Autonics AiCA Series User manual

User Manual
Closed-Loop Stepper System
AiCA-D Series
MMD-AiCAU1-V1.1-2008US
Thank you for purchasing an Autonics product.
This user manual contains information about the product and its proper use,
and should be kept in a place where it will be easy to access.
www.autonics.com

ii © Copyright Reserved Autonics Co., Ltd.

Preface
© Copyright Reserved Autonics Co., Ltd. iii
Preface
Thank you for purchasing Autonics product.
Please familiarize yourself with the information contained in the Safety Considerations
section before using this product.
This manual contains information about the product and its proper use, and should be kept
in a place where it will be easy to access.

User Manual Guide
iv © Copyright Reserved Autonics Co., Ltd.
User Manual Guide
Please familiarize yourself with the information in this manual before using the
product.
This manual provides detailed information on the product's features. It does not offer
any guarantee concerning matters beyond the scope of this manual.
This manual may not be edited or reproduced in either part or whole without
permission.
This manual is not provided as part of the product package.
Visit our website (www.autonics.com) to download a copy.
The manual's content may vary depending on changes to the product's software and
other unforeseen developments within Autonics, and is subject to change without prior
notice. Upgrade notice is provided through out the website.
We contrived to describe this manual more easily and correctly. However, if there are
any corrections or questions, please notify us these on our website.

User Manual Symbols
© Copyright Reserved Autonics Co., Ltd. v
User Manual Symbols
Symbol Descriptions
Supplementary information for a particular feature.
Failure to follow instructions can result in serious injury or death.
Failure to follow instructions can lead to a minor injury or product
damage.
An example of the concerned feature's use.
※1 Annotation mark.

Safety Considerations
vi © Copyright Reserved Autonics Co., Ltd.
Safety Considerations
Following these safety considerations will ensure the safe and proper use of the
product and help prevent accidents, as well as minimizing possible hazards.
Safety considerations are categorized as Warnings and Cautions, as defined below:
Warning Failure to follow these instructions may result in serious
injury or death.
Caution Failure to follow these instructions may result in
personal injury or product damage.
Fail-safe device must be installed when using the unit with machinery that may cause
serious injury or substantial economic loss. (e.g. nuclear power control,
medical equipment, ships, vehicles, railways, aircraft, combustion apparatus, safety
equipment, crime/disaster prevention devices, etc.)
Failure to follow this instruction may result in personal injury, economic loss or fire.
Do not use the unit in the place where flammable/explosive/corrosive gas, humidity,
direct sunlight, radiant heat, vibration, impact or salinity may be present.
Failure to follow this instruction may result in explosion or fire.
Do not connect, repair, or inspect the unit while connected to a power source.
Failure to follow this instruction may result in fire or electric shock.
Install the unit after considering counter plan against power failure.
Failure to follow this instruction may result in personal injury or economic loss or fire.
Re-supply power after min. 20 sec from disconnected power.
Failure to follow this instruction may result in product damage or malfunction.
Check ‘Connections’ before wiring.
Failure to follow this instruction may result in fire.
For installing the unit, ground it exclusively and use over AWG 18 (0.75mm2) ground
cable.
Failure to follow this instruction may result in electric shock.
Do not disassemble or modify the unit.
Failure to follow this instruction may result in fire or electric shock.
Insulate the connector not to be exposed.
Failure to follow this instruction may result in electric shock.
Install the driver in the grounded housing or ground it.
Failure to follow this instruction may result in personal injury, fire or electric shock.
Do not touch the unit during or after operation for a while.
Failure to follow this instruction may result in burn or electric shock due to high
temperature of the surface.
Do not remove the connector during or after operation for a while.
Failure to follow this instruction may result in electric shock or product damage.
Emergency stop directly when error occurs. Failure to follow this instruction may result
in personal injury or fire.

Safety Considerations
© Copyright Reserved Autonics Co., Ltd. vii
When connecting the power input, use AWG 18 (0.75mm2) cable or over.
Brake is non-polar. When connecting the brake, use AWG22 (0.3mm2) cable or over.
Failure to follow this instruction may result in fire or malfunction due to contact failure.
Install overcurrent prevention device (e.g. the current breaker, etc) to connect the driver
with power.
Failure to follow this instruction may result in fire.
Check the control input signal before supplying power to the driver.
Failure to follow this instruction may result in personal injury or product damage by
unexpected signal.
Install a safety device to maintain the vertical position after turn off the power of this
driver.
Failure to follow this instruction may result in personal injury or product damage by
releasing holding torque of the motor.
Use the unit within the rated specifications.
Failure to follow this instruction may result in fire or product damage.
Use dry cloth to clean the unit, and do not use water or organic solvent.
Failure to follow this instruction may result in fire or electric shock.
The driver may overheat depending on the environment.
Install the unit in the well ventilated place and forced cooling with a cooling fan.
Failure to follow this instruction may result in product damage and degradation by
heat.
Keep metal chip, dust, and wire residue from flowing into the unit.
Failure to follow this instruction may result in fire or product damage.
Use the designated motor only.
Failure to follow this instruction may result in fire or product damage.
The above specifications, dimensions, etc. are subject to change and some models may
be discontinued without notice.
Be sure to follow cautions written in the instruction manual, user manual, and the
technical descriptions (catalog, website).

Cautions during Use
viii © Copyright Reserved Autonics Co., Ltd.
Cautions during Use
Follow instructions in 'Cautions during Use'.
Otherwise, it may cause unexpected accidents.
It is recommended to use 485 converter with the separate power.
(Autonics product, SCM-38I, recommended)
Keep the distance between power cable and signal cable more than 10cm.
Motor vibration and noise can occur in specific frequency period.
①Change motor installation method or attach the damper.
②Use and set the gain value.
For using motor, it is recommended to maintenance and inspection regularly.
①Unwinding bolts and connection parts for the unit installation and load connection
②Strange sound from ball bearing of the unit
③Damage and stress of lead cable of the unit
④Connection error with motor
⑤Inconsistency between the axis of motor output and the center,
concentric (eccentric, declination) of the load, etc.
This product does not prepare protection function for a motor.
This unit may be used in the following environments.
①Indoors (in the environment condition rated in 'Specifications')
②Altitude max. 2,000m
③Pollution degree 2
④Installation category II

Table of Contents
© Copyright Reserved Autonics Co., Ltd. ix
Table of Contents
Preface ........................................................................................................................... iii
User Manual Guide ...........................................................................................................iv
User Manual Symbols .......................................................................................................v
Safety Considerations......................................................................................................vi
Cautions during Use.......................................................................................................viii
Table of Contents .............................................................................................................ix
1Product Overview ...................................................................... 12
1.1 Features............................................................................................................ 12
1.2 Components and Configuration Diagram...................................................... 13
1.2.1 Components..............................................................................................13
1.2.2 Configuration Diagram .............................................................................14
1.3 Ordering Information ...................................................................................... 16
1.4 Models.............................................................................................................. 17
1.4.1 Standard Type ...........................................................................................17
1.4.2 Built-in Brake Type....................................................................................17
2Specifications ............................................................................ 18
2.1 Driver................................................................................................................ 18
2.1.1 Factory Default..........................................................................................20
2.1.2 Communication Output ...........................................................................21
2.2 Motor ................................................................................................................ 22
2.2.1 Common Specifications ...........................................................................23
2.2.2 Encoder......................................................................................................24
2.2.3 Brake..........................................................................................................24
3Dimensions................................................................................ 25
3.1 Driver................................................................................................................ 25
3.1.1 Panel Cut-out.............................................................................................25
3.2 Motor ................................................................................................................ 26
3.2.1 Standard Type ...........................................................................................26
3.2.2 Built-in Brake Type....................................................................................27
4Installation ................................................................................ 28
4.1 Installation of Driver........................................................................................ 28
4.2 Installation of Motor........................................................................................ 29
4.2.1 Mounting Direction of Motor ....................................................................29
4.2.2 Mounting of Motor ....................................................................................30
4.2.3 Connection with Load...............................................................................31
4.2.4 Installation Conditions .............................................................................32
5Connection ................................................................................ 33
6Characteristics ........................................................................... 34
6.1 Frame Size 60mm ............................................................................................ 34

Table of Contents
x © Copyright Reserved Autonics Co., Ltd.
6.2 Frame Size 86mm .............................................................................................34
7Driver Unit Descriptions ..............................................................36
7.1 Driver Status Indicator .....................................................................................37
7.2 Switches............................................................................................................38
7.2.1 ID Sel ..........................................................................................................38
7.2.2 ID, TERM.....................................................................................................38
7.3 ConnConnectors...............................................................................................39
7.3.1 CN1: Motor+Encoder Connector ..............................................................39
7.3.2 CN2: Power Connector..............................................................................39
7.3.3 CN3: RS485 Communication Cable Connector .......................................39
7.3.4 CN4: I/O Connector ...................................................................................40
7.3.5 Brake connector ........................................................................................41
7.4 Connector Specifications.................................................................................42
7.5 Sold Separately.................................................................................................43
7.5.1 I/O Cable (CO50-MP□-R, standard: AiC TAG)...........................................43
7.5.2 Motor+Encoder Cable (Normal: C1D14M-□/Moving: C1DF14M-□).......44
7.5.3 Communication Converter.......................................................................44
8Electromagnetic Brake ................................................................45
8.1 Brake Connection.............................................................................................45
8.2 Brake Operation ...............................................................................................46
9Control Input/Output ..................................................................47
9.1 Input..................................................................................................................47
9.1.1 Example of Input Circuit Connection.......................................................47
9.1.2 Exclusive Input ..........................................................................................48
9.1.3 General Input.............................................................................................62
9.2 Output ...............................................................................................................63
9.2.1 Example of Output Circuit Connection....................................................63
9.2.2 Exclusive Output .......................................................................................64
9.2.3 General Output..........................................................................................67
10 Drive ..........................................................................................68
10.1 I/O Signal Control Drive ...................................................................................69
10.1.1 Index Mode ................................................................................................69
10.1.2 Jog Mode ...................................................................................................71
10.1.3 Continuous Mode......................................................................................73
10.1.4 Program Mode...........................................................................................75
10.1.5 Home Search .............................................................................................77
10.2 atMotion Control Drive.....................................................................................85
10.2.1 Jog Mode ...................................................................................................89
10.2.2 Continuous Mode......................................................................................90
10.2.3 Position Mode............................................................................................91
10.2.4 Torque Mode .............................................................................................93
10.2.5 Program Mode...........................................................................................94
10.2.6 Home Search Mode...................................................................................95
11 Program Instructions ................................................................100
11.1 Drive Instruction............................................................................................ 101

Table of Contents
© Copyright Reserved Autonics Co., Ltd. xi
11.1.1 ABS (Absolute position move)................................................................101
11.1.2 INC (Relative position move)..................................................................103
11.1.3 HOM (Home search)................................................................................105
11.2 Input/Output Instruction .............................................................................. 106
11.2.1 ICJ (Input condition jump) .....................................................................106
11.2.2 IRD (Input wait) .......................................................................................106
11.2.3 OPC (Output port ON/OFF).....................................................................106
11.2.4 OPT (Output port ON pulse) ...................................................................107
11.2.5 CMP (Compare output)...........................................................................107
11.3 Program Control Instruction......................................................................... 108
11.3.1 JMP (Jump) .............................................................................................108
11.3.2 REP (Repeat start) ...................................................................................108
11.3.3 RPE (Repeat end) ....................................................................................109
11.3.4 END (Program end) .................................................................................109
11.3.5 POS (Position set) ...................................................................................109
11.3.6 TIM (Ready)..............................................................................................109
11.4 Torque Mode Command ............................................................................... 110
11.4.1 TOQ (Torque mode drive) ....................................................................... 11 0
12 Driver Function ........................................................................ 111
12.1 General Drive ................................................................................................. 111
12.1.1 Fixed Pulse and Continuous Pulse Drive ............................................... 111
12.1.2 Speed Curve ............................................................................................ 113
12.2 Other Functions............................................................................................. 118
12.2.1 Limit Operation....................................................................................... 118
12.2.2 Motor Gain............................................................................................... 119
12.2.3 In-Position ...............................................................................................120
12.2.4 Speed Filter .............................................................................................121
12.2.5 Servo Off..................................................................................................122
12.2.6 Initial Angular Direction..........................................................................122
12.2.7 Motor Direction .......................................................................................122
12.2.8 Position Override ....................................................................................123
13 Protection Function.................................................................. 124
13.1 Alarm .............................................................................................................. 124
13.2 Warning .......................................................................................................... 128
14 Troubleshooting....................................................................... 129

1 Product Overview
12 © Copyright Reserved Autonics Co., Ltd.
1Product Overview
1.1 Features
AiCA Series is a closed- loop stepper motor driver with integrated stepping motor driver and
motion controller, which is able to control up to 31-axis simultaneously or independently
through network communication.
In addition, as AC power system, the SMPS is not required for power connection and motor
system can maintain higher torque during high speed drive compared to DC type motor.
Brake operation for safe control of vertical load at power OFF and alarm occur. (Built-in
brake type)
Real-time position controllable with closed-loop system
Motor driver and controller integral type
Torque control mode surpported
As AC power type, possible to omit SMPS and perform higher torque than DC power type
Able to check alarm and status with Alarm/Warning display (7 segment)
Controllable maximum 31 axis with RS485 communication
Auto Current Down Mode available
C language library provided (32-bit, 64-bit)
Dedicated Windows program (atMotion) provided
Easy to set various Gain with program (GUI)
Applicable to the precision equipment such as optical inspection equipment with the
features of maintaining torque in stop and having no micro vibration (hunting)
10-levels of resolution setting
Frame size 60mm, 86mm (Applied motor: AiA-M Series)

1 Product Overview
© Copyright Reserved Autonics Co., Ltd. 13
1.2 Components and Configuration Diagram
1.2.1 Components
1.2.1.1 Driver
AiCA-D Series Instruction manual
1.2.1.2 Motor
AiA-M Series Instruction manual
1.2.1.3 Connectors
●Power connector ●I/O connector
●Brake connector ●Communication protect connector
Make sure all of the above components are included with your product package before use.
If a component is missing or damaged, please contact Autonics orthe product distributor.
※I/O cable, motor+encoder cable and power cable are sold separately.
For more information, refer to the ‘7.5 Sold Separately’.

1 Product Overview
14 © Copyright Reserved Autonics Co., Ltd.
1.2.2 Configuration Diagram
※The thickness of cable should be same or thicker than the below specifications when
connecting the cable for connector.
①CN1 (motor+encoder connector): AWG22, AWG24
②CN2 (power connector): AWG18
③CN3 (communication cable connector): AWG28
④CN4 (I/O connector): AWG28
⑤ CN5 (brake connector): AWG 22
※In case communication is unstable due to the noise generated by supplied power or
peripheral device, use ferrite core at communication line.
※is sold separately.
※I/O cable, motor+encoder cable and pwer calbe are sold separately.
For more information, refer to ‘7.5 Sold Separately’.

1 Product Overview
© Copyright Reserved Autonics Co., Ltd. 15
Regenerative resistance
Connect Pin No. 1, 2 on power connector (CN2).
Use in condition of the high inertia load or the short deceleration time.
Forced cooling is required in condition of high surface temperature of regenerative
resistance.
Model Specifications Manufacture
IRC100
●Resistance: 100 Ω±5 %
●Specified power: 60 W(standby),
100 W(heatsink attached)
RARA Electronics Corp.
Noise fliter for power
Connect the power to suppress external noise.
- The wires should be connected as short as possible and grounded.
Model Specifications Manufacture
RNS-2006
●Specified power: 250 V
●Specified current: 6 A
●Max. leakage current: 1 mA
Orient Electronics
Surge protector
Protect the product from erxternal nois and surge by connectiong power.
Model Specifications Manufacture
LT-C12G801W
●Nominal discharge current: 2500 A
●Max. discharge current: 5000 A
●Voltage protection level: 1.5 kV
OTOWA Electric Co. Ltd
※Be sure to disconnect the surge protector when testing internal pressure.
It may result in product damage.
Noise filter for signal line
Connect to wiring to suppress external noise.
Depending on frequency, filtered noise may different.
Applications Specifications Manufacture
Comm. wire 28A2025-0A2
Lairdtech
Motor wire 28A5776-0A2
Power wire 28A5131-0A2

1 Product Overview
16 © Copyright Reserved Autonics Co., Ltd.
1.3 Ordering Information
Ai C A - D - 60 M A
①②③④⑤⑥⑦
Item Description
①Series Ai Artificial intelligent
②Category No mark Motor
C Controller
③Power A AC Power
④Item M Motor
D Driver
⑤Motor frame size 60 60ⅹ60mm
86 86ⅹ86mm
⑥Motor axial length
M Middle ‒Frame size 60mm: 48mm,
Frame size 86mm: 60mm
L Long ‒Frame size 60mm: 69mm,
Frame size 86mm: 75mm
⑦Encoder resolution A 10,000PPR (2,500PPRⅹ4-multiply)
⑧Brake No mark Standard type
B Built-in brake type.

1 Product Overview
© Copyright Reserved Autonics Co., Ltd. 17
1.4 Models
1.4.1 Standard Type
Set Driver Motor
AiCA-60MA AiCA-D-60MA AiA-M-60MA
AiCA-60LA AiCA-D-60LA AiA-M-60LA
AiCA-86MA AiCA-D-86MA AiA-M-86MA
AiCA-86LA AiCA-D-86LA AiA-M-86LA
1.4.2 Built-in Brake Type
Set Driver Motor
AiCA-60MA-B AiCA-D-60MA-B AiA-M-60MA-B
AiCA-60LA-B AiCA-D-60LA-B AiA-M-60LA-B
AiCA-86MA-B AiCA-D-86MA-B AiA-M-86MA-B
AiCA-86LA-B AiCA-D-86LA-B AiA-M-86LA-B

2 Specifications
18 © Copyright Reserved Autonics Co., Ltd.
2Specifications
2.1 Driver
Model ※1AiCA-D-60MA(-B) AiCA-D-60LA(-B) AiCA-D-86MA(-B) AiCA-D-86LA(-B)
Power
consumption
Power
supply 200-240 VACᜠ
STOP ※2Max. 60 W Max. 65 W
Max. during
operation Max. 160 W Max. 220 W Max. 250 W Max. 300 W
Max. RUN
current ※32.0 A/Phase
Auxiliary
power ※4
Power
supply 24 VDCᜡ
Input
current 0.3 A 0.5 A
STOP current 20 to 100% of max. RUN current
Rotation speed ※50 to 3000rpm
Resolution ※5500, 1000, 1600, 2000, 3200, 3600, 5000, 6400, 7200, 10000 PPR
Speed filter 0 (disable), 2, 4, 6, 8, 10, 20, 40, 60, 80, 100, 120, 140, 160, 180, 200 ms
Motor GAIN 0 to 30, Fine Gain
Positioning range -2,147,483,648 to +2,147,483,647
In-Position Fast Response: 0 to 7 or Accurate Response: 0 to 7
Motor rotation direction ※5CW, CCW
Status indicator
●Alarm/Status display part: orange LED 7seg.
●Power/Alarm indicator: green/red LED
●In-Position indicator: orange LED
●Servo On/Off indicator: blue LED
I/O Input ※6Exclusive input: 20, general input: 9
Output Exclusive output: 4, general output: 10
External power supply VEX (default: 24 VDCᜡ): 2, GEX (GND): 2
Operation mode Jog / Continuous / Index / Program / Position / Torque mode
Index step 64 steps
Program
function
Step 256 steps
Control
command
ABS (move absolute position), INC (move relative position),HOM (home search),
ICJ (jump input condition), IRD (waiting input),OPC (on/off of output port),
OPT (on pulse from output port), JMP (jump), REP (start repetition),
RPE (end repetition), END (end program), POS (position set), TIM (timer),
CMP (compare output), TOQ (torque control)
Start Power On program auto-start function
Home
search Power On home search auto-start function
RS485 Comm. Comm.speed
※5
9600, 19200, 38400, 57600, 115200 (factory default) bps
Multiaxial control 31-axis

2 Specifications
© Copyright Reserved Autonics Co., Ltd. 19
Model ※1AiCA-D-60MA(-B) AiCA-D-60LA(-B) AiCA-D-86MA(-B) AiCA-D-86LA(-B)
ID setting switch 16-bit rotary switch (0 to F), 1-bit DIP switch (ON/OFF)
Alarm
Over current, over speed, position tracking, over load, over heat,
motor connection, encoder connection, over voltage, under voltage,
motor misalignment, command speed, In-Position, memory, emergency stop,
program mode, index mode, home search mode, brake
Warning ±Software limit, ±hardware limit, over load
Input resistance 4.7 kΩ(Anode Pull-up)
Insulation resistance Over 200 MΩ(at 500 VDCᜡmegger)
Dielectric strength 1,500 VACᜠ60Hz for 1min
Vibration 1.5mm amplitude at frequency of 10 to 55Hz (for 1 min) in each X, Y, Z direction for
2 hours
Shock 300 m/s2(approx. 30 G) in each X, Y, Z direction for 3 times
Environment Ambienttemp. 0 to 50 °C, storage: -10 to 60 °C
Ambient humi. 35 to 85 %RH, storage: 10 to 90 %RH
Sold separately
●I/O cable: CO50-MP□-R ※7(standard: AiC TAG)
●Motor+Encoder cable ‒normal: C1D14M-□※8/ moving: C1DF14M-□※8
●Communication converter: SCM-WF48, SCM-US48I, SCM-38I
Protection structure IP20 (IEC standard)
Approval ᜢ
Weight ※9
●Standard type: Approx. 1,080g (approx. 800g)
●Built-in brake type: Approx. 1,050g (approx. 780g)
※1: The model name indicates driver type (none: standard type, B: built-in brake type)
E.g.) AiCA-D-60MA-B: built-in brake type stepping motor driver.
※2: Based on the ambient temperature 25℃, ambient humidity 55%RH, and STOP current 20%.
※3: RUN current varies depending on the input RUN frequency and max. RUN current at the moment
varies also.
※4: Auxiliary power is only available in built-in brake type. Corresponding specification is not available in
standard type.
※5: Settable with the dedicated program.
※6: Brake ON/OFF function can be changed in general input IN8 in case of built-in brake type only.
※7 □of model name indicates cable length (010, 020, 030, 050, 070, 100, 150, 200).
For corresponding EMC standard, cable length should be below 2m.
E.g.) CO50-MP070-R: 7m I/O cable.
※8 □of model name indicates cable length (1, 2, 3, 5, 7, 10,15, 20).
E.g.) C1DF14M-10: 10m moving type motor+encoder cable.
※9 The weight includes packaging. The weight in parenthesis is for unit only.
※Environment resistance is rated at no freezing or condensation.

2 Specifications
20 © Copyright Reserved Autonics Co., Ltd.
2.1.1 Factory Default
Function Factory default
Resolution 500PPR
Speed filter 0
Motor GAIN 0
In-Position 0
Communication speed 115,200bps
Communication ID setting switch (ID Sel) 1
Communication ID setting /
Terminating resistance setting
DIP switch (ID, TERM)
Communication ID setting (ID) OFF
Terminating resistance setting (TERM) OFF