ACON-CY Controller Solenoid Valve Type Operation Manual Thirteen Edition
Please Read Before Use Thank you for purchasing our product. This Operation Manual explains the handling methods, structure and maintenance of this product, among others, providing the information you need to know to use the product safely. Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of the product. The CD that comes with the product contains operation manuals for IAI products.
CAUTION 1. Use Environment ACON controllers can be used in an environment of pollution degree 2 or equivalent. 2. PC Software and Teaching Pendant Models New functions have been added to the entire ACON controller series. To support these new features, the communication protocol has been changed to the general Modbus (Modbus-compliant) mode. As a result, the existing PC software programs and teaching pendants compatible with RCS controllers can no longer be used.
CAUTION x Changes to Zone Function Applicable application versions: V0015 and later Among the zone signal settings, those that result in “Zone setting+ < Zone setting-” are now effective. V0014 and earlier: “Zone setting+ d Zone setting-” o A zone signal is not output. V0015 and later: “Zone setting+ = Zone setting-” o This is the only condition in which a zone signal is not output.
CE Marking If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.
Table of Contents Please Read Before Use ..................................................................................................................................... 3 Safety Guide ........................................................................................................................................................ 1 1. Overview .................................................................................................................................................. 9 1.
5.2.3 Position Table and Parameter Settings Required for Operation..................................... 48 Test Operation .............................................................................................................. 48 Safety speed during manual feed...................................................................................... 48 Speed override for move commands from the PLC .......................................................... 48 Full-scale Operation .........................
6.2.3 6.2.4 7. Pole Sensing Type (No. 30 PHSP) .............................................................................. 81 Safety Speed (No. 35 SAFV)........................................................................................ 81 Automatic Servo-off Delay Time (No. 36 ASO1/No. 37 ASO2/No. 38 ASO3) ............. 82 Default Standstill Mode (No. 53 CTLF) ........................................................................ 82 Push Speed (No. 34 PSHV) .....................................
Safety Guide When designing and manufacturing a robot system, ensure safety by following the safety guides provided below and taking the necessary measures. Regulations and Standards Governing Industrial Robots Safety measures on mechanical devices are generally classified into four categories under the International Industrial Standard ISO/DIS 12100, “Safety of machinery,” as follows: Safety measures Inherent safety design Protective guards --- Safety fence, etc.
Requirements for Industrial Robots under Ordinance on Industrial Safety and Health Work area Work condition Outside movement range During automatic operation Cutoff of drive source Not cut off Cut off (including stopping of operation) During teaching, etc. Inside movement range Not cut off Cut off During inspection, etc. Not cut off (when inspection, etc., must be performed during operation) 2 Measure Signs for starting operation Installation of railings, enclosures, etc. Sign, etc.
Applicable Models of IAI’ s Industrial Robots Machines meeting the following conditions are not classified as industrial robots according to Notice of Ministry of Labor No. 51 and Notice of Ministry of Labor/Labor Standards Office Director (Ki-Hatsu No.
Notes on Safety of Our Products Common items you should note when performing each task on any IAI robot are explained below. No. Task 1 Model selection z z z 2 Note This product is not planned or designed for uses requiring high degrees of safety. Accordingly, it cannot be used to sustain or support life and must not be used in the following applications: [1] Medical devices relating to maintenance, management, etc.
No. Task 4 Installation/ startup 5 Teaching Note (2) Wiring the cables z Use IAI’s genuine cables to connect the actuator and controller or connect a teaching tool, etc. z Do not damage, forcibly bend, pull, loop round an object or pinch the cables or place heavy articles on top. Current leak or poor electrical continuity may occur, resulting in fire, electric shock or malfunction. z Wire the product correctly after turning off the power.
No. Task 6 Confirmation operation z z z z 7 Automatic operation z z z z z 8 Maintenance/ inspection z z z z z z z z 9 Modification * z z 10 Disposal z z 6 Note After teaching or programming, carry out step-by-step confirmation operation before switching to automatic operation. When carrying out confirmation operation inside the safety fences, follow the specified work procedure just like during teaching. When confirming the program operation, use the safety speed.
Indication of Cautionary Information The operation manual for each model denotes safety guides under “Danger,” “Warning,” “Caution” and “Note,” as specified below. Level Degree of danger/loss Symbol Danger Failure to observe the instruction will result in an imminent danger leading to death or serious injury. Danger Warning Failure to observe the instruction may result in death or serious injury. Warning Caution Failure to observe the instruction may result in injury or property damage.
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1. 1.1 Overview Introduction z Limited I/O positioning points (3 points) The I/O signals are designed to function in the same manner as those of air cylinders. Two operation types are supported. The movement complete signals have different meanings in each type. x Solenoid valve mode 0--- Each movement complete signal works as an auto switch. Even when positioning operation is not performed, a movement complete signal is output once the specified position is passed.
1. Overview 1.2 Differences from Air Cylinders in Control Functions For those of you who have been using air cylinders and have never used motorized cylinders before, this section gives a brief explanation of how this controller is different from air cylinders. Read the following information and implement controls appropriate for your system. Item Drive method Target position setting Air cylinder Air pressure by solenoid valve control. Mechanical stopper (including shock absorber).
[2] Rear end Home position [3] Power-on position ACON When the power is turned on, mechanical coordinates are not stored in the controller and thus the current position is not yet determined. For this reason, a rear end move command must be executed after the power has been turned on, in order to establish coordinates. The actuator performs homing first, and then moves to the rear end. [1] [1] The actuator moves toward the mechanical end on the motor side at the homing speed.
1. Overview 1.
1.4 System Configuration This controller performs positioning to 3 points (rear end, intermediate point, front end) via a PLC and I/O signals. 1. Overview Standard teaching pendant ACON-CY controller Flat cable Cable length: 2 m Host system * If a PLC will not be used, disable the servo-on input by the applicable parameter.
1.5 Steps from Unpacking to Adjustment by Trial Operation 1. Overview If you are using this controller for the first time, refer to the steps explained below and perform the specified tasks carefully by making sure you check all necessary items and connect all required cables. 1. Checking the items in the package Should you find any of the following items missing or of a wrong model type, please contact your IAI sales agent.
6 Turn on the servo 1. Overview Confirm that the slider or rod is not contacting a mechanical end. If the slider/rod is contacting a mechanical end, move it away from the mechanical end. If the actuator is equipped with a brake, turn on the brake forced-release switch to forcibly release the brake before moving the actuator. The load may suddenly drop when the brake is released, so exercise due caution not to pinch your hand or damage the robot hand by the falling load.
1. Overview 1.6 Warranty 1.6.1 Warranty Period One of the following periods, whichever is shorter: Elapse of 18 months after the shipment from IAI Elapse of 12 months after the delivery to the specified location 1.6.2 Scope of Warranty Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty will be replaced or repaired free of charge: (1) The breakdown or problem in question pertains to our product as delivered by us or our authorized dealer.
1.6.6 Limited Liability The price of the product delivered to you does not include expenses associated with programming, the dispatch of engineers, etc. Accordingly, a separate fee will be charged in the following cases even during the warranty period: [1] Guidance for installation/adjustment and witnessing of test operation [2] Maintenance and inspection [3] Technical guidance and education on operating/wiring methods, etc.
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2.2 Name and Function of Each Part of the Controller Status indicator LED PIO connector 6SHFL¿FDWLRQV SV (Green) --- Indicates whether or not the servo is on. If this LED is blinking, the controller is in the automatic servo-off mode. ALM (Red) --- Indicates whether or not an alarm is present. The PIO pattern number is indicated here. If the PIO pattern is different for each system, indicate the applicable PIO pattern here to prevent confusion. Connects the PLC and PIO.
2.3 External Dimensions An external view and dimensions of this product are shown below.
3. Installation and Wiring Pay due attention to the installation environment of the controller. 3.1 Installation Environment 3.2 3. Installation and Wiring (1) When installing and wiring the controller, do not block the cooling ventilation holes. (Insufficient ventilation will not only prevent the controller from demonstrating its full performance, but it may also cause breakdown.) (2) Prevent foreign matter from entering the controller through the ventilation holes.
3.3 Noise Elimination Measures and Grounding The following explains the noise elimination measures that should be taken when using this controller. (1) Wiring and power supply connection 3. Installation and Wiring [1] Grounding must be made by ground resistance of 100 7 or less using a dedicated grounding. Moreover, the thickness of cable shall be 1.6 mm 2 or thicker.
[2] DC solenoid valves, magnet switches and relays Method: Mount diodes in parallel with the coil or use types with built-in diodes. In a DC circuit, connecting a diode in reverse polarity will damage the diode, internal parts of the controller and/or DC power supply, so exercise due caution. 3. Installation and Wiring 3.
3.5 External Connection Diagram An example of standard wiring is shown below. (Note) The PIO signal names when solenoid valve mode 0 is selected are shown below. The color of the encoder relay cable is different for the robot cable specification. Refer to 3.9.2, “Encoder Relay Cable.” ACON-CY controller 3.
3.6 Wiring the Power Supply Connect the positive side and negative side of the 24-VDC power supply to the 24-V terminal and 0-V terminal on the power-supply terminal block, respectively. Push with a flat-head screwdriver to open the cable inlet. Power-supply terminal block Cable inlet 3. Installation and Wiring Input power supply 24 VDC Use a wire satisfying the following specifications. Item Applicable wire Specification Twisted wire: AWG 22 (0.
3.8 3.8.1 Wiring the Emergency Stop Circuit Cutting off the Drive Signal (Standard) The example below shows an emergency stop circuit for the entire system that urgently stops multiple controllers. Note that the entire system cannot be stopped urgently even if emergency stop is applied from the teaching pendant. 3. Installation and Wiring External EMG External EMG circuit reset switch Under normal circumstances, it is jumpered.
Precautions on power supply and emergency stop circuit *1 Refer to the specification list for the load current conducted per controller. *2 The input current to the EMG- terminal per controller is 5 mA. When connecting a relay contact CR to EMG- terminals of several controllers, make sure to check the capacity of the relay contact. *3 When the teaching pendant is inserted to a controller, the controller automatically recognizes that it is connected.
Use an SIO converter if it is desired to stop the entire system urgently by emergent stop via the teaching pendant. The operation on the emergency stop switch of the teaching pendant can also be reflected when a gateway unit is used as well. Port switch 3. Installation and Wiring EMG switch of teaching pendant Under normal circumstances, it is jumpered. If the safety category requires shutting down motor driving source, use the following circuit (the same timing as EMG).
3.9 Connecting the Actuator (9) Dedicated relay cables are used to wire between the controller and actuator. (1) RCA motor cable Model: CB-ACS-MA CB ( indicates the cable length L. Example: 080 = 8 m) Pin assignments 3. Installation and Wiring Cable model marking Controller end Pin No. Pin assignments Actuator end Pin No. Signal name Cable color Wire size Red White Black Housing: DF1E-3S-2.5C (Hirose) Contact: DF1E-2022SC (Hirose) (or DF1B-2022SC) Housing: SLP-03V (J.S.T. Mfg.
3. Installation and Wiring (F12) (3) RCA2 monitor/encoder integrated cable Model: CB-A&6 03$ƑƑƑ (ƑƑƑ LQGicates the cable length L. Example: 080 = 8 m) Cable model marking Actuator end Controller end Housing Contact Pin No. Signal name Pin No. Cable name Red Yellow Black Pin No.
3.
3.11 Connecting the Communication Cable Connect the communication cable to the SIO connector. 3. Installation and Wiring Pin layout of cable-end connector RS485 conversion adapter end Signal Cable color abbreviation Pin No. Controller end Pin No. Signal abbreviation Cable color Brown Yellow Yellow Orange Red Orange Brown/Green Blue Black Green Shorting wire UL1004AWG28 (Black) Not connected to the shield.
4. Position Table Settings To move the actuator to a specified position, basically you must enter the target position in the “Position” field of the position table. A target position can be specified as an absolute coordinate indicating a distance from the home (absolute mode), or as a relative coordinate indicating a relative travel from the current position (incremental mode).
(3) Speed x Enter a speed at which to move the actuator, in mm/sec. The default speed varies depending on the actuator type. (4) Acceleration/ deceleration x Enter an acceleration/deceleration at which to move the actuator, in G. Basically, specify values inside the rated acceleration/deceleration range shown in the catalog. The input range is greater than the rated range specified in the catalog.
(7) Positioning band x What this field means is different in “positioning operation” and “push-motion operation.” “Positioning operation”: In the proximity switch type, this field defines the width within which the movement complete signal turns ON. In the standard type, this field defines how far before the target position the movement complete signal turns ON. The factory setting is “0.1” mm. In case of solenoid valve mode 0 4.
(8) Zone +/– x This field defines the range within which the zone output signal turns ON during operation of solenoid valve mode 1. To increase flexibility, a different range can be set for each target position. [Setting example] Position [mm] Zone + [mm] Zone – [mm] Comment Rear end Front end Rear end Move command to the rear end Home 4.
(9) Acceleration/ deceleration mode x This field defines the acceleration/deceleration pattern characteristics. The factory setting is “0.” 0: Trapezoid pattern 1: S-motion 2: Primary delay filter Trapezoid pattern Speed 4. Position Table Settings Acceleration Deceleration Time * Set the acceleration and deceleration in the “Acceleration” and “Deceleration” fields of the position table.
Primary delay filter When this pattern is selected, the motor operates along a more gradual acceleration/deceleration curve than during linear acceleration/deceleration operation (trapezoid pattern). Use this pattern when you want to prevent the work from receiving microvibration during acceleration or deceleration. 4. Position Table Settings Speed Time * (10) Incremental The level of primary delay is set in Parameter No. 55 (Primary filter time constant for position command).
(12) Standstill mode x This field defines the power-saving mode to be applied while the actuator is standing by after completing the positioning to the target position set in the “Position” field under the applicable position number. 0: Power-saving mode is disabled. * The factory setting is “0” [Disable]. 1: Automatic servo-off mode. The delay time is defined by Parameter No. 36. 2: Automatic servo-off mode. The delay time is defined by Parameter No. 37. 3: Automatic servo-off mode.
5. Operation Using I/O Signals This chapter explains the wiring/connection and operation timings you should know to perform positioning operation using a PLC and I/O signals. For PIO pattern, two types are available. The movement complete signals have different meanings in each type, so select an appropriate type according to your specific application. * Solenoid valve mode 0 is set at the shipment. 5. Operation Using I/O Signals 5.
5.1.2 External Output Specifications Item Specification Number of output points Rated load voltage Maximum current Residual voltage Insolation method 6 points 24 VDC 50 mA per point Max. 2 V Photocoupler Internal circuit configuration [NPN specification] 5.
5.1.3 Recognition of Input Signals The input signals of this controller have an input time constant to prevent malfunction due to chattering, noise, etc. Each input signal is switched when the new signal state has continued for at least 6 msec. In other words, when the input is switched from OFF to ON, the controller will recognize that the input signal is ON after 6 msec. The same applies when the input is switched from ON to OFF. 5.
5.2 Solenoid Valve Mode 0 This type assumes applications where the servo is turned on/off frequently by the PLC or the automatic servo-off function is used. Use this type if your application meets the following conditions: [1] The servo is turned off as a secondary safety measure when the emergency stop circuit is configured to directly cut off the input power.
5. Operation Using I/O Signals Detection Output for Each Position (LS0, LS1, LS2) Just like the LS signals of an air cylinder, each signal turns ON when the current actuator position is inside the positioning band set for the applicable target position. (Note) Even if the servo turns off or an emergency stop is actuated while the actuator is standing still at the target position, the signal will remain ON as long as the actuator position is inside the positioning band.
5.2.2 Timings after Power On Emergency stop cancelled Safety circuit status Supply of 24-VDC I/O power Supply of 24-VDC controller power Initial parameter settings * Servo-on input (SON) SV lamp (front panel) An orange light comes on for 2 seconds, and then turns off. Green Ready output (SV) Max. 1.6 sec * Use a teaching pendant or PC to set optimal values in the respective fields under Nos. 0 to 2 in the position table. If you have changed the value of Parameter No.
z Normal Operating Procedure The operating procedure in a normal condition is explained below. [1] Cancel the emergency stop or connect the motor drive power. [2] Supply the 24-VDC I/O power. [3] Supply the 24-VDC controller power. [4] Input a servo-on signal from the PLC [5] First, input a rear end move command signal from the PLC (to cause the actuator to stand by at the rear end). [6] Start automatic operation. Emergency stop cancelled Safety circuit status 5.
Warning: Since a servo motor is applied as the driving motor, the system performs the excitation phase detection in the first servo ON process after the power is turned ON. Therefore, it is necessary that the actuator is free for operation when the servo is turned ON.
5.2.3 Position Table and Parameter Settings Required for Operation Test Operation Immediately after the system has been started, the movement speed can be reduced as follows to ensure safety of the operator and prevent damage to the jigs, etc. Change the applicable parameters as necessary. o For details on the change operation, refer to the operation manual for the PC/teaching pendant you are using. Safety speed during manual feed 5.
5.
5.2.4 Homing This controller adopts an incremental position detector (encoder), so once the power is cut off, the mechanical coordinates will be lost. Accordingly, homing must be performed to establish the initial mechanical coordinate every time the power is turned on. To perform homing, input a rear end move command (ST0). 5. Operation Using I/O Signals Operation timings PLC processing 1: The rear end move command signal (ST0) turns ON when the start button is pressed.
5.2.5 Positioning Operation This section explains how to move the actuator from the rear end to the front end, by using an actuator with a 400-mm stroke as an example. Although the actuator is not stopped at the intermediate point in this example, you can increase the positioning band and use the intermediate point detection output signal (LS2) just like the zone output signal.
z Meaning of Position Detection Output Signals (LS0, LS1, LS2) These signals are handled in the same way as limit switches (LSs). They turn ON when the following conditions are met: [1] The homing complete output signal (HEND) is ON. [2] The current position is within the allowable distance before or after each target position (inside the positioning band).
z Speed Change during Movement If the load is made of soft material or is a bottle or has other shape that tips over easily, one of the following two methods can be used to prevent the load from receiving vibration or impact upon stopping: [1] Decrease the deceleration to make the deceleration curve more gradual. [2] Initially move the actuator at the rated speed, and decrease the feed speed shortly before the target position. An example of [2], or decreasing the feed speed, is explained.
z Pausing during Movement Move commands are implemented based on signal levels. Accordingly, the actuator moves while the signal is ON, and once the signal turns OFF, the actuator will decelerate to a stop and the operation will end. If you want to pause the actuator as a secondary safety measure, turn the move command signals OFF. (Example) Pausing the actuator while moving toward the front end Front end move command input (ST1) Front end detection output (LS1) 5.
5.3 Solenoid Valve Mode 1 This type assumes situations where the system must achieve high productivity. Use this type if your application meets the following conditions, among others: [1] Use the zone output signal to quicken the operation timings with respect to the respective equipment and thereby reduce the tact time. [2] Use the zone output signal as an interlock signal to prevent contact with peripheral equipment. Caution: 5.3.1 The controller is shipped with solenoid valve mode 0 pre-selected.
5. Operation Using I/O Signals Positioning Complete Output for Each Position (PE0, PE1, PE2) After a move command, the corresponding positioning complete output turns ON when the actuator has entered the positioning band before the target position. When the next move command to a different position is issued, the positioning complete output turns OFF.
5.3.2 Timings after Power On Emergency stop cancelled Safety circuit status Supply of 24-VDC I/O power Supply of 24-VDC controller power Initial parameter settings * Servo-on input (SON) SV lamp (front panel) An orange light comes on for 2 seconds, and then turns off. Green Ready output (SV) Max. 1.6 sec * Use a teaching pendant or PC to set optimal values in the respective fields under Nos. 0 to 2 in the position table. If you have changed the value of Parameter No.
z Normal Operating Procedure The operating procedure in a normal condition is explained below. [1] Cancel the emergency stop or connect the motor drive power. [2] Supply the 24-VDC I/O power. [3] Supply the 24-VDC controller power. [4] Input a servo-on signal from the PLC. [5] First, input a rear end move command signal from the PLC (to cause the actuator to stand by at the rear end). [6] Start automatic operation. Emergency stop cancelled Safety circuit status 5.
Warning: The excited pole phase is detected when the servo is turned on for the first time after the power has been turned on, or before an absolute reset is performed following the connection of a simple absolute unit. For this reason, the actuator moves 0.5 to 2 mm under the normal circumstances, although it depends on the lead length of ball screws. (On rare occasions where the actuator position at which the power is turned on is not ideal, the actuator may move by around one half the ball screw lead.
5.3.3 Position Table and Parameter Settings Required for Operation Test Operation Immediately after the system has been started, the movement speed can be reduced as follows to ensure safety of the operator and prevent damage to the jigs, etc. Change the applicable parameters as necessary. o For details on the change operation, refer to the operation manual for the PC/teaching pendant you are using. Safety speed during manual feed 5.
Full-scale Operation In situations where the actuator remains standstill for a long time at a standby position, this controller provides a mode to reduce power consumption in such standstill state as part of the controller’s energy-saving function. You can also select the positioning complete signal state to be applied when the servo turns off or “position deviation” occurs while the actuator is standing still after completion of positioning.
5.3.4 Homing This controller adopts an incremental position detector (encoder), so once the power is cut off, the mechanical coordinates will be lost. Accordingly, homing must be performed to establish the initial mechanical coordinate every time the power is turned on. To perform homing, input a rear end move command (ST0). 5. Operation Using I/O Signals Operation timings PLC processing 1: The rear end move command signal (ST0) turns ON when the start button is pressed.
5.3.5 Positioning Operation This section explains how to move the actuator from the rear end to the intermediate point and then to the front end, by using an actuator with a 400-mm stroke as an example.
z Meaning of Positioning Complete Output Signals (PE0, PE1, PE2) These signals indicate that the target position has been reached. They turn ON when the following conditions are met: [1] The homing complete output signal (HEND) is ON. [2] The actuator has entered the positioning band before the target position. Each signal can be used as trigger signal for peripheral equipment when the target position is reached.
z Speed Change during Movement If the load is made of soft material or is a bottle or has other shape that tips over easily, one of the following two methods can be used to prevent the load from receiving vibration or impact upon stopping: [1] Decrease the deceleration to make the deceleration curve more gradual. [2] Initially move the actuator at the rated speed, and decrease the feed speed shortly before the target position. An example of [2], or decreasing the feed speed, is explained.
z Pausing during Movement Move commands are implemented based on signal levels. Accordingly, the actuator moves while the signal is ON, and once the signal turns OFF, the actuator will decelerate to a stop and the operation will end. If you want to pause the actuator as a secondary safety measure, turn the move command signals OFF. (Example) Pausing the actuator while moving toward the front end Front end move command input (ST1) Front end positioning complete output (PE1) 5.
z Constant Pitch Feed Since a target position can also be set as a relative distance, an application where the actuator performs positioning to a series of loads placed at equal intervals is also possible. (Example) How to move the actuator from the intermediate point to the front end at a 50-mm pitch is explained. Under No. 1 in the position table, enter “50” (mm) in the “Position” field and “1” in the “Incremental” field. (1 defines that 50 mm is a relative distance.
5. Operation Using I/O Signals Operation timings PLC processing 1: The rear end move command signal (ST0) and front end move command signal (ST1) turn OFF, and the intermediate point move command signal (ST2) turns ON. Operation: [1] The actuator starts moving, and when it reaches the intermediate point, the intermediate point positioning complete output (PE2) turns ON. The zone output signal also turns ON.
5.3.6 Zone Output Signal This signal remains ON while the actuator is inside the zone set in the position table. The zone output signal can be set only at a single point, but a different zone can be set for the move command corresponding to each target position (rear end, front end, or intermediate point). Use the zone output signal in the following situations. [1] Set an interlock signal to prevent contact with peripheral equipment.
5.3.7 Push-motion Operation Just like you can with an air cylinder, you can maintain the actuator in a condition where the tip of the rod is pushing a load. Accordingly, the actuator can be used with systems that clamp, press-fit or otherwise push loads. This function is enabled by entering a current-limiting value in the “Push” field of the position table. * If the “Push” field contains “0,” positioning operation is applied. If the value in this field is other than “0,” push-motion operation is applied.
If the zone output signal dose not turn ON when the front end positioning complete output (PE1) is ON, the condition should be interpreted as “missed load” or “abnormal load installation position.
5.3.8 Examples of Tact Time Reduction Combining Zone Outputs and 3 Stop Points This section explains how the tact time is reduced differently between an application with two stop points only, and an application with three stop points where zone output signals are also used. z 2 Stop Points [Carry-out actuator] 5. Operation Using I/O Signals Rear end Front end [Carry-in actuator] Front end Rear end Machine M Assume that Machine M has completed processing.
(Reference) Timing Charts and Example of Ladder Sequence Circuit Rear end move command for carry-out side Zone II Intermediate point move command for carry-in side Front end move command for carry-in side Intermediate point Front end Machine M is processing. Chuck closed Top end Processing R2 Flat speed 5. Operation Using I/O Signals Horizontal movement of carry-in side Stopped/standing by Intermediate Front end point The Zone II signal turns ON while moving to the intermediate point.
5.4 Power-saving Mode at Standby Positions In situations where the actuator remains standstill for a long time at a standby position, this controller provides a mode to reduce power consumption in such standstill state as part of the controller’s energy-saving function. Use this mode after confirming that it will not cause problems in any part of the system.
Automatic Servo-off Mode The servo automatically turns off after elapse of a specified time following the completion of positioning. (Since no holding current is required, power consumption decreases.) When the PLC issues the next move command, the servo will turn on again and the actuator will start moving. * Since the servo turns off temporarily, slight position deviation may occur. Do not use this mode at a standby position where such position deviation may be detrimental.
6. 6.1 Parameter Settings Parameter List 6. Parameter Settings The parameters are classified into the following four types depending on their function: Types: a: Parameter relating to actuator stroke range b: Parameter relating to actuator operating characteristics c: Parameter relating to external interface d: Servo gain adjustment No.
Type b CTLF Name Default acceleration/deceleration mode 53 b CTLF Default standstill mode 54 55 56 71 d b b d CLPF PLPF SCRV PLFG Current control band number Primary filter time constant for position command S-motion ratio setting Feed-forward gain 77 b LEAD Ball screw lead length 78 b ATYP Axis operation type - 79 b ATYP Rotational axis mode selection - 80 b ATYP Shortcut selection for rotational axis - 83 b ETYP ABS unit [0: Do not used/1: Use] - 88 a SWLM Software lim
6.2 Detail Explanation of Parameters If you have changed any parameter, be sure to restart the controller via a software reset or reconnect the controller power. 6. Parameter Settings 6.2.1 Parameters Relating to Actuator Stroke Range z Soft Limits (No. 3/4 LIMM/LIML) Set the + soft limit in parameter No. 3 and – soft limit in parameter No. 4. Both parameters have been set to the effective actuator length at the factory.
z Home Direction (No. 5 ORG) If not specified by the user, the home direction is set to the motor side before shipment. If you must change the home direction after the actuator has been assembled to your equipment, change the setting of parameter No. 5. Also change the parameters for home offset, soft limits and default direction of excited phase signal detection, if necessary. Caution: Rod-type actuators do not permit reversing of the home direction.
6.2.2 Parameters Relating to Actuator Operating Characteristics z Default Speed (No. 8 VCMD) The factory setting is the rated speed of the actuator. This value is recognized as speed data corresponding to each position number when a target position is entered for that position in the position table where speed is not yet entered. To decrease the default speed from the rated speed, change the value set in Parameter No. 8. 6. Parameter Settings z Default Acceleration/Deceleration (No.
z Speed Override (No. 46 OVRD) Use this parameter if you want to move the actuator at a slow speed to prevent danger during test operation. When issuing move commands from the PLC, the movement speed set in the “Speed” field of the position table can be overridden based on the value set in Parameter No. 46. Actual movement speed = [Speed set in the position table] x [Value of Parameter No. 46] y 100 Example) Value in the “Speed” field of the position table 500 (mm/s) Value of Parameter No.
z Automatic Servo-off Delay Time (No. 36 ASO1/No. 37 ASO2/No. 38 ASO3) This parameter defines the delay time after positioning is completed until the servo turns off automatically when the “Standstill mode” field in the position table is set to any value from “1” to “3” (the automatic servo-off mode is enabled). Meaning of set value: If this parameter is set to “1,” T takes the value of Parameter No. 36. If this parameter is set to “2,” T takes the value of Parameter No. 37.
z Push Speed (No. 34 PSHV) This parameter defines the push speed that applies after the target position has been reached in push-motion operation. Before shipment, a default speed appropriate for the actuator characteristics is set. Depending on the material and shape of the load, etc., set an appropriate speed in Parameter No. 34. Note that, while the maximum speed varies according to the actuator, it should not exceed 20 mm/sec even with the high-speed type. Set a push speed below the maximum speed.
z Enable Function (No. 42 FPIO) Whether to enable or disable the deadman switch function on the ANSI-type teaching pendant is set in Parameter No. 42. * The ANSI-type teaching pendant is currently under development. Enable (Use) Disable (Do not use) Setting 0 1 The factory setting is “1” [Disable]. 6. Parameter Settings z Home Check Sensor Input Polarity (No. 43 AIOF) The home check sensor is not included in the standard specification, but it can be installed as an option.
z Home Sensor Input Polarity (No. 18 AIOF) The input polarity of the home sensor is defined in Parameter No. 18. Since the current RCA actuators do not adopt the home sensor mode, the factory setting is “0” [No sensor]. This parameter is provided to support future extension of actuator function. The customer is advised not to change the setting.
z Ball Screw Lead Length (No. 77 LEAD) This parameter defines the ball screw lead length. A default value appropriate for the characteristics of the actuator is set at the factory. z Axis Operation Type (No. 78 ATYP) This parameter defines the type of the actuator used. Definition of settings : 0 (Linear axis) : 1 (Rotational axis) z Rotational Axis Mode Selection (No.79 ATYP) If the axis operation type (No.
If the actuator is moved in the order to positions 1 Æ 2 Æ 3 Æ 4, the actuator will operate differently depending on whether or not shortcut is selected, as explained below. When shortcut is not selected Point No. 1 Point No. 1 Point No. 2 Point No. 2 Point No. 3 Point No. 4 Point No. 4 Point No. 3 When shortcut is selected 6. Parameter Settings Point No. 1 Point No. 1 Point No. 2 Point No. 2 Point No. 3 Point No. 4 Point No. 4 Point No. 3 z Absolute Unit (No. 83 ETYP) Parameter No.
6.2.3 Parameters Relating to External Interface 6. Parameter Settings z PIO Pattern Selection (No. 25 IOPN) Parameter No. 25 is used to select a desired PIO operation pattern. This is a basic operation parameter, so be sure to set it at the beginning. Setting of Features of PIO pattern Parameter No. 25 0 Solenoid valve mode 0 Each movement complete signal is handled in the same manner as an auto switch of an air cylinder.
z Servo-on Input Disable Selection (No. 21 FPIO) Parameter No. 21 is used to set whether enable or disable the servo-on input signal. Enable (Use) Disable (Do not use) Setting 0 1 The factory setting is “0” [Enable]. z Minimum Delay Time for Slave Transmitter Activation (No. 17 RTIM) It is not necessary to change the setting. It applies to controllers of serial communication type.
6.2.4 Servo Gain Adjustment Since the servo has been adjusted at the factory in accordance with the standard specification of the actuator, the servo gain need not be changed in normal conditions of use. However, vibration or noise may occur depending on how the actuator is affixed, specific load condition, and so on, and therefore the parameters relating to servo adjustment are disclosed to allow the customer to take quick actions should adjustment become necessary.
Speed Loop Integral Gain (No. 32 VLPT) Parameter number Unit Input range Default 32 --- 1 ~ 217270 Set individually in accordance with the actuator characteristics. This parameter determines the level of response with respect to a speed control loop. Decreasing the setting results in lower response to the speed command and decreases the reactive force upon load change. If the setting is too low, compliance with the position command drops and the positioning time increases as a result.
z Feed-forward Gain (No. 71 PLFG) Parameter number Unit Input range Default 71 --- 0 ~ 100 Set individually in accordance with the actuator characteristics. 6. Parameter Settings Set the amount of feed-forward gain of the position control system. Setting this parameter increases the servo gain and improves the response of operation that uses a position control loop. Use this parameter to improve the response of a mechanical system whose rigidity is low or load inertia ratio is high.
7. 7.1 Troubleshooting What to Do When A Problem Occurs If you encountered a problem, follow the steps below to conduct the specified checks to gather information needed to implement quick recovery and prevent recurrence of the problem. Before contacting IAI, please check the items in a through j above. Provide the information to our technical staff.
7.2 Alarm Level Classification The alarms are classified into three levels based on the corresponding symptoms. Alarm level ALM lamp *ALM signal Operation cancellation Lit Output Cold start Lit Output 7. Troubleshooting Note: 94 Condition at occurrence of alarm How to reset The actuator decelerates to a Execute reset using the stop, and then the servo turns off. PC/teaching pendant. The actuator decelerates to a Reconnect the power. stop, and then the servo turns off.
7.3 Alarms, Causes and Actions (1) Operation Cancellation Alarms Code Error Cause/action Position data error Cause: [1] A move command was input when a target position was not yet set in the “Position” field. [2] The target position in the “Position” field is outside the soft limit range. [3] A target position was specified as a relative coordinate in the “Position” field in solenoid valve mode 0. Action: [1] Set a target position first.
7. Troubleshooting Code Error Cause/action 0CC Excessive control power-supply voltage This alarm indicates that the voltage of the 24-V input power supply is excessive (24 V + 20%: 28.8 V or above). Cause: [1] The voltage of the 24-V input power supply is high. [2] Faulty part in the controller Action: Check the input power-supply voltage. If the voltage is normal, contact IAI.
Error Cause/action 0EE Absolute encoder error (2) Cause: [1] The power was turned on for the first time after connecting the battery of the simple absolute unit. [2] Detail code = H’0001 The battery voltage dropped to a level at which the encoder counter in the simple absolute unit could no longer retain the count. [3] Detail code = H’0002 The encoder connector was unplugged or encoder cable suffered a broken wire during power outage. [4] Detail code = H'0003 The parameter was changed.
(2) Cold Start Alarms 7. Troubleshooting Code Error Cause/action 0A1 Parameter data error Cause: The parameter data does not meet the specified input range. (Example) This alarm generates when a pair of values clearly has an inappropriate magnitude relationship, such as when the soft limit + setting is 200.3 mm, while the soft limit – setting is 300 mm. Action: Change the settings to appropriate values.
Code Error Cause/action Current-sensor offset adjustment error The status of the current detection sensor in the controller is checked during the initialization process. This alarm indicates that the sensor was found abnormal as a result of this check. Cause: [1] Faulty current detection sensor or peripheral component [2] Inappropriate offset adjustment Action: The board must be replaced or offset must be adjusted. Contact IAI.
Code Error Cause/action Nonvolatile memory timeout after write This alarm indicates that no response was received within the specified time after writing data to the nonvolatile memory. Cause: [1] Faulty nonvolatile memory [2] The memory has been rewritten more than 100,000 times. (The nominal life of the nonvolatile memory is 100,000 rewrite operations.) Action: If the problem still persists after the power has been reconnected, contact IAI.
7.4 Messages Displayed during Teaching Pendant Operation This section explains the warning messages that may be displayed while operating the teaching pendant. Code Message Description Input data error An inappropriate value was input as a user parameter setting. (Example) “9601” was input as the serial communication speed by mistake. Input an appropriate value again. 113 114 Input value too small Input value too large The input value is under the setting range.
7. Troubleshooting Code Message Description 20C CSTR-ON during operation A move command signal from the PLC turned ON while the actuator was moving, resulting in redundant move commands. 20E Soft limit over A soft limit was reached. 221 Write inhibited in monitor mode A position table field or parameter was written in the monitor mode. 223 Operation inhibited in monitor mode The actuator was moved in the monitor mode.
7.5 Common Problems and Recommended Actions z I/O Signals Cannot Be Sent or Received to/from the PLC. Cause: [1] The 24-V I/O power supply is connected in reverse polarities. (In this case, input circuits are not affected, but output circuits will be damaged.) [2] If an output circuit presents this problem, electrical current exceeding the maximum current flowed due to a large load and a circuit component was damaged. [3] Poor contact at the connector or relay terminal block on the PLC side.
z With an Actuator Installed in Vertical Orientation, Positioning Completes Prematurely. Cause: [1] The ball screw is receiving torsional stress due to the actuator affixing method, uneven tightening of bolts, etc. [2] The slide resistance of the actuator itself is high. Action: Check / Change the parameters set in User Parameter No. 13 (Current Limit at Home Return).
Appendix * Appendix List of Specifications of Connectable Actuators The specifications included in this specification list are limited to those needed to set operating conditions and parameters. For other detailed specifications, refer to the catalog or operation manual for your actuator. Caution x The push force is based on the rated push speed (factory setting) indicated in the list, and provides only a guideline. x Make sure the actual push force is equal to or greater than the minimum push force.
Appendix Actuator series Type RA3R RGD3R Motor No. of Feed output encoder screw pulses [W] Ball screw Ball screw 20 20 800 800 20 * Appendix RA4C Ball screw RCA (rod type) 20 Ball RGS4C screw 20 Ball screw 106 Maximum speed Maximum acceleration/ deceleration [mm/s] [mm/s] [G] 10 12.5 500 0.3 5 Horizontal/ vertical 6.25 250 0.3 2.5 Horizontal/ vertical 3.12 125 0.2 10 Horizontal/ vertical 12.5 500 0.3 5 Horizontal/ vertical 6.25 250 0.3 2.
Appendix Actuator series Type Motor No. of Feed output encoder screw pulses [W] 20 RA4D Ball screw 20 Ball RGS4D screw 20 Ball RGD4D screw 20 Ball screw [mm/s] [G] 12 15 600 0.3 6 Horizontal/ vertical 7.5 300 0.3 3 Horizontal/ vertical 3.75 150 0.2 12 Horizontal/ vertical 15 600 0.3 6 Horizontal/ vertical 7.5 300 0.3 3 Horizontal/ vertical 3.75 150 0.2 12 Horizontal/ vertical 15 600 0.3 6 Horizontal/ vertical 7.5 300 0.3 3 Horizontal/ vertical 3.
Appendix Actuator series Type Motor No. of Feed output encoder screw pulses [W] 20 Ball RGD4R screw RCA (rod type) * Appendix SRGS4R SRGD4R 108 20 Ball screw 20 Ball screw 20 Minimum speed Maximum speed Maximum acceleration/ deceleration [mm/s] [mm/s] [G] 12 Horizontal/ vertical 15 600 0.3 6 Horizontal/ vertical 7.5 300 0.3 3 Horizontal/ vertical 3.75 150 0.2 12 Horizontal/ vertical 15 600 0.3 6 Horizontal/ vertical 7.5 300 0.3 3 Horizontal/ vertical 3.
Appendix Actuator series Type SA4C SA4D SA4R Motor No. of Feed output encoder screw pulses [W] Ball screw Ball screw Ball screw 20 20 20 800 800 800 [mm] SA5D SA5R Ball screw Ball screw Ball screw 20 [mm/s] 10 12.5 665 5 Horizontal/ vertical 6.25 330 2.5 Horizontal/ vertical 3.12 165 10 Horizontal/ vertical 5 Horizontal/ vertical 2.5 Horizontal/ vertical 10 20 800 Maximum acceleration/ deceleration [G] Energy-saving spec.: 0.
Appendix Actuator series Type Motor No.
Appendix Actuator series RCA (slider type) Type SS6D A4R RCA (arm type) A5R RCA2 (rod type) Ball screw 30 800 Lead [mm] 20 Ball screw 20 Ball screw 30 GS3N Lead screw 10 1048 GD3N Lead screw 10 1048 SD3N Lead screw 10 1048 ± ± 3 Horizontal/ vertical 3.
Appendix Actuator series Type Motor No.
Appendix Actuator series Type Motor No. of Feed output encoder screw pulses [W] Lead [mm] 6 SA3C Ball screw 10 800 4 2 6 SA3R Ball screw 10 800 4 2 RCA2 (slider type) 10 SA4C Ball screw 20 800 5 2.5 10 Ball screw 20 800 5 2.
Appendix Actuator series Type Motor No. of Feed output encoder screw pulses [W] Lead Mounting direction [mm] Minimum speed [mm/s] Horizontal 20 25 Vertical SA5C Ball screw 20 800 * Appendix +RUL]RQWDO 12 15 Vertical +RUL]RQWDO RCA2 (slider type) 6 7.5 Vertical +RUL]RQWDO 3 3.75 Vertical +RUL]RQWDO 12 15 Vertical SA5R Ball screw 20 +RUL]RQWDO 800 6 7.5 Vertical +RUL]RQWDO 3 3.
Appendix Actuator series Type Motor No. of Feed output encoder screw pulses [W] Lead Mounting direction [mm] Minimum speed [mm/s] Horizontal 20 25 Vertical SA6C Ball screw 30 800 +RUL]RQWDO 15 Vertical +RUL]RQWDO RCA2 (slider type) 6 7.5 Vertical +RUL]RQWDO 3 3.75 Vertical +RUL]RQWDO 12 15 Vertical SA6R Ball screw 30 +RUL]RQWDO 800 6 7.5 Vertical +RUL]RQWDO 3 3.
Appendix Actuator series Type Motor No.
Appendix Actuator series Type Motor No. of Feed output encoder screw pulses [W] Lead [mm] 6 TA4R Ball screw 10 800 4 2 10 TA5C Ball screw 20 800 5 2.5 10 TA5R Ball screw 20 800 5 2.
118 2 1 0 No.
Appendix Parameter Record Recorded date: No.
Appendix Type 78 b 79 b 80 b 83 b 88 a 91 b * Appendix No.
Appendix Change History Revision Date Description of Revision First edition March 2007 Second edition Third edition Changed the cautions at the front. January 2009 Fifth edition Added "About CE Marking." April, 2010 Sixth edition Added "Please Read Before Use" on the first page after the cover. Added "Safety Guide" on the first page after the Table of Contents. Added "Change History" on the last page. July, 2010 Seventh edition Replaced the warning on p.
Appendix Revision Date December, 2012 Description of Revision Thirteenth edition • Explanation changed for home return current (Parameter No. 13) in P. 80 and 104 • Added "D2 Errer" in P.
Manual No.: ME0167-13A (December 2012) Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan TEL +81-54-364-5105 FAX +81-54-364-2589 website: www.iai-robot.co.
