a rear end, front end or intermediate point move command from the PLC. You can override the “Speed” field of the position table based on the value of Parameter No. 46, in order to reduce the actual speed to below the speed set in the “Speed” field. Actual movement speed = [Speed set in the position table] x [Value of Parameter No. 46] ÷ 100 Example) Value in the “Speed” field of the position table 500 (mm/s)

Value of Parameter No. 46 20 (%) Under the above settings, the actual movement speed becomes 100 mm/s.

The minimum setting unit is 1 (%), and the input range is 1 to 100 (%). The factory setting is 100 (%).

5. Operation Using I/O Signals

 Full-scale Operation

In situations where the actuator remains standstill for a long time at a standby position, this controller provides several modes to reduce power consumption in such standstill state as part of the controller’s energy-saving function. Use these modes after confirming that they will not cause problems in any part of the system.

Power-saving when the standby time after power on is long

In this case, you can select full servo control by Parameter No. 53 (Default standstill mode). (The setting in the “Standstill mode” field of the position table is ignored.) → For details, refer to 5.4, “Power-saving Modes at Standby Positions” and 6.2.2, “Parameters Relating to Actuator

Operating Characteristics.”

Power-saving when the standby time at the target position is long

In this case, you can select one of two modes depending on the value set in the “Standstill mode” field of the position table. (The setting of Parameter No. 53 is ignored.) [1] Full servo control [2] Automatic servo-off → For details, refer to 5.4, “Power-saving Modes at Standby Positions” and 6.2.2, “Parameters Relating to Actuator

Operating Characteristics.”

5. Operation Using I/O Signals

5.2.4 Homing

This controller adopts an incremental position detector (encoder), so once the power is cut off, the mechanical coordinates will be lost. Accordingly, homing must be performed to establish the initial mechanical coordinate every time the power is turned on. To perform homing, input a rear end move command (ST0).

Operation timings

PLC processing 1: The rear end move command signal (ST0) turns ON when the start button is pressed. Operation: [1] The actuator starts moving toward the mechanical end on the home side.

PLC processing 2: The rear end move command signal (ST0) turns OFF. PLC processing 3: The actuator starts continuous operation.

Rear end move

command input (ST0)

Homing complete

output (HEND)

5. Operation Using I/O Signals

Rear end detection

output (LS0)

[2] After contacting the mechanical end, the actuator reverses its direction and temporarily

stops at the home position. → The homing complete signal (HEND) turns ON.

[3] The actuator moves toward the rear end, and stops at the rear end.

→ The rear end detection output (LS0) turns ON.

Max. 6 msec

[1]

Power-on position

Caution: Take note of the following points regarding homing:

[1] Confirm that no obstacle exists between the actuator and the rear end. [2] If an obstacle exists between the actuator and the rear end, move the actuator toward the front end and

remove the obstacle. The controller accepts a front end move command prior to homing to accommodate the aforementioned condition. In this case, the actuator moves forward at the homing speed and once the mechanical end is reached, the front end detection output (LS1) will turn ON. This LS1 signal should be recognized as a tentative signal.

[3] Do not input an intermediate move command. (Even if an intermediate move command is input, it will

be ignored.)

[2]

Mechanical end

[3]

Home position

Rear end

5.2.5 Positioning Operation

This section explains how to move the actuator from the rear end to the front end, by using an actuator with a 400-mm stroke as an example. Although the actuator is not stopped at the intermediate point in this example, you can increase the positioning band and use the intermediate point detection output signal (LS2) just like the zone output signal.

Example of position table

Position

[mm]

Speed [mm/s]

Acceleration

[G]

Deceleration

[G]

Push

[%]

Positioning band [mm]

Comment

Rear end

Front end

Intermediate point

Operation timings

PLC processing 1: The rear end move command signal (ST0) and intermediate point move command signal (ST2)

turn OFF, and the front end move command signal (ST1) turns ON.

Operation: [1] The actuator starts moving toward the front end.

[2] When the actuator passes the position corresponding to 5.1 mm, the rear end detection

output (LS0) turns OFF.

[3] When the actuator reaches the position corresponding to 150 mm, the intermediate point

detection output (LS2) turns ON. The LS2 turns OFF once the actuator passes the position corresponding to 250 mm.

PLC processing 2: If necessary, use the intermediate point detection output (LS2) as a trigger signal for peripheral

equipment. [4] The actuator starts decelerating after reaching the position corresponding approx. 365 mm. [5] When the actuator passes the position corresponding to 379.9 mm, the front end detection

output (LS1) turns ON. [6] The actuator stops after reaching the position corresponding to 380 mm. PLC processing 3: When the front end detection output (LS1) turns ON, the sequence processing is performed at the

front end. Once the sequence processing is completed, the front end move command signal (ST1) turns OFF.

Front end move

command input (ST1)

5. Operation Using I/O Signals

Rear end detection

output (LS0)

Intermediate point

detection output (LS2)

Front end detection

output (LS1)

Sequence is

Speed

performed at the front end

Time

Rear end

5 mm

Intermediate point

200 mm

Front end

380 mm

Caution: Design a ladder sequence circuit where only one move command signal turns ON at a given time. If two or

more signals are input simultaneously, the signals will be processed according to the set priorities. Priorities: [1] Rear end, [2] front end, [3] intermediate point

z Meaning of Position Detection Output Signals (LS0, LS1, LS2)

These signals are handled in the same way as limit switches (LSs). They turn ON when the following conditions are met: [1] The homing complete output signal (HEND) is ON. [2] The current position is within the allowable distance before or after each target position (inside the positioning band). Accordingly, each output signal also turns ON when the actuator is manually moved while the servo is off, in addition to when the actuator is moving following the applicable move command. If an emergency stop is actuated while the actuator is moving and operation must be resumed from the PLC when none of the position detection output signals (LS0, LS1, LS2) is ON, move the actuator manually to the target position to turn on the corresponding position detection output signal.

Caution: All position detection outputs will turn OFF once a phase A/B open detection alarm generates.

z Notes on Setting the Positioning Band

The positioning band setting defines the range of coordinates at which the position detection output signal will turn ON. Condition for a position detection output signal to turn ON = Target position ± (positioning band)

With a normal move command, once the position detection output signal turns ON, the sequence processing will be performed and the move command input signal will turn OFF. Take note that if the positioning band is wide and the move command input signal turns OFF too quickly, the target position may not be achieved.

(Example) If the feed speed is 300 mm/s and deceleration is 0.3 G, the deceleration distance is approx. 15 mm. If the

positioning band is set to 30 mm, the position detection output signal will turn ON before the actuator starts

5. Operation Using I/O Signals

decelerating. If the PLC turns OFF the move command input signal immediately thereafter, the controller will start the deceleration stop processing. As a result, the actuator will stop before the target position.

Front end move

command input (ST1)

Front end detection

output (LS1)

The actuator stops before the front end.

Positioning band

The positioning band is greater than the deceleration distance.

Correct starting point of deceleration

Front end

z Speed Change during Movement

If the work is made of soft material or is a bottle or has other shape that tips over easily, one of the following two methods can be used to prevent the work from receiving vibration or impact upon stopping: [1] Decrease the deceleration to make the deceleration curve more gradual. [2] Initially move the actuator at the rated speed, and decrease the feed speed shortly before the target position.

An example of [2], or decreasing the feed speed, is explained. (Example) When moving the actuator from the rear end to the front end, use the intermediate point as a dummy point.

Set the feed speed to 300 mm/s to the intermediate point, and decrease it to 20 mm/s after the intermediate point.

Example of position table

Position

[mm]

Speed [mm/s]

Acceleration

[G]

Operation timings

PLC processing 1: The rear end move command signal (ST0) and front end move command signal (ST1) turn OFF,

and the intermediate point move command signal (ST2) turns ON.

Operation: [1] The actuator starts moving toward the intermediate point.

[2] When the actuator reaches the position corresponding to 270 mm, the intermediate point

detection output (LS2) turns ON. PLC processing 2: The intermediate point move command signal (ST2) turns OFF, and the front end move

command signal (ST1) turns ON.

[3] The actuator decelerates from 300 mm/s to 20 mm/s, and stops at the front end.

Deceleration

[G]

Push

[%]

Positioning band [mm]

Comment

Rear end

Front end

Intermediate point

5. Operation Using I/O Signals

Intermediate move

command input (ST2)

Front end move

command input (ST1)

Intermediate point

detection output (LS2)

Front end detection

output (LS1)

Speed

Time

Rear end

5 mm

Intermediate point

300 mm

Front end

380 mm

Caution: By setting a wide positioning band for the intermediate point, smooth speed change can be achieved without

the actuator stopping at the intermediate point.

z Pausing during Movement

Move commands are implemented based on signal levels. Accordingly, the actuator moves while the signal is ON, and once the signal turns OFF, the actuator will decelerate to a stop and the operation will end. If you want to pause the actuator as a secondary safety measure, turn the move command signals OFF.

(Example) Pausing the actuator while moving toward the front end

Front end move

command input (ST1)

Front end detection

output (LS1)

Speed

Moving Stopped Moving

Time

Front end

z Forced Return in Case of Emergency

The following example explains how to return the actuator to the standby position (rear end) after an emergency situation occurred while the actuator was moving.

5. Operation Using I/O Signals

(Example) Return the actuator to the standby position (rear end) after an emergency situation occurred while the actuator

was moving toward the front end

Operation timings

PLC processing 1: Upon occurrence of an emergency situation, the rear end move command signal (ST0) turns ON,

Operation: [1] After the front end move command signal (ST1) turns OFF, the actuator decelerates to a

[2] The actuator reverses its direction and starts moving toward the rear end. [3] When the actuator reaches the rear end, the rear end positioning complete output (PE0)

PLC processing 2: The rear end move command signal (ST0) turns OFF.

Front end move

command input (ST1)

Rear end move

command input (ST0)

Rear end detection

output (LS0)

and then the front end move command signal (ST1) turns OFF.

stop.

turns ON.

Occurrence of

emergency situation

Speed

Moving to + direction Moving to - direction

Time

Rear end

5.3 Standard Type

This type assumes situations where the system must achieve high productivity or uses push-motion operation. Use this type if your application meets the following conditions:

[1] Use the zone output signal to quicken the operation timings with respect to the respective equipment and thereby

reduce the tact time. [2] Use the zone output signal as an interlock signal to prevent contact with peripheral equipment. [3] When missed work must be detected in push-motion operation, use the zone output signal as a “simple yardstick” to

determine if the work has been contacted properly or missed.

Caution: The controller is shipped with the proximity switch type pre-selected. If you want to use the standard type, set

the value of Parameter No. 25 (PIO pattern selection) to “1.” → Refer to Chapter 6, “Parameter Settings”

5.3.1 Explanation of I/O Signals

Pin No. Wire color Signal name Signal abbreviation Function overview

1 Brown 1 +24 V P24V 2 Red 1 0 V N

3 Orange 1

4 Yellow 1

5 Green 1

6 Blue 1 Servo-on command input SON

7 Purple 1

8 Gray 1

9 White 1

10 Black 1

11 Brown 2 Homing complete output HEND

12 Red 2 Alarm output *ALM

Rear end move command input Front end move command input Intermediate point move command input

Rear end positioning complete output Front end positioning complete output

Intermediate point positioning complete output

Zone output

ST0 Move command to the rear end

ST1 Move command to the front end

ST2 Move command to the intermediate point

PE0

PE1

PE2

PZONE

I/O power supply

The servo remains on while this signal is ON. The servo remains off while this signal is OFF. This signal turns ON upon completion of movement to the rear end. This signal turns ON upon completion of movement to the front end. This signal turns ON upon completion of movement to the intermediate point.

This signal remains ON while the actuator is inside the range set in the “Zone +” and “Zone –” fields of the position table. This signal is OFF immediately after the power is turned on, and turns ON once homing is completed.

This signal remains ON while the actuator is normal, and turns OFF if an alarm has occurred.

5. Operation Using I/O Signals

 Move Command Input for Each Position (ST0, ST1, ST2)

Input signal Target position Remarks

 Servo-on Command Input (SON)

 Positioning Complete Output for Each Position (PE0, PE1, PE2)

After a move command, the corresponding positioning complete output turns ON when the actuator has entered the positioning band before the target position. When the next move command to a different position is issued, the positioning complete output turns OFF. (Note) If the servo turns off or an emergency stop is actuated while the actuator is standing still at the target position, the

positioning complete output will turn OFF. When the servo subsequently turns on, the output will turn ON again if the actuator is still inside the positioning band.

Output signal Position detected Remarks

PE0 Rear end

PE1 Front end

PE2 Intermediate point

 Zone Output (PZONE)

This signal can be used as a limit switch (LS) at the intermediate point, or as a simple yardstick during push-motion operation. The zone output signal remains ON while the actuator is inside the range specified by the “Zone +” and “Zone –” fields of the position table, and turns OFF once the actuator leaves the range. (Note) This signal is enabled after the coordinate system has been established following the completion of homing. It will

not be output immediately after the power is turned on. As long as homing has already been completed, this signal remains effective while the servo is off or an emergency stop is actuated.

5. Operation Using I/O Signals

 Homing Complete Output (HEND)

This signal is OFF immediately after the power is turned on. To establish the initial coordinate, only a rear end move command is accepted after power on. Once a rear end move command has been input, the actuator performs homing and then moves to the rear end. This signal will turn ON after the homing is completed. Once turned ON, this signal will remain ON until the input power is cut off. Use this signal as an interlock signal before homing. (Reference) Acceptance of each move command before homing is explained below:

[1] A rear end move command is accepted. [2] An intermediate point move command is not accepted. [3] A front end move command is accepted, but once the actuator moves forward at the homing speed and

contacts the mechanical end, the actuator will stop and a front end positioning complete output (PE1) will turn ON. In this case, the PE1 signal should be recognized as a tentative signal. Movement to the front end is permitted to accommodate a situation where there is an obstacle between the actuator and the rear end.

The output position is defined in the “Position” and “Positioning band” fields under Position No. 0. The output position is defined in the “Position” and “Positioning band” fields under Position No. 1. The output position is defined in the “Position” and “Positioning band” fields under Position No. 2.

 Alarm Output (*ALM)

5.3.2 Timings after Power On

z Steps from Initial Startup to Actuator Adjustment

[1] Confirm that the slider or rod is not contacting a mechanical end or that the work is not contacting any peripheral

(Example) • To switch to the standard type, change the value of Parameter No. 25 (PIO pattern selection) to “1.”

• To temporarily disable the servo-on input because the PLC is not yet ready to accept the input, change the value of Parameter No. 21 (Servo-on input disable selection) to “1.”

• To change the feed speed during teaching, change the value of Parameter No. 35 (Safety speed).

[6] Input a servo-on signal from the PLC. [7] Connect a PC or teaching pendant to adjust the actuator.

• Set optimal values in the “Position,” “Speed,” “Acceleration,” “Deceleration” and other fields under Nos. 0 to 2 in the position table.

Emergency stop cancelled

Safety circuit status

Supply of 24-VDC I/O power

Supply of 24-VDC controller power

Initial parameter

settings

5. Operation Using I/O Signals

* Servo-on input (SON)

SV lamp (front panel)

* If you have changed the value of Parameter No. 21 (Servo-on input disable selection) to “1,” the servo-on input signal

is not required.

Caution: In the “Emergency stop actuated → Turn on the power → Servo-on input → Cancel the emergency stop”

sequence, the servo will turn on up to 170 msec after the emergency stop is cancelled.

n orange light comes on for 2 seconds, and then turns off.

Max. 170 msec

Servo-on input

Max. 170 msec

Green

Use a teaching pendant or PC to set optimal values in the respective fields under Nos. 0 to 2 in the position table.

Emergency stop cancelled

Servo on

z Normal Operating Procedure

The operating procedure in a normal condition is explained below. [1] Confirm that the slider or rod is not contacting a mechanical end or that the work is not contacting any peripheral

equipment. [2] Cancel the emergency stop or connect the motor drive power. [3] Supply the 24-VDC I/O power. [4] Supply the 24-VDC controller power. [5] Input a servo-on signal from the PLC. [6] First, input a rear end move command signal from the PLC (to cause the actuator to stand by at the rear end). [7] Start automatic operation.

Safety circuit status

Supply of 24-VDC I/O power

Supply of 24-VDC controller power

Servo-on input (SON)

5. Operation Using I/O Signals

SV lamp (front panel)

Emergency stop cancelled

Green

Max. 170 msec

Rear end move

command input (ST0)

Homing complete

output (HEND)

Rear end positioning

complete output (PE0)

Max. 6 msec

Input a move command following a delay time of at least 170 msec after a SON input. (If the delay time is shorter, the move command will be ignored.)

Start of continuous operation

Rear end

Power-on position

Mechanical end

Home position

Warning: Since the drive motor is a pulse motor, the excited phase is detected when the servo is turned on for the

5. Operation Using I/O Signals

5.3.3 Position Table and Parameter Settings Required for Operation

 Test Operation

Safety speed during manual feed

Speed override for move commands from the PLC

You can reduce the feed speed that applies when the actuator is moved by outputting a move command from the PLC. You can override the “Speed” field of the position table based on the value of Parameter No. 46, in order to reduce the actual speed to below the speed set in the “Speed” field. Actual movement speed = [Speed set in the position table] x [Value of Parameter No. 46] ÷ 100 Example) Value in the “Speed” field of the position table 500 (mm/s)

Value of Parameter No. 46 20 (%) Under the above settings, the actual movement speed becomes 100 mm/s.

The minimum setting unit is 1 (%), and the input range is 1 to 100 (%). The factory setting is 100 (%).

5. Operation Using I/O Signals

 Full-scale Operation

In situations where the actuator remains standstill for a long time at a standby position, this controller provides several modes to reduce power consumption in such standstill state as part of the controller’s energy-saving function. You can also select the positioning complete signal state to be applied when the servo turns off or “position deviation” occurs while the actuator is standing still after completion of positioning. Use these modes after confirming that they will not cause problems in any part of the system.

Power-saving when the standby time after power on is long

Operating Characteristics.”

Power-saving when the standby time at the target position is long

Operating Characteristics.”

Complete signal output mode

You can select the positioning complete signal state to be applied when the servo turns off or “position deviation” occurs while the actuator is standing still after completion of positioning. This setting uses Parameter No. 39. Select an appropriate mode by considering the characteristics of the specific control. → For details, refer to 6.2.3, “Parameters Relating to External Interface.”

5. Operation Using I/O Signals

5.3.4 Homing

Operation timings

PLC processing 1: The rear end move command signal (ST0) turns ON when the start button is pressed. Operation: [1] The actuator starts moving toward the mechanical end on the home side.

PLC processing 2: The rear end move command signal (ST0) turns OFF. PLC processing 3: The actuator starts continuous operation.

Rear end move

command input (ST0)

Homing complete

output (HEND)

5. Operation Using I/O Signals

Rear end positioning

complete output (PE0)

Max. 6 msec

[2] After contacting the mechanical end, the actuator reverses its direction and temporarily

stops at the home position. → The homing complete signal (HEND) turns ON.

[3] The actuator moves toward the rear end, and stops at the rear end.

→ The rear end positioning complete output (PE0) turns ON.

[1]

[2]

[3]

Power-on position

Mechanical end

Caution: Take note of the following points regarding homing:

[1] Confirm that no obstacle exists between the actuator and the rear end. [2] If an obstacle exists between the actuator and the rear end, move the actuator toward the front end and

remove the obstacle. The controller accepts a front end move command prior to homing to accommodate the aforementioned condition. In this case, the actuator moves forward at the homing speed and once the mechanical end is reached, the front end positioning complete output (PE1) will turn ON. This PE1 signal should be recognized as a tentative signal.

[3] Do not input an intermediate move command. (Even if an intermediate move command is input, it will

be ignored.)

Rear end

Home position

5.3.5 Positioning Operation

This section explains how to move the actuator from the rear end to the intermediate point and then to the front end, by using an actuator with a 400-mm stroke as an example.

Example of position table

Position

[mm]

Speed [mm/s]

Acceleration

[G]

Operation timings

PLC processing 1: The rear end move command signal (ST0) and front end move command signal (ST1) turn OFF,

and the intermediate point move command signal (ST2) turns ON.

Operation: [1] The actuator starts moving toward the intermediate point, and the rear end positioning

complete output (PE0) turns OFF.

[2] When the actuator reaches the position corresponding to 199.9 mm, the intermediate point

positioning complete output (PE2) turns ON. [3] After reaching the position corresponding to 200 mm, the actuator stops. PLC processing 2: When the intermediate point positioning complete output (PE2) turns ON, the sequence

processing is performed at the intermediate point. Once the sequence processing is completed, the intermediate point move command signal (ST2) turns OFF, and the front end move command signal (ST1) turns ON.

[4] The actuator starts moving toward the front end, and the intermediate point positioning

complete output (PE2) turns OFF. [5] When the actuator reaches the position corresponding to 379.9 mm, the front end

positioning complete output (PE1) turns ON.

[6] After reaching the position corresponding to 380 mm, the actuator stops.

PLC processing 3: When the front end positioning complete output (PE1) turns ON, the sequence processing is

performed at the front end. Once the sequence processing is completed, the front end move command signal (ST1) turns OFF.

Intermediate point move

command input (ST2)

Front end move command

input (ST1)

Deceleration

[G]

Push

[%]

Positioning

band [mm]

Comment

Rear end

Front end

Intermediate point

5. Operation Using I/O Signals

Rear end positioning

complete output (PE0)

Intermediate point positioning

complete output (PE2)

Front end positioning

complete output (PE1)

Sequence is performed at the front end

Speed

Sequence is performed at the intermediate point

Time

Rear end

5 mm

Intermediate point

200 mm

Front end

380 mm

Caution: Design a ladder sequence circuit where only one move command signal turns ON at a given time. If two or

more signals are input simultaneously, the signals will be processed according to the set priorities. Priorities: [1] Rear end, [2] front end, [3] intermediate point

z Meaning of Positioning Complete Output Signals (PE0, PE1, PE2)

These signals indicate that the target position has been reached. They turn ON when the following conditions are met: [1] The homing complete output signal (HEND) is ON. [2] The actuator has entered the positioning band before the target position.

Each signal can be used as trigger signal for peripheral equipment when the target position is reached. Increasing the positioning band quickens the timing of the next command issued to peripheral equipment, and consequently the tact time becomes shorter. (Note) If the servo turns off or an emergency stop is actuated while the actuator is standing still at the target position,

the output will turn OFF. When the servo subsequently turns on, the output will turn ON again if the actuator is still inside the positioning band.

Caution: All position detection outputs will turn OFF once a phase A/B open detection alarm generates.

z Notes on Setting the Positioning Band

The positioning band setting defines the range of coordinates at which the positioning complete output signal will turn ON.

Condition for a positioning complete output signal to turn ON = The actuator enters the positioning band before the target position

With a normal move command, once the positioning complete output signal turns ON, the sequence processing will be performed and the move command input signal will turn OFF. Take note that if the positioning band is wide and the move command input signal turns OFF too quickly, the target position may not be achieved.

5. Operation Using I/O Signals

(Example) If the feed speed is 300 mm/s and deceleration is 0.3 G, the deceleration distance is approx. 15 mm. If the

positioning band is set to 30 mm, the positioning complete output signal will turn ON before the actuator starts decelerating. If the PLC turns OFF the move command input signal immediately thereafter, the controller will start the deceleration stop processing. As a result, the actuator will stop before the target position.

Front end move

command input (ST1)

Front end positioning

complete output (PE1)

The actuator stops before the front end.

Positioning band

The positioning band is greater than the deceleration distance.

Correct starting point of deceleration

Front end

z Speed Change during Movement

An example of [2], or decreasing the feed speed, is explained. (Example) When moving the actuator from the rear end to the front end, use the intermediate point as a dummy point.

Set the feed speed to 300 mm/s to the intermediate point, and decrease it to 20 mm/s after the intermediate point.

Example of position table

Position

[mm]

Speed [mm/s]

Acceleration

[G]

Operation timings

PLC processing 1: The rear end move command signal (ST0) and front end move command signal (ST1) turn OFF,

and the intermediate point move command signal (ST2) turns ON.

Operation: [1] The actuator starts moving toward the intermediate point.

[2] When the actuator reaches the position corresponding to 270 mm, the intermediate point

positioning complete output (PE2) turns ON. PLC processing 2: The intermediate point move command signal (ST2) turns OFF, and the front end move

command signal (ST1) turns ON.

[3] The actuator decelerates from 300 mm/s to 20 mm/s, and stops at the front end.

Deceleration

[G]

Push

[%]

Positioning band [mm]

Comment

Rear end

Front end

Intermediate point

5. Operation Using I/O Signals

Intermediate point move

command input (ST2)

Front end move command

input (ST1)

Intermediate point positioning

complete output (PE2)

Front end positioning

complete output (PE1)

Speed

Time

Rear end

5 mm

Intermediate point

200 mm

Front end

380 mm

Caution: By setting a wide positioning band for the intermediate point, smooth speed change can be achieved without

the actuator stopping at the intermediate point.

z Pausing during Movement

(Example) Pausing the actuator while moving toward the front end

Front end move

command input (ST1)

Front end positioning

complete output (PE1)

Speed

Moving Stopped Moving

Time

Front end

z Forced Return in Case of Emergency

The following example explains how to return the actuator to the standby position (rear end) after an emergency situation occurred while the actuator was moving.

5. Operation Using I/O Signals

(Example) Return the actuator to the standby position (rear end) after an emergency situation occurred while the actuator

was moving toward the front end

Operation timings

PLC processing 1: Upon occurrence of an emergency situation, the rear end move command signal (ST0) turns ON,

Operation: [1] After the front end move command signal (ST1) turns OFF, the actuator decelerates to a

[2] The actuator reverses its direction and starts moving toward the rear end. [3] When the actuator reaches the rear end, the rear end positioning complete output (PE0)

PLC processing 2: The rear end move command signal (ST0) turns OFF.

Front end move

command input (ST1)

Rear end move

command input (ST0)

Rear end positioning

complete output (PE0)

and then the front end move command signal (ST1) turns OFF.

stop.

turns ON.

Occurrence of

emergency situation

Speed

Moving to + direction Moving to - direction

Time

Rear end

z Constant Pitch Feed

Since a target position can also be set as a relative distance, an application where the actuator performs positioning to a series of works placed at equal intervals is also possible.

(Example) How to move the actuator from the intermediate point to the front end at a 50-mm pitch is explained.

Under No. 1 in the position table, enter “50” (mm) in the “Position” field and “1” in the “Incremental” field. (1 defines that 50 mm is a relative distance.) The PLC manages the number of movements to determine the end of positioning. To be doubly sure, the zone output signal can also be used concurrently.

To front end

50-mm

Rear

end

Intermediate

point

pitch

Last work

5. Operation Using I/O Signals

Zone output signal

Set the coordinate immediately before the last work as the

+ side limit.

Example of position table

Position

[mm]

(Note) When issuing a rear end move command and different zone limits must be set, change the zone

limits.

* On the teaching pendant, an equal sign indicates that the applicable position is set in the incremental mode.

Zone +

[mm]

Zone –

[mm]

Incremental Comment

Rear end (Standby position)

Front end (Pitch)

Intermediate point (Starting point)

Operation timings

PLC processing 1: The rear end move command signal (ST0) and front end move command signal (ST1) turn OFF,

Operation: [1] The actuator starts moving, and when it reaches the intermediate point, the intermediate

PLC processing 2: The intermediate point move command signal (ST2) turns OFF and the sequence processing is

[2] When the actuator starts moving toward the front end, the intermediate point positioning

PLC processing 3: The front end move command signal (ST1) turns OFF, and the sequence processing is

[3] When the actuator starts moving toward the front end, the front end positioning complete

* The same steps are repeated for the number of works.

The PLC should be programmed so that if the zone output signal is OFF when the signal ON/OFF state is checked upon completion of positioning, the PLC will recognize that the applicable work is the last work. If the PLC count and the zone output signal state do not match, the signal timings may not be synchronized.

5. Operation Using I/O Signals

and the intermediate point move command signal (ST2) turns ON.

point positioning complete output (PE2) turns ON. The zone output signal also turns ON.

performed. Once the sequence processing is completed, the front end move command signal (ST1) turns ON.

complete output (PE2) turns OFF.

When the actuator moves 50 mm thereafter, the front end positioning complete output (PE1)

turns ON.

performed. Once the sequence processing is completed, the front end move command signal (ST1) turns ON.

output (PE1) turns OFF.

When the actuator moves 50 mm thereafter, the front end positioning complete output (PE1)

turns ON again.

Intermediate point move

command input (ST2)

Front end move command

input (ST1)

Intermediate point positioning

complete output (PE2)

Front end positioning

complete output (PE1)

Zone output (ZONE)

Speed

[1] [2]

PLC

processing

Intermediate

point

Caution: Note on checking positioning complete signals

When a move command signal turns ON, the relevant positioning complete output signal turns OFF temporarily. To determine if positioning has completed, therefore, check the leading edge of the positioning complete output signal after it has turned OFF.

PLC

processing

[3]

PLC

processing

Time

5.3.6 Zone Output Signal

This signal remains ON while the actuator is inside the zone set in the position table. The zone output signal can be set only at a single point, but a different zone can be set for the move command corresponding to each target position (rear end, front end, or intermediate point).

Use the zone output signal in the following situations. [1] Set an interlock signal to prevent contact with peripheral equipment. [2] Set a trigger signal for peripheral equipment to reduce the tact time. [3] Detect missed work during push-motion operation. [4] Determine the end point when positioning to a series of aligned works via constant pitch feed.

(Note) In constant pitch feed, the “Position” field indicates a relative distance. However, the zone is still set as an

absolute coordinate from the home.

[Setting example]

Move command to the rear end

Position

[mm]

Zone +

[mm]

Home

Zone –

Rear end

[mm]

Comment

Rear end

Front end

Intermediate point

5. Operation Using I/O Signals

Zone output signal

Move command to the front end

Zone output signal

Move command to the intermediate point

Zone output signal

Front end

Intermediate

point

+ side limit

5.3.7 Push-motion Operation

Just like you can with an air cylinder, you can maintain the actuator in a condition where the tip of the rod is pushing a work. Accordingly, the actuator can be used with systems that clamp, press-fit or otherwise push works. This function is enabled by entering a current-limiting value in the “Push” field of the position table. * If the “Push” field contains “0,” positioning operation is applied. If the value in this field is other than “0,” push-motion

operation is applied.

The push torque [N] is determined by the current-limiting value [%] in the “Push” field.

[Basics of push-motion operation]

[1] Enter a current-limiting value in the “Push” field for the front end (Position No. 1) to define that a front end command will

be implemented as push-motion operation. * Determine an appropriate push force based on the characteristics of the work (shape, material, etc.), and obtain a

current-limiting value by using the “push force vs. current-limiting value” correlation diagram (explained later) of the actuator as a reference.

[2] In the “Positioning band” field, enter the maximum travel (relative distance) from the front end permitted during

push-motion operation. (Consider a position error that may generate when the work is installed, as well as a possible depression if the work is made of elastic material.)

[3] If it is possible for the system to miss the work, use the zone output signal to detect missed work. To do this, enter

appropriate values in the “Zone +” and “Zone –” fields to specify a range within which the work is deemed to have been contacted successfully.

[4] Change the value of Parameter No. 6 (Push-motion completion judgment time), if necessary.

(The factory setting is 255 msec, which is the maximum value that can be set for this parameter.)

[5] Change the value of Parameter No. 34 (Push speed), if necessary.

5. Operation Using I/O Signals

(The factory setting is different in accordance with the actuator model.) * For details on these parameters, refer to Chapter 6, “Parameter Settings.”

(Example) An example with a rod actuator with a 200-mm stroke, where the current-limiting value is set to 40%,

maximum travel in push-motion operation to 20 mm, and successful contact range to between 180 and 185 mm, is explained. Under No. 1 in the position table, enter “160” (mm) in the “Position” field, “40” (%) in the “Push” field, “30” mm in the “Positioning band” field, “185” (mm) in the “Zone +” field, and “180” (mm) in the “Zone –” field.

Example of position table

Position

[mm]

Push

[%]

Positioning band [mm]

Zone +

[mm]

Zone –

[mm]

Comment

Rear end (Standby position)

Front end

Intermediate point

Operation timings

PLC processing 1: The rear end move command signal (ST0) and intermediate point move command signal (ST2)

turn OFF, and the front end move command signal (ST1) turns ON.

Operation: [1] The actuator starts moving and upon reaching the front end (160 mm), the actuator

decelerates to the push speed and continues moving at the new speed.

When the actuator contacts the work and the “push-motion completion” condition is satisfied,

the front end positioning complete output (PE1) turns ON.

If the stopped position is between 180 and 185 mm, the zone output signal turns ON. PLC processing 2: When the zone output signal turns ON to indicate that the work has been successfully contacted,

the sequence processing is performed in a “condition where the work is being pushed.” Once the sequence processing is completed, the front end move command signal (ST1) turns OFF and the rear rend move command signal (ST0) turns ON.

[2] When the actuator starts moving toward the rear end, the front end positioning complete

output (PE1) turns OFF and the zone output signal also turns OFF temporarily. Once the

actuator returns to the position corresponding to 100 mm, the zone output signal turns ON

again. When the actuator reaches the rear end thereafter, the rear end positioning complete

output (PE0) turns ON. PLC processing 3: To issue a command to peripheral equipment while the actuator is returning to the rear end, in

order to reduce the tact time, you can use the zone output signal as a trigger signal (the signal turns ON once the actuator has returned to the position corresponding to 100 mm).

* If the zone output signal dose not turn ON when the front end positioning complete output (PE1) is ON, the condition

should be interpreted as “missed work” or “abnormal work installation position.”

Front end move

command input (ST1)

Rear end move

command input (ST0)

5. Operation Using I/O Signals

Front end positioning

complete output (PE1)

Rear end positioning

complete output (PE0)

Zone output

Speed

Sequence

processing

Work

+ direction – direction

Rear end

Front end

command position

contact

Stop position upon

Time

Rear end

Positioning band

The correlation diagram of current-limiting value [%] and push force [N] is shown below for each actuator. Note: For the specific data with the RCP3, check the operation manual for the RCP3.

z Slider Type

(1) SA5C/SA6C/SS7C type (2) SA7C type

Push force (N) Push force (N)

5. Operation Using I/O Signals

Current-limiting value (%) Current-limiting value (%)

Low-speed type

(lead: 3 mm)

Push force (N) Push force (N)

Current-limiting value (%) Current-limiting value (%)

Medium-speed type

(lead: 6 mm)

High-speed type

(lead: 12 mm)

Low-speed type

(lead: 4 mm)

Medium-speed type

(lead: 8 mm)

High-speed type

(lead: 16 mm)

Push force (N)

Current-limiting value (%) Current-limiting value (%)

Caution: Accuracy of push force while the actuator is standing still is not guaranteed. The above figures should be

used for reference purposes only. Take note that if the push force is too small, the actuator may malfunction during push-motion operation due to slide resistance, etc. The maximum current-limiting values are as shown in the graphs above. The minimum current-limiting values should be at least 20%.

Push force (N)

(3) SS8C type

Push force (N) Push force (N) Push force (N)

Low-speed type

(lead: 5 mm)

Current-limiting value (%)

Medium-speed type

(lead: 10 mm)

Current-limiting value (%)

High-speed type

(lead: 20 mm)

5. Operation Using I/O Signals

Current-limiting value (%)

Caution: Accuracy of push force while the actuator is standing still is not guaranteed. The above figures should be

z Rod Type

(1) RA2C type (2) RA3C type

Push force (N)

Current-limiting value (%)

5. Operation Using I/O Signals

Low-speed type

(lead: 2.5 mm)

Push force (N) Push force (N)

Current-limiting value (%)

Medium-speed type

(lead: 5 mm)

Current-limiting value (%)

Caution: Accuracy of push force while the actuator is standing still is not guaranteed. The above figures should be

(3) RA4C type (4) RA6C type

Low-speed type

(lead: 2.5 mm)

Push force (N)

Current-limiting value (%)

Medium-speed type

(lead: 5 mm)

Push force (N)

Low-speed type

(lead: 4 mm)

Current-limiting value (%)

Medium-speed type

(lead: 8 mm)

5. Operation Using I/O Signals

Current-limiting value (%)

High-speed type

(lead: 10 mm)

Push force (N)

Current-limiting value (%)

Caution: Accuracy of push force while the actuator is standing still is not guaranteed. The above figures should be

Push force (N)

Current-limiting value (%)

High-speed type

(lead: 16 mm)

Current-limiting value (%)

5.3.8 Examples of Tact Time Reduction Combining Zone Outputs and 3 Stop Points

This section explains how the tact time is reduced differently between an application with two stop points only, and an application with three stop points where zone output signals are also used.

z 2 Stop Points

Rear end Front end Front end Rear end

Assume that Machine M has completed processing. If there are two stop points, the vertical axis rises from the condition shown above, and thereafter the carry-in side cannot move toward the front end unless it is confirmed that the carry-out side is at the rear end.

5. Operation Using I/O Signals

Machine M stands by during the sequence of “Carry-out side drops → Carry-out side rises → Carry-out side moves backward → Carry-out side is confirmed to be at the rear end → Carry-in side moves forward → Carry-in side is confirmed to be at the front end → Carry-in side drops → Carry-in side rises.” Because there are only two stop points, the up/down heights must also be aligned between the actuators.

z 3 Stop Points Combined with Zone Output Signals

Rear end Front end Front end Rear end

[Carry-out actuator] [Carry-in actuator]

Machine M

[Carry-out actuator]

Intermediate

point

Zone II

[Carry-in actuator]

Intermediate

point

Zone I

Machine M

If there are three stop points, the carry-in side can move to the intermediate point regardless of the condition of the carry-out side. Also, a desired passing point can be set using a zone output signal. In the above example, when the Zone I signal turns ON while the carry-out side is rising, Machine M becomes operable and the carry-out side can move backward. When the Zone II signal turns ON, the carry-in side can move forward. As both actuators can move independently, the tact time can be reduced. Because there are three stop points, there is no need to align the up/down heights between the actuators and a desired layout can be implemented. Control is also simple. When the carry-out side is inside the contact range (the Zone II signal is OFF), the carry-in side is moved to the intermediate point if currently at the top end with the chucks closed. If the Zone II signal turns ON during the aforementioned movement, the command is switched to one that moves the carry-in side toward the front end. Since the carry-in side moves all the way to the front end, the tact time can be further reduced.

(Reference) Timing Charts and Example of Ladder Sequence Circuit

Rear end move command for carry-out side

Zone II

Intermediate point move command for carry-in side

Front end move command for carry-in side

Horizontal movement of

Stopped/standing by

carry-in side

Flat speed

5. Operation Using I/O Signals

Chuck closed

Intermediate

point

Front end Front end

Machine M is processing.

Top end R2

Rear end move

Processing Zone II

Automatic

operation

command for

carry-in side

Intermediate

point

The Zone II signal turns ON while moving to the intermediate point.

Intermediate point

move command for

carry-in side

Intermediate point

Automatic

operation

move command for

carry-in side

5.4 Power-saving Modes at Standby Positions

One general characteristic of pulse motors is that their holding current in standstill state is greater than AC servo motors. For this reason, in situations where the actuator remains standstill for a long time at a standby position, this controller provides several modes to reduce power consumption in such standstill state as part of the controller’s energy-saving function. Use these modes after confirming that they will not cause problems in any part of the system. The respective modes can be used for effective power-saving in the applicable situations specified below. Each mode provides different power-saving benefits, and is suitable for a different standstill condition.

The actuator is standing by while the servo is on after power on

In this case, you can select full servo control by Parameter No. 53 (Default standstill mode). Automatic servo-off cannot be selected. If this parameter is set to “1,” “2” or “3” by mistake, the setting will be ignored. (The setting in the “Standstill mode” field of the position table is ignored.)

The actuator is standing by upon completion of positioning to the target position set in the “Position” field under each position number

Meaning of the setting in the “Standstill mode” field of the position table and setting of Parameter No. 53:

5. Operation Using I/O Signals

All power-saving modes are disabled. (The actuator is completely stopped.) 0 Automatic servo-off mode. The delay time is defined by Parameter No. 36. 1 Automatic servo-off mode. The delay time is defined by Parameter No. 37. 2 Automatic servo-off mode. The delay time is defined by Parameter No. 38. 3 Full servo control mode 4

Setting

 Full Servo Control Mode

The pulse motor is servo-controlled to reduce the holding current. Although the specific level of current reduction varies in accordance with the actuator model, load condition, etc., generally the holding current drops to around a half to one-fourth. The servo remains on, so position deviation does not occur. The actual holding current can be checked in the current monitor screen of the PC software. Note that in a condition where external force is applied or depending on the stopped position, micro-vibration or noise may occur. Do not use this mode in applications where such micro-vibration or noise may be detrimental.

 Automatic Servo-off Mode

Do not use this mode at a standby position where such position deviation may be detrimental.

Move command

Automatic servo-off mode

Servo status

Servo on

(The green LED blinks.)

5. Operation Using I/O Signals

Actuator movement

Target position

In the standard type, the positioning complete signals (PE0, PE1, PE2) turn OFF. However, you can set the applicable parameter to keep these signals ON in conditions where allowing the positioning complete signals to turn OFF will cause problems due to the sequence circuit of the PLC.

Setting of Parameter No. 39

(Positioning complete signal output mode)

0 [PEND] When the servo is off, the positioning complete signal turns OFF

unconditionally. Even when the next move command is issued and the servo turns on again, the signal will remain OFF because the actuator has already started moving to the next target position.

1 [INP] Even when the servo is off, the positioning complete signal turns ON if the

current position is close enough to the target position, or specifically inside the range corresponding to the value set in the “Positioning band” field of the position table. The signal turns OFF if the current position is outside this range.

(Note) The factory setting is “0.”

Positioning complete signal (PE0, PE1, PE2) state

Delay time after completion of positioning until the servo turns off (sec) This delay time is set by a parameter.

Warning: If the next move command is an incremental move command (via constant pitch feed), never use automatic

servo-off. The current position may deviate slightly as the servo turns on.

Caution: In push-motion operation, both the full servo control mode and automatic servo-off mode are not effective if

the work has been contacted successfully. They are effective when the actuator has missed the work. As a basic rule of thumb, do not use either the full servo control mode or automatic servo-off mode in push-motion operation.

5. Operation Using I/O Signals

5.5 Using Rotary Actuators in Multi-rotation Specification

Rotary actuators of multi-rotation specification models can be set to operate in the multi-rotation mode or limited-rotation mode using a parameter.

5.5.1 How to Use

(1) Homing

When a homing command is issued, a signal of the limit switch located in the home direction is detected. Once a limit switch signal is detected, the actuator reverses its direction. Thereafter, the actuator moves until a limit switch signal is no longer detected, and then moves further by the distance specified in Parameter No. 22, “Home offset,” upon which the homing is completed.

(2) Operation commands

5. Operation Using I/O Signals

Limited-rotation specification (Normal mode [Selected by parameter No. 79]) Push-motion operation permitted Push-motion operation inhibited

Absolute coordinate specification - 0.15° to 360.15° Absolute coordinate specification 0.00° to 359.99°

Relative coordinate specification - 360.15° to 360.15° Relative coordinate specification - 360.00° to 360.00°

Multi-rotation specification (Index mode [Selected by parameter No. 79])

Note

Pay attention to the PIO pattern parameter for the following controllers. Each controller does not support relative coordinate specification in the PIO pattern specified below:

[1] PCON-C/CG: PIO pattern = 5 (User parameter No. 25) [2] PCON-CY: PIO pattern = 0 (User parameter No. 25)

• Rotational axes of simple absolute unit specification do not support the index mode. Accordingly, the multi-rotation specification cannot be selected for these axes.

Applicable Models

Actuators

RCP2-RTBL-I-28P-20-360-* PCON-C-28PI-* RCP2-RTBL-I-28P-30-360-* PCON-CG-28PI-* RCP2-RTCL-I-28P-20-360-* PCON-CY-28PI-* RCP2-RTCL-I-28P-30-360-*

Controllers

PCON-SE-28PI-*

6. Parameter Settings

6.1 Parameter List

The parameters are classified into the following four types depending on their function: Types:

a: Parameter relating to actuator stroke range b: Parameter relating to actuator operating characteristics c: Parameter relating to external interface d: Servo gain adjustment

No. Type Symbol Name Unit Factory default

1 a ZONM Zone limit 1 + side mm Effective length of the actuator 2 a ZONL Zone limit 1 – side mm Effective length of the actuator 3 a LIMM Soft limit + side mm Effective length of the actuator 4 a LIML Soft limit – side mm Effective length of the actuator 5 a ORG Home direction [0: Reverse / 1: Forward] - (As specified at the time of order) 6 b PSWT Push-motion completion judgment time msec 255 7 d PLG0 Servo gain number - Set individually in accordance with the actuator characteristics. 8 b VCMD Default speed mm/sec Set individually in accordance with the actuator characteristics. 9 b ACMD Default acceleration/deceleration G Set individually in accordance with the actuator characteristics.

10 b INP Default positioning band (in-position) mm 0.10

12 b SPOW

13 b ODPW Current-limiting value during homing % Set individually in accordance with the actuator characteristics. 16 c BRSL SIO communication speed bps 38400

6. Parameter Settings

17 c RTIM

18 B LS Home sensor input polarity - Set individually in accordance with the actuator characteristics.

21 c FPIO

22 a OFST Home offset mm Set individually in accordance with the actuator characteristics. 23 a ZNM2 Zone limit 2 + side mm Effective length of the actuator 24 a ZNL2 Zone limit 2 – side mm Effective length of the actuator 25 c IOPN PIO pattern selection - 0 [Proximity switch type]

28 b PHSP1

29 b PHSP2 Excited phase signal detection time msec Set individually in accordance with the actuator characteristics. 31 d VLPG Speed loop proportional gain - Set individually in accordance with the actuator characteristics. 32 d VLPT Speed loop integral gain - Set individually in accordance with the actuator characteristics. 33 d TRQF Torque filter time constant - Set individually in accordance with the actuator characteristics. 34 b PSHV Push speed mm/sec Set individually in accordance with the actuator characteristics. 35 b SAFV Safety speed mm/sec 100 36 b ASO1 Automatic servo-off delay time 1 sec 0 37 b ASO2 Automatic servo-off delay time 2 sec 0 38 b ASO3 Automatic servo-off delay time 3 sec 0

39 c FPIO

42 b FPIO Enable function [0: Enable / 1: Disable] - 1 [Disable] 43 b AIOF Home check sensor input polarity - (As specified at the time of order) 45 c SIVM Silent interval multiplication factor times 0 [Multiplication factor disabled] 46 b OVRD Speed override % 100 53 b CTLF Default standstill mode - 0 [Complete stop] 77 b LEAD Ball screw lead - Set individually in accordance with the actuator characteristics. 78 b ATYP Axis operation type - Set individually in accordance with the actuator characteristics. 79 b ATYP Rotational axis mode selection - Set individually in accordance with the actuator characteristics. 80 b ATYP Shortcut selection for rotational axis - Set individually in accordance with the actuator characteristics. 83 b ETYP Absolute unit [0: Do not use / 1: Use] - Set individually in accordance with the actuator characteristics.

(Note) The parameter numbers are shown in the PC software, but not on the teaching pendant.

Missing numbers are not used and therefore skipped. The classification symbols are provided for the sake of convenience and are not shown either in the PC software or on the teaching pendant.

Current-limiting value at standstill after positioning

Minimum delay time for slave transmitter activation

Servo-on input disable selection [0: Enable / 1: Disable]

Default direction of excited phase signal detection [0: Reverse / 1: Forward]

Positioning complete signal output mode [0: PEND / 1: INP]

% Set individually in accordance with the actuator characteristics.

msec 5

- 0 [Enable]

- Set individually in accordance with the actuator characteristics.

- 0 [PEND]

6.2 Detail Explanation of Parameters

If you have changed any parameter, be sure to restart the controller via a software reset or reconnect the controller power.

6.2.1 Parameters Relating to Actuator Stroke Range

z Soft Limits (No.3/4 LIMM/LIML)

Set the + soft limit in parameter No. 3 and – soft limit in parameter No. 4. Both parameters have been set to the effective actuator length at the factory. Change the parameter settings if necessary, such as when an obstacle is present and collision between the actuator and obstacle must be prevented or when the actuator must be operated beyond the effective length. Exercise due caution when setting these parameters, as wrong settings will cause collision with the mechanical end. The minimum setting unit is 0.01 mm. (Note) To change these parameters, set values corresponding to positions that are 0.3 mm wider than the desired effective

range.

Example) Set the effective range to between 0 and 80 mm

Parameter No. 3 (+ side): 80.3 Parameter No. 4 (– side): -0.3

Soft limits set in the controller

6. Parameter Settings

pprox. 0.3 mm

pprox. 0.1 mm

Effective range

pprox. 0.1 mm

Jogging/inching range permitted after homing

pprox. 0.3 mm

z Home Direction (No.5 ORG)

If not specified by the user, the home direction is set to the motor side before shipment. If you must change the home direction after the actuator has been assembled to your equipment, change the setting of parameter No. 5. Also change the parameters for home offset, soft limits and default direction of excited phase signal detection, if necessary.

Caution: Rod-type actuators do not permit reversing of the home direction.

z Home Offset (No.22 OFST)

Parameter No. 22 has been set to an optimal value at the factory so that the distance from the mechanical end to home will remain constant. The minimum setting unit is 0.01 mm. This parameter can be adjusted in the following conditions: [1] Align the actuator’s home with the mechanical home on the equipment after the actuator has been assembled to the

equipment. [2] Set the home position again after reversing the factory-set home direction. [3] Correct the minor position deviation that has generated after the actuator was replaced.

Caution: If you have changed the home offset, the soft limit parameters must also be reviewed.

z Zone Limits (1: No. 1/2 ZONM/ZONL 2: No. 23/24 ZNM2/ZNL2)

This parameter is not used with this controller. It applies to controllers of general-purpose and serial communication types. If this parameter is to be used, set the range within which the zone output signal (ZONE1 or ZONE2) will turn ON. The zone output signal turns ON when the current coordinate is between the (-) setting and (+) setting. For the ZONE1 signal, set the positive-side coordinate in Parameter No. 1 and negative-side coordinate in Parameter No. 2. For the ZONE2 signal, set the positive-side coordinate in Parameter No. 23 and negative-side coordinate in Parameter No. 24. The minimum setting unit is 0.01 mm.

Example) On an actuator with a 300-mm stroke, ZONE1 is used as an intermediate point LS in a range of 100 to 200

6. Parameter Settings

mm, while ZONE2 is used as a simple yardstick in a range of 270 to 275 mm. Parameter No. 1 (+ side): 200 Parameter No. 2 (– side): 100 Parameter No. 23 (+ side): 275 Parameter No. 24 (– side): 270

(Home)

ZONE1 turns ON. ZONE2 turns ON.

6.2.2 Parameters Relating to Actuator Operating Characteristics

Default Speed (No.8 VCMD)

The factory setting is the rated speed of the actuator. This value is recognized as speed data corresponding to each position number when a target position is entered for that position in the position table where speed is not yet entered. To decrease the default speed from the rated speed, change the value set in Parameter No. 8.

Default Acceleration/Deceleration (No.9 ACMD)

The factory setting is the rated acceleration/deceleration of the actuator. This value is recognized as acceleration/deceleration data corresponding to each position number when a target position is entered for that position in the position table where acceleration/deceleration is not yet entered. To decrease the default acceleration/deceleration from the rated acceleration/deceleration, change the value set in Parameter No. 9.

Default Positioning Band (In-position) (No.10 INP)

The factory setting is “0.10” mm. This value is recognized as positioning band data corresponding to each position number when a target position is entered for that position in the position table where positioning band is not yet entered. Increasing this parameter value causes the positioning complete signal to output more quickly. If necessary, change the value set in Parameter No. 10.

Caution: For the positioning band, set the value greater than that of the encoder resolution.

Setting it smaller may cause a servo error.

Current-limiting Value during Homing (No.13 ODPW)

Before shipment, this parameter is set to a current level appropriate for the standard specification of the actuator. Increasing this parameter value increases the homing torque. This parameter need not be changed in normal conditions of use. However, if the actuator is used in vertical orientation and the slide resistance increases due to the affixing method, load condition, etc., homing may complete before the correct position. In this case, the value set in Parameter No. 13 must be increased. (As a guide, the setting should not exceed 100% for the RXA type or 75% for all other types.)

6. Parameter Settings

Current-limiting Value at Standstill after Positioning (No.12 SPOW)

Before shipment, this parameter is set to a current level appropriate for the standard specification of the actuator. Increasing this parameter value increases the holding torque. This parameter need not be changed in normal conditions of use. If the actuator receives large external force while standing still, however, hunting will occur. In this case, the value set in Parameter No. 12 must be increased. (As a guide, the setting should not exceed 100% for the RA3C/RGD3C type or 75% for all other types.)

Speed Override (No.46 OVRD)

Use this parameter if you want to move the actuator at a slow speed to prevent danger during test operation. When issuing move commands from the PLC, the movement speed set in the “Speed” field of the position table can be overridden based on the value set in Parameter No. 46. Actual movement speed = [Speed set in the position table] x [Value of Parameter No. 46] Example) Value in the “Speed” field of the position table 500 (mm/s)

Value of Parameter No. 46 20 (%)

Under the above settings, the actual movement speed becomes 100 mm/s. The minimum setting unit is 1 (%), and the input range is 1 to 100 (%). The factory setting is “100” (%). (Note) This function is not effective on move commands issued from the PC or teaching pendant.

100

z Default Direction of Excited Phase Signal Detection (No.28 PHSP)

The excited phase is detected when the servo is turned on for the first time after turning on the power. This parameter defines the direction of this detection. This parameter need not be changed in normal conditions of use. However, if the actuator is contacting a mechanical end or any obstacle when the power is turned on and cannot be moved by hand, change the direction of detection to one in which the motor can be driven easily. To do this, set the value of Parameter No. 28 to either “0” or “1.” If the direction of detection is to be the same as the home direction, specify the same value currently set in Parameter No. 5, “Home direction.” To set the direction opposite to the home direction, specify the value different from the one currently set in Parameter No. 5, “Home direction.”

(Example 1) The power is turned on when the slider is contacting the bottom mechanical end in a configuration where the

motor is positioned at the top.

6. Parameter Settings

(Example 2) The power is turned on when the slider is contacting the bottom mechanical end in a configuration where the

motor is positioned at the bottom.

Top

Bottom

Top

Bottom

Home direction

Home position

Set to the same value.

Direction of excited

phase signal detection

The slider is contacting the bottom mechanical end.

Direction of excited

phase signal detection

Home position

The slider is contacting the bottom mechanical end.

Home direction

Set to different values.

z Excited Phase Signal Detection Time (No.29 PHSP)

The excited phase is detected when the servo is turned on for the first time after turning on the power. This parameter defines the time of this detection. Before shipment, this parameter is set to a detection time appropriate for the standard specification of the actuator, and thus the setting need not be changed in normal conditions of use. Should an excitation detection error or abnormal operation occur when the servo is turned on for the first time after turning on the power, you can try changing the detection time set in Parameter No. 29 as a possible countermeasure. Before changing this parameter, contact IAI.

z Safety Speed (No.35 SAFV)

This parameter defines the feed speed during manual operation. The factory setting is “100” [mm/sec]. To change the speed, set an optimal value in Parameter No. 35. Since the maximum speed is limited to 250 mm/sec, set the safety speed to below this level.

z Automatic Servo-off Delay Time (No.36 ASO1/ No.37 ASO2/ No.38 ASO3)

This parameter defines the delay time after positioning is completed until the servo turns off automatically when the “Standstill mode” field in the position table is set to any value from “1” to “3” (the automatic servo-off mode is enabled) or the setting of Parameter No. 53 (Default standstill mode) is set to any value from “1” to “3” (the automatic servo-off mode is enabled). Meaning of set value: If this parameter is set to “1,” T takes the value of Parameter No. 36.

If this parameter is set to “2,” T takes the value of Parameter No. 37. If this parameter is set to “3,” T takes the value of Parameter No. 38.

The factory setting is “0” [sec].

Move command

Automatic servo-off mode

(The green LED blinks.)

Servo status

Servo on

Actuator movement

6. Parameter Settings

Target position

Delay time after completion of positioning until the servo turns off (sec)

z Default Standstill Mode (No.53 CTLF)

This parameter defines the power-saving mode to be applied when the standby time while the servo is on is long after power on. You can select the full servo control mode. * Even when the automatic servo-off mode is selected, the selection will be ignored. In Parameter No. 53, define whether or not to implement power-saving.

Setting All power-saving modes are disabled 0 Automatic servo-off mode. The delay time is defined by Parameter No. 36. 1 Automatic servo-off mode. The delay time is defined by Parameter No. 37. 2 Automatic servo-off mode. The delay time is defined by Parameter No. 38. 3 Full servo control mode 4 The factory setting is “0” [Disable].

Auto servo-off mode

Full servo control mode

z Push Speed (No.34 PSHV)

This parameter defines the push speed that applies after the target position has been reached in push-motion operation. Before shipment, a default speed appropriate for the actuator characteristics is set. Depending on the material and shape of the work, etc., set an appropriate speed in Parameter No. 34. Note that, while the maximum speed varies according to the actuator, it should not exceed 20 mm/sec even with the high-speed type. Set a push speed below the maximum speed.

Caution: It is recommended that the push speed be set to 5 mm/sec or above to reduce the effect of varying push

z Push-motion Completion Judgment Time (No.6 PSWT)

6. Parameter Settings

This parameter is used as a condition for determining if the work is contacted and push-motion operation is completed. Specifically, push-motion operation is deemed complete if the current-limiting value set in the position table has been maintained for the time set in Parameter No. 6. Depending on the material and shape of the work, etc., set an optimal value in combination with the current-limiting value. The minimum setting unit is 1 msec, and the maximum value is 9,999 msec. The factory setting is “255” [msec]. (Note) The following shows a case in which the work has shifted and current has changed during push-motion completion

judgment. In this example, the judgment time is set to 255 msec.

Speed

force.

Push current

Push speed

Work

Positioning band

Start position Target position Counting starts

Count to 200

Decrement to 180

Count to 255

Completion of push-motion operation is determined.

If the push current is maintained for 200 msec and then drops for 20 msec thereafter, the counter is decremented by 20. Upon recovery of the push current, counting resumes from 180. If the push current is maintained for 75 msec, the counter will have counted up to 255 and thus completion of push-motion operation is determined. In this case, the judgment requires a total of 295 msec.

z Enable Function (No.42 FPIO)

Whether to enable or disable the deadman switch function on the ANSI-type teaching pendant is set in Parameter No. 42. * The ANSI-type teaching pendant is currently under development.

Setting

Enable (Use) 0

Disable (Do not use) 1

The factory setting is “1” [Disable].

z Home Check Sensor Input Polarity (No.43 AIOF)

The home check sensor is not included in the standard specification, but it can be installed as an option. This parameter need not be changed in normal conditions of use. To change the factory-set mode, change the value of Parameter No. 43.

Definition of settings: 0 (Standard specification; no sensor)

1 (Use the home check sensor, and the sensor polarity conforms to “contact a” logic) 2 (Use the home check sensor, and the sensor polarity conforms to “contact b” logic)

[Explanation of operation] [1] When a homing command is issued, the actuator moves until it contacts a mechanical end, upon which a home check

sensor signal is detected.

[2] Next, the actuator reverses its direction and stops at the home position. [3] If the home check sensor signal has changed its signal state, the controller determines that the homing was completed

successfully. If the signal state has not changed, the controller recognizes “position deviation.” Accordingly, the controller generates a “home sensor non-detection error” and outputs an alarm signal.

6. Parameter Settings

Mechanical end

Home check sensor

Power input position

Home position

z Home Sensor Input Polarity (No. 18, LS)

This parameter is supported by the rotational axes of RCP2-RTB/RTC types adopting the home sensor method. Definition of settings: 0 (Sensor not used)

1 (Sensor polarity of contact a) 2 (Sensor polarity of contact b)

z Ball Screw Lead (No. 77, LEAD)

This parameter defines the ball screw lead. Before shipment, a default value appropriate for the actuator characteristics is set.

z Axis Operation Type (No. 78, ATYP)

This parameter defines the type of the actuator used. Definition of settings: 0 (Linear axis)

1 (Rotational axis)

z Rotational Axis Mode Selection (No. 79, ATYP)

If the axis operation type (No. 78) is set to “Rotational axis,” selecting the index mode fixes the current value to within a range of 0 to 359.99. If the index mode is selected, short-cut control is enabled. Definition of settings: 0 (Normal mode)

1 (Index mode)

6. Parameter Settings

Note: Push-motion operation cannot be performed in the index mode. Even if data is set in the “Push” field of the

position data, in the index mode the data becomes invalid and the actuator moves as normal. Also in the index mode, the positioning band corresponds to the default positioning band set by a parameter.

IAI America PCON-CY User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Please Read Before Use

CAUTION

CE Marking

Table of Contents

1. Overview

1.1 Introduction

1.2 Differences from Air Cylinders in Control Functions

1.3 How to Read Model Name

1.4 System Configuration

1.5 Steps from Unpacking to Adjustment by Trial Operation

1.6 Warranty

2. Specifications

2.1 Basic Specifications

2.2 Name and Function of Each Part of the Controller

2.3 External Dimensions

3.1 Installation Environment

3. Installation and Wiring

3.2 Supplied Voltage

3.3 Noise Elimination Measures and Grounding

3.4 Heat Radiation and Installation

3.5 External Connection Diagram

3.6 Wiring the Power Supply

3.7 Wiring the Brake Forced-release Switch

3.8 Wiring the Emergency Stop Circuit

3.9 Connecting the Actuator

3.10 Connecting the I/O Flat Cable

3.11 Connecting the Communication Cable

4.1 Details of the Position Table

4. Position Table Settings

4.2 Notes on the ROBO Gripper

5.1 Interface Circuit

5. Operation Using I/O Signals

5.2 Proximity Switch Type

5.3 Standard Type

5.4 Power-saving Modes at Standby Positions

5.5 Using Rotary Actuators in Multi-rotation Specification

6.1 Parameter List

6. Parameter Settings

6.2 Detail Explanation of Parameters