IAI ASEP User manual

DSEP Controller
ASEP Controller
PSEP Controller
Instruction Manual Tenth Edition
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[Important]
This Instruction Manual is original.
The product cannot be operated in any way unless expressly specified in this Instruction Manual.
IAI shall assume no responsibility for the outcome of any operation not specified herein.
Information contained in this Instruction Manual is subject to change without notice for the purpose
of product improvement.
If you have any question or comment regarding the content of this manual, please contact the IAI
sales office near you.
Using or copying all or part of this Instruction Manual without permission is prohibited.
The company names, names of products and trademarks of each company shown in the
sentences are registered trademarks.
Please Read Before Use
Thank you for purchasing our product.
This Instruction Manual describes all necessary information items to operate this product safely such as
the operation procedure, structure and maintenance procedure.
Before the operation, read this manual carefully and fully understand it to operate this product safely. The
enclosed CD/DVD in this product package includes the Instruction Manual for this product.
For the operation of this product, print out the necessary sections in the Instruction Manual or display
them using the personal computer.
After reading through this manual, keep this Instruction Manual at hand so that the operator of this
product can read it whenever necessary.

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Table of Contents
Safety Guide.............................................................................................................................1
International Standards Compliances .....................................................................................8
CE Marking...............................................................................................................................9
Precautions in Operation .......................................................................................................10
Name for Each Parts and Their Functions............................................................................14
Actuator Axes .........................................................................................................................16
Starting Procedures ...............................................................................................................18
1. Specifications Check ......................................................................................................19
1.1 Product Check..................................................................................................................................19
1.1.1 Parts …………………………………………………………………………………………… 19
1.1.2 Teaching Tool (to be purchased separately) ………………………………………………… 19
1.1.3 Instruction manuals related to this product, which are contained in the
instruction manual (CD/DVD). ……………………………………………………………… 20
1.1.4 How to read the model plate ………………………………………………………………… 20
1.1.5 How to read the model of the controller……………………………………………………… 20
1.2 Basic Specifications .........................................................................................................................22
1.3 External Dimensions........................................................................................................................24
1.4 I/O Specifications .............................................................................................................................25
1.4.1 PIO Input and Output Interface ……………………………………………………………… 25
1.5 Installation Environment...................................................................................................................26
1.6 Installation and Noise Elimination ...................................................................................................27
2. Wiring ..............................................................................................................................29
2.1 Wiring Diagram (Connection of construction devices) ...................................................................29
2.2 PIO Pattern Selection and PIO Signal ............................................................................................30
2.3 Circuit Diagram (Example) ..............................................................................................................35
2.4 Wiring Method ..................................................................................................................................41
2.4.1 Wiring Layout of Power Supply Connector ………………………………………………… 41
2.4.2 Wiring Layout of FG Terminal Block ………………………………………………………… 42
2.4.3 Connection to Actuator ……………………………………………………………………… 43
2.4.4 Connection of PIO …………………………………………………………………………… 44
2.4.5 SIO Connector Connection…………………………………………………………………… 45
2.4.6 Battery Connector Connection (For Simple Absolute Type) ……………………………… 46

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3. Operation.........................................................................................................................48
3.1 Setting...............................................................................................................................................48
3.1.1 Initial Setting …………………………………………………………………………………… 48
3.1.2 Position Data Setting ………………………………………………………………………… 50
3.1.3 Absolute Reset
(This function is effective only when the controller and actuator are the absolute type). … 54
3.2 Power-up and PIO Control ..............................................................................................................55
3.2.1 Control of Input Signal ………………………………………………………………………… 55
3.2.2 Power Input …………………………………………………………………………………… 56
3.2.3 Home-return …………………………………………………………………………………… 57
3.3 Timing Chart .....................................................................................................................................58
3.4 User Parameters..............................................................................................................................63
3.5 Servo Adjustment.............................................................................................................................65
3.5.1 Adjustment for ASEP and PSEP …………………………………………………………… 65
3.5.2 Adjustment for DSEP ………………………………………………………………………… 66
3.5.3 Servo Parameter ……………………………………………………………………………… 68
3.6 Alarm.................................................................................................................................................69
3.6.1 Alarm Level …………………………………………………………………………………… 69
3.6.2 Alarm Codes and Trouble Shooting ………………………………………………………… 70
4. Appendix .........................................................................................................................75
4.1 List of Specifications of Connectable Actuators..............................................................................75
4.2 Pressing Force and Current Limit Value .........................................................................................99
5. Warranty........................................................................................................................106
5.1 Warranty Period .............................................................................................................................106
5.2 Scope of Warranty .........................................................................................................................106
5.3 Honoring the Warranty...................................................................................................................106
5.4 Limited Liability...............................................................................................................................106
5.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications.....107
5.6 Other Items Excluded from Warranty............................................................................................107
Change History.....................................................................................................................108

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Safety Precautions for Our Products
The common safety precautions for the use of any of our robots in each operation.
No. Operation
Description Description
1 Model Selection ●This product has not been planned and designed for the application
where high level of safety is required, so the guarantee of the protection of
human life is impossible. Accordingly, do not use it in any of the following
applications.
1) Medical equipment used to maintain, control or otherwise affect human
life or physical health.
2) Mechanisms and machinery designed for the purpose of moving or
transporting people (For vehicle, railway facility or air navigation facility)
3) Important safety parts of machinery (Safety device, etc.)
●Do not use the product outside the specifications. Failure to do so may
considerably shorten the life of the product.
●Do not use it in any of the following environments.
1) Location where there is any inflammable gas, inflammable object or
explosive
2) Place with potential exposure to radiation
3) Location with the ambient temperature or relative humidity exceeding
the specification range
4) Location where radiant heat is added from direct sunlight or other large
heat source
5) Location where condensation occurs due to abrupt temperature
changes
6) Location where there is any corrosive gas (sulfuric acid or hydrochloric
acid)
7) Location exposed to significant amount of dust, salt or iron powder
8) Location subject to direct vibration or impact
●For an actuator used in vertical orientation, select a model which is
equipped with a brake. If selecting a model with no brake, the moving part
may drop when the power is turned OFF and may cause an accident such
as an injury or damage on the work piece.
Safety Guide
“Safety Guide” has been written to use the machine safely and so prevent personal injury or property
damage beforehand. Make sure to read it before the operation of this product.

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No. Operation
Description Description
2 Transportation ●When carrying a heavy object, do the work with two or more persons or
utilize equipment such as crane.
●When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
●When in transportation, consider well about the positions to hold, weight
and weight balance and pay special attention to the carried object so it
would not get hit or dropped.
●Transport it using an appropriate transportation measure.
The actuators available for transportation with a crane have eyebolts
attached or there are tapped holes to attach bolts. Follow the instructions
in the instruction manual for each model.
●Do not step or sit on the package.
●Do not put any heavy thing that can deform the package, on it.
●When using a crane capable of 1t or more of weight, have an operator
who has qualifications for crane operation and sling work.
●When using a crane or equivalent equipments, make sure not to hang a
load that weighs more than the equipment’s capability limit.
●Use a hook that is suitable for the load. Consider the safety factor of the
hook in such factors as shear strength.
●Do not get on the load that is hung on a crane.
●Do not leave a load hung up with a crane.
●Do not stand under the load that is hung up with a crane.
3 Storage and
Preservation
●The storage and preservation environment conforms to the installation
environment. However, especially give consideration to the prevention of
condensation.
●Store the products with a consideration not to fall them over or drop due to
an act of God such as earthquake.
4 Installation and
Start
(1) Installation of Robot Main Body and Controller, etc.
●Make sure to securely hold and fix the product (including the work part). A
fall, drop or abnormal motion of the product may cause a damage or injury.
Also, be equipped for a fall-over or drop due to an act of God such as
earthquake.
●Do not get on or put anything on the product. Failure to do so may
cause an accidental fall, injury or damage to the product due to a drop
of anything, malfunction of the product, performance degradation, or
shortening of its life.
●When using the product in any of the places specified below, provide a
sufficient shield.
1) Location where electric noise is generated
2) Location where high electrical or magnetic field is present
3) Location with the mains or power lines passing nearby
4) Location where the product may come in contact with water, oil or
chemical droplets

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No. Operation
Description Description
4 Installation and
Start
(2) Cable Wiring
●Use our company’s genuine cables for connecting between the actuator
and controller, and for the teaching tool.
●Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not
coil it around. Do not insert it. Do not put any heavy thing on it. Failure to
do so may cause a fire, electric shock or malfunction due to leakage or
continuity error.
●Perform the wiring for the product, after turning OFF the power to the unit,
so that there is no wiring error.
●When the direct current power (+24V) is connected, take the great care of
the directions of positive and negative poles. If the connection direction is
not correct, it might cause a fire, product breakdown or malfunction.
●Connect the cable connector securely so that there is no disconnection or
looseness. Failure to do so may cause a fire, electric shock or malfunction
of the product.
●Never cut and/or reconnect the cables supplied with the product for the
purpose of extending or shortening the cable length. Failure to do so may
cause the product to malfunction or cause fire.
(3) Grounding
●The grounding operation should be performed to prevent an electric shock
or electrostatic charge, enhance the noise-resistance ability and control
the unnecessary electromagnetic radiation.
●For the ground terminal on the AC power cable of the controller and the
grounding plate in the control panel, make sure to use a twisted pair cable
with wire thickness 0.5mm2(AWG20 or equivalent) or more for grounding
work. For security grounding, it is necessary to select an appropriate
wire thickness suitable for the load. Perform wiring that satisfies the
specifications (electrical equipment technical standards).
●Perform Class D Grounding (former Class 3 Grounding with ground
resistance 100Ωor below).

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No. Operation
Description Description
4 Installation and
Start
(4) Safety Measures
●When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
●When the product is under operation or in the ready mode, take the safety
measures (such as the installation of safety and protection fence) so that
nobody can enter the area within the robot’s movable range. When the
robot under operation is touched, it may result in death or serious injury.
●Make sure to install the emergency stop circuit so that the unit can be
stopped immediately in an emergency during the unit operation.
●Take the safety measure not to start up the unit only with the power turning
ON. Failure to do so may start up the machine suddenly and cause an
injury or damage to the product.
●Take the safety measure not to start up the machine only with the
emergency stop cancellation or recovery after the power failure. Failure
to do so may result in an electric shock or injury due to unexpected power
input.
●When the installation or adjustment operation is to be performed, give
clear warnings such as “Under Operation; Do not turn ON the power!” etc.
Sudden power input may cause an electric shock or injury.
●Take the measure so that the work part is not dropped in power failure or
emergency stop.
●Wear protection gloves, goggle or safety shoes, as necessary, to secure
safety.
●Do not insert a finger or object in the openings in the product. Failure to do
so may cause an injury, electric shock, damage to the product or fire.
●When releasing the brake on a vertically oriented actuator, exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
5 Teaching ●When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
●Perform the teaching operation from outside the safety protection
fence, if possible. In the case that the operation is to be performed
unavoidably inside the safety protection fence, prepare the “Stipulations
for the Operation” and make sure that all the workers acknowledge and
understand them well.
●When the operation is to be performed inside the safety protection fence,
the worker should have an emergency stop switch at hand with him so that
the unit can be stopped any time in an emergency.
●When the operation is to be performed inside the safety protection fence,
in addition to the workers, arrange a watchman so that the machine can
be stopped any time in an emergency. Also, keep watch on the operation
so that any third person can not operate the switches carelessly.
●Place a sign “Under Operation” at the position easy to see.
●When releasing the brake on a vertically oriented actuator, exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
* Safety protection Fence : In the case that there is no safety protection
fence, the movable range should be indicated.

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No. Operation
Description Description
6 Trial Operation ●When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
●After the teaching or programming operation, perform the check operation
one step by one step and then shift to the automatic operation.
●When the check operation is to be performed inside the safety protection
fence, perform the check operation using the previously specified work
procedure like the teaching operation.
●Make sure to perform the programmed operation check at the safety
speed. Failure to do so may result in an accident due to unexpected
motion caused by a program error, etc.
●Do not touch the terminal block or any of the various setting switches in
the power ON mode. Failure to do so may result in an electric shock or
malfunction.
7 Automatic
Operation
●Check before starting the automatic operation or rebooting after operation
stop that there is nobody in the safety protection fence.
●Before starting automatic operation, make sure that all peripheral
equipment is in an automatic-operation-ready state and there is no alarm
indication.
●Make sure to operate automatic operation start from outside of the safety
protection fence.
●In the case that there is any abnormal heating, smoke, offensive smell,
or abnormal noise in the product, immediately stop the machine and turn
OFF the power switch. Failure to do so may result in a fire or damage to
the product.
●When a power failure occurs, turn OFF the power switch. Failure to do so
may cause an injury or damage to the product, due to a sudden motion of
the product in the recovery operation from the power failure.

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No. Operation
Description Description
8 Maintenance
and Inspection
●When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
●Perform the work out of the safety protection fence, if possible. In the
case that the operation is to be performed unavoidably inside the safety
protection fence, prepare the “Stipulations for the Operation” and make
sure that all the workers acknowledge and understand them well.
●When the work is to be performed inside the safety protection fence,
basically turn OFF the power switch.
●When the operation is to be performed inside the safety protection fence,
the worker should have an emergency stop switch at hand with him so that
the unit can be stopped any time in an emergency.
●When the operation is to be performed inside the safety protection fence,
in addition to the workers, arrange a watchman so that the machine can
be stopped any time in an emergency. Also, keep watch on the operation
so that any third person can not operate the switches carelessly.
●Place a sign “Under Operation” at the position easy to see.
●For the grease for the guide or ball screw, use appropriate grease
according to the Instruction Manual for each model.
●Do not perform the dielectric strength test. Failure to do so may result in a
damage to the product.
●When releasing the brake on a vertically oriented actuator, exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
●The slider or rod may get misaligned OFF the stop position if the servo
is turned OFF. Be careful not to get injured or damaged due to an
unnecessary operation.
●Pay attention not to lose the cover or untightened screws, and make sure
to put the product back to the original condition after maintenance and
inspection works.
Use in incomplete condition may cause damage to the product or an injury.
* Safety protection Fence : In the case that there is no safety protection
fence, the movable range should be indicated.
9 Modification and
Dismantle
●Do not modify, disassemble, assemble or use of maintenance parts not
specified based at your own discretion.
10 Disposal ●When the product becomes no longer usable or necessary, dispose of it
properly as an industrial waste.
●When removing the actuator for disposal, pay attention to drop of
components when detaching screws.
●Do not put the product in a fire when disposing of it.
The product may burst or generate toxic gases.
11 Other ●Do not come close to the product or the harnesses if you are a person who
requires a support of medical devices such as a pacemaker. Doing so may
affect the performance of your medical device.
●See Overseas Specifications Compliance Manual to check whether
complies if necessary.
●For the handling of actuators and controllers, follow the dedicated
instruction manual of each unit to ensure the safety.

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Alert Indication
The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the
warning level, as follows, and described in the Instruction Manual for each model.
Level Degree of Danger and Damage Symbol
Danger
This indicates an imminently hazardous situation which, if the
product is not handled correctly, will result in death or serious
injury.
Danger
Warning
This indicates a potentially hazardous situation which, if the
product is not handled correctly, could result in death or serious
injury.
Warning
Caution
This indicates a potentially hazardous situation which, if the
product is not handled correctly, may result in minor injury or
property damage.
Caution
Notice This indicates lower possibility for the injury, but should be kept to
use this product properly. Notice

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ASEP/PSEP and DSEP comply with the following international standards:
RoHS Directive CE Marking UL (Note)
○○○
(Note) The DSEP is not applicable to UL.
International Standards Compliances

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CE Marking
If a compliance with the CE Marking is required, please follow Overseas Standards Compliance
Manual (ME0287) that is provided separately.

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Precautions in Operation
1. Use the following teaching tools.
Use the teaching tool such as the PC software stated in the next clause as the applicable for this
controller.
●Teaching Tools that is applicable for this controller
[Refer to 1.2.2]
2. Backup the data to secure for breakdown.
A non-volatile memory is used as the backup memory for this controller. All the registered
position data and parameters are written into this memory and backed-up at the same time.
Therefore, you will not usually lose the data even if the power is shut down. However, make sure
to save the latest data so a quick recovery action can be taken in case when the controller is
broken and needs to be replaced with another one.
How to Save Data
(1) Save the data to CD-R or hard disk with using the PC software
(2) Hard-copy the information of position tables and parameters on paper
3. Set the operation patterns.
This controller possesses 6 types of control logics to meet various ways of usage, and changes
the role of each PIO signal following the selected control logic.
The setup can be performed in the initial setting.
[Refer to 2.1]
The PIO pattern is set to “0” (Standard Point-to-Point Movement) when the unit is delivered. Set
the operation pattern setting to the logic that suits to your use after the power is turned on.
Warning:
Please note it is very risky when the control sequence and PIO pattern setting do not match to each
other. It may not only cause the normal operation disabled, but also may cause an unexpected
movement.

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4. Operation cannot be performed unless there is an input of Servo-on
Signal and Pause Signal.
(1) Servo-on Signal (SON)
Servo-on signal (SON) is selectable from either “Enable” or “Disable” by the setting.
It is settable in the initial setting.
[Refer to 2.1 Setting]
If it is set to “Enable”, the actuator would not operate unless turning this signal on.
If it is set to “Disable”, the servo becomes on and the actuator operation becomes enabled
as soon as the power supply to the controller is turned on and the emergency stop signal is
cancelled.
[Refer to 2.1 Setting]
It is set to “Disable” when the unit is delivered. Have the setting that suits to the desirable control
logic.
(2) Pause Signal (*STP)
The input signal of the pause signal (*STP) is always on considering the safety. Therefore, in
general, the actuator would not operate if this signal is not on.
It is available to make this signal to “Not to use”, if this signal is undesirable.
It is settable in the initial setting.
[Refer to 2.1 Setting]
If it is set to “Not to use”, the actuator operation is available even without this signal being on.
It is set to “Not to use” when the unit is delivered.
5. Rotary actuator cannot be set to Multi-Rotation Specification.
Rotary actuator cannot be set to Multi-Rotation Specification since the index mode setting cannot
be performed.

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Output
Process
Input
Process
6. Transference of PIO Signal between Controllers
Please note the following when conducting transference of PIO signal between controllers.
To certainly transfer the signal between controllers with different scan time, it is necessary to
have longer scan time than the one longer than the other controller. To ensure to end the process
safely, it is recommended to have the timer setting more than twice as long as the longer scan
time at least.
●Operation Image
PLC
(e.g. scan time is 20msec)
Also, if one tries to read the signal that is being re-written by the other, the signal may be read wrongly.
Make sure to read the signal after the rewriting is complete. (It is recommended to have more than 2
scan periods to wait.) Make sure not to have the output side to change the output until the other side
completes the reading. Also, a setting is made on the input area not to receive the signal less than a
certain time to prevent a wrong reading of noise. This duration also needs to be considered.
This controller
(scan time 1msec)
As shown in the diagram, the input and output
timings of two devices that have different scan
time do not match, of course, when transferring
a signal.
There is no guarantee that PLC would read the
signal as soon as this controller signal turns on.
In such a case, make the setting to read the
signal after a certain time that is longer than the
longer scan time to ensure the reading process
to succeed on the PLC side.
It is the same in the case this controller side
reads the signal.
In such a case, it is recommended to ensure 2
to 4 times of the scan time for the timer setting
margin.
It is risky to have the setting below the scan
time since the timer is also processed in the
scan process.
In the diagram, PLC can only read the input
once in 20msec even though this controller
output once in 1msec.
Because PLC only conducts output process
once in 20msec, this controller identifies the
same output status for that while.

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7. PLC Timer Setting
Do not have the PLC timer setting to be done with the minimum setting.
Setting to “1” for 100msec timer turns on at the timing from 0 to 100msec while 10msec timer
from 0 to 10msec for some PLC.
Therefore, the same process as when the timer is not set is held and may cause a failure such
as the actuator cannot get positioned to the indicated position number in Positioner Mode.
Set “2” as the minimum value for the setting of 10msec timer and when setting to 100msec, use
10msec timer and set to “10”.
8. Cautions when turning Servo on (for ASEP/PSEP)
The magnetic pole phase detection may not be performed normally if the servo is turned on near
the mechanical end, and may cause such problems like an abnormal operation, magnetic pole
not being defined or electromagnetic detection error.
Put it away from the mechanical end when turning the servo on.
9. Make sure to follow the usage condition, environment and
specifications of the product.
Not doing so may cause a drop of performance or malfunction of the product.

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1) Battery Connector (It is not equipped for Incremental Type and DSEP)
If Absolute Type actuator, it is the battery connector for absolute data retention.
2) LED for ABS (It is not equipped for Incremental Type and DSEP)
Following shows the absolute data retention battery status:
Signal Indication Status Description
2Green Light is turned ON. System Normal
Red Light is turned ON. System abnormality
1
Green Light is turned ON Absolute Unit Reset Complete (ST2 lighting ON in Green)
Red Light is turned ON. • Absolute Unit Reset Incomplete (ST2 lighting ON in Green)
• Hardware Error (ST2 lighting ON in Red)
0
Green Light is turned ON Battery Fully Charged
Orange Light is turned ON. In Battery Charging Operation
Red Light is turned ON. Battery Disconnected
Name for Each Parts and Their Functions
Pictures show ASEP, It should be the same for PSEP and DSEP.
1) Battery Connector
(It is not equipped
for Incremental Type and DSEP)
2) LED for ABS
(It is not equipped
for Incremental Type and DSEP)
3) StatusLED
(for SV, ALM and EMG)
4) SIO Connector
5) PIO Connector
6) Motor · Encoder
Connector
7) Power Supply
Connector
8) FG Terminal Block