ACON-PL/PO Controller Pulse-train Input Type Operation Manual Thirteenth 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 The 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.
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 Safety Guide ...........................................................................................................................................1 1. Overview ..........................................................................................................................................9 1.1 1.2 1.3 1.4 1.5 Introduction .....................................................................................................................................
5. Parameter Settings ........................................................................................................................57 5.1 5.2 Parameter List.............................................................................................................................. 57 Detail Explanation of Parameters ................................................................................................ 59 5.2.1 5.2.2 5.2.3 5.2.4 6. Parameters Relating to Actuator Stroke Range ......
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 Outside movement range Work condition Cutoff of drive source During automatic Not cut off operation Cut off (including stopping of operation) During teaching, etc. Not cut off Inside movement range Cut off During inspection, etc. 2 Not cut off (when inspection, etc., must be performed during operation) Measure Article Signs for starting operation Article 104 Installation of railings, enclosures, 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 Note 1 Model selection z 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.
4 Installation/ startup (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.
6 7 Automatic operation 8 Maintenance/ inspection 9 Modification 10 Disposal z Before commencing automatic operation, make sure no one is inside the safety fences. z Before commencing automatic operation, make sure all related peripherals are ready to operate in the auto mode and no abnormalities are displayed or indicated. z Be sure to start automatic operation from outside the safety fences.
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. Introduction 1. Overview 1.1 Overview This product is a pulse-train input controller used exclusively with RCA, RCA2 and RCL actuators. It can control actuators using the positioning control function of the host controller (PLC). The key features and functions of this controller are summarized below. Dedicated Homing Signal This signal supports IAI’s original homing operation based on push motion at the stroke end.
1. Overview 1.
1.3 System Configuration 1. Overview Standard teaching pendant ACON-PL/PO controller Host system Shield cable 24-VDC I/O power supply Cable length: 2 m PC PC software RS232C type USB type Optional RCA actuator Cable length: 5 m Optional Brake forced-release switch Power-supply terminal block Input power 24 V supply 0V 24 VDC External EMG switch Caution: The BK terminal need not be connected if the actuator has no brake.
1. Overview 1.4 Steps from Unpacking to Adjustment by Trial Operation 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. Setting a mode 7. 1. Overview If you want to use the “push mode” PIO pattern, change the value of Parameter No. 25 to “1.” o Chapter 4, “Operation Using I/Os” * The factory setting is to use the “standard mode.” Setting an electronic gear Determine the unit travel distance of the actuator per one pulse in input command pulse train. o Chapter 4, “Setting Parameters Required for Operation” 8.
1. Overview 1.5 Warranty 1.5.1 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 1.5.2 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] Medical equipment pertaining to maintenance or management of human life or health [2] A mechanism or mechanical equipment intended to move or transport people (such as a vehicle, railway facility or aviation facility) [3] Important safety parts of mechanical equipment (such as safety devices) [4] Equipment used to handle cultural assets, art or other irreplaceable items (3) Contact us at the earliest opportunity if our product is to be used in any condition or environment that differs from what is speci
2. Specifications 2.1 Basic Specifications 6SHFL¿FDWLRQV Specification item Model Number of controlled axes Power-supply voltage Motor power supply Actuator Motor type capacity (Note 1) 10 W RCA/ RCA2 RCL 20 W [Model code: 20] 30 W 20 W [Model code: 20S] For RA3, RA4 and TA5 types only 2W 5W 10 W Description ACON-PL/PO 1 axis per unit 24 VDC r 10% Standard specification/Support high Support power-saving acceleration/deceleration Rated [A] Maximum (Note 2) Rated [A] Maximum (Note 2) 1.3 4.4 1.3 2.
2.2 Name and Function of Each Part of the Controller Status indicator LED PIO connector Input pulse pattern DIF --- Differential line driver mode OC --- Open collector mode Connects the PLC and PIO. SIO connector Connects the teaching pendant/PC. The I/O signal type is indicated here. NPN --- Sink type PNP --- Source type The model of the connected actuator is indicated here. Encoder connector Motor connector Connects the encoder cable. Connects the motor cable.
2.3 External Dimensions 6SHFL¿FDWLRQV 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. 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 or thicker. Controller Connect the ground line to the mounting screw of the Other main unit.
[2] DC solenoid valves, magnet switches and relays Measure --- Install a diode in parallel with the coil or use a built-in diode type. If DC power is used, exercise due caution because the diode, internal controller parts and/or DC power supply may be damaged if the diode is installed in the wrong polarities. 3. Installation and Wiring 3.
3.5 External Connection Diagram An example of standard wiring is shown below. The wire colors of the robot encoder relay cable are different from those of the standard encoder relay cable. Refer to 3.9.2, “Encoder Relay Cable.” 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. Power-supply terminal block Cable inlet Input power supply 24 VDC Use a wire satisfying the following specifications. Item Applicable wire Specification 2 Twisted wire: AWG 22 (0.3 mm ) (copper wire) (Note) Provide proper termination to prevent shorting due to contact with wire offcut.
3.8 3.8.1 Wiring the Emergency Stop Circuit Cutting Off the Drive Signal (Standard) 3. Installation and Wiring Shown below is an example when the emergency stop circuit of the entire system is used to actuate an emergency stop on multiple controllers. However, the emergency stop switch on the teaching pendant cannot actuate an emergency stop of the entire system. External EMG External EMG circuit switch Normally these terminals are connected by jumper wires.
Notes on power supply and emergency stop circuit *1 Refer to the specification list for the load current of one controller. *2 The input current at the EMG- terminal of each controller is 5 mA. If the relay contact CR is to be connected to the EMG- terminals of multiple controllers, check the contact capacity of the relay. *3 When the teaching pendant is plugged into the controller, the controller automatically recognizes the connection. 3.
To actuate an emergency stop on the entire system using the emergency stop switch on the teaching pendant, use a SIO converter. You can also reflect the operation of the teaching pendant’s emergency stop switch when a gateway unit is used. SIO converter 3. Installation and Wiring EMG switch of teaching pendant Normally these terminals are connected by jumper wires. If the applicable safety category requires cutoff of the motor drive source, use the following circuit.
3.9 Connecting the Actuator Pin assignments 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) (2) Housing: SLP-03V (J.S.T. Mfg.) Contact: BSF-21T-P1.4 (J.S.T. Mfg.) RCA encoder cable/encoder robot cable Standard cable model: CB-ACS-PA Robot cable model: CB-ACS-PA-RB (optional) ( indicates the cable length L.
RCA2 monitor/encoder integrated cable Model: CB-ACS-MPA ( indicates the cable length L. Example: 080 = 8 m) 3. Installation and Wiring (I 12) (3) Cable model marking Actuator end Controller end Housing Contact Pin No. Signal name Pin No. Cable name Red Yellow Black Pin No.
3.10 Connecting the I/O Shield Cable Cable model: CB-PACPU-PIO*** (Note: *** indicates the cable length. (Example) 2 m: 020) 3. Installation and Wiring No connector Round terminal Shield cable Housing Contact Pin No.
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. Operation Using I/O Signals This chapter explains the wire connections and operation timings you should know in order to perform positioning operation using a PLC with I/O signals. Two PIO patterns are available for you to choose from in accordance with your specific application. PIO pattern Standard mode (factory setting) Push mode 4. Operation Using I/O Signals 4.1 Setting (User Parameter No.
4.1.2 External Output Specifications 4. Operation Using I/O Signals Item Specification Number of output points 4 points Rated load voltage 24 VDC Maximum current 50 mA per point Residual voltage Max.
4.1.3 Command Pulse Train Input Specifications [Input using a differential line driver] Applicable line driver: 26C31 or equivalent Positioning unit ACON-PL 4. Operation Using I/O Signals 11/PP 12 PP 13/NP 14 NP Mounting plate FG Note: Always connect the shield of the twisted pair cable joined to the connector, to the mounting plate.
4.1.4 Recognition of Input Signals 4. Operation Using I/O 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.
4.2 Standard Mode Choose the PIO pattern of this mode if you wish to perform position control using pulse train input from a PLC. Set User Parameter No. 25 (PIO pattern selection) to “0.” (This parameter has been set to the “standard type” prior to the shipment). 4.2.1 Pin No.
Torque-limit Selection Signal (TL) This signal limits the motor torque. While this signal is ON, the actuator thrust (motor torque) is limited to the torque set in User Parameter No. 57 (Torque limit). 4. Operation Using I/O Signals Caution: Excessive deviation (standing pulses) may generate while torque is limited (while the TL signal is ON) (for example, when the actuator receives load and is prevented from moving just like in push-motion operation).
Command Pulse Input Command pulses can be input in the open collector mode (60 kpps max.) or differential line driver mode (200 kpps max.). You can select a desired input pattern of command pulses from 90q phase-difference (phase-A/B x4) signal, pulse train + forward/reverse signal, and forward pulse/reverse pulse. The positive logic or negative logic can be selected for each of these patterns. Caution: 4.
Positioning Complete Signal (INP) This signal turns ON when the deviation in the deviation counter (standing pulses) is within the positioning band. It remains OFF while the servo is off. 4. Operation Using I/O Signals Caution: z This signal turns ON when the servo is turned on (to perform positioning at the present position). z This signal turns ON simply due to accumulation of deviation (standing pulses).
Alarm Signal (*ALM) This signal turns OFF when the controller’s protective circuit (function) has actuated following an alarm detection and the basic cutoff procedure has been implemented as a result. The signal will turn ON if the RES (reset) signal is turned ON after the cause of the alarm has been removed (except when the alarm relates to a cold-start level error). When an alarm is detected, a red LED light will illuminate on the front panel of the controller.
4.2.2 Setting Parameters Required for Operation The following parameters must always be set prior to every operation. (These parameters are all you need to set to perform operations that only involve positioning.) (1) Electronic gear User Parameter Nos. 65 and 66 (Electronic gear numerator and denominator) 4.
Calculation Example Operate an actuator with a ball screw lead of 6 mm equipped with an encoder of 800 pulses/rev, at a unit travel distance to 0.1 mm (1/10). * The encoder resolution is 800 (pulses/rev) for the RCA and RCA2, and as shown in the table on the previous page for the micro-slider and cylinder series. Encoder pulses (pulses/rev) = Ball screw lead length (mm/rev) x Unit travel distance (mm/pulse) 4.
(2) Command Pulse Mode User Parameter No. 63 (Command-pulse input mode) Name Command-pulse input mode Symbol MOD Unit - Input range 0~2 Default (reference) 1 4. Operation Using I/O Signals Set a pulse-train input pattern for command pulse input (PP•/PP, NP•/NP). * The setting of positive logic or negative logic is explained in (3), “Input Polarity in the Command Pulse Mode.
4. Operation Using I/O Signals 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.
4.2.3 Timings after Power On z Steps from Initial Startup to Actuator Adjustment 4. Operation Using I/O Signals [1] Confirm that the slider or rod is not contacting a mechanical end or that the work is not contacting any peripheral equipment. [2] Cancel the emergency stop or connect the motor drive power. [3] Supply the 24-VDC I/O power: PIO connector pins 1 and 2. [4] Supply the 24-VDC controller power: 24-V and 0-V terminals on the power-supply terminal block. [5] Set the minimum required parameters.
* If Parameter No. 21 (Servo-on input disable selection) is set to “1,” a servo-on signal need not be input. Caution: In the “Emergency stop actuated o Turn on the power o Servo-on input o Cancel the emergency stop” sequence, the servo will turn on up to 1542 msec after the emergency stop is cancelled. Servo-on input Emergency stop cancelled 4. Operation Using I/O Signals Max.
4.3 Push Mode Use the PIO pattern of this mode if you wish to perform position control and push-motion operation using pulse train input from a PLC. Set User Parameter No. 25 (PIO pattern selection) to “1.” 4.3.1 Explanation of I/O Signals 4. Operation Using I/O Signals Pin No.
Torque-limit Selection Signal (TL) This signal limits the motor torque. While this signal is ON, the actuator thrust (motor torque) is limited to the torque set in User Parameter No. 57 (Torque limit). Caution: 4. Operation Using I/O Signals z Do not turn the TL signal OFF while it is ON. z Excessive deviation (standing pulses) may generate while torque is limited (while the TL signal is ON) (for example, when the actuator receives load and is prevented from moving just like in push-motion operation).
Command Pulse Input Command pulses can be input in the open collector mode (60 kpps) or differential line driver mode (200 kpps). You can select a desired input pattern of command pulses from 90q phase-difference (phase-A/B x4) signal, pulse train + forward/reverse signal, and forward pulse/reverse pulse. The positive logic or negative logic can be selected for each of these patterns. 4.
Positioning Complete Signal (INP) This signal turns ON when the deviation in the deviation counter (standing pulses) is within the positioning band. It remains OFF while the servo is off. Caution: z This signal turns ON when the servo is turned on (to perform positioning at the present position). z This signal turns ON simply due to accumulation of deviation (standing pulses).
Alarm Signal (ALM) This signal turns OFF when the controller’s protective circuit (function) has actuated following an alarm detection and the basic cutoff procedure has been implemented as a result. The signal will turn ON if the RES (reset) signal is turned ON after the cause of the alarm has been removed (except when the alarm relates to a cold-start level error). When an alarm is detected, a red LED light will illuminate on the front panel of the controller.
4.3.2 Setting Parameters Required for Operation The following parameters must always be set prior to every operation. (These parameters are all you need to set to perform operations that only involve positioning.) (1) Electronic gear User Parameter Nos. 65 and 66 (Electronic gear numerator and denominator) Symbol CNUM CDEN Unit - Input range 1 ~ 4096 1 ~ 4096 Default (reference) 200 15 4.
Calculation Example Operate an actuator with a ball screw lead of 6 mm equipped with an encoder of 800 pulses/rev, at a unit travel distance to 0.1 mm (1/10). * The encoder resolution is 800 (pulses/rev) for the RCA and RCA2, and as shown in the table on the previous page for the micro-slider and cylinder series. 4.
(2) Command Pulse Mode User Parameter No. 63 (Command-pulse input mode) Name Command-pulse input mode Symbol MOD Unit - Input range 0~2 Default (reference) 1 Set a pulse-train input pattern for command pulse input (PP•/PP, NP•/NP). * The setting of positive logic or negative logic is explained in (3), “Input Polarity in the Command Pulse Mode.” Input terminal Forward Reverse 4.
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. The actuator normally moves by approx. 0.5 to 2 mm due to this detection operation, although the specific distance will vary depending on the ball screw lead.
4.3.3 Timings after Power On z Steps from Initial Startup to Actuator Adjustment Safety circuit status 4. Operation Using I/O Signals [1] Confirm that the slider or rod is not contacting a mechanical end or that the work is not contacting any peripheral equipment. [2] Cancel the emergency stop or connect the motor drive power. [3] Supply the 24-VDC I/O power: PIO connector pins 1 and 2. [4] Supply the 24-VDC controller power: 24-V and N terminals on the power-supply terminal block.
* If Parameter No. 21 (Servo-on input disable selection) is set to “1,” a servo-on signal need not be input. Caution: In the “Emergency stop actuated o Turn on the power o Servo-on input o Cancel the emergency stop” sequence, the servo will turn on up to 1542 msec after the emergency stop is cancelled. Servo-on input 4. Operation Using I/O Signals Emergency stop cancelled Max. 1.
5. Parameter Settings 5.1 Parameter List Caution: This product uses a non-volatile memory (EEPROM) as the storage medium. If the power is cut off while data is still being written, the data may not be written correctly. Exercise due caution to prevent cutoff of power while rewriting parameters. The parameters are classified into the following four types depending on their function: No.
5. Parameter Settings No.
5.2 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. 5.2.1 Parameters Relating to Actuator Stroke Range z Soft Limits (No. 3 LIMM) (No. 4 LIML) 5. Parameter Settings 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.
5.2.2 Parameters Relating to Actuator Operating Characteristics z Default Acceleration/Deceleration (No. 9 ACMD) The factory setting is the rated acceleration/deceleration of the actuator. The value of this parameter sets the acceleration/deceleration to be applied in jogging operation performed on the teaching pendant or using the PC software. To decrease the default acceleration/deceleration from the rated acceleration/deceleration, change the value set in Parameter No. 9.
z Default Direction of Excited Phase Signal Detection The excited phase is detected when the servo is turned on for the first time after turning on the power. This parameter defines the direction of this detection. This parameter need not be changed in normal conditions of use. However, if the actuator is contacting a mechanical end or any obstacle when the power is turned on and cannot be moved by hand, change the direction of detection to one in which the motor can be driven easily.
z Safety Speed (No. 35 SAFV) This parameter defines the feed speed to be applied in jogging operation performed on the teaching pendant or using the PC software. The factory setting is “100” [mm/sec]. To change the speed, set an optimal value in Parameter No. 35. Since the maximum speed is limited to 250 mm/sec, set the safety speed to below this level. * This parameter is invalid during pulse train control. z Torque Limit (No.
z Home Check Sensor Input Polarity [No. 43 HMC] Although standard actuators do not come with a home check sensor, this sensor can be installed as an option. This parameter need not be changed in normal conditions of use. If the customer wishes to change the home check mode after shipment, change the value set in Parameter No. 43.
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. * Do not change the setting. 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) Note: z 5. Parameter Settings 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. When shortcut is not selected Current-limiting value during movement (2.8 to 4 times depending on the characteristics of the actuator) Point No. 1 5. Parameter Settings 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 Point No. 1 Point No. 1 Point No. 2 Point No. 2 Point No.
5.2.3 Parameters Relating to External Interface 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 Parameter No. 25 Features of PIO pattern Standard mode Use the PIO pattern of this type if you wish to perform position control using pulse train input from a PLC.
z Default Acceleration/Deceleration Mode (No. 52 HSTP) Parameter No. 52 Unit - Input range 0~2 Default 0 5. Parameter Settings This parameter sets the acceleration/deceleration mode. When “0” is set: Trapezoid When “2 is set: Primary filter for position command A primary delay is always reflected during movement. The travel corresponds to the specified pulses.
z Torque-limit Command Input (No. 61 TL) Whether to disable or enable the torque-limit command input is set in Parameter No. 61. Setting Enable (Use) 0 Disable (Do not use) The factory setting is “0” [Enable]. 1 z Command-pulse Input Mode (No. 63 MOD) The command pulse pattern, selectable from six types, is set in Parameter No. 63. Input terminal Forward Reverse Setting 5.
5.2.4 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. 5. 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.
6. 6.1 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. 6. Troubleshooting a. Check the status indicator lamps SV (green) --- The servo is on. ALM (red) --- An alarm is present or emergency stop has been actuated, or the motor drive power is cut off. b. Check the host controller for abnormality. c.
6.2 Alarm Level Classification The alarms are classified into three levels based on the corresponding symptoms. Alarm level Operation cancellation Cold start 6. Troubleshooting Note: 74 ALM lamp *ALM signal Lit Output Lit Output Condition at occurrence of alarm How to reset The actuator decelerates to a stop, Execute reset using the PC/teaching and then the servo turns off. pendant. The actuator decelerates to a stop, Reconnect the power. and then the servo turns off.
6.3 Alarms, Causes and Actions (1) Operation Cancellation Alarms Code 0A4 Error Command counter overflow Cause/action Cause: Action: This alarm generates when the value in the command pulse counter deviates from the range of –134217728 to 134217728. Check the setting of command pulses. Phase-Z position error The position at which phase Z was detected during home return was outside the specified range or phase Z could not be detected. Cause: Faulty encoder Action: Contact IAI.
Code 0D2 Error Excessive motor power-supply voltage Cause/action Cause: 6. Troubleshooting Action: 0D8 Deviation overflow The position deviation counter has overflowed. Cause: [1] The work hit a surrounding object during movement and the impact caused the speed to drop. [2] The specified acceleration is too high for the transferred mass. [3] The brake is improperly engaged and cannot be released correctly.
(2) Cold Start Alarms Code 0A1 0A8 Error Parameter data error Motor/encoder type not supported Cause/action Cause: Action: 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. Change the settings to appropriate values.
Code Error Cause/action 0CB 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 Action: The board must be replaced. Contact IAI. 0E0 Overload Cause: 6. Troubleshooting Action: [1] The load increased due to application of external force.
Code Error name Nonvolatile memory write verify error 0F6 Nonvolatile memory write timeout 0F8 Damaged nonvolatile memory 0FA CPU error Cause/Action When data is written in the nonvolatile memory, the written data is read once for a check to verify the data matching. This alarm indicates that the written data is not matching. Cause: [1] Faulty nonvolatile memory [2] The memory has been rewritten more than 100,000 times. (The nominal rewrite limit of the nonvolatile memory is around 100,000 times.
(3) Non-alarm Message Code 6. Troubleshooting FFF 80 Error Power on log Cause/action This is not an error. (It simply means that a rise of controller power has been detected.
6.4 Messages Displayed during Teaching Pendant Operation This section explains the warning messages that may be displayed while operating the teaching pendant or PC software. 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.
6. Troubleshooting Code 82 Message Description 20C CSTR-ON during movement The start signal (CSTR) was turned ON from the PLC while the actuator was moving, resulting in redundant move commands. 20D STOP-OFF during movement The pause signal (*STP) was turned OFF from the PLC while the actuator was moving, disabling the actuator movement. 20E Soft limit over A soft limit was reached. 20F Missed work detected The actuator passed the work without contacting it in push-motion operation.
6.5 Common Problems and Recommended Actions z I/O Signals Cannot Be Sent or Received to/from the PLC. Cause: Action: 6. Troubleshooting Caution: [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.
z The Actuator does not Operate when a Pulse Train is Input. Cause: Action: Caution: [1] [2] [1] [2] The I/O I/F signal issued with the pulse train is invalid. The command-pulse train pattern is not set properly in the parameters. Check the input signal. Check User Parameter No. 63 (Command-pulse input mode) and No. 64 (Polarity in command-pulse input mode).
z The Actuator Malfunctions when the Servo Is Turned On after Turning On the Power. Cause: Action: 6. Troubleshooting Excited phase detection is not performed properly when the servo is turned on, because one of the following conditions exists when the power was turned on: [1] The slider or rod was contacting a mechanical end. [2] The work was pushed by a strong external force. [1] Check if the slider or rod is not contacting a mechanical end.
* 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. * Appendix 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.
Actuator series Type RA3R RGD3R Motor No. of Feed output encoder screw pulses [W] Ball screw Ball screw 20 20 800 800 20 RCA (rod type) 20 Ball RGS4C screw 20 Ball screw 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 2.5 Horizontal/ vertical 3.
Actuator series Type Motor No. of Feed output encoder screw pulses [W] 20 RA4D Ball screw 20 * Appendix Ball RGS4D screw RCA (rod type) 20 Ball RGD4D screw 20 Ball screw 88 Maximum acceleration/ deceleration [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.
Actuator series Type Motor No. of Feed output encoder screw pulses [W] 20 Ball RGD4R screw RCA (rod type) SRGD4R Ball screw 20 Ball screw 20 Maximum speed Maximum acceleration/ deceleration [mm/s] [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 3.75 150 800 2.5 5 800 2.5 5 800 2.
Actuator series Type SA4C SA4D * Appendix SA4R Motor No. of Feed output encoder screw pulses [W] Ball screw Ball screw Ball screw 20 20 20 800 800 800 RCA (slider type) SA5D SA5R Ball screw Ball screw Ball screw 20 20 800 Maximum speed [mm/s] [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.
Actuator series Type Motor No.
Actuator series RCA (slider type) Type SS6D A4R * Appendix RCA (arm type) A5R A6R RCA2 (rod type) Motor No. of Feed output encoder screw pulses [W] 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.
Actuator series Type Motor No.
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 * Appendix 2.5 10 SA4R Ball screw 20 800 5 2.
Actuator series Type Motor No. of Feed output encoder screw pulses [W] Lead Mounting direction [mm] Minimum speed [mm/s] Horizontal 20 25 Vertical Ball screw 20 800 +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.
Actuator series Type Motor No. of Feed output encoder screw pulses [W] Lead Mounting direction [mm] Minimum speed [mm/s] Horizontal 20 25 * Appendix Vertical SA6C Ball screw 30 800 +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 SA6R Ball screw 30 +RUL]RQWDO 800 6 7.5 Vertical +RUL]RQWDO 3 3.
Actuator series Type Motor No.
Actuator series Type TA4R TA5C * Appendix TA5R RCA2 (table type) TA6C TA6R TA7C TA7R RCL 98 Motor No.
Parameter Record Recorded date: Types: a: b: c: d: Parameter relating to actuator stroke range Parameter relating to actuator operating characteristics Parameter relating to external interface Servo gain adjustment No.
No.
Appendix Change History Revision Date Description of Revision First edition Second edition Third edition Fourth edition • Added the additional models on P.2. • Changed the teaching drawing to CON-T on P.3. • Corrected the specifications on P.7. (Added current value of the additional models and encoder resolutions.) • Changed the part about supplied voltage on P.10 (for the additional models).
Appendix Revision Date 2010.07 Description of Revision Eighth edition • Replaced the warning on P.42 2011.01 Ninth edition • Correction made in “Speed loop integral gain” in P.70 2011.04 Tenth edition • Swapped over the page for CE Marking 2011.07 Eleventh edition Change History • Contents changed in 1.5 Warranty in P.14 to P.15 • Contents changed and added in Appendix: List of Specifications of Connectable Actuators. 2012.
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Manual No.: ME0166-13A (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.jp/ Technical Support available in USA, Europe and China Head Office: 2690 W.
