IAI America SCON-C User Manual

Operation Manual Fourteenth Edition

SCON Controller

Please Read Before Use

Thank you for purchasing our product. This Operation Manual explains the handling methods, structure and maintenance of this product, among others,

providing the information you need to know to use the product safely. Before using the product, be sure to read this manual and fully understand the contents explained herein to

ensure safe use of the product. The CD that comes with the product contains operation manuals for IAI products. When using the product, refer to the necessary portions of the applicable operation manual by printing them out or displaying them on a PC.

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

[Important]

 This Operation Manual is original.  The product cannot be operated in any way unless expressly specified in this Operation Manual. IAI shall

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

 Information contained in this Operation Manual is subject to change without notice for the purpose of

product improvement.

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

office near you.

 Using or copying all or part of this Operation Manual without permission is prohibited.  The company names, names of products and trademarks of each company shown in the sentence s are

registered trademarks.

1. PC Software and Teaching Pendant Models

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

Model Remarks

PC software (with RS232C communication cable)

PC software (with USB communication cable)

Teaching pendant CON-T

Teaching pendant RCM-T

Simple teaching pendant RCM-E

Data setting unit RCM-P

Touch panel display RCM-PM-01

2. Recommendation for Backing up Latest Data

This product uses nonvolatile memory to store the position table and parameters. Normally the memory will retain the stored data even after the power is disconnected. However, the data may be lost if the nonvolatile memory becomes faulty. (We strongly recommend that the latest position table and parameter data be backed up so that the data can be restored quickly in the event of power failure, or when the controller must be replaced for a given reason.) The data can be backed up using the following methods: [1] Save to a CD or FD from the PC software. [2] Hand write the position table and parameter table on paper.

3. Using a Rotary Actuator of Multi-rotation Specification

Rotary actuators available in the multi-rotation specification allow the user to select the multi-rotation mode or limited-rotation mode using a parameter. For the parameter setting, refer to 3.2.5, “Linear/Rotary Control” under 3, “Parameter Settings” in Appendix. When using a rotary actuator of multi-rotation specification, the user should take note of the following points: [1] Rotational axes of absolute specification do not support the index mode. Accordingly, these axes

cannot perform multi-rotation operations.

[2] In solenoid valve mode 2 [3-point type]: PIO pattern 5 (parameter No. 25), rotary operations cannot be

performed by means of relative coordinate specification.

Actuator

RCM-101-MW

RCM-101-USB

All are compatible with existing RCS/E-Con controllers.

Cannot be connected to conventional RCS controller

Applicable models

RS-30/60

RCS2-RT6/RT6R/RT7/RT7R

RCS2-RTC8L/RTC8HL/RTC10L/RTC12L

CAUTION

Precautions

Please use rotary actuators of multi-rotation specification within the range where the following formula is satisfied. Moreover, the maximum rotation angle is ±9999 [deg]

±2

Maximum rotation angle [deg]

≥

Unit Travel Distance [deg/pulse]

• Maximum rotation angle: Set the usage conditions (maximum -9999 to 9999 [deg]).

Note 1 :The following models can not be rotated up to ±9999.99 [deg].

deceleration ratio 1/24

1/30 1/50 1/100

Maximum rotation angle

corresponding model

[deg]

±7679.99 RCS2-RTC8、RCS2-RTC10 ±6143.99 ±3685

RCS2-RTC12 RS-30、RS-60

±1842

• Unit movement: The amount of movement per command pulse.

Example) In case RCS2-RTC8L-I-12-24(deceleration ratio：1/24) is operated maximum rotation

angle 6000 [deg].

223

Maximum rotation angle [deg]

≥

Unit Travel Distance [deg/pulse]

≥

±2

Maximum rotation angle [deg]

±2

6000

≥

±2

≥

553600

16384 60

Therefore, the actuator can be operated in this case.

(NOTE1)

(maximum software stroke limit).

No. of Encoder Pluses [pulse/rev]

360[deg/rev] × Rotary Axis

deceleration

Ratio

 About zone function change

Applicable application version: From V001E In zone signal settings, it is now valid to specify plus side zone setting smaller than minus side zone setting. Up to V001D: Zone signals are not output in the case of plus side zone settin g  minus side zone setting only. From V001E: Zone signals are not output in the case of plus side zone settin g = minus side zone setting o nly. With this arrangement, zone output is enabled even if the zone single ON range spans over 0 in the index mode of rotary actuators. An example is shown below.

[In index mode of rotary actuators]

Setting value

Plus side zone setting: 70 Minus side zone setting: 315

[In case of translation axis]

Current position

Zone signal output

Range of zone signal ON

Setting value

Plus side zone setting: 315 Minus side zone setting: 70

Setting value

Plus side zone setting: 70 mm Minus side zone setting: 30 mm

Setting value

Plus side zone setting: 30 mm Minus side zone setting: 70 mm

CAUTION

Safety Guide....................................................................................................Pre-1

Chapter 1 Introduction .........................................................................................1

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

1.1 Introduction........................................................................................................................... 1

1.2 SCON Functions ..................................................................................................................1

1.3 How to Read the Model Specification ..................................................................................4

1.4 System Configuration........................................................................................................... 5

1.5 Procedure from Unpacking to Test Operation and Adjustment............................................ 6

1.6 Warranty Period and Scope of Warranty.............................................................................. 8

2. Specifications..........................................................................................................................9

2.1 Basic Specifications..............................................................................................................9

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

2.3 External Dimensions ..........................................................................................................21

3. Installation and Wiring...........................................................................................................23

3.1 Installation Environment..................................................................................................... 23

3.2 Heat Radiation and Installation ..........................................................................................23

3.3 Noise Elimination Measures and Grounding...................................................................... 24

3.4 Wiring the Power Supply....................................................................................................26

3.5 Connecting the Actuator..................................................................................................... 28

3.6 Connecting the PIO Cable (I/O)......................................................................................... 29

3.7 External Input/Output Specifications.................................................................................. 30

3.8 Connecting the Emergency Stop Input (Wiring to the System I/O Connector).................. 32

3.9 Connecting the Regenerative Unit (RB)............................................................................. 48

3.10 Connecting the Brake Box (RCB-110-RA13-0)..............................................................50

Chapter 2 Positioner Mode................................................................................52

1. I/O Signal Control and Signal Functions...............................................................................52

1.1 PIO Patterns and Signal Assignments ...............................................................................52

1.2 Connecting the I/O Cable................................................................................................... 61

1.3 Details of I/O Signal Functions...........................................................................................67

2. Data Entry.............................................................................................................................77

2.1 Description of Position Table..............................................................................................77

2.2 Explanation of Modes......................................................................................................... 84

2.3 Power-saving Modes at Standby Positions........................................................................ 94

3. Operation..............................................................................................................................96

3.1 How to Start........................................................................................................................96

3.2 How Return Operation...................................................................................................... 107

3.3 Positioning Mode (Back and Forth Movement between Two Points)...............................109

3.4 Push & Hold Mode ............................................................................................................111

3.5 Speed Change during Movement..................................................................................... 114

3.6 Operation at Different Acceleration and Deceleration Settings........................................ 116

3.7 Pause ............................................................................................................................... 118

3.8 Zone Signal Output .......................................................................................................... 120

3.9 Incremental Moves........................................................................................................... 123

Jogging/Teaching Using PIO........................................................................................ 129

3.10

3.11 Operations in Solenoid Valve Mode 1 [7-point Type]....................................................131

3.12 Operations in Solenoid Valve Mode 2 [3-point Type]....................................................135

Chapter 3 Pulse-train Input Mode....................................................................142

1. Overview.............................................................................................................................142

1.1 Features ........................................................................................................................... 142

1.2 Standard Accessories.......................................................................................................143

1.3 Options .............................................................................................................................143

2. Wiring..................................................................................................................................147

2.1 External Connection Diagram..........................................................................................147

2.2 Command Pulse-train Input Specifications ......................................................................148

2.3 Feedback Pulse Output Part ............................................................................................149

3. I/O Signal Control and Signal Functions.............................................................................150

3.1 Input Signals.....................................................................................................................150

3.2 Output Signals..................................................................................................................156

4. How to Switch to the Pulse-train Control Mode...................................................................161

5. Parameters .........................................................................................................................162

5.1 Parameter Settings Required for Operation..................................................................... 162

5.2 Effective Parameters in the Pulse-train Mode.................................................................. 166

* Appendix ..........................................................................................................169

1. Actuator Specification List...................................................................................................169

2. Battery Backup Function.....................................................................................................174

2.1 Absolute-encoder Backup Battery....................................................................................175

3. Parameter Settings.............................................................................................................177

3.1 Parameter Table...............................................................................................................177

3.2 Detail Explanation of Parameters.....................................................................................179

4. PC/Teaching Pendant Connection Method in Multi-axis Configurations.............................202

4.1 Connection Example........................................................................................................202

4.2 Name and Function of Each Part of the SIO Converter...................................................203

4.3 Address Switch.................................................................................................................205

4.4 Connection Cables........................................................................................................... 205

4.5 Detail Connection Diagram ..............................................................................................206

5. Troubleshooting..................................................................................................................207

5.1 Action to Be T aken upon Occurrence of Problem............................................................207

5.2 Alarm Level Classification................................................................................................208

5.3 Alarm Description Output Using PIO................................................................................209

5.4 Alarm Description and Cause/Action ............................................................................... 211

5.5 Messages Displayed during Operation Using the Teaching Pendant..............................220

5.6 Specific Problems.............................................................................................................222

6. Basic Example of Positioning Sequence ............................................................................224

Recording of Parameters ...........................................................................................................227

Change History...................................................................................................229

Safety Guide

This “Safety Guide” is intended to ensure the correct use of this product and prevent dangers and property damage. Be sure to read this section before using your product.

Regulations and Standards Governing Industrial Robots

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

Safety measures Inherent safety design

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

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

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

JIS B 8433 (Manipulating industrial robots – Safety)

Also, Japanese laws regulate the safety of industrial robots, as follows: Industrial Safety and Health Law Article 59

Workers engaged in dangerous or harmful operations must recei ve special education.

Ordinance on Industrial Safety and Health Article 36 --- Operations requiring special education

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

apply)

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

(exceptions apply)

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

Pre-1

Requirements for Industrial Robots under Ordinance on Industrial Safety and

Health

Work area Work condition Cutoff of drive source Measure Article

Signs for starting operation Article 104 Outside Installation of railings, enclosures, etc. Sign, etc., indicating that work is in progress Preparation of work rules Article 150-3 Measures to enable immediate stopping of operation Sign, etc., indicating that work is in progress Provision of special education Article 36-31 Checkup, etc., before commencement of work To be performed after stopping the operation Sign, etc., indicating that work is in progress Preparation of work rules Article 150-5 Measures to enable immediate stopping of operation Sign, etc., indicating that work is in progress Provision of special education (excluding cleaning and lubrication)

Article 150-4 Article 150-3

Article 150-3 Article 150-3

Article 151 Article 150-5 Article 150-5

Article 150-5 Article 150-5 Article 36-32

movement

range

Inside

movement

range

During

automatic

operation

During

teaching, etc.

During

inspection, etc.

Not cut off

Cut off (including

stopping of operation)

Not cut off

Cut off

Not cut off (when

inspection, etc., must

be performed during

operation)

Pre-2

Applicable Modes of IAI’s Industrial Robot

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

(1) Single-axis robo with a motor wattage of 80 W or less (2) Combined multi-axis robot whose X, Y and Z-axes are 300 mm or shorter and whose rotating part, if

any, has the maximum movement range of within 300 mm

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

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

1. Single-axis ROBO Cylinders RCS2/RCS2CR-SS8

2. Single-axis robots The following models whose stroke exceeds 300 mm and who se motor capacity also exceeds 80 W: ISA/ISPA, ISDA/ISPDA, ISWA/ISPWA, IF, FS, NS

3. Linear servo actuators All models whose stroke exceeds 300 mm

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

5. IX SCARA robots

All models whose arm length exceeds 300 mm (All models excluding IX-NNN1205/1505/1805/2515, NNW2515 and NNC1205/1 505/1805/2515)

 whose stroke exceeds 300 mm

including the tip of the rotating part

Pre-3

Notes on Safety of Our Products

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

No. Task Note

1 Model

selection

2 Transportation

3 Storage/

preservation

4 Installation/

startup

 This product is not planned or designed for uses requiring high degrees of safety.

Accordingly, it cannot be used to sustain or support life and must not be used in the

following applications: [1] Medical devices relating to maintenance, management, etc., of life or health [2] Mechanisms or mechanical devices (vehicles, railway facilities, aircraft facilities, etc.)

intended to move or transport people [3] Important safety parts in mechanical devices (safety devices, etc.)

 Do not use this product in the following environments:

[1] Place subject to flammable gases, ignitable objects, flammables, explosives, etc. [2] Place that may be exposed to radiation [3] Place where the surrounding air temperature or relative humidity exceeds the specified

range [4] Place subject to direct sunlight or radiated heat from large heat sources [5] Place subject to sudden temperature shift and condensation [6] Place subject to corrosive gases (sulfuric acid, hydrochloric acid, etc.) [7] Place subject to excessive dust, salt or iron powder [8] Place where the product receives direct vibration or impact

 Do not use this product outside the specified ranges. Doing so may significantly shorten

the life of the product or result in product failure or facility stoppage.

 When transporting the product, exercise due caution not to bump or drop the product.  Use appropriate means for transportation.  Do not step on the package.  Do not place on the package any heavy article that may deform the package.  When using a crane of 1 ton or more in capacity, make sure the crane operators are

qualified to operate cranes and perform slinging work.

 When using a crane, etc., never hoist articles exceeding the rated load of the crane, etc.  Use hoisting equipment suitable for the article to be hoisted. Calculate the load needed

to cut off the hoisting equipment and other loads incidental to equipment operation by

considering a safety factor. Also check the hoisting equipment for damage.

 Do not climb onto the article while it is being hoisted.  Do not keep the article hoisted for an extended period of time.  Do not stand under the hoisted article.

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

Among others, be careful not to cause condensation. (1) Installing the robot, controller, etc.

 Be sure to firmly secure and affix the product (including its work part).

If the product tips over, drops, malfunctions, etc., damage or injury may result.

 Do not step on the product or place any article on top. The product may tip over or the

article may drop, resulting in injury, product damage, loss of/drop in product

performance, shorter life, etc.

 If the product is used in any of the following places, provide sufficient shielding

measures: [1] Place subject to electrical noise [2] Place subject to a strong electric or magnetic field [3] Place where power lines or drive lines are wired nearby [4] Place subject to splashed water, oil or chemicals

Pre-4

No. Task Note

4 Installation/

startup

(2) Wiring the cables

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

tool, etc.

 Do not damage, forcibly bend, pull, loop round an object or pinch the cables or place

heavy articles on top. Current leak or poor electrical continuity may occur, resulting in

fire, electric shock or malfunction.

 Wire the product correctly after turning off the power.  When wiring a DC power supply (+24 V), pay attention to the positive and negative

polarities.

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

malfunction.

 Securely connect the cables and connectors so that they will not be disconnected or

come loose. Failing to do so may result in fire, electric shock or product malfunction.

 Do not cut and reconnect the cables of the product to extend or shorten the cables.

Doing so may result in fire or product malfunction. (3) Grounding

 Be sure to provide class D (former class 3) grounding for the controller. Grounding is

required to prevent electric shock and electrostatic charges, improve noise resistance

and suppress unnecessary electromagnetic radiation. (4) Safety measures

 Implement safety measures (such as installing safety fences, etc.) to prevent entry into

the movement range of the robot when the product is moving or can be moved.

Contacting the moving robot may result in death or serious injury.

 Be sure to provide an emergency stop circuit so that the product can be stopped

immediately in case of emergency during operation.

 Implement safety measures so that the product cannot be started only by turning on the

power. If the product starts suddenly, injury or product damage may result.

 Implement safety measures so that the product will not start upon cancellation of an

emergency stop or recovery of power following a power outage. Failure to do so may

result in injury, equipment damage, etc.

 Put up a sign saying “WORK IN PROGRESS. DO NOT TURN ON POWER,” etc.,

during installation, adjustment, etc. If the power is accidently turned on, electric shock or

injury may result.

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

outage or emergency stop.

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

necessary.

 Do not insert fingers and objects into openings in the product. Doing so may result in

injury, electric shock, product damage, fire, etc.

 When releasing the brake of the vertically installed actuator, be careful not to let the

actuator drop due to its dead weight, causing pinched hands or damaged work part, etc.

5 Teaching

 Whenever possible, perform teaching from outside the safety fences. If teaching must

be performed inside the safety fences, prepare “work rules” and ma ke sure the operator

understands the procedures thoroughly.

 When working inside the safety fences, the operator should carry a handy emergency

stop switch so that the operation can be stopped any time when an abnormality occurs.

 When working inside the safety fences, appoint a safety watcher in addition to the

operator so that the operation can be stopped any time when an abnormality occurs.

The safety watcher must also make sure the switches are not operated inadvertently by

a third party.

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

Pre-5

No. Task Note

5 Teaching  When releasing the brake of the vertically installed actuator, be careful not to let the

actuator drop due to its dead weight, causing pinched hands or damaged lo ad, etc. * Safety fences --- Indicate the movement range if safety fences are not provided.

6 Confirmation

operation

 After teaching or programming, carry out step-by-step confirmation operation before

switching to automatic operation.

 When carrying out confirmation operation inside the safety fences, follow the specified

work procedure just like during teaching.

 When confirming the program operation, use the safety speed. Failure to do so may

result in an unexpected movement due to programming errors, etc., causing injury.

 Do not touch the terminal blocks and various setting switches while the power is

supplied. Touching these parts may result in electric shock or malfunction.

7 Automatic

operation

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

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

 Be sure to start automatic operation from outside the safety fences.  If the product generated abnormal heat, smoke, odor or noise, stop the product

immediately and turn off the power switch. Failure to do so may result in fire or product

damage.

 If a power outage occurred, turn off the power switch. Otherwise, the product may move

suddenly when the power is restored, resulting in injury or product damage.

8 Maintenance/

inspection

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

inside the safety fences, prepare “work rules” and make sure the operator understands

the procedures thoroughly.

 When working inside the safety fences, turn off the power switch, as a rule.  When working inside the safety fences, the operator should carry a handy emergency

stop switch so that the operation can be stopped any time when an abnormality occurs.

 When working inside the safety fences, appoint a safety watcher in addition to the

operator so that the operation can be stopped any time when an abnormality occurs.

The safety watcher must also make sure the switches are not operated inadvertently by

a third party.

 Put up a sign saying “WORK IN PROGRESS” in a conspicuous location.  Use appropriate grease for the guides and ball screws by checking the operation

manual for each model.

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

damage.

 When releasing the brake of the vertically installed actuator, be careful not to let the

actuator drop due to its dead weight, causing pinched hands or damaged work part, etc. * Safety fences --- Indicate the movement range if safety fences are not provided.

9 Modification  The customer must not modify or disassemble/assemble the product or use

maintenance parts not specified in the manual without first consulting IAI.

 Any damage or loss resulting from the above actions will be excluded from the scope of

warranty.

10 Disposal  When the product becomes no longer usable or necessary, dispose of it properly as an

industrial waste.

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

generate toxic gases.

Pre-6

Indication of Cautionary Information

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

Level Degree of danger/loss Symbol

Danger

Warning

Caution

Note

Failure to observe the instruction will result in an imminent danger leading to death or serious injury.

Failure to observe the instruction may result in death or serious injury.

Failure to observe the instruction may result in injury or property damage.

The user should take heed of this information to ensure the proper use of the product, although failure to do so will not result in injury.

Danger

Warning

Caution

Note

Pre-7

CE Marking

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

Pre-8

Chapter 1 Introduction

1. Overview

1.1 Introduction

Thank you for purchasing the SCON controller. Please read this manual carefully to handle the controller with due care while ensuring the correct operation of

the controller. Keep this manual with you so that you can reference the applicable sections whenever necessary.

Should you encounter any trouble when actually starting up your system, also refer to the manuals for the teaching pendant, PC software and other components included in your system, in addition to this manual.

This manual does not cover all possible operations other than normal operations, or unexpected events such as complex signal changes resulting from use of critical timings. Accordingly, you should consider items not specifically explained in this manual as “prohibited.”

* We have made every effort to ensure precision of the information provided in this manual. Should you find an

error, however, or if you have any comment, please contact IAI.

Keep this manual in a convenient place so it can be referenced readily when necessary.

1.2 SCON Functions

The SCON is a single-axis AC servo controller capable of controlling actuators in the position er mode or the pulse-train input mode. The functions of SCON are as follows:

The positioner mode and the pulse-train input mode cannot be used at the same time. Switching of modes uses the piano switch located on the front face of the controller.

Positioner mode

Pulse-train input mode

Positioning mode [Standard type] Teaching mode [Teaching type] 256-point mode [256-point type] 512-point mode [512-point type] Solenoid valve mode 1 [7-point type] Solenoid valve mode 2 [3-point type]

1.2.1 Features of the Positioner Mode

In the positioner mode, one of five PIO patterns is selected using a parameter. The number of positioning points and input/output functions vary depending on the PIO pattern selected. The table below lists the parameter settings and corresponding PIO patterns, as well as the features of each PIO pattern.

Parameter setting Features of PIO pattern

0 Positioning mode [Standard type]

64 positioning points are supported. Available output functions include the moving output and zone output.

1 Teaching mode [Teaching type]

64 positioning points are supported. Normal positioning operation can be performed, along with jogging via I/O operation and writing of the current position to the position table. The MODE input signal is used to switch between the normal positioning operation mode and the teaching mode. The zone output (set by parameters) and brake forced-release input accessible in the standard type are not available in this type.

2 256-point mode [256-point type]

The moving output and zone output (set by parameters) accessible in the standard type are not available in this type.

3 512-point mode [512-point type]

The moving output and zone output (set by parameters/position data) accessible in the standard type are not available in this type.

4 Solenoid valve mode 1 [7-point type]

Seven positioning points are supported. Direct command inputs and position complete outputs are provide d separately for different target positions to simulate air-cylinder control. The moving output accessible in the standard type is not available in this type.

5 Solenoid valve mode 2 [3-point type]

Three positioning points are supported. The function of position complete output signals is different from how these signals function in the 7-point type. The “position detection” function, which operates just like an auto-switch of an air cylinder, is also available. Take note that incremental positioning commands are not supported in this mode.

1.2.2 Features of the Pulse-train Input Mode

 Dedicated home return signal

Home return operation is supported in this mode. When this function is used, home return can be performed automatically without having to program a complex sequence or use an external sensor, etc.

 Brake control function

The electromagnetic brake power is supplied to the controller from a power supply different from the main power. Since the controller controls the brake, there is no need to program a separate sequence. Also, the electromagnetic brake can be released freely after the main power has been cut off.

 Torque limiting function

The torque can be limited (a desired limit can be set by a parameter) using an external signal. When the torque reaches the specified level, a signal will be output. This function permits push & hold operation, pressfit operation, etc.

 Feed-forward control function

With this function, response can be improved in certain situations such as when the load inertia ratio is high. Increasing the parameter value will reduce the deviation (difference between th e position command and the position feedback), thereby improving response.

 Position-command primary filter function

Soft start and stop can be achieved even when the actuator is operated in the command-pulse input mode where acceleration and deceleration are not considered.

 Feedback function

Position detection data is output using pulse trains (differential). The current actuator position can be read in real time from the host controller.

1.3 How to Read the Model Specification

C: Standard type

20: 20W 30D: 30 W for DS 30R: 30 W for RS 60: 60W 100: 100W 150: 150W 200: 200W 200S: 200 W for linear 300S: 300 W for linear 400: 400W 600: 600W 750: 750W

I: Incremental A: Absolute

HA: High acceleration/deceleration specification

<Power-supply voltage>

1: Single phase 100 VAC 2: Single phase 200 VAC

2: 2 m 3: 3 m 5: 5 m 0: Not supplied

NP: NPN specification PN: PNP specification DV: DeviceNet specification CC: CC-Link specification RR: PROFIBUS connection specification

1.4 System Configuration

Regenerative resistance unit It may become necessary depending on the use condition.

Breaker Note) Noise filter

MC1210 by Densei-Lambda

EMG switch

Grounded

Absolute

battery

Host control

system

DC24V

bsolute battery

Brake power supply

ctuato

Teaching

pendant

Caution: The customer must provide a noise filter. A noise filter is always required at the minimum, even

when your system need not conform to the EC Directives. Also add clamp filters, etc., if necessary.

1.5 Procedure from Unpacking to Test Operation and Adjustment

If you are using this product for the first time, carry out each step by referring to the procedure below to ensure that all necessary items are checked and all wires are connected corre ctly. The procedure below covers the flow from unpacking to trial operation using a PC or teaching pendant.

(1) Check the content in the package

If you found any missing part or part specified for a different model, please contact your dealer. * Check that the model specification pasted on the controller and the model specification of the delivered

actuator match.

 Controller SCON-*-  Motor cable  Encoder cable  I/O flat cable  Pulse-train control connector plug: 10114-3000PE (Sumitomo 3M)  Pulse-train control connector housing: 10314-52F0-008 (Sumitomo 3M)  Actuator

Options

 Pulse converter AK-04, JM-08  Teaching pendant COM-T RCM-T RCM-E RCM-P  PC software RCM-101-MW, RCM-101-USB  Regenerative unit  Touch panel display RCM-PM-01 (supported from system software version V0015)



(2) Installation

[1] Affix the actuator. [2] Install the controller.

(3) Wiring/connection

 Connect the motor cable and encoder cable.  Wire the AC power supply.  Connect the grounding wire to ground.  Wire the emergency stop circuit.  Connect the I/O flat cable (wiring with the host PLC and 24-V I/O power supply).  Connect the 24-V brake power supply (only if the actuator is equipped with a brake).  Connect the regenerative unit(s). The need for regenerative unit will vary depending on the use condition.

(4) Turn on the power and check for alarms

[1] If the SCON is to be used in the positioner mode, set piano switch 1 to the OFF position (ri ght side). [2] Connect the PC or teaching pendant, and then set the AUTO/MANU switch to the MANU position. [3] Input the 24-V I/O power. [4] If the actuator is equipped with a brake, turn on the 24-V power supply for the brake. [5] Input the AC power (control power, drive power).

If an emergency stop is actuated, the EMG LED indicator will illuminate in red. If an alarm generates, the ALM LED indicator will illuminate in orange. Check the nature of the alarm using the PC or teaching pendant and remove the cause by referring to Appendix 5, “Troubleshooting.”

 System I/O shorting connector  Power connector  Brake connector

(5) Set parameters

 Before the 24-V I/O power supply is connected, PIO power monitor can be disabled temporarily by changing

the applicable parameter setting. Parameter No. 74, “PIO power monitor”: 0 (Enable)  1 (Disable) Note) After the 24-V I/O power supply has been connected, be sure to reset parameter No. 74 to “0” to

enable PIO power monitor.

 If the host PLC or other host controller is not yet wired and the servo-on signal cannot be input, the servo-on

input can be disabled temporarily by changing the applicable parameter setting. Parameter No. 21, “Servo-on input”: 0 (Enable)  1 (Disable) Note) After the host PLC, etc., has been wired, be sure to reset parameter No. 21 to “0” to enable the

servo-on input. Change the safety speed, if necessary. The factory-set safety speed is “100 mm/sec.” (If the maximum speed is less than 100 mm/sec, the safety speed conforms to the maximum speed.)

 Select a desired PIO pattern using the applicable parameter.

Parameter No. 25, “PIO pattern selection”: 0 to 5

When a parameter has been changed, the new setting will become effective once the power is reconnected or software is reset.

(6) Check the servo-on status

When the servo turns on, the SV LED indicator will illuminate in green. (In the MANU teaching mode, the servo will not turn on even when the servo-on signal is input after the AC power has been turned on. ) If the servo-on input is disabled by the parameter and the controller is in the AUTO mode, the servo will turn on automatically after the controller has started.

(7) Operate with the PC or teaching pendant

While the servo is on, perform the operation check specified below. For details on the operating method, refer to the operation manual for your PC software or teaching pendant. [1] Use the PC or teaching pendant to set a target position in the “Position” field of the position table. [2] Perform home return. [3] Move the actuator to the specified position.

(8) Check the actuation of the emergency stop circuit

While the actuator is operating, press the emergency stop button to confirm that an emergency stop will be actuated.

Caution: When the teaching pendant is disconnected, an emergency stop is actuated momentarily. The

emergency stop will be cancelled immediately thereafter, but the actuator and other equipment that are operating when the teaching pendant is disconnected will stop. Therefore, do not disconnect the teaching pendant when an actuator or any other equipment is operating. Also pay attention to the design of the emergency stop circuit that includes the emergency stop switch on the teaching pendant.

1.6 Warranty Period and Scope of Warranty

The SCON controller you have purchased passed IAI’s shipping inspection implemented under the strictest standards. The unit is covered by the following warranty:

1. Warranty Period

The warranty period shall be one of the following periods, whichever ends first:

 18 months after shipment from our factory  12 months after delivery to a specified location

2. Scope of Warranty

The scope of warranty shall cover our products delivered at cost. If an obvious manufacturing defect is found during the above period under an appropriate condition of use, IAI will repair the defect free of charge. Note, however, that the following items are excluded from the scope of warranty.

 Aging such as natural discoloration of coating  Wear of a consumable part due to use  Noise or other sensory deviation that doesn’t affect the mechanical function  Defect caused by inappropriate handling or use by the user  Defect caused by inappropriate or erroneous maintenance/inspection  Defect caused by use of a part other than IAI’s genuine part  Defect caused by an alteration or other change not approved by IAI or its agent  Defect caused by an act of God, accident, fire, etc.

The warranty covers only the product as it has been delivered and shall not cover any losses arising in connection with the delivered product. The defective product must be brought to our factory for repair.

Please read carefully the above conditions of warranty.

2. Specifications

2.1 Basic Specifications

Item Less than 400 W 400 W or more Applicable motor capacity 20 W to 399 W 400 W to 750 W Power-supply voltage

100 VAC Rush current *1

Leak current *2 3.0 mA (Primary side when noise filter is connected to the power supply line) Heat output 30 W to 58 W Power supply frequency 50/60 Hz PIO interface power supply *3 Solenoid brake power supply (in case of actuators equipped with brake) Resistance against temp orary electric power failure Motor control method Sine wave PWM vector current control Supported encoders Incremental serial encoder

Operation mode Positioner mode/pulser-train control mode (Operation mode is switched with the DIP switch.) mode

Pulse-train mode

Serial communication interface RS485: 1 channel (conforming to Modbus protocol RTU/ASCII)

I/O (PIO) cable length 10 m or less Communication cable length Total cable length shall be 100 m or less (RS485).

Data input method Teaching pendant, PC software Protective functions Overvoltage, motor overcurrent, motor overload, driver temperature error, encoder error, etc. Air cooling method Natural cooling Forced cooling Withstand voltage Between primary and secondary: 1500 VAC, 1 minute

Insulation resistance Environment

Protection class IP20 Weight Approximately 800 g (approximately 25 g more

External dimension 58 (W) x 194 (H) x 121 (D)

*1 Rush current flows approximately 20 ms after turning the power supply on (guideline at 40C). *2 Leak power supply changes depending on the capacity of connected motor, cable length, and surrounding environment. If protection against leak

current is installed, measure leak current at installation location of leak current breaker.

*3 Power supply for I/O signals is not necessary if the controller is operated using field network (CC-Link, DeviceNet, PROFIBUS), gateway unit, or

SIO converter, without using PIO. In this case, set “1” (disabled) for parameter No. 74 (PIO power supply monitoring).

200 VAC

Number of positions 512 points (maximum) Positioner Inputs/outputs 16 dedicated input points / 16 dedicated output points

Feedback pulse frequency The maximum speed with differential pulse is 500 kpps (up to 109 kpps can be output linearly Command pulse multiplier

(electronic gear: A/B)

Dedicated I/O (PIO) 8 input points / 12 output points

Surrounding air temperature Surrounding humidity 85%RH or less (no condensation) Surrounding environment (See the installation environment section.) Storage ambient temperature Storage ambient humidity 90%RH or less (no condensation) Vibration resistance XYZ directions, 10 to 57 Hz, one side width 0.035 mm (continuous), 0.075 mm (intermittent)

Caution: Position data, parameters, etc. are written in EEPROM. The number of writings is limited to approximately 100,000 times.

Single-phase 100 to 115 VAC  10% Single-phase 200 to 230 VAC  10%

20 A (control), 70 A (drive)

24 VDC  10% (Externally supplied) 24 VDC  10% 1 A (peak value)

(Externally supplied) 10 ms (50 Hz), 8 ms (60 Hz)

Absolute serial encoder ABZ (UVW) parallel encoder

Differential pulse MAX. 500 kpps Input pulse frequency Open-collector pulse MAX. 200 kpps (Pulse converter AK-04 is required.)

following the speed of actuators). A, B = 1 to 4096 (Parameter settings)

Speed: 9.6 kpps to 230.4 kpps Control via serial communication is possible with the positioner mode.

Length in case of Fieldbus specifications (CC-Link, DeviceNet, PROFIBUS) depends on each Fieldbus specification.

Between primary and FG: 1500 VAC, 1 minute Between secondary and FG: 500 VDC 100 M or more 0C to 40C

-10C to 65C

in case of absolute specifications) (Installation pitch: 184)



57 to 150 Hz 4.9 m/s2 (continuous), 9.8 m/s2 (ongoing)

Single-phase 200 to 230 VAC  10%

20 A (control), 80 A (drive)

Approximately 1100 g (approximately 25 g more in case of absolute specifications) 72 (W) x 194 (H) x 121 (D) (Installation pitch: 184)

2.2 Name and Function of Each Part

[17] Grounding screw

[1] LED indicators

[2] Rotary switches

[3] Piano switches

[4] System I/O

connector

[5] Regenerative

unit connector

[6] Motor connector

[7] Power connector

[16] Absolute battery holder

[8] Dedicated pulse-

train control connector

[9] PIO connector

[10] AUTO/MANU

selector switch

[11] SIO connector

[12] Brake release switch

[13] Brake power

connector

[14] Encoder/sensor

connector

[15] Absolute battery

connector

[1] LED indicators

These LEDs indicate the condition of the controller.

Name Color Description

PWR Green

This LED illuminates when the system has become ready (after the power has been input and the CPU has started normally).

SV Green This LED illuminates when the servo has turned on.

ALM Orange This LED illuminates while an alarm is present.

EMG Red This LED illuminates while an emergency stop is actuated.

[2] Rotary switches

These switches are used to set the controller address. If two or more controllers are linked via serial communication, set a unique address for each controller. * The address set by the switches will become effective after the power is reconnected or software is reset.

[3] Piano switches

These switches are used to set the various modes of the controller system.

Name Description

Operation mode selector switch

OFF: Positioner mode, ON: Pulse-train control mode * The mode set by the switch will become effective after the power is reconnected.

2 Reserved by the system. (This switch must be set to “OFF.”)

Caution: When controlling the SCON controller via serial communication, a lways set the controller in the

“positioner mode” (piano switch 1: OFF). If it happens to be in the “pulse-train mode” by mistake, the SCON controller may operate erratically because it is operated according to the “pulse-train mode” parameters.

[4] System I/O connector

This connector is used to connect the emergency stop switch, etc. Connector (controller side): MC1.5/4-G-3.5 (Phoenix Contact) Connector (plug-in side): FMC1.5/4-ST-3.5 (Phoenix Contact) Applicable cable diameter: 0.2 to 1.3 mm

(AWG24 to 16)

Pin No. Signal name Description

1 S1 Emergency-stop switch contact output for teaching pendant 2 S2 Emergency-stop switch contact output for teaching pendant 3 EMG+ 24-V output for emergency stop 4 EMG- Emergency sop input

[5] Regenerative unit connector

This connector is used to connect an external regenerative resistance unit. The need for regenerative unit will vary depending on the use condition.

[6] Motor connector

This connector is used to connect the motor power cable of the actuator.

Motor connector specifications

Item Overview Description Connector (cable side) GIC2.5/4-STF-7.52 4-pin, 2-piece connector by Phoenix Contact Connector name M1 to 2 Motor connector Cable size 0.75 mm2 (AWG18

or equivalent) Connected unit Actuator Terminal assignments

1 PE Protective grounding wire 2 Out U Motor drive phase U 3 Out V Motor drive phase V 4 Out W Motor drive phase W

Supplied with the actuator

[7] Power connector

This power connector accepts a 100/200-VAC single-phase power supply. The pins a re divid ed into control power inputs and motor power inputs.

Item Specification Remarks Connector (cable side) Applicable cable size

6-pin, 2-piece connector MSTB2.5/6-STF-5.08

connector by Phoenix Contact Control power: 0.75 mm (AMG18) Motor power: 2 mm

Recommended stripped wire length:

7 mm (AMG14)

Terminal assignments

Pin No. Signal name 1 L1 Motor power AC input 2 L2 Motor power AC input 3 L1C Control power AC input 4 L2C Control power AC input 5 NC Not connected 6 PE Grounding terminal

Signal names are indicated on the mating connector.

[8] Dedicated pulse-train input mode connector

This connector is used when the controller is to be operated in the pulse-train input mode. Do not conn ect it if the controller is to be operated in the positioner mode.

[9] PIO connector

This connector is used to connect to the host controller (PLC, etc.) via the PIO (parallel input/output) cable. It consists of a 40-pin flat connector and constitutes a DIO group of 16 inputs and 16 outputs.

[10] AUTO/MANU switch

The operating mode using the teaching pendant/PC (software) connected to the SIO connector, and PIO input, will change as follows in accordance with the setting of this switch. Prohibition/permission of PIO activation is specified using the PC software/teaching pendant.

MANU

AUTO

PIO activation inhibited (teaching mode 1 or teaching mode 2)

PIO activation permitted (monitor mode 1 or monitor mode 2)

Only monitoring operations are possible using the PC software/teaching pendant. PIO inputs are accepted.

All operations are possible using the PC software/teaching pendant. PIO inputs are not accepted.

Only monitoring operations are possible using the PC software/teaching pendant. PIO inputs are accepted.

* The emergency stop switch on the teaching pendant is enabled when the switch is co nnected,

regardless of the AUTO/MANU mode. Take note that although an emergency stop is actuated momentarily when the teaching pendant or SIO cable is removed, this does not indicate an error condition. Therefore, the actuator and other equipment that are currently operating will stop. Do not disconnect the teaching pendant or SIO communication cable while an actuator or any other equipment is operating.

[11] SIO connector

This connector is used to connect the dedicated communication cable for teaching pendant/PC. It is also used when two or more controllers are linked via serial communi cation.

[12] Brake release switch

This switch forcibly releases the electromagnetic brake of an actuator with brake. RLS: Power is supplied to the brake to forcibly release the brake. NOM: The co ntroller controls ON/OFF of the brake. This setting should be used in normal conditions of use. * A 24-VDC power supply must be connected to drive the brake.

Even if the controller power is not turned on, you can still move the slider or rod manually by turning on the 24-VDC power supply for driving the brake and then forcibly releasing the brake.

[13] Brake power connector

This connector supplies the 24-VDC brake powe r. If an actuator with brake is connected, 24 VDC must be supplied externally.

MC1.5/4-G-3.5 (Phoenix Contact)

* Turn on the 24-VDC brake power before turning on the SCON controller power.

[14] Encoder/sensor connector

This connector is used to connect the encoder/sensor cabl es of the actuator. With the SCON, encoder voltage is adjusted using a parameter (one of four levels is set in accordance with the encoder type and cable length).

Encoder sensor cable Cable model: CB-X1-PA ***

Controller end

Plug connector:

Hood:

(Sumitomo 3M)

Wiring diagram

Wire Color Signal

(soldered)

Orange

Green

Purple

Gray

Red

Black

Blue

Yellow

Connect the shield to the hood using a clamp.

Drain wire and braided shield wire

Plug housing: Socket contact: Retainer:

Signal Color Wire

Purple

Gray

Orange

Green

(pressure-

Red

welded)

Black Drain

Blue

Yellow

(JST)

ctuator end

(JST) X 9

Cable model: CB-X1-PLA ***

Controller end

Plug connector: Hood:

(Sumitomo 3M)

Wiring diagram

Wire Color Signal

White/Blue

White/Yellow

White/Red

White/Black

White/Purple

White/Gray

(soldered)

Orange

Green

Purple

Gray

Red

Black

Blue

Yellow

Connect the shield to the hood using a clamp.

Drain wire and braided shield wire

ctuator end

LS side

Plug housing: Socket contact: Retainer:

Signal Color Wire

White/Blue

White/Yellow

White/Red

(pressure-

White/Black

welded)

White/Purple

White/Gray

Signal Color Wire

Purple

Gray

Orange

Green

Red

(pressure-

welded)

Black Drain

Blue

Yellow

(JST)

LS side

ctuator end

(JST) X 9

(JST) X 6

Cable model: CB-X2-PA ***

Controller end

Plug connector: Hood:

(Sumitomo 3M)

Wiring diagram

Wire Color Signal

(soldered)

White/Blue

White/Yellow

White/Red

White/Black

White/Purple

White/Gray

Orange

Green Purple

Gray Red

Black

Blue

Yellow

Connect the shield to the hood using a clamp.

Drain wire and braided shield wire

Plug housing: Socket contact: Retainer:

Color Wire

Signal

White/Blue

White/Yellow

White/Red

White/Black

White/Purple

White/Gray

Drain

Orange

Green Purple

Gray

Red

Black

Blue

Yellow

(JST) X 2

(pressure-

welded)

(JST)

ctuator

end

(JST) X 15

Cable model: CB-X2-PLA ***

Controller end

Plug connector: Hood:

(Sumitomo 3M)

Wiring diagram

Wire Color Signal

White/Orange

White/Green

Brown/Blue

Brown/Yellow

Brown/Red

Brown/Black

White/Blue

White/Yellow

White/Red

White/Black

White/Purple

White/Gray

Orange

Green

Purple

Gray Red

Black

Blue

Yellow

(soldered)

Connect the shield to the hood using a clamp.

Ground wire and braided shield wire

ctuator end

LS side

Plug housing:

Socket contact:

Retainer:

Plug housing:

Socket contact:

Retainer:

Signal Color Wire

White/Orange

White/Green

Brown/Blue

Brown/Yellow

Brown/Red

Brown/Black

Signal Color Wire

White/Blue

White/Yellow

White/Red

White/Black

White/Purple

White/Gray

Drain

Orange

Green Purple

Gray

Red

Black

Blue

Yellow

(JST) X 2

(JST)

(pressure-

welded)

(pressure-

welded)

(JST)

LS side

ctuator

end

(JST) X 15

(JST) X 6

Cable model: CB-RCS2-PA ***

Controller end

Plug connector: Hood:

(Sumitomo 3M)

Wiring diagram

Wire Color Signal

(soldered)

Connect the shield to the hood using a clamp.

White/Green

Brown/White

Pink Purple White

Blue/Red

Orange/White

Green/White

Blue

Orange

Black Yellow Green

Brown

Gray

Red

Drain wire and braided shield wire

Plug housing: Socket contact: Retainer:

Signal Color Wire

Pink

Purple

White

Blue/Red

Orange/White

Green/White

Brown/White

Drain

Blue

Orange

Black

Yellow Green Brown

Gray/White

Gray Red

(JST) X 2

(pressure-

welded)

(JST)

ctuator

end

(JST) X 17

Cable model: CB-RCS2-PLA ***

Controller end

Plug connector: Hood:

(Sumitomo 3M)

Wiring diagram

Wire Color Signal

Brown/White

Gray/White

Red/White

Black/White

Yellow/Black

Pink/Black

Pink

Purple

(soldered)

Connect the shield to the hood using a clamp.

White

Blue/Red

Orange/White

Green/White

Blue

Orange

Black

Yellow Green Brown

Gray Red

Drain wire and braided shield wire

ctuator end

LS side

Plug housing: Socket contact: Retainer:

Color Wire

Signal

BrownWhite

Gray/White

Red/White

(pressure-

welded)

Black/White

Yellow/Black

Pnk/Black

Signal Color Wire

Pink

Purple

White

Blue/Red

Orange/White

Green/White

(pressure-

welded)

Drain

Blue

Orange

Black Yellow Green

Brown

Gray

Red

(JST) X 2

(JST)

LS side

ctuator end

(JST) X 15

(JST) X 6

[15] Absolute battery connector

This connector is used to connect the absolute-encoder backup battery (required when the controller is of absolute encoder specification).

[16] Absolute battery holder

This battery holder is used to install the absolute-encoder backup battery.

[17] Grounding screw

This screw is used to implement protective grounding. It is connected inside the controlle r to the PE terminal in the power connector. Use this terminal if protective grounding based on a 2-piece connector is not feasible due to conflict with the safety standard or for any other reason.

Item Description Cable size 2.0 to 5.5 mm2 or larger Grounding method Class D grounding

2.3 External Dimensions

External dimensions of models with a power output of less than 400 W

4.2

When the absolute battery is installed (absolute encoder specification)

External dimensions of models with a power output of 400 W or more

4.2

When the absolute battery is installed (absolute encoder specification)

Fan

3. Installation and Wiring

3.1 Installation Environment

(1) When installing and wiring the controller, do not block the ventilation holes for cooling. (Insufficient

ventilation may not only prevent the controller from demonstrating its design performance fully, but it may also cause a breakdown.)

(2) Prevent foreign matter from entering the controller through the ventilation holes. This controller is not

dustproof or splashproof (against water or oil), so avoid using the controller in a place subject to large amounts of dust, oil mist or splashes of cutting fluid.

(3) Keep the controller from direct sunlight or irradiated heat from large heat sources such as heat treatment

furnaces.

(4) Use the controller in an environment of 0 to 40C in surrounding air temperature and 85% or below in

humidity (non-condensing), where the surrounding air is free fro m corrosive or flammable gases.

(5) Use the controller in an environment where it does not receive external vibration or impact. (6) Prevent electrical noise from entering the controller or connected cables.

3.2 Heat Radiation and Installation

Design the control panel size, controller layout and cooling method so that the temperatures around the controller will always be kept to 40C or below. Mount the controller on a wall vertically as shown below. This controller implements cooling by means of f orced ventilation (air is blown out from the top). When installing the controller, observe the aforementioned direction and provide a minimum clearance of 100 mm above and 50 mm below the controller, and 30 mm from an adjacent controller. If you are installing multiple controllers side by side, provide a fan on top of the controllers to agitate the airflows as an effective way to keep the surrounding air temperatures constant. Provide a minimum clearance of 150 mm between the front face of the controller and the wall (cover).

Regenerative boxes

If multiple controllers are linked with the controllers arranged vertically, make sure the exhaust air from a given controller is not sucked into the controller above it. Provide a clearance of approx. 50 mm between a controller and a regenerative b ox, or 10 mm between regenerative boxes.

Air direction

Fan

At least 100 mm

At least 50 mm

At least 150 mm

Airflow

3.3 Noise Elimination Measures and Grounding

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

(1) Wiring and power connection

[1] Provide dedicated class-D grounding (former class-3 grou nding: Grounding resistance 100  or less) using

a grounding wire with a size of 1.6 mm

Controller

Attach the grounding wire to the mounting screw of the main unit.

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

Grounding terminal Grounding terminal

equip-

Class-D grounding (Former class-3 grounding: Grounding resistance 100  or less)

[2] Cautions on wiring method

Separate the controller wiring from high-power lines of motive power circuits, etc. (Do not tie them together or place in the same cable duct.) If the supplied motor or encoder cable is to be extended, consult IAI’s Engineering Service Section or Sales Engineering Section.

(2) Noise sources and elimination

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

[1] AC solenoid valves, magnet switches, relays

Method --- Mount a noise killer in parallel with the coil.

Other

ment

or larger.

Controller

Ground the grounding wire for each controller: do not share with or connect to other equipment.

Other

equip-

ment

Noise killer

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

[2] DC solenoid valve/magnet switch relay

Action --- Install a diode in parallel with the coil or use valve/relay with built-in diode.

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

3.4 Wiring the Power Supply

3.4.1 Connecting the Power Cable

As shown to the left, insert the stripped end of the cable into the connector and screw in the cable using a screwdriver. Recommended cable diameter Motor power (L1, L2): 2 mm (AWG14) Control power (L1C, L2C): 0.75 mm (AWG18) Recommended stripped wire length: 7 mm

As shown to the left, tighten the screws to secure the connector.

Caution: Always install a noise filter.

Recommended noise filter: MC1210 by Densei-Lambda

The power-supply voltage of the controller (100 or 200 V) has been set prior to the shipment.

3.4.2 Power-supply Capacities and Heat Output

Rated power-supply capacity = Motor power-supply capacity + Control power-supply capacity Maximum momentary power-supply capacity = Maximum momentary motor power-supply capacity + Control power-supply capacity

Actuator motor

wattage

Motor power-

supply capacity

[VA]

Maximum

momentary motor

power-supply capacity [VA]

Control power-

supply capacity

[VA]

Rated power-

supply capacity

[VA]

Maximum

momentary power-

supply capacity

[VA]

Heat

output

[W]

(Excluding RS) (Excluding RS)

RS: Rotational axis 200L: 200-W linear actuator 300L: 300-W linear actuator 400L: 400-W linear actuator

3.4.3 Selecting a Breaker

Follow the guidance below when selecting a breaker.  Current 3 times more than the rated current flows in the controller during acceleration/deceleration. Select a

breaker that does not trip when this current is conducted. If a trip occurs, select a breaker with rated current one rank higher.

 Select a breaker that does not trip due to rush current. (Refer to operation characteristic curves described in

catalogues by manufacturers.)

 Select a breaker with rated breaking current values that can break without fails even if short-circuit current is

conducted.

 Rated breaking current > short-circuit current = primary side power supply capacity / power supply voltage

Select a circuit breaker with rated current with sufficient margin.

Rated breaker current > (Rated motor power-supply capacity [VA] + Control power-sup ply capacity [VA]) / AC input voltage

Moreover, leak current breakers must be selected with specific purposes such as protection again st fire, protection of humans and so on. Furthermore, leak current shall be measured at the location where a leak current breaker is installed. Please use a leak current breaker supporting higher harm onics.

3.5 Connecting the Actuator

3.5.1 Connecting the Motor Cable (MOT1, 2)

Connect the motor cable of the actuator to the motor connector on the front face of the controller.

Use a screwdriver to tighten the screws at the top and bottom of the connector to secure the connector.

3.5.2 Connecting the Encoder Cable (PG1, PG2)

Connect the encoder cable of the actuator to the encoder connector on the front face of the controller. Note) If the controller is of absolute specification, disconnect the

absolute battery connector before connecting the encoder cable.

3.6 Connecting the PIO Cable (I/O)

Connect the supplied flat cable. Connect the opposite end of the cable (no connector) to an appropriate peripheral (host PLC, etc.).

Brown-1

Red-1

Orange-1

Yellow-1

Green-1

Blue-1

Purple-1

Gray-1 White-1 Black-1

Brown-2

Red-2

Orange-2

Yellow-2

Green-2

Blue-2

Purple-2

Gray-2 White-2 Black-2



Half-pitch MIL socket: HIF6-40D-1.27R (Hirose)

Signal Color Wire

Flat cable

[A]

(pressure-

welded)

I/O flat cable (supplied) Model: CB-PAC-PIO

 indicates the cable length (L). A cable length of up to 30 m is supported.

* Example: 080 = 8 m

Flat cable: KFX-20 (S) (color) (Kaneko Cord)

No connector

Flat cable (20 cores) x 2

Signal Color Wire

Brown-3

Red-3

Orange-3

Yellow-3 Green-3

Blue-3

Purple-3

Gray-3 White-3 Black-3

Brown-4

Red-4

Orange-4

Yellow-4 Green-4

Blue-4

Purple-4

Gray-4 White-4 Black-4

Flat cable

[B]

(pressure-

welded)

3.7 External Input/Output Specifications

The standard interface specification of the controller is NPN, but the PNP specification is also available as an option. To prevent confusion during wiring, the NPN and PNP specifications use the same power line configuration. Accordingly, there is no need to reverse the power signal assignments for a PNP controller.

3.7.1 External Input Specifications

Item Specification

Number of input points 16 points

Input voltage

Input current 4 mA/point

Insulation method Photocoupler

Internal circuit configuration

[NPN specification]

Each input

[PNP specification]

Each input

24 VDC  10%

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

Logic circuit

Internal

circuit

Internal

circuit

3.7.2 External Output Specifications

Item Specification

Number of output points 16 points

Rated load voltage 24 VDC

Maximum current 100 mA/point 400 mA/8 points

Insulation method Photocoupler

Internal circuit configuration

[NPN specification]

[PNP specification]

Internal

circuit

Internal

circuit

Logic

circuit

Logic

circuit

Load

Each output

Load

Each output

Load

Each output

Load

Each output

3.8 Connecting the Emergency Stop Input (Wiring to the System I/O Connector)

As shown to the left, insert the stripped end of the cable while pressing down the spring using a screwdriver. Applicable cable diameter: 0.2 to 1.3 mm (AWG24 to 16) Recommended stripped wire length: 10 mm

Emergency stop switch

Emergency stop circuit when multiple controllers are linked Internal drive-source cutoff specification (Connections when the entire system requires a level of safety conforming to safety category B) Connect an emergency-stop status relay contact for each controller. Make sure to install a surge-absorbing element for the external relay. S1, S2 contact specification: 30 VDC/0.5 A

SIO

connector

EMG line control relay TP connected: Open TP not connected: Closed

SIO

connector

EMG line control relay TP connected: Open TP not connected: Closed

SIO

connector

EMG line control relay TP connected: Open TP not connected: Closed

External CMG

reset

switch

External CMG

switch

System I/O

connector

System I/O

connector

System I/O

connector

Power connector

Motor power

Power connector

Power

Motor power Motor power

connector

Caution: When the teaching pendant is disconnected, an emergency stop is actuated momentarily. The emergency stop will be cancelled

immediately thereafter, but the actuator and other equipment that are operating when the teaching pendant is disconnected will stop. Therefore, do not disconnect the teaching pendant when an actuator or any other equipment is operating. Also pay attention to the design of the emergency stop circuit that includes the emergency stop switch on the teaching pendant.

 On Support of Safety Categories

[1] System configuration When constructing a system supporting safety categories, use teaching pendant “CON-TG" and TP adapter “RCB-LB-TG." It is possible to support categories from B to 4 by changing connection of the system I/O connector.

Controller/ TP adapter connection cable model: CB-CON-LB005

Controller connector

TP adapter "RCB-LB-TG"

Dummy plug “DP-4”

Teaching pendant “CON-TG”

(or dummy plug “DP-4”)

System I/O connector (The front (ENB*) is the lower side and the back (EMG*) is upper side.)

Safety circuit connection

Teaching pendant connector

[2] Wiring and setting of safety circuit [1] Power supply

If a safety circuit is configured using safety relays and contactors of 24 V specifications, it is recommended to use a separate power supply from the power supply for controllers of 24 V specifications (A CON, PCON etc.). It can be configured using the common power supply between the two, but breakage may occur when falsely wired.

[2] System I/O connector specification

 Connector used: MCDN1.5/6-G1-3.5P26THR (PHOENIX CONTACT)  Cable side connector (accessory: initial wiring already conducted *):

FMC1.5/6-ST-3.5 (PHOENIX CONTACT) Supported wire thickness: AWG24-16, recommended stripped wire length: 7 mm

Pin No. Signal name Explanation

Upper side

(EMG side)

1 EMG12 EMG1+ 3 EMG24 EMG2+

Emergency stop contact 1 (30 VDC or less, 100 mA or less)

Emergency stop contact 2 (30 VDC or less, 100 mA or less)

5 EMGIN Emergency stop detection input 6 EMGOUT 24 V power supply output for emergency stop detection input

Lower side (ENB side)

7 ENB18 ENB1+ 9 ENB2-

10 ENB2+

Enable contact 1 (30 VDC or less, 100 mA or less)

Enable contact 2 (30 VDC or less, 100 mA or less)

11 ENBIN Enable detection input 12 ENBOUT 24 V powe r supply output for enable detection input

* Connectors on the cable side are attached under conditions where initial wiring has been conducted.

In order to support each category, remove the initial wiring and wire your safety circuit.  Upper side (EMG) connector  Lower side (ENB) connector

Wiring Color Signal

Yellow Yellow

Wiring Color Signal

Yellow Yellow

[3] Connection of dummy plug If you operate a controller in the AUTO mode, connect a dummy plug (DP-4) to the TP connector. * Make sure to use “DP-4" as the dummy plug. If “DP-3” is used, the connector does not operate normally.

[4] Enable function If you are using the enable function, set it to Enable using the controller parameter. Parameter No. 42 Enable function

0: Enable 1: Disable [Default setting at shipment]

[3] Examples of safety circuits [1] In case of category 1

Controller

Connection cable CB-CON-LB***

Motor power supply

(or dummy plug: DP-4)

stop

switch

Emergency

Reset

switch

Enable switch

Solenoid contactor

Motor power supply

 Detailed category 1 circuit example

Connect with dedicated cable

At TP detection T24V: Output Bypass relay: OPEN At TP not detected T24V: Not output Bypass relay: CLOSE

TP connection detection

DC bus

Motor power cutoff relay

Regulator

Controller connector

Shell

System I/O connector

TP adapter

stop

switch

Emergency

Reset

switch

External emergency stop circuit category 1

Enable switch

Solenoid contactor

TP connector

Emergency stop

Enable switch

Shell

switch

[2] In case of category 2

Controller

Motor power supply

Connection cable CB-CON-LB***

Emergency stop switch

Enable switch

Reset switch

Solenoid contactor

(or dummy plug: DP-4)

Solenoid contactor

Motor power supply

 Detailed category 2 circuit example

Connect with dedicated cable

At TP detection T24V: Output Bypass relay: OPEN At TP not detected T24V: Not output Bypass relay: CLOSE

TP connection detection

DC bus

Motor power cutoff relay

Regulator

Controller connector

Shell

System I/O connector

Emergency stop switch

TP adapter

External emergency stop circuit category 2

TP connector

Enable switch

Reset switch

Solenoid contactor Solenoid contactor

Emergency stop

switch

Enable switch

Shell

System I/O connector

(Safety unit connection)

[3] In case of category 3 or 4

Controller

Connection cable CB-CON-LB***

Emergency stop switch

Motor power supply

Enable switch

Reset switch

Solenoid contactor

(or dummy plug: DP-4)

Short circuit reset switch if category 3 should be supported

Solenoid contactor

Short circuit only when category 3 should be supported

Motor power supply

 Detailed category 3/4 circuit example

Connect with dedicated cable

Controller connector

At TP detection T24V: Output Bypass relay: OPEN At TP not detected T24V: Not output Bypass relay: CLOSE

TP connection detection

System I/O connector

DC bus

Motor power cutoff relay

Regulator

TP adapter

Shell

Emergency stop switch

External emergency stop circuit category 4

TP connector

Enable switch

Reset switch

Solenoid contactor Solenoid contactor

Emergency stop

switch

Enable switch

Shell

System I/O connector

(Safety unit connection)

Short circuit reset switch if category 3 should be supported

Short circuit only when category 3 should be supported

[4] Appendix [1] TP adapter external dimensions

2-3.5

[2] Connection cable  Controller/TP adapter connection cable

Use this cable to connect the controller and TP adapter (RCB-LB-TG). Model: CB-CON-LB005 (standard cable length: 0.5 m) Maximum cable length: 2.0 m

Color

8-pin MIN DIN connector (mold casting)

Contact: MD-SP2240 (JST) x 8 Metal shell: MD-PS8T (JST) Housing A: MD-PI8A (JST) Housing B: MD-PI8B (JST) Cover: MD-PCC8T (JST)

Signal Brown Yellow

Red

Orange

Blue Green Purple

Gray

Shield

8-pin MIN DIN connector (mold casting)

Color

Signal

Brown

Yellow

Red

Orange

Blue Green Purple

Gray

Shield

Contact: MD-SP2240 (JST) x 8 Metal shell: MD-PS8T (JST) Housing A: MD-PI8A (JST) Housing B: MD-PI8B (JST) Cover: MD-PCC8T (JST)

[3] Dummy plug Connect a dummy plug to the teaching pendant connecting connector. Make sure to connect a dummy plug if the AUTO mode is specified. Model: DP-4

Signal

Plug

Short-circuit processing

Connecting the Pulse-train Control Cable

Use the pulse-train control cable when the controller is operated in the pulse-train input mode. It should not be connected when the controller is operated in the positioner mode. The pulse-train control cable is optional. (Normally the controller comes only with a plug and a shell.)

Connecting the Brake Power Input (for Actuator with Brake)

As shown to the left, insert the stripped end of the cable into the connector and screw in the cable using a screwdriver. Applicable cable: 0.75 to 1.25 mm Recommended stripped wire length: 7 mm

24 VDC  10%,

1 A max.

Connecting the Teaching Pendant/PC Software (TP) (Optional)

If the teaching pendant/PC software cable is used, connect it to the teaching connector on the controller.

Set the AUTO/MANU selector switch to the MANU position (right side).

Caution: When the teaching pendant is disconnected, an emergency stop is actuated momentarily. The

3.9 Connecting the Regenerative Unit (RB)

Regenerative energy produced when the actuator decelerate s to a stop or moves downward in vertical installation is absorbed by means of the capacitor or resistor provided in the controller. If the produced regenerative energy cannot be fully absorbed by the controller, an overheat error (error code: 0CA) will generate. If this is the case, connect one or more regenerative resistance units externally.

3.9.1 Number of Units to Be Connected

Guideline for number of units to be connected

Motor wattage

Horizontal installation Vertical installation

~ 100 W ~ 100 W Not required

~ 400 W, 200 S, 300 S ~ 400 W, 200 S, 300 S 1

~ 750 W ~ 750 W 2

* The above are reference values when the actuator is moved back and forth at an operation duty of 50%

based on the rated acceleration/deceleration, rated load and 1000-mm stroke.

* If the operating duty exceeds 50%, the applicable number of regenerative units shown in the table above

must be increased. The maximum number of external regenerative resistance units that can be connected is as follows: Less than 400 W --- 2 units 400 W or more --- 4 units (Never connect external regenerative resistance units more than the limits shown above, as it may result in system failures.)

3.9.2 Connection Method

Number of regenerative resistance

units to be connected

The figure below illustrates how one regenerative unit, and multiple units, should be connected, respectively. When connecting one regenerative unit, connect the unit using cable [1] explained in 3.9.3. When connecting two or more regenerative units, connect the controller with the first regenerative unit using cable [1], and connect the adjacent regenerative units using cable [2].

[1]

[2] [2]

3.9.3 Connection Cables

The cable used to connect the controller to a regenerative resistance unit is different from the corresponding cable used on conventional controllers (the connectors are not compatible). To conne ct a reg enerative resistance unit to the controller, cable [1] specified below is required.

[1] Regenerative resistance connection ca ble for SCON (CB-SC-REU***)

Controller end

Receptacle housing: Receptacle contact:

Sales model nameplate

Wiring diagram

Wire Color Signal

Light blue

Brown

Green/Yellow

Signal Color

[2] Regenerative resistance connection ca ble for co nventional controllers (X-SEL, E-Con) (CB-ST-REU***)

Controller end

Plug: (Phoenix Contact)

Sales model nameplate

Wiring diagram

Plug: (Phoenix Contact)

Wire Color Signal

Light blue

Brown

Green/Yellow

Signal

External regenerative resistance unit end

Plug: (Phoenix Contact)

Wire

Light blue

Brown

Green/Yellow

External regenerative resistance unit end

Color Wire

Light blue

Brown

Green/Yellow

3.10 Connecting the Brake Box (RCB-110-RA13-0)

One brake box can support 2 actuators.

3.10.1 Installation Standard

Actuator to be used: RCS2-RA13R with brake

3.10.2 Specification

Item Specification Dimension of main unit 162 x 94 x 65.5 mm Power supply voltage, current

Connection cable (sold separately)

3.10.3 External Dimensions

24 VDC  10% 1 A Encoder cable (model specification CB-RCS2-PLA

 indicates cable length

), where

Encoder

connector 1

4-5

Connector 1 for brake release external switch

Power supply input connector

POWER ON LED (Lit in green when power is supplied)

Encoder

connector 2

Connector 2 for brake release external switch

3.10.4 24 V Power Supply Connector

Connector on

cable side

Conforming cable AWG28 to 16

Terminal assignment

* It is necessary to supply +24 V to the brake power supply connector of the controller as well.

1 0 V Power supply ground for brake excitation 2 24 VIN +24 V power supply for brake excitation

MC1.5 / 2-STF-3.5 (Phoenix Contact)

3.10.5 Brake Release External Switch Connectors 1 and 2

Connection

destination device

Connector on

cable side

Switch rating 30 VDC, minimum current 1.5 mA

Terminal assignment

* If the connector pins 1 and 2 are short circuited, the brake is forcefully released.

1 BKMRL Brake release switch input 2 COM Brake release switch input power supply output

Break release switch

XAP-02V-1

(Contact BXA-001T-P0.6) (JST)

3.10.6 Connection

Input +24 V power supply to the 24 V power supply connector of the external brake connection box.

Controller connection diagram

Motor cable

Encoder cable

Actuator

SCON 400 W or higher

External brake connection box

Chapter 2 Positioner Mode

1. I/O Signal Control and Signal Functions

1.1 PIO Patterns and Signal Assignments

This controller provides six PIO pattern types to meet the needs of various applications. To select a desired type, set a corresponding value from 0 to 5 in parameter No. 25 (PIO pattern selection). The features of each PIO pattern are explained below:

Parameter No.

25 setting

Positioning mode [Standard type] A basic type supporting 64 positioning points and two zone outputs. * How to set zone boundaries within which to output a zone signal: Zone boundaries are set using parameter Nos. 1 and 2 for one zon e output, and in the position table for another zone output.

Teaching mode [Teaching type] In this type, 64 positioning points and one zone output (boundaries are set in the position table) are supported. In addition to the normal positioning mode, the user can also select the teaching mode in which the actuator can be jogged via I/Os and the current actuator position can be written to a specified position. (Note) Positions can be rewritten by approximately 100,000 times.

256-point mode [256-point type] The number of positioning points is increased to 256, so only one zone output is available (boundaries are set in the position table).

512-point mode [512-point type] The number of positioning points is increased to 512, so no zone output is available.

Solenoid valve mode 1 [7-point type] The number of positioning points is limited to seven, but separate direct command inputs and position complete outputs are provided. PLC ladder sequence circuits can be designed easily.

Solenoid valve mode 2 [3-point type] Use of the controller as an air cylinder is assumed in this type. The function of position complete output signals is different from how these signals function in the 7-point type. These signals not only indicate that the position specified by each move command “has been reached,” but the also function as a limit switch. This means that the signals will turn ON even when the actuator is moved by hand. Take note that incremental positioning commands are not supported in this mode.

Feature of PIO pattern

Quick reference table for functions available under each PIO pattern (

Zone output

No. 25

Number of

positioning points

Boundaries set by

parameters

(ZONE1)

0 64 points

   

1 64 points x 2 256 points x

Zone output Boundaries set in the position table

(PZONE)

  

3 512 points x x 4 7 points 5 3 points

     

: Available, x: Not available)

Brake release

input signal

(BKRL)

Moving output

signal (MOVE)



x x x x

1.1.1 Explanation of Signal Names

The following explains the signal names, and gives a function overview of each signal. In the explanation of operation timings provided in a later section, each signal is referenced by its selfexplanatory name for clarity. If necessary, however, such as when marker tubes are inserted as a termination of the flat cable, use the signal abbreviations.

 PIO pattern = 0 Positioning mode [Standard type]

Category Signal name

Command position number

Brake release BKRL

Input

Output

Operating mode RMDO Home return HOME Home return operation is started at a rise edge of this signal.

Pause *STP ON: Actuator can be moved, OFF: Actuator decelerates to a stop Start CSTR The actuator will start moving at a rise edge of this signal. Alarm reset RES An alarm is reset at a rise edge of this signal.

Servo ON SON

Completed position number

Moving MOVE

Zone 1 ZONE1

Position zone PZONE

Operating mode status RMDS A signal indicating the operating mode of AUTO or MANU is output. Home return completion HEND

Position complete PEND

Servo-on status SV Emergency stop status *EMGS Alarm *ALM Battery alarm *BALM

Signal

abbreviation PC1 PC2 PC4 PC8 PC16 PC32

PM1 PM2 PM4 PM8 PM16 PM32

Function overview

The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.

This signal is used on an actuator equipped with a brake to forcibly release the brake. This signal switches the operating mode between AUTO and MANU. (ON: MANU, OFF: AUTO)

The servo remains ON while this signal is ON. The servo remains OFF while this signal is OFF.

The relevant position number is output when positioning has completed. The signal will turn OFF when the next start signal is received. It is used by the PLC to check if the commanded position has definitively been reached, and also to provide a position interlock, etc.

This signal will remain ON while the actuator is moving, and OFF while the actuator is standing still. Used to check the operation or determine if the load was missed in push & hold operation. This signal becomes effective after home return. It will turn ON when the current actuator position enters the range set by the parameters and remain ON until the actuator exits the range. This signal becomes effective after a position movement command is input. It will turn ON when the current actuator position enters the range specified in the position table and remain ON until the actuator exits the range.

This signal is OFF immediately after the power is input, and turns ON when home return has completed. This signal turns ON when the actuator has moved to the target position and entered the positioning band. It is used to determine if the positioning has completed. This signal is always output once the servo is turned ON and the controller is ready to operate. When this signal is OFF, it means that an emergency stop is being actuated. This signal remains ON in normal conditions of use and turns OFF when an alarm generates. This signal is ON when the absolute battery voltage is normal or an incremental encoder is used.

 PIO pattern = 1 Teaching mode [Teaching type]

Category Signal name

Command position number

Operation mode MODE Mode selection (ON: Teaching mode, OFF: Normal mode) Jog/inching switching JISL OFF: Jog, ON: Inching

+jog/inching movement JOG+

Input

-jog/inching movement JOG-

Operating mode RMOD

Home return HOME Pause *STP Start CSTR

Current-position write PWRT Alarm reset RES

Servo ON SON

Completed position number

Moving MOVE

Mode status MODES

Position zone PZONE

Output

Operating mode status RMDS Home return completion HEND

Position complete PEND

Write completion WEND Servo-on status SV

Emergency stop status *EMGS Alarm *ALM

Battery alarm *BALM

Signal

abbreviation PC1 PC2 PC4 PC8 PC16 PC32

PM1 PM2 PM4 PM8 PM16 PM32

The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.

The actuator will start jogging or inching in the positive direction at an ON edge of this signal. The actuator will start jogging or inching in the negative direction at an ON edge of this signal.

This signal switches the operating mode between AUTO and MANU.

Home return operation is started at a rise edge of this signal. ON: Actuator can be moved, OFF: Actuator decelerates to a stop The actuator will start moving at a rise edge of this signal. When this signal has remained ON for 20 msec or longer, the current

position will be stored under the position number selected by PC1 to PC32.

An alarm is reset at a rise edge of this signal. The servo remains ON while this signal is ON.

The servo remains OFF while this signal is OFF. The relevant position number is output when positioning has

completed. The signal will turn OFF when the next start signal is received. It is used by the PLC to check if the commanded position has definitively been reached, and also to provide a position interlock, etc.

This signal will remain ON while the actuator is moving, and OFF while the actuator is standing still. Used to check the operation or determine if the load was missed in push & hold operation. This signal is ON when the controller is in the teaching mode, and OFF when the controller is in the normal mode. This signal becomes effective after a position movement command is input. It will turn ON when the current actuator position enters the range specified in the position table and remain ON until the actuator exits the range.

A signal indicating the operating mode of AUTO or MANU is output. This signal is OFF immediately after the power is input, and turns ON

when home return has completed. This signal turns ON when the actuator has moved to the target position and entered the positioning band. It is used to determine if the positioning has completed. This signal is output upon completion of writing to the nonvolatile memory in response to a current-position write command (PWRT). This signal is always output once the servo is turned ON and the controller is ready to operate. OFF: Emergency stop has been actuated This signal remains ON in normal conditions of use and turns OFF when an alarm generates. This signal is ON when the absolute battery voltage is normal or an incremental encoder is used.

Function overview

(ON: MANU, OFF: AUTO)

 PIO pattern = 2 256-point mode [256-point type]

Category Signal name

Command position number

Input

Output

Brake release BKRL Operating mode RMOD

Home return HOME Home return operation is started at a rise ed ge of this signal. Pause *STP ON: Actuator can be moved, OFF: Actuator decelerates to a stop Start CSTR The actuator will start moving at a rise edge of this signal. Alarm reset RES An alarm is reset at a rise edge of this signal.

Servo ON SON

Completed position number

Position zone PZONE

Operating mode status RMDS A signal indicating the operati ng mode of AUTO or MANU is output. Home return completion HEND

Position complete PEND

Servo-on status SV Emergency stop status *EMGS OFF: Emergen cy stop has been actuated Alarm *ALM

Battery alarm *BALM

Signal

abbreviation PC1

PC2 PC4 PC8 PC16 PC32 PC64 PC128

PM1 PM2 PM4 PM8 PM16 PM32 PM64 PM128

The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.

This signal is used on an actuator equipped with a brake to forcibly release the brake. This signal switches the operating mode between AUTO and MANU. (ON: MANU, OFF: AUTO)

The servo remains ON while this signal is ON. The servo remains OFF while this signal is OFF.

This signal becomes effective after a position movement command is input. It will turn ON when the current actuator position enters the range specified in the position table and remain ON until the actuator exits the range.

This signal remains ON in normal conditions of use and turns OFF when an alarm generates. This signal is ON when the absolute battery voltage is normal or an incremental encoder is used.

Function overview

 PIO pattern = 3 512-point mode [512-point type]

Category Signal name

Command position number

Input

Brake release BKRL Operating mode RMOD

Servo ON SON

Completed position number

Output

Operating mode status RMDS A signal indicating the operati ng mode of AUTO or MANU is output. Home return completion HEND

Position complete PEND

Servo-on status SV Emergency stop status *EMGS OFF: Emergen cy stop has been actuated Alarm *ALM

Battery alarm *BALM

Signal

abbreviation PC1

PC2 PC4 PC8 PC16 PC32 PC64 PC128 PC256

PM1 PM2 PM4 PM8 PM16 PM32 PM64 PM128 PC256

The target position number is input. A command position number must be specified by 6 ms before the start signal (CSTR) turns ON.

This signal is used on an actuator equipped with a brake to forcibly release the brake. This signal switches the operating mode between AUTO and MANU. (ON: MANU, OFF: AUTO)

The servo remains ON while this signal is ON. The servo remains OFF while this signal is OFF.

This signal remains ON in normal conditions of use and turns OFF when an alarm generates. This signal is ON when the absolute battery voltage is normal or an incremental encoder is used.

Function overview

 PIO pattern = 4 Solenoid valve mode 1 [7-point type]

Category Signal name

Position No. 0 move Position No. 1 move Position No. 2 move Position No. 3 move Position No. 4 move

Input

Output

Position No. 5 move Position No. 6 move Brake release BKRL

Operating mode RMOD Home return HOME Home return operation is started at a rise edge of this signal.

Pause *STP Alarm reset RES An alarm is reset at a rise edge of this signal.

Servo ON SON Position No. 0 complete PE0 Position No. 1 complete PE1 Position No. 2 complete PE2 Position No. 3 complete PE3 Position No. 4 complete PE4 Position No. 5 complete PE5 Position No. 6 complete PE6

Zone 1 ZONE1

Position zone PZONE Operating mode status RMDS

Home return completion HEND

Position complete PEND

Servo-on status SV Emergency stop status *EMGS OFF: Emergency stop has been actuated Alarm *ALM

Battery alarm *BALM

Signal

abbreviation

ST0 ST1 ST2 ST3 ST4 ST5 ST6

The actuator starts moving to position No. 0 when this signal turns ON. The actuator starts moving to position No. 1 when this signal turns ON. The actuator starts moving to position No. 2 when this signal turns ON. The actuator starts moving to position No. 3 when this signal turns ON. The actuator starts moving to position No. 4 when this signal turns ON. The actuator starts moving to position No. 5 when this signal turns ON. The actuator starts moving to position No. 6 when this signal turns ON. This signal is used on an actuator equipped with a brake to forcibly release the brake. This signal switches the operating mode between AUTO and MANU. (ON: MANU, OFF: AUTO)

ON: Actuator can be moved, OFF: Actuator decelerates to a stop

The servo remains ON while this signal is ON. The servo remains OFF while this signal is OFF. This signal will turn ON when the actuator completes moving to position No. 0. This signal will turn ON when the actuator completes moving to position No. 1. This signal will turn ON when the actuator completes moving to position No. 2. This signal will turn ON when the actuator completes moving to position No. 3. This signal will turn ON when the actuator completes moving to position No. 4. This signal will turn ON when the actuator completes moving to position No. 5. This signal will turn ON when the actuator completes moving to position No. 6. This signal becomes effective after home return. It will turn ON when the current actuator position enters the range set by the parameters and remain ON until the actuator exits the range. This signal becomes effective when the current actuator position is in the range specified in the position table, while a position movement command is input.

A signal indicating the operating mode of AUTO or MANU is output. This signal is OFF immediately after the power is input, and turns

ON when home return has completed. This signal turns ON when the actuator has moved to the target position and entered the positioning band. It is used to determine if the positioning has completed. This signal is always output once the servo is turned ON and the controller is ready to operate.

This signal remains ON in normal conditions of use and turns OFF when an alarm generates. This signal is ON when the absolute battery voltage is normal or an incremental encoder is used.

Function overview

 PIO pattern = 5 Solenoid valve mode 2 [3-point type]

Category Signal name

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

Input

Output

Brake release BKRL Operating mode RMOD

Alarm reset RES An alarm is reset at a rise edge of this signal. Servo ON SON

Rear end position detected Front end position detected Intermediate position detected

Zone 1 ZONE1

Position zone PZONE

Operating mode status RMDS A signal indicating the operati ng mode of AUTO or MANU is output. Home return completion HEND

Servo-on status SV Emergency stop status *EMGS OFF: Emergen cy stop has been actuated Alarm *ALM

Battery alarm *BALM

Signal

abbreviation ST0

ST1 ST2

LS0 LS1 LS2

The actuator will move toward the rear end while this signal remains at ON level. The actuator will move toward the front end while this signal remains at ON level. The actuator will move toward the intermediate point while this signal remains at ON level. This signal is used on an actuator equipped with a brake to forcibly release the brake. This signal switches the operating mode between AUTO and MANU. (ON: MANU, OFF: AUTO)

The servo remains ON while this signal is ON. The servo remains OFF while this signal is OFF. This signal will remain ON while the rear end is recognized. (This signal is not output in the push & hold mode.) This signal will remain ON while the front end is recognized. (This signal is not output in the push & hold mode.) This signal will remain ON while the intermediate point is recognized. (This signal is not output in the push & hold mode.) This signal becomes effective after home return. It will turn ON when the current actuator position enters the range set by the parameters and remain ON until the actuator exits the range. This signal becomes effective when the current actuator position is in the range specified in the position table, while a position movement command is input.

This signal is OFF immediately after the power is input, and turns ON when home return has completed. This signal is always output once the servo is turned ON and the controller is ready to operate.

This signal remains ON in normal conditions of use and turns OFF when an alarm generates. This signal is ON when the absolute battery voltage is normal or an incremental encoder is used.

Function overview

Take note that incremental position commands are not supported in solenoid valve mode 2 [3-point type].

1.1.2 Signal Assignment Table for Respective PIO Patterns

When creating a PLC sequence or wiring signals, assign each pin correctly by referring to the assignm ent table below. When “1 [Teaching type]” is selected, the meaning of each pin number will vary depending on the mode. Accordingly, also pay due attention to the mode switch timings.

Category Wire color

No.

1A 2A 3A Orange - 1 (Not used) 4A Yellow - 1 (Not used) 5A Green - 1 PC1 PC1 PC1 PC1 ST0 ST0 6A Blue - 1 PC2 PC2 PC2 PC2 ST1 ST1 7A Purple - 1 PC4 PC4 PC4 PC4 ST2 ST2 8A Gray - 1 PC8 PC8 PC8 PC8 ST3 -

9A White - 1 PC16 PC16 PC16 PC16 ST4 10A Black - 1 PC32 PC32 PC32 PC32 ST5 11A Brown - 2 - MODE PC64 PC64 ST6 12A Red - 2 - JISE PC128 PC128 - 13A Orange - 2 - JOG+ - PC256 - 14A Yellow - 2 BKRL JOG- BKRL BKRL BKRL BKRL 15A Green - 2 RMOD 16A Blue - 2 HOME 17A Purple - 2 *STP 18A Gray - 2 CSTR 19A White - 2 RES 20A

2B Red - 3 PM2 PM2 PM2 PM2 PE1 LS1

3B Orange - 3 PM4 PM4 PM4 PM4 PE2 LS2

4B Yellow - 3 PM8 PM8 PM8 PM8 PE3 -

5B Green - 3 PM16 PM16 PM16 PM16 PE4 -

6B Blue - 3 PM32 PM32 PM32 PM32 PE5 -

7B Purple - 3 MOVE MOVE PM64 PM64 PE6 -

8B Gray - 3 ZONE1 MODES PM128 PM128 ZONE1 ZONE1

9B White - 3 PZONE PZONE PZONE PM256 PZONE PZONE 10B Black - 3 RMDS 11B Brown - 4 HEND 12B Red - 4 PEND PEND/WND PEND PEND PEND 13B Orange - 4 SV 14B Yello w - 4 *EMGS 15B Green - 4 *ALM 16B 17B Purple -4 (Not used) 18B Gray - 4 (Not used) 19B White - 4 20B

+24V

Input

Output

Upper stage

Brown - 1

Red - 1

Black - 2 SON

Lower stage

Brown - 3

Blue - 4 *BALM

Black - 4

0 1 2 3 4 5

CSTR/PWRT

PM1

Parameter No. 25 setting Pin

P24

CSTR CSTR - -

PM1

PE0

LS0

Caution: [1] The signals indicated by * in the table (*ALM, *STP, *EMGS and *BALM) are based on the negative logic,

meaning that they remain ON in normal conditions of use. [2] Do not connect pins denoted by “Not used” (orange-1, yellow-1, purple-4, gray-4), but insulate them instead. [3] The NPN and PNP specifications use the same power line configuration, so there is no need to reverse the

power signal assignments for a PNP controller.

1.2 Connecting the I/O Cable

 PIO pattern 0 Positioning mode [Standard type]

Host system

<PLC> end

Command position 1 Command position 2 Command position 4

Command position 8 Command position 16 Command position 32

Output side

Input side

Home return completion

Black 4

Brown 1

Brake release

Operating mode

Home return

Completed position 1 Completed position 2 Completed position 4

Completed position 8 Completed position 16 Completed position 32

Position zone

Operating mode status

Position complete

Servo-on status

Emergency stop status

Battery alarm

Bottom

Top

Pause

Reset

Servo on

Moving Zone 1

Alarm

Start

Brown-1

Red-1

Orange-1

Yellow-1 Green-1

Blue-1

Purple-1

Gray-1 White-1 Black-1

Brown-2

Red-2

Orange-2

Yellow-2 Green-2

Blue-2

Purple-2

Gray-2 White-2 Black-2

Brown-3

Red-3

Orange-3

Yellow-3 Green-3

Blue-3

Purple-3

Gray-3 Wihte-3 Black-3

Brown-4

Red-4

Orange-4

Yellow-4 Green-4

Blue-4

Purple-4

Gray-4 White-4 Black-4

Controller end

PIO (signal abbreviation)

(Note) *STP, *ALM, *EMGS and *BALM

are negative-logic signals.

 PIO pattern 1 Teaching mode [Teaching type]

Host system

<PLC> end

Command position 1 Command position 2 Command position 4

Command position 8 Command position 16 Command position 32

Jog/inching switching

Output side

Completed position 1 Completed position 2 Completed position 4

Completed position 8 Completed position 16 Completed position 32

Input side

Operating mode status

Home return completion

Position complete/write

Emergency stop status

Operation mode

+Jog

-Jog

Operating mode

Home return

Pause

Start/position write

Alarm reset

Servo on

Moving

Mode status

Position zone

completion

Servo-on status

Alarm

Battery alarm

Brown-1

Red-1

Orange-1

Yellow-1

Green-1

Blue-1

Purple-1

Gray-1 White-1 Black-1

Brown-2

Red-2

Orange-2

Yellow-2

Green-2

Blue-2

Purple-2

Gray-2 White-2 Black-2

Brown-3

Red-3

Orange-3

Yellow-3

Green-3

Blue-3

Purple-3

Gray-3 Wihte-3 Black-3

Brown-4

Red-4

Orange-4

Yellow-4

Green-4

Blue-4

Purple-4

Gray-4 White-4 Black-4

Black 4

Brown 1

Bottom

Top

Controller end

PIO (signal abbreviation)

(Note) *STP, *ALM, *EMGS and *BALM

are negative-logic signals.

 PIO pattern 2 256-point mode [256-point type]

Host system

<PLC> end

Command position 1 Command position 2 Command position 4

Command position 8 Command position 16 Command position 32 Command position 64

Command position 128

Output side Input side

Completed position 128

Home return completion

Black 4

Brown 1

Break release

Operation mode

Completed position 1 Completed position 2 Completed position 4

Completed position 8 Completed position 16 Completed position 32 Completed position 64

Position zone

Operating mode status

Position complete

Servo-on status

Emergency stop status

Battery alarm

Bottom

Top

Home return

Pause

Start

Alarm reset

Servo on

Alarm

Brown-1

Red-1

Orange-1

Yellow-1

Green-1

Blue-1

Purple-1

Gray-1 White-1 Black-1

Brown-2

Red-2

Orange-2

Yellow-2

Green-2

Blue-2

Purple-2

Gray-2 White-2 Black-2

Brown-3

Red-3

Orange-3

Yellow-3

Green-3

Blue-3

Purple-3

Gray-3 Wihte-3 Black-3

Brown-4

Red-4

Orange-4

Yellow-4

Green-4

Blue-4

Purple-4

Gray-4 White-4 Black-4

Controller end

PIO (signal abbreviation)

(Note) *STP, *ALM, *EMGS and *BALM

are negative-logic signals.

 PIO pattern 3 512-point mode [512-point type]

Host system

<PLC> end

Command position 1 Command position 2 Command position 4

Command position 8 Command position 16 Command position 32 Command position 64

Command position 128 Command position 256

Output side

Completed position 1 Completed position 2 Completed position 4

Completed position 8 Completed position 16 Completed position 32 Completed position 64

Completed position 128 Completed position 256

Input side

Operating mode status

Home return completion

Emergency stop status

Break release

Operation mode

Home return

Pause

Start

Alarm reset

Servo on

Position complete

Servo-on status

Alarm

Battery alarm

Brown-1

Red-1

Orange-1

Yellow-1

Green-1

Blue-1

Purple-1

Gray-1 White-1 Black-1 Brown-2

Red-2

Orange-2

Yellow-2

Green-2

Blue-2

Purple-2

Gray-2 White-2 Black-2 Brown-3

Red-3

Orange-3

Yellow-3

Green-3

Blue-3

Purple-3

Gray-3 Wihte-3 Black-3 Brown-4

Red-4

Orange-4

Yellow-4

Green-4

Blue-4

Purple-4

Gray-4 White-4 Black-4

Black 4

Brown 1

Bottom

Top

Controller end

PIO (signal abbreviation)

(Note) *STP, *ALM, *EMGS and *BALM

are negative-logic signals.

 PIO pattern 4 Solenoid valve mode 1 [7-point type]

Host system

<PLC> end

Output side

Completed position 0 Completed position 1 Completed position 2 Completed position 3 Completed position 4 Completed position 5 Completed position 6

Input side

Operating mode status

Home return completion

Emergency stop status

Start position 0 Start position 1 Start position 2 Start position 3 Start position 4 Start position 5 Start position 6

Break release

Operation mode

Home return

Pause

Alarm reset

Servo on

Zone 1

Position zone

Position complete

Servo-on status

Alarm

Battery alarm

Brown-1

Red-1

Orange-1

Yellow-1

Green-1

Blue-1

Purple-1

Gray-1

White-1

Black-1

Brown-2

Red-2

Orange-2

Yellow-2

Green-2

Blue-2

Purple-2

Gray-2

White-2

Black-2

Brown-3

Red-3

Orange-3

Yellow-3

Green-3

Blue-3

Purple-3

Gray-3

Wihte-3

Black-3

Brown-4

Red-4

Orange-4

Yellow-4

Green-4

Blue-4

Purple-4

Gray-4

White-4

Black-4

Black 4

Brown 1

Bottom

Top

Controller end

PIO (signal abbreviation)

(Note) *STP, *ALM, *EMGS and *BALM

are negative-logic signals.

 PIO pattern 5 Solenoid valve mode 2 [3-point type]

Host system

<PLC> end

Output side Input side

Intermediate point detected

Operating mode status

Home return completion

Emergency stop status

Start position 0 Start position 1 Start position 2

Break release

Operation mode

Alarm reset

Servo on

Rear end detected

Front end detected

Zone 1

Position zone

Servo-on status

Alarm

Battery alarm

PIO (signal abbreviation)

Brown-1

Red-1

Orange-1

Yellow-1 Green-1

Blue-1

Purple-1

Gray-1 White-1 Black-1

Brown-2

Red-2

Orange-2

Yellow-2 Green-2

Blue-2

Purple-2

Gray-2 White-2 Black-2

Brown-3

Red-3

Orange-3

Yellow-3 Green-3

Blue-3

Purple-3

Gray-3 Wihte-3 Black-3

Brown-4

Red-4

Orange-4

Yellow-4 Green-4

Blue-4

Purple-4

Gray-4 White-4 Black-4

Black 4

Brown 1

Bottom

Top

Controller end

(Note) *STP, *ALM, *EMGS and *BALM

are negative-logic signals.

1.3 Details of I/O Signal Functions

An input time constant is provided for the input signals of this controller, in order to prevent malfunction due to chattering, noise, etc. Except for certain signals, switching of each input signal will be effected when the signal has been received continuously for at least 6 msec. For example, when an input is switched from OFF to ON, the controller will only recognize that the input signal is ON after 6 msec. The same applies to switching of input signals from O N to OFF (Fig. 1).

Recognition by controller

1.3.1. Details of Each Input Signal

Input signal

Not recognized

6 [msec] 6 [msec]

Fig. 1 Recognition of Input Signal

 Command position number (PC1 to PC256)

When a movement command is effected upon OFF  ON of the start signal, the nine-bit binary code consisting of signals PC1 to PC256 will be read as the command position number. In the standard or teaching type, six bits of PC1 through PC32 are used. In the 256-point type, eight bits of PC1 to PC128 are used. In the 512-point type, nine bits of PC1 through PC256 are used. The weight of each bit is as follows: 2

for PC1, 21 for PC2, 22 for PC4, …, and 28 for PC256. A desired position

number between 0 and 511 (maximum) can be specified.

 Brake forced-release signal (BKRL)

This signal forcibly releases the brake of an actuator equipped with an electromagnetic brake. If this signal turns ON while the 24-V brake power is supplied to the controller externally and the servo is off, the electromagnetic brake will be forcibly released. This signal is disabled when the actuator is not equipped with electromagnetic brake, 24-V brake power is not supplied externally, servo is on, or brake release switch on the controller is set to the RLS position.

 Operating mode (RMOD)

This signal is used to switch the operating mode of the controller. Turning OFF this signal will switch the operating mode to “AUTO,” while turning it ON will switch the mode to “MANU.” The RMOD signal is enabled when the “AUTO/MANU selector switch” on the front face of the controlle r is set to “AUTO.” For details on the operating modes, refer to 3, “Operation.”

 Home return (HOME)

The controller will start home return operation upon detection of an OFF  ON edge of this signal. When the home return is complete, the HEND signal will be output. The HOME signal can be input as many times as required. (Note) Even if home return is not performed after the power has been input, the actuator will automatically

perform home return and then move to the target position. Therefore, this signal need not be used at all time. The actuator will move to the home position if “0.00 mm” is set in the position data table. However, this signal is useful when the position data table has no available fields or when the controller is used in the teaching mode.

 Pause (*STP)

When this signal turns OFF while the actuator is moving, the actuator will decelerate to a stop. The remaining movement is retained and will be resumed when the signal is turned ON agai n. If you wish to cancel the move command itself while this signal is OFF, turn the RES signal ON while this signal is OFF to cancel the remaining travel distance. The *STP signal can be used for the following purposes: [1] Provide a low-level safety measure to stop the axis while the servo is ON, such as a sensor that detects a

person approaching the system [2] Prevent contact with other equipment [3] Perform positioning based on sensor or LS detection (Note) If the *STP signal is turned OFF while the actuator is performing home return, the home return operation

will be put on hold. Once the signal turns ON, the home return operation will be resumed from the point where the actuator contacts a mechanical end.

 Start (CSTR)

Upon detecting an OFF  ON edge of this signal, the controller will read the target point number (PC1 to PC256) and execute positioning operation to the corresponding target position. Before executing this command, the target position, speed, acceleration and other operation data must be set in the position table using the PC software or teaching pendant. If a start command is issued when home return operation has not been performed yet (the HEND output signal is OFF), the controller will automatically perform home return operation before positioning to the target position.

 Alarm reset (RES)

This signal provides two functions. [1] Reset the alarm output signal (*ALM) that turned OFF due to an alarm

If an alarm has generated, turn ON this signal after confirming the nature of the alarm.

The controller will reset the alarm upon detection of a rise edge of the RES signal.

(Note) Certain alarms cannot be reset by the RES signal. For details, refer to Appendix 5,

“Troubleshooting.”

[2] Cancel the remaining movement when the pause signal is OFF

This function is used when the remaining movement must be cancelled to allow for incremental moves

(movements at a constant increment) from the position where the actuator stopped following a sensor

detection.

 Servo ON (SON)

The servo remains ON while this signal is ON. Use this signal based on the default setting (the factory setting is “0: Enable”) if servo ON/OFF control must be performed by the PLC as part of the operation of the safety circuit covering the entire system. Whether this signal is enabled or disabled is defined by parameter No. 21, “Servo ON input.” If the SON signal is used, set this parameter to “0: [Enable].” If it is not used, set the parameter to “1: [Disable].” (Note) If the SON signal is turned OFF during movement in case of error, the actuator will decelerate to a stop

at the emergency-stop torque and then the servo will turn OFF. At this time, the function selected by a parameter (dynamic brake, electromagnetic brake, or deviation counter clear) is performed.

Dynamic brake

Electromagnetic brake

Lock Release

 Operation mode (MODE)

This signal is enabled when parameter No. 25, “PIO pattern selection” is set to [1] (when the teaching mode [teaching type] is selected). When this signal is turned ON, the normal operation mode will switch to the teaching mode. (Note) For the controller to switch modes, all of the JOG+, JOG-, PWRT and CSTR signals must be OFF and

the actuator must be stopped (except when the actuator is pushing the load).

Once the modes have been switched, the MODES output signal turns ON.

The PLC should be programmed in such a way that it will confirm that the MODES output signal is ON

before accepting any PWRT operation command.

To switch the controller back to the normal operation mode, turn this signal OFF.

The PLC should be programmed in such a way that it will confirm that the MODES output signal is OFF

before accepting any operation command in the normal operation mode. (Note) The controller will not return to the normal operation mode unless the PWRT input signal is OFF.

 Jog/inching switching signal (JISL)

When the jog/inching switching signal (JISL) is OFF, the functions of the JOG+ and JOG- signals are switched to those pertaining to jog operation. When the JISL signal is ON, the functions of the above signals are switched to those relating to inching operation. If the JISL signal is turned ON (switched to inching) while the actuator is jogging, the actuator will decelerate to a stop and enter the inching mode. When the JISL signal is turned OFF (switched to jogging) while the actuator is inching, the actuator will complete the movement and then enter the jogging mode.

 Jog (JOG+, JOG-)

These signals function in two modes, which are toggled according to the input (ON/OFF) of the jog/inching switching signal (JISL). [1] Jog mode: The jog/inching switching signal (JISL) is OFF

The actuator jogs while a jog signal is ON, and will decelerate to a stop when the signal is turned OFF. The JOG+ signal causes the actuator to jog forward, while the JOG- signal causes the actuator to jog backward. If the JOG+ and JOG- signals turn ON simultaneously, the actuator will decelerate to a stop. The travel speed corresponds to the value set in parameter No. 26, “PIO jog speed.”

[2] Inching mode: Jog/inching switching signal (JISL) is ON

Once a jog signal turns ON, the actuator will travel for the specified inching distance. The JOG+ signal causes the actuator to inch forward, while the JOG- signal causes the actuator to inch backward. The distance traveled as a result of a single inching movement (= inching distance) corresponds to the value set in parameter No. 36, “PIO inching distance.” These signals are accepted regardless of whether the actuator is stopped or moving. The total number of times the JOG+ and JOG- signals have been input determines the final stopping position. The travel speed corresponds to the value set in parameter No. 26, “PIO jog speed.”

If a jog signal is turned ON during normal operation, the actuator will continue with its normal operation (the jog signal will be ignored).

(Note) Until home return is completed, the software stroke limits are ineffective and therefore the actuator may

crash into a mechanical end. Exercise due caution.

 Current-position write (PWRT)

This signal is enabled when the aforementioned MODES output signal is ON. If this signal remains ON for 20 msec or more, the controller will read a position number consi sting of the binary code specified by PC1 to PC32 that are currently detected, and write the current position data as a target position in the position data table under the corresponding position number. If data other than the target position (speed, acceleration/deceleration, positioning band, etc.) are yet to be defined, the default parameter settings will be written. When the writing completes successfully, the WEND output signal will turn ON. Configure the system in such a way that the PLC will turn OFF the PWRT signal when WEND turns ON. The controller will turn OFF WEND once the PWRT signal turns OFF. If the PWRT signal is turned OFF before the WEND signal turns ON, the WEND signal will not turn ON. (Note) An alarm will generate if a write command is issued when home return has not been performed yet or

while the actuator is moving.

 Required condition when the servo is on:

This signal is enabled when both the JOG+ and JOG- input signals are OFF, HEND output sig nal is ON, and MOVE output signal is OFF.

 Required condition when the servo is off:

This signal is enabled as long as the HEND output signal is ON. However, whether the actuator is being moved by hand or stopped cannot be distinguished. Therefore, this signal should be input after physically checking the actuator operation to confirm that the actuator is stopped.

 Start position number (ST0 to ST6) Solenoid valve mode 1 [7-point type]

These signals are effective when “4” is set in parameter No. 25 (= when the air-cylinder type is selected). Upon detection of an OFF  ON rise edge or ON level of this signal, the actuator will move to the target position set in the corresponding position data. Before executing this command, the target position, speed and other operation data must be set in the position table using a PC/teaching pendant. If two or more ON signals are detected at the same time, priority will be given to the position command of the smallest number among all detected commands. (Example: If ON signals of ST0 and ST1 are detected at the same time, the actuator will start moving to position 0.) Although commands are executed upon detection of ON signal edge, priority is given to the command that was specified the earliest. In other words, a signal input will not be accepted while the actuator is moving. Even if a different position signal is turned ON while the actuator is moving, the actuator will not commence moving to the new position even after reaching the target position.

Correspondence table of input signals and command positions

Input signal Command position

ST0 Position No. 0 ST1 Position No. 1 ST2 Position No. 2 ST3 Position No. 3 ST4 Position No. 4 ST5 Position No. 5 ST6 Position No. 6

If a movement command is issued when the first home return is not yet completed after the power was input, home return will be performed automatically to establish the coordinates first, after which the actuator will move to the target position.

 Movement to each position (ST0, ST1, ST2) Solenoid valve mode 2 [3-point type]

Since the number of positioning points is limited to three, the actuator can be controlled just like an air cylinder. While this signal is ON, the actuator will move toward the target position. If the signal turns OFF while the actuator is moving, the actuator will decelerate to a stop. Before executing this command, enter a target position in the “Position” field for position No. 0, 1 or 2 in the position table.

Input signal Target position Remarks

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

1.3.2 Details of Each Output Signal

 Completed position number (PM1 to PM256)

These signals can be used to check the completed position number when the PEND signal turns ON. The signals are output as a binary code. Immediately after the power is input, all of the PM1 to PM256 signals are OFF. In the standard or teaching type, six bits of PM1 through PM32 are used. In the 256-point type, eight bits of PM1 through PM128 are used. In the 512-point type, nine bits of PM1 through PM256 are used. All of these signals are OFF also when the actuator is moving. As described above, this signal is output only when positioning is completed. (Note) All of these signals will turn OFF when the servo is turned OFF or an emergency stop is actuated. They

will return to the ON status when the servo is turned ON again, provided that the current position is

inside the positioning band with respect to the target position. If the current position is outside the band

the signals will remain OFF.

When the power is input, the PEND signal will turn ON. These signals are all OFF, this condition is the

same as one achieved after positioning to position “0” is completed.

Check the position of position “0” after the movement command has completed. If an alarm is present, the corresponding alarm code (abbreviated form) consisting of four bits from PM1 to PM8 will be output. The meanings of these signals vary between the normal condition and the alarm condition, so be careful not to use them wrongly in the sequence.

 Moving (MOVE)

This signal is output while the servo is ON and the actuator is moving (also during home return, push & hold operation or jogging). Use the MOVE signal together with the PEND signal to allow the PLC to determine the actuator status. The MOVE signal will turn OFF after positioning or home return is completed or a judgment is made during push & hold operation that the load is being contacted.

 Zone (ZONE1)

This signal will remain ON while the current actuator position is inside the zone specified by parameters No . 1, “Zone 1+ [ZONM]” and No. 2, “Zone 1- [ZONL],” or OFF while the actuator is outside the above zone. This signal is always effective once home return has been completed and is not affected by the servo status or presence of an alarm. (Note 1) This signal becomes effective only after the coordinate system has been established following a

completion of home return. It will not be output immediately after the power is turned on. As long as home return has been completed, this signal is enabled even when the servo is o ff or while an emergency stop is actuated.

(Note 2) The zone functions have been changed due to version upgrade. Refer to the precautions at the outset.

 Position zone signal (PZONE)

This signal will turn ON when the current actuator position enters the area between the zone boundaries set in the position table. After the current position movement command is completed, the signal will remain effective until the next position movement command is received. (Note) The zone functions have been changed due to version upgrade. Refer to the precautions at the outset.

 Operating mode status (RMDS)

The internal operating mode of the controller is output based on the AUTO/MANU selector switch on the controller and the RMOD signal received by the input port. If the selector switch is set to “AUTO” and the RMOD signal is OFF (AUTO), the controller is in the AUTO (OFF) mode. If the selector switch is set to “MANU” and/or the RMOD signal is ON (MANU), the controller is in the MANU (ON) mode. If the RMOD input is disabled by parameter No. 41, the MODE switch status will be output by this signal.

 Home return completion (HEND)

This signal is OFF immediately after the power is input, and turns ON in either of the following two conditions: [1] This signal turns ON when home return operation has completed with respect to the first move command

issued with the start signal.

[2] Home return operation has completed following an input of the home return signal.

Once turned ON, the HEND signal will not turn OFF unless the input power supply is cut off, a soft reset is executed, or the home return signal is input again. The HEND signal can be used for the following purposes:

[1] Check prior to establishing the home if movement toward the home direction is permitted, in cases where

an obstacle is located in the direction of the home [2] Use as a condition for writing the current position in the teaching mode [3] Use as a condition for enabling the zone output signal

 Position complete (PEND)

This signal indicates that the target position was reached and positioning has completed. Use this signal together with the MOVE signal to allow the PLC to determine the positioning status. When the controller becomes ready after the power was input and the servo has turned ON, this signal will turn ON if the position deviation is within the in-position range. Then, when a move command is issued by turning ON the start signal, the PEND signal will turn OFF. Once the start signal turns OFF, the PEND signal will turn ON again when the deviation from the target position falls within the positioning band. Once turned ON, the PEND signal will not turn OFF even when the position subdequently exceed the positioning band. (Note) If the start signal remains ON, the PEND signal will not turn OFF even when the deviation from the target

position falls within the positioning band: it will turn ON when the start signal turns OFF. Even when the motor is stopped, the PEND signal will remain OFF if the pause signal is input or the servo is OFF.

 Ready (SV)

This is a monitor signal indicating that the servo is ON and the motor is ready. The ON/OFF state of this signal is synchronized with the lit/unlit state of the “SV” LED on the front face of the controller enclosure. Use this signal as a condition for starting a movement command on the PLC side. For the signal timings after the power is input, refer to 3.1, “How to Start.”

 Emergency stop status (*EMGS)

This signal remains ON in a normal condition, and will turn OFF if the emergency stop switch is pressed. Program the PLC so that it will monitor this signal and implement appropriate safety measure s for the entire system if the signal turns OFF.

 Alarm (*ALM)

This signal remains ON while the controller is operating properly, and turns OFF whe n an alarm has generated. Provide an appropriate safety measure for the entire system by allowing the PLC to monitor the OFF status of this signal. For details of alarms, refer to Appendix 5, “Troubleshooting.”

 Absolute-battery voltage low warning signal (*BALM)

This signal remains ON while the absolute battery voltage is normal when controller is of absolute specification, or when the controller is of incremental specification. It will turn OFF once the absolute battery voltage drops to

3.1 V. If the voltage drops further to 2.5 V, an alarm will generate and the controller will no longer be able to retain position information. As long as the aforementioned alarm is not present, the controller still retains position information and thus operations can be performed properly even when this signal is OFF.

 Mode status (MODES)

The MODES signal will turn ON when the teaching mode is enabled upon selection of the teaching mode via the operation mode input signal (MODE signal ON). Thereafter, the MODES signal will remain ON until the MODE signal turns OFF. Configure the system in such a way that the PLC will start teaching operation after confirming that the MODES signal has turned ON. This signal is enabled only when the PIO pattern is “teaching type.”

 Write completion (WEND)

The WEND signal is OFF immediately after the controller has switched to the teaching mode. It will turn ON when the writing of position data in response to the current-position write signal is completed. When the current-position write signal turns OFF, this signal will also turn OFF. Configure the system in such a way that the PLC will acknowledge completion of writing when the WEND signal turns OFF. This signal is enabled only when the PIO pattern is “teaching type” and the actuator is currently operating in the teaching mode.

 Current position number signal (PE0 to PE6) Solenoid valve mode 1 [7-point type]

When the PIO pattern is “4” (air-cylinder type), upon completion of positioning the position number (0 to 6) specified in the applicable move command will be output separately. If push & hold operation is specifie d, the corresponding PE signal will turn ON upon detection of successful push & hold operation. However, the corresponding PE signal will also turn ON even after the load has been missed, so it is not recommended to specify push & hold operation when missing of the load must be detected. Simple alarm-code output function is not provided for these signals. If an alarm generates, only the *ALM signal will turn OFF. Check the details of the alarm code by connecting the PC software or teaching pendant.

Correspondence table of output signals and positions completed

Output signal Position completed

PE0 Position No. 0 PE1 Position No. 1 PE2 Position No. 2 PE3 Position No. 3 PE4 Position No. 4 PE5 Position No. 5 PE6 Position No. 6

Note) These signals turn OFF when the servo is turned OFF or an emergency stop is actuated. They will return

to the ON status when the servo is turned ON again, provided that the current position is inside the positioning band with respect to the target position. If the current position is outside the band, the signals will remain OFF.

(Reference) Output Signal Changes in Each Mode Mode classification MOVE PEND SV HEND PM1 ~

Actuator is stopped with the servo ON after the power was input Home return is in progress following an input of the home return signal Home return has completed following an input of the home return signal

OFF ON ON OFF OFF

ON OFF ON OFF OFF

OFF ON ON ON OFF

Actuator is moving in the positioning/push & hold mode ON OFF ON ON OFF Actuator is paused in the positioning/push & hold mode OFF OFF ON ON OFF Positioning has completed in the positioning mode OFF ON ON ON ON Actuator has stopped after contacting the load in the push &

hold mode Actuator has stopped after missing the load (no load) in the push & hold mode

OFF ON ON ON ON OFF OFF ON ON ON

Actuator is stopped with the servo ON in the teaching mode OFF ON ON Actuator is jogging in the teaching mode ON ON ON Actuator is being moved by hand with the servo OFF in the

teaching mode

OFF

OFF ON

Servo is OFF after home return OFF OFF OFF ON OFF Emergency stop has been actuated after home return OFF OFF OFF ON

(Note) Determine whether the actuator has stopped after contacting the load or missing the load from the signal

statuses of MOVE, PEND and PM1 to 8.

 Position detection output at each position (LS0, LS1, LS2) Solenoid valve mode 2 [3-point type]

These signals have the same meanings as the LS signals of an air cylinder. Each signal will turn ON when the current position enters the positioning band of the target position. (Note) Even if the servo turns off or an emergency stop is actuated while the actuator is stopped at the target

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

Output signal Position detected Remarks

LS0 Rear end

LS1 Front end

LS2 Intermediate point

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

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

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

1.3.3 Feedback Output Signal Details of Each Output Signal

Position detection data is output by pulse trains (differential mode). The current position can be read in real time from the host controller. * The controller has been shipped with the feedback pulse output disabled.

To use the feedback pulse output, set user parameter No. 68 to 0 (Enable).

(Note) For details, refer to 2.3, 3.2.8 and 5.2 in Chapter 3, “Pulse Train Input Mode.”

2. Data Entry

To move the actuator to a specified position, a target position must be entered in the “Position” field. A target position can be specified in the absolute mode where a distance from the home is entered, or in the incremental mode where a relative travel from the current position is entered. Once a target position is entered, all other fields will be automatically populated with their default values set by the applicable parameters. The default values vary depending on the characteristics of the actuator.

2.1 Description of Position Table

The position table is explained using an example on the PC software screen. (The items displayed on the teaching pendant are different.)

No.

(1) No.

Position

[mm] 0 5.00 300.00 0.30 0.30 0 0 0.10 1 380.00 300.00 0.30 0.10 0 0 0.10 2 200.00 300.00 0.30 0.10 0 0 0.10

Zone+

0.00 100.00 0 0 0

300.00 400.00 0 0 0

150.00 250.00 0 0 0

[mm]

Speed

[mm/s]

Zone-

[mm]

Acceleration

[G]

Acceleration/

deceleration

mode

 Indicate the position data number.

Deceleration

[G]

Incremental

Push

[%]

Command

mode

Threshold

[%]

Standstill

mode

Positioning

band [mm]

Comment

(2) Position

(3) Speed

(4) Acceleration/deceleration

 Enter the target position to move the actuator to, in [mm].

Absolute mode: Enter the target position to move the actuator to, using

the distance from the home.

Incremental mode: Enter the target position to move the actuator to, using

the distance from the current position. A negative value can also be entered (a negative value indicates a distance in the negative direction of displayed coordinates).

Position

Absolute mode 30 mm from the home Incremental mode +10 mm from the current position

Incremental mode -10 mm from the current position Absolute mode 100mm from the home

On the teaching pendant RCM-T, these signs indicate that the data was entered in the relative coordinate specification mode.

 Enter the speed at which the actuator will be moved, in [mm/sec].

The default value varies depending on the actuator type.

 Enter the acceleration/deceleration at which to move the actuator, in [G].

Basically, the acceleration and deceleration should be inside the rated acceleration/deceleration range specified in the catalog. The input range is greater than the rated range in the catalog to accommodate situations where you want to “reduce the tact time when the load mass is significantly smaller than the rated load capacity.” If vibration of the load causes problem during acceleration/deceleration, decrease the set value.

Speed

Acceleration

0.3G

Starting position

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

Deceleration

0.2G

Target

position

Time

Caution: Refer to the attached list of supported actuator specifications and set appropriate speed and

acceleration/deceleration so that the actuator will not receive excessive impact or vibration under the

applicable installation condition and for the load of the specific shape.

Increasing the speed and acceleration/deceleration may significantly impact the actuator dependi ng on

the load mass, and the actuator characteristics also vary from one model to another. Contact IAI for

the maximum limits that can be entered in your specific application.

(5) Push

 Select either the positioning mode or push & hold mode.

The default setting is “0.” 0: Positioning mode (= normal operation) Other than 0: Push & hold mode [%]

 If the push & hold mode is selected, enter the current-limiting value to be

applied to limit the AC servo motor current during push & hold operation.

Caution: Take note that if the push force is too small, a false detection may occur during push & hold operation

due to sliding resistance, etc.

(6) Threshold

 This field is not used for this controller.

The factory setting is “0.”

(7) Positioning band

 The meaning of this field varies

between “positioning operation” and “push & hold operation.” “Positioning operation”: This field defines how much before the target position the completion signal will turn ON.

The position complete signal turns ON here.

Increasing the positioning band allows the next operation in the sequence to be started early, and consequently the tact time can be

Positioning band

reduced. Set an optimal value by checking the overall balance of the system.

Target position

“Push & hold operation”

This field defines the maximum push distance after reaching the target position in push & hold operation. Consider possible mechanical variation of the load and set an appropriate positioning band that will prevent the positioning from completing before the load is contacted.

The position complete signal turns ON here, as completion of push action is recognized after the load has been contacted.

Load

Target position

Positioning band (maximum push distance)

(8) Zone +/-

Movement command to position No. 0

Movement command to position No. 1

Movement command to position No. 2

(9) Acceleration/deceleration

mode

Trapezoid pattern

 This field defines the zone in which PZONE (zone output signal) will turn ON

during operations in PIO pattern 0, 1, 2, 4 or 5. To add flexibility, a different zone can now be set for each target position.

[Setting example]

No.

Position

[mm]

Zone+

[mm]

Zone-

[mm] 0 5.00 100.00 0.00 1 380.00 400.00 300.00 2 200.00 250.00 150.00

Home

Target

position

Target

position

Target

position

+ limit

* The zone functions have been changed due to version upgrade.

Refer to the precautions at the outset.

 This field defines the acceleration/deceleration pattern.

The factory setting is “0.”

0: Trapezoid pattern 1: S-motion 2: Primary delay filter

Speed

cceleration Deceleration

Time

* Set desired acceleration and deceleration in the “Acceleration” and

“Deceleration” fields of the position table.

S-motion

During acceleration, the actuator operates along an acceleration curve that gradu ally rises until a certain point, and then increases sharply. Use this mode if you wish to set high acceleration/deceleration to meet the required tact time, while still allowing the actuator to accelerate gradually immediately after it starts moving and immediately before stopping. Note, however, that this setting is not reflected in jogging or inching using a PC or teaching pendant.

Speed

Time

* Set a desired S-motion level in parameter No. 56, “S-motion ratio setting.” The

setting unit is %, while the setting range is 0 to 100. (The graph above assumes an S-motion ratio of 100%.) The S-motion function is disabled when “0” is set.

Caution: [1] Even if you issue a position command or high-value command with specified S-motion

acceleration/deceleration in order to change moving speed while the actuator is operating, trapezoid control, rather than S-motion acceleration/deceleration control, is performed. Make sure to issue a command when the actuator is stopped.

[2] S-motion acceleration/deceleration is disabled in the index mode of the rotary actuator.

Trapezoid control is performed even if S-motion acceleration/deceleration control is specified.

[3] If acceleration or deceleration time exceeding 2 seconds is set, do not command S-motion

acceleration/deceleration control. Normal operation cannot be performed.

[4] Do not suspend the operation during acceleration or deceleration. The speed changes

(accelerates), which may be dangerous.

Primary delay filter

The actuator operates along acceleration/deceleration curves that are more gradual than those of linear acceleration/deceleration (trapezoid pattern). Use this mode in situations where you wish to prevent the load from receiving microvibration during acceleration or deceleration. Note, however, that this setting is not reflected in jogging or inching using a PC or teaching pendant.

Speed

Time

* Set a desired primary delay in parameter No. 55, “Position-command primary filter

time constant.” The setting unit is 0.1 msec, while the setting range is 0.0 to 100.0. The primary delay filter is disabled when “0” is set.

(10) Incremental command

 This field defines whether the position is specified in the absolute mode or

incremental mode. The factory setting is “0.”

0: Absolute mode 1: Incremental mode

Warning: On the solenoid valve mode 2 [3-point type], make sure the position is specified in the absolute

mode. If it is specified in the incremental mode, the position date error (OA2) will generate.

(11) Command mode

 This field is not used for this controller.

The factory setting is “0.”

(12) Standstill mode

 Set a desired power-saving mode to be applied while the actuator stands by

after completion of positioning. To save energy when the actuator stands by for a long period of time, this controller provides a mode in which to reduce the power consumption while the actuator is at standstill. The factory setting is “0” (disabled).

0: Power-saving mode is disabled 1: Automatic servo-off mode, with the delay time defined by parameter No. 36 2: Automatic servo-off mode, with the delay time defined by parameter No. 37 3: Automatic servo-off mode, with the delay time defined by parameter No. 38

Automatic servo-off mode

After positioning is completed, the servo will turn off automatically upon elapse of a specified time. (Power is not consumed because holding current does not flow.) When the next movement command is received from the PLC, the servo will turn on and the actuator will start moving.

Start Position complete

Servo-on status

Actuator movement

utomatic servo-off mode

Green LED (SV) blinks.

Servo on

T: Delay time (seconds) after positioning is completed until the servo turns off

When the setting is 1: T corresponds to the value set in parameter No. 36. When the setting is 2: T corresponds to the value set in parameter No. 37. When the setting is 3: T corresponds to the value set in parameter No. 38.

IAI America SCON-C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Please Read Before Use

1. PC Software and Teaching Pendant Models

2. Recommendation for Backing up Latest Data

3. Using a Rotary Actuator of Multi-rotation Specification

CAUTION

Table of Contents

Safety Guide

Regulations and Standards Governing Industrial Robots

Applicable Modes of IAI’s Industrial Robot

Notes on Safety of Our Products

Indication of Cautionary Information

CE Marking

Chapter 1 Introduction

1. Overview

2. Specifications

3. Installation and Wiring

Chapter 2 Positioner Mode

1. I/O Signal Control and Signal Functions

2. Data Entry