IAI America RCM-GW-PR User Manual

ProfiBus Gateway Unit RCM-GW-PR

Operation Manual, Second Edition

CAUTION

Note on Connecting a PC or Teaching Pendant to the Gateway Unit Grounded via the Positive Terminal of Its 24-V Power Supply

If the positive terminal of the gateway unit’s 24-V power supply is grounded, use a SIO converter as shown below to connect a teaching pendant or PC to the gateway unit. In this case, do not connect the FG of the SIO converter.

Teaching pendant

Do not connect the FG.

24-V power

supply

PC, etc.

PC software

RS232 connection type <Model number: RCM-101-MW> USB connection type <Model number: RCM-101-USB> * The cables are supplied with the

PC software.

Controller link cable Model number: CB-RCB-CTL002

SIO converter (optional) (with built-in terminal resistor) Model number: RCB-TU-SIO-A (B)

* One e-CON connector, one junction

and one terminal resistor are supplied with each controller link cable.

Gateway unit

e-CON connector (3-1473562-4 by AMP) Junction (5-1473574-4 by AMP)

Terminal resistor R = 220Ω

If the positive terminal of the gateway unit’s 24-V power supply is grounded, the gateway unit cannot be connected directly to a teaching pendant or PC. If a teaching pendant or PC is connected directly to the gateway unit grounded in this cond ition, the power-supply circuit may be shorted and the PC/teaching pendant may be damaged.

This teaching

pendant cannot be

used this way.

Cannot be connected directly.

CAUTION

Gateway unit

24-V power

supply

PfofiBus Gateway

Table of Contents

1. Overview ................................................................................................................... 1

1.1 ProfiBus Gateway Unit ................................................................................................................ 1

1.2 What Is ProfiBus? .................................................................................................................. ...... 2

1.3 Application Example of Gateway Unit ................................................................. ........................ 3

1.4 Features and Key Functions ....................... ................... ................... .................. ....................... .. 4

1.4.1 Features ............................................ ............... ............... ................... ............... .......... ... 4

1.4.2 Key Functions ......................................... ... .... .... .... .... ....... .... .... .... ... .... ........ ... .... .... .... ... ...... 4

1.5 Description of Model Name ......................................................................................................... 7

1.6 Accessories ..................................... ..................................... .................................. ................... .. 7

2. Specifications and Name of Each Part ...................................................................... 8

2.1 General Specifications ................. ................... ................... ...................... ................... ................. 8

2.2 External Dimensions .................................................................................................................... 9

2.3 Name and Function of Each Part ....... .... .... .... .... ... ........ .... ... .... .... .... ....... .... .... ... .... .... .... ....... .... 10

3. Installation and Noise Elimination Measures ........................................................... 16

3.1 Installation Environment. ........................................................................................................... 16

3.2 Supply Voltage ............................................... .... ... .... .... .... ... ........ .... ... .... .... .... ....... .... .... ........... 16

3.3 Noise Elimination Measures and Grounding ............................................................................. 16

3.4 Installation.................................................................................................................................. 18

4. Wiring ...................................................................................................................... 19

4.1 Overall Configuration .......................................... ................................................................... .... 19

4.2 I/O Signals of Gateway Unit ...................................................................................................... 22

4.3 Design of SIO Communication Network (SIO Communication) ................................................ 25

4.3.1 Wiring ........................................ ........ ....... ........ ....... ............ ....... ........ ....... ........ ........... 25

4.3.2 Axis Number Setting ............................. ........................................................................ 33

4.4 How to Connect the Teaching Tool When the Positive Terminal of the 24-V Power Supply Is

Grounded ................................................................................................................................... 34

5. Address Configuration of Gateway Unit ................................. .. ... .. .. .. .. .................... 35

5.1 Position Number Specification Mode ................................... ..................................................... 35

5.1.1 Overall address configuration ........................... ...................... ................... ................... 36

5.1.2 Gateway Control/Status Si gnals ............................................. ................... ................... 37

5.1.3 Assignment for Each Axis ............................................................................................ 40

5.2 Direct Numerical Specification Mode ........................................................................................ 43

5.2.1 Overall Address Configuration .......... .... ... .... .... .... ... .... .... .... ... .... .... .... .... ... .... .... .... ... .... 44

5.2.2 Gateway Control/Status Si gnals ............................................. ................... ................... 46

5.2.3 Assignment for each axis ............................................................................................. 49

5.3 Command Specification Mode...................................................... .... ... .... .... .... .... ....... .... .... .... ... 53

5.3.1 Overall Address Configuration .......... .... ... .... .... .... ... .... .... .... ... .... .... .... .... ... .... .... .... ... .... 55

5.3.2 Gateway Control/Status Si gnals ............................................. ................... ................... 57

5.3.3 Assignment for Each Axis ............................................................................................ 60

5.3.4 Command Area ............................................................................................................ 65

6 Communication Signal Details ................................................................................ 75

6.1 Overview of Communication Signal Timings ............................................................................. 75

6.2 Communication Signals and Operation Timings ....................................................................... 77

6.3 Basic Operation Timings ................. ....... .... .... ... .... .... .... ....... .... .... .... ... .... ........ ... .... .... .... .... ....... 85

6.4 Command Transmission .................................................................................. ................... ....... 95

PfofiBus Gateway

7. Building Your Network System ................................................................................ 96

7.1 Procedure ........................................ ................................................................... ....................... 96

7.2 Setting the Controller .......................................... ....... .... .... ... .... .... .... ....... .... .... .... ... .... ............... 97

7.3 Setting the Gateway Unit and PLC Master ..................................................................... ........... 99

7.4 PLC Address Assignment ................................................................. ...................... ................. 100

8. Supported S7 Function Blocks/Functions........................... .. .. .. ... .. .. .. .. .. ... .. .. .. .. .. ... 106

8.1 GW_CTL_11 ............................................................................................................................ 107

8.2 RC_NVC_11 ..................................................................................................................... ....... 108

8.3 RC_ESYNC_00 ................................... ........................................................................... ......... 109

8.4 RC_BCMOVP_00 .................................................................................................................... 110

8.5 RC_READ_00 ........................................ ........ ........... ........ ....... ........ ....... ............ ....... ............. 111

8.6 RC_WRITE_00 ................................................................................................................... ..... 112

8.7 RC_PROM_00 ......................................................................................................................... 113

8.8 RC_PMSL_00 .......................................................................................................................... 113

Appendix 1. Sample Programs for S7-300 .............................................. ... .. .. .. .. .. ... 114

Appendix 2. Supply Format and Use Procedure of FB/FCt ..................................... 117

PfofiBus Gateway

1. Overview

1.1 ProfiBus Gateway Unit

The ProfiBus Gateway Unit (hereinafter referred to as “ProfiBus Gateway” or “Gateway Unit”) is used to connect a ProfiBus communication protocol network on which a host programmable controller (hereinafter “PLC”) operates, to a SIO communication sub-network (Modbus communication protocol) linking ROBO Cylinder controllers.

The physical standard to which the SI O com mu nic ation network conforms is RS -48 5, an d the s lav e addresses on this network are 1 through 16.

All data exchanged between the ProfiBus communication network and the Modbus SIO communication network are tentatively saved in the internal memory of the Gateway Unit, and then transferred cyclically. The PLC recognizes the G ateway Unit as a remote I/O device.

The Gateway Unit supports PCON-C/CG/SE, ACON-C/CG/SE, SCON-C and ERC2-NP/PN/SE controllers.

* “Gateway” is a term used in communication networks, referring to a device that converts data to/from

different media and protocols to enable communication be tween networks.

* ProfiBus protocols include ProfiBus-DP for factory automation (FA) and ProfiBus-PA for process

automation (PA). Of these two protoco ls, this ma nua l covers ProfiBus-DP. Accordingly, “Pro fiB us ” refers to ProfiBus-DP throughout this manual.

Caution

This manual only describes the controls feasible using the Gateway Unit. In the event of any conflict between this manual and the operation manual for the controller, the content of this manual will prevail. Refer to the operation manual for each controller for any function, parameter setting, alarm detail or any other information not described in this manual.

PfofiBus Gateway

1.2 What Is ProfiBus?

(1) FA communication system

In FA communication, each communication specification varies depending on the communicating equipment, type of information, and purp os e of c omm unication, among others. In general, however, the FA communication system is divided into the information level, controller level and field level, as shown below.

level

Information

FA computer

Controller level Field level

Device level

Robot

Remote

I/O

Motor driver

Installed

instrument

Solenoid

valve

Sensor level

Limit

switch

(2) Information level

Also called “PLC upper network.” The main purpose of this network level is to transmit production information, etc., to information terminals. Ethernet is the most commonly used communication method for the information level.

(3) Controller level

Also called “Inter-PLC network.” This network level often handles real-time information of production lines.

(4) Field level

Also called “PLC lower network.” This network level is mainly used to save wirings for systems controlled by a single controller. In this sense, this network is regarded as a means for “wire-saving communication.” The field level is largely divided into the device level and the sensor level.

Key open network

PfofiBus Gateway

(5) ProfiBus

ProfiBus is an open field network most commonly used in the world today. It was first established under DIN 19245 (German standard) in Germany in 1989, and standardized under EN 50170 (European standard) in July 1996. In January 2000, ProfiBus became an international standard under IEC 61158. There are two ProfiBus protocols designed for different purposes: ProfiBus-DP for factory automation (FA), and ProfiBus-PA for process automation. This manual covers ProfiBus-DP. The key features of ProfiBus-DP are as follows: [1] A field network realizing complete multi-vendor connectivity [2] Able to send large amounts of data at high speed.

• Up to 244 bytes of data per device

• Maximum baud rate of 12 Mbps

[3] Up to 125 nodes can be connected.

* For details on ProfiBus, refer to the operation manuals for your master unit and PLC.

Along with this manual, also read the operation manual for each controller connected. This ProfiBus Gateway cannot be used in any way not described as feasible in this manual. To prevent malfunction, the customer is also advised not to use settings, wirings and other uses other than those described as feasible in this manual.

1.3 Application Example of Gateway Unit

The network illustrated below gives an application example of the Gateway Unit.

Remote I/O

station

CPU

unit

ProfiBus Gateway

(Remote I/O station)

ProfiBus

unit (master station)

Remote I/O

station

SIO communication network (Modbus)

Remote I/O

station

PfofiBus Gateway

1.4 Features and Key Functions

1.4.1 Features

The ProfiBus gateway unit lets you select a desired operation mode from three modes including the position number specification mode, direct numerical specification mode and command specification mode.

(1) Position number specification mode

In this mode, a desired position number is specified to operate the actuator. Up to 16 axes can be connected. The position data, speed, acceleration/deceleration, etc., must be input to the position table beforehand. Although the input/output of various status signals and completed position number can be read, the current position cannot be monitored in this mode.

(2) Direct numerical specification mode

In the direct numerical specification mode, the position data, speed, acceleration/deceleration, positioning band and push-current limiting value are specified directly as numeric al values to operate the actuator. Various status signals can be input/output and current position data can be read. There are five patterns in the numerical specification mode, each accommodating a different number of connected axes. [1] Direct numerical specification mode/Up to 4 axes can be connected [2] Direct numerical specification mode/Up to 6 axes can be connected [3] Direct numerical specification mode/Up to 8 axes can be connected [4] Direct numerical specification mode/Up to 10 axes can be connected [5] Direct numerical specification mode/Up to 16 axes can be connected

(3) Command specification mode

In this mode, the actuator can be operated in one of two operation patterns: “positioner operation” in which a desired position number is specified to operate the actuator, and “simple direct operation” where only the position data is specified directly as a numerical value and all other items such as the speed, acceleration/deceleration, positioning band and push-current limiting value are specified via a position number. As for the axis configurations, these two operation patterns can be used separately or in combination. If the two patterns are combined, the axis numbers must be assigned sequentially from the axes used in positioner operation, followed by the axes used in simple direct operation. You can select the Large mode (160 input bytes, 160 output bytes), Middle mode (128 input bytes, 128 output bytes) or Small mode (64 input bytes, 64 output bytes) depending on the size of the assigned areas, and up to 16 axes can be connected.

1.4.2 Key Functions

A comparison table of key functions provided by the gateway unit in the respective modes is given on the following page. Use this table as a reference in conjunction with the explanation of each operation mode in Chapter 5.

Key function

Operation by position data specification X (P table specification) Direct specification of speed and acceleration/deceleration Direct specification of positioning band X (P table specification) Push-motion operation { (P table specification) Operation by position number specification Position table enabling Maximum number of storable position numbers Reading of completed position number Selection of controller PIO pattern X X { *2 X Zone (parameter) { (2) X { *3 X Position zone (P table) X X { *4 X Reading of various status signals Speed change during movement Operation at different acceleration and deceleration Monitoring of current position *5 X

Sending/receiving of commands/responses Reading/writing of P table data X X Reading of current position *6 X X Reading of alarm code X X

Command

Broadcasting X X Number of connectable axes 16 4 6 8 10 16 16 16 Maximum specifiable value of position data P table specification 9999.99 mm 9999.99 mm 9999.99 mm

Mode setting SW1 2 0 4 8 13 12 1 5 9 Gateway I/O bytes

Input 48 28 40 52 64 100 160 128 64

Output 48 52 76 100 124 196 160 128 64

Position number

specification mode

X (P table specification)

{ {

64 - 512 512

{

{ { { { { { { {

{ { {

X X

Direct numerical specification

mode

{ { {

{

X X

{

Positioner operation Simple direct operation

{ (P table rewriting) { (P table rewriting) X (P table specification) { (P table rewriting) X (P table specification)

{ (P table specification) { (P table specification)

Large mode Middle mode Small mode

Command specification mode

{

{ { {

{

{ (P table specification)

{ { {

{ { { { {

{

*1 P table: Position table *2 PIO patterns 0 to 4 can be selected. *3 PIO patterns 1 to 3 are not supported. *4 PIO pattern 3 is not supported. *5 In the current position monitoring function, the current position data is assigned to a gateway output signal.

Accordingly, the current position can be read directly from the PLC.

*6 Reading the current position means reading the current position data indirectly with the PLC issuing a read command to the gateway.

PROFIBUS Gateway

Command

ifi ti

PfofiBus Gateway

Next, the relationship of the number of positions supported by each controller under each PIO pattern, and the maximum number of positions that can be stored in the gateway unit, is explained. Take note that the number of positions may become subject to restrictions.

PIO pattern (Parameter No. 25) 0 1 2 3 4

ERC2

PCON ACON SCON

Operation type

Number of positioning points

Home return signal Zone signal

Standard

8 3 16 16 - 64

{ {

Solenoid

type

X X X X

P zone signal X X X

Position number specification mode

Positioner operation

Simple direct

Command

specification

Gateway control

operation

Operation type

Number of positioning points

Home return signal Zone signal

P zone signal

Position number specification mode

Positioner operation

Gateway control

Simple direct

Command

specification

operation

*1 *3

8 (0)

- X - - - - 512

Positioning

mode

Teaching

mode

64 64 256 512 7 64

{ { { { { { {

X X X

{ { {

64 64

64 (0)

64 (1)

- - - - - - 512

Zone

signal

type

{

*1 *3

16 (2)

256-point

mode

256

↓

64 *2

256 (2)

Position

zone type

X -

{

*1 *3

16 (3)

512-point

mode

- 64 64

Solenoid

mode 1

{ {

512

↓

7 64 64

64 *2

512 (3)

7 (4)

Dedicated

SIO

operation

64 (0)

Dedicated

SIO

operation

64 (0)

{ {

{

Maximum

number of

gateway

positions

512

Maximum

number of

gateway

positions

512

*1 In the operation mode based on position number specification, the number of positions is limited

according to the selected PIO pattern (parameter No. 25). (The gateway can handle more positions.)

*2 Since the gateway can handle 64 positions, the number of controller positions is limited. *3 In the case of a positioner operation axes operating in the command specification mode, the PIO

pattern selection parameter of the controller must correspond to the I/O pattern set by gateway control signals PPS0 to PPS2. The numbers of positions shown in parentheses ( ) indicate values set by PPS0 to PPS2.

1.5 Description of Model Name

Base model ProfiBus specification

Gateway Unit

1.6 Accessories

[1] Power-supply input connector plug 1 pc

MC1•5/4-ST-3•5 (Phoenix Contact)

[2] SIO communication connector plug 1 pc

MC1•5/6-ST-3•81 (Phoenix Contact)

PfofiBus Gateway

2. Specifications and Name of Each Part

2.1 General Specifications

Item Specification Power supply Current consumption 300 mA max.

Communication standard Group 2 only server

Communication specification Master-slave connection Bit strobe

Baud rate 9.6 kbps to 12 Mbps (Set automatically) Communication cable length (*1) 9.6 kbps 1500 m

ProfiBus specifications

Transmission path configuration IAI’s original multi-drop differential communication Communication method Half-duplex Synchronization method Asynchronous Transmission path type EIA RS485, 2-wire type Baud rate 230.4 kbps Error control method No parity bit, CRC (*2) Communication cable length Total cable length: 100 m max.

specifications

Communication cable Double shielded twisted-pair cable

SIO communication

Connected units 16 axes max. Ambient operating temperature Ambient operating humidity 85% RH or below (non-condensing) Operating ambience Free from corrosive or flammable gases, oil mist or pow der dust Storage temperature Storage humidity 90% RH or below (non-condensing)

Environment

Vibration durability 4.9 m/s2 (0.5 G) Protection class IP20 Weight 480 g or below

*1 Refer to the operation manuals for your master unit and PLC in the case of T-branch communication. *2 CRC: Cyclic Redundancy Check

A data error detection method commonly used in synchronous transmission.

24 VDC ± 10%

Insulated node of network powered operation type

Polling Cyclic

500 kbps 400 m

1.5 Mbps 200 m 3 Mbps 200 m

12 Mbps 100 m

(Recommended cable: HK-SB/20276 X L, 2P X AWG22 by Taiyo E lectric Wire & Ca ble)

0 to 40°C

-10 to 65° C

2.2 External Dimensions

(Installed dimension)

PfofiBus Gateway

2.3 Name and Function of Each Part

[1] Gateway Status LEDs

RUN: Normal G.ER: Error C.ER: ProfiBus controller error T.ER: SIO link error

[2] SIO communication status

LEDs TxD: Sending data RxD: Receiving data

[3] Mode setting switch

[4] Port switching input

PORT IN: Port switching input PORT N: N

[5] Controller communication lines

SDA: Communication line SDB: Communication line GND: Ground FG: Frame ground

[10] Port switch

ON: Port ON OFF: Port OFF

PfofiBus Gateway

[6] ProfiBus communication connector

[7] Termination switch

[8] Address setting switches

X10 and X1 (decimal, 2 digits)

[9] ProfiBus communication Status LEDs

ON: Online OFF: Offline ERR: Error

[11] Teaching pendant/PC connector

[12] Power-supply input connector

PfofiBus Gateway

[1] Gateway stat us LEDs

Indicated status Description

RUN Steady green The Gateway CPU is operating.

Unlit CPU operation is stopped. If this LED does not come on after turning on

the power, the Gateway is experiencing a CPU error.

G.ER Steady red The Gateway is experiencing a CPU error or major shutdown failure.

Unlit Normal state.

C.ER Steady red The ProfiBus module is experiencing an error or the Gateway CPU

cannot recognize the ProfiBus connection. (Check the ProfiBus communication stat us in [9].) Even if this LED is lit, the teaching pendant or PC software can still be connected as long as the RUN LED is lit.

Blinking red While the port is ON, this LED blinks at 1-second intervals.

Unlit Normal state.

T.ER Steady red All axes generated a communication error based on SIO communication

between the ProfiBus gateway and controller.

Blinking red At least one axis generated a communication error based on SIO

communication between the ProfiBus gateway and controller. (No response, overrun, flaming error or CR C

(*)

error)

Unlit Normal state.

* CRC: Cyclic Redundancy Check

A data error detection method commonly used in synchronous transmission.

[2] SIO communication status LEDs

These LEDs are used to check the communication status between the ProfiBus Gateway and the controller. Each LED blinks when the host PLC and controller are not communicating via the ProfiBus Gateway, or when the controller is communicating with the teaching pendant or PC software connected via the ProfiBus Gateway.

Indicated status Description

TxD Blinking green

Unlit

RxD Blinking green

Unlit

Sending data (ProfiBus Gateway → Controller) Not sending data (ProfiBus Gateway → Controller) Receiving data (Controller → ProfiBus Gateway) Not receiving data (Controller → ProfiBus Gateway)

PfofiBus Gateway

[3] Mode setting switch

This switch is used to set the operation mode of the ProfiBus gateway. Before operating this switch, turn off the ProfiBus gateway power. If any position between No. 1 and No. 5 is selected, the position table settings of the controller will become invalid.

SW1 turns ON when tilted to the right.

{: ON X: OFF

No.

4 3 2 1 Description Output Input

1 X X X X 2 X

{

{ {

5 6 X X

7 X X X 8 X

{

SW1 I/O bytes

{

X X

X X X

{

X X X

{

X X

{ {

Direct numerical specification mode/Up to 4 axes can be connected Direct numerical specification mode/Up to 6 axes can be connected Direct numerical specification mode/Up to 8 axes can be connected Direct numerical specification mode/Up to 10 axes can be connected Direct numerical specification mode/Up to 16 axes can be connected Position-number specification mode, maximum 16 axes

Command specification mode Large 160 160 Command specification mode Middle 128 128 Command specification mode Small 64 64

52 28

76 40 100 52 124 64 196 100

48 48

[4] External port switching input

The ON/OFF status of the teaching pendant/PC connector port can be switched using external signals (no-voltage cont act type). The connector port is enabled when the port switch [10] on the ProfiBus Gateway is OFF. When the input signal is ON, the port is also ON. (Refer to [10], “Port switch.”) PORT IN: Port control input PORT N: Port control input, N side Use an input current of 7 mA and external si gnals of no-voltage contact type

[5] Controller communication lines

This terminal is used to connect the communication lines to the SIO communication connector.

PfofiBus Gateway

[6] ProfiBus communication connector

This connector is used to connect the ProfiBus communication lines.

D-sub, 9-pin connector (female)

ProfiBus communication c onnector

Pin No. Signal name Description

1 NC Not connected 2 NC Not connected 3 B-Line Communication line B (RS485) 4 RTS Request to send 5 GND Signal ground (insulated) 6 +5V +5-V output (insulated) 7 NC Not connected 8 A-Line Communication line A (RS485) 9 NC Not connected

Housing Shield

Cable shield Connected to the frame.

The mating connector (cable end) is not supplied.

[7] Termination switch

A terminal resistor must be provided at the end of the ProfiBus trunk line to prevent bus reflection. Set the termination switch to the ON position when the ProfiBus Gateway is the terminal module. However, the switch should be set to the OFF position if an external termination connector is used. Set the switch to the OFF position if the Gateway is not the terminal module.

[8] Address setting switches

The two rotary switches are used to set a decimal node address in a range of 1 to 99. X10: Set the 10’s digit of the two-digit decimal address. X1: Set the 1’s digit of the two-digit decimal address. This switch is normally set to 2 for the master unit, and 3 or greater for the slave.

PfofiBus Gateway

[9] ProfiBus status LEDs

The three LEDs of (LINE-) ON, LINE-OFF and ERR on the front face of the board indicate the node status and network st atu s. (Th e re ma i ning LED is not used.) These LEDs illuminate in one of two colors (red or green), and each LED indicates a different monitored status, as shown in the table below.

LED name Color Indicated status Description (meaning of indication)

(LINE-) ON

LINE-OFF

ERR

Green

Red

Lit Online

Unlit Not online

Lit Offline

Unlit Not offline

Blinking at 1-Hz

frequency

Configuration error

Example: The I/O size determined by

Blinking at 4-Hz

frequency

Communication ASIC initialization error

Unlit No error

the mode setting switch [3] does not match the I/O size set by the configuration tool.

PfofiBus Gateway

[10] Port switch

This switch is used to enable the teaching pendant/PC connector (TP) (PORT ON = Start communication). Set this switch to the OFF position when connecting/removing the communication cable connector for teaching pendant or PC software. To use the teaching pendant or PC software, plug in the connector first, and then set the switch to the OFF position. (Also check the signal status of the port switching input [4].) Port switch ON: Power (24 VDC) is supplied to the teaching pendant. The emergency stop circuit

of the teaching pendant is enabled.

Port switch OFF: Power (24 VDC) to the teaching pendant is cut off. The emergency stop circuit of

the teaching pendant is disabled.

The baud rate between the teaching pendant or PC software and ProfiBus gateway can be set to a maximum of 115.2 kbps. For your information, the baud rate between the ProfiBus gateway and controller is fixed to 230.4 kbps.

When the port switch is turned ON, no ProfiBus communication error will generate, but the data exchange via SIO communication will stop. Accordingly, the PLC’s output signals (data) will no longer be output to the controller and the input signals (data) from the controller will remain as the values that were effective immediately before the port switch was turned ON. A PORT ON status signal (TPC) is output from the ProfiBus gateway to the PLC, so provide an interlock or other process as necessary.

[11] Teaching pendant/PC connector

This connector is used to connect the communication cable connector for teaching pendant or PC software.

[12] Power-supply input connector

This connector is used to connect the ProfiBus Gateway power (24 VDC).

PfofiBus Gateway

3. Installation and Noise Elimination Measures

Exercise due caution regarding the installation environment.

3.1 Installation Environment.

a. The Gateway Unit is not dustproof or waterproof (oilproof). Accordingly, avoid using the Gateway

Unit in a dusty place or place where the unit may come in contact with oil mist or splashed cutting fluid.

b. Prevent the Gateway Unit from receiving direct sunlight or irradiated heat from large heat

sources such as heat treatment ovens.

c. Use the Gateway Unit in an enviro nment of 0 to 40°C in ambient temperature and 85% or below

in humidity (non-condensing) and free from corrosive or flammable gases.

d. Use the Gateway Unit in an environment where the unit will not receive external vibration or

shock.

e. Prevent electrical noise from entering the Gateway Unit or its cables.

3.2 Supply Voltage

24 VDC ± 10% / Current consumption: 300 mA max.

3.3 Noise Elimination Measures and Grounding

a. Installing the Gateway Unit

Connect the Gateway Unit by directly securing it onto a metal enclosure using screws.

* Provide class D (3) grounding for the enclosure.

Use as thick a cable as possible and connect it over the shortest possible distance.

Metal

enclosure

b. Notes on wiring method

Separate the communication lines of the Gateway Unit and ProfiBus module from lines carrying large current such as power circuits. (Do not bundle them together or place them in the same cable duct.)

c. Noise sources and elimination of noise

There are many noise sources, but the ones you should pay most attention to when building your system are solenoid valves, magnet switches and relays. Noise from these sources can be eliminated using the following measures.

[1] AC solenoid valves, magnet switches, relays

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

[2] DC solenoid valves, magnet switches, relays

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

in accordance with the load capacity.

In a DC system, connecting the diode in reverse polarities may damage the diode, internal controller parts, and DC power supply. Exercise due caution.

+24 V

0 V

PfofiBus Gateway

← Point

Install the surge killer in a location as close as possible to each coil. If the surge killer is installed on a terminal block or away from the coil, its noise elimination effect will decrease.

PfofiBus Gateway

3.4 Installation

Examine appropriate settings for the control box size, installation position of the Gateway Unit and cooling method of the control box, so that the temperature around the Gateway Unit will remain at or below 40°C. Install the Gateway Unit vertically on a wall, as shown below, and provide a minimum clearance of 50 mm above and below the unit, with a minimum clearance of 100 mm provided on all sides for wiring access. If multiple Gateway Units are installed side by side, provide a sufficient space between the adjacent units so that any unit can be installed and removed easily. If heat or noise is of concern, also provide appropriate measures.

4. Wiring

4.1 Overall Configuration

The following is an example of ProfiBus system configuration using the Gateway Unit.

Host system (PLC master)

Gateway

Unit

SIO communication network

Terminal resistor

cable

Controller link

4-way junction

Teaching pendant

PfofiBus Gateway

24-V

power

supply

PfofiBus Gateway

The ProfiBus network is wired as shown below.

For details on ProfiBus-DP, check the operation manual for the master (PLC) or website of the Japanese PROFIBUS Organization.

Master

(Node address 2)

Terminal resistor

Slave

Slave Slave Slave

(Node address 3) (Node address 4) (Node address 5) (Node address 6)

[1] A device connected to a network and assigned an address is called a “node.” A node may be a

master or slave. Up to 32 nodes can be connected to one segment.

[2] It is recommended that the master be connected to one end of the network. Normally the master has

node address 2, while each slave has node address 3 to 32. Node address 0 is reserved for a monitoring or diagnostic device, while node address 1 is reserved

for a monitoring device. [3] One segment of the network must have a terminal resistor connected to both ends. [4] For each ProfiBus cable, use the ProfiBus-DP type A cable specified by the EN 50170 standard. This

cable is a 2-core twisted pair cable with shield.

Cable

Red: Line B (positive side) Green: Line A (negative side)

Shield

[5] All network connectors should be the D-sub, 9-pin connector specified by the EN 50170 standard.

The network bus connector can be of the screw type shown below or the quick connection type

where the wires are inserted into provided holes.

If the connector has a terminal resistor, turn the terminal resistor switch ON only for the terminal slave, and turn the switch OFF for all other slaves.

PfofiBus Gateway

[6] The ProfiBus gateway connector should be the D-sub, 9-pin (female) connector recommended by the

ProfiBus DP Standard under EN 50170, as shown below.

The network connectors are not supplied.

Pin No. Signal name Description

1 NC Not connected 2 NC Not connected 3 B-Line Communication line B (Positive side) 4 NC Not connected 5 GND Signal ground 6 +5V +5-V output 7 NC Not connected 8 A-Line Communication line A (Negative side) 9 NC Not connected

Housing Shield Cable shield

Caution

The ProfiBus gateway has a built-in terminal resistor setting switch. If the ProfiBus gateway becomes a terminal module on the network, turn this terminal resistor setting switch ON. If the ProfiBus gateway is not a terminal module or an external terminal connector is used, turn the switch OFF.

4.2 I/O Signals of Gateway Unit

(1) Connection diagram

ProfiBus communication

Emergency stop signal output for teaching pendant Allowable load voltage: 30 VDC Allowable load current: 1 A

cable

Teaching pendant

Emergency stop

Gateway power supply

24 VDC ±10%,

300 mA max.

External port switching input

(provided by the customer)

(Load: 24 VDC, 7 mA)

SIO communication

cable

PfofiBus Gateway

Gateway Unit

Teaching pendant/ PC connector

Port switch

PfofiBus Gateway

(2) Port control and emergency stop signal output

The teaching pendant/PC connector port can be operated by external signals, other than by ON/OFF

switching of the port switch on the Gateway Unit.

While the port is ON, the Gateway Unit outputs contact signals of the emergency stop pushbutton

switch on the teaching pendant. Therefore, you can design an emergency stop circuit or other

protective circuit for the entire system by incorporating these signals.

External port

switching input

Port switch

OFF OFF Disabled (S1 and S2 shorted) Disabled

ON OFF

ON ON

An example of the emergency stop circuit is shown below.

Emergency stop reset

Emergency stop button switches

Teaching-pendant emergency stop

signal output

S1, S2 =

Enabled

Teaching pendant

Emergency stop

Gateway power supply (24 VDC ± 10%, 300 mA max.)

External port switching input (provided by the customer)

SIO communication cable

Teaching-pendant emergency stop contacts

ProfiBus cable

(Load 24 VDC, 7 mA)

Teaching pendant/PC

connector port

Enabled OFF ON

Gateway unit

Teaching pendant/PC connector

Port switch

(3) I/O signal specifications and wires

Symbol Description Specification Connector and applicable wire

Power-supply

SIO communication

ProfiBus

communication

Positive side of the 24-VDC Gateway power supply Negative side of the 24-VDC Gateway power supply Teaching-pendant emergency stop signal output

External port switching input

24 VDC ±10% Power consumption: 300 mA

max. Allowable load voltage: 30 VDC 0.08 to 1.5 mm2

No-voltage (dry) contact input Load: 24 VDC, 7 mA

input connector

24 V

S1 S2 Allowable load current: 1 A AWG 28 to 16

PORT IN

PORT N

SDA SIO communication line A Align the potential level of the SDB SIO communication line B

GND Ground

connector

FG Frame ground

B-Line

Communication line B (RS485)

connected controller or ERC actuator with the potential level of the GND (ground).

Internally connected to the frame.

RTS Request to send

GND Signal ground (insulated)

+5V +5-V output (insulated)

connector

A-Line

Communication line A (RS485)

0.8 to 1.3 mm AWG 18 to 16

0.08 to 1.5 mm AWG 28 to 16

Double shielded twistedpair cable (AWG22) Recommended cable: HK-SB/20276 X L 2P X AWG22 by Taiyo Electric Wire & Cable

ProfiBus-DP type A cable (2-core twisted pair cable with shield)

The connection plug is a standard accessory. MC1.5/4-ST-3 y 5 (Phoenix Contact)

The connection plug is a standard accessory. MC1.5/6-ST-3 y 81 (Phoenix Contact) The Gateway Unit has a built-in terminal resistor, so connect the terminal resistor at the end of the SIO communication line. The connection plug should be a D-sub, 9-pin connector, but this plug is not supplied. With ProfiBus, a terminal resistor*1 must be connected to both ends of the trunk line. For details, check the operation manual for the master (PLC).

*1 The gateway unit has a built-in terminal resistor. Set the terminal switch ON/OFF to enable/disable this built-in terminal resistor.

PROFIBUS Gateway

PfofiBus Gateway

4.3 Design of SIO Communication Network (SIO Communication)

4.3.1 Wiring

(1) Basics

Item Description Number of connected units Communication cable length Total cable length: 100 m max.

Communication cable Terminal resistor

16 axes max. (The specific number varies depending on the operation mode. Refer to 1.4, “Features of Gateway Unit.”)

Double shielded twisted-pair cable (AWG22) Recommended cable: HK-SB/20276 X L 2P X AWG22

by Taiyo Electric Wire & Cable

220 Ω 1/4 W

Caution

1. Connect the communication path to a bus and always connect a terminal resistor at the end. A terminal resistor is not needed on the Gateway Unit end, as the unit has a built-in terminal resistor.

2. The customer must provide the communication cable. If the recommended cable is not used, make sure the size of the cable to be used is AWG22.

(2) Communication connection for PCON, ACON and SCON

SIO communication trunk line (provided by the customer)

Gateway Unit

(Built-in terminal resistor)

Axis 1 Axis 2 Axis n

*1 A terminal resistor (220 Ω, 1/4 W) is supplied with the controller link cable.

e-CON connector (4-1473562-4 by AMP, green) e-CON connector (3-1473562-4 by AMP, orange)

Junction (5-1473574-4 by AMP) Recommended cable: SB/20276 X L 2P X AWG22

Controller link cable

Terminal resistor *1

PfofiBus Gateway

a. Detail connection diagram

Details of SIO link connection are illustrated below. Controller link cables are available as options, but the customer must provide the communication trunk.

Gateway Unit

Double shielded twisted-pair cable Recommended cable: HK-SB/20276 X L 2P X AWG22 by Taiyo Electric Wire & Cable

Yellow

Orange

Blue

Unit 1 Unit 2

b. Producing a communication trunk

[1] Strip the sheath of a double shielded twisted-pair cable by

approx. 15 to 20 mm.

[2] Twist the shield wires and solder them onto the vinyl

wires of AWG22 or equiv alent. [3] Place a cable protection tube over the cable. [4] Insert the core wires, without stripping them, into the

cable insertion holes in the connector (SDA, SDB,

GND, FG). [5] With the cable inserted in the press-fit cable housing, apply

pressure from above to pressure-weld the core wires. [6] Heat-treat the cable protection tube.

e-CON connect or pin numbers

Always insert a terminal resistor (220 Ω, 1/4 W) at the end of the communication trunk (between pins 1 and 2 of the e-CON connector).

Locking tab

SIO communication trunk

4-way junction (5-1473574-4 by AMP)

e-CON connector (4-1473562-4 by AMP)

Housing color: Green

Controller link cable

Yellow

Orange

Blue

e-CON connector (3-1473562-4 by AMP)

Housing color: Orange

e-CON connector

Apply pressure.

Vinyl wire (AWG22)

Solder

Shield wire

Cable tube

Double shielded twisted-pair shielded

Locking tab

c. Controller link cable (CB-RCB-CTL002)

This is an optional cable for the controller. You must purchase this cable separately.

The following parts are supplied with the controller link cable.

[1] 4-way junction Model: 5-1473574-4 by AMP x 1 unit

[2] e-CON connector 4-1473562-4 by AMP x 1 unit

Outer diameter of applicable wire 1.35 to 1.6 mm

[3] Terminal resistor 220 Ω 1/4 W With e-CON connector x 1 unit

Controller end

Mini DIN connector

Signal

Yellow

Orange

Blue

e-CON connector 3-1473562-4 (Housing color: Orange)

Signal

PfofiBus Gateway

(3) SIO communication connection for ERC2-SE

For details, refer to the ERC2-SE operation manual. Use 4-way junctions to connect the cables as shown below. The power-supply & I/O cable and network connection cable (including the 4-way junction and eCON connector) are standard accessories of the ERC2-SE.

Gateway unit

Fabricated by

the customer

4-way junction

e-CON connector

Terminal resistor

Network connection cable (CB-ERC2-CTL001)

Power-supply & I/O cable (CB-ERC2-PWBIO)

JST JST

PIO & 24-VDC control power, motor

power, brake signal, ground, shield

Axis 1

Axis 2

Axis 3

Axis 16

Caution

(1) When the total communication cable length is 10 m or longer, communication may not be

established properly and a communication error may occur. In this case, connect a terminal

resistor to the last axis. (2) If the actuators have different power supplies, use a common line for 0 [V]. (3) Use a common line for 0 [V] for the power supply of the gateway unit and control power supply of

the ERC2. (4) Connect the shield wire to the FG for each axis. (5) If the total link cable length exceeds 30 m, use wires with a size of 22AWG or larger.

(4) SIO communication connection for ERC2-NP/PN

Use relay terminal blocks to connect the cables as shown below.

Gateway unit

Pair shield cable

(fabricated by the

customer)

Terminal resistor

Relay terminal block

PIO & 24-VDC control power, motor

power, brake signal, ground, shield

Orange (black 1)

Orange (red 1)

PfofiBus Gateway

PIO type power-supply & I/O cable

Axis 1

Axis 2

Axis 16

Caution

(1) When the total communication cable length is 10 m or longer, communication may not be

established properly and a communication error may occur. In this case, connect a terminal

the ERC2. (4) Connect the shield wire to the FG for each axis. (5) If the total link cable length exceeds 30 m, use wires with a size of 22AWG or larger.

PfofiBus Gateway

(5) Wiring the emergency stop (EMG) circuit

When designing an emerg ency stop circuit that incorporates the emergency stop switch on the teaching pendant connected to the Gateway Unit, emergency stop signals output from the “S1” and “S2” terminals of the Gateway Unit can be used. This way, all connected ROBO Cylinder controllers can be stopped instantly in case of emergency by operating the emergency stop switch on the teaching pendant connected to the Gateway Unit.

Caution

1. For details on the emergency stop processing of ROBO Cylinders, refer to the operation manual for

your PCON, ACON, SCON or ERC-2 controller.

[1] Example of cutting off drive signals

Emergency stop reset switch

Teaching

pendant

Emergency stop button

Gatewa

power suppl

Gateway Unit

TP connector

Port

switch

24-VDC input

power supply

(2 A max. per unit)

SIO

communication

SIO connector

Power-supply

terminal block

Power-supply terminal block (unit 2)

Power-supply terminal block (unit 3)

PCON, ACON controller

Motor drive power

Control power

PfofiBus Gateway

Connection detection signal (H)

EMG signal detection (H)

Drive stop

signal (L) Time cons-

tant

SIO

connector

connection

detection

circuit

Motor

drive

circuit

Caution

The input current specification for the EMG terminal is 5 mA. When connecting the EMG relay CR contacts to the EMG terminals of multiple controllers, check the current capacity of the relay contacts.

[2] Example of cutting off motor drive power

Emergency stop reset switch

Teaching

pendant

Emergency stop button

Gatewa

power suppl

Gateway Unit

TP connector

Port

switch

24-VDC input power supply

(2 A max. per unit)

SIO connector

SIO

communication

PCON, ACON controller

Power-supply terminal block

Motor drive power

Control power

Power-supply terminal block (unit 2)

Power-supply terminal block (unit 3)

Connection detection signal (H)

EMG signal detection (H)

Time cons-

tant

PfofiBus Gateway

SIO

connector

connection

detection

circuit

Drive stop signal (L)

Motor

drive

circuit

PfofiBus Gateway

4.3.2 Axis Number Setting

The following explanation applies to PCON, ACON and ERC2 controllers.

Set an axis number as a SIO-linked slave station number. The axis number of axis 1 is “0,” while that of axis 16 is “F.” Set an appropriate axis number using a hexadecimal value between 0 and F. Axis numbers can be set on the teaching pendant or in the PC software.

~ Operation in the PC software

[1] Open the main window → [2] Click Settings (S) → [3] Bring the cursor to Controller

Settings (C) → [4] Click Assign Axis Number (N) → [5] Enter a number in the axis number table.

~ Operation on the teaching pendant RCM-T

[1] Open the User Adjustment window → [2] Bring the cursor to Assigned No. using the T key

→ [3] Enter an axis number, and press Enter → [4] Enter “2” under Adjustment No., and press Enter.

~ Operation on the simple teaching pendant RCM-E

[1] Open the User Adjustment window Æ [2] Press Enter to open the Assigned No. window →

[3] Enter an axis number, and press Enter → [4] Enter “2” under Adjustment No., and press Enter.

For details on each setting method, refer to the operation manual for your teaching pendant or PC software.

Caution

1. Each axis number must be unique.

2. Before setting an axis number for a given axis, disconnect the link cable of the applicable axis.

3. Connect a terminal resistor between SGA and SGB on the terminal module.

PfofiBus Gateway

4.4 How to Connect the Teaching Tool When the Positive Terminal of the 24-V Power Supply Is Grounded

If the positive terminal of the 24-V power supply is grounded (= +24 V is grounded), use a SIO converter as shown below to connect a teaching pendant or PC to the gateway unit. In this case, do not connect the FG of the SIO converter.

Teaching pendant

Do not connect the FG.

24-V power

supply

With the gateway unit system, the negative terminal of the 24-V power supply should be grounded (= 0 V should be grounded), as a rule. Since most teaching pendants and PCs have their communication ground line and FG (frame ground) shorted internally, grounding the positive terminal of the 24-V power supply (= grounding +24 V) will cause shorting of the 24-V power-supply circuit when a teaching pendant or PC is connected to the gateway unit, thereby damaging the teaching pendant or PC.

PC, etc.

PC software

RS232 connection type <Model number: RCM-101-MW> USB connection type <Model number: RCM-101-USB> * The cables are supplied with the

PC software.

Controller link cable Model number: CB-RCB-CTL002

SIO converter (optional) (with built-in terminal resistor) Model number: RCB-TU-SIO-A (B)

* One e-CON c onnector, one junction

and one terminal resistor are supplied with each controller link cable.

Do not allow the FG of the PC to be connected to ground. If the FG may be connected to ground via other COM port, disconnect the communication cable from the applicable COM port.

Gateway unit

e-CON connector (3-1473562-4 by AMP) Junction (5-1473574-4 by AMP)

Terminal resistor

Caution

Do not connect the FG of the SIO converter.

∆

PfofiBus Gateway

5. Address Configuration of Gateway Unit

All data exchanged between the master station and the controller are tentatively stored in the internal memory of the Gateway Unit, and then transmitted cyclically. Accordingly, the PLC program recognizes these data as remote ProfiBus I/Os. Up to 16 ROBO Cylinder controllers can be connected to the Gateway Unit, with the connected controllers assigned an axis number of 0 to 15, respectively. The Gateway Unit simultaneously sends and receives data to/from the master station for all ROBO Cylinder controllers connected via SIO link. As explained in the features of the Gateway unit in section 1.4, controllers can be operated in there major modes. In each mode, an address configuration varies as the slave.

5.1 Position Number Specification Mode

In this operation mode, a desired position number in the position table is specified to operate the actuator, and up to 16 axes can be controlled. The position table must be set for each axis using the PC software or teaching pendant. A desired position number is written in the PLC to operate the actuator. Up to 64 positions from Nos. 0 to 63 can be specified, but the number of positions may be limited depending on the PIO pattern (PIO pattern selection parameter) specified for each axis. (Refer to the table in 1.4.2.)

The key functions that can be controlled in this mode are summarized in the table below.

{: Direct control

Key function

Home return operation Positioning operation

Speed and acceleration/deceleration setting Pitch (incremental) feed

Push-motion operation Speed change during movement

Operation with acceleration and deceleration set differently Pause Zone signal output PIO pattern selection X *1 *1 Since the number of position is limited according to the PIO pattern selection (parameter No. 25)

specified for each connected controller, specify the position numbers in a manner avoiding inconsistency. For your information, up to 64 positions can be specified.

∆: Indirect control X: Disabled

{

∆

{ {

This operation is performed by specifying a number in the position table. Set in the position table.

Set in the position table. Set in the position table. This operation is performed by

combining two or more position numbers. (Refer to the operation manual for the controller.) Set in the position table.

Each zone is set by parameters.

Remarks

PfofiBus Gateway

5.1.1 Overall address configuration

In the position number specification mode, four bytes are used by the gateway control signals, and also by the status signals, to be input/output. For each axis, each control signal occupies two bytes in the PLC I/O area, and a total of 48 bytes are occupied by signal inputs, and also by signal outputs, for the entire gateway unit. The values in parentheses ( ) indicate axis numbers.

Output from PLC ⇒ Gateway Unit ⇒ Input to each axis Output from each axis ⇒ Gateway Unit ⇒ Input to PLC

Upper byte Lower byte

Gateway control signal 0

Gateway control signal 1

Command position

number (0)

Command position

number (1)

Command position

number (2)

Command position

number (3)

Command position

number (4)

Command position

number (5)

Command position

number

(6)

Command position

number (7)

Command position

number (8)

Command position

number (9)

Command position

number (10)

Command position

number (11)

Command position

number (12)

Command position

number (13)

Command position

number (14)

Command position

number (15)

Cannot be used. Cannot be used.

Cannot be used.

Control signal (0)

Control signal (1)

Control signal (2)

Control signal (3)

Control signal (4)

Control signal (5)

Control signal (6)

Control signal (7)

Control signal (8)

Control signal (9)

Control signal (10)

Control signal (11)

Control signal (12)

Control signal (13)

Control signal (14)

Control signal (15)

Cannot be used.

1 byte 1 byte 1 byte

1 byte

* The byte address is indicated as a relative byt e ad dress from the initial byte-address byte of the

gateway.

Byte address

Upper byte Lower byte

Gateway status signal 0

Gateway status signal 1

Completed position

number (0)

Completed position

number (1)

Completed position

number (2)

Completed position

number (3)

Completed position

number (4)

Completed position

number (5)

Completed position

number (6)

Completed position

number (7)

Completed position

number (8)

Completed position

number (9)

Completed position

number (10)

Completed position

number (11)

Completed position

number (12)

Completed position

number (13)

Completed position

number (14)

Completed position

number (15)

Cannot be used.

Status signal (0)

Status signal (1)

Status signal (2)

Status signal (3) Status signal (4)

Status signal (5)

Status signal (6)

Status signal (7)

Status signal (8)

Status signal (9)

Status signal (10)

Status signal (11)

Status signal (12)

Status signal (13)

Status signal (14)

Status signal (15)

Cannot be used.

PfofiBus Gateway

5.1.2 Gateway Control/Status Signals

The initial fixed area in the address configuration is used by signals that control the gat eway unit, and consists of four input bytes and four output bytes. These signals are used to control the ON/OFF of SIO communication and monitor the SIO communication status and gateway unit status.

PLC output

Gateway

control signal 0

Gateway

control signal 1

PLC input

Gateway

status signal 0

Gateway

status signal 1

* The byte address is indicated as a relative byt e ad dress from the initial byte-address byte of the

gateway.

Byte address

PfofiBus Gateway

I/O Signal List

Signal type Byte Bit

Signal

name

SIO link communication will start when this signal is turned ON, and stop when it is turned OFF. Do not turn the MON signal ON when CFG15 to 0 (linked axis connection) are all OFF.

7 MON

Also, do not turn all of CFG15 to 0 OFF when the MON signal is ON. If CFG15 to 0 are all turned OFF and the MON signal turned ON, the Gateway Unit will generate a SIO link error and the LED (T.ER) on the front face of the unit will illuminate.

These bits cannot be used. Always set them to OFF (0).

In all other modes, always set these bits to OFF (”0”). Set the axis number (0 to 16) corresponding to each axis operated by positioner operation, using a 5-bit binary code. *1

These bits are used in the command specification mode. In all other modes, always set these bits to OFF (”0”). Set the I/O pattern (pattern 0 to 4) of the axis using a 3-bit binary code. *2

PLC output

Control

signal 0

6-0 -

7 NPS4 These bits are used in the command specification mode. 6 NPS3 5 NPS2 4 NPS1 3 NPS0 2 PPS2 1 PPS1 0 PPS0 7 CFG15 Link ON Axis No. 15 Specify the axis number 6 CFG14 14 5 CFG13 13

4 CFG12 12 3 CFG11 11 2 CFG10 10 1 CFG9 9

Control

signal 1

0 CFG8 8 7 CFG7 7 6 CFG6 6 5 CFG5 5

4 CFG4 4 3 CFG3 3 2 CFG2 2 1 CFG1 1 0 CFG0 0

*1 If the mode setting switch (SW1) specifies the command specification mode and NPS0 to NPS4 are

set to 0, all axes will become simple direct operation axes.

*2 For positioner operation axes, only one I/O pattern of 0 to 4 can be specified.

Description

corresponding to each axis to be linked. The axis will be connected when the signal is turned ON (1), and disconnected when it is turned OFF (0). ON/OFF switching is permitted even when the MON signal is ON. (Cautions) z Do not turn ON the axis number

signal corresponding to any axis not physically connected.

z Do not turn ON any axis number

signal other than the specifiable number selected by the mode

setting switch. If either of the above conditions is breached, a SIO link error will occur.

Signal type Byte Bit

Status

signal 0

PLC input

Status

signal 1

Signal

name

7 RUN

6 G.ER

Gateway Unit normal output

Gateway Unit error detection output

SIO-link

5 T.ER

communication error detection output

4 TPC Port switch ON output

3 MOD4 2 MOD3 1 MOD2 0 MOD1

7 Major V.4 6 Major V.2 5 Major V.1

Mode setting switch 4 ON output Mode setting switch 3 ON output Mode setting switch 2 ON output Mode setting switch 1 ON output

The major version number is output as a three-bit binary value.

4 Minor V.16 3 Minor V.8 2 Minor V.4 1 Minor V.2

The major version number is output as a five-bit binary value.

0 Minor V.1 7 LNK15 Linked Axis No. 15

6 LNK14 14 5 LNK13 13 4 LNK12 12 3 LNK11 11 2 LNK10 10 1 LNK9 9 0 LNK8 8 7 LNK7 7 6 LNK6 6 5 LNK5 5 4 LNK4 4 3 LNK3 3 2 LNK2 2 1 LNK1 1 0 LNK0 0

PfofiBus Gateway

Description

This signal remains ON while the Gateway Unit is operating normally. The signal is synchronized with the illumination of the LED (RUN) on the front face of the unit. This signal turns ON when a major shutdown failure has been detected. The signal is synchronized with the illumination of the LED (G.ER) on the front face of the unit.

This signal turns ON when a SIO link communication error has been detected. The signal is synchronized with the illumination of the LED (T.ER) on the front face of the unit.

The status of the port switch on the front face of the unit is output. This signal is ON wh ile the por t swi tch i s ON .

The setting status of each pin of the mode setting switch is output. When the switch is turned ON, the applicable bit will turn ON (“1”).

The Gateway version information is output. You may need to check this information in certain situations, such as when the Gateway encountered a problem. Provide the necessary wiring so that these signals can be read by the PLC.

Example) If the version is 1.03, the major

version number is “1” (data:

001), while the minor version number is “3” (data: 00011).

Link connection of an axis selected for link connection by any one of CFG15 to 0 will become enabled when the MON signal is turned ON. The signal corresponding to each axis whose link connection is enabled turns ON.

PfofiBus Gateway

5.1.3 Assignment for Each Axis

The input signal and output signal of each axis consist of two bytes each in the PLC I/O area. Control signals and status signals are ON/OFF signals defined in units of bits. The command position number or completed position number is handled as a 1-byte (8-bit) binary data. Specify each command position number within the range of position numbers set by the controller of each axis.

PLC output

PLC input

Byte address*

Control signal

Command position number

Byte address

Status signal

Completed position number

* Byte: Initial gateway address

n: Axis number (0 to 15)

PfofiBus Gateway

I/O Signal Details

Signal type Bit

Signal

name b7 - Cannot be used. b6 - Cannot be used. b5 - Cannot be used. -

Control

signal

b4 SON Servo on command 6.2 (7) b3 STP Pause command 6.2 (5) b2 HOME Home return command 6.2 (8)

PLC output

b1 CSTR Start command 6.2 (9) b0 RES Reset command 6.2 (4)

Command

position number

6-bit data

(b5-0)

RC 32

PC1

Specify the command position number using a binary value.*1

b7 EMGS Emergency stop 6.2 (2) b6 - Cannot be used. b5 PWR Controller ready 6.2 (1)

Status

signal

b4 SV Ready (servo is on) 6.2 (7) b3 MOVE Moving 6.2 (6) b2 HEND Home return complete 6.2 (8) b1 PEND Positioning complete 6.2 (10) b0 ALM Alarm 6.2 (3)

Zone signal

PLC input

output 2

Zone signal

output 1

Completed

position number

(alarm

output)

ZONE2

b6 ZONE1

6-bit data

(b5-0)

PM32

PM1

The completed position number and zone signal status are output. Read the completed position number as a six-bit binary value. While an alarm is present (= the ALM signal is ON), the content of the alarm is output to the completed position number. (For the contents of alarms that may be output , refer to the table entitled “Alarm List” on the next page.)

*1 With the ERC2-NP/PN, up to 16 positioning points are supported in PIO control. If the gateway unit is

connected, however, up to 64 points can be specified.

*2 [ZONE2] is not supported by the ERC2-NP/PN.

Description Details

6.2 (11)

6.2 (13)

6.2 (12)

PfofiBus Gateway

[Alarm List]

The table below summarizes the content of each alarm that may be output by PM8 to PM1 (as a binary code) while the alarm is present. For details on each alarm, refer to the operation manual for the controller.

{: ON X: OFF ALM PM8 PM4 PM2 PM1

Output

code

X - - - - - Normal

{

X X X

{

X X

{

X 2 For manufacturer’s use *1

1 For manufacturer’s use *1

Movement command issued with servo off (80) Position command issued before completion of home

{

X X

{ {

return (82)

Absolute position movement command issued before completion of home return (83) Movement command issued during home return (84)

{ {

X X

{

X X 4 PCB inconsistency error (F4)

{

5 Non-volatile memory write error (F7) *1

Parameter data er ror (A1)

{

{ {

X 6

Position data error (A2) Position command information data error (A3)

{

{ {

{ { {

X X X 8 Excessive actual speed (C0)

Excitation detection error (B8)

Operation timeout during home return operation (BE)

Overvoltage (C9)

{ {

X X

{

Overheat (CA)

Control power-supply voltage error (CC) Control power-supply voltage low (CE)

{ { { { { { {

{

X X

X A For manufacturer’s use *1

{ {

B Position deviation counter overflow (D8)

X X C Servo error (C1)

Open phase A, B (E8) Open phase A (E9)

{ { {

{

Open phase B (EA)

RCP2 absolute encoder error detection 1 (ED) RCP2 absolute encoder error detection 2 (ED) RCP2 absolute encoder error detection 3 (ED)

{ { { {

X E

CPU error (FA) FPGA error (FB)

Non-volatile memory write count over (F5)

{ { { { {

Non-volatile memory writing timeout (F6) Non-volatile memory data corrupted (F8)

*1 This error will not generate when the gateway unit is used. *2 The corresponding alarm code displayed on the PC software or teaching pendant is shown in

parentheses ( ).

Description *2 Remarks

PfofiBus Gateway

5.2 Direct Numerical Specification Mode

In the direct numerical specification mode, the position data, speed, acceleration/deceleration, positioning band (push band) and push-current limiting value are specified directly as numerical values to operate the actuator. One of five patters can be set according to the maximum number of connected axes. (Mode setting switch SW1) Also, the current position data can be read at any time. The position table need not be set for each axis.

The key functions that can be controlled in this mode are summarized in the table below.

{: Direct control

Key function

∆: Indirect control

X: Disabled Home return operation Positioning operation Speed/acceleration setting

{ { {

Pitch (incremental) feed X Pitch feed data cannot be processed direc tly.

The host PLC must issue each command by adding/subtracting the pitch-feed distance

data to/from the current position. Push-motion operation Speed change during movement

{ {

Speed data is accepted at the start of

positioning. To change the speed during

movement, therefore, change the speed data

during movement and then restart the

positioning operation. Operation with acceleration and

deceleration set differently

{

Acceleration/deceleration data is accepted at

the start of positioning. To specify a

deceleration different from the acceleration,

therefore, change the deceleration data during

movement and then restart the pos itio nin g

operation. Pause

{ Zone signal output X Monitor the current position using the PLC. *1 PIO pattern selection X *2

*1 The current position data does not use strobe signals. Accordingly, to check the current position

using the PLC while the actuator is moving, set a zone and confirm that the data has remained in the specified zone for at least two scan periods.

*2 Set the PIO pattern selection parameter (No. 25) of the connected controller to 0 (standard type).

(PCON-C/CG, ACON-C/CG, SCON-C, ERC-2NP/PN)

Remarks

PfofiBus Gateway

5.2.1 Overall Address Configuration

Four bytes are used by the gateway control signals, and also by the status signals, to be input/output. In the direct numerical specification mode, the control signals of each axis consist of 12 bytes in the PLC output area (gateway input area) and six bytes in the PLC input area (gateway output area). The number of controlled axes is set by the mode setting switch (SW1), and the applicable data areas vary depending on the setting of this switch. The switch settings and corresponding data areas are shown below.

No.

4 3 2 1 Description Output Input

1 X X X X 2 X

{

{ {

{: ON X: OFF

SW1 I/O bytes

{

X X

X X X

{

X X X

Direct numerical specification mode/Up to 4

axes can be connected

Direct numerical specification mode/Up to 6

axes can be connected

Direct numerical specification mode/Up to 8

axes can be connected

Direct numerical specification mode/Up to 10

axes can be connected

Direct numerical specification mode/Up to 16

axes can be connected

52 28

76 40 100 52 124 64 196 100

)

The overall address configuration is shown below. The byte address indicates the initial address of the assigned area in the master. The values in parentheses ( ) indicate axis numbers.

Byte address

Byte+

Output from PLC ⇒ Gateway Unit

⇒ Input to each axis

Gateway control 0 Gateway control 1

Axis control (0)

Axis control (1)

Axis control (2)

Axis control (3)

Axis control (4)

Axis control (5)

Axis control (6)

Axis control (7)

Axis control (8)

Output from each axis ⇒ Gateway Unit ⇒

Byte+

Input to PLC

Gateway status 0 Gateway status 1

Axis status (0) Axis status (1)

Axis status (2) Axis status (3) Axis status (4) Axis status (5)

Axis status (6) Axis status (7)

Axis status (8) Axis status (9)

Axis status (10) Axis status (11) Axis status (12) Axis status (13) Axis status (14) Axis status (15)

Axis control (9)

Axis control (10)

Axis control (11)

Status signal (11 Status signal (11 Current position data (11 Current position data (11 Current position data (11 Cannot be used.

Axis control (12)

Axis control (13)

Axis control (14)

Axis control (15)

Position data specification

(11)

Position data specification

(11)

Position data specification

(11)

Current-limiting value for push motion

Speed specification

(11)

Speed specification

(11) (11)

Speed specification

cceleration/deceleration

specification

(11)

Positioning band specification

(11)

Positioning band specification

(11) Control signal (11)

PfofiBus Gateway

Mode No. 1

Mode No. 2

Mode No. 3

Mode No. 4

Mode No. 5

Byte data

(11)

PfofiBus Gateway

5.2.2 Gateway Control/Status Signals

PLC output

Gateway

control signal 0

Gateway

control signal 1

PLC input

Gateway

status signal 0

Gateway

status signal 1

* The byte address is indicated as a relative byt e ad dress from the initial byte-address byte of the

gateway.

Byte address

PfofiBus Gateway

I/O Signal List

Signal type Byte Bit

Signal

name

SIO link communication will start when this signal is turned ON, and stop when it is turned OFF. Do not turn the MON signal ON when CFG15 to 0 (linked axis connection) are all OFF.

7 MON

These bits cannot be used. Always set them to OFF (0).

In all other modes, always set these bits to OFF (”0”). Set the axis number (0 to 16) corresponding to each axis operated by positioner operation, using a 5-bit binary code. *1

These bits are used in the command specification mode. In all other modes, always set these bits to OFF (”0”). Set the I/O pattern (pattern 0 to 4) of the axis using a 3-bit binary code. *2

signal 0

PLC output

Control

6-0 -

7 NPS4 These bits are used in the command specification mode. 6 NPS3 5 NPS2 4 NPS1 3 NPS0 2 PPS2 1 PPS1 0 PPS0 7 CFG15 Link ON Axis No. 15 Specify the axis number 6 CFG14 14 5 CFG13 13

4 CFG12 12 3 CFG11 11 2 CFG10 10 1 CFG9 9

Control

signal 1

0 CFG8 8 7 CFG7 7 6 CFG6 6 5 CFG5 5

4 CFG4 4 3 CFG3 3 2 CFG2 2 1 CFG1 1 0 CFG0 0

*1 If the mode setting switch (SW1) specifies the command specification mode and NPS0 to NPS4 are

set to 0, all axes will become simple direct operation axes.

*2 For positioner operation axes, only one I/O pattern of 0 to 4 can be specified.

Description

signal corresponding to any axis not physically connected.

z Do not turn ON any axis number

signal other than the specifiable number selected by the mode

setting switch. If either of the above conditions is breached, a SIO link error will occur.

Signal type Byte Bit

Status

signal 0

PLC input

Status

signal 1

Signal

name

7 RUN

6 G.ER

Gateway Unit normal output

Gateway Unit error detection output

SIO-link

5 T.ER

communication error detection output

4 TPC Port switch ON output

3 MOD4 2 MOD3 1 MOD2 0 MOD1

7 Major V.4 6 Major V.2 5 Major V.1

Mode setting switch 4 ON output Mode setting switch 3 ON output Mode setting switch 2 ON output Mode setting switch 1 ON output

The major version number is output as a three-bit binary value.

4 Minor V.16 3 Minor V.8 2 Minor V.4 1 Minor V.2

The major version number is output as a five-bit binary value.

0 Minor V.1 7 LNK15 Linked Axis No. 15

6 LNK14 14 5 LNK13 13 4 LNK12 12 3 LNK11 11 2 LNK10 10 1 LNK9 9 0 LNK8 8 7 LNK7 7 6 LNK6 6 5 LNK5 5 4 LNK4 4 3 LNK3 3 2 LNK2 2 1 LNK1 1 0 LNK0 0

PfofiBus Gateway

Description

This signal turns ON when a SIO link communication error has been detected. The signal is synchronized with the illumination of the LED (T.ER) on the front face of the unit.

The status of the port switch on the front face of the unit is output. This signal is ON wh ile the por t swi tch i s ON .

The setting status of each pin of the mode setting switch is output. When the switch is turned ON, the applicable bit will turn ON (“1”).

Example) If the version is 1.03, the major

version number is “1” (data:

001), while the minor version number is “3” (data: 00011).

PfofiBus Gateway

5.2.3 Assignment for each axis

Control and status signals are set using ON (1)/OFF (0) signal bits, while current-limiting value for push-mode operation and acceleration/deceleration are set using one-byte (eight-bit) hexadecimal data. Speed, target position data, in-position band and current position data are three-byte (24-bit) hexadecimal data. It is recommended that control and status signals be transferred to, and used in, bit registers. Set a desired current-limiting value for push motion, acceleration/deceleration or speed within the corresponding range specified for the applicable actuator, while target position data must be inside the soft stroke limits.

Units: Push-current limiting value = 1%, Acceleration/deceleration = 0.01 G,

Speed = 1/100 mm/sec, Position data/in-position band = 1/100 mm

PLC output = Axis control signal

Byte address

* “Byte+” indicates the Gateway head address,

while n indicates an axis number (0 to 15).

(Sign)

Position data specification (signed 24-bit integer)

Current-limiting value for push motion

Speed specification (24-bit integer)

Acceleration/deceleration specification

Positioning band specification (24-bit integer)

Control signal

PLC input = Axis status signal

Byte address

* “Byte+” indicates the Gateway head address,

while n indicates an axis number (0 to 15).

Sign

(Sign)

Current position data (signed 24-bit integer)

PfofiBus Gateway

Status signal

Caution

1. Signed 24-bit hexadecimal data output or input from/to the PLC is treated as a negative value when the most significant bit is “1.” Take note that all these data are treated as normal numerical data within the PLC.

I/O Signal Details

Signal type Bit

Target

position

data

Current-

limiting

value for

push

motion

PLC output

Speed

Acceleration/

deceleration

24-bit

data

8-bit data

data

8-bit data

Signal

name

PfofiBus Gateway

Description Details

Set a signed 24-bit integer (unit: 0.01 mm) based on hexadecimal notation. Example) To specify +25.4 mm, set “0009ECH”

(“2540” in decimal notation).

z The maximum value that can be set is +9999.99

mm = 999999 (decimal) = 0F423FH (hexadecimal).

z A negative value is indicated by a 2’s complement,

which means that the most significant bit becomes “1.”

z Set position data within the soft stroke limits. To set the push force, set the current-limiting value for

push motion as a hexadecimal value (unit: %). The setting range is from “00H” to “FFH,” with FFH corresponding to 100%. Example) To specify 50%, set “7FH” (corresponding

to the decimal value of 127 obtained by FFH (255) x 50%).

Set a 24-bit integer (unit: 0.01 mm/sec) based on hexadecimal notation. The maximum value is “0F423FH” (“999999” in decimal notation). Example) To specify 200 mm/sec, set “004E20H”

(“20000” in decimal notation). (Cautions) If speed is not set or the set speed is “0,” the actuator will remain stopped. No alarm will generate. If the set speed is changed to “0” during movement, the actuator will decelerate to a stop.

Set an eight-bit integer (unit: 0.01 G) based on hexadecimal notation. Example) To specify 0.2 G, set “14H” (“20” in decimal

notation). The maximum value is “C8H” (“200” in decimal notation) corresponding to 2 G. (Cautions)

Even if acceleration/deceleration is not set, the setting of parameter No. 9, “Default acceleration/deceleration” will not be applied.

6.3 (4)

Signal type Bit

In-position

band

PLC output

Control

signal

Status

signal

PLC input

Current position

data

- b7-b0 - Cannot be used. -

PfofiBus Gateway

Signal

name

Set a 24-bit integer (unit: 0.01 mm) based on

Description Details

6.3 (4) hexadecimal notation. Example) To specify +25.4 mm, set “0009ECH”

(“2540” in decimal notation).

24-bit

data

(Notes)

z Set position data within the soft stroke limits. z Specify the direction of push-motion operation using

DIR.

z Even if in-position band is not set, the setting of

parameter No. 10, “Default in-position band” will not be applied.

b7 - Cannot be used. -

Push direction specification

b6 DIR

(0 = Home return direction,

6.3 (4) 1 = Opposite to home return direction)

b5 PUSH Push-motion operation mode specification 6.3 (4) b4 SON Servo on command 6.2 (7) b3 STP Pause command 6.2 (5) b2 HOME Home return command 6.2 (8) b1 CSTR Start command 6.2 (9) b0 RES Reset command 6.2 (4) b7 EMGS Emergency stop status 6.2 (2) b6 PSFL Missed work 6.3 (4) b5 PWR Controller ready 6.2 (1) b4 SV Ready (servo is on) 6.2 (7) b3 MOVE Moving 6.2 (6) b2 HEND Home return complete 6.2 (8) b1 PEND Positioning complete 6.2 (10) b0 ALM Alarm 6.2 (3)

b7-b0 - Cannot be used. -

The current position data is output as a signed 24-bit

6.3 (4) integer (unit: 0.01 mm) based on hexadecimal

24-bit

data

notation. Example) To specify +25.4 mm, set “0009ECH”

(“2540” in decimal notation). A negative value is indicated by a 2’s complement, which means that the most significant bit becomes “1.”

PfofiBus Gateway

5.3 Command Specification Mode

In this operation mode, one of two patterns can be combined including one (simple direct operation) where only the target position data is specified as a numerical value and all other position data are specified via a position number to operate the actuator, and the other (positioner operation) where the actuator is operated only by specifying a position number. You can also use request commands to read/write the position table, monitor the current value, and broadcast, among others.

Two operation patterns are available: “positioner operation” where the actuator is operated by specifying a position number, and “simple direct operation” where only the target position data is specified as a numerical value and all other position data such as the speed, acceleration/deceleration, positioning band and push-current limiting value are specified via a position number to operate the actuator. As for the axis configuration, these two operation patterns can be used separately or in combination. If the two patterns are combined, the axis numbers must be assigned sequentially from the axes used in positioner operation, followed by the axes used in simple direct operation. You can select the Large mode (160 input bytes, 160 output bytes), Middle mode (128 input bytes, 128 output bytes) or Small mode (64 input bytes, 64 output bytes) depending on the size of the assigned areas, and up to 16 axes can be connected. It is also possible to use request commands to read/write the position table (only in positioner operation), read the current position, and broadcast (only in positioner operation), among others.

Caution

Although the position table can be rewritten only in positioner operation, remember that the position table can be rewritten by up to 100,000 times or so. If the stored positions are not enough, the position table rewrite function can be used to specify additional positions indirectly as numerical values.

∆

PfofiBus Gateway

For all items, the top row indicates positioner operation, while the bottom row indicates simple direct operation.

{: Direct control

Key function

∆: Indirect control

Remarks

X: Disabled

Home return operation Positioning operation

{ {

Specify the position table number. *1 Specify all positioning data other than the

{ ∆

position in the position table, and specify the position data and position table number at the same time.

Speed/acceleration setting

Pitch (incremental) feed

Set in the position table. *1 Set in the position table. Set in the position table. *1 This operation cannot be processed directly.

Issue a command from the host PLC by adding or subtracting an equal pitch data to/from the current position.

Push-motion operation

Speed change during movement

Operation with acceleration and deceleration set differently

Pause Zone signal output

∆

{ {

{

Set in the position table. *1 Set in the position table. This operation is performed by combining two

or more position table numbers. (Refer to the operation manual for the controller.) Set in the position table. *1

Set in the position table.

A zone is set in the position table or using parameters. *2 The current position data is constantly output

from the gateway, so have the PLC monitor the current position data. *3

PIO pattern selection

{

X *5

*1 You can use request commands (position table data write commands) to write (rewrite) data in the

position table from the PLC. In this case, you must write the necessary data in the position table

beforehand. *2 The current position data can be read via request commands, but it is not constantly output. *3. The current position data does not use strobe signals. Accordingly, to check the current position

using the PLC while the actuator is moving, set a zone and confirm that the data has remained in the

specified zone for at least two scan periods. *4 The PCON-SE, ACON-SE and ERC2-SE do not provide the PIO pattern selection parameter (No.

25).

PfofiBus Gateway

5.3.1 Overall Address Configuration

Input/output Gateway control signals consist of four bytes each. Only in this mode, PPS0 to PPS2

and NPS0 to NPS4 of control signal 0 are used to set the pattern and number of position-number

specification axes. The subsequent 14 bytes constitute the command input/output area, and a total of

18 bytes each for input and output, including the Gateway control signals and command area,

constitute the fixed area.

The control area is assigned after the fixed area for each axis. Address assignment is performed from

position-number specification axes first, followed by simple direct mode axes.

Assign the signals so that no gaps remain between the areas of adjacent axes.

The total I/O area size of the Gateway varies in accordance with the setting of the mode setting

switch SW1, as shown in the table below.

Mode

No.

4 3 2 1 7 X X X 8 X

{

Up to 16 axes, including positioner operation axes and simple direct operation axes, can be assigned within the range specified in the table above. The control signals of each axis occupy two input bytes and two output bytes in the case of a positioner operation axis, or six PLC input bytes and eight PLC output bytes in the case of a simple direct operation axis. An example of assigning four positioner operation axes and four simple direct operation axes to be operated in the Small mode is shown on the following page.

SW1

{

X X

- Total I/O area Fixed area

{

Large mode 160 bytes each

{

Middle mode 128 bytes each 110 bytes each

{

Small mode 64 bytes each 46 bytes each

18 bytes each

142 bytes each

Axis control

area

PfofiBus Gateway

Example of Address Configuration

Gateway control area

Command

Command I/O area

I/O area

2 bytes

8 bytes

Small mode

(64 bytes)

Output from PLC ⇒ Gateway Unit

⇒ Input to each axis

Byte

address

Upper byte Lower byte

Gateway control signal 0 Gateway control signal 1

Request command

Data 0 Data 1 Data 2 Data 3

Data 4 Data 5

Positioner operation axis (0) control signal Positioner operation axis (1) control signal Positioner operation axis (2) control signal Positioner operation axis (3) control signal

Simp l e d i r ec t o p er a t i on axis (4)*2 control signal

Simple direct operation axis (5) c o n t r o l s i gnal

Simple direct operation axis (6) c o n t r o l s i gnal

Simple direct operation axis (7) c o n t r o l s i gnal

Cannot be used.

Output from each axis ⇒ Gateway Unit

Positioner operation axis (0) status signal Positioner operation axis (1) status signal Positioner operation axis (2) status signal Positioner operation axis (3) status signal

Simple direct oper at ion axis (4) status signal

Simple direct operation axis (5) status signal

Simple direct operation axis (6) status signal

Simple direct operation axis (7) status signal

⇒ Input to PLC

Upper byte Lower byte

Gateway status signal 0

Gateway status signal 1

Response command

Data 0 Data 1 Data 2

Data 3 Data 4 Data 5

Cannot be used.

Fixed

area

2 bytes

6 bytes

xis control

area

Middle mode

(128 bytes)

Large mode

(160 bytes)

*1 The byte address Byte+ indicates a relative address from the initial byte address of the gateway. *2 The numbers in parentheses ( ) indicate axis numbers on the SIO communication network.

PfofiBus Gateway

5.3.2 Gateway Control/Status Signals

The initial fixed area in the address configuration is used by signals that control the gateway unit, and consists of four input bytes and four output bytes. These signals are used to control the ON/OFF of SIO communication and monitor the SIO communication status and gateway unit status.

PLC output

Gateway

control signal 0

Gateway

control signal 1

PLC input

Gateway

status signal 0

Gateway

status signal 1

* The byte address is indicated as a relative byt e ad dress from the initial byte-address byte of the

gateway.

Byte address

PfofiBus Gateway

I/O Signal List

Signal type Byte Bit

Signal

name

SIO link communication will start when this signal is turned ON, and stop when it is turned OFF. Do not turn the MON signal ON when CFG15 to 0 (linked axis connection) are all OFF.

7 MON

These bits cannot be used. Always set them to OFF (0).

In all other modes, always set these bits to OFF (”0”). Set the axis number (0 to 16) corresponding to each axis operated by positioner operation, using a 5-bit binary code. *1

These bits are used in the command specification mode. In all other modes, always set these bits to OFF (”0”). Set the I/O pattern (pattern 0 to 4) of the axis using a 3-bit binary code. *2

signal 0

PLC output

Control

6-0 -

7 NPS4 These bits are used in the command specification mode. 6 NPS3 5 NPS2 4 NPS1 3 NPS0 2 PPS2 1 PPS1 0 PPS0 7 CFG15 Link ON Axis No. 15 Specify the axis number 6 CFG14 14 5 CFG13 13

4 CFG12 12 3 CFG11 11 2 CFG10 10 1 CFG9 9

Control

signal 1

0 CFG8 8 7 CFG7 7 6 CFG6 6 5 CFG5 5

4 CFG4 4 3 CFG3 3 2 CFG2 2 1 CFG1 1 0 CFG0 0

*1 If the mode setting switch (SW1) specifies the command specification mode and NPS0 to NPS4 are

set to 0, all axes will become simple direct operation axes.

*2 For positioner operation axes, only one I/O pattern of 0 to 4 can be specified.

Description

signal corresponding to any axis not physically connected.

z Do not turn ON any axis number

signal other than the specifiable number selected by the mode

setting switch. If either of the above conditions is breached, a SIO link error will occur.

Signal type Byte Bit

Status

signal 0

PLC input

Status

signal 1

Signal

name

7 RUN

6 G.ER

Gateway Unit normal output

Gateway Unit error detection output

SIO-link

5 T.ER

communication error detection output

4 TPC Port switch ON output

3 MOD4 2 MOD3 1 MOD2 0 MOD1

7 Major V.4 6 Major V.2 5 Major V.1

Mode setting switch 4 ON output Mode setting switch 3 ON output Mode setting switch 2 ON output Mode setting switch 1 ON output

The major version number is output as a three-bit binary value.

4 Minor V.16 3 Minor V.8 2 Minor V.4 1 Minor V.2

The major version number is output as a five-bit binary value.

0 Minor V.1 7 LNK15 Linked Axis No. 15

6 LNK14 14 5 LNK13 13 4 LNK12 12 3 LNK11 11 2 LNK10 10 1 LNK9 9 0 LNK8 8 7 LNK7 7 6 LNK6 6 5 LNK5 5 4 LNK4 4 3 LNK3 3 2 LNK2 2 1 LNK1 1 0 LNK0 0

PfofiBus Gateway

Description

This signal turns ON when a SIO link communication error has been detected. The signal is synchronized with the illumination of the LED (T.ER) on the front face of the unit.

The status of the port switch on the front face of the unit is output. This signal is ON wh ile the por t swi tch i s ON .

The setting status of each pin of the mode setting switch is output. When the switch is turned ON, the applicable bit will turn ON (“1”).

Example) If the version is 1.03, the major

version number is “1” (data:

001), while the minor version number is “3” (data: 00011).

PfofiBus Gateway

5.3.3 Assignment for Each Axis

The I/O signals of each axis vary in terms of the size and content of each applicable area depending on whether the axis is a positioner operation axis or simple direct operation axis.

(1) Control/status signals for positioner operation axis

Each axis consists of two PLC output (control signal) bytes and two PLC input (status signal) bytes, as shown below. Five patterns are available depending on the PIO pattern set by the gateway control signal PPS.

Pattern 0 (standard mode)

Pattern 1 (teaching mode)

Pattern 2 (256 positioning points)

PLC output PLC input

Pattern 3 (512 positioning points)

Pattern 4 (solenoid mode

Pattern 0 (standard mode)

Pattern 1 (teaching mode)

Pattern 2 (256 positioning points)

Pattern 3 (512 positioning points)

Pattern 4 (solenoid mode

* Byte address A: Gateway head address + 18 + 2n

n: Axis number assigned to a positioner operation axis (0 or greater)

Byte address

I/O Signal Details

Signal type Bit

Control

signal

PLC output

Command

position number

Status

signal

PLC input

Completed

position number

b7-b0 PC*** 0 to 3

b6-b0 ST0-ST6 4

b7 to b0 PM*** 0 to 3

b6 to b0

PfofiBus Gateway

Signal

name

Pattern No. Description Details

b7 SON 0 to 4 Servo on command 6.2 (7) b6 RES 0 to 4 Reset command 6.2 (4)

CSTR 0, 2, 3 Start command 6.2 (9)

PWRT 1 Position data load command TEAC 6.2 (17) b4 STP 0 to 4 Pause command 6.2 (5) b3 HOME 0 to 4 Home return command 6.2 (8) b1 BKRL 0, 2 to 4 Forced brake release 6.2 (18) b1 JOG- 1 Jog- command 6.2 (14) b0 JOG+ 1 Jog+ command 6.2 (14) b7 JISL 1 Jog/inching switching 6.2 (15) b6 MOD 1 Teaching mode command 6.2 (16)

Specify the command position number using a binary value.

Specify the start position using a bit pattern.

6.2 (11)

b7 BALM 0 to 4 Battery voltage low alarm b6 ALM 0 to 4 Alarm 6.2 (3) b5 EMGS 0 to 4 Emergency stop 6.2 (2) b4 SV 0 to 4 Ready (servo is on) 6.2 (7) b3 PEND 0, 2 to 4 Positioning complete 6.2 (10)

b3 WEND 1

Position data load command status TEAC

6.2 (17)

b2 HEND 0 to 4 Home return complete 6.2 (8) b1 RMDS 0 to 4 Operation mode status b0 PZONE 0 to 2, 4 Position zone output monitor b7 ZONE1 0, 4 Zone output monitor 1

6.2 (13)

b7 MODS 1 Teaching mode status 6.2 (16) b6 MOVE 0, 1 Moving 6.2 (6)

PE0 to

PE6

The completed position number is read as a binary value.

The completed position is read as a bit pattern.

6.2 (12)

PfofiBus Gateway

(2) Control/status signals for simple direct operation axis

Each axis consists of eight PLC output (control signal) bytes and six PLC input (status signal) bytes, as shown below. The position data specification and current position data signals use singed 32-bit hexadecimals based on integers that are multiples of 0.01 mm.

PLC output = Control signal Byte address*

PLC input = Status signal Byte address

* Byte address B: Initial address of simple direct operation axis m: Axis number assigned only to a simple direct operation axis (0 or greater), indicating each axis as the

nth axis from the first simple direct operation axis.

(Sign)

Position data specification (signed 32-bit integer)

Movement data position number

Control signal

(Cannot be used)

(Sign)

Current position data (signe d 32-bit integer)

Status signal

I/O Signal Details

Signal type Bit

Movement

PLC output

PLC input

Target

position

data

data position number

Control

signal

Current position

data

Status

signal

32-bit

16-bit

B6-b5 - Cannot be used.

b7-b0 - Cannot be used. 32-bit

b7-b1 - Cannot be used.

PfofiBus Gateway

Signal

name

Description Details

Set a signed 32-bit integer (unit: 0.01 mm) based on hexadecimal notation. Example) To specify +25.4 mm, set “0009ECH”

(“2540” in decimal notation).

z The maximum value that can be set is +9999.99

data

mm = 999999 (decimal) = 0F423FH (hexadecimal).

6.3 (5)

z A negative value is indicated by a 2’s complement,

which means that the most significant bit becomes “1.”

z Set position data within the soft stroke limits. All movement data, other than the position data to be

specified, must set in the position table. Specify a desired position number as a hexadecimal code.

6.3 (5)

data

PC1 to

PC32768

B7 BKRL Forced brake release 6.2 (18)

b4 SON Servo on command 6.2 (7) b3 STP Pause command 6.2 (5) b2 HOME Home return command 6.2 (8) b1 CSTR Start command 6.2 (9) b0 RES Reset command 6.2 (4)

The current position data is output as a signed 32-bit

data

integer (unit: 0.01 mm) based on hexadecimal notation.

6.3 (5)

PIO/Modbus switching status

b0 PMSS

0: PIO, 1: Modbus A PIO/Modbus switching command is used to switch

between the two modes. b7 EMGS Emergency stop status 6.2 (2) b6 PSEL Missed work (6.3 (4)) b5 PWR Controller ready 6.2 (1) b4 SV Ready (servo is on) 6.7 (7) b3 MOVE Moving 6.2 (6) b2 HEND Home return complete 6.2 (8) b1 PEND Positioning complete 6. 2 (10) b0 ALM Alarm 6.2 (3)

PfofiBus Gateway

Caution

The corresponding “default parameter value” will not be applied to any movement data that must be specified directly as a numerical value from the PLC. Accordingly, take note that the actuator will not operate or an alarm will generate when any such movement data is not specified as a numerical value. The table below summarizes the method for specifying movement data in each operation mode.

Specified data

Mode

Position number

specification Position Position table Speed

Acceleration/ deceleration

Positioning band Push-current

limiting value

Position table

(Parameter) *1

Position table

(Parameter) *1

Position table

(Parameter) *1

Position table

Direct numerical

specification

PLC numerical

specification

PLC numerical

specification

PLC numerical

specification

PLC numerical

specification

PLC numerical

specification

Positioner operation

*1 (Parameter) indicates that the default parameter value will be applied when the applicable data is not

set in the position table.

Command specification

Simple direct

operation Position table Position table

(Parameter) *1

Position table

(Parameter) *1

Position table

(Parameter) *1

PLC numerical

specification

Position table

(Parameter) * 1

Position table

(Parameter) * 1

Position table

(Parameter) * 1

Position table Position table

PfofiBus Gateway

5.3.4 Command Area

In the command specification mode, command areas are provided to let you use the various commands explained below to read/write the position table, among others.

(1) Address configuration

The request command area and response command area consist of 14 bytes each in the range of (Byte+ 04) to (Byte+ 17).

Output from PLC ⇒ Gateway Unit

⇒ Input to each axis

Upper byte Lower byte Upper byte Lower byte

Request command

Data 0 Data 1 Data 2 Data 3 Data 4 (RSV)*2 Data 5 (RSV)*2

Output from each axis ⇒ Gateway Unit

⇒ Input to PLC

Response command

Data 0 Data 1*3 (Error code) Data 2 Data 3 Data 4 (RSV)*2 Data 5 (RSV)*2

Caution

If a command code is not synchronized with related data, the command does not function properly. With Siemens’s S7 Series PLC, synchronicity (consistency) of ProfiBus I/Os is normally guaranteed only in units of bytes and words. To handle data spanning multiple words synchronously, an applicable item must be set to ensure data consistency in the STEP 7’s HW Config screen (refer to7.4 (5), “Setting for I/O data consistency) and the SFC14 and SFC15 must be used (used in the command function blocks explained in 8).

*1 Byte+ indicates a relative byte address from the initial byte address of the gatew ay. *2 Data 4 (RSV) and data 5 (RSV) are not currently used. *3 If a command error occurs, the most significant bit (b7) of the upper byte of the response command

will turn ON and the applicable error code specified in (4) will be set in response data 1.

(2) Command list

The available commands and commands are listed below.

Function category Code Description

Handshake 0000H Clear a request command. Position table data

write

Position table data read

Writing of position table data to ROM

Present alarm code read

Current value monitor 0440H Monitor the current position of a specified Group broadcast

operation PIO/Modbus control

authority switching

{: Available X: Not available

1000H Write a target position. 1001H Write an in-position band. 1002H Write a speed. 1003H Write a positive boundary for each zone. 1004H Write a negative boundary for each zone. 1005H Write an acceleration. 1006H Write a deceleration. 1007H Write a current-limiting value for push

motion. 1008H Write a load current threshold. 1040H Read a target position. 1041H Read an in-position band. 1042H Read a speed. 1043H Read a positive boundary for each zone. 1044H Read a negative boundary for each zone. 1045H Read an acceleration. 1046H Read a deceleration. 1047H Read a current-limiting value for push

motion. 1048H Read a load current threshold.

0DA0H POS writing coil write

02E0H POS writing complete coil read 0342H

Read an alarm code currently present.

axis.

0D03H Cause all axes in a group to start moving to

the same POS number.

0DA1H

Switch between PIO and Modbus. x

Positioner

operation

axis

{ {

{

{ { { { { {

PfofiBus Gateway

Positioner

operation

axis

{

(3) Each command and data format

[1] Position table data write commands

Command name Byte+*1 PLC output (request) PLC input (response)

Target position write +4 1000H Same as the value in the

6 Position number

8 Position data *2 10 12 Axis number 0 to FH *3 14 (RSV) 16 (RSV)

In-position write +4 1001H Same as the value in the

6 Position number

8 In-position band data *4 10 12 Axis number 0 to FH *3 14 (RSV) 16 (RSV)

Speed write +4 1002H Same as the value in the

6 Position number

8 Speed data *4 10 12 Axis number 0 to FH *3 14 (RSV) 16 (RSV)

Each zone positive boundary write

+4 1003H Same as the value in the

6 Position number

8 Position data *2 10 12 Axis number 0 to FH *3 14 (RSV) 16 (RSV)

Each zone negative boundary write

+4 1004H Same as the value in the

6 Position number

8 Position data *2 10 12 Axis number 0 to FH *3 14 (RSV) 16 (RSV)

Acceleration write +4 1005H Same as the value in the

6 Position number

8 Acceleration data *5 10 0 12 Axis number 0 to FH *3 14 (RSV) 16 (RSV)

request command if normal.

PfofiBus Gateway

Command name Byte+*1 PLC output (request) PLC input (response)

Deceleration write +4 1006H Same as the value in the

6 Position number

request command if normal.

8 Deceleration data *5 10 0 12 Axis number 0 to FH *3 14 (RSV) 16 (RSV)

Push motion currentlimiting value write

+4 1007H Same as the value in the

6 Position number

0000 to 00FFH

(00FFH: maximum current)

request command if normal.

10 0 12 Axis number 0 to FH *3 14 (RSV) 16 (RSV)

Load current threshold write

+4 1008H Same as the value in the

6 Position number

0000 to 00FFH

(00FFH: maximum current)

request command if normal.

10 0 12 Axis number 0 to FH *3 14 (RSV) 16 (RSV)

*1 Relative byte address recognized with respect to the Gateway head address *2 Signed 32-bit integer data *3 Data 00 to 0FH correspond to axis numbers (0) to (15), respectively. *4 32-bit integer data *5 Eight-bit integer data *6 This command is effective only with those position table numbers for which a push-current

limiting value (push-motion operation setting) other than 0 has been set.

[2] Position table data read commands

Command name Byte+*1 PLC output (request) PLC input (response)

Target position read +4 1040H Same as the value in the

6 Position number

request command if normal.

8 0 Target position data *3 10 0 12 Axis number 0 to FH *2 Same as the value in the 14 (RSV)

request command if normal.

16 (RSV)

In-position band read +4 1041H Same as the value in the

6 Position number

request command if normal.

8 0 In-position band data *4 10 0 12 Axis number 0 to FH *2 Same as the value in the 14 (RSV)

request command if normal.

16 (RSV)

Speed read +4 1042H Same as the value in the

6 Position number

request command if normal.

8 0 Speed data *4 10 0 12 Axis number 0 to FH *2 Same as the value in the 14 (RSV)

request command if normal.

16 (RSV)

Each zone positive boundary read

+4 1043H Same as the value in the

6 Position number

request command if normal.

8 0 Positive boundary data for 10 0

each zone *3 12 Axis number 0 to FH *2 Same as the value in the 14 (RSV)

request command if normal. 16 (RSV)

Each zone negative boundary read

+4 1044H Same as the value in the

6 Position number

request command if normal.

8 0 Negative boundary data for

10 0

each zone *3 12 Axis number 0 to FH *2 Same as the value in the 14 (RSV)

request command if normal. 16 (RSV)

Acceleration read +4 1045H Same as the value in the

6 Position number

request command if normal.

8 0 Acceleration data *5 10 0 Same as the value in the 12 Axis number 0 to FH *2

request command if normal. 14 (RSV) 16 (RSV)

PfofiBus Gateway

Command name Byte+*1 PLC output (request) PLC input (response)

Deceleration read +4 1046H Same as the value in the

6 Position number

request command if normal.

8 0 Deceleration data *5 10 0 Same as the value in the 12 Axis number 0 to FH *2

request command if normal. 14 (RSV) 16 (RSV)

Current-limiting value read *6

+4 1047H Same as the value in the

6 Position number 8 0

request command if normal.

0000 to 00FFH

(00FFH: maximum current) 10 0 Same as the value in the 12 Axis number 0 to FH *2

request command if normal. 14 (RSV) 16 (RSV)

Load current threshold read

+4 1048H Same as the value in the

6 Position number 8 0

request command if normal.

0000 to 00FFH

(00FFH: maximum current) 10 0 Same as the value in the 12 Axis number 0 to FH *2

request command if normal. 14 (RSV) 16 (RSV)

*1 Relative byte address recognized with respect to the Gateway head address *2 Data 00 to 0FH correspond to axis numbers (0) to (15), respectively. *3 Signed 32-bit integer data *4 32-bit integer data *5 8-bit integer data *6 This command is effective only with those position table numbers for which a push-current

limiting value (push-motion operation setting) other than 0 has been set.

[3] Position table data ROM write command

Command name Byte+*1 PLC output (request) PLC input (response)

Position table data ROM writing coil write

+4 0DA0H Same as the value in the

6 0

request command if normal.

8 0 10 0 12 Axis number 0 to FH *2 14 (RSV) 16 (RSV)

Position table data ROM writing complete coil read

+4 02E0H Same as the value in the

6 0

request command if normal.

8 0 00FFH = Writing ROM

0000H = ROM writing

complete 10 0 Same as the value in the 12 Axis number 0 to FH *2

request command if normal. 14 (RSV) 16 (RSV)

*1 Relative byte address recognized with respect to the Gateway head address *2 Data 00 to 0FH correspond to axis numbers (0) to (15), respectively.

[4] Present alarm code read command

Command name Byte+*1 PLC output (request) PLC input (response) Alarm code currently present read

+4 0342H Same as the value in the

6 0

request command if normal.

8 0 Alarm code 10 0 Same as the value in the 12 Axis number 0 to FH *2

request command if normal. 14 (RSV) 16 (RSV)

*1 Relative byte address recognized with respect to the Gateway head address *2 Data 00 to 0FH correspond to axis numbers (0) to (15), respectively.

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[5] Current position read command

Command name Byte+*1 PLC output (request) PLC input (r esponse)

Monitor the current position of a specified axis.

+2 0440H Same as the value in the

3 0

request command if normal.

4 0 Current position of the 5 0

specified axis*3

(32-bit signed integer)

6 Axis number 0 to FH *2 7 (RSV)

8 (RSV) *1 Relative byte address recognized with respect to the Gateway head address *2 Data 00 to 0FH correspond to axis numbers (0) to (15), respectively. *3 Signed 32-bit integer data set in units of 0.01 mm

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[6] Group specification broadcast command The axes specified by the group number are started simultaneously to the position specified by the position number. When this command is issued, the Gateway and each controller communicate in the broadcast mode, meaning that the controller does not return any response. The response result indicated by the PLC input only means that the command has been sent successfully to the applicable controllers; it does not indicate the status of each controller. Check the status signal of each axis to determine if the command was executed successfully.

Byte+ PLC output (request) PLC input (response)

+4 0D03H Same as the value in the request

6 Position number *1

command if normal.

8 Group ID number *2 10 0 12 0 14 (RSV) 16 (RSV)

*1 Values that can be specified vary depending on the type and settings of the applicable ROBO

Cylinder controller.

*2 If this number is “0,” all linked axes will move regardless of the group specification.

A desired group number can be set using the applicable system parameter in the PC software.

Caution

1. If a movement command is issued to each axis via a control signal while the movement specified by this command is still in progress, the movement by this command will be cancelled and the operation corresponding to the latest movement command will take place. Since each axis effectively has two movement c omm and inte rfac es, make sure the two interfaces are used exclusively to each other.

2. Even when the link was cancelled by turning OFF the CFG bit of the gateway control signal, once the link is established again the controller will always receive this command to perform the specified operation.

[7] PIO/Modbus switching command

Byte+ PLC output (request) PLC input (response)

+4 0DA1H Same as the value in the request

6 0 8 Coil ON/OFF

00FFH = ON: Modbus (Disable PIO command) 0000H = OFF: PIO (Enable PIO command)

*1 to *3 10 0 12 Axis number 0 to FH 14 0 16 0

*1 The PIO/Modbus switching status is reflected in the status signal PMSS. Also note that this

command cannot be set for position number specification axes (if issued, the command will generate an invalid request command error (0103H)).

*2 Even if the coil is set to OFF (Enable PIO command), axis position data can still be changed

from the PLC via Modbus communication (although the link must be retained).

*3 The controller will still accept and execute movement commands via Modbus communication

even after the control authority is switched to PIO.

command if normal.

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(4) Error response

If a command error occurs, the most significant bit (b7) of the response command will turn ON. In addition, one of the following error codes will be set in response data 1. If no link is currently formed, nothing will be shown in the response command.

Code Description 0101H Invalid address *1 0102H Invalid position number *1 0103H Invalid request command *1 0201H Communication failed 0202H Not executable by the controller

*1) If any of these conditions is found as a result of data check from the PLC, an applicable error

code will be set in the response data without the data being sent to the controller.

(5) How to use commands

To use various commands, proces s the da ta in ea ch c omm a nd a re a according to the flow shown below. This flow assumes that only one command is processed.

Clear the request command area.

Use a command

Response

command area 0?

Write the command code in the

request command area.

Write the necessary data in data

areas 0 to 3.

Response command

= Request command?

Clear data areas 0 to 3.

Clear the request command area

and data areas 0 to 3.

PfofiBus Gateway

6 Communication Signal Details

6.1 Overview of Communication Signal Timings

When a given control signal is turned ON to operate the ROBO Cylinder using the sequence program in the PLC, the maximum response time before a response (status) signal will be received is expressed by the formula below:

Maximum response time (mse c) = Yt + Xt + 2 x Mt + Command processing time (operation time, etc.)

Mt = 10 (msec) x (n+1): SIO link (Modbus) cycle time n: Number of controlled axes Yt: Master → remote I/O station transmission delay Xt: Remote I/O → master station transmission delay

For the master → remote I/O station transmission delay (Yt) and remote I/O → master station transmission delay (Xt), refer to the operation manuals for your ProfiBus master unit and PLC.

PLC sequence program

Control signal

Status signal

Master → remote I/O station transmission delay (Yt)

Remote I/O → master station transmission delay (Xt)

Gateway

Control signal

Status signal

SIO link cycle time SIO link cycle time

Controlle

Control signal

Response

processing time

Status signal

(Note) If a communication error occurs due to a problem along the transmission path, etc.,

a communication retry or retries (up to three times) may occur, in which case the SIO link cycle time (Mt) will be extended.

ProfiBus transmission delay

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6.2 Communication Signals and Operation Timings

(1) Controller ready (PWR) PLC input signal

This signal turns “1” (ON) when the controller becomes ready following the power on.  Function

This signal turns “1” (ON) when the controller has been initialized properly following the power on and becomes ready, regardless of the alarm condition, servo status, etc. Even when an alarm is present, the PWR signal still turns “1” (ON) as long as the controller becomes ready. This signal is synchronized with the status indicator LED (green) on the front panel of the controller.

(2) Emergency stop (EMGS) PLC input signal

This signal turns “1” (ON) when the controller actuates an emergency stop.  Function

This signal turns “1” (ON) when a controller alarm generates, an emergency stop is actuated by the emergency stop circuit (refer to 4.3.1), or the motor drive power is cut off. It will turn “0” (OFF) once the emergency stop is cancelled.

(3) Alarm (ALM) PLC input signal

This signal turns “1” (ON) when the controller’s protective circuit (function) detects an error.  Function

This signal turns “1” (ON) when the controller’s protective circuit (function) is actuated. It will turn “0” (OFF) when the reset (RES) signal is turned “1” (ON) after removing the cause of the problem. (This is not the case with cold-sta rt ala r ms . ) When an alarm is detected, the ALM LED (red) on the front panel of the controller illuminates. This LED remains unlit while the controller is normal. With the ERC2-NP/PN/SE, the LED at the top of the motor unit illuminates in red. When the servo turns on, the LED changes to a steady green light.

(4) Reset (RES) PLC output signal

This signal has two functions. It can be used to reset controller alarms or cancel the remaining travel distance while the actuator is paused.

 Function

[1] When an alarm is present, you can reset the alarm by removing the cause of the alarm and

then turning this signal from “0” (OFF) to “1” (ON). (This is not the case with cold-start alarms.)

[2] While the actuator is paused, you can cancel the remaining travel by turning this signal from

“0” (OFF) to “1” (ON).

PfofiBus Gateway

(5) Pause (STP) PLC output signal

Turning this signal “1” (ON) causes the axis to stop temporarily (decelerate to a stop). Turning it “0” (OFF) resumes the axis movement. The relationship of the STP signal and MOVE (moving) signal is shown below.

tdicm ≤ Acceleration/deceleration tdicp ≤ Yt + 2Mt + Xt + 6 (msec)

(6) Moving (MOVE) PLC input signal

This signal turns “1” (ON) while the actuator is moving with the servo turned on (and also during home return, push-motion operation and jogging). Use the MOVE signal along with PEND for status discrimination on the PLC side. The MOVE signal turns “0” (OFF) upon completion of positioning, home return or push-motion operation, and also while the actuator is paused.

(7) Servo ON command (SON) PLC output signal

Ready (SV) PLC input signal

Turning the SON signal “1” (ON) turns on the servo. Once the servo turns on, the SV LED (green) on the front panel of the controller illuminates. With the ERC2, the LED at the top of the motor unit illuminates in green. The SV signal is synchronized with this LED indicator.

 Function

The controller servo can be turned on/off using the SON (servo ON) signal. While the SV signal is “1” (ON), the controller servo remains on and therefore the controller is operational. The relationship of the SON signal and SV signal is shown below.

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(8) Home return command (HOME) PLC output signal

Home return complete (HEND) PLC input signal

Home return operation starts at the leading edge of the HOME signal from “0” (OFF) to “1” (ON). When the home return is complete, the HEND (home return complete) signal turns “1” (ON). Turn the HOME signal “0” (OFF) after the HEND signal has turned “1” (ON). Once tur n ed “1” (ON), the HEND signal will not turn “0” (OFF) unless the power is turned off or the HOME signal is input again. Accordingly, even after the initial home return is completed you can still perform home return as many times as desired using the HOME signal.

ctuator operation

Mechanical end Stops at the home position.

Caution

1. In the case of a positioner operation axis operating in the position number specification mode or command specification mode, issuing a positioning command to a given position immediately after the power was turned on, without performing the home return first, will cause the actuator to automatically return to its home and then execute the positioning, provided that this is the first operation after the power on.

2. Take note that in any other mode, an alarm “Error code 83: ALARM HOME ABS (absolute position movement command issued before completion of home return)” will generate.

PfofiBus Gateway

(9) Positioning start (CSTR) PLC output signal

Upon detecting the leading edge of this signal from “0” (OFF) to “1” (ON), the controller reads the target position number specified by the binary code of PC1 to PC32768 (the signal varies according to the operation mode), and then performs positioning to the target position corresponding to the applicable position data. The same applies when a numerical value is specified directly in the position data specification area.

Before positioning is performed, the target position, speed and other operation data must be set in the position table using a PC/teaching pendant. If this command is issued before the home return operation is performed following the power on (= while the HEND output signal is “0” (OFF)), the actuator will automatically perform the home return operation and then position itself to the target position. Turn this signal “0” (OFF) after confirming that the PEND signal has turned “0” (OFF).

(10) Positioning complete (PEND) PLC input signal

This signal turns “1” (ON) when the actuator has moved to the target position and entered the positioning band, or when the p ush-motion operation has c ompleted (without missing the load). If the servo has turned ON, the applicable position is set as the target position and accordingly this signal turns “1” (ON). When positioning operation is started using the HOME signal or CSTR signal thereafter, this signal will become “0” (OFF).

Speed

Travel distance

Timing at which the positioning complete signal turns ON

Target position

Time

Positioning band

Caution

If the servo is turned off or an emergency stop is actuated while the actuator is stopped at the target position, the PEND signal turns “0” (OFF). When the servo subsequently turns ON, the signal will turn “1” (ON) again if the actuator is inside the positioning band. If CSTR remains “1” (ON), the PEND signal will not become “1” (ON) even when the current actuator position is inside the positioning band. The PEND signal will turn “1” (ON) when the CSTR signal turns “0” (OFF).

PfofiBus Gateway

(11) Command position number (PC1 to PC512) PLC output signal

A command position number is read as a binary code. The number of command positions varies as follows according to the operation mode:

• Position number specification mode PC1 to PC32 64 points

• Command specification mode, positioner operation PC1 to PC256 512 points

• Command specification mode, simple direct operation PC1 to PC32768

The controller unit reads the PC signal as a binary command position number at the “0” (OFF) Æ “1” (ON) edge of the CSTR si gnal.

(12) Completed position number (PM1 to PM256) PLC input signal

These signals are effective in simple direct operation in the position number specification mode and command specification mode. A completed position number is output as a binary code. When the power is turned on or the actuator is moving, all PM signals from 1 to 256 turn “0” (OFF). When the servo turns off or an emergency stop is actuated, all signals turn "0" (O FF). However, the applicable signal will turn “1” (ON)” again when the servo subsequently turns on, if the actuator is inside the positioning band (INP) relative to the target position. If the actuator has exceeded the positioning band (INP), the signals will remain “0” (OFF). The applicable PM signal will also turn “1” (ON) when the push-motion operation has completed or the actuator has missed the load.

(13) Zone (PZONE, ZONE1, ZONE2) PLC input signal

Each of these signals turns “1” (ON) when the current actuator position is ins ide the specified zone. *1 A desired zone can be set in the position table or using user parameters.

Individual zone boundary fields in position table

User parameter “Zone bou ndary 1” (Parameter No. 1 = + side, No. 2 = - si de ) User parameter “Zone bou ndary 2” (Parameter No. 23 = + side, No. 24 = - side) *1 This signal becomes effective when the home return has completed. As long as the home return

has completed once, this signal remains effective even when the servo is off. *2 PIO pattern 3 is not supported. *3 PIO patterns 1 to 3 are not supported.

Zone signal

ctuator operation

Home

Setting Zone signal

Zone setting- Zone setting+

Position zone

output

PZONE

Zone output 1

ZONE1

Zone output 2

ZONE2

+ direction

Position number

specification

mode

X { *2

{ {

Command

specification

mode, positioner

operation

{ *3

PfofiBus Gateway

(14) Jog+ command/jog- command (JOG+ / JOG-) PLC output signal

These signals are used to operate a positioner operation axis in the command specification mode under PIO pattern 1 (teaching mode). These signals are used to start jogging or inching. When the + command is issued, the actuator moves in the direction opposite home. When the – command is issued, the actuator moves in the direction of home. Jogging or inching is specified by a combination of the JOG signal and JISL signal (jogging/inching switching signal).

[1] Jogging

Jogging is enabled when the jog/inch switching signal (JISL) is “0” (O FF).

While JOG+ is “1” (ON), the actuator moves in the direction opposite home. When the signal

turns “0” (OFF), the actuator decelerates to a stop.

While JOG- is “1” (ON), the actuator moves in the direction of home. When the signal turns “0”

(OFF), the actuator decelerates to a stop.

The operation is set using the following parameter settings:

• Speed: Defined by parameter No. 26 (PIO jog speed)

• Acceleration/deceleration: Rated acceleration/deceleration (varies according to the actuator)

To stop jogging (cause the actuator to decelerate to a stop), turn the current JOG signal from “1”

(ON) to “0” (OFF) or cause both JOG+ and JOG- to turn “1” (ON). [2] Inching

Inching is enabled when the jog/inch switching signal (JISL) is “1” (ON).

The actuator moves by the inching distanc e eve ry time the JO G si gn al turns from “0 ” (O FF) to

“1” (ON).

The actuator inches in the direction opposite home when JOG+ is issued, or in the direction of

home if JOG- is issued.

The operation is set using the following parameter settings:

• Speed: Defined by parameter No. 26 (PIO jog speed)

• Travel distance: Defined by parameter No. 48 (PIO inching distance)

• Acceleration/deceleration: Rated acceleration/deceleration (varies according to the actuator)

During normal operation, the actuator will continue with the normal operation even after the

JOG+ or JOG- signal is turned “1” (ON) (= the JOG signal will be ignored). Also while the

actuator is paused, the actuator will not operate even after the JOG+ or JOG- signal is turned “1”

(ON) (= the JOG signal will be ignored).

Caution

Exercise caution that the actuator may collide with a mechanical end before the home return is completed, because the software stroke limits are still not effective during this period.

PfofiBus Gateway

(15) Jog/inch switching (JISL) PLC output signal

This signal is used to switch between jogging and inching. JISL = “0” (OFF): Jogging JISL = “1” (ON): Inching If the JISL signal switches to “1” (ON) during jogging, the accelerator will decelerate to a stop and the inching function will be enabled. If the JISL signal switches to “0” (OFF) during inching, the actuator will complete the inching and then the jogging function will be enabled.

Jogging and inching commands are issued by a combination of the JISL signal and the JOG+/JOGsignal. The relationships of these signals are summariz ed in the table below.

Jogging Inching

JISL “0” (OFF) “1” (ON)

Speed Parameter No. 26 (jog speed) Parameter No. 26 (jog speed)

Travel distance - Parameter No. 48 (inch distance)

Acceleration/

deceleration

Rated value (varies according to the

actuator)

Rated value (varies according to the

actuator)

(16) Teaching mode command (MOD) PLC output signal

Teaching mode status (MODS) PLC input signal

These signals are used when a positioner operation axis is operated in the command specification mode under PIO pattern 1 (teaching mode). When the MOD signal is turned “1” (ON), the actuator switches from the normal operation mode to the teaching mode. The controller of each axis turns the MODS signal “1” (ON) upon switching to the teaching mode. Be sure to perform teaching operation after confirming on the PLC side that the MODS signal has turned “1” (ON). *1 The following conditions must be satisfied before the actuator can be switched from the normal

operation mode to the teaching mode:

• The actuator (motor) is stop ped

• The JOG+ signal and JOG- signal are “0” (OFF)

• The position data read command (PWRT) signal and positioning start (CSTR) signal are “0”

(OFF) The PWRT signal must also be “0” (OFF) when switching from the teaching mode to the normal operation mode.

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(17) Position data read command (PWRT) PLC output signal

Position data read complete (WEND) PLC input signal

These signals are used when a positioner operation axis is operated in the command specification mode under PIO pattern 1 (teaching mode). The PWRT signal is effective when the MODS signal is “1” (ON). When the PWRT signal is turned “1” (ON) for 20 msec or more (*1), the current position data will be written to the “Position” field under the position number currently specified by the PLC command. (*2) When the writing is complete, the WEND signal turns “1” (ON). The host PLC should turn the PWRT signal “0” (OFF) after the WEND signal has turned “1” (ON). If the PWRT signal is turned “0” (OFF) before the WEND signal turns “1” (ON), the WEND signal will not turn “1” (ON). When the PWRT signal is turned “0” (OFF), the WEND signal turns “0” (OFF). *1 Make sure the signal remains “1” (ON) for 20 msec or more. If the signal is turned “1” (ON) for

less than 20 msec, the data may not be written.

*2 If any data other than position is not yet defined, the default value of the applicable parameter

will be written.

20 msec or more

(18) Forced brake release (BKRL) PLC output signal

You can forcibly release the brake by turning this signal “1” (ON).

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6.3 Basic Operation Timings

(1) Preparation

After confirming that the slider or rod is not colliding with a mechanical end or the load is not contacting any surrounding equipment, start the system by following the procedure below: [1] Cancel the emergency stop or enable the motor drive power supply. [2] Turn on the 24-VDC controller power via the 24-V terminal and 0-V terminal on the power-supply

terminal block.

[3] Set the minimum required parameters.

(Example) • To change the feed speed during teaching:

Change the value of parameter No. 35 (Safety speed).

[4] In the positioner mode or simple direct mode, set appropriate values in the “Position,” “Speed,”

“Acceleration” and “Decele ration” fields, etc., in the position table.

Safety circuit status

24-VDC controller power supply

SV lamp (front panel)

Controller ready

Pause

Servo ON

Ready

Positioning complete

Emergency stop cancelled

Illuminates in orange for 2 seconds, and then turns off.

Default parameter

setting

1.6 sec or less

Green

Pause cancelled

Caution

When the power is turned on while an emergency st op is ac tua te d and the n the e mergency stop is cancelled (= the SON signal is turned “1” (ON)), the servo will turn on up to 1.6 sec after the cancellation of the emergency stop.

1.6 sec or less

Emergency stop cancelled

Servo on

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Warning

With the ACON, excited-phase detection operation is performed when the servo is turned on for the first time following the power on. Because of this detection operation, the actuator normally moves by approx. 0.5 to 2 mm, although the specific dimension varies according to the ball screw lead. (On rare occasions, the actuator may move by up to around a half of the ball screw lead depending on the actuator position when the power is turned on.) Also note that if the power is turned on while the actuator is near a mechanical end, the actuator may contact the mechanical end during the detection operation and reverse its direction as a result. Exercise due caution not to cause the load or robot hand to get damaged as a result of contact with surrounding objects during this detection operation.

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(2) Home return operation

The controller unit uses an incremental position detector (encoder), which means that once the power is cut off, the mechanical coordinates will be lost. Accordingly, home return must be performed after the power is turned on to establish the mechanical coordinates. To perform home return operation, input the home return command (HOME) signal. For your information, home return operation is not required if the simple absolute R unit is connected to the controller unit to convert the axes into absolute axes.

Operation timings PLC process 1: The home return command (HOME) signal turns “1” (ON) when the start button is

pressed.

Operation: [1] The actuator starts moving toward the mechanical end on the home s ide .

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

stops at the home position → The home return complete (HEND) signal turns “1” (ON).

PLC process 2: The home return command (HOME) signal is turned “0” (OFF) after confirmation of the

HEND signal turning “1” (ON).

PLC process 3: The actuator starts continuous operation.

Home return command

Home return complete

Positioning complete

Moving

1 msec or less

Actuator movement

[1] [2]

position

Power inpu

Home position

Mechanical end

Caution

Pay attention to the following points when performing home return: [1] Confirm that no obstacle exists in the direction of home return. [2] Should an obstacle be found in the direction of home return, tentatively move the actuator in the

direction opposite home and remove the obstacle. [3] Turning the HOME signal “1” (ON) turns the PEND signal “0” (OFF) and MOVE signal “1” (ON). Turn the HOME signal “0” (OFF) again after confirming that the HEND signal has turned “1” (ON) while the HOME signal is still “1” (ON).

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(3) Operation by position number specification

Positioner operation in the position number specification mode or command specification mode is explained.

 Operation The actuator is operated by specifying position data in the controller’s position table beforehand, and specifying a desired position number using the link register in the PLC. The push-motion operation, speed change during movement, pitch feed by incremental coordinate specification, etc., are the same in PIO (I/O cable) operation. Refer to the operation manual for your PCON, ACON, SCON or ERC2. [1] Set the position number in the command position number register. [2] Next, turn the start command (CSTR) signal “1” (ON) after confirming that the positioning

complete (PEND) signal is “1” (ON). [3] PEND turns “0” (OFF) tdpf after CSTR has turned “1” (ON). [4] Turn CSTR “0” (OFF) after confirming that PEND has turned “0” (OFF). [5] MOVE turns “1” (ON) simultaneously as PEND turns “0” (OFF) or within 1 Mt thereafter. [6] When the remaining travel falls within the positioning band (INP), PEND turns “1” (ON) if CSTR

is “0” (OFF), and then the completed position number is output.

Accordingly, when reading the completed position number upon completion of positioning, check

the position number after waiting for an appropriate period (time needed to complete the

remaining travel) after PEND has turned “1” (ON).

Caution

• When the start (CSTR) signal turns “1” (ON), the positioning complete (PEND) signal turns “0” (OFF) and moving (MOVE) signal turns “1” (ON). Be sure to turn the CSTR signal OFF after confirming that PEND has turned OFF while the CSTR signal is still ON. If CSTR remain ON, PEND will not turn ON even after the actuator completes its movement, shown below.

Start Positioning complete

Moving

ctuator

Movement complete

• If a movement command is issued to the same position, the positioning complete output will turn OFF, but the moving output will not turn ON.

• The moving output turns OFF the moment the positioning complete output turns ON, even when the actuator is still moving. Accordingly, increasing the positioning band specified by the position data may result in a situation where the moving signal turns OFF the moment the positioning complete output turns ON, but the actuator may be still moving.

• When a soft limit is reached after continuous incremental moves, the actuator will stop at that position and then the positioning complete signal will be output.

[1]

Command position number

Positioning complete

Completed pos i tion

Start command

number

Moving

[2]

[3]

[4]

[6]

[5]

*1 T1: Set T1 to 0 ms or more by considering the scan time of the host controller. *2 Yt+2Mt+Xt≤tdpf≤Yt+2Mt+Xt+7 (ms)

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(4) Operation in the direct numerical specification mode

The actuator is operated not by using the position table of the controller, but by writing the target position data, acceleration/deceleration data, speed data, push-current limiting value data and positioning band data to the link registers in the PLC. All these data must be set in the case of push-motion operation. In the case of normal positioning operation, the push-current limiting value data, PUSH signal and DIR signal are not required. Take note that in either operation, the actuator will not move unless all necessary data is set.

 Operation [Push-motion operation] [1] Set the push start position data in the target position data specification register. [2] Set the speed data until the push start position in the speed specification register, and set the

corresponding acceleration/deceleration data in the acceleration/deceleration register. Take note that even if acceleration/de celeration is not set, the setting of parameter No. 9, “Def ault

acceleration/deceleration” will not be applied. [3] Set the push-motion travel in the positioning band specification register. (*) [4] Set the push-current limiting value data in the push-current limiting value register in order to set

the push force. [5] Turn the PUSH (push-motion operation mode specification) signal “1” (ON). [6] Use the DIR (push direction specification) signal to select the push direction.

When the DIR signal is set to “1” (ON), push-motion operation is performed in the direction

opposite home. When the signal is set to “0” (OFF), push-motion operation is performed in the

direction of home. [7] Next, turn the start command (CSTR) signal “1” (ON) after confirming that the positioning

complete (PEND) signal is “1” (ON).

The data set in [1] to [4] will be read by the controller at the “0” (OFF) Æ “1” (ON) edge of CSTR

(leading edge of the signal). [8] PEND turns “0” (OFF) tdpf after CSTR has turned “1” (ON). [9] Turn CSTR “0” (OFF) after confirming that the PEND signal has turned “0” (OFF) or MOVE

signal has turned “1” (ON). [10] MOVE turns “1” (ON) simultaneously as PEND turns “0” (OFF) or within 1 Mt thereafter. [11] PEND turns “1” (ON) when the motor current reaches the push-current limiting value set in [4]

while CSTR is “0” (OFF). (The push operation has completed.)

If the motor current does not reach the push-current limiting value set in [4] even after the

positioning band set in [3] has been reached, the PSFL (missed load in push operation) signal

turns “1” (ON). In this case, PEND will not turn “1” (ON). (The actuator has missed the load.) [12] The current position data is constantly refreshed. [13] Turn PUSH “0” (OFF) after PEND or PSFL has turned “1” (ON).

* Take note that even if positioning band specification data is not set, the value of parameter

No. 10, “Default positioning band” will not be applied.

[Normal positioning operation]

In the case of normal operation, the operation continues while the PUSH signal is still “0” (OFF)

in [5] above. Setting of push-current limiting value data in [4] is not required. PEND turns “1”

(ON) when the remaining travel falls within the range of positioning band specification data set in

[3], while CSTR is “0” (OFF).

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Set value of target

position data

Set value of speed and

acceleration/deceleration

data

Set value of positioning

band data

Set value of push-current

limiting value data

Push mode

Push direction

Start command

Positioning complete/missed

load in push operation

Current position

Moving

[1]

[2]

[3]

[4]

[5]

[6]

[7]

[13]

[8]

[10]

[9]

[11]

[12]

*1 T1: Set T1 to 0 ms or more by considering the scan time

of the host controller.

*2 Yt+2Mt+Xt≤tdpf≤Yt+2Mt+Xt+7 (ms)

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The target position data, acceleration/deceleration data, speed data, positioning band data and pushcurrent limiting value data can be changed while the actuator is moving. After a given data has been changed, turn CSTR “1” (ON) for at least tdpf. Also, after CSTR is turned “0” (OFF), wait for at least 1 Mt before turning it “1” (ON). An example of changing the speed and acceleration/deceleration data is given below.

Set value of speed and

acceleration/

deceleration data

[1]

[2]

[3]

Actuator

speed

Speed n2

Speed n3

Caution

1. If speed data is not set or the set speed is zero, the actuator will remain standstill and no alarm will generate.

2. If the speed data setting is changed to zero while the actuator is moving, the actuator will decelerate to a stop and no alarm will generate.

3. Even when only the acceleration/deceleration data or speed data is changed while the actuator is moving, the target position data must still be set.

4. Even when only the target position data is changed while the actuator is moving, the acceleration/deceleration data and speed data must still be set.

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(5) Simple direct operation (command specification mode)

The actuator is operated by writing the target position data to the link register in the PLC and specifying other data such as the speed, acceleration/deceleration, positioning band and pushcurrent limiting value in the position table.

 Preparation

Set all position data other than the target position (speed, acceleration/deceleration, positioning band, push-current limiting value, etc.) in the position table.

 Operation [Normal positioning operation] [1] Set the target position data in the position data specification register. [2] Set the position number in the command position number register. [3] Turn the start command (CSTR) signal “1” (ON) after confirming that the positioning complete

(PEND) signal is “1” (ON) or moving (MOVE) signal is “0” (OFF). The target position data will be read by the controller at the “0” (OFF) Æ “1” (ON) edge of CSTR

(leading edge of the signal). [4] PEND turns “0” (OFF) tdpf after CSTR has turned “1” (ON). [5] Turn CSTR “0” (OFF) after confirming that the PEND signal has turned “0” (OFF) or MOVE

signal has turned “1” (ON).

Do not change the target position data until CSTR turns “0” (OFF). [6] MOVE turns “1” (ON) simultaneously as PEND turns “0” (OFF) or within 1 Mt thereafter. [7] The current position data is constantly refreshed. When the remaining travel falls within the

specified positioning band (INP), PEND turns “1” (ON) if CSTR is “0” (OFF).

Accordingly, when reading the completed position number upon completion of positioning, check

the position number after waiting for an appropriate period (time needed to complete the

remaining travel) after PEND has turned “1” (ON).

Also note that the current position data may shift somewhat due to vibration, etc., even while the

actuator is stopped. [8] MOVE turns “0” (OFF) simultaneously as PEND turns “1” (ON) or within 1 Mt thereafter. [9] The target position data can be changed while the actuator is moving.

To change the target position while the actuator is moving, change the target position data, wait

for the PLC scan time, and then turn CSTR “1” (ON).

In this case, turn CSTR “1” (ON) for at least tdpf. Also, after CSTR is turned “0” (OFF), wait for at

least 1 Mt before turning it “1” (ON). [Push-motion operation]

Push-motion operation is performed by setting a push-current limiting value in the Push field of

the position table in the preparation stage, and then performing positioning to the applicable

position number.

PfofiBus Gateway

[1]

Set value of target

position data

Command position

number

Start command

Positioning

complete

Current position

Moving

[2]

[3]

[4]

[5]

[7]

[8]

[6]

*1 T1: Set T1 to 0 ms or more by considering the scan time

of the host controller. *2 Yt+2Mt+Xt≤tdpf≤Yt+2Mt+Xt+7 (ms) *3 twcsON1≥Mt *4 twcsOFF≥1Mt

IAI America RCM-GW-PR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual