X-SEL Controller
JX/KX Type
Operation Manual
Seventh Edition
and 60.
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
For retention of encoder rotation data.
Each battery is of no n-rechargeable type, so u nles s t h e bat tery is replaced befor e its l if e is f ul ly 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.
Output port No. 313 is assigned as the output of voltage low warning for system-memory backup battery.
Output port No. 314 is assigned as the output of voltage low warning for absolute-encoder backup
battery.
These warning output functions are available on controllers shipped on or after May 16, 2005. On
controllers shipped before this date, the functions can be enabled by setting “1” in I/O parameter Nos. 59
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.
Danger
Safety Precautions
Please read the information in “Safety Precautions” carefully before selecting a model and using the
product.
The precautions described below are designed to help you use the product safely and avoid bodily injury
and/or property damage.
Directions are classified as “danger,” “warning,” “caution” and “note,” according to the degree of
risk.
Danger
Failure to observe the instruction will res ult in an imminent danger leading to
death or serious injury.
Warning
Caution
Note
Failure to observe the instruction may result in death or serious injury.
Failure to observe the instruction may result in injury or property damage.
The user should take heed of this information to ensure the proper use of the
product, although failure to do so will not result in injury.
This product has been designed and manufactured as a component for use in general industrial
machinery.
Devices must be selected and handled by a system designer, personnel in charge of the actual operation
using the product or similar individual with sufficient knowledge and experience, who has read both the
catalog and operation manual (particularly the “Safety Precautions” section). Mishandling of the product
poses a risk.
Please read the operation manuals for all devices, including the main unit and controller.
It is the user’s respo ns ib il ity to v er ify and determine the c ompatibility of this pr odu c t with the us er’s system,
and to use them properly.
After reading the catalog, operation manual and other materials, be sure to keep them in a convenient
place easily accessible to the personnel using this product.
When transferring or loaning this product to a third party, be sure to attach the catalog, operation manual
and other materials in a conspicuous location on the product, so that the new owner or user can
understand its safe and proper use.
The danger, warning and caution directions in this “Safety Precauti ons” do not cover every possible case.
Please read the catalog and operation manual for the given device, particularly for descriptions unique to it,
to ensure its safe and proper handling.
[General]
Do not use this product for 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
3. Important safety parts of machinery
This product has not been planned or designed for applications requiring high levels of safety. Use
of this product in such applications may jeopardize the safety of human life. The warranty covers
only the product as it is delivered.
Warning
[Installation]
Do not use this product in a place exposed to ignitable, inflammable or explosive substances. The
product may ignite, burn or explode.
Avoid using the product in a place where the main unit or controller may come in contact with water or
oil droplets.
Never cut and/or reconnect the cables supplied with the product for the purpose of extending or
shortening the cable length. Doing so may result in fire.
[Operation]
If you are using a pace maker or other mechanical implant, do not come within one meter of the
product. The strong magnetic field generated by the product may cause the pace maker, etc., to
malfunction.
Do not pour water onto the product. Spraying water over the product, washing it with water or using it
in water may cause the product to malfunction, resulting in injury, electric shock, fire, etc.
[Maintenance, Inspection, Repair]
Never modify the product. Unauthorized modification may cause the product to malfunction, resulting in
injury, electric shock, fire, etc.
Do not disassemble and reassemble the components relating to the basic structure of the product or its
performance and function. Doing so may result in injury, electric shock, fire, etc.
[General]
Do not use the product outside the specifications. Using the product outside the specifications may
cause it to fail, stop functioning or sustain damage. It may also significantly reduce the service life of
the product. In particular, observe the maximum loading capacity and speed.
[Installation]
If the machine will stop in the case of system problem such as emergency stop or power failure, design
a safety circuit or other device that will prevent equipment damage or injury.
Be sure to provide Class D grounding for the controller and actuator (formerly Class 3 grounding:
Grounding resistance at 100 Ω or less). Leakage current may cause electric shock or malfunction.
Before supplying power to and operating the product, always check the operation area of the
equipment to ensure safety. Supplying power to the product carelessly may cause electric shock or
injury due to contact with the moving parts.
Wire the product correctly by referring to the operation manual. Securely connect the cables and
connectors so that they will not be disconnected or come loose. Failure to do so may cause the
product to malfunction or cause fire.
[Operation]
Do not touch the terminal block or various switches while the power is supplied to the product. Failure
to observe this instruction may result in electric shock or malfunction.
Before operating the moving parts of the product by hand (for the purpose of manual positioning, etc.),
confirm that the servo is turned off (using the teaching pendant). Failure to observe this instruction may
result in injury.
The cables supplied with the product are flexible, but they are not robot cables. Do not store the cables
in a movable cable duct (cable track , etc.) that bends more than the specified bending radius.
Do not scratch the cables. Scratching, forcibly bending, pulling, winding, crushing with heavy object or
pinching a cable may cause it to leak current or lose continuity, resulting in fire, electric shock,
malfunction, etc.
Caution
If the product is generating heat, smoke or a strange smell, turn off the power immediately. Continuing
to use the product may result in product damage or fire.
If any of the internal protective devices (alarms) of the product has actuated, turn off the power
immediately. Continuing to use the product may result in product damage or injury due to malfunction.
Once the power supply is cut off, investigate and remove the cause and then turn on the power again.
If the LEDs on the product do not illuminate after turning on the power, turn off the power immediately.
The protective device (fuse, etc.) on the live side may remain active. Request repair to the IAI sales
office from which you purchased the product.
[Maintenance, Inspection, Repair]
Before conducting maintenance/inspection, parts replacement or other operations on the product,
completely shut down the power supply. At this time, take the following measures:
1. Display a sign that reads, “WORK IN PROGRESS. DO NOT TURN ON POWER” at a conspicuous
place, in order to prevent a person other than the operator from accidentally turning on the power
while the operation is working.
2. When two or more operators are to perform maintenance/inspection together, always call out every
time the power is turned on/off or an axis is moved in order to ensure safety.
[Disposal]
Do not throw the product into fire. The product may burst or generate toxic gases.
[Installation]
Do not use the product under direct sunlight (UV ray), in a place exposed to dust, salt or iron powder,
in a humid place, or in an atmosphere of organic solvent, phosphate-ester machine oil, sulfur dioxide
gas, chlorine gas, acids, etc. The product may lose its function over a short period of time, or exhibit a
sudden drop in performance or its service life may be significantly reduced.
Do not use the product in an atmosphere of corrosive gases (sulfuric acid or hydrochloric acid),
inflammable gases or ign ita ble liquids. Rust may form and reduce the structural strength or the motor
may ignite or explode.
When using the product in any of the places specified below, provide a sufficient shield. Failure to do
so may result in malfunction:
1. Place where large current or high magnetic field is present
2. Place where welding or other operations are performed that cause arc discharge
3. Place subject to electrostatic noise
4. Place with potential exposure to radiation
Install the main unit and controller in a place subject to as little dust as possible. Installing them in a
dusty place may result in malfunction.
Do not install the product in a place subject to large vibration or impact (4.9 m/s2 or more). Doing so
may result in the malfunctioning of the product.
Provide an emergency-stop device in a readily accessible position so the device can be actuated
immediately upon occurrence of a dangerous situation during operation. Lack of such device in an
appropriate position may result in injury.
Provide sufficient maintenance space when installing the product. Routine inspection and maintenance
cannot be performed without sufficient space, which will eventually cause the equipment to stop or the
product to sustain damage.
Do not hold the moving parts of the product or its cables during installation. It may result in injury.
Always use IAI’s genuine cables for connection between the controller and the actuator. Also use IAI’s
genuine products for the key component units such as the actuator, controller and teaching pendant.
Note
Others
Before installing or adjusting the product or performing other operations on the product, display a sign
that reads, “WORK IN PROGRESS. DO NOT TURN ON POWER.” If the power is turned on
inadvertently, injury may result due to electric shock or sudden activation of an actuator.
[Operation]
Turn on the power to individual equipment one by one, starting from the equipment at the highest level
in the system hierarchy. Failure to do so may cause the product to start suddenly, resulting in injury or
product damage.
Do not insert a finger or object in the openings in the product. It may cause fire, electric shock or injury.
Do not bring a floppy disk or other magnetic media within one meter of the product. The magnetic field
generated by the magnet may destroy the data in the floppy disk, etc.
[Maintenance, Inspection, Repair]
When the power was turned off and the cover was opened to replace the battery, etc., do not touch the
condenser terminal in the product immediately after the power was turned off (within 30 seconds).
Residual voltage may cause electric shock.
Do not touch the terminals when performing an insulation resistance test. Electric shock may result.
(Do not perform any withstand voltage tes t, since the pr oduct uses DC vol tag e.)
[General]
If you are planning to use the product under a condition or environment not specified in the catalogs
and operation manual, or in an application requiring strict safety such as aircraft facility, combustion
system, entertainment machine, safety device or other equipment having significant impact on human
life or property, design operating ranges with sufficient margins from the ratings and design
specifications or provide sufficient safety measures such as fail-safes. Whatever you do, always
consult IAI’s sales representative.
[Installation]
Do not place objects around the controller that will block airflows. Insufficient ventilation may damage
the controller.
Do not configure a control circuit that will cause the load to drop in case of power failure. Configure a
control circuit that will prevent the table or load from dropping when the power to the machine is cut off
or an emergency stop is actuated.
[Installation, Operation, Maintenance]
When handling the product, wear protective gloves, protective goggles, safety shoes or other
necessary gear to ensure safety.
[Disposal]
When the product becomes no longer usable or necess ar y, dispose of it proper l y as an indus tria l was te.
IAI shall not be liable whatsoever for any loss or damage ari si ng fro m a fail ure t o
observe the items specified in “Safety Precautions.”
Caution
1. Do not let the cable flex at a single point.
4. Do not let the cable receive a turning force at a
5. When fixing the cable, provide a moderate slack
Steel band
Bundle loosely.
Do not use a spiral tube
Prohibited Handling of Cables
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 O bse r ved!)
2. Do not let the cable bend, kink or twist.
single point.
Use a curly
cable.
(piano wire)
3. Do not pull the cable with a strong force.
and do not tension it too tight.
6. Do not pinch, drop a heavy object onto or cut the
cable.
where the cable flexes
frequently.
8. Do not cause the cables to occupy more than
9. Do not lay signal lines together with circuit lines
Cable
Cable track
Power line
Signal lines (flat cable)
Duct
Cover
Protective layer
Signal line (copper + tin)
7. Do not let the cable got 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).
60% of the space in the cable track.
that create a strong electric field.
10. Always use a robot cable
if the cable is likely to flex significantly.
[Standard structure of cable]
The standard structure of
cable will vary depending on
the manufacturer and t ype of
cable.
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 recom mend that a robot cable
offering significantly higher flexibility be used
in this type of application.
Caution
Caution
Before Use
Caution
1. Be sure to read this operation manual to ensure the proper use of this product.
2. Unauthorized use or reproduction of a part or all of this operation manual is prohibited.
3. Always handle or operate the product in manners specified in this operation manual, by assuming that
whatever is not specified herein is not feasible. The warranty does not cover any defect arising from a
handling or operation not specif ied in this opera tio n manua l.
4. The information contained in this operation manual is subject to change without notice for the purpose
of modification and improvement.
* If you have purchased PC software:
Always back up the parameters after installing the product or changing the parameter settings.
5. The specifications in this manual may not apply to a custom product.
Action to Be Taken in Case of Emergency
If this product is found to be in a dangerous condition, immediately turn off all power switches of the
main unit and connected equipment or immediately disconnect all power cables from the outlets.
(“Dangerous condition” refers to a situation where the product is generating abnormal heat or smoke or
has ignited and a fire or danger to human health is anticipated.)
Table of Contents
Table of Contents
Introduction ...................................................................................................................... 1
Part 1 Installation ........................................................................................................ 2
Chapter 1 Safety Precautions ............................................................................................................... 2
Chapter 2 Warranty Period and Scope of Warranty ............................................................................. 3
Chapter 3 Installation Environment and Noise Measures .................................................................... 4
Chapter 4 Name and Function of Each Part ......................................................................................... 8
1. Front View of Controller .......................................................................................................... 8
2. Explanation of Codes Displayed on the Panel Window ....................................................... 18
Chapter 5 Specifications ..................................................................................................................... 20
1. Controller Specifications ....................................................................................................... 20
2. External I/O Specifications ................................................................................................... 22
3. Power-Source Capacity and Heat Output of the Controller ................................................. 26
4. External Dimensions ............................................................................................................ 27
Chapter 6 System Setup ..................................................................................................................... 29
1. Connection Method of Controller and Robot (KX Type) ....................................................... 29
2. I/O Connection Diagram ....................................................................................................... 31
3. I/O Flat Cable ....................................................................................................................... 33
Chapter 7 Maintenance ...................................................................................................................... 34
Part 2 Operation ........................................................................................................ 41
Chapter 1 Operation ........................................................................................................................... 41
1. Starting a Program by Auto-Start via Parameter Setting ...................................................... 42
2. Starting via External Signal Selection .................................................................................. 43
3. Drive-Source Recovery Request and Operation-Pause Reset Request ............................. 45
Part 3 Controller Data Structure ................................................................................ 46
Chapter 1 How to Save Data .............................................................................................................. 47
1. Factory Settings: When the System-Memory Backup Battery is Used ................................ 47
2. When the System-Memory Backup Battery is Not Used ..................................................... 48
3. Points to Note ....................................................................................................................... 49
Chapter 2 X-SEL Language Data (IX-Series Controller) .................................................................... 50
1. Values and Symbols Used in SEL Language ....................................................................... 50
2. Position Part ......................................................................................................................... 63
3. Command Part ..................................................................................................................... 64
Table of Contents
Part 4 Commands ..................................................................................................... 66
Chapter 1 List of SEL Language Command Codes ........................................................................... 66
Chapter 2 Explanation of Commands ................................................................................................. 78
1. Commands ........................................................................................................................... 78
Chapter 3 Key Characteristics of Horizontal Articulated Robot Operation ....................................... 234
1. CP Operation and PTP Operation ...................................................................................... 234
2. Arm System ........................................................................................................................ 237
3. Coordinate System ............................................................................................................. 245
4. Simple Interference Check Zone ........................................................................................ 255
5. Soft Limits ........................................................................................................................... 258
Chapter 4 Key Characteristics of Actuator Control Commands and Points to Note ......................... 262
1. Continuous Movement Commands
[P A TH, PSPL, CIR2, ARC2, CIRS, ARCS, ARCD, ARCC, CIR, ARC] ............................... 262
2. PATH/PSPL Commands ..................................................................................................... 264
3. CIR/ARC Commands ......................................................................................................... 264
4. CIR2/ARC2/ARCD/ARCC Commands ............................................................................... 264
Chapter 5 Palletizing Function .......................................................................................................... 265
1. How to Use ......................................................................................................................... 265
2. Palletizing Setting ............................................................................................................... 265
3. Palletizing Calculation ........................................................................................................ 271
4. Palletizing Movement ......................................................................................................... 272
5. Program Examples ............................................................................................................. 274
Chapter 6 Pseudo-Ladder Task ........................................................................................................ 278
1. Basic Frame ....................................................................................................................... 278
2. Ladder Statement Field ...................................................................................................... 279
3. Points to Note ..................................................................................................................... 279
4. Program Example ............................................................................................................... 280
Chapter 7 Multi-Tasking .................................................................................................................... 281
1. Difference from a Sequencer ............................................................................................. 281
2. Release of Emergency Stop ............................................................................................... 282
3. Program Switching ............................................................................................................. 283
Table of Contents
Appendix...................................................................................................................... 284
Expansion I/O Board (Optional)............................................................................................... 284
Expanded SIO Specification (Optional) ................................................................................... 285
List of Parameters ................................................................................................................... 291
1. I/O Parameters ................................................................................................................. 292
2. Parameters Common to All Axes ..................................................................................... 302
3. Axis-Specific Parameters ................................................................................................. 304
4. Driver Card Parameters ................................................................................................... 308
5. Encoder Parameters ........................................................................................................ 314
6. I/O-Slot Card Parameters ................................................................................................ 315
7. Other Parameters ............................................................................................................ 316
8. Manual Operation Types .................................................................................................. 321
9. Use Examples of Key Parameters ................................................................................... 322
Error Level Control .................................................................................................................. 326
Error List ................................................................................................................................ 328
Trouble Report Sheet .............................................................................................................. 356
1
Introduction
hours Stopped hours Operating
hours Operating
+
Model
Series
Controller
IX actuator
Standard I/O
specification
Slot 1
Slot 2
Slot 3
Slot 4
Expanded I/O specification (Note 1)
I/O flat cable
Supply
(Compact type)
purpose, global,
(Standard type)
No cable
Introduction
Thank you for purchasing the X-SEL IX-Series 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 IX-Series Controller you have purchased is a new-generation controller that uses an advanced version of
the proven, innovative “SEL” language to perform a range of high functions such as multi-tasking, sequencerless operation, palletizing function and pseudo-sequence function.
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 accuracy. The duty is calculated by the formula below:
Duty (%) =
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.
Do not move the robot arms while the main controller power is still starting. An error, such as “C6C:
Movement error during absolute data acquisition” or “C70: Absolute coordinate non-confirmation error,” may
generate.
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.
X 100
Example of model designation
Model table
type
(Dustproof/splash-proof type)
(General-
purpose type)
(General-
CE-compliant
type)
(Wall mount inverse type)
(Ceiling mount inverse type)
type
(High-speed type)
(Wall mount type)
(Ceiling mount type)
(Cleanroom type)
N1
[32 inputs/16 outputs
NPN board]
N3 (Note 3)
[48 inputs/48 outputs
NPN board]
P1
[32 inputs/16 outputs
PNP board]
P3 (Note 3)
[48 inputs/48 outputs
PNP board]
DV
[DeviceNet
256/256 board]
CC
[CC-Link
256/256 board]
PR
[ProfiBus
256/256 board]
ET
[Ethernet
Data communication
board]
E
(Not used)
C (Note 4)
[CC-Link
16/16 board]
N1
[Expanded I/O
NPN32/16]
N2
[Expanded I/O
NPN16/32]
N3 (Note 4)
[Multi-point I/O
NPN48/48]
P1
[Expanded I/O
PNP32/16]
P2
[Expanded I/O
PNP16/32]
P3 (Note 4)
[Multi-point I/O
PNP48/48]
SA (Note 4)
[Expanded SIO
Type A]
SB (Note 4)
[Expanded SIO
Type B]
SC (Note 4)
[Expanded SIO
Type C ]
E
(Not used)
C (Note 4)
[CC-Link
16/16 board]
N1
[Expanded I/O
NPN32/16]
N2
[Expanded I/O
NPN16/32]
N3 (Note 4)
[Multi-point I/O
NPN48/48]
P1
[Expanded I/O
PNP32/16]
P2
[Expanded I/O
PNP16/32]
P3 (Note 4)
[Multi-point I/O
PNP48/48]
SA (Note 4)
[Expanded SIO
Type A]
SB (Note 4)
[Expanded SIO
Type B]
SC (Note 4)
[Expanded SIO
Type C ]
E
(Not used)
C (Note 4)
[CC-Link
16/16 board]
N1
[Expanded I/O
NPN32/16]
N2
[Expanded I/O
NPN16/32]
N3 (Note 4)
[Multi-point I/O
NPN48/48]
P1
[Expanded I/O
PNP32/16]
P2
[Expanded I/O
PNP16/32]
P3 (Note 4)
[Multi-point I/O
PNP48/48]
SA (Note 4)
[Expanded SIO
Type A]
SB (Note 4)
[Expanded SIO
Type B]
SC (Note 4)
[Expanded SIO
Type C ]
length
(Note 2)
voltage
200-V
specification
2
Caution
Part 1 Installation
Part 1 Installation
Chapter 1 Safety Precautions
This controller has been designed for use exclusively with IAI’s IX-Series Horizontal Articulated Robot,
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.
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. Always use the specified, genuine IAI cables for wiring between the controller and the actuator.
3. 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.
4. 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.
5. 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
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 trai nin g 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
24-VDC fan x 5 (compact type)
24-VDC fan x 6 (general-purpose type)
Part 1 Installation
Chapter 3 Installation Environment and Noise Measures
1. Installation Environment
(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 environm ent where it will not receive external vibration or impact.
(6) Prevent electrical noise from entering the controller or its cables.
Environmental Condition of Controller
Item Specification
Surrounding air temperature range
Forced air-cooling
Surrounding humidity range 30% ~ 85%
Storage temperature range
Dust protection structure IP10
Power-sour c e volta ge 100 to 115/200 to 230 VAC, single-phase
Operating power-source voltage
Rated operating power-source frequency 50 Hz/60 Hz
0°C ~ 40°C
-10°C ~ 65°C
±10%
2. Heat Radiation and Installation
Design the control panel size, controller layout and cooling method so that the ambient 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 a nd pro vide a m inimum 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 ambient temperature.
Provide a minimum clearance of 150 mm between the front side of the controller and a wall
(enclosure).
5
POWERRBM4 M3 M2 M1
PG1
TP
PG2 PG4
I/02 I/01
PG3
CODE
POWERRBM4 M3 M2 M1
PG1
TP
PG2 PG4
I/02 I/01
PG3
CODE
Robot specification
Model
Arm length 700/800 specification, high-speed specification
MXB-1220-33
Other types
MXB-1210-33
Airflow direct io n
Airflow
150 mm min.
150 mm min.
150 mm
200-VAC power source
Class D grounding
Noise
Part 1 Installation
Fan
min.
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 single-phase power source of 200 to 230 VAC.
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 a noise filter in the AC line to prevent the noise generating in the controller from traveling
through the power line to enter other unit.
(protective grounding)
Install the noise filter near the power connector on the X-SEL controller side.
Use of a noise filter by Densei-Lambda is recommended. The applicable noise filter model varies
depending on the robot specification, as shown below.
Recommended noise filter models (by Densei-Lambda)
2
(#AWG17) or more, which should not be smaller
filter
6
AC power source
Class D grounding
Metal enclosure
Surge absorber
ACIN
N
X-SEL
Other
X-SEL
Other
Do not use this method.
Part 1 Installation
[2] 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-eliminat ion grou ndi n g
L
PE
Connect the FG terminal
with the metal enclosure
using a cable of a
maximum allowable size
over the shortest distance.
Provide dedicated FG or PE grounding.
equipment
equipment
controller
controller
(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:
[1] AC solenoid valve, magnet switch, relay
Measure --- Install a surg e absor ber in parallel with the coil.
← 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
Diode
Controller
OUT
CR
+24 V
0 V
100 VAC
CR
0 V
Part 1 Installation
[2] 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.
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
COM
SOL
Surge absorber
Solenoid valve
8
External regenerative unit
Motor connector
Encoder
System I/O
I/O24V power
Panel window (Refer to
FG terminal
Fuse holder
AC input
When this LED is lit in red, a system clock error is present.
gency stop is actuated or CPU hardware error or
Chapter 4 Name and Function of Each Part
1. Front View of Controller
KX type (general-purpose type)
Applicable to robots of all strokes
Alarm and Other LED Indicators
[6] Driver status LEDs
[10] Panel window
4-digit, 7-segment LEDs: Refer to 2, “Explanation of Codes Displayed on the Panel Window.”
The following five LEDs are provided.
connector
connector
: When this LED is lit in orange, the driver is detecting an error.
: When this LED is lit in green, the servo is on and the motor is being driven.
: When this LED is lit in orange, the absolute-encoder b ac k up batter y voltage is lo w.
When this LED is lit in red, a power-system hardware error is present.
When this LED is lit in red, an emer
power-system hardware error is present.
When this LED is lit in red, a CPU alarm (system-down level error) or CPU
hardware error is present.
When this LED is lit in green, the CPU is ready (program operation is enabled).
Driver stat us LEDs
(Refer to the
explanation below.)
connector
Standard I/O
connector
connector
Part 1 Installation
connector
Expansion I/O
connectors
the explanation below.)
Mode switch
Teaching connector
PC connector
9
External regenerative
Motor connector
Encoder
AC input
Driver stat us LEDs
Standard I/O
Expansion I/O
Panel window (Refer to
When this LED is lit in red, an emergency stop is actuated or CPU hardware error or
JX type (compact type)
Applicable to robots of 250/350 strokes
connector
the explanation below.)
connector
unit connector
System I/O connector
System-operation setting switches
Boot-target setting switch
Mode switch
Teaching connector
FG terminal
(Refer to the
explanation below.)
connectors
connector
Alarm and Other LED Indicators
[6] Driver status LEDs
: When this LED is lit in orange, the driver is detecting an error.
: When this LED is lit in green, the servo is on and the motor is being driven.
: When this LED is lit in orange, the absolute-encoder b ac k up batter y voltage is lo w.
[10] Panel window
4-digit, 7-segment LEDs: Refer to 2, “Explanation of Codes Displayed on the Panel Window.”
The following five LEDs are provided.
When this LED is lit in red, a system clock err or is pres ent.
When this LED is lit in red, a power-system hardware error is present.
power-system hardware error is present.
When this LED is lit in red, a CPU alarm (system-down level error) or CPU
hardware error is present.
When this LED is lit in green, the CPU is ready (program operation is enabled).
Part 1 Installation
10
[1] FG terminal
This terminal is used to ground FG on the enclosure. With a general-
Be sure to ground the FG terminal.
[2] Fuse holder (general-
This half-cut fuse holder is used to protect overcurrent in the AC input
and uses a slow-blow fuse specified by IAI.
Melting
characteristics
[3] AC input connector
200-VAC, single-phase input connector.
3-pin, 2-piece connector
Terminal
*
Part 1 Installation
purpose type only)
purpose type, the enclosure is connected to PE in the AC input part inside
the controller.
With a compact type, FG and PE are not connected 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
part. It prevents inflow of abnormal current generated by ground fault, etc.,
Overview of Fuse Holder Specifications
Item Description
Holder F-22001-A1 by Sato Parts
Fuse type TWO 250V20A by Fuji Terminal
Slow-blow
* With a compact type, the fuse holder is mounted on the board. Type:
FGMT5 AC250V10A by Fuji Terminal
AC Power Connector Specifications
Item Overview
Connector name 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
assignments
1 In N AC power input, N side
2 In L AC power input, L side
3
PE (Protective grounding line)
11
[4] External regenerative unit
This connector is used to connect a regenerative resistance unit that may
will be determined by the specific application such as axis configuration.
3-pin, 2-piece connector
Cable size
1.0 mm2 (AWG17 or equivalent), included in the
external regenerative box
(Motor-driving DC voltage)
[5] Motor connector
This connector is used to drive the motor inside the actuator.
Connector
GIC2.5/4-STF-7.62 by Phoenix Contact
4-pin, 2-piece connector
Terminal
the motor drive. The following three LEDs are provided.
The voltage of the absolute-data backup
battery is low.
Part 1 Installation
connector
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
Overview of Fuse Holder Specifications
Item Overview
Connector name RB
Connector GIC2.5/3-STF-7.62 by Phoenix Contact
Connected to External regenerative box
Terminal
assignments
1 Out RB+
Regenerative resistance +
2 In RB– Regenerative resistance –
Overview of Motor Connector Specifications
Item Description
Connector name M
Cable Dedicated motor cable
Connected to Actuator
assignments
1
2 Out U Motor-driving phase U
PE (Protective grounding line)
3 Out V Motor-driving phase V
4 Out W Motor-driving phase W
[6] Driver status LEDs These LEDs monitor the operating status of the driver CPU that controls
Name Color Meaning when lit
ALM Orange The driver is detecting an error.
SVON Green The servo is on and the motor is being driven.
BAT ALM Orange
12
[7] Encoder connector
This 15-pin, D-sub connector is used to connect the actuator’s encoder.
Connector name
PG
Maximum
distance
10 m
Interface
standard
Conforming to RS422
Connected to
Actuator
(Built-in encoder unit inside the actuator)
Connection cable
Terminal
Pin
No.
Signal
name
(Phase U+)
Phase-A differential – input
(Phase U–)
(Phase V+)
Phase-B differential – input
(Phase V–)
(Phase W+)
Phase-Z differential – input
(Phase W–)
switching+)
magnetic-pole switching–)
Backup-battery power
supply
Part 1 Installation
Encoder Connector Specifications
Item Description
Connector High-density D-sub, 15-pin (fem ale)
connection
Dedicated PG cable
assignments
I/O
1 In A+
Phase-A differential + input
Description
2 In A–
3 In B+
Phase-B differential + in pu t
4 In B–
5 In Z+
Phase-Z differential + input
6 In Z–
Send/receive line+
7 IO SRD+
8 IO SRD–
(Pulse/magnetic-pole
Send/receive line– (Pulse/
9 Out BATT
10 Out BATTGND Battery ground
11 Out VCC Encoder power source
12 Out GND GND
13 Out BK–
14 Out BK+
Brake output
15 FG Not used
13
[8] System I/O connector
This connector is used to connect an emergency-stop switch, ENABLE
contact, ready relay, etc.
connector
1
RDY OUT
2
RDY OUT
3
ENB IN
Safety-gate input
4
+24V OUT
+24-V power output for safety gate
5
EMG IN
Emergency-stop input
+24-V power output for emergency
stop
Supported cable size
0.75 ~ 1.25 mm2 (AWG16)
MC1.5/2-ST-3.5 by Phoenix Contact; 2-pin, 2-piece
connector
1
0V
I/O GND
2
24V IN
+24-V power input for I/Os
[10] Panel window
This window consists of a 4-digit, 7-segment LED display and five LED
Name
Status when the LED is lit
RDY
CPU ready (program can be run)
ALM
CPU alarm (system-down level error), CPU hardware error
power-system hardware error
PSE
Power-system hardware error
CLK
System clock error
[11] Mode switch
This alternate switch with lock is used to command a controller operation
(Refer to the types of manual operations explained on p.324.)
Part 1 Installation
[9] I/O24V power connector
(general-purpose type
only)
Connector
Terminal assignments
Pins 1 and 2 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).
Pins 3 and 4 form a contact-B safety-gate input. Operation is enabled when the
pins are shorted, while the drive source is cut off when they are open.
Pins 5 and 6 form a contact-B emergency-stop input. Operation is enabled when
the pins are shorted, while an emergency stop is actuated when they are open.
Current flowing to the emergency stop contacts:
KX type (general-purpose ty pe ) : 43 mA ± 10%
JX type (compact type): 30 mA ± 10%
The controller is shipped with pins 3 and 4, and 5 and 6, shorted by a cable,
respectively.
MC1.5/6-ST-3.5 by Phoenix Contact; 6-pin, 2-piece
Ready-status output contact
6 +24V OUT
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 [14] and
[15] (2-pin, 2-piece connector by Phoenix Contact). 24 V must be supplied
externally.
Connector
Terminal assignments
With a compact type, power is supplied externally to pin Nos. 1 and 50 of
the I/O connector in [14].
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
EMG
Emergency stop has been actuated, CPU hardware error,
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.
14
[12] Teaching connector
When an optional teaching pendant or PC is connected, this D-sub, 25-
Communication
method
RS232C-compliant, start-stop synchronous
method
Maximum
connection distance
Signal
name
Terminal
Power output
teaching pendant)
pin connector will be used to input program and position data in the
MANU mode.
Interface Specifications of Teaching Serial Interface
Item Description
Connector name TP
Connector DSUB-25 XM3B-2542-502L (Omron)
Baud rate 38.4 kbps max.; half-duplex communication
Interface standard RS232C
Connected to X-SEL teaching pendant
Interface Specifications of Teaching Serial Interface
Part 1 Installation
10 m (38.4 kbps)
Item No. Direction
1 FG Frame ground
assignments
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
18 Out VCC
Description
(5-V power source for
19 In ENBTBX Enable input
20 In DTR Terminal ready
21
22
23 Out EMGS Emergency-stop status
24
25 SG Signal ground
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