IAI America XSEL-KET User Manual

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Global Specification Controller X-SEL-KT

X-SEL-KT

XSEL-KT/KET

Eighth Edition

Tenth Edition

Operation Manual Seventh Edition

Tenth Edition

INTELLIGENT ACTUATOR

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 sentences

are registered trademarks.

CAUTION

Operator Calls Regarding Low Battery Voltage

This controller uses the following backup batteries to retain data after the power is cut off:

[1] System-memory backup battery

For retention of position data, global variables/flags, error lists, strings, etc.

[2] Absolute-encoder backup battery (optional)

For retention of encoder rotation data.

Each battery is of non-rechargeable type, so unless the battery is replaced before its life is fully consumed, the battery voltage will eventually drop to a level where data can no longer be retained after the power is cut off. (The specific life of each battery varies depending on the operating time.) Once data is lost, the controller cannot operate properly the next time the power is turned on, in which case additional time will be required for recovery operation.

(Reference) System-memory backup battery --- A voltage low warning will generate when the voltage drops to

approx. 2.6 V from the rated voltage of 3.0 V, and data will be lost once the voltage drops to approx. 2.3 V.

Absolute-encoder backup battery --- A voltage low warning will generate when the voltage drops to

approx. 3.2 V from the rated voltage of 3.6 V, and data will be lost once the voltage drops to approx. 2.7 V.

In view of the above, this controller provides functions that allow voltage low warnings for the two batteries to be output from I/O ports. To output this signal from I/O ports, I/O parameter must be set.

 Warning output of system-memory backup battery Set I/O parameter No. 59 to 1 --- Output port No. 313

 Warning output of encoder battery Set I/O parameter No. 60 to 1 --- Output port No. 314

(Note) When these settgins are made, they cannot be used as general-purpose ports.

It is requested that the aforementioned functions be used to prevent unnecessary problems caused by low battery voltage (consumption of battery life). In particular, design engineers responsible for coordinating the system components should reflect, in the design specifications, appropriate means for warning the operator using the I/O output signals utilizing the above functions. Electrical design engineers should ensure that such means are reflected in the electrical circuits. For the battery replacement procedure, refer to the applicable section in the Operation Manual.

It is recommended that the latest data be constantly backed up to a PC in case of low system-memory backup battery voltage or unexpected controller failure.

(note)

is assigned as the dedicated port.

(note)

is assigned as the dedicated port.

INTELLIGENT ACTUATOR

CE Marking

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

INTELLIGENT ACTUATOR

Table of Contents

Safety Guide............................................................................................................................................

Introduction.................................................................................................................................................... 1

Part 1 Installation........................................................................................................................................... 3

Chapter 1 Safety Precautions .............................................................................................................. 3

Chapter 2 Warranty Period and Scope of Warranty............................................................................. 4

Chapter 3 Installation Environment and Noise Measures .................................................................... 5

Chapter 4 Name and Function of Each Part ........................................................................................ 9

1. Front View of Controller.............................................................................................................. 9

2. Explanation of Codes Displayed on the Panel Window ........................................................... 17

Chapter 5 Specifications..................................................................................................................... 19

1. Controller Specifications........................................................................................................... 19

2. External I/O Specifications........................................................................................................ 20

3. Power-Source Capacity and Heat Output of the Controller...................................................... 24

4. External Dimensions................................................................................................................. 26

Chapter 6 System Setup .................................................................................................................... 27

1. Connection Method of Controller and Actuator (Standard Specification) ................................. 27

2. Drive-Power Cutoff Control Circuit ........................................................................................... 32

Chapter 7 How to Perform An Absolute Encoder Reset..................................................................... 52

Pre-1

Chapter 8 Maintenance ...................................................................................................................... 57

Part 2 Operation .......................................................................................................................................... 62

Chapter 1 Operation........................................................................................................................... 62

1. Starting a Program by Auto-Start via Parameter Setting .......................................................... 63

2. Starting via External Signal Selection....................................................................................... 64

3. Drive-Source Recovery Request and Operation-Pause Reset Request.................................. 66

Part 3 Controller Data Structure .................................................................................................................. 71

Chapter 1 How to Save Data.............................................................................................................. 72

1. Factory Settings: When the System-Memory Backup Battery is Used .................................... 72

2. When the System-Memory Backup Battery is Not Used.......................................................... 73

3. Points to Note ........................................................................................................................... 74

Chapter 2 X-SEL Language Data....................................................................................................... 75

1. Values and Symbols Used in SEL Language........................................................................... 75

2. Position Part ............................................................................................................................. 88

3. Command Part.......................................................................................................................... 89

Part 4 Commands ....................................................................................................................................... 91

Chapter 1 List of SEL Language Command Codes by Function ....................................................... 91

Table of Contents

INTELLIGENT ACTUATOR

Chapter 2

Explanation of Commands .............................................................................................. 101

1. Commands ............................................................................................................................. 101

Chapter 3 Key Characteristics of Actuator Control Commands and Points to Note ........................ 244

1. Continuous Movement Commands [PATH, CIR, ARC, PSPL, CIR2, ARC2, ARCD, ARCC,

CIRS, ARCS] ...................................................................................................................... 244

2. PATH/PSPL Commands ......................................................................................................... 246

3. CIR/ARC Commands ............................................................................................................. 246

4. CIR2/ARC2/ARCD/ARCC Commands................................................................................... 246

Chapter 4 Palletizing Function ......................................................................................................... 247

1. How to Use ............................................................................................................................. 247

2. Palletizing Setting ................................................................................................................... 247

3. Palletizing Calculation ............................................................................................................ 253

4. Palletizing Movement ............................................................................................................. 254

5. Program Examples ................................................................................................................. 256

Chapter 5 Pseudo-Ladder Task........................................................................................................ 264

1. Basic Frame............................................................................................................................ 264

2. Ladder Statement Field .......................................................................................................... 265

3. Points to Note ......................................................................................................................... 265

4. Program Example................................................................................................................... 266

Chapter 6 Application Program Examples ....................................................................................... 267

1. Operation by Jog Command................................................................................................... 267

2. Operation by Point Movement Command .............................................................................. 270

3. Palletizing Operation .............................................................................................................. 273

Part 5 Multi-Tasking................................................................................................................................... 276

Chapter 1 Real-Time Multi-Tasking .................................................................................................. 276

1. SEL Language ........................................................................................................................ 276

2. Multi-Tasking ........................................................................................................................... 277

3. Difference from a Sequencer.................................................................................................. 278

4. Release of Emergency Stop................................................................................................... 279

5. Program Switching.................................................................................................................. 280

Chapter 2 Example of Building a System......................................................................................... 281

1. Equipment............................................................................................................................... 281

2. Operation ................................................................................................................................ 281

3. Overview of the Screw-Tightening System............................................................................. 282

4. Hardware ................................................................................................................................ 283

5. Software.................................................................................................................................. 285

Appendix 287

 Actuator Specification List ........................................................................................................ 287

 Programming Method............................................................................................................... 292

1. Position Table ......................................................................................................................... 292

2. Program Format...................................................................................................................... 293

3. Positioning to Five Positions................................................................................................... 294

4. How to Use TAG and GOTO .................................................................................................. 295

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Reciprocating Operation between Two Points........................................................................ 296

Table of Contents

6. Path Operation........................................................................................................................ 297

7. Output Control during Path Movement................................................................................... 298

8. Circular/Arc Operation ............................................................................................................ 299

9. Home return Complete Output ............................................................................................... 300

10. Axis Movement with Input Waiting and Complete Output ...................................................... 301

11. Travel Speed Change ............................................................................................................. 302

12. Speed Change during Operation............................................................................................ 303

13. Local/Global Variables and Flags........................................................................................... 304

14. How to Use Subroutines......................................................................................................... 305

15. Pause...................................................................................................................................... 306

16. Abort 1 (CANC)....................................................................................................................... 307

17. Abort 2 (STOP)....................................................................................................................... 308

18. Movement by Position Number Specification ......................................................................... 309

19. Movement by External Position Data Input ............................................................................ 310

20. Coordinate Value Output .........................................................................................................311

21. Conditional Jump.................................................................................................................... 312

22. Wait for Multiple Inputs ........................................................................................................... 313

23. How to Use Offset................................................................................................................... 314

24. Repetition of Operation N Times ............................................................................................ 315

25. Constant Pitch Feed Operation .............................................................................................. 316

26. Jogging ................................................................................................................................... 317

27. Program Switching.................................................................................................................. 318

28. Program Abort......................................................................................................................... 319

 Expansion Board (Optional) ..................................................................................................... 320

 Expanded SIO Specification (Optional).................................................................................... 321

 Number of Regenerative Resistance Units (REU-1s) to Be Connected .................................. 327

 Synchro Function...................................................................................................................... 328

1. Common Items (Applicable to both the absolute specification and incremental specification)

............................................................................................................................................ 328

2. Incremental Specification........................................................................................................ 328

3. Absolute Specification (When both the master axis and slave axis are of the absolute

specification)....................................................................................................................... 328

 Absolute Reset of A Synchro Controller ................................................................................... 329

1. Synchro Axes.......................................................................................................................... 329

2. Position Adjustment of Synchro-Axis Sliders.......................................................................... 330

3. Special Absolute-Reset Procedure......................................................................................... 330

4. Standard Absolute-Reset Procedure...................................................................................... 333

5. Notes on Use of the Synchro Function................................................................................... 334

 List of Parameters .................................................................................................................... 335

1. I/O Parameters ....................................................................................................................... 336

2. Parameters Common to All Axes ............................................................................................ 348

3. Axis-Specific Parameters........................................................................................................ 350

4. Driver Card Parameters.......................................................................................................... 355

5. Encoder Parameters............................................................................................................... 359

6. I/O-Slot Card Parameters ....................................................................................................... 360

7. Other Parameters ................................................................................................................... 361

8. Manual Operation Types......................................................................................................... 367

9. Use Examples of Key Parameters.......................................................................................... 368

Table of Contents

INTELLIGENT ACTUATOR

Servo Gain Adjustment........................................................................................................... 374

10.

 Combination Table of X-SEL Linear/Rotational Control Parameters........................................ 377

 Error Level Control ................................................................................................................... 378

 Error List ................................................................................................................................... 380

 Troubleshooting of X-SEL Controller........................................................................................ 409

Trouble Report Sheet............................................................................................................................. 413

Change History.......................................................................................................................................... 414

INTELLIGENT ACTUATOR

Safety Guide

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

Safety Precautions for Our Products

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

No.

1 Model

Operation

Description

Selection

Description

● This product has not been planned and designed for the application where high level of safety is required, so the guarantee of the protection of human life is impossible. Accordingly, do not use it in any of the following applications.

1) Medical equipment used to maintain, control or otherwise affect human

life or physical health.

2) Mechanisms and machinery designed for the purpose of moving or

transporting people (For vehicle, railway facility or air navigation facility)

3) Important safety parts of machinery (Safety device, etc.)

● Do not use it in any of the following environments.

1) Location where there is any inflammable gas, inflammable object or

explosive

2) Place with potential exposure to radiation

3) Location with the ambient temperature or relative humidity exceeding

the specification range

4) Location where radiant heat is added from direct sunlight or other large

heat source

5) Location where condensation occurs due to abrupt temperature

changes

6) Location where there is any corrosive gas (sulfuric acid or hydrochloric

acid)

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

8) Location subject to direct vibration or impact

● Do not use the product outside the specifications. Failure to do so may considerably shorten

Pre-1

INTELLIGENT ACTUATOR

Introduction

No.

Operation

Description

2 Transportation ● When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

● Consider well so that it is not bumped against anything or dropped during the transportation.

● Transport it using an appropriate transportation measure.

● Do not step or sit on the package.

● Do not put any heavy thing that can deform the package, on it.

● When using a crane capable of 1t or more of weight, have an operator who

has qualifications for crane operation and sling work.

● When using a crane or equivalent equipments, make sure not to hang a load that weighs more than the equipment’s capability limit.

● Use a hook that is suitable for the load. Consider the safety factor of the hook in such factors as shear strength.

● Do not get on the load that is hung on a crane.

● Do not leave a load hung up with a crane.

● Do not stand under the load that is hung up with a crane.

3 Storage and

Preservation

● The storage and preservation environment conforms to the installation environment. However, especially give consideration to the prevention of condensation.

4 Installation

and Start

(1) Installation of Robot Main Body and Controller, etc.

● Make sure to securely hold and fix the product (including the work part). A fall, drop or abnormal motion of the product may cause a damage or injury.

● Do not get on or put anything on the product. Failure to do so may cause an accidental fall, injury or damage to the product due to a drop of anything, malfunction of the product, performance degradation, or shortening of its life.

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

1) Location where electric noise is generated

2) Location where high electrical or magnetic field is present

3) Location with the mains or power lines passing nearby

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

chemical droplets

(2) Cable Wiring

● Use our company’s genuine cables for connecting between the actuator and controller, and for the teaching tool.

● Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not coil it around. Do not insert it. Do not put any heavy thing on it. Failure to do so may cause a fire, electric shock or malfunction due to leakage or continuity error.

● Perform the wiring for the product, after turning OFF the power to the unit, so that there is no wiring error.

● When the direct current power (+24V) is connected, take the great care of the directions of positive and negative poles. If the connection direction is not correct, it might cause a fire, product breakdown or malfunction.

● Connect the cable connector securely so that there is no disconnection or looseness. Failure to do so may cause a fire, electric shock or malfunction of the product.

● Never cut and/or reconnect the cables supplied with the product for the purpose of extending or shortening the cable length. Failure to do so may cause the product to malfunction or cause fire.

Pre-2

INTELLIGENT ACTUATOR

No.

Operation

Description

4 Installation

and Start

Description

(3) Grounding

● Make sure to perform the grounding of type D (Former Type 3) for the controller. The grounding operation should be performed to prevent an electric shock or electrostatic charge, enhance the noise-resistance ability and control the unnecessary electromagnetic radiation.

(4) Safety Measures

● When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

● When the product is under operation or in the ready mode, take the safety measures (such as the installation of safety and protection fence) so that nobody can enter the area within the robot’s movable range. When the robot under operation is touched, it may result in death or serious injury.

● Make sure to install the emergency stop circuit so that the unit can be stopped immediately in an emergency during the unit operation.

● Take the safety measure not to start up the unit only with the power turning ON. Failure to do so may start up the machine suddenly and cause an injury or damage to the product.

● Take the safety measure not to start up the machine only with the emergency stop cancellation or recovery after the power failure. Failure to do so may result in an electric shock or injury due to unexpected power input.

● When the installation or adjustment operation is to be performed, give clear warnings such as “Under Operation; Do not turn ON the power!” etc. Sudden power input may cause an electric shock or injury.

● Take the measure so that the work part is not dropped in power failure or emergency stop.

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

● Do not insert a finger or object in the openings in the product. Failure to do so may cause an injury, electric shock, damage to the product or fire.

● When releasing the brake on a vertically oriented actuator, exercise precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity.

Pre-3

INTELLIGENT ACTUATOR

Introduction

No.

Operation

Description

5 Teaching ● When the work is carried out with 2 or more persons, make it clear who is

to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

● Perform the teaching operation from outside the safety protection fence, if possible. In the case that the operation is to be performed unavoidably inside the safety protection fence, prepare the “Stipulations for the Operation” and make sure that all the workers acknowledge and understand them well.

● When the operation is to be performed inside the safety protection fence, the worker should have an emergency stop switch at hand with him so that the unit can be stopped any time in an emergency.

● When the operation is to be performed inside the safety protection fence, in addition to the workers, arrange a watchman so that the machine can be stopped any time in an emergency. Also, keep watch on the operation so that any third person can not operate the switches carelessly.

● Place a sign “Under Operation” at the position easy to see.

● When releasing the brake on a vertically oriented actuator, exercise

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

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

fence, the movable range should be indicated.

6 Trial

Operation

● When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.

● After the teaching or programming operation, perform the check operation one step by one step and then shift to the automatic operation.

● When the check operation is to be performed inside the safety protection fence, perform the check operation using the previously specified work procedure like the teaching operation.

● Make sure to perform the programmed operation check at the safety speed. Failure to do so may result in an accident due to unexpected motion caused by a program error, etc.

● Do not touch the terminal block or any of the various setting switches in the power ON mode. Failure to do so may result in an electric shock or malfunction.

7 Automatic

Operation

● Before the automatic operation is started up, make sure that there is nobody inside the safety protection fence.

● Before the automatic operation is started up, make sure that all the related peripheral machines are ready for the automatic operation and there is no error indication.

● Make sure to perform the startup operation for the automatic operation, out of the safety protection fence.

● In the case that there is any abnormal heating, smoke, offensive smell, or abnormal noise in the product, immediately stop the machine and turn OFF the power switch. Failure to do so may result in a fire or damage to the product.

● When a power failure occurs, turn OFF the power switch. Failure to do so may cause an injury or damage to the product, due to a sudden motion of the product in the recovery operation from the power failure.

Pre-4

INTELLIGENT ACTUATOR

No.

Operation

Description

8 Maintenance

and Inspection

● When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with

Description

each other to ensure the safety of the workers.

● Perform the work out of the safety protection fence, if possible. In the case that the operation is to be performed unavoidably inside the safety protection fence, prepare the “Stipulations for the Operation” and make sure that all the workers acknowledge and understand them well.

● When the work is to be performed inside the safety protection fence, basically turn OFF the power switch.

● Place a sign “Under Operation” at the position easy to see.

● For the grease for the guide or ball screw, use appropriate grease

according to the Operation Manual for each model.

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

● When releasing the brake on a vertically oriented actuator, exercise precaution not to pinch your hand or damage the work parts with the actuator dropped by gravity.

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

fence, the movable range should be indicated.

9 Modification

and Dismantle

● Do not modify, disassemble, assemble or use of maintenance parts not specified based at your own discretion.

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

properly as an industrial waste.

● Do not put the product in a fire when disposing of it. The product may burst or generate toxic gases.

Pre-5

Introduction

INTELLIGENT ACTUATOR

Alert Indication

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

lobmyS egamaD dna regnaD fo eergeD leveL

Danger

Warning

Caution

Notice

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

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

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

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

Danger

Warning

Caution

Notice

Pre-6

INTELLIGENT ACTUATOR

Prohibited Handling of Cables

Caution

When designing an application system using actuators and controllers, incorrect wiring or connection of each cable may cause unexpected problems such as a disconnected cable or poor contact, or even a runaway system. This section explains prohibited handling of cables. Read the information carefully to connect the cables properly.

Ten Rules for Handling Cables (Must be Observed!)

1. Do not let the cable flex at a single point.

2. Do not let the cable bend, kink or twist.

4. Do not let the cable receive a turning force at a single point.

Steel band (piano wire)

Bundle loosely.

3. Do not pull the cable with a strong force.

5. When fixing the cable, provide a moderate slack and do not tension it too tight.

Use a curly

cable.

6. Do not pinch, drop a heavy object onto or cut the cable.

Do not use a spiral tube where the cable flexes frequently.

Pre-7

Introduction

INTELLIGENT ACTUATOR

7. Do not let the cable get tangled or kinked in a cable track or flexible tube. When bundling the cable, keep a certain degree of flexibility (so that the cable will not become too taut when bent).

8. Do not cause the cables to occupy more than 60% of the space in the cable track.

Cable track

Cable

10. Always use a robot cable

if the cable is likely to flex significantly.

9. Do not lay signal lines together with circuit lines that create a strong electric field.

Power line

Duct

Signal lines (flat cable)

[Standard structure of cable] The standard structure of

Cover

Signal line (copper + tin)

cable will vary depending on the manufacturer and type of cable.

Protective layer

Shield

Absorbing material (When the cable is bent, this material is crushed by the surrounding signal lines to maintain the shape of the signal lines.)

Need for Robot Cables A cable connected to a moving part of an actuator system will inevitably receive repeated bending loads at the base of the cable. As a result, the cores in the cable may break over time. To minimize the risk of cable breakage, we strongly recommend that a robot cable

offering significantly higher flexibility be used

in this type of application.

Pre-8

INTELLIGENT ACTUATOR

Introduction

INTELLIGENT ACTUATOR

Introduction

Thank you for purchasing the X-SEL Controller.

Inappropriate use or handling will prevent this product from demonstrating its full function and may even cause unexpected failure or result in a shortened service life. Please read this manual carefully, and handle the product with due care and operate it correctly. Keep this manual in a safe place and reference relevant items when needed.

The X-SEL Controller you have purchased is a new-generation controller that uses a 32-bit RISC (Reduced Instruction Set Computer) CPU and an advanced version of the proven “SEL” language to perform a range of high functions such as multi-tasking, sequencer-less operation, palletizing function and pseudo-sequence function. Refer to the table below for the details of models.

Model

Series

name

XSEL

Controller

type

Global

specification

KET

CE-compliant

global

specification

Number of

axes

(1 axis)

(2 axis)

(3 axis)

(4 axis)

Motor

wattage

(20 W)

30D

(DS type,

30 W)

30R

(RS type,

30 W)

(60 W)

100

(100 W)

150

(150 W)

200

(200 W)

300

(300 W)

400

(400 W)

600

(600 W)

750

(750 W)

(Axis 1) (Axis 3)

Details of Axes 1 to 6

type

Brake

Blank

(Without

brake)

(With brake)

(With creep

Encoder

(Incremental)

(Absolute)

Creep

sensor

Blank

(Witho ut

creep

sensor)

(Axis 2)

Home

sensor

(LS)

Blank

(Without

home

sensor)

(With h ome

sensor)

Synchro

specification

Blank (Witho ut synchro)

M (Master axis specification)

(Slave axis

specification)

Network

(dedicated

slot)

(None)

Standard I/O

(Slot 1)

Expansion PIO

32 inputs/16

outputs

NPN board

Expansion PIO

32 inputs/16

outputs

PNP board

DeviceNet 256/256

board

CC-Link

256/256 board

ProfiBus

256/256 board)

Ethernet

ata communicatio

board

Slot 2

(not used)

CC-Link

connection

16/16 board

Expansion I/O

32 inputs/ 16 outputs

NPN board

Expansion I/O

16 inputs/ 32 outputs

NPN board

Expansion I/O

48 inputs/ 48 outputs

NPN board

Expansion I/O

32 inputs/ 16 outputs PNP board

Expansion I/O

16 inputs/ 32 outputs PNP board

Multi-point I/O

PNP 48/48

Expansion SIO

Type A

Expansion SIO

Type B

Expansion SIO

Type C

Expansion I/O slot

Slot 3 Slo t 4

(not used)

CC-Link

connection

16/16 board

Expansion I/O

32 inputs/ 16 outputs

NPN board

Expansion I/O

16 inputs/ 32 outputs

NPN board

Expansion I/O

48 inputs/ 48 outputs

NPN board

Expansion I/O

32 inputs/ 16 outputs PNP board

Expansion I/O

16 inputs/ 32 outputs PNP board

Multi-point I/O

PNP 48/48

Expansion SIO

Type A

Expansion SIO

Type B

Expansion SIO

Type C

(not used)

CC-Link

connection

16/16 board

Expansion I/O

32 inputs/ 16 outputs

NPN board

Expansion I/O

16 inputs/ 32 outputs

NPN board

Expansion I/O

48 inputs/ 48 outputs

NPN board

Expansion I/O

32 inputs/ 16 outputs PNP board

Expansion I/O

16 inputs/ 32 outputs PNP board

Multi-point I/O

PNP 48/48

Expansion SIO

Type A

Expansion SIO

pe B

Expansion SIO

Type C

I/O flat

cable

length

2: 2 m

(standard)

3: 3 m

5: 5 m

0: None

Power-

supply

voltage

2: Singlephase 200 V

Introduction

INTELLIGENT ACTUATOR

The X-SEL Controller is available with one to four axes. As with the conventional SEL Controller, it can be used with various actuators. When connecting actuators, always use dedicated cables.

 Actuator duty

IAI recommends that our actuators be used at a duty of 50% or less in view of the relationship of service life and precision. The duty is calculated by the formula below:

Duty (%) =

hours Operating



X 100

hours Stopped hours Operating

 After turning off the main power, be sure to wait for at least 5 seconds before turning it on.

Any shorter interval may generate “E88: Power system error (Other).”

 Do not plug in/out the connectors while the power is still supplied to the controller. Doing so may result

in malfunction.

 Item to note when installing the absolute-data backup battery (absolute specification)

The battery installation procedure specified below must be followed to initialize the battery circuit and thereby prevent premature consumption of the battery. Install the battery according to this procedure: [1] Connect the encoder cable. [2] Turn on the power. [3] Install the absolute-data backup battery. The above operation must be performed every time the encoder cable was unplugged to relocate the system, etc.

Read the operation manual for each actuator. If you have purchased our optional PC software and/or teaching pendant, read the respective operation manuals, as well.

* Utmost effort has been made to ensure that the information contained in this manual is true and

correct. However, should you find any error or if you have any comment regarding the content, please contact IAI.

Part 1 Installation

INTELLIGENT ACTUATOR

Part 1 Installation

Caution

Chapter 1 Safety Precautions

The X-SEL Controller can be combined with a maximum of four actuators of different types, and is able to provide integrated control over the entire system including peripherals. In other words, the X-SEL Controller has the ability to control systems of all sizes ranging from a small system to a large factory automation system. In general, however, the occurrence rate of accidents due to wrong operation or carelessness will rise as the system becomes larger and more complex. Please give due consideration to safety measures.

This system product was developed as a drive unit for an automated machine, etc., and as such the maximum torque and speed are limited to levels acceptable for an automatically driven machine. However, strict observance of the following items is requested to prevent unforeseen danger. Also read the appendix entitled, “Safety Rules and Others.”

1. Do not handle this product in manners not specified in this manual. If you have any question regarding the content of this manual, please contact IAI.

2. This controller is designed to perform all cutoff controls of the motor drive power to actuate an emergency stop, enable the controller operation, etc., using an external circuit. Be sure to provide a drive-power cutoff circuit externally to the main controller circuit. The customer must determine and install an appropriate safety circuit meeting the required safety category according to the operating condition of the final system. The motor drive-power circuit has no built-in protective element such as a fuse. The customer must provide appropriate circuit protection.

3. Always use the specified, genuine IAI cables for wiring between the controller and the actuator.

4. Do not enter the operation area of the machine while the machine is operating or ready to operate (the controller power is on). If the machine is used in a place accessible to other people, provide an appropriate safety measure such as enclosing the machine with a cage.

5. When assembling/adjusting or maintaining/inspecting the machine, always turn off the controller power at the source beforehand. The operator should display in a conspicuous place a plate or other sign saying that operation is in progress and that the power should not be turned on. The operator should keep the entire power cable beside him or her to prevent another person from inadvertently plugging in the cable.

6. When two or more operators are to work together, set call-out signals to ensure safety of all personnel during the work. In particular, a person turning on/off the power or moving an axis—either via a motor or manually—must always say what he or she is going to do out loud and confirm the responses from the others first before actually performing the operation.

Part 1 Installation

INTELLIGENT ACTUATOR

Chapter 2 Warranty Period and Scope of Warranty

The X-SEL Controller you have purchased passed our strict outgoing inspection. This unit is covered by the following warranty:

1. Warranty Period

The warranty period shall be either 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

Should the product fail during the above period under a proper use condition due to a fault on the part of the manufacturer, IAI will repair the defect free of charge. However, the following cases are excluded from the scope of warranty:

 Discoloration of paint or other normal aging  Wear of consumable parts due to use  Subjective imperfection, such as noise not affecting 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 unauthorized modification, etc., not approved by IAI or its agent  Defect due to an act of God, accident, fire, etc.

The warranty covers only the product as it is delivered. IAI shall not be liable for any loss arising in connection with the delivered product. The user must bring the defective product to our factory to receive a warranty repair.

3. Scope of Service

The price of the delivered product does not include costs incurred in association with program generation, dispatch of technician, etc. Therefore, a separate fee will be chargeable in the following cases even during the warranty period:

 Guidance on installation/adjustment and witnessing of test operation  Maintenance/inspection  Technical guidance and training on operation, wiring method, etc.  Technical guidance and training regarding programs, such as program generation  Other services and operations where IAI finds a need to charge a separate fee

Part 1 Installation

INTELLIGENT ACTUATOR

Chapter 3 Installation Environment and Noise Measures

1. Installation Environment

As for the use environment, this product can be used in an environment of pollution degree 2 equivalent. *1 Pollution degree 2: Normally only non-conductive pollutants exist, which are expected to be

temporarily conductive due to condensation. (IEC60664-1)

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

(Insufficient ventilation will not only prevent the product from functioning fully, but it may also result in failure.)

(2) Prevent foreign matter from entering the controller through the ventilation holes. Since the controller is

not designed as dustproof or waterproof (oilproof), avoid using it in a dusty place or place subject to oil mist or splashed cutting fluid.

(3) Do not expose the controller to direct sunlight or radiant heat from a high heat source such as a heat-

treating furnace. (4) Use the controller in a non-condensing environment free from corrosive or inflammable gases. (5) Use the controller in an environment where it will not receive external vibration or impact. (6) Prevent electrical noise from entering the controller or its cables.

Environmental Condition of Controller

noitacificepS metI

Surrounding air temperature range

Forced air-cooling

Surrounding humidity range 30% ~ 85%

Storage temperature range

Dust protection structure IP20

Power-source voltage 230 VAC, single-phase

Operating power-source voltage

Rated operating power-source

frequency

24 VDC fan x 5 (2-axis type) 24 VDC fan x 6 (4-axis type)

0?C ~ 40?C

-10?C ~ 65?C

? 10%

50 Hz/60 Hz

2. Heat Radiation and Installation

Design the control panel size, controller layout and cooling method so that the surrounding air temperature around the controller will be kept at or below 40°C.

Install the controller vertically on a wall, as illustrated below. The controller will be cooled by forced ventilation (exhaust air will be discharged from the top). Be sure to install the controller in the aforementioned direction and provide a minimum clearance of 150 mm above and 150 mm below the controller.

If multiple controllers are to be installed side by side, providing additional suction fans on top of the controllers will help maintain a uniform surrounding air temperature.

Provide a minimum clearance of 150 mm between the front side of the controller and a wall (enclosure).

Part 1 Installation

INTELLIGENT ACTUATOR

Airflow direction

Fan

150 mm min.

150 mm

min.

150 mm min.

Airflow

If multiple controllers are to be connected on top of one another, prevent the controller above from taking in the exhaust air from the controller below.

3. Power Source

Provide a 230-VAC, single-phase power source.

4. Noise Measures and Grounding

(1) Wiring and power source

PE on the power terminal block is used for protective grounding. Provide Class D grounding from this

terminal.

Use a grounding cable with a wire size of 1.0 mm

than the AC power cable.

Install an AC line noise filter to prevent noise generating in the controller from traveling through the

power line to affect other devices.

230-VAC power source

Class D grounding (protective grounding)

Drivepower

cutoff

control

circuit

Install a noise filter (MXB-1210-33 by Densei-Lambda) near the power connector on the X-SEL controller side.

(#AWG17) or more, which should not be smaller

X-SEL controller

C.POWER M.POWER

Noise

filter

Accessory



Part 1 Installation

INTELLIGENT ACTUATOR

* Notes on wiring method

Use twisted cables for the AC power cable and 24-VDC external power cable. Wire the controller

cables separately from lines creating a strong electric field such as power circuit lines (by not bundling

them together or placing in the same cable duct).

If you wish to extend the motor cable or encoder cable beyond the length of each supplied cable,

please contact IAI.

(2) Noise-elimination grounding

C.POWER

AC power source

Connect the FG terminal with the metal enclosure using a cable of a maximum allowable size over the shortest distance.

Class D grounding

Metal enclosure

Provide a dedicated grounding of the FG or PE grounding point.

X-SEL

controller

Other

equipment

X-SEL

controller

Other

equipment

Do not use this method.

(3) Noise sources and noise elimination

There are many noise sources, but solenoid valves, magnet switches and relays are of particular

concern when building a system. Noise from these parts can be eliminated using the measures

specified below:

a. AC solenoid valve, magnet switch, relay

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

Surge killer

Point

Wire from each coil over the shortest distance. Installing a surge killer on the terminal block, etc., will be less effective because of a longer distance from the coil.

Part 1 Installation

INTELLIGENT ACTUATOR

b. DC solenoid valve, magnet switch, relay

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

the load capacity.

In a DC circuit, connecting a diode in reversed polarity will damage the diode, internal parts of the controller and DC power supply. Exercise due caution.

Diode

The above noise elimination measures are particularly important when a 24-VDC relay is driven

directly by a controller output and there is also a 100-VAC solenoid valve, etc.

Reference Circuit Diagram

Controller

OUT

COM

+24 V

0 V

100 VAC

SOL

Surge absorber

0 V

Solenoid valve

Part 1 Installation

INTELLIGENT ACTUATOR

Chapter 4 Name and Function of Each Part

1. Front View of Controller

4-axis type

(5)

(6)

CONTROLLER

C.POWER

FUSE

M.POWER

LS4M3LS3M2LS2M1LS1

PG1

BK1

PG2

BK2

(1)

(2)

(3)

(4) (8)

(9)

(10) (18)

(1) FG terminal

This terminal is used to ground FG on the enclosure. The enclosure is connected to PE in the AC input part inside the controller.

FG Terminal Specifications

Item Overview M4 3-point SEMS screw, 5 mm Cable size 2.0 ~ 5.5 mm2 Grounding method Class D grounding

(2) Fuse holder

This half-cut fuse holder is used to protect overcurrent in the AC controlpower input part.

It prevents inflow of abnormal current generated by ground fault, etc., and

uses a slow-blow fuse specified by IAI.

Overview of Fuse Holder Specifications

Item Description Holder F-220-01A2 by Sato Parts Fuse type SG5013 3.15 by Sky Gate Melting characteristics Time lag type

(11)

PG3

BK3

I/O1 I/O2 I/O3 I/O4

PG4

BK4

(12) (13) (14)

CODE

MODE

HOST

(19)

(15)

(16)

(17)

INTELLIGENT ACTUATOR

(3) AC control-power input connector

AC Control-Power Input Connector Specifications

Connector name C.POWER Connector GMSTB2.5/3-STF-7.62 by Phoenix Contact

Supported cable size 1.25 ~ 2.5 mm2 (AWG12 ~ 16)

Connected to AC power source Terminal assignments

(4) AC motor drive-power input connector

AC Motor Drive-Power Input Connector Specifications

Connector name M.POWER Connector PC4/2-7.62

Supported cable size 1.25 ~ 2.5 mm2 (AWG12 ~ 16)

Connected to

Terminal assignments

(5) External regenerative unit connector

External Regenerative Unit Connector Specifications

Connector name RB Connector GIC2.5/3-STF-7.62 by Phoenix Contact

Cable size 1.0 mm2 (AWG17 or equivalent), included in the

Connected to External regenerative box Terminal assignments

Part 1 Installation

An input connector for 230-VAC, single-phase control power.

Item Overview

3-pin, 2-piece connector

N AC power input, N side

L AC power input, L side

PE (Protective grounding line)

An input connector for 230-VAC, single-phase motor drive power.

Item Overview

2-pin, 2-piece connector

AC power source (Noise filter, drive-power cutoff control circuit)

N AC power input, N side

L AC power input, L side

This connector is used to connect a regenerative resistance unit that may be required when the controller is used in a high-speed/high-load environment, etc., and the built-in regenerative resistance capacity is not sufficient. Whether or not an external regenerative resistance is necessary will be determined by the specific application such as axis configuration.

Item Overview

3-pin, 2-piece connector

external regenerative box

Grounding terminal

RB– Regenerative resistance –

RB+

Regenerative resistance + (Motordriving DC voltage)

An insufficient regenerative resistance capacity will cause “E65, F63: Regenerative resistance temperature error.” An insufficient regenerative resistance capacity is also suspected when “E88: Power system error (Other)” occurs.

INTELLIGENT ACTUATOR

(6) Motor connector

Overview of Motor Connector Specifications

Connector name M Connector GIC2.5/4-STF-7.62 by Phoenix Contact

Cable Dedicated motor cable

Connected to Actuator Terminal assignments

(7) Axis-sensor connector

Axis-Sensor Connector Specifications

Connector name LS Connector MC1.5/6-ST-3.5 by Phoenix Contact

Cable Dedicated LS cable

Connected to Actuator Terminal assignments

(8) Absolute-data backup battery

Battery Capacity: 1000 mAh

Current consumption Operating Power is off

Absolute-Battery Connector Specifications

Connector name BAT Connector 3-pin connector

Connected to Absolute-data battery unit by IAI

Part 1 Installation

This connector is used to drive the motor inside the actuator.

Item Description

4-pin, 2-piece connector

PE (Protective grounding line)

U Motor-driving phase U

V Motor-driving phase V

W Motor-driving phase W

This connector is used to connect axis sensors such as LS, CREEP and OT.

Item Description

6-pin, 2-piece connector

24VOUT 24-V power source for driving contacts

0V 24-V ground

LS LS-contact input

CREEP CREEP-contact input

OT OT-contact input

When an absolute encoder is used, this battery unit will be used to back up the encoder data. Nothing is connected here for a non-absolute axis. Model: IA-XAB-BT

3 A 100 A

Item Description

03JQ-ST by Nichiatu

Part 1 Installation

INTELLIGENT ACTUATOR

(9) Brake switch

This alternate switch with lock is used to release the axis brake. To operate the switch, pull it toward you and tilt.

Tilting the switch upward (RLS side) will release the brake forcibly, while

tilting it downward (NOM) will enable an automatic brake control by the controller.

(10) Axis-driver status LEDs

These LEDs monitor the operating status of the driver CPU that controls the motor drive. The following three LEDs are provided.

Name Color Meaning when lit

An error is detected by the driver. Although this LED

ALM Orange

flashes when the power limiter level is exceeded, this does not indicate a problem as long as no error is present.

SVON Green The servo is on and the motor is being driven.

BAT ALM Orange The voltage of the absolute-data backup battery is low.

(11) Encoder connector

This 15-pin, D-sub connector is used to connect the actuator’s encoder.

Encoder Connector Specifications

Item Description

Connector name PG

Connector High-density D-sub, 15-pin (female)

Maximum connection distance Interface standard Conforming to RS422

Connected to Actuator

Connection cable

Terminal assignments

10 m

(Built-in encoder unit inside the actuator)

Dedicated PG cable

Pin No. Signal name Description

1 A+ Phase-A differential + input (Phase U+)

2 A– Phase-A differential – input (Phase U–)

3 B+ Phase-B differential + input (Phase V+)

4 B– Phase-B differential – input (Phase V–)

5 Z+ Phase-Z differential + input (Phase W+)

6 Z– Phase-Z differential – input (Phase W–)

7 SRD+

8 SRD–

9 BATT Backup-battery power supply

10 BATTGND Battery ground

11 VCC Encoder power source

12 GND GND

13 BK–

14 BK+

15 FG Not used

Send/receive line+ (Pulse/magneticpole switching+) Send/receive line– (Pulse/ magnetic-pole switching–)

Brake output

Part 1 Installation

INTELLIGENT ACTUATOR

(12) System I/O connector

This connector is used to connect an emergency-stop switch, ENABLE contact, ready relay, etc.

Connector MC1.5/6-ST-3.5 by Phoenix Contact; 6-pin, 2-piece connector

Terminal assignments

Pins +24V OUT and EMG IN form a contact-B emergency-stop input. Operation is enabled when the pins are shorted. Pins +24V OUT and EMG IN form a contact-B safety-gate input. Operation is enabled when the pins are shorted. Pins RDY OUT form a contact-A output that turns ON under the following condition:  SYSRDY is output (software = PIO trigger program can be run) and hardware is normal

(emergency stop is not being actuated and hardware error is not being detected). +24-V OUT and EMG IN, and +24 V OUT and ENB IN, are shorted by a cable before the shipment.

+24V OUT +24-V power output for emergency stop

EMG IN Emergency-stop input

+24V OUT +24-V power output for safety gate

ENB IN Safety-gate input

RDY OUT

Ready-status output contact

(13) I/O24V power connector

This connector is used to externally supply I/O power to the insulated part when DI and DOs are mounted in the I/O connectors explained in (18) and (19) (2-pin, 2-piece connector by Phoenix Contact). 24 V must be supplied externally.

Supported cable size 0.75 ~ 1.25 mm

Connector MC1.5/6-ST-3.5 by Phoenix Contact; 2-pin, 2-piece connector

Terminal assignments

(AWG16)

24VIN +24-V power input for I/Os

0V I/O GND

(14) Panel window This window consists of a 4-digit, 7-segment LED display and five LED

lamps that indicate the status of the equipment.

For the information shown on the display, refer to 2, “Explanation of Codes

Displayed on the Panel Window” or the “Error Code Table.”

Meanings of Five LEDs

Name Status when the LED is lit

RDY CPU ready (program can be run)

ALM CPU alarm (system-down level error), CPU hardware error

EMG

PSE Power-system hardware error

CLK System clock error

Emergency stop has been actuated, CPU hardware error, power-system hardware error

(15) Mode switch This alternate switch with lock is used to command a controller operation

mode. To operate the switch, pull it toward you and tilt.

Tilting the switch upward will select MANU (manual mode), while tilting it

downward will select AUTO (auto mode). Teaching can be performed only in the MANU mode, but auto program start is not enabled in the MANU mode.

(Refer to the types of manual operations explained on p. 348.)

INTELLIGENT ACTUATOR

(16) Teaching-pendant connector

Interface Specifications of Teaching Serial Interface

Connector name TP Connector DSUB-25 XM3B-2542-502L (Omron) Communication method RS232C-compliant, start-stop synchronous method Baud rate 38.4 kbps max.; half-duplex communication Maximum connection

distance Interface standard RS232C

Connected to X-SEL teaching pendant

Interface Specifications of Teaching Serial Interface

Part 1 Installation

When an optional teaching pendant or PC is connected, this D-sub, 25-pin connector will be used to input program and position data in the MANU mode.

Item Description

10 m (38.4 kbps)

Item No. Direction Signal name Description

Terminal

assignments

1 FG Frame ground 2 Out TXD Transmitted data 3 In RXD Received data 4 Out RTS Request to send 5 In CTS Clear to send 6 Out DSR Equipment ready 7 SG Signal ground 8

9 In Connection prohibited 10 In Connection prohibited 11 12 Out EMGOUT Emergency stop 13 In EMGIN 14 15 Out Connection prohibited 16 Out Connection prohibited 17 Out Connection prohibited

Power output

18 Out VCC

(5-V power source for teaching pendant)

19 In ENBTBX Enable input 20 In DTR Terminal ready 21 22 23 Out EMGS Emergency-stop status 24 25 SG Signal ground

INTELLIGENT ACTUATOR

(17) PC connector

This D-sub, 9-pin connector is used to perform serial communication (RS232C) with the host equipment when AUTO is selected as the operation mode.

* (16) and (17) cannot be used simultaneously.

RS232 Host Connector Specifications

This connector is used to establish a serial connection with a PC or PLC to enable controller control.

Item Description

Connector name HOST

Connector D-sub, 9-pin (DTE); XM2C-0942-502L by Omron Maximum connection

distance Interface standard RS232C

Connected to AT-compatible PC, etc. (half-duplex communication)

Connection cable Dedicated cable Terminal assignments

10 m (38.4 kbps)

Pin No. I/O Signal name Description

1 NC

2 In RD Received data (RXD)

3 Out SD Transmitted data (TXD)

4 In DR Data set ready (DSR)

5 In SG Signal ground

6 Out ER Equipment ready (DTR)

7 Out RS Request to send (RTS)

8 In CS Clear to send (CTS)

9 NC Not used

A dedicated cable must be used if an AT-compatible PC is to be connected.

The PC connector (D-sub, 9-pin) (17) will become available for use by the user only when the teaching-pendant connector (D-sub, 25-pin) (16) is not in use.

The PC connector (D-sub, 9-pin) (17) and teaching-pendant connector (D-sub, 25-pin) (16) cannot be used simultaneously. Setting the mode switch (15) to MANU will select the teaching-pendant connector (16), while setting it to AUTO will select the PC connector (17).

Part 1 Installation

(18) Standard I/O connector

This connector consists of a 50-pin flat connector and comprises 32input/16-output DIOs.

Overview of Standard I/O Interface Specifications

Item Description

Connector name I/O

Connector Flat connector, 50-pin

Power supply

Input 32 points (including general-purpose and dedicated inputs)

Output 16 points (including general-purpose and dedicated outputs)

Connected to External PLC, sensor, etc.

Power is supplied through the I/O24V power connector (13).

INTELLIGENT ACTUATOR

The functions are at the time of shipment. The functions assigned to port Nos. 000 to 015, 300 to 308, 313 and 314 can be changed via I/O parameters. (Refer to Nos. 30 to 54, No. 59 and No. 60 in 1, “I/O Parameters,” of Appendix, “List of Parameters.”)

(19) Expansion I/O connectors

Part 1 Installation

Standard I/O Interface List

Pin No. Category Port No. Function Cable color

1 -

2 000

3 001

4 002

5 003

6 004

7 005

8 006

9 007

10 008

11 009

12 010

13 011

14 012

15 013

16 014

17 015

18 016

19 017

20 018

21 019

22 020

23 021

24 022

25 023

26 024

27 025

28 026

29 027

30 028

31 029

32 030

34 300

35 301

36 302

37 303

38 304

39 305

40 306

41 307

42 308

43 309

44 310

45 311

46 312

47 313

48 314

49 315

Input

Output

NC Brown-1

Program start Red-1

General-purpose input Orange-1

General-purpose input Yellow-1

General-purpose input Green-1

General-purpose input Blue-1

General-purpose input Purple-1

General-purpose input Gray-1

Program specification (PRG No. 1) White-1

Program specification (PRG No. 2) Black-1

Program specification (PRG No. 4) Brown-2

Program specification (PRG No. 8) Red-2

Program specification (PRG No. 10) Orange-2

Program specification (PRG No. 20) Yellow-2

Program specification (PRG No. 40) Green-2

General-purpose input

031

Alarm output Yellow-4

Ready output Green-4

Emergency-stop output Blue-4

General-purpose output

NC Black-5

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 White-3 Black-3 Brown-4 Red-4 Orange-4

Purple-4 Gray-4 White-4 Black-4 Brown-5 Red-5 Orange-5 Yellow-5 Green-5 Blue-5 Purple-5 Gray-5 White-5

These connectors are used to install I/O expansion boards.

Part 1 Installation

INTELLIGENT ACTUATOR

2. Explanation of Codes Displayed on the Panel Window

2-1. Application

Display Priority (*1) Description

1 System-down level error

2 Writing data to the flash ROM.

3 Emergency stop is being actuated (except during the update mode).

4 Safety gate is open (except during the update mode).

5 Cold-start level error

5 Operation-cancellation level error

AC power is cut off (including momentary power failure or drop in power-source voltage).

5 Operation-cancellation level error

Waiting for a drive-source cutoff reset input (except during the update mode). Operation is in pause (waiting for restart) (except during the update mode).

7 All servo axes are interlocked (except during the update mode).

8 Message level error

9 Core update mode

9 Core update is in progress.

9 Core update has completed.

9 Slave update mode

9 Slave update is in progress.

9 Slave update has completed.

Running a program (last started program); “No.” indicates program number.

9 Initialization sequence number

9 Debug mode

9 Ready status (auto mode)

9 Ready status (manual mode)

10 Deadman switch OFF (manual mode)

(*1) The priority increases as the number decreases.

INTELLIGENT ACTUATOR

2-2. Core

play Priority (*1) Description

Dis

AC power is cut off (including momentary power failure or drop in power-source voltage).

1 Cold-start level error

1 Operation-cancellation level error

2 Message level error

2 Application update mode

2 Application update is in progress.

Part 1 Installation

2 Application update has completed.

2 Hardware test mode process

2 Clearing the application flash ROM.

2 Application flash ROM has been cleared.

2 Jump to the application

2 Core flash-ROM check process

2 Application flash-ROM check process

2 SDRAM check process

(*1) The priority increases as the number decreases.

Part 1 Installation

INTELLIGENT ACTUATOR

Chapter 5 Specifications

1. Controller Specifications

Type

Number of controlled axes 1 axis 2 axes 3 axes 4 axes Total output when maximum

number of axes are connected Power-source voltage 230 VAC, single-phase Operating power-source voltage

range Power-source frequency 50 Hz/60 Hz

Insulation resistance

10 M min. (measured at 500 VDC between the power terminal and I/O

terminals and between the external terminals (together) and case) Withstand voltage 1500 VAC for 1 minute (Note) Surrounding air temperature

range Surrounding humidity range 30% ~ 85%

Storage temperature range

Axis control method AC full digital servo

17-bit incremental encoder (wire-saving type)

Position detection methods

17-bit rotation data backup absolute encoder (wire-saving type)

(Both have a control resolution of 14 bits)

Batteries

For backup of absolute data: IA-XAB-BT

For backup of system memory: CR2032

Speed setting 1 mm/sec ~ 2000 mm/sec

Acceleration/deceleration setting 0.01 G ~ 1 G

Programming language Super SEL language

Program steps 6000 steps (total)

Number of positions 3000 positions (total)

Number of programs 64 programs

Multi-tasking 16 programs

Storage device Flash ROM + SRAM battery backup

Data input methods Teaching pendant or PC software

Standard inputs 32 points (total of dedicated inputs + general-purpose inputs)

Standard outputs 16 points (total of dedicated outputs + general-purpose outputs)

Expanded inputs/outputs 48 points per unit (A maximum of 3 units can be added)

Serial communication For connection of teaching pendant or PC

Other inputs/output Emergency-stop input, safety-gate input, system ready output

Motor overcurrent, overload, motor-driver temperature check, overload

Protective functions

check, encoder-open detection, soft limit over, system error, battery

Drive-source cutoff method External relay (Use a safety relay.)

Regenerative resistance

Built-in (220 , 80 W); external regenerative resistance supported Accessory Relay box, noise filter, I/O flat cable

Optional parts and components

Note: The withstand voltage of the actuator motor is 1000 V for 1 minute. When performing a withstand voltage test with the controller and actuator connected, make sure the test voltage and

duration will not exceed 1000 V and 1 minute, respectively.

Teaching pendant, PC software, absolute-data backup battery, I/O

shield cable, I/O expansion board

1600 W

10%

0C ~ 40C

-10C ~ 65C

error



INTELLIGENT ACTUATOR

2. External I/O Specifications

2-1. NPN Specification

(1) Input

part

External Input Specifications (NPN Specification)

Item Specification

Input voltage

Input current 7 mA per circuit

ON/OFF voltage

Insulation method Photocoupler insulation

External devices

24 VDC 10%

ON voltage --- 16.0 VDC min. OFF voltage --- 5.0 VDC max.

(1) No-voltage contact (minimum load of approx. 5 VDC/1 mA) (2) Photoelectric/proximity sensor (NPN type) (3) Sequencer transistor output (open-collector type) (4) Sequencer contact output (minimum load of approx. 5 VDC/1 mA)

Internal circuit

* P24: I/O24V power connector, 24V IN

[Input circuit]

560 

3.3 K

P24*

Input terminal

Part 1 Installation

External power supply 24 VDC 10%

Caution

If a non-contact circuit is connected externally, malfunction may result from leakage current. Use a circuit in which leakage current in a switch-off state does not exceed 1 mA.

 X-SEL controller’s input signal

At the default settings, the system recognizes the ON/OFF durations of input signals if they are approx. 4 msec or longer. The ON/OFF duration settings can also be changed using I/O parameter No. 20 (input filtering frequency).

ON duration

OFF duration

Part 1 Installation

INTELLIGENT ACTUATOR

(2) Output part

External Output Specifications (NPN Specification)

Item Specification

Load voltage 24 VDC

Maximum load current 100 mA per point, 400 mA per 8 ports Note)

Leakage current 0.1 mA max. per point

Insulation method Photocoupler insulation

External devices

Note) 400 mA is the maximum total load current of every eight ports from output port No. 300. (The

maximum total load current of output port No. 300 + n to No. 300 + n + 7 is 400 mA, where n is 0 or a multiple of 8.)

(1) Miniature relay (2) Sequencer input unit

TD62084 (or equivalent)

[Output circuit]

Internal circuit

10 

* P24: I/O24V power connector, 24V IN * N: I/O24V power connector, 0V

P24*

Surge absorber

Load

Output terminal

External power supply 24 VDC  10%

Caution

In the event that the load is short-circuited or current exceeding the maximum load current is input, the overcurrent protection circuit will be actuated to cut off the circuit. However, give due consideration to the circuit connection layout to prevent short-circuit or overcurrent.



INTELLIGENT ACTUATOR

2-2. PNP Specification

(1) Input

part

Item Specification

Input voltage

Input current 7 mA per circuit

ON/OFF voltage

Insulation method Photocoupler insulation

External devices

Internal circuit

Part 1 Installation

External Input Specifications (PNP Specification)

24 VDC 10%

ON voltage --- 8 VDC max. OFF voltage --- 19 VDC min.

(1) No-voltage contact (minimum load of approx. 5 VDC/1 mA) (2) Photoelectric/proximity sensor (PNP type) (3) Sequencer transistor output (open-collector type) (4) Sequencer contact output (minimum load of approx. 5 VDC/1 mA)

[Input circuit]

Input terminal

560 

3.3 K

* N: I/O24V power connector, 0V

External power supply 24 VDC 10%

Caution

If a non-contact circuit is connected externally, malfunction may result from leakage current. Use a circuit in which leakage current in a switch-off state does not exceed 1 mA.

 X-SEL controller’s input signal

ON duration

OFF duration

Part 1 Installation

INTELLIGENT ACTUATOR

(2) Output part

External Output Specifications (PNP Specification)

Item Specification

Load voltage 24 VDC

Maximum load current 100 mA per point, 400 mA per 8 ports Note)

Leakage current 0.1 mA max. per point

Insulation method Photocoupler insulation

External devices

Note) 400 mA is the maximum total load current of every eight ports from output port No. 300. (The

maximum total load current of output port No. 300 + n to No. 300 + n + 7 is 400 mA, where n is 0 or a multiple of 8.)

(1) Miniature relay (2) Sequencer input unit

TD62784 (or equivalent)

[Output circuit]

Internal circuit

* P24: I/O24V power connector, 24V IN * N: I/O24V power connector, 0V

10 

Output terminal

P24

Surge absorber

Load

External power supply 24 VDC 10%

Caution

In the event that the load is short-circuited or a current exceeding the maximum load current is input, the overcurrent protection circuit will be actuated to cut off the circuit. However, give due consideration to the circuit connection layout to prevent short-circuit or overcurrent.

Part 1 Installation

INTELLIGENT ACTUATOR

3. Power-Source Capacity and Heat Output of the Controller

The power-source capacity and heat output of the controller can be obtained using the formulas below:

Power-source capacity [VA] = {Motor drive power [W] + Control power-source

capacity [W]}  Power factor [0.6]

Heat output [W] = Total sum of output stage losses [W] + Control power-source

capacity [W]

Motor Drive Power and Output Stage Loss

Actuator motor wattage Motor drive power [W] Output stage loss [W]

20 W 15.6 1.58

30 W 27.6 2.07

60 W 83.0 3.93

100 W 140.1 6.12

150 W 196.9 8.30

200 W 252.6 9.12

400 W 477.5 19.76

600 W 698.2 27.20

750 W 912.8 29.77

The control power-source capacity varies as follows, depending on the numbers of controller axes and brake axes.

Control Power-Source Capacity

No BK BK X 1 BK X 2 BK X 3 BK X 4

1-axis controller [W] 17.5 27.3

2-axis controller [W] 23.4 33.2 42.9

3-axis controller [W] 29.3 39.1 48.8 58.6

4-axis controller [W] 35.3 45.0 54.8 64.5 74.3

(In the above table, the number of controller axes indicates the number of axes connectable to the controller. It is not the number of axes actually connected.)

Part 1 Installation

INTELLIGENT ACTUATOR

 Calculation example)

A 3-axis controller with a brake, equipped with a 200-W actuator for axis 1, 200-W actuator for axis 2 and 100-W actuator for axis 3

 Power-source capacity

The motor drive power is 252.6 W for axes 1 and 2 and 140.1 W for axis 3. The control power-source capacity is calculated as 39.1 W for “3-axis controller/brake x 1.”

(252.6 + 252.6 + 140.1 + 39.1)  0.6  1141 [VA] The power-source capacity is 1141 [VA].

 Heat output

The output stage loss is 9.12 W for axes 1 and 2 and 6.12 W for axis 3. The control power-source capacity is calculated as 39.1 W for “3-axis controller/brake x 1.”

(9.12 + 9.12 + 6.12) + 39.1  63 [W] The heat output is 63 [W].



INTELLIGENT ACTUATOR

4. External Dimensions

2-axis type (The external dimensions of 1-axis type and 2-axis type are the same.)

34.7

150

4-axis type (The external dimensions of 3-axis type and 4-axis type are the same.)

77.2

150

369.4

454.5

150

34.7

3 -

186

180

77.2

3 -

180

125.3

180

Part 1 Installation

195

125.3

195

Part 1 Installation

INTELLIGENT ACTUATOR

Chapter 6 System Setup

A connection example of a 2-axis controller is given below:

1. Connection Method of Controller and Actuator (Standard Specification)

Note: If multiple controller axes are used, be careful not to connect the actuator cables and connectors

wrongly. Confirm the model type of the actuator connected to each connector. Wrong connections of actuators and connectors may lead to motor or board damage or malfunction.

Note: In the case of an absolute specification, perform an absolute reset after the connection (refer to Chapter 7).

Class D grounding

(protective grounding)

AC power

source

ANSI-compatible teaching pendant

Drive-power cutoff

control circuit

Noise filter

ANSI-compatible

PC cable

Dummy plug (AUTO)

Relay box

Connection cable between relay box and controller

PIO power, 24 VDC

PLC (host side)

Part 1 Installation

INTELLIGENT ACTUATOR

(1) Connect to the controller the motor cable, encoder cable and LS cable (optional) from the

actuator. (2) Connect the controller to the relay box using the supplied relay cable. (3) Connect the relay box to the ANSI-compatible teaching pendant (or ANSI-compatible PC cable).

Set both the mode switch on the controller and the AUTO/MANU selector switch on the relay

box to MANU. (Refer to p. 34) (4) Connect the safety I/O terminals on the relay box to the drive-power cutoff control circuit. (5) Supply the power to the AC control-power input connector.

Caution

Be sure to turn on the motor power after turning on the control power.

(6) The panel window will display the code "rdy" to indicate that the preparation is complete. If "ErG" is displayed, it means that an emergency-stop signal is being input. In the case of an absolute specification, "ECA1" will be displayed. Refer to Chapter 7, "How to

Perform An Absolute Encoder Reset."

Part 1 Installation

INTELLIGENT ACTUATOR

1.2 I/O Connection Diagrams (1) NPN specification

0 V +24 V

Pin No. Category Port No. Function

Cable color

Input

Output

Program start General-purpose input

General-purpose input

Program specification (PRG No.1)

Program specification (PRG No.2)

Program specification (PRG No.4)

Program specification (PRG No.8)

Program specification (PRG No.10)

Program specification (PRG No.20)

Program specification (PRG No.40)

General-purpose input

General-purpose input General-purpose input

General-purpose input

General-purpose input Alarm output

Ready output

Emergency stop output

General-purpose output

General-purpose output General-purpose output

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

White-3

Black-3

Brown-4

Red-4

Orange-4

Yellow-4

Green-4

Blue-4

Purple-4

Gray-4

White-4

Black-4

Brown-5

Red-5

Orange-5

Yellow-5

Green-5

Blue-5

Purple-5

Gray-5

White-5

Part 1 Installation

INTELLIGENT ACTUATOR

(2) PNP specification

+24 V 0 V

Pin No. Category Port No. Function

Cable color

Input

Output

Program start General-purpose input

General-purpose input

Program specification (PRG No.1)

Program specification (PRG No.2)

Program specification (PRG No.4)

Program specification (PRG No.8)

Program specification (PRG No.10)

Program specification (PRG No.20)

Program specification (PRG No.40)

General-purpose input

General-purpose input General-purpose input

General-purpose input

General-purpose input Alarm output

Ready output

Emergency stop output

General-purpose output

General-purpose output General-purpose output

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

White-3

Black-3

Brown-4

Red-4

Orange-4

Yellow-4

Green-4

Blue-4

Purple-4

Gray-4

White-4

Black-4

Brown-5

Red-5

Orange-5

Yellow-5

Green-5

Blue-5

Purple-5

Gray-5

White-5

Part 1 Installation

INTELLIGENT ACTUATOR

1.3 I/O Flat Cable

Socket (with strain relief): XG4M-5030-T (Omron)

No. Color No. Color No. Color No. Color No. Color

1 Brown-1 11 Brown-2 21 Brown-3 31 Brown-4 41 Brown-5 2 Red-1 12 Red-2 22 Red-3 32 Red-4 42 Red-5 3 Orange-1 13 Orange-2 23 Orange-3 33 Orange-4 43 Orange-5 4 Yellow-1 14 Yellow-2 24 Yellow-3 34 Yellow-4 44 Yellow-5 5 Green-1 15 Green-2 25 Green-3 35 Green-4 45 Green-5 6 Blue-1 16 Blue-2 26 Blue-3 36 Blue-4 46 Blue-5 7 Purple-1 17 Purple-2 27 Purple-3 37 Purple-4 47 Purple-5 8 Gray-1 18 Gray-2 28 Gray-3 38 Gray-4 48 Gray-5 9 White-1 19 White-2 29 White-3 39 White-4 49 White-5

10 Black-1 20 Black-2 30 Black-3 40 Black-4 50 Black-5

Flat cable: KFX-50 (S) (Color) (Kaneko Cord)

Flat cable (50 cores)

No connector

Part 1 Installation

INTELLIGENT ACTUATOR

2. Drive-Power Cutoff Control Circuit

This controller has no built-in drive-power cutoff control circuit to actuate an emergency stop, enable the controller operation, etc. The customer must configure this circuit externally to the controller in accordance with the safety category required by the final system. The table below lists the controller-side inputs/outputs and units that are used to configure a drive-power cutoff control circuit.

Connector name Description

AC motor-power input connector

System I/O connector

Teaching-pendant connector

Unit name Description

Relay box

ANSI-compatible teaching pendant (SEL-TD, IA-T-XA)

This connector inputs the externally supplied motor power. Cut off or reset this input using the drive-power cutoff control circuit in response to an emergency-stop or enable operation.

This connector provides emergency-stop input, safety-gate input and controller-ready contact output. It is used as an interface between the external drive-power cutoff control circuit and the controller.

Connect it to IAI's relay box. Connecting the teaching pendant directly to this connector will disable drive-power cutoff action, so exercise caution.

This interface unit connects IAI's teaching pendant to the controller and serves as an interface for emergency-stop and enable actions between the external drive-power cutoff control circuit and the controller. The relay box consists of D-Sub, 25-pin connectors for controller and teaching pendant and a 2-piece connector for drive-power cutoff control circuit interface.

This IP54 teaching pendant has a 3-position enable switch and an emergency-stop switch. Use this teaching pendant if you wish to configure a drive-power cutoff control circuit of category 1 or above.

Standard teaching pendant (SEL-T, IA-T-XD)

This teaching pendant can be used if the drive-power cutoff control circuit only needs to conform to category B.

INTELLIGENT ACTUATOR

2.1 System I/O Connector

The table bel connector.

ow summarizes the detailed explanations of the respective terminals of the system I/O

RDY OUT1

RDY OUT2

Part 1 Installation

A dry contact indicating that the controller has started properly. The contact capacity is 24 VDC, 1 A max. Use this contact for safety circuit interlocking.

S.GATE IN

+24V OUT

EMG IN

+24V OUT

Note) 24V OUT in Nos. 4 and 6 is a dedicated output generated inside the controller. Never use

it for any other purpose.

A safety-gate operation monitor input signal that always remains enabled regardless of the operating mode of the controller. The contact-A input operates the actuator only in MAKE mode. Connect it to the dry contact for safety-gate signal from the external safety circuit. This input must be shorted if not used.

An emergency-stop operation monitor input signal. The contact-B input actuates an emergency stop in BREAK mode. Short this input if a relay box is used.



INTELLIGENT ACTUATOR

2.2 Relay Box

Overview of Relay Box

(1)

The relay box is a unit needed to externally cut off the motor power input to the Global

Specification X-SEL Controller in response to an input action via the emergency-stop button or

deadman switch on the teaching pendant.

The relay box has a connector terminal block providing the contact outputs for emergency-stop

button and deadman switch. These contact outputs are used to cut off the drive power in

accordance with the pressing of the emergency-stop button or deadman switch on the teaching

pendant. (A circuit is required that cuts off the drive power the moment the contact output for

emergency-stop button or deadman switch becomes open.)

The connector terminal block also has terminals for inputting a drive-power cutoff condition such

as "emergency stop" or "enable" to the controller. By inputting an appropriate signal the moment

the drive power is cut off externally, the controller can perform appropriate processing such as

an emergency stop. (A circuit is required that inputs a drive-power cutoff condition such as

"emergency stop" or "enable" to the controller the moment the drive power is cut off.)

IAI's teaching pendant SEL-T and IA-T-XD provide a single contact that responds to both the

emergency-stop button and deadman switch. Therefore, the ANSI-compatible teaching pendant

SEL-TD and IA-T-XA providing two contact outputs must be used if you wish to configure a

control system meeting safety category 3 or 4.

(2) Names of Respective Parts of Relay Box, Connecting Destinations, and Descriptions

[4] [3]

 

[5]

[1]

[2]

Part 1 Installation

INTELLIGENT ACTUATOR

1) Dedicated X-SEL Teaching Pendant Connector

Silkscreen printed

name

Connects the teaching pendant or PC cable. Or, a dummy plug

Connecting

destination,

description

may be connected. Note: Two types of dummy plugs are supplied. Use a dummy

plug appropriate for the teaching pendant you are using. (Refer to page 33.)

Connector D-Sub, 25-pin XM3B-2542-502L (Omron)

2) Relay Cable Connector for Relay Box

Silkscreen printed

name

Connecting

destination,

description

Connects the relay cable for relay box. The relay cable is connected to the Global Specification X-SEL Controller.

Connector D-Sub, 25-pin XM3B-2542-502L (Omron)

3) Safety I/O Terminals

Silkscreen printed

name

These terminals are wired to the external drive-power cutoff control circuit. Pins 1 to 8 serve as outputs for the various safety switch

Connecting

destination,

description

terminals provided on the teaching pendant. Pins 9 to 12 are assigned to the emergency-stop signal and deadman signal in the X-SEL teaching pendant terminals. Pins 10 and 12 are supplied 24 V, just like the X-SEL system I/O terminals. However, pins 10 and 12 must not be connected together since they draw power from different circuits.

Connector MC1.5/12-ST-3.5 (Phoenix Contact)

Part 1 Installation

TP IN

TP OUT

(TO CONTROLLER)

SAFETY IN/OUT

Part 1 Installation

INTELLIGENT ACTUATOR

Terminal Numbers and Descriptions of Safety I/O Terminals

Terminal number Description

(When the ANSI-compatible teaching pendant SEL-TD and IA-T-

5 Contact output 2 for deadman switch 1 on the teaching pendant

XA are used) Contact output 2 for deadman switch 2 on the teaching pendant (When the ANSI-compatible teaching pendant SEL-TD and IA-TXA are used) Contact output 1 for deadman switch 2 on the teaching pendant (When the ANSI-compatible teaching pendant SEL-TD and IA-TXA are used) Contact output 2 for emergency-stop switch 2 on the teaching pendant (When the ANSI-compatible teaching pendant SEL-TD and IA-TXA are used) Contact output 1 for emergency-stop switch 2 on the teaching pendant

6 Contact output 1 for deadman switch 1 on the teaching pendant

Contact output 2 for emergency-stop switch 1 on the teaching pendant

Contact output 1 for emergency-stop switch 1 on the teaching pendant

Enable input to the X-SEL controller (Closing pins 10 and 9 will enable the controller operation.)

24-V power output from the X-SEL controller (Do not connect to pin 12.)

Emergency-stop input to the X-SEL controller (Opening pins 12 and 11 will actuate an emergency-stop.)

24-V power output from the X-SEL controller (Do not connect to pin 10.)

12 1

INTELLIGENT ACTUATOR

4) Internal Circuit Selector Terminals

Silkscreen printed

name

This connector terminal block is used to select internal circuits of

Description

the relay box. The shorting connections between the connector terminals are changed in accordance with the teaching pendant used.

Connector MC1.5/6-ST-3.5 (Phoenix Contact)

Terminal Numbers and Descriptions of Internal Circuit Selector Terminals

Terminal number Description

Shorted to pin 2 when the ANSI-compatible teaching pendant SEL-

TD and IA-T-XA are used. (Opened when the teaching pendant SEL-T and IA-T-XD are used.) Shorted to pin 1 when the ANSI-compatible teaching pendant SEL-

TD and IA-T-XA are used. (Opened when the teaching pendant SEL-T and IA-T-XD are used.) Shorted to pin 4 when the teaching pendant SEL-T and IA-T-XD

are used. (Opened when the ANSI-compatible teaching pendant SEL-TD is used.) Shorted to pin 3 when the teaching pendant SEL-T and IA-T-XD

are used. (Opened when the ANSI-compatible teaching pendant SEL-TD and IA-T-XA are used.) Shorted to pin 6 when the teaching pendant SEL-T and IA-T-XD

are used. (Opened when the ANSI-compatible teaching pendant SEL-TD and IA-T-XA are used.) Shorted to pin 5 when the teaching pendant SEL-T and IA-T-XD

are used. (Opened when the ANSI-compatible teaching pendant SEL-TD and IA-T-XA are used.)

When the teaching pendant

SEL-T and IA-T-XD are

used

6 1 6 1

When this wiring pattern is used, use a dummy plug for IAI’s teaching pendant.

Part 1 Installation

TP (ANSI/IAI) SELECT

When the ANSI-compatible teaching

pendant SEL-TD and IA-T-XA are

When this wiring pattern is used, use a dummy plug for ANSI-compliant teaching pendant.

Part 1 Installation

INTELLIGENT ACTUATOR

5) AUTO/MANU Selector Switch

Silkscreen printed

name

This switch selects the AUTO or MANU mode.

Description

Switch B-22LH (Nihon Kaiheiki)

Setting the switch knob to the AUTO side will short pins 1 and 2 and pins 5 and 6 of the safety I/O terminals 3).

AUTO/MANU

Caution

Set the knob of the controller's mode switch and that of the AUTO/MANU selector switch to the same side.

Part 1 Installation

INTELLIGENT ACTUATOR

(3) Teaching Pendant Operations and Safety I/O Terminal Conditions

1) Safety I/O Terminal (Pins 1 to 8) Conditions upon Pressing of Emergency-Stop Switch on

Teaching Pendant (TP)

Condition of emergency-stop switch on teaching pendant Pressed Released

Condition of AUTO/MANU switch on relay box AUTO MANU AUTO MANU

Safety I/O terminal pin number

1-2

(Contact outputs 1, 2 for enable switch 2 on the ANSI-

- - - -

compatible TP)

3-4

(Contact outputs 1, 2 for emergency-switch 2 on the

open open close close

ANSI-compatible TP)

5-6

(Contact outputs 1, 2 for enable switch 1 on the TP)

- - - -

7-8

(Contact outputs 1, 2 for emergency-stop switch 2 on the

open open close close

TP) Once the teaching pendant is disconnected, the terminal conditions will become the same as those when the emergency-stop switch is "Pressed" as shown in the table above. Set the knob of the controller's mode switch and that of the AUTO/MANU selector switch to the same side.

2) Safety I/O Terminal (Pins 1 to 8) Conditions upon Pressing of Deadman Switch on Teaching

Pendant (TP)

Released

Condition of deadman switch on teaching pendant Pressed

(Pushed in

further)

Condition of AUTO/MANU switch on relay box AUTO MANU AUTO MANU

Safety I/O terminal pin number

Safety I/O terminal (pins 1 to 8)

conditions

1-2

(Contact outputs 1, 2 for deadman switch 2 on the ANSI-

close close close open

compatible TP)

3-4

(Contact outputs 1, 2 for emergency-switch 2 on the

- - - -

ANSI-compatible TP)

5-6

(Contact outputs 1, 2 for deadman switch 1 on the TP)

close close close open

7-8

(Contact outputs 1, 2 for emergency-stop switch 2 on the

- - - -

TP) Once the teaching pendant is disconnected, the terminal conditions will become the same as those when the deadman switch is "Released" as shown in the table above. Set the knob of the controller's mode switch and that of the AUTO/MANU selector switch to the same side.

Part 1 Installation

INTELLIGENT ACTUATOR

(4) Operations to Safety I/O Terminals and X-SEL Controller Conditions

1) X-SEL Controller Conditions upon Opening/Closing Safety I/O Terminal Pins 9 and 10 (Enable

Input and 24 V to X-SEL Controller)

Connection of teaching pendant to relay box Not connected

Condition of AUTO/MANU switch on X-SEL unit AUTO MANU

Condition of pins 9 and 10 open close open close

X-SEL condition (without dummy plug) Ardy Ardy dSF rdy

X-SEL condition (with dummy plug) Ardy Ardy dSF rdy

Connection of teaching pendant to relay box Connected

Condition of AUTO/MANU switch on X-SEL unit AUTO MANU

Condition of pins 9 and 10 open close open close

X-SEL condition Ardy Ardy dSF rdy

(Note) Set the knob of the controller's mode switch and that of the AUTO/MANU selector switch to

the same side.

2) X-SEL Controller Conditions upon Opening/Closing Safety I/O Terminal Pins 11 and 12

(Emergency-Stop Input and 24 V to X-SEL Controller)

Connection of teaching pendant to relay box Not connected

Condition of AUTO/MANU switch on X-SEL unit

(Note)

AUTO MANU

Condition of pins 11 and 12 open close open close

X-SEL condition (without dummy plug) Ardy Ardy EMG rdy

X-SEL condition (with dummy plug) EMG Ardy EMG rdy

Connection of teaching pendant to relay box Connected

Condition of AUTO/MANU switch on X-SEL unit AUTO MANU

Condition of pins 11 and 12 open close open close

X-SEL condition EMG Ardy EMG rdy

(Note) Set the knob of the controller's mode switch and that of the AUTO/MANU selector switch to

the same side.

INTELLIGENT ACTUATOR

2.3 Drive-Power Cutoff Control Circuit

Connection Example of External Drive-Power Cutoff Control Circuit

(1)

The next page shows a sample connection circuit for cutting off the drive power externally for each safety category. For the safety relay unit, the names and arrangements of terminals, etc., will vary depending on the manufacturer, so confirm them in the operating manual for the product used.

The connections shown in this diagram cut off the drive power in accordance with the input from the emergency-stop button, external emergency-stop button and deadman switch on the teaching pendant.

(2) Notes

 The customer must provide the contactors and safety relays to cut off the drive power.  Select contactors with a rated capacity of 10 A or above.  The noise filter for motor power input is supplied by IAI.  The power line cables must be at least 1.0 mm sq. in size.  Do not wire the signal cables such as I/O and emergency-stop cables together with the power

cables, but place them in separate ducts, etc., to provide a sufficient distance between them.

 Provide an external circuit protector with a rated capacity of 10 A or above, in order to cut off

the drive power and control power simultaneously. (This circuit protector is not shown in the diagram on the next page.)

 If the drive power is cut off and turned on repeatedly, provide a minimum interval of 5

seconds between ON and OFF.

 Do not supply the drive power with the control power cut off.  When the mode switch is set to the MANU (manual mode) side, the drive-source cutoff signal

cannot be reset if nothing is connected to the teaching connector. (Refer to 3, “Drive-Source Recovery Request and Operation-Pause Reset Request.”)

Part 1 Installation

INTELLIGENT ACTUATOR

Example of drive-source cutoff circuit conforming

to safety category 1

X-SEL-KT

AC power input

C_POWER

Motor power input

M_POWER

System I/O (Refer to 2.1

for pin assignments.)

N L N L PE

6 1

24 VDC

Noise

filter

Relay

GND

Emergency stop switch

Use an emergency stop switch conforming to EN60947-5-1 or equivalent.

Reset switch

Safety relay

GND

INTELLIGENT ACTUATOR

Example of drive-source cutoff circuit conforming

to safety category 1

AC power input

C_POWER

Motor power input

M_POWER

N L PE

Noise

filter

X-SEL-KT

N L

24 VDC

GND

System I/O

(Refer to 2.1.)

6 1 12

24 VDC

Relay

GND

Part 1 Installation

Teaching pendant SEL-T, IA-T-XD

Relay box

TP OUT TP IN

Safety IN/OUT

(Refer to 2.2.)

24 VDC

Reset switch

Safety relay

GND

A1A

Part 1 Installation

INTELLIGENT ACTUATOR

Example of drive-source cutoff circuit conforming

to safety category 2

X-SEL-KT

AC power input

C_POWER

Motor power input

M_POWER

System I/O

(Refer to 2.1.)

N L PE

6 1

Noise

filter

Emergency stop switch

Use an emergency stop switch conforming to EN60947-5-1 or equivalent.

24 VDC

Reset switch

S33 S11

S34 S12

Safety relay

PSR-SCP-

24UC/ESA2/4X

1/1X2/B by

Phoenix

Relay

GND

13 23 33 43 53

14 24 34 44 52

GND

24 VDC

GND

A1 A

INTELLIGENT ACTUATOR

Example of drive-source cutoff circuit conforming

to safety category 2

X-SEL-KT

AC power input

C_POWER

Motor power input

M_POWER

N L PE

N L

Noise

filter

Reset switch

Safety relay

24UC/ESA2/4X

1/1X2/B by

S33

S34 S12

PSR-SCP-

Phoenix

S11

13 23 33 43

14 24 34 44 52

System I/O

(Refer to 2.1.)

Relay

Part 1 Installation

Teaching pendant SEL-T, IA-T-XD

Relay box

12 1

24 VDC

GND

TP OUT

Safety

IN/OUT

(Refer to

2.2.)

24 VDC

GND

24 VDC

GND

TP IN

Part 1 Installation

INTELLIGENT ACTUATOR

Example of drive-source cutoff circuit conforming to safety category 3

(Resetting the reset input with the emergency stop switch input)

X-SEL-KT

AC power input

C_POWER

Motor power input

M_POWER

System I/O

(Refer to 2.1.)

N L PE

Noise

filter

Emergency stop switch

Use an emergency stop switch conforming to EN60947-5-1 or equivalent.

24 VDC

Relay

T11

T21 B1

T12 T22 X1

Safety relay

G9S-301 by

Omron

Y1 13 23 33 41

14 24 34 42

GND

24 VDC

GND

INTELLIGENT ACTUATOR

Example of drive-source cutoff circuit conforming to safety category 3

(Resetting the reset input with the emergency stop switch input)

X-SEL-KT

AC power input

C_POWER

N L PE

Motor power input

M_POWER

N L

(Refer to 2.1.)

Noise

filter

T11

T21 B1

T12 T22

Safety relay

G9S-301 by

Omron

Y1 13 23 33 41

14 24 34 42

System I/O

Relay

Part 1 Installation

Teaching pendant SEL-T, IA-T-XD

Relay box

24 VDC

GND

TP OUT

Safety IN/OUT

(Refer to 2.2.)

12 1

24 VDC

GND

24 VDC

GND

TP IN

Part 1 Installation

INTELLIGENT ACTUATOR

Example of drive-source cutoff circuit conforming to safety category 3

(Connecting multiple emergency stop switches)

X-SEL-KT

AC power input

C_POWER

Motor power input

M_POWER

System I/O

(Refer to 2.1.)

N L PE

Noise

filter

Emergency stop switch

Use an emergency stop switch conforming to EN60947-5-1 or equivalent.

Reset switch

24 VDC

Relay

T11

T21 B1

T12 T22

Safety relay

G9S-301 by

Omron

Y1 13 23 33 41

14 24 34 42

GND

24 VDC

GND

Part 1 Installation

INTELLIGENT ACTUATOR

Example of drive-source cutoff circuit conforming to safety category 3

(Connecting multiple emergency stop switches)

Teaching pendant SEL-T, IA-T-XD

X-SEL-KT

AC power input

C_POWER

Motor power input

M_POWER

System I/O

(Refer to 2.1.)

Relay box

TP OUT TP IN

Safety

IN/OUT

(Refer to

2.2.)

N L PE

Noise

filter

Emergency stop switch

Use an emergency stop switch conforming to EN60947-5-1 or equivalent.

Reset switch

1 12 1

24 VDC

Relay

T11

T21

T12

Safety relay

G9S-301 by

Omron

T22

13 23 33 41

14 24 34 42

GND

24 VDC

GND

Part 1 Installation

INTELLIGENT ACTUATOR

Example of drive-source cutoff circuit conforming

to safety category 4

X-SEL-KT

AC power input

C_POWER

Motor power input

M_POWER

System I/O

(Refer to 2.1.)

N L PE

Noise

filter

Emergency stop switch

Use an emergency stop switch conforming to EN60947-5-1 or equivalent.

Reset switch

24 VDC

Relay

T21

T11

T12

Safety relay

G9S-301 by

Omron

13 23 33 41

14 24 34 42

T22

GND

24 VDC

GND

INTELLIGENT ACTUATOR

Example of drive-source cutoff circuit conforming

to safet

category 4

AC power input

C_POWER

Motor power input

M_POWER

N L PE

Noise

filter

X-SEL-KT

T21 B1

T11

T12

Safety relay

G9S-301 by

Omron

T22

Reset switch

23 33 41

14 24 34 42

System I/O

(Refer to 2.1.)

Relay

Part 1 Installation

Teaching pendant SEL-T, IA-T-XD

Relay box

12 1

24 VDC

GND

TP OUT

Safety

IN/OUT

(Refer to 2.2.)

24 VDC

GND

24 VDC

GND

TP IN

Part 1 Installation

INTELLIGENT ACTUATOR

Chapter 7 How to Perform An Absolute Encoder Reset

When the absolute-encoder battery voltage of the X-SEL Controller is abnormal or when the battery or encoder cable is disconnected, an encoder battery error will occur and an absolute encoder reset must be performed.

This chapter explains how to perform an absolute encoder reset using the PC software. For the absoluteencoder reset method using the teaching pendant, refer to the operation manual for the teaching pendant. If your system is of the synchro specification, refer to Appendix, “ Absolute Reset of A Synchro Controller.”

1. Preparation

(1) PC

A PC in which IAI’s X-SEL PC software (X_SEL.exe) has been installed

(2) Connection cable (the cable supplied with the PC software)

RS232C cross cable (PC-end: female 9-pin, Controller-end: male 25-pin)

(3) All adjustments other than the encoder reset must have been completed.

2. Procedure

(1) Turn off the X-SEL Controller power. Turn on the PC power and wait for the operating system to

be started.

(2) Connect the 9-pin, D-sub connector on one end of the connection cable to the communication

port on the PC, and connect the 25-pin, D-sub connector on the other end to the 25-pin communication port on the controller.

(3) Turn on the controller power. If an encoder battery error is present but no other adjustments are

pending, the 7-segment LED display will show “ECA1” or "ECA2" indicating that the controller has detected an encoder battery error.

(4) Start the X-SEL PC software (X_SEL.exe) on the PC. The following explains the operation

steps in the X-SEL PC software.

(5) When the [Connection Confirmation] dialog box is displayed, select the port name you are using

on the PC. Click the [OK] button.

(The software will automatically detect the baud rate.)

Part 1 Installation

INTELLIGENT ACTUATOR

(6) The X-SEL PC software window will be displayed. Clicking the [OK] button will clear the error

message.

(7) From the [Monitor (M)] menu, select [Detailed Error Information (E)] to check the current error

status. In the case of an encoder battery error, the following will be displayed (when axis 4 is using an absolute encoder). After checking the error status, close the [Detailed Error Information] window.

Part 1 Installation

INTELLIGENT ACTUATOR

(8) From the [Controller (C)] menu, select [Absolute Reset (A)].

(9) When a [Warning] dialog box is displayed, click the [OK] button.

(10) The [Abs. Encoder Reset] dialog box will be displayed. Click here

to select the axis you wish perform an absolute encoder reset for.

(11) Clicking the [Encoder Rotation Data Reset 1] button will display a [Warning] dialog box. Click the

[Yes] button.

Part 1 Installation

INTELLIGENT ACTUATOR

(12) Another [Warning] dialog box will be displayed. Click the [Yes] button.

(13) When the processing of encoder rotation data reset 1 is complete, the red arrow will move to the

next item. Press the following processing buttons one by one (the red arrow will move to the next item when each process is completed):

1. Reset Controller Error

2. Servo ON

3. Returning Home

4. Servo OFF Note: If the PC software version is 1.1.0.0 or later and the driver CPU version is 0.23 or later, encoder rotation data reset 2 will be performed while the servo power is on. Therefore, the servo-off step will be skipped.

5. Encoder Rotation Data Reset 2

(Note) With early products, “Error No. D10: IPM error” may occur following a controller error

reset. If this error occurs, exit the PC tool and reconnect the controller power, and then repeat from step (2). (As long as the encoder battery is normal, the error will no longer occur when the controller is restarted, and the controller’s 7-segment LED display will show “rdy” or “Ardy.” Note that the axis home has not been adjusted yet.)

When the processing of encoder rotation data reset 2 is complete, the red arrow will return to the position in (10). If you are performing an absolute encoder reset for another axis, select the target axis and perform the steps after (10). To close the [Abs. Encoder Reset] dialog box, click the [Close] button. (Note) If you must perform an absolute encoder reset for multiple axes, always perform steps

(10) through (13) for all axes before performing the software reset in step (14).

(14) From the [Controller (C)] menu, select [Software Reset (R)].

Part 1 Installation

INTELLIGENT ACTUATOR

(15) When the [Confirmation] dialog box is displayed, click the [Yes] button and restart the controller.

(16) If no other error is present, the controller’s 7-segment LED display will show “rdy.”

(17) This completes the absolute encoder reset.

To redo the absolute encoder reset, exit the X-SEL PC software and repeat the procedure from the beginning.

Part 1 Installation

INTELLIGENT ACTUATOR

Chapter 8 Maintenance

 Routine maintenance and inspection are necessary so that the system will operate properly at all

time. Be sure to turn off the power before performing maintenance or inspection.

 The standard inspection interval is six months to one year. If the environment warrants, however, the

interval should be shortened.

(1) Inspection points

 Check to see if the supply voltage to the controller is inside the specified range.  Inspect the ventilation holes in the controller and remove dirt, dust and other foreign attachments, if

any.

 Inspect the controller cables (controller  actuator) and check for any loose screws or cable

disconnection.

 Check the controller mounting screws, etc., for looseness.  Inspect each cable (axis link cable, general-purpose I/O cable, system I/O cable, power cable) for

loose connection, disconnection, play, etc.

(2) Spare consumable parts

Without spare parts, a failed controller cannot be repaired even when the problem is identified quickly. We recommend that you keep the following consumable parts as spares:

Consumable parts

 Cables  System-memory backup battery CR2032 (Note 1) --- 1 year (Note 2)  Absolute-data backup battery by IAI IA-XAB-BT --- 1 year (Note 2)

Temperature

Power supplied

0% of the time CR2032 (Note 1) 1.5 years 3 years IA-XAB-BT by IAI 1 year 2 years

 Fuses

(Note 1) CR2032 refers to a battery conforming to the CR2032 standard, and any CR2032 battery

by any manufacturer can be used.

(Note 2) The actual battery life will vary depending on the use condition.

Memory backup The X-SEL Controller saves program, position and parameter data to its flash memory (when written to the flash memory). The data saved by the battery are positions, SEL global data and error lists. (Refer to Chapter 1, “How to Save Data,” of Part 3.)

When the battery voltage drops, an applicable error code will be displayed on the panel window.

Error Codes Indicating Low Battery Voltage

System-memory backup battery A01 or A02

Absolute-data backup battery A03 or A23

In the case of a low battery voltage of the absolute-data backup battery, the axis-driver status LED will also illuminate.

Condition of use

40C

Temperature

40C

Power supplied 50% of the time

Part 1 Installation

INTELLIGENT ACTUATOR

(3) Replacement procedure for system-memory backup battery (CR2032)

Backing up the system memory If “Other parameter No. 20, Backup-battery installation function type” is set to “2” (installed), the following SRAM data in the X-SEL Controller will be backed up by the system-memory backup battery on the panel board:

 Position data  SEL global data (flags, integer/real variables, string variables)  Error lists

Always follow the procedure below when replacing the system-memory backup battery:

Note: If the system-memory backup battery is removed while “Other parameter No. 20, Backup-battery

installation function type” is still set to “2” (installed), the data stored in the SRAM will be lost.

Note: So that your position data can be restored even after the SRAM data has been cleared, use the

PC software to save the position data to a file before removing the battery. For the method to save position data to a file, refer to 6, “Position Data Edit Window” in the “Operation Manual for X-SEL PC Software.”

[Replacement procedure for system-memory backup battery]

1. Turn on the controller power.

2. Record (write down) the current setting of “Other parameter No. 20, Backup-battery installation function type.” (This will be used when reverting the parameter to its original setting following the replacement of system-memory backup battery.)

3. If the PC software is installed in your PC, save the position data to a file using the PC software. The data will be used as a backup in case the SRAM data saved to the flash ROM fails.

For the method to save position data to a file, refer to 6, “Position Data Edit Window” in the “Operation Manual for X-SEL PC Software.”

4. Change “Other parameter No. 20, Backup-battery installation function type” to “1” and transfer the

setting to the controller, and then perform a flash ROM write. (The position data will be saved to the flash ROM.) * Confirm that the flash ROM writing process has completed.

For the method to edit parameters, refer to 8, “Parameter Edit Window” in the “Operation Manual for X-SEL PC Software.”

5. Perform a software reset to restart the controller. (The SEL global data and error lists will be saved

to the special area in the flash ROM.)

6. When the controller has been restarted, turn off the power.

* Once the controller has been restarted, be sure to keep the power on until the initialization

sequence number is no longer displayed on the panel window (while “InXX” is displayed following “8888”; XX indicates a number).

7. Replace the system-memory backup battery. The battery is mounted on the panel board and can

be removed using two small screwdrivers or the like. When removing the current battery and installing a new one, pay due attention to the following points (SRAM data will be deleted if steps 1 through 6 are not performed properly):

● Do not damage the board patterns.

● Do not short the circuits.

● Connect the battery in the correct polarities.

Part 1 Installation

INTELLIGENT ACTUATOR

Battery Replacement Procedure

1) Remove the 7-segment LED panel from the controller. Slide the panel upward and pull it toward you to remove.

2) As shown at left, remove the battery from the holder using two screwdrivers, and then install a new battery in the holder. Gently lift the top (opening side) of the battery, and then push out the bottom (closing side) to remove the battery.

3) Install the panel in the original position.

8. When the replacement of system-memory backup battery is complete, confirm that the battery is installed securely and then turn on the controller power.

9. Revert “Other parameter No. 20, Backup-battery installation function type” to the value recorded in step 2, transfer the setting to the controller, and then perform a flash ROM write. * Confirm that the flash ROM writing process has completed.

10. Perform a software reset (restart the controller).

11. When the controller has been restarted, confirm that the SRAM data have been restored.

Part 1 Installation

INTELLIGENT ACTUATOR

(4) Reset procedure following a battery-voltage low warning

When a voltage low warning for absolute-encoder battery (error code: A03 or A23) is issued or the battery has been replaced without any warning present, an encoder error reset and software reset must be performed. You need not repeat certain steps in the absolute-encoder reset procedure, such as the processing of returning home.

Keep the main power to the controller on until the following procedure is complete:

1. Start the PC software online.

2. Turn off the servo power (on the position edit window, etc.)

3. Replace the battery (IA-XAB-BT by IAI).

If the voltage of the absolute-data backup battery has dropped, replace the entire battery unit.

As shown at left, use a hex wrench to remove the bolt that is mounting the battery unit onto the front panel. Pull out the battery unit toward you, and install a new battery unit.

4. From the [Controller (C)] menu on the PC software screen, select [Absolute Reset (A)].

5. When a [Warning] dialog box is displayed, click the [OK] button.

Warning

Part 1 Installation

INTELLIGENT ACTUATOR

6. The [Abs. Encoder Reset] dialog box will be displayed.

7. For Axis No., select the number of the axis for which you have just replaced the battery. Note) Do not click the [Encoder

Rotation Data Reset 1] button.

8. Click the [Reset Encoder Error] button.

9. Close the dialog box.

Abs. Encoder Reset

10. From the [Controller (C)] menu on the PC software screen, select [Software Reset (R)], and restart the controller.

Confirmation

This completes the reset procedure following a battery-voltage low warning.

Part 2 Operation

INTELLIGENT ACTUATOR

Part 2 Operation

Chapter 1 Operation

How to Start a Program

With the X-SEL Controller, the stored programs can be started (run) using four methods. Of these methods, two are mainly used to debug programs or perform trial operations, while the remaining two are used in general applications on site.

The former two methods are “starting from the teaching pendant” and “starting from the PC software.”

These methods provide simple means of checking the operation. For details on “starting from the teaching pendant,” read the operation manual for the optional teaching pendant. For “starting from the PC software,” read the applicable explanation in the manual supplied with the PC software.

The latter two methods are “starting automatically via parameter setting” and “starting via external signal selection.” This chapter only explains the methods for “starting automatically via parameter setting” and “starting via external signal selection.”

Teaching pendant

PC software

Start

X-SEL

Controller

Start

Starting

automatically via

parameter setting

Starting via

external signal

selection

INTELLIGENT ACTUATOR

1. Starting a Program by Auto-Start via Parameter Setting

I/O parameter No. 33 (input function selection 003) = 1 (default factory setting)

This parameter is set using the teaching pendant or PC software.

Set an auto-start program number

Reset the controller

Automatically starting the program

Set the number of the program you wish to start automatically in other parameter No. 1 (auto-start program number). Set the controller mode to AUTO.

Reconnect the power, and the controller will be reset.

Once the controller is reset in the above step, the program of the set number will start automatically. *

Part 2 Operation

Caution

[Note on starting a program by auto-start] The automatic operation will begin immediately after the controller is reset, so the user may be surprised by unexpected movements of the equipment, particularly those caused by a sudden activation of the servo actuator. To ensure safety, always provide an interlocking function, such as allowing the program execution to proceed only after receiving a confirmation signal at the beginning of the program.

If you wish to start multiple programs at the same time, write multiple “EXPG” commands at the beginning of the main program to start the remaining programs. Provide safety measures for each program to be started.

* When I/O parameter No. 33 is set to “2” The program of the selected number will start automatically at the ON edge of input signal received by

input port No. 3.

The program will be terminated at the OFF edge.

INTELLIGENT ACTUATOR

2. Starting via External Signal Selection

Select a desired program number externally and then input a start signal.

(1) Flow chart

External device

Power ON

READY signal

confirmed?

Various I/O

processing

Program number

specification

Start signal ON

Emergency-stop

switch ON?

Emergency-stop

signal ON

ALARM signal

confirmed?

ALARM

processing

Controller

Power ON

Ready output

READY signal ON

Program number

confirmed?

Program number

input

Start signal

confirmed?

External start input

Program run

Emergency-stop

signal confirmed?

Emergency-stop

input

Controller

error?

Servo OFF

ALARM signal ON

Alarm output

Part 2 Operation

When the READY signal turns ON, the RDY lamp (green) on the controller front panel will illuminate.

Input a desired program number as a BCD code from the external device.

Input a start signal from the external device.

When the program is run, the number of the started program will be shown in the CODE display area of the controller front panel.

If an emergency-stop signal was input from the external device or a controller error occurred, the controller will turn off the servo power. (The RDY lamp will turn off.)

INTELLIGENT ACTUATOR

(2) Timing chart

[1] Program start

Ready output

Program number input

Program 1 Program 2

External start input

[2] Auto program start

* When I/O parameter No. 33 is set to 2

Ready output

Input of input function 003

Auto program start

[3] Soft reset signal

* When I/O parameter No. 31 is set to 1

Ready output

Input of input function 001

Program starting

[4] Servo ON signal

* When I/O parameter No. 32 is set to 1

Ready output

Input of input function 002

Servo ON

T1 T2

T1 T3

Part 2 Operation

T1: Duration after the ready output turns ON

until input of external start signal is permitted T1 = 10 msec min.

T2: Duration after the program number is input

until input of external start signal is permitted T2 = 50 msec min

T3: Input duration of external start signal

T3 = 100 msec min.

T1: Time after the ready output turns ON

until input function 003 can be input

T1 = 10 msec min.

* Auto program start:

Set the number of the program you wish to start automatically in other parameter No. 1, “Auto-start program number.”

T1: Time after the ready output turns ON

until input function 001 can be input

T1 = 10 msec min.

T2:

Time until the soft reset signal starts functioning T2 = 1 sec min.

T3:

Time after the soft reset signal is reset until the ready signal is output

T1:

Time after the ready output turns ON until input function 002 can be input

T1 = 10 msec min.

T2:

Interval after the servo is turned OFF until it is turned ON again

T2 = 1.5 sec min.

Part 2 Operation

INTELLIGENT ACTUATOR

3. Drive-Source Recovery Request and Operation-Pause Reset Request

(1) Drive-source recovery request

1. How to request a drive-source recovery

A drive-source recovery request can be issued using one of the following methods:

 Set I/O parameter No. 44 to “1” (Input selection function 014 = Drive-source cutoff reset input),

then input the ON edge to input port No. 14.

 Select [Drive-Source Recovery Request (P

screen.

 Select Ctl (controller operation) and RPwr (drive-source recovery request) on the mode selection

screen of the teaching pendant.

2. Case where a drive-source request is required

A drive-source recovery request is required in the following case:

 A drive-source cutoff factor occurred when I/O parameter No. 44 was set to “1”  Recovery after

the cutoff factor is removed.

(2) Operation-pause reset request

1. How to request an operation-pause reset

An operation-pause reset request can be issued using one of the following methods:

 Set I/O parameter No. 35 to “1” (Input selection function 005 = Operation-pause reset signal),

then input the ON edge to input port No. 5.

 Select [Operation-Pause Reset Request (L

screen.

 Select Ctl (controller operation) and RAct (operation-pause reset request) on the mode selection

screen of the teaching pendant.

2. Cases where an operation-pause reset request is required

An operation-pause reset request is required in any of the following cases:

 The automatic operation was stopped using the deadman switch when other parameter No. 9

was set to “2” (Deadman-switch recovery type = Continued operation) (only during automatic operation)  Recovery (reset of operation pause) after the stop is reset.

 An emergency stop was actuated during automatic operation when other parameter No. 10 was

set to “2” (Emergency-stop recovery type = Continued operation) (only during automatic operation)  Recovery (reset of operation pause) after the emergency stop is reset.

 The safety gate was opened during automatic operation when other parameter No. 11 was set to

“2” (Safety-gate open recovery type = Continued operation) (only during automatic operation)  Recovery (reset of operation pause) after the safety gate is closed.

 An OFF-level input signal was received by input port No. 6 when I/O parameter No. 36 was set

to”1” (Input selection function 006 = Operation-pause signal)  Recovery (reset of operation pause) after an ON-level input signal is received by input port No. 6.

* If the case in 2 of (1) and any of the cases in 2 of (2) are present at the same time, a drive-source

recovery request must be issued first, followed by an operation-pause reset request.

)] from the [Controller (C)] menu on the PC software

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

[1] Drive-source cutoff reset after control power ON

Power ON

Control power (AC)

External input for drive-source cutoff (Emergency stop switch, etc.)

The emergency stop switch is not ON.

System I/O RDY OUT

Drive-source cutoff/reset

Be sure to reset within 200 ms.

Servo ON command

Provide at least 1 sec.

[2] Emergency stop switch/safety gate/deadman switch input and drive-source cutoff/reset

Control power (AC)

Cut off Reset

External input for drive-source cutoff (Emergency stop switch, etc.)

System I/O RDY OUT

If the drive source is cut off and the cutoff is reset repeatedly, provide an interval of at least 5 sec.

Drive-source cutoff/reset

Within 200 ms

Be sure to reset within 200 ms.

Servo ON command

Provide at least 1 sec.

The RDY OUT contacts do not open even when the drive source is cut off.

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

[3] Power ON with drive-source cutoff input still effective

Power ON

Control power (AC)

External input for drive-source cutoff (Emergency stop switch, etc.)

System I/O RDY OUT

Reset

Although the RDY OUT contacts close, the internal status of the X-SEL controller will not change to “Drive-source cutoff reset” until the external input for drive-source cutoff is reset.

Drive-source cutoff/reset

Be sure to reset within 200 ms.

Servo ON command

Provide at least 1 sec.

[4] Occurrence of cold-start level alarm during operation

Control power (AC)

External input for drive-source cutoff (Emergency stop switch, etc.)

Occurrence of alarm

Occurrence of alarm Cold-start level

System I/O RDY OUT

The RDY OUT contacts break upon occurrence of a cold-start level error.

Drive-source cutoff/reset

Within 200 ms

* If the contact status of the system I/O “RDY OUT” is not provided to the external input for drive-source

cutoff, Error No. D6E, “Motor drive-source OFF error (MPONSTR-OFF)” may also occur when a coldstart level alarm occurs. However, this does not present any problem.

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

[5] Drive-source cutoff reset after control power ON

(When combined with the drive-source recovery request signal [I/O parameter No. 44 = 1])

Power ON

Control power (AC)

External input for drive-source cutoff (Emergency stop switch, etc.)

The emergency stop switch is not ON.

Drive-source recovery request signal (I/O port IN14)

System I/O RDY OUT

Drive-source cutoff/reset

Be sure to reset within 200 ms.

Servo ON command

Provide at least 1 sec.

* In the MANU mode, do not reset the drive-source cutoff while the PC connection cable is connected

and the PC software is not running. In the above condition, the drive-source recovery request cannot be accepted (PIO start is prohibited), and thus Error No. E6D, “Drive-source cutoff relay error” will occur if the drive-source cutoff is reset.

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

[6] Emergency stop switch/safety gate/deadman switch input and drive-source cutoff/reset

(When combined with the drive-source recovery request signal [I/O parameter No. 44 = 1])

Control power (AC)

Cut off

Reset

External input for drive-source cutoff (Emergency stop switch, etc.)

If the drive source is cut off and the cutoff is reset repeatedly, provide an interval of at least 5 sec.

Drive-source recovery request signal (I/O port IN14)

System I/O RDY OUT

The RDY OUT contacts do not open even when the drive source is cut off.

Drive-source cutoff/reset

Within 200 ms

Be sure to reset within 200 ms.

Servo ON command

Provide at least 1 sec.

* In the MANU mode, do not reset the drive-source cutoff while the PC connection cable is connected

and the PC software is not running. In the above condition, the drive-source recovery request cannot be accepted (PIO start is prohibited),

and thus Error No. E6D, “Drive-source cutoff relay error” will occur if the drive-source cutoff is reset.

If I/O Parameter No. 24 = 0, RDY Out turns OFF when the emergency stop turns ON. In such a case, wait till RDY OUT turns ON before inputting the drive recovery demand signal.

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

Part 3 Controller Data Structure

The controller data consists of parameters as well as position data and application programs used to implement SEL language.

X-SEL Controller Data Structure

Driver

Communication

Parameters

Parameters Parameters

The user must create position data and application programs. The parameters are predefined, but their settings can be changed in accordance with the user’s system. Refer to Appendix, “List of Parameters,” for details on the parameters.

Main

SEL language

Position

data

Application

programs

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

Chapter 1 How to Save Data

Since the X-SEL Controller uses flash memory, some data are saved by battery backup while others are saved in the flash memory.

When data is transferred from the PC software or teaching pendant to the controller, the data is only written to the temporary memory and will be erased once the controller is powered down or reset.

For important data, always write to the flash memory so that they will not be lost.

1. Factory Settings: When the System-Memory Backup Battery is Used

(Other parameter No. 20 = 2 (System-memory backup battery installed))

Data edited on the PC

or teaching pendant

Programs, parameters (content 1),

symbols

Slave cards,

parameters

(content 2)

*Encoder

parameters

Positions

SEL global

data (content

3), error lists

* The encoder parameters are stored in the EEPROM of the actuator’s encoder itself, not in the controller.

The encoder parameters will be read to the controller when the power is turned on or upon software reset.

Data will be retained while

the power is on and

cleared upon reset

Temporary

Transfer

memory

Temporary

memory

Temporary

memory

Transfer

Data will be retained even after the

Write to flash memory

Read for reset

Transfer

Read for reset

Transfer

Read for reset

Battery

backup

memory

Battery

backup

memory

power is turned off

Flash

memory

EEPROM

*Encoder

EEPROM

Write to flash

memory

Flash

memory

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

Since the programs, parameters and symbols are read from the flash memory at restart, the data in the temporary memory will remain the same as the original data before edit unless the edited data are written to the flash memory.

The controller always operates in accordance with the data in the temporary memory (inside the dotted line) (excluding the parameters).

Content 1: Parameters other than content 2 and encoder parameters Content 2: Parameters of driver card, I/O slot card (power system card) Content 3: Flags, variables, strings

2. When the System-Memory Backup Battery is Not Used

Other parameter No. 20 = 0 (System-memory backup battery not installed)

Data edited on the PC

or teaching pendant

Programs, parameters (content 1),

symbols, positions

Slave cards,

parameters

(content 2)

*Encoder

parameters

SEL global

data (content

3), error lists

Since the programs, parameters, symbols and positions are read from the flash memory at restart, the data in the temporary memory will remain the same as the original data before edit unless the edited data are written to the flash memory. The controller always operates in accordance with the data in the temporary memory (inside the dotted line) (excluding the parameters).

Note: SEL global data cannot be retained if the backup battery is not installed.

Data will be retained while

the power is on and

cleared upon reset

Transfer

Temporary

memory

Temporary

memory

Temporary

memory

Temporary

Transfer

memory

Data will be retained even after

the power is turned off

Write to flash memory

Flash

memory

Read for reset

Transfer

EEPROM

Read for reset

Transfer

*Encoder

EEPROM

Read for reset

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

3. Points to Note

Point to note when transferring data and writing to the flash memory

Never turn off the main power while data is being transferred or written to the flash memory. The data will be lost and the controller operation may be disabled.

Point to note when saving parameters to a file

The encoder parameters are stored in the EEPROM of the actuator’s encoder itself (unlike other parameters, they are not stored in the EEPROM of the controller). The encoder parameters will be read from the encoder’s EEPROM to the controller when the power is turned on or upon software reset.

Therefore, if the parameters are saved to a file after turning on the controller (or restarting it via a software reset) without an actuator (encoder) connected, the encoder parameters saved to the file will become invalid.

Point to note when transferring a parameter file to the controller

When a parameter file is transferred to the controller, the encoder parameters will be transferred to the EEPROM of the encoder (excluding manufacturing/function information).

Therefore, if the parameter file transferred to the controller has been read from a controller that was started without an actuator connected, invalid encoder parameters will be written to the encoder’s EEPROM (provided that an actuator is connected to the controller to which the file was transferred).

When saving the parameters to a file, do so with an actuator connected to the controller.

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

Chapter 2 X-SEL Language Data

1. Values and Symbols Used in SEL Language

1-1 List of Values and Symbols Used

The various functions required in a program are represented by values and symbols.

Function Global range Local range Remarks

Input port 000 ~ 299 (300)

Output port 300 ~ 599 (300)

Flag 600 ~ 899 (300) 900 ~ 999 (100)

Variable (integer)

Variable (real)

200 ~ 299 (100)

1200 ~ 1299 (100)

300 ~ 399 (100)

1300 ~ 1399 (100)

String 300 ~ 999 (700) 1 ~ 299 (299)

Tag number 1 ~ 99 (99)

Subroutine number 1 ~ 99 (99)

Zone number 1 ~ 4 (4)

Pallet number 1 ~ 10 (10)

Axis number 1 ~ 4 (4)

Axis pattern 0 ~ 1111

Position number 1 ~ 3000 (3000)

Program number 1 ~ 64 (64)

Step number 1 ~ 6000 (6000)

Task level NORMAL/HIGH (2)

SIO channel number

1 ~ 1 (1) (Also used for

TP/PC)

Wait timer 1

1-shot pulse timer

Ladder timer Local flag (100)

Virtual input port (SEL

system  SEL user

7000 ~ 7299 (300)

program)

Virtual output port (SEL

user program  SEL

7300 ~ 7599 (300)

system)

Number of symbol

definitions

Number of times symbol

can be used in commands

Caution

5000 (including literals)

Used in common from

any program.

 Variables 99 and 199 are special variables this system uses in operations.

Avoid using these two variables for general purposes.

 The values in the table represent ranges that can be processed by software.

Items that require physical devices, such as I/O ports and functions relating

1000

Referenced separately in each program. Cleared when the program is started.

to axis number and SIO, will be determined by possible combinations and models of commercial boards, etc., available for each device application.

1 ~ 99 (99)

1001 ~ 1099 (99)

100 ~ 199 (100)

1100 ~ 1199 (99)

16 (Number of timers

that can be operated

simultaneously)

Varies depending on the function. Varies depending on the function.

99 is used for IN, INB, OUT, OUTB, etc. 199 is used for PPUT, PGET, PARG, etc.

Varies depending on the function.

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

 The variables and flags in the global range will be retained even after the controller power is turned off.

(When other parameter No. 20 is set to “2.” Refer to Chapter 1, “How to Save Data,” of Part 3.)

 The variables and flags in the local range will be cleared when the program is started.

 Ranges of values that can be used in SEL language

Integers and real numbers can be used. However, pay due attention to the following limitations:

(1) Numeric data

The X-SEL Controller can handle values of maximum eight digits including a sign and a decimal point. Integer: -9,999,999 to 99,999,999 Real number: Maximum eight digits including a sign and decimal point, regardless of the size of value Example) 999999.9, 0.123456, -0.12345 If a floating point is used in operations, the number of valid digits will be limited to seven. Also note that operations using a floating point are subject to error.

(2) Position data

The input range of position data consists of four integer digits and three decimal digits. –9999.999 to 9999.999 (The maximum value varies depending on the actuator model.) If position data are used in internal operations as numeric data (repeated multiplications and divisions), the precision of the last digit may decrease.

Consider the above limitations fully when using values. Particularly when the CPEQ command is used in a comparison operation using real numbers, a match will rarely result. In this case, the CPLE or CPGE command that looks at the magnitude relationship of two terms must be used.

1-2 I/O Ports

(1) Input

ports

Used as input ports for limit switches, sensor switches, etc.

Input number assignment

000 to 031 (standard)

(2) Output ports

Used as various output ports.

Output number assignment

300 to 315 (standard)

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

1-3 Virtual I/O Ports

Virtual input ports

(1)

Port No. Function

7000 Always OFF 7001 Always ON 7002 Voltage low warning for system-memory backup battery 7003 Abnormal voltage of system-memory backup battery 7004 (For future extension = Use strictly prohibited) 7005 (For future extension = Use strictly prohibited) 7006 Top-level system error = Message level error is present 7007 Top-level system error = Operation-cancellation level error is present 7008 Top-level system error = Cold-start level error is present 7009 (For future extension = Use strictly prohibited) 7010 Drive-source cutoff factor is present (including when waiting for cutoff reset input)

7011

7012

7013

7014 (For future extension = Use strictly prohibited)

7015

7016

7017

7018

7019

7020

7021

7022

7023 ~ 7030 (For future extension = Use strictly prohibited)

7031

7032 Reading SIO CH2 (expanded SIO)(reception ready) (main application versions 0.41 or later) 7033 Reading SIO CH3 (expanded SIO)(reception ready) (main application versions 0.41 or later) 7034 Reading SIO CH4 (expanded SIO)(reception ready) (main application versions 0.41 or later) 7035 Reading SIO CH5 (expanded SIO)(reception ready) (main application versions 0.41 or later) 7036 Reading SIO CH6 (expanded SIO)(reception ready) (main application versions 0.41 or later)

7037 Reading SIO CH7 (expanded SIO)(reception ready) (main application versions 0.41 or later) 7038 ~ 7040 (For future extension = Use strictly prohibited) 7041 ~ 7070 (For future extension = Use strictly prohibited)

7071

7072 7073 ~ 7100

7101 Running program No. 01 (including during pause)

~ ~

7164 Running program No. 64 (including during pause) 7165 ~ 7299 (For future extension = Use strictly prohibited)

Latch signal indicating that all-operation-cancellation factor is present (latch signal for recognizing 1-shot cancellation factor; latch is cancelled by 7300-ON) All-operation-pause factor is present (including when waiting for restart switch signal) (Valid only during automatic operation recognition) All-servo-axis-interlock factor is present (all-operation-pause factor + interlock input-port factor)

Voltage low warning for axis-1 absolute-data backup battery (main application version 0.28 or later) Abnormal voltage of axis-1 absolute-data backup battery (latched until power-on reset or software reset) (main application version 0.28 or later) Voltage low warning for axis-2 absolute-data backup battery (main application version 0.28 or later) Abnormal voltage of axis-2 absolute-data backup battery (latched until power-on reset or software reset) (main application version 0.28 or later) Voltage low warning for axis-3 absolute-data backup battery (main application version 0.28 or later) Abnormal voltage of axis-3 absolute-data backup battery (latched until power-on reset or software reset) (main application version 0.28 or later) Voltage low warning for axis-4 absolute-data backup battery (main application version 0.28 or later) Abnormal voltage of axis-4 absolute-data backup battery (latched until power-on reset or software reset) (main application version 0.28 or later)

Reading SIO CH1 (standard SIO) (reception ready) (*OFF if used for PC/TP connection) (main application versions 0.41 or later)

AUTO mode (main application version 0.87 or later) Auto operation in progress (main application version 0.87 or later) (For future extension = Use strictly prohibited.)

INTELLIGENT ACTUATOR

(2) Virtual output ports

Port No. Function

Latch cancellation output for a latch signal indicating that all-operation-cancellation factor

7300

is present (7011) (latch is cancelled only when operation-cancellation factor is no longer present) (7300 will be turned OFF following an attempt to cancel latch.)

7301 ~ 7380 (For future extension = Use strictly prohibited)

7381 ~ 7399 (For future extension = Use strictly prohibited)

7400 ~ 7599 (For future extension = Use strictly prohibited)

Part 3 Controller Data Structure

INTELLIGENT ACTUATOR

1-4 Flags

Contrary to its co are used to set or reset data. They correspond to “auxiliary relays” in a sequencer.

Flags are divided into global flags (Nos. 600 to 899) that can be used in all programs, and local flags (Nos. 900 to 999) that can be used only in each program.

Global flags will be retained (backed up by battery) even after the power is turned off.

Local flags will be cleared when the power is turned off.

mmon meaning, the term “flag” as used in programming means “memory.” Flags

Flag number 600 ~ 899 Can be used in all programs “Global flags”

Flag number 900 ~ 999 Used only in each program “Local flags”

Program 1 Program n

BTON 600

Turn on flag 600

(Like this, global flags can be used to exchange signals.)

WTON 600

Wait for flag 600 to turn ON

BTON 900 BTON 900

(Although the number is the same, these are local flags and can exist only in their respective programs.)

INTELLIGENT ACTUATOR

1-5 Variables

Meaning of variable

(1)

“Variable” is a technical term used in software programming. Simply put, it means “a box in which a value is put.” Variables can be used in many ways, such as putting in or taking out a value and performing addition or subtraction.

Command Operand 1 Operand 2

Part 3 Controller Data Structure

A variable can be used in many ways, such as:

Putting in a value (1234),

Taking out a value (456), or

Adding a value (+1).

Variable

box 1

ADD 1 1

If this command is applied to variable box 1, which already contains 2, then 1 will be added to the current value and 3 will result.

1 is added.

Variable

box 1

(Already contains 2)

INTELLIGENT ACTUATOR

(2) Types of variables

Variables are classified into two types, as follows:

1. Integer variables These variables cannot handle decimal places. [Example] 1234

Integer variable number

Real variable number

Caution

2. Real variables Actual values. These variables can handle decimal places. [Example] 1234.567

Caution

Part 3 Controller Data Structure

Integer variable box

Variable

box 1

1 2 3 4

200 ~ 299

1200 ~ 1299

1 ~ 99

1001 ~ 1099

Can be used in all programs “Global integer variables”

Used only in each program “Local integer variables”

Integer 99 is a special register this system uses in integer operations. Any value in the range from –9,999,999 to 99,999,999 can be input in programs.

(Decimal point)

Real ＶＡＲＩＡＢＬＥ

box

Variable

box 1

1234.567

300 ~ 399

1300 ~ 1399

100 ~ 199

1100 ~ 1199

Can be used in all programs “Global real variables”

Used only in each program “Local real variables”

Real number 199 is a special register this system uses in realnumber operations. Any value in the range from –99,999.9 to 999,999.9 (eight digits including a sign) can be input in programs.

IAI America XSEL-KET User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Please Read Before Use

CAUTION

Operator Calls Regarding Low Battery Voltage

CE Marking

Table of Contents

Safety Guide

Prohibited Handling of Cables

Introduction

Part 1 Installation

Chapter 1 Safety Precautions

Chapter 2 Warranty Period and Scope of Warranty

Chapter 3 Installation Environment and Noise Measures

Chapter 4 Name and Function of Each Part

1. Front View of Controller

2. Explanation of Codes Displayed on the Panel Window

2-1. Application

2-2. Core

Chapter 5 Specifications

1. Controller Specifications

2. External I/O Specifications

2-1. NPN Specification

2-2. PNP Specification

3. Power-Source Capacity and Heat Output of the Controller

4. External Dimensions

Chapter 6 System Setup

1. Connection Method of Controller and Actuator (Standard Specification)

2. Drive-Power Cutoff Control Circuit

2.1 System I/O Connector

2.2 Relay Box

2.3 Drive-Power Cutoff Control Circuit

Chapter 7 How to Perform An Absolute Encoder Reset

Chapter 8 Maintenance

Part 2 Operation

Chapter 1 Operation

1. Starting a Program by Auto-Start via Parameter Setting

2. Starting via External Signal Selection

3. Drive-Source Recovery Request and Operation-Pause Reset Request

Part 3 Controller Data Structure

Chapter 1 How to Save Data

1. Factory Settings: When the System-Memory Backup Battery is Used

2. When the System-Memory Backup Battery is Not Used

3. Points to Note

Chapter 2 X-SEL Language Data

1. Values and Symbols Used in SEL Language

1-1 List of Values and Symbols Used

1-2 I/O Ports

1-3 Virtual I/O Ports

1-4 Flags

1-5 Variables