Inovance SC500 Series Manipulator Control System User Guide: Operation Panel, Axis Control and Fault Troubleshooting

The Inovance SC500 Series Manipulator Control System is a purpose-built, multi-axis motion controller designed specifically for the injection molding machine manipulator industry. Unlike conventional servo drives or standard inverters, the SC500 is a complete turnkey solution that integrates a motion control motherboard, a remote IO board, and a teach pendant (示教器). Developed by Inovance Technology to address the unique demands of industrial robot and manipulator applications, this control system offers a compact footprint, robust EtherCAT bus connectivity with Inovance servo drives and motors, automatic servo parameter tuning, and powerful motion control capabilities with intelligent safety features.

This comprehensive guide covers the complete functional application of the SC500 system, including system architecture, teach pendant operation, multi-axis terminal control, program management, parameter configuration, and detailed fault diagnosis procedures.

1. System Overview

The SC500 series manipulator control system represents a paradigm shift in industrial robot control by combining hardware integration with intelligent software automation. The system architecture consists of three primary components: the motion control motherboard, the remote IO board, and the teach pendant. This tightly integrated hardware suite communicates via the EtherCAT industrial Ethernet protocol, enabling real-time deterministic control across all connected axes and peripherals.

1.1 System Architecture

At the heart of the SC500 is the motion control motherboard, which serves as the central processing unit responsible for trajectory planning, motion interpolation, and real-time coordination of up to eight primary axes. The motherboard manages all high-speed motion calculations, synchronizes multi-axis movements, and interfaces directly with the injection molding machine through dedicated local IO terminals.

The remote IO board extends the system’s input and output capabilities, providing configurable digital inputs and outputs for end-effectors, sensors, pneumatic valves, and auxiliary equipment. The remote IO communicates with the motherboard over EtherCAT, ensuring deterministic response times essential for synchronized pick-and-place operations.

The teach pendant serves as the primary human-machine interface (HMI). It features a touchscreen display, physical axis control keys, an emergency stop button, a mode selection rotary switch, and a manual pulse generator (handwheel) for precise micro-positioning. The teach pendant runs the system firmware that manages program storage, parameter configuration, and real-time operation monitoring.

1.2 Supported Axes and Coordinate System

The SC500 supports a comprehensive multi-axis configuration tailored to injection molding manipulators:

Each axis can be configured as either a servo axis (using Inovance EtherCAT bus servo drives) or a pneumatic axis (using valve IO outputs). Additional pneumatic axes U, V, and W are also available exclusively for pneumatic control. This flexible axis definition allows the SC500 to adapt to various manipulator configurations, from simple three-axis pick-and-place arms to complex seven-axis articulated robots with dual arms and rotation capabilities.

1.3 Operating Modes

The SC500 system operates in three distinct modes, selected via the rotary mode switch on the teach pendant:

• Stop Mode: All manipulator motion is halted. This mode allows authorized users to access the settings menu for parameter configuration and program editing when sufficient privileges are granted.
• Manual Mode: Enables jog operation, handwheel micro-positioning, and axis testing. Users with administrator or higher privileges can access the programming interface in manual mode to edit and develop application programs.
• Automatic Mode: The manipulator executes stored programs automatically. Pressing the Start button initiates continuous automatic operation according to the loaded program.

Homing operations and return-to-standby operations can be performed in both Stop and Manual modes. The system implements a multi-level user privilege system: Operator (default at power-on), Administrator, and Senior Administrator, with each level unlocking progressively more advanced functionality.

2. Operation Panel

The SC500 teach pendant operation panel is ergonomically designed for both handheld and stationary operation. Understanding each physical component and the touchscreen interface is essential for efficient manipulator programming and operation.

2.1 Physical Components

2.2 Display Layout and Information Area

The touchscreen interface is divided into three functional zones:

• Information Display Area (Top): Shows system time, homing status, current speed percentage (actual speed = displayed percentage × 3000rpm), current program name, automatic runtime duration, alarm indicators, and production counters.
• Function Editing Area (Center): Displays version information and dynamically changes based on the selected menu, presenting context-sensitive data and editable fields.
• Menu Selection Area (Left): Provides navigation to Handwheel, Mode pages (Stop/Manual/Auto), Monitoring, Alarm, Product/Programming, and Settings.

2.3 Axis Key Operations

In manual mode, the axis keys on the right side of the teach pendant provide direct control over each servo and pneumatic axis. For servo axes, holding a key causes continuous motion; releasing the key stops motion. For pneumatic axes, a single press triggers the corresponding solenoid valve output. The AUX key toggles between the A and B posture axes when they share a single physical key. When an axis key is pressed, the handwheel automatically switches control to that axis for convenient fine adjustment.

3. Multi-Axis Terminal Control

The SC500 provides comprehensive terminal-based control for each axis through its IO architecture. The system distinguishes between local IO (on the motherboard, dedicated to injection molding machine interfacing) and general IO (on the remote IO board, configurable for manipulator peripherals).

3.1 IO Terminal Architecture

The main control board provides dedicated local IO terminals for direct injection molding machine communication. Local inputs include mold lock position, mold open position, safety door status, ejector forward/backward position, core insert/pull position, defective product signal, automatic mode, and emergency stop. Local outputs control mold open permission, mold close permission, ejector forward/backward permission, core insert/pull permission, mold zone safety, conveyor, feeder, and status indicator lamps.

The remote IO board expands the system with configurable digital inputs and outputs. The general IO inputs support up to 84 configurable functions, including clamp confirmation limits, suction confirmation limits, axis origin and limit switches, posture detection sensors, air pressure monitoring, safety zone signals, and reserved inputs. The general IO outputs provide 72 configurable functions, including clamp valves, suction valves, posture valves, rotation valves, stacking completion signals, and auxiliary equipment control.

3.2 Per-Axis Terminal Functions

Each servo axis has dedicated terminal connections for:

• Origin/Home Sensor: Used for homing sequence determination.
• Positive/Negative Limit Switches: Hardware travel limits for mechanical protection.
• Servo Drive EtherCAT Interface: Real-time command and feedback communication.

Pneumatic axes use simple digital output terminals connected to solenoid valves, with optional feedback sensors for confirmation.

3.3 Port Customization

The system supports full port customization through the “Signal Settings → Port Customization” page. Users can remap logical functions to different physical IO ports, rename signals for clarity, and import/export port configurations via USB. Hardware interlocks restrict certain port swaps within predefined groups to prevent dangerous misconfigurations.

4. Motion Programming

The SC500 programming environment provides a powerful yet accessible framework for creating manipulator automation sequences. Each program module contains one main program and up to eight sub-programs, enabling modular and reusable code structures for complex pick-and-place cycles.

4.1 Program Structure

Programs are created, copied, loaded, imported, and exported through the Product page in Stop mode. Program names support up to 20 characters using Chinese characters, letters, and numbers. USB import/export functionality allows convenient offline program development and backup.

4.2 General Programming

The general programming module includes nine action categories:

4.2.1 Axis Motion Programming

Axis motion commands control servo and pneumatic axes. For servo axes, programmers set target position (absolute or relative), motion speed, and delay time. Advanced features include look-ahead ending (allowing the next program step to begin before the axis fully reaches target), look-ahead deceleration (slowing the axis before target), and look-ahead acceleration (starting at reduced speed then ramping up). The “Read” button captures the current axis position directly into the position field, streamlining teach programming.

4.2.2 End-Effector Programming

The system controls four clamp groups and four suction groups. Programming actions include enabling/disabling the output, setting delay times, and configuring confirmation limit detection to verify successful gripping.

4.2.3 Detection Programming

Detection commands verify end-effector status and sensor states. Missing confirmation detection in automatic operation can result in mold damage, making this programming step critical.

4.2.4 Injection Machine Signal Programming

The manipulator can command the injection molding machine to perform mold closing, ejector forward/backward, and core insert/pull actions through dedicated digital outputs.

4.2.5 Wait Programming

Wait commands pause program execution until specific conditions are met: sub-program completion, machine signals (mold open complete, safety door, ejector positions), or end-effector confirmation signals.

4.2.6 Stacking Programming

Stacking commands organize products in regular arrays, free-form patterns, or within containers. The system supports eight stacking groups, with groups 1-5 fixed as regular stacking and groups 6-8 configurable for regular, free, or box stacking modes.

4.3 Advanced Programming

The advanced programming module provides conditional logic, labels, and variable operations:

• Conditional Programming: Triggers sub-programs based on trial production counts, sampling intervals, defective product signals, reserved signal states, or end-effector states. Execution modes include Standard (blocking), Automatic (parallel), and Parallel-Once.
• Label Programming: Adds comments and provides jump targets for conditional returns.
• Logic and Variables: Supports IF/ELSE conditional branching, FOR loops (up to 10 nested levels, 50 total loops per program), 16 user variables with arithmetic operations (+, −, ×, ÷, =), and 9 timers with millisecond resolution.

4.4 Quick Programming

For rapid deployment, the quick programming wizard guides users through a six-step configuration: arm selection, standby point definition, pick position, product placement, sprue placement, and stacking configuration. This feature dramatically reduces setup time for standard applications.

5. Parameter Configuration

Proper parameter configuration is essential for safe and efficient manipulator operation. The SC500 organizes parameters into signal settings, system settings, stacking settings, production settings, safety points, maintenance functions, operating parameters, and machine parameters.

5.1 Signal Settings

Signal settings define the logical behavior of inputs and outputs. Key configurations include:

• Signal Definition: Sets clamp and suction confirmation logic (normal/reverse phase), air pressure detection mode, origin homing conditions, safety door monitoring, and limit detection modes.
• Safety Definition: Configures posture restrictions during traverse and descent, safety door behaviors, and flip restrictions within the mold.
• Reserved Definition: Enables three groups of reserved interlock signals to prevent conflicting outputs.

5.2 System Settings

System settings manage basic configuration, user privileges, data backup/restore, software registration, system information, firmware upgrades, and RS485 communication parameters. The software registration feature requires activation before automatic mode operation is permitted.

5.3 Motion Parameters

Operating parameters control the dynamic behavior of all axes:

• Acceleration/Deceleration Time: Configurable separately for inside-mold and outside-mold automatic operation, as well as manual mode. Synchronization options ensure consistent profiles across all zones.
• Speed Limits: Maximum speed percentages (base 3000rpm) and tolerance values for position following errors.
• Motion Smoothness: Adjustable from 0 to 100 for trapezoidal or S-curve motion profiles.
• Look-Ahead Levels: Uniform percentage-based early-end positions for each axis and direction, reducing cycle time without individual step configuration.

5.4 Machine Parameters

Machine parameters define the physical characteristics of each axis:

5.5 Safety Points

Safety point parameters restrict axis movement based on manipulator position relative to the mold. For X1/X2 axes, configurable limits prevent collisions when Y axes are at specific heights. For Y1/Y2 axes, maximum movement and standby positions restrict descent when the traverse axis is in unsafe zones. Z-axis safety zones distinguish between inside-mold and outside-mold areas. ABC posture axes define safe traverse ranges. These parameters form a critical safety interlock matrix that prevents mechanical collisions and mold damage.

6. Fault Codes

The SC500 provides extensive diagnostic capabilities with categorized alarm codes. Understanding these fault codes enables rapid troubleshooting and minimizes production downtime.

6.1 System-Level Faults (Codes 1-99)

System alarms indicate communication failures, parameter mismatches, initialization errors, and registration issues. Common system faults include:

6.2 Program and Parameter Faults (Codes 100-260)

These alarms indicate programming errors, missing standby points, parameter conflicts, and runtime logic violations. Examples include missing axis standby points (codes 100-107), invalid program pointers, CRC checksum errors, and reserved signal interlock conflicts. Remedies typically involve re-editing programs, saving parameters, or checking mechanical limit configurations.

6.3 Axis Limit and Motion Faults (Codes 300-355)

Axis-specific alarms protect the manipulator from mechanical overtravel and operational conflicts:

6.4 Servo Enable and Axis Definition Faults (Codes 236-251)

These alarms activate when an axis is commanded but not properly configured or enabled. Common causes include attempting servo motion on a pneumatic axis (codes 236-243), servo drive not enabled due to emergency stop state or drive alarm (codes 244-251), or axis definition mismatches. Resolution requires verifying axis definitions in Machine Parameters → Structure, ensuring emergency stop is released, and consulting servo drive manuals for drive-specific alarms.

6.5 Monitoring and Diagnostic Tools

The system provides real-time monitoring of all IO signals and servo parameters. The alarm log records up to 500 historical alarm events with timestamps. The modification log tracks parameter changes and mode switches. The system diagnosis (black box) function captures motion planning data around alarm events, enabling export of detailed diagnostic reports to USB for engineering analysis.

This guide provides the foundational knowledge required to operate, program, and maintain the Inovance SC500 Series Manipulator Control System. For detailed wiring diagrams, hardware installation procedures, and servo drive-specific parameters, refer to the SC500 Hardware Manual (Document 19011609) and the respective servo drive documentation.