Global Specification Controller
X-SEL-KT
X-SEL-KT
X-SEL-KT
X-SEL-KT
X-SEL-KT
XSEL-KT/KET
XSEL-KT/KET
XSEL-KT/KET
XSEL-KT/KET
Eighth Edition
Tenth 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
INTELLIGENT ACTUATOR
Table of Contents
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
INTELLIGENT ACTUATOR
Reciprocating Operation between Two Points........................................................................ 296
5.
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
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
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.
● 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.
● 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
n
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
KT
Global
specification
KET
CE-compliant
global
specification
Number of
axes
1
(1 axis)
2
(2 axis)
3
(3 axis)
4
(4 axis)
Motor
wattage
20
(20 W)
30D
(DS type,
30 W)
30R
(RS type,
30 W)
60
(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
A
I
Brake
Blank
(Without
brake)
B
(With brake)
(With creep
Encoder
(Incremental)
(Absolute)
Creep
sensor
Blank
(Witho ut
creep
sensor)
C
sensor)
(Axis 2)
Home
sensor
(LS)
Blank
(Without
home
sensor)
L
(With h ome
sensor)
Synchro
specification
Blank
(Witho ut
synchro)
M
(Master axis
specification)
S
(Slave axis
specification)
Network
(dedicated
slot)
(None)
Standard I/O
(Slot 1)
N1
Expansion PIO
32 inputs/16
outputs
NPN board
P1
Expansion PIO
32 inputs/16
outputs
PNP board
DV
DeviceNet 256/256
board
CC
CC-Link
256/256 board
PR
ProfiBus
256/256 board)
ET
Ethernet
ata communicatio
board
Slot 2
E
(not used)
C
CC-Link
connection
16/16 board
N1
Expansion I/O
32 inputs/
16 outputs
NPN board
N2
Expansion I/O
16 inputs/
32 outputs
NPN board
N3
Expansion I/O
48 inputs/
48 outputs
NPN board
P1
Expansion I/O
32 inputs/
16 outputs
PNP board
P2
Expansion I/O
16 inputs/
32 outputs
PNP board
P3
Multi-point I/O
PNP 48/48
SA
Expansion SIO
Type A
SB
Expansion SIO
Type B
SC
Expansion SIO
Type C
Expansion I/O slot
Slot 3 Slo t 4
E
(not used)
C
CC-Link
connection
16/16 board
N1
Expansion I/O
32 inputs/
16 outputs
NPN board
N2
Expansion I/O
16 inputs/
32 outputs
NPN board
N3
Expansion I/O
48 inputs/
48 outputs
NPN board
P1
Expansion I/O
32 inputs/
16 outputs
PNP board
P2
Expansion I/O
16 inputs/
32 outputs
PNP board
P3
Multi-point I/O
PNP 48/48
SA
Expansion SIO
Type A
SB
Expansion SIO
Type B
SC
Expansion SIO
Type C
E
(not used)
C
CC-Link
connection
16/16 board
N1
Expansion I/O
32 inputs/
16 outputs
NPN board
N2
Expansion I/O
16 inputs/
32 outputs
NPN board
N3
Expansion I/O
48 inputs/
48 outputs
NPN board
P1
Expansion I/O
32 inputs/
16 outputs
PNP board
P2
Expansion I/O
16 inputs/
32 outputs
PNP board
P3
Multi-point I/O
PNP 48/48
SA
Expansion SIO
Type A
SB
Expansion SIO
Ty
pe B
SC
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
1
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.
2
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.
3
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
4
Part 1 Installation
INTELLIGENT ACTUATOR
Chapter 3 Installation Environment and Noise Measures
1. Installation Environment
*1
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.
or
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).
5
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.
2
(#AWG17) or more, which should not be smaller
X-SEL controller
C.POWER M.POWER
N
L
N
L
Noise
filter
Accessory
6
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
N
L
PE
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.
7
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
CR
+24 V
0 V
100 VAC
CR
SOL
Surge absorber
0 V
Solenoid valve
8
Part 1 Installation
INTELLIGENT ACTUATOR
Chapter 4 Name and Function of Each Part
1. Front View of Controller
4-axis type
(5)
(6)
RB
CONTROLLER
M4
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
TP
HOST
(19)
(15)
(16)
(17)
9
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
10
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
11
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