PULSE DRIVE Operation Manual First Edition
Directions for Safe Use Please read these “Directions for Safe Use” thoroughly before selecting a model and using the product. The following precautions are provided so that you can use this product safely and avoid bodily injury and/or property damage. Please observe these precautions together with the safety regulations of JIS B 8433 (general rules for industrial robots). Directions are classified into “danger,” “warning,” “caution” and “note,” according to the degree of risk.
Installation z Do not use this product in a place where hazardous substances such as combustible, flammable or explosive substances exist. There is a possibility of the product generating sparks, catching fire or causing an explosion. z Do not use this product in a place where there is a possibility of water and oil drops being splashed on the main unit and controller. z Never cut and reconnect the cable of this product in order to change the cable length.
z Turn off the power in case of electric power failure. Failure to do so may cause injury and product damage, since the product may start moving suddenly upon recovery from the electric power failure. z Turn off the power immediately if the product generates abnormal heat, smoke or odor. Failure to do so may lead to product damage or fire. z Turn off the power immediately if the protective device (alarm) of the product is activated.
z Be sure to use genuine parts supplied by IAI for the cable between the actuator and controller. Moreover, be sure to use genuine parts supplied by IAI for each component, such as an actuator, controller or teaching pendant. z Post a display, for instance “Work in Progress: Do not turn on the power,” when performing tasks relating to installation, adjustment, etc., so that the power is not turned on inadvertently.
Before Using the Product Q Precautions (1) Be sure to read this operation manual to ensure the proper use of the product. (2) It is prohibited to use or copy any part of this manual without permission. (3) Please be aware that we shall have no liability for any effects caused by operations not described in this manual. (4) The information provided in this manual is subject to change without notice.
Table of Contents 1. 1.1 1.2 1.3 1.4 1.5 2. 2.1 2.2 3. Overview............................................................................................... 1 Features .......................................................................................................................................... 1 Name and Function of Each Part of the Controller ......................................................................... 2 How to Read the Model Specification .....................................
5. Control and Function of I/O Signals.................................................... 28 5.1 Input Signals ................................................................................................................................. 28 5.1.1 Servo ON Signal (SON)......................................................................................................... 28 5.1.2 Alarm Reset Signal (RES) ..................................................................................................
(23) Maximum Speed at Incomplete Homing................................................................................ 57 (24) Maximum Acceleration Value................................................................................................. 58 (25) Maximum Deceleration Value ................................................................................................ 59 (26) Soft Limit Actual Position Margin ......................................................................................
(2) View Menu (V) ....................................................................................................................... 82 (3) Parameter Menu (P) .............................................................................................................. 82 (4) Monitor Menu (M) .................................................................................................................. 83 (5) Driver Menu (D) ...........................................................................
1. Overview This product is a pulse-train input type controller for actuators manufactured by IAI. It allows controls according to the command signals from the positioning control function of a host controller (PLC). 1.1 Features Q Dedicated Homing Signal P-Driver supports our proprietary stroke end push homing operation. This function allows automatic homing without using complex sequences or external sensors.
1.
(9) System setting switches Used to change the encoder voltage and boot mode (for remote start). (The rotary switch is used for adjustment by the manufacturer.) System setting switches Switch Symbol 1 2 3 4 /BTRT ENCV2 ENCV1 - Function Switch for changing boot mode (Set to OFF.) Switch for adjusting encoder power-supply voltage 2 Switch for adjusting encoder power-supply voltage 1 Not used (Set to OFF.) See the table below for the setting.
1.3 How to Read the Model Specification PDR I 100 B 1 P I: Incremental 20: 20 W 30: 30 W 60: 60 W 100: 100 W 150: 150 W 200: 200 W 400: 400 W 600: 600 W 750: 750 W 1.4 Blank: NPN P: PNP 1: 100 V specification 2: 200 V specification Blank: None B: Brake C: Creep sensor L: Limit switch Applicable Actuators It is possible to control the following types of actuators.
1.5 Options (1) PC Software (Model PDR-101-MW) Content: Floppy disks, PC link cable 1.5 m (Unit model CB-ST-SIO015) Used to set P-Driver parameters, monitor jogging operation during debugging, check various signals, and so on. 1.
(3) Regenerative Resistance Unit (Model REU-1) When the actuator is operating, the motor (drive unit) uses supplied electric energy to rotate. On the contrary, when it decelerates, the motor acts as an electric generator that supplies current back to the controller. This is called a regenerative current. In the case of a vertical application, a large regenerative current will flow into the controller at descending.
2. Specification 2.
External Dimensions 129.1 88.2 φ5 194 184 5 44.1 5 5 2.
3. Installation and Noise Prevention Please pay attention to the controller’s installation environment. 3.1 Installation Environment a. Avoid blocking air vents for cooling when installing and wiring the controller. (Insufficient ventilation prevents the controller from achieving full performance and may also cause failure.) b. Prevent foreign objects from entering the controller through the air vents.
(2) Grounding for Noise Prevention a. It is necessary to ground the controller to prevent noise, regardless of whether it is configured as a 100 or 200 VAC system. Connect the controller unit by affixing it to the metal enclosure directly with screws. 100/200 V controller Protective ground 1 2 (AC power supply) 3 Make the ground wire as thick and short as possible. Metal enclosure b.
(3) Protecting Against Noise Emitting Sources There are many types of noise emitting sources, but the most familiar ones when building a system include solenoid valves, magnet switches and relays. The controller can be protected against noise from such sources by the following actions: a. AC solenoid valves, magnet switches and relays Action: Mount a surge killer in parallel with each coil ← Point Connect the surge killer to each coil with the shortest possible wiring.
3.4 Heat Dissipation and Installation Design the size of the control panel, layout of the controller installation and cooling method so that the peripheral area of the controller is 40°C or less. Install the controller vertically on a wall. The controller is cooled by forced ventilation (a jet on the top part). Observe this direction when installing and ensure a clearance of 100 mm or more above the controller and 50 mm or more below the controller.
4. Wiring 4.1 Configuration [Parts to be prepared by the customer] Single-phase AC power supply 100~115 V 50/60 Hz 200~230 V 50/60 Hz Actuator Power-supply breaker Switches the power supply on/off and prevents damages due to short-circuit current. Electromagnetic contact Used when disconnecting this product from the power supply, such as at emergency stop.
4.2 Connection Diagram The following figure shows a connection diagram of the P-Driver unit.
(2) Option Regenerative resistance unit RB+ RB- PE 24V N Actuator LS CREEP OT RSV 15
4.3 Power-Supply Input Interface Connect the power supply specified in 2.1, “Specification List,” to P-Driver. It must be possible to cut off the AC power supply via an electromagnetic contact in case of an emergency stop. (1) Commercial Power a. 100 V specification: single-phase, 100 to 115 VAC ±10%, 50/60 Hz b. 200 V specification: single-phase, 200 to 230 VAC ±10%, 50/60 Hz List of AC power-supply input connector terminals (Phoenix GMSTB2.5/3-GF-7.
(2) Emergency Stop It must be possible to cut off the AC power supply via an electromagnetic contact in case of an emergency stop. The following figure shows a reference circuit. PB 1 Emergency stop release switch EMG PB Emergency stop switch RY RY Input an alarm/fault signal (ALM) (ON in normal circumstances). In this circuit, when PB 1 is turned on and the power is supplied via MS, MS is self-maintained unless P-Driver enters an alarm status.
(3) Electromagnetic Brake Power-Supply Input This input is required when the actuator has an electromagnetic brake. Connect a dedicated external power supply. 24 VDC ±20% 1.0 A (peak value) Do not use the same power supply for the brake power supply as for the I/O signals. List of electromagnetic brake power-supply input connector terminals (Phoenix MC1.5/2-GF-3.81 DIP) Symbol BK Function + - Electromagnetic brake power-supply input terminals * Connectors (plugs) are standard accessories. 4.
Signal classification Sequence signal input Power supply Command pulse input Pin No. Symbol Signal name Function 9 SON Servo ON Operation of the servo motor is enabled when this signal is turned on. The servo motor is placed in the free-run status when this signal is turned off. In the case of an actuator with a brake, the brake is released when this signal is turned on.
Signal classificati on Pin No. Symbol Signal name 19 AFB +A 20 /AFB -A 21 BFB +B 22 /BFB -B 23 ZFB +Z 24 /ZFB -Z The resolution is determined by the electric gear ratio of the command pulse input. (The position detection data is output with the same resolution as the command signal.) GND Reference potential Line driver ground line for feedback pulse output (Pins 25 and 26 are internally connected.
4.5 I/O Signal Interface Circuit (1) Sequence Input Part Item Specification Input voltage 24 VDC ± 20% Input current 7 mA/circuit ON voltage --- Min. 16 V (4.5 mA) OFF voltage --- Max. 6 V (1.4 mA) Photo-coupler Operating voltage Insulation method NPN specification P-Driver Pin No. 1, 2 COM-B Each input 3.3 KΩ 560 Ω 14 Internal circuit COM-A External power supply 24 VDC Each input PNP specification Pin No. 14 COM-A COM-B Each input 3.
(2) Sequence Output Part Item Rated load voltage Description 24 VDC/60 V (peak; without flywheel diode) Maximum load current 100 mA/circuit Insulation method Photo-coupler Overcurrent protection NPN specification Fuse resistance: 10 Ω, 0.1 W P-Driver Internal circuit Fuse resistance: 10 Ω, 0.1 W Each output Load Each output Load Pin No. 1, 2 External power supply 24 VDC COM-A 14 COM-B PNP specification P-Driver Pin No.
(3) Command Pulse-Train Input Part Differential line-driver input Applicable line driver: 26C31 or equivalent P-Driver Pin No. 15/(17) 16/(18) Open-collector input Pull up with a resistor of 2.2 kΩ. P24 2.2 kΩ P-Driver Pin No.
(4) Feedback Pulse Output Part Applicable line receiver: 26C32 or equivalent P-Driver Pin No. 18/(21)/(23) Pin No.
4.6 Motor Cable Connector List of motor connector terminals (Phoenix GIC2.5/4-GF-7.62 DIP) Symbol Function U V Motor power cable connection terminals of actuator W PE * The connector (plug) is attached to the motor cable. 4.7 Encoder Cable Connector List of encoder connector terminals (Omron XM3B-2542-502L) Pin No.
4.8 Sensor (Optional) Input Connector This is an input connector for LS (limit sensor), OT (over-travel sensor) and CREEP (creep sensor), which are optional sensors that may be attached to the actuator. List of actuator sensor input terminals (Phoenix MC1.5/6-G-3.
4.10 RS232C Interface This is a communication interface for the PC software supporting this product. Use the cable supplied with the PC software (PDR-101-MW) described in 1.5 (1) or equivalent for the connection cable. List of RS232C interface signals (Omron XM2C-0942-502L) Pin No.
5. Control and Function of I/O Signals 5.1 Input Signals Input signals to the controller are filtered using a time constant set in order to prevent malfunction due to chattering, noise, etc. (This does not apply to an external forced stop signal (CSTP) input and command pulse-train input (PP, /PP, NP and /NP).) Therefore, input each input signal continuously for 6 ms or more. Recognized Input signal 6 ms Not recognized Input signal 5.1.
+ Servo OFF status 1. There is no holding torque after stopping. 2. Pulse-train inputs, ORGC (homing command signal), TL (torque limit selection signal) and CSTP (external forced stop signal) are all ignored. 3. Output signals, including RUN (operation ready signal), INP (positioning completion signal), ORGR (homing completion signal) and TLR (torque limiting signal), are all cleared (set to off).
5.1.3 Homing Command Signal (ORGC) This signal commands the actuator to perform automatic homing. Function When the ORGC signal is turned on, this instruction is handled at the rising (ON) edge and the actuator performs the automatic homing operation. When homing is completed, the ORGR (homing completion) output signal is turned on. When the ORGR signal is turned on, set the current value register of the host controller (PLC) to the home value (enter 0) using the current value preset function.
Caution z Do not turn the TL signal off while the TLR signal is turned on. z While the torque is being limited (the TL signal is turned on), excessive deviation (standing pulse) may be generated (if the actuator cannot operate due to applied load, for instance in the push status). If the TL signal is turned off in this status, control at the maximum torque is immediately started and the actuator may operate suddenly or go out of control.
Caution z Note that the actuator moves in the negative direction with a forward pulse (forward for the motor) and in the positive direction with a reverse pulse (reverse for the motor). (Opposite applies to folded motor type actuators). z When considering the forward/reverse direction, pay attention to the settings of the host controller or connection of PP and /PP as well as NP and /NP.
5.2 5.2.1 Output Signals System Ready Signal (SRDY) This signal turns on when control of P-Driver is enabled after the main power supply is turned on. Function This signal turns on when the initialization is normally completed and control of P-Driver is enabled after the main power supply is turned on, regardless of the status of alarm and servo. It is turned on as far as P-Driver is in a controllable status, even if it is in an alarm status.
Caution z This signal turns on when the servo is turned on (because the actuator is positioned at that location). z Since this signal is turned on by the deviation (standing pulse) only, if the in-position width, a position control parameter, is made excessively large, the signal turns on once the actuator enters the in-position range during low-speed operation even if it is operating (positioning is not completed). 5.2.
5.2.6 Alarm/Fault Signal (ALM) This signal turns off when the protection circuit (function) of P-Driver detects an error. Function This signal turns off when an alarm is detected and the protection circuit (function) is actuated, and the base current is interrupted. This signal is normally turned on. After having been turned off, it can be turned on again when the cause of the alarm is removed and the RES (reset) signal is turned on (except in case of alarms at the cold start level).
6. Parameters 6.1 Parameter Configuration The parameters are classified into the following five types depending on the content: a. b. c. d. e. Driver information External interface information Actuator information Position control information Speed/current control information 6.2 Parameter List Default values indicated by [A] are determined according to the actuator specifications. These parameters are set to appropriate values corresponding to the applicable actuator at shipment from the factory.
Name Symbol Default value (reference) Unit 2 Software stroke limit, positive side (actual stroke) LIMM [A] pulse 134217727~ Actual stroke value on positive side (Set by -134217728 the number of pulses.) 3 Software stroke limit, negative side (actual stroke) LIML [A] pulse 13421777~ Actual stroke value on negative side (Set by -134217728 the number of pulses.) 4 Ball screw lead length LEAD [A] mm 0.1~102.
Type No.
Type No.
6.3 Parameter Setting Parameters can be set and changed with the PC software. Parameter settings and changes become valid by performing a “software reset” by the PC software or turning the power supply off and back on again. 6.3.1 Basic Settings This section describes the parameters that must be set in order to operate P-Driver. (P-Driver can be operated simply by setting these parameters, if only positioning operation is required.
The number of pulses of the encoder varies depending on the type of actuator. Actuator type Number of encoder pulses (pulse/rev) RCS-SS(R)/RCS-SM(R)/RCS-RA55/RCS-F55 ISP(D)/IS(D)/IF/FS/SS 12RS-60/12RS-30 DS-SA4/5/6 [T1] RCS-RB7530/7535 RCS-R10I/20I/30I 16384 3072 4096 The gear reduction rate of the rotational axis is as follows: Actuator type 12RS-60 12RS-30 RCS-R10I RCS-R20I RCS-R30I Gear reduction rate 1/50 or 1/100 1/18 1/4 Calculation example If the amount of unit movement is set to 0.
b. Do not enter a value less than the encoder’s resolution for the minimum movement unit. Linear axis encoder resolution (mm/pulse) = Ball screw lead length (mm/rev) Number of encoder pulses (pulse/rev ) 360 (deg/rev) x Rotational axis gear reduction rate Number of encoder pulses (pulse/rev) The actuator will not move until the sum of command pulses sent to P-Driver has accumulated to the level of the encoder’s resolution or more.
6.3.2 Application Settings Set the parameters explained in this section as necessary according to the system and load. Default values indicated by [A] have already been set to appropriate values corresponding to the applicable actuator at shipment from the factory. They normally do not require changing. Some of the parameters must be input as binary values (indicated as bit input in the unit column). [Data structure of bit-input parameters] The layout of numerical values for a setting value is as follows.
(2) Communication Speed Name Symbol Unit Input range Default value (reference) Communication speed BRSL bps 9600~115200 38400 This parameter sets the speed of communication with the PC software.
Calculation formula for stroke pulse value In the case of linear axis: Settingvalue(pulse)= Strokevalue(mm) x Numberof encoderpulses(pulse/rev) Ball screwleadlength(mm/rev) In the case of rotational axis: Settingvalue(pulse)= Strokevalue(deg) x Numberof encoderpulses(pulse/rev) 360 (deg/rev)x Rotationalaxis gear reductionrate Caution z The software stroke limit is set differently according to the setting of homing pattern code (motor revolution direction at homing), a position control information pa
(5) Ball Screw Lead Length Name Symbol Unit Input range Default value (reference) Ball screw lead length LEAD mm 0.1~102.4 [A] Set the ball screw lead length of the actuator in units of millimeter (mm). An appropriate value corresponding to the applicable actuator has been set at shipment from the factory. (6) Motor Type Name Symbol Unit Input range Default value (reference) Motor type MTYP (HEX input) 00~20h [A] Set the type of motor according to the type of actuator.
(7) Encoder Type Name Symbol Unit Input range Default value (reference) Encoder type ETYP (HEX input) 00~20h [A] Set the type of encoder according to the type of actuator. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory. The type of encoder varies depending on the type of actuator. The table below lists setting values for each encoder type according to the type of actuator.
(9) Axis Operation Type Name Symbol Unit Input range Default value (reference) Axis operation type ATYP - 0~1 [A] Set the operation type, i.e., whether the actuator uses a linear axis or rotational axis. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory.
(11) Deviation Error Output Range Name Symbol Unit Input range Deviation error output range ECNT pulse 1~ 99999 Default value (reference) [A] Three times the number of encoder pulses Set the number of pulses at which deviation errors are detected during position control. A deviation error (error code: C6B) occurs if the number of standing pulses counted by the deviation counter exceeds the setting value.
(13) Speed Command Value at Homing Name Symbol Unit Input range Default value (reference) Speed command value at homing OVCM pulse/sec 1~819200 [A] Set the moving speed at homing. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory.
(14) Acceleration Command Value at Homing Name Symbol Unit Input range Default value (reference) Acceleration command value at homing OACC pulse/sec2 1000~19267584 [A] Set the acceleration at homing. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory.
(16) Homing Deviation Pulse Name Symbol Unit Input range Homing deviation pulse OPLS pulse 1~134217727 Default value (reference) [A] Half of the number of encoder pulses Set the amount of deviation at which the mechanical end is detected in a homing operation. The actuator reverses if the amount of deviation reaches the setting value in a push operation to the mechanical end. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory.
(18) Position Command Primary Filter Time Constant Name Symbol Unit Input range Default value (reference) Position command primary filter time constant PLPF msec 0.0~100.0 0.0 With the setting of this parameter, the actuator can be made to accelerate/decelerate according to an S-shaped curve. If a command pulse-train input is given with a constant frequency, the actuator accelerates/decelerates gradually according to the set time constant.
(20) Jog Acceleration Default Value Name Symbol Unit Input range Default value (reference) Jog acceleration default value ACC pulse/sec2 1000~19267584 [A] Set the default acceleration value used when performing jog operation with the PC software. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory.
(21) Jog Deceleration Default Value Name Symbol Unit Input range Default value (reference) Jog deceleration default value DEC pulse/sec2 1000~19267584 [A] Set the default deceleration value used when performing jog operation with the PC software. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory.
(22) Jog Speed Default Value Name Symbol Unit Input range Default value (reference) Jog speed default value VEL pulse/sec 1~1092266 [A] Set the default speed value used when performing jog operation with the PC software. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory.
(23) Maximum Speed at Incomplete Homing Name Symbol Unit Input range Default value (reference) Maximum speed at incomplete homing SVEL pulse/sec 1~819200 [A] Set the speed limit for a jog movement command from the PC software before homing. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory.
(24) Maximum Acceleration Value Name Symbol Unit Input range Default value (reference) Maximum acceleration value ACMX pulse/sec2 1000~19267584 [A] Set the acceleration limit value of the actuator. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory.
(25) Maximum Deceleration Value Name Symbol Unit Input range Default value (reference) Maximum deceleration value ACMX pulse/sec2 1000~19267584 [A] Set the deceleration limit value of the actuator. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory.
(27) FBP Mode (Feedback Pulse Output Mode Selection) Name Symbol Unit Input range Default value (reference) FBP mode FBPT (HEX input) 00~12h 01h Set the pulse train output mode of the feedback pulse outputs (AFB, /AFB, BFB, /BFB, ZFB and /ZFB).
The resolution of the output pulse trains is determined by the electric gear ratio of the command pulse input set in the position control parameters, and the pulses are output with the same resolution as the command signal. These pulse signals can be disabled with the PIO function setting flag explained in (1). Disable them if pulse feedback is not used. Caution z Set the same positive/negative logic as for the command pulse input mode (CPMD) regardless of whether these signals are used or not.
(29) Speed Loop Integration Time Constant Name Symbol Unit Input range Default value (reference) Speed loop integration time constant VLPT msec 0~1000 [A] Set the integration time constant of the control loop. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory. This parameter determines the response of the speed control loop. Set a larger value to make the response to speed commands slower.
(31) Current Control Bandwidth Name Symbol Unit Input range Default value (reference) Current control bandwidth CLPF msec 500~32767 [A] This parameter sets the control bandwidth of the current control system. An appropriate value corresponding to the applicable actuator has been set at shipment from the factory. Never change this parameter. Changing this parameter is very dangerous because the stability of the control system may be lost.
6.4 Servo Adjustment When P-Driver is shipped from the factory, the parameters are set in such a way that the closed-loop operation characteristics at the rated load capacity (maximum load capacity) of the actuator become stable. At the actual operation sites, however, the ideal load conditions (i.e. no resonance, vibration induction or excessive load fluctuation) may not always be guaranteed. For this reason, it may be necessary to adjust the servo loop depending on the operating conditions.
6.4.2 Adjustment 1 (1) The Host Controller is not Equipped with Acceleration/Deceleration Function or the Input Pulse Frequency Changes Sharply Set the “position command primary filter time constant.” See (18) in Section 6.3.2. It is possible to accelerate or decelerate smoothly even if the host controller is not equipped with acceleration/deceleration function or the frequency of the pulse train changes sharply.
(2) The Actual Speed does not Follow Commands Well The actual speed is abnormally slow compared to the commanded speed, vibrations occur during movement, it takes long for the positioning to complete, etc. Increase the “position control loop proportional gain.” Set the “position command primary filter time constant” to “0.” Increase the “speed loop gain.” Decrease the “speed loop integration time constant.” See (17) in Section 6.3.2. See (18) in Section 6.3.2. See (28) in Section 6.3.2.
6.4.3 Adjustment 2 (1) Shocks at Start/Stop It is desired to move smoothly without sudden acceleration/deceleration or accelerate/decelerate smoothly to change the speed to match the command speed (including a speed of 0). Set the “position command primary filter time constant.” See (18) in Section 6.3.2. (2) Abnormal Noise at Low Speed (Stop) High-pitched abnormal noise occurs, in particular, at low speeds (50 mm/sec or less). Set the “torque filter time constant.” See (30) in Section 6.3.2.
7. Troubleshooting 7.1 Handling Problems If problems occur, handle them according to the following procedure for prompt recovery and prevention of recurrence. a. Check the status indicator LEDs RDY (Green) Indicates that P-Driver is operating normally. RUN (Green) Indicates that the servo is on. ALM (Red) Indicates that an alarm is generated. ENC (Yellow) Indicates that the encoder is disconnected or not connected. b. Host controller errors c. Check the voltage of the main power supply d.
7.2.1 Errors Occurring when Turning the Power Supply on When the prescribed power is supplied to the main power supply of P-Driver, the RDY LED of the status indicator turns on. + Contact us if the RDY LED does not turn on even if the prescribed power is supplied (please check the voltage). 7.2.2 Errors Without Alarm Display The ALM LED of the status indicator on the front of P-Driver is not lit. No alarm has been generated even with the PC software connected.
(2) Positioning is not Accurate Positioning is not accurate Are the electronic gear parameters set properly? NO Modify the parameter settings. YES Is the grounding wire properly treated? NO Perform proper grounding treatment. YES When the actuator is stopped, does the current value data of the PC software indicate this fact? NO Keep the wiring of the I/O cable sufficiently distant from the power cable or shield the I/O cable.
7.2.3 Alarms (1) Alarm Levels Alarms are classified into the following three levels according to the error description: Alarm level Alarm code (HEX) ALM LED Message 900~AFF Turned off Condition at occurrence Alarm display in the PC software (The actuator is not stopped.) The actuator is forcibly stopped. Operation cancellation B00~CFF D00~FFF Reset the controller using the alarm reset signal (RES) or the PC software.
(2) List of Alarms a.
b. Operation Cancellation Level (Forced Stop) Alarm code (HEX) B05 B11 C6B C6E C74 CF4 CF5 CF6 CF7 CF8 CF9 CFA CFB CFC Name Estimated stroke over error at homing Home sensor escape timeout error Position deviation error Error in home sensor, creep sensor, etc. Transmission under-run error Error in the FPGA communication processing of a serial encoder (When sending data, the transmission data was not sent to the transmission buffer.
c. Cold Start Level Alarm code (HEX) D03 D08 D09 D0A D10 D12 D13 Name Count error Error status of a serial encoder Encoder communication CRC error Over speed CRC error (reception error) of a serial encoder Encoder out The motor revolution speed exceeded the maximum revolution speed (MAXV) set in the parameter. The effective output torque value exceeded the allowable value of the motor. The output current of the converter part became abnormally large. The encoder is not connected.
8. Operation Procedure Operate P-Driver according to the four-step procedure as specified below: Step 1 Checking unit operation of the delivered product Perform unit operation of the actuator to check that the delivered product operates normally (check wiring, the product and parameter settings). In this test run of the actuator and P-Driver, no workpieces should be mounted on the actuator.
[Test Run Procedure] 1. Temporarily fix the actuator at a safe location. 2. Connect P-Driver and the actuator. (Connect the brake power supply if the actuator is equipped with a brake. If a regenerative resistance unit is used, connect it as well.) 3. Turn the power supply on. Check the SRDY LED. The system is normal if SRDY (green) is lit.
[Test Run Procedure] 1. Temporarily fix the actuator at a safe location. 2. Connect I/O signals to the host controller. (Connect the brake power supply if the actuator is equipped with a brake. If a regenerative resistance unit is used, connect it as well.) 3. Turn the power supply on. Check the SRDY LED. The system is normal if SRDY (green) is lit.
8.4 Step 4 Operate the entire system from the host controller under the actual usage conditions and check that P-Driver operates normally. [Items to be checked] 1. Check the operation status (abnormal noise, vibration). 2. Check the parameters. See 6.4, “Servo Adjustment.” [Test Run Procedure] 1. Operate the entire system with the host controller. Operate the entire system from the host controller and check the operation status (making sure there is no abnormal noise and vibration).
9. PC Software (PDR-101-MW) 9.1 Before Using the PC Software (1) Checking Accessories Before using the software, check that each of the following items is provided: 1) 3.5-inch floppy disks containing the software 2) Software license agreement (description) 3) User registration card (serving as software license agreement; postal card) *1 4) PC connection cable *2 2 disks 1 sheet 1 card 1 piece *1 Please make sure to send the user registration card (software license agreement) back to us.
8) Hard disk space A hard disk with 2 MB or more of free space (This software is installed on the hard disk.) 9) Serial port An RS-232C serial port (D-sub 9-pin) 10) Printer A printer compatible with the PC (3) Installing the Software This software is installed on the hard disk of the PC. This section explains how to install the software. 1) Close all applications. (Resident virus-scan software and similar applications must be disabled temporarily.
9.2 Checking Connection When you start the application, the connection check dialog box (Figure 9.2.1) appears first. The PC communicates with the driver according to the “communication port” and “baud rate” set in the application setting window, which is explained later. When the connection with the driver is checked, the application starts up in the online mode. If the driver cannot be found or the Esc key is pressed, the application starts up in the offline mode.
Figure 9.3.2 Offline Startup Window 9.3.1 Operations from the Main Menu (1) File Menu (F) 1. New (N) Create new parameter data. 2. Open (O) Read data saved in a file. 3. Close (C) Close the currently active window. 4. Print Setting (P) Set the printing font and printer options. 5. Exit (X) Exit the application. (2) View Menu (V) This menu is used to set display options. 1. Font Size (F) Set the size of the font displayed in the window.
(4) Monitor Menu (M) This menu is used to monitor various statuses, port conditions, etc. and reference error histories. 1. Status (S) Open the status monitor window. *1 2. Error List (E) Open the error list window. *1 (5) Driver Menu (D) This menu is used to perform operations related to the driver, such as re-connection and software reset. 1. Jog (J) Open the jog movement window. *1 2. Re-connect (C) 3. Initialize Memory (I) Re-establish communication with the driver.
(8) Help Menu (H) 1. About (A) Display the version information of this application. *1. Valid only in the online mode. 9.3.2 Operations from the Toolbar This section explains the toolbar (Figure 9.3.3) located in the upper area of the main window (below the menu). Figure 9.3.
9.4 9.4.1 Edit Parameter Window Explanation About the Edit Parameter Window a. Select Parameter (P) and then Edit (E) from the menu. b. The Edit Parameter window appears. Select a desired parameter and change the value. Note that values displayed in gray are for reference only, and cannot be changed. Save As Click this button to save parameter data in a file with a new name. Transfer to Driver Same as selecting Parameter (P) Click this button to transfer parameter data to the driver.
* When you open the Edit Parameter window for the first time after starting the application, the parameter input ranges are acquired from the driver. In the offline mode, default values in the application are used for the parameter input ranges. 9.4.2 Saving Parameters and Completing Editing (1) Saving Parameter Data Currently Being Edited to a File Click the Save As button in the Edit Parameter window. * The extension of parameter files is “pdp.
Figure 9.4.3 Confirmation Yes (Y) Transfer the edited data to the driver; then proceed to (3) Restarting the Driver. No (N) Discard the edited data and close the Edit Parameter window. Cancel Cancel closing and return to the Edit Parameter window. * It is recommended to save parameters at delivery or when you startup the system. 9.5 9.5.1 Monitor Status Monitor Window a. Select Monitor (M) and then Status (S) from the menu. b. The Status Monitor window appears.
Figure 9.5.1 Status Monitor Axis Information Click this button to display axis information, such as current position. Axis Status Click this button to display the status of the axis, such as servo status. Axis Sensor Input Status Click this button to display the states of limit switch, etc. Inputs Click this button to display the on/off status of each signal of the input port. Outputs Click this button to display the on/off status of each signal of the output port.
Encoder Status Click this button to display the status of the encoder. * At the point when you open this window, the axis sensor input status and encoder status are not displayed. Click the corresponding button to display each of the states. 9.5.2 Error List Window a. Select Monitor (M) and then Error List (E) from the menu. b. The Error List window appears. This window displays the last 16 alarms/warnings that occurred in the driver in the past, along with their dates and times of occurrence.
Print Click this button to print the error list. Data Acquisition Click this button to update the error list with the latest error information. Error List All Clear Click this button to delete the entire error list of the driver. 9.6 Driver 9.6.1 Jog Movement Window a. Select Driver (D) and then Jog (J) from the menu. b. The Jog Movement window appears. Figure 9.6.
(2) Jog Operation Panel Operate the axis using the Fw (+) and Bw (-) buttons. Select the velocity from 1, 10, 30, 50 or 100 [mm/sec] with the slider bar. Slider bar Figure 9.6.3 Jog Operation Panel (3) Button Panel Mode Switch Every time you click this button, the operation mode of the axis switches between pulse and SIO communication mode. Jog operation can only be performed in the SIO mode. * The mode cannot be switched while the axis is moving. Servo Click this button to turn the servo on/off.
(4) Processing when Closing the Jog Movement Window If you try closing the Jog Movement window in the SIO mode, the confirmation dialog box shown in Figure 9.6.4 appears and asks whether you want to change the operation mode to the pulse operation mode. * If you close the window in the SIO mode, the driver no longer accepts pulse inputs. Figure 9.6.4 Confirmation 9.6.2 Re-Connection a. Select Driver (D) and then Re-connect (C) from the menu. b.
9.6.3 Memory Initialization a. Select Driver (D) and then Initialize Memory (I) from the menu. b. The warning dialog box shown in Figure 9.6.6 appears. Figure 9.6.6 Warning c. Click Yes (Y) to display the Initialize Driver Memory window. Figure 9.6.7 Initialize Driver Memory d. Select Parameter initialization under Initialization type in order to overwrite the parameters with the default values, or select Factory Set Parameters to overwrite the parameters with the values at shipment from the factory.
9.7 9.7.1 Tool Environment Setting a. Select Tool (T) and then Environment Setting (S) from the menu. b. Click the Communication tab to display the window shown in Figure 9.7.1. In this tab, you can set the communication port, baud rate and number of retries. Figure 9.7.
c. Click the Display tab to display the window shown in Figure 9.7.2. In this tab, you can set the display unit and coordinate revised display. Figure 9.7.2 Environment Setting – Display If you set the display unit to Pulses, parameter inputs and the current values in the monitor are displayed in units of pulses. If you select Millimeters, you can input and display values in millimeters, after conversion using parameters such as the lead length and the number of encoder pulses.
d. Click the Timer tab to display the window shown in Figure 9.7.3. In this tab, you can set the timing at which the PC software reads various data from the driver. Under normal circumstances, the information in this tab does not require changing. Figure 9.7.
9.8 9.8.1 Help Version Information a. Select Help (H) and then About (A) from the menu. b. The window shown in the Figure 9.8.1 appears. This window displays the versions of the application and driver (main and driver parts). Figure 9.8.
Manual No.: ME0131-1A (December 2011) 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.
