Robot Module System
Robot Module System
l P Series Module Main Unit
l R Series Module Main Unit
l EXEA Controller
User’s Manual 1
= Installation and Maintenance of EXEA Controller =
1 Installation and Maintenance
2 Programming and Operation
of EXEA Controller
1. Introduction
2. Safety Precautions
3. System Configuration
4. Glossary
5. Reference Number • Specifications
6. Unpacking and Installation
7. Wiring
8. Startup
9. Initial Setting
10. Trial Running
11. Protection and Safety
12. Maintenance • Checking
13. Alarms
14. Troubleshooting
Appendix
3 Installation and Maintenance
of EXEA Controller
15.
16.
17.
18.
Programming
Description of Function
Operation of Robot Module
Remote Control Operation
of Module Main Unit
19.
20.
21.
22.
Reference Number • Specifications
Unpacking
Installation
Maintenance • Checking
M–E099XE0K2–022
Document Number: K20078-01
EC-T
Limited Warranty
NSK Ltd. warrants its products to be free from defects in material and/or workmanship which NSK
Ltd. is notified of in writing within, which comes first, one (1) year of shipment or 2400 total
operation hours. NSK Ltd., at its option, and with transportation charges prepaid by the claimant,
will repair or replace any product which has been proved to the satisfaction of NSK Ltd. to have a
defect in material and/or workmanship.
This warranty is the sole and exclusive remedy available, and under no circumstances shall NSK
Ltd. be liable for any consequential damages, loss of profits and/or personal injury as a result of
claim arising under this limited warranty. NSK Ltd. makes no other warranty express or implied,
and disclaims any warranties for fitness for a particular purpose or merchantability.
Copyright 2000 by NSK Ltd., Tokyo, Japan
All rights reserved.
No part of this publication may be reproduced in any
form or by any means without permission in writing from
NSK Ltd.
NSK Ltd. reserves the right to make changes to any
products herein to improve reliability, function or design
without prior notice and without any obligation.
NSK Ltd. does not assume any liability arising out of the
application or use of any product described herein;
neither does it convey any licence under its present patent
nor the rights of others.
Patents issued and patents pending.
Robot Module System
EC Directives Conformity
NSK Ltd. declares that "Robot Module System" conforms to EC Directive (CE Marking).
However, please note that the following conditions are added for conformity to the EC directive.
¤ EC Declaration of Incorporation
l NSK Ltd. declares that the Robot Module System is a machine component which is to be
incorporated into the machine. ( EC Declaration of Incorporation )
l The Robot Module System must not be operated until it is incorporated to the machine.
l The Robot Module System, as the machine component, conforms with following EC Directives.
à EC Machinery Directive 89/392 as amended 94/368 and 93/44.
à EC Low Voltage Directive 73/23 as amended 93/68.
l The customer has to take appropriate measures to its machine to conform to Electromagnetic
Compatibility Directive. The Robot Module must not put into service until the machinery into
which it to be incorporated has been declared in conformity with the provisions of EC
Directives.
l Our declaration becomes invalid if technical or operational modifications are introduced without
the consent of Mechatronics Technology Department of NSK Ltd.
¤ Remaining Hazards
(Following notes should be observed for your safety.)
l EXEA controller shall be put into the enclosure conforming to relevant European standard in
terms of fire protection and electrical shock protection. The protection grade of the enclosure
must be IP 54 or better. EXEA controller shall not be exposed to water or oil.
l Just after the power is turned on and off, there will be the hazardous voltage on the parts of
EXEA controller, such as the power input terminal, motor connector and connector for an
external regenerative dump resistor. Put covers on those parts to protect from touching when
operating the machine or doing maintenance work.
Furthermore, provide appropriate protection from disconnecting the motor connector accidentally.
l An isolation transformer must be used to prevent electrical shock. The isolation transformer
must have enough capacity for the Robot Module System power consumption.
l Install noise filter in the primary AC power line as a measure for Electromagnetic Compatibility
Directive.
l A circuit breaker must be installed to the primary AC power line of Robot Module System.
l Ground earthing must be provided to EXEA controller.
l Wiring inside of EXEA controller is simply internal wirings and the grounding wire is not
distinguished by color as the protective grounding conductive.
l Secure the controller cables and motor cables firmly so that those cables do not break or have
loose contact.
l Surround the machine, to which the Robot Module System is incorporated, with safety fence to
prevent any personnel from entering its moving range.
—i—
¤ Unit Limitation
l Units of Robot Module System which conform to EC Directives are limited to the following
reference number only.
1. EXEA controller
Reference No. : M-EXEA ¨ – ¨ ¨ ¨ ¨ T ¨ ¨
­
T : Indicates conformity with the Directive
2. Teaching Box
Reference No. : M-EXTB 04
l However, all robot module main units are compatible with the EC Directives. If you require to
build the Robot Module System that complies to the EC Directives, the EXEA controller and
the Teaching Box must be compatible with the EC Directives.
— ii —
Contents
1. Introduction------------------------------------ 1-1
7. Wiring ------------------------------------------- 7-1
1.1. Notes for Safety ------------------------------------------ 1-2
1.2. General Description ------------------------------------- 1-2
1.3. Notes to Users -------------------------------------------- 1-3
1.3.1. Axis Indication ------------------------------------- 1-3
1.3.2. Regeneration--------------------------------------- 1-3
1.3.3. Dynamic Brake ------------------------------------ 1-3
7.1. Connector List--------------------------------------------- 7-1
7.2. Precautions for Wiring ---------------------------------- 7-2
7.2.1. Making Cables ------------------------------------- 7-2
7.2.2. Connection of Cable------------------------------ 7-2
7.2.3. Securing Connectors ----------------------------- 7-2
7.2.4. Grounding ------------------------------------------- 7-3
7.2.5. Measures against Noises ----------------------- 7-5
7.3. Wiring-------------------------------------------------------- 7-6
7.3.1. Wiring Procedures -------------------------------- 7-6
7.3.2. Wiring Example------------------------------------ 7-7
7.4. CN2: RS-232C Connector ----------------------------- 7-8
7.4.1. Cable on the Market (Standard Cable) ------ 7-8
7.4.2. Making RS-232C Cable ------------------------- 7-9
7.5. CN3: Control Input / Output Signal Connector-- 7-10
7.5.1. Precautions for Wiring CN3 ------------------ 7-10
7.5.2. CN3 Signal Function --------------------------- 7-11
7.4.3. CN3: Signal Specification --------------------- 7-12
7.5.3.1. Specification of Control Signal ------- 7-14
7.5.3.2. EMST Input Signal Specification----- 7-14
7.5.3.3. Pulse Train Input
(Single axis controller only)------------ 7-15
7.5.3.4. Specification of Control
Output Signal------------------------------ 7-15
7.6. CN4, CN5: Main Power and Control
Power Connector--------------------------------------- 7-16
7.6.1. Precautions for Wiring of Power Input
Connector ----------------------------------------- 7-16
7.6.2. Power Line Wiring ------------------------------ 7-17
7.7. EXT. IO: General Input / Output Signal
Connector------------------------------------------------- 7-18
7.7.1. Precautions for Wiring ------------------------- 7-18
7.7.2. EXT.IO Signal Function------------------------ 7-19
7.7.3. CN3 Signal Specification---------------------- 7-20
7.7.3.1. Input Signal Specifications ------------ 7-22
7.7.3.2. Output Signal Specifications ---------- 7-22
7.8. Motor and Encoder Connectors -------------------- 7-23
2. Safety Precautions -------------------------- 2-1
2.1. Robot Module System ---------------------------------- 2-1
2.2. EXEA Controller ------------------------------------------ 2-3
2.2.1. Cautions for Storing Data to Memory -------- 2-4
3. System Configuration----------------------- 3-1
3.1. System Setup --------------------------------------------- 3-1
3.1.1. Connection of Module Main Unit and
Controller -------------------------------------------- 3-1
3.1.1.1. Single Axis Configuration ---------------- 3-1
3.1.1.2. Multi-axis Configuration
(Example of 2 axes controller)---------- 3-2
3.1.2. Connecting Peripherals ------------------------- 3-3
3.2. Structure of Module Main Unit ------------------------ 3-6
3.3. Structure of EXEA Controller-------------------------- 3-7
4. Glossary---------------------------------------- 4-1
5. Reference Number • Specifications ---- 5-1
5.1. Specifications of EXEA Controller ------------------- 5-1
5.1.1. Specifications -------------------------------------- 5-1
5.1.1.1. Internal DC 24V Power Supply--------- 5-2
5.1.2. Appearance and Dimensions ------------------ 5-3
5.2. Teaching Box---------------------------------------------- 5-5
5.2.1. Operational Function----------------------------- 5-5
5.2.2. Teaching Box Dimensions ---------------------- 5-6
5.3. Reference Namber--------------------------------------- 5-7
5.3.1. EXEA Controller ----------------------------------- 5-7
5.3.2. Teaching Box -------------------------------------- 5-7
5.3.3. Application Software for
Personal Computer ------------------------------- 5-8
5.3.4. RS-232C Cable------------------------------------ 5-8
8. Startup------------------------------------------ 8-1
6. Unpacking and Installation ---------------- 6-1
6.1. Cautions for Transporting and Storage------------- 6-1
6.2. Unpacking-------------------------------------------------- 6-1
6.2.1. Checking Product --------------------------------- 6-1
6.2.2. Combination Check ------------------------------ 6-2
6.3. Installation of EXEA Controller ----------------------- 6-3
- iii -
8.1. Turn on Power--------------------------------------------- 8-1
8.1.1. Preparation before Turning on Power ------- 8-1
8.1.2. Checks When Turning on Power-------------- 8-2
8.2. Selection of Control Mode------------------------------ 8-4
8.2.1. Teaching Box Operation Mode ---------------- 8-4
8.2.2. Changing to External Control Mode from
Teaching Box Operation Mode ---------------- 8-6
9.7. Parameters for PMD Setting------------------------- 9-42
9.7.1. Parameter List ----------------------------------- 9-42
9.7.2. Parameter Setting Procedure:
PMD Setting -------------------------------------- 9-42
9.8. Parameters for Input Signal Format --------------- 9-44
9.8.1. Parameter List ----------------------------------- 9-44
9.8.2. Parameter Setting Procedure:
Input Signal Format ----------------------------- 9-45
9.9. Parameters for Output Signal Format------------- 9-47
9.9.1. Parameter List ----------------------------------- 9-47
9.9.2. Parameter Setting Procedure:
Output Signal Format--------------------------- 9-48
9.10. Saving Parameter Setting -------------------------- 9-50
9.10.1. Saving Parameters of System Setting --- 9-50
9.10.1.1. Procedure to Save Parameters of
System Setting -------------------------- 9-50
9.10.2. Saving Parameters of Controller Setting 9-51
9.10.2.1. Procedure to Save Parameters of
Controller Setting ----------------------- 9-51
9.11. Initialization of Parameters ------------------------- 9-52
9.11.1. Initialization of Parameters for
System Setting --------------------------------- 9-52
9.11.1.1. Procedure to Initialize System
Setting Parameters -------------------- 9-52
9.11.2. Initialization of Controller
Setting Parameters---------------------------- 9-53
9.11.2.1. Procedure to Initialize Controller
Setting Parameters -------------------- 9-53
9.12. Readout of Parameters ----------------------------- 9-54
9.12.1. Readout of System Setting Parameters - 9-54
9.12.1.1. Readout Procedure:
System Setting Parameters --------- 9-54
9.12.2. Readout of Controller
Setting Parameters --------------------------- 9-55
9.12.2.1. Readout Procedure: Parameters of
Controller Setting ----------------------- 9-55
9. Initial Setting ---------------------------------- 9-1
9.1. Initial Setting Procedure -------------------------------- 9-1
9.2. Initial Setting List ----------------------------------------- 9-2
9.3. Operation Parameter ------------------------------------ 9-9
9.3.1. Parameters for Programmed Operation ---- 9-9
9.3.1.1. Parameter List ------------------------------ 9-9
9.3.1.2. Travel Speed in Programmed
Operation -----------------------------------9-10
9.3.1.3. Acceleration / Deceleration in
Programmed Operation -----------------9-10
9.3.1.4. Parameter Setting Procedure:
Programmed Operation -----------------9-11
9.3.2. Parameters for Home Return Operation ---9-13
9.3.2.1. Parameter List -----------------------------9-13
9.3.2.2. Setting Procedure of Parameter:
Home Return-------------------------------9-14
9.3.3. Parameters for Jog Operation ----------------9-16
9.3.3.1. Parameter List -----------------------------9-16
9.3.3.2. Parameter Setting Procedure:
Jog Operation------------------------------9-16
9.3.4. Parameters for Position and Coordinates -9-18
9.3.4.1. Parameter List -----------------------------9-18
9.3.4.2. Parameter Setting Procedure:
Position and Coordinates ---------------9-19
9.3.5. Parameters for Pulse Train Input
(Single Axis System Only) ---------------------9-21
9.3.5.1. Parameter List -----------------------------9-21
9.3.5.2. Setting Procedure for
Pulse Train Input --------------------------9-21
9.4. Servo Parameters---------------------------------------9-23
9.4.1. Parameters for Servo ---------------------------9-24
9.4.1.1. Parameter List -----------------------------9-24
9.4.1.2. Parameter Setting Procedure:
Servo Parameters ------------------------9-24
9.4.2. Parameters for Filter ----------------------------9-26
9.4.2.1. Parameter List -----------------------------9-26
9.4.2.2. Parameter Setting Procedure:
Filter ------------------------------------------9-26
9.4.3. Parameters for Manual Tuning ---------------9-28
9.4.3.1. Parameter List -----------------------------9-28
9.4.3.2. Parameter Setting Procedure:
Manual Tuning-----------------------------9-29
9.4.4. Parameters for Function Setting -------------9-31
9.4.4.1. Parameter List -----------------------------9-31
9.4.4.2. Parameter Setting Procedure:
Function Setting---------------------------9-31
9.5. Parameters for Unit Setting---------------------------9-33
9.5.1. Parameter List ------------------------------------9-35
9.5.2. Parameter Setting Procedure:
Unit Setting ----------------------------------------9-37
9.5.3. Separating Units for Use -----------------------9-39
9.6. Parameters for Setting Module Type---------------9-40
9.6.1. Parameter List ------------------------------------9-40
9.6.2. Parameter Setting Procedure:
Module Type---------------------------------------9-40
10. Trial Running -------------------------------10-1
11. Protection and Safety--------------------11-1
- iv -
11.1. Guard Fence ------------------------------------------- 11-1
11.2. Power Shut down and Recovery------------------ 11-2
11.3. Protection and Function for Safety --------------- 11-3
11.3.1. Emergency Stop ------------------------------- 11-3
11.3.1.1. State of Emergency Stop------------- 11-3
11.3.1.2. Execution of Emergency Stop ------ 11-3
11.3.1.3. Recovery from Emergency Stop --- 11-4
11.3.1.4. Emergency Stop Circuitry ------------ 11-4
11.3.1.5. Required Distance to Stop for
Emergency Stop ------------------------ 11-4
11.3.2. Deadman Switch------------------------------- 11-5
11.3.3. Brake Control ----------------------------------- 11-5
11.3.4. Detection of Over Travel--------------------- 11-5
11.3.5. Detection of Excessive Position Error---- 11-6
11.3.6. Software Thermal Limit Protection -------- 11-6
11.3.7. Protection from CPU Malfunction --------- 11-6
12. Maintenance • Checking ----------------12-1
14. Troubleshooting ---------------------------14-1
12.1. Maintenance --------------------------------------------12-1
12.2. Checking-------------------------------------------------12-2
12.2.1. Periodical Check -------------------------------12-2
12.2.2. Replacement ------------------------------------12-2
12.3. Warranty Coverage -----------------------------------12-7
12.3.1. Warranty Period --------------------------------12-7
12.3.2. Limit of Warranty -------------------------------12-7
12.3.3. Immunity ------------------------------------------12-7
12.3.4. Service Charge ---------------------------------12-7
14.1. Discription of Troubleshooting--------------------- 14-1
14.1.1. Malfunction -------------------------------------- 14-3
14.1.2. Operation Problem of the System--------- 14-4
14.1.3. Troubleshooting for Home Return--------- 14-8
14.1.4. Troubleshooting for Programmed
Operation ---------------------------------------14-11
14.1.5. Excessive Noise, Vibration and
Overshooting-----------------------------------14-15
14.1.6. Troubleshooting for Rough Motion-------14-16
14.1.7. Cannot Release Brake ----------------------14-17
14.1.8. Unable to Clear Emergency Stop --------14-18
14.1.9. Trouble of Over-travel Limit ----------------14-19
14.1.10. Communication Problem in
Remote Control Mode ---------------------14-21
14.1.11. Problem of Saving Program--------------14-22
14.1.12. Heating Problem ----------------------------14-23
14.2. Inspection of Trouble -------------------------------14-24
14.2.1. Check on Servo Lock------------------------14-26
14.2.2. Check for Brake Function ------------------14-27
14.2.3. Check for Mechanical Back Drive --------14-28
14.2.4. Abnormality of Encoder Signal------------14-29
14.2.5. Action for Malfunction and Collision -----14-30
14.2.6. Monitoring I/O ---------------------------------14-31
14.2.6.1. Indication of Input Port Condition -14-32
14.2.6.2. Indication of Output Port
Condition --------------------------------14-34
14.2.6.3. Monitor Status of Imaginary
Input / Output Port---------------------14-35
14.2.6.4. Monitor Status of Limit Sensor
Port----------------------------------------14-36
14.2.6.5. Indication of Brake State and
ON/OFF ----------------------------------14-37
13. Alarms ---------------------------------------13-1
13.1. Indication of Alarms -----------------------------------13-1
13.1.1. Output of CN3 Connector --------------------13-1
13.1.2. Seven Segments LED ------------------------13-1
13.1.3. Display of Teaching Box----------------------13-2
13.2. Motor Condition in Alarm State --------------------13-3
13.3. Alarm List ------------------------------------------------13-3
13.3.1. Normal State-------------------------------------13-3
13.3.2. Alarm List-----------------------------------------13-4
13.4. Description of Alarm ----------------------------------13-6
13.4.1. Overheat------------------------------------------13-8
13.4.2. Abnormal Main Power Voltage -------------13-9
13.4.3. Over Current----------------------------------- 13-10
13.4.4. Insufficient Voltage to Control Power --- 13-11
13.4.5. Encoder Circuit Error ------------------------ 13-12
13.4.6. Overload (Protection by Software
Thermal Switch) ------------------------------ 13-13
13.4.7. Speed Abnormal------------------------------ 13-14
13.4.8. Home Return Incomplete------------------- 13-15
13.4.9. Battery Error ----------------------------------- 13-16
13.4.10. Memory Error 1------------------------------ 13-16
13.4.11. Memory Error 2------------------------------ 13-17
13.4.12. Memory Error 3------------------------------ 13-18
13.4.13. Memory Error 4------------------------------ 13-19
13.4.14. CPU Error------------------------------------- 13-20
13.4.15. System Error --------------------------------- 13-21
13.4.16. Excessive Position Error------------------ 13-22
13.4.17. Software Travel Limit Switch
(Set by user.) -------------------------------- 13-23
13.4.18. Travel Limit (Mechanical lock)----------- 13-24
13.4.19. Emergency Stop ---------------------------- 13-25
13.4.20. Program Error ------------------------------- 13-26
13.5. Clear Alarm ------------------------------------------- 13-28
13.5.1. Clear Alarm in External Control Mode
(Operation Mode through CN3 Control I/O)---- 13-29
13.5.2. Clear Alarm by Teaching Box
Operation Mode ------------------------------ 13-29
13.5.3. Clear Alarm in Remote Control Mode
(RS-232C Communication Mode) ------- 13-29
13.6. Initialize Memory------------------------------------- 13-30
13.7. Monitoring Software Version and
Alarm History ----------------------------------------- 13-31
13.7.1. Indication of Software Version Number -- 13-31
13.7.2. Indication of Alarm History ----------------- 13-32
Appendix
- v -
Appendix 1: Specification of Motor Connector----------A-1
Appendix 2: Encoder Sensor Connector -----------------A-2
(Blank Page)
- vi -
1 Installation and Maintenance of EXEA Controller “1. Introduction”
1. Introduction
l This manual describes how to build and operate a Cartesian type robot system configured with
the P series and the R series module main units and the EXEA controller.
l This manual covers the EXEA controller, of which version number is 03 or later, for single axis
(one axis) system or multi-axis (2 ~ 4 axes) combination main unit.
Example of Reference number: M–EXEA3–0210C00– 03
Version number
l This manual consists of three volumes. The contents of each volume are listed on the front cover.
Follow the basic procedure as shown below and read the chapters.
Unpacking and Installation
User’s Manual 1 : “6. Unpacking and Installation.”
User’s Manual 3 : “20. Transportation, Storage and Unpacking.”
User’s Manual 3 : “21. Installation.”
Matters of great importance
(We urge you to read it.)
User’s Manual 1 : “1. Introduction”
User’s Manual 1 : “2. Safety Precautions”
User’s Manual 1 : “3. System Configuration”
User’s Manual 1 : “4. Glossary”
User’s Manual 1 : “5. Reference Number • Specifications”
User’s Manual 3 : “19. Reference Number • Specifications”
Wiring
Start up
Initializing
Trial running
Tuning
•
Adjustment
User’s Manual 1 : “7. Wiring.”
* User’s Manual 2 : “18. Remote Control Operation”
User’s Manual 1 : “8. Start up”
User’s Manual 1 : “9. Initial Setting”
* User’s Manual 2 : “18. Remote Control Operation”
User’s Manual 1 : “10. Trial Running”
User’s Manual 1 : “11. Protection and Safety”
Programming
User’s Manual 2 : “15. Programming”
User’s Manual 2 : “16. Description of Function”
* User’s Manual 2 : “18. Remote Control Operation”
Operation of robot
User’s Manual 2 : “17. Operation”
* User’s Manual 2 : “18. Remote Control Operation”
Maintenance
Troubleshoot, maintenance
and checking
User’s Manual 1 : “12. Maintenance • Checking”
User’s Manual 1 : “13. Alarm”
User’s Manual 1 : “14. Troubleshooting”
User’s Manual 3 : “22. Maintenance • Checking”
* Only when using the personal computer through remote commbzbunication.
Note: If the reference number of your modules are different from the information in this manual,
some part of explanation may not be applied to your model. In such a case, ask your local
NSK representative for the information.
— 1-1 —
1 Installation and Maintenance of EXEA Controller “1. Introduction”
1.1. Notes for Safety
l Before operating the robot module system, you should first thoroughly read this manual.
l Following notice are added to the clause of safety precautions to get your attention.
Danger
: Might cause serious injury.
Warning : Might cause injury.
Caution
: Might damage ancillary equipment and/or the end effector.
l Observe the applicable safety regulations for industrial-use robot. Pay great attention for safety
when building and operating the robot system.
l Do not use the robot module system in any manner not shown in this manual.
1.2. General Description
l The robot module main unit and the EXEA controller can configure a Cartesian type robot.
l The EXEA controller is capable of positioning control or external signal control, and is suitable
for pick and place, palletizing, adhesive dispensing, machining and inspecting operations. It may
be used as a component of industrial robot.
— 1-2 —
1 Installation and Maintenance of EXEA Controller “1. Introduction”
1.3. Notes to Users
1.3.1. Axis Indication
l When the matters related to the teaching box are described, the indication of the axes in the
display of the teaching box is basically for two axes combination. For three axes, Z axis will be
added on the display as the third axis and for four axis combination, R axis will be added on the
display as the fourth axis as well. All axes X, Y, Z and R are displayed in teaching process.
For a single axis system, there is the description that is different from the indication of display of
the teaching box. In such a case, refer to the added notes on the description.
When it dose not necessary to indicate number of axis, one axis system is referred to as “single
axis” system and the 2 ~ 4 axes combination is referred to as “multi-axis” combination,
l Relations in initial state between axis indication of program, Jog keys on the teaching box and an
axis number indicated on the controller are shown in Table 1-1 below.
U1: Unit 1
U2: Unit 2
Table 1-1
Axis number on
controller
1st. *
2nd.
3rd.
4th.
Jog keys on the teaching box and indication in a program
Single axis
Two axes
Three axes
Four axes
X*
U1-X
U1-X
U1-X
–
U1-Y
U1-Y
U1-Y
–
–
U1-Z
U2-X
–
–
–
U2-Y
* On the panel of the EXEA controller for single axis, there is no indication of axis number.
Indication of single axis is only “X.”
l You may change the indication of a vertical axis to Z axis in the multi-axis controller.
(Refer to “9.5. Parameter for Unit Setting.”)
1.3.2. Regeneration
l When decelerating or descending a heavy load, a servo motor of the main unit generates the
regenerative current.
l Regenerative current is dissipated by a regenerative dump resistor in the internal circuit of the
controller. However, if the large regeneration of servo motor continues, the regenerative dump
resistor will be overheated and an overheat alarm will arise.
l In such a case, it is necessary to ease up the operational condition. Lower velocity, decrease
acceleration/deceleration and reduce duty cycle.
1.3.3. Dynamic Brake
l When a module main unit is connected to an EXEA controller, the dynamic brake functions
under servo-off or power off condition.
l When moving the slider manually, you feel some resistance. However, this is not an abnormal
phenomenon.
l Dynamic brake does not function if the controller cable is disconnected.
— 1-3 —
1 Installation and Maintenance of EXEA Controller “1. Introduction”
(Blank Page)
— 1-4 —
1 Installation and Maintenance of EXEA Controller
“2. Safety Precautions”
2. Safety Precautions
2.1. Robot Module System
Danger
: Any person in the operating area of robot module may be hit by or caught in
the robot module when a module main unit or the EXEA controller fails or
functions improperly. Such a hazard exists though the system is running
normally at a high speed.
1)
For safety in daily operation, provide guard fences and take the measures to prevent
persons from entry into the robot operating area.
2)
When you must enter the area bound by the guard fences for adjusting or tuning of the
system, keep off the robot operating area and stand in a place where you can see the
motion of the robot module clearly. The traveling speed of module main unit at this
time should be set lower than the safety speed (250 mm/s).
*Jogging and teaching speed are set to 50 mm/second initially.
3)
Before starting maintenance or other work which requires to get in the operating area
of the robot module, be sure to turn off the power of the system.
4)
If it is necessary to go beyond the fence for troubleshooting without turning off the
power, follow the instructions shown in “14. Troubleshooting.” In any other cases, do
not enter in the guard fence without turning off power.
Danger
: If a back drive force is always applied to the ball screw when the power is
turned off (e.g. a vertical axis), use a robot module main unit with motor
brake.
If a module main unit without a brake is used for a vertical axis, the slider (or
the main unit if it is a moving axis type combination) drops or moves when
the power is turned off.
Warning : All models of module main unit employ the same type of connectors
regardless the size and motor rated power.
à Before turning on the power, check if the robot module is connected
with the controller properly.
à If the robot module is operated with improper connection to the
controller, the module may move unexpectedly or the motor may be
broken. See “8.1.1. Preparation before Turning on Power.”
Warning : Any special measures against EMC (Electromagnetic compatibility of CE
Marking) are not taken for the robot module system. Do not use the robot
module in an environment subject to much external noises. In an
environment where noises produced by the robot module system give
influences on your equipment, shield the EXEA controller, use a noise filter
or take other measures.
l The following shows the noise resistance of the EXEA controller itself.
Table 2-1
Specification
Line noise resistance
Static noise resistance
Noise resistance
1000V 1µs
3 kV
— 2-1 —
Remarks
Checked by a noise simulator
1 Installation and Maintenance of EXEA Controller
“2. Safety Precautions”
Warning : The robot module main unit does not have over-travel sensor. Be sure to
set the software over-travel limit switch as soon as Home return operation is
completed after the power is turned on for the first time. (Refer to “9.3.4.
Parameters for Position and Coordinates.”)
Caution
: Before turning off the controller power, be sure to deactivate the servo
system. Otherwise the slider (or the module main unit when the moving axis
combination) of a vertical axis may drop by 5 to 10 mm approximately.
* If a critical failure occurs or the robot module system is stopped in an emergency, the
hardware deactivates immediately and automatically the servo system. The slider (or
the module main unit when the moving axis combination) of a vertical axis may drop
due to the time lag between deactivating servo system and engaging motor brake. This
does not imply any error of the system.
Caution
: Set the system parameter in accordance with the type of module main unit.
Especially improper parameter settings to a module main unit in the
encoder resolution, the ball screw lead, way of motor mounting or the unit
with motor brake will result in malfunction of the system. (Refer to “9.5.
Parameters for Unit Setting.”)
* When a memory error occurs, you must initialize (reset) the system parameters. In such
a case, set the system parameters in accordance with the robot module main unit.
Caution
: The robot module is a precision machinery component. Handle it with great
care not to give any shock to it.
Caution
: An excessive moment load will result in premature failure. Check for an
excessive moment load referring to “19.1.3. Precautions against Use of
Module Main Unit.”
— 2-2 —
1 Installation and Maintenance of EXEA Controller
“2. Safety Precautions”
2.2. EXEA Controller
Danger
: Observe the following environmental conditions when installing and/or
operating the EXEA controller.
Table 2-2
Condition
Operating
Temperature
Storing
Operating
Humidity
Storing
Ambient condition
Environmental condition
0°C ~ 50°C
-10°C ~ 70°C
20% ~ 85% (non-condensation)
Free from dust, corrosive gas and inflammable/explosive gas.
Protected from cutting oil and cooling water.
l If these conditions are not met, it may shorten the life of the EXEA controller, and may induce
malfunction. Also, it may cause serious accident such as electrical shock or fire.
Danger
: The controller has a very high capacity electrolytic condenser in the circuit.
There remains residual voltage for few minutes after the power is turned off.
Do not remove the case or cover unless it is necessary. Please refer to
“12.2.2. Replacement” when removing the case.
Danger
: Be sure to ground the FGND terminal of the EXEA controller to prevent
electric shock. Refer to “7.2.4. Grounding.”
Caution
: Do not conduct an insulation resistance test or a megger test on the EXEA
controller. It may damage the internal circuits.
— 2-3 —
1 Installation and Maintenance of EXEA Controller
“2. Safety Precautions”
2.2.1. Cautions for Storing Data to Memory
l The EXEA controller has two kinds of memory internally. One is a RAM that stores the data
temporarily when the power is on, and loses data as the power is turned off. The data must be
stored to the other memory (flash memory which does not need a back-up battery) that does not
lose data when the power is turned off.
l When you need to store the data such as rewritten programs, teaching data and initial parameter
setting, follow the relevant instructions in this manual.
Caution
: When saving the data to the memory, the display of teaching box reports
“Writing.” Never turn off the power when this “Writing” is displayed.
Otherwise the memory error arises.
(The system does not recover unless the all data, including programs, are
cleared when this alarm arises.)
Example: Procedure to store system parameter
[SYS]
U1
1CLR 2SAV 3LOD 4etc
Press F2 key.
[SYS]S
Push SET
Press SET key.
Do not turn power off while storing the parameters.
[SYS]S
Writing
l The information or the record of parameters which are stored in the EXEA controller may be lost
or changed due to mishandling of the system, external noise, failure of the controller or an
accidental termination of the power in the middle of loading data.
l Keep the record of necessary data or parameters in handwritten notes or in the back-up function
of optional application software beforehand.
l Even initializing the controller for some reason, back up all data and parameters beforehand. The
initialization changes all data and parameters to the shipping set.
— 2-4 —
1 Installation and Maintenance of EXEA Controller “3. System Configuration”
3. System Configuration
l You can build a robot module system that consists of the module main units and EXEA
controller.
3.1. System Setup
3.1.1. Connection of Module Main Unit and Controller
3.1.1.1. Single Axis Configuration
l A module main unit may be fixed to a mounting base from its bottom using bolts. Optional
mounting bracket is available to fix module main unit from top side. (Two mounting brackets
are required for a main unit.)
l Use the controller cable and the cable support to connect a main unit and an EXEA controller.
l The controller cable consists of wiring of motor power, encoder signal and protective ground.
l Fix the end effector to bolt holes on the top of a slider of main unit.
Note: Refer to “21. Installation” for assembly procedure.
Figure 3-1
— 3-1 —
1 Installation and Maintenance of EXEA Controller “3. System Configuration”
3.1.1.2. Multi-axis Configuration (Example of 2 axes controller)
l A module main unit may be fixed from its bottom surface using the bolts. Optional mounting
bracket is available to fix the main unit from its top side.
(Two mounting brackets are required for a main unit.)
l Use the combining brackets to combine two or more main units.
l Use a controller cable and cable support to connect the controller and the main units.
l The wiring of motor power, encoder signal and protective ground are connected to the controller
from the main unit by the controller cable.
l The user does not need to prepare the connector box as it is provided with a cable support.
l User’s signal cable and air tube may be added to the cable support. Refer to “19.3. Cable
Support.”
l Fix an end effector to the bolt holes on the top of the slider of main unit.
Note: Refer to “21. Installation” for assembly procedure.
Figure 3-2
- 3-2 -
1 Installation and Maintenance of EXEA Controller “3. System Configuration”
3.1.2. Connecting Peripherals
l There are three ways to operate the EXEA controller. This section describes the fundamental
ways of connection in case of two axes EXEA controller. For 1, 3 and 4 axes controller, the
connection is basically the same, though the numbers of connecting points of the main power
source and the controller cables are different.
1 Using the teaching box
(Refer to “17.3. Operation by Teaching Box.”)
Figure 3-3
Teaching box (optional)
NSK
NSK
EMG
TEACHING BOX
F1
F2
MODE START
The part to be connected always.
The part to be connected when
required.
F3
F4
STOP
CYC
STOP
EXEA controller
ON OFF
-X
+X
7
8
9
-Y
+Y
4
5
6
-Z
+Z
-R
+R
HIGH
1
2
0
+/-
CLR
3
•
POWER
SET
DISP.
1st
2nd
MOTOR1
MOTOR2
CN4
CN1
MAIN
T/B
CN5
CONT.
CN2
RS-232C
EXT.I/O
CN3
I/O
ALARM
ALARM
Type
No.
FGND
1st
SENSOR
2nd
SENSOR
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EXEA Controller
Module main unit
External control equipment / sensors
(Shall be provided by the user.)
·
·
·
·
Sequencer
I / O control box
Sensors
Switches etc.
To power line
Emergency stop circuit
Frame ground
EREM input circuit
l All operations (initial setting, programming and operation) can be done through the Teaching
box.
l The emergency stop circuit of CN3 connector must be connected, otherwise you cannot move
the robot module.
(Refer to “11.3. Protection and Function for Safety.”)
— 3-3 —
1 Installation and Maintenance of EXEA Controller “3. System Configuration”
2 Operation by remote control mode
(Refer to “17.4. Operation in External Control Mode” for more details.)
Figure 3-4
NSK
NSK
EMG
TEACHING BOX
F1
F2
MODE START
The part to be connected always.
The part to be connected when
required.
F3
F4
STOP
CYC
STOP
ON OFF
-X
+X
7
8
9
-Y
+Y
4
5
6
-Z
+Z
1
2
3
-R
+R
0
+/-
•
HIGH
CLR
EXEA controller
SET
POWER
DISP.
Teaching box (optional)
or
Dummy connector
(provided with EXEA controller)
1st
2nd
MOTOR1
MOTOR2
CN4
CN1
MAIN
T/B
CN5
CONT.
CN2
RS-232C
EXT.I/O
CN3
I/O
ALARM
ALARM
Type
No.
FGND
1st
SENSOR
2nd
SENSOR
Module main unit
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EXEA Controller
External control equipment / sensors
(Shall be provided by the user.)
·
·
·
·
Sequencer
I / O control box
Sensors
Switches etc.
To main power source
Emergency stop circuit
Frame ground
EREM input circuit
l You can operate the robot system through the external equipment.
l You need the teaching box for initial setting, programming and tuning.
l The emergency stop circuit of CN3 connector shall be connected, otherwise you cannot operate
the robot module system.
(Refer to “11.3. Protection and Function for Safety.” )
l For normal operations after setup of the system, you may use the dummy connector instead of
the teaching box.
Danger
: Be sure to turn off the power when connecting or disconnecting the
connectors.
- 3-4 -
1 Installation and Maintenance of EXEA Controller “3. System Configuration”
3 Remote control operation
(Refer to “18. Remote Control Operation” for more details.)
Figure 3-5
NSK
NSK
EMG
TEACHING BOX
F1
F2
MODE START
The part to be connected always.
The part to be connected when
required.
F3
F4
STOP
CYC
STOP
ON OFF
-X
+X
7
8
9
-Y
+Y
4
5
6
-Z
+Z
1
2
3
-R
+R
0
+/-
•
HIGH
CLR
EXEA controller
SET
POWER
DISP.
Teaching box (optional)
or
Dummy connector
(provided with EXEA controller)
1st
2nd
MOTOR1
MOTOR2
CN4
CN1
MAIN
T/B
CN5
CONT.
CN2
RS-232C
EXT.I/O
I/O
ALARM
ALARM
EXEA Controller
Type
No.
FGND
1st
SENSOR
2nd
SENSOR
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RS-232C cable
(optional)
CN3
Module main unit
Personal computer for remote control
(Shall be provided by the user.)
External control equipment / sensors
(Shall be provided by the user.)
·
·
·
·
Sequencer
I / O control box
Sensors
Switches etc.
To main power source
Emergency stop circuit
Frame ground
EREM input circuit
l All operations such as Initial setting, programming and operation, excluding Jog operation, can
be done through the personal computer.
l Purchase the optional application software and RS-232C cable for the external control using a
personal computer.
(Refer to “5.3.3. Application Software for Personal Computer” and “5.3.4. RS-232C Cable.”)
l Wiring of the emergency stop circuit of CN3 and EREM input circuit are required for the
remote control.
Note: Switch the control mode to the remote control mode or the external control mode through
the EREM input circuit. When the EXEA controller is in the external control mode,
turning EREM input on makes to get in the remote control mode. When the EREM
circuit is not wired, you cannot select the remote control mode.
l You may use the dummy connector instead of the teaching box when you do not require the
operations such as Jog or tuning servo..
Danger
: Be sure to turn off the power when connecting or disconnecting the
connectors.
— 3-5 —
1 Installation and Maintenance of EXEA Controller “3. System Configuration”
3.2. Structure of Module Main Unit
l Table below shows components of a module main unit and their functions.
Table 3-1
Component
Motor
·
Encoder
·
Coupling
·
Ball screw
·
NSK linear guide
·
Slider
Motor brake
·
·
·
·
·
Function
Generates driving force (rotational torque) produced by electric current supplied from
the EXEA controller.
Outputs electrical signals in accordance with rotation angles of motor and transmit the
signals to the EXEA controller.
Couples the motor shaft with the ball screw shaft and transmits motor torque to the
ball screw.
Converts rotational torque (rotational motion) of the screw shaft into thrust force
(linear motion) of the ball nut.
Functions as a linear guide way. Supports vertical, lateral and moment loads and
achieves precise linear motion of slider.
Combines the ball screw nut and the ball slides of linear guide for highly precise
linear motion.
An end effector or a combining bracket may be mounted to the slider.
Prevent the slider from dropping when the power of a vertical main unit is turned off.
The brake is released when the current is given from the EXEA controller.
It engages when the power is off.
Module main unit with motor brake is optional.
Figure 3-6 : Components of module main unit
- 3-6 -
1 Installation and Maintenance of EXEA Controller “3. System Configuration”
3.3. Structure of EXEA Controller
l Table 3-2 shows components of controller and their functions.
Table 3-2
Component
·
·
EXEA controller
·
Teaching box
Main console,
sequencer and DC
24V power supply
·
·
·
Function
Controls the entire robot module system.
When the start command is activated, it supplies electric current
to motor(s) to execute the operations in accordance with
programs and system parameters set in the controller.
Realizes highly precise positioning utilizing the encoder signals
as feed back signals of the motion.
Use it to edit programs and set parameters. Can be used to
execute manual operations such as Jog, Home return and
inputting Run command to start a programmed operation.
The unit to input control signal externally when an EXEA
controller is in the external control mode.
Can be used with incorporated DC 24V power supply.
Refer to “5.1.1.1. Internal DC 24V Power Supply” for its
specifications.
Connect the EXEA controller and the external control units
(e. g. main console and sequencer).
CN3: Controller I / O ·
cable*
EXT: General I / O
· Transmit general I / O to control the end effector or other units.
cable*
· The software is compatible to Windows98 and Windows NT4.0
Workstation.
Application software
· You can edit the programs, set and save the parameters of the
EXEA controller.
· Necessary to control an EXEA controller through remote control
Personal computer
mode (personal computer communication control), or through use
of application software.
· Connect an EXEA controller and personal computer for
RS-232C cable*
communication control and for use of the application software.
Power supply cable · Connect main power line to the EXEA controller.
Remarks
Sold separately from the EXEA
controller.
Should be provided by the user.
Should be provided by user.
Should be provided by user.
It is provided in the CD-ROM.
This is separately sold from the
EXEA controller.
Should be provided by user.
Should be provided by user.
Should be provided by user.
* Use the shielded cable for “CN3: Control I/O cable”, “EXT: general I/O cable” and
RS-232C cable.
— 3-7 —
1 Installation and Maintenance of EXEA Controller “3. System Configuration”
(Blank Page)
- 3-8 -
1 Installation and Maintenance of EXEA Controller “4. Glossary”
4. Glossary
u Safeguard
l A fence or cover installed around the robot in order to prevent the operator from entering the
moving range of robot while it is running.
u Safety speed
l A reduced velocity selected by the user which automatically restricts the robot velocity to allow
sufficient time for persons either to withdraw from hazardous motions or to stop the robot.
Recommended safety speed is 250 mm/second or under.
u Moving speed
l The maximum speed of the moving member of the robot (i.e. the slider or the main unit of a
moving axis type robot), which is achieved after completion of accelerating.
u Motion acceleration / deceleration
l Acceleration and deceleration of moving member of the robot (i.e. the slider or main unit of a
moving axis type) when it is starting or stopping. Acceleration and deceleration in an EXEA
controller are set to the same value.
u Operation duty
l The frequency of operation. The ratio of stopping and operating time. Or, in some cases, the
frequency of accelerating and decelerating in the unit time. If accelerating and decelerating are
repeated at all times or frequently, the operation duty is great.
u Moving range
l The largest area occupied by the robot when the robot is combined with all axes, end effectors
are installed, the work piece is set, and the slider or each axis (or a main unit of a moving axis
type robot) moves to the stroke end. If a person exists in this area, he may possibly be hit,
caught or drawn in.
u Servo ON condition
l The condition when the servo is active and the motor can accept an operation command. If no
motion command is input in the servo ON condition, the servo driver keeps current position.
Such a condition is called “servo lock.”
— 4-1 —
1 Installation and Maintenance of EXEA Controller “4. Glossary”
u Servo OFF condition
l In this condition no current flows through the motor, and the motor does not accept an operation
command. Unless a brake is incorporated, movable part can be moved by external force.
u CPU
l Central Processing Unit. In the EXEA controller, CPU performs all processing including motor
control and executing programs.
u Slider movement / moving axis
l The slider moves linearly as the motor rotates. This is referred to as “slider movement” in this
manual. If the slider is stable and main unit moves, the main unit is referred to as “moving axis.”
u Coasting
l Motion of moving member due to its inertia. Although the power is turned off to the motor, the
motor keeps rotating due to kinetic energy acquired up to that point.
u Interpolation
l In a multi-axis combination, a resultant induced by simultaneous operation of multiple axes is
called “interpolation.” It is referred to as linear interpolation for a linear resultant, and as
circular interpolation for a circular resultant.
u Work piece
l An object of robot operation such as machining, assembly, pick and place, packing sealing and
transporting.
u End effector
l A tool which manipulates work pieces. Hand or another additional devices attached to the robot
module to perform its tasks.
u EMC
l Electromagnetic compatibility of noises. To comply to EMC, measures against EMI
(electromagnetic interference: Emission) and EMS (electromagnetic sensitivity: Immunity) must
be taken.
u Flash memory
l Non volatile memory which stores all memories without any back up of electric power.
— 4-2 —
1 Installation and Maintenance of EXEA Controller “5. Reference Number • Specifications”
5. Reference Number • Specifications
5.1. Specifications of EXEA Controller
5.1.1. Specifications
Table 5-1: Power capacity and environmental condition
Item
Power voltage
M-EXEA1-1000¨¨¨
M-EXEA1-0100¨¨¨
M-EXEA1-0010¨¨¨
M-EXEA2-2000¨¨¨
M-EXEA2-1100¨¨¨
M-EXEA2-1010¨¨¨
M-EXEA2-0200¨¨¨
M-EXEA2-0110¨¨¨
M-EXEA2-0020¨¨¨
M-EXEA3-3000¨¨¨
M-EXEA3-2100¨¨¨
M-EXEA3-2010¨¨¨
M-EXEA3-1200¨¨¨
M-EXEA3-1020¨¨¨
M-EXEA3-0300¨¨¨
M-EXEA3-0210¨¨¨
Maximum power
M-EXEA3-0120¨¨¨
capacity *
M-EXEA3-0030¨¨¨
M-EXEA4-4000¨¨¨
M-EXEA4-3100¨¨¨
M-EXEA4-3010¨¨¨
M-EXEA4-2200¨¨¨
M-EXEA4-2110¨¨¨
M-EXEA4-2020¨¨¨
M-EXEA4-1300¨¨¨
M-EXEA4-1210¨¨¨
M-EXEA4-1120¨¨¨
M-EXEA4-1030¨¨¨
M-EXEA4-0400¨¨¨
M-EXEA4-0310¨¨¨
M-EXEA4-0220¨¨¨
M-EXEA4-0130¨¨¨
M-EXEA4-0040¨¨¨
Built-in driver unit capacity
Line noise
Noise resistance
Static noise
Ambient temperature
Operation / storage humidity
Environment
Storage temperature
Specification
Single phase AC200/240V
0.5kVA
0.9kVA
1.6kVA
0.9kVA
1.2kVA
2.0kVA
1.5kVA
2.4kVA
3.1kVA
1.3kVA
1.6kVA
2.5kVA
2.0kVA
3.6kVA
2.4kVA
3.1kVA
4.0kVA
4.7kVA
1.6kVA
2.0kVA
2.9kVA
2.4kVA
3.3kVA
4.0kVA
2.7kVA
3.6kVA
4.3kVA
5.1kVA
3.0kVA
3.9kVA
4.6kVA
5.5kVA
6.2kVA
100W, 200W, 400W
1000V 1µS (by noise simulator)
3kV (by noise simulator)
0 ~ 50℃
20 ~ 85% (No condensation)
Free from dust, corrosive gas, inflammable and/or explosive
gas. Do not expose to cutting oil and lubrication oil.
-10 ~ 70℃
* Exclude inrush current.
— 5-1 —
1 Installation and Maintenance of EXEA Controller “5. Reference Number • Specifications”
Table 5-2 : Inrush current and leakage current
Item
EXEA 1 (Single axis)
210A approx.
Inrush Main power
current Control power
30A approx.
10mA approx.
Leak current
EXEA 2 (Two axes)
210A approx.
30A approx.
25mA approx.
EXEA 3 (Tree axes)
420A approx.
60A approx.
40mA approx.
EXEA 4 (Four axes)
420A approx.
60A approx.
50mA approx.
Table 5-3: Functional specifications
Item
Number of control axes
Teaching
Position data capacity
EXEA
Program capacity
Backup
Speed setting
range
Maximum speed
Acceleration / Maximum
Deceleration
acceleration /
setting range
deceleration
Acceleration / deceleration pattern
1 ~ 4 axes
Motion
Program
2 ~ 4 axes
command
Sequence
Others
Program editing
Control function
Coordinates setting
Alarm • Protection
Exclusive input
Input / Output
Exclusive output
General Input /
Output
1 ~ 4 axes
Numerical data input or teaching
4000 points
Approximately 5000 steps in normal use. (Maximum 45000* steps approximately)
/128 Programs.
* When it consists of simple commands. (Command of which bit length is one
such as RET and END) Refer to “15.2.1. Programming Area” for more details.
Flash memory
0.1 ~ 1200 mm/s
* Actual maximum speed depends on the type of module main unit.
Refer to “19.1.2. Specifications” for more details.
0.1 ~ 35m/s2
Modified sine profile
Home return, PTP
Maximum 3 axes for linear interpolation, maximum 3 axes circular interpolation,
Maximum 3 axes continue pass, arch motion and 2 axes palletizing
General Input / Output, timer, Jump, Conditional Jump
Repeating, subroutine call and interruption (reserved)
Insert step, delete and copy steps
Feed forward, digital filter
Over travel, Home position off-set, reverse the sign of direction (plus/minus)
Over travel, CPU error, Memory error, Encoder disconnection, Excessive position
error, Power voltage abnormal, Over current, Overheat, Overload
Servo ON, Emergency stop, Cycle stop, Hold, Home return start, Programmed
operation start, Resume programmed operation, Alarm clear, Pulse train (single axis
only)
Driver ready, Alarm, Home return complete, Cycle stop, Hold, Program operation
ready Mode status
16 points each. [Can be extended to 64 points. (32 points for single axis system)]
However several inputs and outputs are shared with program selection, position data
selection and FIN signal output.
5.1.1.1. Internal DC 24V Power Supply
Table 5-4: Specifications of Internal DC 24V power supply
Item
Voltage
Maximum output current
Specification
DC24V ±10%
2A*
* This may be used as a power for brake. When using a main unit with brake, take into
the account of current for a brake. A brake requires 250mA.
Caution
: Maximum current should be 2A or less when outputs and inputs, including
motor brake, are simultaneously on. If more current over 2A is required,
provide an extra DC24V power supply. Maximum available current 2A
remains same although the external I/O are added.
— 5-2 —
1 Installation and Maintenance of EXEA Controller “5. Reference Number • Specifications”
5.1.2. Appearance and Dimensions
Figure 5-1 : EXEA controller (Single axis)
Main power input terminal
POWER
DISP.
Control power input terminal
CN4
MAIN
CN1
7-segments LED
T/B
MOTOR
CN5
CONT.
CN2
RS-232C
CN1: Connector for
teaching box
EXT.I/O
CN3
I/O
ALARM
EXEA Controller
Type
No.
N
NS
SK
K Ltd .
MADE IN JAPAN
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CN2: RS-232C connector
Motor connector
Encoder connector
Frame ground
EXT. I/O: General I/O
CN3: Control I/O
· This is for general Input / Output to control slave
unit such as hand or end effector, and for
information input of programmed operation.
· Signal I/O connector to control
EXEA controller
Figure 5-2 : EXEA controller (2 axes)
Main power input terminal
POWER
DISP.
1st
2nd
MOTOR1
MOTOR2
Control power input terminal
CN4
CN1
7-segments LED
MAIN
T/B
Motor connector for 2nd axis
CN5
CONT.
CN2
RS-232C
CN1: Connector for
teaching box
Motor connector for 1st axis
EXT.I/O
I/O
ALARM
ALARM
EXEA Controller
Type
N
NS
S K LLt dd .
1st
SENSOR
MADE IN JAPAN
FGND
2nd
SENSOR
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CN2: RS-232C connector
CN3
Encoder connector for
2nd axis
Encoder connector for
1st axis
Frame ground
EXT. I/O: General I/O
CN3: Control I/O
· This is for general Input / Output to control slave
unit such as hand or end effector, and for
information input of programmed operation.
· Signal I/O connector to control
EXEA controller
— 5-3 —
1 Installation and Maintenance of EXEA Controller “5. Reference Number • Specifications”
Figure 5-2
Single axis
2 axes
175
76
R3
265
165
10.5
17.5
50
10.5
17.5
49.5
POWER
POWER
R3
DISP.
DISP.
MAIN
CN1
1st
2nd
MOTOR1
MOTOR2
CN4
CN4
MAIN
CN1
T/B
T/B
MOTOR
CN5
CN5
CONT.
CONT.
CN2
CN2
RS-232C
215
215
RS-232C
EXT.I/O
CN3
I/O
EXT.I/O
ALARM
Type
No.
ALARM
Type
No.
NSK
K LL t dd .
1st
SENSOR
MADE IN JAPAN
FGND
2nd
SENSOR
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EXEA Controller
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I/O
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EXEA Controller
CN3
4 axes
470
125
125
125
(48)
10.5
17.5
47.5
POWER
R3
POWER
DISP.
1st
2nd
CN4
CN1
160
Bracket may be attached to
either front or rear side.
3rd
4th
MOTOR2
MOTOR3
CN8
MAIN
MAIN
T/B
MOTOR2
MOTOR1
CN5
CN9
CONT.
Connect the connector so that
cut-off corner comes underside.
CONT.
CN2
215
RS-232C
EXT.I/O
CN3
I/O
ALARM
ALARM
ALARM
ALARM
Type
No.
2nd
SENSOR
3rd
SENSOR
FGND
4th
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NS
SK
K L tt d .
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EXEA Controller
Bracket may be attached to
either front or rear side.
* The
dimensions of 3 axes
controller are the same as that of four axes controller.
※3
軸用の外形寸法図は
4 軸用と共通です。
— 5-4 —
1 Installation and Maintenance of EXEA Controller “5. Reference Number • Specifications”
5.2. Teaching Box
5.2.1. Operational Function
Table 5-5
·
·
·
·
·
·
·
·
Setting /
programming
Operation start / stop
Outputs
Monitoring
Other
Internal parameters, servo gain
Programming, teaching
Jog, Home return , Start / stop of programmed operation, emergency stop
Exclusive output, general output and on / off of motor brake
Alarm indication
Monitor control signal and general output
Programmed operation monitor: current position of each axis
Alarm reset
Figure 5-4: Keys on teaching box and their function
Emergency stop button
· Press the button to stop all operations and
gets in servo off state.
· To reset, turn the power off, then turn on
again, or use alarm reset function.
LCD
Emergency stop key (EMG)
· The key has the same function as
the emergency stop button.
Function key
Dead-man switch
· Keys to select function.
· Keep pressing the switch when
executing jog operation and
teaching operation by jogging.
· If the switch is released,
operation is disabled and the
system gets into servo off state.
Mode key
· Selects an operation
menu.
Start key
· Start programmed
operation or Home Return
motion.
Servo ON/OFF keys
· The servo on state is
indicated by an asterisk (*)
in the upper right corner of
the LCD screen.
Jog keys
+ : Positive direction
- : Negative direction
NSK
NSK
EMG
TEACHING BOX
F1
F2
MODE START
F3
F4
STOP
CYC
STOP
Screen control and cursor scroll
Cycle stop key
ON OFF
-X
+X
7
8
9
-Y
+Y
4
5
6
-Z
+Z
1
2
3
-R
+R
0
+/-
•
HIGH
CLR
SET
Jog high speed key
· Press the CLR key to
clear an entered
command or data.
Stop key
· When the key is pressed, the system
decelerates and stops.
Numeric keys
Set key
· Press the HIGH key and a
jog key simultaneously to
increase jog speed.
Clear key
· Press CYC STOP key to stop operation after
completion of the current step.
· Press START key to restart the operation
from a following step.
· Press the SET key to confirm command.
Combination of CLR and SET keys enables to clear alarms.
Refer to “13.5. Alarm Reset Function.”
Danger : Dead-man switch is valid only when JOG operation and
Teaching operation are being executed. For other operations,
dead-man switch is disabled and it does not function even you
release the switch.
— 5-5 —
1 Installation and Maintenance of EXEA Controller “5. Reference Number • Specifications”
5.2.2. Teaching Box Dimensions
Figure 5-5
[Unit: mm]
50
(48)
65
(32)
65
2
F2
F3
F4
STOP
CYC
STOP
(20)
F1
MODE START
(22)
EMG
TEACHING BOX
180
NSK
NSK
ON OFF
-X
+X
7
8
9
-Y
+Y
4
5
6
-Z
+Z
1
2
3
-R
+R
0
+/-
•
HIGH
CLR
4
SET
Connector
TX20A-14PH1-D2P1-D1
95
Cable
130
— 5-6 —
1 Installation and Maintenance of EXEA Controller “5. Reference Number • Specifications”
5.3. Reference Namber
5.3.1. EXEA Controller
l EXEA controller is a versatile controller incorporated with a servo motor driver unit.
à Sequence command --- Timer, conditional jump, repeat
à Motion command ------ Linear interpolation, circular interpolation, continuos path, etc.
à Multi-task operation (parallel operation possible)
à Control slave unit (e. g. hand or end effector), through general input/output
à Program capacity ------ 128 programs, approximately 5000 steps (45000 maximum)
in normal use.
l In addition to the above functions, the higher level of motion control can be achieved utilizing
other functions such as modified sine acceleration / deceleration, feed forward compensation
and digital noise filters.
Figure 5-6: Reference number configuration of EXEA controller
M-EXEA 2 - 1100 T 00
EXEA controller
Serial number
00 : General I/O 16 points each
(standard)
01 : General I/O 32 points each
02 : General I/O 48 points each
03 : General I/O 64 points each
Number of controllable axes
1: 1 axis, 2: 2 axes, 3: 3 axes, 4: 4 Axes.
Incorporated driver unit specification
Number of incorporated driver unit by output power
Example :1
100
Power source voltage
A : AC200/220V
C : AC100/110V
T : Complies to CE Marking
(AC200/240V)
Design serial number of incorporated driver unit
Incorporated number of driver unit for 400W motor
Incorporated number of driver unit for 200W motor
Incorporated number of driver unit for 100W motor
5.3.2. Teaching Box
l Teaching box is to be connected to EXEA controller and is used for initializing parameters,
logging in programs and conducting trial operation.
Figure 5-7: Reference number configuration of teaching box
M-EXTB 04 - 10
Teaching box
Cable length
No indication : 3 m (standard)
-10
: Available on request
03: Standard specification
04: Complies to CE Marking
05 ~ : Specially specification
— 5-7 —
1 Installation and Maintenance of EXEA Controller “5. Reference Number • Specifications”
5.3.3. Application Software for Personal Computer
l This is an application software for a personal computer which is compatible to Windows 98 or
NT 4.0 Workstation to edit programs and set the parameters.
* Windows 98 and NT 4.0 Workstation are registered trademark of Microsoft Corporation
in the United States.
l The application software is for programming, setting parameters and data backup.
Figure 5-8: Reference number
M-EXTA02
5.3.4. RS-232C Cable
l This is the cable to connect the EXEA controller and user’s personal computer to control the
EXEA controller in remote control mode, or to use the application software for personal
computer.
l The connector of the personal computer side must be a D-sub25 pin standard connector (male),
but not for half pitch.
l The user shall provide a cable matcher in accordance with your perusal computer specification
beyond D-sub25 pin.
l Refer to “7.4. CN2: RS-232C Connector” for the connectors.
Figure 5-9: Reference number of RS-232C cable
M-EXTC 040 R01
Cable length: 4m
— 5-8 —
1 Installation and Maintenance of EXEA Controller “6. Unpacking and Installation”
6. Unpacking and Installation
6.1. Cautions for Transporting and Storage
l Do not apply shocks to the module components during transportation.
l Store products indoors in a clean environment, and not to expose to wind, rain or direct sunlight.
For storage temperature and humidity, refer to “5.1.1. Controller Specifications.”
Caution
: The robot module is not provided any special measures against
environmental problems in transportation or storage. Trouble may take
place or the service life may be reduced unless it is handled with great care
as a precision instrument.
6.2. Unpacking
6.2.1. Checking Product
1 Damages to products and missing parts
l Unpack all containers and check for damages on products and missing parts.
2 Check with ordered reference number
l See “Figure 5-6: Reference number configuration of EXEA controller” and check that the
affixed seal on the controller corresponds to your order.
l Data indicated on seal
à Type : Reference number without “M- “ is indicated on the seal.
Last numbers “-01” indicate its version. The numbers will be changed
following its upgrading.
à No. : Serial number
3 Check accessory
l Table 6-1 is the list of the accessories which are provided with the controller.
Table 6-1
Name of part
Dummy connector for
teaching box
Control I / O Connector
and connector shell
Description
· This connector is used as a dummy connector when
operating EXEA controller without the teaching box.
· Cable connector and connector shell for CN3
connector of EXEA controller
General I / O connector
and connector shell
· Cable connector and connector shell for EXT. I / O
connector of EXEA controller
Control power connector
and connector shell
Main power connector
and connector shell
Fuse
Instruction manual
· Cable connector and connector cover for
control power connector of EXEA controller
· User side connector and its cover to wire main power
connector of EXEA controller
· Protection fuse for main power input
· This manual
— 6-1 —
Quantity
Remarks
1
1 set
1 set
1 set
1 set
Maximum 4 sets for option
(2 sets maximum for the
single axis controller)
2 sets for 3 and 4 axes
controller.
2 sets for 3 and 4 axes
controller.
1
1 set
3 volumes
1 Installation and Maintenance of EXEA Controller “6. Unpacking and Installation”
6.2.2. Combination Check
l Please check that the combination of module main units and an EXEA controller matches with
the catalog or your requirement.
Caution
: Improper combination may result in burning of motor and / or driver unit.
1 Is the power voltage to the controller correct?
l Check the indication on power terminal block of controller.
l Do not supply 200 V power to a module main unit of which power specification is 100 V.
2 Are there any discrepancy between motor output of main unit and controller and
connecting axes?
l Make sure that the motor output corresponds to controller reference number.
(See “Figure 5-6: Reference number configuration of EXEA controller.”)
l Rated motor output of main unit
PH module : 200W
PM module : 100W
RH module : 400W
RM module : 400W or 200W
RS module : 200W or 100W
— 6-2 —
1 Installation and Maintenance of EXEA Controller “6. Unpacking and Installation”
6.3. Installation of EXEA Controller
l Prepare a base strong enough to support the weight of the controller. Fix the controller firmly to
the base using U slots for panel mounting.
Danger
: Use the controller at ambient humidity between 20 to 85 % with no dew
condensation.
Protect the controller from splashing water or oil. Also protect it from
conductive fine particles, corrosive gas, inflammable gas and explosive gas.
Insufficient protection may result in a fire, malfunctioning or break down.
1) After installing the EXEA controller, make sure that it is secured to the
base and there is no possibility of danger.
2) EXEA controller adopts natural convection air cooling. Leave a 50 mm
or more spaces above and below of it. Insufficient natural convection
may cause an overheat alarm or excessive temperature rise inside the
controller, resulting in malfunction or reduced service life.
à Maintain the temperature around the controller between 0 to 50°C. In
the temperature over or below of this range, the controller may not
operate normally. When the temperature is close to 50°C, it is
recommended to use a forced cooling system.
Figure 6-1
U slots to secure the panel
(4 places for a single and 2 axes controller,
8 places for 3 and 4 axes controller)
(Note)
50 mm or more
POWER
DISP.
1st
2nd
MOTOR1
MOTOR2
CN4
CN1
MAIN
T/B
CN5
CONT.
CN2
RS-232C
EXT.I/O
CN3
I/O
ALARM
ALARM
Type
No.
MADE IN JAPAN
FGND
1st
SENSOR
2nd
SENSOR
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EXEA Controller
50 mm or more
Mounting bracket
(Note) This clearance is common to the all
controllers for single to 4 axes control
— 6-3 —
1 Installation and Maintenance of EXEA Controller “6. Unpacking and Installation”
(Blank Page)
— 6-4 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7. Wiring
7.1. Connector List
l The connectors for external connection of the EXEA controller are shown in Table 7-1.
l For positions of the connectors, see “5.1.2. Appearance and Dimensions” of the EXEA
controller.
Table 7-1
Name of
Function
connector
CN1
· Connector for the teaching box
CN2
CN3
·
·
CN4, CN5
·
EXT.I/O
·
MOTOR
·
SENSOR ·
FGND
·
Cables / wiring
· Connect the cable supplied with the teaching box.
· Wiring of this connector is not required when the
remote control through RS-232C communication is not
used.
Connector for RS-232C
· Please refer to “7.4. CN2: RS-232C Connector” and
communication
provide them.
· RS-232C cable set for the personal computer is
available from NSK Ltd. (optional)
· Wiring should be provided by user. See “7.5. CN3:
A control Input / Output
Control Input / Output Signal Connector.”
connector to control EXEA
· Connectors and connector shells are provided as
controller externally
accessories.
· Wiring should be provided by customer. See “7.6. CN4,
CN5: Main Power and Control Power Connector.”
Main power (CN4) and control
power (CN5) connectors
· Connectors and connector shells are provided with the
controller as accessories.
· Wiring should be provide by user. See “7.7. EXT IO:
General Input / Output Signal Connector”
General Input / Output connector
· Connectors and connector shells are supplied with the
controller as accessories.
· Exclusive controller cable for the robot module system
Motor connector
is available.
· Refer to “19.2. Controller Cable (common to P and R
series module main unit)” for its reference number.
· See “Appendix 1: Motor Connector” and “Appendix 2:
Encoder connector
Encoder Sensor Connector” for connector specification.
· Be sure to ground the EXEA controller.
Frame ground terminal
· Refer to “7.2.4. Grounding.”
— 7-1 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.2. Precautions for Wiring
7.2.1. Making Cables
l When making cables and selecting parts for the cables, follow the instructions described in the
chapter for each connector.
Warning : Use the optional controller cable and cable support for motor and encoder
cables.
We do not recommend to provide the cables by yourself or modify (i.e.
extend, shorten and/or cut) our optional controller cable to avoid misswiring. If you need to modify the controller cable or the cable support, be
sure not to miss-wire it. Miss-wiring may lead to breakage of the equipment
or malfunction of robot module system.
à We do not compensate for damages or accident induced by miss-wiring by user.
7.2.2. Connection of Cable
Danger
: Do not disconnect cables while power of EXEA controller is turned on.
Such an action may cause short circuit and / or malfunction of the
controller.
Warning : When connecting motor and encoder connectors to the controller, pay
great attention not to connect to a wrong axis connector. When the power is
turned on and operation command is input under improper connection, it
may result in burnt motor or controller malfunction.
PH module : 200W
PM module : 100W
RH module : 400W
RM module : 400W or 200W
RS module : 200W or 100W
Warning : Insert connectors in proper manner as the connectors have orientation for
insertion. Plug in connectors smoothly keeping their orientations. Wrong
connections result in motor breakage or malfunction of the system.
(Refer to Figure 7-17.)
7.2.3. Securing Connectors
l Push connectors to the very end firmly and secure it.
l If a connector is provided with screws, use them to secure connector. If connector does not have
screws, make sure it is locked.
l Take measures not to apply external force to connectors. Fix connector firmly to prevent from
unplugging and losing contact.
Caution
: If a connector is not secured sufficiently, it may be unplugged or loosened,
and may result in malfunctions
— 7-2 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.2.4. Grounding
Danger
: The system must be grounded properly to avoid electric shock or
malfunctions due to noises. Be sure to ground FGND terminal of EXEA
controller.
l Refer to Figure 7-1 for FGND terminal. Though there are two FGND terminals, they are
connected inside of the controller. Connect to either one of them.
l There are two RGND terminals for 3 ~ 4 axes EXEA controllers. Ground them respectively at a
one-point.
Figure 7-1
FGND
FGND terminal
EXEA controller side
l The grounding shall be a one-point and class 3. (Ground resistance: 100 W or less.)
l If another equipment is mounted in the same enclosure, ground the equipment and devices at
one point. (Refer to Figure 7-2.)
l The grounding cable of the controller must be a thick cable as possible, such as a flat braided
copper wire or 3.5 square mm.
Note: The FG pins of each connector of EXEA controller are connected to the FGND in the
controller.
— 7-3 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
Figure 7-2
¡ : Good example (One point grounding)
EXEA controller
Sequencer
FGND
Noise filter
AC power line
• • • • •
FGND
Noise filter
Other controller
and driver
FGND
Noise filter
AC power line
AC power line
× : Bad example
EXEA controller
Sequencer
FGND
Noise filter
AC power line
FGND
Noise filter
AC power line
— 7-4 —
• • • • •
Other controller
and driver
FGND
Noise filter
AC power line
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.2.5. Measures against Noises
Warning : Any special measures against EMC (Electromagnetic compatibility of CE
Marking) are not taken for the robot module system. Do not use the robot
module in an environment subject to much external noises. In an
environment where noises produced by the robot module system give
influences on your equipment, shield the EXEA controller, use a noise filter
or take another measures.
l The following shows the noise resistance of the EXEA controller itself.
Table 7-2
Item
Line noise resistance
Static noise resistance
Caution
Noise resistance
1000V 1µs
3 kV
Remarks
Checked by a noise simulator
: In order to eliminate influences of excessive noises, follow instructions
hereunder.
1) Make sure to connect FGND terminal of the controller to the ground.
2) Separate cable routings of the primary power line (AC line), motor
power line and operation signal (DC line). Never lay these lines in the
same conduit.
3) Use a shielded cable for signal cables. Connect the end of shield to
the ground.
4) Always supply sufficient AC power to the controller. Connect a
controller to the power line with less power variation. Do not connect
to the same power line to which noise emitting machines (e.g. welding
machines, compressors or ultrasonic washing machines) are
connected.
5) Do not use a thin and long cable for the AC main power. Use thicker
and shorter cable as possible.
Caution
: In case of the application that emits electrostatic noises, ground the part of
module system where electrostatic noises pass through (e.g. the slider of
main unit) in order to prevent electrostatic noise from being applied to the
EXEA controller.
— 7-5 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.3. Wiring
7.3.1. Wiring Procedures
Figure 7-3
CN1
: Plug the connector of teaching box cable to CN1 connector
of EXEA controller.
Teaching box
CN3
Control I / O
MOTOR, SENSOR
Motor, encoder
: Plug the cable, provided by user referring to “7.5. CN3: Control
Input / Output Signal Connector”, to the CN3 connector and
secure it. Emergency stop input must be wired, even if the
system is operated by the teaching box only or remotely
controlled through a personal computer without using control
I/O.
: Connect an optional controller cable.
Warning : Make sure that each axis is connected properly.
* Miss-wiring or misconnection may cause motor
burning or system malfunction.
EXT. I/O
: Use an optional cable, if required, referring to “7.7. EXT. IO:
General Input / Output Signal Connector” and connect it.
General Input / Output
CN2
RS-232C
CN4, CN5
: Use an optional cable, if required, referring to “7.4. CN2: RS232C Connector” and connect it to CN2 connector on EXEA
controller, then secure it.
: Wire them referring to “7.6. CN4, CN5: Main Power and
Control Power Connector.”
Power input terminal
— 7-6 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.3.2. Wiring Example
Figure 7-4 Wiring example
1st axis (X axis unit)
Teaching box
CN1
EMG key
Brake
Servo motor
Emergency stop circuit
*1
1st MOTOR
*1
1st SENSOR
Encoder
*2
Internal power
source
DC24V/2A
-
Master controller
(operation consoles
or sequencer)
Input switch
etc.
2nd SENSOR
4th axis (R axis unit)
4th MOTOR
4th SENSOR
• Slave unit
• Condition input unit etc.
Input COMI
EMST+
EMSTSVON
RUN
HOS
HOLD
CSTP
STOP
RSTA
ACLR
EREM
EXT.I/O P1
+24V
Relay and solenoid
valve, etc.
Input COMI
General input × 16
General output × 16
Output COMO
0V
Sensor and switch,
etc.
FG
RDY
WRN
HOMS
HOLDA
RSTAE
CSTPA
DATWT
EDTM
TBXM
MTN
Output COMO
•••
Output relay
etc.
CN3
+24V
2nd MOTOR
•••
+
2nd axis (Y axis unit)
*3
EXT.I/O P4
+24V
Relay and solenoid
valve, etc.
Input COMI
General input × 16
General output × 16
Output COMO
0V
0V
FG
FG
CN4, CN5
~
~
FGND
Noise filter
Sensor and switch,
etc.
*1 In the single axis controller, the
axis number 1st is not indicated.
*2 The part in the dotted lines are for
the multi-axis controller only.
*3 For the single axis controller, this
part shall be “P2.”
Single phase AC 200V/240V
Note: Wiring of CN3 and EXT.I/O in the figure is the example when the internal power
source (+24V, 0V) is used. Do not wire the internal power source when the
external power source is used.
— 7-7 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.4. CN2: RS-232C Connector
l This connector is used to set EXEA controller to RS-232C control (remote control) mode.
l Refer to “18. Remote Control Operation” for the remote control.
7.4.1. Cable on the Market (Standard Cable)
l Refer to Figure 7-5 when using an RS-232C standard cable on the market.
l NSK carries an optional cable for RS-232C. Refer to “RS-232C Cable.”
Note: You must provide a cable matcher in accordance with your personal computer
specification.
l Refer to Table 7-3 for information on the connectors and cables.
Table 7-3: Specifications of connectors and cables
Personal
computer
PC9821(NEC) or
equivalent
PC9821 note
(NEC) or
equivalent
PC98NX or
DOS/V equivalent
Connector on
personal
computer
D-sub 25 pins
(female)
Recommended connectors
Not required
KRS-HA1520fK (Sanwa Supplies)
Half pitch 14 pins
or equivalent
(Centronics)
[Half pitch 14 pins (Centronics) (male) /
(female)
D-sub 25 pins (female)]
D-sub 9 pins
(male)
D09-9F25F (Sanwa Supplies)
[D-sub 9 pins (male) /
25 pins (female)]
Connector on
EXEA controller
Recommended cable
M-EXTC040R01
(Optional cable from NSK)
or
KRS-HA154K
(Sanwa Supplies)
Half pitch 14 pins
(Centronics)
(female)
[D-sub 25 ins (male)/ Half pitch 14
pins (Centronics) (male)]
Figure 7-5: Example of cable /connector combination
POWER
DISP.
1st
2nd
MOTOR1
MOTOR2
CN4
CN1
MAIN
T/B
CN5
CONT.
CN2
RS-232C
EXT.I/O
I/O
Type
No.
FGND
1st
SENSOR
2nd
SENSOR
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N S K LLttd .
MADE IN JAPAN
EXEA connector
(CN2)
— 7-8 —
ALARM
ALARM
EXEA Controller
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Recommended cable
(KRS-HA154K,
Sanwa Supplies)
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Personal computer
D-sub 9 pins for serial
communication
(Normally
indicated.)
Recommended
connector
(D09-9F25F)
CN3
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.4.2. Making RS-232C Cable
l Refer to Table 7-4, Table 7-5 and Figure 7-6 if you make the RS-232C cable for CN2 connector.
Table 7-4: CN2 connector parts
Sumitomo-3M 10214-52A2JL
Sumitomo-3M 10114-3000VE
Sumitomo-3M 10314-52A0-008
Connector, EXEA controller side
Mating connector (cable side)*
Applicable connector shell*
* Shall be prepared by user.
Table 7-5: CN2 signal name and function
Pin No.
1
2
3
4
5
6
7
Signal
TXD
–
–
RTS
–
–
–
I/O
output
output
Function
Transmit data
Ready to send
Pin No.
8
9
10
11
12
13
14
Signal
–
RXD
CTS
–
FGND
FGND
SC
Figure 7-6
RS-232C
(Serial port of a personal
computer, etc.)
EXEA controller
CN2
TXD
1
TXD
RXD
9
RXD
RTS
4
RTS
CTS
10
CTS
SGND
14
SGND
FGND
12
FGND
13
FGND
DSR
DTR
— 7-9 —
I/O
Function
input
input
Receive data
Clear to send
Frame ground
Frame ground
Signal ground
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.5. CN3: Control Input / Output Signal Connector
l Wire Input / Output signal to control the EXEA controller in the external operation mode.
l EMST (emergency stop) input must be wired, even if the system is operated by the teaching box
in a trial operation without using control I/O or, the system is remotely controlled by a personal
computer.
EMST input is a B contact. (normally close)
Note: When using the external DC 24V power supply, it must be turned on simultaneously
with the main power supply of EXEA controller. If not, EMST input is detected as OFF
and the system goes into EMST(emergency stop) state.
Table 7-6: CN3 connector parts
Connector, EXEA controller side
Mating connector (cable side) *
Mating connector shell type (cable side) *
Japan Aviation Electronics Industries Ltd.
DCLC-J37SAF-13L9
Japan Aviation Electronics Industries Ltd.
DC-37PF-N
Japan Aviation Electronics Industries Ltd.
DC-C8-J13-F1-1
* Provided with EXEA controller as an accessory.
7.5.1. Precautions for Wiring CN3
l Be sure to use shielded cable and ground the shield.
l When connect a relay to an output signal, install a surge killer to the relay.
l Lay the CN3 signal wiring apart from the power lines (main power line cable, motor cable). Do
not put them in the same conduit.
l Make CN3 cable short as possible. (3 meters or less) If a longer cable is required, take proper
measures against external noises.
Caution
: Disobedience to the instructions above may result in malfunction or
memory data corruption due to noises.
Caution
: Follow the electric specification shown in Table 7-7 below. In particular, any
of the following three issues may lead to breakage of electrical elements of
the input and output signal.
1) Out of allowable range of power supply voltage (24 VDC ± 10%)
2) Reversed phase connection of the power supply (24 VDC)
3) Output signal exceeds maximum switching ability.
Table 7-7: CN3 signal specification
Classification
Input signal
Input signal *
(Pulse train input)
Output signal
Item
Input voltage
Input impedance
Max. input current
Input voltage
Input impedance
Input current
Maximum switching ability
Saturation voltage
* This is for a single axis controller only.
— 7-10 —
Specification
DC24V ± 10%
3.3kW
10mA (per one point)
DC5V ±10%
240W
25mA or less
DC24V / 100mA
2V or less
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.5.2. CN3 Signal Function
Table 7-8: CN3
Classification
State control
Start
Programmed
operation
control
Signal
name
I/O
SVON
Input
ACLR
Input
EREM
Input
HOS
Input
RUN
Input
RSTA
Input
EMST+
EMST-
Input
STOP
Input
CSTP
Input
HOLD
Input
RDY
WRN
Output
Output
MTN
Output
EDTM
Output
TBXM
Output
HOMS
Output
Stop
Error status
indication
Status
indication
CSTPA Output
HOLDA Output
RSTAE Output
DATWT Output
Function
Select the motor servo state. In some abnormal situation, such as in alarms, inputting
SVON signal does not activate the servo.
· SVON input = ON: Motor is in servo on state.
· SVON input = OFF: Motor is in servo off state.
Clears an alarm. Rising edge detection signal.
When EREM signal is activated, the external control mode is changed to the remote
communication mode and the control and operation through remote command is enabled.
When EREM is off, only monitoring data is possible on remote communication.
Starts Home return operation. Rising edge detection signal.
Starts programmed operation selected by PROG 0 to 6 ports of EXT. IO. Rising edge
detection signal.
Resumes a halted programmed operation when RUN input is turned on while RSTA is
on. However, this command is only effective when RSTAE input is closed. When it is
opened, inputting this command activates “error” message. Refer to “17.5.2. Resume
Programmed Operation” for restart of operation.
Activates emergency stop when + and - of EMST is cut off and motor gets in servo off
state. Once the emergency stop condition is established, operation cannot be started
unless the emergency stop condition is canceled. For canceling emergency stop, refer to
“11.3.1.3. Recovery from Emergency Stop.”
Stops the operation when this input is on. (Motor decelerates and stops.) The program
that has been executed is forced to cancel and the motor goes in servo-lock state. You
cannot resume the operation automatically keeping the signal ON, as the signal is a state
signal (signal level detection). Even the STOP signal is off, the operation won't start
automatically. It requires to make RUN command ON again. The programmed operation
will start from the beginning.
Stops after execution of a program step when CSTP is on during programmed operation.
Motor goes in servo-lock state. (cycle stop) RUN input resumes the programmed
operation from the next step when CSTP input is off. When it is on, a RUN input
executes a programmed step operation. (Each RUN command executes a program in a
program step one by one.)
HOLD input holds a programmed operation being executed. (Makes the motor to
decelerate and stop.) The motor goes in servo-lock state. RUN command after HOLD
input is off will resume the programmed operation from the position at where it stopped.
Normally close. Opens in case of a serious error.
Normally open. Closes in case of a minor error.
Closes during execution of operation such as Home return and programmed operation. It
keeps closing during “cycle stop” or “operation hold.”
Closes while editing the memories through teaching box or remote command, indicating
that the starting operation command is disabled.
Closes to indicate that the external operation and the remote control modes are disabled
when the controller is under teaching box operation mode.
Closes after completion of Home return. It opens to indicate the necessity of Home return
when the encoder is in abnormal condition, or the parameters related to Home return
operation are changed.
Closes during cycle stop.
Closes during HOLD input is on.
Closes when a resuming operation is enabled under temporary discontinuation of
programmed operation.
Closes when writing programs and parameters to the internal flash memory. All data must
be lost if power is turned off at this moment, and may lead to “memory error.”
Operations, such as programmed operation or Home return, are disabled when this output
is closed.
— 7-11 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.4.3. CN3: Signal Specification
Figure 7-7: CN3 pin-out
Pin
+24V
1
0V
2
EMST+
3
EREM
4
HOLD
5
RSTA
6
RUN
7
SVON
8
–
9
CWP+
10
CCWP+
11
DATWT
12
HOLDA
13
HOMS
14
EDTM
15
WRN
16
–
17
0V
18
FG
19
20
COMI
21
–
22
EMST-
23
ACLR
24
CSTP
25
HOS
26
STOP
27
–
28
–
29
CWP-
30
CCWP-
31
RSTAE
32
CSTPA
33
TBXM
34
MTN
35
RDY
36
–
37
COMO
* The pins in the dotted area are for single axis
controller only. Do not connect them for a
multi-axis controller.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Signal
name
+24V
0V
EMST+
EREM
HOLD
RSTA
RUN
SVON
CWP+
CCWP+
DATWT
HOLDA
HOMS
EDTM
WRN
0V
FG
COMI
EMSTACLR
CSTP
HOS
STOP
CWPCCWPRSTAE
CSTPA
TBXM
MTN
RDY
COMO
Input /
Output
output
output
input
input
input
input
input
input
input
input
output
output
output
output
output
output
input
input
input
input
input
input
input
input
output
output
output
output
output
output
Description
+ side output, DC24V internal power supply
- side output, DC24V internal power supply
Emergency stop (+)
Remote control enables
Hold
Restart
Start
Servo on
Do not connect.
CW pulse train (+) *
CCW pulse train (+) *
Writing data
Hold
Home return complete
Remote editing
Warning
Do not connect.
- side output, 24V internal power supply
Frame ground
Common, input
Do not connect.
Emergency stop (-)
Alarm clear
Cycle stop
Home return start
Operation stop
Do not connect.
Do not connect.
CW pulse train (-) *
CCW pulse train (-) *
Resume operation enabled
Stopping (cycle stop)
Teaching box operation
Operating status
Controller ready
Do not connect.
Common, output signal
* These pins are for a single axis controller only.
Do not connect them for a multi-axis controller.
Note: In an operation through the teaching box or a programmed operation, all input signals
other than EMST is not accepted.
— 7-12 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
Figure 7-8: Sample wiring diagram
Sequencer, user device
EXEA controller (CN3)
DC 24V Internal power supply
1
+24V
DC24V
2, 18
0V
0V
+24V
or
+24V 0V
0V
+24V
or
+24V 0V
*
Input
20
4
5
6
7
8
23
24
25
26
3
22
COMI
EREM
HOLD
RSTA
RUN
SVON
ACLR
CSTP
HOS
STOP
EMST+
EMST-
Output
12
13
14
15
16
31
32
33
34
35
37
DATWT
HOLDA
HOMS
EDTM
WRN
RSTAE
CSTPA
TBXM
MTN
RDY
COMO
10
CWP+
29
CWP-
11
CCWP+
30
CCWP-
Frame ground
19
F.G
CW Pulse train
CCW Pulse train
DC5V
* The wiring in the dotted area are for a single axis controller only.
Do not wire them for a multi-axis controller.
Caution
: Do not connect the internal DC 24V power supply if the external DC 24V
power supply is used. It may lead to breakage of the internal power supply.
— 7-13 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.5.3.1. Specification of Control Signal
General input: EREM, HOLD, RSTA, RUN, SVON, ACLR, CSTP, HOS, STOP
Table 7-9
Item
Input voltage
Input impedance
Input current
Specification
DC24V±10%
3.3kW
10mA or less (per port)
Figure 7-9
*
3.3kW
6809
COMI
Input
EXEA controller side
* You may connect here as “Minus common” when the polarity of the external power
supply is reversed.
7.5.3.2. EMST Input Signal Specification
General input: EMST+, EMSTTable 7-10
Item
Required switching ability
Specification
DC24V, 10mA or over
Figure 7-10
Internal DC 24V
3.3kW
EMST+
EMSTInternal DC 0V
EXEA controller side
— 7-14 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.5.3.3. Pulse Train Input (Single axis controller only)
Applicable input: CCWP+, CCWP-, CWP+, CWPTable 7-11
Item
Input voltage
Input impedance
Input current
Specification
DC5V±10%
240W
25mA or less
Figure 7-11
120W
3909
Input+
120W
Input-
EXEA controller side
7.5.3.4. Specification of Control Output Signal
Applicable output : DATWT, HOLDA, HOMES, EDTN, WRN, RSTAE, CSTPA, TBXM, MTN,
RDY
Table 7-12
Item
Maximum switching ability
Saturation voltage
Specification
DC24V/100mA
2V or less
Figure 7-12
Output
COMO
EXEA controller side
* COMO may be either “plus common” or “minus common.”
— 7-15 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.6. CN4, CN5: Main Power and Control Power Connector
7.6.1. Precautions for Wiring of Power Input Connector
l The connector of main power supply must have sufficient capacity for required power
consumption of the EXEA controller.
Table 7-13
Motor power
Required power capacity (per axis)
100W
0.33kVA
200W
0.66kVA
400W
1.5kVA
l Use a 1.25 mm2 power cable for 1.5 kVA or less capacity. Use a 2 mm2 or larger power cable
for 1.5 to 3.0 kVA capacity.
Danger
: An isolation transformer* must be used to avoid electric shock. It must have
enough capacity for the power consumption of EXEA controller.
The isolation transformer should have protection against overheat for both
in normal and abnormal conditions.
Danger
: A circuit breaker* which has enough capacity of EXEA controller power
capacity must be provided to the main power supply line to avoid large
incoming current due to the system failure.
Note*: An isolation transformer and a circuit breaker have to conform to the requirements of
relevant European standard. Refer to “5.1.1. Specifications” for specifications of power
capacity and inrush current.
Danger
: Install noise filter as one of the measures to Electromagnetic compatibility
(EMC). Select the noise filter so that your machine will clear the
requirements of EMC Directive after its installation.
Danger
: Connect the FGND terminal securely to the ground. Improper grounding
may cause electric shock, damages to the equipment or malfunction due to
noises. Refer to “7.2.4. Grounding.”
Danger
: Secure the main power input connector firmly.
Danger
: Connection to a different specification voltage line may cause damages to
controller and / or motor. Refer to Figure 5-6 for reference number of the
EXEA controller and confirm voltage specification of your controller.
Table 7-14
Code on
reference number
Power source
voltage spec.
Main power voltage range
Control power voltage range
T
AC200V / 240V
Single phase
AC180V ~ AC264V
Single phase
AC180V ~ AC264V
Caution
: If it is necessary to provide power line with a magnet switch or earth
leakage breaker, add inrush current at the moment of turning on power and
leakage current* to the power capacity shown above. If the capacity is
insufficient, the contacts may fuse.
* For inrush current and leakage current, refer to “5.1.1. Specifications.”
— 7-16 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
l Use a magnet switch with rated current of 30A or over. Separately install the power supply line
of 3 ~ 4 axes controller and 1 ~ 2 axes controller.
l Be sure to provide a surge killer to coils of magnetic switches, relays and solenoids.
l Install a noise filter between main power supply and controller in order to avoid external noises.
Table 7-15: Recommended noise filter (reference use only)
Shaffner EMC Ltd.
FN2070-10
l Separate the primary wiring from the secondary wiring of noise filter and lay them in different
routs.
l Install the noise filter close to the controller as much as possible and do not install any magnetic
switch or relay between them.
7.6.2. Power Line Wiring
Table 7-16: Terminal and function
Connector
CN4 MAIN
CN5 CONT
FGND
Caution
Terminal code
L
N
L
N
Function
Single phase AC 200 / 240 V main power supply
Single phase AC 200 / 240 V control power supply
Frame ground
: Connection to an improper power voltage may lead to breakdown of the
controller and/or the motor.
— 7-17 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.7. EXT. IO: General Input / Output Signal Connector
l Wire general Input / Output signals for the external control mode to control slave units, or to
input a conditional jump command of EXEA controller.
Table 7-17: EXT. I / O connector parts
Japan Aviation Electronics Industries Ltd
DCLC–J37SAF–13L9
Japan Aviation Electronics Industries Ltd
Mating connector, cable side *
DC–37PF–N
Japan Aviation Electronics Industries Ltd.
Mating connector shell type, cable side *
DC–C8–J13–F1–1
Connector, EXEA controller side
à * These are provided as the accessories.
7.7.1. Precautions for Wiring
l Be sure to use shielded cables and ground the shield securely.
l If it is necessary to install a relay to the output port, a surge killer must be installed to a relay.
l EXT. I / O signal cable must be separated from the power line (main power supply or motor
cable) and do not put then in the same conduit or duct.
l Make EXT. I / O cables short as possible. (3 meters or less) If the cables is longer than this
criterion, take measures against external noise.
Caution
: Failure to observe above notices may lead to malfunction and memory loss
due to the noises.
Caution
: Be sure to meet the electrical specifications in Table 7-18. Especially
following three issues are critical for breakage of electrical element of input
and output circuit.
1) Power supply range (DC24V ±10 %)
2) Reversed connection of power supply polarity (DC24V)
3) Over output switching ability
Table 7-18: EXT. I / O signal electrical specification
Signal
Input signal
Output signal
Item
Input voltage
Input impedance
Maximum current
Maximum switching ability
Maximum saturated voltage
— 7-18 —
specification
DC24V ±10%
3.3kW
10mA (per port)
DC24V / 100mA
2V or less
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.7.2. EXT.IO Signal Function
Table 7-19: EXT: Input / Output
Signal function
name
Signal name
PROG0 ~ PROG6
IN1 ~ IN16
Input /
Output
Select the program number (0 to 127) to be executed.
Input The input is referred when RUN input is on. After
RUN is on it may be used as a general input (USER).
Note 3)
Programmed operation control
(Set to either one of
Note 3)
PROGn/UNTNn
Note 1)
or POSNn/USER)
UNTN0 ~ UNTN2
Input
POSN0 ~ POSN11 Input
USER
Input
RSRV
Input
Note 4)
OUT1 ~ OUT16
Indication of state
Note 2)
(Set either FINn or USER)
Function
FIN1 ~ FIN8
Output
USER
Output
RSRV
Output
Select number of units in the direct operation. This
input is referred when RUN input is on.
This is to select point number (0 to 3999) in the direct
operation. This input is referred when RUN input is on.
This is for general input. It can be applied to a
command using the input signal.
Reserved
It is closed when a designated unit by its number
completes a motion. (Only Unit 1 is set for a single axis
controller) The time for this state is set at the
initialization. When the time expires, this port will
open.
This is the general output. This is the port that can be
outputted during a programmed operation.
Reserved
Note: 1) The shipping set are PROG0 ~ PROG6 (IN1 to IN7), RSVR (IN8) and USER (IN9
to IN16).
2) The shipping set is USER (OUT 1 to OUT16).
3) These are not used for the single axis controller.
4) Only FIN1 is available in the single axis controller.
l Select EXT.IO function at initial setting. Refer to “9.8. Parametes for Input Signal Format” and
“9.9. Parameters for Output Signal Format.”
— 7-19 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.7.3. CN3 Signal Specification
Figure 7-13: EXT. I / O connector pin-out
+24V
1
0V
2
IN16
3
IN14
4
IN12
5
IN10
6
IN8
7
IN6
8
IN4
9
IN2
10
OUT16
11
OUT14
12
OUT12
13
OUT10
14
OUT8
15
OUT6
16
OUT4
17
OUT2
18
—
19
Pin
No.
Signal
name
I/O
Description
20
COMI
1
+24V
output
21
IN15
2
0V
output
22
IN13
23
IN11
24
IN9
25
IN7
26
IN5
27
IN3
28
IN1
29
OUT15
30
OUT13
31
OUT11
32
OUT9
33
OUT7
34
OUT5
35
OUT3
36
OUT1
37
COMO
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
IN16
IN14
IN12
IN10
IN8
IN6
IN4
IN2
OUT16
OUT14
OUT12
OUT10
OUT8
OUT6
OUT4
OUT2
-
COMI
IN15
IN13
IN11
IN9
IN7
IN5
IN3
IN1
OUT15
OUT13
OUT11
OUT9
OUT7
OUT5
OUT3
OUT1
COMO
input
input
input
input
input
input
input
input
output
output
output
output
output
output
output
output
–
input
input
input
input
input
input
input
input
input
output
output
output
output
output
output
output
output
output
Internal DC 24V power supply, + side
output
Internal DC 24V power supply, - side
output
Reserve / POSN11 / USER
Reserve / POSN 9 / USER
Reserve / POSN 7 / USER
Reserve / POSN 5 / USER
Reserve / POSN 3 / USER
PROG5 / POSN1 / USER
PROG3 / Reserve / USER
PROG1 / UNTN1* / USER
Reserve / USER
Reserve / USER
Reserve / USER
Reserve / USER
FIN8* / USER
FIN6* / USER
FIN4* / USER
FIN2* / USER
Do not connect
Input common
Reserve / POSN10 / USER
Reserve / POSN8 / USER
Reserve / POSN6 / USER
Reserve / POSN4 / USER
PROG6 / POSN2 / USER
PROG4 / POSN0 / USER
PROG2 / UNTN2* / USER
PROG0 / UNTN0* / USER
Reserve / USER
Reserve / USER
Reserve / USER
Reserve / USER
FIN7* / USER
FIN5* / USER
FIN3* / USER
FIN1 / USER
Output signal common
* For the singla axis controller these parts
are indicated as “Reserved.”
— 7-20 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
Figure 7-14: Sample wiring diagram
User device (Sequencer)
EXEA controller (EXT. I/O)
Internal DC 24V power supply
1
+24V
DC24V
2
0V
General input
20
COMI
3
IN16
21
IN15
4
IN14
22
IN13
5
IN12
23
IN11
6
IN10
24
IN9
7
IN8
25
IN7
8
IN6
26
IN5
9
IN4
27
IN3
10
IN2
28
IN1
0V +24V
or
+24V 0V
General output
11
OUT16
29
OUT15
12
OUT14
30
OUT13
13
OUT12
31
OUT11
14
OUT10
32
OUT9
15
OUT8
33
OUT7
16
OUT6
34
OUT5
17
OUT4
35
OUT3
18
OUT2
36
OUT1
37
COMO
0V +24V
or
+24V 0V
Caution
: If the external DC24V power supply is used, do not connect the internal
DC24V power supply. It leads to breakage of the power supply if the
connection is made.
— 7-21 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.7.3.1. Input Signal Specifications
General input : IN1 ~ IN16
Table 7-20
Item
Input voltage
Input impedance
Input current
Specification
DC24V±10%
3.3kW
10 ma or less (per port)
Figure 7-15
*
3.3kW
6809
COMI
Input
EXEA controller side
* You may connect here as “Minus common” when the polarity of the external power
supply is reversed.
7.7.3.2. Output Signal Specifications
Applicable output: OUT1 ~ OUT16
Table 7-21
Item
Maximum switching ability
Saturation voltage
Specification
DC24V/100mA
2V or less
Figure 7-16
Output
COMO
EXEA controller side
* COMO can be either “plus” or “minus” common.
— 7-22 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
7.8. Motor and Encoder Connectors
l Connect the controller cable.
Warning : Be sure not to connect to a wrong axis. Wrong connection and improper
wiring may lead to motor breakage or malfunction of EXEA controller.
Warning : Prevent improper insertion of connectors
à Insert connectors in proper manner as the connectors have orientation for insertion.
Forcing to plug in them may result in breakage of the connectors, or malfunction of the
system if the connectors are left in insufficient connection. Confirm their orientations,
insert them smoothly and make a correct connection.
Figure 7-17
265
(48)
Motor
connector
POWER
DISP.
1st
2nd
MOTOR1
MOTOR2
CN4
CN1
MAIN
T/B
Connect the connector
so that cut-off corner
comes underside.
CN5
CONT.
CN2
215
RS-232C
EXT.I/O
160
CN3
I/O
ALARM
ALARM
Type
No.
MADE IN JAPAN
FGND
1st
SENSOR
2nd
SENSOR
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EXEA Controller
— 7-23 —
1 Installation and Maintenance of EXEA Controller “7. Wiring”
(Blank Page)
— 7-24 —
1 Installation and Maintenance of EXEA Controller “8. Startup”
8. Startup
8.1. Turn on Power
8.1.1. Preparation before Turning on Power
1 Check the wiring of controller and robot module cables.
l Make a proper connection of cables referring to the seals affixed to the connectors.
2 Clear emergency stop state.
l Clear EMST input of CN3 connector. (Turn EMST input on.)
3 Connect the teaching box.
l If the teaching box is not used, connect a provided dummy connector, otherwise the system gets
into emergency stop state.
4 Check for the safety.
Danger
: Check if the fixing bolts of module main unit are securely fastened.
à If the bolts are not secured properly, it may cause a serious injuries when robot starts
to move.
Danger
: Check if a vertical axis are securely hold by motor brake.
à If it is not hold, it back-drives and may cause injuries or the damage to the robot and
ancillaries.
Danger
: Do not enter motion range of robot modules when doing start-up, adjusting
and test running.
à Never enter motion range of robot module system, otherwise it may cause serious
accident.
à For maintenance work, observe the notes and safety precautions in “14.
Troubleshooting.”
Warning : Is there any disconnection, defective connection and / or connection to
wrong axis ?
à Normal operation cannot be expected. Make sure for connections because a wrong
connection may cause a defective controller and module main unit.
Caution
: Assure that there is no mechanical interference when all module main units
make their full stroke.
à Mechanical interference may damage the module main unit and other ancillaries.
Note: When turning off the power or servo, the dynamic brake functions. Existence of some
resistance when moving the slider manually is not abnormal. The dynamic brake does
not work when the controller cable is disconnected.
— 8-1 —
1 Installation and Maintenance of EXEA Controller “8. Startup”
8.1.2. Checks When Turning on Power
l Turn on power.
l After turning on the power, confirm that 7 segment LED on the front panel of EXEA controller
is indicating no abnormality, a round green LED over the 7 segment LED is on, and the display
of the teaching box (Figure 8-1) is normal.
Figure 8-1
Turn on power.
Display screen of the
teaching box
NSK CONTROLLER
Typ.EXE****
Ver.0001
******** ********
Indicates information of software of the system.
Typ.EXE****
Indicates the type of controller.
EXE MONO : Single axis controller
EXE2
: Two axes controller
EXE3
: Three axes controller
EXE4
: Four axes controller
Ver.0001
This tells you the version number of the software.
For a single axis controller one version number is
shown and for multi-axis controller, three version
numbers will be indicated.
Note: Though 0 (zero) and 1 (one) are displayed at
the start it is not abnormal.
Indicates [External] automatically.
[External]
1RUN 2IO 3FNC 4etc
l Press MODE key to get in [External] immediately.
l Eliminate cause of an alarm referring to “13. Alarms” and “14. Troubleshooting” when an alarm
is detected.
l At the startup in the first time, or after 20 minutes of controller cable disconnection, the alarm of
encoder will be on. However, this is not abnormal. Execution of Home return after initial setting
will terminate the alarm.
Figure 8-2
Indication of teaching box display
[External]
ALARM [A5]
Encoder2(position)
1RUN 2IO 3FNC 4etc
— 8-2 —
1 Installation and Maintenance of EXEA Controller “8. Startup”
l After the power is turned on, red ALARM LED over SENSOR connector is on sometimes. (See
Figure 8-3.) This is not abnormal. It will be automatically off when a capacitor of smoothing
circuit is charged after SERVO is on.
Figure 8-3
265
(48)
POWER
DISP.
1st
2nd
MOTOR1
MOTOR2
CN4
CN1
MAIN
T/B
CN5
CONT.
CN2
215
RS-232C
EXT.I/O
CN3
I/O
ALARM
ALARM
Type
No.
MADE IN JAPAN
FGND
1st
SENSOR
2nd
SENSOR
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EXEA Controller
— 8-3 —
Red LED
160
1 Installation and Maintenance of EXEA Controller “8. Startup”
8.2. Selection of Control Mode
l The system gets into External control mode automatically after turning on power. At this time,
RDY output (CN3) is closed when it is normal.
l All operations, such as start and stop, are controlled through the control Input / Output signal
(CN3) of EXEA controller.
l The system gets in the external control mode every time the power is turned on.
l In this control mode, the function keys of the teaching box, along with EMG key, are effective.
(Refer to “17.4.6. Teaching Box Operation in External Control Mode.”)
Figure 8-4
Indication of teaching box display
[External]
1RUN 2IO 3FNC 4etc
8.2.1. Teaching Box Operation Mode
l For execution of initial setting, programming and operation through the teaching box, put the
system in the teaching box operation mode pressing F1 TBX after F4 etc. (See Figure 8-5.)
Use Teaching Box for selection of operation mode.
® Refer to “5.2.1. Operational Function” for function of
the keys.)
l Use F1 , F2 and F3 keys for the selection of operation in the display and use F4 key for
selecting the display.
— 8-4 —
1 Installation and Maintenance of EXEA Controller “8. Startup”
Figure 8-5: Changing operation mode
Selected display mode
External control
mode
F1
Menu selection 1
F2
1 RUN
2 IO
F4
F3
F1
Menu selection 2
3 FNC
1 TBX
: Programmed operation monitor
· Mode which monitors external
programmed operation.
: I/O monitor
Teaching box display
External control mode
Menu selection 1
[External]
1RUN
2IO
3FNC
· Mode which monitors state of external
input / output.
: Special function monitor
· Mode which monitors system version
and alarm history.
: Selecting teaching box menu
External control mode
Menu selection 2
[External]
· Selecting function to teaching box main
menu from external control mode.
1TBX
Teaching box
operation mode
F1
1 RUN
Menu selection 1
F2
3 JOG
: Jog operation
F1
· Executes jog operation through
teaching box.
: Programming
2 TCH
: Teaching
[Menu]
1RUN
3 PAL
: Palletizing *
F1
1 SYS
F2
2 CTR
2ORG
4JOG
4etc
Teaching box operation mode
Menu selection 2
[Menu]
· Makes / edits program.
2TCH
3PAL
4etc
· Inputs coordinate data of positioning
point for program.
· Initializes the palletizing program.
* This function is not available for the
single axis controller. (No indication
in a single axis controller.)
Menu selection 3
Teaching box operation mode
Menu selection 1
1EDT
F3
4etc
· Executes Home return operation
through teaching box.
1 EDT
F2
F4
· Executes programmed operation
through teaching box.
: Home return operation
F3
Menu selection 2
: Programmed operation
2 ORG
F4
4etc
: System setting
· Sets the servo gain and system
parameters.
: Setting controller
· Unit setting of controller.
Teaching box operation mode
Menu selection 3
[Menu]
1SYS
2CTR
3IO
4etc
F4
F3
3 IO
F1
1 FNC
Menu selection 4
F3
3 EXT
: I/O monitor / handling
· Monitors state of input / output of
control I /O and general I / O, and
controls output manually.
: Special function
· Displays version number and initialize
parameters.
Teaching box operation mode
Menu selection 4
[Menu]
: Selection of external control
· Changing function to external control
mode from teaching box main menu.
— 8-5 —
1FNC
3EXT
4etc
1 Installation and Maintenance of EXEA Controller “8. Startup”
8.2.2. Changing to External Control Mode from Teaching Box Operation Mode
l To return to the external control mode, press 1 , 2 , 3 keys after F3 key on the display of
menu selection 4 in teaching box operation.
Figure 8-6
Teaching box
operation mode
[MENU]
1FNC
: Teaching box operation mode
Display of menu selection 4
3EXT 4etc
Press F3 key.
[EXT]
Push 1 key
Press 1 key.
[EXT]
Push 2 key
Press 2 key.
[EXT]
Push 3 key
Press 3 key.
: External control mode
[External]
1RUN 22IO
3FNC 4etc
* When this procedure is executed while the system is operating, the controller terminates the
programmed operation and gets in [Eternal] control mode.
— 8-6 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9. Initial Setting
l This chapter describes how to set the EXEA controller according to the combination of the
module main units and the purpose of its use.
l Please refer to this chapter for initializing, adjusting or correcting the setting in the middle of
operation after the startup or initialization of the EXEA controller.
9.1. Initial Setting Procedure
l Use the teaching box or the optional application software for initial setting.
l Refer to “8.2. Selection of Control Mode” and set the objective parameters selected from “9.2.
Initial Setting List.”
l Take the same procedure for the application software. Refer to the instruction manual for the
setting in the personal computer.
l Following initial setting procedures are required after “8. Startup” has competed to operate the
EXEA controller. Observe to set as described hereunder before test running.
Procedure1: Setting type of module main unit.
l Set the type of main units (X-module Name) which are to be connected to the EXEA
controller.
l Set X axis only for the single axis controller while all axes must be set for multi-axis
combination.
l Refer to “9.5. Parameters for Unit Setting” for setting and saving the parameters.
Procedure 2: Setting total load mass
l Set the total load mass to the module main units (Payload).
l For the multi-axis combination, add all payload including the combining bracket to
respective module main units, other than a module main unit to which the effector is
directly attached.
l Refer to “9.4.1. Parameters for Servo” for contents of setting and saving the
parameters.
l Optimum servo parameter shall be set through the payload setting. However, when the
system tends to vibrates set rather lower payload than the actual value.
Caution
: 1) The robot may make unexpected motion or the main unit may break if
the robot system keeps running under wrong setting of the type of
module main unit.
2) Initialize the system parameters when the memory error arises. In such a
case set parameters according to the module main unit again.
— 9-1 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.2. Initial Setting List
l As shown in Figure 9-1(Single axis controller), Figure 9-2 (Multi-axis controller) and Figure 9-3
(Common), the system setting mode and the controller setting mode are drawn like a tree
diagram. Select each parameter setting mode with the function keys of the teaching box.
Figure 9-1: System setting mode list (Single axis controller)
Locus speed
F1
PRG
Programmed
operation
F1
JOB
Operation
parameter
F4
etc
F2
ORG
Home return
operation
F3
JOG
Jog
operation
F1
System
setting
F2
SRV
Servo
F2
FIL
Filter
F2
F3
TUN
F4
etc
F4
etc
F1
CLR
Initialization
F2 SAV
Saving system
setting data
F3
MAN
Manual
tuning
Servo
parameter
F1
Home speed
Home accel
Home search speed
Home direction
Home sequence
Home shift
Home move
Home move mode
Home unit seq.
Home return, speed
Home return, acceleration
Home return, mechanical stopper searching direction
Home return, mechanical stopper searching order
Home return, Home position offset
Home return, moving distance, after
Home return, moving format, after
Home return, motion order of units, after
Jog speed (H)
Jog speed (L)
Jog accel
Jog, high speed
Jog, low speed
Jog, acceleration
Over travel (+)
Over travel (-)
Software over travel position (+)
Software over travel position (-)
Pulse resolution
Resolution, pulse train input
Payload
Servo Gain
Feedforward Gain
Torque Limit
Dead Band
Load mass
Servo gain (Reserved)
Feed forward gain
Torque output limit
Dead band
Low Pass Filter 1
Low Pass Filter 2
Notch Filter
Low pass filter, primary
Low pass filter, secondary
Notch filter, frequency
Position Loop Gain
Velocity Loop Gain
Observer Gain
Observer Limit
Notch Filter Q1
Gain mode
Position loop gain
Velocity loop gain
Observer gain
Observer output limit
Notch filter, Q setting
Gain tuning selection. (Reserved)
Position Direction
Hard. OT Timer
Rated Current
Over Load
Position Error Over
Coordinate direction
Hardware over travel detection timer
Over load limit setting (RC)
Over load limit setting (QL)
Excessive position error limit
CLR (ALL, DEF)?
CLR (UNT, DEF)?
Initialize all unit data
Initialize data of designated unit
Home return, mechanical stopper searching speed
TPL
Pulse train
input
F1
Resultant speed
Resultant accele./deceleration
Speed limit
Acceleration limit
In-position setting, width
In-position confirmation format
Switching FIN signal output
FIN signal outputting time
LMT
position /
coordinates
[SYS]
Locus accel
Max speed
Max accel
Finish width
Finish mode
Fin control
Fin out time
ADL
Function
setting
Write, data for system setting
LOD
Reading out system
setting data
Read out, data for system setting
— 9-2 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-2: System setting mode (Multi-axis controller)
F1
PRG
Programmed
operation
F1
JOB
Operation
parameter
F2
ORG
Home return
operation
F3
JOG
Jog
operation
System
setting
F4
LMT
position /
coordinates
[SYS]
F1
SRV
Servo
F2
FIL
Filter
F2
TUN
Servo
parameter
F4
etc
F3
MAN
Manual
tuning
F4
ADL
Function
setting
F1
CLR
Initialization
F2 SAV
Saving system
setting data
F3
Locus speed
Locus accel
Max speed
Max accel
Finish width
Finish mode
Fin control
Fin out time
Resultant speed
Resultant accele./deceleration
Speed limit
Acceleration limit
In-position setting, width
In-position confirmation format
Switching FIN signal output
FIN signal outputting time
Home speed
Home accel
Home search speed
Home direction
Home sequence
Home shift
Home move
Home move mode
Home unit seq.
Home return, speed
Home return, acceleration
Home return, mechanical stopper searching direction
Home return, mechanical stopper searching order
Home return, Home position offset
Home return, moving distance, after
Home return, moving format, after
Home return, motion order of units, after
Jog speed (H)
Jog speed (L)
Jog accel
Jog, high speed
Jog, low speed
Jog, acceleration
Over travel (+)
Over travel (-)
Escape (upr. Z)
Escape (lwr. Z)
Escape (pos. Z)
Escape (upr. R)
Escape (lwr. R)
Escape (pos. R)
Software over travel position (+)
Software over travel position (-)
Arch motion, upper off-limits boundary
Arch motion, lower off-limits boundary
Arch motion, Turn out position
Reserved
Reserved
Reserved
Payload
Servo Gain
Feedforward Gain
Torque Limit
Dead Band
Load mass
Servo gain (Reserved)
Feed forward gain
Torque output limit
Dead band
Low Pass Filter 1
Low Pass Filter 2
Notch Filter
Low pass filter, primary
Low pass filter, secondary
Notch filter, frequency
Position Loop Gain
Velocity Loop Gain
Observer Gain
Observer Limit
Notch Filter Q1
Gain mode
Position loop gain
Velocity loop gain
Observer gain
Observer output limit
Notch filter, Q setting
Gain tuning selection. (Reserved)
Position Direction
Hard. OT Timer
Rated Current
Over Load
Position Error Over
Coordinate direction
Hardware over travel detection timer
Over load limit setting (RC)
Over load limit setting (QL)
Excessive position error limit
CLR (ALL, DEF)?
CLR (UNT, DEF)?
Initialize all unit data
Initialize data of designated unit
Home return, mechanical stopper searching speed
Write, data for system setting
LOD
Reading out system
setting data
Read out, data for system setting
— 9-3 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-3: Controller setting mode
F1
F2
UNT
Unit
setting
MDL
Module
setting
Reserved (Do not use.)
Controller
setting mode
[CTR]
F1
PMD
Program
mode setting
F2
INP
Input format
setting
F4
etc
F3
Ball screw lead
Encoder resolution
Motor mount direction
Motor output
EMST data save
STOP data save
CSTP data save
ALARM data save
RUN mode
Record operation state, Emergency stop (Reserved)
Record operation state, Halt (Reserved)
Record operation state, Cycle stop (Reserved)
Record operation state, Alarm (Reserved)
Run command format (Reserved)
Ipout ×× (IB×××)
Switch polarity of input port.
Output ×× (OB×××)
Switch polarity of output port.
Initialization
SAV
Save data,
controller setting
F3
User module 1
User module 2 **
User module 3 **
User module 4 **
User module 5 **
User module 6 **
User module 7 **
User module 8 **
CLR
Initialize
parameters
F2
Main unit combination type
Type of main unit (X axis)
Type of main unit (Y axis)
Type of main unit (Z axis)
Type of main unit (R axis)
OUT
Output format
setting
F1
Robot Type *
X-Module Name
Y-Module Name **
Z-Module Name **
R-Module Name **
Write data of controller setting.
LOD
Read out,
controller setting
Read out data of controller setting.
* This setting is not used in a single axis controller.
** For the single axis controller, this function is not available and consequently not indicated.
— 9-4 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
l Table 9-1 and Table 9-2 show the parameters of system setting and the controller setting
respectively.
l We recommend to keep the notes on the right side column of the tables when the user changes a
parameter from the shipping set. When plural units in a multi-axis combination other than U1
are set, make a list for each unit and record the respective settings.
l The parameters once saved to the memory will be backed up after the power is turned off and
they won’t change until the parameters are changed to new setting or are initialized.
Caution
: Save the data before turn off the power. Otherwise initialized data will be
back to original setting (setting before initialization) after the power is turned
off. Refer to the following for saving the settings.
1) System setting mode: “9.10.1.1. Procedure to Save Parameters of
System Setting.”
2) Controller setting mode: “9.10.2.1. Procedure to Save Parameters of
Controller Setting.”
Caution
: When saving the data, the display of teaching box indicates “Writing.” While
it is indicated, do not turn off the power. Otherwise “memory error” alarm
will be given. (All data, including program, must be deleted to recover the
system.)
[Example]: Saving the system parameter
[SYS]
1CLR
U1
2SAV
3SAV
4etc
Press F2 key.
[SYS]
U1
Push set
Press SET key.
[SYS]
U1
· The display indicates “Writing” while the
parameters are being saved.
Caution : Do not turn the power off
while saving data.
Writing
Caution
: Make sure that the servo is inactive while the system parameters are being
set. Do not press the ON key of the teaching box.
Caution
: The system parameters include ones that change settings of coordinates
system. On completion of initial setting, be sure to execute the home return
once. Completion of the home return makes the initial settings of
coordinates system effective.
Caution
: If the memory is initialized, the parameters are reset to the factory settings.
— 9-5 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Table 9-1: Initial setting (System setting mode)
1
Operation
parameter
(JOB)
Classification
2
Locus speed
Locus accel
Max speed
Programmed
Max accel
operation
Finish width
(PRG)
Finish mode
Fin control
Fin out time
Home speed
Home accel
Home search speed
Home return Home direction
operation Home sequence *
(ORG)
Home shift
Home move
Home move mode
Home unit seq. *
Jog speed (H)
Jog
operation Jog speed (L)
(JOG)
Jog accel
Coordinate Overtravel (+)
setting (LMT) Overtravel (-)
Pulse train
input (TPL)
Servo
parameter
(TUN)
3
Pulse resolution **
Payload
Servo Gain
Servo (SRV) Feed forward Gain
Torque Limit
Dead Band
Low Pass Filter 1
Filter (FIL) Low Pass Filter 2
Notch Filter
Gain Mode
Position Loop Gain
Velocity Loop Gain
Manual
tuning (MAN) Observer Gain
Observer Limit
Notch Filter Q1
Position Direction
Hard. OT Timer
Function
Rated Current
setting (ADL)
Over Load
Position Error Over
Unit
Setting range
Shipping set
mm/s
m/s2
mm/s
m/s2
mm
–
–
sec
mm/s
m/s2
mm/s
–
–
mm
mm
–
–
mm/s
mm/s
m/s2
mm
mm
0.1 ~ 1200.0
0.1 ~ 35.0
0.1 ~ 1200.0
0.1 ~ 35.0
0 ~ 99.99, OFF
ONE, ALL
OFF, ON
0 ~ 99.99, OFF
0.1 ~ 50.0
0.1 ~ 35.0
0.1 ~ 10.0
NRM, REV
0~7
0 ~ ±9999.99
0 ~ ±9999.99
NOP, ABS, INC
0~7
0.1 ~ 250.0
0.1 ~ 250.0
0.1 ~ 35.0
0 ~ ±9999.99, OFF
0 ~ ±9999.99, OFF
600.0
0.5
1200.0
35.0
OFF
ALL
OFF
0.1
20.0
0.5
1.0
NRM
0
0
0
NOP
0
100.0
50.0
0.5
OFF
OFF
–
-1 ~ 10
1
kg
Hz
%
%
pulse
Hz
Hz
Hz
–
Hz
Hz
Hz
%
–
–
–
%
–
pulse
0.0 ~ 200.0
(Reserved), OFF
0 ~ 100, OFF
1 ~ 100, OFF
1 ~ 100, OFF
10 ~ 500, OFF
10 ~ 500, OFF
10 ~ 500, OFF
(Reserved), MANU
1.0 ~ 100.0
1.0 ~ 500.0
1.0 ~ 150.0
0.1 ~ 100.0, OFF
0.10 ~ 5.00
NRM/REV
200 ~ 30000, AUTO
0 ~ 100
1 ~ 1000, OFF
0 ~ 30000
5.0
OFF
OFF
OFF
OFF
OFF
30
OFF
MANU
5.0
20.0
10.0
OFF
1.00
NRM
AUTO
43
20
30000
* This part is not used in the single axis controller.
** This function / indication does not exist in the single axis controller.
— 9-6 —
User setting
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Table 9-2: Initial setting: (Controller setting mode)
Classification
1
Unit
setting
(UNT)
Module
setting
(MDL)
PMD
setting
(PMD)
2
Robot Type *
X-Module Name
Y-Module Name **
Z-Module Name **
R-Module Name **
User module 1
User module 2 **
User module 3 **
User module 4 **
User module 5 **
User module 6 **
User module 7 **
User module 8 **
EMST data save
STOP data save
CSTP data save
ALRM data save
RUN mode
Shipping set
User setting
OFF
OFF 1 X
OFF 2 Y
OFF 3 Z
OFF 4 R
L20 R4096 NRM W100 (Do not use.)
L20 R4096 NRM W100 (Do not use.)
L20 R4096 NRM W100 (Do not use.)
L20 R4096 NRM W100 (Do not use.)
L20 R4096 NRM W100 (Do not use.)
L20 R4096 NRM W100 (Do not use.)
L20 R4096 NRM W100 (Do not use.)
L20 R4096 NRM W100 (Do not use.)
NOP
NOP
NOP
NOP
PRG
* This part is not used in the single axis controller.
** This function / indication does not exist in the single axis controller.
— 9-7 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Table 9-2: Initial setting list (controller setting mode) continued
Classification
1
Input
format
setting
(INP)
Output
format
setting
(OUT)
2
Signal
name
Input IP00(IB000)
Input IP00(IB001)
Input IP00(IB002)
Input IP00(IB003)
Input IP00(IB004)
Input IP00(IB005)
Input IP00(IB006)
Input IP00(IB007)
Input IP01(IB010)
Input IP01(IB011)
Input IP10(IB100)
Input IP10(IB101)
Input IP10(IB102)
Input IP10(IB103)
Input IP10(IB104)
Input IP10(IB105)
Input IP10(IB106)
Input IP10(IB107)
Input IP11(IB110)
Input IP11(IB111)
Input IP11(IB112)
Input IP11(IB113)
Input IP11(IB114)
Input IP11(IB115)
Input IP11(IB116)
Input IP11(IB117)
Output OP00(OB000)
Output OP00(OB001)
Output OP00(OB002)
Output OP00(OB003)
Output OP00(OB004)
Output OP00(OB005)
Output OP00(OB006)
Output OP00(OB007)
Output OP01(OB010)
Output OP01(OB011)
Output OP10(OB100)
Output OP10(OB101)
Output OP10(OB102)
Output OP10(OB103)
Output OP10(OB104)
Output OP10(OB105)
Output OP10(OB106)
Output OP10(OB107)
Output OP11(OB110)
Output OP11(OB111)
Output OP11(OB112)
Output OP11(OB113)
Output OP11(OB114)
Output OP11(OB115)
Output OP11(OB116)
Output OP11(OB117)
EMST
SVON
STOP
RUN
HOS
RSTA
CSTP
HOLD
ACLR
EREM
IN1
IN2
IN3
IN4
IN5
IN6
IN7
IN8
IN9
IN10
IN11
IN12
IN13
IN14
IN15
IN16
RDY
WRN
MTN
EDTM
TBXM
HOMS
CSTPA
HOLDA
RSTAE
DATWT
OUT1
OUT2
OUT3
OUT4
OUT5
OUT6
OUT7
OUT8
OUT9
OUT10
OUT11
OUT12
OUT13
OUT14
OUT15
OUT16
Shipping set
Contact
Function
polarity
EMST
SVON
STOP
RUN
HOS
RSTA
CSTP
HOLD
ACLR
EREM
PROG0
PROG1
PROG2
PROG3
PROG4
PROG5
PROG6
RSRV
USER
USER
USER
USER
USER
USER
USER
USER
RDY
WRN
MTN
EDTM
TBXM
HOMS
CSTPA
HOLDA
RSTAE
DATWT
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
B
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
B
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
Function can be changed
Changeable
Polarity
signal name
change
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
UNTN0*/USER/RSRV
UNTN1*/USER/RSRV
UNTN2*/USER/RSRV
USER/RSRV
POSN0/USER/RSRV
POSN1/USER/RSRV
POSN2/USER/RSRV
POSN3/USER
POSN4/RSRV
POSN5/RSRV
POSN6/RSRV
POSN7/RSRV
POSN8/RSRV
POSN9/RSRV
POSN10/RSRV
POSN11/RSRV
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
Cannot change.
FIN1/RSRV
FIN2*/RSRV
FIN3*/RSRV
FIN4*/RSRV
FIN5*/RSRV
FIN6*/RSRV
FIN7*/RSRV
FIN8*/RSRV
RSRV
RSRV
RSRV
RSRV
RSRV
RSRV
RSRV
RSRV
User setting
Signal name
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
* This function or indication does not exist in the single axis controller.
— 9-8 —
Polarity
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.3. Operation Parameter
l There are three types of operation parameter settings.
1)
Programmed operation
2)
Home return operation
3)
Jog operation
9.3.1. Parameters for Programmed Operation
9.3.1.1. Parameter List
Table 9-3: Parameter list of programmed operation
Parameter
Locus speed
Locus accel
Max speed
Max accel
*2
·
·
·
·
·
·
·
·
*2
Finish width
·
·
*2
·
·
·
Finish mode
Fin control
Fin out time
·
·
Description
Unit Setting range Factory set
*1
mm/s 0.1 ~ 1200.0
600.0
Specifies a speed in the programmed operation.
Specifies an acceleration / deceleration in the programmed
2
m/s
0.1 ~ 35.0
0.5
operation. *1
Specifies the speed limit.
Set to 1 200 mm / s for normal operation.
mm/s 0.1 ~ 1200.0
1200.0
Lower speed of either “Locus speed” or “Max speed” is valid.
The maximum speed varies according to a main unit.
Refer to “19.1.2. Specifications.”
Sets the limit of acceleration and deceleration.
m/s2
0.1 ~ 35.0
35.0
Set to 35 m / s2 for a normal operation.
Lower setting of either “Locus accel” or “Max accel” is valid.
Sets the detecting criteria of position error width for completion of
positioning. *3
0.0 ~ 99.99,
When the deviation of error counter falls in the set range, [FIN]
mm
OFF
OFF
output is closed.
[FIN] signal closes when the pulse generation (motion command) is
completed, if this parameter set to OFF.
Defines the detecting format of completion of positioning. * 3
One: Outputs FIN signal when either one of the operating axes
—
ONE, ALL
ALL
completes positioning, not waiting for completion of other axis.
All : Outputs FIN signal when all axes complete positioning.
Setting of [FIN] output.
—
OFF, ON
OFF
ON : Outputs [FIN] signal.
OFF: Does not output [FIN] signal.
0.0 ~ 99.99,
Sets time length for [FIN] output is being on. (FIN spec.)
s
0.1
OFF
OFF : Hold [FIN] outputs till next motion.
Note: Detecting sequence is the same in ONE or All format setting in the single axis system.
*1. The speed denotes the speed of the slider for the single axis system and the resultant
speed for the multi-axis combination.
*2. For a multi-axis combination, set these parameters to all axes to which the type of
module main unit is set including an axis in another unit number. The parameters
won’t be indicated for an axis to which the type of module main unit is not set.
*3. Refer to “17.5.3. Output of In-position” for completion of positioning.
— 9-9 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.3.1.2. Travel Speed in Programmed Operation
l The travel speed in the programmed operation follows the setting of “Locus speed” parameter
unless it is not stated specially in a program.
l Use SPD command to specify travel speed in a program. Setting travel speed in the motion
command is possible. SPD command is effective until other SPD command in the same program
is input latter. The speed set in the motion command is only effective for execution of the
motion.
l When the MOV command without a linear interpolation is set to the multi-axis combination,
each axis travels in the speed set in “Locus speed”
Note: Refer to “15.2.7.3. Program Command” for SPD and MOV commands.
l The maximum speed varies according to the module main unit.
Refer to “19.1.2. Specifications.”
l The “Max speed” may be set to 0.1 mm/s. However, it will be impossible to have smooth
operation due to excessive velocity ripple caused by friction, etc.
Table 9-4: Velocity ripple (Reference only.)
Motor rotational speed
Maximum speed*
Maximum speed* × 0.10
Maximum speed* × 0.01
Velocity ripple (reference only)
1%
5%
30 %
* 1200 mm/s when ball screw lead is 20 mm.
9.3.1.3. Acceleration / Deceleration in Programmed Operation
l The Acceleration and the deceleration in the programmed operation follow the setting of “Locus
accel” parameter unless it is not stated specially in a program.
l Use SPD command to specify acceleration/deceleration in a program.
Setting acceleration/deceleration in the motion command is possible. SPD command is effective
until other SPD command in the same program is input latter. Acceleration/deceleration set in
the motion command is only effective for execution of its motion.
l When the MOV command without a linear interpolation is set to the multi-axis combination,
each axis accelerates or decelerates in the acceleration / deceleration set in “Locus accel.”
Note: Refer to “15.2.7.3. Program Command” for SPD and MOV commands.
l Excessive acceleration and deceleration may cause overshoot or vibration, if the load mass is
too large or a combination type of the main units is not sufficiently rigid for an application.
Do not set excessive acceleration and deceleration. For rigidity of the main unit, refer to “9.1.3.
Precautions against Using Module Main Unit.”
Caution
: If excessive acceleration/deceleration is specified to some combination of
main units, it induces excessive moment load to the main units which is
more than their moment strength limit and consequently, it may damage
the main units. Refer to “19.1.3. Precautions against Using Module Main
Unit.”
— 9-10 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.3.1.4. Parameter Setting Procedure: Programmed Operation
l Set the mode to the system setting mode referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to the programmed
operation parameter setting screen as described hereinafter.
System setting mode [SYS] ® Operation parameter [JOB] ® Programmed operation [PRG]
The parameter setting may start from “Locus speed,” then follow one after another/
l Use
and
l Use
key to start editing.
keys to scroll the screen.
, ,
and
keys to move the cursor when editing the program and selecting an axis
l Use
in multi-axis combination.
l Use
and
keys to scroll the cursor for editing.
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key word. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
and
keys in the screen
l For a multi-axis combination, you may select a unit number using
of system setting mode. It requires to set the unit number besides U1 to set the parameters for
the unit other than U1. Refer to “9.5. Parameters for Unit Setting” to set the unit number.
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.1.1. Procedure to Save
Parameters of System Setting.”
— 9-11 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-4: Parameter Setting Procedure: Programmed Operation
Setting screen of programmed operation parameter
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[SYS]JP
0600.0
4etc
1TBX
[SYS]JP
00.5
4etc
2ORG 3JOG
[SYS]JP
X1200.0
4etc
[SYS]JP
X35.0
*1
3PAL
4etc
3IO
2TUN
U1
: Select axis. (For multi-axis
combination only.)
U1
SET
: Start editing. (Cursor is blinking.)
YOFF
: Select axis. (For multi-axis
combination only.)
Number
SET
[SYS]JP
ALL
U1
: Start editing. (Cursor is blinking.)
• : Select the setting value.
SET
Finish mode
U1 : Operation parameter setting mode
[SYS]J
[SYS]JP
OFF
*2
2ORG
: Start editing. (Cursor is blinking.)
Number
*1
SET
* The setting can be OFF by • .
Press F1 key.
MODE
1PRG
*1
Y35.0
Finish width
: Select unit number.
(Multi-axis combination only)
4etc
: Start editing. (Cursor is blinking.)
Number
U1 : System setting mode
[SYS]
1JOB
[SYS]JP
XOFF
4etc
Press F1 key.
MODE
SET
: Select axis. (For multi-axis
combination only.)
: Teaching box operation mode
Menu selection screen 3
[MENU]
2CTR
U1
Max accel
Press F4 key.
1SYS
*1
Y1200.0
: Teaching box operation mode
Menu selection screen 2
[MENU]
: Start editing. (Cursor is blinking.)
Number
Max speed
Press F4 key.
2TCH
U1
: Teaching box operation mode
Menu selection screen 1
[MENU]
SET
Locus accel
Press F1 key.
1EDT
Number
: External control mode
Menu selection screen 2
[External]
: Start editing. (Cursor is blinking.)
Locus speed
Press F4 key.
1RUN
U1
3JOG
4LMT
Press F1 key.
U1
SET
Fin control
MODE
[SYS]JP
00.10
Fin out time
: Start editing. (Cursor is blinking.)
• : Select the setting value.
U1
: Start editing. (Cursor is blinking.)
Number
SET
* The setting can be OFF by • .
*1 No indication in the dotted lines for the single axis system.
*2 For the single axis system this part in the dotted lines will be “4. etc.”
— 9-12 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.3.2. Parameters for Home Return Operation
9.3.2.1. Parameter List
Table 9-5: List of parameter for home return operation
Parameter
Description
Unit
· Specifies the speed of main unit in the home return operation.
à To Home position of absolute encoder.
mm/s
Home speed
à To offset point by “Home shift.”
à To set position by “Home move.”
· Specifies the maximum acceleration / deceleration of a main
m/s2
Home accel
unit in the home return operation.
Home search · Specifies searching speed of position of mechanical stopper in
mm/s
speed
the home return operation.
· Specifies direction of the home return
Home
–
NRM : Motor side
*1
direction
REV : Opposite to the motor
· Specifies a sequential order for home return of each axis unit.
Home
–
An axis unit with lower number has the priority. Home return
*1 *2
sequence
starts simultaneously when the axis number is the same.
· Specifies offset distance of Home position.
mm
Home shift
· After moving the offset distance from the Zero point, it
completes the home return.
· Specifies the stand-by position after completion of the home
return.
*1
mm
Home move
· When the parameter is set to on, a slider moves to the stand-by
position after completion of the home return.
· Specifies the moving mode described above after the home
return is completed.
NOP : Do not move to the stand-by position
Home move
–
ABS : Move to the stand-by position, of which coordinates
mode
are recognized as absolute position.
INC : (Reserved) When INC is set, it functions same as
ABS.
*2 · Specifies the home return sequential order of the units.
–
Home unit seq. A smaller number unit has the priority If the units have the same
number, they start simultaneously.
Setting range
Factory set
0.1 ~ 50.0
20.0
0.1 ~ 35.0
0.5
0.1 ~ 10.0
1.0
NRM, REV
NRM
0 (fixed)
0
0 ~ ±9999.99
0
0 ~ ±9999.99
0
NOP, ABS, INC
NOP
0 (fixed)
0
*1. For a multi-axis combination, set these parameters to all axis units to which the type of
module main unit is specified including an axis of another unit number. The parameters
won’t be indicated for an axis unit to which the type of module main unit is not
specified.
*2. This parameter is not necessary for the single axis system.
Caution
: Over-travel limit sensors are not provided to the robot module. Therefore,
the slider reaches to a mechanical stopper position when executing Home
return.
— 9-13 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.3.2.2. Setting Procedure of Parameter: Home Return
l Set the mode to the system setting referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to the home return
operation parameter setting screen as shown below.
System setting mode [SYS] ® Operation parameter [JOB] ® Home return operation [ORG]
The parameter setting may start from “Home speed,” then foolow one after another.
l Use
and
l Use
key to start the editing.
keys to scroll the screen.
, ,
and
keys to move the cursor when editing the program and selecting an axis
l Use
in multi-axis combination.
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key word. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
and
keys in the screen
l For a multi-axis combination, you may select a unit number using
of system setting mode. It requires to set the unit number besides U1 to set the parameters for
the unit. Refer to “9.5. Parameters for Unit Setting” to set the unit number.
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.1.1. Procedure to Save
Parameters of System Setting.”
— 9-14 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-5: Parameter Setting Procedure: Home Return
Parameter setting screen of Home return
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[SYS]JO
0020.0
4etc
1TBX
[SYS]JO
00.5
4etc
2ORG 3JOG
[SYS]JO
0001.0
4etc
[SYS]JO
XNRM
*1
3PAL
4etc
2CTR
3IO
2TUN
U1
*1
: Start editing. (Cursor is blinking.)
YNRM
: Select axis. (For multi-axis
combination only.)
Number
U1
*1
SET
: Start editing. (Cursor is blinking.)
Y0
: Select axis. (For multi-axis
combination only.)
Home sequence
: Select unit number
(for multi-axis combination only)
4etc
[SYS]JO
X0000.00
Number
SET
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Number
SET
U1 : Operation parameter setting mode
[SYS]J
[SYS]JO
X0000.00
*2
2ORG
*1 U1
Y0000.00
Home shift
Press F1 key.
MODE
1PRG
SET
U1 : System mode setting screen
[SYS]
1JOB
[SYS]JO
X0
4etc
Press F1 key.
MODE
Number
: Teaching box selection mode
Menu selection screen 3
[MENU]
SET
: Start editing. (Cursor is blinking.)
U1
Home direction
Press F4 key.
1SYS
Number
: Teaching box operation mode
Menu selection screen 2
[MENU]
: Start editing. (Cursor is blinking.)
Home search speed
Press F4 key.
2TCH
U1
: Teaching box operation mode
Menu selection screen 1
[MENU]
SET
Home accel
Press F1 key.
1EDT
Number
: External control mode
Menu selection screen 2
[External]
: Start editing. (Cursor is blinking.)
Home speed
Press F4 key.
1RUN
U1
3JOG
4LMT
Press F2 key.
*1 U1
: Select axis. (For multiaxis combination only.)
Home move
MODE
: Start editing. (Cursor is blinking.)
Y0000.00
[SYS]JO
NOP
Number
U1
: Start editing. (Cursor is blinking.)
• : Select a mode.
Home move mode
[SYS]JO
1
SET
SET
U1
: Start editing. (Cursor is blinking.)
Number
SET
Home unit seq.
*1 No indication in the dotted lines for the single axis system.
*2 For the single axis system this part in the dotted lines will be “4. etc.”
— 9-15 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.3.3. Parameters for Jog Operation
9.3.3.1. Parameter List
Table 9-6: Parameter list of jog operation
Parameter
Jog speed (H)
Jog speed (L)
Jog accel
Description
Unit
Setting range
Factory set
0.1 ~ 250.0
100.0
0.1 ~ 250.0
50.0
0.1 ~ 35.0
0.5
· The speed of an axis is set when HIGH key and Jog key are
mm/s
pressed simultaneously under the jog operation.
mm/s
· Specifies speed of each main unit in Jog operation.
· Specifies acceleration / deceleration of each main unit in the jog
m/s2
operation.
9.3.3.2. Parameter Setting Procedure: Jog Operation
l Set the mode to the system setting referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to Jog operation parameter
setting screen as shown below.
System setting mode [SYS] ® Operation parameter [JOB] ® Jog operation [JOG]
The parameter setting may start from “Jog speed (H),” then follow one after another.
l Use
and
l Use
key to start the editing.
keys to scroll the screen.
, ,
and
keys to move the cursor when editing the program and selecting an axis
l Use
in multi-axis combination.
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key word. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
and
keys in the screen
l For a multi-axis combination, you may select a unit number using
of system setting mode. It requires to set the unit number besides U1 to set the parameters for
the unit. Refer to “9.5. Parameters for Unit Setting” to set the unit number.
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.1.1. Procedure to Save
Parameters of System Setting.”
— 9-16 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-6: Parameter setting procedure: Jog operation
Setting screen of Jog operation parameter
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[SYS]JJ
0100.0
4etc
Number
: External control mode
Menu selection screen 2
[External]
1TBX
[SYS]JJ
0050.0
4etc
U1
: Start editing. (Cursor is blinking.)
Number
: Teaching box operation mode
Menu selection screen 1
2ORG 3JOG
SET
SET
Jog speed(L)
Press F1 key.
[MENU]
: Start editing. (Cursor is blinking.)
Jog speed(H)
Press F4 key.
1RUN
U1
[SYS]JJ
00.5
4etc
U1
: Start editing. (Cursor is blinking.)
Number
SET
Jog accel
Press F4 key.
: Teaching box operation mode
Menu selection screen 2
[MENU]
*1
1EDT
2TCH
3PAL
4etc
Press F4 key.
: Teaching box selection mode
Menu selection screen 3
[MENU]
1SYS
2CTR
3IO
4etc
Press F1 key.
MODE
U1 : System mode setting screen
[SYS]
1JOB
2TUN
: Select unit number
(for multi-axis combination only)
4etc
Press F1 key.
MODE
U1 : Operation parameter setting mode
[SYS]J
*2
1PRG
2ORG
3JOG
4LMT
Press F3 key.
MODE
*1 No indication in the dotted lines for the single axis system.
*2 For the single axis system this part in the dotted lines will be “4. etc.”
— 9-17 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.3.4. Parameters for Position and Coordinates
9.3.4.1. Parameter List
Table 9-7: Parameter List of position and coordinates
Parameter
Over travel (+)
Over travel (-)
Description
· This is to set the detecting position of software over travel
limit in positive (+) direction.
*1
· This is to set the detecting position of software over travel
limit in negative (-) direction.
*1
2
Escape (upr.Z) *
Escape (lwr.Z)
*2
2
Escape (pos.Z) *
2
Escape (upr.R) *
*2
Escape (lwr.R)
2
Escape (pos.R) *
· This is to set the upper limit of off-limits area for the Z axis.
· This is to specify the operating area of the Arch-motion using
a Z axis unit.
· This is to set the lower limit of off-limits area for the Z axis.
· This is to specify the operating area of the Arch-motion using
a Z axis unit.
· Specifies the turnout position of the Z axis.
· This is to specify the operating area of the Arch-motion using
a Z axis unit.
· Reserved
· Reserved
· Reserved
Unit Setting range Shipping set
-9999.99 ~
mm
9999.99,
OFF
OFF
-9999.99 ~
mm
9999.99,
OFF
OFF
mm
-9999.99 ~
9999.99
0
mm
-9999.99 ~
9999.99
0
mm
–
–
–
-9999.99 ~
9999.99,
OFF
–
–
–
OFF
–
–
–
*1 Set to all axes to which the module type are specified in a multi-axis combination
(including axes in different unit numbers.) The parameters for an axis unit of which
module type is not set won’t be indicated.
*2 These parameters do not function and are not indicated for a single axis system.
Caution
: Software over-travel limit is valid after completion of the home return. Be
sure to execute the home return when the software over-travel limit is
newly set, or changed.
— 9-18 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.3.4.2. Parameter Setting Procedure: Position and Coordinates
l Set the mode to the system setting referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to the position and
coordinates parameter setting screen as shown below.
System setting mode [SYS] ® Operation parameter [JOB] ® Position and coordinates [LMT]
The parameter setting may start from “Over travel (+),” then follow one after another.
l Use
and
l Use
key to start the editing.
keys to scroll the screen.
, ,
and
keys to move the cursor when editing the program and selecting an axis
l Use
in multi-axis combination.
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key word. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
and
keys in the screen
l For a multi-axis combination, you may select a unit number using
of system setting mode. It requires to set the unit number besides U1 to set the parameters for
the unit. Refer to “9.5. Parameters for Unit Setting” to set the unit number.
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.1.1. Procedure to Save
Parameters of System Setting.”
— 9-19 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-7: Parameter setting procedure: Position and coordinates
Setting screen of parameter for Position and Coordinates
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[SYS]JL
XOFF
4etc
1TBX
[SYS]JL
XOFF
2ORG 3JOG
[SYS]JL
0000.00
[SYS]JL
0000.00
*1
[SYS]JL
OFF
4etc
: Select unit number
(Multi-axis combination only.)
[SYS]JL
0000.00
[SYS]JL
0000.00
3JOG 4LMT
*3
1LMT
2TPL
SET
* Pressing • makes the setting OFF.
U1
: Start editing. (Cursor is blinking.)
Number
SET
* In the single axis system, this screen
won't be indicated.
U1
: Start editing. (Cursor is blinking.)
Number
Escape (lwr.R)
SET
* In the single axis system, this screen
won't be indicated.
MODE
MODE
[SYS]J
: Start editing. (Cursor is blinking.)
Number
Escape (upr.R)
Press F4 key.
*3
U1
* In the single axis system, this screen
won't be indicated.
*2
*3
SET
U1 : Operation parameter setting mode
[SYS]J
2ORG
: Start editing. (Cursor is blinking.)
* In the single axis system, this screen
won't be indicated.
Escape (pos.Z)
Press F1 key.
MODE
1PRG
U1
U1 : System setting mode
4etc
SET
* In the single axis system, this screen
won't be indicated.
Number
Press F1 key.
2TUN
SET
: Start editing. (Cursor is blinking.)
Number
: Teaching control mode
Menu selection screen 3
[SYS]
1JOB
U1
Escape (lwr.Z)
Press F4 key.
MODE
Number
Escape (upr.Z)
3PAL 4etc
3IO
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
: Teaching box control mode
Menu selection screen 2
[MENU]
SET
* Pressing • makes the setting OFF.
4etc
[MENU]
2CTR
U1
: Teaching box control mode
Menu selection screen 1
Press F4 key.
1SYS
*1
YOFF
Over travel (-)
Press F1 key.
2TCH
Number
* Pressing • makes the setting OFF.
4etc
[MENU]
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
: External control mode
Menu selection screen 2
[External]
1EDT
U1
Over travel (+)
Press F4 key.
1RUN
*1
YOFF
[SYS]JL
OFF
U1 : Operation parameter setting mode
4etc
Additional screen
(Single axis system only.)
Press F1 key.
Escape (pos.R)
: Start editing. (Cursor is blinking.)
Number
SET
* Pressing • makes the setting OFF.
* In the single axis system, this screen
won't be indicated.
*3
*3
MODE
U1
*1 This part won't be indicated in a single axis system.
*2 Indication of inside of dotted lines will be 4 etc in a single axis system.
*3 Screens are shown in the order of dotted lines for a single axis system.
— 9-20 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.3.5. Parameters for Pulse Train Input (Single Axis System Only)
9.3.5.1. Parameter List
Table 9-8: Parameter list of pulse train input
Parameter
Description
Sets resolution of pulse train input.
· 1 ~ 10
Parameter sets a multiplying factor to pulse train input.
The resolution will be 0.01 mm × data.
·0
The pulse train input is invalid.
Pulse resolution · -1
The resolution is obtained by a formula below.
Ball screw lead
× speed reduction ratio [mm]
Encoder resolution
* Refer to “ Table 19-1. Description code” for an adoption of speed
reduction.
Unit
Setting
range
Shipping
set
–
-1~10
1
9.3.5.2. Setting Procedure for Pulse Train Input
l Set the mode to the system setting mode referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to Pulse train input screen
[TPL].
System setting [SYS] ® Operation parameter [JOB] ® Pulse train input [TPL]
l Use
key to start the editing.
l Use
and
keys to move the cursor.
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l In each display screen, pressing MODE key makes the screen to go one step back.
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.1.1. Procedure to Save
Parameters of System Setting.”
— 9-21 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-8: Parameter setting procedure : Pulse train input
Setting screen for Pulse train input
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[SYS]JT
X 01
4etc
Pulse resolution
Press F4 key.
: External control mode
Menu selection screen 2
[External]
1TBX
4etc
Press F1 key.
: Teaching box operation mode
Menu selection screen 1
[MENU]
1RUN
2ORG 3JOG
4etc
Press F4 key.
: Teaching box operation mode
Menu selection screen 2
[MENU]
1EDT
2TCH
4etc
Press F4 key.
: Teaching box operation mode
Menu selection screen 3
[MENU]
1SYS
2CTR
3IO
4etc
Press F1 key.
MODE
U1 : System setting mode
[SYS]
1JOB
2TUN
4etc
Press F1 key.
MODE
U1 : Operation parameter setting mode
[SYS]J
1PRG
2ORG
3JOG
4etc
Press F4 key.
MODE
[SYS]J
1LMT
2TPL
U1
4etc
Press F2 key.
MODE
— 9-22 —
U1
: Start editing. (Cursor is blinking.)
Number
SET
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.4. Servo Parameters
l These are tuning parameters of EXEA controller such as “servo gain” and “filters.”
l Be sure to check around the robot system for safety, then perform tuning or adjusting work of
the system. Setting improper gain to the system may result in hunting (large vibration). Thus,
take a great care for tuning the robot module system.
l There are four kinds of servo parameters
à Motor control
à Filter
à Manual tuning
à Function setting
l Tuning is greatly affected by setting of acceleration and deceleration as well as the servo
parameters. Do not set excessive acceleration and deceleration.
Danger
: Tighten the fixing bolts of module main units.
à Loose bolts may cause a serious accident.
Danger
: Do not allow any personnel in the robot operation area while tuning the
system.
à Never enter the robot operation area. Put the guard fence to prevent from the entry
when the robot is operating.
Warning : Confirm that there is no disconnected cables, insufficient connection of
connectors and miss-connection of cables to wrong axis.
à If the cables are connected improperly, the system fails to demonstrate its full
performance. The controller or motors may become defective.
Caution
: Check for interference of each axis when the axis makes its full stroke.
à Mechanical interference may damage the robot, end effector and the ancillaries.
— 9-23 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.4.1. Parameters for Servo
9.4.1.1. Parameter List
l The servo parameters have been set to the values for the normal use before shipment. However,
be sure to set the actual load mass (Payload) of each module main unit.
l For a multi-axis combination set the servo parameters to respective axes of all units to which the
module type is assigned. Parameters won’t be indicated for axis units to which the module type
is not set.
Table 9-9: Parameter list of servo
Classification
Parameter
Description
Unit Setting range
Shipping set
· Specifies load mass to be applied to an axis unit.
· For multi-axis combination add all mass of main
Payload
Servo Gain
SRV
Feedforward
Gain
Torque Limit
Dead Band
·
·
·
·
·
·
·
units and combining brackets to be applied to a
kg
slider of all units other than the one to which the
work or end effector is attached.
Reserved. (Do not use.)
Hz
Do not set any value other than OFF.
Specifies feed forward gain.
This is to improve the system ability of command
tracking. However, setting excessive gain likely
%
causes overshoot or vibration.
In normal operation, it shall be set to OFF.
Stets the limit of output torque.
%
Specifies dead band.
pulse
0 ~ 200.0
5.0
OFF
OFF
0 ~ 100, OFF
OFF
1 ~ 100, OFF
1 ~ 100, OFF
OFF
OFF
9.4.1.2. Parameter Setting Procedure: Servo Parameters
l Set the mode to the system setting referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to Servo [SRV] setting
screen as shown below.
System setting mode [SYS] ® Servo parameter [TUN] ® Servo [SRV]
l Use
and
l Use
key to start the editing.
l Use
and
, ,
l Use
combination.
keys to scroll the screen.
keys to scroll the cursor for editing.
and
keys to move the cursor to edit or select an axis of multi-axis
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key words. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
and
keys to select a unit number. Prior to set the
l In the system setting screen use
parameters of each unit other than U1, it is necessary to specify unit number using “parameters
related to unit.” Refer to “9.5. Parameters for Unit Setting.”
— 9-24 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.1.1. Procedure to Save
Parameters of System Setting.”
Figure 9-9: Parameter setting procedure: Servo
Servo parameters setting screen
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[SYS]TS
X05.0
4etc
1TBX
[SYS]TS
XOFF
4etc
2ORG 3JOG
[SYS]TS
XOFF
4etc
[SYS]TS
XOFF
4etc
3IO
U1
Number
SET
*1
U1
YOFF
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Number
SET
* Pressing • makes the setting OFF.
[SYS]TS
XOFF
Dead Band
Press F1 key.
*1
YOFF
U1
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Number
SET
* Pressing • makes the setting OFF.
U1 : System setting mode
2TUN
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Torque Limit
4etc
[SYS]
1JOB
*1
YOFF
: Teaching box control mode
Menu selection screen 3
[MENU]
SET
* Pressing • makes the setting OFF.
Press F4 key.
MODE
Number
Feedfoward gain
*1
3PAL
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
: Teaching box control mode
Menu selection screen 2
[MENU]
2CTR
U1
SET
* Pressing • makes the setting OFF.
Press F4 key.
1SYS
*1
YOFF
: Teaching box control mode
Menu selection screen 1
[MENU]
2TCH
Number
Servo Gain
Press F1 key.
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
: External control mode
Menu selection screen 2
[External]
1EDT
U1
Payload
Press F4 key.
1RUN
*1
Y05.0
: Select unit number.
(Multi-axis combination only.)
4etc
Press F2 key.
MODE
U1 : Servo parameter setting mode
[SYS]T
*2
1SRV
2FIL
3MAN
4ADL
Press F1 key.
*1 A part in the dotted lines won't be indicated for a single axis system.
*2 Indication in the dotted lines will be “4 etc” for a single axis system.
MODE
— 9-25 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.4.2. Parameters for Filter
l When the noise and vibration are large, yet the system is operating smoothly, setting adequate
filter (FIL) may improve noise and vibration without affecting other Servo parameters (without
worsening positioning performance).
1)
Low pass filter (Low pass filter 1, 2)
Controls the frequency band over the set value. It has primary low pass
characteristics.
2)
Notch filter
Controls the frequency band in the proximity of set value. Range of frequency
band can be varied by changing Q of notch filter (Notch Filter Q1).
Caution
: Vibration is likely to occur when filters are set in multi-steps. As the
secondary low pass filter is set as shipping set, user shall set either one of
primary low pass filter or notch filter. Do not set excessively low frequency
because it may lead to hunching.
9.4.2.1. Parameter List
Table 9-10: Parameter list : Filter
Abbreviation
FIL
Parameter
Description
Low Pass Filter 1 · Sets the primary low pass filter frequency.
Low Pass Filter 2 · Sets the secondary low pass filter frequency.
· Sets Notch filter cut-off frequency.
Notch Filter
Unit
Setting range
Shipping set
Hz
Hz
Hz
10 ~ 500, OFF
10 ~ 500, OFF
10 ~ 500, OFF
OFF
30
OFF
* For a multi-axis combination set the servo parameters to respective axes of all units to
which the module type is assigned. Parameters won’t be indicated for axis units to which
the module type is not set.
9.4.2.2. Parameter Setting Procedure: Filter
l Set the mode to the system setting referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to Filter [FIL] setting
screen as shown below.
System setting mode [SYS] ® Servo parameter [TUN] ® Filter [FIL]
l Use
and
l Use
key to start the editing.
, ,
l Use
combination.
keys to scroll the screen.
and
keys to move the cursor to edit or select an axis of multi-axis
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key words. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
and
keys to select a unit number. Prior to set the
l In the system setting screen use
parameters of each unit other than U1, it is necessary to specify unit number using “parameters
related to unit.” Refer to “9.5. Parameters for Unit Setting.”
— 9-26 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.1.1. Procedure to Save
Parameters of System Setting.”
Figure 9-10: Parameter setting procedure: Filter
Filter parameter setting screen
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[SYS]TF
XOFF
4etc
U1
Number
1TBX
[SYS]TF
X030
4etc
*1
U1
Y030
Number
[SYS]TF
XOFF
4etc
*1
YOFF
Notch Filter
Press F4 key.
U1
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Number
SET
* Pressing • makes the setting OFF.
: Teaching box control mode
Menu selection screen 2
[MENU]
SET
* Pressing • makes the setting OFF.
: Teaching box control mode
Menus selection screen 1
2ORG 3JOG
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Low Pass Filter2
Press F1 key.
[MENU]
SET
* Pressing • makes the setting OFF.
: External control mode
Menus selection screen 2
[External]
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Low Pass Filter1
Press F4 key.
1RUN
*1
YOFF
*1
1EDT
2TCH
3PAL
4etc
Press F4 key.
: Teaching box control mode
Menu selection screen 3
[MENU]
1SYS
2CTR
3IO
4etc
Press F1 key.
MODE
U1 : System setting mode
[SYS]
1JOB
2TUN
: Select unit number
(Multi-axis combination only.)
4etc
Press F2 key.
MODE
U1 : Servo parameter setting mode
[SYS]T
*2
1SRV
2FIL
3MAN
4ADL
Press F2 key.
*1 This part in the dotted lines won't be shown in a single axis system.
*2 Indication in the dotted lines will be “ 4 etc” for a single axis system.
MODE
— 9-27 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.4.3. Parameters for Manual Tuning
l When motion of the robot is not smooth due to unmatched factory setting of the servo
parameters other than an applied load mass (Payload), the manual tuning parameter (MAN) may
be adjusted as described hereunder.
As it is dangerous to perform the tuning under high speed or acceleration, set them to low value
to begin with.
1)
Adjusting Velocity Loop Gain
Set it higher as possible until the robot starts vibration and/or overshooting. It
improves rigidity of Servo and command tracking ability as well as
overshooting.
2)
Adjusting Observer Gain
Set it higher as possible just before vibration or overshooting is observed. It
improves overshooting and settling, and consequently, shorten the time for
positioning. It is effective to improve convergence against external disturbance.
3)
Adjusting Position Loop Gain
Set it higher as possible until the robot starts vibration and/or overshooting.
Criterion is a quarter of Velocity Loop Gain. This is to shorten the positioning
time.
9.4.3.1. Parameter List
Table 9-11: Parameter List: Manual tuning
Classification
Parameter
Gain mode
Position Loop
Gain
Description
· Sets the mode to adjust Servo gain.
· Setting to MANU makes the following parameters
·
·
·
·
·
Velocity Loop
Gain
·
MAN
·
·
Observer Gain
·
Observer Limit
·
·
·
Notch Filter Q1 ·
effective. Do not set other than MANU.
Sets Position Loop Gain.
Shorten the positioning time. However vibration and
overshooting are likely observed if it is set too high.
Set it approximately a quarter of Velocity Loop Gain.
Sets Velocity Loop Gain.
It improves Servo stiffness and command tracking as
well as overshooting.
When heavy work or low stiffness work is attached to
the slider, resonance is likely observed. Do not set too
much gain.
Sets Observer Gain.
It improves overshooting and settling as well as
convergence against external disturbance.
When the gain is set too high, high overshooting and
vibration will be induced.
Sets Observer Gain output limit.
This might be an effective way to improve
overshooting without lowering Observer Gain.
However, set it OFF normally.
Sets shape of notch filter.
When it is set too high, frequency range which are cut
by notch filter gets steeper. Set to 1.00 normally.
Unit Setting range
Shipping
set
–
AUTO, MANU
MANU
Hz
1.0 ~ 100.0
5.0
Hz
1.0 ~ 500.0
20.0
Hz
1.0 ~ 150.0
10.0
%
0.1 ~ 100.0, OFF
OFF
–
0.10 ~ 5.00
1.00
* For a multi-axis combination, set the servo parameters to respective axes of all units to
which the module type is assigned. Parameters won’t be indicated for axis units to which
the module type is not set.
— 9-28 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.4.3.2. Parameter Setting Procedure: Manual Tuning
l Set the mode to the system setting referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to Manual tuning [MAN]
setting screen as shown below.
System setting mode [SYS] ® Servo parameter [TUN] ® Manual tuning [MAN]
l Use
and
l Use
key to start the editing.
keys to scroll the screen.
, ,
l Use
combination.
and
keys to move the cursor to edit or select an axis of multi-axis
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key words. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
and
keys to select a unit number. Prior to set the
l In the system setting screen use
parameters of each unit other than U1, it is necessary to specify unit number using “parameters
related to unit.” Refer to “9.5. Parameters for Unit Setting.”
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.1.1. Procedure to Save
Parameters of System Setting.”
— 9-29 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-11: Parameter setting procedure: Manual tuning
Parameter setting screen for manual tuning
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[SYS]TM
MANU
4etc
1TBX
[SYS]TM
X05.0
4etc
2ORG 3JOG
[SYS]TM
X020.0
4etc
[SYS]TM
X010.0
*1
3PAL
4etc
*1
3IO
[SYS]TM
XOFF
4etc
U1
2TUN
U1
YOFF
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Number
[SYS]TM
X01.00
*1
Y01.00
Notch Filter Q1
Press F2 key.
MODE
SET
SET
* Pressing • makes the setting OFF.
: Select unit number
(Multi-axis combination only.)
4etc
: Start editing. (Cursor is blinking.)
Number
U1 : System setting mode
[SYS]
SET
: Select axis. (For multi-axis
combination only.)
Observer Limit
Press F1 key.
: Start editing. (Cursor is blinking.)
Number
Y010.0
*1
SET
: Select axis. (For multi-axis
combination only.)
: Teaching box control mode
Menu selection screen 3
[MENU]
1JOB
U1
Y020.0
Observer Gain
Press F4 key.
MODE
Number
: Teaching box control mode
Menu selection screen 2
[MENU]
2CTR
*1
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Velocity Loop Gain
Press F4 key.
1SYS
U1
: Teaching box control mode
Menus selection screen 1
[MENU]
2TCH
*1
Y05.0
Position Loop Gain
Press F1 key.
1EDT
• : Select a mode. SET
: External control mode
Menus selection screen 2
[External]
: Start editing. (Cursor is blinking.)
Gain Mode
Press F4 key.
1RUN
U1
U1
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Number
SET
U1 : Servo parameter setting mode
[SYS]T
*2
1SRV
2FIL
3MAN
4ADL
Press F3 key.
*1 This part in the dotted lines won't be shown in a single axis system.
*2 Indication in the dotted lines will be “ 4 etc” for a single axis system.
MODE
— 9-30 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.4.4. Parameters for Function Setting
9.4.4.1. Parameter List
Table 9-12: Parameter List: Function Setting
Classification Parameter
Position
direction
Hard. OT
Timer
ADL
Rated
current
Over Load
Position
error over
Description
Unit
Setting
range
· This is to set direction of the coordinate.
· Positive side (+) of the coordinate is opposing to the motor
–
NRM, REV
when NRM is set, while it is negative side (-) when REV is set.
· This sets the time to arise over travel alarm after the limit is
activated in normal operation.
This parameter shall be set when the over travel alarm (F3:
mechanical lock) arises frequently because of load condition in
200 ~ 30000,
which the motor duty exceeds its rated power, or because of
–
AUTO
external load being applied to the slider.
· Criterion of the time may be 50% of the setting in millisecond.
· Set to AUTO normally as the motor may overheat under these
condition.
· This is to set converting rate of the motor rated current.
%
0 ~ 100
(Do not change.)
· This parameter sets the criterion of electrical power for
1 ~ 1000,
–
detecting level of overloaded motor alarm. (Do not change.)
OFF
· Sets number of pulses for the criterion of excessive position
error alarm.
pulse 0 ~ 30000
· Refer to “11.3.5. Detection of Excessive Position Error” for the
excessive position error.
Shipping
set
NRM
AUTO
43
20
30000
* For multi-axis combination, set to all axes of all units to which the type of module main
unit is set respectively. These parameters won’t be indicated for an axis to which the type
of module main unit is not set.
9.4.4.2. Parameter Setting Procedure: Function Setting
l Set the mode to the system setting referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to Function setting [ADL]
screen as shown below.
System setting mode [SYS] ® Servo parameter [TUN] ® Function setting [ADL]
l Use
and
l Use
key to start the editing.
, ,
l Use
combination.
keys to scroll the screen.
and
keys to move the cursor to edit or select an axis of multi-axis
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key words. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
and
keys to select a unit number. Prior to set the
l In the system setting screen use
parameters of each unit other than U1, it is necessary to specify unit number using “parameters
related to unit.” Refer to “9.5. Parameters for Unit Setting.”
— 9-31 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.1.1. Procedure to Save
Parameters of System Setting.”
Figure 9-12: Parameter setting procedure: Function Setting
Parameter setting screen for function setting
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[SYS]TA
XNRM
4etc
1TBX
[SYS]TA
XAUTO
4etc
2ORG 3JOG
[SYS]TA
X043
4etc
[SYS]TA
X0020
4etc
3IO
U1
Number
SET
*1
U1
Y0020
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Number
SET
* Do not change the settings.
[SYS]TA
X30000
*1
Y30000
Position Error Over
Press F1 key.
U1
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Number
SET
* Do not change the settings.
U1 : System setting mode
2TUN
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
Over Load
4etc
[SYS]
1JOB
*1
Y043
: Teaching box control mode
Menus selection screen 3
[MENU]
SET
* Do not change the settings.
Press F4 key.
MODE
Number
Rated Current
*1
3PAL
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
: Teaching box control mode
Menus selection screen 2
[MENU]
SET
* Pressing • makes setting OFF.
Press F4 key.
2CTR
U1
YAUTO
: Teaching box control mode
Menus selection screen 1
[MENU]
1SYS
Number
Hard. OT Timer
Press F1 key.
2TCH
*1
: Start editing. (Cursor is blinking.)
: Select axis. (For multi-axis
combination only.)
: External control mode
Menu selection screen 2
[External]
1EDT
U1
Position Direction
Press F4 key.
1RUN
*1
YNRM
: Select unit number
(Multi-axis combination only.)
4etc
Press F2 key.
MODE
U1 : Servo parameter setting mode
[SYS]T
*2
1SRV
2FIL
3MAN
4ADL
Press F4 key.
*3
MODE
*3
MODE
U1 : Additional screen for servo parameter
[SYS]T
1ADL
setting mode (for single axis system
only)
4etc
Press F1 key.
*3
*3
MODE
*1 This part in the dotted lines won't be shown in a single axis system.
*2 Indication in the dotted lines will be “ 4 etc” for a single axis system.
*3 Procedures will be shown in the order of dotted lines for a single axis system.
— 9-32 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.5. Parameters for Unit Setting
l This parameter sets the type of module main unit and axis name to respective main units which
are to be connected to EXEA controller.
l An operating axis unit will be assigned by the axis name set by the parameter in EXEA
controller.
[Example]
The example in Figure 9-13 shows a typical setting in which an X axis module main
unit (X-Module) is named “X axis.”
The setting indicates that:
à Set U1 as a unit number.
à Axis name is X axis in EXEA controller.
(EXEA controller indicates and operates the main unit as X axis of Unit 1.
Initialization and teaching will be done as X axis of Unit 1 as well. )
à An amplifier to be connected is “1st.”
à Module type is XY-HRS020-PH200.
Figure 9-13
Module type to be connected
Unit number
[CTR]U
XY-HRS020-PH200
1
X
X-Module Name
Amplifier number of EXEA controller
Note: In a multi-axis combination, set amplifiers
numbers 1 to 4 which are actually connected
to main units. ( Multi-axis controller indicates
the number as 1st to 4th.)
It is always 1 for a single axis system.
U1
Axis name in EXEA controller: “X” is set to the
example.
Note: Either one of X, Y, Z and R shall be set for a
multi-axis combination. You may not set the same
axis name in the same unit. It is always “X” in a
single axis system.
l It shall be basically treated in the order of X (X-Module) to Y (Y-Module) from a base axis
main unit to upper one.
[Example] G-HM combination
— 9-33 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
l Unit is a group to be assigned to respective main units.
Grouping is meaningless for a normal two axes EXEA controller. The grouping to a
Unit is useful to operate two of two axes combination systems simultaneously (parallel
processing) by a two axes controller in multitask operation. You may program the
same operation for both X axes and execute it to X axis of Unit1 and X axis of Unit2.
l You can name the second axis “Z” in two axes combination. (When first axis is named “X” it
will be indicated as X-Z combination and initializing or teaching may be performed under this
name.)
Caution
: Arch motion cannot be performed if an axis name of “Z” is not set. Be sure
to set Z axis to the one which moves to turnout position in arch motion
operation.
Figure 9-14: Example when second axis is set to Z
Module main unit to be connected
Unit number
[CTR]U
XY-HRS020-PM102
2
Z
Y-Module Name
Amplifier number of EXEA controller
— 9-34 —
U1
Name of axis in EXEA controller:
It is set to “Z” axis in this example.
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.5.1. Parameter List
l Be sure to set Module Name always according to a module main unit to be used.
l Module Name USR1 to USR 8: These types shall be set for a specific module main unit.
(Reserved.) Refer to “9.6. Parameters for Setting Module Type.”
l Refer to Tables 9-14 and 9-15 for specifications of a module main unit.
Table 9-13: Parameter list: Unit setting
Parameter
Description
Type
· Reserved.
· Set to OFF normally.
X-Module Name
· Input a type of module main unit for X axis. *1
Y-Module Name *3 · Input a type of module main unit for Y axis. *1
· Input a type of module main unit for Z axis. *1
Z-Module Name *3
R-Module Name *3
(It is not necessary to set for a two axes controller.)
· Input a type of module main unit for R axis. *1
(It is not necessary to set for a two and three axes controller.)
Module type
Factory set
OFF
Do not set other than OFF
OFF
even other setting is
indicated.
USR1~USR8, *2
XY-HRS¨¨¨-PH200,
XY-HRS¨¨¨-PM200,
XY-HRS¨¨¨-PH102,
XY-HRS¨¨¨-PM102,
XY-HRS¨¨¨-PH100,
XY-HRS¨¨¨-PM100,
XY-HRS¨¨¨-PH212,
XY-HRS¨¨¨-PM212,
XY-HRS¨¨¨-RH200,
XY-HRS¨¨¨-RH102,
XY-HRS¨¨¨-RH202,
XY-HRS¨¨¨-RH204,
XY-HRS¨¨¨-RH208,
XY-HRS¨¨¨-RH405,
XY-HRS¨¨¨-RH409,
XY-HRS¨¨¨-RH207,
XY-HRS¨¨¨-RH211,
XY-HRS¨¨¨-RH206,
XY-HRS¨¨¨-RH210,
XY-HRS¨¨¨-RH407,
XY-HRS¨¨¨-RH411,
XY-HRS¨¨¨-RM200,
OFF
XY-HRS¨¨¨-RM204,
XY-HRS¨¨¨-RM208,
XY-HRS¨¨¨-RM405,
XY-HRS¨¨¨-RM409,
XY-HRS¨¨¨-RM134,
XY-HRS¨¨¨-RM234,
XY-HRS¨¨¨-RM238,
XY-HRS¨¨¨-RM238,
XY-HRS¨¨¨-RM242,
XY-HRS¨¨¨-RM239,
XY-HRS¨¨¨-RM243,
XY-HRS¨¨¨-RM439,
XY-HRS¨¨¨-RM443,
XY-HRS¨¨¨-RS104,
XY-HRS¨¨¨-RS108,
XY-HRS¨¨¨-RS204,
XY-HRS¨¨¨-RS208,
XY-HRS¨¨¨-RS106,
XY-HRS¨¨¨-RS110,
XY-HRS¨¨¨-RS138,
XY-HRS¨¨¨-RS142,
OFF
Ditto
OFF
Ditto
–
Ditto
–
*1. 10th digit of indicated module main unit type is always “–.” For a clean room
specification main unit, whose 10th digit is “C,” select the one after “–” is identical.
*2. Only USR1 will be indicated for a two axes controller.
*3. It won’t be indicated for a single axis system.
— 9-35 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Table 9-14: Specifications for P type module main unit
Reference number
XY-HRS¨¨¨*-PH
XY-HRS¨¨¨*-PM
200
212
100
102
200
212
100
102
Motor power
[W]
200
100
Ball screw lead
Motor mounting direction
[mm]
20
Direct
20
Indirect, back mount
10
Direct
10
Direct
20
Direct
20
Indirect, back mount
10
Direct
10
Direct
Negative actuation
motor brake
–
–
–
ü
–
–
–
ü
Table 9-15: Specifications of R type module main unit
Reference number
XY-HRS¨¨¨*-RS
or
XY-HRS¨¨¨*CRS
XY-HRS¨¨¨*-RM
or
XY-HRS¨¨¨*CRM
XY-HRS¨¨¨*-RH
or
XY-HRS¨¨¨*CRH
104
108
106
110
204
208
138
142
200
204
208
134
234
238
242
239
243
405
409
439
443
102
200
204
208
207
211
202
206
210
405
409
407
411
Motor power
[W]
100
200
200
400
200
400
400
Ball screw lead
Motor mounting direction
[mm]
10
Indirect, right
10
Indirect, left
10
Indirect, right
10
Indirect, left
20
Indirect, right
20
Indirect, left
10
Indirect, right
10
Indirect, left
20
Direct
20
Indirect, right
20
Indirect, left
10
Direct
20
Direct
20
Indirect, right
20
Indirect, left
20 (10) **
Indirect, right
20 (10) **
Indirect, left
40 (20)
Indirect, right
40 (20)
Indirect, left
40 (20)
Indirect, right
40 (20)
Indirect, left
10
Direct
20
Direct
20
Indirect, right
20
Indirect, left
20 (10) **
Indirect, right
20 (10) **
Indirect, left
20
Direct
20
Indirect, right
20
Indirect, left
40 (20)
Indirect, right
40 (20)
Indirect, left
40 (20)
Indirect, right
40 (20)
Indirect, left
Negative actuation
motor brake
–
–
ü
ü
–
–
ü
ü
–
–
–
ü
ü
ü
ü
ü
ü
–
–
ü
ü
ü
–
–
–
ü
ü
ü
ü
ü
–
–
ü
ü
* ¨¨¨ indicate stroke of a main unit.
Example 040: 400 mm
** The ball screw lead in the parentheses is an actual setting as a timing belt is used to
reduce the ball screw rotational speed to 1/2.
— 9-36 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.5.2. Parameter Setting Procedure: Unit Setting
l Set the mode to controller setting referring to “ 8.2. Selection of Control Mode.”
l Refer to “ 9.1. Initial Setting Procedure” and scroll the display to Unit setting [UNT] screen as
shown below.
Controller setting mode [CTR] ® Unit setting [UNT] ® Each parameter setting screen
l Scroll the screen using
l Use
and
keys.
key to start the editing.
l Use
, ,
and
axis combination.
keys to move the cursor when editing and selecting an axis in multi-
l Use 0 ~ 9 , CLR and ± keys to set numbers.
l • key is to be used to set or select keywords (OFF etc,).
l Pressing MODE key switches to the screen backward in each display screen.
l The first letter on third line in the unit parameter setting screen in Figure 9-15 indicates number
of amplifier to be connected to a main unit. Numbers 1, 2 ---- correspond to respective
indications of 1st, 2nd --- on the front panel of EXEA controller. It is set to 1 for a single axis
system.
Caution
: Amplifier number 1 and 2 for a 2 axes controller and 1 to 4 for a four axes
controller are valid. Amplifier numbers 5 to 8 are not valid. (Reserved)
l Number of amplifier shall be treated as an independent number regardless the unit number U1 to
U8. When the same amplifier number is assigned to different unit, the unit of which number is
the smallest has precedence, and then the setting to other unit becomes invalid.
When the same amplifier number is set to different main units in the same unit, the precedence
shall be given in the order as shown below.
X-Module Name ® Y-Module Name ® Z-Module Name ® R-Module Name
l 2nd letters in the 3rd line of parameter setting screen indicates an axis number of each unit.
(Refer to Figure 9-15.) Be careful not to duplicate the axis number in the same unit in multi-axis
combination. If it is duplicated, the precedence is given in the order shown below.
X-Module Name ® Y-Module Name ® Z-Module Name ® R-Module Name
Caution
: After inputting parameters, be sure to save them. Otherwise they will be
lost when the power is turned off. Refer to “9.10.2.1. Procedure to Save
parameters of Controller Setting.”
— 9-37 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-15: Parameter setting procedure: Unit setting
Parameter setting screen: Unit setting
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[CTR]U
OFF
4etc
U1
Robot Type
Press F4 key.
: External control mode
Menu selection screen 2
[External]
1TBX
* Do not set anything as this
part is reserved.
[CTR]U
OFF
1
X
X-Module Name
4etc
Press F1 key.
U1
: Start editing. (Cursor is blinking.)
: Set items.
: Select setting value.
SET
: Teaching box operation mode
Menu selection screen 1
[MENU]
1RUN
2ORG 3JOG
*1
[CTR]U
OFF
2
Y
Y-Module Name
4etc
Press F4 key.
*2
3PAL
[CTR]U
4etc
3IO
*2
[CTR]U
4etc
2MDL
U1
: Start editing. (Cursor is blinking.)
: Set items.
: Select setting value.
R-Module Name
SET
U1 : Controller setting mode
[CTR]
1UNT
: Select setting value.
SET
Press F2 key.
MODE
: Start editing. (Cursor is blinking.)
Z-Module Name
: Teaching box operation mode
Menu selection screen 3
[MENU]
2CTR
U1
: Set items.
Press F4 key.
1SYS
: Select setting value.
SET
*1
2TCH
: Start editing. (Cursor is blinking.)
: Set items.
: Teaching box operation mode
Menu selection screen 2
[MENU]
1EDT
U1
: Select unit number
(Multi-axis combination only)
4etc
*1 There will be o indication in the dotted lines for a single axis system.
*2 For Z and R axes, get in “start editing” state (The cursor is blinking.),
then use
keys to indicate the selection screen of items.
Press F1 key.
Note: Refer to Figure 9-16 to delete a unnecessary
module main unit setting.
MODE
— 9-38 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.5.3. Separating Units for Use
l This chapter is for a Multi-axis combination only.
l All main units are set to Unit 1 when the controller is shipped. (However, two X-Y axis
combinations are set to Unit 1 and Unit 2 for a 4 axes controller.) If Unit1 shall be split into
some units for use, it requires to set other unit number accordingly.
l Following is a way to split Unit1 into some units.
1)
2)
Clear axes not required for Unit1.
Set the cleared axes to other unit.
l An example in Figure 9-16 shows a way to split a two axes controller to X axis of Unit 1 and X
axis of Unit 2.
Figure 9-16
U1 : Controller setting mode screen
[CTR]U
[CTR]U
1UNT 2MDL
U2
: Start editing. (Cursor is blinking.)
4etc
Press F1 key.
[CTR]U
OFF
Y-Module Name
: Select type of module main unit.
(Example: XY-HRS020-PM200)
U1
[CTR]U
XY-HRS020-PM200
1_
X
Y-Module Name
Robot Type
[CTR]U
OFF
1
X
X-Module Name
: Start editing. (Cursor is blinking.)
U1
Note: If the power amplifier number remains 1
this setting will be disregarded as the
number is still same as the Unit1.
: Select a setting.
SET
U1
[CTR]U
U1
SET
: Start editing. (Cursor is blinking.)
CLR : Clear Y axis of Unit1.
SET
: Move the cursor to the power
amplifier number.
: Select power amplifier number 2.
: Select an item.
[CTR]U
OFF
2
Y
Y-Module Name
U2
[CTR]U
XY-HRS020-PM200
2
X
Y-Module Name
U2
Y-Module Name
Press MODE key.
U1 : Controller setting mode screen
[CTR]U
1UNT 2MDL
4etc
: Select U2.
[CTR]U
1UNT 2MDL
U2
4etc
Press F1 key.
Note: Number of power amplifiers to be connected to module main unit shall be different
between respective units. If the same amplifier number is set to two different units, a unit
with smaller number takes precedence and the setting for the other unit is ignored. When
the number of power amplifier of Y-module of Unit2 is still set to 1 (one) in an example
above, Unit 2 is ignored and consequently, only X axis of Unit1 is considered to be exist.
— 9-39 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.6. Parameters for Setting Module Type
l Reserved. (Do not use.)
l This parameter is to register a module type specific to a user. Setting a specific module type is
not necessary if it is combined with a standard robot module.
l Module type shall be set to the user module type (USR1 to USR8) in Chapter 9.5 when using a
module main unit set by these parameters. The parameters are not valid unless the user module
type is not set.
l Following parameters shall be tuned to respective module main units other than a standard
module main unit. Refer to relevant chapters in this user’s manual as shown below.
Parameters for servo -------------- Chapter 9.4.1.
Parameters for filter --------------- Chapter 9.4.2.
Parameters for manual tuning --- Chapter 9.4.3.
9.6.1. Parameter List
Table 9-16: Parameter list: Module type setting
Parameter
User module 1
User module 2 *
User module 3 *
User module 4 *
User module 5 *
User module 6 *
User module 7 *
User module 8 *
Description
· A specific module type shall be set by
four parameters below.
1. Ball screw lead (L)
[mm]
2. Encoder resolution (R) [pulse/rev.]
3. Motor mount direction
4. Motor power (W)
[W]
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
Setting range
L: 05 ~ 40
R: 1000 ~ 8192
NRM: (Motor direct mound)
REV: (motor indirect mount)
W: 100, 200, 400, 800
Shipping set
L: 20
R: 4096
NRM
W: 100
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
Ditto
* This is not indicated for a single axis system.
9.6.2. Parameter Setting Procedure: Module Type
l Set the mode to “Controller setting” referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the screen as shown below.
Controller setting mode [CTR] ® Module setting mode [MDL] ® Each parameter setting
l Use
and
l Use
key to start editing.
,
,
l Use
combination.
keys to scroll the screen.
and
to move the cursor when editing and selecting an axis in multi-axis
l Use 0 ~ 9 , CLR and ± keys to set numbers.
l • is to be used to set or select keywords (OFF etc,).
— 9-40 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
l Pressing MODE key switches to the screen backward in each display screen.
l These parameters do not have any relations with the unit number. Ignore the unit number on the
parameter setting screens.
Caution
: After inputting parameters, be sure to save them. Otherwise they will be
lost when the power is turned off. Refer to “9.10.2.1. Procedure to Save
parameters of Controller Setting.”
Figure 9-17: Parameter setting procedure: Module type
Parameter setting screen for Module type
: External control mode
Menu setting screen 1
[External]
1RUN
2IO
3FNC
[CTR]M
L20
R4096
NRM
W100
User module1
4etc
Press F4 key.
U1
: Start editing. (Cursor is blinking.)
: Set an item.
Number or
SET
: External control mode
Menu setting screen 2
[External]
1TBX
*1
[CTR]M
L20
R4096
NRM
W100
User module2
4etc
Press F1 key.
1RUN
U1
2ORG 3JOG
: Start editing. (Cursor is blinking.)
: Set an item.
Number or
SET
: Teaching box operation mode
Menu setting screen 1
[MENU]
: Select the
setting.
: Select the
setting.
4etc
Press F4 key.
: Teaching box operation mode
Menu setting screen 2
[MENU]
*1
1EDT
2TCH
3PAL
[CTR]M
L20
R4096
NRM
W100
User module8
4etc
Press F4 key.
1SYS
2CTR
3IO
: Set an item.
Number or
: Select the
setting.
4etc
Press F2 key.
MODE
U1 : Controller setting mode screen
[CTR]
1UNT
: Start editing. (Cursor is blinking.)
SET
: Teaching box operation mode
Menu setting screen 3
[MENU]
U1
2MDL
4etc
Press F2 key.
*1 The part in the dotted lines won't be indicated for a single axis system.
MODE
— 9-41 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.7. Parameters for PMD Setting
9.7.1. Parameter List
Table 9-17: Parameter list of PMD setting
Parameter
Description
EMST data save No function. Do not set other than NOP.
STOP data save No function. Do not set other than NOP.
Saves the data to resume programmed operation* after
CSTP data save
disturbed by power shut down.
ALRM data save No function. Do not set other than NOP.
Selects operation start format.
PRG: Selects programmed operation.
RUN mode
POS: Selects direct operation.
Setting range
NOP, SAVE
NOP, SAVE
Shipping set
NOP
NOP
NOP, SAVE
NOP
NOP, SAVE
NOP
PRG, POS
PRG
à * Refer to “17.5.2. Resume Programmed Operation” to resume operation.
9.7.2. Parameter Setting Procedure: PMD Setting
l Set the mode to the controller setting referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to PMD [PMD] setting
screen as shown below.
Controller setting mode [CTR] ® PMD setting [PMD] ® Each parameter setting
l Use
and
l Use
key to start the editing.
keys to scroll the screen.
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key words. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
l The parameters in this section have no relations with the Unit number. Disregard the unit
numbers which appears in the parameter screens.
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.2.1. Procedure to Save
Parameters of Controller Setting.”
— 9-42 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-18: Parameter setting procedure: PMD setting
Parameter setting screen for PMD setting
: External control mode
Menu setting screen 1
[External]
1RUN
2IO
3FNC
[CTR]P
NOP
4etc
: Select setting.
EMST data save
Press F4 key.
SET
: External control mode
Menu setting screen 2
[External]
1TBX
[CTR]P
NOP
4etc
Press F1 key.
U1
: Start editing. (Cursor is blinking.)
: Select setting.
STOP data save
SET
: Teaching box operation mode
Menu setting screen 1
[MENU]
1RUN
: Start editing. (Cursor is blinking.)
U1
2ORG 3JOG
4etc
[CTR]P
NOP
Press F4 key.
U1
: Start editing. (Cursor is blinking.)
: Select setting.
CSTP data save
SET
: Teaching box operation mode
Menu setting screen 2
[MENU]
*1
1EDT
2TCH
3PAL
4etc
[CTR]P
NOP
Press F4 key.
U1
: Select setting.
ALARM data save
1SYS
2CTR
3IO
4etc
2MDL
U1
: Start editing. (Cursor is blinking.)
: Select setting.
SET
4etc
Press F4 key.
MODE
U1 : Controller setting mode screen 2
[CTR]
1PMD
RUN mode
U1 : Controller setting mode screen 1
[CTR]
1UNT
[CTR]P
PRG
Press F2 key.
MODE
SET
: Teaching box operation mode
Menu setting screen 3
[MENU]
: Start editing. (Cursor is blinking.)
2INP
3OUT
4etc
Press F1 key.
*1 This part won’t be shown for a single axis system.
MODE
— 9-43 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.8. Parameters for Input Signal Format
9.8.1. Parameter List
l Switches function and polarity of input port.
Polarity A: Normally open
Polarity B: Normally close
l Indication of input port
[Example]
Input
Input
IP00(IB00 0)
Input port No.
Input bit No.
Table 9-18: Parameter list: Input signal function
Connector
Input
Input
Input
Input
Input
CN3
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
P1-EXT-I/O
Input
Input
Input
Input
Input
Input
Input
Input
Input port
IP00(IB000)
IP00(IB001)
IP00(IB002)
IP00(IB003)
IP00(IB004)
IP00(IB005)
IP00(IB006)
IP00(IB007)
IP01(IB010)
IP01(IB011)
IP10(IB100)
IP10(IB101)
IP10(IB102)
IP10(IB103)
IP10(IB104)
IP10(IB105)
IP10(IB106)
IP10(IB107)
IP11(IB110)
IP11(IB111)
IP11(IB112)
IP11(IB113)
IP11(IB114)
IP11(IB115)
IP11(IB116)
IP11(IB117)
Setting range
Signal
name
May be changed to:
EMST±
SVON
STOP
RUN
HOS
RSTA
CSTP
HOLD
ACLR
EREM
IN1
IN2
IN3
IN4
IN5
IN6
IN7
IN8
IN9
IN10
IN11
IN12
IN13
IN14
IN15
IN16
Cannot change
Cannot change
Cannot change
Cannot change
Cannot change
Cannot change
Cannot change
Cannot change
Cannot change
Cannot change
PROG0/UNTN0*/USER/RSRV
PROG1/UNTN1*/USER/RSRV
PROG2/UNTN2*/USER/RSRV
PROG3/USER/RSRV
PROG4/POSN0/USER/RSRV
PROG5/POSN1/USER/RSRV
PROG6/POSN2/USER/RSRV
RSRV/POSN3/USER
USER/POSN4/RSRV
USER/POSN5/RSRV
USER/POSN6/RSRV
USER/POSN7/RSRV
USER/POSN8/RSRV
USER/POSN9/RSRV
USER/POSN10/RSRV
USER/POSN11/RSRV
Shipping set
Switching
Contact
Signal function
polarity
polarity
* This part won’t be indicated for a single axis system.
— 9-44 —
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
EMST
SVON
STOP
RUN
HOS
RSTA
CSTP
HOLD
ACLR
EREM
PROG0
PROG1
PROG2
PROG3
PROG4
PROG5
PROG6
RSRV
USER
USER
USER
USER
USER
USER
USER
USER
B
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.8.2. Parameter Setting Procedure: Input Signal Format
l Set the mode to the controller setting referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to Input Signal Format
[INP] setting screen as shown below.
Controller setting mode [CTN] ® INP setting [INP] ® Each parameter setting
l Use
and
l Use
key to start the editing.
l Use
and
keys to scroll the screen.
keys to scroll the cursor for editing.
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key words. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
l The parameters in this section have no relations with the Unit number. Disregard the Unit
numbers which appears in the parameter screens.
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.1.1. Procedure to Save
Parameters of System Setting.”
— 9-45 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-19: Parameter setting procedure: Input signal format
Setting screen: Input signal format
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[CTR]I
EMST
4etc
U1
: Start editing. (Cursor is blinking.)
B
: Select an item.
: Select setting.
Input IP00(IB000)
Press F4 key.
SET
: External control mode
Menu selection screen 2
[External]
1TBX
[CTR]I
SVON
4etc
Press F1 key.
2ORG 3JOG
: Start editing. (Cursor is blinking.)
: Select an item.
: Select setting.
Input IP00(IB001)
SET
: Teaching box operation mode
Menu selection screen 1
[MENU]
1RUN
U1
A
4etc
Press F4 key.
: Teaching box operation mode
Menu selection screen 2
[MENU]
*1
1EDT
2TCH
3PAL
4etc
[CTR]I
USER
Press F4 key.
U1
: Start editing. (Cursor is blinking.)
A
: Select an item.
: Select setting.
Input IP11(IB117)
: Teaching box operation mode
Menu selection screen 3
[MENU]
1SYS
2CTR
3IO
4etc
Press F2 key.
MODE
U1 : Controller setting mode screen 1
[CTR]
1UNT
2MDL
4etc
Press F4 key.
MODE
U1 : Controller setting mode screen 2
[CTR]
1PMD
SET
2INP
3OUT
4etc
Press F2 key.
*1 There will be no indication in the dotted lines for a single axis system.
MODE
— 9-46 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.9. Parameters for Output Signal Format
9.9.1. Parameter List
l Switches function and polarity of input port.
Polarity A: Normally open
Polarity B: Normally close
l Indication of input port
[Example]
Output
Output
OP00(OB00 0)
Output port No.
Output bit No.
Table 9-19: Parameter list: Output signal format
Connector
CN3
P1-EXT-I/O.
Output port
Output OP00(OB000)
Output OP00(OB001)
Output OP00(OB002)
Output OP00(OB003)
Output OP00(OB004)
Output OP00(OB005)
Output OP00(OB006)
Output OP00(OB007)
Output OP01(OB010)
Output OP01(OB011)
Output OP10(OB100)
Output OP10(OB101)
Output OP10(OB102)
Output OP10(OB103)
Output OP10(OB104)
Output OP10(OB105)
Output OP10(OB106)
Output OP10(OB107)
Output OP11(OB110)
Output OP11(OB111)
Output OP11(OB112)
Output OP11(OB113)
Output OP11(OB114)
Output OP11(OB115)
Output OP11(OB116)
Output OP11(OB117)
Setting range
Switching
May be changed to:
polarity
RDY
Cannot change.
No
WRN
Cannot change.
Yes
MTN
Cannot change.
Yes
EDTM
Cannot change.
Yes
TBXM
Cannot change.
Yes
HOMS
Cannot change.
Yes
CSTPA
Cannot change.
Yes
HOLDA
Cannot change.
Yes
RSTAE
Cannot change.
Yes
DATWT
Cannot change.
Yes
OUT1
USER/FIN1/RSRV
Yes
OUT2
Yes
USER/FIN2*/RSRV
Yes
USER/FIN3*/RSRV
OUT3
Yes
USER/FIN4*/RSRV
OUT4
Yes
USER/FIN5*/RSRV
OUT5
Yes
USER/FIN6*/RSRV
OUT6
OUT7
Yes
USER/FIN7*/RSRV
OUT8
Yes
USER/FIN8*/RSRV
OUT9
Yes
USER/RSRV
OUT10
Yes
USER/RSRV
OUT11
Yes
USER/RSRV
OUT12
Yes
USER/RSRV
OUT13
Yes
USER/RSRV
OUT14
Yes
USER/RSRV
OUT15
Yes
USER/RSRV
OUT16
Yes
USER/RSRV
Signal
name
* This part won’t be indicated for a single axis system.
— 9-47 —
Shipping set
Signal function
RDY
WRN
MTN
EDTM
TBXM
HOMS
CSTPA
HOLDA
RSTAE
DATWT
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
USER
Contact
polarity
B
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.9.2. Parameter Setting Procedure: Output Signal Format
l Set the mode to the controller setting referring to “8.2. Selection of Control Mode.”
l Refer to “9.1. Initial Setting Procedure” and scroll the display screen to Output signal format
[OUT] setting screen as shown below.
Controller setting mode [CTN] ® OUT setting [OUT] ® Each parameter setting
l Use
and
l Use
key to start the editing.
l Use
and
keys to scroll the screen.
keys to scroll the cursor for editing.
l Use 0 ~ 9 numeric keys, CLR key and ± key to input numbers.
l • key is used to set or select key words. (OFF etc.)
l In each display screen, pressing MODE key makes the screen to go one step back.
l The parameters in this section have no relations with the Unit number. Disregard the Unit
numbers which appears in the parameter screens.
Caution
: After inputting the parameters, be sure to save them. Otherwise, they will
be lost when the power is turned off. Refer to “9.10.2.1. Procedure to Save
Parameter of Controller Setting.”
— 9-48 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
Figure 9-20: Parameter setting procedure: Output signal format
Setting screen: Output signal format
: External control mode
Menu selection screen 1
[External]
1RUN
2IO
3FNC
[CTR]O
RDY
4etc
U1
: Start editing. (Cursor is blinking.)
B
: Select an item.
: Select setting.
Output OP00(OB000)
Press F4 key.
SET
: External control mode
Menu selection screen 2
[External]
1TBX
[CTR]O
WRN
4etc
Press F1 key.
2ORG 3JOG
: Start editing. (Cursor is blinking.)
: Select an item.
: Select setting.
Output OP00(OB001)
SET
: Teaching box operation mode
Menu selection screen 1
[MENU]
1RUN
U1
A
4etc
Press F4 key.
: Teaching box operation mode
Menu selection screen 2
[MENU]
*1
1EDT
2TCH
3PAL
4etc
[CTR]O
USER
Press F4 key.
U1
: Start editing. (Cursor is blinking.)
A
: Select an item.
: Select setting.
Output OP11(OB117)
: Teaching box operation mode
Menu selection screen 3
[MENU]
1SYS
2CTR
3IO
4etc
Press F2 key.
MODE
U1 : Controller setting mode screen 1
[CTR]
1UNT
2MDL
4etc
Press F4 key.
MODE
U1 : Controller setting mode screen 2
[CTR]
1PMD
SET
2INP
3OUT
4etc
Press F2 key.
*1 There will be no indication in the dotted lines for a single axis system.
MODE
— 9-49 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.10. Saving Parameter Setting
9.10.1. Saving Parameters of System Setting
l This section describes how to save parameters of the System settings listed below to the flash
memory.
1)
2)
3)
4)
5)
6)
7)
8)
9)
Programmed operation
Home return
Jog
Position • Coordinates
Pulse train input (Single axis system only.)
Servo
Filter
Manual tuning
Function setting
9.10.1.1. Procedure to Save Parameters of System Setting
Caution
: When saving parameters, “Writing” message appears in the screen. Do not
disconnect the power while this message is on the screen. Otherwise
“memory error” alarm is on and all settings will be lost.
(Initialization including programming is necessary to recovery.)
Figure 9-21: Saving procedure: System setting parameters
Each parameter setting
: In the screen of individual parameter setting, press MODE
MODE
[SYS]
1JOB
U1
2TUN
key several times to display System setting screen 1.
: System setting mode screen 1
4etc
: Press F4 key to move to system setting screen 2.
Press F4 key.
[SYS]
U1
: System setting mode screen 2
1CLR 2SAV 33LOD 4etc
Press F2 key.
: Press F2 key to show the screen for Saving parameter
of System setting.
[SYS]
U1
Push SET
: Press SET key to save the parameters. “Writing”
Press SET key.
message appears in the screen while executing saving.
[SYS]
U1
Writing
: Returns to System setting mode screen 2 when “Writing” is
completed.
— 9-50 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.10.2. Saving Parameters of Controller Setting
l This section describes how to save parameters of Controller settings listed below to the flash
memory.
1)
2)
3)
4)
5)
Unit number
Module setting
PMD setting (Program mode)
Input signal format
Output signal format
9.10.2.1. Procedure to Save Parameters of Controller Setting
Caution
: When saving parameters, “Writing” message appears in the screen. Do not
disconnect the power while this message is on the screen. Otherwise
“memory error” alarm is on and all settings will be lost.
(Initialization including programming is necessary for recovery.)
Figure 9-22: Saving parameter: Controller setting parameter
Each parameter setting screen
: In the screen of individual parameter setting, press
MODE
[CTR]
1UNT 2MDL
U1
: Controller setting
mode screen 1
U1
[CTR]
U1
setting screen 1 or screen 2.
: Controller setting
mode screen 2
1PMD 2INP 3OUT 4etc
4etc
Press F4 key twice.
[CTR]
MODE key several times to display Controller
MODE
Press F4 key.
: Press F4 key to move to Controller setting screen 3.
: Controller setting
mode screen 3
1CLR 2SAV 3LOD 4etc
Press F2 key.
[SYS]
: Press F2 key to move System setting screen.
U1
Push SET
: Pressing SET key to start saving the parameters.
Press SET key.
[SYS]
“Writing” message appears on the screen while
executing saving.
U1
Writing
: Return to Controller setting mode screen 3 when the
saving is completed.
— 9-51 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.11. Initialization of Parameters
9.11.1. Initialization of Parameters for System Setting
l This section describes how to initialize parameters of system setting listed below to the flash
memory.
1) Programmed operation
2) Home return
3) Jog
4) Position • Coordinates
5) Pulse train input (Single axis system only.)
6) Servo
7) Filter
8) Manual tuning
9) Function setting
9.11.1.1. Procedure to Initialize System Setting Parameters
Figure 9-23: Procedure to initialize system setting parameters
Each parameter setting
: Press MODE key several times to get in System
setting screen 1 from “Each parameter setting state.”
MODE
U1 : System setting mode screen 1
[SYS]
1JOB
2TUN
: Selection of unit number
(Multi-axis combination only.)
4etc
: Press F4 key to change the screen to System setting
Press F4 key.
U1 : System setting mode screen 2
[SYS]
1CLR
2SAV
mode 2. When only a designated unit is to be initialized,
set its unit number using
and
(Multi-axis combination only.)
keys.
3LOD 4etc
: Press F1 to change to System initializing screen.
Press F1 key.
[SYS]C
U1
CLR(ALL, DEF)?
Press SET key.
: Select an area to be
initialized.
: Use
and
keys to select to initialize all unit data or data of
designated unit only.
The unit number of designated unit is indicated on the upper
right corner of the screen.
CLR (ALL,DEF) ® Initialize data of all unit.
CLR (UNT,DEF) ® Initialize data of a designated unit.
Use
and
keys to select initializing range.
Press
and to change to DEF
MDC
AT.
DEF : Initialize to a default parameter.
MDC : Initialize parameters to match the module main unit.
AT
[SYS]
: Auto tuning. (Reserved)
U1
: Press SET key to start initializing.
Executing
“Executing” message appears in the screen when initializing.
: The screen returns to System setting mode screen 2 when
initialization is completed.
Note: Refer to “9.10. Saving Parameter Setting” to save the initialized parameters. All
parameter returns to the state before initialization if the power is turned off before
saving the initialized data.
— 9-52 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.11.2. Initialization of Controller Setting Parameters
l This section describes how to initialize Controller setting parameters listed below.
1)
2)
3)
4)
5)
Unit number
Module setting
PMD setting (Program mode)
Input signal format
Output signal format
9.11.2.1. Procedure to Initialize Controller Setting Parameters
Figure 9-24: Procedure to initialize controller setting parameters
Each parameter setting screen
: In the screen of individual parameter setting, press
MODE
[CTR]
1UNT 2MDL
U1
: Controller setting
mode screen 1
U1
[CTR]
U1
setting screen 1 or screen 2.
: Controller setting
mode screen 2
1PMD 2INP 3OUT 4etc
4etc
Press F4 key twice.
[CTR]
MODE key several times to display Controller
MODE
Press F4 key.
: Press F4 key to move to Controller setting screen 3.
: Controller setting
mode screen 3
1CLR 2SAV 3LOD 4etc
Press F1 key.
: Press F1 key to move the Initializing Controller
setting screen.
[CTR]C
Push SET
: Pressing SET key to start saving the parameters.
Press SET key.
[CTR]
“Executing” message appears on the screen while
executing saving.
U1
Executing
: Return to Controller setting mode screen 3 when the
initialization completes.
Note: Refer to “9.10. Saving Parameter Setting” to save the initialized parameters. All
parameter returns to the state before initialization if the power is turned off before
saving the initialized data.
— 9-53 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.12. Readout of Parameters
9.12.1. Readout of System Setting Parameters
l This section describes how to read out stored parameters of system settings listed blow.
1)
2)
3)
4)
5)
6)
7)
8)
9)
Programmed operation
Home return
Jog
Position • Coordinates
Pulse train input (Single axis system only.)
Servo
Filter
Manual tuning
Function setting
9.12.1.1. Readout Procedure: System Setting Parameters
Figure 9-25: Parameter readout: System setting
Each parameter setting
: In the individual parameter setting screen, press MODE key several times to move to
MODE
System setting screen 1.
[SYS]
1JOB 2TUN
U1
: System setting mode screen 1
4etc
Press F4 key.
[SYS]
U1
: Press F4 key to move System setting screen 2.
: System setting mode screen 2
1CLR 2SAV 3LOD 4etc
Press F3 key.
: Press F3 key to get the screen to readout System setting.
Press SET key.
: Pressing SET key starts readout. “Reading” message appears in the screen while
[SYS]L
Push SET
reading out.
[SYS]
Reading
U1
: System setting mode screen is displayed after completion of readout.
— 9-54 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
9.12.2. Readout of Controller Setting Parameters
l This section describes how to readout the stored parameters of Controller setting listed below.
1)
2)
3)
4)
5)
Unit number
Module setting
PMD setting (Program mode)
Input signal format
Output signal format
9.12.2.1. Readout Procedure: Parameters of Controller Setting
Figure 9-26: Readout procedure: Controller setting parameters
Each parameter setting screen
: In the screen of individual parameter setting, press
MODE
[CTR]
1UNT 2MDL
U1
: Controller setting
mode screen 1
U1
[CTR]
U1
setting screen 1 or screen 2.
: Controller setting
mode screen 2
1PMD 2INP 3OUT 4etc
4etc
Press F4 key twice.
[CTR]
MODE key several times to display Controller
MODE
Press F4 key.
: Press F4 key to move to Controller setting screen 3.
: Controller setting
mode screen 3
1CLR 2SAV 3LOD 4etc
Press F3 key.
: Press F3 key to move the readout screen of
Controller setting.
[CTR]L
Push SET
: Pressing SET key to start the readout of
Press SET key.
[SYS]
parameters. “Reading” message appears on the
screen while executing readout.
U1
Reading
: Return to Controller setting mode screen 3 when the
readout completes.
— 9-55 —
1 Installation and Maintenance of EXEA Controller “9. Initial Setting”
(Blank Page)
— 9-56 —
1 Installation and Maintenance of EXEA Controller “10. Trial Running”
10. Trial Running
l Conduct trial running following the procedures described hereunder when the initial setting for
startup or the initialization of replaced main unit or EXEA controller is completed. (Refer to “9.
Initial Setting.”)
l Trial running is supposed to be a manual operation using the teaching box. You cannot operate
Jog without the teaching box.
Procedure 1: Home return
l Execute Home return through either one of the teaching box operation, external control
operation and the remote control operation.
l Refer to the following chapters for Home return.
“17.3.1. Home Return” in the teaching box operation.
“17.4.3. Home Return” in the external control operation.
l Alarm of Home return incomplete (A5) is off when the Home return is completed. If the
alarm is still on, execute the home return again after checking the setting of EXEA
controller and mounting condition of the module main units.
Procedure 2: Indication of the Home position
l Set the home position matching to the slider position after the Home return.
l Be sure that the module main unit does not move after turning off the servo. Then affix
a seal (provided with a main unit) which indicates the positions of the home and the
mechanical stopper. Affix them to all main units in case of a mult-axis combination.
原
点
MN
メカストッパー
MN
原
点
メカストッパー
Home position
Mechanical stopper
Procedure 3: Trial running by jog operation
l Execute the jog operation through the teaching box. Refer to “17.3.2. Jog Operation” in
the teaching box operation.
l Confirm that all module main units operate smoothly. If not, adjust the parameters
again referring to “9. Initial Setting.”
(Next page)
— 10-1 —
1 Installation and Maintenance of EXEA Controller “10. Trial Running”
Procedure 4: Set detecting position of software over travel limit.
l Set detecting position of software over travel limit to all module main units in the vicinity
of its stroke end checking the coordinates under the jog operation.
l Set the positions inside of mechanical stoppers on the motor side and opposite to the
motor side.
l Set the position referring to the coordinates displayed on the screen of the teaching
box in the jog operation mode.
Be sure to set the home position in effective range as the standard home position is
close to the mechanical stopper. Refer to “9.3.4. Parameters for Position and
Coordinate” for the setting.
Procedure 5: Turn the power off.
l Turn off the servo, then power off after the trial running.
Caution : The slider of a vertical axis may drop 5 ~ 10 mm when the
power is turned while the servo remains on.
l Do not input external control signal such as “servo on” or “Move” other than “emergency stop”
through CN3 connector while executing the trial running.
Danger
: Before starting trial running, be sure nobody is in the working area of the
robot.
— 10-2 —
1 Installation and Maintenance of EXEA Controller “11. Protection and Safety”
11. Protection and Safety
11.1. Guard Fence
l Provide the guard fence to prevent from entry of persons during operation of the robot.
Danger
: Any person in the robot module working area may be crushed by, or caught
in the robot module when the module unit or the EXEA controller fails or
malfunctions. Such a hazard exists even when the system is running
normally at a high speed.
1)
For your safety in daily operation, provide guard fences and take action to prevent
from entry of persons into the robot working area.
2)
When you must enter the area bound by the guard fences to adjust or conduct teaching
of the system, keep off the robot working area and stand in a place where you can see
the motion of the robot module clearly. The operating speed at this time should be
lower than the safety speed of 250 mm/second.
* Shipping set is 50 mm/second for jog and teaching speed.
— 11-1 —
1 Installation and Maintenance of EXEA Controller “11. Protection and Safety”
11.2. Power Shut down and Recovery
l When the main power is shut off due to failure of the power line, the EXEA controller stops a
programmed operation.
Caution
: When the power is shut off in the middle of operation, EXEA controller gets
into “Servo off” state. As though dynamic brake is incorporated, the slider
(or main unit for the main unit stroke), other than that of a main unit with a
motor incorporated with magnetic brake, may coast before it stops.
l Even if the power is recovered, the programmed operation won’t resume automatically. It needs
normal procedures to start operation. When starting, the program begins from the top. You may
not resume the operation from the point where it was interrupted.
l After the power recovers, it is possible to resume an interrupted programmed operation if RSTA
command is set to execute initialization. (Refer to “15.2. Programming.”)
Caution
: If the master controller (a sequencer or a controller that controls the EXEA
controller: it should be provided by the user.) does not detect the power
failure and continues to supply operating commands, it leads to an
unexpected malfunction.
à When the power to the EXEA controller is interrupted, RDY output of the control
input / output (CN3) is opened (= gets into alarm state). Be sure to monitor the RDY
output in the master controller, and to stop giving the operating command to EXEA
controller when the RDY output is opened.
à When the power recovers and the RDY output closes, remove the errors resulting from
the interruption of programmed operation, then start the system from the beginning.
— 11-2 —
1 Installation and Maintenance of EXEA Controller “11. Protection and Safety”
11.3. Protection and Function for Safety
11.3.1. Emergency Stop
l In case of system malfunction or an accident is foreseen, activate the emergency stop function to
shut off the current to motors and stop all operations instantly.
11.3.1.1. State of Emergency Stop
l All operation commands are canceled and the motors get in servo-off state.
l The general outputs keep their status before the emergency stop is on until the power to the port
is shut off or the OUT command is issued to change the output status.
l The internal registers such as data register will be reset.
l Indication: 1) Front panel LED : F4
2) CN3 control output : RDY --- open, WRN --- Open
(It closes if other minor alarm such as F5 arises simultaneously.)
3) Teaching box
: EMST
11.3.1.2. Execution of Emergency Stop
l There are three ways to execute the emergency stop as shown below. You may execute the
emergency stop with one of the following ways.
1 Press EMG key on the teaching box.
Note: (1) As the emergency stop circuit is a B contact (= normally close), disconnection of the
connector CN1 on the teaching box will create state of emergency stop.
(2) When operating the system without the teaching box, turn off the power and plug in
the dummy connector (provided with EXEA controller as an accessory) to the CN1
connector of EXEA controller, then turn on the power again. Contacts of emergency
stop circuit are shorted in the dummy connector.
2 Turn off the EMST input of the control inputs / outputs (Connector CN3)
Note: (1) As the emergency stop circuit is B contact (= normally close), turn on EMST input
when the power is turned on, otherwise the system gets into emergency stop state.
3 Execute EMST command in the remote control mode.
— 11-3 —
1 Installation and Maintenance of EXEA Controller “11. Protection and Safety”
11.3.1.3. Recovery from Emergency Stop
1 Call off the emergency stop state (Turn on an input of CN3 connector).
* This procedure is not necessary for recovery from emergency stop state caused by
EMG key of teaching box and EMST command of remote control mode. Simply
follow the procedures hereunder.
2 Turn the power on again.
* The emergency stop can be called off by resetting the alarm after executing the
procedure described above.
l Recovery through the teaching box
Press CLR then press SET key in “Teaching box control” mode.
* Do not press CLR and SET keys simultaneously. Press SET key after clear your
finger from CLR key, otherwise you won’t be able to get out from emergency stop state.
* This procedure is invalid in the remote control mode.
l Recovery by control input /output (External control mode)
* In the remote control mode, turning on ACLR input of the control input / output (CN3)
recovers the system from the emergency stop.
l Recovery by remote control
* Inputting the commands ACLR All makes to remove the emergency stop state.
( is the space code (20H).)
Note: (1) Lifting the emergency stop state does not start operation automatically. It needs a
normal procedure to start the operation from the beginning.
(2) Operation starts from the top of the program but not from the point at where the
program was interrupted.
11.3.1.4. Emergency Stop Circuitry
Figure 11-1: Emergency stop circuitry
CN3 EMST input
Teaching box
EMG key
Normally close
Normally close
(Emergency stop when opened.)
Emergency stop circuit
Motor
servo-off
Normally close
11.3.1.5. Required Distance to Stop for Emergency Stop
l When “Emergency stop” is on, the motors get in servo off state and dynamic brake functions.
l It requires approximately 100 mm (coasting distance) to come to complete stop after the
emergency stop is on if each module main unit is carrying its allowable transporting load and is
running under maximum speed.
— 11-4 —
1 Installation and Maintenance of EXEA Controller “11. Protection and Safety”
11.3.2. Deadman Switch
l Keep pressing the deadman switch when executing jog operation or teaching.
l In jog operation and teaching by jog operation, releasing the deadman switch makes the motor
servo off and the robot stops. (The magnetic brake incorporated in the motor engages.)
Warning : Deadman switch does not function other than jog operation or teaching in
jog operation. Be sure to use the emergency stop switch in other
operation mode.
11.3.3. Brake Control
l There are two types of braking function. One is the dynamic braking and the other is the
magnetic brake incorporated into the motor.
The magnetic brake is used for a vertical axis unit to prevent back drive of ball screw when the
power is shut off.
l The magnetic brake is a negative type. The brake engages when the current to the brake is off.
l Refer to “Appendix 1. Motor Connector” for the wiring of the magnetic brake.
l The followings are the occasions when both dynamic brake and magnet brake function.
1)
Turn off EXEA controller power.
2)
Servo-off
3)
When an alarm which leads to servo-off arises.
Caution
: The dynamic brake does not function if controller cable is disconnected.
(EXEA controller and a main unit are not connected.)
l The magnetic brake can be switched on and off manually through the teaching box when
conducting trial running or adjusting the robot. Refer to “14.2.6.5 Indication of Brake Status and
Handling.”
l Disconnect controller cable to cancel dynamic brake function.
Caution
: Be sure to connect the controller cable properly when connect it again.
11.3.4. Detection of Over Travel
l You can set and monitor the software over travel limit based on the absolute coordinates defined
by Home return. Refer to “Over travel (+) and (-)” in “9.3.4. Parameter for Position and
Coordinates” and “10. Trial Running” for setting of software over travel limit.
Caution
: It is essential to set the software over travel limit as the robot module main
unit does not have the over travel limit switch.
— 11-5 —
1 Installation and Maintenance of EXEA Controller “11. Protection and Safety”
11.3.5. Detection of Excessive Position Error
l The position command is always subtracted by actual position of the slider in the differential
error counter. If, for any reason, the slider cannot move or slow to respond to the position
command, the subtraction in the differential error counter exceeds the set limit, and
consequently, an excessive position error alarm arises. Refer to “position error over” in “9.4.4.
Parameter for Function Setting” for detection level of the excessive position error.
l When the variation of differential error counter exceeds the set level, RDY output opens and the
motor gets into servo-off state.
Figure 11-2: Detection timing of excessive position error
Detection
level
Differential error
counter
0
Close
Open
Recover power or reset of alarm
11.3.6. Software Thermal Limit Protection
l This is to protect the motor from burning by monitoring the mean value of current to motor and
to give an alarm if it exceeds the rating of motor.
Caution
: This protection won’t work if the main unit is miss-connected to improper
motor driver unit.
à Example :
If a main unit with 100 W motor is connected to 200 W output of the controller,
EXEA controller gives the current for 200 W motor, twice of rating current of
100 W motor, and eventually results in burning motor.
à Connect the main unit to a proper driver unit.
l We set limit level of software thermal as a shipping set. Do not change the setting.
11.3.7. Protection from CPU Malfunction
l The alarms of EXEA controller is managed by software.
l The following measures are taken by the software to maintain safety and protection from CPU
malfunction and failure.
1)
Two software systems are provided to watch malfunction and failure of CPU.
2)
Both systems stop the operation by making motor in servo-off and give an alarm when
CPU fails to report to the monitoring systems.
— 11-6 —
1 Installation and Maintenance of EXEA Controller “12. Maintenance • Checking”
12. Maintenance • Checking
12.1. Maintenance
l We recommend to prepare the back up parts for quick recovery from unexpected break down of
the system.
l Write down all parameter settings and keep the notes in case of system failure.
l Refer to “9.2. Initial Setting List” for setting of the parameters.
— 12-1 —
1 Installation and Maintenance of EXEA Controller “12. Maintenance • Checking”
12.2. Checking
l Check the parts periodically and replace them if necessary for prolonged use of the robot
module.
12.2.1. Periodical Check
l The checking shown in Table 12-1 should be performed at least once a month.
Table 12-1: Check List
Check point
Inspection
· Inspect for loose screws of FGND terminal block and AC main
power source connector.
· Tighten screws if necessary.
· Clean dust and remove foreign substances from the controller.
Looseness of
screws
Cleaning
Danger
: Do not conduct the checking with main power on. Touching the controller is
very dangerous as a high tension exists. Before checking, wait for five
minutes approximately after turning power off.
Danger
: Disconnected FGND terminal cable due to loose screws leads to a hazard
of electric shock and short circuit. Be sure to fasten loose screws.
12.2.2. Replacement
l The parts listed in Table 12-2 below are subject to aging or deterioration because of repeated
use, possibly affecting system performance and causing a system failure.
l Replace them when it reaches its criterion of life described in Table 12-2.
Table 12-2: Replacement parts
Item
Function
Lithium battery
Memory back up
(absolute position data)
Relay
Contact point of motor
brake.
Electric condenser
Smoothing voltage of
main power
Criterion of life
· Total power shut-off time of EXEA controller: 50 000
hours
(Approximately 5 years without turning power on.)
However, if a main unit is moved manually without
power on, it may shorten the battery life less than 50
000 hours as an encoder of motor consumes the battery
power.
· Total number of times of brake on/off: 100 000 times
(Approximately 9 years when frequency of 30 times of
on/off per day.)
· Criterion: 5 to 10 years (varies according to
environmental condition, especially sensitive to
temperature.)
Danger
: Do not charge the lithium batteries. If charged, they may burst or burn.
Caution
: The battery may burst if it is not handled properly. Be sure to use an
optional battery set (Reference number : M-FK123) when replace it.
Observe the following for disposal of the battery.
1) When dispose it, cover its part of connector with a friction tape so that
the plus and minus electrodes are not shortened.
2) Dispose it as a general incombustible garbage.
3) Do not throw it into the fire or destroy it by an incinerator.
4) Do not pile them up rashly.
— 12-2 —
1 Installation and Maintenance of EXEA Controller “12. Maintenance • Checking”
How to replace the lithium battery
l Follow the procedures below when replace the lithium battery.
Caution
: Be sure to turn off the power when replace the lithium battery.
1 Preparation
l Philips screwdriver for M3 screw.
l Battery set (optional)
Reference number: M-FK123 (Battery and fixing band)
2 Procedure
1)
Remove the screws and detach the bottom cover of an EXEA controller.
(1)
Remove 8 screws as shown in Photo 12-1 and 12-2 for a single axis controller.
Photo 12-1: Indication of screws to be removed. <Single axis controller>
Screw 1
M3 cross recessed
pan head screw
Screw 2
M3 cross recessed
pan head screw
Screw 3
M3 cross recessed
pan head screw
Photo 12-2: Indication of screws to be removed <Single axis controller>
Screw 4
M3 cross recessed
countersunk head screw
Screw 6
M3 cross recessed
countersunk head screw
— 12-3 —
Screw 5
M3 cross recessed
countersunk head screw
Screw 7
M3 cross recessed
countersunk head screw
Screw 8
M3 cross recessed
countersunk head screw
1 Installation and Maintenance of EXEA Controller “12. Maintenance • Checking”
(2)
Remove 8 screws as shown in Photo 12-3 and 12-4 for a 2 axes controller.
Photo 12-3: Indication of the screws to be removed. (1) <2 axes controller>
Screw 1
M3 cross recessed
countersunk head screw
Screw 2
M3 cross recessed
countersunk head screw
Screw 3
M3 cross recessed
countersunk head screw
Photo 12-4: Indication of the screws to be removed (2)
Screw ④
M3 cross recessed
countersunk head screw
Screw ⑥
M3 cross recessed
countersunk head screw
— 12-4 —
<2 axes controller>
Screw ⑤
M3 cross recessed
countersunk head screw
Screw ⑦
M3 cross recessed
countersunk head screw
Screw ⑧
M3 cross recessed
countersunk head screw
1 Installation and Maintenance of EXEA Controller “12. Maintenance • Checking”
(3)
Remove 13 screws as shown in Photo 12-5 and 12-6 for a 3 and 4 axes controller.
Photo 12-5: Indication of screws to be removed (1)
Screw ①
M3 cross recessed
countersunk head screw
Screw ②
M3 cross recessed
countersunk head screw
Screw ⑥
M3 cross recessed
countersunk head screw
Screw ④
M3 cross recessed
countersunk head screw
Screw ③
M3 cross recessed
countersunk head screw
Screw ⑤
M3 cross recessed
countersunk head screw
Photo 12-6: Indication of screws to be removed (2)
Screw ⑦
M3 cross recessed
countersunk head screw
Screw ⑨
M3 cross recessed
countersunk head screw
Screw ⑧
M3 cross recessed
countersunk head screw
Screw ⑪
M3 cross recessed
countersunk head screw
Screw ⑩
M3 cross recessed
countersunk head screw
— 12-5 —
Screw ⑬
M3 cross recessed
countersunk head screw
Screw ⑫
M3 cross recessed
countersunk head screw
1 Installation and Maintenance of EXEA Controller “12. Maintenance • Checking”
2)
You can see the battery which is fixed on a circuit board when the cover is removed as shown in
Photo 12-3.
Photo 12-7: A view when the cover is removed. <Single axis controller>
Battery
3)
Cut the band which fixes the battery to a board, and disconnect the battery and circuit board
connectors.
Photo 12-8: The way how the battery is fixed
Fixing band
4)
Fix the new battery with the fixing band and connect the connectors firmly.
5)
Attach the cover.
— 12-6 —
Connector
1 Installation and Maintenance of EXEA Controller “12. Maintenance • Checking”
12.3. Warranty Coverage
12.3.1. Warranty Period
l The warranty is effective in one year from the delivery of the product or 2400 working hours
whichever comes first.
12.3.2. Limit of Warranty
1)
The warranty shall be given to the products which NSK Ltd. have manufactured and shipped to
users.
2)
NSK Ltd. will repair or replace any products which have been proved to the satisfaction of NSK
Ltd. to have a defect in material and/or workmanship.
3)
Repair cost will be charged to a user after the warranty period stated above has expired.
12.3.3. Immunity
l NSK Ltd. shall not be liable for any circumstances described bellow.
(1)
Failure of a unit/system due to installation or operation not in accordance with the
instruction manual specified by the supplier.
(2)
Failure of a unit/system due to improper handling, operation, modification and
careless handling by a user.
(3)
Failure by modification and/or repair without manufactures consent.
(4)
Damages caused by natural disaster or uncontrollable circumstances by the supplier.
(5)
Designated parts as expendable.
(Fuse of EXEA controller, cable support and timing belt)
l NSK Ltd. warrants for its products and, under no circumstances, is not liable for any
consequential damages, loss of profits and/or injury of personal as a result of claim arising
under this limited warranty.
12.3.4. Service Charge
l The price of the product does not include the engineering service charges incurred after the
shipment.
l Service fee according to the supplier’s standard will be charged for field service even in the
warranty period.
l Service fee will be charged based on the relevant standard of NSK Ltd.
— 12-7 —
1 Installation and Maintenance of EXEA Controller “12. Maintenance • Checking”
(Blank Page)
— 12-8 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13. Alarms
l This section describes the alarms of the EXEA controller.
13.1. Indication of Alarms
l EXEA controller indicates the alarms by the outputs of CN3 (control I/O connector), the seven
segments LED on the front panel and the display of the teaching box.
l In remote control mode through RS-232C interface, the readout command is to report the state
of alarms.
13.1.1. Output of CN3 Connector
l It outputs RDY and WRN. The meanings of each output are:
à RDY (Ready)
: Opens in case of a serious failure.
à WRN (Warning) : Closes in case of a minor failure
l Alarm signals are always outputted regardless the control mode such as external control mode,
teaching mode through the teaching box and remote control mode.
13.1.2. Seven Segments LED
l The seven segments LED displays alarm codes by time sharing as shown in examples below as
it cannot indicate more than two letters simultaneously.
Figure 13-1: Example of alarm indication
(1) Emergency stop
(2) When more than one alarms have arisen: Emergency stop and program error
— 13-1 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.1.3. Display of Teaching Box
l It indicates an alarm on the third line of the screen.
l If there are two or more alarms, the indication comes on in turn in every one (1) second.
Figure 13-2: Example of the teaching box display
[External]
ALARM[F4]
EMST
1RUN 2IO 3FNC 4etc
¬ Emergency stop
Note: The display does not indicate the contents of alarm in the teaching box control mode. In
such a case, return to [MENU] screen and confirm content of alarm.
Figure 13-3: Return to [MENU] screen to confirm an alarm.
Teaching box control mode
Press MODE key several times.
[MENU]
ALARM[F4]
EMST
1RUN 2ORG
3JOG
4etc
[MENU]
ALARM[F4]
EMST
1EDT 2TCH
*
3PAL
[MENU]
ALARM[F4]
EMST
1SYS 2CTR
4etc
3IO
4etc
[MENU]
ALARM[F4]
EMST
1FNC
3EXT
4etc
* The part in dotted lines won’t be indicated for a single axis system.
— 13-2 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.2. Motor Condition in Alarm State
l In case of a minor failure (WRN output closed), the motor gets in “servo-lock” state. (You can
operate system in the state of “Home return incomplete” alarm. Complete the Home return.)
l In case of a serious failure (RDY output opened), the motor gets in “servo-off” state.
13.3. Alarm List
13.3.1. Normal State
l Table 13-1 shows the conditions in normal state.
Table 13-1: Normal state
7 segment LED
Off
LED
Green
RDY output
close
WRN output
open
Indication of teaching box
–
l Even the system is in the normal state, there may be no indication on 7 segments LED or the
outputs of RDY may indicate the abnormality in some cases. In such a case, refer to the table
below.
Table 13-2: Exceptions in normal state
Motor
7 segments
LED
LED
RDY WRN
output output
Servo off
Off
Off
Open
Initializing CPU
Servo off
(When the power is on.)
Off
Item
Power is not on.
— 13-3 —
Orange Open
Cause
Remedy
Turn on
power.
Wait for
Open Initializing CPU.
a while.
Open
Power off
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.3.2. Alarm List
l The alarms given by EXEA controller in abnormal conditions are listed in Table 13-3.
Table 13-3: Alarm List (1/2)
Motor
7 segments
LED
Servo off
P0
Servo off
P4
Orange Open
Open
Overheat 2
(resistor)
Servo off
P1
Orange Open
Open
Main Power
voltage
Servo off
P2
Orange Open
Open
Overcurrent
Servo off
P3
Orange Open
Open
Ctrl. Power
voltage
Servo off
A0
Orange Open
Open
Encoder 1
(loss)
Servo off
A3
Orange Open
Open
Thermal
Speed abnormal Servo off
A4
Orange Open
Open
Speed
Home return
incomplete
Normal
operation
A5
Green
Battery error
Servo off
A7
Orange Open
Open
Encoder 3
(battery)
Memory error 1
Servo off
E0
Orange Open
Open
Memory 1
(data)
Memory error 2
Servo off
E1
Orange Open
Open
Memory 2
(backup)
Memory error 3
Servo off
E2
Orange Open
Memory error 4
Servo off
E3
Orange Open
CPU error
Servo off
Alarm
Overheat 1
(Heat sink)
Overheat 2
(Regeneration
resistor)
Abnormal Main
power voltage
Excessive
current
Insufficient
voltage to the
control power
Encoder circuit
error
Overload
RDY WRN Teaching box
Symptom • Cause
*1
output output indication
Overheat 1
Internal heat sink of power amplifier
Orange Open Open
(heatsink)
output circuit has overheated.
LED
Close Close
Not settle or
Orange Open
E6
Overheat of regeneration resister.
Voltage of main power is too high or
low.
Excessive current has applied to the
motor.
Control power voltage is too low.
Snapped encoder wiring or abnormal
signal.
Motor operating duty exceeds the
rated value.
Motor exceeded its maximum
rotational speed.
Coordinate cannot be set as Home
position is not defined.
Encoder data is lost due to low
voltage of battery for encoder backup. (A0 is reported simultaneously.)
Inrush noise has destroyed data of
parameters or internal data.
External noise has destroyed
memory back up for parameters and
data.
Failure to write back up data to the
flash memory.
External noise changed contents of
system program.
Encoder 2
(Position)
Memory 3
(write)
Memory 4
Open
(code)
Cpu
(*****)
Open
or
ツウシンフノウ
Open
System error
Servo off
E7
Orange Open Close
Excessive
position error
Servo off
F1
Orange Open
Open
— 13-4 —
*2
External noise caused CPU
malfunction.
Combination of motor and power
amplifier has changed.
Position error in the differential error
Position Error counter have exceeded the set value
to detect excessive error.
System
1 Installation and Maintenance of EXEA Controller “13. Alarms”
Table 13-3 (2/2)
Alarm
Motor
Servo lock
for one
direction
Servo lock
Travel limit
for one
(Mechanical lock)
direction
Servo off
Emergency stop
Travel limit
(Set by user)
Program error
Servo on
7 segments
LED
LED
RDY WRN Indication of
*1
output output teaching box
F2
Green
The slider moved exceeding the
Close Close Soft. OT limit limit position set by user. (Initial
setting ‘Over travel’)
F3
Green
Close Close Hard. OT limit
F4
Orange Open
F5
Green
Symptom • Cause
The slider collides with mechanical
stopper.
Open
EMST
Emergency stop has been activated.
Prg
Syntax error in a program or input
Close Close
( * * * * * ) *3 improper program.
*1. In case of teaching box control mode, contents of alarm might not be shown in some
cases.
Return to [MENU] screen and identify an alarm in such a case. Refer to “13.1.3. Display
of Teaching Box.”
*2. “ツウシンフノウ” message, which means “communication disabled” in Japanese, may
appear in some cases besides CPU error.
[Example] When a key is pressed :
• while saving the programs in Program mode.
• while initializing special function operating mode.
*3. ( * * * * * ) ----- Varies by the contents of Program error.
— 13-5 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4. Description of Alarm
Danger
: Check the followings before attempting to investigate the cause of an alarm
or take necessary action according to the description in this paragraph. If
these items are not observed, the checking work itself can be dangerous
and further critical accident may occur due to burning motor or the system
malfunction.
1 Matching of module main unit and power amplifier of the controller
l Check that the motor power output of the main module unit conforms with output of the driver
unit in the controller.
Example of error: Connect a 200 W controller to a 100 W module main unit.
2 Do you use the standard controller cable from NSK ?
l If you have modified the standard cable or you have made the cable by yourself, take a great
care to have proper wiring.
Example of error:
Example 1: If you have faulty wiring on U, V, and W wires for motor power line, the
motor may malfunction.
Example 2: If you have faulty encoder wiring, it causes the system malfunction.
3 Check that the power supply voltage is correct.
à EXEA ¨ - ¨¨¨¨ - A ¨¨ : Single phase AC 180V ~ 242V
à EXEA ¨ - ¨¨¨¨ - C ¨¨ : Single phase AC
90V ~ 121V
l If the voltage exceeds the above range, the driver may be burned.
4 Make sure that the FGND terminal is not connected to the AC power line.
l If AC power is connected to the FGND terminal or the ground, the controller may function
improperly and furthermore, the controller might be burned.
— 13-6 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
Danger
: Before attempting to investigate the cause of an alarm and, to take actions
for recovery according to descriptions of this paragraph, check that the
module main unit has completely stopped, then turn off the main power for
your safety. This is necessary to prevent the operator from being crushed
or being caught by the unit. If you must work with entire system active, take
full safety measures referring to the following.
(1)
Do not enter the area bound by the guard fence.
(2)
When working inside of the guard fence observe the following.
à Set the controller to the teaching operation mode and set the system to servo off state.
Take possible means to prevent to turn servo on or operate the system from the out
side of the guard fence.
[External]
1RUN 2IO
*
: Confirm that the operation mode is not the
external control. Do not operate the system
with the display shown in the left.
4FNC 4etc
[Menu]
1RUN 2ORG 3JOG 4etc
: Confirm that the servo on indicator (*) on
upper right corner of the screen is off.
Indicates the servo is off.
à When operation of the system or making motor in servo-on state is necessary, make
sure that no other person and no obstacle are in the motion range of robot. Then set the
moving speed to 250 mm / sec. and start the work. Be sure to provide necessary means
to prevent entry of other persons into the area while you are operating the system.
à Keep the teaching box handy to the operator for immediate termination of operation in
an emergency.
à Before starting the work, check that the emergency stop circuit works when the
emergency button is pressed. (‘Emergency stop’ circuit must be provided by the user.)
à Do not touch the primary power supplying area to avoid electric shock. Do not turn on
the power before closing enclosure cover.
— 13-7 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.1. Overheat
Table 13-4
Motor condition 7 segments LED LED
Servo off
P0
Orange
Servo off
P4
Orange
DRDY output WRN output
Open
Open
Open
Open
Display of teaching box
Overheat1 (heatsink)
Overheat2 (resistor)
Warning : Be careful not to be burned as the heat sink and the dump resistor are hot
when this alarm is given.
l There are two types of overheat alarm (P0 and P4). The alarm reports overheat when either one
or both of thermal sensors installed on the following two points are turned off.
1)
P0: Internal heat sink on the output port of power amplifier.
2)
P4: Internal dump resistor.
3)
P4: External dump resistor for processing regeneration. (Optional)
l When this alarm arises, EXEA controller terminates its operation immediately and the motor
enters servo off state. Turn the power off and cool the controller entirely, then investigate the
cause and take actions for recovery.
Table 13-5
Classification
Power
amplifier
output stage
Regenerative
dump resistor
Cause
· High ambient temperature.
· High operation duty or load.
* As these two factors shall be covered by
software thermal, normally the overload
alarm will be given before the overheat is
detected.
· Defective thermal sensor or snapped
internal wiring.
· High ambient temperature.
· Regenerative energy is too much to be
processed by the external dump resistor.
This leads to overheat.
® Long stroke and/or high load of the
vertical.
® High acceleration/deceleration and
frequent accelerating/decelerating.
· Defective thermal sensor (optional) or
snapped internal wiring.
— 13-8 —
·
·
·
·
Action
Lower ambient temperature.
Forcibly cool the heat sink with a fan.
Relax the operation duty or the load.
Reduce acceleration / deceleration.
· Replace the controller.
® Contact your local NSK representative.
· Lower ambient temperature.
· Lower the load.
· Decrease acceleration / deceleration.
· Install external dump resistor.
® Contact your local NSK representative.
· Replace the thermal sensor or the
controller.
® Contact your local NSK representative.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.2. Abnormal Main Power Voltage
Caution
: Turn off the power immediately when this alarm arises. Otherwise the
internal circuit of EXEA controller might be burned due to high voltage
exceeding AC 264 volts.
Table 13-6
Motor condition 7 segments LED LED
Servo off
P1
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Main Power voltage
l This function is to monitor the voltage of the main power system and give an alarm if main
power voltage exceeds the criteria.
l There are two types of main power voltage abnormality.
(These are not discriminated by the alarm display.)
1)
Excess voltage: Main power voltage after rectification exceeds 400 V.
2)
Low voltage: Main power voltage after rectification drops below 60 V.
l When this alarm arises, EXEA controller terminates its operation immediately and the motor
gets into the servo off state. Immediately turn off the main power, investigate the cause and take
the necessary actions.
Table 13-7
Abnormality
Excessive
voltage
Low voltage
Cause
· Very high voltage is applied to the main power. :
Example : 400 V
· Faulty power source (very wide voltage variation)
· The source voltage is increased as the regenerative
energy is too much to be processed by the internal
regenerative dump resistor.
* Normally the aforementioned overheat alarm
should be given (regeneration) before this alarm is
detected.
· Defective internal dump resistor has resulted in
high voltage of main power.
· The monitoring circuit of excessive voltage is
defective.
· Snapped, defective electric contact or mistaken
wiring of main power line.
· Defective power source. (too much voltage
variation in the power line.)
· The monitoring circuit of excessive voltage is
defective, the internal power line is snapped or the
line has defective electrical contact.
— 13-9 —
Remedy
· Rectify the problem of power
source. (Change the source to
normal power line.)
· Reduce the load.
· Reduce acceleration and
deceleration.
· Replace the controller.
® Contact your local NSK
representative.
· Check for defective wiring and
correct it.
· Use a normal power line with
less voltage variation
· Replace the controller.
® Contact your local NSK
representative.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.3. Over Current
Table 13-8
Motor condition 7 segments LED LED
Servo off
P2
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Overcurrent
l This function is to monitor the current to the motor and gives an alarm when it exceeds three
times of rated current of the motor.
l Alarm will arise immediately after the power is turned on when the current detective circuit is
not functioning normally.
l When this alarm arises, EXEA controller terminates its operation immediately and the motor
gets in the servo off state. Turn off the main power, investigate the cause and take the necessary
actions to rectify the problem.
Table 13-9
Cause
· Motor windings or motor cable is short circuited (short
circuit between two wires) and an excessive current is
applied to the motor.
· The motor winding or motor cable is grounded (short to the
earth wire) and the excessive current is given.
· Over current is applied to the motor due to steep rise of
current command from the controller.
® Excessive acceleration/deceleration or load to the motor.
® An acute angle in the path of continue path program.
· The monitoring circuit of current is defective or internal
wiring is snapped.
— 13-10 —
Remedy
· Check the motor and motor cable and
replace it if necessary.
· Check the motor and cable. Replace them
if necessary.
· Reduce acceleration/deceleration and/or
load.
· Provide a radius to the acute direction
change in the continue path program.
· Replace the controller.
® Contact your local NSK representative.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.4. Insufficient Voltage to Control Power
Table 13-10
Motor condition 7 segments LED LED
Servo off
P3
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Ctrl. Power voltage
l The function of this alarm is to detect low voltage of the control power (70V or less after
rectification) and terminate operation of the system to prevent malfunction of the control board
due to unstable control power (DC 5V system).
l When the main power voltage drops, this alarm reports abnormality before the main power
voltage alarm (low voltage) is detected.
l When this alarm arises, EXEA controller terminates the operation of the system immediately,
and the motor gets in the servo off state. Turn off the main power, investigate the cause and take
the necessary actions.
Table 13-11
Cause
· Abnormal power supply. (too much voltage variation)
· The power supply cable is too thin and too long.
® Voltage drops when the maximum current is applied.
· The power supply cable is snapped, or it has defective
wiring.
· The monitoring circuit of control power is defective or the
internal wiring of power supply is snapped or has defective
contacts.
— 13-11 —
Remedy
· Check the power line voltage and use a
normal power supply.
· Use more thicker and shorter cable.
· Check for the wiring
· Replace the controller.
® Contact your local NSK representative.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.5. Encoder Circuit Error
Table 13-12
Motor condition 7 segments LED LED
Servo off
A0
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Encoder1 (loss)
l This function is to monitor the signal level of line driver differential output from the encoder
and an alarm arises when the encoder signal is none differential output and is considered to be
abnormal.
l When this alarm is reported, EXEA controller terminates its operation immediately and the
motor gets in the servo off state. Turn off the main power, investigate the cause and take the
actions for recovery.
Caution
: The coordinate data of EXEA controller and Encoder are off when this
alarm arises. Be sure to operate Home return after turning on the power.
Table 13-13
Cause
· The encoder cable is shorted, grounded or disconnected.
· Improper wiring.
· The line driver of encoder signal output is defective.
· Monitoring circuit of encoder disconnection is defective.
· Power source of switching in the controller is defective.
· Error due to defective back up battery. (Low voltage,
improper wiring of battery)
Remedy
· Check the controller cable and cable
support for continuity. Check each signals
for short circuit and grounding. Replace
the cable if necessary.
· Replace the module main unit.
® Contact your local NSK representative.
· Replace the controller.
® Contact your local NSK representative.
· Replace battery.
· Check the wiring of battery.
* When the cable is shorted and/or grounded, the encoder as well as the receiving circuit
of encoder signal may be damaged. If the system does not recover even after the cable is
replaced, the damages on encoder and its signal receiving circuit are suspected to be defective.
l This alarm arises in case of “Encoder alarm” as well. The detailed code of encoder alarm is
indicated by the 2 digits in hexadecimal notation when the power is turned on again after the
alarm has arisen.
Encoder 1 (loss) - **
(** : 2 digits code by hexadecimal notation)
l Confirm the contents of corresponding bit by converting the 2 digits code of hexadecimal
notation to binary number.
Table 13-14: Details of Encoder alarm.
Bit
7
3
6
2
5
1
Contents
Over speed of first or third axis
Over speed of second or fourth axis
Absolute error of first or third axis
Absolute error of second or fourth axis
Check sum error of first or third axis
Check sum error of second or fourth axis
Remedy
Take measures not to move a main unit when the
power of EXEA controller is turned on again.
4
Backup alarm of first or third axis
0
Backup alarm of second or fourth axis
This alarm may arise simultaneously with “Battery
error.” Take the same measures against the “Battery
error” alarm.
Replace the motor when the system does no recover
by turning on the power again.
Note: Only the alarms of the first axis is indicated for a single axis system.
— 13-12 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.6. Overload (Protection by Software Thermal Switch)
Table 13-15
Motor condition 7 segments LED LED
Servo off
A3
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Thermal
l This function is to monitor the average of current command to the motor and give an alarm
when the current command exceeds rated current of the motor.
l When this alarm arises, EXEA controller terminates its operation immediately and the motor
gets in the servo off state. Turn the power off, then investigate the cause and take necessary
actions.
Table 13-16
Cause
· Excessive motor duty, load and
acceleration/deceleration.
· Improper initial setting of software thermal
switch.
· Continued operation without releasing the motor
brake.
® Disconnected brake line wiring of controller
cable and support cable.
® Built in DC24V power supply to EXEA
controller is defective.
· Snapped motor winding or motor cable.
— 13-13 —
Remedy
· Relax motor duty and decrease load and
acceleration/deceleration.
· Air-cool the motor after terminate operation as it is
overheated. (Keep the controller power turned on
while cooling the motor.)
· Set the software thermal switch properly.
· Check DC24V power supply and wiring. Rectify
the problems.
· Investigate brake line wiring of controller cable and
cable support. Replace defective cable.
· Replace the controller.
® Contact your local NSK representative.
· Check for motor winding and/or motor cable.
Replace them if required.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.7. Speed Abnormal
Table 13-17
Motor condition 7 segments LED LED
Servo off
A4
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Speed
l This function is to monitor rotational speed of the motor and gives an alarm if it exceeds the
allowable maximum speed.
l Rotational speed of the motor may exceed the limit due to influence of noise to motor cable and
the controller.
l When this alarm arises, EXEA controller terminates its operation immediately and the motor
gets in the servo off state. As though the alarm may be cleared by “alarm clear,” investigate the
cause and take necessary actions.
Table 13-18
Cause
· Module main unit moved very fast due to an
external load or gravity under servo off state.
· Noise has caused an excessive motion command
or too much position deviation.
· Encoder error or internal data error
— 13-14 —
Remedy
· Take an appropriate measure not to move the module
main unit exceeding its maximum speed criterion.
· Take sufficient measures against noises.
® Review all wiring of grounding.
® Check the power line. ---- Do not use the same
power line with the equipment such as a
compressor which causes unstable power variation.
® Do not install the robot module system near
equipment such as an welding machine which
generates noises.
® Refer to “7.2.5. Measures against Noises.”
· Replace the module main unit.
® Contact your local NSK representative.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.8. Home Return Incomplete
Table 13-19
Motor condition 7 segments LED
Normal
A5
operation
LED
DRDY output WRN output
Green
Close
Close
Display of teaching box
Encoder 2 (position)
l The controller gives this alarm when Home return is not completed in the following cases.
1)
After power is turned on.
2)
After initialization.
3)
When combination of module main unit and controller is changed.
l The alarm will be reported in the following cases even though the home return has been
completed and no alarm has not arisen.
1)
When the type of a main unit is changed.
2)
The power is turned off without saving the change of a main unit type (in case of
above example) after the home return was conducted again.
3)
Home return is interrupted by the stopping, an alarm or shutdown of the power when
conducting the home return again.
4)
When an alarm of encoder error (A0) arises.
l You cannot perform positioning in absolute coordinate format or programmed operation during
this alarm is active.
l This alarm may arise when EXEA controller and a module main unit are connected after their
disconnection for transportation. This is caused by disconnection of the back up power to the
encoder from EXEA controller.
Table 13-20
Cause
· The coordinates of EXEA controller and encoder do no
conform as the Home position is not defined yet.
— 13-15 —
Remedy
· Execute home return.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.9. Battery Error
Table 13-21
Motor condition 7 segments LED LED
Servo off
A7
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Encoder 3 (battery)
l This function is to give an alarm for low voltage (2.8 V or less) of a battery for encoder back-up.
l This alarm may occur when wiring of battery has snapped wire or insufficient contact.
Caution
: The controller cannot recover until the battery is changed when this alarm
is given.
Be sure to change to a new battery.
Caution
: After replace of battery, be sure to perform Home return operation.
Table 13-22
Cause
· Low battery voltage.
Remedy
· Replace a battery of an encoder that has lost
coordinates data.
® Refer to “12.2.2.2. Replacement” for procedures.
· Wiring of battery has snapped wire or insufficient · Replace the battery. Contact your local NSK
connection.
representative if the alarm is given again after change
of the battery.
13.4.10. Memory Error 1
Table 13-23
Motor condition 7 segments LED LED
Servo off
E0
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Memory 1 (data)
l The EXEA controller checks the contents of memories after the power is turned on and
periodically thereafter. This function gives the alarm when there is abnormality in the parameter
data currently being used and the data of internal memories.
l When this alarm arises, the EXEA controller terminates its operation immediately and the motor
gets in the servo off state.
l Turn on power again for recovery.
Table 13-24
Cause
· A large inrush current intruded into the control
board, caused memory circuit malfunction and
resulted in the memory destruction.
— 13-16 —
Remedy
· Take appropriate measures for noise.
® Review ground wiring.
® Look again the power line. Do not use the same
power line with an equipment which tends to
disturb the power line such as an air compressor.
® Do not install EXEA controller close to a machine
such as a welding machine which generates a lot of
noises.
® Refer to “7.2.5. Measures against Noises.”
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.11. Memory Error 2
Table 13-25
Motor condition 7 segments LED LED
Servo off
E1
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Memory 2 (backup)
l This function is to give an alarm on memory error of program/point register. EXEA controller
conducts check of the memory when turning on the power. When abnormal results on check is
observed, it gives the memory error alarm.
l When this alarm arises, EXEA controller terminates its operation immediately and the motor
gets in the servo off state.
l Initialize the memory, then input program and conduct teaching data of point register.
Refer to “13.6. Initialize Memory.”
l It may give the alarm when turn off the power in the middle of saving the parameters and data to
the memory. While saving the parameters and data, the teaching box display indicates “Writing”
and the control output DATWT (CN3) is closed. Do not turn off the power when the display is
indicating “Writing” and DATWT out put is closed.
Table 13-26
Cause
Remedy
· Take appropriate measures for noise.
· A large inrush noise intruded into the
control board, caused the memory circuit to ® Review ground wiring.
malfunction, and resulted in memory
® Check again the power source. Do not use the same
destruction.
power line with an equipment tends to disturb power
source such as an air compressor.
® Do not install EXEA controller close to a machine, such
as a welding machine, which generates noises.
® Refer to “7.2.5. Measures against Noises.”
· The power is interrupted in the middle of
· Connect to stable power supply line.
rewriting memory.
— 13-17 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.12. Memory Error 3
Table 13-27
Motor condition 7 segments LED LED
Servo off
E2
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Memory 3 (write)
l This is to give an alarm when saving the parameters and data is not completed normally due to
some disturbance.
l When this alarm arises, EXEA controller stops its operation immediately and the motor gets in
servo off state.
l Initialize the memory, then input program and conduct teaching data of point register. (Refer to
“13.6. Initialize Memory.”)
l It may give the alarm when turn off the power in the middle of saving the parameters and data to
the memory. During saving the parameters and data, the teaching box display indicates
“Writing” and the control output DATWT (CN3) is closed. Do not turn off the power when the
display is indicating “Writing” and DATWT out put is closed.
Table 13-28
Cause
Remedy
· A large inrush noise intruded into the control
· Take appropriate measures for noise.
board, caused the memory circuit to malfunction, ® Review ground wiring.
and resulted in memory destruction.
® Check again the power source. Do not use the same
power line with an equipment tends to disturb
power source such as an air compressor.
® Do not install EXEA controller close to a machine,
such as a welding machine, which generates noises.
® Refer to “7.2.5. Measures against Noises.”
— 13-18 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.13. Memory Error 4
Table 13-29
Motor condition 7 segments LED LED
Servo off
E3
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Memory 4 (code)
l EXEA controller conducts check of the memory after turning on the power. This alarm function
is to check the system ROM.
l When this alarm arises, EXEA terminates its operation immediately and the motor gets in the
servo off state.
l Turn on power again for recovery. Replace EXEA controller when it does not recover by
turning on power again.
Table 13-30
Cause
· A large inrush noise intruded into the control
board and lead to memory destruction due to
memory circuit malfunction.
· Defective hardware of controller.
— 13-19 —
Remedy
· Take appropriate measures against noise.
® Review ground wiring.
® Look again the power line. Do not use the same
power line with an equipment which tends to
disturb the power line such as an air compressor.
® Do not install EXEA controller close to a machine
such as a welding machine which generates a lot of
noises.
® Refer to “7.2.5. Measures against Noises.”
· Replace the controller.
® Contact your local NSK representative.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.14. CPU Error
Table 13-31
Motor condition 7 segments LED
Servo off
Indefinite / E6
LED
DRDY output WRN output
Orange
Open
Open
Display of teaching box
Hold previous display
Cpu ( * * * * * )
( * * * * * ) --- Differs with contents of alarms.
l This function is to monitor CPU malfunction and data exchange between the CPUs through
monitoring circuits such as watchdog timer.
l When this alarm arises, EXEA controller terminates its operation immediately and the motor
gets in the servo off state. In case of momentary malfunction, remake main power for recovery.
If the system does not recover, hardware circuit failure is suspected.
Table 13-32
Cause
· A large inrush noise intruded into the control
board and caused CPU malfunction.
· CPU or the watchdog circuit has failed.
— 13-20 —
Remedy
· Remake the power.
· Take appropriate measures for noise.
® Review ground wiring.
® Check again the power source. Do not use the same
power line with an equipment tends to disturb to
power source such as an air compressor.
® Do not install EXEA controller close to a machine
such as a welding machine which generates noises.
® Refer to “7.2.5. Measures against Noises.”
· Replace the controller.
® Contact your local NSK representative.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.15. System Error
Table 13-33
Motor
condition
Servo off
7 segments
LED
E7
LED
Orange
DRDY
output
Open
WRN
output
Open
Display of teaching box
System ( * * * * * )
( * * * * * ) --- Differs with contents of alarms.
l This function is to give an alarm when composition of system at initialization of controller
differs with the one at the moment of turning on power after initialization.
Power Amp : Composition of power amplifier of the controller differs with the one at the
initialization.
Motor
: Type of motor set to power amplifier differs with setting at the initialization.
Version
: Version number of CB board differs with the one at the initialization.
Cpu
: Composition of CB board differs with the one at the initialization.
l It may occur for defective power amplifier or extend CB board for three/four axes, or also occur
when power amplifier or CB board is replaced to repair the controller.
l Initialization of the controller will recover from the alarm. If not, defective circuit of hardware
such as a power amplifier is suspected.
Table 13-34
Cause
Remedy
· Defective amplifier disturbs to identify the types. · Replace the controller.
® Contact your local NSK representative.
· System configuration has been changed due to
· Initialize EXEA controller.
replacement of controller, or exchanging
hardware.
— 13-21 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.16. Excessive Position Error
Table 13-35
Motor condition 7 segments LED LED
Servo off
F1
Orange
DRDY output WRN output
Open
Open
Display of teaching box
Position Error
l This function is to give an alarm when position error in differential error counter exceeds the
preset limit. This limit may be specified by “POS over” parameter at initial setting.
l This alarm is to give the warning that the position control is disturbed for some reason
(mechanical interruption to module main unit, etc.).
l EXEA controller terminates its operation immediately when this alarm arises and the motor gets
in servo off state,
Table 13-36
Cause
· Improper setting of POS.err over parameter.
Remedy
· Set correctly.
® Reset to the shipping set.
· Optimize gain setting.
· Improper gain setting.
* Generally this alarm tends to occur when position gain is set ® Reset to the shipping set if the load is not
too low.
heavy.
However, it won’t occur unless the gain setting is extremely ® Increase gain for heavy load.
deviated.
· Brake of module main unit is not released.
· Release the brake.
· Refer to “14.2.2. Check Function of Brake Control.”
* In such a case, overload alarm may come up first. Refer to
the clause for overload alarm.
· A module main unit is interfered or defective.
· Investigate back drive force, motor lock
and interference of robot motion, then
remove the cause or replace unit (parts) if
necessary.
· Output of motor power does not conform to specification.
· Refer to specification then correct or
® Example: 200 V module is connected to 100 V power line. replace the unit as required.
· The motor does not rotate.
· Check the cables and correct or replace it
as required.
® Examples: Miss-wiring of motor cable and the snapped
wire.
— 13-22 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.17. Software Travel Limit Switch (Set by user.)
Table 13-37
Motor condition 7 segments LED
Servo is locked
for one
F2
direction.
LED
DRDY output WRN output
Green
Close
Close
Display of teaching box
Soft. OT limit
l This function is to give an alarm if the slider travels (= motor rotates) beyond the software travel
limit. Software travel limit is set by “Over travel” parameter as an initial setting.
l This alarm is invalid unless “Over travel” parameter is set numerically. The shipping set is
“OFF.”
l This function is invalid unless Home return is completed and the coordinates are set.
l When this alarm arises, EXEA controller terminates its operation immediately, and the motor
gets in “servo lock” state for one direction not to execute the command to near further to the
limit. The system accepts commands to move slider to opposite direction. Move the slide
opposite direction by jog or other move command to get out from the limit area.
Table 13-38
Cause
· Improper setting of parameter “Over travel.”
· Current position is in software over-travel limit.
— 13-23 —
Remedy
· Set parameter properly.
· Get out from the limit range.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.18. Travel Limit (Mechanical lock)
Table 13-39
Motor condition 7 segments LED
Servo is locked
for one
F3
direction.
LED
DRDY output WRN output
Green
Close
Close
Display of teaching box
Hard. OT limit
l This function is to give a warning when the slider gets in mechanically locked state and cannot
move one direction because it hits a mechanical stopper at stroke end or it is interfered
externally.
l This alarm may occur due to extremely heavy load exceeding specification limit as well.
l In such a case, relax acceleration and deceleration and lower the load to fit into specification.
l When this alarm arises, EXEA controller terminates its operation immediately, and the motor
gets in “servo lock” state for one direction not to execute the command to near further to the
limit. Check for cause of mechanical lock and remove the obstacles in motion range of slider.
Relief the motor from servo lock state moving the slider in opposite direction, if necessary, by
Jog or other motion command. Pay special attention for the slider of vertical axis.
l The system accepts command to move the slider to opposite direction in this alarm state. If there
is no mechanical obstacles, you may move the slider into opposite direction of mechanical
stopper by Jog or other motion command.
l When the slider hits the mechanical stopper on stroke end frequently, review the coordinate data
of position and perform Home return.
Table 13-40
Cause
· The coordinate setting does not meet stroke end position, or
the relation of coordinates between the motor and encoder is
shifted due to sudden noise disturbance.
· The slider is locked by external obstacle.
· Load that brings torque exceeding the motor capacity is
applied to the robot.
Remedy
· Execute Home return and check
coordinates again.
· Remove the obstacles by Jog or servo off.
· Decrease load.
· Relax acceleration and deceleration.
l If this alarm arises frequently even there is no problems on the load mass, the operational
conditions and the motor is not overheated, set the travel limit timer (Hard OT Timer) manually.
At this time, set the timer in the range not to arise an overload (A3) alarm.
Caution
: Do not set the travel limit timer manually in the following conditions.
à when the motion of main unit is not smooth in Servo on or Servo off.
à when main unit shows unstable motion due to vibration or hunting.
— 13-24 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.19. Emergency Stop
Table 13-41
Motor condition 7 segments LED LED
Servo off
F4
Orange
DRDY output WRN output
Open
Open
Display of teaching box
EMST
l This function is to give an alarm when the emergency stop command is inputted to EXEA
controller and the system gets in the emergency stop state.
Table 13-42
Cause
· Execute an emergency stop operation.
· Got in the emergency stop state without any command was
called for, or cannot lift the emergency stop state.
Example 1: Incorrect wiring, none wiring or disconnected
wire of CN3EMST input
Example 2: EMST input is considered to be off as the rising
of external DC 24V power supply for CN3
connector is slower than rising of EXEA
controller. (when DC 24V is supplied externally.)
Example 3: Teaching box is disconnected, or EMST switch
of teaching box is defective.
Example 4: Malfunction of EMST line due to an external
noise.
Example 5: Failure of internal circuit of EXEA controller.
— 13-25 —
Remedy
· Call off the emergency stop state, execute
alarm reset process or remake main power
again. Refer to “11.3.1.3. Recovery from
Emergency Stop” for recovery.
· Review all wiring and correct as required.
· Check on wiring of DC 24V power supply
and correct as required.
· Check on DC 24V power supply and
review sequence of start up.
Replace teaching box.
Take measures against noise. Refer to
“7.2.5. Measures against Noises.”
* Refer to “14.1.8. Unable to Clear
Emergency Stop.”
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.4.20. Program Error
Table 13-43
Motor
condition
Servo lock
7 segments
LED
F5
LED
Green
DRDY
output
Close
WRN
output
Close
Display of teaching box
Prg ( * * * * * )
l This function is to give an alarm when a program which has syntax mistake or, a program that is
impossible to execute is inputted during the operation. This alarm is given when a programmed
operation is interrupted by an emergency stop or servo-off command as well.
l When this alarm arises, EXEA controller terminates its operation immediately and motor gets in
servo lock state. Cancel the alarm referring to “13.5. Clear Alarm”, investigate the cause and
correct the program as required. (Refer to “15.2. Programming” again.)
Table 13-44: Program Error (1/2)
Teaching box display
Cause
Prg ( * * * * * )
Prog not found
· Attempted to execute empty program.
Step not found
· Program is not written to the end. (= END command is not set to the end of the program.)
· In circular/circular arc interpolation and continue path, the data is not properly set.
[Examples]
1
à Four axes coordinates data are set to the point registers.
Axis mismatch *
à Required data is not specified. (Only one axis coordinates data is set, etc.)
· Teaching data of axis unit is mismatched. (the combination of XY and XZ is mixed up, etc.)
· The set data exceeds upper or lower limit.
Data range over
· Decimals are set to a data to which only an integer can be set.
Undefind TAG
· A TAG which is designated as the destination of Jump is not set in the same program.
Duplicate TAG
· Several TAGS with the same name exist in the same program.
Too many CALL
· The nesting of CALL command are 5 or more. (Allowable nesting loop is four or under.)
Without CALL
· Attempted to execute REP command before CALL command is set.
Too many REP
· The nesting of REP command are 5 or more. (Allowable nesting loop is four or under.)
Without REP
· Attempted to execute NXT command before REP command is set.
Cannot execute circular / circular arc interpolation due to following reasons.
· Attempted an interpolation which includes an moving axis in a multitask operation.
· Designated three points are not on a circle or arc. (Example: They make a line.)
*1
Can’t make cir
· Starting point of circular / circular arc interpolation and current position are different in ABS
coordinate format.
· Omitted the starting point in INC coordinate format.
· Attempted to execute MOVE command in servo off state.
Servo off
® Start operation again after turn on the servo.
*1
Axis offline
· Attempted to execute a command to use an axis not specified.
— 13-26 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
Table 13-45: Program Error (2/2)
Teaching box display
Prg ( * * * * * )
Origin not exe.
Can’t make path
*1
*1
Without CPS
*2
Undefined cmnd
Can’t restart
R. Prg not found
Task full
Unit offline
Axis overlap
Over travel
Alarm
Undefined PRG
Duplicate PRG
*1
Undefined PAL
*1
Duplicate PAL
Not Init. PAL
*1
*1
overlap PAL
Without CHLD
Cmnd mismatch
Can’t make mov
*1
Cause
· Attempted to execute motion command before completion of Home return.
® Start operation again after Home return is completed.
Cannot execute continue path due to following reasons.
· More than 101 steps are set between CPS and CPE.
· The same settings which cause “Can’t make cir” exist in the program of continue path.
· Attempted to execute CPE command without CPS command.
· The program command that does not exist is set.
Cannot resume programmed operation due to following reasons.
· Attempted to resume the programmed operation while the cycle stop has not been completed ( =
The step has not been completed.) after the interruption of the program.
· Attempted to resume an interrupted program after execution of a command equivalent to END
command mistakenly such as Emergency stop (EMST) or Forced stop (STOP).
· Attempted to resume interrupted program not in accordance with the description of the
instruction manual.
· Attempted to resume the interrupted program before the conditions described in the instruction
manual are not met.
· When resuming the interrupted program. nothing is set to the initializing program for resumption
even it is set by RSTA command.
· More than 17 tasks are specified. (More than 5 tasks for a single axis system.)
· Attempted to operate a Unit that is not specified.
· Attempted to operate an axis, that is used in a multitask, simultaneously in the other operation.
· Stopped due to over travel.
· Stopped because of an alarm.
· There is no program specified by the name.
· There are several programs with the same name.
· There is no palletizing program with a specified name.
· There are several palletizing program with the same name.
· The palletizing program is not initialized: Attempted to execute a palletizing operation even
PALI command is not set.
· Tried to operate the same palletizing program which are under execution.
· Attempted to execute ENDC command even CHLD command is not set.
· More than 101 steps are inserted between CPS and CPE. (for multi-axis combination only.)
· A command other than MOV, MOVM, CIR, ARC, OUT and SPD is set between CPS and CPE.
(for multi-axis combination only.)
· Attempted to execute a special command such as “MOV RSTA,” or “OUT OP ** = RSTA” even
it is not in initializing program of resumption which is set by RSTA command.
· Combination of motion which is impossible to make is set.
* 1. This function or indication does not exist for a single axis system.
* 2. This alarm does not arise in normal state. Memory initialization and re-programming are
required when the alarm arises.
— 13-27 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.5. Clear Alarm
l Clearing an alarm is to set off a latch, which is set to EXEA controller internally, and this does
not do anything with removing the cause of an alarm. Unless the cause has not been removed,
the same alarm will arise.
Caution : When an alarm is reported, investigate the cause and remove it first.
Repeating “clearing an alarm and alarm reporting” without removing the
cause might damage the controller, the module main unit and ancillaries.
Table 13-45: Alarm that can be cleared
Classification
LED
indication
Alarm
Abnormal main power
voltage
Over load
Speed abnormal
Excessive error
Alarm related to Over travel limit
control
Emergency stop
Program error
Alarm related to
power amplifier
Alarm related to
servo motor
Teaching box
display
P1
Main Power voltage
A3
A4
F1
F3
F4
F5
Thermal
Speed
Position error
Hard. OT limit
EMST
Prg ( * * * * * )
Remarks
Table 13-46: Alarm that cannot be cleared
Classification
LED
indication
Teaching box
display
P0
Overheat 1 (heatsink)
P4
Overheat 2 (resistor)
P2
Overcurrent
P3
Ctrl. Power voltage
Encoder circuit error
A0
Encoder 1 (loss)
Home return incomplete
A5
Encoder (Position)
Battery error
A7
Encoder (battery)
Alarm
Overheat 1 (heat sink)
Overheat (regeneration
Related to
dump resistor)
power amplifier Excessive current
Insufficient voltage to
control power
Alarm related
to servo motor
Alarm related
to control
Memory error 1
Memory error 2
Memory error 3
Memory error 4
CPU error
E0
E1
E2
E3
E6 etc.
Memory 1 (data)
Memory 2 (backup)
Memory 3 (write)
Memory 4 (code)
Cpu ( * * * * * )
System error
E7
System
Travel limit (set by user)
F2
Soft. OT limit
— 13-28 —
Remarks
Home return is necessary
after recovery.
Home return is necessary
after battery is replaced.
Reset after initialization of
memory.
Replace EXEA controller.
Reset after initialization of
memory.
Alarm is automatically
cleared when slider gets out
the over travel limit range.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.5.1. Clear Alarm in External Control Mode
(Operation Mode through CN3 Control I/O)
l Alarm is cleared by rising signal from OFF to ON of ACLR input of CN3 pin No.23.
Figure 13-4
20 ms or more
ACLR input
ON
OFF
Alarm state
Clear alarms
Alarm
13.5.2. Clear Alarm by Teaching Box Operation Mode
l Return to Menu selecting screen by pressing MODE key. Confirm the indication of alarm.
l Clear alarm by CLR and SET keys.
l There are two types of alarms. One is cleared by pressing only CLR key and the other type is
cleared by pressing SET key after CLR key.
* When pressing SET key after pressing CLR key, press SET key after removing your finger
from CLR key. When CLR and SET keys are pressed simultaneously, an alarm cannot be
cleared.
Table 13-47
CLR key
Teaching box operation
Alarms that can be cleared.
· Program error
CLR key ® SET key
All alarms listed in Table 13-45.
13.5.3. Clear Alarm in Remote Control Mode
(RS-232C Communication Mode)
l Alarms can be cleared by ACLR command and ACLR ALL* command.
l See the table below for the distinction of alarms that can be cleared by ACLR command or
ACLR ALL* command.
Table 13-48
Remote control
Alarms that can be cleared.
ACLR command
· Program error
* : is a space code (20H).
— 13-29 —
ACLR ALL* command
All alarms listed in Table 13-45.
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.6. Initialize Memory
l When memory error arises, all data, such as initial setting data, program editing data, point data
and palletizing data must be initialized.
(Palletizing data is for multi-axis combination only.)
l You can initialize all memories of EXEA controller following the procedures in Figure 13-5
bellow. The initialization will set all memories to the shipping set.
l You must conduct the initial setting, programming, teaching, and making palletizing data again
in case of a multi-axis combination.
Figure 13-5: Procedure of initializing memory.
: Menu selection screen 4
[MENU]
1FNC
· Set to the menu selection screen 4 in the teaching box
operation mode referring to “8.2. Selection of Control
Mode.”
3EXT 4etc
Press F1 key.
[FNC]
1VER
2ALM
3DAT
4etc
Press F4 key.
: Selection screen of
initialization
[FNC]
1INI
· Pressing F4 key in the selection screen of
initializing makes possible to initialize memory.
4etc
Press F1 key.
[FNC]I
· Press SET key. It starts initializing.
Push SET
Press SET key.
· The screen indicates “Writing” while the initialization.
[FNC]I
Caution : Do not turn off the power while the screen
indicates “Writing.” Otherwise “memory error”
alarm arises.
Writing
· The screen indicates “Complete” when the
initialization is finished. Press MODE to return to
the selection screen of initialization.
[FNC]I
Complete
Press MODE key.
— 13-30 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.7. Monitoring Software Version and Alarm History
l You may check software version number and monitor history of alarm in the selection screen of
function.
l The screen indicates software version number (VER) and history of alarm (ALM). Function of
(DAT) is reserved.
Figure 13-6: Selection screen of function
: Menu selection screen 4
[MENU]
1FNC
3EXT
· Set the screen to selection screen 4 of teaching box
operation mode referring to “8.2. Selection of Control
Mode.”
4etc
Press F1 key.
: Selection screen of function
[FNC]
1VER
2ALM
3DAT
4etc
13.7.1. Indication of Software Version Number
l The display indicates version number of software by pressing F1 key (VER) in the selection
screen of function.
Figure 13-7: Screen indicating software version number. (Example of single axis system)
F1
[FNC]
1VER
2ALM
3DAT
4etc
[FNC]V
Typ.EXE MONO
Ver.0001
MODE
Figure 13-8: Screen indicating software version number. (Example of two axes combination)
F1
[FNC]
1VER
2ALM
3DAT
4etc
MODE
[FNC]V
Typ.EXE2
Ver.0001
0001/0001
— 13-31 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
13.7.2. Indication of Alarm History
l You can monitor history of alarm by pressing F2 key (ALM) in the selection screen of
function.
l Indication of history:
(Refer to Table 13-49 for details.)
à In the second line: History number, alarm code and alarm detection code.
à In the third line: Name of alarm
à Smaller history number indicates newer alarm.
l Use
to scroll history of alarm.
l Use F2 key to switch indication of an axis or a power amplifier number as the alarm detection
code, on which alarm is reported.
Figure 13-9: Screen indicating alarm history (Example for two axes combination)
F2
[FNC]
1VER 2ALM
MODE
Alarm detection code
U1XY ® Alarm is on for X and Y axes of Unit1.
A12 ® Alarm is on for Amplifier 1 and 2.
Alarm code
History number
Name of alarm
[FNC]A
01 A5 U1XY
Encoder2(position)
1CLR 2AMP
F2
[FNC]A
01 A5 A12
Encoder2(position)
1CLR 2AXS
l Press F1 key (CLR) in the indication screen of alarm history to clear the alarm history.
— 13-32 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
Table 13-49: Contents of alarm history
Classification of
indication
History number
Alarm code
Contents
· The history number is assigned to detected alarms in the order so that the
smaller number indicates newer alarm. The numbers can be 0 (zero), as the
newest, to the maximum of 31.
· Following alarms will be listed on the alarm history every time these alarms
are reported as they are critical ones.
F4: Emergency stop
P1: Abnormal power supply
P3: Abnormal control power
P4: Regeneration resistor overheat
E0 ~ E3 and E6: Memory error
A5: Home return incomplete
· Reports an alarm code which is being indicated by 7 segments LED.
1) Alarms which have arose from respective axis units
· An amplifier number is indicated on which an alarm has been reported when
“AMP” is selected by F2 key.
A****: Only number “1” is indicated in case of single axis system.
Numbers of amplifier “1” ~ “4” will be indicated in accordance
with faulty axis units in multi-axis combination.
[Example]
A24: An alarm, of which nature is indicated by the alarm code, arises
from the amplifier number 2 and 4 in four axes controller.
· A Unit number is indicated on which an alarm has been reported when “AXS”
is selected by F2 key.
U***** : Only “U1X” is indicated in case of single axis
In case of multi-axis combination,system.
U*****
Alarm detection
code
Name of axis (X ~ R)
Unit number.
[Example]
U3XZ: An alarm of which nature is indicated by alarm code arises
from X and Z axes of Unit 3 of four axes controller.
2) In case of alarms which occur in no relation with axis unit
· It indicates a part of processing software on which an alarm is reported.
Controller
Single axis
Multi-axis
P***
1
2
3
1
2
5
7
Part on which alarm is reported
Processing servo
Processing pulse
Processing main part
Processing servo of first and second axes
Processing servo of third and forth axes
Processing pulse
Processing main part
[Example]
P27: Alarm occurs to the parts of three axes servo processing and
main part processing of three axes controller.
— 13-33 —
1 Installation and Maintenance of EXEA Controller “13. Alarms”
(Blank Page)
— 13-34 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14. Troubleshooting
14.1. Discription of Troubleshooting
Danger
: Before troubleshooting, take the following precautions. If these precautions
are not observed, the troubleshooting itself can be dangerous as further
critical accidents may occur due to secondary accidents such as motor
burning or controller malfunction.
1 Matching of module main unit and power amplifier
l Check that the motor output specification of the module main unit conforms to the specification
of driver of the controller.
Wrong example: EXEA controller (200W) and a main unit (100W) are incorrectly connected.
2 Do you use standard controller cable from NSK ?
l If you provide the cable by yourself or use a modified cable from NSK standard cable, be sure
that the cable is correctly wired.
Wrong example 1: The system may lose control of motor if U, V and W cables of motor power
line are wired incorrectly.
Wrong example 2: The system may lose control if encoder signal line is wired incorrectly.
3 Investigate specification of main power supply voltage
à EXEA¨-¨¨¨¨T¨¨: single phase AC180V/264V
l If the power line voltage exceeds above specification, the motor driver may burn.
4 Check if the FGND terminal and AC power line is mistakenly connected.
l If the FGND terminal is connected to AC power supply line, or AC power supply terminals are
grounded, the controller does not function properly and, further more, it may result in a trouble
such as burning of controller.
— 14-1 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
Danger
: Before troubleshooting, make sure that the moving parts of a module main
unit has completely stopped, turn the servo off, then turn off the power. This
is necessary to prevent the operator from being crushed, caught or pulled
in for an accident. If you must conduct troubleshooting with power on for an
unavoidable reason, take the following measures for your safety.
à Set the controller to teaching box operation mode and turn servo off so that the
controller is not turned to servo on and not to be operated externally.
[External]
1RUN 2IO
*
: Be sure that operation mode is not set to external control
mode. Do not do troubleshooting when the display shows
it is in the external mode as shown in the left.
3FNC 4etc
[Menu]
1RUN 2ORG 3JOG 4etc
: Make sure that the servo on indicator (*) on the upper
right corner of the display is off.
Indication of servo off.
à When you perform troubleshooting while turning servo on, make sure that no one and
no obstacle is in the robot working range, then set speed of robot to 250 mm/sec.
Furthermore, provide necessary measure to prevent from entry of other person while
you are operating the system.
à The teaching box must be in the reaching area of operator so that it can be handled
quickly in an emergency.
à Check that the emergency stop function is working before troubleshooting. (Perform
troubleshooting after making sure the emergency stop function is surely functioning.)
à Do not touch the primary power supplying area to avoid an electric shock. Do not turn
on main power leaving the enclosure cover opened.
* The following descriptions in this paragraph have been made on the basis that all precautions
aforementioned in the provisions of (1) to (4) have been observed.
Warning : Move the slider of the vertical axis (main unit for moving main unit
combination) to the bottom of stroke when motor brake of vertical axis is
going to be released. When the slider (or main unit) has stopped in the
middle of stroke, it may back-drive by its own weight as the brake is
released.
— 14-2 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.1. Malfunction
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
l If, as a result of controller malfunction, a main unit should collide with the stroke end (or the
work) severely, check the damage to the module main unit referring to “14.2.5. Measures for
Malfunction and Collisions.”
Figure 14-1: Troubleshooting for malfunction
Malfunction
Check for wiring of
encoder and encoder signal receiving circuit.
® Refer to “14.2.4. Abnormality of
Encoder Signal.”
Incorrect
Correct
Replace cable
Recovered
Replace defective cable.
® Contact your local NSK
representative.
Not recovered
Encoder or controller may be defective.
® Replace module main unit or controller.
® Contact your local NSK representative.
YES
Check motor cover for overheating.
NO
* If surface temperature of the encoder exceeds 70°C, position
signal may not be transmitted correctly and it may lead to
malfunction . Refer to “14.1.12. Heating Problem” as well.
• Is the motor brake functioning normal?
The motor with motor brake may be overheated if it is operated
without releasing motor brake. Refer to “14.2.2. Check for Brake
Function” and take necessary actions if required.
• If the brake control function is normal, lower ambient
temperature, relax duty cycle and/or acceleration/deceleration.
• Contact your local NSK representative if abnormal temperature
rise seems to be irrelevant to ambient temperature, operation
duty nor acceleration/deceleration.
Check for mistakes in
programs and teaching point data.
• Moved to a point beyond the effective stroke.
• Excessive speed or acceleration/deceleration
is set.
Not appropriate
Appropriate
Contact your local NSK representative.
— 14-3 —
Set appropriate value in
program or teaching data.
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.2. Operation Problem of the System
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-2: Does not run entirely. Troubleshooting 1: Nothing is displayed on the screen.
Do not run entirely. The screen
does not display anything.
Is normal power source
supplied to the terminal block of
controller?
Abnormal
Supply normal power to the controller.
* Fuses may be blown if AC100V is supplied to a AC200V
main unit and operated at the maximum output.
* If a main unit of AC 100V specification is operated under
200 V, the internal circuitry will be burned.
Normal
Does remaking power fix the
problem?
Fixed
Not fixed
Does display of teaching box
work?
Troubleshooting completes.
• If the trouble recurs frequently, it is possible that the CPU
may be interfered by the noise and resulted in
malfunction. Reinforce measures against noises.
® Refer to “7.2.5. Measures against Noises.”
• If the measures against noises do not work, the controller
may be defective.
® Contact your local NSK representative.
NO
YES
Does 7 segments LED of the
controller indicating green?
YES
It indicates CPU.
NO
Replace the controller.
® Contact your local NSK representative.
— 14-4 —
It is possible that the teaching box
is defective.
® Replace the teaching box.
® Contact your local NSK
representative.
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-3: Does not run entirely. Troubleshooting 2: Alarm is reported.
Does not move entirely. The display
shows an alarm.
Is the alarm reported
from the beginning?
YES
NO
An alarm is on when the
robot is operated.
Program error or other alarms.
Refer to “13.4. Description of
Alarm” and take required actions.
• Excessive position error
• Overload
* Overload alarm shall be reported
sometime after starting operation.
Check the back
drive force of mechanism.
® Refer to “14.2.3. Check for
Mechanical Back Drive.”
Abnormal
Replace the module main unit.
® Contact your local NSK representative.
Abnormal
Replace controller cable.
® Contact your local NSK representative.
Normal
Check for snapped
controller cable. Examine
wiring of those cables.
Normal
Excessive position error or overload alarm arises when the motor does not rotate in
spite of a run command. If there is no mechanical problem and no problem on
cables, motor driver unit of the controller or motor itself may be defective.
® Replace module main unit or controller.
® Contact your local NSK representative.
— 14-5 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-4: Does not move entirely. Troubleshooting 3: Display shows the system is in normal
state.
Does not run entirely. No alarm is reported.
(Display is showing normal state.)
Is the servo locked?
NO
YES
Check if the servo can be switched on and off
normally through the teaching box referring to
“14.2.1. Check on Servo Lock.”
Is the servo locked?
NO
YES
When servo on and off is switched normally by the teaching box
while it cannot be performed by external control or remote control,
recheck if the procedure to turn servo on is appropriate.
YES
Is the servo locked?
NO
Check again that if the operation procedure is
appropriate when you cannot operate the system
even the servo lock is performed.
NO
If servo lock is not performed in any operational
mode, the following defects are considered.
• Defective main unit: Defective motor or coupling.
• Snapped motor power cable.
• Defective controller: Motor drivers.
® Contact your local NSK representative.
• If operation by teaching box control mode is
normal, the system must function normally when
no alarm is given.
• In remote control mode, the system should
function when the operating procedure is proper
and no abnormal state is reported.
Defective interface is suspected when the system
is not functioning even the servo is locked in
external control mode.
Defective interface is suspected when servo
cannot be locked in external control mode.
Servo is locked in external control mode, while the
system does not function entirely or does not give any
alarm. (Display shows normal state.)
Servo lock is effected in teaching box control mode,
while it cannot be effected in external control mode.
[ Continue to next page. ]
[ Continue to the next page. ]
— 14-6 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-5: Troubleshooting when servo-lock is not effected
Servo is locked in external control mode, while the
system does not function entirely or does not give
any alarm. (Display shows normal state.)
Servo lock is effected in teaching box control mode, while
it cannot be effected in external control mode.
Defective interface is suspected if it occurs in external control mode.
EXEA controller receives
input signal correctly.
NO
YES
Check CN3 connector for
incorrect wiring or missing wires.
Check DC 24V power supply.
Normal
Abnormal
Wire correctly.
It is suspected that the hardware of input/output interface is defective.
* EXEA controller does not accept control input if the photo-coupler is
damaged due to reversed wiring of DC 24V power supply.
® Contact your local NSK Representative.
(1) Review timing of input/output signal if the system does not move entirely even though servo lock is effected.
* Precaution when the system does not move entirely even the servo can be effected.
• Watch for rising timing of HOS and RUN input. HOS and RUN inputs are detected rising of signal
voltage, not detected by the level of signal voltage.
Put HOS and RUN input when all conditions are met for starting operation. The system does not start
when HOS and Run signals are set from the beginning.
• The system doe not start if HOS and RUN input signals are on.
(2) If you cannot lock the servo while SVON (CN3) is on, external control mode may have been selected, or an
alarm may be given. Review the system.
— 14-7 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.3. Troubleshooting for Home Return
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-6: Troubleshooting for Home return 1: Does not function properly.
Home return does not function properly.
YES
Does an alarm arise?
NO
Rectify the problem referring to “13.4. Recovery from Alarm.”
NO
Can you start the system?
YES
Refer to “14.1.2. Operation Problem of the System.”
Can you complete Home return?
YES
NO
Refer to “Troubleshooting for Home return 2: Cannot complete Home return.”
Refer to “Troubleshooting for Home return 3: Home position shifts.”
Refer to “Troubleshooting for Home return 4: Starts to opposite direction.”
The followings are normal.
Moves to the stroke end even Home position is set to the center of stroke by Home
position off-set function.
® Wherever the Home position is off-set, the slider always moves to the stroke
end because position of the first rising position of Z phase signal, after it hits
the stroke end and reverses its motion, is set as Home position.
® However you may select which stroke end the slider moves to.
— 14-8 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-7: Troubleshooting for Home return 2: Cannot complete Home return.
It does not complete Home return.
Does the slider reverse at
the stroke end?
NO
YES
Replace the cable.
Did not recover.
Contact your local
NSK representative.
Does the slider stop after
reversing its motion?
Recovered.
Replace defective cable.
® Contact your local NSK
representative.
NO
YES
Replace cable.
Did not recover.
Encoder might be defective.
® Replace motor.
® Contact your local NSK
representative.
Refer to “Troubleshooting for Home
return 3: Home position shifts.”
[ Continue to the next page. ]
— 14-9 —
Recovered.
Replace defective cable.
® Contact your local NSK
representative.
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-8: Troubleshooting for Home return 3: Home position shifts.
Home position shifts.
Motor indirect mount type ® Refer to “22.2.1. Periodical Checking [Timing Belt]
(only for indirect mount type).”
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-9: Troubleshooting for Home return 4: Starts to opposite direction.
The slider starts opposite direction for Home return operation.
Initial setting of parameter of EXEA controller is not set properly.
Does the parameter for motor mounting match to the module main unit?
® Refer to [Home direction] in “9.3.2. Parameters for Home Return Operation.”
— 14-10 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.4. Troubleshooting for Programmed Operation
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-10: Troubleshooting for programmed operation 1: Incomplete execution of program
Programmed operation cannot be
executed properly.
Is any indication of alarm?
NO
Can you start programmed
operation?
YES
YES
Take action referring to “13.4. Description of Alarm.”
NO
Refer to “14.1.2. Operation Problem of the System.”
Go to next procedure.
Troubleshooting for programmed operation 2: Stops halfway
of program. Gives no alarm.
Troubleshooting for programmed operation 3: Improper
setting of coordinates
• Stroke is twice the programmed distance or only one-half.
• The plus and minus direction of the coordinates are
reversed.
Troubleshooting for programmed operation 4: Does not
follow programmed sequence.
Troubleshooting for programmed operation 5: Does not
function properly.
• Positioning error. Reports no alarm.
— 14-11 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-11: Troubleshooting for programmed operation 2: Slider stops halfway.
The slider stops halfway of program.
No alarm output.
Find out what part of the program it stops using
monitoring function of programmed operation.
Is there any noticeable tendency
for stopping?
NO
YES
If it has a tendency, improper programming is suspected.
Example 1: END command is executed as a conditional jump is
effected unexpectedly under unintentional condition.
Example 2: Unexpected stop command from master controller is
inputted under unintentional condition.
® Review all programs including master controller.
® You can monitor the state of the general input in a running
programmed operation.
Is there any possibility of snapped cable?
If a cable is almost snapped it may come down temporarily then recover. The
slider stops in the middle of operation without reporting alarm in such a case.
* The cable temporally snapped by bending of cable support makes the slider
stop on the same position as it is related to bending angle of cable support.
Example: Slider stops at the position close to a stroke end.
NO
Replace cable.
Recovered.
Not recover.
Consult to your local NSK representative.
— 14-12 —
End of troubleshooting.
• Defective cable.
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-12: Troubleshooting for programmed operation 3: Incorrect setting of the coordinates
Setting of the coordinates is not correct.
• Slider travels twice or one half of programmed distance.
• Direction of plus (positive) and minus (negative) of the coordinates is reversed.
・ Initial settings of parameters to EXEA controller are not compatible with the module
main unit. Set the parameters of the main units correctly.
Slider travels twice or one half of programmed distance.
• Combination of resolution of encoder and ball screw lead.
Check that the parameter settings of a main unit in “9.5.1. Parameter List” match
with its reference number.
® Refer to “9. Initial Setting” for the specifications of module main unit.
* Resolution of encoder is 4096.
Directions of plus and minus of the coordinates are reversed.
• Possibly the parameter setting of motor mount does not conform to module main
unit, or parameter of “reverse direction of minus/minus direction” is set.
* If parameter of motor mounting is set incorrectly, direction of Home return is also
reversed. Review the parameter settings of a main unit in “9.5.1. Parameter List”
are compatible with its reference number.
® Refer to “9. Initial Setting” for the specifications of module main unit.
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-13: Troubleshooting for programmed operation 4: Does not follow the sequence as
programmed.
The system does not follow the sequence as programmed.
Find out at what part the system does not follow the sequence through monitor function of program.
In most cases the cause of the problems is “improper programming” or “time lag of timing of control
input/output.”
Example 1: The conditions of a conditional jump are met accidentally.
Example 2: Control input from master controller is inputted accidentally.
® Review the program and timing of input/output, including master controller.
— 14-13 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-14: Troubleshooting for programmed operation 5: Cannot execute program properly.
Exists position error. No alarm is given.
Is Home position normal at the
end of Home return?
YES
Refer to “14.1.3. Troubleshooting for Home Return, Home
position shifts.”
NO
If position of the slider is correct, cause of the problem might
be in end effctors. Confirm if end effectors are normal.
NO
Is the slider in its position
properly?
YES
Is the teaching point data
overwritten in the program?
NO
YES
Confirm that the point data of the position,
at where position error occurs, is correctly
overwritten as intended.
Is rewriting of teaching
point data normal?
Abnormal
Review the program to have proper
overwritten of point data.
Normal
The cause might be looseness or slip of coupling or pulley.
Motor indirect mount
® Refer to “22.2.1. Periodical Checking [Timing belt (motor
indirect mount type)],” then check the pulley and coupling.
— 14-14 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.5. Excessive Noise, Vibration and Overshooting
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-15: Troubleshooting for noise and vibration
Excessive noise, vibration and overshooting
Does an alarm arise?
YES
Refer to “13.4. Description of Alarm.”
NO
Confirm that all stiffness
of mechanically assembled parts
are sufficient.
YES
Reset the servo parameters
to the factory set.
NO
If mechanical stiffness is insufficient, the measures against noise or
vibration do not work effectively.
® Fix module main unit securely to the mount base.
® Is the bracket combining two main units fastened securely?
® Is an end effector or work firmly bolted to the base?
If the work is heavy, the hand assembly and structure of its base
must be rigid.
Improved noise/vibration.
No improvement
End.
Adjust servo parameter if noise/vibration is still large
after resetting servo parameters to the factory set.
Refer to “9.4. Servo Parameters.”
— 14-15 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.6. Troubleshooting for Rough Motion
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-16: Troubleshooting for rough motion
Does not run smoothly.
Is the brake of motor
functioning normally?
It is possible that the brake of motor is not released.
Refer to “14.2.2. Check for Brake Function” and confirm that
the brake is surely released.
NO
YES
YES
Is the brake normal?
NO
Refer to “14.1.7. Cannot Release Brake.”
Check for mechanical
back drive.
® Refer to “14.2.3. Check for
Mechanical Back Drive.”
Abnormal
Replace the module main unit.
® Contact your local representative.
Normal
Are servo parameters normal?
NO
Reset to the factory set, or adjust them.
YES
Replace a cable.
Recovered
(normal motion)
Replace the defective cable.
® Contact your local representative.
Does not recover
Module main unit uses three-phase servo motor. If one of three phases fails, the slider does not move smoothly. If the
cable is normal in such a case, motor itself or motor driver of the controller is possibly defective.
* The same problem will occur when the motor burns due to miss-connection of 100W motor to 200W motor driver.
® Replace main unit or controller.
® Contact your local NSK representative.
— 14-16 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.7. Cannot Release Brake
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-17: Troubleshooting for releasing brake
Cannot release brake.
Refer to “14.2.2. Check for Brake Function”
and confirm if the brake function is normal.
Is function of brake
control normal?
Normal
The problem is not related to
brake function.
Brake functions
normal.
Replace the defective cable.
® Contact your local NSK
representative.
Abnormal
Change cables.
Brake function normal.
If cables and controller are both normal and still you cannot release
the brake, it is possible that the module main unit is defective.
® Replace module main unit.
® Contact your local NSK representative.
— 14-17 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.8. Unable to Clear Emergency Stop
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-18: Troubleshooting for emergency stop
Cannot clear emergency stop.
When remake the power,
does the system recover?
YES
End of troubleshooting.
If the problem recurs frequently, noise is possibly the cause.
® Refer to “7.2.5. Measures against Noise.”
NO
Is the teaching box connected
to CN1 firmly?
NO
• Connect the teaching box firmly.
• When you don’t use the teaching box, connect a dummy
connector which is provided as an accessory.
YES
• EMST (CN3: control input) may not be on.
® Recheck wiring of CN3. Particularly observe the followings.
(1) Recheck if DC 24V power is supplied when using external DC 24V power.
If rise of DC 24V power is later than rise of EXEA controller, the system judges that input of EMST is
off. Make sure that DC 24V rises first.
(2) EMST input is B (normally closed) contact. It should be always on.
• If wiring and DC 24V power are normal, it is possible that internal circuit of EXEA controller is defective.
® Contact your local NSK representative.
— 14-18 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.9. Trouble of Over-travel Limit
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
l When the slider does not stop and collide to the stroke end or an obstacle severely, check
damages to the module main unit referring to “14.2.5. Action for Malfunction and Collisions.”
Figure 14-19: Troubleshooting for over-travel limit 1: Does not stop at stroke end.
Slider does not stop at stroke end in operation.
• Confirm that the software over-travel limit is set properly.
[Example] Software over-travel limit is set beyond the effective stroke, or
its position is the same as a mechanical stopper.
• User must set the software over-travel limit.
® Refer to “9.3.4. Parameters for Position and Coordinates.”
Is the software over-travel
limit set properly?
NO
Set properly.
YES
Is any alarm on to lead to
servo-off?
YES
NO
Is “Servo-off” command
inputted?
YES
If the servo is off when the slider is moving, it coasts by
inertia. In normal operation, the dynamic brake functions
to stop the slider. However if the slider is near the
mechanical stopper at the moment of servo off, it collides
to the stopper.
* The software over-travel limit does not function when
the servo is off.
NO
Confirm if the type of module main unit which is described in “9.5.1. Parameter
List” conforms to the module main unit actually used. If setting of ball screw lead
does not match, the position of software over-travel limit may not conform to
effective stroke length.
— 14-19 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-20: Troubleshooting for over-travel limit 2: Stops in the middle of stroke.
The slider stops in the range of effective stroke.
Is indication of alarm F2 ?
(F2: travel limit, user setting)
YES
NO
If the indication of alarm is F3, mechanical lock of the
slider, excessive load mass or excessive external force
to the slider may be the cause.
Check the motion of the slider, load conditions and
influence of external load referring to “13.4.18. Travel
Limit (Mechanical lock).” If there is no problem with the
conditions, set and adjust the travel limit timer so that it
doses not arise the alarm A3 (overload).
· Check the coordinates of stopped position.
· Check for the position of software over travel limit.
Does the slider stop
at the same position of software
over travel limit?
NO
YES
Reset the software over travel
limit if it is not on the intended
position.
Replace the controller.
® Contact your local NSK representative.
— 14-20 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.10. Communication Problem in Remote Control Mode
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-21: Troubleshooting for remote control mode
Communication is unable in the remote control mode.
Does the controller give
an alarm?
YES
Take action referring to “13.4. Description of Alarm.”
NO
Is color of LED of
controller green?
NO
Replace the controller.
® Contact your local NSK representative.
YES
Defective RS-232C cable or improper communication program in the personal computer is suspected.
(1) In case of defective RS-232C cable:
• Check thoroughly referring to “7.4. CN2: RS-232C Connector.”
(2) In case of improper communication program:
•Recheck the program referring to “18. Remote Control Operation.”
Is any defective part?
YES
Correct defective part.
NO
Serial port of controller may be defective.
® Replace controller.
® Contact your local NSK representative.
— 14-21 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.11. Problem of Saving Program
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-22: Troubleshooting for saving program
Unable to save program, even an instruction of initializing memory is not given.
Initializing memory can be instructed through the teaching box. There cannot be other reason for
losing memory. Therefore it is necessary to take actions for “memory error” to resolve the problem of
saving program.
The causes of memory error can be noises or abnormal power line.
• Be sure to take measures against noise referring to “7.2.5. Measures against Noises.”
• Provide stable power source. Do not turn the power off when “Writing” is indicated or control output
DATWAT (CN3) is closed. (during saving data to memory)
— 14-22 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.1.12. Heating Problem
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-23: Troubleshooting for heat generation of motor
Motor generates heat.
Is ambient temperature
lower than 40°C?
NO
YES
Ambient temperature shall be under 40°C.
The motor may not be operated under continuous rated output if
the ambient temperature is over 40°C.
Even operating under rated power, the motor generates heat and
may lead to the motor burning.
Normally it is not the problem if surface temperature of encoder is 70℃ or lower.
In such case, the temperature of motor cover is approximately 50°C.
Relax operation duty or lower acceleration/deceleration if temperature exceeds the criterion.
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
Figure 14-24: Troubleshooting for heat generation of controller
Controller generates heat.
Is ambient temperature of
controller less than 50°C?
YES
NO
Use the robot module system under ambient temperature of
50°C or under.
You may not continue the rated operation of motor when
temperature exceeds 50°C.
We recommend to provide forced cooling of the controller
when ambient temperature reaches around 50°C.
(1) Total power loss of EXEA controller (heating loss under rated operation) are described hereunder.
• 100W driver per one axis : approximately 40W
• 200W driver per one axis : approximately 50W
• Internal power source: approximately 10W
Example: EXEA1-1100T00
50W + 10W ----- about 60W
® The motor generates considerable heat when it is set in a closed and narrow room, depending on the
conditions. Keep sufficient room around the controller.
® Contact NSK if the controller generates heat abnormally.
(2) Heating of heat sink
• The most hottest part of EXEA controller is the heat sink. When temperature of heat sink reaches 80°C, the
controller gives over-heat alarm. The heat sink won’t exceed 80°C if ambient temperature is 50°C and the
motor is in its rated operation.
® Consult with NSK when over-heat recurs frequently regardless ambient temperature and operation duty.
— 14-23 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2. Inspection of Trouble
Danger
: Observe the items described hereafter prior to troubleshoot. Otherwise the
troubleshooting itself can be dangerous and further critical accident may
occur due to secondary problems, such as burning motor or malfunction of
the system.
1 Check for matching of module main unit and power amplifier
l Make sure that power output of main unit motor conforms to the driver specification of
controller.
Incorrect example: Mistakenly connect EXEA controller (200W) to a main unit (100W).
2 Use NSK standard cable for the controller cable.
l Be sure not to miss-wire when you provide the controller cable by yourself or modify NSK
standard cable.
Incorrect example 1: Motor may malfunction if U, V and W phase wires are wired
incorrectly.
Incorrect example 2: Motor may malfunction if encoder signal wires are wired incorrectly.
3 Make sure that the power source voltage is compatible with the main unit.
à EXEA¨-¨¨¨¨T¨¨ : Single phase AC180V ~ 264V
l The driver may burn when excessive voltage shown above is applied.
4 Check if FGND terminals and AC power line terminals are mistakenly connected.
l If AC power line is connected to FGND terminal, or earth the AC power terminal, the controller
not only functions abnormally but induces troubles such as burning.
— 14-24 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
Danger
: 1) Before troubleshooting, be sure that the moving part of module main unit
has completely stopped.
2) The following must be observed when approaching to the main unit or
adjusting the moving part of module main unit for troubleshooting.
à Set the controller to teaching box operation mode, turn servo off so that the controller
is not turned on and not to be operated from outside.
[External]
1RUN 2IO
*
: Be sure that the controller is not in external control mode.
3FNC 4etc
[Menu]
1RUN 2ORG 3JOG 4etc
: Check that the servo on indicator (*) on upper right of
screen is off.
Indicates servo is off.
à When it necessitates to turn servo on or to operate the robot during trouble shooting
for an unavoidable reason, make sure no person and/or no obstacle which is possible
to be broken by module main unit is in working area of the robot module. Furthermore
provide necessary measures to prevent from entry of other person in the working area
of robot module while you are operating the system.
à The teaching box must be put in your reaching area so that it can be handled
immediately in an emergency.
à Be sure to check the function of emergency stop works properly prior to get in
troubleshoot.
(Adjusting or checking operation must be made after examination of emergency stop
function surely works.)
3) When releasing motor brake of vertical main unit, move the slider to the
bottom stroke end in advance, then release the brake to prevent injury of
person and damage to the unit.
— 14-25 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.1. Check on Servo Lock
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
l If an alarm arises, refer to “13.4. Description of Alarm” and remove the cause of alarm before
troubleshooting.
Figure 14-25: Procedure to check on servo lock state
• Make sure that moving part of main unit stops completely, then turn off servo.
(Press OFF key in the teaching box operation mode.)
* The “servo-on” indicator (*) on upper right corner of
[Menu]
the teaching box screen is off in “servo-off” state.
Not indicated
1RUN 2ORG 3JOG 4etc
• Move the moving part of module main unit manually. (normally slider, or main unit in case of moving main unit
combination)
* Release the motor brake before moving the part if the main unit has a motor with brake.
Does it move by hand?
Yes
No
«
It is possible that the main unit is blocked or the motor brake is not
released.
® Refer to “14.1.7. Cannot Release Brake.”
® Contact your local NSK representative if the main unit is defective.
It is in normal “servo-off” state.
• Make “servo-on” in this state. (Press ON key in the teaching box control mode.)
* The “servo-on” indicator (*) on upper corner of the
[Menu]
display will appear.
*
Servo on indicator
1RUN 2ORG 3JOG 4etc
Dose it move by hand?
No
Yes
When the servo gain is low it moves to some extent. If it moves easily,
the following causes are possibly considered.
• Abnormality of main unit: Breakage of motor, coupling or timing belt.
Motor indirect mount: Refer to “22.2.1. Periodical Checking:
[Timing Belt (motor indirect mount type)]”
• Snapped motor power cable.
• Defective controller: Motor driver
It is in normal servo on state. This state is called “servo lock.”
« It needs considerable power to move the moving part as dynamic brake is functioning. Move slowly.
— 14-26 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.2. Check for Brake Function
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
l If an alarm arises, refer to “13.4. Description of Alarm” and remove the cause of alarm before
troubleshooting.
l This section is only applicable to the main unit with motor brake.
Figure 14-26: Procedure to check brake function
(1) Make sure that moving part of main unit stops completely, then turn off servo.
(Press OFF key in the teaching box operation mode.)
* For a vertical axis main unit, move the slider to the bottom stroke end by jog operation
and start troubleshooting.
(2) Move the moving part of main unit (normally slider, or main unit for moving main unit
combination) manually. Normally it won’t move as the brake is not released.
The brake is defective.
® Replace main unit.
® Contact your local NSK representative.
YES
Does it move manually?
NO
(3) Release the brake.
Refer to “14.2.6.5. Indication of Brake
Status and ON/OFF.”
Does it move manually?
YES
«
Brake control function is normal.
NO
Brake control does not function properly. The followings might be the cause.
• The brake itself is defective. : Operating main unit without releasing the brake
may lead to brake trouble.
• The brake signal line in the controller cable is snapped.
« It needs considerable force as the dynamic brake is functioning. Move it slowly.
— 14-27 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.3. Check for Mechanical Back Drive
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
l If an alarm arises, refer to “13.4. Description of Alarm” and remove the cause of alarm before
troubleshooting.
Figure 14-27: Procedure to check on mechanical back drive
(1) Make sure that moving part of main unit stops completely, then turn the servo off.
(2) Release brake of a main unit with motor brake.
® Refer to “14.2.6.5. Indication of Brake Status and ON/OFF.”
(3) Examine the force for back driving under following conditions by moving manually the moving part of
main unit (normally the slider, or main unit for moving main unit combination).
• The moving part is interfered by an obstacle.
• It is too heavy to move manually, or hard to move.
* It can be moved manually to overcome resistance of dynamic brake, though it needs
considerable force.
* Disconnect the motor cable connector to avoid the effects of dynamic brake. The back
drive force will be lightened. However, for the main unit with motor brake, the brake will be
on as the motor cable supplies power for releasing motor brake.
• There are unsteady spikes and variation of ball screw rotating torque, which the operation by
motor may not overcome.
• It gets heavier at the end of stroke.
• It makes abnormal noise sounds like hitting mechanical parts.
Is back drive force normal?
Normal
End
Abnormal
• If other troubles exist, for which the main unit is not responsible, take appropriate measure against it.
• Variation of back drive force to some extent is normal.
• If it does not move, make sure that the motor brake is released.
® Refer to “14.2.2. Check for Brake Function.”
• If it is hard to decide whether the robot is defective, note the reference number and serial number, then
consult with NSK.
If the robot is obviously defective, contact your local NSK representative.
— 14-28 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.4. Abnormality of Encoder Signal
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
l If an alarm arises, refer to “13.4. Description of Alarm” and remove the cause of alarm before
troubleshooting.
Figure 14-28: Procedure to check encoder condition
(1) Make sure that moving part of main unit stops completely, then turn the servo off.
(2) Set to Jog operation mode referring to “8.2. Selection of Control Mode.”
(3) Note down the coordinate data of each axis indicated in the jog operation mode.
Unstable
Are the coordinate data stable?
It is abnormal that the coordinate data indication is unstable
in servo off state under no effect of external force.
Stable
(4) Move the moving part of main unit (normally slider, main unit in case of moving main unit combination)
manually. In case of main unit with motor brake, release the brake, move the slider manually, then put
the brake on again.
® Refer to “14.2.6.5. Indication of Brake Status and ON/OFF.”
(5) Set to jog operation mode again, then take note the coordinates data. As the moving part has been
moved manually, the coordinates data of the axis must be changed.
Do the coordinates data
change accordingly?
YES
Encoder is normal.
NO
Change the cable
to correct one.
Did not recover.
Recovered.
Replace the defective cable.
® Contact your local NSK
representative.
Defective encoder or the signal receiving circuit of controller is suspected.
® Replace defective module main unit or controller.
® Contact your local NSK representative.
— 14-29 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.5. Action for Malfunction and Collision
n Check for the damage following the procedure described in Figure 14-29, if severe collision occurs at the
stroke end.
l Be sure to observe all safety precautions described on Page 14-1 and 14-2.
l If an alarm arises, refer to “13.4. Description of Alarm” and remove the cause of alarm before
troubleshooting.
Figure 14-29: Procedure for checking damage by malfunction and collision
(1) Make sure that moving part of main unit stops completely, then turn servo off.
(2) Release the brake in case of main unit with motor brake.
® Refer to “14.2.6.5. Indication of Brake Status and ON/OFF.”
(3) Move the moving part of main unit manually and check the following.
Does the stroke end shift?
*1
(approximately 3 mm) .
Yes
No
*2
Is back drive force normal? .
Abnormal
Normal
Is the Home position shifted?
Yes
Overhaul of the main unit is necessary as the shock absorbing
material is possibly damaged. It is dangerous to keep using the
main unit. Contact your local NSK representative.
Danger : The slider hits mechanical stopper directly as the shock
absorbing material is completely damaged. The slider
may be off the main unit base when the slider hits the
mechanical stopper again.
• Variation of back drive force to some extent is normal.
• If it does not move, make sure that the motor brake is released.
® Refer to “14.2.2. Check for Brake Function.”
• If it is hard to decide whether the robot is defective, note down the
reference number and serial number, then consult with NSK.
• If the robot is obviously defective, replace or overhaul the main
unit.
® Contact your local NSK representative.
It is suspected looseness or slip on the pulley or the coupling.
Motor indirect mount: Refer to “22.2.1. Periodical Checking
[Timing Belt (motor indirect mount type)].”
No
*3
It is possible to use continuously.
Fasten tighter the fixing bolts of
main unit and combining bracket, then conduct trial running.
*1. Move the slider to the stroke end manually, then confirm whether the position of stroke end is shifted by checking
the seals affixed to main unit to indicate position of stroke end and Home position in “21. Installation.”
*2. It hardly moves manually, gets heavier at end of stroke or the motion is jerky, etc.
*3. Even though the robot has no problem from external checking, there might be dent on the ball grooves of linear
guide and ball screw, and these dents may shorten their life. We recommend you to return the main unit to the
manufacturer and have them overhauled it.
— 14-30 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.6. Monitoring I/O
l Get the menu selection screen 3 in the teaching box operation mode referring to “8.2. Selection
of Control Mode.”
l When F3 key (IO) is selected in the menu selection screen, the screen for indication/selection
of I/O signal condition appears as shown in Figure 14-30. In the indication/selection screen, use
F1 ~ F4 keys for selection.
l Subjects which can be indicated:
INP : Input port
OUT : Output port
MEM : Virtual input/output port
LMT : Limit port
Figure 14-30: I/O selecting screen
: Menu selection screen 3, teaching
operation mode
[MENU]
1SYS 2CTR 3IO
4etc
MODE
Press F3 key.
[I/O]
1INP 2OUT 3MEM 4etc
[I/O]
Press F4 key.
1LMT 2BRK
— 14-31 —
4etc
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.6.1. Indication of Input Port Condition
1 Monitor status of input port.
l Indication screen of Input port condition appears when F1 key (INP) in the I/O
indication/selection screen is pressed.
l I is indicated next to the [I/O] in the screen.
l Status of four input ports are shown in the second and third line. Use
to scroll the cursor.
,
,
and
keys
l The first line indicates the name of the port of which bit are selected by the cursor.
l When there are four or more input ports, use
and
keys to scroll the indication.
Figure 14-31: Screen indicating the input port condition
Name of port
[I/O]I
EMST
00 00000000 00000000
10 00000000 00000000
1CHK
l Indications of status on the second and third lines are, from left to right, port number, status of
the port, and status of next port (port number +1).
l Status of port is indicated by 8 bits. Left side is bit 7 and right side is bit 0.
l The status of the port is indicated by 0 (off) and 1 (on) regardless the logic of port (normally
open/normally close).
Figure 14-32: Example of input port indication
Status of
port 00
Port
number
00
00000000
bit7
Status of
port 01
00000000
bit0
— 14-32 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
2 Checking input port status.
l The following screen of input port status appears when F1 key is pressed in the screen to
indicate input port condition.
l Two conditions (current status and history of changes) of two different input port are indicated
on the second and third line. Use
and
keys to move position of the cursor.
l The name of the port of which bit is indicated by the cursor is on the first line.
l Use
and
keys to scroll the indication if the input ports are more than two.
Figure 14-33: Example: Screen of setting input port
Name of port
[I/O]I
EMST
00 00000000 00000000
×××××××× ××××××××
1NRM 2RST
l The figure below shows the state of input port indicated on the second and third line.
Port
number
00
Status of
port 00
Status of
port 01
00000000 00000000
×××××××× ××××××××
Current state
History of changes
l History on the third line indicates changes of input port status after DRDY is on, or after F2
(RST) key is pressed.
l Each bit is one to one correspondence to a bit on the second line.
l × changes to 1 when the port state changes to 1 from 0 after start of monitoring, while x changes
to 0 when the state of the port changes to 0 from 1. The bit of which state is changed will keep
its state till F2 key (RST) is pressed.
(Current status on the second line changes in real time basis.)
Figure 14-34: Example: History of input port changes
Start
monitoring
0
×
0
1
1
1
Start
monitoring
1
×
0
0
1
0
l Press F1 key (NRM) in the I/O indication/selection screen to return to the screen of input port
status.
— 14-33 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.6.2. Indication of Output Port Condition
l Status screen of output port appears when F2 key (OUT) is pressed in the I/O
indication/selection screen.
l O appears next to [I/O] in the screen.
l State of four output ports are shown in the second and third line. Use
scroll the cursor.
,
,
and
keys to
l The first line indicates the name of the port of which bit are selected by the cursor.
l When there are four or more output ports, use
and
keys to scroll the indication.
Figure 14-35: Indication of output port status
Name of port
[I/O]O
RDY
00 00110000 00000000
10 00000000 00000000
1CHK
3USR
l Functions and the composition of indications are the same as the screen of input port status.
However, pressing F3 key (USR) makes it possible to switch ON and OFF of the bit
temporarily, on which the cursor is put, by using 0 and 1 keys.
Figure 14-36
[I/O]0
RDY
00 00110000 00000000
10 00000000 00000000
1CHK
3USR
Press F3 key.
[I/O]0
RDY
00 00110000 00000000
10 00000000 00000000
1CHK
3SYS
: Switch ON and OFF of the bit temporarily, on which the
cursor is put, using 0 and 1 keys.
0 --- Put the port off.
1 --- Put the port on.
* 0 is off and 1 is on regardless the logic of port (normally
open/normally close).
l Changed state are valid till pressing F3 (SYS) key again or MODE key. These keys make the
state to the previous setting.
— 14-34 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.6.3. Monitor Status of Imaginary Input / Output Port
1 Monitoring Status of Imaginary Input/ Output Port
l Press F3 key (MEM) in the I/O monitor screen to get in the monitoring screen of imaginary
input/output port.
l “M” appears on the side of [I/O] in the monitoring screen as shown in Figure 14-37.
l Current status of two imaginary ports will be displayed on the second line of the screen. Use
and
keys to move the cursor.
Figure 14-37: Monitoring screen of imaginary port of Input / Output
[I/O]M
0
00000000
00000000
1CHK
l Indications of the second line are, from left to right, a port number, status of the port (designated
by the port number), and status of a port (of which number is +1 of the previous one).
l The status of a port is indicated by a unit of 8 bit, the left side is bit 7 and the right side is bit 0.
l Indication of status is 0 (zero) for OFF and 1 (one) for ON regardless logic of port (normally
open /normally close).
Figure 14-38: Monitoring example of input / output port
Status of port
number 00
Port
number
Status of port
number 01
0 00000000 00000000
bit7
bit0
2 Checking imaginary input / output port status
l Press F1 key (CHK) in the monitoring screen of imaginary input / output to get in the screen of
status checking screen.
l Two kinds of status (current and history of change) for 2 imaginary input / output ports will be
indicated on the second and third line. Use
and
keys to move the cursor for selection.
l Refer to “14.2.6.1. Indication of Input Port Condition . 2 Checking input port” for the way how
to check the status of the port.
— 14-35 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.6.4. Monitor Status of Limit Sensor Port
l This is to indicate conditions of hardware travel limit.
l Status screen of limit sensor port appears when LMT is selected in the I/O indication/selection
screen.
l L appears next to [I/O] in the screen.
and
l Current state of limit sensor of designated unit is indicated on the second line. Use
keys to move position of the cursor for selection. (in case of multi-axis combination)
l Name of the limit, on which bit the cursor is put, is indicated on the first line.
and
keys to switch the screen for a unit when two or more units are set to a multul Use
axis combination.
l Functions and composition of indication are the same as the input port.
Figure 14-39: Monitor limit sensor port
Name of the hardware limit.
[I/O]L OTM
X00
Y00
Z00
U1
*
R00
1CHK
* The part indicated by dotted lines won’t be indicated in case of a single axis system.
— 14-36 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
14.2.6.5. Indication of Brake State and ON/OFF
Warning : Move the slider of the vertical axis to the bottom stroke end when releasing
the brake. (for moving main unit combination move the main unit)
The slider (or main unit for moving main unit combination) falls by its own
weight (back drive) when it is in the middle of the stroke as the brake is
released.
l Select BRK in the I/O indication/selection screen to lead the screen of brake status.
l B appears next to [I/O] in the screen.
l Current status of designated unit on the second line in for a multi-axis combination, and use
and
keys to move position of the cursor.
and
l Use
combination.
keys to scroll the indication when two or more unit are set to a multi-axis
Figure 14-40: Monitor brake condition
[I/O]B
X1
Y1
*
Z1
R1
* The part indicated by dotted lines won’t be displayed for a single axis system.
3USR
l Pressing F3 key (USR) makes it possible to switch temporarily ON and OFF of the bit, on
which the cursor is put, by using 0 and 1 keys.
Figure 14-41
[I/O]B
X1
Y1
*
Z1
R1
3USR
F3 キーを押す
[I/O]B
X1
Y1
Z1
3SYS
*
R1
: Switch On/ Off of a brake by 0 and 1 keys.
0 • • • Brake is off. (release)
1 • • • Brake is on.
* The part indicated by dotted lines won’t be displayed for a single axis system.
l Settings are valid until F3 key (SYS) is pressed again or MODE key is pressed. Pressing
either key makes to return to the setting of previous one.
— 14-37 —
1 Installation and Maintenance of EXEA Controller “14. Troubleshooting”
(Blank Page)
— 14-38 —
1 Installation and Maintenance of EXEA Controller “Appendix”
Appendix 1: Specification of Motor Connector
Table A-1: Used Connectors
EXEA controller side
Mating connector (cable side)
Mating connector shell type (cable side)
Phoenix Contact: GIC2.5/6-GF-7.62
Phoenix Contact: GIC2.5/6-STF-7.62
Phoenix Contact: KGS-MSTB2.5/9
Figure A-1: Pin out
6
U
5
V
4
W
3
F.GND
2
BRK+
1
BRK-
Table A-2: Pin out and signal
Pin
1
2
3
4
5
6
Signal name
BRKBRK+
F.GND
W
V
U
Function
Brake power: 0V output
Brake power: 24V output
Frame ground
Motor, Phase W
Motor, Phase V
Motor, Phase U
* The connector of EXEA controller indicates the name of axis as shown below.
First axis (X axis): 1st
Table A-3: Motor power specification
Motor output
Output voltage
Current for rated output
Current for maximum output
100W
±280VPWM
0.87Arms
2.8Arms
Table A-4: Brake power specification
Output voltage
Rated output voltage
Output format
Type of brake
DC24V
400mA
Relay contact
Negative activation
— A-1 —
200W
±280VPWM
2.0Arms
6.0Arms
400W
±280VPWM
2.6Arms
7.8Arms
1 Installation and Maintenance of EXEA Controller “Appendix”
Appendix 2: Encoder Sensor Connector
Table A-5:Used connector
EXEA controller side
Mating connector, cable side
Mating connector shell type, cable side
Japan Aviation Electronics Industries Ltd.
: DBLC-J25SAF-13L9
Japan Aviation Electronics Industries Ltd.: DB-25PF-N
Japan Aviation Electronics Industries Ltd.: DB-C4-J11-S1
Figure A-2: Pin out
F.GND
1
–
2
ENC_PWR
3
A+
4
B+
5
Z+
6
*ENC_RST
7
N.C.
8
N.C.
9
N.C.
10
N.C.
11
N.C.
12
N.C.
13
14
–
15
–
16
D.GND
17
A-
18
B-
19
Z-
20
ENC_BAT
21
N.C.
22
N.C.
23
N.C.
24
N.C.
25
N.C.
— A-2 —
1 Installation and Maintenance of EXEA Controller “Appendix”
Table A-6: Pin out and signal
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Signal name Input/output
Function
F.GND
–
Frame ground
–
–
Do not connect.
ENC_PWR
output
Encoder power
A+
input
Encoder signal (A+)
B+
input
Encoder signal (B+)
Z+
input
Encoder signal (Z+)
*ENC_RST
output
Reset encoder
N.C.
–
Do not connect.
N.C.
–
Do not connect.
N.C.
–
Do not connect.
N.C.
–
Do not connect.
N.C.
–
Do not connect.
N.C.
–
Do not connect.
–
–
Do not connect.
–
–
Do not connect.
D.GND
–
Signal ground
Ainput
Encoder signal (A-)
Binput
Encoder signal (B-)
Zinput
Encoder signal (Z-)
ENC_BAT
output
Battery power
N.C.
–
Do not connect.
N.C.
–
Do not connect.
N.C.
–
Do not connect.
N.C.
–
Do not connect.
N.C.
Do not connect.
Table A-7: Encoder input signal
Item
Power source voltage
DC5V power output
Maximum current
Input format
Used line receiver
Deferential-mode input thrush hold voltage
Input impedance
Maximum common-mode input voltage
— A-3 —
Specification
DC5V ±10%
250mA
Deferential line receiver
TI SN75175NS or equivalent
±0.2V
2209
±12V
1 Installation and Maintenance of EXEA Controller “Appendix”
(Blank Page)
— A-4 —
World-wide Manufacturing and Marketing Organization
NSK Ltd. INTERNATIONAL DIVISION
NSK-RHP FRANCE S.A.
JAPAN: Tokyo
FRANCE : Paris Phone:1.30.57.39.39
: Lyon Phone: 72.15.29.00
Phone: 03-3779-7120
NSK CORPORATION
U.S.A.: Ann Arbor
NSK-RHP NEDERLAND B.V.
Phone: 313-761-9500
NETHERLAND: Amsterdam
[Precision Products Business Unit]
U.S.A. : Chicago
Phone: 630-924-8000
: Los Angeles Phone: 562-926-3578
: Ann Arbor
Phone: 761-761-9500
NSK-RHP ITALIA S.p.A.
NSK•RHP CANADA INC.
SPAIN: Barcelona
CANADA : Toront
: Montreal
: Vancouver
ITALIA: Milano
Phone: 905-890-0740
Phone: 514-633-1240
Phone: 800-663-5445
Phone: 93-575-1662
NSK-RHP AUSTRALIA PTY, LTD.
Phone: 5-301-2741,5-301-3115
NSK DO BRASIL INDUSTRIA E COMÉRCIO DE
ROLAMENTOS LTDA.
AUSTRALIA : Melbourne
: Sydney
: Brisbane
: Adelaide
: Perth
Phone: 03-9764-8302
Phone: 02-9893-8322
Phone: 07-3393-1388
Phone: 08-8373-4811
Phone: 089-434-1311
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BRASIL : São Paulo
Phone: 001-269-4700
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Phone: 051-222-1324
: Belo Horizonte Phone: 031-224-2508
Phone: 09-276-4992
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KOREA: Seoul
NSK-RHP UK LTD
ENGLAND : Ruddington
Phone: 02-995191
NSK-RHP IBERICA, S.A.
NSK RODAMIENTOS MEXICANA, S.A. DE C.V.
MEXICO: Mexico City
Phone: 020-6470711
Phone: 02-3287-6001
NSK SINGAPORE (PRIVATE) LTD.
Phone: 0115-936-6600
SINGAPORE: Singapore
NSK-RHP DEUTSCHLAND G.m.b.H
Phone: 2781711
NSK BEARINGS (THAILAND) CO., LTD.
GERMANY : Düsseldorf Phone: 02102-4810
: Stuttgart
Phone: 0711-79082-0
: Leipzig
Phone: 0341-5631241
THAILAND : Bangkok
Phone: 2-6412150-60
: Chiang mai Phone: 053-246993~4
TAIWAN NSK PRECISION CO., LTD.
TAIWAN: Taipei
Phone: 02-591-0656
Robot Module System
l P Series Module Main Unit
l R Series Module Main Unit
l EXEA Controller
User’s Manual 1
= Installation and Maintenance of EXEA Controller =
Document Number: K20078-01
August 3, 2000
NSK Ltd.
EC-T
1st Edition 1st Printing
1st Edition, 1st Printing
August 3, 2000
Document Number: K20078-01
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