RCS Series ROBO Cylinder Controller RCS-C Type Operation Manual Nineteenth Edition
CAUTION (1) Hold · Servo ON Signal When operating the RCS (ROBO cylinder) controller, you will need to turn ON the Hold & Servo ON signal Input Signal of PIO. In case the Hold Stop Input Signal of PIO remains OFF, RCS controller will not move due to hold status. Therefore, please be careful. (2) The 100-V controller looks the same as the 200-V controller. However, the 100-V controller will be damaged if 200 V is supplied. Pay due attention when connecting the controller to a power source.
Safety Precautions (Please read before using the product.) Before installing, operating, maintaining or inspecting this product, please peruse this operating manual as well as the operating manuals and other related documentations for all equipment and peripheral devices connected to this product in order to ensure the correct use of this product and connected equipment/devices.
[Installation] Do not use this product in a place exposed to ignitable, inflammable or explosive substances. The product may ignite, burn or explode. Avoid using the product in a place where the main unit or controller may come in contact with water or oil droplets. Never cut and/or reconnect the cables supplied with the product for the purpose of extending or shortening the cable length. Doing so may result in fire.
Turn off the power to the product in the event of power failure. Failure to do so may cause the product to suddenly start moving when the power is restored, thus resulting in injury or product damage. If the product is generating heat, smoke or a strange smell, turn off the power immediately. Continuing to use the product may result in product damage or fire. If any of the internal protective devices (alarms) of the product has actuated, turn off the power immediately.
Before installing or adjusting the product or performing other operations on the product, display a sign that reads, “WORK IN PROGRESS. DO NOT TURN ON POWER.” If the power is turned on inadvertently, injury may result due to electric shock or sudden activation of an actuator. [Operation] Turn on the power to individual equipment one by one, starting from the equipment at the highest level in the system hierarchy.
Before Use Caution [1] [2] [3] [4] Be sure to read this operation manual to ensure the proper use of this product. Unauthorized use or reproduction of a part or all of this operation manual is prohibited. IAI shall not be liable whatsoever for any loss or damage arising from a handling or operation not specified in this operation manual. The information contained in this operation manual is subject to change without notice.
Table of Contents 1. Note to the User ......................................................................................1 1.1 1.2 1.3 1.4 1.5 1.6 Introduction .................................................................................................................................. 1 How to Read Model Number ....................................................................................................... 2 Safety Precautions .................................................................
3.4 Connection Method ................................................................................................................... 40 3.4.1 Standard Type....................................................................................................................... 40 3.4.2 Absolute Specifications......................................................................................................... 41 3.5 Supplied Cables ......................................................................
(1) (2) (3) 7.5 Message Alarms ................................................................................................................... 93 Operation Cancellation Alarms ............................................................................................. 94 Cold Start Alarms.................................................................................................................. 96 Messages Displayed during Operations Using Teaching Pendant or PC Software ..................
1. Overview 1.1 Introduction Thank you for purchasing the RCS controller. This manual explains the features and operating procedures of the product. If not used or handled properly, any product cannot fully demonstrate its function or may cause an unexpected breakdown or end its life prematurely. Please read this manual carefully and handle the product with utmost care while ensuring its correct operation.
* We have made every effort to ensure accuracy of the information provided in this manual. Should you find an error, however, or if you have any comment, please contact IAI. Keep this manual in a convenient place so it can be referenced readily when necessary. 1.
1.3 Safety Precautions Read the following information carefully and provide safety measures with due consideration. This system product has been developed as a drive component for automated machinery and the like, and is therefore designed not to generate excessive torque or speed beyond the levels needed to drive automated equipment. However, the following instructions must be strictly observed to prevent an unexpected accident. 1. Do not handle this product in any manner not specified in this manual.
1.4 Warranty Period and Scope of Warranty The RCS controller you have purchased passed IAI’s shipping inspection implemented under the strictest standards. The unit is covered by the following warranty: 1. Warranty Period The warranty period shall be one of the following periods, whichever ends first: 18 months after shipment from our factory 12 months after delivery to a specified location 2.
1.5 Installation Environment and Noise Elimination Pay due attention to the installation environment of the controller. 1.5.1 Installation Environment (1) When installing and wiring the controller, do not block the cooling ventilation holes. (Insufficient ventilation will not only prevent the controller from demonstrating its full performance, but it may also cause breakdown.) (2) Prevent foreign matter from entering the controller through the ventilation holes.
[2] 24-VDC controller The power terminal block does not have a protective grounding terminal, but the user must separately provide a noise elimination measure and grounding. (2) Grounding for noise elimination Regardless of whether the power supply is 100/200 VAC or 24 VDC, the controller must always be grounded to eliminate noise. [1] Connect the controller by directly screwing it onto a metal frame.
(3) Noise sources and elimination Among the numerous noise sources, solenoid valves, magnet switches and relays are of particular concern when building a system. Noise from these sources can be eliminated by implementing the measures specified below. [1] AC solenoid valves, magnet switches and relays Measure: Install a surge absorber in parallel with the coil. Point Install a surge absorber to each coil over a minimum wiring length.
1.6 Heat Radiation and Installation Design the control panel size, controller layout and cooling method in such a way that the temperature around the controller will not exceed 40C. Install the controller vertically on a wall, as shown below. Since cooling is provided by way of natural convection, always observe this installation direction and provide a minimum clearance of 50 mm above and below the controller to ensure sufficient natural airflows.
2. Specification for 24-VDC Input Power 2.1 Basic Specifications Item Specification 24 VDC 10% Supply voltage Supply current [A] Maximum motor output Surrounding air temperature/humidity Surrrounding environment Weight Protective functions LED indicators DI/DO interface 8 dedicated input ports Input/output 10 dedicated output ports Type Rating RA35 Peak 1.8 RA45, F45 4.3 2.4 RB75 (60 W) 6.0 3.9 1.2 3.7 SA6 1.4 3.
2.1.1 Backup Battery (Absolute Specification) (1) Battery Specification Item Model number Type Manufacturer Description AB-1 Lithium battery Toshiba Battery Co., Ltd. (ER6VP) Nominal voltage 3.6 V Rated capacity 2000 mAh Weight Battery retention time Note 1) Approx. 8.5 g Approx. 20,000 hours (at surrounding air temperature of 20C). Note 1) Approx. 100 A of current is consumed while data is backed up by the absolute data backup battery (as opposed to approx.
2.2 2.2.1 Names and Functions of Parts Names [1] Battery connector (BAT) (absolute specification) [9] LED indicators [2] Motor connector (M) [3] Brake release switch (BK) [4] SIO connector (SIO) [5] Port switch (PORT) [6] Main communication port connector (PORT IN) [7] Regenerative resistor connector (RB) [10] Encoder/brake connector (ENC) [11] Piano switches 3 (SW3) [12] Piano switches 2 (SW2) [13] Piano switches 1 (SW1) [14] PIO connector (PIO) [8] Power/emergency-stop terminal block 2.2.
[5] Port switch (PORT) ON: The PORT IN port (teaching pendant/PC software) becomes active. If a dedicated teaching pendant or cable is not connected to this port, the controller will recognize an emergency-stop condition. OFF: The PORT IN port (teaching pendant/PC software) becomes inactive. (Controller-to-controller communication is possible.) [6] Main communication port connector (PORT IN) A connector for receiving the communication cable from a dedicated teaching pendant or external equipment.
[13] Piano switches 1 (SW1) Nos. 1 to 4 --- Address switches Use these switches to set the address of the applicable actuator if two or more axes are connected to the SIO connector. A desired address between 0 to 15 can be set. (The factory setting is OFF for all of switch Nos. 1 to 4. This setting represents a condition where only one axis is used.) Use these switches to set a desired address for each controller. Make sure no address is duplicated among the controllers.
2.2.3 Pin Assignments of the Communication Ports Pin assignments of the SIO connector Pin No. 1 2 3 4 5 6 Signal name (+5V) SGA GND SGB GND (+5V) Function (5-VDC power output) or (preliminary signal terminal) Positive logic side of the line transceiver I/O Communication ground Negative logic side of the line transceiver I/O Communication ground 5-VDC power output Pin assignments of the main communication port Pin No.
Encoder/brake connector [High-density D-sub, DE-15 type] Pin No.
2.3 2.3.
2.3.
2.4 Connection Method 2.4.1 Standard Type Teaching pendant Optional Cable length: 5 m ROBO Cylinder The cables are optional. Host system Supplied flat cable External unit Optional Cable length: 5 m Cable length: 2 m PC External unit Optional Cable length: 5 m PC software Optional EMG switch 24-VDC power supply 18 Do not insert/remove the connectors when the power is on, except for the main communication port connector (PORT IN).
2.4.2 Absolute Specifications ROBO Cylinder The absolute specification cannot be used with a standard actuator. The cables are optional. Other connections are the same as those of the standard type.
2.5 Supplied Cable 2.5.
2.5.2 Motor Extension Cable Actuator end Controller end Signal Cable color abbreviation Pin no. Signal abbreviation Cable color Red Red White White Black Black Receptacle: 5557-04R (Molex) Female terminal: 5556-TL (Molex) 2.5.3 Pin no. Plug housing: SLP-03V (JST) Socket contact BSF-21T-P1.4 (JST) Encoder Extension Cable Actuator end Controller end Cable color Signal abbreviation Pin no. Pin no.
2.6 Wiring 2.6.1 Wiring for Power Supply/Emergency Stop Power/emergency-stop terminal block * The two EMG terminals are contact-b inputs used for connecting an emergency-stop switch. The controller is shipped with these terminals shorted, so that an emergency stop will not be actuated. 24 VDC is output to EMG of pin No. 3. The current consumption of the emergency-stop circuit is approx. 35 mA (24-V controller).
2.6.
2.6.3 PIO Interface A PIO interface list is given below. The PIO cable is a flat cable with no connector attached on the end connected to the external equipment. PIO connector (40 pins) Pin No. Category Reference Signal name No. Cable color Pin No. 2 1 [1] COMOA Brown-1 3 [2] COMOB Category Reference No.
[1] [2] COMOA Power supply for output ports COMOB Connect the 24-VDC power supply for output ports between COMOA and COMOB. COMOA and COMOB have no polarities. Pin Nos. 1 & 2, and 3 & 4 are connected internally. [3] Alarm This signal will turn OFF when an alarm occurs. It remains ON as long as the controller is operating properly. To reset an alarm, remove the cause of the alarm, and then input a reset signal or reconnect the power.
[9] Emergency stop This signal will turn OFF when an emergency stop is actuated. It remains ON as long as the controller is operating properly. When the emergency stop is cancelled, the signal will turn ON. [10] COMIA Power supply for input ports [11] COMIB Connect the 24-VDC power supply for input ports between COMIA and COMIB. Pin Nos. 21 & 22, and 23 & 24 are connected internally. [12] Pause This is a contact-b input.
2.6.4 External I/O Specifications Input Part Item Number of input points Input voltage Input current Operating voltage Isolation method Specification 8 points 24 VDC 20 7 mA per circuit ON voltage --- 16 V min. (4.5 mA) OFF voltage --- 6 V max. (1.4 mA) Photocoupler Internal circuit configuration (Standard NPN specification) Pin No. External power supply 24 VDC Internal circuit Rectifier Each input Connect a 24-V power supply between COMIA and COMIB.
Output Part 100-mA output circuit by power MOSFET Item Number of output points Rated load voltage Maximum load current Residual voltage Isolation method Overcurrent protection Specification 10 points 24 VDC; 60 VDC (peak) (without flywheel diode) 100 mA per point 1.8 V / 100 mA Photocoupler Fuse resistance: 10 , 0.1 W Internal circuit configuration (Standard NPN specification) Each output Load Fuse resistance: Internal circuit Load Pin No.
3. Input Power 100/200 VAC Specification 3.
3.1.1 Backup Battery (Absolute Specification) (1) Battery specifications Item Model number Classification Manufacturer Nominal voltage Rated capacity Weight Battery retention time Note 1) Description AB-1 Lithium battery Toshiba Battery (ER6VP) 3.6 V 2000 mAh Approx. 8.5 g Approx. 20,000 hours (at surrounding air temperature of 20C) Note 1) The absolute-data backup battery consumers approx. 100 A during backup. (When the main controller power is on, the current consumption is approx. 4 A.
If the battery was replaced while the controller power was off, the position information (absolute data) may or may not be retained depending on how long the controller remained without battery. Time without battery Retention of position information (absolute data) Less than 5 minutes Position information (absolute data) is retained. Absolute reset is not necessary. A battery alarm occurs. Position information is retained. Absolute reset is not necessary. A battery error occurs.
3.2 Names and Functions of Parts 3.2.1 Names [1] Battery connector (absolute specification) [7] LED indicators [2] Port switch [8] Encoder/brake connector [3] Brake release switch [4] Emergency-stop terminal block [9] Piano switches 3 [10] Piano switches 2 [5] Motor connector [11] Piano switches 1 [12] PIO connector [13] Main communication port connector [6] Power terminal block [14] SIO connector 3.2.
[5] Motor connector A connector for the actuator’s motor power cable. [6] Power terminal block L/N: An AC-power connection terminal. PE: A protective grounding terminal. Provide class D grounding. [7] LEDs RDY: Indicate that the CPU is operating normally. RUN: This LED turns on while the actuator is moving. ENC: This LED turns on when the encoder cable is open or otherwise the encoder cannot be recognized. The LED also turns on when the voltage of the absolute-data backup battery drops.
[11] Piano switches 1 (SW1) Nos. 1 to 4 --- Address switches Use these switches to set the address of the applicable actuator if two or more axes are connected to the SIO connector. A desired address between 0 to 15 can be set. (The factory setting is OFF for all of switch Nos. 1 to 4. This setting represents a condition where only one axis is used.) Use these switches to set a desired address for each controller. Make sure no address is duplicated among the controllers.
[12] PIO connector (PIO) A connector for PIO cable. [13] Main communication port connector (PORT IN) A connector for receiving the communication cable from a dedicated teaching pendant or external equipment. It also receives a controller link cable when two or more axes are connected. [14] SIO connector (SIO) A connector for linking another controller when two or more controllers are connected.
3.2.3 Signal Tables of Connectors and Terminal Blocks Pin assignments of the SIO connector Pin No. Signal name 1 (+5V) 2 SGA 3 GND 4 SGB 5 GND 6 (+5V) Function (5-VDC power output) or (preliminary signal terminal) Positive logic side of the line transceiver I/O Communication ground Negative logic side of the line transceiver I/O Communication ground 5-VDC power output Pin assignments of the main communication port Pin No.
Encoder/brake connector [High-density D-sub, DE-15 type] Pin No.
3.3 3.3.
3.3.
3.4 3.4.1 Connection Method Standard Type ROBO Cylinder The cables are optional.
3.4.2 Absolute Specifications Battery connector ROBO Cylinder The absolute specification cannot be used with a standard actuator. The cables are optional. Other connections are the same as those of the standard type.
3.5 Supplied Cables 3.5.1 I/O Flat Cable Accessory I/O Connector (40P) Flat Cable I/O connector (40P) No. 1 Signal Name C OMOA Color Brown - 1 No.
3.5.2 Motor Extension Cable Actuator end Controller end Cable color Signal abbreviation Pin no. Pin no. Cable color Green Red Red White White Black Black Green Reverse plug: GIC2.5/4-STF-7.62 (Phoenix) 3.5.3 Signal abbreviation Encoder Extension Cable Plug housing: SLP-04V (JST) Socket contact BSF-21T-P1.4 (JST) Actuator end Controller end Cable color Signal abbreviation Pin no. Pin no.
3.6 Wiring 3.6.1 Wiring for Power Supply/Emergency Stop AC power supply Class D grounding (protective grounding) Power terminal block Emergency-stop terminal block * The two EMG terminals are contact-b inputs used for connecting an emergency-stop switch. The controller is shipped with these terminals shorted, so that an emergency stop will not be actuated. 24 VDC is output to EMG of pin No. 1. The current consumption of the emergency-stop circuit is approx. 15 mA (100/200-V controller).
External Connection Diagram Screw onto a metal frame directly. Controller Start Command position 1 Encoder Encoder Command position 2 Output Command position 4 Host system Command position 8 Brake Pause Reset Servo ON Completed position 1 Completed position 2 Completed position 4 Completed position 8 Position complete Motor Input Home return completion Zone Alarm Moving Emergency stop Battery alarm Main communication port Power supply Conversion adapter 3.6.
3.6.3 PIO Interface A PIO interface list is given below. The PIO cable is a flat cable with no connector attached on the end connected to the external equipment. PIO connector (40 pins) Pin No. Reference No. Signal name Cable color Pin No. 1 [1] COMOA Brown-1 2 3 [2] COMOB Category Category Reference No.
[1] [2] [3] [4] [5] COMIA Power supply for output ports COMIB Connect the 24-VDC power supply for output ports between COMOA and COMOB. COMOA and COMOB have no polarities. Pin Nos. 1 & 2, and 3 & 4, are connected internally. Alarm This signal will turn OFF when an alarm occurs. It remains ON as long as the controller is operating properly. To reset an alarm, remove the cause of the alarm, and then input a reset signal or reconnect the power.
[9] [10] [11] [12] [13] [14] [15] [16] [17] Moving This signal remains ON while the actuator is moving. Use this signal if you want to detect stopping of the motor during pause. Emergency stop This signal will turn OFF when an emergency stop is actuated. It remains ON as long as the controller is operating properly. (Contact-b signal) When the emergency stop is cancelled, the signal will turn ON.
3.6.4 External I/O Specifications Input Part Item Number of input points Input voltage Input current Operating voltage Isolation method Specification 8 points 24 VDC 20 7 mA per circuit ON voltage --- 16 V min. (4.5 mA) OFF voltage --- 6 V max. (1.4 mA) Photocoupler Internal circuit configuration (Standard NPN specification) Pin No. External power supply 24 VDC Internal circuit Rectifier Each input Connect a 24-V power supply between COMIA and COMIB.
Output Part 100-mA output circuit by power MOSFET Item Specification Number of output points 11 points Rated load voltage 24 VDC; 60 VDC (peak) (without flywheel diode) Maximum load current 100 mA per point Residual voltage 1.8 V / 100 mA Isolation method Photocoupler Overcurrent protection Fuse resistance: 10 0.1 W Internal circuit configuration (Standard NPN specification) Each output Load Fuse resistance: Internal circuit Load Pin No.
4. Data Entry This controller doesn’t use command words, so there is no need to create a program. All you need is to enter position data in the position-data table, and the actuator will move to the specified position. Position data consists of number (No.), position (Position), speed (Speed), acceleration/deceleration (ACC), push (Push), positioning band (Pos. band), and acceleration only MAX (ACC MAX). The description in parentheses is as displayed on the teaching pendant.
4.1 Description of Position-Data Table (1) No. Indicate the position data number. To enter an incremental movement, press the minus key in this column. On the teaching pendant, a “=” will be displayed between the number and position columns. The minus key need not be pressed in the absolute mode. (2) Position (Position) Enter the target position to move the actuator to, in [mm]. Absolute mode: Enter the distance to the target actuator position from the home. Negative values cannot be entered.
Select the positioning mode or push & hold mode. The default value is “0.” 0: Positioning mode (= Normal operation) Other than 0: Push & hold mode [%] In the push & hold mode, enter the current-limiting value to be applied to the servo motor while the load is being pushed. With the RCS, set the current-limiting value to approx. 70%. The controller will not operate properly if this value is 30% or below. (5) Push (Push) The table in 4.1.
Select the specified acceleration or maximum acceleration by entering “0” or “1.” The default value is “0.” 0: Specified acceleration --- The value entered in (4) becomes the actual acceleration/deceleration. 1: Maximum acceleration --- The maximum acceleration set according to the load is used. The deceleration conforms to the value entered in (4).
4.1.1 Push Force at Standstill In the push & hold mode, enter a current-limiting value (%) in the position-data table under “Push.” With the RCS, use a push force at standstill corresponding to a current-limiting value of approx. 70%. The push force at standstill can be increased or decreased by increasing or decreasing the current-limiting value. However, take note that the controller will not operate properly if the current-limiting value is 30% or below.
4.2 Explanation of Modes Positioning Mode Push = 0 Speed 4.2.1 Position complete signal Completed position number Moving OFF Output Moving distance (1) The position complete output will turn ON and moving output will turn OFF at a position preceding the target position by the positioning band. A completed position number signal will be output at the same time. Positioning band Push & Hold Mode Push = Other than 0 (1) Load was contacted successfully Speed 4.2.
(2) Load was not contacted (missed) Speed Completed position number Moving OFF Output Moving distance Positioning band (3) Load moves during push & hold operation [1] Load moves in the pushed direction Speed Position complete signal Completed position number Output Moving OFF Moving distance Speed [2] Positioning band (1) After reaching the target position, the actuator will move at low speed.
Speed (4) Positioning band was entered with a wrong sign If the positioning band is entered with a wrong sign, the position will deviate by twice the positioning band, as shown to the left, so exercise due caution. Moving distance 4.2.3 Positioning Positioning band band 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.
4.2.5 Pause This signal can be used to stop the actuator in case of emergency. The movement of the actuator can be paused via an external input signal (pause). For safety reasons, this signal is provided as a contact-b input (based on the negative logic). The actuator will decelerate to a stop when the pause input is turned OFF, and resume movement when the pause input is turned ON.
4.2.7 Home Return With the standard specification, home return must be performed after the power has been input or an encoder open or CPU error alarm has been reset. Selecting a position number and then initiating a start will cause the controller to automatically perform home return before commencing the subsequent operation. Once home return is complete, the home return completion output will turn ON (standard specification). Home return alone cannot be performed using PIO.
4.4 Items to Note on Gripper (RCS-G20) (1) Finger Operation [1] Definition of position The stroke in the specification table indicates a sum of travels of both fingers. In other words, the travel of each finger is a half of the stroke. The specified position therefore represents the distance traveled by each finger from its home position toward the closing side. [2] Definition of speed and acceleration Speed and acceleration command values indicate a sum of both fingers.
5. Using the Controller 5-1 How to Start (Standard Specification) (Refer to 5-2, “How to Execute An Absolute Reset,” for the absolute specification.) (1) Confirm that both Nos. 1 and 2 of piano switch 2 (SW2) are set to OFF. If these switches are set to ON, tilt them back to the OFF positions. (2) Connect the motor/brake cables and encoder cable to the controller. (3) Connect the host PLC to the PIO connector using the supplied flat cable.
5.2 How to Execute Absolute Reset (Absolute Specification) Note) With the absolute specification, an encoder receive error (0E5) will occur when the power is turned on for the first time after the battery or PG cable was disconnected. This does not indicate fault. If this error occurs, execute an absolute reset by following the specified procedure. The specific method to execute an absolute reset will vary depending on the controller version.
How to Execute an Absolute Reset on a Controller of Version J* or Earlier [1] [2] [3] Connect the motor and encoder/brake cables to the controller. Connect the host PLC to the PIO connector using the supplied flat cable. If two or more axes are connected, set the address using SW1 on the controller. For details, refer to 2.2, “Names and Functions of Parts” and 3.
5.3 Movement after Power On (Standard Type) Example of use in operation) After the power is turned on, move the actuator to the position 150 mm from the home at a speed of 200 mm/sec. Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 1 0 150 100 200 Acceleration/ deceleration 0.3 0.3 Push Positioning band 0 0 0.1 0.
Power ON Servo ON Command position Position 1 Start Note Pause Position complete Alarm Emergency stop Position 1 Completed position * Home return completion Speed Positioning band Moving Time *Actuator movement The position complete output will turn ON when the controller becomes ready following the power ON. (The position complete output will not turn ON if the servo ON input is OFF.) To check if the controller is ready, always check if the position complete output is ON.
5.4 Positioning Mode (Back and Forth Movement between Two Points) Example of use in operation) The actuator moves back and forth between two positions. The position 250 mm from the home is set as position 1, and the position 100 mm from the home is set as position 2. The travel speed to position 1 is set as 200 mm/sec, and to position 2 is set as 100 mm/sec. RCS controller PIO Signal name Reference flow Category [13] [10] [5] [2] Start [1] [9] [1] Select/enter command position 1.
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 * * Acceleration/ deceleration * 1 250 200 2 100 100 Push Positioning band * * Acceleration only MAX * 0.3 0 0.1 0 0.3 0 0.
5.5 Push & Hold Mode Example of use in operation) The actuator is caused to move back and forth in the push & hold mode and positioning mode. The position 280 mm from the home is set as position 1, and the position 40 mm from the home is set as position 2. Movement to position 1 is performed in the push & hold mode (the actuator is caused to contact the load and push it in the counter-motor direction).
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 * * Acceleration/ deceleration * 1 280 200 2 40 100 Push Positioning band * * Acceleration only MAX * 0.3 50 15 0 0.3 0 0.
5.6 Speed Change during Movement Example of use in operation) Method) The actuator speed is reduced at a certain point during movement. The position 150 mm from the home is set as position 1, and the position 200 mm from the home is set as position 2. The actuator is initially located between the home and position 1. The actuator is moved to position 2 being the target position, at a travel speed of 200 mm/sec to position 1 and that of 100 mm/sec from position 1 to position 2.
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 * * Acceleration/ deceleration * 1 150 200 0.3 2 200 100 0.3 Push Positioning band * * Acceleration only MAX * 0 1 0 0 0.
5-7 Operation at Different Acceleration and Deceleration Settings Example of use in operation) Positioning is performed to the position 150 mm from the home (position 1) at a speed of 200 mm/sec. The actuator will accelerate at the maximum acceleration set according to the load, and decelerate at 0.1 G. Method) Entering “1” under “Acceleration only MAX” in the position data will automatically adjust the acceleration to the maximum acceleration set according to the load. Entering “0.
Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 * * Acceleration/ deceleration * 1 150 200 0.1 Command position Position 1 Push Positioning band * * Acceleration only MAX * 0 0.1 1 Start Position complete Position 1 Completed position Moving Speed Positioning band Actuator movement T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON (The scan time of the host controller must be considered.
5.8 Pause Example of use in operation) The actuator is paused during movement. Method) Use the pause input. RCS controller PIO Signal name [5] [2] Reference flow Category Select/enter a desired command position. [2] Start input ON Start Command position 1 [1] [1] Command position 2 Command position 4 Movement to the selected position starts.
Command position Start Note Position complete Completed position Pause Moving Speed 4 msec or less Actuator movement T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON (The scan time of the host controller must be considered.) Note: When the start signal turns ON, the position complete output will turn OFF and the moving output will turn ON.
5.9 Zone Signal Output Example of use in operation) While the actuator is moving a zone signal is output inside the zone enclosed by distances of 40 mm and 120 mm from the home. (40 mm Zone signal output 120 mm) Method) Use the parameters “Zone boundary+” and “Zone boundary–” to set the zone in which the zone signal is output, as shown below: Zone boundary+ Zone boundary– 120 40 RCS controller PIO Signal name [5] [2] Reference flow Category Select/enter a desired command position.
Command position Note Start Position complete Completed position Zone Moving Speed Actuator movement T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON (The scan time of the host controller must be considered.) Note: When the start signal turns ON, the position complete output will turn OFF and the moving output will turn ON. The start signal must be turned OFF with the confirmation that the moving output has turned ON while the start signal remains ON.
5.10 Returning Home Example of use in operation) Home return alone cannot be performed using PIO. Method) Create point data of 0 distance from the home, and move the actuator to that position. Enter home data in position 0. To return home, move the actuator to position 0. Position-data table (Field(s) within thick line must be entered.) No. Position Speed 0 0 100 Acceleration/ deceleration 0.3 1 * * * Push Positioning band 0 0.
Command position Start Turn all of command positions 1, 2, 4 and 8 OFF. Position 0 Note Position complete Completed positions 1, 2, 4 and 8 all turn OFF. Completed position Moving Speed Actuator movement T1: 5 msec or more; time after selecting/entering a command position until the start input turns ON (The scan time of the host controller must be considered.) Data of 0 distance from the home need not be always entered in position 0.
5.11 Incremental Moves Example of use in operation) The actuator is caused to move from the home to the 30-mm position, from which it will be moved repeatedly in increments of 10 mm. The travel speed from the home to the 30-mm position is set as 100 mm/sec, and that for 10-mm incremental moves is set as 20 mm/sec. RCS controller PIO Signal name [13] [10] [5] [2] [1] [9] Reference flow Category [2] Start input ON Start Command position 1 Movement to position 1 starts.
Position-data table (Field(s) within thick line must be entered.) Acceleration/ deceleration * No. Position Speed 0 * * 30 100 0.3 10 20 0.3 1 2 = Push Positioning band * * Acceleration only MAX * 0 0.1 0 0 0.
5.12 Notes on Incremental Mode (1) Notes on positioning operation Selecting/entering a position number using relative coordinates during positioning will cause the actuator to move to the position corresponding to the initial position plus the increment. (If the increment is a negative value, the actuator will move to the position corresponding to the initial position minus the increment.
Example) If the start signal for movement to position 2 is input while the actuator is moving to position 1 in the push & hold mode, the actuator will move to the position 10 mm from where it was when the input signal was input. Command position Position 1 Position 2 No.
6. Parameters 6.1 Parameter Classification The parameters are classified into the following four types depending on their function: Types: a: Parameter relating to actuator stroke range b: Parameter relating to actuator operating characteristics c: Parameter relating to external interface d: Servo gain adjustment 6.2 No.
6.3 Parameter Settings If you have changed any parameter, be sure to restart the controller via a software reset or reconnect the controller power. 6.3.1 Parameters Relating to Actuator Stroke Range Soft limits Set the + soft limit in parameter No. 3 and - soft limit in parameter No. 4. Both parameters have been set to the effective actuator length at the factory.
Home offset Parameter No. 22 has been set to an optimal value at the factory so that the distance from the mechanical end to home will remain constant. The minimum setting unit is 0.01 mm. This parameter can be adjusted in the following conditions: [1] Align the actuator’s home with the mechanical home on the equipment after the actuator has been assembled to the equipment. [2] Set the home position again after reversing the factory-set home direction.
Push & hold recognition time This parameter is used as a condition for determining if the actuator has contacted the work part and completed its push-mode operation. Specifically, push-mode operation is deemed complete if the current limit value set in the position table has been maintained for the time set in parameter No. 6. Set this parameter to an optimal value in accordance with the current limit value, by considering the shape and strength of the work part, etc.
Movement flag during stop This parameter defines whether to enable or disable the dynamic brake while the actuator is stopped. It has been set to “1” (Enable) at the factory. This parameter need not be changed in normal conditions of use, but there are situations where the actuator must be moved by hand with the servo turned OFF but the actuator does not move smoothly due to large slide resistance (this often occurs with actuators having a short ball screw lead).
6.3.3 Parameters Relating to External Interface ● Hold input disable selection Parameter No. 15 sets whether to enable or disable the hold input signal. Setting Enable (Use) 0 Disable (Do not use) 1 This parameter has been set to “0” (Enable) at the factory. ● Servo ON input disable selection Parameter No. 21 sets whether to enable or disable the servo ON input signal. Setting Enable (Use) 0 Disable (Do not use) 1 This parameter has been set to “0” (Enable) at the factory.
Appendix Appendix 7. 7.1 Troubleshooting What to Do When A Problem Occurs If you encountered a problem, follow the steps below to conduct the specified checks to gather information needed to implement quick recovery and prevent recurrence of the problem. a. b. c. d. e. f. g. h. i. j. k. l. Check the status indicator lamps RDY (green) --- The controller is receiving power and the CPU is operating normally. RUN (green) --- The servo is ON and the actuator is moving. ALM (red) --- An alarm is present.
7.2 Alarm Level Classification The alarms are classified into three levels based on the corresponding symptoms. Alarm level ALM lamp *Alarm Condition at occurrence of alarm How to reset Message Unlit Not output An error is displayed on the PC software screen or teaching pendant. Operation cancellation Lit Output The actuator decelerates to a stop, and then the servo turns off. Input a reset signal from the PLC. Execute reset using the PC/teaching pendant.
Appendix Appendix 7.4 (1) Alarms, Causes and Actions Message Alarms Code Error Cause/action 040 Emergency stop Cause: An emergency stop status was detected. (This is not an error.) 05A Receive overrun 05B Receive framing error 05C Receive timeout error 05D Header error 05E Delimiter error An error occurred during operation using the PC software/teaching pendant or serial communication via PLC’s communication module.
(2) Operation Cancellation Alarms Code 0B0 Error Bank 30 data error Cause/action Cause: Action: 0B1 Bank 31 data error Cause: Action: 0BE Homing timeout Cause: Action: 0C0 Excessive actual speed Cause: Action: 0C9 Overvoltage Cause: Action: 94 Out-of-range or invalid data is included in the parameter area of the memory. (This alarm does not occur as a result of normal parameter input operation, but it may occur during serial communication using the PLC’s communication module.
Appendix Appendix Code Error Cause/action 0CA Overheat The surrounding air temperature of the power transistor in the controller rose excessively (to 95C or above). Cause: [1] High surrounding air temperature of the controller [2] Defective internal part of the controller Action: [1] Lower the surrounding air temperature of the controller. If the surrounding air temperature is normal, please contact IAI.
(3) Cold Start Alarms Code 0C8 Error Overcurrent Cause/action Cause: Action: The output current from the power circuit became abnormally high. This alarm does not occur in normal conditions of use, but it may occur when the motor coil isolation has deteriorated. Measure inter-phase resistance between motor connection leads U, V and W as well as isolation resistance relative to the ground, to check for deterioration of isolation. Please contact IAI before performing these measurements.
Appendix Appendix Code Error Cause/action 0E5 Encoder receive error The controller and encoder exchange position data via serial communication. This error occurs when the encoder did not return correct data in response to a request from the controller, or the battery voltage became law. Cause: [1] Law battery voltage (Absolute controllers are shipped with the encoder cable removed. On these controllers, this error always occurs when the power is turned on for the first time at the user’s site.
Code Error Cause/action 0E7 Phase A/B/Z open Encoder signal cannot be detected properly. Cause: [1] Open encoder extension cable or supplied actuator cable, or poor connector contact [2] Faulty encoder Action: [1] Check the connector for possibility of open circuit, and examine the connection condition. (Perform a continuity check by referring to 2-5, “Supplied Cables.”) If the cable is normal, the encoder may be faulty. Please contact IAI.
Appendix Appendix 7.5 Messages Displayed during Operations Using Teaching Pendant or PC Software The warning messages that may be displayed during operations using the teaching pendant or PC software are explained below. Code Message Description 112 Input data error An inappropriate value was input as a user parameter setting. (Example) “9601” was input as the serial communication speed by mistake. Input an appropriate value again.
Code Message Description 20C CSTR-ON during operation The start signal (CSTR) was turned ON by the PLC while the actuator was moving. As a result, duplication of movement commands occurred. 20D STP-OFF during operation The hold signal (*STP) was turned OFF by the PLC while the actuator was moving. As a result, the actuator stopped. 20E Soft limit over A soft limit was reached. 20F Missed work part in push-motion operation The actuator missed the work part in push-motion operation.
Appendix Appendix * Appendix Specification List of Supported Actuators Rated Loading capacity acceleration (Note 2) HorizonHorizonVertical Vertical tal tal Rod type Slider type Model number Stroke (mm), maximum speed (mm/sec) (Note 1) Model number Model number (Note 1) (Note 2) The figure in each elongated circle represents the maximum speed for the applicable stroke(s). The loading capacity is calculated by assuming actuator operation at the rated acceleration.
Appendix Rated Loading capacity acceleration (Note 2) Horizon- Vertical Horizon- Vertical tal tal Flat type Rod type Model number Stroke (mm), maximum speed (mm/sec) (Note 1) Rotary (Note 1) The figure in each elongated circle represents the maximum speed for the applicable stroke(s). (Note 2) The loading capacity is calculated by assuming actuator operation at the rated acceleration. (Note 3) Refer to the table on the next page. Gripper 102 2.
Appendix Appendix Flat Type (F45, 55) - Moments and Loading Capacity The directions of moments generated around the flat type are shown in the figure below. The points of action of Ma and Mb moments are shown in the figure below. Point of action Point of action If the flat type is used horizontally, make sure the load applied to the end of the plate does not exceed the Ma moment. Refer to the table below listing the allowable loads at the tip as calculated from the Ma moment at each stroke.
Appendix Example of Basic RCS Positioning Sequence An example of basic sequence is given below for reference when creating an RCS positioning sequence. indicates a PIO signal of the RCStroller. (Completed position decoding circuit) Positioning complete Completed position code (Not less than the PLC’s scan time) Waiting for completed position to be read Completed position 1 Completed position 2 Completed position 3 Completed position 4 Completed position 5 To be created for the number of positions.
Appendix Appendix (Position 2 positioning circuit) Position 2 positioning start request Position 2 poisoning start pulse Position 2 positioning start request Position 2 poisoning start pulse, auxiliary Current positioning completed position Position 2 poisoning start, auxiliary Start signal Moving signal Position 2 start confirmation Next positioning start auxiliary signal Position 2 positioning complete Use of a circuit like this, which enables determination of the current position in the sequence ev
Appendix Command position 1 Position 3 set signal Position 5 set signal Command position 2 Position 3 set signal Position 6 set signal Command position 4 Command position 8 (Start signal circuit) Waiting for start 5 msec or more (Not less than the PLC’s scan time) Positioning start signal for other position Start signal 106
Appendix Appendix Position Table Record Recorded date: No.
Appendix Parameter Record Recorded date: Type No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 108 Type a a a a a b d b b b b b b b c c c c a a: b: c: d: Parameter relating to actuator stroke range Parameter relating to actuator operating characteristics Parameter relating to external interface Servo gain adjustment Name Zone limit + side Zone limit – side Soft limit + side Soft limit – side Home direction [0: Reverse/1: Forward] Push & hold recognition time Servo gain No.
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