5.

How to read the model of the controller Description

Item

POWER CON PCON-CA-56P I-NP-2-0-ABU-DN-** PCON-CA PCON-CFA

<Identification for IAI use only> Environment Surrounding Air 0 to 40C
<Series> Temperature
* There is no identification in some cases
<Type> Surrounding Humidity 85%RH or less (non-condensing)
CA : Standard Type <Type of Installation> Surrounding [Refer to Installation Environment]

PCON-CA CFA : High-Thrust Actuator

Connection Type
(Not Specified) : Screw Attachment Type
DN : DIN Rail Mounting Type
Environment
Surrounding Storage
Temperature
-20 to 70C (Excluding battery)

<Detail of Connected Axis> <Applicable to Simplified Absolute Unit>

First Step Guide Fifth Edition

Usage Altitude 1000m or less
[Motor Type] AB : Simple Absolute Type
(With the Absolute Battery) Protection Class IP20
20P : 20 pulse motor, 20SP : 20 pulse motor
28P : 28 pulse motor, 28SP : 28 pulse motor ABU : Simple Absolute Type Vibration Durability Frequency 10 to 57Hz / Swing width : 0.075mm
2
42P : 42 pulse motor, 56P : 56 pulse motor (With the Absolute Battery Unit Frequency 57 to 150Hz / Acceleration 9.8m/ S
60P : 60 pulse motor, 86P : 86 pulse motor (SEP-ABU)) XYZ directions Sweep time : 10 minutes Number of sweep : 10 times
Thank you for purchasing our product.
Make sure to read the Safety Guide and detailed Instruction Manual (CD/DVD) included with the product in addition to [Encoder Type] ABUN : Simple Absolute Type Note1 Value increases in 0.3A for Fieldbus Type
I : Incremental (With no Absolute Battery) Note2 In-rush current will flow for approximately 5msec after the power is turned on (at 40C).
this First Step Guide to ensure correct use.
This Instruction Manual is original. Note that the value of in-rush current differs depending on the impedance of the power supply line.
<I/O Type> <Power-supply Voltage> Note3 Value increases in 30g for Field Network Type.
NP : NPN Type (Sync. Type) (Standard) 0 : 24V DC
Warning : Operation of this equipment requires detailed installation and operation instructions which are
provided on the CD/DVD Manual included in the box this device was packaged in. It should be PN : PNP Type (Source Type)
<I/O Cable Length>
retained with this device at all times.
A hardcopy of the Manual can be requested by contacting your nearest IAI Sales Office listed at
PLN : Pulse Train Control NPN Type
(Sync. Type) 0 : Equipped with no cable External Dimensions (CA Type)
PLP : Pulse Train Control PNP Type 2 : 2m (Standard)
the back cover of the Instruction Manual or on the First Step Guide.
(Source Type) 3 : 3m Screw fixed type
Using or copying all or part of this Instruction Manual without permission is prohibited. DV : DeviceNet Connection Type 5 : 5m
Incremental Type (Standard) Simplified Absolute Type (Option)
The company names, names of products and trademarks of each company shown in the sentences are registered CC : CC-Link Connection Type
trademarks. PR : PROFIBUS-DP Connection Type 84.8
CN : CompoNet Connection Type 35 5 35 5
69.1
ML : MECHATROLINK Connection Type
EC : EtherCAT Connection Type
Product Check EP : EtherNet/IP Connection Type

The standard configuration of this product is comprised of the following parts.

If you find any fault with the product you have received, or any missing parts, contact us or our distributor.
Basic Specifications
1. Parts List of Specifications
No. Part Name Model Quantity Reference Description
Item
Refer to How to read the model plate, PCON-CA PCON-CFA
1 Controller Main Body 1
How to read the model of the controller Number of controlled axes 1-axis
Accessories Power-supply Voltage 24V DC 10%

170.5
178.5
170.5
178.5
*** shows the cable RCP2 Motor 20P, 28P, 28SP MAX. 1A
2 I/O Flat Cable CB-PAC-PIO*** 1 Load
length RCP3 Type 42P, 56P MAX. 2A
Capacity
Recommended cable size (including 60P, 86P Rated 4.2A / MAX. 6A
FMC1.5/8-ST-3.5 (Supplier : PHOENIX
3 Power Connector 1 AWG16 to 20 control side RCP4 Motor 42P, 56P
CONTACT) High-thrust function
(1.25 to 0.5mm2) current MAX.2.2A
Type is disabled
If applicable for Simple consumption)
4 Absolute Battery (Option) AB-7 or SEP-ABU* 1 High-thrust function Rated 3.5A /
Absolute Type (Note1)
is enabled MAX. 4.2A
5 First Step Guide 1
Power Supply for Electromagnetic Brake
6 Instruction Manual (CD/DVD) 1 24V DC 10% 0.15A (MAX.)
(for actuator equipped with brake)
7 Safety Guide 1 Heat Generation RCP2, RCP3 5W 26.4W
2. Teaching Tool (to be purchased separately) RCP4 8W
5 5
A teaching tool such as PC software is necessary when performing the setup for position setting, parameter Rush Current(Note2) 8.3A 10A Side View (Common)
(40.5)
setting, etc. that can only be done on the teaching tool. Transient Power Cutoff Durability MAX. 500s
Please prepare either of the following teaching tools. (58)
Motor Control System Weak field-magnet vector control
No. Part Name Model Corresponding Encoder Incremental Encoder Resolution 800pulse/rev
PC Software Actuator Cable Length MAX. 20m
DIN rail fixed type
1 RCM-101-MW
(with RCS232C converter adapter + external equipment communication cable) Serial Communication Interface RS485 : 1 channel (based on Modbus Protocol RTU/ASCII) Incremental Type (Standard) Simplified Absolute Type (Option)
PC Software (SIO Port) Speed : 9.6 to 230.4Kbps
2 RCM-101-USB
(with USB converter adapter + USB cable + external equipment communication cable) Control available with serial communication in the modes other than the pulse
93.3
3 Teaching Pendant (Touch Panel Teaching) CON-PTA train
77.6
4 Teaching Pendant (Touch Panel Teaching with deadman switch) CON-PDA External Interface PIO Signal I/O dedicated for 24V DC (selected from NPN/PNP) Input 16 points 35 35
Specification max., output 16 points max. 8.5

35.4 (Width of 35mm DIN rail)

5 Teaching Pendant (Touch Panel Teaching with deadman switch + TP Adapter (RCB-LB-TG)) CON-PGA
Cable length MAX. 10m
3. Instruction Manuals related to this product, which are contained in the Instruction Manual (CD/DVD). Field Network DeviceNet, CC-Link, PROFIBUS, CompoNet, MECHATROLINK,

104 from DIN rail center

No. Name Manual No. Specification EtherCAT, EtherNet/IP
1 PCON-CA Controller Instruction Manual ME0289 Data Setting and Input PC Software, Touch Panel Teaching, Teaching Pendant
2 PC Software RCM-101-MW/ RCM-101-USB Instruction Manual ME0155 Data Retention Memory Saves position data and parameters to non-volatile memory
3 Touch Panel Teaching CON-PTA/PDA/PGA Instruction Manual ME0295 (There is no limitation in number of writing)
4 Instruction Manual for the Serial Communication [for Modbus] ME0162 Operation Mode Positioner Mode/Pulse Train Control Mode (selected by parameter setting)
5 CC-Link Instruction Manual ME0254 Number of Positions in Positioner Mode Standard 64 points, MAX. 512 points (PIO Specification)
(Note) Number of positions differs depending on the selection in PIO pattern
6 DeviceNet Instruction Manual ME0256
and fieldbus operation mode.
7 PROFIBUS-DP Instruction Manual ME0258

178.5

178.5
Pulse Train Input Pulse Frequency Differential System (Line Driver System) : MAX. 200kpps
8 CompoNet Instruction Manual ME0220

185

185
Interface Cable length MAX. 10m 4
9 MECHATROLINK Instruction Manual ME0221 Open Collector System : Not applicable.
10 EtherCAT Instruction Manual ME0273 * If the host applies the open collector output, prepare AK-04 (option) separately
11 EtherNet/IP Instruction Manual ME0278 to convert to the differential type.
4. How to read the model plate Command Pulse 1/50 < A/B < 50/1
Multiplying Factor Setting Range of A and B (set to parameter) : 1 to 4096
Model Model
SER NO. ********* (Electrical Gear : A/B)
Input *********
DC24V A
*
Serial number Output
Actuator
0-24Vac,3ph,0-333Hz,
*A
IP20 Feedback Pulse Output None
*****
CAUTION: Connect the wiring correctly and LED Display SV (GN)/ALM (RD) : Servo ON/Alarm generated
properly, use IAI specified cables
or min 60C Cu wire. (mounted on Front Panel) STS0 to 3 : Status display
RDY (GN)/ALM (RD) : Absolute function in normal / absolute function error (for
the simple absolute type) M3 M3
1, 0 (GN) (RD) : Absolute function status display (for the simple absolute Side View (Common)
(for FG cable (for FG cable
type)

(5)

(5)
attachment) attachment)
Electromagnetic Brake Compulsory Release Switch Switching NOM (standard)/BK RLS (compulsory release) (58)
(mounted on Front Panel)
Insulation Resistance 500V DC 10M or more
Protection Function against Electric Shock Class I basic insulation
Weight(Note3) Incremental Type Screw fixed type : 250g or less Screw fixed type : 270g or less
DIN rail fixed type : 285g or less DIN rail fixed type : 305g or less
Simple Absolute Type Screw fixed type : 450g or less
(including 190g for battery) DIN rail fixed type : 485g or less
Cooling Method Natural air-cooling Forced air-cooling
Screw fixed type : 35W178.5H69.1D Screw fixed type : 35W190H69.1D
External dimensions
DIN rail fixed type : 35W185H77.6D DIN rail fixed type : 35W196.3H77.6D
 Connection to RCP2 (High-Thrust) Series
External Dimensions (CFA Type) Installation and Noise Elimination
PCON-CA
Screw fixed type 1. Noise Elimination Grounding (Frame Ground) Connection
Screw fixed type DIN rail fixed type

1)
Cable(Note1)
Motor/

e
ot
69.9 Encoder Connector

(N

(7)
Other
Controller
5
35 69.1 equipment
Connect the ground line Connect the ground cable
together to the main unit using the tapped hole for
using the fixing screw. FG connection on the main unit. Connection to RCP3 and RCP4 Series
Copper wire:
Other Other
Connect a ground wire with a Controller equipment equipment PCON-CA
diameter of 1.6mm (2mm2) or larger. M3 x 5 nickeled pan head
machine screw
(enclosure dedicated for Connection Cable(Note1)
(Note 1) Detach the fan unit Earth Terminal DIN rail fixed type) Motor/
before attaching Formerly Class-III grounding Do not share the ground wire with or connect Encoder Connector
screws to the main (Grounding resistance at 100 or less) to other equipment. Ground each controller.

unit.
2. Precautions regarding wiring method Surge absorber
190

1) Wire is to be twisted for the 24V DC power supply.

170.5

Note 1 Applicable Connection Cable Model Codes : Cable Length Example) 030 = 3m
2) Separate the signal and encoder lines from the power
supply and power lines. R Model Name Cable Reference
Relay RCP2 CB-PSEP-MPA Robot cable from 0.5 to 20m
3. Noise Sources and Elimination coil
C
Carry out noise elimination measures for power devices on RCP3 CB-APSEP-MPA Robot cable from 0.5 to 20m
the same power path and in the same equipment. RCP3 CB-APSEP-MPA-LC Standard cable from 0.5 to 20m
The following are examples of measures to eliminate noise RCP4 CB-CA-MPA-RB Robot cable from 0.5 to 20m
sources. RCP4 CB-CA-MPA Standard cable from 0.5 to 20m
1) AC solenoid valves, magnet switches and relays Relay coil
+24V 0V High-Thrust CB-CFA-MPA- Standard cable from 0.5 to 20m for CFA
[Measure] Install a Surge absorber parallel with the coil.
2) DC solenoid valves, magnet switches and relays High-Thrust CB-CFA-MPA--RB Robot cable from 0.5 to 20m for CFA
[Measure] Install a diode parallel with the coil. Use a DC
5 relay with a built-in diode. + -
4. Heat Radiation and Installation +24V 0V Power Supply and Emergency Stop Circuit
Design and Build the system considering the size of the controller box, location of the controller and
cooling factors to keep the ambient temperature around the controller below 40C This shows the circuit example when the emergency stop switch in the teaching pendant is enabled on the
DIN rail fixed type emergency stop circuit to be built up by the client.
78.4 Emergency-stop Switch on the
77.6
Teaching Pendant

8.5
35 MIN. 100mm Emergency Stop Emergency Stop
24V Reset Switch Switch 0V
(7)

(Note 4)
(Note 1) PCON PCON CR1
S1 S2 S1 -CA S2 S1 -CA S2
2nd unit nth unit
CR1 PCON-CA
35.4(Width of 35mm DIN rail)
115 from DIN rail center

1st unit
CR1 CR2

MIN. 100mm
Ensure enough space
for wiring.
(Note 2)
PCON-CA
CR2
MPI
190

Motor power supply

MPO
4
MIN. MIN. MIN. MIN.
30mm 30mm 30mm 30mm MIN. 50mm 24V 0V
Control power supply
(Note 3)
CR1
EMG-
Emergency Stop Control Circuit

BKLS
Connection Diagram Brake forced
Brake Release Power Supply
(Note) When connecting actuator equipped with
release switch brake and having the brake to compulsorily
PLC (Please prepare separately) release, supply 24V power.
Teaching Pendant
(Note 2)
Touch Panel Teaching Controller Status CR2
(5)

MPI
(to be purchased separately) Display LED
MPO PCON-CA 0V

Installation Environment 24V 2nd unit

EMG-
Power Source I/O Control
This product is capable for use in the environment of pollution degree 2*1 or equivalent. (24V DC BKLS
*1 Pollution Degree 2: Environment that may cause non-conductive pollution or transient conductive Please prepare separately) Brake forced
pollution by frost (IEC60664-1) AK -04
release switch
1. Installation Environment CR2
(Note 2)
Way to lay out wirings differs
Do not use this product in the following environment MPI
Location where the surrounding air temperature exceeds the range of 0 to 40C depending on the specifications of
the host when pulse train control MPO PCON-CA 0V
Location where condensation occurs due to abrupt temperature changes
Location where relative humidity exceeds 85%RH mode (for PLN and PLP types only). 24V nth unit
Location exposed to corrosive gases or combustible gases [Refer to Pulse Train Mode
EMG-
Location exposed to significant amount of dust, salt or iron powder Operation described later.]
Location subject to direct vibration or impact BKLS
Location exposed to direct sunlight Brake forced
Location where the product may come in contact with water, oil or chemical droplets release switch
Environment that blocks the air vent [Refer to Installation and Noise Elimination] Actuator
When using the product in any of the locations specified below, provide a sufficient shield.
Location subject to electrostatic noise Note 1 When the teaching pendant is not connected, S1 and S2 become short-circuited inside the controller.
Location where high electrical or magnetic field is present CB-APSEP Note 2 When the motor driving source is cut off externally for a compliance with the safety category, connect a contact such
Location with the mains or power lines passing nearby PC Software -AB005 as a contactor to the wires between MPI and MPO.
(to be purchased Emergency Stop Circuit Note 3 The rating for the emergency stop (EMG-) signal to turn ON/OFF at contact CR1 is 24V DC and 10mA.
2. Storage and Preservation Environment separately) Absolute Note 4 For CR1, select the one with coil current 0.1A or less.
Storage and preservation environment follows the installation environment. Especially in a long-term storage, consider Battery Unit Note 5 When rebooting after shutting down, leave for 1sec or more.
to avoid condensation of surrounding air. (SEP-ABU*)
Unless specially specified, moisture absorbency protection is not included in the package when the machine is (or Simple Control/Driving Power Supply Caution If supplying power with using a 24V DC, having it turned on/off, keep the 0V connected and have the
delivered. In the case that the machine is to be preserved in an environment where dew condensation is anticipated, Absolute Type) +24V supplied/cut (cut one side only).
(24V DC
take the condensation preventive measures from outside of the entire package, or directly after opening the package.
Please prepare separately)
 Signal Assignment for Each Mode NPN Specification PNP Specification
I/O Signal The signal assignment of I/O flat cable by the PIO pattern is as shown below. Follow the following table to connect the external equipment (such as PLC).
Selection in Parameter No. 25 (PIO Pattern)
0 1 2 3 4 5 6 Pin No. Pin No.
Explanation of I/O Signal Functions Electro- Electro-
Category PIO Functions Pulse train
Abbreviated Positioning Teaching 256-point 512-point magnetic magnetic
Category Signal Name Contents of Functions control
Code mode mode mode mode valve mode valve mode
mode
1 2
CSTR PTP Strobe (Start Signal) Starts moving toward the position set in Command Position No.
Number of Positioning
PC1 to PC256 Command Position No. To input position No. desired to move (binary input). 64 points 64 points 256 points 512 points 7 points 3 points
Points
Brake Compulsory Pin Home Return Signal { { { { { {
BKRL To release the brake compulsorily. Load Load
Release No. Jog Signal {
Input
Operation Mode can be changed over when MODE Switch on the controller Teaching Signal
Operation Mode (Current Position {
RMOD is on AUTO.
Changeover Writing)
(The setting is AUTO when signal is OFF, and MANU when ON.)
When this signal is turned OFF while in move, the actuator decelerates Brake Release { { { { { {
*STP Pause and then stops. The remaining movement is in a hold while the actuator is Signal during
{ {
stopped and will resume when the signal turns back ON. Operation
Output
Zone Signal { (Note1) (Note1) { { {
Turn the signal ON to reset the alarm. Also, when it is turned ON in the I/O Cable
RES Reset pause mode (*STP is turned OFF), the remaining movement amount can Position Zone Signal { { { { {
1A 24V P24 Model : CB-PAC-PIO
be cancelled.
2A 24V P24 (Enter the cable length (L) in Example. 020 = 2m)
The servo remains ON while this signal is ON, or OFF while this signal is
SON Servo ON 3A PP L
OFF.
4A /PP
The controller will perform home return operation when this signal is 5A IN0 PC1 PC1 PC1 PC1 ST0 ST0 SON
HOME Home Return
turned ON. ST1 BK-4
The operating mode will change to the teaching mode when this signal is 6A IN1 PC2 PC2 PC2 PC2 ST1 RES
(JOG+) No treatment B
Input MODE Teaching Mode turned ON. The mode will not be switched over unless CSTR, JOG+ and 7A IN2 PC4 PC4 PC4 PC4 ST2 ST2(Note2) HOME conducted
20A 20B

JOG are all OFF and the actuator operation is stopped. 8A IN3 PC8 PC8 PC8 PC8 ST3 TL BR-3
Jog Operation can be performed with JOG+ and JOG while this signal is 9A IN4 PC16 PC16 PC16 PC16 ST4 CSTP BK-2
JISL Jog/Inching Changeover OFF. 10A IN5 PC32 PC32 PC32 PC32 ST5 DCLR
Inching Operation is performed with JOG+ and JOG when it is ON. 11A IN6 MODE PC64 PC64 ST6 BKRL No treatment
A
1A 1B
conducted
Jog Operation is performed to positive direction by detecting ON edge of 12A Input IN7 JISL PC128 P128 RMOD Half Pitch MIL Socket
HIF6-40D-1.27R (Hirose Electric)
BR-1
JOG+ signal and to negative direction by JOG signal while JISL signal is 13A IN8 JOG+ PC256
JOG+
Jog OFF. The actuator will decelerate and stop if OFF edge is detected while in 14A IN9 BKRL JOG BKRL BKRL BKRL BKRL
JOG Flat Cable (20-core) 2
each Jog Operation. 15A IN10 RMOD RMOD RMOD RMOD RMOD RMOD
Inching Operation is performed while JISL signal is ON. 16A IN11 HOME HOME HOME HOME HOME No. Signal Name Cable Color Wiring No. Signal Name Cable Color Wiring
Write the current position to the indicated position if indicating the written 17A IN12 *STP *STP *STP *STP *STP 1A 24V BR-1 1B OUT0 BR-3
PWRT Current Position Writing position and turn this signal ON for more than 26ms during the Teaching 18A IN13 CSTR CSTR/PWRT CSTR CSTR
Mode. 2A 24V RD-1 2B OUT1 RD-3
19A IN14 RES RES RES RES RES RES
The actuator moves to the commanded position with this signal ON during 20A IN15 SON SON SON SON SON SON 3A PP OR-1 3B OUT2 OR-3
ST0 to ST6 Start Signal PM1 PM1 PM1 PM1 4A /PP YW-1 4B OUT3 YW-3
the electromagnetic valve mode. 1B OUT0 PE0 LS0 PWR
(ALM1) (ALM1) (ALM1) (ALM1) 5A IN0 GN-1 5B OUT4 GN-3
Turning it continuously input for more than 16ms compulsorily stops the
CSTP Compulsory Stop PM2 PM2 PM2 PM2 LS1
actuator. 2B OUT1 PE1 SV 6A IN1 BL-1 6B OUT5 BL-3
(ALM2) (ALM2) (ALM2) (ALM2) (TRQS)
Puts torque limitation to the motor with the signal on and the value set to PM4 PM4 PM4 PM4 7A IN2 PL-1 7B OUT6 PL-3
TL Torque Limit Select 3B OUT2 PE2 LS2(Note2) INP
the parameter. (ALM4) (ALM4) (ALM4) (ALM4) 8A IN3 GY-1 8B OUT7 GY-3
DCLR Deviation Counter Clear This is the signal to clear up the differential counter. PM8 PM8 PM8 PM8
4B OUT3
(ALM8) (ALM8) (ALM8) (ALM8)
PE3 HEND 9A IN4 WT-1 Flat Cable A 9B OUT8 WT-3 Flat Cable B
Turns ON in the positioning band range after actuator operation. The INP
PEND/INP Position Completion signal will turn OFF if the position deviation exceeds the in-position range. 5B OUT4 PM16 PM16 PM16 PM16 PE4 TLR 10A IN5 BK-1 (Insulation-Displacement 10B OUT9 BK-3 (Insulation-Displacement
PEND and INP can be switched over by the parameter. 6B OUT5 PM32 PM32 PM32 PM32 PE5 *ALM 11A IN6 BR-2 Connectors) 11B OUT10 BR-4 Connectors)
The position No. reached after the positioning completion, is output (binary 7B OUT6 MOVE MOVE PM64 PM64 PE6 *EMGS 12A IN7 RD-2 AWG28 12B OUT11 RD-4 AWG28
PM1 to PM256 Completion Position No. Output
output). 8B OUT7 ZONE1 MODES PM128 PM128 ZONE1 ZONE1 RMDS
13A IN8 OR-2 13B OUT12 OR-4
PZONE/ PZONE/ PZONE/ PZONE/ PZONE/
Turns ON when home-return operation is complete. It will be kept ON 9B OUT8 PM256 ALM1 14A IN9 YW-2 14B OUT13 YW-4
HEND Home Return Completion ZONE2 ZONE1 ZONE1 ZONE2 ZONE2
unless the home position is lost. 10B OUT9 RMDS RMDS RMDS RMDS RMDS RMDS ALM2 15A IN10 GN-2 15B OUT14 GN-4
ZONE1 Turns ON if the current actuator position is within the range set to the 11B OUT10 HEND HEND HEND HEND HEND HEND ALM4
Zone 16A IN11 BL-2 16B OUT15 BL-4
ZONE2 parameter. 12B OUT11 PEND PEND/WEND PEND PEND PEND ALM8
Turns ON when the current actuator position gets into the range set to the 13B OUT12 SV SV SV SV SV SV *ALML 17A IN12 PL-2 17B NP PL-4
position data during the move towards the position. Even though it can be 14B OUT13 *EMGS *EMGS *EMGS *EMGS *EMGS *EMGS 18A IN13 GY-2 18B /NP GY-4
PZONE Position Zone
used together with ZONE1, PZONE will become only available for 15B OUT14 *ALM *ALM *ALM *ALM *ALM *ALM ZONE1 19A IN14 WT-2 19B 0V WT-4
operation by the set position number. LOAD/TRQS LOAD/TRQS LOAD/TRQS LOAD/TRQS
16B OUT15 *ALML *ALML ZONE2 20A IN15 BK-2 20B 0V BK-4
Outputs the operation mode status. It turns ON when the controller is ON *ALML *ALML *ALML *ALML
RMDS Operation Mode Output 17B NP
Manual Mode.
Turns ON when controller in normal condition, and OFF when alarm is 18B /NP Operation in Pulse Train Control Mode
*ALM Alarm
generated.
The detail of the alarm is output with binary code when an alarm more than
19B
20B
0V
0V
N
N (function for PLN and PLP Types only)
ALM1 to 8 Alarm Code (Note) * in codes above shows the signal of the active low.
the operation cancel level is issued. Pulse Train Input and Output Interface
PM1 to PM8 indicate the alarm binary code output signal when an alarm is generated. [Refer to the Instruction Manual
Turns ON while the actuator is moving (including home return and for the details] Category Abbreviated Code Signal Name Contents of Functions
MOVE While in Operation
pressing operations). (Note 1) The setting can be changed over to PZONE if set in the parameter setting.
SV Servo ON Turns ON when the servo is ON. PP, /PP Inputs the command pulse train.
(Note 2) It is invalid before home-return operation.
Turns ON when the controller emergency stop is cancelled, and OFF Input Command Pulse Input Input pulse frequency differs depending on the type.
*EMGS Emergency Stop Output (Reference) Signal of Active Low
during the emergency stop (regardless of alarms). NP, /NP [Refer to Basic Specifications]
Signal with * expresses the signal of active low. A signal of active low is a signal that the input signal is processed when it is
Output Turns ON when it turns to the Teaching Mode by MODE signal input. It is
MODES Teaching Mode Output turned OFF, output signal is ordinary on while the power is ON, and turns OFF when the signal is output. When Host Unit is Differential System
OFF in the normal mode. PCON
It is OFF during the teaching mode and turns ON when the writing by PIO Input and Output Interface Host Unit
WEND Writing Complete PIO Connector
PWRT Signal is complete. It turns OFF when PWRT Signal turns OFF. Input section Output section Positioning Unit
3A
Turns ON when moving to the target position is complete in Input voltage 24V DC10% Load voltage 24V DC PP
Specification

PE0 to PE6 Current Position Number

Electromagnetic Valve Mode. Pulse Command 4A
Peak load electric 17B
/PP
Turns ON when the current actuator position is within the range of Input current 5mA 1 circuit 50mA/1 point (Line Driver:
NP
positioning band () of the target position. It is output even before the current 26C31 or equiv.)
18B
LS0 to LS2 Limit Switch Output /NP
movement command and the servo is OFF if the home-return operation is ON voltage MIN. 18V DC
completed. ON/OFF voltage Leak Current MAX.2mA/1 point
OFF voltage MAX. 6V DC
Loadcell Calibration Turns ON after loadcell calibration is complete. This signal turns OFF if
CEND
Complete CLBR signal is turned OFF. External
Controller Controller
Power Supply
Outputs when a message level alarm is generated. P24 P24
Internal

Source
*ALML Light Error Output 24V DC
Power

(Parameter setting necessary)

Internal

Source
Power

680
NPN

Output
Load
Output is made when the current exceeded the value set in Threshold for 5.6K 15 Terminal
Note1 : Use the same power source (0V) for the host open collector output, AK-04.
certain time (Note) within the range of Zone+ and Zone- in the position Input
(Note1) Load Output Judgment data during the pressing operation. Terminal
External
Power Supply When Host Unit is Open Collector System [AK-04 (option) is required]
LOAD N
Signal (Note) Setting to be established in Parameter No. 50
24V DC
Pulse Converter
It is used for judgments such as to determine if press-fitting process is AK-04
completed normally. Host Unit 24V (to be purchased separately) PCON
Controller Controller
Turns ON when the motor current has exceeded the value set in Positioning Unit DC 0V PIO Connector
Input
P24
Threshold in the position table in such cases as the slider (or rod) hitting
Internal

Source

Terminal 5.6K 1 24V PP 1

Power

TRQS(Note1) Torque Level Output 3A

Internal

External
an obstacle while in pressing operation, and turns OFF when current goes
Source

PP
Power
PNP

Power Supply
680 2 0V /PP 2
below the value Output
24V DC 24V 4A
/PP
15 Terminal Load
TLR Torque Limit Restricted Turns ON when torque reaches the limit while in torque restriction. External N
3 PP NP 3 17B
NP
Power Supply Pulse 4 NP /NP 4 18B
Signal with * expresses the signal of active low. It is ON when the power is applied to the controller, and turns OFF when the 24V DC N Command /NP
signal is output.
(Note 1) It is a signal dedicated for High-Thrust Actuator (CFA Type). Use this as a reference output for other actuators. 19B
0V
20B
0V
0V 0V

Note1 : 1) Use the same power source (0V) for the host open collector output, AK-04.
2) Have the cables as short as possible between the host unit and AK-04.
 [In the case of Pulse Train Control Mode (for PLN and PLP types only)]
Starting Procedures
PIO Pattern Settings
When using this product for the first time, make sure to avoid mistakes and incorrect wiring by referring to Set the used PIO pattern to Parameter No. 25.
the procedure below. PC stated in this section means PC software.
Set the Electronic Gear Check Item
[Refer to Instruction Manual] Is the minimum unit of operation set to the value bigger than the
Check of Packed Items No
Contact us or our distributor. Set the electronic gear ratio based on the minimum resolution of the encoder?
Are there all the delivered items? amount of actuator operation per pulse in Is the fraction of the electronic gear ratio reduced to its lowest terms?
Yes Parameters No.65 and 66.
Installation and Wiring Point Check Item Yes
Perform the installation of and wiring for the Is frame ground (FG) connected?
actuator and controller. Has the noise countermeasure been taken? Pulse Train Input Output Mode Setting [Refer to Instruction Manual]
Yes Set the command pulse train input status for the parameter No.63 and No.64.
Put Operation Mode Setting Switch to AUTO side when the setting is complete.
Power Supply and Alarm Check
Connect a teaching tool such as PC, turn the
Check Item No Connect the teaching tool Servo ON Check Item
operation mode setting switch to MANU side and Is the Controller Status such as PC to confirm the No Confirm the content of alarm on the teaching
turn the power ON for unit. Input servo ON signal Is the Controller Status Display
Display LED turned OFF? content of alarm and have tool such as PC to have an appropriate treatment.
Select [Teaching Mode 1 Safety Speed Activated / from PLC. LED turned ON in green [SV]?
an appropriate treatment.
PIO Operation Invalid] in the teaching tool such as Yes Yes
PC.
Have the settings and checks suitable for the used Safety Circuit Check
mode selected from Positioner Mode and Pulse Check that the emergency stop circuit (or motor
Train Control Mode below. drive-power cutoff circuit) operates normally to turn
OFF the servo.
[In the case of Positioner Mode]
PIO Pattern Settings Yes
Set the used PIO pattern to Parameter No.25. Test Run Adjustment 1 Check Item
[Operation Mode MANU] No Check if there is any problem in the way
Is there any risk of
Safety Speed Setting Check with a teaching tool such as the of actuator mount.
interfering with peripheral
Set the Parameter No.35 if necessary. PC software with no work being loaded, equipment?
The safety speed is set to 100mm/s at the delivery. and check the operation range with JOG
If an alarm is generated, operation with the work being loaded.
Servo ON Check Item connect the PC or teaching Yes
Turn the servo ON with the operation on the Is the Controller Status Display No pendant and check the
teaching tool such as PC. LED turned ON in green [SV]? content of the alarm to have
the right treatment. Test Run Adjustment 2 Can the positioning No Check the electronic gear ratio setting.
Caution [Operation Mode AUTO] operation be performed Confirm the command pulse train input
Please perform this process with the actuator away from the mechanical end or Output the pulse train from PLC normally? mode setting.
interfering subjects as much as possible. Yes to the controller and check the
Yes
Put the actuator away if it interferes with surroundings. It may generate an alarm system operation.
if the actuator hit the mechanical end or interfering subjects when the servo is
Confirm that there is no problem in the
Is it in condition without No actuator installation, the actuator operation
turned ON. any vibration and
The slider may get slightly dropped by self-weight if servo ON and OFF is condition demands a voltage more than rated
abnormal noise? voltage, and appropriate pulse trains are input.
repeatedly performed at the same position. Be careful not to pinch the hand or
Yes
damage the work.
Test Run Adjustment 3
Check the system operation conducted by PLC.
Safety Circuit Check
Does the emergency stop circuit (drive cutoff circuit) work properly and No
Check the emergency stop circuit.
turn the servo OFF?
Action to Take When Error Occurred
Yes Shown below are the alarms that you may often see after power up. Have an appropriate treatment following
Target Position Setting the instructions below.
Set the target position in Position Box in each position table. Please refer to the Instruction Manual for other alarms.
Perform a home-return operation first when Direct Teaching is to be performed. When moving the actuator manually, set
Error Code Error Description Cause and Treatment
the Brake Release Switch to BK RLS side for the brake equipped type. Put the switch back after the setting is complete.
It indicates the calendar function has stopped and the current
Warning Be careful not to pinch fingers or damage the work with the dropped actuator when releasing the brake Real Time Clock
069 time data has lost.
in vertical orientation. Operation Stop Detection
Have the clock settings again from the teaching tool.

The detection of excitation is conducted when the servo is turned
Test Run Adjustment 1 Check if there is any problem with the ON for the first time after the power is supplied. The status is that
Check the operation without mounting a

Check Item No installation of the actuator and the condition the detection did not complete even after a certain time (set in
work and set the safety speed invalid on Any vibration or of the actuator use exceeds the ranges of the Parameter No.29) was passed.
the teaching tool such as PC, and then abnormal noise? rated values. 1) Connection error or wire breakage of motor/encoder cables
check the operation with a work mounted. Adjust the servo if necessary. 0B8 Excitement Detection Error
2) Brake is not released (when equipped with a brake).
Caution To ensure safety, it is recommended that safety Yes 3) Load to the motor is high due to external force. Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan
speed be enabled during initial movements. 4) Power was turned on while touching to the mechanical end. TEL +81-54-364-5105 FAX +81-54-364-2589
5) The slide resistance of the actuator itself is large. website: www.iai-robot.co.jp/
Test Run Adjustment 2
Those described above can be considered.
1) Set the operation mode setting switch to AUTO.
2) Output the operation command from PLC to the controller and check the system operation. This error code appears when the right signal was not received
from the encoder side to the controller command. Check if any
wire breakage on a connector and the condition of wire Technical Support available in USA, Europe and China
0E5 Encoder Receive Error connections. If no error is generated under the condition that the
power to all the peripheral equipment is shut and operate only
this controller and the actuator, noise can be considered as the
cause of the problem. Head Office: 2690 W. 237th Street, Torrance, CA 90505
TEL (310) 891-6015 FAX (310) 891-0815
It is the condition that the encoder signal is not properly
Chicago Office: 1261 Hamilton Parkway, Itasca, IL 60143
A- and B-Phases detected.
0E8 TEL (630) 467-9900 FAX (630) 467-9912
Breakage Error Check if any wire breakage on a connector and the condition of
Atlanta Office: 1220 Kennestone Circle, Suite 108, Marietta, GA 30066
wire connections.
TEL (678) 354-9470 FAX (678) 354-9471
This error code appears when the absolute encoder PCB cannot website: www.intelligentactuator.com
detect the position information properly. The voltage for the
Absolute Encoder Error absolute data battery is dropped. Check the battery alarm output
0EE
Detection 2 on PIO, and if it is off, replace the battery. Perform Absolute
Reset after the replacement.
Check the encoder cable connection.
It shows the operation command was generated in the condition Ober der Rth 4, D-65824 Schwalbach am Taunus, Germany
Servo OFF While in TEL 06196-88950 FAX 06196-889524
20A that the servo is OFF.
Operation
Resume the operation after turning the servo ON.

SHANGHAI JIAHUA BUSINESS CENTER A8-303, 808, Hongqiao Rd. Shanghai 200030, China
TEL 021-6448-4753 FAX 021-6448-3992
website: www.iai-robot.com
Manual No.: ME0288-5A