ERC2 Actuator with Integrated Controller (SIO Type) Operation Manual Seventh 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 or DVD that comes with the product contains operation manuals for IAI products.
CAUTION 1. Using Multiple 24-V Power Supplies If multiple 24-V power supplies are used, always connect the 0-V lines of all power supplies. If not, damage to the controller board, SIO converter or other components may occur.
CAUTION 2. PC Software and Teaching Pendant Models This product offers new functions not available in the conventional ERC series. To support these new functions, the communication protocol has been changed to a general Modbuscompliant protocol. Accordingly, the PC software programs and teaching pendants that have been used with the ERC series are no longer compatible with the ERC2 series. Select a compatible program or teaching pendant from among the models listed below.
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 Introduction .................................................................................................................................. 9 1.
4.2.3 Connecting an Emergency Stop Circuit, Etc................................................................. 46 5. Explanation of Operating Functions..................................................................................................... 47 5.1 Description of Position Table ..................................................................................................... 48 5.1.1 Relationship of Push Force at Standstill and Current-Limiting Value ........................... 52 5.
10.1.3 ERC2-RA6C .......................................................................................................................... 117 10.1.4 ERC2-RA7C .......................................................................................................................... 118 10.1.5 ERC2-RGS6C ....................................................................................................................... 119 10.1.6 ERC2-RGS7C ................................................................
Safety Guide This “Safety Guide” is intended to ensure the correct use of this product and prevent dangers and property damage. Be sure to read this section before using your product. 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.
Safety Guide Safety Guide This “Safety Guide” is intended to ensure the correct use of this product and prevent dangers and property “Safety Guide” has this been writtenbefore to useusing the machine safely and so prevent personal injury or property damage. Be sure to read section your product. damage beforehand. Make sure to read it before the operation of this product.
Requirements for Industrial Robots under Ordinance on Industrial Safety and Health Operation No. Description Description Cutoff of drive 2 Transportation work with two or more persons or Work area Work conditionƔ When carrying a heavy object, do the Measure Article source utilize equipment such as crane.
Applicable Modes of IAI’s Industrial Robot Operation No. Description Description Machines meeting the following conditions are not classified as industrial robots according to Notice of Ministry Installation (2) Cable Wiring of Labor 4 No. 51 and Notice of Ministry of Labor/Labor Standards Office Director (Ki-Hatsu No. 340): and Start Ɣ Use our company’s (1) Single-axis robo with a motor wattage of 80 genuine W or lesscables for connecting between the actuator andwhose controller, the teaching tool.
Notes on Safety of Our Products Operation Common items you should note when performing each task on any IAI robot are explained below. No. Description Description 4 Installation (4) Safety Measures No. Task Note and Start Ɣ When the work is carried out with 2 or more persons, make it clear who is z This product is not planned or designed for uses requiring high degrees of safety.
No. Task Note (2) Wiring the cables 4 Installation/ Operation z Use IAI’s genuine cables to connect the Description actuator and controller or connect a teaching startup No. Description tool, etc. 6 Trial Operation Ɣ When the workbend, is carried 2 oran more persons, make it clear or who is z Do not damage, forcibly pull, out loopwith round object or pinch the cables place heavy articles Current electrical continuity may occur, well resulting to beon thetop.
No. Task Note 5 Teaching z When releasing the brake of the vertically installed actuator, be careful not to let the Operation actuator drop due to its dead weight, causing pinched hands or damaged work part, No. Description Description etc. 8 Maintenance Ɣ When work is carried out with 2 orifmore make clear who is * Safety fences ---the Indicate the movement range safetypersons, fences are notit provided.
Indication of Cautionary Information The operation manual for each model denotes safety precautions under “Danger,” “Warning,” “Caution” and Alert Indication “Note,” as specified below. The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the warning level, as follows, andDegree described in the Instruction Manual for each model.
Caution in Handling 1. Do not set speeds and accelerations/decelerations equal to or greater than the respective ratings. If the actuator is operated at a speed or acceleration/deceleration exceeding the allowable value, abnormal noise or vibration, failure, or shorter life may result. In the case of interpolated operation of combined axes, the speed and acceleration/deceleration settings should correspond to the minimum values among all combined axes. 2. Keep the load moment within the allowable value.
1. Overview Introduction Thank you for purchasing the Easy All-in-One ROBO Cylinder (hereinafter referred to as “ERC2-SE”). This product retains all benefits of the conventional ERC series, while incorporating new features that provide greater convenience and enhanced safety to the users. Among the ERC2 Series actuators, this product can be operated via serial communication in the position number specification mode or the direct numerical specification mode.
1. Overview 1.2 Key Features and Functions (1) Input/output of control signals by means of RS485 serial communication (conforming to the Modbus protocol) (2) 64 positioning points (3) Variable zone output boundaries Before, zone output boundaries were set by parameters and therefore fixed. For greater convenience, this product permits setting of zone output boundaries in the position table.
1.3 Differences from Air Cylinder Control Position No. Target position detection Speed setting Acceleration/ deceleration setting Position [2] Numerical specification mode: Specify a desired value directly. A reed switch or other Whether or not the target position has been reached is external detection sensor is determined based on the internal coordinate information installed. received from the position detector (encoder). Accordingly, no external detection sensor is required.
1. Overview Item Position check upon power on Air cylinder Determined using a reed switch or other external detection sensor. This controller Immediately after the power has been turned on, the current position is indeterminable because no mechanical coordinates are stored in the controller. After the power is turned on, therefore, a home return command must always be issued to establish coordinates.
1.4 Meaning of the Model Number 1. Overview ERC2-SA6C-I-PM-12-300-SE-S-NM Slider type x SA6C x SA7C Rod type x RA6C x RA7C x RGS6C x RGS7C x RGD6C x RGD7C Blank: No option B: With brake NM: Reversed-home specification FT: Foot bracket (Specified only for rod types.
1. Overview 1.5 Specifications Payload capacity (Note 2) Horizontal Vertical Rated acceleration Horizontal Vertical Rod type Slider type Model Stroke (mm) and maximum speed (mm/sec) (Note 1) (Note 1) (Note 2) 6 14 The figures in blank bands indicate the maximum speeds for respective strokes. The maximum speeds during vertical operation are shown in parentheses. The payload capacity is based on operation at the rated acceleration.
1.5.1 Correlation Diagrams of Speed and Payload Capacity – Slider Type Load capacity (kg) Load capacity (kg) High-speed type Speed (mm/sec) Load capacity (kg) Load capacity (kg) Medium-speed type Speed (mm/sec) Speed (mm/sec) Load capacity (kg) Load capacity (kg) Speed (mm/sec) Low-speed type 1. Overview Vertical installation Horizontal installation Speed (mm/sec) Speed (mm/sec) (Note) In the above graphs, the number after each type name indicates the lead.
Correlation Diagrams of Speed and Payload Capacity – Rod Type Vertical installation Load capacity (kg) Load capacity (kg) High-speed type Horizontal installation Speed (mm/sec) Load capacity (kg) Load capacity (kg) Medium-speed type Speed (mm/sec) Speed (mm/sec) Load capacity (kg) Load capacity (kg) Speed (mm/sec) Low-speed type 1. Overview 1.5.2 Speed (mm/sec) Speed (mm/sec) (Note) In the above graphs, the number after each type name indicates the lead.
Load Applied to the Actuator 1. Overview (1) Slider type x Keep the load applied to the slider below the value stated in the applicable specification item. In particular, pay attention to the moment applied to the slider, allowable overhang length and payload capacity. x If the slider is used in an overhang application with the load overhanging in the Y-axis direction, keep moments Ma and Mc to one-half the rated moment or less to prevent the base from deforming.
1. Overview Warranty 1.61.6Warranty Period and Scope of Warranty The ERC2-SE you have purchased passed IAI’s shipping inspection implemented under the strictest standards. The1unitWarranty is coveredPeriod by the following warranty: One of the following periods, whichever is shorter: 18 months after shipment from our company 1.
of Conformance withofApplicable 1.65 Conditions Warranty Period and Scope WarrantyStandards/Regulations, Etc., and Applications responsible for confirming that such combination with our product conforms to the applicable standards, etc. In such a case we will not be liable for the conformance of our product with the 1. Warranty Periodstandards, etc. applicable (2) Our product is for general industrial use.
1. Overview 1.7 1.7.1 Transportation and Handling Handling before Unpacking Exercise due caution when transporting or handling the box containing the actuator, by not applying impact on the box as a result of collision or dropping. x x x x If the box is heavy, one person should not carry it by himself. Place the box in a level surface. Do not step on the box. Do not place on the box any heavy object that may cause the box to deform or other object with a section where loads will concentrate. 1.7.
1.8 Installation Environment and Noise Elimination 1. Overview Pay due attention to the installation environment of the controller. 1.8.1 Installation Environment The installation environment must satisfy the following conditions: No. Use environment/condition [1] Not exposed to direct sunlight. [2] The actuator is not subject to irradiated heat from a large heat source, such as a heat treatment furnace. [3] Ambient temperature of 0 to 40qC. [4] Humidity of 85% or less without condensation.
1. Overview 1.8.3 Power Supply The control/motor-drive power supply specification is 24 VDC r 10% (2 A max). 1.8.4 Noise Elimination This section explains how to eliminate noise in the use of the controller. (1) Wiring and power supply [1] Provide a dedicated class D grounding using a wire with a size of 0.75 mm2 or larger. Actuator with integrated controller Class D grounding [2] Other equipment Good Actuator with integrated controller Other equipment Avoid this grounding method.
[1] AC solenoid valves, magnet switches and relays Measure: Install a surge absorber in parallel with the coil. Surge absorber m [2] Point Install a surge absorber to each coil over a minimum wiring length. Installing a surge absorber to the terminal block or other part will be less effective because of a longer distance from the coil. DC solenoid valves, magnet switches and relays Measure: Install a diode in parallel with the coil. Determine the diode capacity in accordance with the load capacity.
1. Overview 1.9 Cabling x When storing a extension cable in a moving wiring duct, use a robot cable. x In an application where the cable cannot be fixed, keep the cable from receiving a deflecting load exceeding its own weight, use a self-standing cable hose, provide a large bending radius along the wiring path, or provide other measure to minimize the load applied to the cable. x Do not cut the cable for the purpose of extension, length reduction or reconnection.
Prohibitions/Notes on Handling Cables 1. Do not let the cable flex at a single point. Steel band (piano wire) Bundle loosely. 2. Do not let the cable bend, kink or twist. 3. Do not pull the cable with a strong force. 4. Do not let the cable receive a turning force at a single point. 5. When fixing the cable, provide a moderate slack and do not tension it too tight. Use a curly cable. 6. Do not pinch, drop a heavy object onto or cut the cable.
Notes on use of cable tracks Robot cable 1. Overview 7.
2. Installation 2.1 Name of Each Part 2.1.1 Slider Type (SA6C/SA7C) 2. Installation Coupling bolt Screw cover Right Non-motor Motor end Side cover Left Top Front bracket Rear bracket LED Motor bracket Rear cover Slider 2.1.
2. Installation 2.1.
2.2 2.2.1 Installation Slider Type z Installing the actuator The side and bottom faces of the actuator base are parallel with the guides. If high slide precision is required, install the actuator by using these surfaces as references. Install the actuator in the mounting holes provided in the base. Secure the actuator in place using M4 hex cap bolts. Slider type (Note) Reduced flatness due to installation of an overhang load will cause the base to deform and inhibit smooth movement of the slider.
2.2.2 Rod Type A rod-type actuator can be installed in the following two ways: 2. Installation z Affixing with a flange Install the actuator by tightening from the motor end side with hex cap bolts using the holes provided in the flange. Hex cap bolt Caution: If the actuator is installed horizontally, exercise caution not to let the actuator receive excessive forces. Hole in flange Flange tightening bolts Model Nominal thread size Tightening torque RA6C M5 3.4 Nm (0.35 kgfm) RA7C M6 5.
z Affixing with foot brackets (optional) If optional foot brackets are used, install the foot brackets using hex cap bolts. Model RA6C RGS6C RGD6C RA7C RGS7C RGD7C 22 Nominal thread size Tightening torque M6 5.4 Nm (0.55 kgf-m) M8 11.5 Nm (1.17 kgf-m) 31 2.
2.2.3 Installing the Load 2. Installation z Slider Type Four tapped holes are provided in the slider, so affix the load using these holes (indicated by arrows in the figure shown to the left). Type SA6C, SA7C Nominal thread size M5 Slider mounting hole M5, depth 9 mm Tightening torque Bolt bearing surface: steel Bolt bearing surface: aluminum 7.3 Nm (0.74 kgfm) 3.4 Nm (0.35 kgfm) The affixing method of the load shall conform to the installation method of the actuator.
z Rod Type A bolt is attached on the rod end bracket, so use this bolt to affix the load. (Use the supplied nut, if necessary.) 2. Installation Rod end bracket Model RA6C RA7C Note) Rod end bracket M8, length 18 mm M10, length 21 mm Apply a spanner wrench at the rod end bracket to prevent the rod from receiving any rotating moment when the load is installed. Applying excessive rotating moment to the rod may damage the rod.
3. Electrical Specifications 3.1 Controller 3. Electrical Specifications Specification item Description Number of controlled axes 1 axis/unit Supply voltage 24 VDC r10% Supply current 2 A max. Control method Weak field-magnet vector control Position number specification, numerical specification, simple numerical/position number specification Maximum 64 points Position table data and parameters are saved in nonvolatile memory. Serial EEPROM can be rewritten 100,000 times.
3.2 Input/Output Interfaces Signal name SGA SGB 5V GND 24V BKR MPI GND Description RS485 serial communication Control power, 24 V Brake release (The brake is released when 24 V, 150 mA is supplied.) Motor drive power, 24 V Control power, 0 V Shield J.S.T. Mfg. Receptacle housing Pin contact 26 35 3. Electrical Specifications Connector pin No.
3.2.1 Extension Cable This cable is a standard accessory of the controller. (1) Power & I/O cable (Model number: CB-ERC2-PWBIO***/CB-ERC2-PWBIO***-RB) 3. Electrical Specifications (Note) CB-ERC2-PWBIO***-RB indicates a robot cable. CN2 Manufacturer: J.S.T. Mfg. Housing: Contact: Kaneko Cord Connector cover No connector at cable end Model number nameplate Manufacturer: J.S.T. Mfg. Model: V0.5-3 Signal name Wire Color CN1 Manufacturer: J.S.T. Mfg.
3.
[4] D-sub, 9-pin connector (RS232C) A connection port with the PLC’s communication module. You can also connect a PC here. For the communication cable, use a RS232C crossed cable as explained below. 3. Electrical Specifications [5] Mini DIN, 8-pin connector (RS485) A connection port with the teaching pendant. For the communication cable, use the cable (with RS232C/RS485 converter) supplied with the PC software (RCM-101-MW). [6] PORT switch A switch for enabling/disabling the mini-DIN connector.
4. 4.1 Wiring Basic Configuration with SIO Converter Connect a teaching pendant, PC or PLC using a SIO converter (for RS232C/RS485 conversion), as shown below. PC software RS232C type USB type Optional 4. Wiring Teaching pendant Optional Cable length: 5 m (Male) RS232C crossed cable (generic brand) (Female) *1 Connect the communication line from the actuator to either TB1 or J4 (J5) on the SIO converter, as shown below.
z Connection diagram An example of serial communication connection, including an emergency stop circuit, is shown below. Emergency stop is actuated by means of cutting off the motor drive power. Teaching pendant EMG pushbutton SIO converter TP connector 4. Wiring ERC2-SE actuator EMG EMG reset switch pushbutton Terminal block I/F connector Orange (Blue) Blue (Yellow) Serial communication Brown (Red) Power supply The brake is released when the contacts are closed.
4.1.1 SIO Communication Connection Using a Relay Terminal Block Teaching pendant PC, PLC Relay terminal block 4. Wiring SIO converter (Fabricated by the customer) Power & I/O cable J.S.T. Mfg. J.S.T. Mfg. Actuator 1 Actuator 2 Actuator 3 One-pair shielded cable (Fabricated by the customer) Terminal resistor 1/2W, 220 : Actuator 16 24-VDC control power, motor power, brake signal, ground, shield * The emergency stop circuit is the same as illustrated on the previous page.
4.1.2 SIO Communication Connection Using a 4-Way Junction PC, PLC 4. Wiring Teaching pendant Network connection cable Power & I/O cable e-CON connector e-CON connector J.S.T. Mfg. J.S.T. Mfg. Fabricated by the customer Actuator 1 Actuator 2 Actuator 3 Actuator 16 24-VDC control power, motor power, brake signal, ground, shield (Note 1) If the total length of the communication cable is 10 m or longer and you experience communication errors, connect a terminal resistor to the last axis.
4.1.3 Address Assignment If multiple axes are connected, a slave number must be assigned to each axis so that the host can recognize the corresponding actuator. Assign addresses in the setting screen of the teaching pendant or PC. Refer to the operation manual for your teaching pendant or PC software for the specific operating procedure. Caution: In the actual process of assigning addresses, the teaching pendant or PC and the target actuator must have a one-on-one link.
4.2 4.2.1 Configuration Using a Gateway Unit SIO Communication Connection Using a Relay Terminal Block 4. Wiring PC software RS232C type USB type Optional Gateway unit Fabricated by the customer Teaching pendant Relay terminal block J.S.T. Mfg. Power & I/O cable J.S.T. Mfg.
4.2.2 SIO Communication Connection Using a 4-Way Junction PC software RS232C type USB type Optional 4. Wiring Gateway unit Network connection cable 4-way junction Teaching pendant e-CON connector Power & I/O cable J.S.T. J.S.T. Mfg. Mfg.
4.2.3 Connecting an Emergency Stop Circuit, Etc. Emergency stop is actuated by means of cutting off the motor drive power. Teaching pendant EMG pushbutton Gateway unit TP connector 4. Wiring ERC2-SE actuator EMG EMG reset switch pushbutton I/F connector Gateway power Orange (Blue) Port switch Blue (Yellow) Serial communication Brown (Red) Power supply The brake is released when the contacts are closed.
5. Explanation of Operating Functions 38 47 5. Explanation of Operating Functions ERC2-SE actuators support two operation modes: [1] “position number specification mode” in which the actuator is operated by specifying position numbers, and [2] “numerical specification mode” in which the actuator is operated by directly specifying values relating to the intended operation.
5.1 Description of Position Table Create a position table using the PC software or teaching pendant. Refer to the operation manual for the PC software or teaching pendant you are using. This section explains the position table by using the PC software screen as an example. (The displayed items are different on the teaching pendant.) 5.
(4) Acceleration/Deceleration x Enter the acceleration/deceleration at which the actuator will be moved, in [G]. Basically, you should set values within the rated range specified in the catalog. The input range is greater than the rated range in the catalog, in order to accommodate situations where you want to “shorten the tact time when the load is much smaller than the rated transferring mass.” If the load vibrates during acceleration/deceleration and causes problem, decrease the set values.
“Push & hold operation” The set value defines the maximum distance the actuator will push the work part in the push & hold mode upon reaching the target position. Consider the mechanical variations of the work part and set an appropriate positioning band so that positioning will not complete before the actuator contacts the work part. The position complete signal turns ON here, because the actuator has contacted the load and the controller has determined that the push & hold operation has completed.
(9) Acceleration/deceleration x This field is not used for this controller. mode The factory setting is “0.” x This setting defines whether to use the absolute mode or incremental mode. The factory setting is “0.” 0: Absolute mode 1: Incremental mode (11) Command mode x This field is not used for this controller. The factory setting is “0.” (12) Standstill mode x This field is not used for this controller. The factory setting is “0.
5.1.1 Relationship of Push Force at Standstill and Current-Limiting Value When performing operation in the push & hold mode, enter the current-limiting value (%) in the push column of the position table. Determine the current-limiting value (%) from the push force to be applied to the work part at standstill.
z Rod type (1) RA6C type (2) RA7C type Low-speed type (Lead: 4 mm) Push force (N) Push force (N) Low-speed type (Lead: 3 mm) 5.
5.2 Data Set in the Numerical Specification Mode When the actuator is operated in the numerical specification mode, specify data relating to the intended operation (target position, speed, acceleration/deceleration, positioning band, current-limiting value during push & hold operation, etc.) directly. Take note that the position table may or may not be required depending on the operation mode.
' Set acceleration and deceleration differently in the position table. ' Set in the position table. ' Set in the position table. ' Combine two or more position numbers. { { Zone signals are set in the position table or using user parameters. PZONE, ZONE1 and ZONE2 can be output.
5.3.1 Control Signals and Control Data To operate the actuator via serial communication, the internal 16-bit memory (Modbus registers and statuses) of the controller must be written/read. The key signals and symbols used in these operations are explained below. For details, refer to the Operation Manual for Serial Communication Protocol. (1) Controller input signals (PLC o Controller) 5.
(PLC o Controller) 48 Signal symbol Signal name Description - - - PC32 PC16 PC8 PC4 PC2 PC1 - Specify a command position number using a 6-bit binary code. Positioning operation will start when the positioning start signal bit CSTR is changed to “1.” - - - PC32 PC16 PC8 PC4 PC2 PC1 - This register is the same as the one explained above, except that with this register, positioning operation will start the moment a command position number is written.
(PLC o Controller) 5. Explanation of Operating Functions Register Address PCMD Position data specification [Numerical specification] INP Positioning band specification Description Upper Sign Lower Signed 32-bit integer (unit: 0.01 mm) Setting range: FFF0BBC1H to 000F423FH (-999999 to 999999) x A negative value is indicated by a 2’s complement. Accordingly, the most significant bit becomes “1.” Positioning operation will start when the lower word (9901H) of this register is rewritten.
(PLC o Controller) Register Currentlimiting value during push & hold operation [Numerical specification] Address Description 16-bit integer (unit: %, setting range: 00H to FFH/ 0 to 100 %) (Note) Movement will start when this register is rewritten. CTLF Control flag 5. Explanation of Operating Functions [Numerical specification] This flag sets a bit pattern to specify operation settings.
(2) Controller output signals (Controller o PLC) 5.
(Controller o PLC) Register Zone status register ZONS Address 9013H Position number status register POSS Address 9014H [POS specification] 0147H Signal symbol Signal name Description - - - 8 PZONE 7 to 2 - 014EH 1 ZONE2 014FH 0 ZONE1 013AH 013BH 013CH 013DH 013EH 013FH 15 to 6 5 4 3 2 1 0 PM32 PM16 PM8 PM4 PM2 PM1 Position zone output If individual zone boundaries are set in the position table, this bit will turn “1” when the current position enters the range specified by the boundari
5.3.2 Timings after Power On Follow the procedure below to turn on the power after confirming that the slider or rod is not contacting a mechanical end nor the load is contacting any peripheral equipment: [1] Cancel the emergency stop or turn on the motor drive power. [2] Supply the 24-VDC controller power. If 24 VDC is supplied in a condition where no emergency stop is actuated, the servo will be turned on automatically in the controller. 5.
Controller ready (PWR) This signal indicates whether the controller can be controlled externally. When the signal bit is “0,” the controller is busy. When the bit is “1,” the controller is ready. The controller does not become busy in normal conditions of use. Servo ON command (SON) The servo will turn on when this signal bit turns “1.” Use this signal if servo on/off must be controlled to provide a safety circuit for the entire system on the PLC side.
5.3.3 Home Return Operation Operation timings PLC processing 1: The home return command (HOME) signal turns ON when the start button is pressed. Operation: [1] The actuator starts moving toward the mechanical end on the home side. [2] The actuator contacts the mechanical end and reverses its direction, moves to the home position, and then pauses. o The home return completion (HEND) signal turns ON. PLC processing 2: The home return command (HOME) signal turns OFF.
Home return command (HOME) Home return operation will start upon detection of the “0” o “1” edge of this signal bit. When home return is completed, the home return completion (HEND) signal will be output. The HOME signal can be input as many time as desired even after home return has been completed once. (Note) Even if home return is not performed after the power has been turned on, the actuator will automatically perform home return operation as part of the first positioning operation (CSTR signal).
5.3.4 Positioning Operation First, change the position complete (PEND) signal bit to “1” by turning on the 24-VDC power by referring to 5.3.2. Home return is not yet complete immediately after the power has been turned on. Accordingly, home return operation must be performed using the home return command (HOME) as explained in 5.3.3.
Explanation of operation Caution: When the start signal turns ON, the position complete signal will turn OFF and the moving output will turn ON. Always turn OFF the start signal after confirming that the moving output has turned ON (position complete output has turned OFF). If the start input remains ON, the position complete output will not turn ON even after the actuator has completed the specified movement, as shown below. Start Position complete Moving 1 msec max. Actuator Movement is complete.
5. Explanation of Operating Functions Positioning start (CSTR) Upon detecting the “0” o “1” leading edge of this signal bit, the controller will read the target position number specified by a binary code consisting of six bits from PC1 to PC32 (in the position number specification register) and cause the actuator to move to the target position of the corresponding position data.
Position complete (PEND) This signal indicates that the target position has been reached, and turns ON only when the following conditions are satisfied: [1] The servo ready (SV) bit is “1” AND [2] the current position has reached the positioning band before each target position OR [3] the actuator has not missed the work part during push & hold operation. Use this signal as a trigger signal to operate peripheral equipment upon reaching the target position.
5.3.5 Push & Hold Operation Just like with an air cylinder, the end of the rod can be pressed against a work part and maintained in this condition. The push & hold operation is useful in clamping or press-fitting of work parts. 5. Explanation of Operating Functions (1) Basic operation As shown below, the actuator moves to the specified target position, after which it will move at the specified push speed to push the work part over a distance up to the specified positioning band.
Warning x If the actuator contacts the work part before reaching the target position, a servo error alarm will generate. Pay due attention to the position relationship of the target position and the work part. x Even when the actuator appears stationary, it actually continues to push the work part at the push force determined by the current-limiting value. Since the actuator is not physically stopped, exercise due caution when handling any actuator-related operation during this period. 62 71 5.
(2) The work part is missed during push & hold operation If the actuator did not contact the work part after moving the specified positioning band (= the motor current does not reach the current-limiting value during push & hold operation), the position complete signal will not be output. However, the applicable completed position number will still be output. At that time, the PSFL bit in the device status register (DSS1) will turn “1.
(4) The push direction is set incorrectly Exercise caution when setting the push direction, because if the direction is set incorrectly, the position will deviate by twice the positioning band, as shown below. Speed Intended operation Actual operation Travel Positioning band Positioning band Positioning band 64 5.
5.3.6 Pause When the pause command (STP) bit is changed to “1” while the actuator is moving, the actuator will decelerate to a stop. Since the remaining travel is held, changing STP to “0” again will resume the movement to complete the remaining travel. Command position Positioning start (CSTR) 5. Explanation of Operating Functions Position complete (PEND) Completed position Pause command (STP) Moving (MOVE) 4 msec max.
5.3.7 Speed Change during Movement Speed control involving multiple speed levels is possible in a single operation. The actuator speed can be decreased or increased at a certain point during movement. However, the position at which to implement each speed change must be set.
(Note) If a pause command is issued while home return is in progress, the movement command will be held if the actuator has not yet contacted the mechanical end. If the actuator has already contacted the mechanical end and reversed, home return will be performed again from the beginning. 5. Explanation of Operating Functions Alarm reset (RES) Alarms will be reset at the “0” o “1” leading edge of this signal bit. If any alarm remains whose cause is not yet removed, the same alarm will generate again.
5.3.8 Operation at Different Acceleration and Deceleration (1) When the actuator is used in the position number specification mode, acceleration and deceleration can be set differently in the position table. (2) Numerical specification mode Acceleration/deceleration data (set in the register 9906H) becomes effective when the data is received. To set a deceleration different from an acceleration, therefore, change the acceleration/deceleration data while the actuator is moving.
5.3.9 Zone Signal 5. Explanation of Operating Functions This signal is output (the bit turns “1”) when the current actuator position is inside the specified zone.
5.3.10 Pitch Feed by Incremental Specification A target position can be specified in the position table using an incremental travel. This function is useful in operation involving multiple positioning points set apart by an equal distance (constant pitch feed). (1) Operation example in the position number specification mode The following example explains how to perform positioning at a 50-mm pitch, starting from position No. 1. In this case, create the position table shown below.
Command position Position 1 Position 2 Start (CSTR) Position complete (PEND) Completed position Position 1 Position 2 5. Explanation of Operating Functions Moving (MOVE) Zone signal (PZONE) Speed [1] [2] [3] [4] Position 2 [5] Actuator movement Time Distance from home *T1: Set to T1 t 0 (ms) by considering the scan time of the host controller. [Explanation of operation] [1] Perform positioning operation to position 1 (100.00 mm).
(2) Note on positioning operation If a start signal is input after selecting and inputting a position number by incremental specification while the actuator is performing positioning operation, the actuator will move to the position representing the initial position plus the incremental travel. (If the specified incremental travel is a negative value, the actuator will move to the position representing the initial position minus the specified travel.
(3) Note on push & hold operation If a start signal is input after selecting and inputting a position number (for push & hold operation) by incremental specification while the actuator is moving in the push & hold mode, the actuator will move by the incremental travel from where the start signal was input. Therefore, the end position will become indeterminate.
5.3.11 Power-Saving Mode at Standby Positions One general feature of pulse motors is that their holding current is greater than AC servo motors in a standstill state. Therefore, we provide a power-saving mode to reduce power consumption in situations where the actuator remains standstill for a long period at a standby position. Use this function after confirming that it will not present problems to any part of your system.
6. Parameter Settings 6.1 Parameter Table Parameters are classified into four types according to their content. Category: a: Parameter relating to the actuator stroke range b: Parameter relating to the actuator operating characteristics c: Parameter relating to the external interface d: Servo gain adjustment 6. Parameter Settings No.
6.2 Detailed Explanation of Parameters If a parameter has been changed, always restart the controller using a software reset command or by reconnecting the power. 6.2.1 Parameters Relating to the Actuator Stroke Range Soft limits set in the controller Approx. 0.3 mm Approx. 0.3 mm Effective range Approx. 0.1 mm 0 8 0 Approx. 0.1 mm Allowable jogging/inching range after home return z Home return direction (No.
z Home return offset (No.22 OFST) The controller is shipped from the factory with an optimal value set in parameter No. 22, so the distance from each mechanical end to the home becomes uniform. The minimum setting unit is “0.01 [mm].
6.2.2 Parameters Relating to the Actuator Operating Characteristics z Default speed (No.8 VCMD) The factory setting is the rated speed of the actuator. When a target position is set in an unregistered position table, the setting in this parameter will be used as the speed data for the applicable position number. To reduce the default speed from the rated speed, change the setting in parameter No. 8. z Default acceleration/deceleration (No.
z Default direction of excited-phase signal detection (No.28 PHSP1) When the servo is turned on for the first time after a power on, excited phase is detected. This parameter defines the direction of this detection. The parameter need not be changed in normal conditions. In certain situations, such as when the actuator was contacting a mechanical end or obstacle when the power was turned on and cannot be moved by hand, change the direction that allows the motor to operate smoothly.
z Default standstill mode (No.53 CTLF) This parameter defines the power-saving mode to be applied when the actuator stands by for a long time while the machine is operating; the actuator stands by for a long time after completing home return operation; or the actuator stands by for a long time after completing positioning operation in the numerical specification mode. Define whether to enable or disable power-saving in parameter No. 53. All power-saving modes are disabled.
z Push speed (No.34 PSHV) This parameter defines the push speed to be applied after the actuator reaches the target position in push & hold operation. Before the shipment, this speed has been set to a default value appropriate for the characteristics of the actuator. Set an appropriate speed in parameter No. 34 by considering the material and shape of the work part, and so on. Take note that the maximum speed is limited to 20 [mm/sec] even on high-speed types.
6.2.3 Parameters Relating to the External Interface Setting of parameter No. 39 0 [PEND] Description [1] When the servo is on The position complete signal remains ON even after the current position has exited the range set by the specified “positioning band” with respect to the target position. [2] When the servo is off The position complete signal is OFF unconditionally regardless of the current position.
6. Parameter Settings z Silent interval multiplication factor (No.45 SIVM) It is applied to controllers of RS485 serial communication type. If specified, this parameter defines the multiplication factor to be applied to the silent interval time for delimiter judgment in the RTU mode. The default setting is the communication time corresponding to 3.5 characters in accordance with the Modbus specification. This setting need not be changed for normal operations performed with a PC or teaching pendant.
6.2.4 Servo Gain Adjustment Before the shipment, the servo has been adjusted in accordance with the standard specification of the actuator. Accordingly, the servo settings need not be changed in normal conditions. Nonetheless, the parameters relating to servo adjustment are made accessible by the customer so that speedy actions can be taken in situations where vibration or noise occurs due to the affixing method of the actuator, load condition, or the like.
z Speed loop integral gain (No.32 VLPT) Parameter No. Unit Input range 32 --- 1 ~ 217270 Default Set individually in accordance with the actuator characteristics. This parameter is used to determine the response of the speed control loop. Reducing the set value lowers the response to speed commands, meaning that the reactive force that generates in response to load change becomes smaller.
7. 7.1 Troubleshooting Action to Be Taken upon Occurrence of Problem Upon occurrence of a problem, take appropriate action according to the procedure below in order to ensure speedy recovery and prevent recurrence of the problem. Check the status indicator lamps. Illuminating in green --- The servo is ON. Illuminating in red --- An alarm is present or the motor drive power is cut off. b) Check for error in the host controller. c) Check the voltage of the main 24-VDC power supply. d) Check for alarm.
7.2 Alarm Level Classification Alarms output from the controller are classified into two levels according to the symptoms they represent. Alarm level Operation cancellation 7. Troubleshooting Cold start 7.2.1 ALM lamp On (Red) On (Red) Failure status register What happens when alarm generates How to reset ALMH is “1” The actuator decelerates to a stop and then the servo turns OFF. x Perform an alarm reset from a PC/teaching pendant. x Input a RES signal from the PLC.
7.3 Alarm Description and Cause/Action (1) Operation-cancellation level alarms Code Error name 080 Movement command at servo off 083 Numerical command before home return Cause: Action: Cause: Action: 084 090 88 Cause: Action: Position number error Cause: during movement Action: Soft reset at servo on Cause: Action: 97 7. Troubleshooting 085 Movement command during home return Cause/Action A movement command was issued by numerical specification when the servo was off.
7. Troubleshooting Code Error name 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 name Cause/Action This alarm indicates that the motor supply voltage is excessive (24 V + 20%: 28.8 V or more). Cause: [1] High voltage of the 24-V input power supply [2] Faulty internal part of the controller Action: Check the voltage of the input power supply. If the voltage is normal, please contact IAI. 0CA Overheating The temperature around the power transistor in the controller is too high (95qC or above).
(2) Cold-start level alarms 7. Troubleshooting Code Error name 0B8 Excitation detection error Cause/Action This controller detects excited phase when the servo is turned on for the first time after a power on. This alarm indicates that the specified encoder signal level cannot be detected after the specified period of excitation. Cause: [1] Loose or disconnected connector of the motor extension cable [2] The brake cannot be released (if the actuator is equipped with a brake).
Code Error name 0F5 Verification error of data written to nonvolatile memory Timeout writing to nonvolatile memory 0F8 Damaged nonvolatile memory 0FA CPU error 92 101 7. Troubleshooting 0F6 Cause/Action When data was written to the nonvolatile memory, the written data is read and compared (verified) against the original data. This alarm indicates that the read data does not mach the original data written.
7.4 Messages Displayed during Operation Using the Teaching Pendant or PC Software This section explains the warning messages that may be displayed during operation using the teaching pendant or PC software. 7. Troubleshooting Code Error name Cause/Action 112 Invalid data An inappropriate value was entered in a parameter. (Example) 9601 was entered as the serial communication speed by mistake. Enter an appropriate value again.
Code Error name Cause/Action This message indicates that the start signal (CSTR) was turned ON by the PLC while the actuator was moving, and that duplicate movement commands occurred as a result. 20D STP-OFF during operation This message indicates that the pause signal was output by the PLC while the actuator was moving, and that the movement was disabled as a result. 20E Soft limit over This message indicates that a soft limit was reached.
7.5 Specific Problems 7. Troubleshooting z The LED lamp does not illuminate after the power is input. Cause: [1] Reverse connection of the 24-V power supply [2] Faulty controller board If the power supply is connected properly, probably the controller board is faulty. Please contact IAI. (Note) If the 24-V power supply is connected in reverse, the controller may not fail immediately but its service life will likely be shortened. z The LED illuminates in red when the power is turned on.
z The actuator overshoots when decelerated to a stop. Cause: The load inertia is high in view of the balance of loading mass and deceleration. Action: Decrease the deceleration setting. z The home and target positions sometimes shift on the rod-type actuator. Cause: The current-limiting value is lower than what is required in view of the loading mass and slide resistance. Action: The actuator may have to be replaced in some cases. Please contact IAI. z The speed is slow during push & hold operation.
8. Maintenance and Inspection 8.1 Inspection Items and Schedule Perform maintenance and inspection per the schedule specified below. This schedule assumes eight hours of operation a day. Shorten the inspection intervals if the utilization is higher, such as when the actuator is operated continuously day and night. 8.
8.4 Internal Check (Slider Type) [1] With the SA6 and SA7, the screw cover and side covers can be removed using a hex wrench with 1.5 mm width across flats. x The front and rear brackets are supporting the ball screw, so do not disassemble these brackets. x Precision instrument is assembled into the motor cover, so do not disassemble the motor cover. Warning: The encoder phase is adjusted precisely to enable detection of rotation angle and home signal.
8.5 Internal Cleaning (Slider Type) x Wipe off dirt using a soft cloth, etc. x Do not blow compressed air at high speed. Doing so may cause dust to enter the actuator through gaps. x Do not use petroleum solvent, neutral detergent or alcohol. Caution: Do not use cleaning oil, molybdenum grease or rustproof lubricant. If a large amount of foreign object is contained in the grease, wipe off the dirty grease before applying new grease. 8.6 Greasing the Guide (Slider Type) (1) Applicable grease 8.
(2) Greasing method Grease the guide by following the procedure below: [1] Apply grease between the slider and base, as shown to the left. Apply grease on the opposite side in the same manner. [3] Move the slider back and forth several times by hand. [4] Repeat steps [1], [2] and [3]. [5] Use a waste cloth, etc., to wipe off excess grease from the slider. Caution: In case the grease got into your eye, immediately go to see the doctor to get an appropriate care.
8.7 Greasing the Ball Screw (Slider Type) (1) Applicable grease The following special grease is applied to the ball screw prior to shipment: Kyodo Yushi Multemp LRL3 This grease generates less heat and has other excellent properties suitable for ball screws. For equivalent grease products, refer to the brands specified for the guide (lithium grease). 8. Maintenance and Inspection Note: Never use fluorine grease.
8.8 Greasing the Rod Slide Surface (1) Applicable grease The following grease is applied to the rod slide surface prior to shipment: Kyodo Yushi Multemp LRL3 Use lithium grease for maintenance. 8. Maintenance and Inspection Note: Never use fluorine grease. If fluorine grease is mixed with lithium grease, the grease function will drop and it causes damage to the mechanism. Caution: In case the grease got into your eye, immediately go to see the doctor to get an appropriate care.
8.9 Motor Replacement Procedure Before replacing the motor, save the latest parameter and position data. Save the data by one of the following methods: x Save the data to a file using the PC software. x Prepare position/parameter tables and manually write the values. When a new motor has been installed, enter the parameter/position data to the controller.
x Installation [1] Place the coupling spacer in the coupling hub. [2] Insert the motor unit into the rear bracket while paying attention to the phase of the coupling hub with respect to the coupling spacer. (When inserting the motor unit, exercise due caution to prevent pinching of parts.) [3] Insert the coupling bolt into the fitting hole in the motor unit from over the rear bracket, and tighten the bolt using a wrench with 3 mm width across flats. Motor unit Coupling bolt 8.
9. Operation Examples Refer to the operation manuals specified below for operation examples using this product: 9.
Appendix 0. External Dimensions 0. . ERC -SA C 60 50 5 4-M5 Depth 10 9 32p 0.02 9 (300) Cable joint connector (Reamer Pitch Tolerance p0.02) 22 31 37.4 5 Ma Moment Offset Datum Position Stroke 60 Home S.E. 50.9 13.5 2.5 M.E.*2 S E : Stroke End ME : Mechanical End Teaching Port 118.5 58 Secure at least 100 PIO type (6) 25 S-4.5 Drilled Hole, F 8 Counter Boring Depth 4.5 55 Part A 25 37.5 49.1 2.3 M.E. L 36 80.6 59 50 48.5 32 10 2-F5Ｈ7 Reamed, Depth 10 (6) 10.
Acceleration/ Zone– Command Standstill 4.5 4 deceleration Incremental [mm] mode mode mode ERC -SA C Cable joint connector Stroke 75 L Home S.E. S E : Stroke End ME : Mechanical End 2-F5Ｈ7 Reamed, Depth 10 55.2 16 2.5 Ｍ.E.*2 Teaching Port 118.5 at least 100 PIO type (3.5) S-4.5 Drilled Hole, F 8 Counter Boring Depth 4.5 Secure (3.5) 22.5 22.5 51.5 10 49.8 3 Ｍ.E. Appearance Figure for Brake-equipped Type 40 F4.5 B A Ns100 P Positioning Zone+ band [mm] [mm] 50 16 50 49 118.
Acceleration/ Command Standstill deceleration Incremental mode mode mode ERC -RA C L B Zone– [mm] M.E. : Mechanical End Teaching Port C 8 A PIO type Secure at least 100 118.5 20 20 37.5 7 2 18 31.7 49.7 13 (2 ) es ac tf fla SIO type *There is no Teaching Port for SIO Type. Appearance Figure for Brake-equipped Type *Brake-equipped type is longer in 43.5mm and weight heavier in 0.5kg than the standard type. 4 - F5.5 44 54 58 43.5 118.
Acceleration/ Command Standstill deceleration Incremental mode mode mode ERC -RA C 4 M.E. M.E. : Mechanical End Teaching Port 51.5 C 8.5 A PIO type Secure at least 100 118.5 20 20 2 40 61 SIO type *There is no Teaching Port for SIO Type. Appearance Figure for Brake-equipped Type *Brake-equipped type is longer in 43.5mm and weight heavier in 0.5kg than the standard type. 4- F 6.6 17 (2 ) es ac tf fla 50 64 89.
Acceleration/ Command Standstill deceleration Incremental mode mode mode 51.7 ME : Mechanical End ST 58.3 20 23.7 8 55 ST 3.3 57 13 10 F34 F10 12.5 12.5 6-M5 M.E. 54 24 3 54 ST 91 20 2 Home 3 30 Zone– [mm] 22.5 37 106.5 40 7 52 54 ERC -RGS C Recorded date: 0. . Positioning Zone+ band [mm] [mm] 58 50 0.2 1.8 100 0.2 1.9 150 0.3 2.1 200 0.3 2.3 250 0.3 2.4 300 0.4 2.6 Appendix ERC -RGS C 62 ST 61 ME : Mechanical End 6-M6 30 10 57.5 ST 3.
Acceleration/ Command Standstill deceleration Incremental mode mode mode 0. . ERC -RGD C 53 52 30 20 4-M5 54 20 23.7 8 55 ST 3.3 54 Positioning Zone+ band [mm] [mm] ST M.E. 51.7 ST 58.3 50 0.4 2.0 Stroke Guide Weight [kg] Weight of Guide Main Unit [kg] 100 0.4 2.1 150 0.5 2.3 200 0.6 2.6 250 0.6 2.7 300 0.7 2.9 4-M6 F36 F12 12.5 64 125 170 65 145 8-M6 Acceleration Deceleration [G] [G] 30 10 57.5 ST 3.5 64 Speed [mm/s] 22 Position [mm] Home 4 M.E. 62 ST 61 250 0.9 4.
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 0 1 No. Speed [mm/s] Acceleration Deceleration [G] [G] Recording of Position Table Position [mm] 10.
122 107 41 40 39 37 38 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 19 20 No.
63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 42 43 No.
10.3 Parameter Records Category: Appendix No.
Change History Revision Date January 2011 Description of Revision Fifth edition Added “Before Use.” Changed “Safety Precautions” to “Safety Guide.” P. 9: Added 1.5.3, “The sound pressure level of this product does not exceed 70 dB.” P. 16: Moved “Prohibitions/Notes on Handling Cables” to after 1.9, “Wiring.” P. 85: Changed the description relating to the speed loop integral gain. April 2011 Sixth edition A page for CE Marking added March 2012 Seventh edition P.
Manual No.: ME0159-7A (March 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.
