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Robot Module System

1. Locus accel Resultant accele deceleration F1_ PRG m Max speed Speed limit Programmed Max accel Acceleration limit operation Finish width In position setting width LEinish mode In position confirmation format F1 JOB Fin control Fin out time Operation t Home accel Home return acceleration F2 ORG Home search speed F4 Home direction Home return mechanical stopper searching direction etc Henan Home sequence Home return mechanical stopper searching order operation E g Home shift Home return Home position offset gt Home move Home move mode F3 JOG 4 Home unit seq Home return motion order of units after 3 operation F1_ LMT position j Over travel setting coordinates Over travel SYS F2 TPL Pulse train F E Pulse resolution Resolution pulse train input Load mass Servo Gain Feedforward Gain Torque Limit Torque output limit F2 FIL Dead Band Dead band Low Pass Filter 1 Low pass filter primar Low Pass Filter 2 Notch Filter Notch filter frequency Position Loop Gain Position loop gain Sane L_ Manual H observer Gain parameter tuning Observer Limit Observer output limit Notch Filter Q1 Notch filter Q setting Gain mode Gain tuning selection Reserved Be F4 F1 ADL Position Direction Coordinate direction etc ae Hard OT Timer Rated Current Over load limit setting RC Over Load Over load li
2. AXA AANA ANANANA NAAN pay ie ee Installation and Maintenance of EXEA Controller 6 Unpacking and Installation Blank Page Installation and Maintenance of EXEA Controller 7 Wiring 7 Wiring 7 1 Connector List The connectors for external connection of the EXEA controller are shown in Table 7 1 For positions of the connectors see 5 1 2 Appearance and Dimensions of the EXEA controller Table 7 1 connector CN1 e Connector for the teaching box e Connect the cable supplied with the teaching box e Wiring of this connector is not required when the remote control through RS 232C communication is not used Please refer to 7 4 CN2 RS 232C Connector and 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 Control Input Output Signal Connector Connectors and connector shells are provided as accessories Wiring should be provided by customer See 7 6 CN4 e Main power CN4 and control CN5 Main Power and Control Power Connector power CNS 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 Connectors and connector shells are supplied with the controller as accessories Ex
3. 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 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 Check CN3 connector for incorrect wiring or missing wires Check DC 24V power supply 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 y 1 Review timing of input output signal if the system does not move entirely even t
4. 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 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
5. 1 3 1 3 1 Axis Indication 1 3 1 3 2 Regeneration 1 3 1 3 3 Dynamic Brake 1 3 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 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 Glossary 4 1 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
6. MOTORI Connect the connector so that cut off corner comes underside ExT 9 38 j EXEA Controller i ES MADE IN JAPAN reno o o Ast 3 sensor 3 aeoe o 7 23 Installation and Maintenance of EXEA Controller 7 Wiring Blank Page 72 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 Make a proper connection of cables referring to the seals affixed to the connectors 2 Clear emergency stop state Clear EMST input of CN3 connector Turn EMST input on Connect the teaching box 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 Check if the fixing bolts of module main unit are securely fastened Ifthe bolts are not secured properly it may cause a serious injuries when robot starts to move Check if a vertical axis are securely hold by motor brake Ifit is not hold it back drives and may cause injuries or the damage to the robot and ancillaries Do not enter motion range of robot modules when doing start up adjusting and test running Never enter motion range of ro
7. 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 10 Trial Running 10 1 11 Protection and Safety 11 1 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
8. Personal computer for remote control Shall be provided by the user External control equipment sensors Shall be provided by the user e Sequencer e O control box e Sensors To main power source Emergency stop circuit EREM input circuit Frame ground All operations such as Initial setting programming and operation excluding Jog operation can be done through the personal computer 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 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 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 Installation and Maintenance of EXEA Controller 3 System Configuration 3 2 Structure of Module Main Unit Table below shows components of a module main u
9. Screw a M3 cross recessed pan head screw Screw D M3 cross recessed pan head screw Screw 3 M3 cross recessed pan head screw Photo 12 2 Indication of screws to be removed lt Single axis controller gt Screw 4 M3 cross recessed countersunk head screw Screw 6 M3 cross recessed countersunk head screw Screw 6 M3 cross recessed countersunk head screw Screw TD M3 cross recessed countersunk head screw Screw M3 cross recessed countersunk head screw 12 3 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 lt 2 axes controller gt Screw 1 M3 cross recessed countersunk head screw Screw 3 M3 cross recessed countersunk head screw M3 cross recessed countersunk head screw Photo 12 4 Indication of the screws to be removed 2 lt 2 axes controller gt Screw Screw M3 cross recessed M3 cross recessed countersunk head screw countersunk head screw Screw Screw Screw M3 cross recessed M3 cross recessed M3 cross recessed countersunk head screw countersunk head screw countersunk head screw ee a 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 an
10. 9 3 Installation and Maintenance of EXEA Controller 9 Initial Setting Figure 9 3 Controller setting mode Unit setting Controller setting mode CTR F2 MDL Module setting Re served Do not use F1 PMD Program mode setting F2 INP Input format setting F3 OUT Output format setting F1 CLR pa nitialize rameters F2 SAV Save data controller setting F3 LOD Read out controller setting p Main unit combination type e User module 1 Ball screw lead User module 2 Encoder resolution User module 3 Motor mount direction Motor output Ipout xx IBxxx Switch polarity of input port Output xx OBxxx Switch polarity of output port Initialization Write data of 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 Installation and Maintenance of EXEA Controller 9 Initial Setting Table 9 1 and Table 9 2 show the parameters of system setting and the controller setting respectively 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 ax
11. Is color of LED of Replace the controller controller green Contact your local NSK representative Defective RS 232C cable or improper communication program in the personal computer is suspected 1 In case of defective RS 232C cable e 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 Correct defective part Serial port of controller may be defective Replace controller Contact your local NSK representative 14 21 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 1 11 Problem of Saving Program 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 e Be sure to take measures against noise referring to 7 2 5 Measures against Noises e Provide stable power source Do not turn the power off when Writing is indic
12. ve CSE NSK Ltd MADE IN JAPAN 20000000000000000 EA SESSSSSOODOOOOOODD SESSSSSODDOOOOOODD FGND FOND EA SESS SESS lo 160 Bracket may be attached to either front or rear side Connect the connector so that cut off corner comes underside EXEA Controller J NSK Lta MADEIN JAPAN EA Fon o En EA EA o lo n Bracket may be attached to 1 M N either front or rear side The dimensions of 3 axes controller are the same as that of four axes controller 5 4 5 2 Teaching Box 5 2 1 Operational Function Table 5 5 Setting programming Operation start stop Outputs Monitoring Other Installation and Maintenance of EXEA Controller 5 Reference Number Specifications e Internal parameters servo gain e Programming teaching e Jog Home return Start stop of programmed operation emergency stop e Exclusive output general output and on off of motor brake e Alarm indication e Monitor control signal and general output e Programmed operation monitor current po
13. 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 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 7 Wiring 7 1 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
14. 13 4 Installation and Maintenance of EXEA Controller 13 Alarms Table 13 3 2 2 7 segments RDY WRN Indication of Travel limit Servo lock The slider moved exceeding the for one F2 Green Close Close Soft OT limit limit position set by user Initial Set by user aes meet direction setting Over travel a Servo lock i i Travel limit fev one F3 Green Close Close Hard OT limit The slider collides with mechanical Mechanical lock direction stopper Emergency stop EMST Emergency stop has been activated Program error Servo on F5 Green Close Close Pre 3 Syntax ertor ma REO ee 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 V DY YT 2 Y message which means communication disabled in Japanese may appear in some cases besides CPU error Example When a key is pressed e while saving the programs in Program mode e while initializing special function operating mode X3 k k kk k Varies by the contents of Program error 13 5 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 Description of Alarm Check the followings before attempting to investigate the cause of an alarm or take necessary action according to the description in thi
15. Use A and keys to scroll the screen Use gt key to start the editing Use 4 gt A and Y keys to move the cursor to edit or select an axis of multi axis combination Use o 9 numeric keys key and key to input numbers o e key is used to set or select key words OFF etc In each display screen pressing MODE key makes the screen to go one step back In the system setting screen use and P keys to select a unit number Prior to set the 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 Installation and Maintenance of EXEA Controller 9 Initial Setting 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 gt Start editing Cursor is blinking 1RUN 210 3FNC 4etc L i P gt Select axis For multi axis combination only Position Direction Rasa E External External control mode W Menu selection screen 2 External External control mode Menu selection screen 1 TSS gt Start editing Curs
16. 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 The teaching box must be put in your reaching area so that it can be handled immediately in an emergency 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 1 Check on Servo Lock Be sure to observe all safety precautions described on Page 14 1 and 14 2 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 combination e Make sure that moving part of main unit stops completely then turn off servo Press key in the teaching box operation mode The servo on indicator on upper
17. 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 iv 12 Maintenance Checking 12 1 14 Troubleshooting 14 1 12 1 Maintenance 12 1 14 1 Discription of Troubleshooting 14 1 12 2 Checking 12 2 14 1 1 Malfunction 14 3 12 2 1 Periodical Check 12 2 14 1 2 Operation Problem of the System 14 4 12 2 2 Replacement 12 2 14 1 3 Troubleshooting for Home Return 14 8 12 3 Warranty Coverage 12 7 14 1 4 Troubleshooting for Programmed 12 3 1 Warranty Period 12 7 Operation 14 11 12 3 2 Limit of Warranty 12 7 14 1 5 Excessive Noise Vibration and 12 3 3 Immunity 12 7 Ovefshooting en S 14215 12 3 4 Service Charge 12 7 14 1 6 Troubleshooting for Rough Motion 14 16 14 1 7 Cannot Release Brake 14 17 13 Alarms 13 1 14 1 8 Unable to Clear Emergency Stop
18. Refer to 14 1 3 Troubleshooting for Home Return Home Is Home position normal at the position shifts end of Home return Is the slider in its position If position of the slider is correct cause of the problem might properly be in end effctors Confirm if end effectors are normal Is the teaching point data overwritten in the program Confirm that the point data of the position at where position error occurs is correctly overwritten as intended Is rewriting of teaching Normal point data normal Abnormal 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 Review the program to have proper overwritten of point data 14 14 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 1 5 Excessive Noise Vibration and Overshooting 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 Refer to 13 4 Description of Alarm Confirm that all stiffness of mechanically assembled parts are sufficient If mechanical stiffness is insufficient the measures against noise or vibration do not work effectively Fix module
19. SYS System mode setting screen lt Select unit number SYS Jo gt Start editing Cursor is blinking for multi axis combination only 0600200 1JOB 2TUN 4etc A lt Select axis For multi axis combination only ODE Press key oe Operation parameter setting mode isvejuo gt Start editing Cursor is blinking 1PRG 20RG 3906 ROQO NOY lt lt gt Select axis For multi axis combination only Press key Home move a lv gt Start editing Cursor is blinking NOP L Select a mode Home move mode SET a lv gt Start editing Cursor is blinking 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 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 Setting range_ Factory set e The speed of an axis is set when HIGH key and Jog key are pressed simultaneously under the jog operation Jog speed H mm s 0 1 250 0 100 0 Jog speed L e Specifies speed of each main unit in Jog operation 0 1 250 0 50 0 e Specifies acceleration deceleration of each main unit in the jog ms 0 1 35 0 0 5 Jog a
20. Use 0 T 9 numeric keys key and key to input numbers J e key is used to set or select key words OFF etc In each display screen pressing MODE key makes the screen to go one step back In the system setting screen use 4 and P keys to select a unit number Prior to set the 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 Installation and Maintenance of EXEA Controller 9 Initial Setting 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 gt Start editing Cursor is blinking External External control mode Menu selection screen 1 IRUN 210 3FNC 4etc 2 a lt Select axis For multi axis combination only Low Pass Filterl Press Fa key ia External External control mode Iv Pressing L makes the setting OFF Menus selection screen 2 gt Start editing Cursor is blinking 4etc J Select axis For multi axis K gt combination only Low Pass Filter2 Press F1 key a Teaching box control mode Iv Pressing L makes the setting OFF Menus select
21. Use o a 9 numeric keys key and key to input numbers o e key is used to set or select key words OFF etc In each display screen pressing MODE key makes the screen to go one step back In the system setting screen use 4 and keys to select a unit number Prior to set the 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 Installation and Maintenance of EXEA Controller 9 Initial Setting 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 sys Ts gt Start editing Cursor is blinking IRUN 210 3ENC 4etc X03540 lt Select axis For multi axis combination only Payload Press key External control mode Menu selection screen 2 External control mode Menu selection screen 1 External External gt Start editing Cursor is blinking 4etc J Select axis For multi axis K gt l combination only Servo Gain Press F1 key Teaching box control mode Pressing L makes the setting OFF Menu selection screen 1 gt Start editing Cur
22. 14 26 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 2 Check for Brake Function Be sure to observe all safety precautions described on Page 14 1 and 14 2 If an alarm arises refer to 13 4 Description of Alarm and remove the cause of alarm before troubleshooting 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 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 Does it move manually Replace main unit Contact your local NSK representative NO y 3 Release the brake Refer to 14 2 6 5 Indication of Brake Status and ON OFF Does it move manually Brake control function is normal Brake control does not function properly The followings might be the cause e The brake itself is defective Operating main unit without releasing the brake may lead to brake trouble e The brake signal line in the controller cable is snapped It needs considerable for
23. 14 18 14 1 9 Trouble of Over travel Limit 14 19 Me eA a GN Alarms ena ea Tearar terrane 1 14 1 10 Communication Problem in 13 1 1 Output of CN3 Connector 13 1 Remote Control Mode 14 21 13 1 2 Seven Segments LED 13 1 14 1 11 Problem of Saving Program 14 22 13 1 3 Display of Teaching Box 13 2 14 1 12 Heating Problem 14 23 13 2 Motor Condition in Alarm State 13 3 14 2 Inspection of Trouble 14 24 13 3 Alarm LiSt 13 3 14 2 1 Check on Servo Lock 14 26 13 3 1 Normal State 13 3 14 2 2 Check for Brake Function 14 27 13 3 2 Alarm LiSt 13 4 14 2 3 Check for Mechanical Back Drive 14 28 13 4 Description of Alarm 13 6 14 2 4 Abnormality of Encoder Signal 14 29 13 4 1 Overheat 13 8 14 2 5 Action for Malfunction and Collision 14 30 13 4 2 Abnormal Main Power Voltage 13 9 14 2 6 Monitoring I O 14 31 13 4 3 Over Current 13 10 14 2 6 1 Indication of Input Port Condition 14 32 13 4 4 Insufficient Voltage t
24. Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 6 1 Indication of Input Port Condition 1 Monitor status of input port Indication screen of Input port condition appears when key INP in the I O indication selection screen is pressed is indicated next to the I O in the screen Status of four input ports are shown in the second and third line Use 4 A and Y keys to scroll the cursor The first line indicates the name of the port of which bit are selected by the cursor When there are four or more input ports use A and v Figure 14 31 Screen indicating the input port condition Name of port I O I EMST 00 00000000 00000000 10 00000000 00000000 1CHK keys to scroll the indication 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 Status of port is indicated by 8 bits Left side is bit 7 and right side is bit 0 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 Port Status of Status of number port 00 port 01 00 00000000 00000000 14 32 Installation and Maintenance of EXEA Controller 14 Troubleshooting 2 Checking input port status The
25. There are four kinds of servo parameters Motor control Filter Manual tuning Function setting Tuning is greatly affected by setting of acceleration and deceleration as well as the servo parameters Do not set excessive acceleration and deceleration Tighten the fixing bolts of module main units Loose bolts may cause a serious accident Do not allow any personnel in the robot operation area while tuning the system 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 Ifthe cables are connected improperly the system fails to demonstrate its full performance The controller or motors may become defective Check for interference of each axis when the axis makes its full stroke Mechanical interference may damage the robot end effector and the ancillaries 9 23 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 4 1 Parameters for Servo 9 4 1 1 Parameter List 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 For a multi axis combination set the servo parameters to respective axes of all units to which the module type is assigned Parameters won
26. Unit setting UNT Each parameter setting screen Scroll the screen using 4 and Y keys Use P key to start the editing Use 4 gt A and keys to move the cursor when editing and selecting an axis in multi axis combination Use 0 fe 9 and keys to set numbers J key is to be used to set or select keywords OFF etc Pressing MODE key switches to the screen backward in each display screen 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 Ist 2nd on the front panel of EXEA controller It is set to 1 for a single axis system 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 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 gt Y Module Name gt Z Module Name gt R Module Name 2nd letters in the 3rd line
27. lt gt Set items Press key Z Module a Y Select setting value SET 1EDT 2TCH Teaching box operation mode Menu selection screen 3 gt Start editing Cursor is blinking i lt gt Set items Press key Roodie ally Select setting value SET 1syS 2CTR 310 4etc CTR Controller setting mode lt Select unit number Multi axis combination only 1UNT 2MDL 4etc 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 Press key then use a yl keys to indicate the selection screen of items Note Refer to Figure 9 16 to delete a unnecessary MODE module main unit setting 9 38 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 5 3 Separating Units for Use This chapter is for a Multi axis combination only 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 Unit shall be split into some units for use it requires to set other unit number accordingly Following is a way to split Unit1 into some units 1 Clear axes not required for Unitl 2 Set the cleared axes to other unit An example in Figure 9 16 shows a way to split a two axes controller to X axis
28. memory Alarm related Memory 4 code to control o aee oP PAEA onko Home return is necessary after battery is replaced Reset after initialization of memory Alarm is automatically Travel limit set by user F2 Soft OT limit cleared when slider gets out the over travel limit range 13 28 Installation and Maintenance of EXEA Controller 13 Alarms 13 5 1 Clear Alarm in External Control Mode Operation Mode through CN3 Control I O Alarm is cleared by rising signal from OFF to ON of ACLR input of CN3 pin No 23 Figure 13 4 ACLR input Alarm state Clear alarms Alarm 13 5 2 Clear Alarm by Teaching Box Operation Mode Return to Menu selecting screen by pressing MODE key Confirm the indication of alarm Clear alarm by and keys There are two types of alarms One is cleared by pressing only key and the other type is cleared by pressing key after key When pressing key after pressing key press key after removing your finger from key When and keys are pressed simultaneously an alarm cannot be cleared Table 13 47 Teaching box operation key key gt key Alarms that can be cleared All alarms listed in Table 13 45 13 5 3 Clear Alarm in Remote Control Mode RS 232C Communication Mode Alarms can be cleared by ACLR command and ACLR ALL command See the table below for the distinction of alarms that can be cleared by ACLR command or ACLR ALL command
29. 13 12 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 DRDY output WRN output Display of teaching box Servo off Thermal 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 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 e Excessive motor duty load and acceleration deceleration e Improper initial setting of software thermal switch e 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 e Snapped motor winding or motor cable 13 13 Remedy e Relax motor duty and decrease load and acceleration deceleration e Air cool the motor after terminate operation as it is overheated Keep the controller power turned on while cooling the motor e Set the software thermal switch properly e Check DC24V power supply and wiring Rectify the problems e Investigate brake line wiring of controller cable and cable support Replace defective cable e Replace the controller Con
30. 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 8 Startup 8 1 8 1 Turn on P
31. Je EXEA Controller a le i Su Red LED MADE IN JAPAN rw o O 4st sensor osoo Installation and Maintenance of EXEA Controller 8 Startup 8 2 Selection of Control Mode The system gets into External control mode automatically after turning on power At this time RDY output CN3 is closed when it is normal All operations such as start and stop are controlled through the control Input Output signal CN3 of EXEA controller The system gets in the external control mode every time the power is turned on In this control mode the function keys of the teaching box along with key are effective Refer to 17 4 6 Teaching Box Operation in External Control Mode Figure 8 4 Indication of teaching box display External RUN 210 3FNC 4etc 8 2 1 Teaching Box Operation Mode For execution of initial setting programming and operation through the teaching box put the system in the teaching box operation mode pressing TBX after 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 Use F1 and keys for the selection of operation in the display and use key for selecting the display Installation and Maintenance of EXEA Controller 8 Startup Figure 8 5 Changing operation
32. NSK Robot Module System P Series Module Main Unit R Series Module Main Unit EXEA Controller User s Manual 1 Installation and Maintenance of EXEA Controller 1 Installation and Maintenance 2 Programming and Operation 3 Installation and Maintenance of EXEA Controller of EXEA Controller of Module Main Unit Introduction 15 Programming 19 Reference Number Specifications Safety Precautions 16 Description of Function 20 Unpacking System Configuration 17 Operation of Robot Module 21 Installation Glossary 18 Remote Control Operation 22 Maintenance Checking Reference Number Specifications Unpacking and Installation Wiring Startup Initial Setting OANANINHNDN BPWN Trial Running Protection and Safety Maintenance Checking Alarms Troubleshooting Appendix M E099XE0K2 022 NSK Ltd Document Number K20078 01 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
33. 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 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 3 2 2 Setting Procedure of Parameter Home Return Set the mode to the system setting referring to 8 2 Selection of Control Mode 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 Use Use Use A gt and keys to scroll the screen key to start the editing lt gt IA and v keys to move the cursor when editing the program and selecting an axis in multi axis combination Use 0 9 numeric keys key and key to input numbers J key is used to set or select key word OFF etc In each display screen pressing MODE key makes the screen to go one step back For a multi axis combination you may select a unit number using lt and gt keys in the screen of system setting mode It requires to set the unit number besides U1 to set the parameters for the unit Refer to 9 5 Param
34. Ul The part indicated by dotted lines won t be indicated in case of a single axis system 14 36 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 6 5 Indication of Brake State and ON OFF 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 Select BRK in the I O indication selection screen to lead the screen of brake status B appears next to I O in the screen Current status of designated unit on the second line in for a multi axis combination and use lt and keys to move position of the cursor Use A and keys to scroll the indication when two or more unit are set to a multi axis combination Figure 14 40 Monitor brake condition 3USR The part indicated by dotted lines won t be displayed for a single axis system Pressing key USR makes it possible to switch temporarily ON and OFF of the bit on which the cursor is put by using o and 1 keys Figure 14 41 j F3 4 mt Switch On Off of a brake by 0 and keys 0 Brake is off release e e e Brake is on The part indicated by dotted lines won t be displayed
35. e A large inrush noise intruded into the control board and caused CPU malfunction Remedy e Remake the power e 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 e Replace the controller Contact your local NSK representative e CPU or the watchdog circuit has failed 13 20 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 15 System Error Table 13 33 Motor 7 segments DRDY WRN Servo off System x xx Differs with contents of alarms 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 Jt may occur for defective power amplifier or extend CB board for three four axes or also occur when power amp
36. 0 1 1200 mm s Maximum speed Actual maximum speed depends on the type of module main unit Refer to 19 1 2 Specifications for more details Program capacity Speed setting range Acceleration Maximum Deceleration acceleration 0 1 35m s setting range _ deceleration Acceleration deceleration pattern Modified sine profile Home return PTP Motion Maximum 3 axes for linear interpolation maximum 3 axes circular interpolation Program 2 4 axes Maximum 3 axes continue pass arch motion and 2 axes palletizing command General Input Output timer Jump Conditional Jump Repeating subroutine call and interruption reserved Program editing Insert step delete and copy steps Control function Feed forward digital filter Coordinates setting 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 Exclusive input operation start Resume programmed operation Alarm clear Pulse train single axis only Input Output Exclusive output 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 selec
37. 3J0G 4etc Teaching box operation mode Menu setting screen 1 Press key 1EDT 2TCH Teaching box operation mode Menu setting screen 2 Press key 1SYS 2CTR 310 4etc Teaching box operation mode Menu setting screen 3 Press key CTR 1UNT 2MDL 4etc Controller setting mode screen 1 Press key CTR 1PMD 2INP 30UT 4etc Controller setting mode screen 2 Press key Installation and Maintenance of EXEA Controller 9 Initial Setting PMD setting Parameter setting screen for PMD setting NOP EMST data save a Y NOP STOP data save a lv gt Start editing Cursor is blinking a Y Select setting SET gt Start editing Cursor is blinking a Y Select setting SET NOP CSTP data save a Y NOP ALARM data save a lv CTR P PRG RUN mode gt Start editing Cursor is blinking a Y Select setting SET gt Start editing Cursor is blinking a v Select setting SET gt Start editing Cursor is blinking a v Select setting SET This part won t be shown for a single axis system 9 43 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 8 Parameters for Input Signal Forma
38. Abnormality of Encoder Signal Recovered Correct Replace cable Not recovered Replace defective cable Contact your local NSK representative Encoder or controller may be defective Replace module main unit or controller Contact your local NSK representative Check motor cover for overheating 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 e 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 e 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 Not appropriate __ e Excessive speed or acceleration deceleration Set appropriate value in program or teaching data Appropriate Contact your local NSK representative 44 3 Installation and Maintenance of EXEA Controller 14 Troubleshooting
39. Cursor is blinking lt gt Select axis For multi axis combination only Pressing L makes the setting OFF gt Start editing Cursor is blinking In the single axis system this screen won t be indicated SYS JL 0000 00 Escape lwr gt Start editing Cursor is blinking In the single axis system this screen won t be indicated OFF Escape pos SYS JL 0000 00 Escape upr SYS JL 0000 00 Escape lwr 1LMT 2TPL Additional screen Single axis system only 4etc Operation parameter setting mode gt Start editing Cursor is blinking Pressing L makes the setting OFF In the single axis system this screen won t be indicated gt Start editing Cursor is blinking Tn the single axis system this screen won t be indicated gt Start editing Cursor is blinking In the single axis system this screen won t be indicated OFF Escape pos 9 20 gt Start editing Cursor is blinking Pressing B makes the setting OFF In the single axis system this screen won t be indicated 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 Installation and Maintenance
40. 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 The robot module is a precision machinery component Handle it with great care not to give any shock to it 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 929 Installation and Maintenance of EXEA Controller 2 Safety Precautions 2 2 EXEA Controller Observe the following environmental conditions when installing and or operating the EXEA controller Table 2 2 Condition Environmental condition Temperature 0 C 50 C i 10 C 70 C Operating Humidity 20 85 non condensation Free from dust corrosive gas and inflammable explosive gas Ameen condon Protected from cutting oil and cooling water 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 The controller has a very high capacity electrolytic condenser in the circuit There remains residu
41. For multi axis combination only Observer Press Fa key Teaching box control mode Menu selection screen 3 SYS TM gt Start editing Cursor is blinking XOFF F i i i 1SYS_2CTR_3IO 4etc L P gt Select axis For multi axis combination only D Press Ei key oe SYS System setting mode Pressing E makes the setting OFF lt Select unit number SYS T gt Start editing Cursor is blinking Multi axis combination only Laan f 1JOB_ 2TUN detec i b lt gt Select axis For multi axis combination only Notch Filter Q1 ODE Press F2 key Servo parameter setting mode 1SRV 2FIL Press key 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 9 30 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 4 4 Parameters for Function Setting 9 4 4 1 Parameter List Classification ADL Table 9 12 Parameter List Function Setting range set bastion e This is to set direction of the coordinate direction e Positive side of the coordinate is opposing to the motor NRM REV NRM 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 Thi
42. Locus accel parameter unless it is not stated specially in a program 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 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 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 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 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 3 1 4 Parameter Setting Procedure Programmed Operation Set the mode
43. Press key sys s Do not turn power off while storing the parameters Writing 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 Keep the record of necessary data or parameters in handwritten notes or in the back up function of optional application software beforehand 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 Installation and Maintenance of EXEA Controller 3 System Configuration 3 System Configuration 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 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 Use the controller cable and the cable support to connect a main unit and an EXEA controller The controller cable consists of wiring of motor power encoder signal and protective ground Fix the end effector to bolt holes on the top of a slider of main unit Note Refer
44. Specifies a sequential order for home return of each axis unit sequence gt 2 An axis unit with lower number has the priority Home return 0 fixed 0 starts simultaneously when the axis number is the same e Specifies offset distance of Home position Home shift e After moving the offset distance from the Zero point it completes the home return e Specifies the stand by position after completion of the home 4 return e When the parameter is set to on a slider moves to the stand by position after completion of the home return e Specifies the moving mode described above after the home return is completed NOP Do not move to the stand by position 9999 99 0 Home move 9999 99 0 Home move mode ABS Move to the stand by position of which coordinates are recognized as absolute position INC Reserved When INC is set it functions same as ABS NOP ABS INC NOP 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 0 fixed 0 z B B 3 number they start simultaneously 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
45. Table 13 48 Remote control ACLR command ACLR ALL command Alarms that can be cleared All alarms listed in Table 13 45 is a space code 20H 13 29 Installation and Maintenance of EXEA Controller 13 Alarms 13 6 Initialize Memory 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 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 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 Set to the menu selection screen 4 in the teaching box operation mode referring to 8 2 Selection of Control Mode 3EXT 4etc Press VER 2ALM 3DAT 4etc Press key Selection screen of e Pressing key in the selection screen of initialization initializing makes possible to initialize memory INI 4etc Press key FNC I Push SET e Press key It starts initializing Press key FNC I e The screen indicates Writing while the initialization Caution Do not turn off the power while the screen Writing indicates Writing Otherwise memory error
46. USER USER USER USER USER USER USER USER USER USER USER USER USER IN2 RSRV IN3 RSRV IN4 RSRV IN5 RSRV IN6 RSRV IN7 RSRV IN8 RSRV RSRV RSRV RSRV RSRV RSRV RSRV RSRV RSRV csi icsi icsi pee peo ies gel A Camotchange ys A Camotchange Ys yes ye es S S KIKIKI IK KK IK IK IK IK I lt lt lt g 2 g 2 2 lt This function or indication does not exist in the single axis controller 9 8 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 3 Operation Parameter 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 Setting range Factory set Locus speed e Specifies a speed in the programmed operation 0 1 1200 0 600 0 ini ewer TS Specifies an acceleration deceleration in the programmed 0 1 35 0 0 5 operation e Specifies the speed limit e Set to 1 200 mm s for normal operation Max speed 2 e Lower speed of either Locus speed or Max speed is valid mm s 0 1 1200 0 1200 0 e The maximum speed varies according to a main unit Refer to 19 1 2 Specifications e Sets the limit of acceleration and deceleration Max accel e Set to 35 m s for a normal operation e Lower setting of
47. a directiei e ne cco hese te coo Indirect left TEE 10 J Direct o a a ene 20 Direct aaa aaa XY HRSOOO RM 238 2 ba 20 Fie Indirect right J in oo p22 ee as 20 L mdirect left a oe rs XY HRSOOO CRM _239 h 20 10 ole co We right J Nt 20 10 Indirect left v J OU Soe SCE right a ts Indirect left 40 20 ____ ___Jpdirect at I a 40 20 Indirect left v pane a ae ae a besten LSS Rieter I C ESS eater sence ae MEPs 20 J AM CE right oc Ig 2 ey basse 20 Indirect left aaa a 20 10 ______Jdirect right tM XY HRSOOD RH 211 h 20 10 _ Damien US 22 Se Re eee a and eae Ce or nn 202 400 Jo 20 d Direct an Ne e eee XY HRSOOO CRH 206 J fa 20 d Mdirect right aaa HES 20 eo Undine deft ae a a E40 RO ai o o direcg Tight lt N en ena E a 40 C0 NN rape CE left Jaaa 40 20 Indirect right 40 20 Indirect left v OOO 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 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 5 2 Parameter Setting Procedure Unit Setting Set the mode to controller setting referring to 8 2 Selection of Control Mode Refer to 9 1 Initial Setting Procedure and scroll the display to Unit setting UNT screen as shown below Controller setting mode CTR
48. key Press key to move System setting screen 2 sys Ul System setting mode screen 2 m 1CLR 2SAV 3LOD 4etc Press F3 key Press key to get the screen to readout System setting SYS L Push SET Press key Pressing key starts readout Reading message appears in the screen while reading out SYS U1 Reading System setting mode screen is displayed after completion of readout Es 9 54 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 12 2 Readout of Controller Setting Parameters This section describes how to readout the stored parameters of Controller setting listed below 1 Unit number 2 Module setting 3 PMD setting Program mode 4 Input signal format 5 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 MODE key several times to display Controller setting screen 1 or screen 2 Controller setting mode screen 1 Controller setting mode screen 2 1PMD 2INP 30UT 4etc key twice key Press F4 key to move to Controller setting screen 3 CTR Controller setting mode screen 3 m 4 1CLR 2SAV 3LOD 4etc Press F3 key Press key to move the readout screen of C
49. t be indicated for axis units to which the module type is not set Table 9 9 Parameter list of servo Classification Setting range Shipping set e Specifies load mass to be applied to an axis unit e For multi axis combination add all mass of main Payload units and combining brackets to be applied to a kg 0 200 0 5 0 slider of all units other than the one to which the work or end effector is attached i e Reserved Do not use e Specifies feed forward gain e This is to improve the system ability of command tracking However setting excessive gain likely 0 100 OFF OFF causes overshoot or vibration e In normal operation it shall be set to OFF Torque Limit e Stets the limit of output torque 1 100 OFF OFF Dead Band fe Specifies dead band 1 100 OFF OFF 9 4 1 2 Parameter Setting Procedure Servo Parameters SRV Feedforward Gain Set the mode to the system setting referring to 8 2 Selection of Control Mode 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 Use A and keys to scroll the screen Use P key to start the editing Use 4 and keys to scroll the cursor for editing Use 4 gt A and Y keys to move the cursor to edit or select an axis of multi axis combination
50. 1 CTR O gt Start editing Cursor is blinking WRN A lt gt Select an item Press key Output OP00 0B001 allv Select setting 4etc SET Teaching box operation mode Menu selection screen 1 1RUN 2ORG 3J0G 4etc a Press key v Teaching box operation mode Menu selection screen 2 i l 1 I I 1 1 i 1 1 i L L I 1 I 1 L i 1 v 1EDT 2TCH CTR O gt Start editing Cursor is blinking Press key veer i lt gt Select an item Output OP11 0B117 al v Select setting SET Teaching box operation mode Menu selection screen 3 1syS 2CTR 310 4etc Press key CTR Controller setting mode screen 1 1UNT 2MDL 4etc MODE Press key CTR Controller setting mode screen 2 1PMD 2INP 30UT 4etc Press key There will be no indication in the dotted lines for a single axis system 9 49 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 10 Saving Parameter Setting 9 10 1 Saving Parameters of System Setting 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 9 10 1 1 Procedure to S Programmed operation Home return Jog Position Coordinates Pulse train input Single axis system
51. 1 Procedure to Save Parameters of Controller Setting 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 SYS Ul Controller setting 1PMD 2INP 30UT 4etc Press key Writing Oooo CTR mode screen 1 1UNT 2MDL 4etc Press F4 key twice CTR y1 Controller setting mode screen 3 le 1CLR 2SAV 3LOD 4etc Press F2 key SYS UL Push SET 9 51 Controller setting mode screen 2 key In the screen of individual parameter setting press Press F4 key to move to Controller setting screen 3 Press key to move System setting screen Pressing key to start saving the parameters Return to Controller setting mode screen 3 when the MODE key several times to display Controller setting screen 1 or screen 2 Writing message appears on the screen while executing saving saving is completed Installation and Maintenance of EXEA Controller 9 Initial Setting 9 11 Initialization of Parameters 9 11 1 Initialization of Parameters for System Setting This section describes ho
52. 1 8 Unable to Clear Emergency Stop 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 End of troubleshooting If the problem recurs frequently noise is possibly the cause Refer to 7 2 5 Measures against Noise When remake the power does the system recover e Connect the teaching box firmly Is the teaching box connected e When you don t use the teaching box connect a dummy to CN1 firmly connector which is provided as an accessory e 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 e 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 1 9 Trouble of Over travel Limit Be sure to observe all safety precautions described on Page 14 1 and 14 2 When the slider does not stop and collide to the stroke end or an obstacle severely check damages to the mo
53. 14 1 2 Operation Problem of the System 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 Does remaking power fix the problem Not fixed 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 Troubleshooting completes e 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 e If the measures against noises do not work the controller may be defective Contact your local NSK representative Does display of teaching box work It indicat y Replace the controller Contact your local NSK representative Does 7 segments LED of the V controller indicating green It is possible that the teaching box is defective Replace the teaching box Contact your local NSK representative 14 4 Installation and Maintenance of EXEA Controller 14 Trou
54. 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
55. Auckland Phone 09 276 4992 NSK KOREA CO LTD KOREA Seoul Phone 02 3287 6001 NSK SINGAPORE PRIVATE LTD SINGAPORE Singapore Phone 2781711 NSK BEARINGS THAILAND CO LTD 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 P Series Module Main Unit R Series Module Main Unit EXEA Controller User s Manual 1 Installation and Maintenance of EXEA Controller Document Number K20078 01 August 3 2000 1st Edition 1st Printing NSK Ltd NSK 1st Edition 1st Printing August 3 2000 Document Number K20078 01
56. Component Remarks e Controls the entire robot module system e When the start command is activated it supplies electric current to motor s to execute the operations in accordance with EXEA controller programs and system parameters set in the controller e Realizes highly precise positioning utilizing the encoder signals as feed back signals of the motion e Use it to edit programs and set parameters Can be used to Teaching box execute manual operations such as Jog Home return and inputting Run command to start a programmed operation e The unit to input control signal externally when an EXEA Sold separately from the EXEA controller Main console controller is in the external control mode sequencer and DC fe Can be used with incorporated DC 24V power supply Should be provided by the user 24V power supply Refer to 5 1 1 1 Internal DC 24V Power Supply for its specifications CN3 Controller O e Connect the EXEA controller and the external control units je i Should be provided by user cable e g main console and sequencer EXT General O cable e Transmit general I O to control the end effector or other units Should be provided by user e The software is compatible to Windows98 and Windows NT4 0 Workstation It is provided in the CD ROM This is separately sold from the EXEA controller Application software d PP e You can edit the programs set and save the parameters of the EXEA contro
57. E6 Memory error A5 Home return incomplete Alarm code e Reports an alarm code which is being indicated by 7 segments LED 1 Alarms which have arose from respective axis units e An amplifier number is indicated on which an alarm has been reported when AMP is selected by 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 e A Unit number is indicated on which an alarm has been reported when AXS is selected by key Uss Only U1X is indicated in case of single axis In case of multi axis combination system U k kok Name of axis X R Alarm detection Unit number code 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 e It indicates a part of processing software on which an alarm is reported Controller Part on which alarm is reported Processing servo Processing pulse Processing main part Processing servo of first and second axes Single axis Multi axis Processing pulse Processing main part Example P27 Alarm occurs to the parts of three axes servo p
58. Maintenance of EXEA Controller Appendix Blank Page World wide Manufacturing and Marketing Organization NSK Ltd INTERNATIONAL DIVISION JAPAN Tokyo Phone 03 3779 7120 NSK CORPORATION U S A Ann Arbor Phone 313 761 9500 Precision Products Business Unit U S A Chicago Phone 630 924 8000 Los Angeles Phone 562 926 3578 Ann Arbor Phone 761 761 9500 NSKeRHP CANADA INC CANADA Toront Phone 905 890 0740 Montreal Phone 514 633 1240 Vancouver Phone 800 663 5445 NSK RODAMIENTOS MEXICANA S A DE C V MEXICO Mexico City Phone 5 301 2741 5 301 3115 NSK DO BRASIL INDUSTRIA E COMERCIO DE ROLAMENTOS LTDA BRASIL Sao Paulo Phone 001 269 4700 Porto Alegre Phone 051 222 1324 Belo Horizonte Phone 031 224 2508 NSK RHP UK LTD ENGLAND Ruddington Phone 0115 936 6600 NSK RHP DEUTSCHLAND G m b H GERMANY Dusseldorf Phone 02102 4810 Stuttgart Phone 0711 79082 0 Leipzig Phone 0341 5631241 NSK RHP FRANCE S A FRANCE Paris Phone 1 30 57 39 39 Lyon Phone 72 15 29 00 NSK RHP NEDERLAND B V NETHERLAND Amsterdam Phone 020 6470711 NSK RHP ITALIA S p A ITALIA Milano Phone 02 995191 NSK RHP IBERICA S A SPAIN Barcelona Phone 93 575 1662 NSK RHP AUSTRALIA PTY LTD AUSTRALIA Melbourne Phone 03 9764 8302 Sydney Phone 02 9893 8322 Brisbane Phone 07 3393 1388 Adelaide Phone 08 8373 4811 Perth Phone 089 434 1311 NSK RHP BEARINGS NEW ZEALAND LTD NEW ZEALAND
59. OV is used Do not wire the internal power source when the external power source is used ey Ay po Installation and Maintenance of EXEA Controller 7 Wiring 7 4 CN2 RS 232C Connector This connector is used to set EXEA controller to RS 232C control remote control mode Refer to 18 Remote Control Operation for the remote control 7 4 1 Cable on the Market Standard Cable Refer to Figure 7 5 when using an RS 232C standard cable on the market 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 Refer to Table 7 3 for information on the connectors and cables Table 7 3 Specifications of connectors and cables Connector on Personal Connector on personal Recommended connectors Recommended cable computer computer EXEA controller PC9821 NEC or D sub 25 pins equivalent female Romreued M EXTC040R01 PC9821 note Half pitch 14 pins KRS HA1520fK Sanwa Supplies Optional cable from NSK NEC or Centronics or equivalent or Half pitch 14 pins eaiivale t female iat pitch 14 pins Centronics male i KRS HA154K Centronics q D sub 25 pins female Sanwa Supplies female PC98NX or Disita pins D09 9F25F Sanwa Supplies DOS V equivalent D sub 25 ins male Half pitch 14 male D sub 3 pins male pins Centronics male 25 pins female Figure 7 5 Example of c
60. 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 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 5 Parameters for Unit Setting This parameter sets the type of module main unit and axis name to respective main units which are to be connected to EXEA controller 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 Set U1 as a unit number 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 An amplifier to be connected is 1st 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 Axis name in EXEA controller X is set to the Note In a multi axis combination set amplifiers example numbers 1 to 4 which are actually connected to main units Multi axis controller indicates Note Either one of X Y Z and R shall be set for a the number as 1st to 4th multi axis combination You may not set the same It is always 1 f
61. e Check for the wiring wiring e The monitoring circuit of control power is defective or the e Replace the controller internal wiring of power supply is snapped or has defective Contact your local NSK representative contacts 13 11 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 5 Encoder Circuit Error Table 13 12 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo off Encoder loss 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 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 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 Remedy e The encoder cable is shorted grounded or disconnected e Check the controller cable and cable e Improper wiring support for continuity Check each signals for short circuit and grounding Replace the cable if necessary e The line driver of encoder signal output is defective e Replace the module main unit Contact your local NSK representative e Monitoring circuit of encoder disconnec
62. following screen of input port status appears when key is pressed in the screen to indicate input port condition Two conditions current status and history of changes of two different input port are indicated on the second and third line Use Land gt keys to move position of the cursor The name of the port of which bit is indicated by the cursor is on the first line Use A 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 XXXXXXXX XXXXXXXX 1NRM 2RST The figure below shows the state of input port indicated on the second and third line Port Status of Status of number port 00 port 01 Current state 00 00000000 00000000 XXXXXXXX XXXXXXXX History of changes History on the third line indicates changes of input port status after DRDY is on or after RST key is pressed Each bit is one to one correspondence to a bit on the second line x 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 0 1 Start monitoring monitoring Pr
63. for a single axis system Settings are valid until key SYS is pressed again or MODE key is pressed Pressing either key makes to return to the setting of previous one 14 37 Installation and Maintenance of EXEA Controller 14 Troubleshooting Blank Page 14 38 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 The connector of EXEA controller indicates the name of axis as shown below First axis X axis Ist Table A 3 Motor power specification Motor output 400W Output voltage 280VPWM 280VPWM 280VPWM Current for rated output 0 87Arms 2 6Arms Current for maximum output 7 8Arms Table A 4 Brake power specification Output voltage DC24V Rated output voltage 400mA Output format Relay contact Type of brake Negative activation A1 Installation and Maintenance of EXEA Controller Appendix Appendix 2 Encoder Sensor Connector Table A 5 Used connector 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 EXEA contro
64. 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 1100 Design serial number of incorporated driver unit Incorporated number of driver unit for 400W motor Incorporated number of driver unit for 200W motor Power source voltage A AC200 220V C AC100 110V T Complies to CE Marking AC200 240V Incorporated number of driver unit for 100W motor 5 3 2 Teaching Box 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 Installation and Maintenance of EXEA Controller 5 Reference Number Specifications 5 3 3 Application Software for Personal Computer This is an appl
65. including the combining bracket to respective module main units other than a module main unit to which the effector is directly attached Refer to 9 4 1 Parameters for Servo for contents of setting and saving the parameters 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 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 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 2 Initial Setting List 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
66. initial setting be sure to execute the home return once Completion of the home return makes the initial settings of coordinates system effective If the memory is initialized the parameters are reset to the factory settings 9 5 Installation and Maintenance of EXEA Controller 9 Initial Setting Table 9 1 Initial setting System setting mode essificaian 3 unit Setting range Shipping set User setting Locus accel m s 0 1 35 0 Picante Max speed 0 1 1200 0 1200 0 Max accel m s 0 1 35 0 35 0 operation PRG Finish width Finish mode Fin control Fin out time Home speed Home accel Home search speed 0 99 99 OFF ONE ALL OFF ON OFF 0 99 99 OFF 0 1 50 0 0 1 35 0 0 1 10 0 OFF c 20 0 p 9 gt DJU AER Operation area parameter Home return Home direction NRM REV NRM JOB operation Homesequence 0 7 0o ORG Home shift mm 0 29999 99 o mm 0 9999 99 0 Home move mode NOP aBs nc Nop Home unitseg 07 0o Jog operation JOG m s 0 49999 99 OFF setting LMT 0 9999 99 OFF OFF a oe 1 Servo SRV Feed forward Gain _ OFF OFF Filter FIL OFF Servo GainMode_ Reserved MANU Manu parameter TUN Manual tuning MAN OFF Notch FitterQi oio s5s0o0 10 Position Direction NRMREV_ NM Function Hatd OT Timer 200 30000 AUTO i setting ADL
67. key e Press the SET key to confirm command Combination of and 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 Installation and Maintenance of EXEA Controller 5 Reference Number Specifications 5 2 2 Teaching Box Dimensions Figure 5 5 Unit mm NSK TEACHING BOX EMG JEL 1 stor Connector TX20A 14PH1 D2P1 D1 Installation and Maintenance of EXEA Controller 5 Reference Number Specifications 5 3 Reference Namber 5 3 1 EXEA Controller EXEA controller is a versatile controller incorporated with a servo motor driver unit Sequence command Timer conditional jump repeat Motion command Linear interpolation circular interpolation continuos path etc Multi task operation parallel operation possible Control slave unit e g hand or end effector through general input output Program capacity 128 programs approximately 5000 steps 45000 maximum in normal use In addition to the above functions the higher level of motion control can be achieved utilizing other
68. 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 NSK Ltd declares that the Robot Module System is a machine component which is to be incorporated into the machine EC Declaration of Incorporation The Robot Module System must not be operated until it is incorporated to the machine The Robot Module System as the machine component conforms with following EC Directives EC
69. 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 Change the cable Recovered to correct one y Encoder is normal Replace the defective cable Contact your local NSK representative Did not recover 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 5 Action for Malfunction and Collision E Check for the damage following the procedure described in Figure 14 29 if severe collision occurs at the stroke end Be sure to observe all safety precautions described on Page 14 1 and 14 2 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 st
70. 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 Reset the servo parameters Improved noise vibration to the factory set No improvement 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 1 6 Troubleshooting for Rough Motion 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 eae brake ce It is possible that the brake of motor is not released oe S DraKEO motor Refer to 14 2 2 Check for Brake Function and confirm that functioning normally the brake is surely released Is the brake normal Refer to 14 1 7 Cannot Release Brake Check for mechanical back drive Abnormal Replace the module main unit Refer to 14 2 3 Check for Contact your local representative Mechanical Back Drive Are servo parameters normal Reset to the factory set or adjust them Recovered Reblace a cable normal motion Replace the defective cable P Contact you
71. 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 range set Sets resolution of pulse train input e1 10 Parameter sets a multiplying factor to pulse train input The resolution will be 0 01 mm x data 0 The pulse train input is invalid e l The resolution is obtained by a formula below Ball screw lead Encoder resolution Refer to Table 19 1 Description code for an adoption of speed reduction Pulse resolution x speed reduction ratio mm 9 3 5 2 Setting Procedure for Pulse Train Input Set the mode to the system setting mode referring to 8 2 Selection of Control Mode 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 Use P key to start the editing Use 4 and P keys to move the cursor Use o 9 numeric keys key and key to input numbers In each display screen pressing MODE key makes the screen to go one step back 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 Installation and Maintenance of EXEA Control
72. 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 O signal electrical specification Signal specification Input voltage DC24V 10 Input signal Input impedance 3 3kQ 10mA per port Output sianal Maximum switching ability DC24V 100mA per eg Maximum saturated voltage 2V or less 7 18 Installation and Maintenance of EXEA Controller 7 Wiring 7 7 2 EXT IO Signal Function Table 7 19 EXT Input Output Signal name Signal function Input Function name Output Select the program number 0 to 127 to be executed PROGO PROGS6 Input The input is referred when RUN input is on After RUN is on it may be used as a general input USER IN1 IN16 Norea Select number of units in the direct operation This Programmed operation control SREO UNEN input is referred when RUN input is on a w 3 POSNO POSN11 Input This is to select point number 0 to 3999 in the direct or POSNn USER Note 1 p operation This input is referred when RUN input is on USER Input This is for general input It can be applied to a p command using the input signal RSRV Reserved It is closed when a designated unit by its number Note 4 completes a motion Only Unit 1 is set for a single axis OUT1 OUT16 FIN1 FIN8 Output controller The time for this state is set at the ini
73. 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 gt Y Module Name Z Module Name gt R Module Name 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 Installation and Maintenance of EXEA Controller 9 Initial Setting Figure 9 15 Parameter setting procedure Unit setting Parameter setting screen Unit setting Do not set anything as this part is reserved External External control mode Menu selection screen 1 1RUN 2IO 3FNC 4etc OFF Press key Robot TYPE External External control mode Menu selection screen 2 gt Start editing Cursor is blinking U 4etc OFE Set items 1 a gt a Select setting value Press key ZMOTE a 3 Teaching box operation mode Menu selection screen 1 gt Start editing Cursor is blinking l P gt Set items Press key Y Module al Select setting value SET 1RUN 2ORG 3J0G 4etc Teaching box operation mode Menu selection screen 2 i gt Start editing Cursor is blinking
74. only Servo Filter Manual tuning Function setting ave 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 IJOB 2 m In the screen of individual parameter setting press MODE key several times to display System setting screen 1 System setting mode screen 1 TUN Press key Press key to move to system setting screen 2 System setting mode screen 2 1CLR 2SAV 33LOD 4etc Press key Press key to show the screen for Saving parameter Writing of System setting Push SET Press SET y Press key to save the parameters Writing message appears in the screen while executing saving Returns to System setting mode screen 2 when Writing is completed 9 50 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 10 2 Saving Parameters of Controller Setting 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
75. to 21 Installation for assembly procedure Figure 3 1 Teaching box Controller Module main unit Connector box Controller cable a see Installation and Maintenance of EXEA Controller 3 System Configuration 3 1 1 2 Multi axis Configuration Example of 2 axes controller 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 Use the combining brackets to combine two or more main units Use a controller cable and cable support to connect the controller and the main units The wiring of motor power encoder signal and protective ground are connected to the controller from the main unit by the controller cable The user does not need to prepare the connector box as it is provided with a cable support User s signal cable and air tube may be added to the cable support Refer to 19 3 Cable Support 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 Teaching Cable support Controller Connector box moving side Controller cable 3 2 Installation and Maintenance of EXEA Controller 3 System Configuration 3 1 2 Connecting Peripherals There are three ways to operate the EXEA controller T
76. 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 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 Confirm that the operation mode is not the external control Do not operate the system with the display shown in the left Menu Confirm that the servo on indicator on xX upper right corner of the screen is off RUN 20RG 3J0G 4etc Indicates the servo is off 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 Keep the teaching box handy to the operator for immediate termination of operation in an emergency Before starting the work check that the emergency stop circuit works
77. to the system setting mode referring to 8 2 Selection of Control Mode 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 Use A and keys to scroll the screen Use P key to start editing Use 4 gt A and Y keys to move the cursor when editing the program and selecting an axis in multi axis combination Use 4 and gt keys to scroll the cursor for editing Use o i 9 numeric keys key and key to input numbers o e key is used to set or select key word OFF etc In each display screen pressing MODE key makes the screen to go one step back For a multi axis combination you may select a unit number using and keys in the screen 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 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 Installation and M
78. too low heavy However it won t occur unless the gain setting is extremely Increase gain for heavy load deviated e Brake of module main unit is not released e Release the brake e 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 e A module main unit is interfered or defective e Investigate back drive force motor lock and interference of robot motion then remove the cause or replace unit parts if necessary e Output of motor power does not conform to specification e Refer to specification then correct or Example 200 V module is connected to 100 V power line replace the unit as required e The motor does not rotate e Check the cables and correct or replace it Examples Miss wiring of motor cable and the snapped as required wire 13 22 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 DRDY output WRN output Display of teaching box Servo is locked for one F2 Green Close Close Soft OT limit direction 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 This alarm is invalid unless Over travel parameter is set numerically The shipp
79. 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 Execute EMST command in the remote control mode 11 3 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 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 Recovery through the teaching box Press then press key in Teaching box control mode Do not press and keys simultaneously Press key after clear your finger from key otherwise you won t be able to get out from emergency stop state This procedure is invalid in the remote control mode Recovery by control input output External co
80. 0B116 Output OP11 0B117 Input Input Input Input Input Input o Signal name Function can be changed Function polarity Input IPOO IB000 EMST EMsT B Input 1P10 1B100 N1 Progo A __ UNTNO USER RSRV Yes Input Input IP10 1B101 IN2_ PRoGi A UNTNIWUSER RSRV Yes format Input IP10 1B102 N3 PROG2 A _ UNTN2 USER RSRV Yes setting Input IP10 1B103 N4 PRoG3s A usermsrv ys INP A Input_1P10 1B8105 N6 PROGS a POSNI USER RSRV Yes A Input_1P10 18107 N8 RSRV_ a posnzuser Yes a posnarsrv__ Yes user a posnsmsry yes a posnersry Yes a posnyrsrRy Yes a posnsmsry Yes a posnorsry Yes signal name Cannot change Cannot change Cannot change Cannot change Cannot change Cannot change Cannot change Cannot change Cannot change POSNO USER RSRV POSN2 USER RSRV User setting change No o Yes Yes Yes Yes Yes Yes Yes eves o A PosniorsRv_ Yes SER A POSNII RSRV__ Yes RDY B Cannotchange No USER USER USER USER USER RDY RDY WRN A Cannot change A Camotchange ys C EDM EDTM A Cannotchange Yes TexM TBXM_ A Camotchange Yes HOMS RSTAE DATWT OUT6 OUT7 OUT8 OUT9 OUT10 OUT11 OUT12 OUT13 OUT14 OUT15 gt gt gt A USER
81. 100W 2 Use NSK standard cable for the controller cable 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 Make sure that the power source voltage is compatible with the main unit EXEAD OOOOTOU Single phase AC180V 264V The driver may burn when excessive voltage shown above is applied 4 Check if FGND terminals and AC power line terminals are mistakenly connected 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 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 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 Be sure that the controller is not in external control mode Menu i j Check that the servo on indicator on upper right of aR is off RRE S iae Indicates servo is off
82. 3 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 Blank Page yi Installation and Maintenance of EXEA Controller 1 Introduction 1 Introduction 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 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 A Version number 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 20 Transportation Storage and Unpacking User s Manual 21 Installation Matters of great importan
83. 5 Turn the power off Turn off the servo then power off after the trial running The slider of a vertical axis may drop 5 10 mm when the power is turned while the servo remains on e Do not input external control signal such as servo on or Move other than emergency stop through CN3 connector while executing the trial running Before starting trial running be sure nobody is in the working area of the robot 10 2 Installation and Maintenance of EXEA Controller 11 Protection and Safety 11 Protection and Safety 11 1 Guard Fence Provide the guard fence to prevent from entry of persons during operation of the robot 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 Installation and M
84. EA controller information input of programmed operation Figure 5 2 EXEA controller 2 axes Main power input terminal Ast _ Control power input terminal 7 segments LED i E _ era oa Motor connector for 2nd axis CN1 Connector for Motor connector for 1st axis teaching box CN2 RS 232C connector EXEA Controller Type e Connect personal computer We a NSK Ltd MADE IN JAPAN Ast 2nd SENSOR SENSOR Encoder connector for 2nd axis FGND 0000000000 000000000000 00000000000 000000000000 e o Encoder connector for A 1st axis Frame ground EXT I O General I O CN3 Control I O e This is for general Input Output to control slave e Signal I O connector to control unit such as hand or end effector and for EXEA controller information input of programmed operation 5 3 Installation and Maintenance of EXEA Controller 5 Reference Number Specifications Figure 5 2 Single axis 49 5 J RY S ce seg T TB MOTORI EXEA Controller EXEA Controller m C NSK Ltd MADEIN JAPAN
85. EF Initialize to a default parameter MDC Initialize parameters to match the module main unit AT Auto tuning Reserved Press 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 CLR ALL DEF 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 9 11 2 Initialization Installation and Maintenance of EXEA Controller 9 Initial Setting of Controller Setting Parameters 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 Controller setting mode screen 1 Controller setting mode screen 2 1PMD 2INP 30UT 4etc CTR 1CLR 2SAV 3LOD 4etc Press F1 CTR C Push SET Executing Press key In the screen of individual parameter setting press MODE
86. EMST Table 7 10 Item Specification Required switching ability DC24V 10mA or over Figure 7 10 Internal DC 24V j 3 3kQ PK V Internal DC OV EXEA controller side Ti Installation and Maintenance of EXEA Controller 7 Wiring 7 5 3 3 Pulse Train Input Single axis controller only Applicable input CCWP CCWP CWP CWP Table 7 11 Item Specification Input voltage DC5V 10 Input impedance 2400 Input current 25mA or less Figure 7 11 Yak 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 Specification Maximum switching ability DC24V 100mA Saturation voltage 2V or less Figure 7 12 EXEA controller side COMO may be either plus common or minus common 7 15 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 The connector of main power supply must have sufficient capacity for required power consumption of the EXEA controller Table 7 13 Motor power 100W 200W 400W Required power capacity per axis 0 33kKVA 0 66kVA 1 5kVA Use a 1 25 mm power cable for 1 5 kVA or le
87. ER 27 PROG2 UNTN2 USER 28 PROGO UNTNO USER 29 Reserve USER 30 Reserve USER 31 Reserve USER Reserve USER 33 FIN7 USER 34 FIN5 USER 35 FIN3 USER 36 FINI USER 37 Output signal common For the singla axis controller these parts are indicated as Reserved SOO DO GOOS 8 OOOO O 2 W D Q D p 5 Q amp f 7 20 Installation and Maintenance of EXEA Controller 7 Wiring Figure 7 14 Sample wiring diagram User device Sequencer EXEA controller EXT I O rr OV 24V lt or 24V OV Internal DC 24V power supply General input COMI IN16 IN15 IN14 IN13 IN12 IN11 IN10 Ep IN9 ie 9 IN8 IN7 IN6 IN5 IN4 IN3 IN2 General output OUT16 OUT15 OUT14 OUT13 OUT12 OUT11 OUT10 OUT9 OUT8 OUT OUT6 OUTS OUT4 OUT3 OUT2 OUT1 COMO AlAIAIAIAIALA A A A A AIAIALAIA o o o o o o o o o o o o oo 0 0 eM MMMM MOMOMO 00000 0 0 0 0 00 0 0 0 OV 24V or 24V OV 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 Installation and Maintenance of
88. 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 3kQ 10 ma or less per port Figure 7 15 Vat 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 l Specification Maximum switching ability DC24V 100mA Saturation voltage 2V or less Figure 7 16 EXEA controller side COMO can be either plus or minus common 7 22 Installation and Maintenance of EXEA Controller 7 Wiring 7 8 Motor and Encoder Connectors Connect the controller cable 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 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 Motor connector
89. MODE key several times to display Controller setting screen 1 or screen 2 key twice key Press F4 key to move to Controller setting screen 3 Controller setting mode screen 3 le key Press F1 key to move the Initializing Controller setting screen Pressing key to start saving the parameters Executing message appears on the screen while executing saving 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 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 12 Readout of Parameters 9 12 1 Readout of System Setting Parameters This section describes how to read out stored parameters of system settings listed blow 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 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 System setting screen 1 System setting mode screen 1 SYS U1 1J0B 2TUN 4etc Press F4
90. Machinery Directive 89 392 as amended 94 368 and 93 44 EC Low Voltage Directive 73 23 as amended 93 68 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 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 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 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 An isolation transformer must be used to prevent electrical shock The isolation transformer must have enough capacity for the Robot Module Syst
91. Overload 1000 0FF 20 pulse This part is not used in the single axis controller This function indication does not exist in the single axis controller Installation and Maintenance of EXEA Controller 9 Initial Setting Table 9 2 Initial setting Controller setting mode Classificati assification Shipping set User setting RUN mode PRG ee es Unit setting UNT L20 R4096 NRM W100 Do not use ing MDL L20 R4096 NRM W100 Do not use L20 R4096 NRM W100 Do not use L20 R4096 NRM W100 Do not use PMD setting NOP PMD RUNmode This part is not used in the single axis controller This function indication does not exist in the single axis controller Installation and Maintenance of EXEA Controller 9 Initial Setting Table 9 2 Initial setting list controller setting mode continued Classification IP11 IB110 IP11 IB111 IP11 IB112 IP11 IB113 IP11 IB114 IP11 IB115 Input 1P11 1IB116 Input 1P11 1IB117 Output OP00 OB000 Output OP00 OB001 Output OP00 OB002 Output OP00 OB003 Output OP00 OB004 Output OP00 OB00 Output OP00 OB006 Output OP00 OB007 Output OP01 OB010 Output OP01 OB011 Output OP10 0B100 Output Output OP10 0B101 format setting OUT Output OP10 0B104 Output OP10 0B105 Output OP10 0B106 Output OP10 0B107 Output OP11 0B110 Output OP11 0B111 Output OP11 0B112 Output OP11 0B113 Output OP11 0B114 Output OP11 0B115 Output OP11
92. 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 e Check the coordinates of stopped position e Check for the position of software over travel limit 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 Does the slider stop at the same position of software over travel limit Reset the software over travel limit if it is not on the intended position Replace the controller Contact your local NSK representative 14 20 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 1 10 Communication Problem in Remote Control Mode 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 Take action referring to 13 4 Description of Alarm
93. R4096 lt gt Set an item NRM W100 Press key User modulet Number or ally Select the setting External External control mode Menu setting screen 1 External External control mode Menu setting screen 2 gt Start editing Cursor is blinking P gt Set an item NRM W100 Press key User module Number or ally Select the setting SET 4etc Teaching box operation mode Menu setting screen 1 1RUN 2ORG 3J0G 4etc a gt Press key Teaching box operation mode Menu setting screen 2 i CTR M gt Start editing Cursor is blinking L20 R4096 r Set an item NRM W100 lt gt Press key i User module8 Number or a Y Select the setting SET 3 1EDT 2TCH i Teaching box operation mode Menu setting screen 3 1sYyS 2CTR 310 4etc Press key CTR Controller setting mode screen 1UNT 2MDL 4etc Press key 7 NEEE T y MODE 1 The part in the dotted lines won t be indicated for a single axis system 9 41 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 Shipping set EMST data save NOP STOP data save NOP disturbed by power shut down ALRM data save NOP Selects op
94. a single axis system T2 This alarm does not arise in normal state Memory initialization and re programming are required when the alarm arises 13 27 Installation and Maintenance of EXEA Controller 13 Alarms 13 5 Clear Alarm 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 Alarm D Teacmng pox Remarks indication display Alarm related to Abnormal main power PI Raia powa vole power amplifier voltage Alarm related to servo motor Alarm related to contro Table 13 46 Alarm that cannot be cleared Classification Alarm LED Teaching box Remarks indication displa Overheat 1 heat sink PO Overheat 1 heatsink Overheat regeneration a a Ear fc Insufficient voltage to 8 Ctrl Power voltage control power Home return is necessar Alarm related Encoder circuit error Encoder 1 loss y after recovery to servo motor 7 FE Home return incomplete Encoder Position Memory 1 data Memory 2 backup _ Reset after initialization of Memory 3 write
95. able connector combination lt p l v Recommended Recommended cable connector KRS HA154K D09 9F25F Sanwa Supplies Personal computer D sub 9 pins for serial communication Normally O10 indicated EXEA connector CN2 7 8 Installation and Maintenance of EXEA Controller 7 Wiring 7 4 2 Making RS 232C Cable 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 Connector EXEA controller side Mating connector cable side Applicable connector shell Sumitomo 3M 10214 52A2JL Sumitomo 3M 10114 3000VE Sumitomo 3M 10314 52A0 008 Shall be prepared by user Table 7 5 CN2 signal name and function Function Function Transmit data i E aa eee Receive data Clear to send Frame ground Frame ground Signal ground el eel Ready to send ieee e Figure 7 6 RS 232C Serial port of a personal computer etc fea e eae Installation and Maintenance of EXEA Controller 7 Wiring 7 5 CN3 Control Input Output Signal Connector Wire Input Output signal to control the EXEA controller in the external operation mode EMST emergency stop input must be wired even if the system is op
96. ables while power of EXEA controller is turned on Such an action may cause short circuit and or malfunction of the controller 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 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 Push connectors to the very end firmly and secure it If a connector is provided with screws use them to secure connector If connector does not have screws make sure it is locked Take measures not to apply external force to connectors Fix connector firmly to prevent from unplugging and losing contact If a connector is not secured sufficiently it may be unplugged or loosened and may result in malfunctions 7 2 Installation and Maintenance of EXEA Controller 7 Wiring 7 2 4 Grounding The system must be grounded properly to avoid electric shock or malfunctions due to noises Be sure to ground FGND terminal of EXEA controller Refer to Figu
97. aintenance of EXEA Controller 11 Protection and Safety 11 2 Power Shut down and Recovery When the main power is shut off due to failure of the power line the EXEA controller stops a programmed operation 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 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 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 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 O 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 whe
98. aintenance of EXEA Controller 9 Initial Setting Figure 9 4 Parameter Setting Procedure Programmed Operation Setting screen of programmed operation parameter SYS JP gt Start editing Cursor is blinking 1RUN 210 3FNC 4ete ce eae Press key Locus speed External External control mode Menu selection screen 1 External External control mode Menu selection screen 2 SYS JP gt Start editing Cursor is blinking 00 5 Press F1 key Locus accel Teaching box operation mode Menu selection screen 1 SYS JP gt Start editing Cursor is blinking 1RUN 20RG3J0G_ 4etc X1200 0 1 1200 0 lt Select axis For multi axis combination only Max speed Press F4 key Teaching box operation mode Menu selection screen 2 SYS JP gt Start editing Cursor is blinking 1EDT 2TCH X35 0 i gt Select axis For multi axis combination only Max accel Press key Teaching box operation mode Menu selection screen 3 SYS JP gt Start editing Cursor is blinking 1SYS_2CTR 310 dete XOEE i lt 4 gt Select axis For multi axis combination only Finish width Press key System setting mode The setting can be OFF by E 4 P Select unit number JP gt Start editing Cursor is blinking Multi axis combination o
99. al 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 Be sure to ground the FGND terminal of the EXEA controller to prevent electric shock Refer to 7 2 4 Grounding Do not conduct an insulation resistance test or a megger test on the EXEA controller It may damage the internal circuits 9tas Installation and Maintenance of EXEA Controller 2 Safety Precautions 2 2 1 Cautions for Storing Data to Memory 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 When you need to store the data such as rewritten programs teaching data and initial parameter setting follow the relevant instructions in this manual 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 l Press key SYS S Push SET
100. alarm arises e The screen indicates Complete when the initialization is finished Press MODE to return to the selection screen of initialization Complete Press MODE key 13 30 Installation and Maintenance of EXEA Controller 13 Alarms 13 7 Monitoring Software Version and Alarm History You may check software version number and monitor history of alarm in the selection screen of function 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 Set the screen to selection screen 4 of teaching box operation mode referring to 8 2 Selection of Control Mode 3EXT 4etc Press key Selection screen of function VER 2ALM 3DAT 4etc 13 7 1 Indication of Software Version Number The display indicates version number of software by pressing key VER in the selection screen of function Figure 13 7 Screen indicating software version number Example of single axis system FNC V Typ EXE MONO Ver 0001 1VER 2ALM 3DAT 4etc FNC V Typ EXE2 Ver 0001 1VER 2ALM 3DAT 4etc 0001 0001 13 31 Installation and Maintenance of EXEA Controller 13 Alarms 13 7 2 Indication of Alarm History You can monitor history of alarm by pressing key ALM
101. allation and Maintenance of EXEA Controller 7 Wiring 7 3 2 Wiring Example Figure 7 4 Wiring example Teaching box CN1 Servo motor gt Emergency stop circuit 1 4st MOTOR R 1 4st SENSOR Encoder Internal power source _ 2nd MOTOR DC24V 2A 2nd SENSOR 4th MOTOR Master controller i operation consoles or sequencer fat SENSOR e Slave unit e Condition input unit etc Relay and solenoid Input switch i EXT I O P1 i valve etc ale elo i booo a vi Fe nput COMI General input x 16 i General output x 16 7 Output COMO i oo V FG i Relay and solenoid EXT I O P4 valve etc ei oa es Sem a a A a i E OO 0 hey nput COMI Output relay General input x 16 to ed General output x 16 Output COMO i E i FG _ i Sensor and switch i V FG 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 Noise filt 3 For the single axis controller this part shall be P2 V V 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
102. ample above Unit 2 is ignored and consequently only X axis of Unitl is considered to be exist 9 39 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 6 Parameters for Setting Module Type Reserved Do not use 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 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 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 Shipping set e A specific module type shall be set by L 05 40 L 20 four parameters below R 1000 8192 R 4096 1 Ball screw lead L mm NRM Motor direct mound NRM 2 Encoder resolution R pulse rev REV motor indirect mount 3 Motor mount direction W 100 200 400 800 W 100 4 Motor power W W User module 2 Ditto User module 3 Ditto User module 4 Ditto User module 5 Ditto User modu
103. ance of EXEA Controller 9 Initial Setting 9 5 1 Parameter List Be sure to set Module Name always according to a module main unit to be used 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 Refer to Tables 9 14 and 9 15 for specifications of a module main unit Table 9 13 Parameter list Unit setting Parameter Factory set OFF e Reserved Do not set other than OFF e Set to OFF normally even other setting is indicated USR1 USR8 XY HRSOOO PH200 XY HRSOOO PM200 XY HRSOOO PH102 XY HRSOOO PM102 XY HRSOOO PH100 XY HRSOOO PM100 XY HRSOOO PH212 XY HRSOOO PM212 XY HRSOOO RH200 XY HRSOOO RH102 XY HRSOOO RH202 XY HRSOOO RH204 XY HRSOOO RH208 XY HRSOOO RH405 XY HRSOOO RH409 XY HRSOOO RH207 XY HRSOOO RH211 XY HRSOOO RH206 XY HRSOOO RH210 XY HRSOOO RH407 i XY HRSOOO RH411 X Module Name e Input a type of module main unit for X axis XY HRSOOOD RM200 OFF XY HRSOOO RM204 XY HRSOOO RM208 XY HRSOOO RM405 XY HRSOOO RM409 XY HRSOOO RM134 XY HRSOOO RM234 XY HRSOOO RM238 XY HRSOOO RM238 XY HRSOOO RM242 XY HRSOOO RM239 XY HRSOOO RM243 XY HRSOOO RM439 XY HRSOOO RM443 XY HRSOOLO RS104 XY HRSOOL RS108 XY HRSOODO RS204 XY HRSOOLO RS208 XY HRSOOL RS106 XY HRSOOL RS110 XY HRSOOL RS138 XY HRSOOLD RS142 Type OFF OFF Y Module Name e Input a type of module main un
104. ated or control output DATWAT CNS is closed during saving data to memory 14 22 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 1 12 Heating Problem 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 Ambient temperature shall be under 40 C The motor may not be operated under continuous rated output if Is ambient temperature the ambient temperature is over 40 C lower than 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 C 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 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 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 Is ambient temperature of controller less than 50 C 1 Total power loss of EXEA con
105. ation deceleration amplifier software thermal normally the overload output stage alarm will be given before the overheat is detected e Defective thermal sensor or snapped e Replace the controller internal wiring Contact your local NSK representative e High ambient temperature e Lower ambient temperature e Regenerative energy is too much to be e Lower the load processed by the external dump resistor e Decrease acceleration deceleration This leads to overheat Long stroke and or high load of the vertical High acceleration deceleration and frequent accelerating decelerating e Defective thermal sensor optional or e Replace the thermal sensor or the snapped internal wiring controller e Install external dump resistor Contact your local NSK representative Regenerative dump resistor Contact your local NSK representative 13 8 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 2 Abnormal Main Power Voltage 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 DRDY output WRN output Display of teaching box Servo off Main Power voltage This function is to monitor the voltage of the main power system and give an alarm if main power voltage exceeds the criteria There are two types of mai
106. axis 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 Coasting 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 Interpolation 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 Work piece An object of robot operation such as machining assembly pick and place packing sealing and transporting End effector A tool which manipulates work pieces Hand or another additional devices attached to the robot module to perform its tasks EMC Electromagnetic compatibility of noises To comply to EMC measures against EMI electromagnetic interference Emission and EMS electromagnetic sensitivity Immunity must be taken Flash memory Non volatile memory which stores all memories without any back up of electric power 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 environmen
107. ber Prior to set the 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 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 Installation and Maintenance of EXEA Controller 9 Initial Setting Figure 9 11 Parameter setting procedure Manual tuning Parameter setting screen for manual tuning SYS TM gt Start editing Cursor is blinking MANU 1RUN 210 3FNC 4etc Select a mode Press key gain Mode External External control mode Menu selection screen 1 External External control mode Menus selection screen 2 TESI gt Start editing Cursor is blinking 4etc lt gt Select axis For multi axis combination only Position Loop Gain Press key Teaching box control mode Menus selection screen 1 ES gt Start editing Cursor is blinking 1RUN 20RG 3J0G 4etc 4020 0 020 0 lt Select axis For multi axis combination only Velocity Loop Gain Press Fa key Teaching box control mode Menu selection screen 2 sys gt Start editing Cursor is blinking xo10o 0 axi 1EDT 2TCH b P Select axis
108. bleshooting 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 An alarm is on when the Program error or other alarms z Refer to 13 4 Description of robot is operated Alarm and take required actions e Excessive position error e Overload Overload alarm shall be reported sometime after starting operation Check the back drive force of mechanism Abnormal Replace the module main unit Refer to 14 2 3 Check for Mechanical Back Drive Contact your local NSK representative Check for snapped controller cable Examine wiring of those cables Abnormal Replace controller cable Contact your local NSK representative 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting Be sure to observe all safety precautions described on Page 14 1 and 14 2 Figure 14 4 Does not move ent
109. bot module system otherwise it may cause serious accident 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 Normal operation cannot be expected Make sure for connections because a wrong connection may cause a defective controller and module main unit Assure that there is no mechanical interference when all module main units make their full stroke 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 Installation and Maintenance of EXEA Controller 8 Startup 8 1 2 Checks When Turning on Power Turn on power 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 NSK CONTROLLE Indicates information of software of the system teaching box Typ EXE Typ SE X Bik kK Indicates the type of controller EXE MONO Single axis control
110. ccel operation 9 3 3 2 Parameter Setting Procedure Jog Operation Set the mode to the system setting referring to 8 2 Selection of Control Mode 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 Use A and keys to scroll the screen Use P key to start the editing Use 4 gt A and Y keys to move the cursor when editing the program and selecting an axis in multi axis combination Use 0 9 numeric keys key and key to input numbers o key is used to set or select key word OFF etc In each display screen pressing MODE key makes the screen to go one step back For a multi axis combination you may select a unit number using 4 and keys in the screen 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 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 Installation and Maintenance of EXEA Co
111. ce User s Manual 1 1 Introduction We urge you to read it Wiring Start up gt Initializing Trial running Tuning Adjustment gt Programming User s Manual User s Manual User s Manual User s Manual User s Manual User s Manual User s Manual User s Manual User s Manual User s Manual User s Manual User s Manual User s Manual User s Manual User s Manual 2 Safety Precautions 3 System Configuration 4 Glossary 5 Reference Number Specifications 19 Reference Number Specifications 7 Wiring 18 Remote Control Operation 8 Start up 9 Initial Setting 18 Remote Control Operation 10 Trial Running 11 Protection and Safety 15 Programming 16 Description of Function 18 Remote Control Operation Operation of robot User s Manual 2 17 Operation User s Manual 18 Remote Control Operation eg Maintenance Troubleshoot maintenance and checking User s Manual 12 Maintenance Checking User s Manual 13 Alarm User s Manual 14 Troubleshooting User s Manual 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 i
112. ce as the dynamic brake is functioning Move it slowly 14 27 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 3 Check for Mechanical Back Drive Be sure to observe all safety precautions described on Page 14 1 and 14 2 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 e The moving part is interfered by an obstacle e 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 e There are unsteady spikes and variation of ball screw rotating torque which the operation by motor may not overcome e It gets heavier at the end of stroke e It makes abnor
113. clusive controller cable for the robot module system MOTOR e Motor connector is available Refer to 19 2 Controller Cable common to P and R series module main unit for its reference number SENSOR Je Encoder connector e See Appendix 1 Motor Connector and Appendix 2 Encoder Sensor Connector for connector specification e Be sure to ground the EXEA controller BGI S eee ce onne terminal e Refer to 7 2 4 Grounding e Connector for RS 232C communication CN2 e A control Input Output CN3 connector to control EXEA controller externally e e CN4 CN5 EXT I O e General Input Output connector ey ey eee Installation and Maintenance of EXEA Controller 7 Wiring 7 2 Precautions for Wiring 7 2 1 Making Cables When making cables and selecting parts for the cables follow the instructions described in the chapter for each connector 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 miss wiring 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 We do not compensate for damages or accident induced by miss wiring by user 7 2 2 Connection of Cable Do not disconnect c
114. ctor o provided with EXEA controller A Module main unit External control equipment sensors Shall be provided by the user e Sequencer e O control box e Sensors e Switches etc To main power source Emergency stop circuit Frame ground You can operate the robot system through the external equipment You need the teaching box for initial setting programming and tuning 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 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 Installation and Maintenance of EXEA Controller 3 System Configuration Remote control operation Refer to 18 Remote Control Operation for more details Figure 3 5 e The part to be connected always The part to be connected when required EXEA controller Teaching box optional T or Si Dummy connector _ provided with EXEA controller A Module main unit RS 232C cable optional
115. d 4 axes controller Photo 12 5 Indication of screws to be removed 1 Screw M3 cross recessed countersunk head screw Screw M3 cross recessed countersunk head screw Screw M3 cross recessed countersunk head screw Screw M3 cross recessed countersunk head screw Screw Screw M3 cross recessed countersunk head screw M3 cross recessed countersunk head screw Photo 12 6 Indication of screws to be removed 2 Screw M3 cross recessed countersunk head screw Screw D M3 cross recessed countersunk head screw Screw M3 cross recessed countersunk head screw Screw M3 cross recessed countersunk head screw Screw M3 cross recessed countersunk head screw Screw 4D Screw M3 cross recessed countersunk head screw M3 cross recessed countersunk head screw 12 5 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 lt Single axis controller gt 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 S 4 Fix the new battery with the fixing band and connect the connectors firmly 5 Attach the cover 12 6 I
116. data of internal memories When this alarm arises the EXEA controller terminates its operation immediately and the motor gets in the servo off state Turn on power again for recovery Table 13 24 Cause e A large inrush current intruded into the control board caused memory circuit malfunction and resulted in the memory destruction Remedy e 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 13 16 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 11 Memory Error 2 Table 13 25 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo off Memory 2 backup 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 When this alarm arises EXEA controller terminates its operation immediately and the motor gets in the servo off state Initialize the memory then input program and conduct teaching data of point register Refer to 13 6 Initialize Memory I
117. dule 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 e 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 e 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 Set properly Is any alarm on to lead to If the servo is off when the slider is moving it coasts by servo off 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 Is Servo off command the servo is off inputted 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting Be sure to observe all safety precautions described on
118. e Refer to 9 1 Initial Setting Procedure and scroll the display screen to Output signal format OUT setting screen as shown below eu eU eu eU Controller setting mode CTN gt OUT setting OUT Each parameter setting se A and Y keys to scroll the screen se gt key to start the editing se 4 and gt keys to scroll the cursor for editing se o 9 numeric keys key and key to input numbers e key is used to set or select key words OFF etc In each display screen pressing MODE key makes the screen to go one step back The parameters in this section have no relations with the Unit number Disregard the Unit numbers which appears in the parameter screens 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 Installation and Maintenance of EXEA Controller 9 Initial Setting Figure 9 20 Parameter setting procedure Output signal format Setting screen Output signal format ei P gt Start editing Cursor is blinking 1RUN 210 3FNC 4etc RDY P gt Select an item Select setting Press Rey Output OP00 ne ally g SET External External control mode W Menu selection screen 2 External External control mode Menu selection screen
119. e an axis not specified 13 26 Table 13 45 Teaching box display Prg Origin not exe Can t make path Without CPS Undefined cmnd Can t restart R Prg not found Task full Unit offline Axis overlap Over travel Alarm Undefined PRG Duplicate PRG Undefined PAL Duplicate PAL Not Init PAL overlap PAL Without CHLD Cmnd mismatch Can t make mov Installation and Maintenance of EXEA Controller 13 Alarms Program Error 2 2 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
120. e home position matching to the slider position after the Home return 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 Home position Mechanical stopper Procedure 3 Trial running by jog operation Execute the jog operation through the teaching box Refer to 17 3 2 Jog Operation in the teaching box operation Confirm that all module main units operate smoothly If not adjust the parameters again referring to 9 Initial Setting wes Next page 10 1 Installation and Maintenance of EXEA Controller 10 Trial Running Procedure 4 Set detecting position of software over travel limit 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 Set the positions inside of mechanical stoppers on the motor side and opposite to the motor side 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
121. e 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 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 The magnetic brake is a negative type The brake engages when the current to the brake is off Refer to Appendix 1 Motor Connector for the wiring of the magnetic brake 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 The dynamic brake does not function if controller cable is disconnected EXEA controller and a main unit are not connected 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 Disconnect controller cable to cancel dynamic brake function Be sure to connect the controller cable properly when connect it again 11 3 4 Detection of Over Travel You can set and monitor the software over travel limit based on the absolute c
122. either Locus accel or Max accel is valid e Sets the detecting criteria of position error width for completion of positioning Finish width 2 When the deviation of error counter falls in the set range FIN ma 0 0 99 99 OFF output is closed OFF e FIN signal closes when the pulse generation motion command is 0 1 35 0 35 0 3 One Outputs FIN signal when either one of the operating axes completes positioning not waiting for completion of other axis All Outputs FIN signal when all axes complete positioning e Setting of FIN output Finish mode completed if this parameter set to OFF e Defines the detecting format of completion of positioning ONE ALL ALL OFF ON OFF Fin control ON Outputs FIN signal OFF Does not output FIN signal e Sets time length for FIN output is being on FIN spec 0 0 99 99 pa parE OFF Hold FIN outputs till next motion z OFF ue 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 positi
123. em power consumption Install noise filter in the primary AC power line as a measure for Electromagnetic Compatibility Directive A circuit breaker must be installed to the primary AC power line of Robot Module System Ground earthing must be provided to EXEA controller Wiring inside of EXEA controller is simply internal wirings and the grounding wire is not distinguished by color as the protective grounding conductive Secure the controller cables and motor cables firmly so that those cables do not break or have loose contact Surround the machine to which the Robot Module System is incorporated with safety fence to prevent any personnel from entering its moving range Unit Limitation Units of Robot Module System which conform to EC Directives are limited to the following reference number only 1 EXEA controller Reference No M EXEAO OOOOTOO t T Indicates conformity with the Directive 2 Teaching Box Reference No M EXTB 04 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 Contents Introduction 1 1 1 1 Notes for Safety 1 2 1 2 General Description 1 2 1 3 Notes to Users
124. erated 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 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 Connector EXEA controller side Mating connector cable side Mating connector shell type cable side Provided with EXEA controller as an accessory 7 5 1 Precautions for Wiring CN3 Be sure to use shielded cable and ground the shield When connect a relay to an output signal install a surge killer to the relay Lay the CN3 signal wiring apart from the power lines main power line cable motor cable Do not put them in the same conduit Make CN3 cable short as possible 3 meters or less If a longer cable is required take proper measures against external noises Disobedience to the instructions above may result in malfunction or memory data corruption due to noises Follow the electric specification shown in Table 7 7 below In particular any of the following three issues may lead to breakage of elec
125. eration start format RUN mode PRG Selects programmed operation PRG POS Selects direct operation Refer to 17 5 2 Resume Programmed Operation to resume operation 9 7 2 Parameter Setting Procedure PMD Setting Set the mode to the controller setting referring to 8 2 Selection of Control Mode Refer to 9 1 Initial Setting Procedure and scroll the display screen to PMD PMD setting screen as shown below Controller setting mode CTR gt PMD setting PMD Each parameter setting Use A and keys to scroll the screen Use P key to start the editing Use o 9 numeric keys key and key to input numbers e e key is used to set or select key words OFF etc In each display screen pressing MODE key makes the screen to go one step back The parameters in this section have no relations with the Unit number Disregard the unit numbers which appears in the parameter screens 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 Figure 9 18 Parameter setting procedure External 1RUN 210 3FNC 4etc External control mode Menu setting screen 1 Press key External 4etc External control mode Menu setting screen 2 Press key 1RUN 20RG
126. ernal 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 The following shows the noise resistance of the EXEA controller itself Table 2 1 1000V Ips Specification Remarks Line noise resistance Static noise resistance Checked by a noise simulator 2 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 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 Tf 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 Set the system parameter in accordance with the type of module main unit
127. ess key NRM in the I O indication selection screen to return to the screen of input port status 14 33 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 6 2 Indication of Output Port Condition Status screen of output port appears when key OUT is pressed in the I O indication selection screen O appears next to I O in the screen State of four output ports are shown in the second and third line Use lt 4 A and Y keys to scroll the cursor The first line indicates the name of the port of which bit are selected by the cursor When there are four or more output ports use LA 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 Functions and the composition of indications are the same as the screen of input port status However pressing 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 0 0 RDY 00 00110000 00000000 10 00000000 00000000 1CHK 3USR i Press key I O 0 RDY Switch ON and OFF of the bit temporarily on which the 00 00110000 00000000 cursor is put using 0 and 1 keys 10 00000000 00000000 1CHK 3SYS 0 Put the port off Put the port on 0 is
128. eters for Unit Setting to set the unit number 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 Installation and Maintenance of EXEA Controller 9 Initial Setting Figure 9 5 Parameter Setting Procedure Home Return Parameter setting screen of Home return SYS JO gt Start editing Cursor is blinking 0020 0 1RUN 210 3FNC 4etc Press key Home apero External External control mode Menu selection screen 1 External External control mode W Menu selection screen 2 SYS JO gt Start editing Cursor is blinking 00 5 Press key Home accel ni Teaching box operation mode lv Menu selection screen 1 SYS JO gt Start editing Cursor is blinking 0001 0 1RUN 2ORG 3J0G 4etc Home search speed Press key E Teaching box operation mode Menu selection screen 2 gt Start editing Cursor is blinking 1EDT 2TCH z lt Select axis For multi axis combination only Press F4 key Teaching box selection mode Menu selection screen 3 gt Start editing Cursor is blinking 1SYS_2CTR 310 4etc oe lt gt Select axis For multi axis combination only Press F1 key
129. f the program e In circular circular arc interpolation and continue path the data is not properly set Examples Four axes coordinates data are set to the point registers Required data is not specified Only one axis coordinates data is set etc e Teaching data of axis unit is mismatched the combination of XY and XZ is mixed up etc e The set data exceeds upper or lower limit e Decimals are set to a data to which only an integer can be set e A TAG which is designated as the destination of Jump is not set in the same program e Several TAGS with the same name exist in the same program e The nesting of CALL command are 5 or more Allowable nesting loop is four or under e Attempted to execute REP command before CALL command is set e The nesting of REP command are 5 or more Allowable nesting loop is four or under e Attempted to execute NXT command before REP command is set Cannot execute circular circular arc interpolation due to following reasons e Attempted an interpolation which includes an moving axis in a multitask operation e Designated three points are not on a circle or arc Example They make a line e Starting point of circular circular arc interpolation and current position are different in ABS coordinate format e Omitted the starting point in INC coordinate format e Attempted to execute MOVE command in servo off state Start operation again after turn on the servo e Attempted to execute a command to us
130. ff AO Ornice Open Ose Encoder 1 Snapped encoder wiring or abnormal error loss signal Overload Servo off A3 Orange Open Open Thermal Motor ops ratineddty e Kengdsthe rated value Motor exceeded its maximum Speed abnormal Servo off A4 Orange Open Open Speed rotational speed Home return Normal Encoder 2 Coordinate cannot be set as Home AS Green Close Close ae ee incomplete operation Position position is not defined Encoder 3 Encoder data is lost due to low Battery error Servo off A7 Orange Open Open voltage of battery for encoder back battery up AO is reported simultaneously Memory 1 __ Inrush noise has destroyed data of Memory 2 External noise has destroyed Memory error 2 Servo off El Orange Open Open i y memory back up for parameters and backup dais Memory error 3 Servo off E2 Orange Open Open Memory Se Ratlie to waiter bac te up dale iine write flash memory Memory error 4 Servo off res Open Open oe 4 External noise changed contents of oe system program Cpu CPU error Servo off Not or Onge Opa Ope External noise caused CPU or a pnafimenon Varna ae eas ae Combination of motor and power System error Servo off E7 Orange Open Close System i p amplifier has changed Eyte iva Position error in the differential error a Servo off F1 Orange Open Open Position Error counter have exceeded the set value position error to detect excessive error
131. 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 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 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 Remedy e The coordinate setting does not meet stroke end position or e Execute Home return and check the relation of coordinates between the motor and encoder is coordinates again shifted due to sudden noise disturbance e The slider is locked by external obstacle e Remove the obstacles by Jog or servo off e Load that brings torque exceeding the motor capacity is e Decrease load applied to the robot e Relax acceleration and deceleration 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 Do not set the tra
132. ge regeneration of servo motor continues the regenerative dump resistor will be overheated and an overheat alarm will arise 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 When a module main unit is connected to an EXEA controller the dynamic brake functions under servo off or power off condition When moving the slider manually you feel some resistance However this is not an abnormal phenomenon Dynamic brake does not function if the controller cable is disconnected 2428 Installation and Maintenance of EXEA Controller 1 Introduction Blank Page Installation and Maintenance of EXEA Controller 2 Safety Precautions 2 Safety Precautions 2 1 Robot Module System 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 u
133. he unit number 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 Installation and Maintenance of EXEA Controller 9 Initial Setting Figure 9 7 Parameter setting procedure Position and coordinates External 1RUN 210 3FNC 4etc External control mode Menu selection screen 1 Press key External External control mode Menu selection screen 2 4etc Press key 1RUN 2ORG 3J0G 4etc Menu selection screen 1 Press key 1EDT 2TCH Menu selection screen 2 Press key 1SYS 2CTR Teaching control mode Menu selection screen 3 310 4etc Press key 1JOB 2TUN System setting mode 4etc Press key 1PRG 2ORG 3006 Press key Teaching box control mode Teaching box control mode lt Select unit number Multi axis combination only Operation parameter setting mode Setting screen of parameter for Position and Coordinates Over travel a ly Over travel a lv SYS JL 0000 00 Escape upr gt Start editing Cursor is blinking lt gt Select axis For multi axis combination only Pressing L makes the setting OFF gt Start editing
134. his 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 The part to be connected always The part to be connected when required EXEA controller EXEA Controller Module main unit External control equipment sensors Shall be provided by the user ve Sequencer e O control box e Sensors e Switches etc To power line Frame ground All operations initial setting programming and operation can be done through the Teaching box 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 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 e The part to be connected always The part to be connected when required EXEA controller Teaching box optional 7 or r 0 Dummy conne
135. hough servo lock is effected Precaution when the system does not move entirely even the servo can be effected e 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 e 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 SAT Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 1 3 Troubleshooting for Home Return 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 lt a 3 NO Rectify the problem referring to 13 4 Recovery from Alarm Can you start the system NO YES Refer to 14 1 2 Operation Problem of the System Can you complete Home return NO YES 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 y The followings are n
136. ication 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 The application software is for programming setting parameters and data backup Figure 5 8 Reference number M EXTA02 5 3 4 RS 232C Cable 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 The connector of the personal computer side must be a D sub25 pin standard connector male but not for half pitch The user shall provide a cable matcher in accordance with your perusal computer specification beyond D sub25 pin 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 Installation and Maintenance of EXEA Controller 6 Unpacking and Installation 6 Unpacking and Installation 6 1 Cautions for Transporting and Storage Do not apply shocks to the module components during transportation 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 The robot module is not provided any specia
137. in the selection screen of function Indication of history Refer to Table 13 49 for details In the second line History number alarm code and alarm detection code In the third line Name of alarm Smaller history number indicates newer alarm Use Y to scroll history of alarm Use 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 FNCJA 01 A5 U1XY Encog r2 position 1VER 2ALM LOIR 2AMP U1XY gt Alarm is on for X and Y axes of Unit1 A12 Alarm is on for Amplifier 1 and 2 TEENCIJA por as ai2 _Encoder2 position 1CLR 2AXS Press key CLR in the indication screen of alarm history to clear the alarm history 13 32 Installation and Maintenance of EXEA Controller 13 Alarms Table 13 49 Contents of alarm history Classification of a ye Contents indication e 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 e Following alarms will be listed on the alarm history every time these alarms are reported as they are critical ones History number F4 Emergency stop P1 Abnormal power supply P3 Abnormal control power P4 Regeneration resistor overheat EO E3 and
138. in 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 6 Monitoring I O Get the menu selection screen 3 in the teaching box operation mode referring to 8 2 Selection of Control Mode When 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 keys for selection 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 1SYS 2CTR 310 4etc i l Press key I O 1INP 20UT 3MEM 4etc Press F4 key 1LMT 2BRK 14 31
139. ing se 4 and gt keys to scroll the cursor for editing se o 9 numeric keys key and key to input numbers e key is used to set or select key words OFF etc In each display screen pressing MODE key makes the screen to go one step back The parameters in this section have no relations with the Unit number Disregard the Unit numbers which appears in the parameter screens 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 Installation and Maintenance of EXEA Controller 9 Initial Setting Figure 9 19 Parameter setting procedure Input signal format Setting screen Input signal format CTR I P gt Start editing Cursor is blinking 1RUN 210 3FNC 4etc EMST gt Select an item Select setting ides Rey Input IP00 a a Y g SET External External control mode W Menu selection screen 2 External External control mode Menu selection screen 1 CTR I gt Start editing Cursor is blinking SVON lt gt Select an item Press key Input IP00 IB001 Al Select setting SET 4etc Teaching box operation mode Menu selection screen 1 1RUN 2ORG 3J0G 4etc Press key Teaching box operation mode Menu se
140. ing of motor mount does not conform to module main unit or parameter of reverse direction of minus minus direction is set gt 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 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 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
141. ing set is OFF This function is invalid unless Home return is completed and the coordinates are set 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 e Improper setting of parameter Over travel e Set parameter properly e Current position is in software over travel limit e Get out from the limit range 13 23 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 18 Travel Limit Mechanical lock Table 13 39 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo is locked for one F3 Green Close Close Hard OT limit direction 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 This alarm may occur due to extremely heavy load exceeding specification limit as well In such a case relax acceleration and deceleration and lower the load to fit into specification When this alarm arises EXEA controller terminates its operation immediately and the motor gets in servo lock state
142. ion screen 1 gt Start editing Cursor is blinking 1RUN 20RG 3J0G 4etc J lt gt Select axis For multi axis combination only Notch Filter Press F4 key Teaching box control mode Pressing C makes the setting OFF Menu selection screen 2 1EDT 2TCH 3 Press key Teaching box control mode Menu selection screen 3 1syS 2CTR 310 4etc Press key SYS System setting mode lt Select unit number Multi axis combination only 1JOB 2TUN 4etc Press key SYS T Servo parameter setting mode 1SRV 2FIL Press key 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 9 27 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 4 3 Parameters for Manual Tuning 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 ove
143. irely Troubleshooting 3 Display shows the system is in normal state Does not run entirely No alarm is reported Display is showing normal state s thaseniologkedo 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 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 Is the servo locked yw YV Check again that if the operation procedure is appropriate when you cannot operate the system V even the servo lock is performed mode the following defects are considered If servo lock is not performed in any operational e Defective main unit Defective motor or coupling e If operation by teaching box control mode is Snapped motor power cable normal the system must function normally when Defective controller Motor drivers no alarm is given Contact your local NSK representative e 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 Defective interface is suspected when servo is not functioning even the servo is locked in cannot be locked in external control mode external control mode
144. is combination other than U1 are set make a list for each unit and record the respective settings 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 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 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 U1 1CLR 2SAV 3SAV 4etc Press key SYS U1 Push set Press key SYS U1 e The display indicates Writing while the parameters are being saved Writing Do not turn the power off while saving data Make sure that the servo is inactive while the system parameters are being set Do not press the key of the teaching box The system parameters include ones that change settings of coordinates system On completion of
145. is miss connected to improper motor driver unit 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 Connect the main unit to a proper driver unit We set limit level of software thermal as a shipping set Do not change the setting 11 3 7 Protection from CPU Malfunction The alarms of EXEA controller is managed by software 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 Installation and Maintenance of EXEA Controller 12 Maintenance Checking 12 Maintenance Checking 12 1 Maintenance We recommend to prepare the back up parts for quick recovery from unexpected break down of the system Write down all parameter settings and keep the notes in case of system failure Refer to 9 2 Initial Setting List for setting of the parameters 12 1 Installation and Maintenance of EXEA Controller 12 Maintenance Checking 12 2 Checking Check the parts periodically and replace them if necessary for prolonged use of the rob
146. it for Y axis OFF a a Z Module Name Input a type of module main unit for Z axis Ditto 7 It is not necessary to set for a two axes controller 4 R Module Name Input a type of module main unit for R axis Ditto 7 It is not necessary to set for a two and three axes controller 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 Installation and Maintenance of EXEA Controller 9 Initial Setting Table 9 14 Specifications for P type module main unit Reference number Motor power Ball screw lead Motor mounting direction Negative actuation w mm motor brake o Deoa ae Indirect back mount ET E a 20 O Drea XY HRSOOO PM a 100 e E mount Table 9 15 Specifications of R type module main unit Reference number Motor power Ball screw lead Motermountingsliracton Negative actuation W aml motor brake Indirect right Indirect left sS XK cee AO a es NOt right a es aes ne Ines nes PARSER A Ca naan coe ee XY HRSOoOoO cRS ees Sena SPE ______Indirect right__ See cane eee ce d EMPRESA Indirect left OT alll 2 Un EI NE are a el Mt Indirect left v PEE Oy td ot ad Direct a Os ts ee td el aa ete op allie
147. l 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 Unpack all containers and check for damages on products and missing parts 2 Check with ordered reference number See Figure 5 6 Reference number configuration of EXEA controller and check that the affixed seal on the controller corresponds to your order Data indicated on seal Type Reference number without M is indicated on the seal Last numbers 01 indicate its version The numbers will be changed following its upgrading No Serial number Check accessory Table 6 1 is the list of the accessories which are provided with the controller Table 6 1 Name of part Quantity Remarks Dummy connector for e This connector is used as a dummy connector when 1 teaching box operating EXEA controller without the teaching box Control O Connector e Cable connector and connector shell for CN3 eet and connector shell connector of EXEA controller General O connector e Cable connector and connector shell for EXT I O Mein Seis for ption and connector shell connector of EXEA controller bet e soe munum forithe single axis controller Control power connector 2 sets for 3 and 4 axes and connector shell control power connector
148. le 6 Ditto User module 7 Ditto User module 8 Ditto This is not indicated for a single axis system User module 1 9 6 2 Parameter Setting Procedure Module Type Set the mode to Controller setting referring to 8 2 Selection of Control Mode Refer to 9 1 Initial Setting Procedure and scroll the screen as shown below Controller setting mode CTR gt Module setting mode MDL gt Each parameter setting Use A and keys to scroll the screen Use gt key to start editing Use 4 gt A and to move the cursor when editing and selecting an axis in multi axis combination Use o gt 9 and keys to set numbers o e is to be used to set or select keywords OFF etc 9 40 Installation and Maintenance of EXEA Controller 9 Initial Setting Pressing MODE key switches to the screen backward in each display screen These parameters do not have any relations with the unit number Ignore the unit number on the parameter setting screens 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 CTR M gt Start editing Cursor is blinking 1RUN 210 3FNC 4etc L20
149. lection screen 2 et eae A 1EDT 2TCH CTR I gt Start editing Cursor is blinking USER D lt gt Select an item Input IP11 IB117 Al Select setting SET Press key Teaching box operation mode Menu selection screen 3 1syS 2CTR 310 4etc Press key CTR Controller setting mode screen 1 1UNT 2MDL 4etc MODE Press key CTR Controller setting mode screen 2 1PMD 2INP 30UT 4etc Press key There will be no indication in the dotted lines for a single axis system 9 46 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 9 Parameters for Output Signal Format 9 9 1 Parameter List Switches function and polarity of input port Polarity A Normally open Polarity B Normally close Indication of input port Example Output OP00 OB00 0 Va Output Output port No Output bit No Table 9 19 Parameter list Output signal format Ga Shipping set polarity polarity B WRN ans ER od eed Od ed iriiria jle Yes P1 EXT I O Yes USER OUT16 USER RSRV USER This part won t be indicated for a single axis system 9 47 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 9 2 Parameter Setting Procedure Output Signal Format Set the mode to the controller setting referring to 8 2 Selection of Control Mod
150. ler 9 Initial Setting Figure 9 8 Parameter setting procedure Pulse train input Setting screen for Pulse train input External 1RUN 2IO 3FNC 4etc External control mode Menu selection screen 1 Press key External 4etc External control mode Menu selection screen 2 Press key 1RUN 20RG 3J0G 4etc Teaching box operation mode Menu selection screen 1 Press key 1EDT 2TCH 4etc Press 1sYyS 2CTR 310 4etc Teaching box operation mode Menu selection screen 2 key Teaching box operation mode Menu selection screen 3 Press key SYS 1JOB 2TUN 4etc System setting mode ODE Press key SYS J 1PRG 20RG 3J0G 4etc Operation parameter setting mode ODE Press SYS J 1LMT 2TPL 4etc Press key SYS JT X 01 Pulse resolution 9 22 gt Start editing Cursor is blinking Installation and Maintenance of EXEA Controller 9 Initial Setting 9 4 Servo Parameters These are tuning parameters of EXEA controller such as servo gain and filters 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
151. ler 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 Ver 0001 KKKKKKKK KKKKKKKK lt Note Though 0 zero and 1 one are displayed at the start it is not abnormal Y External Indicates External automatically RUN 210 3FNC 4etc Press MODE key to get in External immediately Eliminate cause of an alarm referring to 13 Alarms and 14 Troubleshooting when an alarm is detected 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 External Indication of teaching box display ALARM A5 1 ncoder2 position RUN 210 3FNC 4etc E Es Installation and Maintenance of EXEA Controller 8 Startup 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 MOTORI o Zia 5l EXTIO fo
152. lifier or CB board is replaced to repair the controller 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 Remedy e Replace the controller Contact your local NSK representative e Initialize EXEA controller Cause e Defective amplifier disturbs to identify the types e System configuration has been changed due to replacement of controller or exchanging hardware 13 21 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 16 Excessive Position Error Table 13 35 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo off Position Error 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 This alarm is to give the warning that the position control is disturbed for some reason mechanical interruption to module main unit etc EXEA controller terminates its operation immediately when this alarm arises and the motor gets in servo off state Table 13 36 Cause Remedy e Improper setting of POS err over parameter e Set correctly Reset to the shipping set e Improper gain setting e Optimize gain setting Generally this alarm tends to occur when position gain is set Reset to the shipping set if the load is not
153. ll input signals other than EMST is not accepted 7 12 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 j E Tu Se 24V ov 6 RSA e svon A 10 cwe 29 CWR 11 CCWP 30 CCWP eo o QIQ A i AJAJAJA A eeeee 0 OOII ov 24v lt Frame ground The wiring in the dotted area are for a single axis controller only Do not wire them for a multi axis controller 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 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 Specification Input voltage DC24V 10 Input impedance 3 3kQ Input current 10mA or less per port Figure 7 9 Abst 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
154. ller e Necessary to control an EXEA controller through remote control mode personal computer communication control or through use Should be provided by user of application software S e Connect an EXEA controller and personal computer for R9220 cable communication control and for use of the application software Ahonld De p orined by Wirt Power supply cable e Connect main power line to the EXEA controller Should be provided by user Use the shielded cable for CN3 Control I O cable EXT general I O cable and RS 232C cable Personal computer 37 Installation and Maintenance of EXEA Controller 3 System Configuration Blank Page Installation and Maintenance of EXEA Controller 4 Glossary 4 Glossary Safeguard 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 Safety speed 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 Moving speed 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 Motion acceleration deceleration Acceleration and deceleration of moving member of the robo
155. ller side Mating connector cable side Mating connector shell type cable side Figure A 2 Pin out j ENC_PWR ENC_RST ENC_BAT N C N C N C N C N C N C N C N C N C OJOSIOIVIOIOIOIOIOIOIOO N C N C A E Oaa aa Oe A 2 Installation and Maintenance of EXEA Controller Appendix Table A 6 Pin out and signal Pin Function F GND Sil Frame ground Do not connect Encoder power Encoder signal A Encoder signal B Encoder signal Z Reset encoder ONC Do not connect 9 Nc Do not connect 10 Nc Do not connect 11 Nc Do not connect 12 NC Donotconnect 13 Nc Do not connect 4 Do not connect 15 Do not connect 16 DGND Signal ground 17 Encoder signal A 18 B input __ Encoder signal B 19 Encoder signal Z 20 Battery power 21 Nc Donotconnect 22 NC Donotconnect 23 Nc Do not connect 24 Nc Donotconnect 25 ONG o e Do not connect Table A 7 Encoder input signal CON OD or BR orm Item Specification DCSV 10 DC5V power output 250mA Input format Deferential line receiver Used line receiver TI SN75175NS or equivalent Deferential mode input thrush hold voltage 0 2V Input impedance 2200 Maximum common mode input voltage 12V A 3 Installation and
156. mal noise sounds like hitting mechanical parts Normal Is back drive force normal Abnormal If other troubles exist for which the main unit is not responsible take appropriate measure against it e 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 itis 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 4 Abnormality of Encoder Signal Be sure to observe all safety precautions described on Page 14 1 and 14 2 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 It is abnormal that the coordinate data indication is unstable in servo off state under no effect of external force Are the coordinate data stable 4 Move the moving part of
157. mit setting QL F1 CLR Position Error Over CLR ALL DEF CLR UNT DEF F2 _ SAV Saving system Write data for system setting setting data F3 LOD Reading out system setting data Read out data for system setting Installation and Maintenance of EXEA Controller 9 Initial Setting Figure 9 2 System setting mode Multi axis controller Acceleration limit In position setting width In position confirmation format Locus speed Locus accel Max speed Max accel Finish width Finish mode F1 PRG Programmed operation F1 JOB Ein control Switching FIN signal output Operation Fin out time FIN signal outputting time Home speed Home return speed Home accel Home return acceleration Home return mechanical stopper searching speed 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 F2 ORG m Home search speed Home direction Home return i Home sequence operation 7 Home shift Home move m Home move mode F3 JOG Home unit seq Jog Jog high speed operation Jog acceleration Software over travel
158. mode Selected display mode Menu selection 1 Programmed operation monitor External control mode 1 Menu selection 2 1 1 e Mode which monitors external programmed operation I O monitor e Mode which monitors state of external input output Special function monitor e Mode which monitors system version and alarm history Selecting teaching box menu e Selecting function to teaching box main menu from external control mode Teaching box _ operation mode Menu selection 1 Programmed operation Y e Executes programmed operation through teaching box Home return operation e Executes Home return operation through teaching box Jog operation e Executes jog operation through teaching box Programming Menu selection 2 A Menu selection 4 e Makes edits program Teaching e Inputs coordinate data of positioning point for program Palletizing Initializes the palletizing program This function is not available for the single axis controller No indication in a single axis controller System setting e Sets the servo gain and system parameters Setting controller e Unit setting of controller O monitor handling e Monitors state of input output of control I O and general I O and controls output manually Special function e Displays version number a
159. n 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 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 Remedy e Very high voltage is applied to the main power e Rectify the problem of power Example 400 V source Change the source to e Faulty power source very wide voltage variation normal power line e The source voltage is increased as the regenerative e Reduce the load energy is too much to be processed by the internal e Reduce acceleration and Exendene regenerative dump resistor deceleration Normally the aforementioned overheat alarm voltage should be given regeneration before this alarm is detected e Defective internal dump resistor has resulted in e Replace the controller high voltage of main power Contact your local NSK e The monitoring circuit of excessive voltage is representative defective e Snapped defective electric contact or mistaken e Check for defective wiring and e Defective power source too much voltage e Use a normal power line with Low voltage less voltage variation e The monitoring circuit of excessive voltage is e Replace the c
160. n servo lock state RUN command after HOLD input is off will resume the programmed operation from the position at where it stopped Error status Normally close Opens in case of a serious error indication Normally open Closes in case of a minor error Output Closes during execution of operation such as Home return and programmed operation It MTN Output EN eee f K keeps closing during cycle stop or operation hold Closes while editing the memories through teaching box or remote command indicating EDTM Output S ae that the starting operation command is disabled Closes to indicate that the external operation and the remote control modes are disabled TBXM Output 7 when the controller is under teaching box operation mode Closes after completion of Home return It opens to indicate the necessity of Home return Status HOMS Output when the encoder is in abnormal condition or the parameters related to Home return operation are changed indicano CSTPA Output Closes during cycle stop HOLDA Output Closes during HOLD input is on RSTAE Output 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 P
161. n the RDY output is opened 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 Installation and Maintenance of EXEA Controller 11 Protection and Safety 11 3 Protection and Function for Safety 11 3 1 Emergency Stop Incase 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 All operation commands are canceled and the motors get in servo off state 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 The internal registers such as data register will be reset Indication 1 Frontpanel 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 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
162. n 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 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 Table 1 1 U2 Unit 2 Axis number on Jog keys on the teaching box and indication in a program controller Four axes 1st U1 X 2nd Oo o o S aayi ayw y 3rd 4th On the panel of the EXEA controller for single axis there is no indication of axis number Indication of single axis is only X 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 When decelerating or descending a heavy load a servo motor of the main unit generates the regenerative current Regenerative current is dissipated by a regenerative dump resistor in the internal circuit of the controller However if the lar
163. n 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 Installation and Maintenance of EXEA Controller 1 Introduction 1 1 Notes for Safety Before operating the robot module system you should first thoroughly read this manual Following notice are added to the clause of safety precautions to get your attention Might cause serious injury Might cause injury Might damage ancillary equipment and or the end effector Observe the applicable safety regulations for industrial use robot Pay great attention for safety when building and operating the robot system Do not use the robot module system in any manner not shown in this manual 1 2 General Description The robot module main unit and the EXEA controller can configure a Cartesian type robot 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 Installation and Maintenance of EXEA Controller 1 Introduction 1 3 Notes to Users 1 3 1 Axis Indication 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 o
164. n to an improper power voltage may lead to breakdown of the controller and or the motor 7 17 Installation and Maintenance of EXEA Controller 7 Wiring 7 7 EXT IO General Input Output Signal Connector 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 DC 37PF N Japan Aviation Electronics Industries Ltd DC C8 J13 F1 1 Connector EXEA controller side Mating connector cable side Mating connector shell type cable side These are provided as the accessories 7 7 1 Precautions for Wiring Be sure to use shielded cables and ground the shield securely If it is necessary to install a relay to the output port a surge killer must be installed to a relay 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 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 Failure to observe above notices may lead to malfunction and memory loss due to the noises Be sure to meet the electrical specifications in Table 7 18 Especially following three issues are critical for breakage
165. nates 9 3 4 1 Parameter List Table 9 7 Parameter List of position and coordinates Parameter Shipping set 9999 99 9999 99 OFF OFF 9999 99 9999 99 OFF OFF 4 e This is to set the detecting position of software over travel Over travel ice oe ties limit in positive direction e This is to set the detecting position of software over travel 4 Over travel limit in negative direction e This is to set the upper limit of off limits area for the Z axis Escape upr Z e This is to specify the operating area of the Arch motion using a Z axis unit e This is to set the lower limit of off limits area for the Z axis Escape Iwr Z 2 e This is to specify the operating area of the Arch motion using a Z axis unit e Specifies the turnout position of the Z axis 9999 99 Escape pos Z e This is to specify the operating area of the Arch motion using 9999 99 OFF a Z axis unit e Reserved e Reserved e Reserved 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 9999 99 9999 99 9999 99 9999 99 Escape upr R x2 Escape Iwr R Escape pos R Software over travel limit is valid after completion of the home
166. ncoder do no conform as the Home position is not defined yet Remedy e Execute home return 13 15 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 9 Battery Error Table 13 21 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo off Encoder 3 battery This function is to give an alarm for low voltage 2 8 V or less of a battery for encoder back up This alarm may occur when wiring of battery has snapped wire or insufficient contact The controller cannot recover until the battery is changed when this alarm is given Be sure to change to a new battery After replace of battery be sure to perform Home return operation Table 13 22 Cause Remedy e Low battery voltage e Replace a battery of an encoder that has lost coordinates data Refer to 12 2 2 2 Replacement for procedures e Wiring of battery has snapped wire or insufficient e 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 DRDY output WRN output Display of teaching box Servo off Memory 1 data 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
167. nd initialize parameters Selection of external control e Changing function to external control mode from teaching box main menu 8 5 Teaching box display External control mode Menu selection 1 External 1RUN 210 3FNC 4etc External control mode Menu selection 2 External 1TBX 4etc Teaching box operation mode Menu selection 1 Menu 1RUN 2ORG 4JOG 4etc Teaching box operation mode Menu selection 2 Menu 1EDT 2TCH 3PAL 4etc Teaching box operation mode Menu selection 3 Menu 1SYS 2CTR 310 4etc Teaching box operation mode Menu selection 4 Menu 1 FNC 3EXT 4etc Installation and Maintenance of EXEA Controller 8 Startup 8 2 2 Changing to External Control Mode from Teaching Box Operation Mode To return to the external control mode press 1 2 keys after key on the display of menu selection 4 in teaching box operation Figure 8 6 Teaching box operation mode Teaching box operation mode Display of menu selection 4 3EXT 4etc Press key Push 1 key ii Press 1 key EXT Push 2 key i Press 2 key EXT Push 3 key l Press 3 key External External control mode 1RUN 2210 3FNC 4etc When this procedure is executed while the system is operating the controller terminates the programmed operation and gets in Ete
168. ng 7 2 5 Measures against Noises 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 The following shows the noise resistance of the EXEA controller itself Table 7 2 Remarks 1000V lus Caution In order to eliminate influences of excessive noises follow instructions hereunder Line noise resistance hecked b ise simulat Static noise resistance Checked Dy anoa eraat 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 In case of the a
169. nit and their functions Table 3 1 Component Function e Generates driving force rotational torque produced by electric current supplied from Motor the EXEA controller e Outputs electrical signals in accordance with rotation angles of motor and transmit the Encoder f signals to the EXEA controller l e Couples the motor shaft with the ball screw shaft and transmits motor torque to the Coupling ball screw e Converts rotational torque rotational motion of the screw shaft into thrust force Ball screw linear motion of the ball nut e Functions as a linear guide way Supports vertical lateral and moment loads and achieves precise linear motion of slider e Combines the ball screw nut and the ball slides of linear guide for highly precise Slider linear motion e Anend effector or a combining bracket may be mounted to the slider e Prevent the slider from dropping when the power of a vertical main unit is turned off e The brake is released when the current is given from the EXEA controller It engages when the power is off e Module main unit with motor brake is optional NSK linear guide Motor brake Figure 3 6 Components of module main unit Coupling Slider Encoder Motor brake Main body Ball screw 3 6 Installation and Maintenance of EXEA Controller 3 System Configuration 3 3 Structure of EXEA Controller Table 3 2 shows components of controller and their functions Table 3 2
170. nit 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 itis 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 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 All models of module main unit employ the same type of connectors regardless the size and motor rated power Before turning on the power check if the robot module is connected with the controller properly 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 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 ext
171. nly TJOB 2TUN fete AEE L Select the setting value ODE Press key Finish mode SET Operation parameter setting mode gt Start editing Cursor is blinking 1PRG 20RG 3J0G ORE El Select the setting value Press key Fin control SET a lv SYS JP gt Start editing Cursor is blinking ee Fin out time The setting can be OFF by E t 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 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 Setting range_ Factory set e Specifies the speed of main unit in the home return operation To Home position of absolute encoder i mm 1 50 20 Flome speed To offset point by Home shift 9 ony ee To set position by Home move Heine Acc l Specifies the maximum acceleration deceleration of a main we 0 1 35 0 05 unit in the home return operation Home search Je Specifies searching speed of position of mechanical stopper in 0 1 10 0 1 0 speed the home return operation Home e Specifies direction of the home return direction NRM Motor side NRM REV NRM REV Opposite to the motor Home
172. nst Noises e Replace the module main unit Contact your local NSK representative e Encoder error or internal data error 13 14 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 8 Home Return Incomplete Table 13 19 Motor condition 7 segments LED DRDY output WRN output Display of teaching box operation 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 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 AO arises You cannot perform positioning in absolute coordinate format or programmed operation during this alarm is active 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 e The coordinates of EXEA controller and e
173. nstallation and Maintenance of EXEA Controller 12 Maintenance Checking 12 3 Warranty Coverage 12 3 1 Warranty Period 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 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 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 The
174. ntrol mode In the remote control mode turning on ACLR input of the control input output CN3 recovers the system from the emergency stop Recovery by remote control Inputting the commands ACLR All makes to remove the emergency stop state a 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 4 Normally close Normally close Emergency stop when opened Emergency stop circuit A Teaching box key 4 Normally close 11 3 1 5 Required Distance to Stop for Emergency Stop When Emergency stop is on the motors get in servo off state and dynamic brake functions 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 ee ee Installation and Maintenance of EXEA Controller 11 Protection and Safety 11 3 2 Deadman Switch Keep pressing the deadman switch when executing jog operation or teaching In jog operation and teaching by jog operation releasing the deadman switch makes the motor servo off and th
175. ntroller 9 Initial Setting Figure 9 6 Parameter setting procedure Jog operation Setting screen of Jog operation parameter SYS JJ gt Start editing Cursor is blinking 0100 0 1RUN 210 3FNC 4etc External External control mode Menu selection screen 1 Press key Jog Try External External control mode W Menu selection screen 2 SYS JJ gt Start editing Cursor is blinking 0050 0 J a L Press key Og SREeAC a Teaching box operation mode lv Menu selection screen 1 SYS JJ gt Start editing Cursor is blinking 00 5 1RUN 20RG 3J0G 4etc Number SET Press key Jog accel I Teaching box operation mode Menu selection screen 2 TEDT 2TCH i Press key Teaching box selection mode Menu selection screen 3 1syS 2CTR 310 4etc Press key SYS System mode setting screen lt Select unit number for multi axis combination only 1JOB 2TUN 4etc ODE Press key SYS J Operation parameter setting mode 1PRG 20RG 3J0G Press key 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 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 3 4 Parameters for Position and Coordi
176. o Control Power 13 11 14 2 6 2 Indication of Output Port 13 4 5 Encoder Circuit Error 13 12 Condition 14 34 13 4 6 Overload Protection by Software 14 2 6 3 Monitor Status of Imaginary Thermal Switch 13 13 Input Output Port 14 35 13 4 7 Speed Abnormal 13 14 14 2 6 4 Monitor Status of Limit Sensor 13 4 8 Home Return Incomplete 13 15 EOS Sete tes eS ee 14 36 13 4 9 Battery Error 13 16 14 2 6 5 er i ARE ee 13 4 10 Memory Error 1 13 16 13 4 11 Memory Error 2 13 17 Appendix 13 4 12 Memory Error 3 13 18 13 4 13 Memory Error 4 13 19 Appendix 1 Specification of Motor Connector A 1 13414 CPU HOR eden oie pelt 13 20 Appendix 2 Encoder Sensor Connector A 2 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 1
177. of EXEA controller controller Main power connector 2 sets for 3 and 4 axes and connector shell connector of EXEA controller controller Fuse e Protection fuse for main power input Instruction manual l set _ 3 volumes 6 1 Installation and Maintenance of EXEA Controller 6 Unpacking and Installation 6 2 2 Combination Check Please check that the combination of module main units and an EXEA controller matches with the catalog or your requirement Improper combination may result in burning of motor and or driver unit 1 Is the power voltage to the controller correct Check the indication on power terminal block of controller 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 Make sure that the motor output corresponds to controller reference number See Figure 5 6 Reference number configuration of EXEA controller 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 G20 Installation and Maintenance of EXEA Controller 6 Unpacking and Installation 6 3 Installation of EXEA Controller 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 Use the controller at ambient h
178. of Unit 1 and X axis of Unit 2 Figure 9 16 Controller setting mode screen gt Start editing Cursor is blinking 1UNT 2MDL 4etc Press Y Module Name Select type of module main unit 4 v Example XY HRS020 PM200 CTR U U1 OFF CTR U U2 gt Move the cursor to the power Robot Type XY HRS020 PM200 amplifier number ally Dee Y Module Name CTR U gt Start editing Cursor is blinking Select power amplifier number 2 OES lt gt Select an item Iv 1 X i Note If the power amplifier number remains 1 X Mod le Name 4 v Select a setting this setting will be disregarded as the a lv SET number is still same as the Unit1 SET CTR U U1 gt Start editing Cursor is blinking OFF CTR U 5 5 Clear Y axis of Unit e eae ne SET 2 x Y Module Name Y Module Name Y Module Name Press MODE key u1 Controller setting mode screen UNT 2MDL 4etc P Select U2 UNT 2MDL 4etc Press 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 ex
179. off and 1 is on regardless the logic of port normally open normally close Changed state are valid till pressing SYS key again or MODE key These keys make the state to the previous setting 14 34 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 Press key MEM in the I O monitor screen to get in the monitoring screen of imaginary input output port M appears on the side of I O in the monitoring screen as shown in Figure 14 37 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 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 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 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 Port Status of port Status of port number number 00 number 01 O 00000000 00000000 2 Checking imaginary in
180. on for completion of positioning 9 9 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 3 1 2 Travel Speed in Programmed Operation The travel speed in the programmed operation follows the setting of Locus speed parameter unless it is not stated specially in a program 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 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 The maximum speed varies according to the module main unit Refer to 19 1 2 Specifications 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 Velocity ripple reference only Maximum speed 1 Maximum speed x 0 10 5 Maximum speed x 0 01 30 1200 mm s when ball screw lead is 20 mm 9 3 1 3 Acceleration Deceleration in Programmed Operation The Acceleration and the deceleration in the programmed operation follow the setting of
181. ontroller defective the internal power line is snapped or the Contact your local NSK line has defective electrical contact representative 13 9 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 3 Over Current Table 13 8 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo off Overcurrent 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 Alarm will arise immediately after the power is turned on when the current detective circuit is not functioning normally 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 Remedy e Motor windings or motor cable is short circuited short e Check the motor and motor cable and circuit between two wires and an excessive current is replace it if necessary applied to the motor e The motor winding or motor cable is grounded short to the e Check the motor and cable Replace them earth wire and the excessive current is given if necessary e Over current is applied to the motor due to steep rise of e Reduce acceleration deceleration and or current command from the controller load Excessive acceleration deceleration or load to the motor e Pr
182. ontroller setting CTR L Push SET Pressing key to start the readout of Press key F pena parameters Reading message appears on the screen while executing readout Reading Return to Controller setting mode screen 3 when the readout completes 9 55 Installation and Maintenance of EXEA Controller 9 Initial Setting Blank Page 9 56 Installation and Maintenance of EXEA Controller 10 Trial Running 10 Trial Running 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 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 Execute Home return through either one of the teaching box operation external control operation and the remote control operation 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 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 Set th
183. oordinates 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 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 Installation and Maintenance of EXEA Controller 11 Protection and Safety 11 3 5 Detection of Excessive Position Error 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 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 Recover power or reset of alarm 11 3 6 Software Thermal Limit Protection 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 This protection won t work if the main unit
184. op CEP EP ED 2 When more than one alarms have arisen Emergency stop and program error cIEPEPEPEPERE 13 1 Installation and Maintenance of EXEA Controller 13 Alarms 13 1 3 Display of Teaching Box Jt indicates an alarm on the third line of the screen 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 LARM F4 lt Emergency stop A E 1RUN 2IO 3FNC 4etc 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 t MENU ALARM F4 EMST 1RUN 2ORG 3JOG 4etc MENU ALARM F4 EMST 1EDT 2TCH 4etc MENU ALARM F4 EMST 1syS 2CTR 310 4etc MENU ALARM F4 EMST 1LENC 3EXT 4etc The part in dotted lines won t be indicated for a single axis system 13 2 Installation and Maintenance of EXEA Controller 13 Alarms 13 2 Motor Condition in Alarm State Incase 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 Incase of a serio
185. ops 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 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 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 Does the stroke end shift approximately 3 mm se e Variation of back drive force to some extent is normal Abnormal If it does not move make sure that the motor brake is released Is back drive force normal Refer to 14 2 2 Check for Brake Function e 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 Yes It is suspected looseness or slip on the pulley or the coupling Is the Home position shifted Motor indirect mount Refer to 22 2 1 Periodical Checking Timing Belt motor indirect mount type Normal It is possible to use continuously Fasten tighter the fixing bolts of ma
186. or a single axis system axis name in the same unit It is always X in a single axis system 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 X Module X axis Y Module Y axis 9 33 Installation and Maintenance of EXEA Controller 9 Initial Setting 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 Unit and X axis of Unit2 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 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 XY HRSO20 PM102 2 Z Unit number M Y Module ee Amplifier number of EXEA controller Name of axis in EXEA controller It is set to Z axis in this example 9 34 Installation and Mainten
187. or is blinking 4etc XAUTO J lt gt Select axis For multi axis combination only Press key faa eT nr Number SET Teaching box control mode W Pressing L makes setting OFF Menus selection screen 1 gt Start editing Cursor is blinking 1RUN 20RG 3J0G 4etc J P gt Select axis For multi axis combination only Rated Current Press Fa key Do not change the settings Teaching box control mode Menus selection screen 2 SYS TA gt Start editing Cursor is blinking 1EDT 2TCH PAL i lt Select axis For multi axis combination only Over Load Press F4 key Do not change the settings Teaching box control mode Menus selection screen 3 sys TA gt Start editing Cursor is blinking x30000 f ayj 1SYS_2CTR_3IO 4etc L 2i P gt Select axis For multi axis combination only Position Error Over Press key Do not change the settings System setting mode lt Select unit number Multi axis combination only 4etc Press key Servo parameter setting mode Additional screen for servo parameter setting mode for single axis system only 4etc Press key 31 o l is o 1 This part in the dotted lines won t be shown in a single axis system 8 2 Indication in the dotted lines will
188. ormal 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 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 Replace the cable Recovered Did not recover Replace defective cable Contact your local NSK representative Contact your local NSK representative Does the slider stop after reversing its motion R d Replace cable ecovere y Did not recover Replace defective cable Contact your local NSK Encoder might be defective representative Replace motor Contact your local NSK representative Refer to Troubleshooting for Home return 3 Home position shifts Continue to the next page 14 9 Installation and Maintenance of EXEA Controller 14 Troubleshooting Be sure to observe all
189. ot module 12 2 1 Periodical Check The checking shown in Table 12 1 should be performed at least once a month Table 12 1 Check List Check point Inspection e Inspect for loose screws of FGND terminal block and AC main Looseness of power source connector screws e Tighten screws if necessary Cleaning e Clean dust and remove foreign substances from the controller 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 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 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 Replace them when it reaches its criterion of life described in Table 12 2 Table 12 2 Replacement parts Item Criterion of life e 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 e Total number of times of brake on off 100 000 times Approximately 9 years when frequency of 30 times of on off per day e C
190. ovide a radius to the acute direction An acute angle in the path of continue path program change in the continue path program e The monitoring circuit of current is defective or internal e Replace the controller wiring is snapped Contact your local NSK representative 13 10 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 4 Insufficient Voltage to Control Power Table 13 10 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo off Ctrl Power voltage 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 When the main power voltage drops this alarm reports abnormality before the main power voltage alarm low voltage is detected 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 Remedy e Abnormal power supply too much voltage variation e Check the power line voltage and use a normal power supply e The power supply cable is too thin and too long e Use more thicker and shorter cable Voltage drops when the maximum current is applied e The power supply cable is snapped or it has defective
191. ower 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 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
192. position Software over travel position Arch motion upper off limits boundar Arch motion lower off limits bounda setting F4_ LMT coordinates Arch motion Turn out position H ra Payload Servo Gain Feedforward Gain Torque Limit Dead Band Load mass Servo gain Reserved Feed forward gain Torque output limit Dead band F2 FIL Low Pass Filter 1 Low Pass Filter 2 Notch Filter Low pass filter primar Low pass filter seconda Notch filter frequenc Observer gain Gain tuning selection Reserved Filter Position Loop Gain Velocity Loop Gain Observer Gain Observer Limit Notch Filter Q1 Gain mode F2_ TUN Servo parameter F4 etc Coordinate direction Hardware over travel detection timer Over load limit setting RC Over load limit setting QL Excessive position error limit F1 CLR Initialization CLR ALL DEF Initialize all unit data CLR UNT DEF Initialize data of designated unit F2 SAV Position Direction Hard OT Timer Rated Current Over Load Position Error Over Saving system setting data Write data tor system seting o F3 LOD Reading outsystem Read out data for system setting setting data
193. pplication 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 Installation and Maintenance of EXEA Controller 7 Wiring 7 3 Wiring 7 3 1 Wiring Procedures Figure 7 3 CN1 Teaching box CN3 Control O MOTOR SENSOR Motor encoder CN4 CN5 Power input terminal Plug the connector of teaching box cable to CN1 connector of EXEA controller 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 Make sure that each axis is connected properly Miss wiring or misconnection may cause motor burning or system malfunction Use an optional cable if required referring to 7 7 EXT lO General Input Output Signal Connector and connect it Use an optional cable if required referring to 7 4 CN2 RS 232C 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 27 6 Inst
194. price of the product does not include the engineering service charges incurred after the shipment Service fee according to the supplier s standard will be charged for field service even in the warranty period Service fee will be charged based on the relevant standard of NSK Ltd 12 7 Installation and Maintenance of EXEA Controller 12 Maintenance Checking Blank Page 12 8 Installation and Maintenance of EXEA Controller 13 Alarms 13 Alarms This section describes the alarms of the EXEA controller 13 1 Indication of Alarms 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 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 It outputs RDY and WRN The meanings of each output are RDY Ready Opens in case of a serious failure WRN Warning Closes in case of a minor failure 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 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 st
195. put output port status Press key CHK in the monitoring screen of imaginary input output to get in the screen of status checking screen 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 Mand keys to move the cursor for selection 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 6 4 Monitor Status of Limit Sensor Port This is to indicate conditions of hardware travel limit Status screen of limit sensor port appears when LMT is selected in the I O indication selection screen L appears next to I O in the screen Current state of limit sensor of designated unit is indicated on the second line Use Hand gt keys to move position of the cursor for selection in case of multi axis combination Name of the limit on which bit the cursor is put is indicated on the first line Use A and Y keys to switch the screen for a unit when two or more units are set to a multu axis combination Functions and composition of indication are the same as the input port Figure 14 39 Monitor limit sensor port Name of the hardware limit x00 1CHK I O L OTM
196. r 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 1 7 Cannot Release Brake 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 The problem is not related to Is function of brake Normal brake function control normal Brake functions Replace the defective cable Change cables normal gt Contact your local NSK representative 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14
197. r recovery e Review all wiring and correct as required e Check on wiring of DC 24V power supply and correct as required e 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 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 20 Program Error Table 13 43 Motor 7 segments DRDY WRN Servo lock TELLIS 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 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 Pra Prog not found Step not found Axis mismatch Data range over Undefind TAG Duplicate TAG Too many CALL Without CALL Too many REP Without REP Can t make cir Servo off Axis offline Cause e Attempted to execute empty program e Program is not written to the end END command is not set to the end o
198. r voltage range reference number voltage spec Single phase Single phase ATAUN AON AC180V AC264V AC180V AC264V 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 Installation and Maintenance of EXEA Controller 7 Wiring Use a magnet switch with rated current of 30A or over Separately install the power supply line of 3 4 axes controller and 2 axes controller Be sure to provide a surge killer to coils of magnetic switches relays and solenoids 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 l FN2070 10 Separate the primary wiring from the secondary wiring of noise filter and lay them in different routs 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 Terminal code Function CN4 MAIN Single phase AC 200 240 V main power supply CN5 CONT Single phase AC 200 240 V control power supply FGND Frame ground Connectio
199. re 7 1 for FGND terminal Though there are two FGND terminals they are connected inside of the controller Connect to either one of them There are two RGND terminals for 3 4 axes EXEA controllers Ground them respectively at a one point Figure 7 1 FGND terminal O EXEA controller side The grounding shall be a one point and class 3 Ground resistance 100 Q or less If another equipment is mounted in the same enclosure ground the equipment and devices at one point Refer to Figure 7 2 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 fea ae Installation and Maintenance of EXEA Controller 7 Wiring Figure 7 2 O Good example One point grounding EXEA controller FGND Sequencer FGND Other controller and driver Noise filter Noise filter AC power line AC power line Noise filter AC power line X Bad example EXEA controller FGND Sequencer FGND Other controller and driver Noise filter Noise filter AC power line AC power line Noise filter AC power line Installation and Maintenance of EXEA Controller 7 Wiri
200. return Be sure to execute the home return when the software over travel limit is newly set or changed 9 18 9 3 4 2 Parameter Setting Procedure Position and Coordinates Installation and Maintenance of EXEA Controller 9 Initial Setting Set the mode to the system setting referring to 8 2 Selection of Control Mode 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 Use Use Use A gt and keys to scroll the screen key to start the editing lt gt IA and v keys to move the cursor when editing the program and selecting an axis in multi axis combination Use 0 9 numeric keys key and key to input numbers J e key is used to set or select key word OFF etc In each display screen pressing MODE key makes the screen to go one step back For a multi axis combination you may select a unit number using lt and gt keys in the screen 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 t
201. right corner of the teaching box screen is off in servo off state LASS e Move the moving part of module main unit manually normally slider or main unit in case of moving main unit Release the motor brake before moving the part if the main unit has a motor with brake Menu N gt Not indicated 1RUN 2ORG 3JOG 4etc Does it move by hand 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 display will appear e Make servo on in this state Press key in the teaching box control mode The servo on indicator on upper corner of the Menu o MT Servo on indicator 1RUN 2ORG 3J0G 4etc Dose it move by hand When the servo gain is low it moves to some extent If it moves easily the following causes are possibly considered e 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 e 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
202. riterion 5 to 10 years varies according to environmental condition especially sensitive to temperature Memory back up absolute position data Lithium battery Contact point of motor Relay brake Smoothing voltage of Electric condenser main power Do not charge the lithium batteries If charged they may burst or burn 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 Installation and Maintenance of EXEA Controller 12 Maintenance Checking How to replace the lithium battery Follow the procedures below when replace the lithium battery Be sure to turn off the power when replace the lithium battery 1 Preparation Philips screwdriver for M3 screw 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 lt Single axis controller gt
203. rmance 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 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 Shipping set OFF FIL 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 Set the mode to the system setting referring to 8 2 Selection of Control Mode 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 gt Filter FIL Use A and keys to scroll the screen Use gt key to start the editing Use 4 P A and Y keys to move the cursor to edit or select an axis of multi axis combination
204. rn on power again for recovery Replace EXEA controller when it does not recover by turning on power again Table 13 30 Cause e A large inrush noise intruded into the control board and lead to memory destruction due to memory circuit malfunction Remedy e 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 e Replace the controller Contact your local NSK representative e Defective hardware of controller 13 19 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 14 CPU Error Table 13 31 Motor condition 7 segments LED DRDY output WRN output Differs with contents of alarms Display of teaching box Hold previous display Cpu OK k ok k This function is to monitor CPU malfunction and data exchange between the CPUs through monitoring circuits such as watchdog timer 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
205. rnal control mode Installation and Maintenance of EXEA Controller 9 Initial Setting 9 Initial Setting This chapter describes how to set the EXEA controller according to the combination of the module main units and the purpose of its use 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 Use the teaching box or the optional application software for initial setting Refer to 8 2 Selection of Control Mode and set the objective parameters selected from 9 2 Initial Setting List Take the same procedure for the application software Refer to the instruction manual for the setting in the personal computer 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 Set the type of main units X module Name which are to be connected to the EXEA controller Set X axis only for the single axis controller while all axes must be set for multi axis combination Refer to 9 5 Parameters for Unit Setting for setting and saving the parameters Procedure 2 Setting total load mass Set the total load mass to the module main units Payload For the multi axis combination add all payload
206. rocessing and main part processing of three axes controller 13 33 Installation and Maintenance of EXEA Controller 13 Alarms Blank Page 13 34 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 Troubleshooting 14 1 Discription of Troubleshooting 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 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 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 Investigate specification of main power supply voltage EXEAD OOOOTUUO single phase AC180V 264V If the power line voltage exceeds above specification the motor driver may burn 4 Check if the FGND terminal and AC po
207. rogrammed operation RSTA control Input STOP Input Stop CSTP DATWT Output 7 11 Installation and Maintenance of EXEA Controller 7 Wiring 7 4 3 CN3 Signal Specification Figure 7 7 CN3 pin out Pin Description 1 side output DC24V internal power supply 2 side output DC24V internal power supply 3 Emergency stop 4 Remote control enables 5 Hold 6 Restart 7 8 OO O OO Start Servo on 9 Ee ee Do not connect 10 CW pulse train 11 CCW pulse train 12 Writing data 13 Hold 14 Home return complete 15 Remote editing 16 Warning 17 ee eee Do not connect 18 side output 24V internal power supply 19 FG Frame ground 20 Common input 21 ee ee Do not connect 22 Emergency stop 23 Alarm clear 24 Cycle stop 25 Home return start 26 Operation stop 27 an kas Do not connect 283 Donot connect 29 CW pulse train 30 CCW pulse train 31 Resume operation enabled 32 Stopping cycle stop Teaching box operation Operating status 35 Controller ready The pins in the dotted area are for single axis 36 Pe Do not connect controller only Do not connect them for a 37 Common output signal multi axis controller OCS OOOO D D D Q Q Q A O f 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 a
208. rshooting 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 e Sets the mode to adjust Servo gain Gain mode Setting to MANU makes the following parameters AUTO MANU MANU effective Do not set other than MANU e Sets Position Loop Gain Position Loop Shorten the positioning time However vibration and Gain 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 Velocity Loop well as overshooting Gain When heavy work or low stiffness work is attached to the slider resonance is likely observed Do not set too MAN much gain Sets Observer Gain It improves overshooting and settling as well as Observer Gain convergence against external disturbance 1 0 150 0 10 0 When the gain is set too high high overshooting and vibration will be induced Sets Observer Gain output limit E ee A 0 1 100 0 OFF OFF overshooting without lo
209. ry then input program and conduct teaching data of point register Refer to 13 6 Initialize Memory 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 e A large inrush noise intruded into the control board caused the memory circuit to malfunction and resulted in memory destruction Remedy e 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 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 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 13 Memory Error 4 Table 13 29 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo off Memory 4 code EXEA controller conducts check of the memory after turning on the power This alarm function is to check the system ROM When this alarm arises EXEA terminates its operation immediately and the motor gets in the servo off state Tu
210. s 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 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 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 Check that the power supply voltage is correct EXEA O 0000 A OU Single phase AC 180V 242V EXEA O 0000 C OO Single phase AC 90V 121V 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 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 Installation and Maintenance of EXEA Controller 13 Alarms Before attempting to investigate the cause of an alarm and to take actions for recovery according
211. s parameter shall be set when the over travel alarm F3 mechanical lock arises frequently because of load condition in which the motor duty exceeds its rated power or because of 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 Rated e This is to set converting rate of the motor rated current 0 100 43 current Do not change Ouerieeas Ie This parameter sets the criterion of electrical power for 1 1000 a0 detecting level of overloaded motor alarm Do not change OFF e Sets number of pulses for the criterion of excessive position Position error alarm F zi l 0 30000 30000 error over e Refer to 11 3 5 Detection of Excessive Position Error for the P excessive position error 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 200 30000 AUTO Hard OT Timer AUTO 9 4 4 2 Parameter Setting Procedure Function Setting Set the mode to the system setting referring to 8 2 Selection of Control Mode 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 gt Function setting ADL
212. 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 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 1 4 Troubleshooting for Programmed Operation 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 Ferenc Take action referring to 13 4 Description of Alarm Can you start programmed NO operation y 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
213. se 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 toa stroke end m Replace cable Not recover Consult to your local NSK representative Recovered End of troubleshooting Defective cable 14 12 Installation and Maintenance of EXEA Controller 14 Troubleshooting 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 e Slider travels twice or one half of programmed distance e 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 e 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 e Possibly the parameter sett
214. 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 e Positioning error Reports no alarm 14 11 Installation and Maintenance of EXEA Controller 14 Troubleshooting 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 y V 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 ca
215. sition of each axis e Alarm reset Figure 5 4 Keys on teaching box and their function Emergency stop button e Press the button to stop all operations and gets in servo off state e To reset turn the power off then turn on again or use alarm reset function Emergency stop key EMG e The key has the same function as Function key e Keys to select function the emergency stop button Dead man switch e Keep pressing the switch when executing jog operation and Mode key e Selects an operation menu Start key teaching operation by jogging e f the switch is released operation is disabled and the system gets into servo off state e Start programmed operation or Home Return Screen control and cursor scroll motion Servo ON OFF keys e The servo on state is indicated by an asterisk Cycle stop key e Press CYC STOP key to stop operation after completion of the current step e Press START key to restart the operation in the upper right corner of the LCD screen from a following step Jog keys Positive direction Negative direction Stop key e When the key is pressed the system decelerates and stops Jog high speed key e Press the HIGH key and a jog key simultaneously to increase jog speed Clear key e Press the CLR key to clear an entered command or data Numeric keys Set
216. sor is blinking 1RUN 20RG 3J0G 4etc J lt gt Select axis For multi axis combination only Press E4 key Teaching box control mode Pressing C makes the setting OFF Menu selection screen 2 gt Start editing Cursor is blinking 1EDT 2TCH PAL i lt Select axis For multi axis combination only Press key Torque Ir Nanis ISET Teaching box control mode Iv Pressing C makes the setting OFF Menu selection screen 3 sys 7S l P Start editing Cursor is blinking XOFF i aay 1s S 2CTR 310 4etc L 4 P Select axis For multi axis combination only d d Press ET key aaa SYS System setting mode Pressing L makes the setting OFF lt Select unit number Multi axis combination only 1JOB 2TUN 4etc Press key SYS T Servo parameter setting mode 1SRV 2FIL Press key 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 9 25 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 4 2 Parameters for Filter 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 perfo
217. ss capacity Use a 2 mm or larger power cable for 1 5 to 3 0 kVA capacity 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 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 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 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 Secure the main power input connector firmly 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 Power source Main power voltage range Control powe
218. t 9 8 1 Parameter List Switches function and polarity of input port Polarity A Normally open Polarity B Normally close Indication of input port Input Input port No Input bit No Table 9 18 Parameter list Input signal function Signal Setting range Shipping set Input port name May be changed to Switching Signal function Contact polarity polarity Input 1P00 IBO00 EMST Cannot change No EMST Input__1P10 IB100 INI Input 1P10 IB101 Input _1P10 1B102 Input _1P10 1B103 Input _1P10 1B104 Input _IP10 1B105 Input _1P10 1B106 Input _1P10 1B107 P1 EXT I O Input _1P11 1B110 Input _1P11 1B111 Input _1P11 1B112 Input _IP11 1B113 Yes Connector o Nn s Input _1P11 1B114 Input 1P11 1B115 USER POSN9 RSRV Yes Yes This part won t be indicated for a single axis system 9 44 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 8 2 Parameter Setting Procedure Input Signal Format Set the mode to the controller setting referring to 8 2 Selection of Control Mode Refer to 9 1 Initial Setting Procedure and scroll the display screen to Input Signal Format INP setting screen as shown below eu eU eu eU Controller setting mode CTN gt INP setting INP Each parameter setting se A and Y keys to scroll the screen se gt key to start the edit
219. t 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 Operation duty 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 Moving range 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 Servo ON condition 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 Installation and Maintenance of EXEA Controller 4 Glossary Servo OFF condition 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 CPU Central Processing Unit In the EXEA controller CPU performs all processing including motor control and executing programs Slider movement moving
220. t 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 e A large inrush noise intruded into the control board caused the memory circuit to malfunction and resulted in memory destruction Remedy e 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 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 e The power is interrupted in the middle of e Connect to stable power supply line rewriting memory 13 17 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 12 Memory Error 3 Table 13 27 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo off Memory 3 write This is to give an alarm when saving the parameters and data is not completed normally due to some disturbance When this alarm arises EXEA controller stops its operation immediately and the motor gets in servo off state Initialize the memo
221. tact your local NSK representative e Check for motor winding and or motor cable Replace them if required Installation and Maintenance of EXEA Controller 13 Alarms 13 4 7 Speed Abnormal Table 13 17 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo off Speed This function is to monitor rotational speed of the motor and gives an alarm if it exceeds the allowable maximum speed Rotational speed of the motor may exceed the limit due to influence of noise to motor cable and the controller 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 e Module main unit moved very fast due to an external load or gravity under servo off state e Noise has caused an excessive motion command or too much position deviation Remedy e Take an appropriate measure not to move the module main unit exceeding its maximum speed criterion e 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 agai
222. tal condition Item Specification Power voltage Single phase AC200 240V 0 5kVA 0 9kVA LLOkVA 0 9kVA 1 2kVA 2 0kVA M EXEA2 020000101 1 5kVA 2 4kVA 3 1kVA 1 3kVA L 6kVA 2 5kVA 2 0kVA 3 6kVA 2 4kVA Maximum power ae eae 4OKVA 4 7kVA L 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 Built in driver unit capacity 100W 200W 400W Noise resistancg 1000V luS by noise simulator 3kV by noise simulator Ambient temperature 0 50 C Operation storage humidity 20 85 No condensation Free from dust corrosive gas inflammable and or explosive gas Do not expose to cutting oil and lubrication oil Storage temperature 10 70 C Environment Exclude inrush current 5 1 Installation and Maintenance of EXEA Controller 5 Reference Number Specifications Table 5 2 Inrush current and leakage current Inrush current Leak current Table 5 3 Functional specifications EXEA 4 Four axes 420A approx 60A approx 50mA approx Item EXEA Number of control axes 1 4 axes Teaching Numerical data input or teaching Position data capacity 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 Backup Flash memory
223. 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 This function or indication does not exist for
224. 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 EMST Activates emergency stop when and of EMST is cut off and motor gets in servo off input state Once the emergency stop condition is established operation cannot be started EMST 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 Input 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 HOLD Input decelerate and stop The motor goes i
225. tialization When the time expires this port will Indication of state open Set either FINn or USER Note a USER This is the general output This is the port that can be epu outputted during a programmed operation RSRV Output Reserved Note 1 The shipping set are PROGO 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 FINI is available in the single axis controller 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 Installation and Maintenance of EXEA Controller 7 Wiring 7 7 3 CN3 Signal Specification Figure 7 13 EXT I O connector pin out No name Pe Internal DC 24V power supply side output OV output 2 3 IN16 Reserve POSN11 USER 4 IN14 Reserve POSN 9 USER 5 IN12 Reserve POSN 7 USER 6 7 8 j Reserve POSN 5 USER Reserve POSN 3 USER PROGS POSN1 USER 9 PROG3 Reserve USER 10 PROGI UNTN1 USER 11 Reserve USER 12 Reserve USER 13 Reserve USER 14 Reserve USER 15 output FIN8 USER 16 FIN6 USER 17 output FIN4 USER 18 FIN2 USER 19 ae ee Do not connect 20 Input common 21 Reserve POSN10 USER 22 Reserve POSN8 USER 23 Reserve POSN6 USER 24 Reserve POSN4 USER 25 PROG6 POSN2 USER 26 PROG4 POSNO US
226. ting the system The teaching box must be in the reaching area of operator so that it can be handled quickly in an emergency Check that the emergency stop function is working before troubleshooting Perform troubleshooting after making sure the emergency stop function is surely functioning 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 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 g Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 1 1 Malfunction Be sure to observe all safety precautions described on Page 14 1 and 14 2 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 Incorrect Refer to 14 2 4
227. tion position data selection and FIN signal output Alarm Protection General Input Output 5 1 1 1 Internal DC 24V Power Supply Table 5 4 Specifications of Internal DC 24V power supply Specification DC24V 10 2A Item Voltage Maximum output current 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 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 rae 5 ee 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 Control power input terminal 7 segments LED CN1 Connector for Motor connector teaching box CN2 RS 232C connector EXEA Controller Type e Connect personal computer Wo NSK Ltd MADE IN JAPAN FGND Encoder connector Frame ground EXT I O General I O CN3 Control I O e This is for general Input Output to control slave e Signal T O connector to control unit such as hand or end effector and for EX
228. tion is defective e Replace the controller e Power source of switching in the controller is defective Contact your local NSK representative e Error due to defective back up battery Low voltage e Replace battery improper wiring of battery e 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 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 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 Remedy Take measures not to move a main unit when the power of EXEA controller is turned on again Replace the motor when the system does no recover by turning on the power again Backup alarm of first or third axis This alarm may arise simultaneously with Battery error Take the same measures against the Battery Backup alarm of second or fourth axis error alarm Note Only the alarms of the first axis is indicated for a single axis system
229. trical 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 Specification Input voltage DC24V 10 Input signal 3 3kQ LOmA per one point ee DCSV 10 nea 2400 25mA or less Sree DC24V 7 100mA 2V or less This is for a single axis controller only 7 10 Installation and Maintenance of EXEA Controller 7 Wiring 7 5 2 CN3 Signal Function Table 7 8 CN3 Classification Function name Select the motor servo state In some abnormal situation such as in alarms inputting SVON signal does not activate the servo e SVON input ON Motor is in servo on state Stat trol e SVON input OFF Motor is in servo off state AS CONG Clears an alarm Rising edge detection signal When EREM signal is activated the external control mode is changed to the remote EREM Input communication mode and the control and operation through remote command is enabled SVON Input When EREM is off only monitoring data is possible on remote communication Starts Home return operation Rising edge detection signal Start 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
230. troller heating loss under rated operation are described hereunder e 100W driver per one axis approximately 40W e 200W driver per one axis approximately 50W e 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 e 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 Installation and Maintenance of EXEA Controller 14 Troubleshooting 14 2 Inspection of Trouble 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 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
231. umidity 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 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 i e U ce CN4 MAIN Note 50 mm or more J and MOTOR1 CNS CONT EXEA Controller Type Ne NSK Ltd MADEN JAPAN FGND lt I 50 mm or more Mounting bracket TITITITITTT7 Note This clearance is common to the all controllers for single to 4 axes control
232. us failure RDY output opened the motor gets in servo off state 13 3 Alarm List 13 3 1 Normal State Table 13 1 shows the conditions in normal state Table 13 1 Normal state 7 segment LED RDY output WRN output Indication of teaching box Off Green close 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 7 segments RDY WRN power Initializing CPU Se cae Wait for a while Turn on 13 3 Installation and Maintenance of EXEA Controller 13 Alarms 13 3 2 Alarm List The alarms given by EXEA controller in abnormal conditions are listed in Table 13 3 Table 13 3 Alarm List 1 2 7 segments he AED Teaching box Overheat 1 Overheat _ Internal heat sink of power amplifier Heat sink ee Po Orange Open heatsink output circuit has overheated Overheat 2 Overheat 2 Regeneration Servo off Orange Open Open S Overheat of regeneration resister resistor resistor Abnormal Main Servo off Pl Grande Open z Main Power S of main power is too high or power voltage voltage ow Excessive Servo off fee e orean Open ae current has applied to the current motor Insufficient Ctrl Power voltage to the Servo off Orange Open Open ales Z Control power voltage is too low control power 8 Encoder circuit Servo o
233. vel limit timer manually in the following conditions when the motion of main unit is not smooth in Servo on or Servo off when main unit shows unstable motion due to vibration or hunting 13 24 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 19 Emergency Stop Table 13 41 Motor condition 7 segments LED DRDY output WRN output Display of teaching box Servo off F4 Orange Open Open Open EMST 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 e Execute an emergency stop operation e Got in the emergency stop state without any command was called for Example 1 Example 2 Example 3 Example 4 Example 5 or cannot lift the emergency stop state Incorrect wiring none wiring or disconnected wire of CN3EMST input 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 Teaching box is disconnected or EMST switch of teaching box is defective Malfunction of EMST line due to an external noise Failure of internal circuit of EXEA controller 13 25 Remedy e 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 fo
234. w 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 System setting mode screen 1 lt gt Selection of unit number Multi axis combination only 1J0B 2TUN 4etc Press key Press key to change the screen to System setting mode 2 When only a designated unit is to be initialized set its unit number using KI and P keys Multi axis combination only System setting mode screen 2 1CLR 2SAV 3LOD 4etc Press key Press to change to System initializing screen A v Select an area tobe Use A and W keys to select to initialize all unit data or data of initialized designated unit only The unit number of designated unit is indicated on the upper right corner of the screen Press key CLR ALL DEF gt Initialize data of all unit CLR UNT DEF gt Initialize data of a designated unit Use and gt keys to select initializing range Press Aland to change to DEF lt gt MDC lt gt ay D
235. wer line is mistakenly connected 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 Se Installation and Maintenance of EXEA Controller 14 Troubleshooting 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 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 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 Menu gt Make sure that the servo on indicator on the upper i ck corner of the display is off Indication of servo off 1RUN 2ORG 3J0G 4etc 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 opera
236. wering Observer Gain However set it OFF normally e Sets shape of notch filter j ose Notch Filter Q1 fe When it is set too high frequency range which are cut 0 10 5 00 1 00 by notch filter gets steeper Set to 1 00 normally 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 Hz 1 0 100 0 5 0 1 0 500 0 20 0 9 28 Installation and Maintenance of EXEA Controller 9 Initial Setting 9 4 3 2 Parameter Setting Procedure Manual Tuning Set the mode to the system setting referring to 8 2 Selection of Control Mode 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 gt Manual tuning MAN Use A and keys to scroll the screen Use P key to start the editing Use 4 P A and Y keys to move the cursor to edit or select an axis of multi axis combination Use 0 9 numeric keys key and key to input numbers J e key is used to set or select key words OFF etc In each display screen pressing MODE key makes the screen to go one step back In the system setting screen use and P keys to select a unit num
237. when the emergency button is pressed Emergency stop circuit must be provided by the user Do not touch the primary power supplying area to avoid electric shock Do not turn on the power before closing enclosure cover 13 7 Installation and Maintenance of EXEA Controller 13 Alarms 13 4 1 Overheat Table 13 4 Motor condition Servo off Servo off 7 segments LED DRDY output WRN output Be careful not to be burned as the heat sink and the dump resistor are hot when this alarm is given Display of teaching box Overheat heatsink Overheat2 resistor There are two types of overheat alarm PO and P4 The alarm reports overheat when either one or both of thermal sensors installed on the following two points are turned off 1 PO Internal heat sink on the output port of power amplifier 2 P4 Internal dump resistor 3 P4 External dump resistor for processing regeneration Optional 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 Action e High ambient temperature e Lower ambient temperature e Forcibly cool the heat sink with a fan e High operation duty or load e Relax the operation duty or the load Power As these two factors shall be covered by e Reduce acceler

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